PARTS LIST MANUAL 1600E OPEN FRAME R01 WARRANTY NOTICE

Transcription

1 PARTS LIST MANUAL 1600E OPEN FRAME WARRANTY NOTICE Failure to follow the instructions and procedures in this manual or, misuse of this equipment will VOID its warranty! PART NUMBER: R01 KEEP FOR FUTURE REFERENCE COPYRIGHT 2013 SULLAIR The information in this manual is current as of its publication date, and applies to compressor serial number: and all subsequent serial numbers.

2 AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance, and servicing of Sullair products. Individual seminars on portable compressors and compressor electrical systems are offered at regular intervals throughout the year at Sullair s corporate headquarters training facility located at Michigan City, Indiana. Instruction includes training on the function and installation of Sullair service parts, troubleshooting common faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance, contractor maintenance, and service personnel. For detailed course outlines, schedule, and cost information contact: SULLAIR TRAINING DEPARTMENT SULLAIR or (ext. 5623) training@sullair.com - Or Write - Sullair 3700 E. Michigan Blvd. Michigan City, IN Attn: Service Training Department.

3 TABLE OF CONTENTS PAGE SECTION DESCRIPTION PAGE SECTION DESCRIPTION PROCEDURE FOR ORDERING PARTS RECOMMENDED SPARE PARTS LIST COMPRESSOR SYSTEM 750XHH E FRAME ASSEMBLY ENGINE & COMPRESSOR SYSTEM 750XHH E ENGINE EXHAUST SYSTEM 750XHH XH EXHAUST SYSTEM 1600E ONLY INLET VALVE ASSEMBLY AIR INLET VALVE SUBASSEMBLY RECEIVER TANK ASSEMBLY 1600E TANK, AIR-OIL SEPARATOR COOLING SYSTEM SINGLE TURBO COOLING SYSTEM TWIN TURBO DRAIN LINES COOLING SYSTEM ASSEMBLY LIFT BAIL ASSEMBLY LIFT BAIL ASSEMBLY 1525XH ONLY AIR INLET SYSTEMS 750XHH XH AIR INLET SYSTEM XH ONLY ELECTRICAL SYSTEM DRAWING ELECTRIC AND AIR PARTS HIGH PRES- SURE HIGH PRESSURE ELECTRICAL AND PNEUMATIC CONTROL SYSTEMS HIGH PRESSURE SUB-ASSEMBY CON- TROLS INSTRUMENT PANEL DISCHARGE SYSTEM, NON-AFTER- COOLED CONTROL LINES ELECTRIC & AIR CONTROLS WITH HIGH TEMPERATURE SOLENOID VALVE FUEL SYSTEM, OPTIONAL EXPORT ONLY FUEL SYSTEM OPTIONAL EXPORT ONLY DISCHARGE SYSTEM AFTERCOOLED ONLY, OPTIONAL WATER SEPARATOR AFTERCOOLED ONLY, OPTIONAL AIR START SYSTEM, OPTIONAL CAPACITY CONTROL, OPTIONAL

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

5 Parts List 1.1 PROCEDURE FOR ORDERING PARTS Sullair 3700 East Michigan Boulevard Michigan City, Indiana, U.S.A. Telephone: 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 Number, Plate 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 Number, Plate Location 1600E Open Frame ( R01) 5

6 1.2 Recommended Spare Parts List KEY PART NO. QTY DESCRIPTION NOTE ELEMENTS replacement for air filter element - primary replacement for air filter element - secondary (safety) replacement air filter element - primary 1525XH[A] only replacement air filter element - secondary 1525XH[A] only replacement for compressor oil filter replacement for engine (CAT) oil filter - 1R1808 (I) replacement for engine (CAT) fuel filter - primary: replacement for engine (CAT) fuel filter - secondary: 1R0749 KITS replacement kit for receiver tank separator elements (3 element pack) replacement for starter solenoid repair kit for inlet valve (springs included) repair kit for inlet valve (no springs included) repair kit for start/run solenoid - coil only replacement for high/low solenoid (coil only) repair kit for blowdown valve repair kit for pressure differential valve repair kit for control pressure reducing regulator repair kit for back pressure regulator - high repair kit for back pressure regulator - low repair kit for compressor oil thermostat (230 F [110 C]) rebuild kit for compressor oil stop valve master maintenance kit - 50 Hour filter element filter master maintenance kit Hour replacement for engine (CAT) oil filter - 1R replacement for engine (CAT) fuel filter - primary: E Open Frame ( R01) 6

7 1.2 Recommended Spare Parts List KEY PART NO. QTY DESCRIPTION NOTE replacement for engine (CAT) fuel filter - secondary: 1R filter element replacement for air filter element - primary replacement for air filter element - secondary (safety) filter master maintenance kit Hour 1525XH[A] Only replacement for engine (CAT) oil filter - 1R replacement for engine (CAT) fuel filter - primary: replacement for engine (CAT) fuel filter - secondary: 1R filter element replacement for air filter element - primary replacement for air filter element - secondary (safety) filter MISCELLANEOUS 25 Call Customer Care 1 replacement for engine/compressor drive coupling replacement for 2" SAE split-flange w/viton o-ring replacement for 3" SAE split-flange w/viton o-ring replacement for compressor intake filter restriction switch replacement for engine intake filter restriction switch replacement for exhaust muffler replacement for exhaust muffler 1525XH[A] only replacement for engine coolant radiator replacement for compressor oil cooler - primary replacement for compressor oil cooler - secondary replacement for engine charge air cooler replacement for compressor discharge aftercooler (AC machines only) replacement for fuel level sender (if equipped with on board fuel tank) replacement for compressor interstage temperature (IT) switch replacement for receiver tank temperature (RTT) switch replacement for Compass Controller 1600E Open Frame ( R01) 7

8 1.2 Recommended Spare Parts List KEY PART NO. QTY DESCRIPTION NOTE replacement for Compass Controller enclosure access key replacement for containment frame adjustable drain plug replacement for fuel supply quick disconnect - male replacement for fuel return quick disconnect - male replacement for battery disconnect switch replacement for ambient temperature sensor replacement for compressor discharge temperature sensor replacement for fuel tank vent (if equipped with on board fuel tank) replacement for fuel tank filler cap replacement for engine coolant level sensor replacement for compressor lubricant - AWF (5 gallons/18.9 liters) replacement for psi / MPa transducer (XH and XHH machines only) replacement for receiver tank lid o-ring LUBRICATION replacement for compressor lubricant - AWF (55 gallons/208 liters) replacement for compressor lubricant - AWF (5 gallons/18.9 liters) (I) CAT C-18 requires 2 oil filters PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR CAUTION Mixing of other lubricants within the compressor unit will void all warranties. 1600E Open Frame ( R01) 8

9 Notes 1600E Open Frame ( R01) 9

10 1.3 COMPRESSOR SYSTEM 750XHH E R01 S1 1600E Open Frame ( R01) 10

11 1.3 COMPRESSOR SYSTEM 750XHH E R01 S2 1600E Open Frame ( R01) 11

12 1.3 COMPRESSOR SYSTEM 750XHH E KEY QTY DESCRIPTION NOTES 1 1 FILTER, AIR 2 1 GAUGE, AIR FILTER RESTRICTION 3 1 INLET VALVE 4 1 COMPRESSOR 5 2 VALVE, RELIEF 6 2 SWITCH, TEMPERATURE 7 1 SENSOR, TEMPERATURE 8 2 SENSOR, PRESSURE 9 1 VALVE, DISCHARGE CHECK 10 1 RECEIVER, AIR/OIL 11 1 GLASS, SIGHT OIL LEVEL 12 1 VALVE, MINIMUM PRESSURE 13 2 VALVE, BALL 14 1 COOLER, AIR (OPTIONAL) 15 2 SEPARATOR, MOISTURE 16 1 TRAP, DRAIN 17 5 ORIFICE 18 2 VALVE, BLOWDOWN (RUNNING N.C.) 19 2 STRAINER 20 1 SIGHTGLASS, ORIFICE BLOCK 21 2 VALVE, THERMAL BYPASS 22 2 COOLER, OIL 23 1 FILTER, OIL 24 1 VALVE, OIL STOP 25 3 VALVE, REGULATOR BACKPRESS 26 1 VALVE, SHUTTLE (DOUBLE CHECK) 27 2 GAUGE, PRESSURE 28 1 VALVE, PRESSURE REGULATOR 1600E Open Frame ( R01) 12

13 1.3 COMPRESSOR SYSTEM 750XHH E KEY QTY DESCRIPTION NOTES 29 2 VALVE, CHECK 30 3 VALVE, SOLENOID 3-WAY ELECT 31 1 VALVE, SOLENOID 2-WAY ELECT 32 3 SEPERATOR, ELEMENT 33 1 VALVE, SHUTTLE (DOUBLE CHECK) 34 1 VENT, AIR 35 1 CYLINDER, AIR (OPTIONAL) 36 2 VALVE, PRESSURE DIFF. BYPASS 37 1 VALVE, BUTTERFLY 8 (OPTIONAL) 38 1 MANIFOLD, OIL CONTROL 39 1 VALVE, BLOWDOWN (SHUTDOWN N.O.) 40 1 TRAP, STEAM TRAP COMPONENT DESCRIPTION P1 DRY SIDE PRESSURE P2 CONTROL PRESSURE P3 WET SIDE PRESSURE T1 COMPRESSOR DISCHARGE TEMPERATURE SENSOR T2 INTERSTAGE TEMPERATURE SWITCH T3 RECEIVER TANK TEMPERATURE SWITCH (RTT) 1600E Open Frame ( R01) 13

14 1.4 FRAME ASSEMBLY R E Open Frame ( R01) 14

15 1.4 FRAME ASSEMBLY KEY PART NUMBER QTY DESCRIPTION NOTES SUPT, ENCL COMPASS $ MANF BLK EYE, TOW SS OF/LRG EYE, TOW CS OF/LRG SUPPORT,BATTERIES 1600 T3 OPEN FRAME CHAIN, TETHER FRAME DRAIN PLUG GUARD, FORMED SS REAR 1600D T3 OF GUARD, FORMED SS FRONT 1600D T3 OF GUARD, FORMED CS REAR 1600D T3 OF GUARD, FORMED CS FRONT 1600D T3 OF SUPT, FORMED GUARD 1600D T3 OF PLATE, DIAMOND ANTI-SLIP GRATING FASTENER, DIAMOND ANTI-SLIP GRATE PLUG, 2-1/2 X 1-3/16 SS/NITRIL VALVE,BALL 1/2 NPT NUT, HEX F PLTD 5/ NUT, HEX LOCKING 5/ CAPSCR, HEX GR5 3/8-16 X 1 1/ CAPSCR, HEX GR5 3/4-10 X 2 1/ BOLT, CARRIAGE 5/16 X SCREW, HEX SER WASHER 5/16-18 X SCREW, HEX SER WASHER 3/8-16 X 1 1/ WASHER, SPR LOCK REG PLTD 3/ WASHER, SPR LOCK REG PLTD 3/ WASHER, PL-B REG PLTD 5/ WASHER, PL-B REG PLTD 3/ ELBOW, 37FL 90F 3/4 X 3/ NIPPLE, PIPE-XS PLT 1/2 X CL CONN, 37 FL 5/8 X 3/4 NPT 1600E Open Frame ( R01) 15

16 1.4 FRAME ASSEMBLY KEY PART NUMBER QTY DESCRIPTION NOTES PLUG, PIPE CORED 3 150# PLT 30 SEE_CHART 1 FRAME ASSEMBLY 31 SEE_CHART_LB 1 SA, LIFT BAIL 1600 T3 FRAME ASSEMBLY Chart FRM ASSY, 1600E W/O FT FRM ASSY, 1600E W/FUEL TANK LIFT-BAIL SUB-ASSEMBLY SA, LIFT BAIL 1600E SA, LIFT BAIL 1500EXH 1600E Open Frame ( R01) 16

17 Notes 1600E Open Frame ( R01) 17

18 1.5 ENGINE & COMPRESSOR SYSTEM 750XHH E R03 S1 1600E Open Frame ( R01) 18

19 1.5 ENGINE & COMPRESSOR SYSTEM 750XHH E R03 S2 1600E Open Frame ( R01) 19

20 1.5 ENGINE & COMPRESSOR SYSTEM 750XHH E KEY PART NUMBER QTY DESCRIPTION NOTES SUPPORT, UNIT/ENG H900/ BUSHING, TAPER LOCK 4040 W/2.75 BORE SPACER, FAN CAT C / 1260 mm FAN FAN, 58 / 1473 mm DIA 9-BLADE SUPT, ENG FRT 1600 FAM TIER III SW,HIGH TEMP 280 F / 138 C CORD, THERMO 120V F / C HTR, IMMERSION JCKT WTR SAE HOSE, BALL VLV DRAIN TO SEP TNK VLV,ASSY AIR SHUTOFF 4 C GUARD, BELOW ALT 1600D COVER, HP UNIT ADPT 1600D SHIELD, HEAT TURBO 1500XH SA, INLET VLV 8 HPC 1600E GASKET, 11 X 8 5/8 X 1/32 / x x 0.8 mm GAUGE, CTL AIR PRESS PSI / MPa WASHER, SNUBBING 1 BOLT ADAPTER, ENG/COMPR 900XH ISOLATOR, VIBRATION 500 LB / kg CAPACITY VALVE, DRAIN 1-1/8-12UNF NUT, THIN HEX 3/ WASHER,.500 HARDENED NUT, HEX F PLTD 3/ NUT, HEX LOCKING 3/ CAPSCR, FERRY HD 1/2-13 X 1 3/ CAPSCR, HEX GR5 3/8-16 X 3/ CAPSCR, HEX GR5 7/16-14 X CAPSCR, HEX GR5 1/2-13 X 3 1/2 1600E Open Frame ( R01) 20

21 1.5 ENGINE & COMPRESSOR SYSTEM 750XHH E KEY PART NUMBER QTY DESCRIPTION NOTES CAPSCR, HEX GR5 5/8-11 X 1 3/ CAPSCR, HEX GR5 3/4-10 X 2 1/ CAPSCR, HEX GR5 3/4-10 X CAPSCR, HEX GR5 3/4-10 X 5 1/ CAPSCR, HEX GR5 1-8 X 6 1/ SCREW, HEX SER WASHER #10-24 X SCREW, HEX SER WASHER 3/8-16 X 1 1/ SCREW, TC-HEX 5/16-18 X 3/ WASHER, SPR LOCK REG PLTD 7/ WASHER, SPR LOCK REG PLTD 1/ WASHER, SPR LOCK REG PLTD 5/ WASHER, SPR LOCK REG PLTD 3/ WASHER, SPR LOCK REG PLTD WASHER, PL-B REG PLTD 5/ WASHER, PL-B REG PLTD 3/ ELBOW, 37FL 90M 1/4 X 1/ TEE, 37FL M BR 1/4 X 1/ NUT, HX JAM RH PLTD 1/ TEE, PIPE PLTD 1/ NIPPLE, PIPE-HX PLTD 1/4 X 1/ CONN, STR X JIC 1 1/16 X 3/ CONN, 90D STR X JIC 9/16 X 9/ CONN, 90D STR X JIC 3/4 X 9/ STUD, THRD 3/4-10 X 3 PLT PLUG, STR THD HOL HX 9/ WASHER, NORD-LOCK PL 3/8 SP ELB,45 DEG STR THD 1 1/16 X 1 HOSE 56 SEE_CHART_CPLG 1 COUPLING, DRIVE ACT / E Open Frame ( R01) 21

22 1.5 ENGINE & COMPRESSOR SYSTEM 750XHH E KEY PART NUMBER QTY DESCRIPTION NOTES 57 SEE_CHART_ENG 1 ENG, DSL CAT C15 TIER III (SEE BOM) 58 SEE_CHART_UNIT 1 COMPRESSOR, UNIT AND PARTS (SEE BOM) NOTES: A1: REMOVE FILTERS FROM ENGINE AND MOUNT TO SUPTS AND ON LIFTING BAIL. A2: CONNECT TO ENGINE FUEL PUMP A3: FUEL SUPPLY TO ENGINE A4: FUEL RETURN FROM ENGINE A5: STANDARD ON 1500XH MACHINES, OPTIONAL ON ALL OTHERS. B1: ENGINE OIL DRAIN B2: ENGINE COOLANT DRAIN B3: STARTER POSITIVE C1: MAKE SURE THREADS ARE CLEAN AND FREE OF OIL, APPLY LOCTITE 2440 SULLAIR P/N TO THREADS OF SCREW AND TORQUE TO 77 FT-LBS / 104 Nm C2: INSTALL TAPER LOCK PER MANUFACTURER S INSTRUCTIONS PROVIDED WITH PART. SCREWS ARE SUPPLIED WITH TAPER LOCK. KEY SUPPLIED WITH COMPRESSOR UNIT. Q1: SEE ASSEMBLY DRAWING E Open Frame ( R01) 22

23 Notes 1600E Open Frame ( R01) 23

24 1.6 ENGINE EXHAUST SYSTEM 750XHH XH R E Open Frame ( R01) 24

25 1.6 ENGINE EXHAUST SYSTEM 750XHH XH KEY PART NUMBER QTY DESCRIPTION NOTES RAIN-CAP, EXHAUST 5.75 TO 6.35 / TO mm DIA PIPE MUFFLER, EXH ENG 1600D PIPE, EXH ELBOW 1600D SUPT, MUFFLER TURBO SIDE SUPT, MUFFLER 1600 T3 CS WRAP, BLANKET MUFFLER 1600D WRAP, BLANKET EXH ELB 1600D CLAMP, SEAL 5 / 127 mm CAPSCR, HEX GR5 3/8-16 X 1 1/ CAPSCR, HEX GR5 1/2-13 X 1 1/ WASHER, NORD-LOCK PL 3/8 SP WASHER, NORD-LOCK PL 1/2 SP 1600E Open Frame ( R01) 25

26 1.7 EXHAUST SYSTEM 1600E ONLY R E Open Frame ( R01) 26

27 1.7 EXHAUST SYSTEM 1600E ONLY KEY PART NUMBER QTY DESCRIPTION NOTES AID, STARTING ELEC 24V C MUFFLER, EXH ENG 1500XH OF ELBOW, EXH 1500XH T CAP, RAIN 8 / 203 mm PIPE, EXH FLGD 8 / 203 mm 1500XH SUPT, MUFFLER FRONT (1) 1500XH SUPT, MUFFLER FRONT WRAP, BLKT EXH MUFFLER 1500XH WRAP, BLKT EXH PIPE 1500XH WRAP, BLKT EXH ELB 1500XH GASKET, EXH 8 / 203 mm CAT FLG 1500XH GASKET, EXH 8 / 203 mm FLG 1500XH SUPT, MUFFLER REAR 1600E SUPT,EXHST FLANGE 1600E CLAMP, HOSE 9/16 / 14.3 mm ID CLAMP, HOSE 7/8 / 22.2 mm ID NUT, HEX PLTD 3/ NUT, HEX PLTD 1/ NUT, HEX PLTD 3/ NUT, HEX F PLTD 1/ CAPSCR, HEX GR5 3/8-16 X 1 3/ CAPSCR, HEX GR5 1/2-13 X 1 3/ CAPSCR, HEX GR5 5/8-11 X 1 1/ CAPSCR, HEX GR5 5/8-11 X 2 3/ CAPSCR, HEX GR5 3/4-10 X SCREW, HEX SER WASHER 1/4-20 X SCREW, HEX SER WASHER 5/16-18 X 3/ WASHER, SPR LOCK REG PLTD 3/8 1600E Open Frame ( R01) 27

28 1.7 EXHAUST SYSTEM 1600E ONLY KEY PART NUMBER QTY DESCRIPTION NOTES WASHER, SPR LOCK REG PLTD 1/ WASHER, SPR LOCK REG PLTD 5/ WASHER, SPR LOCK REG PLTD 3/ WASHER, PL-B REG PLTD 3/ WASHER, PL-B REG PLTD 1/ WASHER, PL-B REG PLTD 5/ WASHER, PL-B REG PLTD 3/4 NOTES A1: CONNECT TO ENGINE A2: CONNECT TO UNIT A3: ROUTE ETHER START HARNESS THROUGH CLAMPS ATTACHED TO INSIDE FLANGE OF EXHAUST SUPPORT A4: ROUTE AIR STOP HARNESS THROUGH CLAMPS ATTACHED TO OUTSIDE FLANGE OF EXHAUST SUPPORT 1600E Open Frame ( R01) 28

29 Notes 1600E Open Frame ( R01) 29

30 1.8 INLET VALVE ASSEMBLY R E Open Frame ( R01) 30

31 1.8 INLET VALVE ASSEMBLY KEY PART NUMBER QTY DESCRIPTION NOTES VLV,CHK 1/4 NPTF VITON SEAT HOSE,MP 5/16 X 12 LG 37 DEG ST ORF, FNPT X.25 MNPT VLV,BLWDN N.C. 8:1 RATIO HOSE, MP 1/4 ID X 12 OAL CLP,HOSE 9/16 MED DUTY/GALV PLUG, OIL FILLER 8 VLV 5/16 37 FL SA, 8 INLET VALVE HOSE, MP 1/4 ID X 12 OAL 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/ ELBOW, PIPE-90M 1/4 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 PLUG, PIPE 1/2 3000# STL PLT UNION, PIPE-BRS SEAT 1/2 300# PLT 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: FLOW DIRECTION Q1: SEE ASSY DRAWING E Open Frame ( R01) 31

32 1.9 AIR INLET VALVE SUBASSEMBLY R E Open Frame ( R01) 32

33 1.9 AIR INLET VALVE SUBASSEMBLY KEY PART NUMBER 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 SPRING, COMP. 144 LBS INTER SHAFT, 8 INLET VALVE SPRING, COMP. 109 LBS / 485 N OUTER SPRING, COMP LBS / 11.6 N CAPSCR, HX GR5 1/ 4-20 X 3/ WASHER, SPRLOCK REG PL TD 1/ RING, VITON 45/8 x 1/ D-RING, VITON 1 x 1/ SCREW, FERRY HD, 3/8-16 x 1 3/4 LG PLUG, PIPE 1/2 STL PLTD ORIFICE,.063 x.125m x.125f NOTES: 1. SEAL WITH SULLAIR GASKET COMPOUND #5910 COLOR CODE: PURPLE. 2. TORQUE PER SULLAIR SPEC. PE APPLY ANTI-SEIZE. 4. LOCK WITH SULLAIR ADHESIVE #5910, COLOR CODE: PURPLE. 1600E Open Frame ( R01) 33

34 1.10 RECEIVER TANK ASSEMBLY 1600E R E Open Frame ( R01) 34

35 1.10 RECEIVER TANK ASSEMBLY 1600E KEY PART NUMBER QTY DESCRIPTION NOTES PLUG, SIGHT GLASS 1-7/8 SAE FLG, 3 SAE J518 CODE VLV,CHK 1/4 NPTF VITON SEAT FILTER, ASSEMBLY SCREEN FILTER ORF,PLUG BRASS 1/8 NPT x 3/ SIGHTGLASS, ORF BLOCK SAE VLV, REL 1 MNPT 600PSIG / 4.14 MPa ASME/CE VALVE, MIN PRESS CHECK H.P SW,HTM 300 DEG F - 3/4-16 SAE SPACER, REC TANK 1600D OF TANK, AIR-OIL SEP 600PSIG / 4.14 MPa 1600D XDCR,PRESS 0-750PSIG / MPa 1-5VDC PLUG, O-RING BOSS SAE 1 1/ ORF, CTL.062 1/8 FNPT X 1/8 MNPT VALVE, PNEU(NO)500#-SHTDN BDV NUT, HEX LOCKING 5/ O-RING, VITON 3 3/8 X 1/ CAPSCR, HEX GR5 5/8-11 X 2 1/ CAPSCR, HEX GR5 5/8-11 X WASHER, SPR LOCK REG PLTD 5/ WASHER, PL-B REG PLTD 5/ CONN, 37 FL/MPT PLTD 1/4 X 1/ ELBOW, 37FL 90M 1/4 X 1/ ELBOW, 37FL 90M 1/2 X 1/ ELBOW, PIPE-90M 1/4 X 1/ TEE, 37FL M RN 1/2 X 1/ NIPPLE, PIPE-XS PLT 1/2 X CL BUSHING, RED PLTD 3/4 X 1/2 1600E Open Frame ( R01) 35

36 1.10 RECEIVER TANK ASSEMBLY 1600E KEY PART NUMBER QTY DESCRIPTION NOTES TEE, PIPE PLTD 1/ NIPPLE, PIPE-HX PLTD 1/4 X 1/ NIPPLE, HALF-PLTD 1 1/2 X CONN, STR X JIC 7/16 X 7/ CONN, STR X JIC 3/4 X 7/ CONN, 37FL SW F 1/4 X 1/4 NOTES: A1: CE APPROVED TANK = A2: RECIEVER TANK PORT A3: CE APPROVED FLANGE = E Open Frame ( R01) 36

37 Notes 1600E Open Frame ( R01) 37

38 1.11 TANK, AIR-OIL SEPARATOR R03 S1 1600E Open Frame ( R01) 38

39 1.11 TANK, AIR-OIL SEPARATOR R03 S2 1600E Open Frame ( R01) 39

40 1.11 TANK, AIR-OIL SEPARATOR KEY PART NUMBER QTY DESCRIPTION NOTES DAVIT ASSY, WELDED (SEE SHT 2) TUBE, OIL SCAVENGE (SEE SHT 2) LID ASSY, 600PSI / 4.14 MPa TANK (SEE SHT 2) FLANGE, 3 CODE-61 THREADED FLANGE, 3 CODE-61 W/PIN ELEMENT, SEPERATOR ELP 1600D-T PLATE, GROUNDING SS 1600 T BAFFLE, REC TANK 1600 T3 HP SUPT, DAVIT ARM ASSY 1600 T COUPLING, PIPE 1/4 3000# COUPLING, HALF 1/8 3000# COUPLING, HALF 3/4 3000# COUPLING, HALF # ELBOW, WLD 45DEG 2 LR STD NUT, HEX PLTD 3/ O-RING, VITON 17 1/2 X 1/ PIN, DOWEL UNFIN 1/4 X PIN, DOWEL UNFIN 1/4 X 1 1/ CAPSCR, HEX GR5 1/2-13 X 1 3/ CAPSCR, HEX GR5 3/4-10 X CAPSCR, HEX GR5 7/8-9 X 3 3/ WASHER, SPR LOCK 1/ WASHER, PL-B REG PLTD 1/ WASHER, PL-B REG PLTD 7/ WASHER, NORD-LOCK 1/4 SP SS CAPSCR, HEX GR5 1/4-20 X 3/4 SS 1600E Open Frame ( R01) 40

41 1.11 TANK, AIR-OIL SEPARATOR KEY PART NUMBER QTY DESCRIPTION NOTES NOTES: 1. VESSEL TO BE CLEAN, DRY, AND FREE OF ANY WELD SLAG, SPATTER OR FOREIGN MATERIAL INSIDE AND OUTSIDE. 2. POWDER COAT TANK PER SILVAN SPEC: C CORVEL(TM) JD DULL BLACK. TANK TO BE POWDER COATED INSIDE (DRY SIDE ONLY EXCEPT BAFFLE PLATE) AND OUTSIDE. 3. MAWP TO BE 600 PSIG / 4.14 MPa 4. WORKING TEMP RANGE : -20 F MIN, 450 F MAX / -29 C MIN, 232 C MAX. 5. SHIP WITH ALL GRADE 5 CAPSCREWS AND HARDENED FLAT WASHERS SECURING (TORQUE PER ASME REQUIREMENTS) THE LID TO THE TANK. (WASHERS PER ASTM SPEC. F ). 6. SAE PORT DETAIL PER SAE 1926/1. THREAD SPEC. PER SAE J475 (ISO R725) 7. SHELL/HEAD/COVER MATERIAL TO MEET ASME REQUIREMENTS. 8. PRESSURE VESSEL MUST MEET ASME CODES AND MUST BE INSPECTED AND STAMPED UNDER THE NATIONAL BOARD FORM FURNISHED. 9. THE TANK MUST BE REGISTERED WITH THE CANADIAN DEPARTMENT OF LABOR AND STAMPED WITH THE APPLICABLE SULLAIR PART NO. AND CRN NO. FOR ALL PROVINCES. 10. MUST COMPLY WITH SULLAIR CE DOCUMENT WC EACH TANK TO BE SUPPLIED WITH OPERATING/INSTALLATION/SAFETY INSTRUCTIONS IF APPLICABLE. 12. APPLY SIL-GLIDE TO ALL O-RINGS. 13. ALL PORTS TO BE PLUGGED WITH PLASTIC PLUGS/CAPS. 14. REFERENCE: THIS TAB DRAWING IS SIMILAR TO E Open Frame ( R01) 41

42 1.12 COOLING SYSTEM SINGLE TURBO R04 S1 1600E Open Frame ( R01) 42

43 1.12 COOLING SYSTEM SINGLE TURBO R04 S2 1600E Open Frame ( R01) 43

44 1.12 COOLING SYSTEM SINGLE TURBO KEY PART NUMBER QTY DESCRIPTION NOTES CLAMP, T-BOLT SS BAND 4.50 ID HOSE, HUMP CHRG AIR 4 ID X 6 LG PLUG,SIGHT GLASS 1 5/16 SAE FLG, KIT SAE SPLT 2 - VITON HINGE, CANOPY DOOR L&R CLAMP, HOSE CONST TORQUE CLAMP, HOSE CONST TORQUE SUPT, COOLERS 1600 T SUPT, CLR MOUNT 1600 T ELEMENT, FILTER CORLESS BOWL, OIL FLTR 1600 FAM TIER HOSE,ENG RAD UPPER CAT C15 T PIPE, CAC HOT/UPPER 1600D SNSR,TEMP RTD 3/4 O-RING PIPE, ENG RAD LOWER 1600 T HOSE, RAD LOWER 3 ID X 5 LG HOSE,ASSY HP OIL 2 REC OIL RT SUPPORT, COOLER GUARD SS SUPPORT, COOLER GUARD CS SNSR, ENGINE COOLANT CAT HOSE,ASSY OIL 2 SS BRAID PIPE, ASSY OIL FAM T GUARD, COOLER PACK O.F. W/FUEL TANK GUARD, BATTERY OPEN FRAME W/FUEL TANK SUPT, ANL FRMD AMB TEMP SENDOR SEAL, ALUM 2 JIC 37DEG FLARE SUPT, GUSSET FAN GUARD 1600D-T HANDLE, 1/2 ROD 1600D 1600E Open Frame ( R01) 44

45 1.12 COOLING SYSTEM SINGLE TURBO KEY PART NUMBER QTY DESCRIPTION NOTES WRAP, BLANKET CAC PIPE 1600D GUARD, FAN/BELT WIREFORM SPLIT SS 1600D GUARD, FAN/BELT WIREFORM SPLIT CS 1600D SUPT, LOWER CAC PIPE 1600D PIPE, ASSY CAC COOL/LOWER CAT C15 T VLV,CAC DRAIN VALVE CLR, ASSY 600PSI / 4.14 MPa 1600E PURCH PANEL, FUEL FILL COVER SHRD, FAN 58 DIA FBRGLS 1600E HOSE, ASSY HP OIL 2 CLR OUT 1600E CNTR, ENG COOLANT OVERFLOW HOSE, ASSY HP OIL 2 CLR OUT SA, DRAIN LINES 1600E GA, DELTA-P IND W/SUPT TUBE, 1/4 SS FORMED TUBE, 1/4 SS FORMED HOSE,ASSY HP OIL 2 CLR IN CAP, CAC AIR INLET 1600E HOSE, CAC AIR INLET CAP 1600E MANF, COMPR FILTER & FLOW CONTROL CLP, 2 PIPE CLP,CUSHION 2 PIPE CLAMP, HOSE 13/16 TO 1-1/ CLAMP, HOSE 1/ HOSE,RAD UPPER 2-1/2 X CONN, TUBE-M 1/4 X 1/ ELBOW, TUBE 90 DEG M 1/4 X 1/ NUT, HEX F PLTD 1/ E Open Frame ( R01) 45

46 1.12 COOLING SYSTEM SINGLE TURBO KEY PART NUMBER QTY DESCRIPTION NOTES NUT, HEX F PLTD 3/ NUT, HEX LOCKING 5/ NUT, HEX LOCKING 3/ NUT, HEX LOCKING 1/ CAPSCR, HEX 8.8 M10 X 30MM CAPSCR, HEX GR5 5/16-18 X 1 1/ CAPSCR, HEX GR5 5/16-18 X CAPSCR, HEX GR5 1/2-13 X 3 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 SCREW, HEX SER WASHER 3/8-16 X 1 1/ SCREW, HEX SER WASHER 1/2-13 X WASHER, SPR LOCK REG PLTD 5/ WASHER, PL-B REG PLTD 5/ WASHER, PL-B REG PLTD 3/ WASHER, PL-B REG PLTD 1/ WASHER, PL-B WIDE PLTD 3/ HOSE, FUEL LINE 5/16 (FT) U-BOLT, 3/8 X 3 1/2 PIPE PLTD CONN, 45 DEG STR X JIC 2 1/2 X 2 1/ CONN, 90D STR X JIC 2 1/2 X 2 1/ WASHER, NORD-LOCK PL M CONN, STR THD/ORFS 2 1/2 X 2 1/ HOSE,HTR HEAVY WALL 1 (FT) ELB,45 DEG STR THD 1 1/16 X 1 HOSE TEE, HOSE BARB 3/8 BRASS ELBOW, ST THD/ORFS 2 1/2 X E Open Frame ( R01) 46

47 1.12 COOLING SYSTEM SINGLE TURBO KEY PART NUMBER QTY DESCRIPTION NOTES A1: TO RECEIVER TANK A2: TO COMPRESSOR A3: TO ENGINE TURBO OUTLET A4: TO ENGINE INTAKE MANIFOLD A5: TO ENGINE WATER PUMP INLET A6: TO ENGINE WATER PUMP OUTLET A7: TO TOP OF WATER PUMP A8: TO INSIDE CONTAINMENT FRAME B1: MOUNT TO FRAME B2: OIL MANF SUPPORT B3: ENGINE COOLANT SENSOR B4: SENSOR INSTALLED IN AC FOR AC MACHINES B5: IS BULK PACKAGED FOR FACTORY. FOR REPLACEMENT ELEMENT USE: B6: IS ONLY SUPPLIED WITH LESS FUEL TANK DESIGN Q1: REFERANCE SUBASSEMBLY DRAWING NOTES: 1600E Open Frame ( R01) 47

48 1.13 COOLING SYSTEM TWIN TURBO R05 S1 1600E Open Frame ( R01) 48

49 1.13 COOLING SYSTEM TWIN TURBO R05 S2 1600E Open Frame ( R01) 49

50 1.13 COOLING SYSTEM TWIN TURBO KEY PART NUMBER QTY DESCRIPTION NOTES CLAMP, T-BOLT SS BAND 4.50 ID HOSE, HUMP CHRG AIR 4 ID X 6 LG PLUG,SIGHT GLASS 1 5/16 SAE FLG, KIT SAE SPLT 2 - VITON CLAMP, HOSE CONST TORQUE CLAMP, HOSE CONST TORQUE ELEMENT, FILTER CORLESS BOWL, OIL FLTR 1600 FAM TIER HOSE,ENG RAD UPPER CAT C15 T SNSR,TEMP RTD 3/4 O-RING PIPE, ENG RAD LOWER 1600 T HOSE, RAD LOWER 3 ID X 5 LG HOSE,ASSY HP OIL 2 REC OIL RT SUPPORT, COOLER GUARD SS SUPPORT, COOLER GUARD CS SNSR, ENGINE COOLANT CAT HOSE,ASSY OIL 2 SS BRAID PIPE, ASSY OIL FAM T SUPT, ANL FRMD AMB TEMP SENDOR SEAL, ALUM 2 JIC 37DEG FLARE SUPT, GUSSET FAN GUARD 1600D-T HANDLE, 1/2 ROD 1600D GUARD, FAN/BELT WIREFORM SPLIT SS 1600D GUARD, FAN/BELT WIREFORM SPLIT CS 1600D SUPT, LOWER CAC PIPE 1600D PIPE, ASSY CAC COOL/LOWER CAT C15 T VLV,CAC DRAIN VALVE CLR, ASSY 600PSI / 4.14 MPa 1600E PURCH SHRD, FAN 58 DIA FBRGLS 1600E HOSE, ASSY HP OIL 2 CLR OUT 1600E 1600E Open Frame ( R01) 50

51 1.13 COOLING SYSTEM TWIN TURBO KEY PART NUMBER QTY DESCRIPTION NOTES CNTR, ENG COOLANT OVERFLOW HOSE, ASSY HP OIL 2 CLR OUT SA, DRAIN LINES 1600E GA, DELTA-P IND W/SUPT TUBE, 1/4 SS FORMED TUBE, 1/4 SS FORMED PIPE, CAC UPPER1 1500XH PIPE, CAC UPPER2 1500XH HOSE,ASSY HP OIL 2 CLR IN MANF, COMPR FILTER & FLOW CONTROL CLP, 2 PIPE CLP,CUSHION 2 PIPE CLAMP, HOSE 13/16 TO 1-1/ CLAMP, HOSE 1/ HOSE,RAD UPPER 2-1/2 X CONN, TUBE-M 1/4 X 1/ ELBOW, TUBE 90 DEG M 1/4 X 1/ NUT, HEX F PLTD 1/ NUT, HEX F PLTD 3/ NUT, HEX LOCKING 5/ NUT, HEX LOCKING 3/ CAPSCR, HEX 8.8 M10 X 30MM CAPSCR, HEX GR5 5/16-18 X 1 1/ SCREW, HEX SER WASHER 1/4-20 X 3/ SCREW, HEX SER WASHER 3/8-16 X SCREW, HEX SER WASHER 3/8-16 X 1 1/ SCREW, HEX SER WASHER 1/2-13 X WASHER, SPR LOCK REG PLTD 5/ WASHER, PL-B REG PLTD 3/ WASHER, PL-B WIDE PLTD 3/8 1600E Open Frame ( R01) 51

52 1.13 COOLING SYSTEM TWIN TURBO KEY PART NUMBER QTY DESCRIPTION NOTES HOSE, FUEL LINE 5/16 (FT) U-BOLT, 3/8 X 3 1/2 PIPE PLTD CONN, 45 DEG STR X JIC 2 1/2 X 2 1/ CONN, 90D STR X JIC 2 1/2 X 2 1/ WASHER, NORD-LOCK PL M CONN, STR THD/ORFS 2 1/2 X 2 1/ HOSE,HTR HEAVY WALL 1 (FT) ELB,45 DEG STR THD 1 1/16 X 1 HOSE TEE, HOSE BARB 3/8 BRASS ELBOW, ST THD/ORFS 2 1/2 X 2 Notes: A1: TO RECEIVER TANK A2: TO COMPRESSOR A3: TO ENGINE TURBO OUTLET A4: TO ENGINE INTAKE MANIFOLD A5: TO ENGINE WATER PUMP INLET A6: TO ENGINE WATER PUMP OUTLET A7: TO TOP OF ENGINE WATER PUMP A8: TO INSIDE CONTAINMENT FRAME B1: MOUNT TO FRAME B2: OIL MANF SUPPORT B3: ENGINE COOLANT SENSOR B4: SENSOR INSTALLED IN AC FOR AC MACHINES B5: IS BULK PACKAGED FOR FACTORY. FOR REPLACEMENT ELEMENT USE: Q1: REFERANCE SUBASSEMBLY DRAWING E Open Frame ( R01) 52

53 Notes 1600E Open Frame ( R01) 53

54 1.14 DRAIN LINES R04 S1 1600E Open Frame ( R01) 54

55 1.14 DRAIN LINES R04 S2 1600E Open Frame ( R01) 55

56 1.14 DRAIN LINES KEY PART NUMBER QTY DESCRIPTION NOTES SPACER, BRAKE LEVER 250P TUBE, 1/2 RADIATOR DRAIN TUBE, 1/2 RADIATOR DRAIN TUBE, 5/8 ENGINE OIL DRAIN TUBE, 5/8 RECEIVER TANK DRAIN TUBE, 1/2 RADIATOR DRAIN HOSE, MP 1/2 ID X 12 OAL HOSE, MP 3/4 ID X 19 OAL HOSE, MP 1/2 ID X 17 OAL SUPT,SS TUBING 1600 OF TUBE, 1/2 OIL COOLER DRAIN TUBE, 1/2 OIL COOLER DRAIN TUBE, 1/2 OIL COOLER DRAIN PLT,CVR 1/2 & 5/8 TUBE CLAMP CLP, 1/2 TUBE HALVES HOSE, MP 1/2 ID X 24 OAL CLAMP, HOSE 13/16 TO 1-1/ CLAMP, TUBE 1/ NUT, HEX F PLTD 1/ SCREW, HEX SER WASHER 1/4-20 X 1/ SCREW, HEX SER WASHER 5/16-18 X 1 1/ SCREW, SELF-DRILL 1/4 X 3/ WASHER, PL-B REG PLTD 1/ CONN, 37 FL/MPT PLTD 1/2 X 1/ CONN, 37 FL/MPT PLTD 5/8 X 1/ CONN, STR X JIC 3/4 X 3/ TEE, 37FL UNION 1/ UNION, 37FL BHD 1/ ELBOW, 37FL/37FL 1/2 X 1/2 1600E Open Frame ( R01) 56

57 Notes 1600E Open Frame ( R01) 57

58 1.15 COOLING SYSTEM ASSEMBLY R E Open Frame ( R01) 58

59 1.15 COOLING SYSTEM ASSEMBLY KEY PART NUMBER QTY DESCRIPTION NOTES FLG, KIT SAE SPLT VITON CLR, ENG RAD 1600E CLR, ENG AIR (CAC) 1600E CLR, UNIT OIL 600PSI / 4.14 MPa PRI 1600E SUPT, CLR ASSY BTM 1600E SUPT, CLR ASSY VERT SS 1600E SUPT, CLR ASSY VERT CS 1600E SUPT, CLR ASSY TOP 1600E VLV, THERMO CLR BYPASS HOSE, ASSY HP OIL 2 BYPASS CLR, UNIT OIL 600PSI / 4.14 MPa SEC 1600E PIPE ASSY, 1600E CLR BYPASS NUT, HEX F PLTD 3/ NUT, HEX F PLTD 1/ SCREW, HEX SER WASHER 3/8-16 X SCREW, HEX SER WASHER 1/2-13 X 1 1/ WASHER, PL-B REG PLTD 3/ WASHER, PL-B REG PLTD 1/ CONN, STR X JIC 1 5/8 X 1 5/ ELBOW,PIPE 45M 1/4 X 5/16 HOSE NOTES: 1. ALL PARTS SUPPLIED FROM VENDOR WITH HARDWARE. 2. INSPECT ALL PARTS INDIVIDUALLY PER PARTS LIST. 3. COOLER ASSEMBLY TO BE SEALED WITH WEATHER STRIPPING/FOAM AND ALL PORTS TO BE PLUGED. 4. SULLAIR PART NUMBER AND REVISION TO BE MARKED ON ASSEMBLY. 1600E Open Frame ( R01) 59

60 1.16 LIFT BAIL ASSEMBLY R E Open Frame ( R01) 60

61 1.16 LIFT BAIL ASSEMBLY KEY PART NUMBER QTY DESCRIPTION NOTES BAIL, LIFTING 1600D SUPT,PRIMARY FUEL FLTR C15 T SUPT, SECOND FUEL FLTR 1600 T SUPPORT, PIPE 4 CAC SUPPORT, RELAY & SWITCH COVER, ACCESS RELAY & SWITCH SHIELD, HEAT TURBO 1600D SUPT, OIL FILTER MANF BLOCK 1500XH NUT, HEX PLTD 3/ NUT, HEX LOCKING 3/ CAPSCR, HEX GR5 3/8-16 X 1 1/ CAPSCR, HEX GR5 3/8-16 X CAPSCR, HEX GR5 1-8 X 2 1/ SCREW, HEX SER WASHER 1/4-20 X 1/ SCREW, HEX SER WASHER 1/4-20 X WASHER, SPR LOCK REG PLTD 3/ WASHER, SPR LOCK REG PLTD WASHER, PL-B REG PLTD 3/ WASHER, PL-B REG PLTD U-BOLT, 3/8 X 4 PIPE PLTD REFERENCE: 1. THIS ASSEMBLY DRAWING IS SIMILAR TO THIS DRAWING IS FOR MACHINES WITH MUFFLER WRAP. 1600E Open Frame ( R01) 61

62 1.17 LIFT BAIL ASSEMBLY 1525XH ONLY R E Open Frame ( R01) 62

63 1.17 LIFT BAIL ASSEMBLY 1525XH ONLY KEY PART NUMBER QTY DESCRIPTION NOTES BAIL, LIFTING SUPT, PRIMARY FUEL FL TR C15 T SUPT, SECOND FUEL FL TR 1600 T SUPPORT, REL AY & SWITCH COVER, ACCESS REL AY & SWITCH SUPT, OIL FILTER MANF BLOCK 1500XH NUT, HEX PLTD 3/ CAPSCR, HEX GR5 3/8-16 X CAP SCR, HEX GR5 1-8 X 2 1/ SCREW, HEX SER WASHER 1/ 4-20 X 1/ SCREW, HEX SER WASHER 1/4-20 X Q94 5 WASHER, SPR LOCK REG PLTD 3/ WASHER, SPR LOCK REG PLTD Q71 5 WASHER, PL-B REG PLTD 3/ WASHER, PL-B REG PLTD E Open Frame ( R01) 63

64 1.18 AIR INLET SYSTEMS 750XHH XH R E Open Frame ( R01) 64

65 1.18 AIR INLET SYSTEMS 750XHH XH KEY PART NUMBER QTY DESCRIPTION NOTES TUBE,NYLON X.0 4W BLACK (FT) TUBE,ALUM AIR INLET 8 00 X 6 LG INO,SWT FLR ELEM CMACS RIGHT INO,SWT FLR ELEM CMACS LEFT AID,STARTING ELEC 24V C FILTER, AIR T CLP, 18 AI R FILTER 1600 T SUPT, A I R FL TRS HP LEG 1 TIER III SUPT, A I R FL TRS HP LEG2 TIER III SUPT, A I R FL TRS HP MTG TIER III HOSE, HUMP REDUCING 8 X TUBE, ALUM A I R INLET 8 00 X 17 LG TUBE, ALUM A I R INLET B 00 X 34 LG TUBE, ALUM AIR INLET 8 00 X 4 LG TUBE, ALUM AIR INLET ASSY 8 00 X SUPT, AIR INLET TUBE T3 O.F TUBE, ALUM A I R INLET ASSY 8 00 X SUPT, AIR INLET TUBES O.F CLAMP, HOSE 6 1/ BAND, MOUNTING ELBOW, A I R I N LET 90 RUBBER HOSE, HUMP 8 X CLAMP, HOSE HOSE, HUMP 8 X ELBOW, RUBBER 8 X 45 DEGREES TUBE, ALUM AIR INLET 8 00 X 12 LG ELBOW, 90D 1/4 TUBE X 1/8 FNPT NUT, HEX F PL TD 5/ E Open Frame ( R01) 65

66 1.18 AIR INLET SYSTEMS 750XHH XH KEY PART NUMBER QTY DESCRIPTION NOTES NUT, HEX F PLTD 3/ NUT, HEX LOCKING # CAPSCR, HEX GR5 3/8-16 X CAPSCR, HEX GR5 3/8-16 X 1 1/ SCREW, HEX SER WASHER 5/16-18 X 3/ SCREW, HEX SER WASHER 3/8-16 X SCREW, MACH-PAN HD #6-32 X 3/ WASHER, SPR LOCK REG PL TD 3/ WASHER, PL-B REG PL TD 3/8 NOTES: A1: MOUNT TO COOLER ASSY A2: MOUNT TO LIFTING BAIL A3: MOUNT TO FRAME A4: USE EXISTING HARDWARE B1: REFERENCE: ENGINE AND COMPRESSOR B2: REFERENCE: ENGINE FLUID RECOVERY TANK 1600E Open Frame ( R01) 66

67 Notes 1600E Open Frame ( R01) 67

68 1.19 AIR INLET SYSTEM XH ONLY R03 S1 1600E Open Frame ( R01) 68

69 1.19 AIR INLET SYSTEM XH ONLY R03 S2 1600E Open Frame ( R01) 69

70 1.19 AIR INLET SYSTEM XH ONLY KEY PART NUMBER QTY DESCRIPTION NOTES TUBE, NYL.25 OD X.040W BLK (FT) IND,SWT FLR ELEM CMACS RIGHT HOSE, HUMP REDUCING 8 X FILTER, AIR POWERCORE PIPE, AIR INLET UNIT TEE SUPT, AIR FLTRS SQ TUBE 1500XH SUPT, AIR FLTRS BOT 1500XH SUPT, AIR INLET TUBES 1500XH PIPE, AIR INLET 6 C18TT TURBO PIPE, AIR INLET 6 C18TT TURBO TUBE, ALUM AIR INLET 6 OD X 90 LG SUPT, AIR PIPING SS SUPT, AIR PIPING CS GUARD, CLR ASSY 1500XH TUBE, ALUM AIR INLET 8 OD X 30 LG GRD, CLR ASSY CS 1500XH GRD, CLR ASSY SS 1500XH SHLD,HT UPPER CAC TUBE 1500XH SUPT, AIR FILTERS 1500XH SUPT, CAC SHLD LIFT-BAIL 1500XH SUPT, CAC SHLD TUBES 1500XH CLP, T-BOLT SS BAND CONNECTOR, HUMP HOSE 6 ID BAND, MOUNTING CLAMP, T-BOLT SS BAND 5.50 ID ELBOW, AIR INLET 90 RUBBER HOSE, HUMP 8 X ELBOW, RUBBER RED 6 TO E Open Frame ( R01) 70

71 1.19 AIR INLET SYSTEM XH ONLY KEY PART NUMBER QTY DESCRIPTION NOTES CLAMP, HOSE 6-9/16 TO 6-1/ ELBOW,90DEG M SWVL 1/4T X 1/8NPT NUT, HEX F PLTD 5/ NUT, HEX F PLTD 3/ NUT, HEX LOCKING # NUT, HEX LOCKING 5/ NUT, HEX LOCKING 3/ CAPSCR, HEX GR5 5/16-18 X 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/ SCREW, MACH-PAN HD #6-32 X 3/ WASHER, PL-B REG PLTD 5/ WASHER, PL-B REG PLTD 3/ U-BOLT, 3/8 X 3 1/2 PIPE PLTD SCREW, HEX SERR WASHER M8 X 20 NOTES: A1: CONNECT TO FRAME A2: CONNECT TO LIFTING BAIL A3: CONNECT TO ENGINE TURBO A4: CONNECT TO COMPR UNIT A5: CONNECT TO MOUNT OF COOLER B1: REFERENCE E Open Frame ( R01) 71

72 1.20 ELECTRICAL SYSTEM DRAWING R E Open Frame ( R01) 72

73 1.20 ELECTRICAL SYSTEM DRAWING KEY PART NUMBER QTY DESCRIPTION NOTES SOL, SPNO 24VDC CONT-DUTY CABLE,BATY 2/0 X 34 LG. BLACK GRIP,CD N X 1/ WASHER, EXTERNAL SERRATED M ROD, 3/8-16 X SWITCH, BATTERY DISCONNECT 6-36V; 175 AMPS CONTINUOUS SWITCH, E-STOP HD PUSH-PULL RED GASKET, E-STOP LARGE PORTABLE MACH ENCL, LARGE PORTABLE E-STOP PLATE, COVER LARGE PORTABLE E-STOP LOCK, BATT DISCONNECT SWITCH MAT, ANTI-SLIP BATTERY BATY, 8D/12 VOLT - WET SUPT, BRKT BATTERY 1600D/DE CABLE, BATTERY 2/0 159 LG BLACK CABLE, BATTERY 2/0 125 LG RED ISOLATOR, VIBRATION 1 OD X 3/4 TALL CABLE, BATT #0 X CABLE, BATTERY UNIVERSAL TERMINALS CLAMP, HOSE 5/8 I.D CLAMP, HOSE 7/8 I.D NUT, HEX PLTD 3/ NUT, HEX F PLTD 1/ NUT, HEX F PLTD 3/ NUT, HEX LOCKING # NUT, HEX LOCKING 3/ SCREW, TC-HEX 1/4-20 X 3/ WASHER, SPR LOCK REG PLTD 3/8 1600E Open Frame ( R01) 73

74 1.20 ELECTRICAL SYSTEM DRAWING KEY PART NUMBER QTY DESCRIPTION NOTES WASHER, PL-B REG PLTD 3/ WRAP, TIE NYLON TY 23MX WRAP, TIE NYLON TF4-8X SCREW,RND PHILLIPS X 1/ CAPSCR, SOC BTN HD M4 X 16MM TUBING, CORRUGATED LOOM 1/ TUBING, CORRUGATED LOOM 1 1/ TUBING, CORRUGATED LOOM 2 37 SEE CHART 1 HARNESS, MAIN NOTES: A1: YELLOW SIDE OUT A2: REFERENCE FUEL TANK A3: SEE WORK-CENTER INSTRUCTIONS FOR LOCATION OF CLAMPS AND TIE WRAPS. A4: REFERENCE SUPT, RELAY AND SWITCH (MOUNT TO LIFTING BAIL) A: - TO DISCONNECT SWITCH (SHOWN) B: - CONNECTION AT STARTER C: - CONNECT TO FRAME (AT LIFTING BAIL) D: + CONNECT TO STARTER WIRING HARNESS CHART 1600E EXH E Open Frame ( R01) 74

75 Notes 1600E Open Frame ( R01) 75

76 1.21 ELECTRIC AND AIR PARTS HIGH PRESSURE R E Open Frame ( R01) 76

77 1.21 ELECTRIC AND AIR PARTS HIGH PRESSURE Key Part Number Qty Description Notes HOSE, MED PRESS 0.25 X SUPT, COMPASS ENCLOSURE 1600 T CONTROLLER, COMPASS H.P WS, EPDM 65 SHORE/SPGE RUBBER BLACK HOSE,MANF-CTL SYS VENT PLUG, ELECT COMPASS AUX CONNECTOR SUPT, CONTROLS HPC SA SA, HPC CONTROLS SA HOSE,MP 1/4 ID X 16 OAL SA,CTRLS 1600 T3 HP INNER SUPT,BRKT CTRL ASSY INNER ENCL,COMPASS 1600 HP T RTNR,REGULATOR 1600C & E SPCR,ASSY 1600C & E CNTRLS CONNECTOR, HOSE 5/16 HOSE X 1/4 NPT CLAMP, HOSE 3/ CLAMP, HOSE 9/16 ID NUT, HEX F PLTD 1/ NUT, HEX F PLTD 5/ SCREW, HEX SER WASHER 1/4-20 X 3/ SCREW, HEX SER WASHER 1/4-20 X 1 1/ SCREW, HEX SER WASHER 5/16-18 X 1/ SCREW, HEX SER WASHER 5/16-18 X 3/ SCREW, HEX SER WASHER 5/16-18 X 1 1/ SCREW, HEX SER WASHER 3/8-16 X 3/ HOSE, FUEL LINE 5/16 (FT) RIVET, POP 1/8 X 1/ UNION, 37FL BHD 1/4 SS 1600E Open Frame ( R01) 77

78 1.21 ELECTRIC AND AIR PARTS HIGH PRESSURE Key Part Number Qty Description Notes U-BOLT, 1/4 X 1 1/2 PIPE PLTD NUT, HEX LOCKING SS CAPSCR,SOC BTN HD SS #4-40 X 1/ ADPT,1/2F X 1/4M BRS CONN, 37 FL/MPT SS 1/2 X 1/ U-BOLT, 1/4 X 3/4 PIPE LG LEG NOTES: A1: MOUNT PANEL RECEPTACLE HERE (INCLUDED WITH THE MAIN HARNESS) 1600E Open Frame ( R01) 78

79 Notes 1600E Open Frame ( R01) 79

80 1.22 HIGH PRESSURE ELECTRICAL AND PNEUMATIC CONTROL SYSTEMS R E Open Frame ( R01) 80

81 1.22 HIGH PRESSURE ELECTRICAL AND PNEUMATIC CONTROL SYSTEMS Key Part Number Qty Description Notes REG, BACK PRESS CONTROL 1/ VALVE, PRESSURE REGULATOR VLV, PRESS DIFFERENTIAL VLV,SOL 2-WAY HI-TEMP 600PSI TUBE,ELBOW 1/4 SS 7 X TUBE,PILOT HI/LO SOL 1/4 SS VALVE, REGULATOR 400 PSI GAUGE, CTL AIR PRESS PSI VALVE, SHUTTLE 1/4 (DBL CHK) BULKHEAD, PIPE 1/4 NPT CONN, TUBE-M 1/4 X 1/4 SS ELBOW, TUBE 90 DEG M 1/4 X 1/8 SS ELBOW, TUBE 90 DEG M 1/4 X 1/4 SS ELBOW, PIPE 90M/F 1/4 x 1/4 BRASS NIPPLE, PIPE-HX BRASS 1/4 X 1/ CONN, 37 FL/MPT SS 1/4 X 1/ ELBOW, 37FL 90M SS 1/4 X 1/ NIPPLE, PIPE HXL BRASS 1/4 X CROSS, PIPE 1/4 FORGED SS NOTES: A1: TRIM TO FIT 1600E Open Frame ( R01) 81