PARTS LIST MANUAL REMANUFACTURED PORTABLE AIR COMPRESSOR [A] AFTERCOOLED MODELS [F] FILTERED MODELS CATERPILLAR TIER R00

Transcription

1 PARTS LIST MANUAL REMANUFACTURED PORTABLE AIR COMPRESSOR 1600H[A][F] [A] AFTERCOOLED MODELS [F] FILTERED MODELS CATERPILLAR TIER 3 WARRANTY NOTICE Failure to follow the instructions and procedures in this manual or, misuse of this equipment will VOID its warranty! PART NUMBER: R00 KEEP FOR FUTURE REFERENCE COPYRIGHT 2013 SULLAIR The information in this manual is current as of its publication date, and applies to: From remanufacture date June 2013 through present This manual only applies to remanufactured machines.

2 The Sullair Certified Remanufacturing Program Thank you for your choice to invest in a quality remanufactured Sullair portable air compressor. Sullair Certified REMAN is a factory authorized remanufacturing program for Sullair 1600H AF portable air compressors, featuring genuine OEM parts, and product testing that meets the same high standards as new Sullair portable air compressors. Sullair Certified REMAN begins with a Sullair used air compressor core that is fully disassembled. Components are then inspected, cleaned, serviced or replaced. As the REMAN air compressor is assembled, all parts must meet the same specifications as new. The Difference Between Remanufactured and Rebuilt The Sullair REMAN Program is not a repair, refurbish, rebuild or overhaul program where parts and components are changed only when broken or unusable and may not meet the OEM performance and quality standards. Sullair remanufactured parts must meet the same tolerances and specifications as brand new genuine Sullair parts. A Sullair Certified REMAN compressor will perform like new, meeting the tough application demands you expect from a reliable Sullair portable air compressor. Your REMAN Compressor Your fully remanufactured compressor has been disassembled down to its core components, which are completely cleaned by using the best alternative cleaning methods identified for each component. All items then receive detailed inspections to establish the criteria for either the replenishment of existing parts or replacement with new genuine Sullair parts. The remanufacturing assembly process brings the compressor back together to original technical specifications. The entire remanufactured product is then tested and inspected on multiple points to the precise technical specifications expected of a Sullair air compressor.

3 How to identify your remanufactured machine: In order to properly maintain or service your remanufactured compressor, you will need to specify your particular model when contacting Sullair Service. For support services, you will need to supply two identifiers for your compressor - your Serial Number and the Bill of Materials (BOM). This information can be found on the machine s nameplate. The table below indicates which type of machine you have based on the BOM number identification. BOM Number* , , Tier 3 SAE Tier 3 SAE w/cold wthr pkg Nameplate: See Figure 1-1 for the nameplate s location on the compressor.

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5 TABLE OF CONTENTS PAGE SECTION DESCRIPTION PAGE SECTION DESCRIPTION PROCEDURE FOR ORDERING PARTS RECOMMENDED SPARE PARTS FRAME ASSEMBLY WITH ELECTRIC BRAKES ENGINE & COMPRESSOR INLET VALVE INLET VALVE SUBASSEMBLY AIR INLET SA - TRANSDUCER MOUNTING PLATE EXHAUST SYSTEM AFTERCOOLED & FILTERED COOLING SYSTEM AFTERCOOLED LOUVERS DISCHARGE SYSTEM - AFTERCOOLED WATER TRAP - AFTERCOOLED FIL- TERED RECEIVER TANK - AFTERCOOLED FILTER CHECK ORIFICE OIL FILL FUEL SYSTEM WITH FUEL COOLER ELECTRICAL PARTS BATTERY QUICK DISCONNECT ELECTRICAL & AIR PARTS ASSEMBLY INSTRUMENT PANEL CONTROLLER - DUAL PRESSURE MANIFOLD - DUAL PRESSURE CONTROL LINES CANOPY AFTERCOOLED ACOUSTICAL PANELS AFTERCOOLED DECAL LOCATIONS, DTQ BLOCK HEATER

6 TABLE OF CONTENTS (Continued) PAGE SECTION DESCRIPTION PAGE SECTION DESCRIPTION

7 Parts List 1.1 PROCEDURE FOR ORDERING PARTS. Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the address, phone numbers or fax numbers below. When ordering parts always indicate the Serial Number of the compressor. This can be obtained from the Bill of Lading for the compressor or from the Serial Number Plate located on the compressor. See Figure 1-1: Serial Plate/Serial Number Location. The genuine Sullair service parts listed meet or exceed the demands of this compressor. Use of replacement parts other than those approved by Sullair may lead to hazardous conditions over which Sullair has no control. Such conditions include, but are not limited to, bodily injury and compressor failure. Figure 1-1: Serial Plate/ Serial Number Location SULLAIR 3700 East Michigan Boulevard Michigan City, Indiana, U.S.A. Telephone: R(HAF) R00 7

8 1.2 RECOMMENDED SPARE PARTS KEY PART NO. QTY DESCRIPTION NOTES ELEMENTS ELEMENT, PRIMARY FOR AIR FILTER NO ELEMENT, SECONDARY FOR AIR FILTER NO ELEMENT, REPLACEMENT FILTER FOR SEPARATOR TANK ELEMENT, FLUID FILTER KITS KIT, THERMOSTAT REPLACEMENT KIT, INLET VALVE REPAIR KIT WITH SPRINGINGS KIT, INLET VALVE REPAIR KIT WITHOUT SPRINGINGS KIT, SHAFT SEAL REPAIR MANIFOLD REBUILD KIT - DUAL PRESSURE MANIFOLD REBUILD KIT - SINGLE PRESSURE RECIRCULATION SOLENOID REPAIR KIT RUN/START SOLENOID REPAIR KIT HI/LO SOLENOID REPAIR KIT MODULE, AIR FILTER MONITORING MODULE, AIR FILTER MONITORING KIT, MINIMUM PRESSURE CHECK VALVE REPAIR NO. MISCELLANEOUS SWITCH, REPLACEMENT HIGH TEMPERATURE SHUTDOWN 250 F CONTROL RELAY CONTROL BREAKER 50A FRAME DRAIN HOLE PLUG SENSOR, PRESSURE 225 PSIG 1-5V DC SENSOR, AMBIENT TEMPERATURE SENSOR, DISCHARGE TEMPERATURE SENSOR, ENGINE COOLANT LEVEL 1600R(HAF) R00 8

9 1.2 RECOMMENDED SPARE PARTS KEY PART NO. QTY DESCRIPTION NOTES SENSOR, FUEL LEVEL LUBRICATION LUBRICANT, AWF FLUID LUBRICANT, AWF FLUID ENGINE OIL FILTER FUEL FILTER (PRIMARY) FUEL FILTER (SECONDARY) 1600R(HAF) R00 9

10 1.3 FRAME ASSEMBLY WITH ELECTRIC BRAKES R09 S1 1600R(HAF) R00 10

11 1.3 FRAME ASSEMBLY WITH ELECTRIC BRAKES R09 S2 1600R(HAF) R00 11

12 1.3 FRAME ASSEMBLY WITH ELECTRIC BRAKES R09 S3 1600R(HAF) R00 12

13 1.3 FRAME ASSEMBLY WITH ELECTRIC BRAKES KEY PART NO. QTY DESCRIPTION NOTES SUPPORT, FRAME SKIRT FRT 900XH SUPPORT, FRAME SKT REAR 900XH BAIL,LFT900/350 H AXLE, ELECTRIC BRAKE 77 TRCK X 62 S.C NUT, SHACKLE (DEXTER 6-7) BOLT, SHACKLE (DEXTER 7-17) CHAIN, ASSY 3/8 X 48 W/HOOK COUPLING LINK, SAFETY CHAIN CABLE, BRK 54 LG 600H TIRE, WHEEL ASSY 16.00* JACK, ASSY RECTR CHAIN, TETHER FRAME DRAIN PLUG FRAME,900XH-1900C FULL CONT DRWBR, (B) T PANEL, SKT SS FRT TRI 900XH PANEL, SKT SS TRI R 900XH PANEL, SKT CS TRI FRT 900XH PANEL, SKT CS TRI R 900XH PLUG, 2 X 1-3/16 SS/NITRILE EQUALIZER, RUNNING GEAR SWITCH, BREAKAWAY CABLE ACTUATED SUPPORT, BRACKET BATT BREAKAWAY COUPLING, CHAIN SAFETY BOLT, KEEPER (DEXTER ) NUT, KEEPER (DEXTER ) LEVER, HANDBRAKE PIN, YOKE EQUALIZER, 5 X 1-1/2 X 1/4 1600R(HAF) R00 13

14 1.3 FRAME ASSEMBLY WITH ELECTRIC BRAKES KEY PART NO. QTY DESCRIPTION NOTES YOKE, 5/16-24 THRD SPACER, LEVER ASSEMBLY ANGLE, HANGER ASSY MOUNTING CS ANGLE, HANGER ASSY MOUNTING SS ROD, THIRD 5/16-24 X 6 1/ SPACER, BREAK LEVER 250P EYE, LUNETTE 3 X 60,000# RIGID CLAMP, HOSE 9/16 ID CLAMP, HOSE 7/8 I.D NUT, HEX F PLTD 5/ NUT, HEX LOCKING 1/ NUT, HEX METRIC M6 X CAPSCREW, HEX GR5 3/8-16 X 2 1/ CAPSCREW, HEX GR5 1/2-13 X 3 1/ CAPSCREW, HEX GR5 3/4-10 X CAPSCREW, HEX GR5 3/4-10 X 2 1/ CAPSCREW, HEX GR5 1-8 X SCREW, SOC ISO 4762 M6 X 25MM SCREW, HEX SER WASHER 1/4-20 X SCREW, HEX SER WASHER 5/16-18 X 3/ SCREW, TC-HEX 1/4-20 X 1/ WASHER, SPRING LOCK REG PLTD 1/ WASHER, SPRING LOCK REG PLTD 3/ WASHER, SPRING LOCK REG PLTD WASHER, PL-B REG PLTD 1/ WASHER, PL-B REG PLATED 1/ WASHER, PL-B REG PLATED 3/ WASHER, SPRINGING LOCK-METRIC PLATED M6 1600R(HAF) R00 14

15 1.3 FRAME ASSEMBLY WITH ELECTRIC BRAKES KEY PART NO. QTY DESCRIPTION NOTES NUT, HX JAM RH PLATED 5/ GROMMET, RUBBER 7/8X5/8X1/ CAPSCREW, HEX GR5 5/16-18 X 3/4 ADH CAPSCREW, HX GR5 1/2-13 X 1/2 ADH CAPSCREW, HX GR5 1/2-13 X 1 1/2 PLT CAPSCREW, HEX GR5 5/8-11 X 3/4 ADH NOTES: A1: TORQUE BOLTS TO 483FT/LBS. A2: TORQUE BOLTS TO 201FT/LBS. A3: INCLUDED WITH REFERENCE SULLAIR FASTENER TORQUE SPEC PE R(HAF) R00 15

16 1.4 ENGINE & COMPRESSOR R13 S1 1600R(HAF) R00 16

17 1.4 ENGINE & COMPRESSOR R13 S2 1600R(HAF) R00 17

18 1.4 ENGINE & COMPRESSOR KEY PART NO. QTY DESCRIPTION NOTES SUPPORT, ENG/COMP Q ADAPTER, COMPRESSOR INLET 8 INL VALVE SA, 8 INLET VALVE HOSE, RAD LOWER CAT BUSHING, TAPER LOCK 4040 W/2.75 BORE COUPLING, DRIVE ACT / PANEL, HEAT SHIELD TUBE, RAD UPPER 900XH SENSOR, TEMP THERMISTOR BRASS HOSE, RAD DRAIN-TEE FTG FAN, DIA 10 BLD CAT T HOSE, 3/4 ENG OIL DRAIN SPCR, FAN.25 THK 1600C HOSE, 37FL 3/4-16 X LG FTG, HOSE 90DEG BULK HEAD ELB 1/ FTG, HOSE BULK HEAD TEE 1/2 37FL PANEL, ACOUSTIC 2.50 UNDER ENG CS PANEL, ACOUSTIC 2.50 UNDER ENG SS HOSE, RUB X.75 OD HOSE, RUB X.75 OD CLAMP, HOSE GASKET, 11 X 8 5/8 X 1/ CLAMP, HOSE 13/16 TO 1-1/ GASKET,.06 x 10.5ID x 13.25OD CLAMP, HOSE 1/ CONNECTOR, HOSE 5/16 HOSE X 1/4 NPT VALVE, BALL 1/2 NPT WASHER, SNUBBING 1 BOLT 1600R(HAF) R00 18

19 1.4 ENGINE & COMPRESSOR KEY PART NO. QTY DESCRIPTION NOTES ADAPTER, E&C SAE1 TO 20S ISOLATOR, VIBRATION 500 LB. CAPACITY SUPPORT, FRT ENG MNT 3408 DITA VALVE, DRAIN 1-1/8-12UNF NUT, THIN HEX 3/ WASHER,.500 HARDENED ADPT, SAE O RING 1/2FNPT X 1-1/16 SAE HOSE, RAD UPPER 2-1/2 X ADAPTER, FEMALE PIPE 1/2 X 1/ KEY, SQ CL1 5/8 X NUT, HEX LOCKING 3/ CAPSCREW, HEX GR8 1/2-13 X CAPSCREW, HEX GR5 1/2-13 X CAPSCREW, HEX GR5 5/8-11 X 1 3/ CAPSCREW, HEX GR5 3/4-10 X 1 1/ CAPSCREW, HEX GR5 3/4-10 X 2 1/ CAPSCREW, HEX GR5 1-8 X 5 1/ WASHER, SPRING LOCK REG PLTD 1/ WASHER, SPRING LOCK REG PLTD 5/ WASHER, SPRING LOCK REG PLTD 3/ WASHER, PL-B REG PLTD 3/ HOSE, FUEL LINE 5/16 (FT) CONN, 37 FL/MPT PLTD 1/2 X 1/ CONN, 37 FL/MPT PLTD 3/4 X 1/ ELBOW, 37FL 90M 1/4 X 1/ ELBOW, PIPE-90M 1/2 X 1/ BUSHING, RED PLTD 1/2 X 1/ CAPSCREW, FERRY HD PLTD 1/2-13 X 1 3/4 1600R(HAF) R00 19

20 1.4 ENGINE & COMPRESSOR KEY PART NO. QTY DESCRIPTION NOTES CAPSCREW, FERRY HD PLTD 7/8-9 X CONN, STR X JIC 1 1/16 X 3/ STUD, THIRD 3/4-10 X 3 PLT REF-CHART- ENG SEE_CHART_ UNIT 1 ENGINE, DIESEL C15 540HP 1 COMPRESSOR & PART, (SEE BOM) A1- ENGINE OIL DRAIN-TO BALL VALVE AT FRAME. A2- DISCHARGE TEMP SENSOR-TO COMPASS. A3- TO RECEIVER TANK SCAVENGE LINE. A4- USE EXISTING BOLTS ON ENGINE TO MOUNT HEAT SHIELD. A5- INSTRUMENT TAPER LOCK PER MANUFACTURER S INSTRUCTIONS PROVIDED WITH PART. A6- MAKE SURE THREADS ARE CLEAN AND FREE OF OIL APPLY LOCTITE 242 SULLAIR P/N TO THREADS OF BOLTS-TORQUE TO 77 FT-LBS. A7- MAKE SURE THREADS ARE CLEAN AND FREE OF OIL APPLY LOCTITE 242 SULLAIR P/N TO THREADS OF BOLTS-TORQUE TO 54 FT-LBS. A8- TO FUEL TANK. A9- NOT USED IN LRC MODELS. 1. ENGINE USE COMPONENTS: BELT,V FAN SET 4N8220 C15/C PUL,FAN DRVN 0.8 RATIO C15 ONLY USED IN: EPA AND EU. EXPLODED VIEW NOTES: NOTES: 1600R(HAF) R00 20

21 1.4 ENGINE & COMPRESSOR COMPRESSOR SIZE SPECIFIC PARTS MACHINE SIZE ENGINE UNIT FAN 1600H R SAE H R R(HAF) R00 21

22 1.5 INLET VALVE R R(HAF) R00 22

23 1.5 INLET VALVE KEY PART NO. QTY DESCRIPTION NOTES HOUSING, BODY 8 INLET VALVE COVER, ASSEMBLY 8 INLET VALVE PLATE, FLOW CONTROL 8 INLET VALVE COVER, INTER 8 INLET VALVE PISTON, 8 INLET VALVE SPRINGING, COMP. 144 LBS INTER SHAFT, 8 INLET VALVE SPRINGING, COMP. 109 LBS OUTER SPRINGING, COMP LBS CAPSCREW, HX GR5 1/4-20 X 3/ WASHER, SPRINGLOCK REG PLTD 1/ O-RING, VITON 4 5/8 x 1/ O-RING, VITON 1 x 1/ SCREW, FERRY HD, 3/8-16 x 1 3/4 LG PLUG, PIPE 1/4 3000# STL PLT ORIFICE,.093 x.125m x.125f NOTES: 1. SEAL WITH SULLAIR GASKET COMPOUND #5910 COLOR CODE: PURPLE. 2. TORQUE GRADE 5 BOLTS PER SULLAIR SPEC (A00-P-8) CONDITION B. BOLT SIZE TORQUE 1/ FT-LBS. 3/ FT-LBS. 1/ FT-LBS. 5/ FT-LBS. 3/ FT LBS. 3. APPLY ANTI-SEIZE. 4. LOCK WITH SULLAIR ADHESIVE #5910, COLOR CODE: PURPLE. 1600R(HAF) R00 23

24 1.6 INLET VALVE SUBASSEMBLY R R(HAF) R00 24

25 1.6 INLET VALVE SUBASSEMBLY KEY PART NO. QTY DESCRIPTION NOTES SA, 8 INLET VALVE HOSE, MP 5/16 X 12 LG 37 DEG ST ORF, FNPT X.25 MNPT VLV, BLWDN N.C. 8:1 RATIO HOSE, ASSY 7/16-20 X 15 LG CLP, HOSE 9/16 MED DUTY/GALV PLUG, OIL FILLER 8 VLV 5/16 37 FL VALVE, INLINE CHECK(1/4 NPT)DC ORIFICE, M X.50M NUT, CAP 37F X WASHER,.500 HARDENED SCREW, HEX SER WASHER 1/2-13 X 3/ ELBOW, 37FL 45M 5/16 X 1/ ELBOW, 37FL 45M 1/2 X 1/ CONN, 37 FL/MPT PLTD 1/4 X 1/ ELBOW, 37FL 90M 1/4 X 1/ ELBOW, 37FL 90M 1/2 X 1/ TEE, 37FL M BR 1/4 X 1/ TEE, 37FL M RN 1/4 X 1/ NIPPLE, PIPE-XS PLT 1/2 X ELBOW, PIPE 90 DEG 300# PLT 1/ TEE, PIPE PLTD 1/ NIPPLE, PIPE-HX PLTD 1/4 X 1/ BUSHING, RED HEX PLTD 1/2 X 1/4 EXPLODED VIEW NOTES A1: BLOWDOWN VALVE FLOW DIRECTION A2: CHECK VALVE FLOW DIRECTION Q1: SEE ASSY DRAWING R(HAF) R00 25

26 1.7 AIR INLET R R(HAF) R00 26

27 1.7 AIR INLET KEY PART NO. QTY DESCRIPTION NOTES SEAL, DOOR EXTRUDED SPONGE (FT) FILTER, AIR 18 DIA 1600 CFM BAFFLE, AIR INLET 18 FILTER FILTER, AIR 18 DIA 6 OUTLET 1600 CFM TUBE, NYLON.25 OD X.04W BLACK (FT) CLAMP, T-BOLT SS BAND 4.50 ID ELBOW, CHRG AIR CLR 4 ID X 45 DEG HOSE, HUMP CHRG AIR 4 ID X 6 LG WEATHERSTRIP, GASKET TRIM-LOC (FT) TUBE, ALUM STL 4 OD 90 BEADED IND, SWITCH FLR ELEM CMACS RIGHT IND, SWITCH FLR ELEM CMACS LEFT TUBE, ALUM STL 4 BEADED SS II SA, XDCR MOUNT PLATE 1600C LP TUBE, ALUM AIR INLET 6 OD X 5 LG ELBOW, RUBBER 6 ID X 45 DEG ELBOW, RUBBER 6 ID X 90 DEG CLAMP, T-BOLT SS BAND 6.50 ID ELBOW, AIR INLET 90 RUBBER CLAMP, HOSE ELBOW, RUBBER 8 X 45 DEGREES DUCT, AIR INLET 8 X CLAMP, HOSE 6-9/16 TO 6-1/ WEATHERSTRIP, 3/16 X 3/8 FT ELBOW, 90D 1/4 TUBE X 1/8 FNPT TUBE, ALUM AIR INLET 6 OD X 11 1/2 LG SCREW, HEX SER WASHER 5/16-18 X 3/ NUT, RETAINER J 5/ NOTES: A1: TO CHARGE AIR COOLER. A2: FROM CHARGE AIR COOLER. 1600R(HAF) R00 27

28 1.8 SA - TRANSDUCER MOUNTING PLATE R R(HAF) R00 28

29 1.8 SA - TRANSDUCER MOUNTING PLATE KEY PART NO. QTY DESCRIPTION NOTES SENSOR, PRESS 225PSIG 1-5VDC BAFFLE, AIR INLET 18 FILTER PLT, TRANSDUCER MT 18 FILTER HARN, WIRING XDRC 1600C WEATHERSTRIP, RIBBED 3/16 X 3/8 (FT) NUT, HEX UNFIN # SCREW, HEX SER WASHER 1/4-20 X 1/ WASHER, SPRING LOCK # WASHER, PL-B REG PLTD # BULKHEAD, PIPE 1/8 NPT SCREW,PAN PHIL #6-32 X 3/4 NOTES: A1 P1 (DRY SIDE PRESSURE) A2 P2 (CONTROL) A3 P3 (WET SIDE PRESSURE) 1600R(HAF) R00 29

30 1.9 EXHAUST SYSTEM AFTERCOOLED & FILTERED R R(HAF) R00 30

31 1.9 EXHAUST SYSTEM AFTERCOOLED & FILTERED KEY PART NO. QTY DESCRIPTION NOTES BAFFLE, MUFFLER MOUNTING RAIN-CAP, EXHAUST 5.75 TO 6.35 DIA PIPE SIL, EXHAUST 22 5 IN 6 OUT MOUNT, MUFFLER 1200H AC TUBE, EXHAUST W/FLARE & SSTL FLEX 1600 INTERIM SUPPORT, MUFFLER 1600C AF CLAMP, SEAL NUT, HEX PLTD 5/ NUT, HEX PLTD 1/ CAPSCREW, HEX GR8 5/16-18 X 3/ CAPSCREW, HEX GR5 1/2-13 X 1 1/ WASHER, NORD-LOCK PL 5/16 SP WASHER, NORD-LOCK PL 1/2 SP EXPLODED NOTES A1: CLAMP PROVIDED WITH ENGINE REFERENCE SULLAIR P/N A2: REFERENCE SULLAIR P/N , SUPPORT,FILTER/WATER TRAP 1600C FROM SULLAIR P/N , DWG, ASSY FILTER/WATER TRAP 1600C 1600R(HAF) R00 31

32 1.10 COOLING SYSTEM AFTERCOOLED R07 S1 1600R(HAF) R00 32

33 1.10 COOLING SYSTEM AFTERCOOLED R07 S2 1600R(HAF) R00 33

34 1.10 COOLING SYSTEM AFTERCOOLED KEY PART NO. QTY DESCRIPTION NOTES HOSE, MED PRESS 2 X X HOSE, MED PRESS 2 X X HOSE, MED PRESS 2 X X HOSE, MED PRESS 2 X X BAFFLE, CANOPY SS 1200 ACF BAFFLE, CANOPY CS 1200 ACF PLT, HOSE BAFFLE HALF 2-1/ HOSE, MP 2.50 X 129 LG CHANNEL, EXT RUB U 3/32 (FT) VENTURI, SPECIAL FLG, KIT SAE SPLT 2 - VITON CNTNR, RAD FLUID RECOVERY 5QT SUPPORT, BRACKET OIL FILTER FILTER, OIL ASSY PARKER SUPPORT, CLR OIL/AIR 1600H COOLER, AIR CAT 3406E TIER II COOLER, OIL CA 3406 TIER II 1600H SUPPORT, HOSE AFTCLR BAFFLE, RADIATOR CS 900XH AC BAFFLE, RADIATOR SS 900XH AC TRIM, CLIP-ON GRIP DUQ SENSOR, TEMP RTD 3/4 O-RING INSUL,O-CELL FOAM 2.00 THICK RAD, W/FRT DRN 900XH PIPE,2-1/2 SCH80 CLR SYS 1600C PLT, CVR STANDARD AIR 1600C GD, FAN 1600C CS GD, FAN 1600C SS GD, BELT/ALTERNATOR, 1600C CS GD, BELT 1600C SS 1600R(HAF) R00 34

35 1.10 COOLING SYSTEM AFTERCOOLED KEY PART NO. QTY DESCRIPTION NOTES ACOUSTIC PANEL, O-CELL FOAM 2.00 TNI HOSE, MP 200PSI 2 X38 0X90DEG CLAMP, HOSE 3/ HOSE, MED PRESS.25 X 30 LG GROMMET, RUBBER 1-3/4 HOLE ELBOW, 90DEG 2 SPLIT FLANGE VALVE, OIL STOP 2 SAE CODE WEATHERSTRIP, 1 THICK X 1 WIDE (FT) NUT, HEX PLTD 1/ NUT, HEX F PLTD 5/ NUT, HEX LOCKING 5/ NUT, HEX LOCKING 3/ CAPSCREW, HEX GR5 5/16-18 X CAPSCREW, HEX GR5 3/8-16 X CAPSCREW, HEX GR5 3/8-16 X 1 1/ CAPSCREW, HEX GR5 1/2-13 X 1 1/ CAPSCREW, HEX GR5 3/4-10 X 1 1/ SCREW, HEX SER WASHER 5/16-18 X 3/ SCREW, HEX SER WASHER 3/8-16 X SCREW, SELF-DRILL 1/4 X 3/ SCREW, SELF-DRILL 5/16 X WASHER, SPRING LOCK REG PLTD 5/ WASHER, SPRING LOCK REG PLTD 1/ WASHER, PL-B REG PLTD 1/ WASHER, PL-B REG PLTD 5/ WASHER, PL-B REG PLTD 3/ WASHER, PL-B REG PLTD 3/ HOSE, FUEL LINE 3/8 (FT) CLAMP, CONDUIT 2-1/ CONN, 37 FL/MPT PLTD 1/4 X 1/4 1600R(HAF) R00 35

36 1.10 COOLING SYSTEM AFTERCOOLED KEY PART NO. QTY DESCRIPTION NOTES CONN, 37 FL/MPT PLTD 2 1/2 X 2 1/ ELBOW, 37FL 90M 1/4 X 1/ NIPPLE, PIPE-XS PLT 2 1/2 X NIPPLE, PIPE-XS PLT 2 1/2 X NIPPLE, PIPE-XS PLT 2 1/2 X PLUG, PIPE 1/4 3000# STL PLT ELBOW, PIPE 90 DEG 300# PLT 2 1/ BUSHING, RED PLTD 3/8 X 1/ BUSHING, RED PLTD 2 1/2 X 1/ CAPSCREW, FERRY HD PLTD 5/16-18 X TEE, PIPE PLTD 2 1/ ADAPTOR, MALE PIPE 1/2 X 3/ TABLE 1 CLR,AIR AC 1200CFM 150PSIG EXPLODED VIEW NOTES A1: P/N: USED ON 1300H ONLY. A2: P/N S: & MOUNTED TO LIFTING BAIL. A3: P/N: MOUNTED TO FRAME. A4: SEE SHEET 2 FOR PLACEMENT OF P/N: A5: DETAIL OF VENTURI MOUNTING. A6: ONE OF TWO 1 DOWELS WELDED TO FRAME. A7: MOUNTING PLATE WELDED TO BOTTOM OF COOLER A8: SECTION VIEW SHOWING LOCATION OF COOLER & FRAME MOUNT. A9: DIRECT THIS END OF HOSE INTO CONTAINMENT FRAME. A10: AFTER-COOLED DISCHARGE A11: TO PRESSURE PICK UP FOR OIL STOP VALVE. A12: ENGINE COOLANT SENSOR A13: SUB-ASSEMBLY USED ON LOUVERED BILLS ONLY. A14: P/N NOT TO BE USED ON 1300H 1600R(HAF) R00 36

37 1.10 COOLING SYSTEM AFTERCOOLED AFTER-COOLER COOLER, AFTER 1600C(H) R(HAF) R00 37

38 1.11 Louvers R R(HAF) R00 38

39 1.11 Louvers KEY PART NO. QTY DESCRIPTION NOTES ELBOW, 90 3/8 TUBE X 1/4 NPT M TUBE, NYL 3/8 O.D. X.063W ORF, FNPT X.25MNPT CLP, HOSE 3/8 OD CONN, 3/8 TUBE X 1/4NPT SUPPORT, ANGLE FRAMED AMB TEMP SENDOR SOL, VALVE 24V NC 2WAY HEATER, COLD WEATHER 1600C SUPPORT, BRACKET 1600C LOUVERS CLAMP, HOSE 7/8 I.D TEE, TUBE-M BR 3/8 X 1/ SCREW, HEX SER WASHER 5/16-18 X 3/ WASHER, PL-B REG PLTD 1/ NIPPLE, PIPE-XS PLT 1/4 X 1 1/ TEE, PIPE PLTD 1/ GROMMET, RUBBER 7/16X11/16X16GA EXPLODED VIEW NOTES: A1: DAMPER IN OPENED POSITION A2: CONNECT TO WIRE HARNESS PLUG LABELED LOUVER SOLENOID A3: TO SOLENOID VALVE 1600R(HAF) R00 39

40 1.12 DISCHARGE SYSTEM - AFTERCOOLED R R(HAF) R00 40

41 1.12 DISCHARGE SYSTEM - AFTERCOOLED KEY PART NO. QTY DESCRIPTION NOTES ANGLE, DISCHARGE PIPE SUPPORT FLANGE, SPLIT 4 SAE J HOSE, ASSY 4 DISCHARGE PIPE, DISCH. SERVICE 3 (23.5) HOSE, 3/4 NPT X 3/4 FSN37 57 LG VALVE, BALL 1/2 NPT MOUNT, VIBRATION (50 DUROMETER) MOUNT, VIBRATION ISOLATOR 185Q GASKET, ASA FLG 150# GASKET, DISCH PIPE 1250/ VALVE, SERVICE 3 BALL WASHER,.625 HARDENED NUT, HEX LOCKING 5/ CAPSCREW, HEX GR8 5/8-11 X 3 1/ CAPSCREW, HEX GR5 5/8-11 X 3 1/ WASHER, SPRING LOCK REG PLTD 1/ WASHER, SPRING LOCK REG PLTD 5/ WASHER, PL-B REG PLTD 1/ WASHER, PL-B REG PLTD 5/ CONN, 37 FL/MPT PLTD 3/4 X 1/ ELBOW, PIPE-90M 1/2 X 1/ CAPSCREW, FERRY HD PLTD 5/8-11 X 1 3/ U-BOLT, 1/2 X 3 PIPE PLTD REF SEE CHART REF-CHART- REC 1 SA,H2O TRAP 1600C LP 1 SA,REC 1600C LP-AC CMPS 1600R(HAF) R00 41

42 1.12 DISCHARGE SYSTEM - AFTERCOOLED KEY PART NO. QTY DESCRIPTION NOTES A1 A2 A3 A4 A5 A6 A7 EXPLODED VIEW NOTES: TO AIR PRESSURE CONTROL LINE-TO COMPASS CONTROLLER FURNISHED WITH U-BOLT TO P3 AT COMPASS CONTROLLER (WET) TO P1 AT COMPASS CONTROLLER (DRY) RTT (RECEIVER TANK TEMPERATURE) TO COMPASS CONTROLLER TO AFTERCOOLER INLET TO GREEN HOSE ON HOSE BUNDLE Module Description SA, REC 1600C SA, H20 LP Sub-Assembly 1600C LP M, Disch 1600C LP AF R(HAF) R00 42

43 Notes 1600R(HAF) R00 43

44 1.13 WATER TRAP - AFTERCOOLED FILTERED R01S1 1600R(HAF) R00 44

45 1.13 WATER TRAP - AFTERCOOLED FILTERED R01S2 1600R(HAF) R00 45

46 1.13 WATER TRAP - AFTERCOOLED FILTERED KEY PART NO. QTY DESCRIPTION NOTES ADAPTER,1/2NPT FEM X 1/2BSP MALE INSERT, NYLON TUBING 1/4 OD ANGLE, DISCHARGE PIPE SUPPORT SUPPORT, H20 TRAP 1200 ACF HOSE, MP 2.50 X 42 LG HOSE, MP 5/16 X 54 LG 37$s JIC CONN, 5/16 TUBE X 1/4 NPT TUBE, 5/16 OD X.040 WALL FLG, 3 SAE J518 CODE SUPPORT, FILTER MOUNT 1200 AC ORF, FNPT X.25 MNPT VLV, BLWDN N.C. 8:1 RATIO SCF-1315N 3 NPT W/AUTO DRAINS SCH-1315N 3 NPT W/AUTO DRAINS KIT,SC HEAD CLAMP SEP, WTR TRAP FLOAT 600PSIG SUPPORT, WATER TRAP 600PSI SEP, WTR SCWS-1700N 3 L/AD PIPE,3 FLR INLET H PIPE ASSY, DISCH C SUPPORT, FILTER/WATER TRAP ASY 1600C HOSE, 3/4 NPT X 3/4 FSN37 57 LG ADPT, TUBE 3 ASSY W/4-BOLT FLNG SHIM, FLR ASY BRACKET 1600C SWITCH, DIFF PRESS 750B/1600C AF HARN, WRG 1600C FILTERED TUBE,1/4 OD SS 1600C AF FLTRS TUBE,1/4 OD SS 1600C AF FLTRS 1600R(HAF) R00 46

47 1.13 WATER TRAP - AFTERCOOLED FILTERED KEY PART NO. QTY DESCRIPTION NOTES SPCR, AF 1600C 1.25OD X 1.00LG SUPPORT, BRACKET 1600C PRESS DIFF SW HOSE, MOISTURE TRAP TO TEE 1/2 ID X 20 OAL HOSE, POPPET VALVE TO TEE1/2 ID X 13 OAL HOSE, TEE TO DRAIN 1/2 ID X 22 OAL HOSE, TEE TO TEE 1/2 ID X 40 OAL VALVE, INLINE CHECK(1/4 NPT)DC VALVE, SERVICE 3 BALL ELBOW, TUBE 90 DEG M 1/4 X 1/ NUT, HEX F PLTD 3/ CAPSCREW, HEX GR5 5/8-11 X 3 1/ CAPSCREW, HEX GR5 3/4-10 X 1 1/ SCREW, HEX SER WASHER 1/4-20 X 1/ SCREW, HEX SER WASHER 3/8-16 X 3/ SCREW, HEX SER WASHER 3/8-16 X 1 1/ WASHER, SPRING LOCK REG PLTD 5/ WASHER, PL-B REG PLTD 3/ CONN, 37 FL/MPT PLTD 5/16 X 1/ CONN, 37 FL/MPT PLTD 1/2 X 1/ CONN, 37 FL/MPT PLTD 2 1/2 X 2 1/ ELBOW, 37FL 90M 5/16 X 1/ ELBOW, PIPE 90M/F 1/2 X 1/ NIPPLE, PIPE-XS PLT 1/4 X CL NIPPLE, PIPE-XS PLT 3/4 X CL NIPPLE, PIPE-XS PLT 3 X NIPPLE, PIPE-XS PLT 3 X PLUG, PIPE 3/8 3000# STL PLT ELBOW, PIPE 90 DEG 300# PLT 1/4 1600R(HAF) R00 47

48 1.13 WATER TRAP - AFTERCOOLED FILTERED KEY PART NO. QTY DESCRIPTION NOTES ELBOW, PIPE 90 DEG 300# PLT 3/ ELBOW, PIPE 90 DEG 300# PLT BUSHING, RED PLTD 1/2 X 1/ BUSHING, RED PLTD 1 X 1/ BUSHING, RED PLTD 1 X 3/ BUSHING, RED PLTD 3 X 2 1/ U-BOLT, 1/2 X 3 PIPE PLTD TEE, PIPE PLTD 1/ TEE, PIPE PLTD 1/ NIPPLE, PIPE-HX PLTD 1/4 X 1/ BUSHING, RED HEX PLTD 1/2 X 1/ ELBOW, PIPE 45 DEG 300# PLT TEE, 37FL UNION 1/ UNION, PIPE-BRS SEAT 3 GAL 300# CONN, TUBE-M 1/4 X 1/4 SS EXPLODED VIEW NOTES: A1: TO AFTERCOOLER OUTLET A2: THIS END TO COMPASS AUX CONNECTION A3: 1 CONNECTION TO EACH PRESSURE SENSOR BEFORE & AFTER FILTERS A4: SCREWS INCLUDED WITH KIT 1600R(HAF) R00 48

49 Notes 1600R(HAF) R00 49

50 1.14 RECEIVER TANK - AFTERCOOLED R R(HAF) R00 50

51 1.14 RECEIVER TANK - AFTERCOOLED KEY PART NO. QTY DESCRIPTION NOTES SA, RECEIVER OIL FILL CONN, TUBE OIL RETURN 5/16X1/ PIPE, DISCH REC TANK 1300H SW, HTM 250 DEG F 3/4-16 SAE ADPT, MALE PIPE 1/2 X 3/ SA, LOW-PRESS FLTR/CHECK/ORF VALVE, RELIEF 1-1/ STRAINER, Y-LINE 3/ VALVE, MIN PRESSURE CHK TUBE, OIL RETURN 1200/1600 CFM VALVE, ASM-THRM/BYP 2 (170DEG) ELEMENT, OIL SEP 1200/1600 CFM O-RING, VITON 2 1/4 X 1/ WASHER, SPRING LOCK REG PLTD 1/ CONN, 37 FL/MPT PLTD 1/2 X 3/ CONN, 37 FL/MPT PLTD 3/4 X 3/ CONN, 37 FL/MPT PLTD 2 1/2 X 2 1/ NIPPLE, PIPE-XS PLT 3/4 X NIPPLE, PIPE-XS PLT 3/4 X NIPPLE, PIPE-XS PLT 1 1/2 X CL NIPPLE, PIPE-XS PLT 2 1/2 X CL NIPPLE, PIPE-XS PLT 3 X CL NIPPLE, PIPE-XS PLT 3 X PLUG, PIPE 1/4 3000# STL PLT PLUG, PIPE 1/2 3000# STL PLT BUSHING, RED PLTD 1/4 X 1/ BUSHING, RED PLTD 3/4 X 1/ BUSHING, RED PLTD 3 X 2 1/2 1600R(HAF) R00 51

52 1.14 RECEIVER TANK - AFTERCOOLED KEY PART NO. QTY DESCRIPTION NOTES CAPSCREW, FERRY HD PLTD 1/2-13 X 2 1/ TEE, PIPE PLTD 3/ TEE, PIPE PLTD ELBOW, PIPE 45 DEG 300# PLT 2 1/2 33 TABLE 1 TANK, OIL SEPARATOR 28 O.D. EXPLODED VIEW NOTES: A1 TO DISCHARGE PIPE A2 TO SCAVENGE LINE-TO AIR END A3 TO P3 AT COMPASS CONTROLLER (WET) A4 TO AFTERCOOLER INLET A5 TO AIR PRESSURE CONTROL LINE-TO COMPASS CONTROLLER A6 TO P1 AT COMPASS CONTROLLER (DRY) A7 TO AIR END DISCHARGE HOSE A8 RTT (RECEIVER TANK TEMPERATURE) TO COMPASS CONTROLLER A9 TO AIR CONTROL MANIFOLD BLOCK A10 RELIEF VALVE OUTLET TO BE ROTATED TOWARDS CANOPY WALL AS SHOWN 1600R(HAF) R00 52

53 Notes 1600R(HAF) R00 53

54 1.15 FILTER CHECK ORIFICE R R(HAF) R00 54

55 1.15 FILTER CHECK ORIFICE KEY PART NO. QTY DESCRIPTION NOTES ELBOW, TUBE 90 DEG M 5/16 X 1/ VALVE, INLINE CHECK(1/4 NPT)DC NIPPLE, PIPE-HX PLTD 1/4 X 1/ CONN, 37FL SW F 1/4 X 1/ CONN, STR X JIC 7/16 X 7/ FILTER, ASSEMBLY SCREEN FILTER SIGHTGLASS, ORF BLOCK SAE ORF, PLUG BRASS 1/8 NPT x 3/ ELBOW, 37FL 90M 1/4 X 1/4 1600R(HAF) R00 55

56 1.16 OIL FILL R R(HAF) R00 56

57 1.16 OIL FILL KEY PART NO. QTY DESCRIPTION NOTES ADPT, RECEIVER OIL FILL 185DPQ GL, SIGHT OIL LEVEL 1-1/2 PLTD PLUG, O-RING BOSS SAE 1 1/ TEE, PIPE PLTD 1 1/2 1600R(HAF) R00 57

58 1.17 FUEL SYSTEM WITH FUEL COOLER R02 S1 1600R(HAF) R00 58

59 1.17 FUEL SYSTEM WITH FUEL COOLER R02 S2 1600R(HAF) R00 59

60 1.17 FUEL SYSTEM WITH FUEL COOLER KEY PART NO. QTY DESCRIPTION NOTES TUBE, ASSY FUEL PICK-UP 1600Q STRIP, WEATHER 1 X 1/8 FOAM (FT) GROMMET, RUB MTG 35 LBS VALVE, CHECK FUEL 1/2 NPT VLV,THRM BYPASS 3/4 -NPT DE HOSE, FUEL RTRN SWV/SWV 3/8* COOLER, OIL ES-6 FUEL DE SENDER, FUEL LEVEL AID, STARTING ELEC 24V C PANEL,FBRGLS FRONT TANK 1600 INTERIM SUPPORT,BAFFLES OVER FUEL TNK 1600 INTERIM DESIGN STRAP,FUEL TANK SUPPORT 1600 INTERIM HOSE,FUEL 1/2 X 98 X FEM SWIV STRAP, INSUL FUEL TANK 1600C FLTR,FUEL TANK VENT 1/2NPT HOSE,MP 5/16 ID X 18 OAL TNK,FUEL 1600C 190 GAL SUPPORT,BRACKET FUEL COOLER RH SUPPORT,BRACKET FUEL COOLER LH SUPPORT,BRK AMOT VALVE 1600C SUPPORT,BRACKET FUEL HOSE SUPPORT,BRACKET FUEL HOSE HOSE,MP 5/16 ID X 24 OAL BAR,BAFFLE HOLD DOWN VALVE,BALL 1/2 NPT GASKET, FUEL GAUGE NEOPRENE CLAMP,TUBE 5/ CLAMP,TUBE 7/8 1600R(HAF) R00 60

61 1.17 FUEL SYSTEM WITH FUEL COOLER KEY PART NO. QTY DESCRIPTION NOTES CLAMP, TUBE RUBR CTD 1-3/8 DIA NUT, HEX F PLTD 1/ NUT, HEX F PLTD 5/ NUT, HEX LOCKING 3/ NUT, HEX LOCKING 1/ CAPSCREW, HEX GR5 3/8-16 X SCREW, HEX SER WASHER 1/4-20 X 1/ SCREW, HEX SER WASHER 5/16-18 X 3/ SCREW, HEX SER WASHER 5/16-18 X WASHER, PL-B REG PLTD 1/ WASHER, PL-B REG PLTD 5/ WASHER, PL-B REG PLTD 3/ WASHER, PL-B REG PLTD 1/ ELBOW, 37FL 45M 3/8 X 1/ CONN, 37 FL/MPT PLTD 1/2 X 1/ ELBOW, 37FL 90M 3/8 X 1/ ELBOW, 37FL 90M 3/8 X 1/ TEE, 37FL M BR 3/8 X 1/ WASHER, FLT LG 8 X 30 BN WASHER, FLT LG 10 X 35 BN ELBOW, PIPE 90 DEG PLT 1/ NIPPLE, PIPE PLTD 1/2 X PLUG, PIPE 1/2 3000# STL PLT ELBOW, PIPE 90 DEG 300# PLT 1/ BUSHING, RED PLTD 3/4 X 1/ BUSHING, RED PLTD 1 1/2 X 3/ NIPPLE, PIPE-HX PLTD 1/2 X 1/ CONN, STR X JIC 9/16 X 3/4 1600R(HAF) R00 61

62 1.17 FUEL SYSTEM WITH FUEL COOLER KEY PART NO. QTY DESCRIPTION NOTES CONN, STR X JIC 7/8 X 9/ CONN, STR X JIC 3/4 X 9/ CONN, 90D STR X JIC 9/16 X 9/ ELBOW, 37 SW 90M 1/2 X 1/ NIPPLE, PIPE SS 300# 3/4 X CL NOTES: A1: FUEL RETURN A2: FUEL SUPPLY 1600R(HAF) R00 62

63 Notes 1600R(HAF) R00 63

64 1.18 ELECTRICAL PARTS R01 S1 1600R(HAF) R00 64

65 1.18 ELECTRICAL PARTS R01 S2 1600R(HAF) R00 65

66 1.18 ELECTRICAL PARTS R01 S3 1600R(HAF) R00 66

67 1.18 ELECTRICAL PARTS KEY PART NO. QTY DESCRIPTION NOTES SOL, SPNO 24VDC CONT-DUTY COVER, BATTERY RUBBER 900/ PLATE, BATTERY COVER 1300H GRIP,CD N X 1/ ROD, 3/8-16 X SUPPORT,BRACKET RELAY CONTACTOR DE WASHER, FLAT 5/16 X 11/16 SS BLACK ENCLOSURE, MANUAL-PAK SWITCH, E-STOP HD PUSH-PULL RED GASKET, E-STOP LARGE PORTABLE MACH ENCL, LARGE PORTABLE E-STOP PLATE, COVER LARGE PORTABLE E-STOP SUPPORT, PLATE ADAPTER MANUAL SA,BAT QUICK DISC 1600C FAM CABLE, BATTERY UNIVERSAL TERMINALS SUPPORT,BRACKET BATTERY 1600C SUPPORT,BRACKET BATTERY 1600C BATY, 8D/12 VOLT - WET SUPPORT,BRACKET BATTERY 1600C SUPPORT, BRACKET CIRCUIT BREAKER 750B SPCR, 1/2 HEX MALE-FEMALE HARN, BATY CABLE 1600C PANEL, COV SS BAFFLE 1600C HARNESS,MAIN 1600C LP T SA, CNTRL LINES 1600C LP ISOLATOR, VIBRATION 1 OD X 3/4 TALL CABLE, BATT 34 3/8-1/2 EYE (BLACK) CLAMP, HOSE 9/16 ID 1600R(HAF) R00 67

68 1.18 ELECTRICAL PARTS KEY PART NO. QTY DESCRIPTION NOTES CLAMP, HOSE 5/8 I.D CLAMP, HOSE 7/8 I.D NUT, WING PLTD 3/ NUT, HEX PLTD 3/ NUT, HEX F PLTD 1/ NUT, HEX F PLTD 5/ NUT, HEX F PLTD 3/ CAPSCREW, HEX GR5 5/8-11 X 1 3/ SCREW, HEX SER WASHER 1/4-20 X 1/ SCREW, HEX SER WASHER 1/4-20 X 3/ SCREW, HEX SER WASHER 5/16-18 X 1/ SCREW, HEX SER WASHER 5/16-18 X 3/ SCREW, HEX SER WASHER 3/8-16 X 3/ SCREW, HEX SER WASHER 3/8-16 X WASHER, SPRING LOCK REG PLTD 3/ WASHER, SPRING LOCK REG PLTD 5/ WASHER, PL-B REG PLTD 5/ WASHER, PL-B REG PLTD 3/ WASH, CHNL 1/2 ZINC PLTD CAPSCREW, SOC BTN HD M4 X 16MM SCREW, HEX SER WASHER #10-24 X 1/2 50 SEE_CHART_ CTL 1 ELECTRIC/AIR CONTROLLER SA, CNTRL / AIR MANF DUAL 1600C LP CONTROLS / AIR MANIFOLD 1600R(HAF) R00 68

69 Notes 1600R(HAF) R00 69

70 1.19 BATTERY QUICK DISCONNECT R R(HAF) R00 70

71 1.19 BATTERY QUICK DISCONNECT KEY PART NO. QTY DESCRIPTION NOTES SWITCH, BATTERY DISCONNECT 6-36V; 175 AMPS CONTINUOUS SUPPORT, RELAY & SWITCH LOCK, BATT DISCONNECT SWITCH COVER, ACCESS RELAY & SWITCH SUPPORT,BRACKET BAT DISC 1600C CABLE,BATY 2/0 36 L NUT, HEX F PLTD 1/ NUT, HEX F PLTD 5/ NUT, HEX LOCKING # SCREW, HEX SER WASHER 1/4-20 X 1/ SCREW, HEX SER WASHER 5/16-18 X 3/ SCREW, HEX SER WASHER 5/16-18 X SCREW,RND PHILLIPS X 1/ R06 s2 1600R(HAF) R00 71

72 1.20 ELECTRICAL & AIR PARTS ASSEMBLY R0 1600R(HAF) R00 72

73 1.20 ELECTRICAL & AIR PARTS ASSEMBLY KEY PART NO. QTY DESCRIPTION NOTES PLUG,PIPE-BRASS-1/8 -CAJON ENCL, COMP & MANIF BLK T SUPPORT, COMPASS ENCLOSURE 1600 T SUPPORT, ENCL COMPASS & MANF BLK WS, EPDM 65 SHORE/SPGE RUBBER BLACK SUPPORT, MANIFOLD 900HAF & 1600 T HOSE,MANF-BLW DN VLV SUPPLY HOSE,MANF-BLWDWNVLVDISCH HOSE,MANF-RECIRC VALVE HOSE,MANF-RUN/START HOSE,MANF-CTL SYS VENT HOSE, CONTROL SYS BOLT, SHOULDER 5/16-18 X FTG, HOSE BLKHD ELBOW 1/4 37 FLR DECAL, HOSE CTL LINE LOC-ENCL BSHG, OPEN/CLOSED PLUG, ELECT COMPASS AUX CONNECTOR HARNESS, MANIFOLD BLK 1600C LP CONNECTOR, HOSE 5/16 HOSE X 1/4 NPT CLAMP, HOSE 3/ GAUGE, CTL AIR PRESS PSI NUT, HEX F PLTD 5/ NUT, HEX F PLTD 3/ CAPSCREW, HEX GR5 3/8-16 X SCREW, HEX SER WASHER 5/16-18 X 1/ SCREW, HEX SER WASHER 5/16-18 X 3/ SCREW, HEX SER WASHER 3/8-16 X SCREW, HEX SER WASHER 3/8-16 X 1 1/4 1600R(HAF) R00 73

74 1.20 ELECTRICAL & AIR PARTS ASSEMBLY KEY PART NO. QTY DESCRIPTION NOTES WASHER, SPRING LOCK REG PLTD 3/ WASHER, PL-B REG PLTD 7/ HOSE, FUEL LINE 5/16 (FT) CONN, HOSE #10 X 1/ RIVET, POP 1/8 X 1/ UNION, 37FL BHD 1/ NUT, HEX LOCKING SS SCREW,PAN HD PH #4-40 X 1/2 SS HOSE, VITON 1/4OD X 1/8 ID SEE_CHART_C NTL SEE_CHART_ MANF 1 CONTROLLER, COMPASS L.P. 1 MANIFOLD, AIR CONTROLS L.P. A1: REAR VIEW. A2: WIRING HARNESS CONNECTOR. A3: USE ON OPEN FRAMES MACHINES ONLY. A4: MOUNT TO PEM NUTS IN A5: START/RUN A6: RECIRC A7: HI/LOW A8: WIRING HARNESS DETAILS. A9: DECAL LOCATION. EXPLODED/VIEW NOTES: 1600R(HAF) R00 74

75 1.20 ELECTRICAL & AIR PARTS ASSEMBLY CONTROLLER DUAL PRESSURE MODEL MANIFOLD DUAL PRESSURE MODEL 1600R(HAF) R00 75

76 1.21 INSTRUMENT PANEL R R(HAF) R00 76

77 1.21 INSTRUMENT PANEL KEY PART NO. QTY DESCRIPTION NOTES CONNECTOR, ELECTRICAL ECM MODULE CAP, RECEPTACLE ECM MODULE GASKET, ELECT. CONN. ECM MODULE GAUGE, PRESS PSI W/LCD ACTIA GAUGE, TEMP/TACH/FUEL ACTIA INSTRUMENT, WARNING BANK MOD CMACS GAUGE, PRESS PSI W/LCD ACTIA SWITCH, START-ON-OFF CMACS CONTROLS SWITCH, RESET CMACS CONTROLS SWITCH, HI/LO CMACS CONTROLS HEATER,24V W/MNTG PLT & THERMOSTAT CONN, DEUTSCH HDP PN CONN, DEUTSCH HDP PN PANEL, SUB ELECTRICAL CMACS CONTROLS DECAL, OVERLAY CMACS 14X14 ENCL RELAY,75VDC CMACS SOCKET, RELAY 18-20GA WIRE CMACS CB,50A AUTO RESTART CMACS CONTROLS GASKET, NEOPRENE CL CELL CMACS ENCLOSURE, COMPASS N4X SCREW, MACH-RD HD 1/4-20 X 1/ SCREW, PAN HD PH #4-40 X 1/2 SS NUT, HEX #4-40 SS 1600R(HAF) R00 77

78 1.22 CONTROLLER - DUAL PRESSURE R06 S1 1600R(HAF) R00 78

79 1.22 CONTROLLER - DUAL PRESSURE R06 S2 1600R(HAF) R00 79

80 1.22 CONTROLLER - DUAL PRESSURE KEY PART NO. QTY DESCRIPTION NOTES CONNECTOR, ELECTRICAL ECM MODULE CAP, RECEPTACLE ECM MODULE GASKET, ELECT. CONN. ECM MODULE GAUGE, TEMP/TACH/FUEL ACTIA INSTRUMENT, WARNING BANK MOD CMACS GAUGE, PRESS PSI W/LCD ACTIA SWITCH, START-ON-OFF CMACS CONTROLS SWITCH, RESET CMACS CONTROLS SWITCH, HI/LO CMACS CONTROLS HEATER,24V W/MNTG PLT & THERMOSTAT CONN, DEUTSCH HDP PN CONN, DEUTSCH HDP PN PANEL, SUB ELECTRICAL CMACS CONTROLS DECAL, OVERLAY CMACS 14X14 ENCL RELAY,75VDC CMACS SOCKET, RELAY 18-20GA WIRE CMACS CB,15A AUTO RESTART CMACS CONTROLS GASKET, NEOPRENE CL CELL CMACS ENCLOSURE, COMPASS N4X KEY, COMPASS REPLACEMENT SCREW, HEX SER WASHER 1/4-20 X 1/2 NOTES: 1. DESIGN PER SPEC REFER TO ID DRAWING FOR ASSEMBLY OF REPLACEMENT PARTS. 3. MARK/TAG CONTROLLER WITH SULLAIR P/N. NO VENDOR NAME ON ANY PARTS. 4. ACTIA P/N: R(HAF) R00 80

81 Notes 1600R(HAF) R00 81

82 1.23 MANIFOLD - DUAL PRESSURE R R(HAF) R00 82

83 1.23 MANIFOLD - DUAL PRESSURE KEY PART NO. QTY DESCRIPTION NOTES NUT, HEX PLTD 1/ NUT, HEX PLTD 5/ CAPSCREW, HEX GR5 1/4-20 X 1 1/ CAPSCREW, HEX GR5 5/16-18 X 1 3/ CONN, HOSE #10 X 1/ CONN, 37 FL/MPT PLTD 1/4 X 1/ CONN, 37 FL/MPT PLTD 1/2 X 1/ ELBOW, 37FL 90M 1/4 X 1/ ELBOW, 37FL 90M 1/4 X 1/ ELBOW, 37FL 90M 1/2 X 1/ ELBOW, 37FL 90M 3/4 X 3/ NIPPLE, PIPE-HEX 1/4 X 1/ TEE, PIPE 1/4 3000# PLT BUSHING, RED HEX PLTD 1/4 X 1/8 NOTES: 1) VENDOR TO SUPPLY ALL INTERNAL PARTS. 2) BLACK ANODIZED BODY (E-COAT) (MILL-A-8625 TYPE II CLASS 2) 3) APPROVED VENDOR: CASH VALVE INC.PART NUMBER: ) SEE FOR P & ID A1: 1/4 NPT(PRESSURE GAUGE) A2: 3/8-16 TAPPED.50 DEEP MOUNTING HOLES(4-PLACES) A3: INFORMATION PLATE TO INCLUDE THE FOLLOWING: SULLAIR NAME AND LOGO SULLAIR P/N SET PRESSURE(S) 1600R(HAF) R00 83

84 1.23 MANIFOLD - DUAL PRESSURE KEY PART NO. QTY DESCRIPTION NOTES PRESSURE RANGE MAX. INLET PRESSURE DATE CODE (NO VENDOR INFO) A4: REFERENCE:.062 ORIFICE LOCATED BELOW THIS ELBOW A5: THE REDUCING REGULATOR THREADS AND THE MATING THREADS IN THE MANIFOLD ARE TO HAVE LOCTITE 7649 PRIMER N APPLIED PER MANUFACTURES INSTRUCTIONS PRIOR TO APPLYING LOCTITE 271 HIGH STRENGTH THREAD LOCKER TO THE REDUCING REGULATOR HOUSING THREADS AND INSTRUMENTING INTO THE BLOCK. TIGHTEN THE REGULATOR HOUSING TO 65 LB-FT OF TORQUE. 1600R(HAF) R00 84

85 Notes 1600R(HAF) R00 85

86 1.24 CONTROL LINES R03 S1 1600R(HAF) R00 86

87 1.24 CONTROL LINES R03 S2 1600R(HAF) R00 87

88 1.24 CONTROL LINES R03 S3 1600R(HAF) R00 88

89 1.24 CONTROL LINES R03 S4 1600R(HAF) R00 89

90 1.24 CONTROL LINES KEY PART NO. QTY DESCRIPTION NOTES HOSE, BNDL CTL LINES 1600-T3 LP HOSE, CTL PANEL-DRY PRESS REC TN SUPPORT, UPR BRACKET TUBE 1600C TUBE, SS P3 SEC-B 1600C LP TUBE, SS P1 SEC-A 1600C LP TUBE, SS P2 SEC-A 1600C LP TUBE, SS P3 SEC-A 1600C LP SUPPORT, BRACKET TUBE 1600C LP TUBE, SS P2 SEC-B 1600C LP TUBE, SS P1 SEC-B 1600C LP CLAMP, SPEED TUBE 1/ UNION, TUBE 1/4 STAINLESS STL CLAMP, HOSE 2 3/8 I.D NUT, HEX F PLTD 1/ SCREW, HEX SER WASHER 1/4-20 X 3/ SCREW, HEX SER WASHER 5/16-18 X 3/ SCREW, HEX SER WASHER 3/8-16 X 1 1/ CONN, 37 FL/MPT PLTD 1/4 X 1/ CONN, 37 FL/MPT PLTD 1/2 X 1/ CONN, TUBE-M 1/4 X 1/8 SS CONN, TUBE-M 1/4 X 1/4 SS ELBOW, TUBE 90 DEG M 1/4 X 1/4 SS TEE, PIPE 1/4 2000# SS NIPPLE, PIPE-HX BRASS 1/4 X 1/ CONN, 37 FL/MPT SS 1/4 X 1/ ELBOW, 37FL 90M SS 1/2 X 1/2 1600R(HAF) R00 90

91 1.24 CONTROL LINES KEY PART NO. QTY DESCRIPTION NOTES NOTES A1: GREEN - AIR CONTROL MANIFOLD BLOCK TO DRY PRESSURE RECEIVER TANK A2: BLUE - AIR CONTROL MANIFOLD BLOCK TO VALVE BODY TOP PORT A3: PURPLE - AIR CONTROL MANIFOLD BLOCK TO FRONT OF FLOW CONTROL PLATE A4: RED - AIR CONTROL MANIFOLD BLOCK TO SPRINGING CHAMBER A5: WHITE - AIR CONTROL MANIFOLD BLOCK TO VALVE BODY BOTTOM PORT A6: YELLOW - AIR CONTROL MANIFOLD BLOCK TO CONTROL SIGNAL PORT A7: ORANGE - RECEIVER TANK SCAVENGE LINE PORT TO COMPRESSOR A8: AIR CONTROL MANIFOLD BLOCK TO DRY PRESSURE RECEIVER TANK A9: TRIM EXCESS TUBING LENGTH TO ALLOW CONDENSATE WITHIN TUBE TO DRAIN TO TANK. A10: TRIM EXCESS TUBING LENGTH FOR PROPER FIT. A11: REFERENCE P & I A12: P1 DRY SIDE PRESSURE A13: P2 CONTROL PRESSURE A14: P3 WET SIDE PRESSURE A15: ON 200PSI MACHINES IT MAY BE NECESSARY TO SUBSTITUTE LINE WITH BECAUSE OF RECEIVER TANK PORT DIFFERENCES. 1600R(HAF) R00 91