PORTABLE AIR COMPRESSOR
185H, 210H, 260 CFM CATERPILLAR & JOHN DEERE
OPERATOR’S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number
02250156---375 Sullair Corporation
The information in this document is correct correct at the time of printing for Portable Compressor Serial Number
004 150300 and all subsequent Serial Numbers.
AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are courses that provide hands --- on instruction in the proper operation, maintenance and service of Sullair equipment. Individual semi semina nars rs on Porta Portabl ble e comp compre resso ssors rs are prese present nted ed at regu regula larr inte interva rvals ls throug througho hout ut the year year at a dedica dedicate ted d trainin training g facili facility ty at the Sullai Sullairr corpo corporate rate headquarters in Michigan City, Indiana. Instruction includes includes discussion of the function and installation 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, City, IN 46360 Attn: Service Training Department
TABLE OF CONTENTS
OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL
Section 1
SAFETY
1
1.1 GENERAL
1
1.2 TOWING
3
1.3 PRESSURE PRESSURE RELEASE RELEASE
4
1.4 FIRE AND EXPLOSION
5
1.5 MOVING PARTS
5
1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
5
1.7 TOXIC AND IRRITATING SUBSTANCES
6
1.8 ELECTRICAL ELECTRICAL SHOCK
6
1.9 LIFTING
6
1.10 ENTRAPMENT ENTRAPMENT
7
1.11 JUMP STARTING
9
2.1 INTRODUCTION
9
2.2 DESCRIPTION OF COMPONENTS
10
2.3 SULLAIR COMPRESSOR UNIT, UNIT, FUNCTIONAL DESCRIPTION
11
2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION
11
2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION
12
2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
15
2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
15
2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION
15
2.9 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION
16
2.10 SHUTDOWN SYSTEM, FUNCTIONAL DESCRIPTION
21
3.1A SPECIFICATIONS --- JOHN DEERE
22
3.1B SPECIFICATIONS --- CATERPILLAR
23
3.2 LUBRICATION GUIDE
23
3.3 APPICATION GUIDE
23
3.4 LUBRICATION GUIDE --- ENGINE
Section 2
DESCRIPTION
Section 3
SPECIFICATIONS
TABLE OF CONTENTS
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
27
5.1 GENERAL
27
5.2 DAILY OPERATION
27
5.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
27
5.3A MAINTENANCE EVERY 50 HOURS
27
5.4 MAINTENANCE EVERY 100 HOURS
27
5.5 MAINTENANCE EVERY 250 HOURS
28
5.6A MAINTENANCE EVERY 1500 HOURS OR ANUALLY
28
5.6B MAINTENANCE EVERY YEAR OR 12,000 MILES
28
5.7 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
Section 5
MAINTENANCE
28
COMPRESSOR FLUID CHANGE PROCEDURE
28
COMPRESSOR FLUID FILTER ELEMENT REPLACEMENT
28
AIR FILTER MAINTENANCE
29
SPEARATOR ELEMENT REPLACEMENT
29 31
PROCEDURE FORSETTINGSPEED ANDPRESSURE CONTROLS ON PORTABLE COMPRESSOR WITH POPPET VALVE BEARING LUBRICATION
31
5.8 TROUBLESHOOTING --- INTRODUCTION
32
5.9 TROUBLESHOOTING --- GUIDE
37
6.1 NOISE EMISSIONS WARRANTY
37
6.2 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
37
6.3 NOISE EMISSIONS MAINTENANCE AND MAINTENANCE RECORD LOG
41
7.1 PROCEDURE FOR ORDERING PARTS
42
7.2 RECOMMENDED SPARE PARTS LIST
44
7.3A ENGINE, COMPRESSOR & PARTS--- 185H & 210H CATERPILLAR
48
7.3B ENGINE, COMPRESSOR & PARTS--- 260 CATERPILLAR
52
7.3C ENGINE, COMPRESSOR & PARTS--- 185H & 210H JOHN DEERE
56 60
7.3D ENGINE, COMPRESSOR & PARTS--- 260 JOHN DEERE 7.4A AIR INLET AND EXHAUST --- ALL CATERPILLAR MODELS
62
7.4B AIR INLET AND EXHAUST --- ALL JOHN DEERE MODELS
Section 6
NOISE CONTROL
Section 7
ILLUSTRATIONS AND PARTS LIST
TABLE OF CONTENTS Section 7
ILLUSTRATIONS AND PARTS LIST (CONT)
64
7.5 AIR INLET VALVE ASSEMBLY --- 260 JOHN DEERE AND CATERPILLAR
66
7.6 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM - ALL MODELS
70 74 78 82
7.7A FRAME, RUNNING GEAR & PARTS --- ALL MODELS
82
7.9B REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY -- ALL 260 MODELS
84
7.10 ELECTRIC PARTS --- ALL MODELS
86 88 90 94
711A FUEL TANK AND PARTS -- ALL CATERPILLAR MODELS
96
7.14A INSTRUMENT PANEL AND PARTS -- 185H AND 210H CATERPILLAR (STANDARD GAUGE)
98
7.14B INSTRUMENT PANEL AND PARTS --- --- 260 CATERPILLAR (STANDARD GAUGE)
100
7.14C INSTRUMENT PANEL AND PARTS --- 185H AND 210H JOHN DEERE (STANDARD GAUGE)
102
7.14D INSTRUMENT PANEL AND PARTS --- 260 JOHN DEERE
7.7B FRAME, LESS RUNNING GEAR & PARTS --- ALL MODELS 7.8 DISCHARGE SYSTEM AND PARTS --- ALL MODELS 7.9A REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY -- ALL 185H & 210H MODELS
7.11B FUEL TANK AND PARTS -- ALL JOHN DEERE MODELS 7.12 CANOPY, ACOUSTICAL PANELS & PARTS--- ALL MODELS 7.13 INSTRUMENT PANEL & PARTS--- ALL MODELS
(STANDARD GAUGE)
104
7.14E INSTRUMENT PANEL AND PARTS --- 185H AND 210H CATERPILLAR (FULL GAUGE)
106
7.14F INSTRUMENT PANEL AND PARTS --- 260 CATERPILLAR (FULL GAUGE)
108
7.14G INSTRUMENT PANEL AND PARTS --- 185H AND 210H JOHN DEERE (FULL GAUGE)
110
7.14H INSTRUMENT PANEL AND PARTS --- 260 JOHN DEERE (FULL GAUGE)
112 114 116 118
7.15 SINGLE HOSE REEL OPTION --- ALL MODELS
120 122
7.19 CANADIAN TAIL / CLEARANCE LIGHTS --- ALL MODELS
132 134
7.21 DECAL LOCATIONS
7.16 DUAL HOSE REEL OPTION--- ALL MODELS 7.17 ONE PINT OILER OPTION--- ALL MODELS 7.18 ONE QUART OILER / MOISTURE SEPARATOR OPTION -- ALL MODELS
7.20 DECALS
7.22 DRAWBAR AND PARTS--- ALL MODELS
Section 1
SAFETY 1.1 GENERAL Sullair Corporation designs and manufactures all of its products so they can be operated safely. However, the responsibility for safe operation rests with those who use and maintain these products. The following safety precautions are offered as a guide which, if conscientiously followed, will minimize the possibility of accidents throughout the useful life of this equipment. Read the CIMA Safety Manual prior to compressor operation and towing, if applicable in your area. The air compressor should be operated only by those who have been trained and delegated to do so, and who have read and understood this Operator’s Manual. Failure to follow the instructions, procedures and safety precautions in this manual can result in accidents and injuries. NEVER start the air compressor unless it is safe to do so. DONOT attempt to operate the aircompressor with a known unsafecondition. Tag the air compressor and render it inoperative by disconnecting the battery so others who may not know of the unsafe condition will not attempt to operate it until the condition is corrected. Use and operate the air compressor only in full compliance with all pertinent OSHA requirements and/or all pertinent Federal, State and Local codes or requirements. DO NOT modify the compressor except with written factory approval. Each day walk around the air compressor and inspect for leaks, loose or missing parts, damaged parts or parts out of adjustment. Perform all recommended daily maintenance. Inspect for torn, frayed, blistered or otherwisedeteriorated and degraded hoses. Replace as required. NOTE Estimated hose life based on a 5 ---day 8 ---hour work week is 3 years. These conditions exist on an 8---hour shift only. Any other operation of the equipment other than 8---hour shifts would shorten the hose life based on hours of operation.
1.2 TOWING (I) A. PREPARING TO TOW !
WARNING
DO NOTtowthe compressorshoulditsweightexceedthe ratedlimit ofthe tow vehicle,as the vehicle may not brake safely with excess weight. See rated limit in tow vehicle Operator’s Manual, and reviewits instructions and other requirements for safe towing.
1. Prior to hitching the air compressor to the tow vehicle, inspect all attachment parts and equipment, checking for (i) signs of excessive wear or corrosion, (ii) parts that are cracked, bent,
dented or otherwisedeformedor degraded, and (iii) loose nuts, bolts or other fasteners. Should any such condition be present, DO NOT TOW until the problem is corrected. 2. Back the tow vehicle to the compressor and position it in preparation for coupling the compressor. 3. If the compressor is provided with a drawbar latched in the vertical upright position, carefully unlatch drawbar and lower it to engage the coupling device. If not, raise drawbar to engage coupling device or otherwise couple the compressor to the towing vehicle. !
WARNING
This equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle.
Use the screw jack provided or a chain fall if you cannot lift or lower it without avoiding injury to yourself or others. Keep hands and fingers clear of the coupling device and allother pinchpoints. Keep feet clear of drawbar to avoid injury incase it should slip from your hands. 4. Make sure the coupling device is fully engaged, closed and locked. 5. If chains are provided, pass each chain through itspoint of attachment on thetowing vehicle; then hook each chain to itself by passing the grab hook over (not through) a link. Cross chains under front of drawbar before passing them through points of attachment on towing vehicle to support front of drawbar in case it should accidentally become uncoupled. 6. Make sure that the coupling device and adjacent structures on thetowing vehicle (and also,if utilized, chain adjustment, brake and/or electrical interconnections) DO NOT interfere with or restrict motion of any part of the compressor, including its coupling device, with respect to the towing vehicle when maneuvering over any anticipated terrain. 7. If provided, make sure chain length, brake and electrical interconnections provide sufficient slack to prevent strain when cornering and maneuvering, yet are supported so they cannot drag or rubon road, terrain ortowing vehicle surfaces which might cause wear that could render them inoperative. !
WARNING
Retract the front screw jack only after attaching the compressor to the tow vehicle. Raise the screw jack to its full up position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsertthe pin. Make sure thejack is secured in place prior to towing. Ifa caster wheelis providedon the screwjack itis part of the screw jack and can not be removed. Follow the same procedure for stowing away the
1
Section 1
SAFETY wheeledjackas youwould forthe standardscrew jack. Pull thepin connectingthe jackto thedrawbar andraise the screwjackto its full upposition. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. !
WARNING
This equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle.
8. On two---wheeled models, fully retract front screw jack and any rear stabilizer legs. If a caster wheel isprovided onthe screw jack itis part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack toits fullup position. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. 9. Make sure tires are in good condition and are the size (load range)specified andare inflated to the specified pressures. DO NOT change the tire size or type. Also, make sure wheel bolts, lugs or nuts are tightened to the specified torques. 10. If provided, make sure alldualstop, tail directional and clearance lights are operating properly and that their lenses are clean and functional. Also, make sure all reflectors and reflecting surfaces, including the slow moving vehicle emblem on compressors provided with same, are clean and functional. 11. Make sure all service air hoses (not air brake hoses) are disconnected or are fully stowed and secured on hose reels, if provided. 12. Make sure all access doors and toolbox covers are closed and latched. If the compressor is large enough to hold a man, make sure all personnel are out before closing and latching access doors. 13. Make sure parking brakes in towing vehicle are set, orthat its wheel are chocked orblocked, or that it is otherwise restrained from moving. Then, release the compressor parking brakes, if provided. 14. Make sure the compressor wheels are not chocked or blocked, and that all tie---downs, if any, are free. 15. Test running brake operation, including breakaway switch operation if provided, before attempting to tow the compressor at its rated speed or less when conditions prevail. 16. DO NOT carry loose or inappropriate tools, equipment or supplies on or in the compressor.
2
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 towability of this equipment and may increase the possibility of tipping, rolling over, jackknifing, etc. Loss of control of the towing vehicle may result. B. TOWING 1. Observe all Federal, State, and Local laws while towing this equipment (including those specifying minimum speed). 2. DO NOT exceed the towing speeds listed below under ideal conditions. Reduce your speed according to posted speed limits, weather, traffic, road or terrain conditions.
a. Two axle four--- wheel steerable models: 15MPH (24KMPH). b. All other models: 55 MPH (88KMPH). 3. Remember that the portable air compressor may approach or exceed the weight of the towing vehicle. Maintain increased stopping distances accordingly. DO NOT make sudden lane changes, U---turns, or other maneuvers. Such maneuvers can cause the compressor to tip, roll over, jackknife or slide and cause loss of control of the towing vehicle. Tipping, rolling over, etc. can occur suddenly without warning. U---turns especially should be made slowly and carefully. 4. Avoid grades in excess of 15 (27%). 5. Avoid potholes, rocks and other obstructions, and soft shoulders or unstable terrain. 6. Maneuver in a manner that will not exceed the freedom of motion of the compressor’s drawbar and/or coupling device, in or on the towing vehicle’s coupling device and/or adjacent structure whether towing forward or backing up, regardless of the terrain being traversed. 7. DO NOT permit personnel to ride in or on the compressor. 8. Make sure the area behind, in front of, and under the compressor is clear of all personnel and obstructions prior to towing in any direction. 9. DO NOT permit personnel to stand or ride on the drawbar, or to stand or walk between the compressor and the towing vehicle. _
C. PARKING OR LOCATING COMPRESSOR 1. Park or locate compressor on a level surface, if possible. If not, park or locate compressor across grade so the compressor does not tend to roll downhill. DO NOT park or locate compressor on grades exceeding 15 (27%). 2. Make sure compressor is parked or located on a firm surface than can support its weight. 3. Park or locate compressor so the wind, if any, tends to carry the exhaust fumes and radiator heat away from the compressor air inlet openings, and also where the compressor will not be exposed to excessive dust from the work site. _
Section 1
SAFETY 4. On four---wheel models, park compressor curely latched in the vertical upright position. with front wheels in straight ahead position. Keep feet clear of drawbar at all times to avoid crushing accidents in case it should slip from 5. Set parking brakes and disconnect your hands or otherwise fall to the ground. breakaway switch cable and all other intercon12. Move the towing vehicle well clear of the necting electrical and/or brake connections, if parked compressor and erect hazard indicaprovided. tors, barricades and/or flares (if at night) if com6. Block or chock both sides of all wheels. pressor is parked on or adjacent to public roads. 7. If provided, unhook chains and remove them Park so as not to interfere with traffic. from the points of chain attachment on the towing vehicle, then hook chains to bail on drawbar (I) While not towed in the usual sense of the word, or wrap chains around the drawbar and hook many of these instructions are directly applicathem to themselves to keep chains off the ble to skid---mounted portable air compressors ground which might accelerate rusting. as well. 8. Lower front screw jack and/or any front and rear stabilizer legs. Make sure the surface they 1.3 PRESSURE RELEASE A. Open the pressure relief valve at least weekly to contact has sufficient load bearing capability to make sure it is not blocked, closed, obstructed or support the weight of the compressor. otherwise disabled. ! WARNING B. Install an appropriate flow---limiting valve beRetract the front screw jack only after attaching tween the compressor service air outlet and the the compressor to the tow vehicle. Raise the shutoff (throttle) valve, when an air hose exceedscrew jack to its full up position and pull the pin ing 1/2” (13mm) inside diameter is to be connected connecting the jack to the drawbar. Rotate the to shut---off (throttle) valve, to reduce pressure in screw jack to its stowed position, parallel to the drawbar, and reinsertthe pin. Make sure thejack case of hose failure, per OSHA Standard 29 CFR is secured in place prior to towing. 1926.302 (b) (7) or any applicable Federal, State and Local codes, standards and regulations. Ifa caster wheelis providedon the screwjack itis part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeledjackas youwould forthe standardscrew jack. Pull thepin connectingthe jackto thedrawbar andraise the screwjackto its full upposition. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. !
WARNING
This equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle.
9. If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Raise the screw jack to its full up position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. 10. Disconnect coupling device, keeping hands and fingers clear of all pinch points. If the compressor is provided with a drawbar, DO NOT attempt to lift the drawbar or if hinged, to raise it to the upright position, by hand, if the weight is more than you can safely handle. Use a screw jack or chain fall if you cannot lift or raise the drawbar without avoiding injury to yourself or others. 11. When possible, stow hinged drawbar in the vertical upright position. Make certain it is se-
C. When the hose is to be used to supply a manifold, install an additional appropriate flow---limiting valve between the manifold and each air hose exceeding 1/2” (13mm) inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure. D. Provide an appropriate flow---limiting valve for each additional 75 feet (23 meters) of hose in runs of air hose exceeding 1/2” (13mm) inside diameter to reduce pressure in case of hose failure. E. Flow---limiting valves are listed by pipe size and rated CFM. Select appropriate valve accordingly. F. DO NOT use tools that are rated below the maximum rating of this compressor. Select tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT exceed manufacturer’s rated safe operating pressures for these items. G. Secure all hose connections by wire, chain or other suitable retaining device to prevent tools or hose ends from being accidentally disconnected and expelled. H. Open fluid filler cap only when compressor is not running and is not pressurized. Shut down the compressor and bleed the sump (receiver) to zero internal pressure before removing the cap. I. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other component, such as filters and line oilers, and before attempting to refill optional air line anti--icer systems with antifreeze compound.
3
Section 1
SAFETY J. Keep personnel out of line with and away from the discharge opening of hoses, tools or other points of compressed air discharge. K. DO NOT use air at pressures higher than 30 psig (2.1bar) forcleaning purposes, and then only with effective chip guarding and personal protective equipment per OSHA Standard 29 CFR 1910.242 (b) or any applicable Federal, State and Local codes, standards and regulations. L. DO NOT engage in horseplay with air hoses as death or serious injury may result. M. This equipment is supplied with an ASME designed pressure vessel protected by an ASME rated relief valve. Lift the handle once a week to make sure the valve is functional. DO NOT lift the handle while machine is under pressure. N. If the machine is installed in an enclosedarea it is necessary to vent the relief valve to the outside of the structure or to an area of non---exposure. O. DO NOT remove radiator filler cap until the coolant temperature is below its boiling point. Then loosen cap slowly to its stop to relieve any excess pressure and make sure coolant is not boiling before removing cap completely. Remove radiator filler cap only when cool enough to touch with a bare hand. P. The ethyl ether in the replaceable cylinders used in diesel ether starting aid systems (optional) is under pressure. DO NOT puncture or incinerate those cylinders. DO NOT attempt to remove the center valve core or side pressure relief valve from these cylinders regardless of whether they are full or empty. Q. If a manual blowdown valve is provided on the receiver, open the valve to insure all internal pressure has been vented prior to servicing any pressurized component of the compressor air/fluid system. 1.4 FIRE AND EXPLOSION A. Refuel at a service station or from a fuel tank designed for its intended purpose. If this is not possible, ground the compressor to the dispenser prior to refueling. B. Clean up spills of fuel, fluid, battery electrolyte or coolant immediately if such spills occur. C. Shut off air compressor and allow it to cool. Then keep sparks, flames and other sources of ignition away and DO NOT permit smoking in the vicinity when adding fuel, or when checking or adding electrolyte to batteries, or when checking or adding fluid, or when checking diesel engine ether starting aid systems or replacing cylinders, or when refilling air line anti---icer systems antifreeze compound.
4
D. DO NOT permit liquids, including air line anti--icer system antifreeze compound or fluid film to accumulate on bottom covers or on, under or around acoustical material, or on any external or internal surfaces of the air compressor. Wipe down using an aqueous industrial cleaner or steam clean as required. If necessary remove acoustical material, clean all surfaces and then replace acoustical material. Any acoustical material with a protective covering that has been torn or punctured should bereplaced immediately to prevent accumulation of liquids or fluid film within the material . DO NOT use flammable solvents for cleaning purposes. E. Disconnect the grounded (negative) battery connection prior to attempting anyrepairs or cleaning inside the enclosure. Tag the battery connections so others will not unexpectedly reconnect it. F. Keep electrical wiring, including the battery terminals and other terminals, in good condition. Replace any wiring that has cracked, cut abraded or otherwise degraded insulation or terminals that are worn, discolored or corroded. Keep all terminals clean and tight. G. Turn off battery charger before making or breaking connections to the battery. H. Keep grounded conductive objects such as tools away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition. I. Replace damaged fuel tanks or lines immediately rather than attempt to weld or otherwise repair them. DO NOT store or attempt to operate the compressor with any known leaks in the fuel system. Tag the compressor and render it inoperative until repair can be made. J. Remove any acoustical material or other material that may be damaged by heat or that may support combustion prior to attempting weld repairs. Remove diesel engine ether starting aid cylinders and air line anti---icer system components containing antifreeze compound, prior to attempting weld repairs in any place other than the fuel system. DO NOT weld on or near the fuel system. K. Keep a suitable fully charged class BC or ABC fire extinguisher or extinguishers nearby when servicing and operating the compressor. L. Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor. M. Open all access doors and allow the enclosure to ventilate thoroughly prior to attempting to start the engine. N. DO NOT operate compressor under low overhanging leaves or permit such leaves to contact hot exhaust system surfaces when operating the compressor in forested areas. O. Ethyl ether used in diesel engine ether starting aid systems is extremely flammable. Change cylin-
Section 1
SAFETY ders, or maintain or troubleshoot these systems only in well--- ventilated areas away from heat, open flame or sparks. DO NOT install, store or otherwise expose ether cylinders to temperatures above 160 F (71 C). Remove ether cylinder from the compressor when operating in ambient temperatures above 60 F (16 C). _
_
_
_
P. DO NOT attempt to use ether as a starting aid in gasoline engines or diesel engines with glow plugs as serious personnel injury or property damage may result. Q. DO NOT spray ether into compressor air filter or into an air filter that serves both the engine and the compressor as serious damage to the compressor or personal injury may result. R. Antifreeze compound used in air line anti---icer systems contains methanol which is flammable. Use systems and refill with compound only in well--ventilated areas away from heat, open flames or sparks. DO NOT expose any part of these systems or the antifreeze compound to temperatures above 150 F (66 C). Vapors from the antifreeze compound are heavier than air. DO NOT store compound or discharge treated air in confined or unventilated areas. DO NOT store containers or antifreeze compound in direct sunlight. _
_
S. Store flammable fluids and materials away from your work area. Know where fire extinguishers are and how to use them, and for what type of fire they are intended. Check readiness of fire suppression systems and detectors if so equipped. 1.5 MOVING PARTS A. Keep hands, arms and other parts of the body and also clothing away from belts, pulleys and other moving parts. B. DO NOT attempt to operate the compressor with the fan or other guards removed. C. Wear snug---fitting clothing and confine long hair when working around this compressor, especially when exposed to hot or moving parts inside the enclosure. D. Keep access doors closed except when making repairs or adjustments, performing service or when starting or stopping the compressor. E. Make sure all personnel are out of and clear of the compressor prior to attempting to start or operate it. F. Shut off engine before adding fuel, fluid, coolant lubricants, air line antifreeze compound or battery electrolyte, or before replacing ether starting aid cylinders. G. Disconnect the grounded negative battery connection to prevent accidental engine operation prior to attempting repairs or adjustments. Tag the
battery connection so others will not unexpectedly reconnect it. H. When adjusting the controls, it may require operation of the equipment during adjustment. DO NOT come in contact with any moving parts while adjusting the control regulator and setting the engine RPM. Make all other adjustments with the engine shut off. When necessary, make adjustment, other than setting control regulator and engine RPM, with the engine shut off. If necessary, start the engine and check adjustment. If adjustment is incorrect, shut engine off, readjust, then restart the engine to recheck adjustment. I. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water, antifreeze or other liquids to minimize possibility of slips and falls. 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS A. Avoid bodily contact with hot fluid, hot coolant, hot surfaces and sharp edges and corners. B. Keep all parts of the body away from all points of air discharge and away from hot exhaust gases. C. Wear personal protective equipment including gloves and head covering when working in, on or around the compressor. D. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. DO NOT ignore small cuts and burns as they may lead to infection. 1.7 TOXIC AND IRRITATING SUBSTANCES A. DO NOT use air from this compressor for respiration (breathing) except in full compliance with OSHA Standards 29 CFR 1920 and any other Federal, State or Local codes or regulations. !
DANGER
Death or serious injury may occur from inhaling compressed air without using proper safety equipment. See OSHA standards, and/or any Federal, State or Local codes or regulations on safety equipment.
B. DO NOT use air line anti---icer systems in air lines supplying respirators or other breathing air utilization equipment and DO NOT discharge air from these systems into unventilated or other confined areas. C. Operate the compressor only in open or well--ventilated areas. D. If the compressor is operated indoors, discharge engine exhaust fumes outdoors. E. Locate the compressor so that exhaust fumes are not apt to be carried towards personnel, air intakes servicing personnel areas or towards the air intake of any portable or stationary compressor.
5
Section 1
SAFETY F. Fuels, fluids, coolants, lubricants and battery electrolyte used in the compressor aretypicalof the industry. Care should be taken to avoid accidental ingestions and/or skin contact. In the event of ingestion seek medical treatment promptly. DO NOT induce vomiting if fuel is ingested. Wash with soap and water in the event of skin contact. G. Wear an acid---resistant apron and a face shield or goggles when servicing the battery. If electrolyte is spilled on skin or clothing, immediately flush with large quantities of water.
D. Stay clear of the compressor during electrical storms! It can attract lightning. 1.9 LIFTING A. If the compressor is provided with a lifting bail, then lift by the bail provided. If no bail is provided, then lift by sling. Compressors to be air lifted by helicopter must not be supported by the lifting bail, but by slings instead. In any event, lift only in full compliance with OSHA Standards 29 CFR 1910 subpart N or any other Local, State, Military and Federal regulations that may apply.
H. Ethyl ether used in diesel engine ether starting aid systems is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, DO NOT induce vomiting, but call a physician immediately.
B. Inspect lifting bail and points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts or nuts prior to lifting.
I. Wear goggles or a full face shield when testing ether starting aid systems or when adding antifreeze compound to air line anti---icer systems. Keep openings of valve or atomizer tube of ether starting aid system pointed away from yourselfand other personnel.
C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition and has a rated capacity ofat least the net weight of the compressor plus an additional 10% allowance for weight of snow, ice, mud or stored tools and equipment. If your are unsure of the weight, then weigh compressor before lifting.
J. If ethyl ether or air line anti---icer system antifreezecompoundenters theeyes or if fumes irritate the eyes, they should be washed with large quantities of clean water for 15 minutes. A physician, preferably any eye specialist, should be contacted immediately. K. DO NOT store ether cylinders or air line anti--icer system antifreeze compound in operator’s cabs or in other similar confined areas. L. The antifreeze compound used in air line anti --icer systems contains methanol and is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, induce vomiting by administering a tablespoon of salt in each glass of clean warm water untilvomit is clear, then administer two tablespoons of baking soda in a glass of clean water. Have patient lay down and cover eyes to exclude light. Call a physician immediately. 1.8 ELECTRICAL SHOCK A. Keep the towing vehicle or equipment carrier, compressor hoses, tools and all personnel at least 10 feet (3 meters) from power lines and buried cables.
D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and latched on the bail. E. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear of the ground. F. DO NOT attempt to lift in high winds. G. Keep all personnel out from under and away from the compressor whenever it is suspended. H. Lift compressor no higher than necessary. I. Keep lift operator in constant attendance whenever compressor is suspended. J. Set compressor down only on a level surface capable of supporting at least its net weight plus an additional 10% allowance for the weight of snow, ice, mud or stored tools and equipment. K. If the compressor is provided with parking brakes, make sure they are set, and in any event, block or chock both sides of all running wheels before disengaging the lifting hook.
B. Keep all parts of the body and any hand---held 1.10 ENTRAPMENT A. Make sure all personnel are out compressor betools or other conductive objects away from exfore closing and latching enclosure doors. posed live parts of electrical system. Maintain dry footing, stand on insulating surfaces and DO NOT B. If the compressor is large enough to hold a man contact any other portion of the compressor when and if it is necessary to enter it to perform service making adjustments or repairs to exposed live adjustments, inform other personnel before doing parts of the electrical system. so, orelse secure the access door inthe open posiC. Attempt repairs only in clean, dry and well--tion to avoid the possibility of others closing and lighted and ventilated areas. possibly latching the door with personnel inside.
6
Section 1
SAFETY 1.11 JUMP STARTING A. Observe all safety precautions mentioned elsewhere in this manual. B. Batteries may contain hydrogen gas which is flammable and explosive. Keep flames, sparks and other sources of ignition away. C. Batteries contain acid which is corrosive and poisonous. DO NOT allow battery acid to contact eyes, skin, fabrics or painted surfaces as serious personal injury or property damage could result. Flush any contacted areas thoroughly with water immediately. Always wear an acid---resistant apron and face shield when attempting to jump start the compressor. D. Remove all vent caps (if so equipped) from the battery or batteries in the compressor. DO NOT permit dirt or foreign matter to enter the open cells. E. Check fluid level. If low, bring fluid to proper level before attempting to jump start (not applicable to maintenance---free batteries). F. DO NOT attempt to jump start if fluid is frozen or slushy. Bring batteries up to at least 60 F (16 C) before attempting to jump start or it may explode. _
_
G. Coveropen cells of allcompressor batteries with clean dampened cloths before attempting to jump start. H. Attempt to jump start only with a vehicle having a negative ground electrical system with the same voltage, and is also equipped with a battery or batteries of comparable size or larger than supplied in the compressor. DO NOT attempt to jump start using motor generator sets, welders or other sources of DC power as serious damage may result. I. Bring the starting vehicle alongside the compressor, but DO NOT permit metal to metal contact between the compressor and the starting vehicle. J. Set theparking brakes of both thecompressor( if provided) and the starting vehicle or otherwise block both sides of all wheels. K. Place the starting vehicle in neutral or park, turn off all non---essential accessory electrical loads and start its engine. L. Use only jumper cables that are clean, in good condition and are heavy enough to handle the starting current. M. Avoid accidental contact between jumper cable terminal clips or clamps and any metallic portion of either the compressor or the starting vehicle to minimize the possibility of uncontrolled arcing which might serve as a source of ignition.
N. Positive battery terminals are usually identified by a plus (+) sign on the terminal and the letters POS adjacent to the terminal. Negative battery terminals are usually identified by the letters NEG ad jacent to the terminal or a negative ( ---) sign. O. Connect one end of a jumper cable to the positive (POS) (+) battery terminal in the starting vehicle. When jump starting 24V compressors and if thestarting vehicle is providedwith two(2) 12Vbatteries connected in series, connect the jumper cable to the positive (POS) (+) terminal of the ungrounded battery. P. Connect the other end of the same jumper cable to the positive (POS) (+) terminal of the starter motor battery in the compressor, or when jump starting 24V compressor, to the positive (POS) (+) terminal of the ungrounded battery in the compressor. Q. Connect one end of the other jumper cable to the grounded negative (NEG) (---) terminal of the battery in the starting vehicle. When jump starting 24V compressors and if the starting vehicle is provided with two (2) 12V batteries connected in series, connect the jumper cable to the negative (NEG) (---) terminal of the grounded battery. R. Check your connections. DO NOT attempt to start a 24V compressor with one 12V battery in the starting vehicle. DO NOT apply 24V toone12V battery in the compressor. S. Connect theotherend of this same jumpercable to a clean portion of the compressor engine block away from fuel lines, the crank case breather opening and the battery. T. Start the compressor in accordance with normal procedure. Avoid prolonged cranking. U. Allow the compressor to warm up. When the compressor is warm and operating smoothly at normal idle RPM, disconnect the jumper cable from the engine block in the compressor, then disconnect the other end of this same cable from the grounded negative (NEG) (---) terminal of the battery in the starting vehicle. Then disconnect the other jumper cable from the positive (POS) (+) terminal of the battery in the compressor, or if provided with two (2) 12V batteries connected in series, from the ungrounded battery in the compressor, and finally, disconnect the other end of this same jumper cable from the positive (POS) (+) terminal of the battery in the starting vehicle or from the positive (POS) (+) terminal of the ungrounded battery in the starting vehicle, if it is provided with two (2) 12V batteries connected in series. V. Remove and carefully dispose of the dampened cloths, as they may now be contaminated with acid, then replace all vent caps.
7
NOTES
8
Section 2
DESCRIPTION 2.1 INTRODUCTION 2.2 DESCRIPTION OF COMPONENTS The Sullair 185H, 210H and 260 CFM Portable Air Refer to Figures 2---1. The components and assemCompressors offer superior performance and reliblies of the Sullair Portable Air compressor are ability along with a minimal amount of maintenance clearly shown. The package includes a heavy duty rotary screw air compressor, a diesel engine, requirements. fuel tank, compressor inlet system, compressor cooling and lubrication system, compressor disThe compressor is equipped with a Sullair rotary charge system, capacity control system, instruscrew compressor unit. Compared to other comment panel and electrical system. pressors, the Sullair is unique in mechanical reliability and compressor durability. No inspection is re A low profile canopy offers improved handling and quired of the working parts within the compressor mobility. Large side service doors provide easy acunit. cess to all serviceable components.
As you continue reading this manual and come to learn how the compressor operates andis cared for, you will see how surprisinglyeasyit is tokeepa Sullair compressor in top operating condition. Read Section 5 (Maintenance) and learn how to keep your compressor in top operating condition. Should any problem or question arise which cannot be answered in this text, contact your nearest Sullair representative or the Sullair Corporation Service Department.
This model meets EPA regulations for 76dbA at 7 meters (23 feet). The Sullair air compressors are capable of delivering capacities as follows: Model 185H: 185 CFM @ 150 psig (10.3 bar) Model 210H: 210 CFM @ 150 psig (10.3 bar) Model 260: 260 CFM @ 100 psig (6.9 bar) The control system can easily be adjusted for pres-
Figure 2 ---1 Sullair Rotary Screw Portable Air Compressor --- General Arrangement All Models
9
Section 2
DESCRIPTION Figure 2---2 Compressor Cooling and Lubrication System
185H & 210 MODELS
260 MODELS
sures from 80 to 125 psig (5.5 to 8.6 bar) for standard machines and from 80 to 150 psig (5.5 to 10.3 bar) for H machines. The compressor unit is driven by an industrial diesel engine designed to provide enough horsepower for more than adequate reserve at rated conditions. Refer to the Engine Operator’s Manual for a more detailed description of the engine. “
”
The same fan also cools the fluid in the compressor cooling and lubrication system. The engine radiator and the compressor fluid cooler sit side by side which allows the fan air to push through both simultaneously. As air passes through the fluid cooler, the heat of compression is removed from the fluid. The compressor is supplied with a large capacity fuel tank which will keep the compressor running through one (1) eight hour shift under normal operating conditions.
The engine cooling system is comprised of a radiator, high capacity fan and thermostat. The highca- 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION pacity fan pushes air through the radiator, keeping the engine at the proper operating temperature. Sullair compressors feature the Sullair compressor
10
Section 2
DESCRIPTION unit, a single---stage, positive displacement, flood lubricated---type compressor. This unit provides continuous (pulse---free) compression to meet your needs. With a Sullair compressor, no maintenance or inspection of the internal parts of the compressor unit is required.
thermostatic control opens, allowing a portion of the fluid to the cooler. When the temperature reaches 140_F (60_C), the thermostat is fully open allowing all fluid entering the thermal valve to be directed to the cooler.
The cooler is a radiator---type that works in conjunction with the engine fan. The fan pushes air through Fluid is injected into the compressor unit where it the cooler removing the heat of compression from mixes directly with the air as the rotors turn, comthe fluid. From the cooler, the fluid is then routed pressing the air. The fluid flow has three main funcback through the fluid filter. All fluid flowing to the tions: compressor unit passes through this filter. The fluid 1. As coolant, it controls the rise of air temperature leaving the filter flows to the compressor unit where normally associated with the heat of compresit lubricates, seals and cools the compression sion. chamber as well as lubricates the bearings and 2. Seals the leakage paths between the rotors and gears. the stator and also between the rotors them- 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCselves. TIONAL DESCRIPTION 3. Acts as a lubricating film between the rotors allowRefer to Figures 2---3, 2---4A, and 2--- 4B. The Sullair ing one rotor to directly drive the other. compressor unit discharges compressed air/fluid mixture into the sump. The sump has three func After the air/fluid mixture is discharged from the tions: compressor unit, the fluid is separated from the air. At this time, the air flows to your service line and the 1. It acts as a primary fluid separator. fluid is cooled in preparation for re---injection. 2. Serves as the compressor fluid sump. 3. Houses the air/fluid separator. 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION The compressed air/fluid mixture enters the sump Refer to Figure 2---2. The compressor cooling and and is directed against the side of the sump. By lubrication system is designed to provide adequate change of direction and reduction of velocity, large lubrication as well as maintain the proper operating droplets of fluid separate andfall to the bottom ofthe temperature of the compressor. In addition to the sump. The fractional percentage of fluid remaining fluid cooler and interconnecting piping, the sysin the compressed air collects on the surface of the tem consists also of three other components: a final separator element as the compressed air flows fluid filter, thermal valve, and a fan which perform through the separator. As more and more fluid colthe following functions: lects on the element surface, the fluid descends to the bottom of the separator. A return line (or scavS The fluid filter filters the fluid. enge tube) leads from the bottom of the separator The thermal valve functions as a temperature reguS element to the inlet region of the compressor unit. lator directing fluid either to the cooler or to the comFluid collecting on the bottom of the separator elepressor unit, bypassing the cooler as will be exment is returned to the compressor by the pressure plained later. difference between the area surrounding the sepaThe fan pushes air through the cooler removing S rator element and the compressor inlet. An orifice the heat of compression from the fluid. (protected by a strainer) is includedin this returnline to assure proper flow. The functions of the lubrication system are explained in more detailbelow. Fluid is used in the sysThe sump is ASMEcode rated at 200 psig (13.8 bar) tem as a coolant and as a lubricant. It is housed in working pressure. A minimum pressure device lothe receiver/sump which, will from this time forward, cated downstream from the separator, assures a be referred to as the SUMP. minimum receiver pressure of 85 psig (5.9 bar) during all conditions. This pressure is necessary for Upon start---up, fluid flows from the sump to the fluid proper air/fluid separation and proper fluid circulathermal valve. Fluid circulation is achieved by forction. ing the fluid from the high pressure region of the sump to a lower pressure area in the compressor A pressure relief valve (located on the wet side of the unit. A minimum pressure device (see Section 2.5 separator) is set to open if the sump pressure exCompressor Discharge System) is provided to asceeds 200 psig (13.8 bar). A temperature switch will sure adequate fluid flow under all conditions. shut down the compressor if the discharge temperature reaches the specified limit given in Section When entering thethermal valve upon start---up, the 3, Specifications. fluid temperature is cool and thus it is not necessary Fluid is added to the sump via a capped fluid filler. to route it through the cooler. Hence the fluid flows through the fluid filter and on to the compressor unit ! WARNING bypassing the cooler. As the compressor continues to operate, the temperature of the fluid rises and the DO NOT remove caps, plugs, and/or other compo-
11
Section 2
DESCRIPTION Figure 2---3 Compressor Discharge System
nents when compressor is running or pressurized. Stop compressor andrelieve allinternal pressure before doing so.
2.6 CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figures 2---3, 2---4A or 2---4B. The purpose of the control system is to regulate the amount of air intake in accordance with the amount of compressed air being used. The control system consists of a pressure regulating valve(s), air inlet valve, system blowdown valve, and tubing connecting the various components to the compressor and engine governor. The functional descrip-
12
tions of the control system are given in four distinct phases of operation. It applies to any control system with the exception of those with stated pressures which are dependent on pressure requirements. The pressures stated will be in accordance with a compressor having an operating pressure range of 100 to 110 psig (6.9 to 7.6bar). START -- 0 TO 40 PSIG (0 TO 2.8 BAR) COLD WEATHER To minimize problems in cold weather, starting aids, engine coolant heaters and dry---side receiver relief valves should be used. Refer to the engine operators manual for additional information.
Section 2
DESCRIPTION Figure 2 ---4A Control System with Piping and Instrumentation --- 185H & 210H Models
13
Section 2
DESCRIPTION Figure 2---4B Control System with Piping and Instrumentation --- 260 Models
14
Section 2
DESCRIPTION COLD START terconnecting piping to the engine and compresWhen the compressor is started, the sump pressure sor. will quickly rise from 0 to 40 psig (0 to 2.8 bar). DurThe air filters are two---stage dry element---type filing this period the pressure regulator valve is inacters. These filters are capable of cleaning extremely tive. At this pressure range the idle warm---up condirty air. However, in such cases, frequent checks of trol maintains a closed inlet valve for engine idle opthe air filter will be required. eration. After engine start---up, turn the handle of the selector valve warm---up control (located on the SeeSection 5 for Air Filter MaintenanceProcedures. instrument panel) from the “start” to the “run” position within the first 30 seconds of operation. The in- 2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL DEstrument panel annunciator light will go off after 30 SCRIPTION seconds. The inlet valve is fully open due to inlet air Refer to Figure 2---6. The instrument panel group pressure, and the compressor operates at full caconsists of a molded panel containing an air prespacity operation. As the compressor operates at full sure gauge, hourmeter, ignition/start switch, ancapacity, the engine runs at full speed. nunciator light, idle warm--up control, and a cold weather starting aid button. A high--low NORMAL OPERATION -- 55 TO 100 PSIG (3.8 TO pressure selector switch is located on the panel 6.9 BAR) OR 55 TO 150 PSIG (3.8 TO 10.3 BAR) for 185H and 210H compressors. FOR “H” MACHINES When the warm---up control selector valve handle is moved to the “run” position, the sump pressure Refer to Figure 2---6 for locations of the following inrises above 85 psig (5.9 bar). At this time, the inlet dicators and controls: valve remains fully open for maximum air output. S The air pressure gauge continually monitors the The engine will continue to run at full speed during sumppressure at various load or unload conditions. this phase of operation. S The hourmeter indicates the accumulative hours of compressor operation. This is useful for planning MODULATION -- 100 TO 110 PSIG (6.9 TO 7.6 and logging service operations. BAR) OR 150 TO 165 PSIG (10.3 TO 11.4 BAR) S The engine switch is used to energize the electriFOR “H” MACHINES cal system and start the compressor. The starter Should less than the rated capacity of air be used, switch is pressed to the on position to energize the the service line pressure will rise above 100psig (6.9 electrical system and momentarily pressed to the bar) low or single pressure rating, 150 psig (10.3 start position to engage the starter and start the bar) dual or high pressure rating. The pressure regcompressor. ulating valve gradually opens, applying pressure to S The idle warm--up valve control is turned from the inlet valve piston and speed control cylinder . start to run after engine start is achieved for fullcomThis causes the inlet valve to partially close and repressor operation. duces the speed of the engine. As the pressure inS The Pressure selector switch (185H & 210H creases, the inlet valve piston will further close the Models) allows the selection of the compressor opinlet valve and continue reducing the speed until it erating pressure range, 85 to 110 psig (5.9 to 7.6 reaches a pre---set idle speed. Now as air demand bar) or 85 to 160 psig (5.9 to 11.0 bar). increases, the sump pressure will fall below the 110 S The cold weather starting aid should be used psig (7.6 bar) or 165 psig (11.4 bar) for “H” mawhen starting in cold amibients. Press the button chines. and hold for 10---30 seconds (depending upon temThe pressure regulating valve will close, the air inlet perature). valve will fully open and the engine will once again S The annunciator light indicates compressor saferun at a pre---set full load speed. ty shutdown status.
Between the pressure regulating valve and inlet valve, a small orifice is installed which vents a small amount of air to the atmosphere, when the pressure regulating valve is open. This allows variance of air output to match air demand. The orifice also bleeds any accumulated moisture from the regulator.
2.9 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figure 2---6 . The electrical system is comprised of not only the necessary equipment required to operate the compressor, but also a system which shuts down the compressor in the event of a malfunction. The components of the electrical sysSHUTDOWN tem are an engine starter, a battery, an alternator The blowdown valve is normally closed. Upon shutwith a built--in voltage regulator, a fuel solenoid, down, the back pressure in the compressor inlet a compressor discharge temperature switch, signals the blowdown valve to vent the sump preswhich will shut down the compressor should the sure to the atmosphere. compressor temperature exceed 250_F (121_C), 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPan engine water temperature switch set to shut TION down the compressor when water temperature Refer to Figure 2---5. The air inlet system consists of reaches 225_F (107_C) and an engine oil prestwo air filters, a compressor air inlet valve and insure switch. The engine oil pressure switch is
15
Section 2
DESCRIPTION Figure 2 ---5 Air Inlet System (typical)
providedto shut down the compressor when theengine oil pressure becomes insufficient. The low speed switch is provided to shutdown the compressor if engine speed falls below 1500 RPM. 2.10 SHUTDOWN SYSTEM DESCRIPTION The Shutdown System and Annunciation Module (SSAM) continually monitors the status of the compressor . In the event of a shutdown condition, the SSAM will shutdown the compressor and flash the appropriate code on the instrument panel annunciator light. The flash code will remain active (flashing) until the ignition switch is turned OFF. The flash codes are as follows:
1 flash : high compressor temperature 2 flashes: high engine coolant temperature
16
3 flashes: low engine oil pressure 4 flashes: low engine speed 5 flashes: low fuel level (optional) The SSAM also provides startup logic for the compressor. When the ignition switch is placed in the ON position, the annunciator light will come on for 30 seconds. During this 30 second period, ignition switch activation to the START position will engage the engine starter. The low engine oil pressure switch and the low engine speed switch will remain inactive during thethis 30 second period. At the end of the 30 second period, the annunciator light will go off and the engine START cycle will be disabled. At this time, all safety system checks become active including low fuel level (if equipped).
Section 2
DESCRIPTION Figure 2---6 Instrument Panel Group
17
Section 2
DESCRIPTION Figure 2---7 Electrical System --- JOHN DEERE
02250144--- 446R05
18
Section 2
DESCRIPTION Figure 2 ---7A Electrical System --- CATERPILLAR
P02250144---395R04
19
NOTES
20
Section 3
SPECIFICATIONS 3.1A SPECIFICATIONS -- JOHN DEERE Model Series
Length (I)
mm
in 185H,210H,260 2Wheel 185H,210H,260 LRG
143.3 3640 85.1 2162
Width in 65.4 47.5
Height
mm 1661 1207
in 59.9 49
Weight (wet)(II)
mm
lb
1522 1245
kg
2840 2585
1288 1173
(I) Length over drawbar. (II)Weight shown is for 260 models. Deduct 120 lbs.(55kg) for 185H and 210H models.
COMPRESSOR:
185H
210H
260
Type Maximum Operating Pressure Delivery Fluid Lubricating Compressor Sump Capacity
Rotary Screw 150 psig (10.3 bar)
Rotary Screw 150 psig (10.3bar)
Rotary Screw 100 psig (6.9bar)
185 Free CFM (87 L/S) Compressor Fluid See Lubrication Guide 3 U.S. Gallons (11 Liters) 55 in. (1397 mm)
210 Free CFM (99L/S) Compressor Fluid See Lubrication Guide 3 U.S. Gallons (11 Liters) 55 in. (1397 mm)
260 Free CFM (122L/S) Compressor Fluid See Lubrication Guide 3 U.S. Gallons (11 Liters) 55 in. (1397 mm)
50 psig (3.5 bar) 60 ft.---lbs. (81 Nm) 15 X 5 15 Degrees 12 Volt Shutdown 250_F (121_C) (2) 3/4” 55 mph (88 kmph) 3500 lbs. (1588 kg) 150 psig (10.3 bar) 76 dBA at 7 meters
50 psig (3.5 bar) 60 ft.---lbs. (81 Nm) 15 X 5 15 Degrees 12 Volt Shutdown 250_F (121_C) (2) 3/4” 55 mph (88 kmph) 3500 lbs. (1588 kg) 150 psig (10.3 bar) 76 dBA at 7 meters
50 psig (3.5 bar) 60 ft.---lbs. (81 Nm) 15 X 5 15 Degrees 12 Volt Shutdown 250_F (121_C) (2) 3/4” 55 mph (88 kmph) 3500 lbs. (1588 kg) 100 psig (7 bar) 76 dBA at 7 meters
Diesel John Deere 5030T 186 cu. in. (3.0L) 5 3.39 x 4.13 in. (86mm x 105mm) 2600 RPM 82 HP ( 61 kW) See Engine Operator’s Manual 35 Gallons (132 liters) 3 U.S. Gallons (11.4 liters) Shutdown 225 _F (107_C) 1800 RPM (II) 70 amp
Diesel John Deere 5030T 186 cu. in. (3.0L) 5 3.39 x 4.13 in. (86mm x 105mm) 2500 RPM 82 HP ( 61 kW) See Engine Operator’s Manual 35 Gallons (132 liters) 3 U.S. Gallons (11.4 liters) Shutdown 225_F (107_C) 1800 RPM (II) 70 amp
Diesel John Deere 5030T 186 cu. in. (3.0L) 5 3.39 x 4.13 in. (86mm x 105mm) 2500 RPM 82 HP ( 61 kW) See Engine Operator’s Manual 35 Gallons (132 liters) 3 U.S. Gallons (11.4 liters) Shutdown 225_F (107_C) 1800 RPM (II) 70 amp
Track Width Tire Size (Load Range) Tire Pressure Lug Nut Torque Wheel Size Operating Tilt (maximum) Electrical System Compressor Discharge Temp. Service Valves Maximum Towing Speed Axle Rating Rated Pressure Sound Level ENGINE:
Type Make Model Displacement Cylinders Bore x Stroke Rated Speed Rated Power Type of Motor Oil Fuel Tank Capacity Radiator Capacity Engine Water Temperature Minimum Idle Speed Alternator Rating
(II) DO NOT allowengineidle rpmto dropbelowminimumidle speed. Compressorand/or coupling damagewilloccur. Thecompressor 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 -- CATERPILLAR Model Series
Length (I)
mm
in 185H,210H,260 2Wheel 185H,210H,260 LRG
143.3 3640 85.1 2162
Width in 65.4 47.5
Height
mm 1661 1207
in 59.9 49.0
Weight (wet)(II)
mm
lb
1522 1245
kg
2760 2505
1251 1136
(I) Length over drawbar. (II) Weight shown is for 260 models. Deduct 120 lbs.(55kg) for 185H and 210H models.
COMPRESSOR:
185H
210H
260
Type Maximum Operating Pressure Delivery Fluid Lubricating Compressor Sump Capacity
Rotary Screw 150 psig (10.3 bar)
Rotary Screw 150 psig (10.3 bar)
Rotary Screw 100 psig (6.9 bar)
185 Free CFM (87 L/S) Compressor Fluid See Lubrication Guide 3 U.S. Gallons (11 Liters) 55 in. (1397 mm)
210 Free CFM (99 L/S) Compressor Fluid See Lubrication Guide 3 U.S. Gallons (11 Liters) 55 in. (1397 mm)
260 Free CFM (122 L/S) Compressor Fluid See Lubrication Guide 3 U.S. Gallons (11 Liters) 55 in. (1397 mm)
50 psig (3.5 bar) 60 ft.---lbs. (81 Nm) 15 X 5 15 Degrees 12 Volt Shutdown 250_F (121_C) (2) 3/4” 55 mph (88 kmph) 3500 lbs. (1588 kg) 150 psig (10.3 bar) 76 dBA at 7 meters
50 psig (3.5 bar) 60 ft.---lbs. (81 Nm) 15 X 5 15 Degrees 12 Volt Shutdown 250_F (121_C) (2) 3/4” 55 mph (88 kmph) 3500 lbs. (1588 kg) 150 psig (10.3 bar) 76 dBA at 7 meters
50 psig (3.5 bar) 60 ft.---lbs. (81 Nm) 15 X 5 15 Degrees 12 Volt Shutdown 250_F (121_C) (2) 3/4” 55 mph (88 kmph) 3500 lbs. (1588 kg) 100 psig (7 bar) 76 dBA at 7 meters
Diesel Caterpillar 3044T 201 cu. in. ( 3.3 L) 4 3.70 x 4.72 in. ( 94 mm x 120 mm) 2600 RPM 80 HP (60 kW) See Engine Operator’s Manual 35 Gallons (132 liters) 3 U.S. Gallons (11.4 liters) Shutdown 225 _F (107_C) 1800 RPM (III) 90 amp
Diesel Caterpillar 3044T 201 cu. in. ( 3.3 L) 4 3.70 x 4.72 in.. ( 94 mm x 120 mm) 2500 RPM 80HP ( 60 kW) See Engine Operator’s Manual 35 Gallons (132 liters) 3 U.S. Gallons (11.4 liters) Shutdown 225_F (107_C) 1800 RPM (III) 90 amp
Diesel Caterpillar 3044T 201 cu. in. ( 3.3 L) 4 3.70 x 4.72 in.. ( 94 mm x 120 mm) 2500 RPM 80HP ( 60 kW) See Engine Operator’s Manual 35 Gallons (132 liters) 3 U.S. Gallons (11.4 liters) Shutdown 225_F (107_C) 1800 RPM (III) 90 amp
Track Width Tire Size (Load Range) Tire Pressure Lug Nut Torque Wheel Size Operating Tilt (maximum) Electrical System Compressor Discharge Temp. Service Valves Maximum Towing Speed Axle Rating Rated Pressure Sound Level ENGINE:
Type Make Model Displacement Cylinders Bore x Stroke Rated Speed Rated Power Type of Motor Oil Fuel Tank Capacity Radiator Capacity Engine Water Temperature Minimum Idle Speed Alternator Rating
(III) DONOT allow engineidle rpm to dropbelow minimum idlespeed. Compressorand/or coupling damagewill occur. The compressor is equipped with a Low Speed Shutdown System that will shutdown the compressor if engine speed falls below 1500 rpm.
22
Section 3
SPECIFICATIONS 3.2 LUBRICATION GUIDE -- COMPRESSOR FLUID TYPE
CHANGE PERIOD, HOURS
Sullair AWF (I) D---A Torque Fluid SAE10W SE, SF, SG, CD MIL---L---2104E 10W
1200 300 300 300
AMBIENT TEMPERATURE RANGE _F (_C)
---20 to 125 (--- 29 to 52) 10 to 110 (---12 to 43) 0 to 100 (---18 to 38) 0 to 100 (---18 to 38)
(I) Sullair part numbers for Sullair AWF are 250030---757 (5 gallons/20 liters) and 250030 ---758 (55 gallon drum/208 liters).
3.3 APPLICATION GUIDE Sullair Air Compressors are supplied with Sullair AWF which is heavy duty multi---viscosity, all--weather fluid. Sullair AWF also allows an extended change interval. Detergent motor oils (SAE 10W Class SE,SF, SG or CD) can also be used. Any of these oils are suitable under conditions where severe oil oxidations can occur.
Water must be drained from the receiver periodically. In high ambient temperature and high humidity conditions, condensed moisture may emulsify with the oil forming a milky” color. SAE 10W is especially prone to this condition. The fluid should be changed if this condition develops. “
DO NOT mix types of fluids. Combinations of different fluids may lead to operational problems such as foaming, filter plugging, orifice or line plugging.
When ambient conditions exceed those noted or if conditions warrant use of other extended life lubricants, contact Sullair for recommendations. Sullair encourages the user to participate in a fluid analysis program. This couldresult in a fluid change interval differing from that stated in the manual. Sullair Corporation offers a fluid analysis program for Sullair AWF. Contact your local Sullair representative for details. D---A Lubricantr Company Inc. offers an analysis program for usersof D--- A productsand SullairAWF. Contact your D---A lubricant supplier or Sullair representative for details. 3.4 LUBRICATION GUIDE -- ENGINE For engine oil specifications, refer to the Engine Operator’s Manual.
23
NOTES
24
Section 4
OPERATION 4.1 GENERAL While Sullair hasbuilt into this compressor a comprehensive array of controls and indicators to assure you that it is operating properly, you will want to recognize and interpret the reading which will call for
service or indicate the beginning of a malfunction. Before starting your Sullair compressor, read this section thoroughly and familiarize yourself with the controls and indicators --- theirpurpose, location and use.
4.2 PURPOSE OF CONTROLS CONTROL OR INDICATOR
ENGINE SWITCH
COLD WEATHER STARTING AID BUTTON AIR PRESSURE GAUGE
PURPOSE
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. Pressthe switch to the “OFF” position to shut the compressor down. This switch is located on the instrument panel. Push thisbutton, prior tocompressor start---up, toallowthe engine to warm---up for easy starting. 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 compressor is shut down and on level ground.
COMPRESSOR DISCHARGE TEMPERATURE SWITCH
Opens the electrical circuit to shut down the compres--sor when the discharge temperature reaches a specific value (see Section 3, Specifications).
THERMAL VALVE
Functions as a temperature regulator directing the compressor fluid either to the cooler or to the compressor unit.
MINIMUM PRESSURE DEVICE
Maintains the minimum of 85 psig (5.9 bar) in the compressor 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 according to demand.
SHUTDOWN SYSTEM/ANNUNCIATOR MODULE (SSAM) Monitors the compressor safety system for shutdown conditions. The annunciator module on the instrument panel will flash a code indicating the reason for compressor shutdown.
25
Section 4
OPERATION 4.2 PURPOSE OF CONTROLS (Continued) CONTROL OR INDICATOR
PURPOSE
BLOWDOWN VALVE
Vents sump pressure to the atmosphere at shutdown.
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.
shipment. Refer to your Engine Operator’s Manual 4.3 START-- UP PROCEDURE The following procedure should be used to make the for details and specific engine requirements. initial start---up of your compressor: 1. Position the compressor on a level surface so that 4.4 SUBSEQUENT START-- UP PROCEDURE On subsequent starts, follow the procedure exproper amounts of liquid can be added if necesplained below: sary. (I) 2. Check oil and fluid levels both in the engine and 1. Check engine oil, water and fuel levels. the cooling system(s). Maintain the proper level; 2. Check compressor fluid level (should be visible in add if necessary. sight glass). Drain water from the fuel---water 3. Fill the fuel tank. Drain water from the fuel---water separator. separator. 3. Check dust collectors and clean if necessary. 4. Crack open one service line. 4. Crack open service valve. 5. Bleed fuel injection lines if necessary (see Engine 5. Bleed fuel injection lines if necessary (see Engine Operator’s Manual). Operator’s Manual). 6. Turn the warm---up control selector valve to the 6. Turn the warm---up control selector valve to the start position. start position. 7. In cold weather, engage cold weather starting aid 7. In cold weather, engage cold weather starting aid button. Hold button for 5---10 seconds and then button. Hold button for 5---10 seconds and then release. release. 8. Press the engine switch to the “ON” position. 8. Press the engine switch to the “ON” position. 9. Press the engine switch to the “START” position 9. Press the engine switch to the “START” position momentarily to engage starter, when engine momentarily to engage starter, when engine starts release switch. starts release switch. 10. After the engine starts, turn the idle warm---up se10. Allow for sufficient warm up of compressor before lector valve from start to run for full compressor operating. operation within the first 30 seconds of operation. 11. After the engine starts, turn the idle warm---up se After 30 seconds, the annunciator light will go off. lector valve from the start to run position for full 11. Close canopy in order to maintain proper noise operation within the first 30 seconds of operation. control. 4.5 SHUTDOWN PROCEDURE 12. After the initial run, shut the compressor down and To shut the compressor down, close the service refill theradiatorand compressor fluid sump as revalves and runcompressor for approximately 5 minquired. Tighten any loose fittings and check fan utes to allow the compressor to cool down and belt tension. press the engine switch to the OFF position. In case of emergency where immediate shutdown is required, this procedure is not necessary. The en(I) The radiator is filled with a 50/50 mixture of ethylene glycol and water. All engines receive Supplegine switch should be pressed to the OFF position mental Coolant Additive (SCA) at the factory before immediately.
26
Section 5
MAINTENANCE 4. Check fuel filter for water. A good maintenance program is the key to long 5.3A MAINTENANCE EVERY 50 HOURS compressor life. Below is a program that, when ad1. Inspect and replace air filter elements (if rehered to, should keep thecompressor in topoperatquired). ing condition. For maintenance requirements on engine, refer to the Engine Operator’s Manual for a de2. Check fuel filter for water. tailed description of service instructions. See Section 5.7, Parts Replacement and Adjustment Proce- 5.4 MAINTENANCE EVERY 100 HOURS After 100 hours of operation, it will be necessary to dures for a detailed description of specific compresperform the following: sor system components. Prior to performing main1. Clean the radiator and cooler exteriors. tenance, read the CIMA Safety Manual, if applicable in your area. 2. Check Engine Operator’s Manual for required service. ! WARNING 5.5 MAINTENANCE EVERY 250 HOURS Perform the following after every 250 hours of operaDO NOT remove caps, plugs and/or other components when compressor is running or pressurtion: ized. 1. Check fan belt tension. Stop compressor and relieve all internal pressure 2. Clean the radiator and cooler exterior. Depending before doing so. on how contaminated the atmosphere may be, more frequent cooler and radiator cleaning may 5.2 DAILY OPERATION be necessary. Prior to starting the compressor, it is necessary to 3. Change engine oil and filter. check the fluid level in the sump. Shouldthe level be low, simply add the necessary amount. If the addition of fluid becomes toofrequent, a simple problem NOTE has developed which is causing this excessive loss. Fluid change period will vary according to fluid See the Troubleshooting Sections (5.8 and 5.9) unbrand. Refer to Lubrication Guide in Section 3. der Excessive Fluid Consumption for a probable Perform the following after every 250 hours of operacause and remedy. Also check the engine oil level tion: and the radiator coolant level and drain water from the engine fuel/water separator prior to starting. 4. Change the compressor fluid and fluid filter, if not using Sullair AWF. Run the compressor for 5 to 10 minutes to warm the fluid. Shut the compresNOTE sor off and relieve all internal pressure before The radiator and engine cooling system must be proceeding. Drain the fluid sump by removing drained and flushed every two (2) years. Replace the plug at the bottom of the sump tank. For fluid the coolant with a solution of 50% ethylene glycol filter element replacement, see Filter Element and 50% water or as required for your geographic location. DO NOT use a lea k sealing type of anti--Replacement under the Maintenance Section freeze. Allengines musthave Supplemental Cool5.7 Parts Replacement and Adjustment Proceant Additive (SCA) added to the engine coolant dures. Fill the sump with fluid according to specisystem. Refer to your Engine Operator’s Manual fications in Section 3. Remove any accumulated for details and specific engine requirements. dirt from the fluid filler cap prior to filling the sump. After a routine start has been made, observe the instrument panel gauge and be sure it monitors the 5. Replace return line strainer. correct reading for that particular phase of opera6. Check the engine RPM. Idle speeds should never tion. After the compressor has warmed up, it is recbe allowed to fall below the minimums (see Secommendedthat a general check on the overall comtion 3 Specifications). pressor and instrument panel be made to assure 7. Changethe fuel filter . Should persistant clogging that the compressor is running properly. Also check be evident, changethe fuel filter more frequently. the air filter maintenance indicators if supplied. 8. Change engine fuel---water separator. 5.3 MAINTENANCE AFTER INITIAL 50 HOURS 9. Change the air filter (s) primary elements. OF OPERATION 10.Change compressor fuild filter. After the initial 50 hours of operation, a few maintenance requirements are needed to rid the system of NOTE any foreign materials. Perform the following maintenance operations to prevent unnecessary probOperation at speeds below the minimum idle speeds shown in the Table in Section 3, Specificalems. tions will damage the compressor. Extended op1. Clean the return line orifice and strainer. eration below those speeds will induce coupling and/or compressor failures. 2. Change compressor fluid filter. 11. Lubricate the control linkage. 3. Check Engine Operator’s Manual for required service. 12. Check Engine Manual for required service.
5.1 GENERAL
27
Section 5
MAINTENANCE Figure 5---1 Compressor Fluid Filter
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. Continuetightening theelement by hand an additional 1/2 to 3/4 turn. 6. Restart the compressor and check for leaks. AIR FILTER MAINTENANCE
Refer to Figure 5---2. Air filter maintenance should be performed as often as conditions require. If the filters are equipped with an optional maintenance indicator, maintenance should be done when the indicator shows red. The following procedure will explain how to replace the air filter element. AIR FILTER ELEMENT REPLACEMENT
* Replacement Element Kit P/N 250028---032
1. Loosen and remove the air filter end cover. 2. Remove element. 3. Clean the body and cover with a damp cloth inside and out. 4. Replace the new filter element. 5. Reposition the cover and lock into position. 6. Reset the air filter restriction indicator if so equipped, and the unit will be ready for operation. ELEMENT INSPECTION
13. Clean the return line orifice.
5.6A MAINTENANCE EVERY 1500 HOURS OR ANNUALLY 1. When using Sullair AWF, change the compressor fluid and replace the fluid filter element (See maintenance procedures in Section 5.7). 2. Service engine cooling system.
1. Place a bright light inside the element to inspect for damage or leak holes. Concentrated light will Figure 5---2 Air Filter
5.6B MAINTENANCE EVERY YEAR OR 12,000 MILES 1. Lubricate axle bearings on wheel---mounted units. 5.7 PARTS REPLACEMENT AND ADJUSTMENT 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 opening the valve at the bottom of the sump tank. Change the compressor fluid and replace the fluid filter element. For element replace-
28
*Filter Element P/N 02250122---816 (2 req’d)
Section 5
MAINTENANCE Figure 5---3 Air/Fluid Separator
*Replacement Separator Kit P/N 02250078---031
shine through the element and disclose any holes. 2. Inspect all gaskets and gasket contact surfaces of the housing. Should faultygaskets be evident, correct the condition immediately. 3. If the clean element is to be stored for later use, it must be stored in a clean container. 4. After the element has been installed, inspect and tighten all air inlet connections prior to resuming operation. SEPARATOR ELEMENT REPLACEMENT Refer to Figure 5---3. When fluid carry over is evident after the fluid return line strainer and orifice as well as the blowdown valve seal hasbeen 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 theold 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 should extend to the bottom of the separatorelement. This will assurethe properfluid returnflow. 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 PRESSURE CONTROLS ON PORTABLE COMPRESSORS WITH POPPET VALVE Refer to Figure 5---4. Prior to adjusting the Control System, it is necessary to determine the rated full load pressure and the high/low RPM settings for your particular compressor. This information can be obtained from the Operator’s Manual (Specifications Section) or by contacting your local authorized Sullair Representative. The following explanation applies to a compressor with 100 psig (6.9 bar) rated full load pressure.
1. Start the compressor and allow the engine to warm---up to normal operating temperature with the service valve closed. 2. With the service valve closed, set the engine low speed (idle) to its specified setting with the idle stop screw on the engine injector pump. NOTE Operation at speeds below the minimum idle speeds shown in Section 3 under Specifications will damage the compressor. Extended operation below those speeds will induce coupling and/or compressor failures.
3. Adjust the pressure regulator so that the compressor maintains 115 psig (8 bar). 4. Gradually open the service valve to atmosphere until the engine comes up in speed and sump pressure is held at 100 psig (6.9 bar). At this point, set the engine high speed to its specified setting by adjusting the high idle threaded rodlocated on the engine speed control (where applicable). To raise or lower the speed, lengthen or shorten the rod respectively. 5. Open the service valve to100 psig(6.9 bar)(rated full load pressure) and recheck top engine speed and control response. Close the service 29
Section 5
MAINTENANCE Figure 5---4 Control System Adjustment
185H & 210 MODELS
260 MODELS
30
Section 5
MAINTENANCE Figure 5 ---5 Typical E ---Z Lube Axle
valve and allow the compressor to cycle and recheck low engine speed (idle). The following explanation applies to “H” compressor with dual pressure controls. 1. Start the compressor and allow the engine to warm---up to normal operating temperature with the service valve closed and the pressure selector switch set to the “low” position. 2. Follow the procedure for setting the controls at 100 psig (6.9 bar) rated full load pressure as described in Steps 2 through 5 above. 3. Switch the pressure selector switch to the “high” position with the service valve closed. 4. Adjust the high pressure regulator so that the compressor maintains 165 psig (11.4 bar). 5. Gradually open the service valve to atmosphere until the engine comes up in speed and sump pressure is held at 150 psig (10.3 bar). At this point the engine shouldbe at rated speed. If necessary, to raise or lower the speed, lengthen or shorten the rod respectively.
frequently to help insure proper performance. Use wheel bearing grease that conforms to military specification MIL---G---10924 or a high temperature wheel bearing grease such as lithium complex NLGI Consistency #2. If your axle is equipped with the E---Z Lube feature, the bearings can be periodically lubricated without removing the hubs from the axle. This feature consists of axle spindles that have been specially drilled and fitted with a grease zerk in their ends. When grease is pumped into the zerk, it is channeled to the inner bearing and then flows back to the outer bearing and eventually back out of the grease cap hold (see Figure 5---5). The procedure is as follows: 1. Remove the rubber plug from the end of the grease cap. 2. With a standard grease gun filled with a quality wheel bearing grease, place the gun onto the grease zerk located in the end of the spindle. Make sure the grease gun nozzle is fully engaged on the fitting. 3. Pump grease into the zerk. The old, displaced grease will begin to flow back out the caparound the grease gun nozzle. 4. When the new, clean grease is observed, remove thegrease gun, wipe off anyexcess, andreplace the rubber plug in the cap.
OPERATING ADJUSTMENTS The first step is to start the compressor according to the instructions in Section 4, Subsequent Start---up. Allow the engine to operate until it reaches the normal operating temperature. Open the service valve until the engine speed increases to, or close to, the 5.8 TROUBLESHOOTING -- INTRODUCTION maximum specified operating speed. The following Troubleshooting Chart is based upon BEARING LUBRICATION the data obtained both from testing at the factory Refer to Figure 5---5. Proper lubrication is essential and from applied situations in the field. It contains to the proper functioning and reliability of your porsymptoms and usual causes for the described table compressor axle. Wheel bearings should be problems, however DO NOT assume that these are lubricated at least once every 12 months, or more the only problems that may occur. All available data
31
Section 5
MAINTENANCE concerning the trouble should be systematically analyzed before undertaking any repairs or component replacement procedures. A detailed visual inspection is worth performing for almost all problems. Doing so may prevent unnecessary additional damage to the compressor. Always remember to: 1. Check for loose wiring.
2. Check for damaged piping. 3. Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor. Should the problem(s) persist after making the recommended check, consult your nearest Sullair representative or the Sullair Corporation.
5.9 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 necessary. Check ground wire forproperattachment toframe. Tighten as required.
Low Voltage or Battery disconnected
Recharge or replace battery if required.
Blown fuse in wiring harness
Remove and inspect fuse. Replace if necessary.
Instrument panel connectors loose or disconnected
Checked instrument panel connectors and reattach if required. Check instrument panel wires for broken connections or corrosion. Clean and/or replace if required
FLASH CODE: ONE FLASH
Faulty SSAM module
Replace the SSAM Module.
Compressor temperature switch is open
Check wiring connection to switch and tighten as required. Check switch continuity to ground and replace if necessary. If the compressor feels hot --- see symptom “COMPRESSOR OVERHEATING”.
FLASH CODE: TWO FLASHES
Engine coolant temperature switch is open
Check wiring connection to switch and tighten as required. Check switch continuity to ground and replace if necessary. If the compressor feels hot --- see symptom “ENGINE OVERHEATING”.
FLASH CODE: FOUR FLASHES
Did not attempt to start compressor within 30 seconds of turning ignition switch ON.
When starting the compressor, immediately turn the Ignition Switch to the START position and begin the engine cycle.
L ow Batter y Voltag e
L oose battery cables and tigh ten if n ecesssary. Recharge or replace battery if necessary.
32
No fuel
Check fuel level and fuel if necessary.
Water/dirt in fuel and/or fuel filter
Drain water from fuel water separators on fuel filters. Siphon water from fuel tank and clean fuel tank if necessary.
Plugged fuel filter
Replace fuel filter if necessary.
Section 5
MAINTENANCE 5.9 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM
PROBABLE CAUSE
REMEDY
FL ASH C ODE : FO UR FL ASHE S (cont)
P lu gged air f ilter
C lean an d rep lace if necessary.
Engine problems may have developed
Refer to Engine Operator’s Manual.
Starter solenoid relay does not engage
Check wiring and tighten all connections. Replace relay.
Alternator failure
Check outp ut of alternator frequency terminal
COMPRESSOR SHUTS DOWN: NO FLASH CODE:
FLASH CODE: ONE FLASH
Blown fuse in wiring harness
Remove/Inspect fuse and replace if necessary.
Instrument panel connectors loose or disconnected.
Check instrumentpanel connectors and reattach if required
Instrument panel connectors loose or disconnected.
Check instrument panel wires for broken connec tions or c orrosion. Clean a nd/or r eplace if required.
Faulty SSAM module
Replace the SSAM Module
Faulty compressor temperature switch
Check wiring connection to switch and tighten as required. Check switch continuity when cool and replace if necessary.
FLASH CODE: TWO FLASHES
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.
Faulty Engine coolant temperature switch
Check wiring connection to switch and tighten as necessary. Check switch continuity to ground when cool and replace if necessary.
FLASH CODE: THREE FLASHES
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 developed.
Refer to engine operators manual.
No engine coolant
Check engine coolant level and fill with proper wa ter/glycol mixture as required.
Faulty engine oil pressure switch
Check wiring connection to switch and tighten as 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 En gine Operator’s Manual.
33
Section 5
MAINTENANCE 5.10 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM
PROBABLE CAUSE
FLASH CODE: FOUR FLASHES
No/Low fuel
Check fuel level and add fuel if necessary.
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 fromfuel water separatorson fuelfilters Siphon water from fuel tank and clean fuel tank it. necessary.
COMPRESSOR WILL NOT BUILD UP FULL DISCHARGE PRESSURE
IMPROPER UNLOADING WITH AN EXCESSIVE PRESSURE BUILD---UP CAUSING PRESSURE RELIEF VALVE TO OPEN
REMEDY
For compressors with idle warm--- up controls, switch toggle to “run” for full operation. 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.
Pressure Regulating Valve Is Set Too High
Readjust.
Leak In Control System Causing Loss Of Pressure Signal
Check control lines. Defective pressure regulating valve; repair valve (kit available).
Inlet Valve Jammed FLASH CODE: FIVE FLASHES (option) No/low fuel IMPROPER UNLOADING WITH AN EXCESSIVE PRESSURE BUILD---UP CAUSING PRESSURE RELIEF VALVE TO OPEN (continued)
INSUFFICIENT AIR DELIVERY
34
Free or replace valve. Check fuel level & add fuel if necessary.
Restriction In The Control System
Check all control lines and components. Ice and/or other contaminants could cause .
Defective Pressure Relief Valve Opening At Too Low Of Pressure
Replace pressure relief valve.
Defective Pressure Regulator
Check diaphragm and replace if necessary (kit available).
Engage Idle Warm---up Control In “Run” 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.
Section 5
MAINTENANCE 5.9 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM
PROBABLE CAUSE
EXCESSIVE COMPRESSOR FLUID CONSUMPTION
Clogged Return Line
Clear orifice and return line strainer.
Leak In The Lubrication System
Check all pipes, connections and components.
Separator Element Damaged Or Not Functioning Properly
Change separator element.
Low Sump Fluid Level
Fill.
Loose Or Broken Fan Belt
Tighten or change belt.
Dirty Fluid Cooler Core
Clean core thoroughly.
Plugged Compressor Fluid Filter
Change element.
Faulty Thermostat
Change thermostat element.
Plugged Fluid Cooler Tube (Internal)
Replace cooler.
Loose Or Broken Fan Belt
Tighten or change belt.
Dirty Radiator Core
Clean thoroughly.
Low Fluid Level
Refill.
Faulty Water Pump
Change pump.
Plugged Radiator
Clean and flush thoroughly.
Defective Engine Thermostat
Replace engine thermostat.
COMPRESSOR OVERHEATING
ENGINE OVERHEATING
REMEDY
35
NOTES
36
Section 6
NOISE CONTROL 6.1 NOISE EMISSIONS WARRANTY Sullair Corporation warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed, built and equipped to conform at the time of sale to the first retail purchaser, with all applicable U.S. E.P.A. and/or any Federal, State or Local noise control regulations.
This warranty is not limited to any particular part, component, or system of the air compressor. Defects in thedesign, assembly, or in any part, component, or system of the compressor which, at thetime of sale to the first retail purchaser, caused noise emissions to exceed Federal standards are covered by this warranty for the life of the air compressor. 6.2 TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal Law prohibits the following acts or thecausing thereof:
2. The use of the compressor after such device or element of design has been removed or rendered inoperative by any person. Among those acts included in the prohibition against tampering are the acts listed below: 1. Removal or rendering inoperative any of the following: a. Engine exhaust system or parts thereof b. Compressor air intake system or part thereof c. Enclosure of part thereof 2. Removal of any of the following: a. Vibration isolators b. Control silencer c. Floor panel d. Fan shroud e. Acoustical materialsincluding fiberglass foam or foam tape 3. Operation with canopy doors open for any purpose other than starting, stopping, adjustment, repair, replacement of parts or maintenance.
1. The removal or rendering inoperative by any persons, other than for purposes of maintenance, 6.3 NOISE EMISSIONS MAINTENANCE AND MAINrepair, or replacement, of any device or element TENANCE RECORD LOG of design incorporated intoany new compressor The following instructions and maintenance record for the purpose of noise control prior toits saleor log book, for the proper maintenance, use and redelivery to the ultimate purchaser or while it is in pair of this compressor, is intended to prevent noise use. emission degradation (refer to Figure 6---1). 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 andconnections aretight, andthat themuffler is in good condition. DONOT operate compressor with defective exhaust system. Remove and replace any defective parts by ordering with part numbers indicated in the Parts List.
Maintenance Performed By Location Date
Maintenance Performed By Location Date
DDDDDDDDDDDDDDDDD
37
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 airfilter(s) andentire 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 DDDDDDDDDDDDDDDDD
3. ANNUAL ENGINE VIBRATION MOUNT INSPECTION At least annually inspect engine vibration mounts for security of attachment and to make sure the resilient parts areintact. DONOT operate compressor with defectiveengine mountingsystem. Remove and replace defective parts by ordering with part numbers indicated in Parts List.
Maintenance Performed By Location Date
Maintenance Performed By Location Date
DDDDDDDDDDDDDDDDD
38
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 operate 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
DDDDDDDDDDDDDDDDD
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 compressor 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
DDDDDDDDDDDDDDDDD
39
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 andinspect to make sure all systems are operating properly andthat engine runs at rated speed andpressure. DONOT 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
DDDDDDDDDDDDDDDDD
40
Section 7
ILLUSTRATIONS AND PARTS LIST 7.1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor was purchased. If for any reason parts cannot be obtainedin this manner, contact the factory directly at the address, phone or fax numbers below.
Whenorderingparts always indicate the Serial Number of thecompressor. This canbe obtainedfrom 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 Michigan City, Indiana 46360 U.S.A. Telephone: 1--800--SULLAIR (U.S.A.) or 1--219--879--5451 Fax: (219) 874--1273 www.sullair.com
SULLAIR EUROPE, S.A.
Zone Des Granges BP 82 42602 Montbrison Cedex, France Telephone: 33--477968470 Fax: 33--477968499 www.sullaireurope.com
SULLAIR ASIA, LTD.
Sullair Road, No. 1 Chiwan, Shekou Shenzhen, Guangdong PRV. PRC POST CODE 518068 Telephone: 86--755--2--6851686 Fax: 86--755--2--6853473 www.sullair-asia.com
Parts Department 1--888--SULLAIR (U.S.A.) Fax: (219) 874--1835 www.sullair.com
Telephone:
Service Department 1 -- 888--775 -- 1604 (U.S.A.) Fax: (219) 874--1205 www.sullaircompressors.com
Telephone:
CHAMPION COMPRESSORS, LTD. 11--15 Mario Place Princes Highway Hallam, Victoria 3803 Australia Telephone: 61--3 --9 -- 796--4000 Fax: 61--3--9--703--8053 www.championcompressors.com.au/
41
Section 7
ILLUSTRATIONS AND PARTS LIST 7.2 RECOMMENDED SPARE PARTS LIST KEY
DESCRIPTION
PART
NUMBER
QUANTITY
NUMBER
ELEMENTS:
1 2 3 4 5 6 7
element, replacement for air/fluid separator element for engine oil filter (Caterpillar ) element for engine fuel filter (Caterpillar ) element for engine oil filter (John Deere ) element for engine fuel filter (John Deere ) element, replacement for air filter 8” primary element for thermal valve 130 F
02250078 -- 031
1
02250150 -- 119
1
02250150 -- 120
1
02250144 -- 815
1
02250144 -- 814
1
02250122 -- 816
2
02250104 -- 907
1
02250153 -- 904
1
250028 -- 032
1
02250147 -- 737
1
250019 -- 453
1
250026 -- 758 02250046 -- 397 02250051 -- 338
1 1 1
repair kit for return line strainer 241771 241772 02250103 -- 596 kit, coupling lord (185H, 210H) kit, coupling lord (260) 02250099 -- 930 repair kit for inlet valve (185H, 210H) 02250109 -- 684 repair kit for inlet valve no. 02250088--- 348 2--- 1/2” (260) 250019 -- 451 kit, spring replacment for inlet valve no. 02250088---348 2---1/2” (260) 250029 -- 315
1
˚
KITS:
8 9 10 11 12
kit, element fuel manager kit, element for main compressor fluid filter kit, repair for regulator/blowdown valve manifold kit, repair for pressure regulator valve 250017---280 maintenance for minimum pressure/check valve no. 02250088---349: repair kit repair kit, cap 1 1/4” repair kit, piston S S S
13 14 15 16 17 18
1 1 1 1 1
LUBRICATION:
19 20
Sullair AWF---5 gallons (18.9 liter) Sullair AWF---55 gallon drum (208 liter)
250030 -- 757
1
250030 -- 758
1
250023 -- 146
1
MISCELLANEOUS:
21
manual, portable air compressor “CIMA”
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
42
Section 7
ILLUSTRATIONS AND PARTS LIST NOTES
43
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3A ENGINE, COMPRESSOR & PARTS -- 185H & 210H CATERPILLAR
02250149--- 637R02
44
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3A ENGINE, COMPRESSOR & PARTS -- 185H & 210H CATERPILLAR key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
description
spacer, brake lever 250p conn, female pipe 1/8---27 npt elbow, 90 3/8”tube x 1/4”npt m bshg, tpr qd sd 38mm bore 185q spring, extension 3.0lg 4.52lb/in .313od washer, snubbing vibration mount mount, vibration isolator 185 tee, male branch 3/8”tube x 1/8”npt hose, parkrimp 3/4 x 32 valve, check 1/8 female --- male engine, diesel ca 804---33t 185h/260 (I) support, engine l&r 185h --- 260 pe spacer, fan 1.5” lg 185h --- 260 pe fan, 18” blower 185h---260 pe rod, speed ctl 185dpq jd support, speed cyl 185h --- 260 ca/pe cover, eng pto 185h---260 cat gasket, eng pto 185h--- 260 cat orifice, .062” x .25m x .25m nptf clamp, hose 13/16” to 1---1/2” joint, ball female 1/4” l.h. joint, ball female 1/4” r.h. elbow, 90 1/4”tube x 1/8”npt cylinder, speed 3/4 x 1 stroke coupling, eng---compr lord 250 (II) pin, drive coupling 250 jd elbow, 90d 1/4” tube x 1/4”fnpt nut, hex locking 1/4---20 nut, hex locking 1/2---13 capscrew, hex 8.8 m6 x 16mm capscrew, hex 8.8 m8 x 65mm capscrew, hex 8.8 m10 x 25mm
part number
quantity
02250064---594 02250097---138 02250099---626 02250103---559 02250124---065 02250125 --- 471 02250125---472 02250138 --- 698 02250139---776 02250142--- 248 02250146 --- 013 02250146 --- 146 02250146 --- 479 02250146---549 02250148---086 02250149 --- 240 02250150---197 02250150 --- 198 027443 040513 250011---578 250011---597 250018---429 250024---272 250034 --- 921 250035---041 250041---287 825504---145 825508---262 828006---016 828008---065 828010---025
1 1 1 1 1 6 4 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 8 1 2 2 1 4 2
(Continued on page 47)
(I) For in depth coverage of the engine, consult the Engine Operator’s Manual. For maintenance on Cater-
pillar engine oil filter, order replacement filter no. 02250150--- 119. For maintenance on Caterpillar engine fuel filter, order replacment filter no. 02250150---120.
(II) For maintenance on coupling, order repair kit no. 02250103---596.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
45
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3A ENGINE, COMPRESSOR & PARTS -- 185H & 210H CATERPILLAR
02250149--- 637R02
46
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3A ENGINE, COMPRESSOR & PARTS -- 185H & 210H CATERPILLAR (continued) key number
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
description
part number
capscrew, hex 8.8 m10 x 35mm 828010---035 capscrew, hex 8.8 m12 x 25mm 828012---025 capscrew, hex 8.8 m12 x 75mm 828012---075 capscrew, hex gr5 1/2 --- 13 x 3 1/4 829108 --- 325 screw, socket iso 4762 m10 x 40mm 829310 --- 040 washer, pl---b reg pltd 1/2 838208---112 washer, spr lock --- metric pltd m8 838808 --- 200 washer, spr lock --- metric pltd m10 838810 --- 220 hose, heater 3/4 842115---075 key, paral iso r773 10x8x40 865210---040 nut, hex jam lh pltd 1/4---28 866604---164 capscrew, ferry head hd pltd 1/4 --- 20 x 1 867304 --- 100 capscrew, ferry head hd pltd 1/4---20 x 1 1/2 867304---150 nut, hex jam rh pltd 1/4---28 868204---164 connector, 45 deg str x jic 1 7/8 x 1 7/8 870524 --- 024 connector, 90d str x jic 1 1/16 x 1 1/16 870612 --- 012 adapter, pipe male 7/16 orng x 1/8 877202 --- 012 washer, nord---lock pl 1/2” 878608--- 077 (III) compressor & part, dxx102147e washer, rtnr ctl cyl spring 5/16” 02250078 --- 842
quantity
12 8 2 2 8 2 4 14 5 ft 1 1 1 1 2 1 1 1 8 1 1
(III) There is an exchangeprogram whereby a remanufactured compressor unit can be obtained from Sullair
distributors or the factory at less cost than the owner could repair the unit. For information regarding the unit exchange program, contact your nearest Sullair representative or the Sullair Corporation. Theshaft seal is not considered part of the compressor unit in regardto the twoyear warranty. The normal Sullair parts warranty applies. For shaft seal repairs consult factory. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
47
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3B ENGINE, COMPRESSOR & PARTS -- 260 CATERPILLAR
02250149--- 631R02
48
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3B ENGINE, COMPRESSOR & PARTS -- 260 CATERPILLAR key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
description
key, .375 x .312 x 1.80 class #2 spacer, brake lever 250p valve, air inlet 2 1/2” black (I) elbow, 90 3/8”tube x 1/4”npt m spring, extension 3.0lg 4.52lb/in .313od washer, snubbing vibration mount mount, vibration isolator 185 hose, parcrimp 3/4 x 26 tee, male branch 3/8”tube x 1/4”npt m support, compressor 12s 260dpq support, engine l&r 185h --- 260 pe spacer, fan 1.5” lg 185h --- 260 pe fan, 18” blower 185h---260 pe hose, 1 --- 1/2 --- 18” 185h --- 260dpq rod, speed ctl 185dpq jd support, speed cyl 185h --- 260 ca/pe cover, eng pto 185h---260 cat gasket, eng pto 185h--- 260 cat orifice, .062” x .25m x .25m nptf clamp, hose 13/16” to 1---1/2” compr model, 12series unit joint, ball female 1/4” l.h. joint, ball female 1/4” r.h. elbow, 1/4” tube x 1/4” npt spacer, air conn vlv 250q cylinder, speed 3/4 x 1 stroke housing, adapter (250034 --- 402c)
part number
02250060---568 02250064---594 02250088 --- 348 02250099---626 02250124---065 02250125 --- 471 02250125---472 02250126---680 02250136 --- 998 02250146 --- 142 02250146 --- 146 02250146 --- 479 02250146---549 02250146 --- 978 02250148---086 02250149 --- 240 02250150---197 02250150 --- 198 027443 040513 (II)
250011---578 250011---597 250018---430 250022---950 250024---272 250034 --- 403
quantity
1 1 1 1 1 4 4 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
(Continued on page 51)
NOTE: For in depth coverage of theengine, consult the EngineOperator’s Manual. For maintenance on Caterpillar engine oil filter, order replacement filter no. 02250150---119. For maintenance on Caterpillar engine fuel filter, order replacment filter no. 02250150---120. (I) See Section 7.5 for breakdown of the inlet filter. For maintenance on air inlet valve no. 02250088 --- 348,
order repair kit no. 250019---451, or spring replacement kit no. 250029---315.
(II) There is an exchangeprogram whereby a remanufactured compressor unit can be obtained from Sullair
distributors or the factory at less cost than the owner could repair the unit. For information regarding the unit exchange program, contact your nearest Sullair representative or the Sullair Corporation. The shaft seal is not considered part of the compressor unit in regard to the two year warranty. The normal Sullair parts warranty applies. For shaft seal repairs consult factory.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
49
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3B ENGINE, COMPRESSOR & PARTS -- 260 CATERPILLAR
02250149--- 631R02
50
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3B ENGINE, COMPRESSOR & PARTS -- 260 CATERPILLAR (continued) key number
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57
description
bushing, taper wood---sd 1.75 coupling, eng---compr lord 250 (III) pin,drive coupling 250 jd elbow, 90d 1/4” tube x 1/4”fnpt nut, hex locking 1/4---20 nut, hex locking 1/2---13 o--- ring, neoprene 3 1/2 x 1/8” capscrew, hex 8.8 m6 x 16mm capscrew, hex 8.8 m8 x 65mm capscrew, hex 8.8 m10 x 25mm capscrew, hex 8.8 m10 x 35mm capscrew, hex 8.8 m12 x 25mm capscrew, hex gr5 1/2---13 x 1 capscrew, hex gr5 1/2 --- 13 x 1 1/4 capscrew, hex gr5 1/2 --- 13 x 3 1/4 capscrew, hex gr5 5/8 --- 11 x 1 1/4 screw, socket iso 4762 m10 x 40mm washer, spr lock reg pltd 1/2 washer, spr lock reg pltd 5/8 washer, pl---b reg pltd 1/2 washer, spr lock --- metric pltd m8 washer, spr lock --- metric pltd m10 hose, heater 3/4 nut, hex jam lh pltd 1/4---28 plug, pipe 1/8” 3000# stl plt capscrew, ferry head hd pltd 1/4 --- 20 x 1 capscrew, ferry head hd pltd 1/4---20 x 1 1/2 nut, hex jam rh pltd 1/4---28 connector, 90d str x jic 1 7/8 x 1 7/8 washer, nord---lock pl 1/2”
part number
quantity
250034---920 250034 --- 921 250035---041 250041---287 825504---145 825508---262 826202---238 828006---016 828008---065 828010---025 828010---035 828012---025 829108---100 829108 --- 125 829108 --- 325 829110 --- 125 829310 --- 040 837808---125 837810---156 838208---112 838808 --- 200 838810 --- 220 842115---075 866604---164 866900---005 867304 --- 100 867304---150 868204---164 870624 --- 024 878608---077
1 1 8 1 2 4 1 1 4 2 12 8 14 4 4 4 8 8 4 4 4 14 1 ft 1 1 1 1 2 1 8
(III) For maintenance on coupling, order repair kit no. 02250099---930.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
51
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3C ENGINE, COMPRESSOR & PARTS -- 185H & 210H JOHN DEERE
02250149--- 639R02
52
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3C ENGINE, COMPRESSOR & PARTS -- 185H & 210H JOHN DEERE key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
description
spacer, brake lever 250p conn, female pipe 1/8---27 npt elbow, 90 3/8”tube x 1/4”npt m bshg, tpr qd sd 38mm bore 185q washer, snubbing vibration mount mount, vibration isolator 185 tee, male branch 3/8”tube x 1/8”npt hose, parkrimp 3/4 x 32 valve, check 1/8 female --- male engine, diesel jd5030tf270 83hp (I) support, eng frt rh 185h --- 260 jd support, eng frt lh 185h--- 260 jd rod, speed ctl 185dpq jd cylinder, speed air 1 --- 1/16 bore 1’ stk support, low rpm stop 185 jd spring, extension spd ctl 185 jd fan, 18” blwr cw 185h---260 jd valve, eng oil drain m22x1.5 spacer, fan 3.50lg 2.5bc 185h jd clip, spring spd ctl 185---260 support, spd ctl 185---260 jd orifice, .062” x .25m x .25m nptf rod end, spherical rh 5/16 clamp, hose 1/2” joint, ball female 1/4” l.h. elbow, 90 1/4”tube x 1/8”npt coupling, eng---compr lord 250 (II) pin, drive coupling 250 jd elbow, 90d 1/4” tube x 1/4”fnpt nut, hex pltd 1/4---20 nut, hex locking 1/4---20 nut, hex locking 1/2---13 capscrew, hex 8.8 m8 x 20mm
part number
quantity
02250064---594 02250097---138 02250099---626 02250103---559 02250125 --- 471 02250125---472 02250138 --- 698 02250139---776 02250142 --- 248 02250145 --- 523 02250146 --- 143 02250146 --- 144 02250148---086 02250148 --- 089 02250148---091 02250148 --- 166 02250148---498 02250148---791 02250148 --- 826 02250152---418 02250152---439 027443 040136 043197 250011---578 250018---429 250034 --- 921 250035---041 250041---287 825204---226 825504---145 825508---262 828008---020
1 1 1 1 6 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 1 1 1 2 3
(Continued on page 55)
(I) For in depth coverage of the engine, consult the Engine Operator’s Manual. For maintenance on John
Deere engine oil filter, order replacement filter no. 02250144---815. For maintenance on John Deere engine fuel filter, order replacment filter no. 02250144---814.
(II) For maintenance on coupling, order repair kit no. 02250103---596.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
53
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3C ENGINE, COMPRESSOR & PARTS -- 185H & 210H JOHN DEERE
02250149--- 639R02
54
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3C ENGINE, COMPRESSOR & PARTS -- 185H & 210H JOHN DEERE (continued) key number
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
description
capscrew, hex 8.8 m8 x 120mm capscrew, hex 8.8 m10 x 35mm capscrew, hex 8.8 m12 x 75mm capscrew, hex 8.8 m16 x 30mm capscrew, hex gr5 1/4---20 x 1 capscrew, hex gr5 1/2 --- 13 x 3 1/4 washer, pl---b reg pltd 5/16 washer, pl---b reg pltd 1/2 washer, spr lock --- metric pltd m8 washer, spr lock --- metric pltd m10 hose, heater 5/8 key, paral iso r773 10x8x40 nut, hex jam lh pltd 1/4---28 capscrew, ferry head hd pltd 1/4 --- 20 x 1 capscrew, ferry head hd pltd 1/4---20 x 1 1/2 capscrew, ferry head hd pltd 3/8---16 x 1 1/2 nut, hex jam rh pltd 1/4---28 nut, hex jam rh pltd 5/16---24 connector, 45 deg str x jic 1 7/8 x 1 7/8 connector, 90d str x jic 1 1/16 x 1 1/16 adapter, pipe male 7/16 orng x 1/8 washer, nord---lock pl 5/8” compressor & part, dxx102147e
part number
828008---120 828010---035 828012---075 828016---030 829104---100 829108 --- 325 838205---071 838208---112 838808 --- 200 838810 --- 220 842115---062 865210---040 866604---164 867304 --- 100 867304---150 867306---150 868204---164 868205---195 870524 --- 024 870612 --- 012 877202 --- 012 878610--- 100 (III)
quantity
4 12 2 4 1 2 3 2 6 12 1 ft 1 1 1 1 8 1 1 1 1 1 4 1
(III) There is an exchange program whereby a remanufactured compressor unit can be obtained from Sull-
air distributors or the factory at less cost than the owner could repair the unit. For information regarding the unit exchange program, contact your nearest Sullair representative or the Sullair Corporation. The shaft seal is not considered part of the compressor unit in regard to the two year warranty. The normal Sullair parts warranty applies. For shaft seal repairs consult factory.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
55
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3D ENGINE, COMPRESSOR & PARTS -- 260 JOHN DEERE
02250149--- 634R02
56
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3D ENGINE, COMPRESSOR & PARTS -- 260 JOHN DEERE key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
description
key, .375 x .312 x 1.80 class #2 spacer, brake lever 250p vlv, air inlet 2 1/2” black (I) elbow, 90 3/8”tube x 1/4”npt m washer, snubbing vibration mount mount, vibration isolator 185 hose, parcrimp 3/4 x 26 tee, male branch 3/8”tube x 1/4”npt m engine, diesel jd5030tf270 83hp (II) support, compressor 12s 260dpq support, eng frt rh 185h --- 260 jd support, eng frt lh 185h--- 260 jd rod, speed ctl 185dpq jd cylinder, speed air 1 --- 1/16 bore 1’ stk support, low rpm stop 185 jd spring, extension spd ctl 185 jd fan, 18” blwr cw 185h---260 jd valve, eng oil drain m22x1.5 spacer, fan 3.50lg 2.5bc 185h jd clip, spring spd ctl 185---260 support, spd ctl 185---260 jd orifice, .062” x .25m x .25m nptf rod end, spherical rh 5/16 clamp, hose 1/2” compr model, 12 series unit joint, ball female 1/4” l.h. elbow, 90 1/4t pls x 1/4 npt m spacer, air conn vlv 250q
part number
02250060---568 02250064---594 02250088 --- 348 02250099---626 02250125 --- 471 02250125---472 02250126---680 02250136 --- 998 02250145 --- 523 02250146 --- 142 02250146 --- 143 02250146 --- 144 02250148---086 02250148 --- 089 02250148---091 02250148 --- 166 02250148---498 02250148---791 02250148 --- 826 02250152---418 02250152---439 027443 040136 043197 (III)
250011---578 250018---430 250022---950
quantity
1 1 1 1 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
(I) See Section 7.5 for breakdown of the inlet filter. For maintenance on air inlet valve no. 02250088---348,
order repair kit no. 250019---451, or spring replacement kit no. 250029---315.
(II) For in depth coverage of the engine, consult the Engine Operator’s Manual. For maintenance on John
Deere engine oil filter, order replacement filter no. 02250144---815. For maintenance on John Deere engine fuel filter, order replacment filter no. 02250144---814.
(III) There is an exchangeprogram whereby a remanufactured compressor unit can be obtained from Sullair
distributors or the factory at less cost than the owner could repair the unit. For information regarding the unit exchange program, contact your nearest Sullair representative or the Sullair Corporation. The shaft seal is not considered part of the compressor unit in regard to the two year warranty. The normal Sullair parts warranty applies. For shaft seal repairs consult factory. (Continued on page 59)
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
57
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3D ENGINE, COMPRESSOR & PARTS -- 260 JOHN DEERE (continued)
02250149--- 634R02
58
Section 7
ILLUSTRATIONS AND PARTS LIST 7.3D ENGINE, COMPRESSOR & PARTS -- 260 JOHN DEERE (continued) key number
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
description
housing, adapter (250034 --- 402c) bushing, taper wood---sd 1.75 coupling, eng---compr lord 250 (IV) pin, drive coupling 250 jd elbow, 90d 1/4” tube x 1/4”fnpt nut, hex pltd 1/4---20 nut, hex locking 1/4--- 20 nut, hex locking 1/2--- 13 o---ring, neoprene 3 1/2 x 1/8” capscrew, hex 8.8 m8 x 20mm capscrew, hex 8.8 m8 x 120mm capscrew, hex 8.8 m10 x 35mm capscrew, hex 8.8 m16 x 30mm capscrew, hex gr5 1/4---20 x 1 capscrew, hex gr5 1/2---13 x 1 capscrew, hex gr5 1/2 --- 13 x 1 1/4 capscrew, hex gr5 1/2 --- 13 x 3 1/4 capscrew, hex gr5 5/8 --- 11 x 1 1/4 washer, spr lock reg pltd 1/2 washer, spr lock reg pltd 5/8 washer, pl---b reg pltd 5/16 washer, pl---b reg pltd 1/2 washer, spr lock --- metric pltd m8 washer, spr lock --- metric pltd m10 hose, heater 5/8 nut, hex jam lh pltd 1/4---28 plug, pipe 1/8” 3000# stl plt capscrew, ferry head hd pltd 1/4 --- 20 x 1 capscrew, ferry head hd pltd 1/4---20 x 1 1/2 capscrew, ferry head hd pltd 3/8---16 x 1 1/2 nut, hex jam rh pltd 1/4---28 nut, hex jam rh pltd 5/16--- 24 connector, 90d str x jic 1 7/8 x 1 7/8 washer, nord---lock pl 5/8”
part number
quantity
250034--- 403 250034---920 250034 --- 921 250035---041 250041---287 825204---226 825504---145 825508---262 826202---238 828008---020 828008---120 828010---035 828016---030 829104---100 829108---100 829108 --- 125 829108 --- 325 829110 --- 125 837808---125 837810---156 838205---071 838208---112 838808 --- 200 838810 --- 220 842115---062 866604---164 866900---005 867304 --- 100 867304---150 867306---150 868204---164 868205---195 870624 --- 024 878610---100
1 1 1 8 1 1 1 4 1 3 4 12 4 1 14 4 4 4 8 4 3 4 6 12 1 ft 1 1 1 1 8 1 1 1 4
(IV) For maintenance on coupling, order repair kit no. 02250099---930.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
59
Section 7
ILLUSTRATIONS AND PARTS LIST 7.4A AIR INLET AND EXHAUST -- ALL CATERPILLAR MODELS
02250149--- 632R00
60
Section 7
ILLUSTRATIONS AND PARTS LIST 7.4A AIR INLET AND EXHAUST -- ALL CATERPILLAR MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
description
elbow, 90m 5/16 tube x 1/8 npt muffler, exhaust 185---8f cat clamp, muffler 3/8 bent rod filter, air 8 plastic 250q (I) hose, hump red 3 x 3.5 x 4.00lg support, filter compr 185h --- 260dpq support, filter eng’s 185h --- 260dpq hose, air inl unit 185hdpq hose, air inlet 185h --- 260dpq pe filter, air 8 plastic 185h---260 (II) tube, exhaust 185h--- 260dpq pe supt, muffler 185h--- 260dpq pe shield, heat exht 185h --- 260 pe/ca gasket, exhaust 185h --- 260 pe/cat shield, heat fuel tank 185h cat clamp, hose 1 13/16 x 2 3/4 adj. clamp, exhaust 2---1/2 clamp, exhaust 2 clamp, hose 2---13/16 to 3---3/4 clamp, hose 5/8 i.d. nut, hex f pltd 5/16---18 nut, hex locking 3/8---16 nut, hex metric m8 x 1.25 capscr, hex 8.8 m8 x 20mm screw, hex ser washer 5/16 --- 18 x 3/4 washer, pl---b reg pltd 3/8 washer, spr lock --- metric pltd m8 washer, metric---iso7089--- 8 plug, pipe 1/8 3000# stl plt
part number
quantity
02250109---423 02250116---163 02250116---227 02250122 --- 797 02250123---376 02250146 --- 126 02250146 --- 127 02250146---129 02250146 --- 134 02250146 --- 137 02250146 --- 155 02250146 --- 416 02250149 --- 252 02250149 --- 406 02250151---050 40083 43203 44135 250018---550 408300---005 825305---283 825506--- 198 825908---125 828008---020 829705 --- 075 838206---071 838808 --- 200 865408---170 866900---005
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 3 1 1 2 2 1 3 3 1
(I) For maintenance on air filter no. 02250122---797, order replacement element no. 02250122---816. (II) For maintenance on air filter no. 02250146---137, order replacement element no. 02250122---816 .
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
61
Section 7
ILLUSTRATIONS AND PARTS LIST 7.4B AIR INLET AND EXHAUST -- ALL JOHN DEERE MODELS
02250149--- 636R00
62
Section 7
ILLUSTRATIONS AND PARTS LIST 7.4B AIR INLET AND EXHAUST -- ALL JOHN DEERE MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
description
elbow, 90m 5/16 tube x 1/8 npt clamp, muffler 3/8 bent rod filter, air 8 plastic 250q (I) hose, hump red 3 x 3.5 x 4.00lg clp, v---band jd 4024t 185dpq support, filter compr 185h --- 260dpq support, filter eng’s 185h --- 260dpq hose, air inl unit 185hdpq hose, air inlet 185h---260 jd filter, air 8 plastic 185h---260 (II) muffler, exhaust 185h --- 260 jd support, muffler 185h --- 260dpq jd tube, exhaust 185h---260 jd clamp, hose 1 13/16 x 2 3/4 adj. clamp. exhaust 3 clamp, hose 2---13/16 to 3---3/4 clamp, hose 5/8 i.d. nut, hex f pltd 5/16---18 nut, hex locking 3/8---16 capscr, hex 8.8 m8 x 20mm screw, hex ser washer 5/16 --- 18 x 3/4 washer, pl---b reg pltd 3/8 washer, spr lock --- metric pltd m8 washer, metric---iso7089--- 8 plug, pipe 1/8 3000# stl plt
part number
quantity
02250109---423 02250116---227 02250122 --- 797 02250123---376 02250137---896 02250146 --- 126 02250146 --- 127 02250146---129 02250146---131 02250146 --- 137 02250146 --- 159 02250146 --- 429 02250150---280 40083 43713 250018---550 408300---005 825305---283 825506--- 198 828008---020 829705 --- 075 838206---071 838808 --- 200 865408---170 866900---005
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 4 2 8 4 2 8 8 1
(I) For maintenance on air filter no. 02250122---797, order replacement element no. 02250122---816. (II) For maintenance on air filter no. 02250146---137, order replacement element no. 02250122---816 .
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
63
Section 7
ILLUSTRATIONS AND PARTS LIST 7.5 AIR INLET VALVE ASSEMBLY -- 260 JOHN DEERE AND CATERPILLAR
02250088--- 348R01
64
Section 7
ILLUSTRATIONS AND PARTS LIST 7.5 AIR INLET VALVE ASSEMBLY -- 260 JOHN DEERE AND CATERPILLAR key number
1 2 3 4 5 6 7 8 9
description
control vlv sa cast body --- painted iron p/n/alum. disc seal hex ret. cap spring for piston piston piston o---ring viton spring for cont. vlv. retaining ring (split)
part number
quantity
250035---309 250039 --- 716 250039---717 250039---669 250039--- 718 250039---670 250039---671 250039--- 719 250039---720
1 1 1 1 1 1 1 1 1
NOTE 1: For maintenance on inlet valve (185H, 210H John Deere), order repair kit no. 02250109---684. NOTE 2: O---ring no. 826202---238 is used to seal off the inlet valve assembly with the compressor unit. NOTE3: For maintenane on inlet valve (260 John Deere), orderrepair kit no. 250019---451, or springreplacement kit no. 250029---315. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
65
Section 7
ILLUSTRATIONS AND PARTS LIST 7.6 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM -- ALL MODELS
02250149--- 629R00
66
Section 7
ILLUSTRATIONS AND PARTS LIST 7.6 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM -- ALL MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
description
container, radiator fluid recovery element, thermal valve 130 deg f 185q (I) hose, parkrimp 3/4 x 26 hose, hydparkrimp 3/4 x 88 guard, fan 20 (110 --- 130 & 185h) hose, parcrimp 3/4 x 26 hose, parkrimp 3/4 x 66 manifold, thrm by --- pass 185 bdr seal, clip--- on baffles 185 60hp hose, parkrimp 3/4 x 32 cooler, oil 185h---260 t2 hose, radiator lower 185h jd 5030 hose, radiator upper 185h jd hose, radiator upper 185h --- 260 pe/cat baffle, clr/rad lower 185h --- 260dpq supt, clr/rad mid 185h --- 260dpq support, thermo valve 185h --- 260 shroud, rad/oil clr 185h --- 260 cat hose, radiator low 185h --- 260 pe shroud, rad/oil clr 185h --- 260jd radiator, eng. 185h---260 t2 baffle, clr/rad rh 185h---260 baffle, clr/rad lh 185h --- 260dpq baffle, clr/rad top 185h --- 260dpq clamp, hose 1 5/16 to 2 1/4 adj. drainlock, 1/4 clamp, hose 1 13/16 x 2 3/4 adj. adapter, oil filter .970 --- 20 x 3/4 --- 16 elem, fluid filter (ref 250025---523 tab) (II) weatherstrip, 1 thick x 1 wide plug, straight thread 3/4 --- 16 viton clamp, hose 5/8 i.d. clamp, hose 1 13/16 i.d. nut, hex f pltd 1/4---20
part number
quantity
02250083 --- 466 02250104 --- 907 02250107---492 02250107--- 494 02250112 --- 141 02250126---680 02250126---681 02250132 --- 254 02250137 --- 297 02250139---776 02250142---907 02250143 --- 199 02250143---200 02250146 --- 070 02250146 --- 074 02250146 --- 075 02250146 --- 140 02250146 --- 478 02250146 --- 566 02250148 --- 825 02250149--- 985 02250149---990 02250149 --- 991 02250149 --- 992 40014 40061 40083 250025 --- 914 250026 --- 982 250041---174 250042 --- 623 408300---005 408300---009 825304---236
1 1 1 1 1 1 1 1 7 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 2 ft 1 1 1 6
(Continued on page 69)
(I) For maintenance on thermal valve assembly, order erplacement element no. 02250104---907 .
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
67
Section 7
ILLUSTRATIONS AND PARTS LIST 7.6 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM -- ALL MODELS
02250149--- 629R00
68
Section 7
ILLUSTRATIONS AND PARTS LIST 7.6 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM -- ALL MODELS (continued) key number
35 36 37 38 39 40 41 42 43 44 45 46 47 48
description
nut, hex f pltd 5/16---18 o---ring, viton 1 1/2 x 3/32 capscr, hex gr5 3/8---16 x 3/4 screw, hex ser washer 1/4 --- 20 x 3/4 screw, hex ser washer 5/16 --- 18 x 3/4 screw, hex ser washer 5/16 --- 18 x 1 washer, spr lock reg pltd 3/8 washer, pl---b reg pltd 1/4 hose, fuel line 1/4 plug, pipe 1/2 3000# stl plt rdc, str thrd viton 1 x 3/4 conn, str x jic 1 1/16 x 1 1/16 conn, 45 deg str x jic 1 1/16 x 1 1/16 conn, 90d str x jic 1 1/16 x 1 1/16
part number
quantity
825305---283 826502---128 829106---075 829704 --- 075 829705 --- 075 829705 --- 100 837806---094 838204---071 842315---025 866900---020 870016---012 870112--- 012 870512 --- 012 870612--- 012
30 1 2 20 22 8 2 2 4 ft 1 1 3 1 2
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
69
Section 7
ILLUSTRATIONS AND PARTS LIST 7.7A FRAME, RUNNING GEAR & PARTS -- ALL MODELS
02250155--- 667R00
70
Section 7
ILLUSTRATIONS AND PARTS LIST 7.7A FRAME, RUNNING GEAR & PARTS -- ALL MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
description
refl, red 3 truck---lite refl, yellow 3 truck---lite tire, assembly f78---15 (c) anl, can supt lift bail 185q8e supt, lifting bail l&r 185q 8f plate, lifting bail eye 185h --- 260 plug, 4 round black plastic axle, assy 3500# 55tr x 41.5sc jack, hd w/pad 185---425 std drawbar, std pivot 185dpq supt, shipping 185 pivot drbar support, dr--- bar swivel 185q frame, assembly 185h --- 260dpq fender, 15 wheel 185h --- 260dpq baffle, front inlet 185h --- 260dpq insul, frm frt rh 185h---260 insul, frm frt 185h---260 insul, frm rear 185h---260 insul,toolbox rear 185h---260 insul, frm side out r&l 185h insul, clr baff fill 185h insul, toolbox pnl 185h---260 insul, baff frt 185h---260 supt, lifting bail 185h---260 striker, latch frt---bk---sides 185h---260 panel, toolbox w/cut 185h --- 260dpq panel, filter access 185h --- 260 bumper, baf 185h--- 260 dpq tab pnl, frm frt 185h tab w/cutouts pnl, frm lh w/outlet 185h tab pnl, frm rh w/outlet 185h tab pnl, frm rear 185h --- 260 dpq tab bracket, spring hanger rear bracket, spring hanger front eye, 3 lunette demountable kit, hdwr 175/185 running gear weatherstrip, 3/16 x 3/8 screw, #12 wing head
part number
02250052---701 02250052---702 02250101---234 02250101---983 02250105---978 02250105 --- 981 02250106---068 02250107---053 02250116---794 02250133---864 02250133---984 02250141---183 02250146 --- 077 02250146 --- 111 02250146 --- 123 02250147---120 02250147---121 02250147---122 02250147---123 02250147---125 02250147---126 02250147---127 02250147--- 129 02250149---137 02250149---684 02250150 --- 086 02250150--- 087 02250150--- 221 02250151---338 02250151---341 02250151---398 02250151--- 921 250002---070 250002---071 250002---221 250002---968 250022---436 407514
quantity
2 2 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 2 1 1 1 3 1 1 1 1 1 1 1 2 2 1 1 16 ft 2
(Continued on page 73) PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
71
Section 7
ILLUSTRATIONS AND PARTS LIST 7.7A FRAME, RUNNING GEAR & PARTS -- ALL MODELS
02250155--- 667R00
72
Section 7
ILLUSTRATIONS AND PARTS LIST 7.7A FRAME, RUNNING GEAR & PARTS -- ALL MODELS (continued) key number
39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61
description
retainer, screw assy recepticle, clip on nut, hex f pltd 5/16---18 nut, hex locking #8---32 nut, hex locking #10---24 nut, hex locking 5/16---18 nut, hex locking 1/2---13 nut, hex locking 5/8---11 capscr, hex gr5 5/16---18 x 1 capscr, hex gr5 1/2---13 x 1 1/4 capscr, hex gr5 1/2---13 x 1 3/4 capscr, hx gr5 5/8---11 x 4 3/4 screw, hex ser washer 5/16 --- 18 x 3/4 washer, spr lock reg pltd 1/2 washer, pl---b reg pltd 5/16 washer, pl---b reg pltd 1/2 washer, pl---b reg pltd 5/8 washer, pl---b wide pltd 5/16 nut, retainer 5/16---18 .092 capscr, hx gr5 1/2---13 x 1 1/4 plt screw, flt phillips 8--- 32 x 3/4 screw, rnd phillips 10---24 x 3/4 washer, nord---lock pl 1/2
part number
quantity
407515 407516 825305---283 825501---070 825502---083 825505--- 166 825508--- 262 825510--- 329 829105---100 829108--- 125 829108--- 175 829110---475 829705 --- 075 837808---125 838205---071 838208---112 838210---112 838305---071 861405---092 875608---125 875901---075 876002---075 878608---077
2 2 22 4 6 2 8 2 5 22 4 2 56 18 42 20 4 1 13 8 4 6 8
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
73
Section 7
ILLUSTRATIONS AND PARTS LIST 7.7B FRAME LESS RUNNING GEAR & PARTS -- ALL MODELS
02250151--- 314R00
74
Section 7
ILLUSTRATIONS AND PARTS LIST 7.7B FRAME LESS RUNNING GEAR & PARTS -- ALL MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
description
latch, pivot slam pad lck blk grommet, rub 5.75 od 185 60hp hinge, side doors 185h --- 260dpq baffle, canopy frt rh 185h --- 260 baffle, canopy frt lh 185h --- 260 insul, clr baff fill 185h insul, air fltr brkt 185h insul, can door frt 185h---260 insul, can door sides 185h --- 260 insul can roof lh 185h---260 insul, can rear lh 185h---260 insul, baff frt rear l&r 185h insul, baff frt side l&r 185h insul, roof frt 185h---260 insul, roof rear 185h---260 insul, can side rear rh 185h hng, can door frt 185h --- 260dpq support, insullation roof 185h support, insull roof mid 185h pnl,can door sides 185hdpq tab door, can frt 185h --- 260 dpq tab pnl, can rear lh 185h---260 tab pnl, can frt 185h---260dpq tab panel, canopy frt rh 185h --- 260dpq tab pnl, can rear rh 185h --- 260dpq tab pnl, can roof 185h --- 260 dpq tab pnl, can rear bolt --- on 185h tab insul, can door rear 185h--- 260 weatherstrip, 3/16 x 3/8 screw, mach phill #10---24 x 1/2 hook, door latch male ss catch, door latch female ss insert, 1/4---20 blind bumper, rubber 1/2 dia nut, hex f pltd 1/4---20 nut, hex locking #10---24 nut, hex locking 1/4---20
part number
02250107---837 02250138---688 02250146 --- 104 02250146 --- 684 02250146 --- 685 02250147---126 02250147---128 02250147---130 02250147--- 131 02250147---136 02250147---138 02250147---139 02250147---140 02250147--- 141 02250147---142 02250147--- 157 02250149--- 691 02250150---056 02250150--- 057 02250150 --- 225 02250150--- 227 02250151---316 02250151---348 02250151 --- 402 02250151 --- 407 02250151 --- 830 02250151--- 835 02250151 --- 906 250022---436 250025---692 250033---828 250033---829 250034---538 250035---095 825304---236 825502---083 825504---145
quantity
3 1 2 1 1 2 1 1 1 1 1 2 2 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 31 ft 36 3 3 10 5 6 36 12
(Continued on page 77) Note: Consult factory when ordering exterior panels for specific color panel part numbers. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
75
Section 7
ILLUSTRATIONS AND PARTS LIST 7.7B FRAME LESS RUNNING GEAR & PARTS -- ALL MODELS
02250151--- 314R00
76
Section 7
ILLUSTRATIONS AND PARTS LIST 7.7B FRAME LESS RUNNING GEAR & PARTS -- ALL MODELS (continued) key number
38 39 40 41 42
description
capscr, hex gr5 1/4---20 x 1/2 screw, hex ser washer 5/16 --- 18 x 3/4 washer, pl---b reg pltd 1/4 washer, pl---b reg pltd 5/16 nut, retainer 5/16---18 .092
part number
quantity
829104---050 829705 --- 075 838204---071 838205--- 071 861405---092
22 32 34 6 13
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
77
Section 7
ILLUSTRATIONS AND PARTS LIST 7.8 DISCHARGE SYSTEM AND PARTS -- ALL MODELS
02250149--- 638R01
78
Section 7
ILLUSTRATIONS AND PARTS LIST 7.8 DISCHARGE SYSTEM AND PARTS -- ALL MODELS
key number
1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 26 27 28
part number
quantity
02250052---841 02250054---860 02250054---861 02250064---595 02250078 --- 029 02250081---220 02250081---779 02250083 --- 049 02250099--- 052 02250099---626 02250108 --- 700 02250114 --- 091 02250139--- 950 02250139--- 951 02250139---952 02250139---953 02250139---954 02250142 --- 844 02250142 --- 908 02250146 --- 978 02250146---980 02250149 --- 628 02250150 --- 360 40029 40513 241771
2 3 ft 4 ft 1 1 4 1 1 4 1 1 1 5 4 5 5 6 1 1 1 1 1 1 1 1 1
description
insert, nylon tubing 1/4 od tube, nyl .25 od x 040w wht tube, nylon .25 od x .04w black adpt, receiver oil fill 185dpq elem, sep 100---250/100, 185/150 (I) tube, 5/16 od x .040 wall gl, sight oil level 1---1/2 pltd vlv, 1 --- 1/4 npt min press chk (II) insert, nyl tubing 3/8 od elbow, 90 3/8 tube x 1/4 npt m connector, tube oil return 1/4 x 1/4 tube, oil siphon 1/4 od 110 --- 185 tbg, nylon---11 3/8 od red tbg, nylon---11 3/8 od yellow tbg ,nylon--- 11 3/8 od green tbg, nylon--- 11 3/8 od blue tbg, nylon---11 3/8 od orange valve, drain 1 --- 1/16 --- 12unf o --- ring tank, air/oil sep 185h --- 260dpq hose, 1 --- 1/2 --- 18 185h --- 260dpq hose, 1 x 18 w/37deg swvls sa, reg/bd manifold 260dpq (III) sa, reg/bd vlv 185h---210h (IV) plug, o---ring boss sae 1 1/4 clamp, hose 13/16 to 1---1/2 strainer, v---type 300psix1/4 (V)
(Continued on page 81)
(I) For maintenance on separator, order replacement element no. 02250078---031. (II) For maintenance on minimum pressure / check valve no. 02250083---049, order as follows:
repair kit repair kit, cap 1 1/4” repair kit, piston
250026--- 758 02250046---397 02250051---338
1 1 1
(III) For a breakdown of this sub---assembly’s parts, consult Section 7.9B. (IV) For a breakdown of this sub---assembly’s parts, consult Section 7.9A. (V) For maintenance on v---type strainer no. 241771, order repair kit no. 241772.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
79
Section 7
ILLUSTRATIONS AND PARTS LIST 7.8 DISCHARGE SYSTEM AND PARTS -- ALL MODELS
02250149--- 638R01
80
Section 7
ILLUSTRATIONS AND PARTS LIST 7.8 DISCHARGE SYSTEM AND PARTS -- ALL MODELS (continued) key number
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55
description
valve, relief 140psi 1/2 npt conn, 1/4t x 1/4 npt str valve, ball 3/4 service coupling, 3/4 male npt am7 washer, .500 hardened conn, tube---m 1/4 x 1/4 nut, hex locking 1/2---13 capscr, hex gr8 1/2---13 x 1 1/2 capscr, hex gr5 1/2---13 x 1 1/2 screw, hex ser washer 3/8 --- 16 x 1/2 washer, pl---b reg unfin 1/2 washer, spr lock reg pltd 3/8 washer, pl---b reg pltd 3/8 hose, heater 3/4 elbow, 37fl 45m 1 x 1 conn, 37 fl/mpt pltd 1 x 1 nipple, pipe---xs plt 3/4 x cl nipple, pipe---xs plt 1 x cl nipple, pipe---xs plt 1 1/4 x cl nipple, pipe---xs plt 1 1/2 x cl elbow, pipe 90 deg 300# plt 1 bushing, red pltd 1 1/4 x 1 tee, pipe pltd 1 1/2 tee, red pltd 1 x 3/4 x 3/4 conn, 90d str x jic 1 1/16 x 1 1/16 conn, 90d str x jic 1 7/8 x 1 7/8 tee, str thd m---rn viton 1 1/16
part number
quantity
249807 250018---428 250019---865 250031---648 250040---099 810204--- 025 825508---262 828208--- 150 829108--- 150 829706 --- 050 837208---112 837806---094 838206---071 842115---075 860016---100 860116---100 866412---000 866416---000 866420---000 866424---000 867030--- 040 867105---040 868430---060 868604---033 870612--- 012 870624---024 871800---106
1 1 2 2 8 1 3 8 3 2 6 2 2 1 ft 1 1 2 2 1 1 1 1 1 1 1 1 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
81
Section 7
ILLUSTRATIONS AND PARTS LIST 7.9A REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY--ALL 185H & 210H MODELS 7.9B REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY--ALL 260 MODELS
02250150--- 361R00 / 022500149--- 098R00
82
Section 7
ILLUSTRATIONS AND PARTS LIST 7.9A REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY--ALL 185H & 210H MODELS key number
1 2 3 4 5 6 7 8 9 10
description
connector, 5/16”tube x 1/4”npt tee, m run 3/8”tube x 1/4”npt elbow, 90 3/8”tube x 1/4”npt m connector, 3/8 tube x 1/4npt manifold, press reg/bd 150psi 185h valve, pressure regulator (I) connector, 1/4”tube x 1/4”npt tee, pipe 150# plt 1/4 bushing, red pltd 1/2 x 1/4 nipple, pipe---hx pltd 1/4 x 1/4
part number
quantity
02250081---219 02250099---615 02250099---626 02250148---188 02250151 --- 201 250017 --- 280 250018---428 866815---010 867102---010 868504---025
1 1 2 1 1 1 1 1 1 2
(I) For maintenance on pressure regulator valve no. 250017---280, order repair kit no. 250019---453.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
7.9B REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY--ALL 260 MODELS key number
1 2 3 4 5 6
description
conn, 5/16 tube x 1/4 npt tee, m run 3/8 tube x 1/4 npt conn, 3/8tube x 1/2npt manifold, regulator blowdown 185 (I) conn, 3/8 tube x 1/4npt conn, 1/4 tube x 1/4 npt
part number
quantity
02250081---219 02250099--- 615 02250129---957 02250146 --- 046 02250148---188 250018---428
1 1 1 1 1 1
(I) For maintenance on regulator blowdown manifold no. 02250147---046, order repair kit no.
02250147---737.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
83
Section 7
ILLUSTRATIONS AND PARTS LIST 7.10 ELECTRICAL PARTS--ALL MODELS
02250148--- 897R00
84
Section 7
ILLUSTRATIONS AND PARTS LIST 7.10 ELECTRICAL PARTS--ALL MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
description
channel, extruded rubber u .25 w washer, external serrated m10 cable, ground 4---gauge strap battery, grp 31 760 cca hold--- down, battery 11 j --- bolt harn, wrg std light 4---wire 185 lamp, license plate std bracket, license plate lamp switch, engine oil pressure n.o. switch, temp n.c. 250 f, single pole sw, engine hi---temp, 225f nc support, battery hold 185h --- 260dpq sw, eng hi---temp, 225f nc m16 boot, battery terminal adapter, 1/8npt x 1/8jap pt nut, plastic square license plate angle, hold--- down battery cable, batt 0 ga x 15 black fuse, blade type atc 30amp lamp, tail/turn/stop (shock mtg) cable, batt 0 ga x 54 red nut, hex f pltd 5/16---18 nut, hex locking #10---24 screw, hex ser washer 5/16 --- 18 x 3/4 wrap, tie nylon tf4---8 wrap, tie nylon ty 272mx nipple, pipe---xs plt 1/8 x cl tee, pipe 150# plt 1/8 plug, pipe 1/8 3000# stl plt screw, rnd phillips 10---24 x 3/4 ˚
part number
quantity
02250086 --- 448 02250092---169 02250101---258 02250104--- 192 02250104 --- 193 02250119---646 02250119---658 02250119---678 02250130 --- 668 02250133 --- 513 02250138---107 02250146 --- 116 02250150---295 041561 250004---618 250006--- 076 250019--- 104 250019---480 250023--- 996 250028---415 250030---047 825305---283 825502---083 829705 --- 075 843200---025 843201---272 866402---000 866815---005 866900---005 876002---075
1ft 2 1 1 2 1 1 1 1 1 1 1 1 2 1 4 1 1 1 2 1 1 2 4 8 2 1 1 1 2
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
85
Section 7
ILLUSTRATIONS AND PARTS LIST 7.11A FUEL TANK AND PARTS -- ALL CATERPILLAR MODELS
02250148--- 847R01
86
Section 7
ILLUSTRATIONS AND PARTS LIST 7.11A FUEL TANK AND PARTS -- ALL CATERPILLAR MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
description
adpt, 1/2str oring x 1/4 fnpt cap, fuel fill buttress thread tube, fuel return 1/4 jd 185q connector, tube oil return 1/4 x 1/4 filter, ass’y fuel/water sep (I) plug, fuel/water sep 1/2 --- 20 unf conn, tube oil return 5/16x1/4 support, fuel filter mtg. 250 adpt, fuel pick---up 185 60hp tube, fuel pick --- up 185dpq 60hp tank, fuel 34 gallon 185h --- 260dpq strap, fuel tnk hold 185h --- 260 support, fuel fltr 185h --- 260 pe/ca connector, hose 5/16 hose x 1/4 npt clamp, hose 3/8 gasket, fuel gauge neoprene elbow, 5/16 hose x 1/4 npt clamp, hose 1 13/16 i.d. nut, hex f pltd 5/16---18 nut, hex locking 5/16---18 screw, hex ser washer 5/16 --- 18 x 3/4 screw, hex ser washer 5/16 --- 18 x 1 washer, spr lock reg pltd #10 washer, pl---b reg pltd 5/16 hose, fuel line 1/4 hose, fuel line 5/16 plug, pipe 1/8 3000# stl plt screw, rnd phillips 10---24 x 3/4
part number
quantity
02250075--- 714 02250094---791 02250102---573 02250108 --- 700 02250118 --- 494 02250118 --- 524 02250118---809 02250123---128 02250137---526 02250139 --- 885 02250146 --- 112 02250146 --- 113 02250149 --- 381 043258 047235 250004---752 406615 408300---009 825305---283 825505--- 166 829705 --- 075 829705 --- 100 837802---047 838205--- 071 842315---025 842315---031 866900---005 876002---075
4 1 1 1 1 4 1 1 1 1 1 2 1 2 9 1 2 1 10 4 6 4 5 4 4 ft 3 ft 1 5
(I) For maintenance on fuel/water assembly filter no. 02250118---494, order repair kit no. 02250153---904.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
87
Section 7
ILLUSTRATIONS AND PARTS LIST 7.11B FUEL TANK AND PARTS -- ALL JOHN DEERE MODELS
02250149--- 635R01
88
Section 7
ILLUSTRATIONS AND PARTS LIST 7.11B FUEL TANK AND PARTS -- ALL JOHN DEERE MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
description
tube, nyl .25 od x .040w blk adapter, 1/2str oring x 1/4 fnpt cap, fuel fill buttress thread conn, female pipe 1/8---27 npt tube, fuel return 1/4” jd 185q connector, tube oil return 1/4 x 1/4 filter, ass’y fuel/water sep (I) plug, fuel/water sep 1/2 --- 20 unf connector, tube oil return 5/16x1/4 support, fuel filter mtg. 250 tube, fuel pick --- up 185dpq 60hp tank, fuel 34 gallon 185h --- 260dpq strap, fuel tank hold 185h--- 260 adapter, fuel pickup 185 60hp silencer, exhaust 1/8npt tm---18w70 micron connector, hose 5/16”hose x 1/4”npt clamp, hose 3/8” gasket, fuel gauge neoprene conn, 1/4” tube x 1/8” npt elbow, 90 1/4”tube x 1/8”npt elbow, 5/16”hose x 1/4”npt clamp, hose 9/16”id nut, hex f pltd 1/4---20 nut, hex f pltd 5/16---18 nut, hex locking 5/16---18 screw, hex ser washer 1/4 --- 20 x 3/4 screw, hex ser washer 5/16 --- 18 x 3/4 screw, hex ser washer 5/16 --- 18 x 1 washer, spr lock reg pltd #10 washer, pl---b reg pltd 1/4 washer, pl---b reg pltd 5/16 hose, fuel line 1/4 hose, fuel line 5/16 screw, rnd phillips 10 --- 24 x 3/4”
part number
quantity
02250054--- 861 02250075---714 02250094---791 02250097---138 02250102---573 02250108 --- 700 02250118 --- 494 02250118 --- 524 02250118 --- 809 02250123---128 02250139 --- 885 02250146 --- 112 02250146 --- 113 02250152---163 02250152---316 043258 047235 250004---752 250018---427 250018---429 406615 408300---001 825304---236 825305---283 825505---166 829704 --- 075 829705 --- 075 829705 --- 100 837802---047 838204---071 838205---071 842315---025 842315---031 876002 --- 075
2 ft 2 1 1 1 1 1 2 1 1 1 1 2 1 1 1 7 1 1 1 1 1 1 6 4 1 4 2 5 1 4 4 ft 3 ft 5
(I) For maintenance on fuel/water assembly filter no. 02250118---494, order repair kit no. 02250153---904.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
89
Section 7
ILLUSTRATIONS AND PARTS LIST 7.12 CANOPY, ACOUSTICAL PANELS & PARTS -- ALL MODELS
02250151--- 313R00
90
Section 7
ILLUSTRATIONS AND PARTS LIST 7.12 CANOPY, ACOUSTICAL PANELS & PARTS -- ALL MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
description
channel, utility mount 100 --- 250 anl, can supt lift bail 185q8e supt, lifting bail l&r 185q 8f plate, lifting bail eye 185h --- 260 plug, 4 round black plastic frame, assembly 185h --- 260dpq baffle, front inlet 185h --- 260dpq insul, frm frt rh 185h---260 insul, frm frt 185h---260 insul, frm rear 185h---260 insul,toolbox rear 185h---260 insul, frm side out r&l 185h insul, clr baff fill 185h insul, toolbox pnl 185h---260 insul, baff frt 185h---260 supt, lifting bail 185h---260 striker, latch frt---bk---sides185h---260 panel, toolbox w/cut 185h --- 260dpq panel, filter access 185h --- 260 bumper, baf 185h--- 260 dpq tab pnl, frm frt 185h tab w/cutouts pnl, frm lh w/outlet 185h tab pnl, frm rh w/outlet 185h tab pnl, frm rear 210h --- 260 dlq tab weatherstrip, 3/16 x 3/8 screw, #12 wing head retainer, screw assy recepticle, clip on nut, hex f pltd 5/16--- 18 nut, hex locking #10---24 nut, hex locking 5/16---18 nut, hex locking 1/2---13 capscr, hex gr5 5/16---18 x 1 capscr, hex gr5 1/2---13 x 1 1/4 capscr, hex gr5 1/2---13 x 1 3/4 screw, hex ser washer 5/16 --- 18 x 3/4 washer, spr lock reg pltd 1/2 washer, pl---b reg pltd 5/16
part number
02250044 --- 205 02250101---983 02250105---978 02250105 --- 981 02250106---068 02250146--- 077 02250146 --- 123 02250147---120 02250147--- 121 02250147---122 02250147---123 02250147---125 02250147---126 02250147---127 02250147--- 129 02250149---137 02250149---684 02250150 --- 086 02250150--- 087 02250150--- 221 02250151---338 02250151---341 02250151---398 02250155 --- 687 250022---436 407514 407515 407516 825305--- 283 825502---083 825505---166 825508---262 829105---100 829108---125 829108---175 829705 --- 075 837808---125 838205---071
quantity
2 1 2 1 1 1 1 1 1 1 1 2 2 1 1 1 3 1 1 1 1 1 1 1 16 ft 2 2 2 22 6 2 4 5 12 4 50 12 36
(Continued on page 93) PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
91
Section 7
ILLUSTRATIONS AND PARTS LIST 7.12 CANOPY, ACOUSTICAL PANELS & PARTS -- ALL MODELS
02250151--- 313R00
92
Section 7
ILLUSTRATIONS AND PARTS LIST 7.12 CANOPY, ACOUSTICAL PANELS & PARTS -- ALL MODELS (continued) key number
39 40 41 42
description
washer, pl---b reg pltd 1/2 washer, pl---b wide pltd 5/16 nut, retainer 5/16---18 .092 screw, rnd phillips 10---24 x 3/4
part number
quantity
838208---112 838305---071 861405---092 876002---075
8 1 13 6
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
93
Section 7
ILLUSTRATIONS AND PARTS LIST 7.13 INSTRUMENT PANEL & PARTS -- ALL MODELS
02250151--- 313R00
PART NUMBER REFERENCE
MODEL
GAUGE CONFIGURATION
REFER TO SECTION
02250154--335
185H & 210H Caterpillar
Standard
7.14A
02250154 -- 337
260 Caterpillar
Standard
7.14B
02250154 -- 440
185H & 210H
Standard
7.14C
7.14D
John Deere 02250154 -- 442
260 John Deere
Standard
02250154 -- 336
185H & 210H Caterpillar
Full
7.14E
02250154 -- 338
260 Caterpillar
Full
7.14F
02250154 -- 441
185H & 210H John Deere
Full
7.14G
02250154 -- 443
260 John Deere
Full
7.14H
94
Section 7
ILLUSTRATIONS AND PARTS LIST 7.13 INSTRUMENT PANEL & PARTS -- ALL MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
description
hinge, instrument panel door 185q --- 8f scrw, phil pan hd #6---32 x3/8 latch, locking instrument panel door, instrument panel 185 60hp pnl,inst std 185h dpq jd t2 pnl,can frt 185h---260dpq tab weatherstrip, 3/16 x 3/8 screw, mach phill #10---24 x 1/2 bumper, rubber 1/2 dia nut, hex locking #6---32 nut, hex locking #8---32 nut, acorn pltd #8---32 washer, pl---b reg pltd #6 screw, flt phillips 8--- 32 x 3/4 screw, rnd phillips 8---32 x 3/8
part number
quantity
02250103 --- 623 02250112---009 02250125 --- 511 02250138 --- 181 02250147--- 486 02250151--- 348 250022---436 250025--- 692 250035---095 825500--- 102 825501--- 070 825615--- 002 838200---045 875901---075 876001---038
1 4 1 1 1 1 3 ft 8 2 4 1 2 4 1 2
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
95
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14A INSTRUMENT PANEL AND PARTS -- 185H AND 210H CATERPILLAR (STANDARD GAUGE)
02250154--- 335R01
96
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14A INSTRUMENT PANEL AND PARTS -- 185H AND 210H CATERPILLAR (STANDARD GAUGE) key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
description
gauge, pressure air 0--- 300 2” hour --- meter, 12 --- 24vdc 10000hr 2” tee, m run 3/8”tube x 1/4”npt elbow, 90 3/8”tube x 1/4”npt m tube, nylon .375”od x .050w black controller, 185/375 shutdown module (ssam) lense, cliplite led panel, instrument plastic ssam decal, dual pressure 185 --- 375 ssam decal, starting aid 185 --- 375 cat decal, group std panel (ssam) switch, engine ignition 12 --- volt valve, ball 2---way 1/4”npt elbow, 90 f 3/8”tube x 1/4”npt cover, access ssam molded abs harness, wiring 210h --- 260 cat t2 switch, starter push---button screw, tc---f rd hd #6---32 x 1/2 washer, pl---b reg pltd #6 bushing, red pltd 1/4 x 1/8
part number
quantity
02250044---361 02250050 --- 517 02250099---615 02250099---626 02250099 --- 630
1 1 2 2 2 ft
02250126---682 02250129---189 02250129---190 02250130 --- 630 02250130 --- 631 02250131---485 02250132 --- 883 02250136--- 999 02250137---033 02250137 --- 265 02250154 --- 334 040038 835700---050 838200---045 867100--- 005
1 1 1 1 1 1 1 2 1 1 1 1 2 2 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
97
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14B INSTRUMENT PANEL AND PARTS -- 260 CATERPILLAR (STANDARD GAUGE)
02250154--- 337R01
98
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14B INSTRUMENT PANEL AND PARTS -- 260 CATERPILLAR (STANDARD GAUGE) key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
description
gauge, pressure air 0--- 300 2” hour --- meter, 12 --- 24vdc 10000hr 2” elbow, 90 3/8”tube x 1/4”npt m tube,nylon .375”od x .050w black controller, 185/375 shutdown module (ssam) lense, cliplite led panel, instrument plastic ssam decal ,starting aid 185 --- 375 cat decal, group std panel (ssam) switch, engine ignition 12 --- volt tee, male branch 3/8”tube x 1/4”npt m valve, ball 2---way 1/4”npt elbow, 90 f 3/8”tube x 1/4”npt cover, access ssam molded abs harness, wiring 210h --- 260 cat t2 switch, starter push---button screw, tc---f rd hd #6---32 x 1/2 washer, pl---b reg pltd #6 bushing, red pltd 1/4 x 1/8
part number
quantity
02250044---361 02250050 --- 517 02250099---626 02250099 --- 630
1 1 1 1 ft
02250126---682 02250129---189 02250129---190 02250130 --- 631 02250131--- 485 02250132 --- 883 02250136 --- 998 02250136--- 999 02250137---033 02250137 --- 265 02250154 --- 334 040038 835700---050 838200---045 867100--- 005
1 1 1 1 1 1 1 1 1 1 1 1 2 2 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
99
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14C INSTRUMENT PANEL AND PARTS -- 185H AND 210H JOHN DEERE (STANDARD GAUGE)
02250154--- 440R01
100
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14C INSTRUMENT PANEL AND PARTS -- 185H AND 210H JOHN DEERE (STANDARD GAUGE) key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
description
gauge, pressure air 0 --- 30 300 2” hour ----- me meter, 12 ----- 24 24vdc 10000hr 2” tee, m run 3/8”tube x 1/4”npt elbow, 90 3/8”tube x 1/4”npt m tube, nylon .375”od x .050w black lense, cliplite led panel, instrument plastic ssam decal, dual pressure 185 ----- 37 375 ssam decal, starting aid 185 --- 37 375 cat decal, group std panel (ssam) switch, engine ignition 12 --- vo volt valve, ball 2 --- way 1/4”npt elbow, 90 f 3/8”tube x 1/4”npt cover, access ssam molded abs controller, ssam 185 --- 60hp harness, wiring 210h --- 26 260 jd t2 switch, starter push --- button screw, tc --- f rd hd #6 --- 32 x 1/2 washer, pl --- b reg pltd #6 bushing, red pltd 1/4 x 1/8
part number
quantity
02250044 --- 361 02250050 ----- 51 517 02250099 --- 615 02250099 --- 626 02250099 --- 63 630 02250129 --- 189 02250129 --- 190 02250130 ----- 63 630 02250130 --- 63 631 02250131 --- 485 02250132 ----- 88 883 02250136 --- 999 02250137 --- 033 02250137 --- 26 265 02250139 --- 296 02250154 --- 43 439 040038 835700 --- 050 838200 --- 045 867100 --- 005
1 1 2 2 2 ft 1 1 1 1 1 1 2 1 1 1 1 1 2 2 1
PLEASE NOTE: WHEN ORDERING PARTS, PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR COMPRESSOR
101
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14D INSTRUMENT PANEL AND PARTS -- 260 JOHN DEERE (STANDARD GAUGE)
02250154--- 442R01
102
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14D INSTRUMENT PANEL AND PARTS -- 260 JOHN DEERE (STANDARD GAUGE) key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
description
gauge, pressure air 0 --- 30 300 2” hour ----- me meter, 12 ----- 24 24vdc 10000hr 2” elbow, 90 3/8”tube x 1/4”npt m tube, nylon .375”od x .050w black lense, cliplite led panel, instrument plastic ssam decal, starting aid 185 --- 37 375 cat decal, group std panel (ssam) switch, engine ignition 12 --- vo volt tee, male branch 3/8”tube x 1/4”npt m valve, ball 2 --- way 1/4”npt elbow, 90 f 3/8”tube x 1/4”npt cover, access ssam molded abs controller, ssam 185 --- 60hp harness, wiring 210h --- 26 260 jd t2 switch, starter push --- button screw, tc --- f rd hd #6 --- 32 x 1/2 washer, pl --- b reg pltd #6 bushing, red pltd 1/4 x 1/8
part number
quantity
02250044 --- 361 02250050 ----- 51 517 02250099 --- 626 02250099 --- 63 630 02250129 --- 189 02250129 --- 190 02250130 --- 63 631 02250131 --- 485 02250132 --- 88 883 02250136 ----- 99 998 02250136 --- 999 02250137 --- 033 02250137 --- 26 265 02250139 --- 296 02250154 --- 43 439 040038 835700 --- 050 838200 --- 045 867100 --- 005
1 1 1 1 ft 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1
PLEASE NOTE: WHEN ORDERING PARTS, PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR COMPRESSOR
103
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14E INSTRUMENT PANEL AND PARTS -- 185H AND 210H CATERPILLAR (FULL GAUGE)
02250154--- 336R02
104
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14E INSTRUMENT PANEL AND PARTS -- 185H AND 210H CATERPILLAR (FULL GAUGE) key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
description
gauge, pressure air 0--- 300 2” gauge, volt --- meter 12 volt 2” gauge, pressure mech 0 --- 100psi 2” hour --- meter, 12 --- 24vdc 10000hr 2” tee, m run 3/8”tube x 1/4”npt elbow, 90 3/8”tube x 1/4”npt m tube, nylon .375”od x .050w black gauge, temp mech 48” 140 --- 300$sf controller, 185/375 shutdown module (ssam) lense, cliplite led panel, instrument plastic ssam decal, dual pressure 185 --- 375 ssam decal, starting aid 185 --- 375 cat harness, voltmeter 125 --- 425 jd/cat decal, group full gauge (ssam) switch, engine ignition 12 --- volt valve, ball 2---way 1/4”npt elbow, 90 f 3/8”tube x 1/4”npt cover, access ssam molded abs gauge, temp mech 8ft 140 --- 300$sf harness, wiring 210h --- 260 cat t2 adapter, red 1/2 --- 14 npt murphy thrd switch, starter push---button screw, tc---f rd hd #6---32 x 1/2 washer, pl---b reg pltd #6 bushing, red pltd 1/4 x 1/8
part number
quantity
02250044---361 02250044---366 02250050 --- 516 02250050 --- 517 02250099---615 02250099---626 02250099 --- 630 02250102 --- 619
1 1 1 1 2 2 2 ft 1
02250126---682 02250129---189 02250129--- 190 02250130 --- 630 02250130 --- 631 02250130 --- 635 02250131 --- 486 02250132 --- 883 02250136--- 999 02250137---033 02250137 --- 265 02250143 --- 278 02250154 --- 334 02250155 --- 384 040038 835700---050 838200---045 867100--- 005
1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 2 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
105
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14F INSTRUMENT PANEL AND PARTS -- 260 CATERPILLAR (FULL GAUGE)
02250154--- 338R02
106
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14F INSTRUMENT PANEL AND PARTS -- 260 CATERPILLAR (FULL GAUGE) key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
description
gauge, pressure air 0--- 300 2” gauge, volt --- meter 12 volt 2” gauge, pressure mech 0 --- 100psi 2” hour --- meter, 12 --- 24vdc 10000hr 2” elbow, 90 3/8”tube x 1/4”npt m tube, nylon .375”od x .050w black gauge, temp mech 48” 140---300 f controller, 185/375 shutdown module (ssam) lense, cliplite led panel, instrument plastic ssam decal, starting aid 185 --- 375 cat harness, voltmeter 125 --- 425 jd/cat decal, group full gauge (ssam) switch, engine ignition 12 --- volt tee, male branch 3/8”tube x 1/4”npt m valve, ball 2---way 1/4”npt elbow, 90 f 3/8”tube x 1/4”npt cover, access ssam molded abs gauge, temp mech 8ft 140---300 f harness, wiring 210h --- 260 cat t2 adapter, red 1/2 --- 14 npt murphy thrd switch, starter push---button screw, tc---f rd hd #6---32 x 1/2 washer, pl---b reg pltd #6 bushing, red pltd 1/4 x 1/8 ˚
˚
part number
quantity
02250044---361 02250044---366 02250050 --- 516 02250050 --- 517 02250099---626 02250099 --- 630 02250102---619
1 1 1 1 1 1 ft 1
02250126---682 02250129---189 02250129--- 190 02250130 --- 631 02250130 --- 635 02250131 --- 486 02250132 --- 883 02250136 --- 998 02250136--- 999 02250137---033 02250137 --- 265 02250143---278 02250154 --- 334 02250155 --- 384 040038 835700---050 838200---045 867100--- 005
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
107
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14G INSTRUMENT PANEL AND PARTS -- 185H AND 210H JOHN DEERE (FULL GAUGE)
02250154--- 441R02
108
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14G INSTRUMENT PANEL AND PARTS -- 185H AND 210H JOHN DEERE (FULL GAUGE) key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
description
gauge, pressure air 0--- 300 2” gauge, volt --- meter 12 volt 2” gauge, pressure mech 0 --- 100psi 2” hour --- meter, 12 --- 24vdc 10000hr 2” tee,m run 3/8”tube x 1/4”npt elbow, 90 3/8”tube x 1/4”npt m tube, nylon .375”od x .050w black gauge, temp mech 48” 140---300 f lense, cliplite led panel, instrument plastic ssam decal, dual pressure 185 --- 375 ssam decal, starting aid 185 --- 375 cat harness, voltmeter 125 --- 425 jd/cat decal, group full gauge (ssam) switch, engine ignition 12 --- volt valve, ball 2---way 1/4”npt elbow, 90 f 3/8”tube x 1/4”npt cover, access ssam molded abs controller, ssam 185---60hp gauge, temp mech 8ft 140---300 f harness, wiring 210h--- 260 jd t2 adapter, red 1/2 --- 14 npt murphy thrd switch, starter push---button screw, tc---f rd hd #6---32 x 1/2 washer, pl---b reg pltd #6 bushing, red pltd 1/4 x 1/8 ˚
˚
part number
quantity
02250044---361 02250044---366 02250050 --- 516 02250050 --- 517 02250099---615 02250099---626 02250099 --- 630 02250102---619 02250129---189 02250129--- 190 02250130 --- 630 02250130 --- 631 02250130 --- 635 02250131 --- 486 02250132 --- 883 02250136--- 999 02250137---033 02250137 --- 265 02250139---296 02250143---278 02250154 --- 439 02250155 --- 384 040038 835700---050 838200---045 867100--- 005
1 1 1 1 2 2 2 ft 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 2 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
109
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14H INSTRUMENT PANEL AND PARTS -- 260 JOHN DEERE (FULL GAUGE)
02250154--- 443R02
110
Section 7
ILLUSTRATIONS AND PARTS LIST 7.14H INSTRUMENT PANEL AND PARTS -- 260 JOHN DEERE (FULL GAUGE) key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
description
gauge, pressure air 0--- 300 2” gauge, volt --- meter 12 volt 2” gauge, pressure mech 0 --- 100psi 2” hour --- meter, 12 --- 24vdc 10000hr 2” elbow, 90 3/8”tube x 1/4”npt m tube, nylon .375”od x .050w black gauge, temp mech 48” 140---300 f lense, cliplite led panel, instrument plastic ssam decal, starting aid 185 --- 375 cat harness, voltmeter 125 --- 425 jd/cat decal, group full gauge (ssam) switch, engine ignition 12 --- volt tee, male branch 3/8”tube x 1/4”npt m valve, ball 2---way 1/4”npt elbow, 90 f 3/8”tube x 1/4”npt cover, access ssam molded abs controller, ssam 185---60hp gauge, temp mech 8ft 140---300 f harness, wiring 210h--- 260 jd t2 adapter, red 1/2 --- 14 npt murphy thrd switch, starter push---button screw, tc---f rd hd #6---32 x 1/2 washer, pl---b reg pltd #6 bushing, red pltd 1/4 x 1/8 ˚
˚
part number
quantity
02250044---361 02250044---366 02250050 --- 516 02250050 --- 517 02250099---626 02250099 --- 630 02250102---619 02250129---189 02250129---190 02250130 --- 631 02250130 --- 635 02250131 --- 486 02250132 --- 883 02250136 --- 998 02250136--- 999 02250137---033 02250137 --- 265 02250139---296 02250143---278 02250154 --- 439 02250155 --- 384 040038 835700---050 838200---045 867100--- 005
1 1 1 1 1 1 ft 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
111
Section 7
ILLUSTRATIONS AND PARTS LIST 7.15 SINGLE HOSE REEL OPTION -- ALL MODELS
02250151--- 192R01
112
Section 7
ILLUSTRATIONS AND PARTS LIST 7.15 SINGLE HOSE REEL OPTION -- ALL MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
description
support, manifold single hose reel hose, medium pressure 1”jic x 32”long draw---bar, long pivot 185dpq reel, hose 100ft 3/4”hose x 3/4”npt hose, assembly 5/8”id x 18”long valve, air velocity flow 3/4”npt adapter, swivel 90deg 3/4”h x 3/4”p support, service manifold oiler, 1qt microfog nogren u --- bolt, hose reel mount 110 --- 250 valve, ball 3/4” service coupling, 3/4” male npt am7 lubricator, cf 1 pt 1” 30cf oiler, line 2---quart 1” npt nut, hex f pltd 1/4---20 nut, hex f pltd 5/16---18 nut, hex locking 3/8---16 capscrew, hex gr5 3/8---16 x 1 screw, hex ser washer 5/16 --- 18 x 3/4 washer, pl---b reg pltd 1/4 washer, pl---b reg pltd 5/16 washer, pl---b reg pltd 3/8 connector, 37 fl/mpt pltd 1 x 1 elbow, 37fl 90m 1 x 1 nipple, pipe---xs plt 3/4 x cl nipple, pipe---xs plt 1 x cl nipple, pipe---xs plt 1 x 2 nipple,pipe---xs plt 1 x 7 plug, pipe 1” 3000# stl plt elbow, pipe 90 deg 300# plt 3/4” elbow, pipe 90 deg 300# plt 1” bushing, red pltd 1 x 3/4 coupling, pipe 1 300# plt union, pipe---brs seat 1 300# plt u---bolt, 1/4” x 1” pipe pltd u---bolt, 5/16” x 1 1/4” pipe pltd tee, pipe pltd 1
part number
quantity
02250054 --- 447 02250054 --- 969 02250136---247 040170 040885 043480 045241 250002---145 250005---016 250008 --- 322 250019---865 250031---648 251315 405403 825304---236 825305---283 825506---198 829106---100 829705 --- 075 838204---071 838205---071 838206---071 860116---100 860216---100 866412---000 866416---000 866416---020 866416---070 866900---040 867030---030 867030---040 867104---030 867430---040 868030---040 868304---100 868305---125 868430---040
1 1 1 1 1 1 1 1 1 2 2 2 1 1 4 4 8 4 2 4 4 8 1 1 4 5 1 1 1 1 1 2 1 1 2 1 2
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
113
Section 7
ILLUSTRATIONS AND PARTS LIST 7.16 DUAL HOSE REEL OPTION -- ALL MODELS
02250141--- 690R02
114
Section 7
ILLUSTRATIONS AND PARTS LIST 7.16 DUAL HOSE REEL OPTION -- ALL MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
description
support, hose reel manifold 110 --- 250 support, hose reel 110 --- 250 portables hose, medium pressure 1”jic x 32”long draw---bar, long pivot 185dpq support, dr---bar swivel 185q reel, hose 100ft 3/4”hose x 3/4”npt hose, assembly 5/8”id x 18”long valve, air velocity flow 3/4”npt adapter, swivel 90deg 3/4”h x 3/4”p support, service manifold oiler, 1qt microfog nogren u --- bolt, hose reel mount 110 --- 250 valve, ball 3/4” service coupling, 3/4” male npt am7 lubricator, cf 1 pt 1” 30cf oiler, line 2---quart 1” npt nut, hex f pltd 1/4---20 nut, hex f pltd 5/16---18 nut, hex locking 3/8---16 capscrew, hex gr5 3/8---16 x 1 screw, hex ser washer 5/16 --- 18 x 3/4 washer, pl---b reg pltd 1/4 washer, pl---b reg pltd 5/16 washer, pl---b reg pltd 3/8 connector, 37 fl/mpt pltd 1 x 1 elbow, 37fl 90m 1 x 1 nipple, pipe---xs plt 3/4 x cl nipple, pipe---xs plt 1 x cl nipple, pipe---xs plt 1 x 2 plug, pipe 1” 3000# stl plt elbow, pipe 90 deg 300# plt 3/4” bushing, red pltd 1 x 3/4 coupling, pipe 1 300# plt cross, pipe 1” plt union, pipe---brs seat 1 300# plt u---bolt, 1/4” x 1” pipe pltd u---bolt, 5/16” x 1 1/4” pipe pltd tee, pipe pltd 1 coupling, pipe 1 150# plt
part number
quantity
02250048 --- 573 02250048 --- 574 02250054 --- 969 02250136---247 02250141---183 040170 040885 043480 045241 250002---145 250005---016 250008 --- 322 250019---865 250031---648 251315 405403 825304---236 825305---283 825506---198 829106---100 829705 --- 075 838204---071 838205---071 838206---071 860116---100 860216---100 866412---000 866416---000 866416---020 866900---040 867030---030 867104---030 867430---040 867830---040 868030---040 868304---100 868305---125 868430---040 869015---040
1 1 2 1 1 2 2 2 2 1 1 2 3 3 1 1 4 4 12 8 2 4 4 12 1 1 7 5 1 1 2 3 1 1 1 2 1 1 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
115
Section 7
ILLUSTRATIONS AND PARTS LIST 7.17 ONE PINT OILER OPTION -- ALL MODELS
02250151--- 189R00
116
Section 7
ILLUSTRATIONS AND PARTS LIST 7.17 ONE PINT OILER OPTION -- ALL MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
description
support, service manifold valve, ball 3/4 service coupling, 3/4 male npt am7 lubricator, cf 1 pt 1 30cf nut, hex f pltd 1/4---20 nut, hex f pltd 5/16---18 screw, hex ser washer 5/16 --- 18 x 3/4 washer, pl---b reg pltd 1/4 washer, pl---b reg pltd 5/16 nipple, pipe---xs plt 3/4 x cl nipple, pipe---xs plt 1 x cl nipple, pipe---xs plt 1 x 2 nipple, pipe---xs plt 1 x 4 nipple, pipe---xs plt 1 x 7 elbow, pipe 90 deg 300# plt 1 bushing, red pltd 1 x 3/4 union, pipe---brs seat 1 300# plt elbow, red 1 x 3/4 plt u---bolt, 1/4 x 1 pipe pltd tee, pipe pltd 1
part number
quantity
250002---145 250019---865 250031---648 251315 825304---236 825305---283 829705 --- 075 838204---071 838205---071 866412---000 866416---000 866416---020 866416---040 866416---070 867030---040 867104---030 868030---040 868104---075 868304---100 868430---040
1 2 2 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
117
Section 7
ILLUSTRATIONS AND PARTS LIST 7.18 ONE QUART OILER / MOISTURE SEPARATOR OPTIONS --ALL MODELS
02250151--- 191R00
118
Section 7
ILLUSTRATIONS AND PARTS LIST 7.18 ONE QUART OILER / MOISTURE SEPARATOR OPTIONS --ALL MODELS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
description
separator, moisture support, service manifold oiler, 1qt microfog nogren valve, ball 3/4 service coupling, 3/4 male npt am7 nut, hex f pltd 1/4---20 nut, hex f pltd 5/16---18 screw, hex ser washer 5/16 --- 18 x 3/4 washer, pl---b reg pltd 1/4 washer, pl---b reg pltd 5/16 nipple, pipe---xs plt 3/4 x cl nipple, pipe---xs plt 1 x cl nipple, pipe---xs plt 1 x 2 nipple, pipe---xs plt 1 x 4 nipple, pipe---xs plt 1 x 7 elbow, pipe 90 deg 300# plt 1 bushing, red pltd 1 x 3/4 union, pipe---brs seat 1 300# plt elbow, red 1 x 3/4 plt u---bolt, 1/4 x 1 pipe pltd tee, pipe pltd 1
part number
quantity
02250127---121 250002---145 250005---016 250019--- 865 250031---648 825304---236 825305---283 829705 --- 075 838204---071 838205--- 071 866412---000 866416---000 866416---020 866416---040 866416---070 867030---040 867104---030 868030---040 868104---075 868304---100 868430---040
1 1 1 2 2 2 2 2 2 2 2 3 1 1 1 1 1 1 1 1 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
119
Section 7
ILLUSTRATIONS AND PARTS LIST 7.19 CANADIAN TAIL / CLEARANCE LIGHTS -- ALL MODELS
02250150--- 874R00
120
Section 7
ILLUSTRATIONS AND PARTS LIST 7.19 CANADIAN TAIL / CLEARANCE LIGHTS -- ALL MODELS key number
1 2 3 4 5 6 7 8 9 10
description
nameplate, vin can dual lang cover, vin canada harness, wirinr clearance lts reflector, 3” dia adhs mtg red reflector, 3” dia yellow lamp, side clearance red lamp, side clearance yellow holder, lamp side clearance blk nut, hex locking #10 --- 24 screw, rnd phillips 10 --- 24 24 x 3/4”
part number
quantity
02250101 --- 371 02250101 --- 403 02250122 --- 197 02250129 --- 278 02250129 --- 279 02250139 --- 569 02250139 --- 570 02250139 --- 57 571 825502 --- 083 876002 --- 07 075
1 1 1 4 2 2 2 4 8 8
PLEASE NOTE: WHEN ORDERING PARTS, PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR COMPRESSOR
121
Section 7
ILLUSTRATIONS AND PARTS LIST 7.20 DECALS
122
Section 7
ILLUSTRATIONS AND PARTS LIST 7.20 DECALS key number
1 2 3 4 5 6 7 8
description
sign, caution towing 55mph sign, warning compressor fluid fill cap sign, warning crush/sever decal, side door t---latch sign, warning sever fan port decal, doors closed decal, PE designation decal, earth ground
part number
quantity
250005---578 049685 408919 02250136---670 049965 250038--- 030 02250075---540 02250075---046
1 1 1 2 2 4 1 3
(Continued on page 125) NOTE: SEE SECTION 7.21 FOR MOST DECAL LOCATIONS PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
123
Section 7
ILLUSTRATIONS AND PARTS LIST 7.20 DECALS
124
Section 7
ILLUSTRATIONS AND PARTS LIST 7.20 DECALS (continued) key number
9 10 11 12 13 14 15
description
decal, warning 100/1600 (I) decal, warning tougue heavy sign, warning hot surfaces decal, warning pressurized clg sys sign, warning sever belt drive decal, diesel fuel decal, overfill
part number
quantity
250028 --- 258 02250077---929 407408 02250051 --- 826 049964 040248 02250142---530
1 1 2 1 1 1 2
(Continued on page 127)
(I) OSHA guidelines are superceded by any Federal, State or Local regulations whenever applicable.
NOTE: SEE SECTION 7.21 FOR MOST DECAL LOCATIONS PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
125
Section 7
ILLUSTRATIONS AND PARTS LIST 7.20 DECALS
126
Section 7
ILLUSTRATIONS AND PARTS LIST 7.20 DECALS (continued) key number
16A 16B 17A
description
decal, rated speed 2600/1800 RPM decal, rated speed 2500/1800 RPM decal, “185H side decal, 185H front decal, 210H side decal, 210H front decal,260 side decal, 260 front decal, noise emission control (U.S. compressors only) decal, operation start/stop decal, warning proposition 65 (U.S. compressors only) decal, Sullair logo --- black S
17B
S
17C 18 19 20 21
S
part number
quantity
02250149 --- 907 02250149 --- 908 02250150---039 02250109---740 02250150---040 02250136---964 02250150---041 02250127---644
1 1 2 2 2 2 2 2
049463 02250133---511
1 1
02250118--- 638 02250059---054
1 2
(Continued on page 129) NOTE: SEE SECTION 7.21 FOR MOST DECAL LOCATIONS PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
127
Section 7
ILLUSTRATIONS AND PARTS LIST 7.20 DECALS
128
Section 7
ILLUSTRATIONS AND PARTS LIST 7.20 DECALS (continued) key number
22A 22B 23 24 25 26 27
description
decal, maintenance 210H ----- 26 260 Cat decal, maintenance 210H --- 26 260 JD reflector, red reflector, amber decal, water drain decal, Sullair AWF decal, axle lub instructions
part number
02250154 ----- 37 3747 02250154 ----- 34 348 040103 250034 --- 319 040345 250032 --- 902 250042 --- 543
quantity
1 1 2 2 2 1 2
(Continued on page on page 131) 131) NOTE: SEE SECTION SEE SECTION 7.21 FOR 7.21 FOR MOST DECAL LOCATIONS PLEASE NOTE: WHEN ORDERING PARTS, PARTS, INDICATE SERIAL SERIAL NUMBER OF COMPRESSOR
129
Section 7
ILLUSTRATIONS AND PARTS LIST 7.20 DECALS
130
Section 7
ILLUSTRATIONS AND PARTS LIST 7.20 DECALS (continued) key number
28 29 30 31 32 33 34 35 36 37 38
description
decal, Need An Air Tool decal, Sullair AWF decal, ISO 9001 decal, drawbar installation decal, wiring diagram nameplate, Sullair serial no. (II) tag, rpm (II) seal, wire (II) nut, hex locking (II) rivet, pop (II) screw (II)
part number
quantity
02250140 --- 925 02250097 --- 455 02250057 --- 624 02250142 --- 050 02250144 --- 447 02250108 ----- 07 078 250025 --- 43 437 250026 --- 96 962 825501 --- 07 070 843102 --- 03 038 875901 --- 07 075
1 1 1 1 1 1 1 1 4 1 4
(II) Not shown.
NOTE: SEE SECTION SEE SECTION 7.21 FOR 7.21 FOR MOST DECAL LOCATIONS PLEASE NOTE: WHEN ORDERING PARTS, PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR COMPRESSOR
131
Section 7
ILLUSTRATIONS AND PARTS LIST 7.21 DECAL LOCATIONS
02250149--- 633R01
132
Section 7
ILLUSTRATIONS AND PARTS LIST 7.21 DECAL LOCATIONS key number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
description
decal,iso 9001 blk 3.44x5.75 decal,”sullair” 2.50 x 20.0 decal,earth ground decal,pe designation decal, warning tongue heavy 100 --- 375 decal,5 year warranty nameplate, sullair serial no. 185q --- 8f decal,”185h sullair” front decal,lead warning proposition 65 decal,”260 sullair” front decal, operator procedure start stop 185 decal, warning side door t --- latch decal,”210h sullair” front decal,”need an air tool?” sml decal,drwbr instl 185q pe std decal,caution --- do not overfill decal, wiring diagram 375 cat tier ii w/ssam decal, wiring diagram 185 pe/cat/jd tier ii decal,rated 2600 odle 1800 (I) decal,rated 2500 idle 1800 (II) decal,”185h” 2.5 tall black decal,”210h” 2.5” tall black decal,”260” 2.5” tall black decal,maintenance 210h---260 catterpillar decal,maintenance 210h---260 john deere reflector, red 1.68 x 4.25 decal diesel fuel decal,noise emission control reflector, amber 1.68 x 4.25 rivet, pop 1/8 x 3/8
part number
quantity
02250057--- 624 02250059---054 02250075---046 02250075---540 02250077 --- 929 02250097---455 02250108 --- 078 02250109--- 781 02250118 --- 638 02250127---644 02250133---511 02250136 --- 670 02250136---964 02250140---925 02250142---050 02250142 --- 530 02250144---396 02250144---447 02250149 --- 907 02250149 --- 908 02250150---039 02250150---040 02250150---041 02250154---347 02250154---348 040103 040248 049463 250034--- 319 843102---038
1 3 2 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 2 2 2 1 1 4 1 1 2 4
(I) For 185H and 210 models. (II) For 260 models.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
133
Section 7
ILLUSTRATIONS AND PARTS LIST 7.22 DRAWBAR INSTALLATION -- ALL MODELS
02250141--- 874R00
134
Section 7
ILLUSTRATIONS AND PARTS LIST 7.22 DRAWBAR INSTALLATION -- ALL MODELS key number
1 2 3
description
washer, pl---b reg plted 1/2” (I) capscr, hx gr5 1/2---13 x 1 1/4 plt (I) washer, nord---lock pl 1/2” (I)
part number
quantity
838208 --- 112 875608 --- 125 878608 --- 077
8 8 8
(I) These items shipped as loose parts.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
135
