Manual de Mantenimiento Sullair 185

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.
AIR CARE
SEMINAR TRAINING
Sullair Air Care Seminars are 3-day courses that provide hands-on instruction in the
proper operation, maintenance and service of Sullair equipment. Individual seminars on
Portable compressors are presented at regular intervals throughout the year at a dedi-
cated training facility at the Sullair corporate headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service parts,
troubleshooting of the most common problems, and actual equipment operation. The
seminars are recommended for rental house and Contractor Maintenance and service
personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department

1-888-SULLAIR or 219-879-5451 (ext. 5363)
www.sullair.com
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department
TABLE OF CONTENTS
OPERATOR IS REQUIRED TO READ

ENTIRE INSTRUCTION MANUAL
Section 1 PAGE
SAFETY 1 1.1 GENERAL
1 1.2 TOWING
3 1.3 PRESSURE RELEASE
4 1.4 FIRE AND EXPLOSION
5 1.5 MOVING PARTS
6 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
6 1.7 TOXIC AND IRRITATING SUBSTANCES
6 1.8 ELECTRICAL SHOCK
7 1.9 LIFTING
7 1.10 ENTRAPMENT
7 1.11 JUMP STARTING
Section 2
DESCRIPTION
9 2.1 INTRODUCTION
9 2.2 DESCRIPTION OF COMPONENTS
10 2.3 SULLAIR COMPRESSOR UNIT,
FUNCTIONAL DESCRIPTION
10 2.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
10 2.5 COMPRESSOR DISCHARGE SYSTEM,
12 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
16 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
16 2.8 INSTRUMENT PANEL GROUP,
18 2.9 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION
18 2.10 SHUTDOWN SYSTEM, FUNCTIONAL DESCRIPTION
Section 3
SPECIFICATIONS 21 3.1A SPECIFICATIONS - PERKINS AND CATERPILLAR
22 3.1B SPECIFICATIONS - JOHN DEERE 125, 130
(2-WHEEL AND LRG)
23 3.1C SPECIFICATIONS - JOHN DEERE 49HP, 160H, 185
(2-WHEEL AND LRG)
Continued...
TABLE OF CONTENTS
Section 3 PAGE
SPECIFICATIONS 24 3.2 LUBRICATION GUIDE
(CONTINUED) 24 3.3 APPLICATION GUIDE
24 3.4 LUBRICATION GUIDE - ENGINE
Section 4
OPERATION 25 4.1 GENERAL
25 4.2 PURPOSE OF CONTROLS
26 4.3 START-UP PROCEDURE
26 4.4 SUBSEQUENT START-UP PROCEDURE
26 4.5 SHUTDOWN PROCEDURE
Section 5
MAINTENANCE 27 5.1 GENERAL
27 5.2 DAILY OPERATION
27 5.3 MAINTENANCE AFTER INITIAL 50 HOURS
OF OPERATION
27 5.4 MAINTENANCE EVERY 50 HOURS
28 5.9 MAINTENANCE ANNUALLY OR EVERY 1500 HOURS
28 5.10 MAINTENANCE EVERY YEAR OR 12,000 MILES
28 5.11 PARTS REPLACEMENT AND ADJUSTMENT
PROCEDURES
28 COMPRESSOR FLUID CHANGE PROCEDURE
28 AIR FILTER MAINTENANCE
29 SEPARATOR ELEMENT REPLACEMENT
29 PROCEDURE FOR SETTING SPEED AND PRESSURE
CONTROLS ON PORTABLE COMPRESSORS WITH
POPPET VALVE
31 OPERATING ADJUSTMENTS
31 BEARING LUBRICATION
32 5.12 TROUBLESHOOTING INTRODUCTION
32 5.13 TROUBLESHOOTING GUIDE
Section 6
NOISE CONTROL 35 6.1 NOISE EMISSIONS WARRANTY
35 6.2 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
35 6.3 NOISE EMISSIONS MAINTENANCE AND
MAINTENANCE RECORD LOG
Continued...
TABLE OF CONTENTS
Section 7 PAGE
ILLUSTRATIONS
AND PARTS LIST 39 7.1 PROCEDURE FOR ORDERING PARTS
40 7.2 RECOMMENDED SPARE PARTS LIST
42 7.3A ENGINE, COMPRESSOR AND PARTS - PERKINS
AND CAT MODELS 125, 130 & 185
46 7.3B ENGINE, COMPRESSOR AND PARTS - JOHN
DEERE MODELS 125, 130, 185 & 49HP
50 7,.3C ENGINE, COMPRESSOR AND PARTS - JOHN
DEERE MODEL 160H
54 7.4A AIR INLET AND EXHAUST - PERKINS AND CATERPILLAR
MODELS 125, 130 & 185
56 7.4B AIR INLET AND EXHAUST - JOHN DEERE MODELS 125,
130, 185, 49HP & 160H
58 7.5 RADIATOR AND COMPRESSOR FLUID COOLING SYSTEM -
ALL MODELS
62 7.6 FRAME, RUNNING GEAR AND PARTS - ALL MODELS
66 7.7A DISCHARGE SYSTEM AND PARTS - ALL MODELS
EXCEPT JOHN DEERE 160H
70 7.7B DISCHARGE SYSTEM AND PARTS - JOHN DEERE
MODEL 160H
74 7.8A REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY -
ALL MODELS EXCEPT JOHN DEERE 160H
74 7.8B REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY -
JOHN DEERE MODEL 160H
76 7.9 ELECTRIC PARTS - ALL MODELS
78 7.10 FUEL TANK AND PARTS - ALL MODELS
80 7.11 CANOPY, ACOUSTICAL PANELS AND PARTS -
ALL MODELS
82 7.12 INSTRUMENT PANEL, PANEL DOOR AND MOUNTING
PARTS - ALL MODELS
84 7.13A INSTRUMENT PANEL AND PARTS - JOHN DEERE /
CATERPILLAR / PERKINS MODELS 125, 130, 185,
49HP (STANDARD GAUGE)
86 7.13B INSTRUMENT PANEL AND PARTS - JOHN DEERE
MODEL 160H (STANDARD GAUGE)
88 7.13C INSTRUMENT PANEL AND PARTS - CATERPILLAR
AND PERKINS (AUSTRALIAN) MODELS 130-185
90 7.13D INSTRUMENT PANEL AND PARTS - JOHN DEERE /
CATERPILLAR / PERKINS MODELS 125, 130, 185 & 49HP
(FULL GAUGE)
92 7.13E INSTRUMENT PANEL AND PARTS - JOHN DEERE
MODEL 160H (FULL GAUGE)
Continued...
TABLE OF CONTENTS
Section 7 PAGE
ILLUSTRATIONS
AND PARTS LIST
(CONTINUED) 94 7.14 SINGLE HOSE REEL OPTION - ALL MODELS
96 7.15 DUAL HOSE REEL OPTION- ALL MODELS
100 7.16A ONE PINT OILER OPTION- ALL MODELS
102 7.16B ONE QUART OILER / MOISTURE SEPARATOR OPTION -
ALL MODELS
104 7.17 DECALS
116 7.18 DECAL LOCATIONS - ALL MODELS
120 7.19 CANADIAN TAIL / CLEARANCE LIGHTS - ALL MODELS
122 7.20 DRAWBAR INSTALLATION - STANDARD
Section 1
SAFETY
1.1 GENERAL
Sullair Corporation designs and manufactures all of N NOTE (CONT.)
its products so they can be operated safely. See rated limit in tow vehicle Operator’s Manual,
However, the responsibility for safe operation rests and review its instructions and other require-
with those who use and maintain these products. ments for safe towing.
The following safety precautions are offered as a
guide which, if conscientiously followed, will mini- A. PREPARING TO TOW
mize the possibility of accidents throughout the 1. Prior to hitching the air compressor to the tow
useful life of this equipment. Read the CIMA Safety vehicle, inspect all attachment parts and equip-
Manual prior to compressor operation and towing, if ment, checking for (i) signs of excessive wear or
applicable in your area. corrosion, (ii) parts that are cracked, bent, dented
The air compressor should be operated only by or otherwise deformed or degraded, and (iii) loose
those who have been trained and delegated to do nuts, bolts or other fasteners. Should any such con-
so, and who have read and understood this dition be present, DO NOT TOW until the problem
Operator’s Manual. Failure to follow the instruc- is corrected.
tions, procedures and safety precautions in this 2. Back the tow vehicle to the compressor and posi-
manual can result in accidents and injuries. tion it in preparation for coupling the compressor.
NEVER start the air compressor unless it is safe to 3. If the compressor is provided with a drawbar
do so. DO NOT attempt to operate the air com- latched in the vertical upright position, carefully
pressor with a known unsafe condition. Tag the air unlatch drawbar and lower it to engage the coupling
compressor and render it inoperative by discon- device. If not, raise drawbar to engage coupling
necting the battery so others who may not know of device or otherwise couple the compressor to the
the unsafe condition will not attempt to operate it towing vehicle.
until the condition is corrected.
Use and operate the air compressor only in full WARNING
compliance with all pertinent OSHA requirements
and/or all pertinent Federal, State and Local codes This equipment may be tongue heavy. DO NOT
attempt to raise or lower the drawbar by hand if
or requirements. the weight is more than you can safely handle.
DO NOT modify the compressor except with written
factory approval. Use the screw jack provided or a chain fall if you
Each day walk around the air compressor and cannot lift or lower it without avoiding injury to your-
inspect for leaks, loose or missing parts, damaged self or others. Keep hands and fingers clear of the
parts or parts out of adjustment. Perform all recom- coupling device and all other pinch points. Keep
mended daily maintenance. feet clear of drawbar to avoid injury in case it should
slip from your hands.
Inspect for torn, frayed, blistered or otherwise dete-
riorated and degraded hoses. Replace as required. 4. Make sure the coupling device is fully engaged,
closed and locked.
NOTE 5. If chains are provided, pass each chain through
its point of attachment on the towing vehicle; then
Estimated hose life based on a 5-day 8-hour
work week is 3 years. These conditions exist on hook each chain to itself by passing the grab hook
an 8-hour shift only. Any other operation of the over (not through) a link. Cross chains under front
equipment other than 8-hour shifts would short- of drawbar before passing them through points of
en the hose life based on hours of operation. attachment on towing vehicle to support front of
1.2 TOWING (I) drawbar in case it should accidentally become
uncoupled.
NOTE 6. Make sure that the coupling device and adjacent
DO NOT tow the compressor should its weight structures on the towing vehicle (and also, if uti-
exceed the rated limit of the tow vehicle, as the lized, chain adjustment, brake and/or electrical
vehicle may not brake safely with excess weight. interconnections) DO NOT interfere with or restrict
continued motion of any part of the compressor, including its
(I) While not towed in the usual sense of the word, many of these instructions are directly applicable to skid-mount-
ed portable air compressors as well.
1
Section 1
SAFETY
coupling device, with respect to the towing vehicle pressors provided with same, are clean and func-
when maneuvering over any anticipated terrain. tional.
7. If provided, make sure chain length, brake and 11. Make sure all service air hoses (not air brake
electrical interconnections provide sufficient slack hoses) are disconnected or are fully stowed and
to prevent strain when cornering and maneuvering, secured on hose reels, if provided.
yet are supported so they cannot drag or rub on 12. Make sure all access doors and tool box covers
road, terrain or towing vehicle surfaces which might are closed and latched. If the compressor is large
cause wear that could render them inoperative. enough to hold a man, make sure all personnel are
out before closing and latching access doors.
WARNING 13. Make sure parking brakes in towing vehicle are
Retract the front screw jack only after attaching set, or that its wheel are chocked or blocked, or that
the compressor to the tow vehicle. Raise the it is otherwise restrained from moving. Then,
screw jack to its full up position and pull the pin
release the compressor parking brakes, if provided.
connecting the jack to the drawbar. Rotate the
screw jack to its stowed position, parallel to the 14. Make sure the compressor wheels are not
drawbar, and reinsert the pin. Make sure the jack chocked or blocked, and that all tie-downs, if any,
is secured in place prior to towing.
are free.
If a caster wheel is provided on the screw jack it
is part of the screw jack and can not be removed. 15. Test running brake operation, including break-
Follow the same procedure for stowing away the away switch operation if provided, before attempt-
wheeled jack as you would for the standard ing to tow the compressor at its rated speed or less
screw jack. Pull the pin connecting the jack to
the drawbar and raise the screw jack to its full up
when conditions prevail.
position. Rotate the screw jack to its stowed 16. DO NOT carry loose or inappropriate tools,
position, parallel to the drawbar, and reinsert the
equipment or supplies on or in the compressor.
pin. Make sure the jack is secured in place prior
to towing. 17. DO NOT load this equipment with accessories
or tools such that it is unbalanced from side to side
or front to back. Such unbalance will reduce the
WARNING towability of this equipment and may increase the
This equipment may be tongue heavy. DO NOT possibility of tipping, rolling over, jackknifing, etc.
attempt to raise or lower the drawbar by hand if Loss of control of the towing vehicle may result.
the weight is more than you can safely handle.
B. TOWING
8. On two-wheeled models, fully retract front screw 1. Observe all Federal, State, and Local laws while
jack and any rear stabilizer legs. If a caster wheel towing this equipment (including those specifying
is provided on the screw jack it is part of the screw minimum speed).
jack and can not be removed. Follow the same 2. DO NOT exceed the towing speeds listed below
procedure for stowing away the wheeled jack as under ideal conditions. Reduce your speed accord-
you would for the standard screw jack. Pull the pin ing to posted speed limits, weather, traffic, road or
connecting the jack to the drawbar and raise the terrain conditions.
screw jack to its full up position. Rotate the screw a. Two axle four-wheel steerable models:
jack to its stowed position, parallel to the drawbar, 15MPH (24KMPH).
and reinsert the pin. Make sure the jack is secured
in place prior to towing. b. All other models: 55 MPH (88KMPH).
9. Make sure tires are in good condition and are the 3. Remember that the portable air compressor may
size (load range) specified and are inflated to the approach or exceed the weight of the towing vehi-
specified pressures. DO NOT change the tire size cle. Maintain increased stopping distances accord-
or type. Also, make sure wheel bolts, lugs or nuts ingly. DO NOT make sudden lane changes, U-
are tightened to the specified torques. turns, or other maneuvers. Such maneuvers can
cause the compressor to tip, roll over, jackknife or
10. If provided, make sure all dual stop, tail direc- slide and cause loss of control of the towing vehi-
tional and clearance lights are operating properly cle. Tipping, rolling over, etc. can occur suddenly
and that their lenses are clean and functional. Also, without warning. U-turns especially should be
make sure all reflectors and reflecting surfaces, made slowly and carefully.
including the slow moving vehicle emblem on com-
4. Avoid grades in excess of 15° (27%).
2
Section 1
SAFETY
5. Avoid potholes, rocks and other obstructions, and
soft shoulders or unstable terrain. WARNING (cont).
6. Maneuver in a manner that will not exceed the Raise the screw jack to its full up position and
freedom of motion of the compressor’s drawbar pull the pin connecting the jack to the drawbar.
and/or coupling device, in or on the towing vehicle’s Rotate the screw jack to its stowed position, par-
coupling device and/or adjacent structure whether allel to the drawbar, and reinsert the pin. Make
sure the jack is secured in place prior to towing.
towing forward or backing up, regardless of the ter-
If a caster wheel is provided on the screw jack it
rain being traversed. is part of the screw jack and can not be removed.
7. DO NOT permit personnel to ride in or on the Follow the same procedure for stowing away the
compressor. wheeled jack as you would for the standard
screw jack. Pull the pin connecting the jack to
8. Make sure the area behind, in front of, and under the drawbar and raise the screw jack to its full up
the compressor is clear of all personnel and position. Rotate the screw jack to its stowed
position, parallel to the drawbar, and reinsert the
obstructions prior to towing in any direction. pin. Make sure the jack is secured in place prior
9. DO NOT permit personnel to stand or ride on the to towing.
drawbar, or to stand or walk between the compres-
sor and the towing vehicle.
WARNING
C. PARKING OR LOCATING COMPRESSOR
1. Park or locate compressor on a level surface, if This equipment may be tongue heavy. DO NOT
possible. If not, park or locate compressor across attempt to raise or lower the drawbar by hand if
the weight is more than you can safely handle.
grade so the compressor does not tend to roll
downhill. DO NOT park or locate compressor on 9. If a caster wheel is provided on the screw jack it
grades exceeding 15° (27%). is part of the screw jack and can not be removed.
2. Make sure compressor is parked or located on a Follow the same procedure for stowing away the
firm surface than can support its weight. wheeled jack as you would for the standard screw
jack. Raise the screw jack to its full up position and
3. Park or locate compressor so the wind, if any, pull the pin connecting the jack to the drawbar.
tends to carry the exhaust fumes and radiator heat Rotate the screw jack to its stowed position, paral-
away from the compressor air inlet openings, and lel to the drawbar, and reinsert the pin. Make sure
also where the compressor will not be exposed to the jack is secured in place prior to towing.
excessive dust from the work site.
10. Disconnect coupling device, keeping hands and
4. On four-wheel models, park compressor with fingers clear of all pinch points. If the compressor is
front wheels in straight ahead position. provided with a drawbar, DO NOT attempt to lift the
5. Set parking brakes and disconnect breakaway drawbar or if hinged, to raise it to the upright posi-
switch cable and all other interconnecting electrical tion, by hand, if the weight is more than you can
and/or brake connections, if provided. safely handle. Use a screwjack or chain fall if you
6. Block or chock both sides of all wheels. cannot lift or raise the drawbar without avoiding
injury to yourself or others.
7. If provided, unhook chains and remove them
from the points of chain attachment on the towing 11. When possible, stow hinged drawbar in the ver-
vehicle, then hook chains to bail on drawbar or wrap tical upright position. Make certain it is securely
chains around the drawbar and hook them to them- latched in the vertical upright position. Keep feet
selves to keep chains off the ground which might clear of drawbar at all times to avoid crushing acci-
accelerate rusting. dents in case it should slip from your hands or oth-
erwise fall to the ground.
8. Lower front screw jack and/or any front and rear
stabilizer legs. Make sure the surface they contact 12. Move the towing vehicle well clear of the parked
has sufficient load bearing capability to support the compressor and erect hazard indicators, barricades
weight of the compressor. and/or flares (if at night) if compressor is parked on
or adjacent to public roads. Park so as not to inter-
WARNING fere with traffic.
Retract the front screw jack only after attaching
1.3 PRESSURE RELEASE
the compressor to the tow vehicle. A. Open the pressure relief valve at least weekly to
make sure it is not blocked, closed, obstructed or
continued
3
Section 1
SAFETY
otherwise disabled. M. This equipment is supplied with an ASME
B. Install an appropriate flow-limiting valve between designed pressure vessel protected by an ASME
the compressor service air outlet and the shutoff rated relief valve. Lift the handle once a week to
(throttle) valve, when an air hose exceeding 1/2” make sure the valve is functional. DO NOT lift the
(13mm) inside diameter is to be connected to shut- handle while machine is under pressure.
off (throttle) valve, to reduce pressure in case of N. If the machine is installed in an enclosed area it
hose failure, per OSHA Standard 29 CFR 1926.302 is necessary to vent the relief valve to the outside
(b) (7) or any applicable Federal, State and Local of the structure or to an area of non-exposure.
codes, standards and regulations. O. DO NOT remove radiator filler cap until the
C. When the hose is to be used to supply a mani- coolant temperature is below its boiling point. Then
fold, install an additional appropriate flow-limiting loosen cap slowly to its stop to relieve any excess
valve between the manifold and each air hose pressure and make sure coolant is not boiling
exceeding 1/2” (13mm) inside diameter that is to be before removing cap completely. Remove radiator
connected to the manifold to reduce pressure in filler cap only when cool enough to touch with a
case of hose failure. bare hand.
D. Provide an appropriate flow-limiting valve for P. The ethyl ether in the replaceable cylinders used
each additional 75 feet (23 meters) of hose in runs in diesel ether starting aid systems (optional) is
of air hose exceeding 1/2” (13mm) inside diameter under pressure. DO NOT puncture or incinerate
to reduce pressure in case of hose failure. those cylinders. DO NOT attempt to remove the
E. Flow-limiting valves are listed by pipe size and center valve core or side pressure relief valve from
rated CFM. Select appropriate valve accordingly. these cylinders regardless of whether they are full
or empty.
F. DO NOT use tools that are rated below the max-
imum rating of this compressor. Select tools, air Q. If a manual blowdown valve is provided on the
hoses, pipes, valves, filters and other fittings receiver, open the valve to insure all internal pres-
accordingly. DO NOT exceed manufacturer’s rated sure has been vented prior to servicing any pres-
safe operating pressures for these items. surized component of the compressor air/fluid sys-
tem.
G. Secure all hose connections by wire, chain or
other suitable retaining device to prevent tools or 1.4 FIRE AND EXPLOSION
hose ends from being accidentally disconnected A. Refuel at a service station or from a fuel tank
and expelled. designed for its intended purpose. If this is not pos-
sible, ground the compressor to the dispenser prior
H. Open fluid filler cap only when compressor is not to refueling.
running and is not pressurized. Shut down the
compressor and bleed the sump (receiver) to zero B. Clean up spills of fuel, fluid, battery electrolyte or
internal pressure before removing the cap. coolant immediately if such spills occur.
I. Vent all internal pressure prior to opening any C. Shut off air compressor and allow it to cool.
line, fitting, hose, valve, drain plug, connection or Then keep sparks, flames and other sources of
other component, such as filters and line oilers, and ignition away and DO NOT permit smoking in the
before attempting to refill optional air line anti-icer vicinity when adding fuel, or when checking or
systems with antifreeze compound. adding electrolyte to batteries, or when checking or
adding fluid, or when checking diesel engine ether
J. Keep personnel out of line with and away from starting aid systems or replacing cylinders, or when
the discharge opening of hoses, tools or other refilling air line anti-icer systems antifreeze com-
points of compressed air discharge. pound.
K. DO NOT use air at pressures higher than 30 D. DO NOT permit liquids, including air line anti-
psig (2.1 bar) for cleaning purposes, and then only icer system antifreeze compound or fluid film to
with effective chip guarding and personal protective accumulate on bottom covers or on, under or
equipment per OSHA Standard 29 CFR 1910.242 around acoustical material, or on any external or
(b) or any applicable Federal, State and Local internal surfaces of the air compressor. Wipe down
codes, standards and regulations. using an aqueous industrial cleaner or steam clean
L. DO NOT engage in horseplay with air hoses as as required. If necessary remove acoustical mate-
death or serious injury may result. rial, clean all surfaces and then replace acoustical
4
Section 1
SAFETY
material. Any acoustical material with a protective only in well-ventilated areas away from heat, open
covering that has been torn or punctured should be flame or sparks. DO NOT install, store or otherwise
replaced immediately to prevent accumulation of expose ether cylinders to temperatures above
liquids or fluid film within the material. DO NOT use 160°F (71°C). Remove ether cylinder from the com-
flammable solvents for cleaning purposes. pressor when operating in ambient temperatures
E. Disconnect the grounded (negative) battery con- above 60°F (16°C).
nection prior to attempting any repairs or cleaning P. DO NOT attempt to use ether as a starting aid in
inside the enclosure. Tag the battery connections gasoline engines or diesel engines with glow plugs
so others will not unexpectedly reconnect it. as serious personnel injury or property damage
F. Keep electrical wiring, including the battery ter- may result.
minals and other terminals, in good condition. Q. DO NOT spray ether into compressor air filter or
Replace any wiring that has cracked, cut abraded into an air filter that serves both the engine and the
or otherwise degraded insulation or terminals that compressor as serious damage to the compressor
are worn, discolored or corroded. Keep all termi- or personal injury may result.
nals clean and tight. R. Antifreeze compound used in air line anti-icer
G. Turn off battery charger before making or break- systems contains methanol which is flammable.
ing connections to the battery. Use systems and refill with compound only in well-
H. Keep grounded conductive objects such as tools ventilated areas away from heat, open flames or
away from exposed live electrical parts such as ter- sparks. DO NOT expose any part of these systems
minals to avoid arcing which might serve as a or the antifreeze compound to temperatures above
source of ignition. 150°F (66°C). Vapors from the antifreeze com-
pound are heavier than air. DO NOT store com-
I. Replace damaged fuel tanks or lines immediately pound or discharge treated air in confined or unven-
rather than attempt to weld or otherwise repair tilated areas. DO NOT store containers or
them. DO NOT store or attempt to operate the antifreeze compound in direct sunlight.
compressor with any known leaks in the fuel sys-
tem. Tag the compressor and render it inoperative S. Store flammable fluids and materials away from
until repair can be made. your work area. Know where fire extinguishers are
and how to use them, and for what type of fire they
J. Remove any acoustical material or other materi- are intended. Check readiness of fire suppression
al that may be damaged by heat or that may sup- systems and detectors if so equipped.
port combustion prior to attempting weld repairs.
Remove diesel engine ether starting aid cylinders 1.5 MOVING PARTS
and air line anti-icer system components containing A. Keep hands, arms and other parts of the body
antifreeze compound, prior to attempting weld and also clothing away from belts, pulleys and other
repairs in any place other than the fuel system. DO moving parts.
NOT weld on or near the fuel system. B. DO NOT attempt to operate the compressor with
K. Keep a suitable fully charged class BC or ABC the fan or other guards removed.
fire extinguisher or extinguishers nearby when serv- C. Wear snug-fitting clothing and confine long hair
icing and operating the compressor. when working around this compressor, especially
L. Keep oily rags, trash, leaves, litter or other com- when exposed to hot or moving parts inside the
bustibles out of and away from the compressor. enclosure.
M. Open all access doors and allow the enclosure D. Keep access doors closed except when making
to ventilate thoroughly prior to attempting to start repairs or adjustments, performing service or when
the engine. starting or stopping the compressor.
N. DO NOT operate compressor under low over- E. Make sure all personnel are out of and clear of
hanging leaves or permit such leaves to contact hot the compressor prior to attempting to start or oper-
exhaust system surfaces when operating the com- ate it.
pressor in forested areas. F. Shut off engine before adding fuel, fluid, coolant
O. Ethyl ether used in diesel engine ether starting lubricants, air line antifreeze compound or battery
aid systems is extremely flammable. Change cylin- electrolyte, or before replacing ether starting aid
ders, or maintain or troubleshoot these systems cylinders.
5
Section 1
SAFETY
G. Disconnect the grounded negative battery con- ventilated areas.
nection to prevent accidental engine operation prior D. If the compressor is operated indoors, discharge
to attempting repairs or adjustments. Tag the bat- engine exhaust fumes outdoors.
tery connection so others will not unexpectedly
reconnect it. E. Locate the compressor so that exhaust fumes
are not apt to be carried towards personnel, air
H. When adjusting the controls, it may require oper- intakes servicing personnel areas or towards the air
ation of the equipment during adjustment. DO NOT intake of any portable or stationary compressor.
come in contact with any moving parts while adjust-
ing the control regulator and setting the engine F. Fuels, fluids, coolants, lubricants and battery
RPM. Make all other adjustments with the engine electrolyte used in the compressor are typical of the
shut off. When necessary, make adjustment, other industry. Care should be taken to avoid accidental
than setting control regulator and engine RPM, with ingestions and/or skin contact. In the event of
the engine shut off. If necessary, start the engine ingestion seek medical treatment promptly. DO
and check adjustment. If adjustment is incorrect, NOT induce vomiting if fuel is ingested. Wash with
shut engine off, readjust, then restart the engine to soap and water in the event of skin contact.
recheck adjustment. G. Wear an acid-resistant apron and a face shield
I. Keep hands, feet, floors, controls and walking or goggles when servicing the battery. If electrolyte
surfaces clean and free of fluid, water, antifreeze or is spilled on skin or clothing, immediately flush with
other liquids to minimize possibility of slips and large quantities of water.
falls. H. Ethyl ether used in diesel engine ether starting
1.6 HOT SURFACES, SHARP EDGES AND SHARP aid systems is toxic, harmful or fatal if swallowed.
CORNERS Avoid contact with the skin or eyes and avoid
A. Avoid bodily contact with hot fluid, hot coolant, breathing the fumes. If swallowed, DO NOT induce
hot surfaces and sharp edges and corners. vomiting, but call a physician immediately.
B. Keep all parts of the body away from all points of I. Wear goggles or a full face shield when testing
air discharge and away from hot exhaust gases. ether starting aid systems or when adding
antifreeze compound to air line anti-icer systems.
C. Wear personal protective equipment including Keep openings of valve or atomizer tube of ether
gloves and head covering when working in, on or starting aid system pointed away from yourself and
around the compressor. other personnel.
D. Keep a first aid kit handy. Seek medical assis- J. If ethyl ether or air line anti-icer system
tance promptly in case of injury. DO NOT ignore antifreeze compound enters the eyes or if fumes
small cuts and burns as they may lead to infection. irritate the eyes, they should be washed with large
1.7 TOXIC AND IRRITATING SUBSTANCES quantities of clean water for 15 minutes. A physi-
A. DO NOT use air from this compressor for respi- cian, preferably any eye specialist, should be con-
ration (breathing) except in full compliance with tacted immediately.
OSHA Standards 29 CFR 1920 and any other K. DO NOT store ether cylinders or air line anti-icer
Federal, State or Local codes or regulations. system antifreeze compound in operator’s cabs or
in other similar confined areas.
DANGER L. The antifreeze compound used in air line anti-
Death or serious injury may occur from inhaling icer systems contains methanol and is toxic, harm-
compressed air without using proper safety ful or fatal if swallowed. Avoid contact with the skin
equipment. See OSHA standards, and/or any or eyes and avoid breathing the fumes. If swal-
Federal, State or Local codes or regulations on
safety equipment.
lowed, induce vomiting by administering a table-
spoon of salt in each glass of clean warm water
until vomit is clear, then administer two tablespoons
B. DO NOT use air line anti-icer systems in air lines of baking soda in a glass of clean water. Have
supplying respirators or other breathing air utiliza- patient lay down and cover eyes to exclude light.
tion equipment and DO NOT discharge air from Call a physician immediately.
these systems into unventilated or other confined
areas. 1.8 ELECTRICAL SHOCK
A. Keep the towing vehicle or equipment carrier,
C. Operate the compressor only in open or well-
6
Section 1
SAFETY
compressor hoses, tools and all personnel at least K. If the compressor is provided with parking
10 feet (3 meters) from power lines and buried brakes, make sure they are set, and in any event,
cables. block or chock both sides of all running wheels
B. Keep all parts of the body and any hand-held before disengaging the lifting hook.
tools or other conductive objects away from 1.10 ENTRAPMENT
exposed live parts of electrical system. Maintain dry A. Make sure all personnel are out compressor
footing, stand on insulating surfaces and DO NOT before closing and latching enclosure doors.
contact any other portion of the compressor when B. If the compressor is large enough to hold a man
making adjustments or repairs to exposed live parts and if it is necessary to enter it to perform service
of the electrical system. adjustments, inform other personnel before doing
C. Attempt repairs only in clean, dry and well- light- so, or else secure the access door in the open posi-
ed and ventilated areas. tion to avoid the possibility of others closing and
D. Stay clear of the compressor during electrical possibly latching the door with personnel inside.
storms! It can attract lightning. 1.11 JUMP STARTING
1.9 LIFTING A. Observe all safety precautions mentioned else-
A. If the compressor is provided with a lifting bail, where in this manual.
then lift by the bail provided. If no bail is provided, B. Batteries may contain hydrogen gas which is
then lift by sling. Compressors to be air lifted by hel- flammable and explosive. Keep flames, sparks and
icopter must not be supported by the lifting bail, but other sources of ignition away.
by slings instead. In any event, lift only in full com- C. Batteries contain acid which is corrosive and poi-
pliance with OSHA Standards 29 CFR 1910 subpart sonous. DO NOT allow battery acid to contact
N or any other Local, State, Military and Federal eyes, skin, fabrics or painted surfaces as serious
regulations that may apply. personal injury or property damage could result.
B. Inspect lifting bail and points of attachment for Flush any contacted areas thoroughly with water
cracked welds and for cracked, bent, corroded or immediately. Always wear an acid-resistant apron
otherwise degraded members and for loose bolts or and face shield when attempting to jump start the
nuts prior to lifting. compressor.
C. Make sure entire lifting, rigging and supporting D. Remove all vent caps (if so equipped) from the
structure has been inspected, is in good condition battery or batteries in the compressor. DO NOT per-
and has a rated capacity of at least the net weight mit dirt or foreign matter to enter the open cells.
of the compressor plus an additional 10% E. Check fluid level. If low, bring fluid to proper level
allowance for weight of snow, ice, mud or stored before attempting to jump start (not applicable to
tools and equipment. If your are unsure of the maintenance-free batteries).
weight, then weigh compressor before lifting.
F. DO NOT attempt to jump start if fluid is frozen or
D. Make sure lifting hook has a functional safety slushy. Bring batteries up to at least 60°F (16°C)
latch or equivalent, and is fully engaged and latched before attempting to jump start or it may explode.
on the bail.
G. Cover open cells of all compressor batteries with
E. Use guide ropes or equivalent to prevent twisting clean dampened cloths before attempting to jump
or swinging of the compressor once it has been lift- start.
ed clear of the ground.
H. Attempt to jump start only with a vehicle having
F. DO NOT attempt to lift in high winds. a negative ground electrical system with the same
G. Keep all personnel out from under and away voltage, and is also equipped with a battery or bat-
from the compressor whenever it is suspended. teries of comparable size or larger than supplied in
H. Lift compressor no higher than necessary. the compressor. DO NOT attempt to jump start
using motor generator sets, welders or other
I. Keep lift operator in constant attendance whenev- sources of DC power as serious damage may
er compressor is suspended. result.
J. Set compressor down only on a level surface I. Bring the starting vehicle alongside the compres-
capable of supporting at least its net weight plus an sor, but DO NOT permit metal to metal contact
additional 10% allowance for the weight of snow, between the compressor and the starting vehicle.
ice, mud or stored tools and equipment.
7
Section 1
SAFETY
J. Set the parking brakes of both the compressor (if compressors and if the starting vehicle is provided
provided) and the starting vehicle or otherwise with two (2) 12V batteries connected in series, con-
block both sides of all wheels. nect the jumper cable to the negative (NEG) (-) ter-
K. Place the starting vehicle in neutral or park, turn minal of the grounded battery.
off all non-essential accessory electrical loads and R. Check your connections. DO NOT attempt to
start its engine. start a 24V compressor with one 12V battery in the
L. Use only jumper cables that are clean, in good starting vehicle. DO NOT apply 24V to one 12V
condition and are heavy enough to handle the start- battery in the compressor.
ing current. S. Connect the other end of this same jumper cable
M. Avoid accidental contact between jumper cable to a clean portion of the compressor engine block
terminal clips or clamps and any metallic portion of away from fuel lines, the crank case breather open-
either the compressor or the starting vehicle to min- ing and the battery.
imize the possibility of uncontrolled arcing which T. Start the compressor in accordance with normal
might serve as a source of ignition. procedure. Avoid prolonged cranking.
N. Positive battery terminals are usually identified U. Allow the compressor to warm up. When the
by a plus (+) sign on the terminal and the letters compressor is warm and operating smoothly at nor-
POS adjacent to the terminal. Negative battery ter- mal idle RPM, disconnect the jumper cable from the
minals are usually identified by the letters NEG engine block in the compressor, then disconnect
adjacent to the terminal or a negative (-) sign. the other end of this same cable from the grounded
O. Connect one end of a jumper cable to the posi- negative (NEG) (-) terminal of the battery in the
tive (POS) (+) battery terminal in the starting vehi- starting vehicle. Then disconnect the other jumper
cle. When jump starting 24V compressors and if the cable from the positive (POS) (+) terminal of the
starting vehicle is provided with two (2) 12V batter- battery in the compressor, or if provided with two (2)
ies connected in series, connect the jumper cable 12V batteries connected in series, from the
to the positive (POS) (+) terminal of the unground- ungrounded battery in the compressor, and finally,
ed battery. disconnect the other end of this same jumper cable
from the positive (POS) (+) terminal of the battery in
P. Connect the other end of the same jumper cable the starting vehicle or from the positive (POS) (+)
to the positive (POS) (+) terminal of the starter terminal of the ungrounded battery in the starting
motor battery in the compressor, or when jump vehicle, if it is provided with two (2) 12V batteries
starting 24V compressor, to the positive (POS) (+) connected in series.
terminal of the ungrounded battery in the compres-
sor. V. Remove and carefully dispose of the dampened
cloths, as they may now be contaminated with acid,
Q. Connect one end of the other jumper cable to then replace all vent caps.
the grounded negative (NEG) (-) terminal of the bat-
tery in the starting vehicle. When jump starting 24V
8
Section 2
DESCRIPTION
2.1 INTRODUCTION blies of the Sullair Portable Air compressor are
The Sullair 125, 130, 160H, 185 CFM and 49 HP clearly shown. The package includes a heavy duty
Portable Air Compressors offer superior perform- rotary screw air compressor, a diesel engine,
ance and reliability along with a minimal amount of fuel tank, compressor inlet system, compressor
maintenance requirements. cooling and lubrication system, compressor
The compressor is equipped with a Sullair rotary discharge system, capacity control system,
screw compressor unit. Compared to other com- instrument panel and electrical system.
pressors, the Sullair is unique in mechanical relia- A low profile canopy offers improved handling and
bility and compressor durability. No inspection is mobility. The clamshell canopy provides easy
required of the working parts within the compressor access to all serviceable components.
unit. This model meets EPA regulations for 76dbA at 7
As you continue reading this manual and come to meters (23 feet).
learn how the compressor operates and is cared The Sullair air compressors are capable of deliver-
for, you will see how surprisingly easy it is to keep a ing capacities as follows:
Sullair compressor in top operating condition.
Model 125 125 CFM @ 100 psig (6.9 bar)
Read Section 5 (Maintenance) and learn how to
keep your compressor in top operating condition. Model 130 130 CFM @ 100 psig (6.9 bar)
Should any problem or question arise which cannot
Model 49 HP 160 CFM @ 100 psig (6.9 bar)
be answered in this text, contact your nearest
Sullair representative or the Sullair Corporation Model 185 185 CFM @ 100 psig (6.9 bar)
Service Department.
Model 160H 160 CFM @ 150 psig (10.3 bar)
2.2 DESCRIPTION OF COMPONENTS
Refer to Figure 2-1. The components and assem- The control system can easily be adjusted for pres-
Figure 2-1 Sullair Rotary Screw Portable Air Compressor
9
Section 2
DESCRIPTION
sures from 85 to 125 psig (5.9 to 8.6 bar) for stan- lubrication system is designed to provide ade-
dard machines, and from 85 to 150 psig (5.9 to 10.3 quate lubrication as well as maintain the proper
bar) for “H” machines. The compressor unit is driv- operating temperature of the compressor. In addi-
en by an industrial diesel engine designed to pro- tion to the fluid cooler and interconnecting pip-
vide enough horsepower for more than adequate ing, the system consists also of three other compo-
reserve at rated conditions. Refer to the Engine nents: a fluid filter, thermal valve, and a fan
Operator’s Manual for a more detailed description which perform the following functions:
of the engine. • The fluid filter filters the fluid.
The engine cooling system is comprised of a • The thermal valve functions as a tempera-
radiator, high capacity fan and thermostat. The ture regulator directing fluid either to the
high capacity fan pushes air through the radiator, cooler or to the compressor unit, bypassing
keeping the engine at the proper operating temper- the cooler as will be explained later.
ature.
• The fan pushes air through the cooler
The same fan also cools the fluid in the compressor removing the heat of compression from the
cooling and lubrication system. The engine radiator fluid.
and the compressor fluid cooler sit side by side
which allows the fan air to push through both simul- The functions of the lubrication system are
taneously. As air passes through the fluid cooler, explained in more detail below. Fluid is used in the
the heat of compression is removed from the fluid. system as a coolant and as a lubricant. It is housed
in the receiver/sump which, will from this time for-
The compressor is supplied with a large capacity ward, be referred to as the SUMP.
fuel tank which will keep the compressor running
through one (1) eight hour shift under normal oper- Upon start-up, fluid flows from the sump to the fluid
ating conditions. thermal valve. Fluid circulation is achieved by forc-
ing the fluid from the high pressure region of the
2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL sump to a lower pressure area in the compressor
DESCRIPTION unit. A minimum pressure device (see Section 2.5
Sullair compressors feature the Sullair compres- Compressor Discharge System) is provided to
sor unit, a single-stage, positive displacement, assure adequate fluid flow under all conditions.
flood lubricated-type compressor. This unit pro-
vides continuous (pulse-free) compression to meet When entering the thermal valve upon start-up, the
your needs. With a Sullair compressor, no mainte- fluid temperature is cool and thus it is not necessary
nance or inspection of the internal parts of the com- to route it through the cooler. Hence the fluid flows
pressor unit is required. through the fluid filter and on to the compressor unit
bypassing the cooler. As the compressor continues
Fluid is injected into the compressor unit where it to operate, the temperature of the fluid rises and the
mixes directly with the air as the rotors turn, com- thermostatic control opens, allowing a portion of
pressing the air. The fluid flow has three main func- the fluid to the cooler. When the temperature reach-
tions: es 160°F (71°C), the thermostat is fully open allow-
1. As coolant, it controls the rise of air tem- ing all fluid entering the thermal valve to be direct-
perature normally associated with the heat ed to the cooler.
of compression. The cooler is a radiator-type that works in conjunc-
2. Seals the leakage paths between the rotors tion with the engine fan. The fan pushes air through
and the stator and also between the rotors the cooler removing the heat of compression from
themselves. the fluid. From the cooler, the fluid is then routed
3. Acts as a lubricating film between the rotors back through the fluid filter. All fluid flowing to the
allowing one rotor to directly drive the other. compressor unit passes through this filter. The fluid
leaving the filter flows to the compressor unit where
After the air/fluid mixture is discharged from the it lubricates, seals and cools the compression
compressor unit, the fluid is separated from the air. chamber as well as lubricates the bearings and
At this time, the air flows to your service line and the gears.
fluid is cooled in preparation for reinjection.
2.5 COMPRESSOR DISCHARGE SYSTEM, FUNC-
2.4 COMPRESSOR COOLING AND LUBRICATION TIONAL DESCRIPTION
SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figures 2-3, 2-4A, 2-4B or 2-4C. The
Refer to Figure 2-2. The compressor cooling and
10
Section 2
DESCRIPTION
Figure 2-2 Compressor Cooling and Lubrication System
Sullair compressor unit discharges compressed (protected by a strainer) is included in this return
air/fluid mixture into the sump. The sump has three line to assure proper flow.
functions: The sump is ASME code rated at 200 psig (13.8
1. It acts as a primary fluid separator. bar) working pressure. A minimum pressure device
2. Serves as the compressor fluid sump. located downstream from the separator, assures a
minimum receiver pressure of 85 psig (5.9 bar) dur-
3. Houses the air/fluid separator. ing all conditions. This pressure is necessary for
The compressed air/fluid mixture enters the sump proper air/fluid separation and proper fluid circula-
and is directed against the side of the sump. By tion.
change of direction and reduction of velocity, large A pressure relief valve (located on the wet side of
droplets of fluid separate and fall to the bottom of the separator) is set to open if the sump pressure
the sump. The fractional percentage of fluid remain- exceeds 200 psig (13.8 bar). A temperature switch
ing in the compressed air collects on the surface of will shut down the compressor if the discharge tem-
the final separator element as the compressed air perature reaches the specified limit given in Section
flows through the separator. As more and more fluid 3, Specifications.
collects on the element surface, the fluid descends
to the bottom of the separator. A return line (or scav- Fluid is added to the sump via a capped fluid filler.
enge tube) leads from the bottom of the separator
element to the inlet region of the compressor unit. WARNING
Fluid collecting on the bottom of the separator ele-
DO NOT remove caps, plugs, and/or other com-
ment is returned to the compressor by the pressure ponents when compressor is running or pres-
difference between the area surrounding the sepa- surized.
rator element and the compressor inlet. An orifice
11
Section 2
DESCRIPTION
Figure 2-3 Compressor Discharge System
Stop compressor and relieve all internal pressure tors manual for additional information.
before doing so. COLD START
2.6 CAPACITY CONTROL SYSTEM, FUNCTIONAL When the compressor is started, the sump pressure
DESCRIPTION will quickly rise from 0 to 40 psig (0 to 2.8 bar).
Refer to Figures 2-3, 2-4A, 2-4B or 2-4C. The pur- During this period the pressure regulator valve is
pose of the control system is to regulate the amount inactive. At this pressure range the idle warm-up
of air intake in accordance with the amount of com- control maintains a closed inlet valve for engine idle
pressed air being used. The control system con- operation. After engine start-up, turn the handle of
sists of a pressure regulating valve(s), air inlet the selector valve warm-up control (located on the
valve, system blowdown valve, and tubing con- instrument panel) from the “start” to the “run” posi-
necting the various components to the compressor tion within the first 30 seconds of operation. The
and engine governor. The functional descriptions of instrument panel annunciator light will go off after
the control system are given in four distinct phases 30 seconds. The inlet valve is fully open due to inlet
of operation. It applies to any control system with air pressure, and the compressor operates at full
the exception of those with stated pressures which capacity operation. As the compressor operates at
are dependent on pressure requirements. The pres- full capacity, the engine runs at full speed.
sures stated will be in accordance with a compres- NORMAL OPERATION - 85 TO 100 PSIG (5.9 TO
sor having an operating pressure range of 100 to 6.9 BAR) OR 85 TO 150 PSIG (5.9 TO 10.3 BAR)
110 psig (6.9 to 7.6 bar). FOR “H” MACHINES
START - 0 TO 40 PSIG (0 to 2.8 BAR) When the warm-up control selector valve handle is
COLD WEATHER moved to the “run” position, the sump pressure
To minimize problems in cold weather, starting aids, rises above 85 psig (5.9 bar). At this time, the inlet
engine coolant heaters and dry-side receiver relief valve remains fully open for maximum air output.
valves should be used. Refer to the engine opera- The engine will continue to run at full speed during
this phase of operation.
12
Section 2
DESCRIPTION
Figure 2-4A Control System with Piping and Instrumentation - 125 and 130 Models (Caterpillar and Perkins)
13
Section 2
DESCRIPTION
Figure 2-4B Control System with Piping and Instrumentation - 125, 130, 49HP and 185 Models (Caterpillar and
Perkins)
14
Section 2
DESCRIPTION
Figure 2-4C Control System with Piping and Instrumentation - 160H Models (John Deere)
15
Section 2
DESCRIPTION
MODULATION - 100 TO 110 PSIG (6.9 TO 7.6 output to match air demand. The orifice also bleeds
BAR) OR 150 TO 165 PSIG (10.3 TO 11.4 BAR) any accumulated moisture from the regulator.
FOR “H” MACHINES SHUTDOWN
Should less than the rated capacity of air be used, The blowdown valve is normally closed. Upon shut-
the service line pressure will rise above 100 psig down, the back pressure in the compressor inlet
(6.9 bar) low or single pressure rating, 150 psig signals the blowdown valve to vent the sump pres-
(10.3 bar) dual or high pressure rating. The pressure to the atmosphere.
sure regulating valve gradually opens, applying
pressure to the inlet valve piston and speed control 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIP-
cylinder . This causes the inlet valve to partially TION
close and reduces the speed of the engine. As the Refer to Figure 2-5A or 2-5B. The air inlet system
pressure increases, the inlet valve piston will further consists of two air filters, a compressor air inlet
close the inlet valve and continue reducing the valve and interconnecting piping to the engine
speed until it reaches a pre-set idle speed. Now as and compressor.
air demand increases, the sump pressure will fall The air filters are two-stage dry element-type filters.
below the 110 psig (7.6 bar) or 165 psig (11.4 bar) These filters are capable of cleaning extremely dirty
for “H” machines. air. However, in such cases, frequent checks of the
The pressure regulating valve will close, the air inlet air filter will be required.
valve will fully open and the engine will once again See Section 5 for Air Filter Maintenance
run at a pre-set full load speed. Procedures.
Between the pressure regulating valve and inlet 2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL
valve, a small orifice is installed which vents a small DESCRIPTION
amount of air to the atmosphere, when the pressure Refer to Figure 2-6. The instrument panel group
regulating valve is open. This allows variance of air consists of a molded panel containing an air pres-
Figure 2-5A Air Inlet System - Caterpillar and Perkins Models
16
Section 2
DESCRIPTION
Figure 2-5B Air Inlet System - John Deere Models
sure gauge, hourmeter, ignition/start switch, Figure 2-6 Instrument Panel Group
annunciator light, idle warm-up control, and a
cold weather starting aid button.
Refer to Figure 2-6 for locations of the following
indicators and controls:
• The air pressure gauge continually moni-
tors the sump pressure at various load or
unload conditions.
• The hourmeter indicates the accumulative
hours of compressor operation. This is use-
ful for planning and logging service opera-
tions.
• The engine switch is used to energize the
electrical system and start the compressor.
The starter switch is pressed to the on posi-
tion to energize the electrical system and
momentarily pressed to the start position to
engage the starter and start the compressor.
• The idle warm-up valve control is turned
from start to run after engine start is
achieved for full compressor operation.
• The pressure selector switch (160H
Models) allows the selection of the com-
pressor operating pressure range, 85 to 110
17
Section 2
DESCRIPTION
psig (5.9 to 7.6 bar) or 85 to 160 psig (5.9 to 2.10 SHUTDOWN SYSTEM DESCRIPTION
11.0 bar). The Shutdown System and Annunciation Module
• The cold weather starting aid should be (SSAM) continually monitors the status of the com-
used when starting in cold amibients. Press pressor . In the event of a shutdown condition, the
the button and hold for 5-10 seconds prior SSAM will shutdown the compressor and flash the
to starting (depending upon temperature). appropriate code on the instrument panel annunci-
ator light. The flash code will remain active (flash-
• The annunciator light indicates compres- ing) until the ignition switch is turned OFF. The
sor safety shutdown status. flash codes are as follows:
2.9 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIP- 1 flash : high compressor temperature
TION
Refer to Figure 2-7. The electrical system is com- 2 flashes: high engine coolant temperature
prised of not only the necessary equipment 3 flashes: low engine oil pressure
required to operate the compressor, but also a sys- 4 flashes: low engine speed
tem which shuts down the compressor in the event
of a malfunction. The components of the electrical 5 flashes: low fuel level (optional)
system are an engine starter, a battery, an alter- The SSAM also provides startup logic for the com-
nator with a built-in voltage regulator, a fuel pressor. When the ignition switch is placed in the
solenoid, a compressor discharge temperature ON position, the annunciator light will come on for
switch, which will shut down the compressor 30 seconds. During this 30 second period, ignition
should the compressor temperature exceed 250°F switch activation to the START position will engage
(121°C), an engine water temperature switch set the engine starter. The low engine oil pressure
to shut down the compressor when water tempera- switch and the low engine speed switch will remain
ture reaches 225°F (107°C) and an engine oil inactive during the this 30 second period. At the
pressure switch. The engine oil pressure switch is end of the 30 second period, the annunciator light
provided to shut down the compressor when the will go off and the engine START cycle will be dis-
engine oil pressure becomes insufficient.The low abled. At this time, all safety system checks
speed switch is provided to shutdown the compres- become active including low fuel level (if
sor if engine speed falls below 1500 RPM. equipped).
18
Section 2
DESCRIPTION
Figure 2-7 Electrical System - All Models
02250144-446R01
19
NOTES
20
Section 3
SPECIFICATIONS
3.1A SPECIFICATIONS - PERKINS AND CATERPILLAR
Model Series Length (I) Width Height Weight (wet)
in mm in mm in mm lb kg
125, 130, 185 2-wheel 130.8 3322 59.2 1504 53.8 1368 2130 966
125, 130, 185 LRG 69.1 1765 40.9 1040 41.7 1060 1885 855
(I) Length over drawbar.
COMPRESSOR : 125 130 185

Type : Rotary Screw Rotary Screw Rotary Screw
Maximum Operating Pressure : 125 psig (8.6 bar) 125 psig (8.6 bar) 125 psig (8.6 bar)
Delivery : 125 Free CFM (59 l/s) 130 Free CFM (61 l/s) 185 Free CFM (87 l/s)
Fluid : Compressor Fluid Compressor Fluid Compressor Fluid
Lubricating Compressor : See Lubrication Guide See Lubrication Guide See Lubrication Guide
Sump Capacity : 3 U.S. Gallons / 11 liters 3 U.S. Gallons / 11 liters 3 U.S. Gallons / 11 liters
Track Width : 50.9 in. (1294 mm) 50.9 in. (1294 mm) 50.9 in. (1294 mm)
Tire Size (Load Range) : ST175/80D13 ST175/80D13 ST175/80D13
Tire Pressure : 50 psig (3.5 bar) 50 psig (3.5 bar) 50 psig (3.5 bar)
Lug Nut Torque : 60 ft.-lbs. (81 Nm) 60 ft.-lbs. (81 Nm) 60 ft.-lbs. (81 Nm)
Wheel Size : 13 x 4.5 13 x 4.5 13 x 4.5
Operating Tilt (maximum) : 15 Degrees 15 Degrees 15 Degrees
Electrical System : 12 Volt 12 Volt 12 Volt
Compressor Discharge : Shutdown 250 °F (121 °C) Shutdown 250 °F (121 °C) Shutdown 250 °F (121 °C)
Service Valves : (2) 3/4” (2) 3/4” (2) 3/4”
Maximum Towing Speed : 55 mph (88 kmph) 55 mph (88 kmph) 55 mph (88 kmph)
Axle Rating : 3500 lbs. (1588 kg) 3500 lbs. (1588 kg) 3500 lbs. (1588 kg)
Rated Pressure : 100 psig (7 bar) 100 psig (7 bar) 100 psig (7 bar)
Sound Level : 76 dBA @ 7 meters 76 dBA @ 7 meters 76 dBA @ 7 meters
ENGINE
Type : Diesel Diesel Diesel
Make : Perkins & Caterpillar Perkins & Caterpillar Perkins & Caterpillar
Model : 404C-22T & 3024CT 404C-22T & 3024CT 404C-22T & 3024CT
Displacement : 134 cu. in. (2.2L) 134 cu. in. (2.2L) 134 cu. in. (2.2L)
Cylinders : 4 4 4
3.30 x 3.94 in. 3.30 x 3.94 in. 3.30 x 3.94 in.
Bore x Stroke :
(84 mm x 100 mm) (84 mm x 100 mm) (84 mm x 100 mm)
Rated Speed : 2550 RPM 2650 RPM 2800 RPM
Rated Power : 59 HP (44.0 kW) 60 HP (44.7 kW) 60 HP (44.7 kW)
See Engine Operator's See Engine Operator's
Type of Motor Oil : See Engine Operator's Manual
Manual Manual
Fuel Tank Capacity : 20 Gallons (76 liters) 20 Gallons (76 liters) 20 Gallons (76 liters)
Radiator Capacity : 2.5 U.S. Gallons (9.5 liters) 2.5 U.S. Gallons (9.5 liters) 2.5 U.S. Gallons (9.5 liters)
Engine Water Temperature: Shutdown 225 °F (107 °C) Shutdown 225 °F (107 °C) Shutdown 225 °F (107 °C)
Minimum Idle Speed : 2550 RPM (II) 2650 RPM (II) 2200 RPM (II)
Alternator Rating : 65 amp 65 amp 65 amp
(II) DO NOT allow engine idle rpm to drop below minimum idle speed. Compressor and/or coupling damage will occur. The com-
pressor is equipped with a Low Speed Shutdown System that will shutdown the compressor if engine speed falls below 1500 rpm.
21
Section 3
SPECIFICATIONS
3.1B SPECIFICATIONS - JOHN DEERE 125, 130 (2-WHEEL AND LRG)
125, 130 2-wheel 130.8 3322 59.2 1504 53.8 1368 2255 1023
125, 130 LRG 69.1 1765 40.9 1040 41.7 1060 2115 960
COMPRESSOR : 125 130

Type : Rotary Screw Rotary Screw
Maximum Operating Pressure : 125 psig (8.6 bar) 125 psig (8.6 bar)
Delivery : 125 Free CFM (59 l/s) 130 Free CFM (61 l/s)
Fluid : Compressor Fluid Compressor Fluid
Lubricating Compressor : See Lubrication Guide See Lubrication Guide
Sump Capacity : 3 U.S. Gallons / 11 liters 3 U.S. Gallons / 11 liters
Track Width : 50.9 in. (1294 mm) 50.9 in. (1294 mm)
Tire Size (Load Range) : ST175/80D13 ST175/80D13
Tire Pressure : 50 psig (3.5 bar) 50 psig (3.5 bar)
Lug Nut Torque : 60 ft.-lbs. (81 Nm) 60 ft.-lbs. (81 Nm)
Wheel Size : 13 x 4.5 13 x 4.5
Operating Tilt (maximum) : 15 Degrees 15 Degrees
Electrical System : 12 Volt 12 Volt
Compressor Discharge : Shutdown 250 °F (121 °C) Shutdown 250 °F (121 °C)
Service Valves : (2) 3/4” (2) 3/4”
Maximum Towing Speed : 55 mph (88 kmph) 55 mph (88 kmph)
Axle Rating : 3500 lbs. (1588 kg) 3500 lbs. (1588 kg)
Rated Pressure : 100 psig (7 bar) 100 psig (7 bar)
Sound Level : 76 dBA @ 7 meters 76 dBA @ 7 meters
ENGINE
Type : Diesel Diesel
Make : John Deere John Deere
Model : 4024T 4024T
Displacement : 149 cu. in. (2.44L) 149 cu. in. (2.44L)
Cylinders : 4 4
Bore x Stroke : 3.39 x 4.13 in. (86 mm x 105 mm) 3.39 x 4.13 in. (86 mm x 105 mm)
Rated Speed : 2550 RPM 2650 RPM
Rated Power : 60 HP (44.7 kW) 60 HP (44.7 kW)
Type of Motor Oil : See Engine Operator's Manual See Engine Operator's Manual
Fuel Tank Capacity : 20 Gallons (76 liters) 20 Gallons (76 liters)
Radiator Capacity : 2.5 U.S. Gallons (9.5 liters) 2.5 U.S. Gallons (9.5 liters)
Engine Water Temperature: Shutdown 225 °F (107 °C) Shutdown 225 °F (107 °C)
Minimum Idle Speed : 2000 RPM (II) 2000 RPM (II)
Alternator Rating : 65 amp 65 amp
22
Section 3
SPECIFICATIONS
3.1C SPECIFICATIONS - JOHN DEERE 49HP, 160H, 185 (2-WHEEL AND LRG)
49 HP, 160H, 185 2-wheel 130.8 3322 59.2 1504 53.8 1368 2255 1023
49 HP, 160H, 185 LRG 69.1 1765 40.9 1040 41.7 1060 2115 960
COMPRESSOR : 49 HP 185 160H

Type : Rotary Screw Rotary Screw Rotary Screw
Maximum Operating Pressure : 125 psig (8.6 bar) 125 psig (8.6 bar) 150 psig (10.3 bar)
Delivery : 160 Free CFM (75 l/s) 1850 Free CFM (87 l/s) 160 Free CFM (75 l/s)
Fluid : Compressor Fluid Compressor Fluid Compressor Fluid
Lubricating Compressor : See Lubrication Guide See Lubrication Guide See Lubrication Guide
Sump Capacity : 3 U.S. Gallons / 11 liters 3 U.S. Gallons / 11 liters 3 U.S. Gallons / 11 liters
Track Width : 50.9 in. (1294 mm) 50.9 in. (1294 mm) 50.9 in. (1294 mm)
Tire Size (Load Range) : ST175/80D13 ST175/80D13 ST175/80D13
Tire Pressure : 50 psig (3.5 bar) 50 psig (3.5 bar) 50 psig (3.5 bar)
Lug Nut Torque : 60 ft.-lbs. (81 Nm) 60 ft.-lbs. (81 Nm) 60 ft.-lbs. (81 Nm)
Wheel Size : 13 x 4.5 13 x 4.5 13 x 4.5
Operating Tilt (maximum) : 15 Degrees 15 Degrees 15 Degrees
Electrical System : 12 Volt 12 Volt 12 Volt
Compressor Discharge : Shutdown 250 °F (121 °C) Shutdown 250 °F (121 °C) Shutdown 250 °F (121 °C)
Service Valves : (2) 3/4” (2) 3/4” (2) 3/4”
Maximum Towing Speed : 55 mph (88 kmph) 55 mph (88 kmph) 55 mph (88 kmph)
Axle Rating : 3500 lbs. (1588 kg) 3500 lbs. (1588 kg) 3500 lbs. (1588 kg)
Rated Pressure : 100 psig (7 bar) 100 psig (7 bar) 100 psig (7 bar)
Sound Level : 76 dBA @ 7 meters 76 dBA @ 7 meters 76 dBA @ 7 meters
ENGINE
Type : Diesel Diesel Diesel
Make : John Deere John Deere John Deere
Model : 4024T 4024T 4024T
Displacement : 149 cu. in. (2.44L) 149 cu. in. (2.44L) 149 cu. in. (2.44L)
Cylinders : 4 4 4
3.39 x 4.13 in. 3.39 x 4.13 in. 3.39 x 4.13 in.
Bore x Stroke :
(86 mm x 105 mm) (86 mm x 105 mm) (86 mm x 105 mm)
Rated Speed : 2650 RPM 2800 RPM 2800 RPM
Rated Power : 49 HP (36.5 kW) 60 HP (44.7 kW) 66 HP (49.2 kW)
See Engine Operator's See Engine Operator's
Type of Motor Oil : See Engine Operator's Manual
Manual Manual
Fuel Tank Capacity : 20 Gallons (76 liters) 20 Gallons (76 liters) 20 Gallons (76 liters)
Radiator Capacity : 2.5 U.S. Gallons (9.5 liters) 2.5 U.S. Gallons (9.5 liters) 2.5 U.S. Gallons (9.5 liters)
Engine Water Temperature: Shutdown 225 °F (107 °C) Shutdown 225 °F (107 °C) Shutdown 225 °F (107 °C)
Minimum Idle Speed : 2000 RPM (II) 2000 RPM (II) 2000 RPM (II)
Alternator Rating : 65 amp 65 amp 65 amp
23
Section 3
SPECIFICATIONS
3.2 LUBRICATION GUIDE - COMPRESSOR
AMBIENT TEMPERATURE RANGE
FLUID TYPE CHANGE PERIOD (HOURS)
°F (°C)
Sullair AWF (I) 1500 -20 to 125 (-29 to 52)
D-A Torque Fluid 300 10 to 110 (-12 to 43)
SAE10W SE, SF, SG, CD 300 0 to 100 (-18 to 38)
MIL-L-2104E 10W 300 0 to 100 (-18 to 38)
(I) Sullair part numbers for Sullair AWF are 250030-757 (5 gallons /18.9 liters), and 250030-758 (55 gallons /208 liters).
3.3 APPLICATION GUIDE When ambient conditions exceed those noted or if

Refer to Figure 3-1. Sullair Air Compressors are conditions warrant use of other extended life lubri-
supplied with Sullair AWF which is heavy duty multi- cants, contact Sullair for recommendations.
viscosity, all-weather fluid. Sullair AWF also allows Sullair encourages the user to participate in a fluid
an extended change interval. Detergent motor oils analysis program. This could result in a fluid change
(SAE 10W Class SE,SF, SG or CD) can also be interval differing from that stated in the manual.
used. Any of these oils are suitable under condi- Sullair Corporation offers a fluid analysis program
tions where severe oil oxidations can occur. for Sullair AWF. Contact your local Sullair represen-
Water must be drained from the receiver periodical- tative for details.
ly. In high ambient temperature and high humidity D-A Lubricant® Company Inc. offers an analysis
conditions, condensed moisture may emulsify with program for users of D-A products and Sullair AWF.
the oil forming a “milky” color. SAE 10W is espe- Contact your D-A lubricant supplier or Sullair repre-
cially prone to this condition. The fluid should be sentative for details.
changed if this condition develops.
3.4 LUBRICATION GUIDE - ENGINE
DO NOT mix types of fluids. Combinations of differ- For engine oil specifications, refer to the Engine
ent fluids may lead to operational problems such as Operator’s Manual.
foaming, filter plugging, orifice or line plugging.
Figure 3-1 Fluid and Fuel Fill Port Locations
NOTE
When performing a fluid
change or topping off the
fill, the proper level should
be at half of the sight glass,
with the machine off.
24
Section 4
OPERATION
4.1 GENERAL will call for service or indicate the beginning of a
While Sullair has built into this compressor a com- malfunction. Before starting your Sullair compres-
prehensive array of controls and indicators to sor, read this section thoroughly and familiarize
assure you that it is operating properly, you will yourself with the controls and indicators - their pur-
want to recognize and interpret the reading which pose, location and use.
4.2 PURPOSE OF CONTROLS
CONTROL OR INDICATOR PURPOSE
ENGINE SWITCH Press this switch to the “ON” (ignition) position to energize
the electrical system of the compressor. Press the switch to
the “START” position to momentarily engage the starter and
start the compressor. Press the switch to the “OFF” position
to shut the compressor down. This switch is located on the
instrument panel.
COLD WEATHER STARTING AID BUTTON Push this button, prior to compressor start-up, to allow the
engine to warm-up for easy starting.
AIR PRESSURE GAUGE Continually monitors the pressure inside the receiver sump
at various load and unload conditions.
HOURMETER Indicates the accumulated hours of operation. Useful for
planning and logging service schedules.
FLUID LEVEL SIGHT GLASS Monitors the fluid level in the sump. Proper level is visible
halfway up the sight glass. Check the level when the com-
pressor is shut down and on level ground.
COMPRESSOR DISCHARGE TEMPERATURE Opens the electrical circuit to shut down the compressor
SWITCH when the discharge temperature reaches a specific value
(see Section 3, Specifications).
THERMAL VALVE Functions as a temperature regulator directing the compres-

sor fluid either to the cooler or to the compressor unit.
MINIMUM PRESSURE DEVICE Maintains the minimum of 85 psig (5.9 bar) in the compres-
sor sump.
PRESSURE RELIEF VALVE Opens sump pressure to the atmosphere should pressure
inside the sump exceed 200 psig (13.8 bar).
AIR INLET VALVE Regulates the amount of air allowed to enter the air inlet
valve. This regulation is determined by a pressure signal
from the pressure regulator.
PRESSURE REGULATOR (S) Allows a pressure signal to reach the engine speed control
cylinder and the air inlet valve to control air delivery accord-
ing to demand.
SHUTDOWN SYSTEM/ANNUNCIATOR MODULE (SSAM) Monitors the compressor safety system for shut-
down conditions. The annunciator module on the instrument
panel will flash a code indicating the reason for compressor
shutdown.
BLOWDOWN VALVE Vents sump pressure to the atmosphere at shutdown.
Continued...
25
Section 4
OPERATION
4.2 PURPOSE OF CONTROLS (CONTINUED)
CONTROL OR INDICATOR PURPOSE
IDLE WARM-UP CONTROL Maintains a closed air inlet valve for reduced compressor
load on start-up. After engine starts, turn the handle of the
selector valve from the “start” to the “run” position for full
operation within the first minute of operation.
PRESSURE SELECTOR SWITCH (“H” MODELS) Allows compressor operation in the ”low” range from 85 to
110 psig (5.9 to 7.6 bar) or in the “high” range from 85 to 160
psig (5.9 to 11 bar) for “H” models.
4.3 START-UP PROCEDURE explained below:

The following procedure should be used to make 1. Check engine oil, water and fuel levels.
the initial start-up of your compressor:
2. Check compressor fluid level (should be visible in
1. Position the compressor on a level surface so sight glass). Drain water from the fuel-water
that proper amounts of liquid can be added if separator.
necessary. (I)
3. Check dust collectors and clean if necessary.
2. Check oil and fluid levels both in the engine and
the cooling system(s). Maintain the proper level; 4. Crack open service valve.
add if necessary. 5. Bleed fuel injection lines if necessary (see Engine
3. Fill the fuel tank. Drain water from the fuel-water Operator’s Manual).
separator. 6. Turn the warm-up control selector valve to the
4. Crack open one service line. start position. For “H” models, turn the pressure
selector switch to the “low” position.
5. Bleed fuel injection lines if necessary (see Engine
Operator’s Manual). 7. In cold weather, engage cold weather starting aid
button. Hold button for 5-10 seconds and then
6. Turn the warm-up control selector valve to the release.
start position. For “H” models, turn the pressure
selector switch to the “low” position. 8. Press the engine switch to the “ON” position.
7. In cold weather, engage cold weather starting aid 9. Press the engine switch to the “START” position
button. Hold button for 5-10 seconds and then momentarily to engage starter, when engine
release. starts release switch.
8. Press the engine switch to the “ON” position. 10. Allow for sufficient warm up of compressor
before operating.
9. Press the engine switch to the “START” position
momentarily to engage starter, when engine 11. After 30 seconds (the annunciator light will go off
starts release switch. after 30 seconds) turn the idle warm-up selector
valve from “START” to “RUN” for full compressor
10.After 30 seconds (the annunciator light will go off operation.
after 30 seconds) turn the idle warm-up selector
valve from “START” to “RUN” for full compressor 4.5 SHUTDOWN PROCEDURE
operation. To shut the compressor down, close the service
valves and run compressor for approximately 5 min-
11. Close canopy in order to maintain proper noise utes to allow the compressor to cool down and
control. press the engine switch to the OFF position. In
12. After the initial run, shut the compressor down case of emergency where immediate shutdown is
and refill the radiator and compressor fluid sump required, this procedure is not necessary. The
as required. Tighten any loose fittings and check engine switch should be pressed to the OFF posi-
fan belt tension. tion immediately.
4.4 SUBSEQUENT START-UP PROCEDURE
On subsequent starts, follow the procedure
(I) The radiator is filled with a 50/50 mixture of ethylene glycol and water. All engines receive Supplemental Coolant
Additive (SCA) at the factory before shipment. Refer to your Engine Operator’s Manual for details and specific engine
requirements.
26
Section 5
MAINTENANCE
5.1 GENERAL 5.3 MAINTENANCE AFTER INITIAL 50 HOURS OF
A good maintenance program is the key to long OPERATION
compressor life. Below is a program that, when After the initial 50 hours of operation, a few mainte-
adhered to, should keep the compressor in top nance requirements are needed to rid the system of
operating condition. For maintenance requirements any foreign materials. Perform the following mainte-
on engine, refer to the Engine Operator’s Manual nance operations to prevent unnecessary prob-
for a detailed description of service instructions. lems.
See Section 5.11, Parts Replacement and 1. Clean the return line orifice and change the
Adjustment Procedures for a detailed description of strainer.
specific compressor system components. Prior to
performing maintenance, read the CIMA Safety 2. Change compressor fluid filter.
Manual, if applicable in your area. 3. Check Engine Operator’s Manual for required
service.
WARNING 4. Check fuel filter for water.
DO NOT remove caps, plugs and/or other com- 5. Confirm that sump cover bolts are tightened to 60
ponents when compressor is running or pres- ft.-lbs. (81 Nm).
surized.
5.4 MAINTENANCE EVERY 50 HOURS
Stop compressor and relieve all internal pres-
sure before doing so. 1. Inspect and replace air filter elements (if
required).
5.2 DAILY OPERATION 2. Check fuel filter for water.
Prior to starting the compressor, it is necessary to 5.5 MAINTENANCE EVERY 100 HOURS
check the fluid level in the sump. Should the level After 100 hours of operation, it will be necessary to
be low, simply add the necessary amount. If the perform the following:
addition of fluid becomes too frequent, a simple
1. Clean the radiator and cooler exteriors.
problem has developed which is causing this
excessive loss. See the Troubleshooting Section 2. Check Engine Operator’s Manual for required
(5.13) under Excessive Fluid Consumption for a service.
probable cause and remedy. Also check the engine 5.6 MAINTENANCE EVERY 200 HOURS
oil level and the radiator coolant level and drain Perform the following after every 200 hours of oper-
water from the engine fuel/water separator prior to ation:
starting.
1. Check fan belt tension.
2. Clean the radiator and cooler exterior. Depending
NOTE on how contaminated the atmosphere may be,
The radiator and engine cooling system must be more frequent cooler and radiator cleaning may
drained and flushed every two (2) years. Replace be necessary.
the coolant with a solution of 50% ethylene glycol
and 50% water or as required for your geograph- 3. Check Engine Operator’s Manual for required
ic location. DO NOT use a leak sealing type of service.
anti-freeze. All engines must have Supplemental
Coolant Additive (SCA) added to the engine
5.7 MAINTENANCE EVERY 250 HOURS
coolant system. Refer to your Engine Operator’s 1. Change engine oil and filter.
Manual for details and specific engine require-
ments.
NOTE
After a routine start has been made, observe the Fluid change period will vary according to fluid
brand. Refer to Lubrication Guide in Section 3.
instrument panel gauge and be sure it monitors the
correct reading for that particular phase of opera-
2. Change the compressor fluid filter.
tion. After the compressor has warmed up, it is rec-
ommended that a general check on the overall 3. Change the return line strainer.
compressor and instrument panel be made to 4. Change the engine fuel filter.
assure that the compressor is running properly. 5. Change the engine fuel-water separator.
Also check the air filter maintenance indicators if
supplied. 6. Change the air filter elements.
27
Section 5
MAINTENANCE
7. Check Engine Operator’s Manual for required tional 1/2 to 3/4 turn.
service. 6. Restart the compressor and check for leaks.
5.8 MAINTENANCE EVERY 500 HOURS AIR FILTER MAINTENANCE
Perform the following after every 500 hours of oper- Refer to Figure 5-2. Air filter maintenance should
ation: be performed as often as conditions require. If the
1. Check the engine RPM. Idle speeds should filters are equipped with an optional maintenance
never be allowed to fall below the minimums indicator, maintenance should be done when the
(see Section 3 Specifications). indicator shows red. The following procedure will
explain how to replace the air filter element.
NOTE AIR FILTER ELEMENT REPLACEMENT
Operation at speeds below the minimum idle 1. Loosen and remove the air filter end cover.
speeds shown in the Table in Section 3,
Specifications will damage the compressor. 2. Remove element.
Extended operation below those speeds will 3. Clean the body and cover with a damp cloth
induce coupling and/or compressor failures.
inside and out.
3. Lubricate the control linkage. 4. Replace the new filter element.
4. Check Engine Manual for required service. 5. Reposition the cover and lock into position.
5.9 MAINTENANCE ANNUALLY OR EVERY 1500 6. Reset the air filter restriction indicator if so
HOURS equipped, and the unit will be ready for opera-
1. When using Sullair AWF, change the compressor tion.
fluid. (See maintenance procedures in Section ELEMENT INSPECTION
5.9).
1. Place a bright light inside the element to inspect
2. Change the engine coolant. for damage or leak holes. Concentrated light will
3. Change the separator element. shine through the element and disclose any
5.10 MAINTENANCE EVERY YEAR OR 12,000 MILES holes.
1. Lubricate axle bearings on wheel-mounted units. 2. Inspect all gaskets and gasket contact surfaces
5.11 PARTS REPLACEMENT AND ADJUSTMENT
Figure 5-1 Compressor Fluid Filter
PROCEDURES
COMPRESSOR FLUID CHANGE PROCEDURE
Warm-up compressor for 5 to 10 minutes to warm
the fluid. Shut the compressor off and relieve all
internal pressure before proceeding. Drain the fluid
sump by removing the plug at the bottom of the
sump tank. Change the compressor fluid and
replace the fluid filter element. For element replace-
ment see procedure for servicing the fluid filter in
this section. Fill the sump with fluid according to
specifications in Section 3.
COMPRESSOR FLUID FILTER ELEMENT
REPLACEMENT
Refer to Figure 5-1.
1. Using a strap wrench, remove the old element.
2. Clean the gasket seating surface.
3. Apply a light film of fluid to the new gasket.
4. Hand tighten the new element (from kit P/N
250028-032) until the new gasket is seated on
the gasket seat.
5. Continue tightening the element by hand an addi-
*Replacement Element Kit P/N 250028-032
28
Section 5
MAINTENANCE
Figure 5-2 Air Filter should extend to the bottom of the separator ele-
ment. This will assure the proper fluid return
flow.
9. Clean the fluid return line strainer and clear the
orifice prior to restarting the compressor.
10. After 24 hours of operation, tighten sump cover
bolt to torque specification listed in step number
7.
PROCEDURE FOR SETTING SPEED AND PRES-
SURE CONTROLS ON PORTABLE COMPRES-
SORS WITH POPPET VALVE
Refer to Figure 5-4A or 5-4B. Prior to adjusting the
Control System, it is necessary to determine the
rated full load pressure and the high/low RPM set-
*Filter Element Kit P/N 02250102-158 (2 required) tings for your particular compressor. This informa-
tion can be obtained from the Operator’s Manual
of the housing. Should faulty gaskets be evident, (Specifications Section) or by contacting your local
correct the condition immediately. authorized Sullair Representative. The following
explanation applies to a compressor with 100 psig
3. If the clean element is to be stored for later use, (6.9 bar) rated full load pressure.
it must be stored in a clean container.
1. Start the compressor and allow the engine to
4. After the element has been installed, inspect and
warm-up to normal operating temperature with
tighten all air inlet connections prior to resuming
the service valve closed.
operation.
SEPARATOR ELEMENT REPLACEMENT
Refer to Figure 5-3. When fluid carry over is evident Figure 5-3 Air / Fluid Separator
after the fluid return line strainer and orifice as well
as the blowdown valve seal has been inspected
and found to be in satisfactory condition, separator
element replacement is necessary. Use separator
element part number no. 250034-112 and follow
the procedure explained below.
1. Remove all piping connected to the sump cover
to allow removal (return line, service line, etc.).
2. Remove the fluid return line from the fitting in the
cover.
3. Remove the eight (8) cover bolts and washers
and lift the cover from the sump.
4. Remove the separator element.
5. Scrape the old gasket material from the cover
and the flange on the sump. Be sure to keep all
scrapings from falling inside tank.
6. Install the new element.
7. Replace the sump cover and bolts. Run the cover
bolts in finger tight, then gradually tighten in a
crisscross pattern in 4 to 5 steps. Always tighten
the bolts alternately at opposite sides of the
cover. Never tighten bolts adjacent to each
other. Torque bolts to 60 ft.-lbs. (81 Nm).
8. Reconnect all piping. The fluid return line tube *Replacement Element Kit P/N 250034-112
29
Section 5
MAINTENANCE
Figure 5-4A Control System Adjustment - 125, 130, 185 and 49HP Models
Figure 5-4B Control System Adjustment - 160H Models
30
Section 5
MAINTENANCE
2. With the service valve closed, set the engine low tor switch set to the “low” position.
speed (idle) to its specified setting with the idle 2. Follow the procedure for setting the controls at
stop screw on the engine injector pump. 100 psig (6.9 bar) rated full load pressure as
previously described in Steps 2 through 5.
NOTE 3. Switch the pressure selector switch to the “high”
Operation at speeds below the minimum idle position with the service valve closed.
speeds shown in Section 3 under Specifications
4. Adjust the high pressure regulator so that the
will damage the compressor.
Extended operation below those speeds will compressor maintains 165 psig (11.4 bar).
induce coupling and/or compressor failures. 5. Gradually open the service valve to atmosphere
until the engine comes up in speed and sump
3. Adjust the pressure regulator so that the com- pressure is held at 150 psig (10.3 bar). At this
pressor maintains 120 psig (8.3 bar). point the engine should be at rated speed. If
4. Gradually open the service valve to atmosphere necessary, to raise or lower the speed, lengthen
until the engine comes up in speed and sump or shorten the rod respectively.
pressure is held at 100 psig (6.9 bar). At this OPERATING ADJUSTMENTS
point, set the engine high speed to its specified The first step is to start the compressor according to
setting by adjusting the high idle threaded rod the instructions in Section 4, Subsequent Start-up.
located on the engine speed control (where Allow the engine to operate until it reaches the nor-
applicable). To raise or lower the speed, length- mal operating temperature. Open the service valve
en or shorten the rod respectively. until the engine speed increases to, or close to, the
5. Open the service valve to 100 psig (6.9 bar) maximum specified operating speed.
(rated full load pressure) and recheck top engine BEARING LUBRICATION
speed and control response. Close the service Refer to Figure 5-5. Proper lubrication is essential
valve and allow the compressor to cycle and to the proper functioning and reliability of your
recheck low engine speed (idle). portable compressor axle. Wheel bearings should
The following explanation applies to “H” com- be lubricated at least once every 12 months, or
pressors with dual pressure controls: more frequently to help insure proper performance.
Use wheel bearing grease that conforms to military
1. Start the compressor and allow the engine to specification MIL-G-10924 or a high temperature
warm-up to normal operating temperature with wheel bearing grease such as lithium complex
the service valve closed and the pressure selec-
Figure 5-5 Typical E-Z Lube Axle
31
Section 5
MAINTENANCE
NLGI Consistency #2. grease will begin to flow back out the cap around
If your axle is equipped with the E-Z Lube feature, the grease gun nozzle.
the bearings can be periodically lubricated without 4. When the new, clean grease is observed, remove
removing the hubs from the axle. This feature con- the grease gun, wipe off any excess, and
sists of axle spindles that have been specially replace the rubber plug in the cap.
drilled and fitted with a grease zerk in their ends. 5.12 TROUBLESHOOTING INTRODUCTION
When grease is pumped into the zerk, it is chan- The following Troubleshooting Chart is based upon
neled to the inner bearing and then flows back to the data obtained both from testing at the factory
the outer bearing and eventually back out of the and from applied situations in the field. It contains
grease cap hold (see Figure 5-5). The procedure is symptoms and usual causes for the described prob-
as follows: lems, however DO NOT assume that these are the
1. Remove the rubber plug from the end of the only problems that may occur. All available data
grease cap. concerning the trouble should be systematically
2. With a standard grease gun filled with a quality analyzed before undertaking any repairs or compo-
wheel bearing grease, place the gun onto the nent replacement procedures.
grease zerk located in the end of the spindle. A detailed visual inspection is worth performing for
Make sure the grease gun nozzle is fully almost all problems. Doing so may prevent unnec-
engaged on the fitting. essary additional damage to the compressor.
3. Pump grease into the zerk. The old, displaced
5.13 TROUBLESHOOTING GUIDE

SYMPTOM PROBABLE CAUSE REMEDY
ENGINE DOES NOT CRANK OR CRANKS ONLY WITHOUT STARTING:

NO FLASH CODE: Low Voltage or Battery Disconnected Check battery cables and tighten if neces-
sary.
Check ground wire for proper attachment to
frame. Tighten as required.
Recharge or replace battery if required.
Blown Fuse in Wiring Harness Remove and inspect fuse. Replace if neces-
sary.
Instrument Panel Connectors Loose or Checked instrument panel connectors and
Disconnected reattach if required.
Check instrument panel wires for broken con-
nections or corrosion. Clean and/or replace
if required.
Faulty SSAM Module Replace the SSAM Module.
COMPRESSOR SHUTS DOWN:
NO FLASH CODE: Blown Fuse in Wiring Harness Remove/Inspect fuse and replace if neces-
sary.
Instrument Panel Connectors Loose or Check instrument panel connectors and
Disconnected. reattach if required.
Check instrument panel wires for broken con-

nections or corrosion. Clean and/or replace
if required.
Faulty SSAM Module Replace the SSAM Module.
Continued...
32
Section 5
MAINTENANCE
5.13 TROUBLESHOOTING GUIDE (CONTINUED)
FLASH CODE: Faulty Compressor Temperature Check wiring connection to switch and tighten as
ONE FLASH Switch required.
Check switch continuity when cool and replace if

necessary.
Cooling Air Flow is Insufficient Clean cooler and check for proper ventilation.
Low Compressor Fluid Sump Level

Add fluid as required.
Clogged Compressor Fluid Filter

Change filter element.
Faulty Thermostat
Change the thermostat element.
Loose or Broken Fan Belt

Check fan belt and tighten/replace as necessary.
Plugged Fluid Cooler Tube (Internal) Replace cooler.

FLASH CODE: Faulty Engine Coolant Temperature Check wiring connection to switch and tighten as
TWO FLASHES Switch necessary.
Check switch continuity to ground when cool and

replace if necessary.
Cooling Air Flow is Insufficient Clean cooler and check for proper ventilation.
Loose or Broken Fan Belt Check fan belt and tighten/replace as necessary.
Engine Problems May Have Refer to engine operators manual.

Developed
No Engine Coolant Check engine coolant level and fill with proper
water/glycol mixture as required.
FLASH CODE: Faulty Engine Oil Pressure Switch Check wiring connection to switch and tighten as
THREE FLASHES required.
Install gauge in parallel with switch. Replace switch
if pressure exceeds 15 psig and switch stays open.
If pressure is less than 15 psig, refer to Engine
Operator’s Manual.
FLASH CODE: No/Low Fuel Check fuel level and add fuel if necessary.
FOUR FLASHES
Plugged Fuel Filter Replace and clean as required.
Plugged Air Filter Replace and clean as required.
Water/Dirt in Fuel and/or Fuel Filter Drain water from fuel water separators on fuel fil-
ters. Siphon water from fuel tank and clean fuel
tank if necessary.
Continued...
33
Section 5
MAINTENANCE
5.13 TROUBLESHOOTING GUIDE (CONTINUED)
COMPRESSOR For compressors with idle warm-up controls,

WILL NOT BUILD UP switch toggle to “run” for full operation.
FULL DISCHARGE
PRESSURE Air Demand Is Too Great Check service lines for leaks or open valves.
Dirty Air Filter Check the filter indicator and change element
if required.
Defective Pressure Regulator Check diaphragm and replace if necessary

(kit available).
Defective Idle Warm-up Control Replace control.
IMPROPER Pressure Regulating Valve Is Set Too Readjust.

UNLOADING WITH High
AN EXCESSIVE
Leak In Control System Causing Loss Check control lines.
PRESSURE BUILD-
Of Pressure Signal
UP CAUSING PRES- Defective pressure regulating valve; repair
SURE RELIEF valve (kit available).
VALVE TO OPEN
Inlet Valve Jammed Free or replace valve.
Restriction In The Control System Check all control lines and components. Ice
and/or other contaminants could cause
restrictions.
Defective Pressure Relief Valve Replace pressure relief valve.
Opening At Too Low Of Pressure
Defective Pressure Regulator Check diaphragm and replace if necessary

(kit available).
INSUFFICIENT AIR Engage Idle Warm-up Control In “Run”
DELIVERY Position For Full Compressor
Operation
Plugged Air Filter Replace.
Plugged Air/Fluid Separator Replace separator element and also change
compressor fluid and fluid filter at this time.
Defective Pressure Regulator Adjust or repair.
Engine Speed Too Low Readjust engine speed.
Defective Idle Warm-up Control Replace control.
EXCESSIVE COM- Clogged Return Line Clear orifice and return line strainer.
PRESSOR FLUID
Leak In The Lubrication System Check all pipes, connections and compo-
CONSUMPTION
nents.
Separator Element Damaged Or Not Change separator element.
Functioning Properly
34
Section 6
NOISE CONTROL
6.1 NOISE EMISSIONS WARRANTY dered inoperative by any person.
Sullair Corporation warrants to the ultimate pur- Among those acts included in the prohibition
chaser and each subsequent purchaser that this air against tampering are the acts listed below:
compressor was designed, built and equipped to
conform at the time of sale to the first retail pur- 1. Removal or rendering inoperative any of the fol-
chaser, with all applicable U.S. E.P.A. and/or any lowing:
Federal, State or Local noise control regulations. a. Engine exhaust system or parts thereof
This warranty is not limited to any particular part, b. Compressor air intake system or part
component, or system of the air compressor. thereof
Defects in the design, assembly, or in any part, c. Enclosure of part thereof
component, or system of the compressor which, at 2. Removal of any of the following:
the time of sale to the first retail purchaser, caused
a. Vibration isolators
noise emissions to exceed Federal standards are
covered by this warranty for the life of the air com- b. Control silencer
pressor. c. Floor panel
6.2 TAMPERING WITH THE NOISE CONTROL SYS- d. Fan shroud
TEM IS PROHIBITED e. Acoustical materials including fiberglass
Federal Law prohibits the following acts or the foam or foam tape
causing thereof:
3. Operation with canopy doors open for any pur-
1. The removal or rendering inoperative by any per- pose other than starting, stopping, adjustment,
sons, other than for purposes of maintenance, repair, replacement of parts or maintenance.
repair, or replacement, of any device or element
6.3 NOISE EMISSIONS MAINTENANCE AND MAIN-
of design incorporated into any new compressor
TENANCE RECORD LOG
for the purpose of noise control prior to its sale
The following instructions and maintenance record
or delivery to the ultimate purchaser or while it is
log book, for the proper maintenance, use and
in use.
repair of this compressor, is intended to prevent
2. The use of the compressor after such device or noise emission degradation (refer to Figure 6-1).
element of design has been removed or ren-
Figure 6-1 Noise Emission Maintenance and Maintenance Record Log

1. ANNUAL MUFFLER AND EXHAUST SYSTEM INSPECTION
At least annually inspect muffler(s) and engine exhaust system to make sure all parts are securely mounted,
that all joints and connections are tight, and that the muffler is in good condition. DO NOT operate compres-
sor with defective exhaust system. Remove and replace any defective parts by ordering with part numbers indi-
cated in the Parts List.
Maintenance
Performed
By
Location
Date
Maintenance
Performed
By
Location
Date
••••••••••••
35
Section 6
NOISE CONTROL
2. ANNUAL AIR FILTER(S) AND AIR INLET SYSTEM INSPECTION
In addition to the instructions in the Maintenance section of the Operator’s Manual, the air filter(s) and entire
air inlet system should be inspected at least annually, to make sure all parts are securely mounted, that all
joints and connections are tight, that there are no other leaks in the system, and that the filter element(s) are
intact. DO NOT operate compressor with defective air inlet system. Remove and replace defective parts by
ordering with part numbers indicated in the Parts List.
Maintenance
Performed
By
Location
Date
Maintenance
Performed
By
Location
Date
••••••••••••
3. ANNUAL ENGINE VIBRATION MOUNT INSPECTION

At least annually inspect engine vibration mounts for security of attachment and to make sure the resilient parts
are intact. DO NOT operate compressor with defective engine mounting system. Remove and replace defec-
tive parts by ordering with part numbers indicated in Parts List.
Maintenance
Performed
By
Location
Date
Maintenance
Performed
By
Location
Date
••••••••••••
36
Section 6
NOISE CONTROL
4. ANNUAL FRAME, CANOPY, AND PARTS INSPECTION
At least annually inspect frame, canopy and parts, for security of attachment. Make sure there are not any
missing or deformed members, including all hinged doors, covers and their fastening devices. DO NOT oper-
ate compressor with defective frame, canopy and parts. Remove and replace defective parts by ordering with
part numbers indicated in Parts List.
Maintenance
Performed
By
Location
Date
Maintenance
Performed
By
Location
Date
••••••••••••
5. ANNUAL ACOUSTICAL MATERIALS INSPECTION

At least annually inspect all acoustical materials, if any, for security of attachment. Make sure that there is not
any material missing or damaged (refer to Parts List). Clean or replace, if necessary. DO NOT operate com-
pressor with defective acoustical material. Remove and replace defective parts by ordering with part numbers
indicated in the Parts List.
Maintenance
Performed
By
Location
Date
Maintenance
Performed
By
Location
Date
••••••••••••
37
Section 6
NOISE CONTROL
6. ANNUAL INSPECTIONS FOR PROPER OPERATION OF ALL SYSTEMS
In addition to other instructions in the Operator’s Manual, at least annually, operate compressor and inspect to
make sure all systems are operating properly and that engine runs at rated speed and pressure. DO NOT
operate malfunctioning or improperly adjusted compressor. Repair or adjust, per instructions in Operator’s
Manual, as required.
Maintenance
Performed
By
Location
Date
Maintenance
Performed
By
Location
Date
••••••••••••
38
Section 7
ILLUSTRATIONS AND PARTS
7.1 PROCEDURE FOR ORDERING PARTS
Parts should be ordered from the nearest Sullair Representative or the Representative from whom the com-
pressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly
at the addresses, websites, telephone 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 7-1).
Figure 7-1 Serial Number Plate Location
NOTE: For future convenience, write the machine serial number below:
Serial Number _______________________________________________________________________
SULLAIR CORPORATION
3700 East Michigan Boulevard PARTS DEPARTMENT
Michigan City, Indiana 46360 U.S.A. : 1-888-SULLAIR
www.sullair.com Fax: (219) 874-1835
www.sullair.com
: 1-800-SULLAIR (U.S.A. Only)
SERVICE DEPARTMENT
or 1-219-879-5451
: 1-888-775-1604 (U.S.A. & Canada Only)
Fax: (219) 874-1273 Fax: (219) 874-1205
www.sullaircompressors.com
SULLAIR ASIA, LTD. CHAMPION SULLAIR EUROPE, S.A.

Sullair Road, No. 1 COMPRESSORS, LTD. Zone Des Granges BP 82
Chiwan, Shekou Princes Highway 42602 Montbrison Cedex,
Shenzhen, Guangdong PRV. Hallam, Victoria 3803 France
PRC POST CODE 518068 Australia : 33-477968470
: 755-6851686 : 1800-810-015 (for Australia
Fax: 33-477968499
Fax: 755-6853473 -wide Branch Network Only) www.sullaireurope.com
www.sullair-asia.com
: 61-3-9796-4000
Fax: 61-3-9703-8053
www.championcompressors.com.au
39
Section 7
7.2 SPARE PARTS LIST

LIST DESCRIPTION ORDER QTY
REFERENCE KIT NUMBER
1 element for air filter assy. 02250102-158 2
2 element for main compressor fluid filter 250028-032 1
3 element for air/fluid separator 250034-112 1
4 element for engine fuel/water separator 02250118-495 1
5 repair kit for regulator/blowdown valve manifold 02250147-737 1
6 element for thermal valve 02250124-404 1
7 repair kit for return line strainer 241771 241772 1
8 repair kit for low pressure regulator (“H” models) 250019-453 1
9 replacement, valve dust ejector 02250115-271 1
10 kit, coupling 02250139-986 1
11 repair kit for inlet valve 02250109-684 1
12 element for engine oil filter (Caterpillar & Perkins) 02250140-049 1
13 element for engine fuel filter (Caterpillar & Perkins) 02250140-048 1
14 kit, 50 hour maintenance 02250152-936 1
15 kit, 250 hour maintenance (Caterpillar) 02250152-937 1
• kit, 250 hour maintenance (John Deere) 02250152-943 1
• kit, 250 hour maintenance (Perkins) 02250152-940 1
16 kit, 1500 hour maintenance (Caterpillar) 02250152-938 1
• kit, 1500 hour maintenance (John Deere) 02250152-944 1
• kit, 1500 hour maintenance (Perkins) 02250152-941 1
17 Sullair AWF - 5 gallons (18.9 liter) 250030-757 1
18 Sullair AWF - 55 gallon drum (208 liter) 250030-758 1
19 manual, AEM safety 250023-146 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
40
Section 7
NOTES
41
Section 7
7.3A ENGINE, COMPRESSOR AND PARTS - PERKINS AND CATERPILLAR MODELS 125, 130 AND 185
02250141-110R05
42
Section 7
key part
number description number quantity
1 rod, threaded speed control 1/4-28 02250064-593 1

2 spacer, brake lever 250p 02250064-594 1
3 adapter, sae #4 to 10 series 02250071-119 1
4 elbow, 90 3/8”tube x 1/8”npt m 02250099-622 1
5 spring, extension .31 x 7.5#/in 02250112-337 1
6 washer, snubbing vibration mount 02250125-471 6
7 mount, vibration isolator 185 02250125-472 4
8 support, engine front ca 185dpq 60hp 02250136-993 2
9 coupling, assy ktr 185dpq 60hp 02250138-058 1
10 tee, male branch 3/8”tube x 1/8”npt 02250138-698 1
11 switch, engine sht dwn 230 185 60hp 02250139-887 1
12 capscrew, hex met fine m14-1.5x30 02250139-888 8
13 support, fuel fltr perkins 185q 02250139-916 1
14 valve, check 1/8 female - male 02250142-248 1
15 support,spd ctl 185dpq pe 60hp 02250143-546 1
16 fan, 18” blower 185 pe/cat 02250147-425 1
17 spacer, fan 1.50 185 cat 02250148-573 1
18 joint, ball female 1/4” l.h. 250011-578 1
19 joint, ball female 1/4” r.h. 250011-597 1
20 cylinder, speed 3/4 x 1 stroke 250024-272 1
21 clamp, hose 5/8” i.d. 408300-005 2
22 clamp, hose 1 13/16” i.d. 408300-009 1
23 key, square cl2 3/8” x 1 1/2 821206-150 1
24 nut, hex locking 1/4-20 825504-145 2
25 nut, hex locking 1/2-13 825508-262 2
26 capscrew, hex 8.8 m6 x 65mm 828006-065 4
28 capscrew, hex gr5 3/8-16 x 1 1/4 829106-125 19
29 capscrew, hex gr5 1/2-13 x 3 1/4 829108-325 2
30 screw, socket iso 4762 m10 x 20mm 829310-020 8
31 washer, spr lock reg pltd 3/8 837806-094 12
32 washer, pl-b reg pltd 1/2 838208-112 2
Continued on page 45
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR
43
Section 7
02250141-110R05
44
Section 7
7.3A ENGINE, COMPRESSOR AND PARTS - PERKINS AND CATERPILLAR MODELS 125, 130 & 185 (CON-
TINUED)
key part
33 washer, spr lock-metric pltd m6 838806-160 4

34 nut, hex jam lh pltd 1/4-28 866604-164 1
35 capscrew, ferry head hd pltd 1/4-20 x 1 867304-100 1
36 capscrew, ferry head hd pltd 1/4-20 x 1 1/2 867304-150 1
37 nut, hex jam rh pltd 1/4-28 868204-164 2
38 washer, nord-lock pl 9/16” 878609-091 8
39 engine (I) 1
40 compressor & part,dxx102147e (I) 1
(I) Consult factory with serial number to determine part number.

45
Section 7
7.3B ENGINE, COMPRESSOR AND PARTS - JOHN DEERE MODELS 125, 130, 185 & 49HP
02250144-142R04
46
Section 7
key part

3 elbow, 90 3/8”tube x 1/8”npt m 02250099-622 1
6 switch,engine hi-temp, 225f nc 02250138-107 1
8 coupling, assembly ktr w/hub 185q 60hp 02250139-986 1
10 support, engine front rh 185jd 60hp 02250143-547 1
11 support, engine front lh 185jd 60hp 02250143-548 1
12 fan, 18” blower cw rot 185jd 02250147-741 1
13 rod, speed ctl 185dpq jd 02250148-086 1
14 cylinder, speed air 1-1/16 bore 1’ stk 02250148-089 1
15 support, low rpm stop 185 jd 02250148-091 1
16 spring, extension spd ctl 185 jd 02250148-166 1
17 valve, eng oil drain m22x1.5 02250148-791 1
18 spacer, fan 3.50lg 2.5bc 185h jd 02250148-826 1
19 clip, spring spd ctl 185-260 02250152-418 1
20 support, spd ctl 185-260 jd 02250152-439 1
21 rod end, spherical rh 5/16 040136 1
22 clamp, hose 13/16” to 1-1/2” 040513 1
24 clamp, hose 5/8” i.d. 408300-005 3
25 clamp, hose 1 13/16” i.d. 408300-009 1
26 key, square cl2 3/8” x 1 1/2 821206-150 1
27 nut, jam rh unfin 5/16-24 824605-195 1
28 nut, hex pltd 1/4-20 825204-226 1
29 nut, hex locking 1/4-20 825504-145 2
30 nut, hex locking 1/2-13 825508-262 2
47
Section 7
02250144-142R04
48
Section 7
7.3B ENGINE, COMPRESSOR AND PARTS - JOHN DEERE MODELS 125, 130, 185 & 49HP (CONTINUED)
key part

36 capscrew, socket hd 3/8-16 x 3/4 828306-075 8
37 capscrew, hex gr5 1/4-20 x 1 829104-100 1
38 capscrew,hex gr5 3/8-16 x 1 1/4 829106-125 8
39 capscrew,hex gr5 1/2-13 x 3 1/4 829108-325 2
44 hose,heater 5/8 (ft) 842115-062 1
49 engine, jd 4024t 60hp 185dpq (I) 1
50 compressor & part,dxx102147e (I) 1

49
Section 7
7.3C ENGINE, COMPRESSOR AND PARTS - JOHN DEERE MODEL 160H
02250153-408R00
50
Section 7
key part

3 elbow, 90 3/8”tube x 1/8”npt m 02250099-622 1
6 switch,engine hi-temp, 225f nc 02250138-107 1
8 coupling, assembly ktr w/hub 185q 60hp 02250139-986 1
10 support, engine front rh 185jd 60hp 02250143-547 1
11 support, engine front lh 185jd 60hp 02250143-548 1
12 fan, 18” blower cw rot 185jd 02250147-741 1
13 rod, speed ctl 185dpq jd 02250148-086 1
14 cylinder, speed air 1-1/16 bore 1’ stk 02250148-089 1
15 support, low rpm stop 185 jd 02250148-091 1
16 spring, extension spd ctl 185 jd 02250148-166 1
17 valve, eng oil drain m22x1.5 02250148-791 1
18 spacer, fan 3.50lg 2.5bc 185h jd 02250148-826 1
19 clip, spring spd ctl 185-260 02250152-418 1
20 support, spd ctl 185-260 jd 02250152-439 1
21 rod end, spherical rh 5/16 040136 1
22 clamp, hose 13/16” to 1-1/2” 040513 1
24 clamp, hose 5/8” i.d. 408300-005 3
25 clamp, hose 1 13/16” i.d. 408300-009 1
26 key, square cl2 3/8” x 1 1/2 821206-150 1
27 nut, jam rh unfin 5/16-24 824605-195 1
28 nut, hex pltd 1/4-20 825204-226 1
29 nut, hex locking 1/4-20 825504-145 2
30 nut, hex locking 1/2-13 825508-262 2
51
Section 7
02250153-408R00
52
Section 7
7.3C ENGINE, COMPRESSOR AND PARTS - JOHN DEERE MODEL 160H (CONTINUED)
key part

36 capscrew, socket hd 3/8-16 x 3/4 828306-075 8
37 capscrew, hex gr5 1/4-20 x 1 829104-100 1
38 capscrew,hex gr5 3/8-16 x 1 1/4 829106-125 8
39 capscrew,hex gr5 1/2-13 x 3 829108-300 2
44 hose, heater 5/8 842115-062 1 ft.
49 engine, jd 4024t 66hp 160h (I) 1
50 compressor & part, dxx102147e (I) 1

53
Section 7
7.4A AIR INLET AND EXHAUST - PERKINS AND CATERPILLAR MODELS 125, 130 & 185
02250141-018R03
54
Section 7
7.4A AIR INLET AND EXHAUST - PERKINS AND CATERPILLAR MODELS 125, 130 & 185
key part
1 elbow, 90m 5/16”tube x 1/8”npt 02250109-423 1

2 filter, air plastic strt inl (I) 02250110-197 1
3 support, air fltrs 185dpq 60hp 02250136-929 1
4 hose, air inl unit 186dpq 60hp 02250136-931 1
5 muffler, jd cat 185dpq 60hp 02250136-942 1
6 support, muff cat 185dpq 60hp 02250136-995 1
7 tube, exhaust outlet cat 185 60hp 02250136-996 1
8 tube, exhaust inlet cat 185 60hp 02250136-997 1
9 shield, heat exhaust 185q cat 02250139-771 1
10 adapter, air inlet eng.breath 185ca 02250140-051 1
11 filter, air 7” plstc 90 non cint. (I) 02250140-440 1
12 hose, air inl fltr 185q 60hp 02250140-875 1
13 hose, air inlet eng 185q 60hp 02250140-876 1
14 tube, engine vent 185dpq pe 02250147-925 1
15 clamp, hose spring 3/4 od ss 02250148-054 2
16 baffle, frm low frt 185 dlq 02250157-075 1
17 elbow, exh outlet cat 185dlq 02250157-090 1
18 baffle, air exhst frt 185dlq 02250158-022 1
19 clamp, hose 1 13/16” x 2 3/4” adj. 040083 3
20 clamp, exhaust 2-1/2” 043203 2
21 band, mounting 6 1/2” 043370 2
22 clamp, hose 2-13/16 to 3-3/4” 250018-550 3
23 nut, hex f pltd 5/16-18 825305-283 10
24 nut, hex locking 3/8-16 825506-198 2
26 capscrew, hex gr5 3/8-16 x 1 829106-100 2
27 screw, hex ser washer 5/16-18 x 3/4 829705-075 8
28 screw, mach-hex 1/4-20 x 2 1/2 830104-250 2
30 hose, heater 1/2” 842115-050 2 ft.
(I) For maintenance on air filter, order replacement element no. 02250102-158, and/or dust ejector valve
no. 02250115-271.
55
Section 7
7.4B AIR INLET AND EXHAUST - JOHN DEERE MODELS 125, 130, 185, 49HP & 160H
02250144-143R02
56
Section 7
7.4B AIR INLET AND EXHAUST - JOHN DEERE MODELS 125, 130, 185, 49HP & 160H
key part
1 elbow, 90m 5/16”tube x 1/8”npt 02250109-423 1

3 hose, air inl unit 186dpq 60hp 02250136-931 1
4 muffler, jd cat 185dpq 60hp 02250136-942 1
5 tube, exhaust outlet 185dpq 60hp 02250136-943 1
6 clamp, v-band jd 4024t 185dpq 02250137-896 1
7 filter, air 7” plstc 90 non cint. (I) 02250140-440 2
8 support, muffler jd 185dpq 60hp 02250143-583 1
9 hose, air inl jd 185dpq 60hp 02250143-584 1
10 tube, exhaust inlet 185dpq jd 60hp 02250143-585 1
11 support, air filter 185 dpq jd eng 02250146-699 1
12 shield, heat muffler top 185jd 02250147-977 1
13 shield, muffler frt mnt 185q jd 02250156-122 1
14 baffle, frm low frt 185 dlq 02250157-075 1
15 elbow , exh outlet 185dlq jd 02250157-081 1
16 tube, exhaust flex 185dlq jd 02250157-082 1
17 angle, exhst supt 185dlq jd 02250157-085 1
18 baffle, air exhst frt 185dlq 02250158-022 1
19 clamp, hose 1 13/16” x 2 3/4” adj. 040083 1
20 clamp, exhaust 2-1/2” 043203 4
21 band, mounting 6 1/2” 043370 2
22 clamp, hose 2-13/16 to 3-3/4” 250018-550 3
23 nut, hex f pltd 1/4-20 825304-236 2
24 nut, hex f pltd 5/16-18 825305-283 10
25 nut, hex metric m8 x 1.25 825908-125 2
30 screw, mach-hex 1/4-20 x 2 1/2 830104-250 2
33 washer, metric-iso7089- 12 865412-240 4
34 plug, pipe 1/8” 3000# stl plt 866900-005 1
(I) For maintenance on air filter, order replacement element no. 02250102-158, and dust ejector valve no.
02250115-271 (please note quantity of two air filters).
57
Section 7
7.5 RADIATOR AND COMPRESSOR FLUID COOLING SYSTEM - ALL MODELS
02250140-864R00
58
Section 7
7.5 RADIATOR AND COMPRESSOR FLUID COOLING SYSTEM - ALL MODELS
key part
1 bucket, radiator fluid recovery 02250083-466 1

2 channel, extruded rubber “u” .25”w 02250086-448 1 ft.
3 hose, hydparkrimp 3/4” x 72” 02250107-493 1
4 hose, fuel 3/4” x 50” 375dpq 02250108-406 1
5 guard, fan 20” (110-130 & 185 cat) 02250112-141 1
6 element, therm vlv 160deg setting (I) 02250124-404 1
7 manifold, thrm by-pass 185 bdr 02250132-254 1
8 support, manf thrm vlv 185 60hp 02250132-260 1
9 receiver, air oil 10” 185 60hp 02250136-539 1
11 seal, clip-on baffles 185 60hp 02250137-297 4
12 baffle, cooler r.h. 185dpq ca 60hp 02250139-755 1
13 baffle, cooler l.h. 185dpq ca 60hp 02250139-756 1
14 baffle, cooler upper 185dpq ca 60hp 02250139-757 1
15 baffle, cooler lower 185dpq ca 60hp 02250139-758 1
16 radiator, 185dpq ca 60hp 02250139-760 1
17 cooler, oil blower 185dpq 60hp 02250139-761 1
18 hose, rad upper cat 185 60hp 02250139-762 1
19 hose, rad lower cat 185 60hp 02250139-763 1
20 support, cooler rad 185dpq ca 60hp 02250139-768 1
21 hose, hydraulic parkrimp 3/4 x 24 02250139-775 1
22 hose, hydraulic parkrimp 3/4 x 32 02250139-776 1
23 guard, fan 185q 60hp 02250140-186 1
24 shroud, fan 18” dia 185q 60hp cat 02250140-228 1
25 panel, acoustic clg baf rh lower 02250140-235 1
26 panel, acoustic clg baf lh lower 02250140-236 1
27 panel, acoustic top baffle rh 02250140-238 1
28 panel, acoustic top baffle lh 02250140-239 1
29 hose, radiator upper 185jd 60hp 02250143-579 1
30 hose, radiator lower 185jd 60hp 02250143-580 1
(I) For maintenance on thermal valve, order replacement element no. 02250124-404.
59
Section 7
7.5 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM - ALL MODELS
02250140-864R00
60
Section 7
7.5 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM - ALL MODELS (CONTINUED)
key part
31 shroud, fan 18” 185jd 60hp 02250143-581 1

32 clamp, hose 1 5/16” to 2 1/4” adj. 040014 3
33 drainlock, 1/4” 040061 1
34 clamp, hose 1 13/16” x 2 3/4” adj. 040083 1
35 grommet, rubber 1” hole 040162 1
36 clamp, hose 3/8” 047235 2
37 adapter, oil filter .970-20 x 3/4-16 250025-914 1
38 element, fluid filter (I) 250026-982 1
39 weatherstrip, 1”thick x 1”wide 250041-174 2 ft.
40 plug, straight thread 3/4-16 viton 250042-623 1
41 clamp, hose 5/8” i.d. 408300-005 1
42 clamp, hose 1 13/16” i.d. 408300-009 1
43 clamp, hose 2 3/8” i.d. 408300-010 1
44 nut, hex f pltd 1/4-20 825304-236 2
45 nut, hex f pltd 5/16-18 825305-283 9
46 nut, hex locking 1/4-20 825504-145 1
47 o-ring, viton 1 1/4 x 1/8” 826502-218 1
48 capscrew, hex gr5 3/8-16 x 3/4 829106-075 1
51 screw, hex ser washer 5/16-18 x 1 829705-100 4
55 washer, pl-b wide pltd 5/16 838305-071 1
56 hose, fuel line 1/4 842315-025 2 ft.
57 hose, fuel line 5/16 842315-031 1 ft.
58 reducer, str thrd viton 1 x 3/4 870016-012 1
59 connector, straight x jic 1 1/16 x 1 1/16 870112-012 5
60 connector, 90d str x jic 1 1/16 x 1 1/16 870612-012 3
61 tee, straight thd m-rn viton 1 1/16” 871800-106 1
(I) For maintenance on fluid filter, order replacement element kit no. 250028-032.
61
Section 7
7.6 FRAME, RUNNING GEAR AND PARTS - ALL MODELS
02250140-871R03
62
Section 7
key part
1 reflector, red 3” truck-lite 02250052-701 2

2 reflector, yellow 3” truck-lite 02250052-702 2
3 chain, 1/4 x 72 w/2 ez3 hooks 02250094-269 1
4 connector, delta-shaped chain 1/4” 02250100-538 1
5 jack, hd w/pad 185-425 std 02250116-794 1
6 stud, ball gas spring 5/16th x .54l 02250121-515 2
7 washer, snubbing 375 vibration mount 02250125-604 2
8 drawbar, std pivot 185dpq 02250133-864 1
9 support, shipping 185 pivot drbar 02250133-984 1
10 panel, frame rear 185dpq 60hp 02250134-142 1
11 panel, frame frt 185dpq 60hp 02250134-143 1
12 panel, frame lh 185dpq 60hp 02250134-144 1
13 panel, frame rh 185dpq 60hp 02250134-145 1
14 hinge, canopy 185 clam 02250134-494 1
15 axle, torsional 3500 lb 185 std 02250134-853 1
16 fender, plastic 185dpq 60hp 02250134-854 2
17 tire, assy st175/80d13 02250136-005 2
18 support, latch striker 185 60hp 02250136-794 1
19 seal, clip-on baffles 185 60hp 02250137-297 10
20 catch, assembly pinned 185q 60hp 02250139-967 1
21 pin, safety snap 1/4x 2-1/4 ss 02250139-975 1
22 cable, lanyard 1/16x6 loop&eye 02250139-977 1
23 frame assembly, 185q 60hp 02250140-184 1
24 bumper, baffle 185q 60hp 02250140-185 1
25 panel, acoustic frame panel front 02250140-244 1
26 panel, acoustic bumper baffle 02250140-246 1
27 plate, lift bail cover 185 02250140-880 1
28 support, dr-bar swivel 185q 02250141-183 1
29 angle, machine tie down 185q60hp 02250141-345 1
30 panel, toolbox expanded 185pe 02250142-977 1
31 panel, toolbox 185jd 60hp 02250143-807 1
32 panel, toolbox rear 185pe 02250143-986 1
33 bail, lifting assy 185dpq 60hp 02250152-910 1
63
Section 7
02250140-871R03
64
Section 7
7.6 FRAME, RUNNING GEAR AND PARTS - ALL MODELS (CONTINUED)
key part
34 eye, 3” lunette demountable 250002-221 1

35 screw, mach phill #10-24 x 1/2 250025-692 4
36 nut, hex f pltd 5/16-18 825305-283 25
37 nut, hex locking #8-32 825501-070 4
38 nut, hex locking #10-24 825502-083 5
39 nut, hex locking 1/2-13 825508-262 4
40 nut, hex locking 5/8-11 825510-329 2
41 capscrew, hex gr5 1/2-13 x 1 1/4 829108-125 7
42 capscrew, hex gr5 5/8-11 x 1 1/2 829110-150 4
43 capscrew, hex gr5 5/8-11 x 4 3/4 829110-475 2
50 capscrew, hex gr5 1/2-13 x 1 1/4 plt 875608-125 8
51 screw, flt phillips 8-32 x 3/4” 875901-075 4
52 screw, rnd phillips 10-24 x 3/4” 876002-075 1
65
Section 7
7.7A DISCHARGE SYSTEM AND PARTS - ALL MODELS EXCEPT JOHN DEERE 160H
02250140-633R03
66
Section 7
key part
1 insert, nylon tubing 1/4”od 02250052-841 4

2 tube, nyl .25 od x 040w wht 02250054-860 2 ft.
3 tube, nyl .25 od x .040w blk 02250054-861 5 ft.
4 adapter,receiver oil fill 185dpq 02250064-595 1
5 tube, 5/16 od x .040 wall 02250081-220 1
6 glass, sight oil level 1-1/2” pltd 02250081-779 1
7 conn, female pipe 1/8-27 npt - 02250097-138 1
8 insert, nyl tubing 3/8”od 02250099-052 5
9 elbow, 90 3/8”tube x 1/8”npt m 02250099-622 1
10 elbow, 90 3/8”tube x 1/4”npt m 02250099-626 1
11 connector, tube oil return 1/4 x 1/4 02250108-700 1
12 orifice, .040” x .25m x .25m nptf 02250109-215 1
13 valve, inline check 1” npt ball 02250109-661 1
14 tube, oil siphon 1/4”od 110-185 02250114-091 1
15 orifice, min pressure nylon 9mm 02250121-007 1
16 switch, temp n.c. 250$sf, single pole 02250133-513 1
19 hose, hydraulic parkrimp 1-1/4 x 18 02250139-774 1
20 hose, hydraulic parkrimp 1” x 72lg 02250139-778 1
21 tbg, nylon-11 3/8”od red 02250139-950 4
22 tbg, nylon-11 3/8”od yellow 02250139-951 2
23 tbg ,nylon-11 3/8”od green 02250139-952 2
24 tbg, nylon-11 3/8”od blue 02250139-953 5
25 tbg, nylon-11 3/8”od orange 02250139-954 4
29 valve, drain 1-1/16-12unf o-ring 02250142-844 1
30 tank, receiver air/oil 185q pe 02250142-979 1
31 sub assembly, manf regulator-blowdown 185 (I) 02250148-203 1
32 plug, o-ring boss sae 1 1/4 040029 1
(I) For complete breakdown of this sub-assembly, refer to Section 7.8A.

67
Section 7
02250140-633R03
68
Section 7
7.7A DISCHARGE SYSTEM AND PARTS - ALL MODELS EXCEPT JOHN DEERE 160H (CONTINUED)
key part
33 clamp, hose 13/16” to 1-1/2” 040513 1

34 strainer, v-type 300psix1/4 (I) 241771 1
35 valve, pressure relief 200 psig 250006-938 1
36 connector,1/4”tube x 1/4”npt 250018-428 1
37 elbow, 90 1/4”tube x 1/8”npt - 250018-429 1
38 valve, ball 3/4” service 250019-865 2
39 coupling, 3/4” male npt am7 250031-648 2
40 element, sep-fin 10 25/30 (II) 250034-143 1
41 connector,fem 1/4t x 1/4 npt 250041-084 1
42 connector, tube-m 1/4 x 1/4 810204-025 1
43 nut, hex locking 3/8-16 825506-198 2
44 capscrew,hex gr5 3/8-16 x 1 1/4 829106-125 2
48 hose, heater 3/4 842115-075 1 ft.
49 elbow, 37fl 45m 1 x 1 860016-100 1
50 connector,37 fl/mpt pltd 1 x 1 860116-100 1
51 elbow, pipe 90 deg plt 1/2” 866215-020 1
52 elbow, pipe 90 deg plt 1 1/2” 866215-060 1
53 nipple, pipe-xs plt 1/2 x cl 866408-000 1
55 nipple, pipe-xs plt 1 x cl 866416-000 1
56 nipple, pipe-xs plt 1 x 2 866416-020 2
58 nipple, pipe-xs plt 1 1/2 x cl 866424-000 1
59 elbow, pipe 90 deg 300# plt 1” 867030-040 2
60 tee, reducing pltd 1 x 3/4 x 3/4 868604-033 1
61 reducer, str thrd viton 1 1/2 x 1 1/4 870024-020 1
65 adapter, pipe male 7/16 orng x 1/8 877202-012 1
(I) For maintenance on v-type strainer no. 241771, order repair kit no. 241772.
(II) For maintenance on air/fluid separator no. 250034-143, order replacement element kit no. 250034-112.
69
Section 7
7.7B DISCHARGE SYSTEM AND PARTS - JOHN DEERE MODEL 160H
02250153-406R01
70
Section 7
key part
1 insert, nylon tubing 1/4”od 02250052-841 4

2 tube, nyl .25 od x 040w wht 02250054-860 2 ft
4 adapter, receiver oil fill 185dpq 02250064-595 1
5 tube ,5/16 od x .040 wall 02250081-220 1
6 glass, sight oil level 1-1/2” pltd 02250081-779 1
7 conn, female pipe 1/8-27 npt - 02250097-138 1
8 insert, nyl tubing 3/8”od 02250099-052 5
9 elbow, 90 3/8”tube x 1/8”npt m 02250099-622 1
10 elbow, 90 3/8”tube x 1/4”npt m 02250099-626 1
12 orifice, .040” x .25m x .25m nptf 02250109-215 1
13 valve, inline check 1” npt ball 02250109-661 1
14 tube, oil siphon 1/4”od 110-185 02250114-091 1
15 orifice, min pressure nylon 9mm 02250121-007 1
19 hose, hydraulic parkrimp 1-1/4 x 18 02250139-774 1
20 hose, hydraulic parkrimp 1” x 72lg 02250139-778 1
21 tbg, nylon-11 3/8”od red 02250139-950 4
22 tbg, nylon-11 3/8”od yellow 02250139-951 2
23 tbg ,nylon-11 3/8”od green 02250139-952 2
24 tbg, nylon-11 3/8”od blue 02250139-953 2
25 tbg, nylon-11 3/8”od orange 02250139-954 4
29 valve, drain 1-1/16-12unf o-ring 02250142-844 1
30 tank, receiver air/oil 185q pe 02250142-979 1
31 sub assembly, manf reg/blwdn 160hdpq-jd (I) 02250153-397 1
32 plug, o-ring boss sae 1 1/4 040029 1
(I) For complete breakdown of this sub-assembly, refer to Section 7.8B.

71
Section 7
02250153-406R01
72
Section 7
7.7B DISCHARGE SYSTEM AND PARTS - JOHN DEERE MODEL 160H (CONTINUED)
key part
33 clamp, hose 13/16” to 1-1/2” 040513 1

34 strainer, v-type 300psix1/4 (II) 241771 1
35 valve, pressure relief 200 psig 250006-938 1
36 connector,1/4”tube x 1/4”npt 250018-428 1
37 elbow, 90 1/4”tube x 1/8”npt - 250018-429 1
39 element, sep-fin 10 25/30 (III) 250034-143 1
40 connector, fem 1/4t x 1/4 npt 250041-084 1
41 connector, tube-m 1/4 x 1/4 810204-025 1
42 nut, hex locking 3/8-16 825506-198 2
43 capscrew, hex gr5 3/8-16 x 1 1/4 829106-125 2
47 hose, heater 3/4 842115-075 1 ft.
48 elbow, 37fl 45m 1 x 1 860016-100 1
49 connector,37 fl/mpt pltd 1 x 1 860116-100 1
50 elbow, pipe 90 deg plt 1/2” 866215-020 1
51 elbow, pipe 90 deg plt 1 1/2” 866215-060 1
57 nipple, pipe-xs plt 1 1/2 x cl 866424-000 1
59 tee, reducing pltd 1 x 3/4 x 3/4 868604-033 1
60 reducer, str thrd viton 1 1/2 x 1 1/4 870024-020 1
64 adapter, pipe male 7/16 orng x 1/8 877202-012 1
(II) For maintenance on v-type strainer no. 241771, order repair kit no. 241772.
(III) For maintenance on air/fluid separator no. 250034-143, order replacement element kit no. 250034-
112.
73
Section 7
7.8A REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY - ALL MODELS EXCEPT JOHN DEERE 160H
02250148-570R04
7.8B REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY - JOHN DEERE MODEL 160H
02250153-405R01
74
Section 7
7.8A REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY - ALL MODELS EXCEPT JOHN DEERE 160H
key part
1 elbow, 90d 5/16” tube x 1/4”npt 02250081-218 1

2 elbow, 90 3/8”tube x 1/4”npt m 02250099-626 1
3 connector, 3/8tube x 1/2npt 02250129-957 1
4 manifold, regulator blowdown 185 (I) 02250146-046 1
5 connector, 3/8 tube x 1/4npt 02250148-188 2
6 support, manifold reg. bd 185q 02250148-190 1
7 elbow, 90 1/4t pls x 1/4 npt m 250018-430 1
10 nipple, pipe-hex 1/4 x 1/4 860404-025 1
11 tee, pipe 150# plt 1/4 866815-010 1
7.8B REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY - JOHN DEERE MODEL 160H
key part
1 elbow, 90d 5/16” tube x 1/4”npt 02250081-218 1

2 elbow, 90 3/8”tube x 1/4”npt m 02250099-626 1
3 connector, 3/8 tube x 1/4npt 02250148-188 4
4 elbow, 90 1/4t pls x 1/4 npt m 250018-430 1
7 nipple, pipe-hex 1/4 x 1/4 860404-025 3
8 tee, pipe 150# plt 1/4 866815-010 2
9 bushing, red pltd 1/2 x 1/4 867102-010 1
10 support, manifold reg. bd 185q 02250148-190 1
11 valve, pressure regulator (II) 250017-280 1
12 manifold, press reg/bd 150psi 185h 02250151-201 1
(I) For maintenance on regulator blowdown manifold no. 02250146-046, order repair kit no. 02250147-
737.
(II) For maintenance on pressure regulator no. 041517, order repair kit no. 041742.
75
Section 7
7.9 ELECTRICAL PARTS - ALL MODELS
02250141-108R01
76
Section 7
7.9 ELECTRICAL PARTS - ALL MODELS
key part
1 channel, extruded rubber “u” .25”w 02250086-448 1 ft.

2 washer, external serrated m10 02250092-169 2
3 conn, female pipe 1/8-27 npt 02250097-138 1
4 cable, ground 4-gauge strap 02250101-258 1
5 battery, c30h 12 volt 02250104-192 1
6 hold-down, battery 11” j-bolt 02250104-193 2
7 spring, extension .50 dia 30 lbs 02250110-529 1
8 lamp, license plate std 02250119-658 1
9 bracket, license plate lamp 02250119-678 1
10 switch, engine oil pressure n.o. 02250130-668 1
12 tray, battery 185dpq 60hp 02250137-492 1
13 harness, wire std lt 4-wire 185q 60hp 02250139-964 1
14 boot, battery terminal 041561 2
15 nut, plastic square license plate 250006-076 4
16 angle, hold-down battery 250019-104 1
17 cable, batt 0 ga x 15” black 250019-480 1
18 fuse, blade type atc 30amp 250023-996 1
19 lamp, tail/turn/stop (shock mtg) 250028-415 2
20 cable, batt 0 ga x 54 red 250030-047 1
21 nut, hex f pltd 5/16-18 825305-283 1
22 nut, hex locking #10-24 825502-083 1
23 nut, hex metric m8 x 1.25 825908-125 1
24 capscrew, hex gr5 3/8-16 x 1 829106-100 1
27 wrap, tie nylon tf4-8 843200-025 1
29 tee, pipe 150# plt 1/8 866815-005 1
30 plug, pipe 1/8” 3000# stl plt 866900-005 1
77
Section 7
7.10 FUEL TANK AND PARTS - ALL MODELS
02250141-107R03
78
Section 7
7.10 FUEL TANK AND PARTS - ALL MODELS
key part

2 adapter, 1/2str oring x 1/4 fnpt 02250075-714 2
3 cap, fuel fill buttress thread 02250094-791 1
4 conn, female pipe 1/8-27 npt 02250097-138 1
5 tube, fuel return 1/4” jd 185q 02250102-573 1
7 filter, ass’y fuel/water sep (I) 02250118-494 1
8 plug, fuel/water sep 1/2-20 unf 02250118-524 2
9 connector, tube oil return 5/16x1/4 02250118-809 1
10 tank, fuel 20 gal 185dpq 60hp 02250132-591 1
11 strap, hold down fuel frt 60hp 02250137-493 1
12 strap, holddown fuel rear 60hp 02250137-494 1
13 tube, fuel pick-up 185dpq 60hp 02250139-885 1
14 tube, fuel return 185dpq jd 02250139-886 1
15 support, fuel fltr perkins 185q 02250139-916 1
16 adapter, fuel pickup 185 60hp 02250152-163 1
17 silencer, exhaust 1/8npt tm-18w70 micron 02250152-316 1
18 clamp, hose 3/8” 047235 11
19 gasket, fuel gauge neoprene 250004-752 1
20 conn, 1/4” tube x 1/8” npt 250018-427 2
21 elbow, 5/16”hose x 1/4”npt 406615 2
22 clamp, hose 9/16”id 408300-001 1
23 nut, hex f pltd 5/16-18 825305-283 4
24 nut, hex locking 5/16-18 825505-166 4
25 screw, hex ser washer 5/16-18 x 1 829705-100 4
26 washer, spr lock reg pltd #10 837802-047 5
28 hose, fuel line 1/4 842315-025 4 ft.
29 hose, fuel line 5/16 842315-031 4 ft.
(I) For maintenance on fuel/water separator assembly filter no. 02250118-494, order replacement element
no. 02250118-495.
79
Section 7
7.11 CANOPY, ACOUSTICAL PANELS AND PARTS - ALL MODELS
02250141-109R02
80
Section 7
7.11 CANOPY, ACOUSTICAL PANELS AND PARTS - ALL MODELS
key part
1 stud, ball gas spring 5/16th x .54l 02250121-515 2

2 panel, canopy side rh 185 clam 02250134-135 1
3 panel, canopy side lh 185 clam 02250134-136 1
4 gussett, can frm supt 185 clam 02250134-137 4
5 panel, canopy top 185 clam 02250134-138 1
6 channel, canopy supt frt-r 185 clam 02250134-140 2
7 channel, canopy supt sides 185 clam 02250134-141 2
8 hinge, canopy 185 clam 02250134-494 1
9 support, gas sprng can 185 60hp 02250134-568 2
10 louver, canopy ends 185q 60hp 02250134-713 2
11 spring, gas canopy 900n 185 60hp 02250137-298 2
12 grommet, rubber 5.75 od 185 60hp 02250138-688 1
13 striker, latch 185 canopy 02250139-985 1
14 screw, shldr 1/4-20 x 1/4 ss 02250142-100 16
15 washer, flat 5/16 x 11/16 ss black 02250142-101 16
16 panel, accust louvers 185 02250155-717 20
17 nut, hex f pltd 5/16-18 825305-283 36
81
Section 7
7.12 INSTRUMENT PANEL, PANEL DOOR AND MOUNTING PARTS - ALL MODELS
02250155-950R00
82
Section 7
7.12 INSTRUMENT PANEL, PANEL DOOR AND MOUNTING PARTS - ALL MODELS
key part
1 hinge, instrument panel door 185q-8f 02250103-623 1

2 screw, phil pan hd #6-32 x3/8 02250112-009 4
3 catch, locking instrument panel 02250125-511 1
4 door, instrument panel 185 60hp 02250138-181 1
5 weatherstrip, 3/16 x 3/8 250022-436 3 ft.
6 screw, mach phill #10-24 x 1/2 250025-692 8
7 bumper, rubber 1/2 dia 250035-095 3
8 nut, hex locking #6-32 825500-102 4
9 nut, hex locking #8-32 825501-070 1
10 nut, acorn pltd #8-32 825615-002 2
11 washer, pl-b reg pltd #6 838200-045 4
14 pnl, instrument panel & parts See Table Below 1
PART NUMBER GAUGE

MODEL REFER TO SECTION
REFERENCE CONFIGURATION
John Deere 125, 130, 185
02250155-952 Standard 7.13A
& 49HP
Perkins / Caterpillar
02250155-955 Standard 7.13A
125, 130, 185
02250153-403 John Deere 160H Standard 7.13B

Perkins / Caterpilliar
02250155-958 (Australian) Standard 7.13C
130, 185
John Deere 125, 130,
02250155-953 Full 7.13D
185 & 49HP
Perkins / Caterpillar
02250155-956 Full 7.13D
125, 130, 185
02250154-137 John Deere 160H Full 7.13E
83
Section 7
7.13A INSTRUMENT PANEL AND PARTS - JOHN DEERE / CATERPILLAR / PERKINS MODELS 125, 130,
185, 49HP (STANDARD GAUGE)
02250155-952R01
02250155-955R01
84
Section 7
7.13A INSTRUMENT PANEL AND PARTS - JOHN DEERE / CATERPILLAR / PERKINS MODELS 125, 130,
185, 49HP (STANDARD GAUGE)
key part
1 gauge, pressure air 0-300 2” 02250044-361 1

2 hour-meter, 12-24vdc 10000hr 2” 02250050-517 1
3 elbow, 90 3/8”tube x 1/4”npt m 02250099-626 1
4 tube, nylon .375”od x .050w black 02250099-630 1 ft.
5 lense, cliplite led 02250129-189 1
6 panel, instrument plastic ssam 02250129-190 1
7 decal, starting aid 185-375 cat 02250130-631 1
8 decal, group std panel (ssam) 02250131-485 1
9 switch, engine ignition 12-volt 02250132-883 1
10 tee, male branch 3/8” tube x 1/4”npt m 02250136-998 1
11 valve, ball 2-way 1/4”npt 02250136-999 1
12 elbow, 90 f 3/8”tube x 1/4”npt 02250137-033 1
13 cover, access ssam molded abs 02250137-265 1
14 controller, ssam 185-60hp 02250139-296 1
15 harness, wiring 185 (John Deere) TII 02250155-951 1
• harness, wiring 185 (Caterpillar & Perkins) TII 02250155-954 1
16 switch, starter push-button 040038 1
17 screw, tc-f rd hd #6-32 x 1/2 835700-050 2
85
Section 7
7.13B INSTRUMENT PANEL AND PARTS - JOHN DEERE MODEL 160H (STANDARD GAUGE)
02250153-403R03
86
Section 7
7.13B INSTRUMENT PANEL AND PARTS - JOHN DEERE MODEL 160H (STANDARD GAUGE)
key part

2 hour-meter, 12-24vdc 10000hr 2” 02250050-517 1
3 elbow, 90 3/8”tube x 1/4”npt m 02250099-626 2
4 tube,nylon .375”od x .050w black 02250099-630 2 ft.
10 tee, male branch 3/8”tube x 1/4”npt m 02250136-998 2
12 elbow, 90 f 3/8”tube x 1/4”npt 02250137-033 1
15 harness, wiring 185 jd tii 02250155-951 1
17 screw, tc-f rd hd #6-32 x 1/2 835700-050 2
20 decal, dual pressure 185-375 ssam 02250130-630 1
87
Section 7
7.13C INSTRUMENT PANEL AND PARTS - CATERPILLAR AND PERKINS (AUSTRALIAN) MODELS 130-185
02250155-958R01
88
Section 7
7.13C INSTRUMENT PANEL AND PARTS - CATERPILLAR AND PERKINS (AUSTRALIAN) MODELS 130-185
key part

2 hour-meter, 12-24vdc 10000hr 2” 02250050-517 1
3 elbow, 90 3/8”tube x 1/4”npt m 02250099-626 1
11 elbow, 90 f 3/8”tube x 1/4”npt 02250137-033 1
15 harness, wiring 185 aus p/c tier ii 02250155-957 1
17 screw, tc-f rd hd #6-32 x 1/2 835700-050 2
89
Section 7
7.13D INSTRUMENT PANEL & PARTS - JOHN DEERE / CATERPILLAR / PERKINS MODELS 125, 130, 185,
49HP (FULL GAUGE)
02250155-956R01
02250155-953R01
90
Section 7
7.13D INSTRUMENT PANEL & PARTS - JOHN DEERE / CATERPILLAR / PERKINS MODELS 125, 130, 185,
49HP (FULL GAUGE)
key part

2 gauge, volt-meter 12 volt 2” 02250044-366 1
3 gage, temperature mech 72” 130-250f 2” 02250050-513 1
4 gauge, pressure mech 0-100psi 2” 02250050-516 1
5 hour-meter, 12-24vdc 10000hr 2” 02250050-517 1
6 elbow, 90 3/8”tube x 1/4”npt m 02250099-626 1
11 harness, voltmeter 125-425 jd/cat 02250130-635 1
12 decal, group full gauge (ssam) 02250131-486 1
16 elbow, 90 f 3/8”tube x 1/4”npt 02250137-033 1
19 gauge, temp mech 8ft 140-300$sf 02250143-278 1
20 adapter, red 1/2-14 npt murphy thrd 02250155-384 1
21 harness, wiring 185 (John Deere) TII 02250155-951 1
• harness, wiring 185 (Caterpillar & Perkins) TII 02250155-954 1
23 screw, tc-f rd hd #6-32 x 1/2 835700-050 2
91
Section 7
7.13E INSTRUMENT PANEL & PARTS - JOHN DEERE MODEL 160H (FULL GAUGE)
02250154-137R04
92
Section 7
7.13E INSTRUMENT PANEL & PARTS - JOHN DEERE MODEL 160H (FULL GAUGE)
key part

2 gauge, volt-meter 12 volt 2” 02250044-366 1
3 gage, temperature mech 72” 130-250f 2” 02250050-513 1
4 gauge, pressure mech 0-100psi 2” 02250050-516 1
5 hour-meter, 12-24vdc 10000hr 2” 02250050-517 1
6 elbow, 90 3/8”tube x 1/4”npt m 02250099-626 2
11 harness, voltmeter 125-425 jd/cat 02250130-635 1
12 decal, group full gauge (ssam) 02250131-486 1
16 elbow, 90 f 3/8”tube x 1/4”npt 02250137-033 1
19 gauge, temp mech 8ft 140-300$sf 02250143-278 1
20 o-ring, str thd 70 vit 1/2”-908 250042-643 1
21 harness, wiring 185 jd tii 02250155-951 1
23 screw, tc-f rd hd #6-32 x 1/2 835700-050 2
26 decal, dual pressure 185-375 ssam 02250130-630 1
93
Section 7
7.14 SINGLE HOSE REEL OPTION - ALL MODELS
02250141-718R02
94
Section 7
7.14 SINGLE HOSE REEL OPTION - ALL MODELS
key part
1 valve, air velocity flow 3/4”npt 02250045-062 1

2 support, manifold single hose reel 02250054-447 1
3 hose, medium pressure 1”jic x 32”long 02250054-969 1
4 draw-bar, long pivot 185dpq 02250136-247 1
5 reel, hose 100ft 3/4”hose x 3/4”npt 040170 1
6 hose, assembly 5/8”id x 28”long 040701 1
7 valve, air velocity flow 3/4”npt 043480 1
8 adapter, swivel 90deg 3/4”h x 3/4”p 045241 1
9 support, service manifold 250002-145 1
10 oiler, 1qt microfog nogren 250005-016 1
11 u-bolt, hose reel mount 110-250 250008-322 2
14 lubricator, cf 1 pt 1” 30cf 251315 1
15 oiler, line 2-quart 1” npt 405403 1
16 nut, hex f pltd 1/4-20 825304-236 4
17 nut, hex f pltd 5/16-18 825305-283 4
18 nut, hex locking 3/8-16 825506-198 8
19 capscrew, hex gr5 3/8-16 x 1 829106-100 4
24 connector, 37 fl/mpt pltd 1 x 1 860116-100 1
25 elbow, 37fl 90m 1 x 1 860216-100 1
29 plug, pipe 1” 3000# stl plt 866900-040 1
30 elbow, pipe 90 deg 300# plt 3/4” 867030-030 1
31 bushing, red pltd 1 x 3/4 867104-030 2
32 coupling, pipe 1 300# plt 867430-040 1
33 union, pipe-brs seat 1 300# plt 868030-040 1
34 u-bolt, 1/4” x 1” pipe pltd 868304-100 2
35 u-bolt, 5/16” x 1 1/4” pipe pltd 868305-125 1
36 tee, pipe pltd 1 868430-040 2
95
Section 7
7.15 DUAL HOSE REEL OPTION - ALL MODELS
0225002250141-690R02
96
Section 7
key part
1 support, hose reel manifold 110-250 02250048-573 1

2 support, hose reel 110-250 portables 02250048-574 1
3 hose, medium pressure 1”jic x 32”long 02250054-969 2
4 draw-bar, long pivot 185dpq 02250136-247 1
5 support, dr-bar swivel 185q 02250141-183 1
6 reel, hose 100ft 3/4”hose x 3/4”npt 040170 2
7 hose, assembly 5/8”id x 18”long 040885 2
8 valve, air velocity flow 3/4”npt 043480 2
9 adapter, swivel 90deg 3/4”h x 3/4”p 045241 2
12 u-bolt, hose reel mount 110-250 250008-322 2
16 oiler, line 2-quart 1” npt 405403 1
17 nut, hex f pltd 1/4-20 825304-236 4
18 nut, hex f pltd 5/16-18 825305-283 4
19 nut, hex locking 3/8-16 825506-198 12
20 capscrew, hex gr5 3/8-16 x 1 829106-100 8
25 connector, 37 fl/mpt pltd 1 x 1 860116-100 1
26 elbow, 37fl 90m 1 x 1 860216-100 1
30 plug, pipe 1” 3000# stl plt 866900-040 1
31 elbow, pipe 90 deg 300# plt 3/4” 867030-030 2
97
Section 7
0225002250141-690R02
98
Section 7
7.15 DUAL HOSE REEL OPTION - ALL MODELS (CONTINUED)
key part
34 cross, pipe 1” plt 867830-040 1

36 u-bolt, 1/4” x 1” pipe pltd 868304-100 2
37 u-bolt, 5/16” x 1 1/4” pipe pltd 868305-125 1
38 tee, pipe pltd 1 868430-040 1
99
Section 7
7.16A ONE PINT OILER OPTION - ALL MODELS
02250141-726R01
100
Section 7
7.16A ONE PINT OILER OPTION - ALL MODELS
key part

5 nut, hex f pltd 1/4-20 825304-236 2
6 nut, hex f pltd 5/16-18 825305-283 2
7 capscrew, hex gr8 5/16-18 x 3/4 827905-075 2
13 nipple, pipe-xs plt 1 x 3 1/2 866416-035 1
16 elbow, red 1 x 3/4 plt 868104-075 1
17 u-bolt, 1/4” x 1” pipe pltd 868304-100 1
18 tee, pipe pltd 1 868430-040 1
101
Section 7
7.16B ONE QUART OILER / MOISTURE SEPARATOR OPTIONS - ALL MODELS
02250141-727R01
102
Section 7
7.16B ONE QUART OILER / MOISTURE SEPARATOR OPTIONS - ALL MODELS
key part
1 separator, moisture 02250127-121 1

6 nut, hex f pltd 1/4-20 825304-236 1
7 nut, hex f pltd 5/16-18 825305-283 1
14 nipple, pipe-xs plt 1 x 3 1/2 866416-035 2
18 elbow, red 1 x 3/4 plt 868104-075 1
19 u-bolt, 1/4” x 1” pipe pltd 868304-100 1
20 tee, pipe pltd 1 868430-040 1
103
Section 7
7.17 DECALS
104
Section 7
7.17 DECALS
key part
1 sign, caution towing 55 mph 250005-578 1

2 sign, warning compressor fluid fill cap 049685 1
3 sign, warning crush/sever 408919 1
4 sign, warning sever fan port 049965 2
5 decal, warning pressurized clg sys 02250051-826 1
6 decal, doors closed 250038-030 4
7 decal, PE designation 02250075-540 1
8 decal, earth ground 02250075-046 3
105
Section 7
7.17 DECALS
106
Section 7
7.17 DECALS (CONTINUED)
key part
9 decal, warning 100/1600 (II) 250028-258 1

10 decal, warning tougue heavy 02250077-929 1
11 sign, warning sever belt drive 049964 1
12 sign, warning hot surfaces 407408 2
13 decal, diesel fuel 040248 1
14 decal, caution - do not overfill 02250142-530 1
15 decal, noise emission control 049463 1
(U.S. compressors only)
107
Section 7
7.17 DECALS
108
Section 7
key part
16A decal, rated speed 2550/2550 RPM 02250141-346 1

16B decal, rated speed 2550/2000 RPM 02250148-781 1
16C decal, rated speed 2650/2650 RPM 02250141-347 1
16D decal, rated speed 2650/2000 RPM 02250148-780 1
16E decal, rated speed 2800/2200 RPM 250023-694 1
16F decal, rated speed 2800/2000 RPM 02250142-212 1
17A decal, 125 02250141-348 2
17B decal, 130 02250141-349 2
17C decal, 49HP 02250147-899 2
17D decal, 185 02250140-918 2
17E decal, 160H 02250153-399 2
18 decal, Sullair logo - black 02250059-058 2
109
Section 7
7.17 DECALS
110
Section 7
key part
19A decal, maintenance 185 DPQ 60HP CAT 02250148-628 1

19B decal, maintenance 185 DPQ Perkins 02250148-627 1
19C decal, maintenance 185 John Deere, 60HP 02250144-813 1
20 decal, Sullair AWF - 5 year warranty 02250097-455 1
21 decal, Sullair AWF 250032-902 1
22 decal, axle lub instructions 250042-543 2
23 decal, drawbar installation 02250142-050 1
111
Section 7
7.17 DECALS
112
Section 7
key part
24 decal, Need An Air Tool 02250138-370 1

25 decal, warning proposition 65 02250118-638 1
(U.S. compressors only)
26 decal, ISO 9001 02250057-624 1
27 decal, water drain 040345 2
28 reflector, red 040103 2
29 reflector, amber 250034-319 2
113
Section 7
7.17 DECALS
114
Section 7
key part
32 decal, operation instructions 02250140-065 1

33 decal, wiring diagram 02250144-447 1
34 nameplate, Sullair serial no. (I) 02250108-078 1
35 tag, rpm (I) 250025-437 1
26 seal, wire (I) 250026-962 1
28 nut, hex locking (I) 825501-070 4
29 rivet, pop (I) 843102-038 1
30 screw (I) 875901-075 4
(I) Not shown.

115
Section 7
7.18 DECAL LOCATIONS - ALL MODELS
02250141-293R04
116
Section 7
key part

3 decal, ISO 9001 blk 3.44x5.75 02250057-624 1
4 decal, “Sullair” 3.50 x 28.0 02250059-058 2
5 decal, earth ground 02250075-046 1
6 decal, pe designation 02250075-540 1
7 decal, warning tongue heavy 100-375 02250077-929 1
8 decal, 5 year warranty 02250097-455 1
9 nameplate, Sullair serial no. 185q-8f 02250108-078 1
10 decal ,lead warning proposition 65 02250118-638 1
11 decal, operator instruction - perkins 02250140-065 1
12 decal, ”185” 3 inches high 02250140-918 2
13 decal, ”need an air tool?” sml 02250140-925 1
14 decal, rated 2550 idle 2550 rpm 02250141-346 1
15 decal, rated 2650 idle 2650 rpm 02250141-347 1
18 decal, drwbr instl 185q pe std 02250142-050 1
19 decal, rated 2800 idle 2000 02250142-212 1
20 decal, caution- do not overfill 02250142-530 1
21 decal, wiring diagram 185 pe/cat/jd tier ii 02250144-447 1
22 decal, maintenance 185dpq 60hp john deer 02250154-344 1
23 decal, 49hp 02250147-899 2
24 decal, maintenance 185dpq 60hp perkins 02250154-346 1
25 decal, maintenance 185dpq 60hp caterpilla 02250154-345 1
26 decal, rated 2650 idle 2000 02250148-780 1
27 decal, rated 2550 idle 2000 02250148-781 1
28 reflector, red 1.68 x 4.25 040103 4
29 decal, diesel fuel 040248 1
30 decal, noise emission control 049463 1
31 decal, rated 2800 idle 2200 250023-694 1
32 tag, rpm warranty void 250025-437 1
33 seal, wire w/lead disk 250026-962 1
117
Section 7
02250141-293R04
118
Section 7
7.18 DECAL LOCATIONS - ALL MODELS (CONTINUED)
key part
34 reflector, amber 1.68 x 4.25 250034-319 2

35 decal, axle lube instructions 250042-543 1
36 nut, hex locking #8-32 825501-070 4
37 rivet, pop 1/8 x 3/8 843102-038 4
39 decal, ”160H” 3 inches high 02250153-399 2
40 decal, operator procedure start stop 185 02250133-511 1
119
Section 7
7.19 CANADIAN TAIL / CLEARANCE LIGHTS - ALL MODELS
02250141-883R00
120
Section 7
7.19 CANADIAN TAIL / CLEARANCE LIGHTS - ALL MODELS
key part
1 npl, vin canada dual language 02250101-371 1

2 cvr, vin canada 02250101-403 1
3 reflector, 3" dia adhs mtg red 02250129-278 4
4 reflector, 3" adhs mtg yellow 02250129-279 2
5 lamp, led side clearance red 02250139-566 4
6 hldr, lamp s i de clearance blk 02250139-571 4
7 harn,wrg std lt 4-wire 1850 60hp 02250139-964 1
8 nut, hex locking #10-24 825502-083 8
9 screw, rnd phillips 10-24 x 3/4" 876002-075 8
121
Section 7
7.20 DRAWBAR INSTALLATION - STANDARD
02250141-874R00
122
Section 7
7.20 DRAWBAR INSTALLATION - STANDARD
key part

2 capscr, hx gr5 1/2-13 x 1 1/4 plt 875608-125 8
3 washer, nord -lock pl 1/2yy 878608-077 8
123
NOTES
124
WORLDWIDE SALES AND SERVICE
SULLAIR ASIA, LTD. CHAMPION COMPRESSORS,

Sullair Road, No. 1 LTD.
Chiwan, Shekou Princes Highway
Shenzhen, Guangdong PRV. Hallam, Victoria 3803
PRC POST CODE 518068 Australia
: 755-6851686 : 61-3-9796-4000
Fax: 755-6853473 Fax: 61-3-9703-8053
www.sullair-asia.com www.championcompressors.com.au/
SULLAIR EUROPE, S.A.

Zone Des Granges BP 82
42602 Montbrison Cedex, France
: 33-477968470
Fax: 33-477968499
www.sullaireurope.com
SULLAIR CORPORATION
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
www.sullair.com
: 1-800-SULLAIR (U.S.A. & Canada Only)
or 1-219-879-5451
Fax: (219) 874-1273
PARTS DEPARTMENT
: 1-888-SULLAIR
Fax: (219) 874-1835
www.sullair.com
SERVICE DEPARTMENT
: 1-888-775-1604 (U.S.A. & Canada Only)
Fax: (219) 874-1205
www.sullaircompressors.com
Printed in the U.S.A.

Specifications Subject To
Change Without Prior Notice
E05

Manual de Mantenimiento Sullair 185

Uploaded by

Copyright:

Available Formats

Manual de Mantenimiento Sullair 185

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual de Mantenimiento Sullair 185

Uploaded by

Copyright:

Available Formats

PORTABLE AIR

The information in this document

For detailed course outlines, schedule and cost information contact:

Sullair Corporate Training Department

OPERATOR IS REQUIRED TO READ

Figure 2-1 Sullair Rotary Screw Portable Air Compressor

Figure 2-5A Air Inlet System - Caterpillar and Perkins Models

(I) Length over drawbar.

COMPRESSOR : 125 130 185

(I) Length over drawbar.

COMPRESSOR : 125 130

(I) Length over drawbar.

COMPRESSOR : 49 HP 185 160H

3.3 APPLICATION GUIDE When ambient conditions exceed those noted or if

4.2 PURPOSE OF CONTROLS

CONTROL OR INDICATOR PURPOSE

THERMAL VALVE Functions as a temperature regulator directing the compres-

4.3 START-UP PROCEDURE explained below:

Figure 5-4B Control System Adjustment - 160H Models

Figure 5-5 Typical E-Z Lube Axle

5.13 TROUBLESHOOTING GUIDE

ENGINE DOES NOT CRANK OR CRANKS ONLY WITHOUT STARTING:

Check instrument panel wires for broken con-

Faulty SSAM Module Replace the SSAM Module.

Check switch continuity when cool and replace if

Low Compressor Fluid Sump Level

Clogged Compressor Fluid Filter

Loose or Broken Fan Belt

Plugged Fluid Cooler Tube (Internal) Replace cooler.

Check switch continuity to ground when cool and

Engine Problems May Have Refer to engine operators manual.

Plugged Air Filter Replace and clean as required.

SYMPTOM PROBABLE CAUSE REMEDY

COMPRESSOR For compressors with idle warm-up controls,

Defective Pressure Regulator Check diaphragm and replace if necessary

Defective Idle Warm-up Control Replace control.

IMPROPER Pressure Regulating Valve Is Set Too Readjust.

Defective Pressure Regulator Check diaphragm and replace if necessary

Figure 6-1 Noise Emission Maintenance and Maintenance Record Log

3. ANNUAL ENGINE VIBRATION MOUNT INSPECTION

5. ANNUAL ACOUSTICAL MATERIALS INSPECTION

Figure 7-1 Serial Number Plate Location

SULLAIR ASIA, LTD. CHAMPION SULLAIR EUROPE, S.A.

7.2 SPARE PARTS LIST

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

1 rod, threaded speed control 1/4-28 02250064-593 1

33 washer, spr lock-metric pltd m6 838806-160 4

(I) Consult factory with serial number to determine part number.

1 spacer, brake lever 250p 02250064-594 2

33 capscrew, hex 8.8 m10 x 35mm 828010-035 12

(I) Consult factory with serial number to determine part number.

1 spacer, brake lever 250p 02250064-594 2

33 capscrew, hex 8.8 m10 x 35mm 828010-035 12

(I) Consult factory with serial number to determine part number.

1 elbow, 90m 5/16”tube x 1/8”npt 02250109-423 1

1 elbow, 90m 5/16”tube x 1/8”npt 02250109-423 1

1 bucket, radiator fluid recovery 02250083-466 1

31 shroud, fan 18” 185jd 60hp 02250143-581 1

1 reflector, red 3” truck-lite 02250052-701 2

34 eye, 3” lunette demountable 250002-221 1