Sullair 125 User Manual

PORTABLE AIR
COMPRESSOR
125, 130, 160H, 185 CFM
and 49 HP Models
CATERPILLAR, JOHN DEERE, PERKINS
OPERATOR’S
MANUAL AND
PARTS LIST
KEEP FOR
FUTURE
REFERENCE
Part Number
02250159-733
©Sullair Corporation
The information in this document
is correct at the time of printing
for Portable Compressor Serial
Number :
004-151422
and all subsequent Serial
Numbers.

Sullair 125 Specifications

General

Brand	Sullair
Model	125
Category	Air Compressor
Language	English

Summary

Section 1 SAFETY

1.1 GENERAL

General safety precautions and responsibilities for safe operation.

1.2 TOWING

Procedures and warnings related to safely towing the compressor.

1.3 PRESSURE RELEASE

Instructions for safely releasing internal pressure from the compressor.

1.4 FIRE AND EXPLOSION

Precautions to prevent fire and explosion hazards during operation and refueling.

1.5 MOVING PARTS

Safety guidelines regarding contact with moving parts to avoid injury.

1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS

Warnings about hot surfaces and sharp edges to prevent burns and cuts.

1.7 TOXIC AND IRRITATING SUBSTANCES

Information on hazardous substances and safe handling procedures.

1.8 ELECTRICAL SHOCK

Safety precautions to prevent electrical shock hazards.

1.9 LIFTING

Procedures for safely lifting and suspending the compressor.

1.10 ENTRAPMENT

Safety measures to prevent personnel entrapment in the compressor enclosure.

1.11 JUMP STARTING

Step-by-step guide for safely jump-starting the compressor's engine.

Section 2 DESCRIPTION

2.1 INTRODUCTION

Introduction to the compressor, its capabilities, and maintenance.

2.2 DESCRIPTION OF COMPONENTS

Detailed breakdown and illustration of compressor components.

2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION

Functional description of the Sullair rotary screw compressor unit.

2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION

Explanation of the cooling and lubrication system's operation.

2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION

Functional description of the compressor's discharge system.

2.6 CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION

Description of how the capacity control system regulates air output.

2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

Functional description of the air inlet system, including filters.

2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION

Description of the instrument panel, gauges, and controls.

2.9 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION

Functional description of the compressor's electrical system.

2.10 SHUTDOWN SYSTEM DESCRIPTION

Description of the shutdown system and its error codes.

Section 3 SPECIFICATIONS

3.1A SPECIFICATIONS - PERKINS AND CATERPILLAR

Specific technical details for Perkins and Caterpillar engine models.

3.1B SPECIFICATIONS - JOHN DEERE 125, 130 (2-WHEEL AND LRG)

Technical specs for John Deere 125 and 130 models.

3.1C SPECIFICATIONS - JOHN DEERE 49HP, 160H, 185 (2-WHEEL AND LRG)

Technical specs for John Deere 49HP, 160H, and 185 models.

3.2 LUBRICATION GUIDE - COMPRESSOR

Guide for selecting and changing compressor fluid.

3.3 APPLICATION GUIDE

Guidance on fluid application and conditions.

3.4 LUBRICATION GUIDE - ENGINE

Information on engine oil specifications and maintenance.

Section 4 OPERATION

4.1 GENERAL

General overview of compressor operation and controls.

4.2 PURPOSE OF CONTROLS

Description of the function and location of various controls and indicators.

4.3 START-UP PROCEDURE

Step-by-step procedure for starting the compressor.

4.4 SUBSEQUENT START-UP PROCEDURE

Procedure for starting the compressor after initial setup.

4.5 SHUTDOWN PROCEDURE

Procedure for safely shutting down the compressor.

Section 5 MAINTENANCE

5.1 GENERAL

General information and recommendations for a maintenance program.

5.2 DAILY OPERATION

Daily checks and observations before and during compressor operation.

5.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION

Specific maintenance tasks required after the first 50 hours.

5.4 MAINTENANCE EVERY 50 HOURS

Maintenance tasks to be performed every 50 hours of operation.

5.5 MAINTENANCE EVERY 100 HOURS

Maintenance tasks to be performed every 100 hours of operation.

5.6 MAINTENANCE EVERY 200 HOURS

Maintenance tasks to be performed every 200 hours of operation.

5.7 MAINTENANCE EVERY 250 HOURS

Maintenance tasks to be performed every 250 hours of operation.

5.8 MAINTENANCE EVERY 500 HOURS

Maintenance tasks to be performed every 500 hours of operation.

5.9 MAINTENANCE ANNUALLY OR EVERY 1500 HOURS

Annual or 1500-hour maintenance tasks.

5.10 MAINTENANCE EVERY YEAR OR 12,000 MILES

Yearly or 12,000-mile maintenance tasks.

5.11 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES

Procedures for replacing parts and making adjustments.

5.12 TROUBLESHOOTING INTRODUCTION

Introduction to the troubleshooting guide and its methodology.

5.13 TROUBLESHOOTING GUIDE

A guide to diagnosing and resolving common compressor problems.

Section 6 NOISE CONTROL

6.1 NOISE EMISSIONS WARRANTY

Details about the warranty related to noise emissions.

6.2 TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED

Legal prohibition against tampering with noise control components.

6.3 NOISE EMISSIONS MAINTENANCE AND MAINTENANCE RECORD LOG

Procedures for maintaining noise control and logging maintenance.

Section 7 ILLUSTRATIONS AND PARTS

7.1 PROCEDURE FOR ORDERING PARTS

Instructions on how to order replacement parts.

7.2 SPARE PARTS LIST

A comprehensive list of common spare parts with order numbers.

7.3A ENGINE, COMPRESSOR AND PARTS - PERKINS AND CATERPILLAR MODELS 125, 130 AND 185

Illustrated parts breakdown for Perkins/Caterpillar engines and compressor.

7.3B ENGINE, COMPRESSOR AND PARTS - JOHN DEERE MODELS 125, 130, 185 & 49HP

Illustrated parts breakdown for John Deere engines and compressor.

7.3C ENGINE, COMPRESSOR AND PARTS - JOHN DEERE MODEL 160H

Illustrated parts breakdown for John Deere 160H engine and compressor.

7.4A AIR INLET AND EXHAUST - PERKINS AND CATERPILLAR MODELS 125, 130 & 185

Illustrated parts for air inlet and exhaust systems.

7.4B AIR INLET AND EXHAUST - JOHN DEERE MODELS 125, 130, 185, 49HP & 160H

Illustrated parts for John Deere air inlet and exhaust systems.

7.5 RADIATOR AND COMPRESSOR FLUID COOLING SYSTEM - ALL MODELS

Illustrated parts for the radiator and cooling system.

7.6 FRAME, RUNNING GEAR AND PARTS - ALL MODELS

Illustrated parts for the frame, running gear, and chassis.

7.7A DISCHARGE SYSTEM AND PARTS - ALL MODELS EXCEPT JOHN DEERE 160H

Illustrated parts for the discharge system (excluding JD 160H).

7.7B DISCHARGE SYSTEM AND PARTS - JOHN DEERE MODEL 160H

Illustrated parts for the discharge system of the JD 160H model.

7.8A REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY - ALL MODELS EXCEPT JOHN DEERE 160H

Illustrated parts for regulator/blowdown valve assembly.

7.8B REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY - JOHN DEERE MODEL 160H

Illustrated parts for JD 160H regulator/blowdown valve assembly.

7.9 ELECTRICAL PARTS - ALL MODELS

Illustrated parts list for the electrical system.

7.10 FUEL TANK AND PARTS - ALL MODELS

Illustrated parts for the fuel tank and related components.

7.11 CANOPY, ACOUSTICAL PANELS AND PARTS - ALL MODELS

Illustrated parts for the canopy and acoustical panels.

7.12 INSTRUMENT PANEL, PANEL DOOR AND MOUNTING PARTS - ALL MODELS

Illustrated parts for the instrument panel, door, and mounting hardware.

7.13A INSTRUMENT PANEL AND PARTS - JOHN DEERE / CATERPILLAR / PERKINS MODELS 125, 130, 185, 49HP (STANDARD GAUGE)

Illustrated parts for instrument panels (standard gauge).

7.13B INSTRUMENT PANEL AND PARTS - JOHN DEERE MODEL 160H (STANDARD GAUGE)

Illustrated parts for JD 160H instrument panel (standard gauge).

7.13C INSTRUMENT PANEL AND PARTS - CATERPILLAR AND PERKINS (AUSTRALIAN) MODELS 130-185

Illustrated parts for Australian models instrument panel.

7.13D INSTRUMENT PANEL & PARTS - JOHN DEERE / CATERPILLAR / PERKINS MODELS 125, 130, 185, 49HP (FULL GAUGE)

Illustrated parts for instrument panels (full gauge).

7.13E INSTRUMENT PANEL & PARTS - JOHN DEERE MODEL 160H (FULL GAUGE)

Illustrated parts for JD 160H instrument panel (full gauge).

7.14 SINGLE HOSE REEL OPTION - ALL MODELS

Illustrated parts for the single hose reel option.

7.15 DUAL HOSE REEL OPTION - ALL MODELS

Illustrated parts for the dual hose reel option.

7.16A ONE PINT OILER OPTION - ALL MODELS

Illustrated parts for the one-pint oiler option.

7.16B ONE QUART OILER / MOISTURE SEPARATOR OPTIONS - ALL MODELS

Illustrated parts for oiler and moisture separator options.

7.17 DECALS

Illustrations and list of various decals used on the compressor.

7.18 DECAL LOCATIONS - ALL MODELS

Diagrams showing the placement of decals on the compressor.

7.19 CANADIAN TAIL / CLEARANCE LIGHTS - ALL MODELS

Illustrated parts for Canadian tail and clearance lights.

7.20 DRAWBAR INSTALLATION - STANDARD

Instructions and illustration for drawbar installation.