august 2013 - pemco, s.a. (manual del usuario y lista de rep… · i.ii manual organization anyone...

User ManualPortable Air Compressors2013

AUGUST

210 cfmJohn Deere Diesel Engine

Wheel-Mounted

DC210PHJD DE210PHJD DF210PHJD

Document: 05018730 0160 / 01 Issued: August 13, 2013

DOCUMENT INFORMATION:© Sullivan-Palatek, Inc. ALL RIGHTS RESERVEDPart Number: 05018730 0160 Revision: 01

CONTACT INFORMATION:Sullivan-Palatek, Inc. 1201 West US Highway 20 Michigan City, IN 46360 Tel: 219-874-2497 Fax: 219-872-5043 Toll Free: 800-438-6203 Website: www.sullivanpalatek.com

RECORD KEEPING:Record the model and serial number of the compressor for future reference when contacting the factory for service or parts.

Model Number:

Serial Number:

DISCLAIMER:Although this manual is checked for conformity with the machines described, we cannot guarantee that all errors will be excluded. Necessary corrections will be made in future editions of this manual. This manual is subject to change without notice.

REVISION HISTORY:# DATE SECTION(S) DESCRIPTION

00 2013-05-01 --- Released for publication

01 2013-13-08 8.4 Updated RECOMMENDED SPARE PARTS LIST

8.10 Updated COMPRESSOR ASSEMBLY 00717488 0087 to (REV 05)

8.11 Replaced INLET VALVE ASSEMBLY 00717985 0002 with 00717985 0045 (REV 00)

8.13 Replaced RECEIVER ASSEMBLY 00717884 0150 with 00717884 0159 (REV 00)

8.14 Added SERVICE VALVE OUT 00717885 0005 (REV 00)

8.15 Added DISCHARGE HOSE 00717886 0003 (REV 00)

8.16 Added CONTROL TUBING 00717887 0002 (REV 00)

8.20 Replaced INSTRUMENT PANEL ASSEMBLY 00717680 0075 with 00717680 0132 (REV 00)

8.21 Added 8.21.1 ENCLOSURE 03903168 0093 (REV C)

WARRANTY Portable Compressors

Sullivan-Palatek, Inc. warrants its new portable air compressor products to be free from defects in material and workmanship, subject to the following provisions:Warranty Registration: To validate the warranty for each product the purchaser shall complete and return the warranty registration form within 30 days of delivery to the first user or rental.Warranty Period: The warranty period for applicable Sullivan-Palatek products is as follows (subject to the Exclusions and Limitations noted below):Air ends on new machines – stator and rotor assembly: Single stage compressor models: the first to expire; 42 months from shipment by Sullivan-Palatek or 36 months from delivery to the first user. Two stage high pressure compressor models: the first to expire; 30 months from shipment by Sullivan-Palatek or 24 months from delivery to the first user. Remainder of new portable air compressor machines: the first to expire; 18 months from shipment by Sullivan-Palatek or 12 months from delivery to the first user.Parts, accessories and attachments sold separately from machines, excluding warranty replacement parts and hand tools: the first to expire; 6 months from shipment by Sullivan-Palatek or 3 months from delivery to the first user.Warranty replacement parts: remainder of the original warranty period of the replaced part.Sullivan-Palatek’s Obligations: Sullivan-Palatek’s exclusive obligations with respect to breach of warranty are (i) to repair or replace (at Sullivan-Palatek option and subject to return of defective parts) any defective part, (ii) to pay the reasonable cost of making the repair or reinstalling the replacement part and (iii) only for air compressors having two or more axles, to reimburse up to four hours travel labor at the travel reimbursement rate and mileage at the mileage reimbursement rate for up to 200 miles (100 miles travel radius) per event to make repairs.Customer’s Responsibility: As a condition to Sullivan-Palatek’s obligations under this warranty, Customer shall (i) give Sullivan-Palatek written notice of any warrantable failure of any Sullivan-Palatek product within the applicable warranty period, (ii) make the product available for repair at a Sullivan-Palatek authorized repair facility, (iii) pay all costs of returning failed parts to Sullivan-Palatek, (iv) pay shipping costs for replacement parts, (v) pay reasonable travel expenses for field repairs performed at customer’s request and (vi) pay the costs of investigating performance complaints that are not covered by this warranty.Exclusions and Limitations: Air end seals are not warranted. Engines, tires and batteries are not warranted by Sullivan-Palatek and are warranted only by the manufacturers of these components. Sullivan-Palatek has no obligation for product failures or defects resulting from overloading, misuse, neglect, accident, failure to comply with Sullivan-Palatek’s product manual or failure to install product improvements provided by Sullivan-Palatek . Use on a product of attachments, accessories or service parts not supplied or recommended by Sullivan-Palatek may, at Sullivan-Palatek’s option, void the warranty of that product. Sullivan-Palatek has no obligation to pay costs of returning defective parts to Sullivan-Palatek or shipping replacement parts to customer.THIS WARRANTY IS SULLIVAN-PALATEK’S ONLY WARRANTY OF ITS PORTABLE AIR COMPRESSOR PRODUCTS AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED. ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED. SULLIVAN-PALATEK HAS NO OBLIGATION UNDER THIS WARRANTY OR OTHERWISE (REGARDLESS OF THE FORM OF ACTION) FOR SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES, INCLUDING WITHOUT LIMITATION LOST PROFITS OR LOST INCOME.This warranty applies to all Sullivan-Palatek portable air compressors shipped after April 1, 2011 unless expressly superseded by a later warranty. In the event of any conflict between this warranty and earlier warranty statements, the terms of this warranty will apply.

CALIFORNIAPROPOSITION 65 WARNING

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth

defects and other reproductive harm.

V

I AbOUT THIS MANUAL

I.I SAFETY INSTRUCTIONSInstructions for the safe operation and maintenance of the Sullivan-Palatek air compressor are located throughout this manual. These instructions are presented with different labels according to the level of risk involved, described as follows.

WARNING! is used when death or personal injury could occur if the instruction is not followed.

CAUTION! is used when damage to property could occur if the instruction is not followed.

NOTE! is used to inform the reader of installation, operation or maintenance information that is important but not hazardous.

I.II MANUAL ORGANIZATIONAnyone operating or servicing the Sullivan-Palatek air compressor should read this entire manual and be familiar with its information. The chart below is a quick guide to the contents in this manual.

SECTION 1: SAFETYThis section contains important basic information regarding the compressor such as general safety precau-tions for maintaining and operating portable air compressors.

SECTION 2: SPECIFICATIONSThis section contains all the engineering information related to the specific air compressor such as applica-tion data, dimensional drawings and wiring diagrams.

SECTION 3: COMPONENT DESCRIPTIONThis section contains information about how the different systems and components function within an air compressor.

SECTION 4: TRANSPORTING AND LOCATINGThis section contains instructions and safety guidelines for transporting and locating a portable air compressor.

SECTION 5: OPERATIONThis section contains an overview of the compressor controls, initial start-up procedures, and how to start and stop the air compressor.

SECTION 6: MAINTENANCEThis section contains a maintenance schedule and step-by-step instructions for performing common main-tenance procedures.

SECTION 7: TROUBLESHOOTINGThis section contains symptoms, causes and remedies for common air compressor malfunctions.

SECTION 8: PARTS CATALOGThis section contains procedures for ordering parts, a list of recommended spare parts to keep on hand, and exploded assembly drawings with corresponding parts lists of all the parts on the air compressor.

I.III SUPPLEMENTAL DOCUMENTSFor more detailed information on certain components or optional equipment specific to this compressor, supplemental documents are provided in addition to the standard compressor manual.

VI ABOUT THIS MANUAL

VII

II CONTENTS

I ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VI.I Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vI.II Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vI.III Supplemental Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 Pressure Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 Fires and Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 Moving Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.5 Hot Surfaces, Sharp Edges, Sharp Corners and Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.6 Toxic and Irritating Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.7 Electrical Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.8 Entrapment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.2 Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.3 Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 COMPONENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93.1 Portable Compressor Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.3 Airend Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.4 Discharge System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.5 Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.6 Capacity Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.7 Noise Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.8 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.9 Electrical and Protective Circuit System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.10 Engine Shutdown Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 TRANSPORTING AND LOCATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174.1 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184.2 Drawbars and Brake Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184.3 Preparing to Tow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184.4 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.5 Parking or Locating Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215.1 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225.2 Receiving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235.3 Pneumatic Tools Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235.4 Preparing for Initial Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235.5 Normal Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245.6 Normal Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245.7 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245.8 Operating Under Extreme Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245.9 Operating Suggestions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255.10 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286.2 Bolt Torque Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296.3 Compressor Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296.4 Compressor Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306.5 Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316.6 Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

VIII CONTENTS

6.7 Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316.8 Control Linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316.9 Air Intake Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316.10 Oil Return Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316.11 Air/Oil Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326.12 Thermal By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326.13 Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326.14 Compressor Shaft Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336.15 Control Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367.2 Unplanned Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367.3 Discharge Pressure Is Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377.4 Discharge Pressure is Too High or Relief Valve Blows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377.5 Relief Valve Blows With Throttle Lever In Idle Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377.6 Pressure Does Not Blow Down After Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377.7 Compressor Oil Level Is Decreasing Excessively . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387.8 Oil In Service Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387.9 Engine Does Not Accelerate Or Will Not Maintain Full Load Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387.10 Separator Plugging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387.11 Engine Speed Control Lever Does Not Move To Idle Position With Service Valves Closed . . . . . . . . . . . 397.12 Engine Speed Control Lever Does Not Move To Full Speed With Air Demand . . . . . . . . . . . . . . . . . . . . . 397.13 Full Load Speed Cannot Be Obtained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397.14 Idle Speed Difficult To Set After Full Load Speed Has Been Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397.15 Engine Stalls When Air Demand Is Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407.16 Compressor Oil Leaking in Control Lines/Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8 PARTS CATALOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .418.1 Ordering Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428.2 Parts Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428.3 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428.4 Recommended Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438.5 Service Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438.6 Engine Assembly, Flex & Canadian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448.7 Engine Assembly, Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468.8 Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488.9 Exhaust Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508.10 Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528.11 Inlet Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548.12 Air Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568.13 Receiver Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608.14 Receiver Air Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 748.15 Discharge Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 768.16 Control Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 788.17 Cooling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808.18 Oil Filter and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 828.19 Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 848.20 Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 868.21 Enclosure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 928.22 Machine Dress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1008.23 Chassis Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1028.24 Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1048.25 Tire and Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1108.26 Bumper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1128.27 Drawbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1148.28 Swivel Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1168.29 Safety Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1

1 SAFETY

TOPICS IN THIS SECTION: » 1.1 General Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 » 1.2 Pressure Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 » 1.3 Fires and Explosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 » 1.4 Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 » 1.5 Hot Surfaces, Sharp Edges, Sharp Corners and Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 » 1.6 Toxic and Irritating Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 » 1.7 Electrical Shock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 » 1.8 Entrapment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2 SAFETY

1.1 GENERAL SAFETYSafety is a prime consideration in the design and manufacture of the compressor. Ultimately, the respon-sibility for safe operation rests with the individuals who use and maintain the compressor. The following safety precautions are offered as a guide for the safe operation and maintenance of this machinery.Only trained and authorized personnel who have read and understand this operator’s manual should operate the air compressor. Failure to follow the instructions, procedures, and safety precautions in this manual will increase the possibility of accidents and injuries.Never start the air compressor unless it is safe to do so. Do not attempt to operate the air compressor with a known unsafe condition. If an unsafe condition exists or maintenance is required, tag the air compressor and render it inoperative by disconnecting the battery so others who may not know of the unsafe condition cannot attempt to operate it until the unsafe condition is corrected.Use and operate the air compressor only in full compliance with all pertinent Federal, State and Local codes or requirements including OSHA, EPA and other relevant agency requirements.Do not modify this compressor or install attachments without consulting the manufacturer.Known and potential hazards associated with the operating and servicing of portable air compressors are detailed in the following paragraphs. Not all hazards can be anticipated and the operator of the equipment is ultimately responsible for identifying hazardous and dangerous conditions, avoiding dangerous opera-tion and preventing accidents.

1.2 PRESSURE RELEASEDo not open sump (receiver) oil filler cap when compressor is running and air system is pressurized. Shut down the compressor and bleed the sump (receiver) pressure to zero before removing the oil filler cap.Do not remove radiator cap until the coolant temperature is below its boiling point. Then loosen cap slowly to its stop, to relieve any excess pressure. Make sure coolant is not boiling before removing cap completely.The ethyl ether in the replaceable cylinders used in diesel engine ether starting aid systems is under pres-sure. Do not puncture or incinerate these 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.

1.3 FIRES AND EXPLOSIONWARNING! Fire or explosion can result from electrical arcing from terminal, battery connections and improperly

grounded equipment.

WARNING! Fire or explosion can result from spilled fuel, oil and other flammable liquids.

Refuel at a service station or from a fuel tank designed for the purpose. Ground the machine to mobile dispensers prior to refueling.Immediately clean up any spills or leaking fuel, battery electrolyte, oil, or anti-freeze solution.Shut off the air compressor and allow it to cool. Keep sparks, flames, and other sources of ignition away and do not permit smoking in the vicinity when adding fuel, checking or adding electrolyte to batteries, checking or adding oil, checking diesel engine ether starting aid systems or replacing ether cylinders, or when refilling air line anti-icing systems with anti-freeze.Do not permit liquids to accumulate in bottom of the compressor frame. Prevent contact with acoustical 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. Do not use flammable solvents for cleaning purposes.Disconnect the grounded (negative) battery connection prior to attempting any repairs or cleaning inside the enclosure. Tag the ground cable with a warning not to reconnect until servicing is complete.Keep electrical wiring, battery terminals and other terminals in good condition. Replace any wiring, which has cracked, cut, abraded, or otherwise degraded insulation. Replace terminals, which are worn, discol-ored, or corroded. Keep all terminals clean and tight. Turn off battery charger before making or breaking connections to the battery. Wear a face shield whenever servicing or working on the battery.Keep tools and other grounded conductive objects away from exposed live electrical parts to avoid arcing, which might serve as a source of ignition.

3SAFETY

Replace damaged fuel tanks or lines. Do not store or attempt to operate the compressor with any known leaks in the fuel system or oil lines.Prior to welding or making weld repairs on the compressor, remove any acoustical material or other mate-rial that may be damaged by heat or that may support combustion, including diesel engine ether starting aid cylinders and anti-icing system components containing anti-freeze compound.Keep a suitable fully charged class BC or ABC fire extinguisher or extinguishers nearby when servicing and operating the compressor.Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor.Open all access doors and allow the enclosure to ventilate prior to attempting to start the engine. Use this time to check the engine and compressor oil levels, etc.Do not operate compressor under low overhanging leaves or permit leaves and foliage to contact hot exhaust system surfaces when operating in forested areas.Ethyl ether used in diesel engine ether starting aid systems is extremely flammable. Change cylinders and service 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).

WARNING! Use only properly installed and plumbed ether starting aid systems connected to the diesel engine. Do not spray ether into compressor air inlet filter or into an air filter that serves both the engine and the compressor. Serious damage to the compressor or personal injury may result.

Anti-freeze compound used in airline anti-icing 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 anti-freeze compound to temperatures above 150°F (65°C). Vapors from the anti-freeze compound are heavier than air. Do not store compound or discharge treated air in confined or unventilated area. Do not store containers or anti-freeze compound in direct sunlight.

1.4 MOVING PARTSKeep hands, arms, and other parts of the body as well as clothing away from belts, pulleys, and other moving parts.Do not attempt to operate the compressor with the fan guard or other guards removed.Wear snug fitting clothing and confine long hair when working around compressors or any machinery.Keep access doors closed except when repairing, adjusting or performing service, or when starting or stop-ping the compressor.Make sure all personnel are clear of the compressor prior to starting, operating, or shutting the compres-sor off.Shut off engine before servicing. This includes, but is not limited to, adding fuel, oil, coolant, lubricants, airline anti-freeze compound, or battery electrolyte, or before replacing ether starting aid cylinders.Disconnect the grounded negative battery connection to prevent accidental engine operation prior to attempting repair of adjustments. Tag the battery connection so others will not unexpectedly reconnect it.Shut down the engine before making adjustments. Make adjustment, and then start engine to check adjustment. If adjustment is incorrect, shut off the engine, readjust, then restart engine to recheck the adjustment.Avoid slips and falls when working around the compressor. Keep hands, feet, floors, controls, and walking surfaces clean and free of oil, water, anti-freeze, or other liquids to minimize the possibility of slips or falls. Use extreme caution when ground is covered with ice or snow.

1.5 HOT SURFACES, SHARP EDGES, SHARP CORNERS AND VACUUMAvoid contact with hot oil, hot coolant, hot surfaces, and sharp edges and corners.Keep all parts of the body away from all points of air discharge and away from hot exhaust gases.Wear personal protective equipment, including gloves and head covering when working in, on, or around the compressor.Keep a first aid kit available. Seek medical assistance promptly in case of injury. Do not ignore small cuts and burns. They may lead to infection.

4 SAFETY

Keep all loose clothing and parts of the body away from engine and/or compressor intakes or air filter intakes.

1.6 TOXIC AND IRRITATING SUbSTANCESWARNING! Do not use air from this compressor for breathing air. Breathing unfiltered air from this compressor can

result in serious injury or death.

NOTE! Under specific guidelines and in full compliance with OSHA Standards 29 CFR 1920 and any other federal, state, or local codes or regulations compressed air can be used for breathing air. Sullivan-Palatek does not provide equipment and instructions for this application and its products are not produced for this application or use.Do not use airline anti-icing systems in airlines supplying respirators or other breathing air utilization and equipment, and do not discharge air from these systems in unventilated or other confined areas.Operate the compressor only in open or well-ventilated areas.Carbon monoxide will kill. If the machine is operated indoors, discharge engine exhaust outdoors and be certain that there are no exhaust system leaks that can discharge exhaust within the building.Locate this compressor so that exhaust will not be carried toward personnel, air intakes servicing person-nel areas, or toward the air intake of this or any other portable or stationary compressor.Fuel, oil, coolant, lubricant, and battery electrolyte used in this compressor are typical of the industry. Care should be taken to avoid accidental ingestion or skin or eye contact. In the event of ingestion or contact, seek medical treatment promptly. Do not induce vomiting if fuel is ingested. Wash with soap and water in the event of skin contact.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 and wash with large quantities of water.

WARNING! Ethyl ether used in diesel engine starting aid systems is toxic, harmful, and can be fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, do not induce vomiting but seek medical help immediately.

Wear goggles or a full face shield when testing ether starting aid systems or adding anti-freeze compound to air line anti-icing systems. Keep openings of valve, tube, or atomizer or ether starting aid system pointed away from yourself and other personnel.If ethyl ether or air line anti-icing system anti-freeze compound enters the eyes or if fumes irritate the eyes, they should be washed with large quantities of clean water for at least 15 minutes. Medical attention should be obtained immediately.Do not store ether cylinders or airline anti-icing system anti-freeze compound in operator’s cabs or in unap-proved containers.The anti-freeze compound used in airline anti-icing 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 a glass of clean, warm water until vomit is clear, then administer two teaspoons of baking soda in a glass of clean water. Have patient lie down and cover eyes to exclude light. Seek medical assistance.

1.7 ELECTRICAL SHOCKKeep the towing vehicle or equipment carrier, compressor hoses, tools, and all personnel at least 10 feet from power lines and buried cables. Greater separation from power lines may be prudent when working around high voltage. Contact the utility company for guidance.Keep all parts of the body, any hand-held tools, or other conductive objects away from exposed live parts of the compressor electrical system. Maintain dry footing, stand on insulating surfaces and do not contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system.

1.8 ENTRAPMENTMake sure all personnel are out of compressor before closing and latching enclosure doors. Larger compressors can hold a man. If it is necessary to enter the enclosure to perform service or adjustments, secure the access door in the open position to avoid the possibility of others closing and latching the door and inform personnel before entering the enclosure.

5

2 SPECIFICATIONS

TOPICS IN THIS SECTION: » 2.1 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 » 2.2 Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 » 2.3 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

6 SPECIFICATIONS

2.1 TECHNICAL DATA2.1.1 D210PHJDCOMPRESSORType Single Stage, Oil Flooded Rotary ScrewRated Delivery cfm (m3/min) 210 (5.9)Rated Operating Pressure psig (bar) 150 (10.3)Rated Operating Pressure Range psig (bar) 70-165 (4.9-11.4)Ambient Temperature Range °F (°C) -20 to +125 (-29 to +52)Oil Capacity gallons (L) 5.5 (21)Total Receiver Volume ft3 (L) 1.7 (48)Air Service Connector NPT Two 3/4-inType Cooling System Oil to AirType Air Intake System Two Stage DryType of Control 0-100% DemandTire Size ST 205/75D15 Highway TubelessEstimated Weight, Serviced lbs (kg) 2385 (1082)

ENGINEType DieselEngine Make John DeereEngine Model 4045TF290 (Tier 4 Interim)Number of Cylinders 4Bore and Stroke in (mm) 4.19 x 5.00 (106 x 127)Displacement in3 (L) 276 (4.5)Horsepower @ Rated RPM hp (kW) 74 (55.2)Total Oil Capacity qts (liters) 9 (8.5)Cooling System Capacity qts (liters) 14 (13.2)Battery Rating Volts volts 12Cold Cranking Amps @ 0°F (-18°C) amps 800Full Load Speed rpm 2500Idle Speed rpm 1650Fuel Tank Capacity gallons (L) 29 (109.8)

7SPECIFICATIONS

2.2 DIMENSIONAL DRAWING

39.5

2in

1003

.89m

m

17.40in441.96mm

50.08in1272.03mm

AIR OUTLET

49.1

3in

1247

.78m

m

46.5

0in

1181

.13m

mTR

AC

K W

IDTH

61.40in1559.51mm

13.6

1in

345.

67m

mM

IN. R

EQ

'DTO

OP

EN

DO

OR

72.73in1847.31mm

OPEN DOOR HEIGHT

2239

.01m

m

40.1

3in

EN

CLO

SU

RE

LE

NG

TH

ENCLOSURE HEIGHT1060.70mm

133.

82in

1019

.29m

m

88.1

5in

MA

CH

INE

LE

NG

TH33

99.0

9mm

41.76in

16.7

3in

425.

06m

m

54.7

5in

1390

.65m

mD

OO

R L

EN

GTH

1:1

1 O

F 1

D18

5-25

0P

D18

5-25

0P

11/8

/12

JPC

11/8

/12

MFP

NO

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FIGURE 2-1. D185-250 GENERAL DIMENSIONS - S

8 SPECIFICATIONS

2.3 WIRING DIAGRAM

FIGURE 2-2. WD 15056 DIAGRAM, WIRING 125-375QHJD (REV A)

9

3 COMPONENT DESCRIPTIONTOPICS IN THIS SECTION: » 3.1 Portable Compressor Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 » 3.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 » 3.3 Airend Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 » 3.4 Discharge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 » 3.5 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 » 3.6 Capacity Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 » 3.7 Noise Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 » 3.8 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 » 3.9 Electrical and Protective Circuit System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 » 3.10 Engine Shutdown Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

10 COMPONENT DESCRIPTION

3.1 PORTAbLE COMPRESSOR PACKAGEThe compressor is a single stage, oil flood lubricated rotary screw air compressor. The compressor package is available as a portable wheel-mounted unit, utility mounted unit or galvanized skid-mounted unit for offshore applications. All models are enclosed in a weather-resistant acoustical enclosure. The complete operating unit consists of a diesel engine for power, a compressor assembly, air/oil separator system, cooling system for the engine and compressor oil, instrumentation, pneumatic control system, and acoustical enclosure.

3.2 ENGINEThe compressor is powered by a diesel engine. For detailed information on the diesel engine refer to the Engine Operators Manual provided with each compressor.

3.2.1 ENGINE COOLING SYSTEMThe engine cooling system utilizes a conventional engine radiator, thermostat, water pump, and fan to maintain the engine coolant at a desired operating temperature. An additional charge air cooler is required for some diesel engines in order to meet EPA emission standards under tier II regulations.

3.2.2 ENGINE TO COMPRESSOR DRIVEThe compressor and engine are connected through a non-lubricated spline coupling. It consists of a drive ring registered and bolted directly to the engine flywheel and either a splined hub or a disc attached to the compressor drive shaft. Because of low starting torque, no clutch is required.

3.3 AIREND ASSEMbLYThe compressor assembly is an oil flooded, positive displacement, single stage rotary screw unit. Compo-nents include a stator housing, male and female rotors, bearings, and bearing supports. Engine power is transferred to the male rotor through a coupling and, if a gear-driven unit, through gears in the gear housing. The male rotor drives the female rotor.

3.3.1 COMPRESSION CYCLE

FIGURE 3-1. DIAGRAM, COMPRESSION CYCLE

Air at atmospheric pressure is drawn in through the inlet and compressed by the rotation of the rotors. During the compression cycle, oil is injected into the compressor performing three important functions: 1. Lubricate the rotating parts and bearings.2. Provide cooling for the compressed air.3. Seal the running clearances between the rotors.

3.4 DISCHARGE SYSTEM3.4.1 RECEIVER/SUMPFrom the compressor discharge, oil-laden air enters the receiver/sump tank above the oil level and most of the oil is separated from the air by gravity. The oil runs downward and accumulates for recirculation, while the remaining oil mist passes through the separator element. The oil separator is located in the upper portion of the receiver/sump. When air is demanded at the service line, it passes through the separator element, which provides the final stages of air/oil separation.

3.4.2 MINIMUM PRESSURE VALVEA minimum pressure valve is provided at the service air outlet (at the top of the separator). This valve serves to maintain a minimum discharge pressure of 65 to 80 psig in operation, which is required to assure proper air/oil separation. At normal operating pressure of 90 to 125 psig, this valve is wide open, effectively removing any restriction to airflow.

11COMPONENT DESCRIPTION

3.5 LUbRICATION SYSTEM

FIGURE 3-2. DIAGRAM, OIL PIPING 185-375 (REV 00)

Oil from the compressor oil sump at compressor discharge pressure is directed through the cooling system and oil filter to a lower pressure region of the compressor stator. At the same time, oil is directed to the bearings and shaft seal of the compressor. The oil-laden air is then discharged back into the sump.The compressor cooling system consists of an oil cooler mounted adjacent to the engine radiator. Cooling air is drawn through the cooler by the engine fan while oil is circulated through it by the receiver/sump pressure.

3.5.1 OIL RETURN LINEThe oil that is removed by the separator, gravitates to the bottom of the separator and is returned through an orifice in the oil return line, which leads to a lower pressure region of the compressor.

3.5.2 THERMAL BY-PASS VALVEThe thermal by-pass valve is the center of the compressor temperature regulating system. The valve is designed to be fully open, allowing the oil to bypass the cooler until the oil temperature reaches 110°F. Above 110°F, the valve gradually closes down and becomes completely closed when the oil tempera-ture reaches approximately 140°F. The valve has a built-in pressure relief feature so that a pressure drop across the valve of 50 PSI will cause it to open. Therefore, if the cooler should become plugged the thermal valve will open regardless of temperature, thus providing lubrication to the compressor until the protective circuit shuts the machine down due to high compressor discharge temperature.


3.5.3 OIL FILTERThe compressor oil filter is of the full-flow replaceable element type. The filter has an internal by-pass valve to assure adequate oil flow with cold oil or a plugged oil filter element.

3.6 CAPACITY CONTROL SYSTEMThe control system is designed to match air supply to air demand and to prevent excessive discharge pres-sure when the compressor is operating but air is not being used. Control of air delivery is accomplished both by inlet valve regulation and engine speed control as directed by the adjustable discharge pressure regulator valve.

COLD START SOLENOID(OPTIONAL ON SOME MODELS)

PRESSUREREGULATOR

NOTE:1. SOLID PIPE CONNECTIONS REPRESENTED BY THIN LINES.2. UNLESS SPECIFICALLY NOTED, INDIVIDUAL PART ORIENTATIONS ARE FOUND ON ASSEMBLY DRAWINGS

VENT DOWN TOATMOSPHERE



START/RUN

ATMOSPHEREVENT DOWN TO

GAUGEPRESSURE

VALVE

INLET VALVE

THROTTLE CYLINDER

BLOWDOWN VALVE

ATMOSPHEREVENT DOWN TO

RECEIVER TANK

3. UNLESS SPECIFICALLY NOTED, IMAGES OF PARTS ARE FOR REPRESENTATION ONLY, ACTUAL PARTS MAY VARY IN APPEARANCE.IT IS LOANED SUBJECT TO RETURN UPON DEMAND, IS NOT TO BE USED DIRECTLY OR INDIRECTLY IN ANYWAY DETRIMENTAL TO SULLIVAN-PALATEK'S INTEREST.

MATERIAL: DRAWING NO:

DPROJECTION

1201 West US Highway 20, Michigan City IN 46360 1-800-438-6203

SHEET SCALE:

TOLERANCES AS FOLLOWS:

REV

DESCRIPTION

THIS DRAWING AND ALL INFORMATION THEREIN IS THE PROPERTY OF SULLIVAN-PALATEK, INC. IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED.

WWW.SULLIVANPALATEK.COM

SULLIVAN-PALATEKCHECKED BY: DATE:

DATE:DRAWN BY:

FIRST USED ON:

ANGLES: + OR - 1/2 DEG.

DIMENSIONS ARE IN INCHESUNLESS OTHERWISE NOTED

X.XXX + OR - 0.005X.XX + OR - 0.020

DECIMAL: X.X + OR - 0.0503RD ANGLE

SIZE

BA

4

DC

1

3

4

5

A B C D E F

5

3

2

1

FE

2

AS NOTED

1:1 1 OF 1

DIAGRAM, CONTROL D185-250P3/28/13MFP

JPC 3/28/13

00CD 00006

LOW PRESSURE PNEUMATIC CONTROL

ITEM # PART NUMBER DESCRIPTION QTY1 00910084 0002 TUBING,NYLON 3/8" BLUE 12.5"2 00910084 0005 TUBING,NYLON 3/8" YELLOW 10"3 00910084 TUBING,NYLON 3/8" BLACK 15.5"4 00910084 TUBING,NYLON 3/8" BLACK 32"5 00910084 0004 TUBING,NYLON 3/8" RED 32"6 00910084 0004 TUBING,NYLON 3/8" RED 12.5"7 00910084 0004 TUBING,NYLON 3/8" RED 9"8 00910084 0003 TUBING,NYLON 3/8" GREEN 42"

FIGURE 3-4. CD 00006 DIAGRAM, CONTROL D185-250 LOW PRESSURE PNEUMATIC CONTROL (REV 00)

The following discussion explains the operation of the control from a condition of “no load” to a condition of “full capacity” at working pressure. For the working pressure range of your machine, refer to applicable data in the specifications section. The inlet valve cylinder pressure chamber is pneumatically connected to the dry side of the receiver via the pressure regulator valve that when the separator pressure is below the set point of the regulator valve no pressure will exist in the inlet valve cylinder, and the modulating piston will be held at the fully-opened position by the pre-load of the modulating spring. Under these conditions, the inlet valve will remain wide open, causing the compressor to deliver full capacity. As the demand for air decreases, the receiver pressure will rise, and when this pressure level exceeds the set point of the pres-sure regulator valve, control signal pressure will be allowed to enter the inlet valve chamber which in turn will move the modulating piston and the valve plate to a closed condition, thereby throttling the incoming air. A separate throttle air cylinder controls engine speed. The air cylinder is spring loaded in the full speed position when there is no air signal from the pressure regulator valve. Whenever less than full capacity is required, receiver pressure increases, thereby opening the pressure regulator, which allows a pressure signal to enter the throttle air cylinder and reduce the engine speed until it matches the air requirements from 100% down to 60%. From 60% down to 0% both engine speed reduction and inlet valve modulation act together to reduce air output.

3.6.1 INLET VALVEThe inlet valve assembly is the heart of the control system, which regulates the amount of air entering the compressor. A separate air cylinder regulates engine speed. From full to approximately 60 percent capacity, the delivery is controlled by engine speed and a gradual closing of the inlet valve. When unloaded the inlet valve is closed to prevent atmospheric air from entering the compressor.


3.6.2 BUTTERFLY VALVE (1300–1800 CFM)On 1300-1800 cfm units the air intake system consists of a normally closed butterfly valve used in conjunction with a pneumatic type inlet valve. During start-up the butterfly valve remains closed, which results in reduced engine load. The butterfly valve has a built-in passage that permits a small amount of air to enter the compressor. As the pressure increases over 8 psi, the butterfly valve begins to open, admitting more air to the compressor. When the receiver pressure reaches 13 to 14 psi, the butterfly valve will be fully open and the pneumatic valve will take over. With the start-run valve in the start position, the unit will unload when the air receiver reaches 20 psi.

3.6.3 START-RUN VALVEThe start-run valve is used to by-pass the compressor pressure regulator valve. This results in reduced load and reduced engine speed at start-up. Once the engine is warmed up, the valve is moved to the RUN posi-tion. In the START position, the start-run valve is open. In the RUN position, it is closed.

3.6.4 REGULATOR VALVE (DISCHARGE PRESSURE)This valve is used to select the desired discharge pressure within the operating pressure range. Turning the regulator adjustment screw clockwise increases the unloaded pressure, and counter-clockwise reduces the unloaded pressure. Observe discharge pressure gauge on the instrument panel for compressor discharge pressure.

3.6.5 AUTOMATIC BLOWDOWN VALVEThis valve relieves pressure in the system upon shutdown. It is closed when the compressor is in operation; however, at shutdown, the inlet valve closes, the unit becomes pressurized and sends a pressure pulse to open the normally closed blow down valve.

3.6.6 RECIRCULATING VALVEThis valve functions automatically in response to the regulated control pressure. Receiving the unload signal to the inlet valve, the recirculation valve is opened allowing a small quantity of pressurized sump air to be recirculated through the compressor in order to hold a positive pressure signal on the inlet side of the air end to prolong the shaft seal life.

3.7 NOISE CONTROL SYSTEMSNoise control systems incorporated in this compressor have been designed to meet the requirements of federal noise control regulations. The principal components of the noise control systems include the enclo-sure, engine exhaust system, and compressor intake system. The enclosure has been designed to provide the required noise reduction while maintaining a good distribution of cooling airflow to the radiator and oil cooler. Additionally, low noise emission is a key factor in selecting diesel engines to power the compressors.

3.8 INSTRUMENT PANELThe instrument panel contains all the necessary controls and instrumentation for operation. It is conve-niently located and enclosed by a lockable, hinged door. Following is an explanation of the principal controls and instruments:

3.8.1 START-RUN SWITCHThe start-run (load-unload) valve is provided to unload the compressor for easier start-up in cold weather. When positioned on START (UNLOAD), this valve bypasses the pressure-regulating valve, thereby closing the inlet valve with reduced discharge pressure. After the compressor is warmed up, the start-run (load-unload) valve can be turned to RUN (LOAD) position. The unit is then ready for full-load operations. Prior to shutdown, the start-run (load-unload) valve must be turned to the START position and the service valve opened and closed to reduce pressure to approximately 70 psi. Shutdown under full load can damage the compressor and put unnecessary strain on the drive components.

3.8.2 VOLTMETER (OPTIONAL)The voltmeter indicates the condition of the battery prior to start-up. When running, it tells whether the alternator and voltage regulator are operating properly. The normal reading should be 13 to 15 volts during operation in a 12-volt system and 25 to 27 volts in a 24-volt system.

3.8.3 HOURMETERThe hourmeter records the total number of operating hours. It serves as a guide for following the recom-mended inspection and maintenance schedule as outlined in the Lubrication and Maintenance section of this manual.


3.8.4 ENGINE OIL PRESSURE GAUGEThe engine oil pressure gauge shows the engine oil pressure. Do not operate the engine if oil pressure is not indicated immediately after starting. For details, refer to Engine Operator and Maintenance Manual.

3.8.5 COMPRESSOR DISCHARGE PRESSURE GAUGEThis gauge indicates the discharge air pressure. Normal operating pressure is 70 to 115 psig or, for single stage high-pressure compressors, 70 to 150 psig.

3.8.6 ENGINE WATER TEMPERATURE GAUGEThe engine water temperature gauge shows the temperature of the engine coolant.

3.8.7 FUEL GAUGEThe fuel gauge indicates the fuel level of the engine fuel tank. To prevent air from entering the fuel system, the tank should not be allowed to run empty. It should be kept filled, even when not in operation, in order to minimize condensation. Add fuel conditioner if the compressor will be idle for an extended period. An optional low-fuel shutdown system is available to prevent accidental fuel exhaustion.

3.8.8 IGNITION SWITCHIn the START position it is used to electrically energize the engine starter motor solenoid. For diesel engines it also controls the engine fuel solenoid.

3.9 ELECTRICAL AND PROTECTIVE CIRCUIT SYSTEMThe compressor electrical system is a 12-volt negative ground system used on smaller-capacity compres-sors and a 24-volt negative ground system used on larger capacity compressors. It is equipped with a protective circuit to minimize damage. This could be caused by high compressor discharge temperature, high engine water temperature, or low engine oil pressure. Refer to Wiring Diagram, Diesel Engine, as required. The following conditions will cause automatic shutdown of the compressor. 1. Compressor discharge air temperature (CDT) approximately 265°F (116°C). 2. Low engine oil pressure (EOP) of approximately 15 psi (100 kpa). 3. High water temperature (EWT) approximately 215°F (101°C).

3.10 ENGINE SHUTDOWN PROTECTIONSullivan-Palatek uses electronically controlled engines in the 375-1800 CFM lines of compressors. Person-nel operating and maintaining these compressors MUST be familiar with and understand the operation and protection features available with these engines.

WARNING! Failure to follow the electronic control warnings and attempts to override, bypass or ignore these warnings can lead to severe engine damage. This damage will not be covered by either the engine manufacturer’s or Sullivan-Palatek’s warranty.

Electronically controlled engines have software that monitors engine parameters during operation. If the parameters exceed the normal operating threshold, the engine software will take appropriate actions to protect the engine from damage. There are two levels of action: derate and shutdown. If either of these actions are initiated, the software will also activate the amber warning light and red engine shutdown/diag-nostic light on the compressor instrument panel.

3.10.1 ENGINE DERATEThe first level of protection offered by the controller is the derate feature. The engine will derate the power output of the engine by 35% in an attempt to correct the parameters that are out of range. In almost every case, power deration will result in the engine stalling, which will protect the engine from damage.

NOTE! The warning and shutdown lights will be lit on the control panel at this time.

3.10.2 ENGINE SHUTDOWNThe second level of protection offered by the controller is to shut down the engine. If the derate feature cannot correct the unsafe parameters or the engine does not stall, the controller will shut the engine down to protect it from damage.

NOTE! The warning and shutdown lights will be lit on the control panel at this time.If either of these protection features activate, the engine needs to be checked by an authorized distributor of Sullivan-Palatek products or an authorized engine manufacturer’s dealer before attempting to run the machine again.


WARNING! Failure to inspect and correct the fault in the engine or at the point of the external sensor will result in repeated derates and shutdowns, which can and will often lead to engine damage.

NOTE! The engine software stores all derate and shutdown information to be reviewed by the engine manufacturer’s representative. Attempts to restart the compressor without repairing the fault sensed by the protection system will also be stored by the engine software and will void the engine manufacturer’s warranty.

NOTE! The Sullivan-Palatek Inc. warranty DOES NOT COVER the engine. The engine and its components are warrantied only by the engine manufacturer.Operators, rental customers and anyone responsible for the operation and maintenance of these compres-sors MUST be instructed and briefed on the proper responses to control module warnings. In particular, they must be instructed to report these instances and not attempt restarting the compressor until faults are cleared by certified personnel.

17

4 TRANSPORTING AND LOCATINGTOPICS IN THIS SECTION: » 4.1 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 » 4.2 Drawbars and Brake Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 » 4.3 Preparing to Tow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 » 4.4 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 » 4.5 Parking or Locating Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

18 OPERATION

4.1 LIFTINGThis compressor is provided with a lifting bail for routine lifting and loading such as onto trucks or oil plat-forms. It is not intended for extended airlift such as by helicopter. Support the compressor by slings under the main frame with appropriate spreader bars when air lifting the machine. Lift only in full compliance with OSHA Standards 29 CFR 1910 subpart N and other applicable regulations.Prior to lifting, inspect lifting bail and points of attachment for cracked welds and cracked, bent, corroded or otherwise degraded members, and for loose bolts or nuts.Make sure entire lifting, rigging, and supporting structure has been inspected, is in good condition and had a rated capacity of at least the net weight of the compressor plus an additional 10% allowance for the weight of snow, ice, mud, or stored tools and equipment. If you are unsure of the weight, then weigh the compressor before lifting.Make sure lifting hook has a functional safety latch, or equivalent, and is fully engaged before lifting compressor from the ground.Do not attempt to lift in high winds.Keep all personnel out from under and away from the compressor when suspended.Lift compressor slowly and smoothly, without jerking.Lift compressor no higher than necessary, use guidelines and have spotters properly located.Do not leave suspended compressor unattended.Set compressor down only on level surfaces capable of supporting at least its net weight plus an addi-tional 10% allowance for the weight of snow, ice, mud, or stored tools and equipment. If the compressor is provided with parking brakes, make sure they are set; and always, block or chock both sides of all running wheels plus drawbar stabilizer leg before disengaging the lifting hook.

4.2 DRAWbARS AND bRAKE ACTUATORSWARNING! Proper alignment and installation of mounting hardware is essential when installing the drawbars and

actuators. Check nut threads and start attachment bolt by hand to prevent cross-threading. Failure to comply with this warning may cause property damage and serious bodily harm or death. Maintain torque within recommended ranges.

4.3 PREPARING TO TOWDamaged or worn towing components can result in separation of the compressor from the towing vehicle during towing. Inspect all towing components of both the compressor and towing vehicle for cracks, exces-sive wear or damage. Check for loose or damaged bolts, nuts or other fasteners. Replace or repair any damaged or worn parts before towing the compressor.The towing vehicle and its coupling device and points of attachment must be rated for towing the wet weight of the air compressor and the weight of stored tools, hose and other equipment plus parasitic accu-mulation such as mud, snow and ice.Always back the towing vehicle to the compressor and position it for coupling the compressor.Use a lifting device such as a jack or chain hoist to lift or lower unit to avoid injury to yourself or others. Do not attempt to raise or lower drawbar by hand if the weight is more than can be safely handled.Avoid pinch and crushing injury. Keep hands and fingers clear of the coupling device and all other pinch points. Keep feet clear of drawbar in case it should slip.The coupling device must be fully engaged, closed, locked and the safety latches are engaged.The towing restraint chains must be attached to the tow vehicle to support the drawbar in the event of acci-dental uncoupling. Cross chains under front of drawbar before passing them through points of attachment on towing vehicle. Pass each towing restraint chain through its point of attachment on the towing vehicle. Hook each chain to by passing the grab hook over, not through, a link.The coupling device must be free to move throughout the full range of travel while towing. Verify that other components, wires, chains and vehicle attachments do not interfere with or restrict motion of any part of the compressor.

19OPERATION

Make sure chain length, and if provided, brake and electrical interconnections have sufficient slack to prevent strain when turning and maneuvering. All chains and connections must be supported so they cannot drag or rub on road, terrain, or towing vehicle surfaces. Dragging or rubbing of this equipment will cause wear resulting in damage, and render this equipment inoperative.Fully retract front stabilizer screw jack and any rear stabilizer legs (if provided). If a retractable caster wheel is provided, pull the lock pin, raise and fold the caster wheel, then make sure pin is re-engaged to secure caster wheel in full up and locked position with the wheel horizontal.Tires must be in good condition, the correct size and load range, and be inflated to the specified pressures. Do not change tire size or type.Wheel lug nuts must be tightened to the specified torque.If provided, make sure all stop, tail, directional, and clearance lights are operating properly and that lenses are clean and unbroken. Ensure that all reflectors and reflecting surfaces including the slow moving vehicle emblem on the compressor are clean and functional.Make sure air delivery hoses are disconnected or fully retracted and secured on hose reels, if provided.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.Make sure parking breaks on towing vehicle are set and that wheels are chocked or blocked before releas-ing the compressor parking brakes, if provided.Before beginning to tow the compressor, test brake operation, including breakaway switch operation if provided.

4.4 TOWINGWARNING! Maintain proper torque on wheel lug nuts:

Single axle: 85 to 95 LB-FT Two and three axle: 65 to 75 LB-FT Failure to maintain lug tightness may result in a wheel loosening and leaving the compressor and causing injury or death or property damage.

Observe and follow all local, state and federal traffic laws. Note and adhere to speed limits and minimum highway speed.Do not exceed maximum towing speeds. Reduce speed accordingly, as dictated by posted signs, weather, road, or terrain conditions.Remember that portable air compressors may approach or exceed the weight of the towing vehicle. Main-tain increased stopping distance accordingly.Grades in excess of 15° (27%) or any grade that would over-extend the towing or braking ability of the towing vehicle should be avoided.When towing the compressor, avoid potholes, rocks, rough terrain, obstructions and soft shoulders. Damage to the undercarriage and suspension can result.Do not permit any person to ride in or on the compressor while being towed. Serious injury can result.Make sure the area behind and under the compressor is clear of all persons, animals and obstructions prior to backing.Do not permit anyone to stand or ride on the drawbar, or to stand or walk between the compressor and the towing vehicle. Serious injury or death can result.

4.4.1 MAXIMUM TOWING SPEEDS ON SMOOTH, DRY ROADSSingle axle compressors:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55mph (90kmh)Two and three axle compressors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50mph (80kmh)

WARNING! Failure to comply with maximum towing speeds may cause property damage and serious bodily injury or death.

20 OPERATION

4.5 PARKING OR LOCATING COMPRESSORPark or locate compressor on level ground or across grade.Make sure compressor is parked or located on a firm surface that can support its weight.Park or locate compressor to cause the prevailing wind to direct the exhaust fumes and radiator heat away from the compressor air inlet openings and to prevent ingestion of dust and debris from the work site.Set parking brakes and disconnect breakaway switch cable and all other interconnecting electrical and break connections, if provided.Block or chock both sides of all wheels.Block or chock both sides of drawbar stabilizer leg or jack.Unhook chains and remove them from the points of attachment on the towing vehicle, then hook chains to each other on drawbar or wrap chains around the drawbar in order to keep them off the ground.If provided, lower front screw jack and rear stabilizer legs, if provided. Make sure the ground is firm and capable of supporting the weight of the compressor.If the compressor is provided with a swivel caster wheel, pull pin and lower caster wheel, then make sure pin is re-engaged to secure caster wheel in the full-down and locked position.Disconnect coupling device, keeping hands and fingers clear of all pinch points. Do not attempt to lift the drawbar of portable compressors by hand if the weight is more than you can safely handle - usually weights in excess of 50 pounds. Use a lifting device such as a jack or chain hoist to lift the drawbar to avoid injury to yourself or others.Keep feet clear of drawbar at all times to avoid crushing accidents in case it should slip from your hands or otherwise fall to the ground.

NOTE! These guidelines also apply for locating and securing non-towed compressors (skid mounted and utility models). Obviously, reference to towing may not apply.

21

5 OPERATION

TOPICS IN THIS SECTION: » 5.1 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 » 5.2 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 » 5.3 Pneumatic Tools Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 » 5.4 Preparing for Initial Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 » 5.5 Normal Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 » 5.6 Normal Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 » 5.7 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 » 5.8 Operating Under Extreme Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 » 5.9 Operating Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 » 5.10 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

22 OPERATION

5.1 INSTRUMENT PANEL

IGNITION

ALTERNATOR

FUEL DISCHARGE AIRPRESSURE

ENGINE WATERTEMPERATURE

ENGINE OILPRESSURE

ETHER

RUN START OFFON

START

FUSE

BYPASS

0

50

100

150

200

HOURS0 0 0 0 0

E

FUEL

F

1/2AIR

PRESS

FIGURE 5-2. INSTRUMENT PANEL D210

ITEM NAME DESCRIPTION1 Fuse Fuse to protect the engine during start-up. Turn and pull to remove.2 Discharge Air Pressure Gauge displays discharge air pressure of compressor.3 Engine Oil Pressure Gauge displays oil pressure of the engine.4 Ignition Switch START position electrically energizes engine starter motor solenoid.5 By-Pass Button Pressing button overrides the normally open low engine oil pressure

switch to allow start-up.6 Start-Run Switch START allows compressor to be started. RUN allows full-load operation.7 Ether (Option) Optional Ether starting-aid for cold weather starting.8 Engine Water Temp. Gauge displays engine coolant temperature.9 Fuel Gauge Gauge displays compressor fuel level.10 Alternator Light RPM sensitive diagnostic light for troubleshooting problems with the

alternator.11 Hourmeter Hourmeter records total number of compressor operating hours.

NOTE! For more information about the function of the instrumental panel componenents, refer to 3.8 INSTRUMENT PANEL.

23OPERATION

5.2 RECEIVINGEach compressor is operated and tested at the factory before shipment. This testing assures that the unit is operating properly and that the compressor will deliver its rated capacity. Regardless of the care taken at the factory, there is a possibility that adjustments may be altered or damage may occur during shipment. For this reason it is recommended that the unit be checked for proper operation and carefully inspected before it is put in service. The machine should be observed for any possible malfunction during the first few hours of operation.

NOTE! Satisfactory performance of the compressor depends upon the operator’s knowledge of the controls, instruments, and recommended operating procedures. Consequently, the preceding sections of this manual and also the entire Engine Operator’s Manual should be read and understood before attempting to start and operate this machine.

5.3 PNEUMATIC TOOLS APPLICATIONWARNING! Compressed air can be dangerous. Serious injury or death can result from the improper selection, use or

application of tools and attachments to this compressor.

WARNING! Never inject compressed air into a bodily orifice.

WARNING! Never direct compressed air at or toward a person or animal.

WARNING! Do not breathe air produced by a portable air compressor.

Install an appropriate flow-limiting valve between the compressor service air outlet and the shut-off (throttle) valve when an air hose exceeding 1/2” inside diameter is to be connected to the shut-off (throt-tle) valve. This is to reduce pressure in case of hose or connection failure, per OSHA Standard 29 CFR 1926.302 (as) (7).When a hose will be used to supply a manifold, install an appropriate flow-limiting valve between the mani-fold and each air hose exceeding 1/2” inside diameter that is to be connected to the manifold. This will reduce pressure in case of hose failure.Provide an appropriate flow-limiting valve for each additional 75 feet of hose in runs of air hose exceeding 1/2” inside diameter to reduce pressure in case of hose failure.Flow limiting valves are listed by pipe size and rated CFM. Select appropriate valves accordingly.Do not use tools that are rated below the maximum relief valve rating on this compressor. Do not exceed manufacturer’s rated safe operating pressures for these items.Secure all hose connections by wire, chain, or other suitable retaining devices to prevent tools or hose ends from being accidentally disconnected. Unrestrained disconnected hoses can flail around an cause injury or damage.Vent and release all internal pressure prior to opening any line, fitting, hose, valve, drain plug or connection. This includes components such as filters, line oilers and optional airline anti-icing systems.

WARNING! Serious injury can result from the direct discharge of compressed air. Do not allow personnel to be in line or front of the discharge opening of the service valve, hoses or tools or other points of compressed air discharge.

Air gun cleaning devices must not be used and pressures above 30 psig (2 Bars). Always use an appro-priate regulator to reduce pressure at the cleaning tool and always use with effective chip guarding and personal protective equipment per OSHA Standard 29 CFR 1910.242 (b).

WARNING! Serious injury or death may result from horseplay with air hoses and compressed air. HORSEPLAY - DO NOT DO IT, DO NOT ALLOW IT!

5.4 PREPARING FOR INITIAL START-UP1. Inspect the compressor, engine, and other assemblies for damage or loose connections which might

have occurred during shipment.2. Check the engine’s crankcase oil level. If required, add oil as recommended in the Engine Manual.3. Check the radiator coolant level. Also, if the machine will be exposed to sub-freezing temperatures,

check the specific gravity to ascertain the freezing point of the coolant.4. Fill the fuel tank with fuel recommended in the Engine Manual.

WARNING! Never add gasoline to diesel fuel tank - serious damage to the engine will result.

24 OPERATION

5. If necessary, add lubricating oil to the compressor sump. Refer to the Lubrication and Maintenance section for lubricating oil specifications.

6. Check battery posts and cable clamps to assure proper contact. Connect positive cable and negative cable battery terminals. Turn ignition switch to accessories position. Check gauge panel light or voltmeter. If connections are secure light will be on, or voltmeter will register voltage. If not, the battery may need an initial charge to activate it.

5.5 NORMAL STARTING1. Inspect the compressor, engine and other assemblies for damage or loose connections. 2. Check engine water, oil fuel, and battery fluid levels. Check compressor receiver oil level.3. Close service valves. Set start-run valve to START position.4. Turn ignition circuit breaker switch to ON position.5. Turn engine start switch to allow unit to rotate a few revolutions so that the unit will turn freely.6. Turn ignition switch to START position and hold until engine starts.7. Let engine warm up. Turn start-run valve to RUN position. Compressor is now ready for full load

operation.NOTE! If the engine stops, do not attempt to restart with the oil receiver under pressure.

5.6 NORMAL STOPPING1. Position start-run (load-unload) valve to START (UNLOAD) and close all service valves, allowing

compressor to unload. 2. Operate compressor in unloaded condition two to five minutes to allow machine to cool down. 3. Open and close the service valve to reduce pressure to approximately 70 psi.4. Turn ignition switch to OFF.

5.7 EMERGENCY STOPTurn ignition switch to OFF.

5.8 OPERATING UNDER EXTREME CONDITIONS5.8.1 COLD WEATHER OPERATIONUse the correct coolant anti-freeze solution for the lowest possible temperature expected.When operating the compressor at ambient temperatures below 20°F, use lubricants suited for these conditions. Refer to the Lubrication and Maintenance section of this manual.Optional starting aids and component pre-starting warming devices are available for some models for cold weather starting.

WARNING! Do not inject ether starting fluid directly into air intake.

5.8.2 HOT WEATHER OPERATIONKeep the engine cooling system filled with clean coolant. Check the coolant level daily or before each shift.Keep the outside of the radiator and oil cooler clean.Locate the unit in a well-ventilated area.When operating in humid conditions, change the compressor oil more frequently.

5.8.3 DUSTY OR SANDY AREASWhen possible, wet down the area surrounding the operating site to keep dust and blowing sand to a minimum.Inspect air filters before each operating shift or daily.Keep radiator and oil cooler clean. Check daily and wash or blow clean as needed.

WARNING! Check the compressor sump oil level only when the compressor is not operating and system is completely relieved of pressure. Open pressure relief valve to ensure relief of system air pressure when performing maintenance on compressor air/oil system. Failure to comply with this warning may cause property damage and serious bodily harm or death.

25OPERATION

5.9 OPERATING SUGGESTIONSReplace any faulty gauge immediately.Allow at least ten feet of unobstructed area in front of cooling air inlets and outlets to assure good airflow.If compressor is connected to a common header with one or more compressors, a check valve must be provided between each compressor and header.Check instruments periodically during operation. If not in a normal operating zone, refer to the section on troubleshooting.Make sure that the correct type and viscosity of lubricating oils and fuel are used, especially in extreme ambient temperatures.Keep batteries fully charged and properly maintained.Keep control linkage clean and lightly lubricated.

5.10 JUMP STARTINGWARNING! Batteries may contain hydrogen gas, which is flammable and explosive. Keep flames, sparks, and other

sources of ignition away.

WARNING! Batteries contain acid which is corrosive. Do not allow battery acid to contact eyes, fabrics, or painted surfaces. Serious personal injury or property damage may result. Flush contacted areas thoroughly with water immediately. Wear an acid resistant apron and face shield when jump starting the compressor.

1. Remove all vent caps from the battery or batteries in the compressor. Do not permit dirt or foreign matter to enter the open cells.

2. Check fluid level. If low, bring to a proper level before attempting to jump-start.CAUTION! Attempt jump-starting from another vehicle or piece of equipment with a negative ground electrical

system and with the same voltage and battery size as the battery or batteries supplied with the compressor.

CAUTION! Do not attempt to jump-start using motor generator sets, welders, or other sources of DC power. Serious damage may result.

3. Bring the starting vehicle beside the compressor, but do not permit metal-to-metal contact between the compressor and the starting vehicle. Set the parking brakes of the compressor (if provided) and the starting vehicle, or chock or block both sides of all wheels. Place the starting vehicle in neutral or park, turn off nonessential accessory electrical loads and start its engine.

CAUTION! Use only jumper cables that are clean, in good condition, and are heavy enough to handle the starting current.

CAUTION! Prevent accidental contact between jumper cable terminal clips or clamps or any metallic portion of either the compressor or the starting vehicle to eliminate the possibility of arcing, which might serve as a source of ignition.

NOTE! Positive battery terminals are usually identified by a plus (+) sign on the terminal and the letters POS near the terminal. A negative sign (-) or the letters NEG near the terminal usually identify the negative battery terminals.4. Connect one end of a jumper cable to the positive battery terminal in the starting vehicle. When jump-

starting a 24V compressor, and if the starting vehicle is provided with two (2) 12V batteries connected in series, connect the jumper cable to the positive terminal of the ungrounded battery.

5. Connect one end of the other jumper cable to the grounded negative terminal of the battery in the starting vehicle. When jump starting a 24V compressor, and if the starting vehicle is provided with (2) 12V batteries connected in series, connect the jumper cable to the negative terminal of the grounded compressor battery.

6. Check your connections. Do not attempt to start a 24V compressor with a 12V system in the starting vehicle. Do not apply 24V to a 12V system in the compressor. Connect the other end of the same jumper cable to a clean portion of the compressor engine block away from fuel lines, the crankcase breather opening, and the battery.

7. Start the compressor following normal procedure. Avoid prolonged cranking. Damage to the starter may occur.

26 OPERATION

8. 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 on the compressor, and then disconnect the other end of the same cable from the grounded negative terminal of the battery on the starting vehicle.

9. Then disconnect the other jumper cable from the positive terminal of the battery in the compressor, or if provided with (2) 12V batteries connected in series, from an ungrounded battery in the compressor.

10. Finally, disconnect the other end of the same jumper cable from the positive terminal of the battery in the starting vehicle, or from the positive terminal of the ungrounded battery in the starting vehicle if it is provided with two (2) 12V batteries connected in series.

11. Remove and carefully dispose of the dampened cloths. They may be contaminated with acid. Replace vent caps. The use of maintenance-free batteries my obviate this step.

27

6 MAINTENANCE

TOPICS IN THIS SECTION: » 6.1 Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 » 6.2 Bolt Torque Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 » 6.3 Compressor Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 » 6.4 Compressor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 » 6.5 Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 » 6.6 Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 » 6.7 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 » 6.8 Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 » 6.9 Air Intake Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 » 6.10 Oil Return Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 » 6.11 Air/Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 » 6.12 Thermal By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 » 6.13 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 » 6.14 Compressor Shaft Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 » 6.15 Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

28 MAINTENANCE

6.1 MAINTENANCE SCHEDULECOMPRESSOR MAINTENANCE SCHEDULE

PROCEDURE

FREQUENCY (HOURS)

SEE NOTE REF.

DAILY

50 250

1000

2000

AS REQ

UIRED

Check oil level (before starting) x 1 6.4Check radiator coolant level x 1Check fuel supply (after starting) x 1Check air filter elements x 1,7 6.9Check for fuel, oil air and water leaks x 1Check for throttle control linkage x 2Drain water from compressor sump x 2 6.4Drain water and sediment from fuel tank x 2,7Change compressor oil and oil filter element x x 2,4,6 6.4 & 6.5Check drawbar and bolt torque x 3 6.2Check wheel lug nuts x 3Check tire pressure x 3Inspect lifting frame (before each lift) x 3Change compressor air filter element x 4,7 6.9Lubricate control linkage with light machine oil x 4 6.8Check axle spring shackles and mounting bolts x 4Clean battery terminals x 4Check battery hold-downs and cables for wear x 4Check compressor shaft seal for leaking x 4 6.14Check air filter piping, fittings and clamps x 4Check radiator hoses and clamps x 4Check engine and compressor supports x 4Replace air/oil separator element x 5 6.11Check all door gaskets, hinges and latches x 5Drain engine radiator coolant x 5Clean and flush cooling system x 5 6.13Check protective circuits and verify proper function x 5Check sump pressure relief valve x 5Inspect and clean oil system thermostat x 6 6.12Check control adjustment x 6 6.15Re-pack wheel bearings x 6

NOTES1. Or every 10 hours of operation or on rent

return2. Or weekly3. Or before returning to ready line4. Or 6 months

5. Or annually6. After first 50 hours of operation7. More frequently in extreme operating

conditions (dusty, humid, low temperature)

29MAINTENANCE

6.2 bOLT TORQUE GUIDELINES6.2.1 INCH FASTENERSInch Fasteners Torque

SizeSAE Grade 5 (ft-lb) SAE Grade 8 (ft-lb)Dry Oiled Dry Oiled

1/4-20 8 6 12 95/16-18 17 13 25 183/8-16 30 23 45 357/16-14 50 35 70 551/2-13 75 55 110 809/16-12 110 80 150 1105/8-11 150 110 220 1703/4-10 260 200 380 280

6.2.2 TORQUE SEQUENCETypical bolt Torque Patterns

Circular Pattern (8-Bolt) Square Pattern Flange Pattern

6.3 COMPRESSOR LUbRICANT SPECIFICATIONSWEATHER-ALL™ COMPRESSOR FLUID is designed for all types of rotary screw air compressors used in varying conditions encountered in the construction industry. Sullivan-Palatek ’s Weather-All is formulated as a 5W-20 Multi-Viscosity fluid with additives for maximum protection against scuffing and wear to bear-ings and rotors. Extensive testing has shown this fluid exhibits excellent resistance to foaming, oil oxidation and corrosion. Special attention has been made toward limiting rust of ferrous metals and corrosion of yellow metals.

6.3.1 PRODUCT FEATURES AND BENEFITSOur Weather-All lubricant will provide extended life compared to other brand oils. Weather-All fluid provides quick water separation which helps protect equipment in wet and humid service environments.Our compressor fluid has an excellent viscosity index (180), as well as, low pour point (-40°F).This specially formulated multi-viscosity compressor fluid provides wear control for steel and brass parts when operating at maximum pressure ratings, resulting in excellent compressor operation.Weather-All Compressor 5W-20 Fluid combines the superior additive technology and quality hydrocarbon based oils for Extended Life and is a custom-formulated lubricant specifically designed for long life under the severe, demanding conditions normally encountered in recirculating systems such as rotary screw compressors.Weather-All combines the advantages of a synthesized hydrocarbon, which results in performance improve-ments beyond conventional mineral oils and many synthetic oils.

30 MAINTENANCE

6.3.2 CHARACTERISTICS » Exceptional oxidative stability » Low sludging tendency » Thermal & hydrolytic stability » Improved performance » Rust and corrosion inhibited

» Viscosity stability » Lower equipment maintenance » Extended anti-wear protection » Longer life » Low evaporation loss

WEATHER-ALL COMPRESSOR FLUIDISO Viscosity Grade 32SAE Viscosity Grade SW-20Viscosity, cst. 210°F 50 SUSViscosity, cst. 100°F 170 SUSNormal Service Life 2000 hoursViscosity Index 180Pour Point -40°C

-40°FFlash Point 199°C

NOTE! These values are not intended for use in preparing specifications.

6.4 COMPRESSOR LUbRICATIONChange oil at least once a year, even if the normal oil change period in hours has not yet been reached.

CAUTION! Never mix synthetic lubricants with hydrocarbon lubricants. Never mix synthetic lubricants manufactured from different base products. Severe damage to the compressor system may result.

Contamination of non-detergent mineral oils with traces of ATF, or detergent motor oils, may lead to prob-lems such as foaming, and plugging of filters, orifices, and lines. Lubricant manufacturers include a variety of additives in the blending process to enhance lubrication, product life and performance. Mixing different types or brands of lubricants is not recommended due to the possibility of a dilution of the additives or a reaction between additives of different types. Environmental conditions in the area of compressor operation such as the presence of reactive gases or vapors in the air may lead to chemical changes and premature degradation of the lubricant. The useful life of synthetic lubricants may extend the normally recommended drain and replace period; however, the user is encouraged to closely monitor the lubricant condition and to participate in an oil analysis program with the fluid supplier. When ambient conditions exceed those noted, or if conditions warrant use of “extended life” lubricants, contact Sullivan-Palatek for a recommendation.

6.4.1 FILLBefore adding or changing compressor oil, completely relieve the sump of pressure. Venting the sump tank pressure relief valve will do this.

6.4.2 LEVELThe proper oil level, when unit is shut down and oil has had time to settle, is across the center of the oil level sight glass. For oil sump capacity, see the Compressor Specifications section.

WARNING! Compressor must be shut down and pressure completely relieved from system before checking fluid levels. Open pressure relief valve to assure relief of system air pressure. Failure to comply with this warning may cause property damage and serious bodily harm or death.

6.4.3 DRAINAlways warm compressor thoroughly prior to changing the compressor oil. A drain valve is provided at the bottom of the sump tank and oil cooler. When changing the oil, make sure system is completely drained to reduce potential contamination. Oil is added at the fill plug on the side of the sump tank.

WARNING! Do not attempt to drain water, remove the oil level fill plug, or break any connection in the air or oil system until all the pressure has been relieved. Check by manually opening the sump pressure relief valve. Serious injury or death may result if this warning is not followed.

31MAINTENANCE

6.5 COMPRESSOR OIL FILTERReplace the oil filter element once after the first 50 hours of operation, then every 1,000 hours or before returning to the ready line. Replace more frequently in extreme operation conditions such as high temperatures, low temperatures or high humidity.

6.5.1 INSPECTIONThe compressor oil filter should be checked making sure it has the proper element and it is properly installed and not leaking.

6.5.2 REMOVAL1. Make sure the system pressure is relieved.2. Place oil spill pan under filter.3. Remove oil filter element by unscrewing it from the filter head (turn counterclockwise) and discard. The

use of a strap-type wrench may be necessary.6.5.3 INSTALLATION1. Install a new oil filter by applying a thin film of oil to the seal. Screw the oil filter on by hand, turning it

clockwise until the gasket seats. Then turn an additional 1/2 to 3/4 turn by hand.2. Check for leaks in operation.

6.6 ENGINE LUbRICATIONRefer to Engine Operator’s Manual for recommended engine lubricating oil, service intervals and mainte-nance practices.

6.7 GREASEUse a multi-purpose type grease (MKG) or multi-purpose type grease with molybdenum disulfide (MPGM) conforming to MIL-L-7866 for all parts.

6.8 CONTROL LINKAGEControl linkage should be cleaned and lightly oiled at all joints every 1,000 hours or 6 months.

6.9 AIR INTAKE FILTERCheck daily, every 10 hours of operation or on rent return. Replace every 1,000 hours or 6 months. Replace more frequently in dusty conditions.

6.9.1 INSPECTIONThe air filter element should be thoroughly inspected for holes by placing a lamp inside and carefully check-ing for areas of bright light passing through the element. Inspect for dust leaking past the air filter element, seal, and retaining bolt. Maximum pressure drop for proper operation is 20 inches of water. Air filter element condition indicators are available as optional equipment on most models.

6.9.2 REMOVAL1. Open the locking devices and remove air filter cover.2. Remove the used element by turning counter-clockwise to unscrew.6.9.3 INSTALLATION1. Screw the new filter into place by turning clockwise.2. Place cover back on air filter and close locking devices.The air intake filters are heavy duty, two-stage dry elements to protect the engine and compressor from dust and foreign objects.

6.10 OIL RETURN LINECheck the oil return line periodically to make sure that it does not become clogged. A clogged line results in excessive oil consumption and oil in the service lines.

6.10.1 INSPECTIONInspect oil return line for clogging.

32 MAINTENANCE

6.10.2 CLEANINGIf clogging is indicated, check and clean the entire line, including the orifice fitting at the compressor end, and the siphon tube inside the separator. Usually, blowing with a reverse flow of compressor air will clean the line.

6.11 AIR/OIL SEPARATORReplace the air/oil separator every 2,000 hours or annually. The air/oil separator employs a unitized element.

The separator element is a single piece unit, which requires replacement when it fails to remove the oil from the discharge air. Prior to replacing the separator element be sure to check the oil return line and orifice for plugging or restrictions.

WARNING! Prevent separator flash or fire. Maintain the separator element in proper condition and do not allow it to become plugged with dirt and oxidized oil. Be certain that the sump lid is properly grounded to the sump when installing a new separator.

WARNING! The combination of a build-up of dirt and oxidized oil can clog the element causing an increase in air velocity at narrow points on the element media. Elevated temperatures at these points can result in ignition of the fluid in the oil sump.

6.11.1 REMOVAL1. Relieve sump pressure to zero pressure.2. Disconnect oil return line. Loosen fitting and pull siphon tube up out of separator.3. Remove service air piping from minimum pressure valve.4. Mark and disconnect necessary tubing at separator cover and then remove cover.6.11.2 INSTALLATION

WARNING! Failure to properly ground the sump lid and separator can result in the build-up of an electric charge leading to ignition inside the sump (do not remove staples in separator gasket). Failure to comply with this warning may cause property damage and serious bodily harm or death.

1. Remove and replace element. WARNING! Lid and sump tank top must be clean to ensure proper grounding between element and tank. Make sure

grounding staples are in top and bottom gasket.

2. Replace separator cover; tighten bolts gradually in an opposing manner until required torque is reached. Refer to 6.2 Bolt Torque Guidelines.

3. Install service air piping and reconnect all tubing. When replacing the oil return siphon tube, allow it to contact the bottom of the sump tank then back off about 1/8 inch.

4. Clean oil return line and orifice.NOTE! If the separator element has to be replaced frequently because it is plugged, it is an indication that dirt is

entering the inlet system, the compressor oil filter is faulty, or the oil is breaking down. The complete inlet system, starting with the air cleaner, and all joints in piping to the inlet valve, should be checked for leaks.

6.12 THERMAL bY-PASS VALVEInspect and clean the thermal by-pass valve if the unit shuts down because of high compressor discharge air temperature.

6.12.1 INSPECTIONInspect the valve by removing it from the by-pass housing. Sediment particles may lodge in the valve-seat-ing surface and prevent it from closing, thereby allowing hot oil to pass directly to the compressor without being cooled.

6.13 OIL COOLERThe interior of the oil cooler should be cleaned every 2,000 hours, annually or when the pressure drop across the cooler at full load exceeds 25 psi.

6.13.1 INSPECTIONInspect compressor oil system for signs of varnish.

33MAINTENANCE

6.13.2 REMOVAL1. Drain compressor fluid.2. Remove oil cooler.6.13.3 CLEANINGCirculate a suitable solvent to dissolve and remove varnish and sludge.

6.13.4 INSTALLATION1. Replace oil cooler and fill compressor with fresh oil.2. Operate the machine normally for 50 hours.3. After 50 hours, change compressor oil and install a new oil filter element.

6.14 COMPRESSOR SHAFT OIL SEALCheck the compressor shaft seal for leaking oil every 1,000 hours or 6 months.

6.14.1 INSPECTIONInspect the compressor shaft seal for signs of leaking oil.

NOTE! If replacement is necessary, removal and installation instructions will be provided with the shaft seal kit.

6.15 CONTROL ADJUSTMENTSThe engine speed governer and interconnecting linkage are preset at the factory and normally require no servicing other than keeping the linkage joints clean and lubricated. However, if it becomes necessary to make adjustments, use the following procedures.

6.15.1 DISCHARGE PRESSURE ADJUSTMENTTo increase pressure, loosen locknut on pressure regulator adjustment screw and turn screw clockwise. Lower the operating pressure by turning screw counterclockwise. Reset locknut after adjustment is completed. Check engine speed adjustments whenever pressure settings have been changed. Only the unloaded pressure can be selected with the pressure-regulating valve. Full and part load pressures are a function of air usage.

6.15.2 ENGINE SPEED ADJUSTMENTSFor proper adjustment the engine must be started and warmed up. The proper grade of oil and fuel must be used and a clean air filter must be in place. Prior to making any adjustment, be sure that the regula-tor setting is high enough to prevent air leakage from the regulator vent hole. Close the service air valve so that the unit unloads. Check the compressor discharge pressure gauge for approximately 125 psig. If necessary, make pressure discharge adjustment as described above. Make engine speed adjustments as follows.

6.15.3 FULL LOAD SPEEDOpen the service air valve so that the compressor loads then throttle as necessary to hold discharge pres-sure at desired setting. Be sure there is no air leakage from the pressure regulator or control line. If speed is too high reposition the throttle control air cylinder. If speed is too low make the opposite adjustment. Secure locknuts after proper speed is obtained.

NOTE! For full load speed and discharge pressure see dimension and specifications pages.

6.15.4 IDLE SPEEDOnce the full load speed adjustment has been made, the idle speed should be in the range of 1400 RPM. To check the idle speed, close the service air valve so that the compressor unloads. If idle speed is too high, reposition throttle control air cylinder or lengthen linkage rod to engine slightly. Make opposite adjust-ment to lower speed.It may be necessary to repeat both of the adjustments several times before the settings balance out, to get the recommended idle and full load speed.

34 MAINTENANCE

35

7 TROUbLESHOOTING

TOPICS IN THIS SECTION: » 7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 » 7.2 Unplanned Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 » 7.3 Discharge Pressure Is Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 » 7.4 Discharge Pressure is Too High or Relief Valve Blows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 » 7.5 Relief Valve Blows With Throttle Lever In Idle Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 » 7.6 Pressure Does Not Blow Down After Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 » 7.7 Compressor Oil Level Is Decreasing Excessively. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 » 7.8 Oil In Service Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 » 7.9 Engine Does Not Accelerate Or Will Not Maintain Full Load Speed . . . . . . . . . . . . . . . . . . . . . . .38 » 7.10 Separator Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 » 7.11 Engine Speed Control Lever Does Not Move To Idle Position With Service Valves Closed . . . . .39 » 7.12 Engine Speed Control Lever Does Not Move To Full Speed With Air Demand . . . . . . . . . . . . . . .39 » 7.13 Full Load Speed Cannot Be Obtained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 » 7.14 Idle Speed Difficult To Set After Full Load Speed Has Been Set . . . . . . . . . . . . . . . . . . . . . . . . . .39 » 7.15 Engine Stalls When Air Demand Is Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 » 7.16 Compressor Oil Leaking in Control Lines/Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

36 TROUBLESHOOTING

7.1 INTRODUCTIONThis section contains instructions for troubleshooting the equipment following a malfunction. Each symptom of trouble for a component or system is followed by a list of probable causes of the trouble and suggested procedures to be followed to eliminate the cause.The procedures listed should be performed in the order in which they are listed, although the order may be varied if the need is indicated by conditions under which the trouble occurred. In any event, the procedures, which can be performed in the least amount of time and with the removal or disassembly of the fewest parts, should be performed first.

7.2 UNPLANNED SHUTDOWNPOSSIbLE CAUSE ACTIONLow Fuel Fill the machine with fuel and retest.Water or contamination in fuel filter Replace all fuel filters and drain the water from the

fuel tank(s).Improper fan belt tension Adjust or replace the fan belt as needed.Obstruction in radiator and/or oil cooler Remove any external obstructions and clean the

coolers. Broken hoses or oil lines Repair/Replace any broken hoses or oil lines.Loose or broken wires Repair/Replace any loose or broken wires.Water temperature switch open Check the engine coolant level. Add as needed.

Clean the coolers. Check the fan belt tension. Adjust or replace as needed.Refer to engine manufacturer’s manual.

Compressor discharge temperature switch open Check compressor oil level. Add as needed.Clean the coolers and pressure check.Check the fan belt tension. Adjust or replace as needed.Verify correct operation of thermal by-pass valve.Change compressor oil and oil filter element.Clean oil cooler internally.

Engine oil pressure switch open Check engine oil. Add as needed.Verify the engine oil pressure exceeds 12 psi with the engine running.

*If none of the above caused the shutdown, restart the engine and observe the engine oil pressure, engine water temperature, and compressor discharge temperature and pressure gauges. Refer to the wiring diagrams and information on the protection circuits for shutdown conditions. If it is found that low engine oil pressure or high engine water temperature is causing the shutdown, refer to the engine manufacturer’s manual.

37TROUBLESHOOTING

7.3 DISCHARGE PRESSURE IS TOO LOWPOSSIbLE CAUSE ACTIONStart/Run valve in the START position Move the Start/Run valve to the RUN position and

retest.Too much air demand Add additional compressor to handle the demand

or decrease the air demand.Service valve open Close service valve and retest.Service line leaks Repair any leaks found and retest.Compressor inlet air filter restricted Replace the air filter and retest.Improper control operation See improper control operation section.Regulator valve faulty or misadjusted Properly adjust the regulator.

Replace the regulator valve if necessary.

7.4 DISCHARGE PRESSURE IS TOO HIGH OR RELIEF VALVE bLOWSPOSSIbLE CAUSE ACTIONInlet valve not closing properly Check the white sealing ring for the poppet valve,

to ensure it is intact and not damaged. (185–375 CFM Compressors)

Discharge pressure gauge faulty Replace the faulty gauge.Regulator valve faulty or misadjusted Properly adjust the regulator.

Replace the regulator if necessary.Oil separator plugged Replace the oil separator.

Clean the scavenger tube.Pressure relief valve faulty Replace the faulty relief valve.Compressor shaft seal leaking Replace the compressor shaft seal and retest.Ice or debris in control lines Clean the control lines of debris.

Thaw out the control lines to remove the ice build-up. Optional heater kit available. Direct the lines so there is a low point to drain any condensate.

7.5 RELIEF VALVE bLOWS WITH THROTTLE LEVER IN IDLE POSITIONPOSSIbLE CAUSE ACTIONInlet valve not closing properly Check the white sealing ring for the poppet valve,

to ensure it is intact and not damaged. (185–375 CFM Compressors)

Regulator valve faulty or misadjusted Properly adjust the regulator.Replace the regulator if necessary

Control system leaks Repair any leaks and retest.

7.6 PRESSURE DOES NOT bLOW DOWN AFTER SHUTDOWNPOSSIbLE CAUSE ACTIONAutomatic blow down valve may be faulty Check operation of the automatic blow down valve.

Replace if necessary.Air line from inlet valve or sump to blow down valve may be restricted

Verify the pilot signal is reaching the automatic blow down valve.Verify the blow down valve is plumbed correctly.

38 TROUBLESHOOTING

7.7 COMPRESSOR OIL LEVEL IS DECREASING EXCESSIVELYPOSSIbLE CAUSE ACTIONOil line leaking Repair or replace any leaking lines and retest.Oil cooler leaking Repair or replace the leaking oil cooler and retest.Compressor shaft seal leaking Replace the compressor shaft seal and retest.Oil in service line See oil in service line section.

7.8 OIL IN SERVICE LINEPOSSIbLE CAUSE ACTIONOil return line plugged or restricted Remove the oil return line and clean.Separator element plugged or damaged Replace the separator element and change com-

pressor oil.Discharge pressure below 70 psi The air demand maybe too much. Add compressors

or decrease the demand.Adjust the discharge pressure above 70 psi.Check MPV operation, rebuild/replace as needed

7.9 ENGINE DOES NOT ACCELERATE OR WILL NOT MAINTAIN FULL LOAD SPEEDPOSSIbLE CAUSE ACTIONCompressor discharge pressure too high Adjust the pressure to the maximum operating

pressure for the machine.Improper control operation See Improper control operation sectionEngine idle speed set too low Adjust the idle speed to the Sullivan-Palatek recom-

mended rpm.Operating above maximum altitude rating of engine Refer to engine manufacturer's recommendation

on maximum altitude.Engine problem Have an authorized engine repair facility inspect

the engine.

7.10 SEPARATOR PLUGGINGPOSSIbLE CAUSE ACTIONDirt and dust blockage in air inlet filters Replace the air inlet filtersCheck compressor oil filter element Replace the compressor oil and filter if necessary.

If the separator element has to be replaced frequently because it is plugging up, it is an indication that foreign material may be entering the compressor inlet or the compressor oil is breaking down. Compressor oil can break down prematurely for a number of reasons: 1. Extreme operating temperature2. Failure to drain condensate from oil sump3. Using the improper type of oil4. Mixing different types of oil5. Prolonged operation at extreme ambient temperatures6. Foreign material, gases or vapors entering compressor inlet

39TROUBLESHOOTING

7.11 ENGINE SPEED CONTROL LEVER DOES NOT MOVE TO IDLE POSITION WITH SERVICE VALVES CLOSED

POSSIbLE CAUSE ACTIONInsufficient pressure in control line to operate throttle cylinder (185-375 CFM Compressors)

Check the t-handle adjustment in the control line.

Pressure in control line to operate throttle cylinder is present (750-1800 CFM Compressors)

Inspect the control lines for blockage, dirt, or debris.

Control system is blocked between the sump and inlet valve

Clean the control lines and retest.

Control system leaks between sump and inlet valve Repair any leaks found and retestEngine governor speed control lever binding or throttle cylinder faulty

Inspect the control lever, lubricate or replace as needed.

Discharge pressure regulator faulty Properly adjust the regulator.Replace the regulator if necessary

Inlet valve faulty Inspect the inlet and rebuild/replace as needed.Broken or worn rings in modulation valve.

7.12 ENGINE SPEED CONTROL LEVER DOES NOT MOVE TO FULL SPEED WITH AIR DEMANDPOSSIbLE CAUSE ACTIONStart/Run valve is positioned in START instead of RUN.

Move the Start/Run valve to the RUN position.

Engine governor speed control lever binding or throttle cylinder faulty.

Inspect the control lever, lubricate or replace as needed.

Modulating spring broken. Inspect inlet valve, rebuild/replace as necessary.Control rod disconnected between the engine gov-ernor and cylinder.

Reconnect the control rod and retest

Discharge pressure regulator faulty or improperly set.

Properly adjust the regulator.Replace the regulator if necessary

Insufficient pressure in control line to operate throttle cylinder. (750–1800 cfm compressors)

Inspect the control lines for leaks, repair as needed.

7.13 FULL LOAD SPEED CANNOT bE ObTAINEDPOSSIbLE CAUSE ACTIONThrottle cylinder rod to engine governor is incor-rectly set or binding

Inspect cylinder rod to engine and adjust, lubricate, or replace as necessary.

Inlet valve faulty Inspect the inlet and rebuild/replace as needed.Broken or worn rings in modulating piston.

Engine governor incorrectly set Adjust the engine rpms to the Sullivan-Palatek the proper specifications.

operating above maximum altitude rating of engine Refer to engine manufacturer's recommendation on maximum altitude.

7.14 IDLE SPEED DIFFICULT TO SET AFTER FULL LOAD SPEED HAS bEEN SETPOSSIbLE CAUSE ACTIONEngine governor linkage binding or incorrectly set Inspect governor linkage and adjust, lubricate, or

replace as necessary.Engine governor idle speed control lever too long Adjust the idle speed to the Sullivan-Palatek recom-

mended rpm.

40 TROUBLESHOOTING

7.15 ENGINE STALLS WHEN AIR DEMAND IS LOWPOSSIbLE CAUSE ACTIONIdle speed may be set too low. Adjust the idle speed to the Sullivan-Palatek recom-

mended rpm.

7.16 COMPRESSOR OIL LEAKING IN CONTROL LINES/ORIFICESPOSSIbLE CAUSE ACTIONCompressor oil level in sump tank too full. Check and adjust compressor oil as needed.Diaphragm in recirculation valve ruptured. Inspect the diaphragm, rebuild/replace as needed.Blow down valve O-ring faulty. Inspect the blow down valve, rebuild/replace as

needed.Inlet valve modulating piston ring faulty. Inspect the inlet valve, rebuild/replace as needed.High compressor discharge temperature Check the compressor oil level, Add oil as needed.

Clean the oil cooler.Check the fan belt. Adjust or replace as needed.Check thermal by-pass valve (compressor oil ther-mostat).Change compressor oil and oil filter element.Clean the oil cooler internally.

41

8 PARTS CATALOG

TOPICS IN THIS SECTION: » 8.1 Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 » 8.2 Parts Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 » 8.3 Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 » 8.4 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 » 8.5 Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 » 8.6 Engine Assembly, Flex & Canadian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 » 8.7 Engine Assembly, Export. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 » 8.8 Battery Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 » 8.9 Exhaust Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 » 8.10 Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 » 8.11 Inlet Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 » 8.12 Air Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 » 8.13 Receiver Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 » 8.14 Receiver Air Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 » 8.15 Discharge Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 » 8.16 Control Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 » 8.17 Cooling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 » 8.18 Oil Filter and Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 » 8.19 Fuel Tank Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 » 8.20 Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 » 8.21 Enclosure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 » 8.22 Machine Dress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 » 8.23 Chassis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 » 8.24 Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 » 8.25 Tire and Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 » 8.26 Bumper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 » 8.27 Drawbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 » 8.28 Swivel Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 » 8.29 Safety Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

42 PARTS CATALOG

8.1 ORDERING PARTSOn the following pages are a list of recommended spare parts to keep on hand to minimize downtime for the most common maintenance and a complete parts listing with exploded drawings for all the parts on the compressor.Parts should be ordered from the nearest full-service distributor or factory authorized compressor center. Only call the factory if parts cannot be obtained locally. Before calling to order parts, please have the model and serial number information available. This information can be found on the serial number plate located on the compressor.

NOTE! Use the space provided on the inside cover of the manual to record the model and serial number of the compressor for future reference.

8.1.1 CONTACT INFORMATIONFor replacement parts and manuals, contact us at:Sullivan-Palatek, Inc. 1201 West US Highway 20 Michigan City, IN 46360 T: 219-874-2497 F: 219-872-5043 Toll Free: 800-438-6203 www.sullivanpalatek.com

8.2 PARTS DRAWINGSThe parts drawings are exploded drawings of the various assemblies and sub-assemblies which make up this machine. Standard models and more popular options available are covered.

NOTE! In referring to the rear, the front or to either side of the unit, always consider the drawbar end of the unit as the front. Standing at the rear of the unit facing the drawbar (front) will determine the right and left sides.

8.3 FASTENERSBoth SAE/inch and ISO/metric hardware have been used in the design and assembly of these units. In the disassembly and reassembly of parts, extreme care must be taken to avoid damaging threads by the use of wrong fasteners.

43Parts Catalog

8.4 RECOMMENDED SPARE PARTSDESCRIPTION QTY PART NUMBER

ElEMENt, aIr FIltEr (PrIMarY) 1 01900522 0008

ElEMENt, aIr FIltEr (sECoNDarY) 1 01900522 0022

ElEMENt, oIl FIltEr (CoMPrEssor) 1 01900520 0012

ElEMENt, oIl FIltEr (ENgINE) 1 01900520 0030

ElEMENt, FUEl FIltEr (PrIMarY) 1 05018155 0013

ElEMENt, aIr/oIl sEParator 1 00543117 0026

FlUID, CoMPrEssor WEatHEr-all (5 galloN) 1 00823062 0009

FlUID, CoMPrEssor WEatHEr-all (55 galloN) 1 00823062 0010

sWItCH, CoMPrEssor DIsCHargE tEMP. 1 05019415 0029

sWItCH, IgNItIoN 1 00600701 0406

sWItCH, ENgINE oIl PrEssUrE 1 00519344

ValVE, saFEtY 1 03100-008

ValVE, 2-WaY 1/4 NPt (start-rUN) 1 05019820 0001

ValVE, PrEssUrE rEgUlator 1 09661-002

BElt, FaN 1 r123432

NOTE! Use only service parts supplied or recommended by Sullivan-Palatek. Use of substitutes may void warranty. See Warranty for details.

8.5 SERVICE KITSservice kits are available for basic servicing of the compressor and engine. Buying kits offers savings over buying individual parts. there are annual kits (wet or dry) for a year’s worth of compressor and engine servicing and line service kits for a single compressor and engine service.

DESCRIPTION CONTENTS PART NUMBER

sErVICE KIt, aNNUal (WEt) 4 ElEMENt, aIr FIltEr (PrIMarY) 2 ElEMENt, oIl FIltEr (CoMPrEssor) 2 ElEMENt, oIl FIltEr (ENgINE) 2 ElEMENt, FUEl FIltEr 1 ElEMENt, sEParator 2 FlUID, CoMPrEssor WEatHEr-all (5 galloN)

00717701 0057

sErVICE KIt, aNNUal (DrY) 4 ElEMENt, aIr FIltEr (PrIMarY) 2 ElEMENt, oIl FIltEr (CoMPrEssor) 2 ElEMENt, oIl FIltEr (ENgINE) 2 ElEMENt, FUEl FIltEr 1 ElEMENt, sEParator

00717701 0058

sErVICE KIt, lINE 2 ElEMENt, aIr FIltEr (PrIMarY) 1 ElEMENt, oIl FIltEr (CoMPrEssor) 1 ElEMENt, oIl FIltEr (ENgINE) 1 ElEMENt, FUEl FIltEr 1 FlUID, CoMPrEssor WEatHEr-all (5 galloN)

00717701 0067

44 PARTS CATALOG

8.6 ENGINE ASSEMbLY, FLEX & CANADIAN

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45PARTS CATALOG

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1900

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4-28

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230

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ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY44

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000

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E 1/

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1/8

X 1/

8 N

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1

46 PARTS CATALOG

8.7 ENGINE ASSEMbLY, EXPORT

NO

DR

AWIN

G A

VAIL

ABLE

FIGURE 8-2. 00717585 0230 ENGINE ASSY,DE210PHJD IT4 EXP (REV 00)

47PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0390

3000

003

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APTE

R, M

ETRI

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12

0090

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5/8

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X 2

1/2

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65

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25 X

100

MM

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10.9

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020

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IND

ER1

705

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20 0

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CABL

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VE1

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20 0

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COUP

LIN

G, D

RIVE

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CTOR

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LTER

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1900

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2100

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124

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325

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25 X

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SPAC

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230

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PAR

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UM

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DES

CRIP

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NQ

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TUBE

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WIR

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ONG

1

48 PARTS CATALOG

8.8 bATTERY ASSEMbLY

FIGURE 8-3. 00717820 0050 BATTERY GROUP STANDARD (REV 0)

49PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

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0321

000

3W

ASH

ER, F

LAT

5/16

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200

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003

NUT

, WIN

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18"

23

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D, T

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5/1

6" X

10"

LON

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401

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002

BRKT

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T H

OLD

DOW

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505

0171

95 0

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BATT

ERY,

STA

NDA

RD 1

2V1

50 PARTS CATALOG

8.9 EXHAUST ASSEMbLY

7

9

9

8

6

3

9

10

4

4

9

11

5

6

12

1

MO

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TS T

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DW

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13

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OF

EN

GIN

E B

LOC

K

US

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NG

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SU

PP

LIE

DB

OLT

HE

RE

13 14

13

FIGURE 8-4. 00717796 0136 EXHAUST SYSTEM D210PHJD (REV 04)

51PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

9311

5-00

2BO

LT, W

HIZ

LOC

K 5/

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3/4

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C PL

ATED

42

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5-00

3N

UT, W

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HEX

5/1

6-18

43

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036

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T, E

XHAU

ST A

ND

INTA

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D21

01

405

0187

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017

MOU

NTI

NG

BAN

D2

501

9015

64 0

109

TUBE

, 2-1

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LBOW

, SH

ORT

16

0051

9470

000

3CL

AMP,

GUI

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3"

27

0190

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007

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AUST

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JD1

801

9015

64 0

108

TUBE

, 2-1

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, LON

G1

900

5194

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001

CLAM

P,M

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0187

85 0

025

MUF

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5, D

210

111

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C PL

ATED

814

0092

5025

101

7BO

LT, H

EX H

EAD

M10

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X 2

5MM

2

52 PARTS CATALOG

8.10 COMPRESSOR ASSEMbLY

FIGURE 8-5. 00717488 0087 COMPRESSOR AND MTG PARTS (REV 05)

53PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0050

1170

124

3AI

R EN

D A

SSEM

BLY,

108

MM

12

0092

5012

102

1SC

REW

, M10

X 1

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35M

M L

G10

54 PARTS CATALOG

8.11 INLET VALVE ASSEMbLY

APP

LY T

HE

FOLL

OW

ING

SEA

LAN

TS T

OA

LL B

ELO

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TITE

242

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EQ

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ALE

NT

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TO A

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ASK

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FAC

ES:

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GR

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S: L

OC

TITE

567

TH

RE

AD

SE

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NT

OR

EQ

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NT

7

2

9

2

4

3

6

1

1

5

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1:1

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F 1

D21

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JD

MFP

3/20

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JPC

3/20

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18

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DRAW

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HERE

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THE P

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T NOT

BE M

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OR C

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WW

W.S

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NPA

LATE

K.C

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AN

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LAT

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DATE

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USE

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:

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OR -

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SIONS

ARE I

N INC

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NOTE

D

X.XXX

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X + O

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0

MATE

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IT IS

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L TO

SULL

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PALA

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INTE

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.

DRAW

ING NO

:

DSIZE

FIGURE 8-6. 00717985 0045 INLET VALVE ASSY, D185-210 (REV 00)

55PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

9311

5-01

4BO

LT, W

HIZ

LOC

K .5

0-13

X 1

.000

ZIN

C PL

ATED

42

0091

5557

006

4EL

BOW

, .37

5 TU

BE X

.25

0 M

NPT

BRA

SS2

300

9011

79 0

047

NIP

PLE,

PIPE

.250

X 1

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SCH

801

400

9078

64 0

238

O-RI

NG

, 3.5

ID X

3.7

5 OD

15

0091

0239

000

5OR

IFIC

E, .0

63 X

1/4

" MN

PT X

FN

PT B

RASS

16

0090

1108

000

2PI

PE, C

ROSS

1/4

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# G

ALV

17

0091

5564

006

4TE

E, M

ALE

RUN

1/4

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PT X

3/8

" TUB

E BR

ASS

18

0090

3872

037

5VA

LVE,

TH

AND

LE .2

5MN

PT X

.375

T1

900

5011

74 1

202

VALV

E,AS

Y IN

LET

2.5"

108

MM

1

56 PARTS CATALOG

8.12 AIR FILTER ASSEMbLY

APP

LY T

HE

FOLL

OW

ING

SEA

LAN

TS T

OA

LL B

ELO

W L

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D P

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OLT

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TITE

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NT

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ES:

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567

TH

RE

AD

SE

ALA

NT

OR

EQ

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ALE

NT

7

2

9

9

1

1

411

4

13

3

5

3

1:4

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D21

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JD

AS

NO

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4/9/

13

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4/9/

13

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TER

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FILT

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112

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451

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FIGURE 8-7. 00717642 0144 AIR FILTER ASSY, D210PJD (REV 01)

57PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0501

7180

BAN

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NER

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16

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, AIR

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R IN

TAKE

3.0

0 D

185-

210

113

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014

5TU

BE, E

NG

INE

INTA

KE 3

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JD40

451

58 PARTS CATALOG

APP

LY T

HE

FOLL

OW

ING

SEA

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TS T

OA

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ELO

W L

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D P

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DRAW

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DSIZE

FIGURE 8-8. 00717642 0144 AIR FILTER ASSY, D210PJD (REV 01)

59PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

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001

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OSE

3.98

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O 4.

500

45

0091

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000

4EL

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90

DEG

3.0

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16

9141

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5EL

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3.5"

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EG1

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85FI

LTER

, AIR

8.0

0 2

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012

SLEE

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025

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VE, 3

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112

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1567

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8TU

BE, C

OMPR

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R IN

TAKE

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0 D

185-

210

113

0190

1567

014

5TU

BE, E

NG

INE

INTA

KE 3

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JD40

451

60 PARTS CATALOG

8.13 RECEIVER ASSEMbLY

APP

LY T

HE

FOLL

OW

ING

SEA

LAN

TS T

OA

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ELO

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FIGURE 8-9. 00717884 0159 RECEIVER ASSY, D185-210 SINGLE PRESSURE (REV 00)

61PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

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5-01

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42

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15

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75 T

UBE

X .2

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16

0054

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A LO

K BR

ASS

17

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62 PARTS CATALOG

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13

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3/8

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EE

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8

1

76

2

53

4

FIGURE 8-18. CD 00006 DIAGRAM, CONTROL D185-250 LOW PRESSURE PNEUMATIC CONTROL (REV 00)

79PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0091

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000

2 TU

BIN

G,N

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3/8

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E 12

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200

9100

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005

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NG

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ON 3

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ELLO

W

10"

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BIN

G,N

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3/8

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CK

15.5

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NG

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ON 3

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000

4 TU

BIN

G,N

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3/8

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4 TU

BIN

G,N

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3/8

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12

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9100

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004

TUBI

NG

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ON 3

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ED

9"8

0091

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000

3 TU

BIN

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42"

80 PARTS CATALOG

8.17 COOLING ASSEMbLYIT

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RT

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98

20

19

27

18

23

30

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FIGURE 8-19. 00717532 0119 COOLING ASSY, D210PHJD & D3125JD (REV 0)

81PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

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FOR

M9

82 PARTS CATALOG

8.18 OIL FILTER AND PIPING

FIGURE 8-20. 00717620 0020 OIL FILTER ASSY, D185-210 (REV A)

83PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

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011

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(OPT

ION

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215

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001

2FI

LTER

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ELE

MEN

T1

84 PARTS CATALOG

8.19 FUEL TANK ASSEMbLY

FIGURE 8-21. 00717972 0078 FUEL TANK AND MTG PARTS (REV F)

85PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

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9475

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FUE

L 30

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END

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301

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066

TUBE

, FUE

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002

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HOS

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I.D

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PSI

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112

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86 PARTS CATALOG

8.20 INSTRUMENT PANEL ASSEMbLY

APP

LY T

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05018845 0136 00

5/20/13JPC5/20/13MFP

3 OF 3

DC

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3RD ANGLEPROJECTION

1201 West US Highway 20, Michigan City IN 46360 1-800-438-6203

SHEET SCALE:

TOLERANCES AS FOLLOWS:

REV

DESCRIPTION

THIS DRAWING AND ALL INFORMATION THEREIN IS THE PROPERTY OF SULLIVAN-PALATEK, INC. IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED.

WWW.SULLIVANPALATEK.COM

SULLIVAN-PALATEKCHECKED BY: DATE:

DATE:DRAWN BY:

FIRST USED ON:

ANGLES: + OR - 1/2 DEG.

DIMENSIONS ARE IN INCHESUNLESS OTHERWISE NOTED

X.XXX + OR - 0.005X.XX + OR - 0.020

DECIMAL: X.X + OR - 0.050

MATERIAL:

IT IS LOANED SUBJECT TO RETURN UPON DEMAND, IS NOT TO BE USED DIRECTLY OR INDIRECTLY IN ANYWAY DETRIMENTAL TO SULLIVAN-PALATEK'S INTEREST.

DRAWING NO:

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901

9007

52 0

034

HIN

GE,

PAN

EL 2

" CON

T. A

LUM

INIU

M1

1001

9004

16 0

095

COVE

R, E

XHAU

ST P

IPE

HOL

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1101

9001

04 0

273

ANG

LE,D

OOR

BOTT

OM,G

ALVA

NN

EAL

212

0122

8269

002

0SP

RIN

G1

1301

9001

68 0

005

BOLT

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1/4

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ZIN

C1

1400

9090

88 0

005

NUT

,SPE

ED 5

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18 U

-TYP

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1501

9015

20 0

281

SUPP

ORT,

SER

VICE

AIR

PIP

E1

160

A222

351

HOL

DER

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R LA

TCH

417

0190

0416

012

2CO

VER,

RAD

IATO

R FI

LL1

1800

9137

92 0

038

SCRE

W,1

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0 X

1/2"

TH

D F

ORM

4019

0091

6867

042

1RI

VET,

3/16

" X .1

26 -.

250

RAN

GE

132

2000

9137

92 0

039

SCRE

W,5

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18 X

1/2

" TH

D F

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821

0090

0321

000

2W

ASH

ER,F

LAT

1/4

1N

I00

9137

92 0

055

SCRE

W,5

/16-

18 X

3/4

TH

D F

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8N

I05

0186

50 0

024

LATC

H,S

LAM

,W/

MOU

NT.

HOL

ES2

98 PARTS CATALOG

FIGURE 8-28. 03903168 0093 ENCLOSURE, UPPER ASSY D185-250 (REV C)

99PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0190

1000

071

0PA

NEL

, FRO

NT

CAN

OPY

D18

5-25

01

201

9010

00 0

711

PAN

EL, R

EAR

D18

5-25

01

301

9010

00 0

709

PAN

EL, R

OOF

14

0190

0485

003

2D

OOR,

SID

E AC

CESS

D18

5-25

02

501

9004

85 0

030

DOO

R, IN

STRU

MEN

T PA

NEL

ACC

ESS

16

0190

0480

004

3D

OOR,

REA

R AC

CESS

PAN

EL1

700

9004

90 0

071

NUT

,NYL

OK 1

/4-2

01

801

9007

52 0

055

HIN

GE,

SID

E AC

CESS

DOO

R2

901

9007

52 0

034

HIN

GE,

PAN

EL 2

" CON

T. A

LUM

INIU

M1

1001

9004

16 0

095

COVE

R, E

XHAU

ST P

IPE

HOL

E2

1101

9001

04 0

273

ANG

LE,D

OOR

BOTT

OM,G

ALVA

NN

EAL

212

0122

8269

002

0SP

RIN

G1

1301

9001

68 0

005

BOLT

,EYE

1/4

-20

ZIN

C1

1400

9090

88 0

005

NUT

,SPE

ED 5

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18 U

-TYP

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1501

9015

20 0

281

SUPP

ORT,

SER

VICE

AIR

PIP

E1

160

A222

351

HOL

DER

,DOO

R LA

TCH

417

0190

0416

012

2CO

VER,

RAD

IATO

R FI

LL1

1800

9137

92 0

038

SCRE

W,1

/4-2

0 X

1/2"

TH

D F

ORM

4019

0091

6867

042

1RI

VET,

3/16

" X .1

26 -.

250

RAN

GE

132

2000

9137

92 0

039

SCRE

W,5

/16-

18 X

1/2

" TH

D F

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821

0090

0321

000

2W

ASH

ER,F

LAT

1/4

1N

I00

9137

92 0

055

SCRE

W,5

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18 X

3/4

TH

D F

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8N

I05

0186

50 0

024

LATC

H,S

LAM

,W/

MOU

NT.

HOL

ES2

100 PARTS CATALOG

8.22 MACHINE DRESS

NO

DR

AWIN

G A

VAIL

ABLE

FIGURE 8-29. 00717752 0177 MACHINE DRESS, D210PHJD (REV G)

101PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0 2

2248

7TI

E,PL

ASTI

C 8

1/2"

LG

.3

200

8090

22AN

TI-F

REEZ

E PE

RMAN

ENT

3.75

G3

0081

6708

DIE

SEL

FUEL

-GRA

DE

#25

G4

0082

3062

OIL,

WEA

THER

-ALL

, BUL

K PE

R G

AL6.

5 G

500

9102

70 0

001

RIVE

T,.1

25 D

IA. X

.232

LG

SS

26

0091

6867

043

0RI

VET,

5/32

" X 1

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GRI

P8

701

2283

78 0

005

DEC

AL,D

ANG

ER -

HOT

OIL

28

0190

0190

001

0BO

X, M

ANUA

L H

OLD

ER 8

.5"X

11"

19

0190

0224

000

5BU

MPE

R,D

OOR

410

0190

0456

005

9D

ECAL

, PRO

P 65

WAR

NIN

G C

ALIF

OR1

1101

9004

64 0

007

DEC

AL,R

OTAT

ING

PAR

TS2

1201

9004

64 0

094

DEC

AL, Q

UALI

TY A

CCEP

TED

113

0190

0464

010

4D

ECAL

,AM

ERIC

AN F

LAG

114

0190

0464

014

8D

ECAL

,FUE

L W

ARN

ING

115

0190

0464

030

4D

ECAL

, OPE

RATI

NG

INST

RUCT

ION

S1

1601

9004

64 0

314

DEC

AL,"S

ULLI

VAN

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ATEK

", BL

K1

1701

9004

64 0

318

DEC

AL"S

ULLI

VAN

PAL

ATEK

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1801

9004

64 0

323

LABE

L, L

OW S

ULFE

R FU

EL1

1901

9004

64 0

338

DEC

AL, W

EATH

ER-A

LL C

OMPR

FLU

ID1

2001

9011

36 0

003

PLAT

E,ID

ENTI

FICA

TION

121

0190

1201

000

4RE

FLEC

TOR,

3" D

IA. (

AMBE

R)2

2201

9012

01 0

005

REFL

ECTO

R, 3

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. (RE

D)

223

0501

8650

002

4LA

TCH

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M,W

/ M

OUN

T. H

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224

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8730

002

3PA

RTS

CAT.

,JD40

45,P

T.N

O.PC

2521

125

0501

8730

009

7M

ANUA

L, 4

045T

F280

, OM

RG37

708

1

102 PARTS CATALOG

8.23 CHASSIS ASSEMbLY

NO

DR

AWIN

G A

VAIL

ABLE

FIGURE 8-30. 00717464 0095 CHASSIS ASSEMBLY,D210-250 (REV 00)

103PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0190

0007

030

1AC

OUST

IC, A

IR P

IPIN

G 1

85-2

102

200

9001

15 0

001

BOLT

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1/4

-20

X 3/

4 G

R54

300

9001

15 0

025

BOLT

,HEX

5/8

-11

X 1

1/4

GR5

44

0090

0016

002

5BO

LT,H

EX 5

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1 X

1 1/

4 G

R82

501

9004

16 0

121

COVE

R,CO

RNER

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VAN

IZED

26

0190

0416

012

0CO

VER,

RAD

. & O

IL D

RAIN

,GAL

VAN

.1

703

9031

68 0

106

FRAM

E, D

125-

250

18

0501

8635

005

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MP,

STOP

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RN W

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LECT

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903

9030

09 0

063

LIFT

ING

BAI

L, 4

045

TIII

110

0090

0490

007

1N

UT,N

YLOK

1/4

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411

0090

0490

006

2N

UT,N

YLOK

5/1

6-18

412

0190

1000

073

0BPA

NEL

, CUR

BSID

E BL

ACK

113

0190

1000

071

2BPA

NEL

, FRO

NT

BLAC

K1

1401

9010

00 0

729B

PAN

EL, R

EAR

BLAC

K1

1501

9010

00 0

731B

PAN

EL, S

TREE

TSID

E BL

ACK

116

0190

1000

071

9PA

NEL

, TOO

L BO

X (C

URB)

117

0190

1000

071

8PA

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, TOO

L BO

X (S

TREE

T)1

1801

9010

00 0

706

PAN

EL,F

END

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ALVA

NIZ

ED2

1900

9137

92 0

038

SCRE

W,1

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0 X

1/2"

TH

D F

ORM

160

2000

9137

92 0

039

SCRE

W,5

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18 X

1/2

" TH

D F

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221

0190

1485

000

1ST

RIKE

R PL

ATE

222

0190

1520

028

8SU

PPOR

T, D

RAW

BAR

123

0080

0120

TAPE

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PREN

E 1/

4" T

K X

1"1

FT24

0090

0321

000

3W

ASH

ER,F

LAT

5/16

4

104 PARTS CATALOG

8.24 AXLE ASSEMbLY

1

3

4

2

ITE

MS

NO

T S

HO

WN

:

1) 4

X 0

0900

115

0034

SC

RE

W, 1

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3 x

1-1/

2" L

G G

D 5

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1901

696

0024

WA

SH

ER

, RU

BB

ER

, 1/2

" ID

x 2

-1/4

3) 2

X 0

3903

464

0144

LE

G, S

HIP

PIN

G

FIGURE 8-31. 00717401 0021 AXLE ASSEMBLY 185-375 (REV C)

105PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0501

7120

036

9AX

LE A

SSY,

D18

51

201

6615

80 0

003

LIN

K, S

HAC

KLE,

SM

ALL

- MED

. LIN

E4

301

2283

33 0

001

BOLT

, SH

ACKL

E, 9

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18 x

3"

64

0122

8249

000

3LO

CKN

UT, S

HAC

KLE

BOLT

, 9/1

6-18

6

106 PARTS CATALOG

8.24.1 AXLE

2

73

6

54

1

NO

TE: S

EE

HU

B D

RA

WIN

G 0

5018

515

0023

FOR

RE

PLA

CE

ME

NT

PA

RTS

FIGURE 8-32. 05017120 0369 AXLE, ASSY 3500# (REV-03)

107PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0190

0146

000

6BE

AM,A

XLE

3500

# 2-

3/8

DIA

.1

201

9001

60 0

007

U-BO

LT,1

/2-2

0 X

2-3/

8 TU

BE D

IA4

301

9009

20 0

015

NUT

, WH

EEL

LUG

104

0190

0920

001

7N

UT, U

-BOL

T, 1

/2-2

08

501

9011

12 0

555

TIE

PLAT

E, T

YPE

I, RD

. AXL

E2

601

9014

33 0

009

SPRI

NG

ASS

Y2

705

0185

15 0

023

HUB

ASS

Y. ID

LER

2

108 PARTS CATALOG

8.24.2 HUB ASSEMBLY

5

8

3

9

7

1

4

2

6

FIGURE 8-33. 05018515 0023 HUB ASSY. IDLER (REV-02)

109PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0090

0620

002

0PI

N,C

OTTE

R 1/

8 X

1 3/

4 LG

12

0190

0248

001

4CA

P, G

REAS

E H

UB1

301

9008

48 0

018

IDLE

R, W

HEE

L 5

X 4.

51

401

9009

20 0

016

SPIN

DLE

NUT

15

0190

1296

000

3SE

AL, G

REAS

E H

UB1

601

9015

12 0

011

STUD

,IDLE

R H

UB 1

/2-2

0 X

1.81

57

0190

1696

001

3W

ASH

ER, S

PIN

DLE

18

0501

7229

000

7BE

ARIN

G, I

NN

ER1

905

0172

29 0

008

BEAR

ING

, OUT

ER1

110 PARTS CATALOG

8.25 TIRE AND WHEEL ASSEMbLY

FIGURE 8-34. 05019880 0036 WHEEL ASSY, ST205-75D15

111PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0190

1550

002

9TI

RE, S

T205

/75D

151

205

0198

95 0

003

WH

EEL,

WH

ITE

SPOK

ED 1

5" X

6"

1

112 PARTS CATALOG

8.26 bUMPER ASSEMbLY

FIGURE 8-35. 00717703 0158

113PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0190

0224

001

8BU

MPE

R, R

EAR,

14

GA.

GAL

VAN

IZED

12

0190

1416

005

2SP

ACER

, 2.5

" LG

/ 1

/2" E

MT

TUBE

43

0090

0115

013

4SC

REW

, 1/2

-13

X 4"

LON

G G

D 5

44

0090

0321

000

5W

ASH

ER, F

LAT

1/2"

ZIN

C PL

ATED

4

114 PARTS CATALOG

8.27 DRAWbAR ASSEMbLY

1

6A

LL

DE

TA

IL V

IEW

S S

HO

WIT

EM

1 H

IDD

EN

DE

TA

IL D

DE

TA

IL F

4

8

5

DE

TA

IL B

DE

TA

IL A

32

DE

TA

IL C

DE

TA

IL E 3

7

.

..

DC

1345

AB

CD

EF

5 3 2 1

FE

BA

SCA

LE:

CLA

REM

ON

T, N

H REV

MIC

HIG

AN

CIT

Y, I

N

DR

AW

ING

NO

:

OF

SHEE

T

SIZE

CA

D B

Y:

DO

NO

T S

CA

LE

DR

AW

ING

4

2

THIR

D A

NG

LE

.SE

E BO

M

NO

NEDR

AW

BAR

ASS

EMBL

Y

1

0071

7554

007

431

MA

Y06

REL

EASE

D F

OR

PR

OD

UC

TIO

NPH

DC

BC78

81

31M

AY

06

PR

OJE

CTI

ON

DW

A

48" S

TRA

IGH

T, S

TAN

DA

RD

HEI

GH

T

. ..

.

..

..

..

..

..

..

..

..

..

..

..

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NO

TE

:C

HE

CK

TH

AT

ALL

NU

T T

HR

EA

DS

AR

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RE

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F P

AIN

T O

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IRT

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ST

AR

T A

TT

AC

HIN

G B

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S B

Y H

AN

D T

O P

RE

VE

NT

CR

OS

S T

HR

EA

DIN

G.

2.S

EC

UR

ELY

TIG

HT

EN

ALL

DR

AW

BA

R M

OU

NT

ING

BO

LTS

TO

140

LB

-FT

(D

RY

) M

AX

.

3.

FIGURE 8-36. 00717554 0074 DRAWBAR ASSY 48.00 STRAIGHT D185-210 (REV 0)

115PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0390

3136

015

8D

RAW

BAR,

48" S

TRAI

GH

T,ST

D H

GT1

200

9000

16 0

035

HH

CS,5

/8-1

1 X

1-1/

2" L

G G

D 8

23

0090

9994

581

1N

UT,C

ENTE

RLOC

K,5/

8-11

44

0090

0016

019

8H

HCS

,1"-8

X 5

-1/2

" LG

GD

81

500

9000

16 0

025

HH

CS,5

/8-1

1 X

1-1/

4" L

G G

D 8

16

0501

7420

001

6H

ARN

ESS,

DRA

WBA

R,ST

D1

700

9000

42 0

155

HH

CS 5

/8-1

1 X

4.5

GR8

28

0090

0321

000

6W

ASH

ER,F

LAT,

5/8"

ZIN

C PL

ATED

39

0090

2905

000

1CL

AMP,

SUP

PORT

, .50

ID3

1000

9137

92 0

039

SCRE

W, 5

/16-

18 X

1/2

TH

D F

ORM

411

0090

0490

012

5N

UT, N

YLOK

1-8

ZIN

C PL

ATED

1

116 PARTS CATALOG

8.28 SWIVEL JACK

1

FIGURE 8-37. 05018590 0012 JACK, SWIVEL D185

117PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0501

8590

001

2JA

CK, S

WIV

EL1

118 PARTS CATALOG

8.29 SAFETY CHAIN

BLB

B1

:

REL

EASE

D F

OR

PR

OD

UC

TIO

NPH

D

2

BLB

FOR

REC

OR

D O

NLY

FOR

REC

OR

D O

NLY

35

"

05

01

74

95

00

27

BLB

SA

FE

TY

CH

AIN

AS

SE

MB

LY

------

------

-

DC

1345

AB

CD

EF

5 3 2 1

FE

BA

SCA

LE:

CLA

REM

ON

T, N

H REV

MIC

HIG

AN

CIT

Y, I

N

DR

AW

ING

NO

:

OF

SHEE

T

SIZE

CA

D B

Y:

DO

NO

T S

CA

LE

DR

AW

ING

4

2

02/2

8/08

PR

OJE

CTI

ON

08/1

6/06

CBC

810

08/1

6/06

------

------

-

THIR

D A

NG

LE

02/2

8/08

2

1

FIGURE 8-38. 05017495 0027 SAFETY CHAIN ASSY (REV B)

119PARTS CATALOG

ITEM

PAR

T N

UM

bER

DES

CRIP

TIO

NQ

TY1

0090

2051

000

4SH

ACKL

E, C

HAI

N 7

/16"

ROU

ND

PIN

12

0190

0251

000

9SA

FETY

CH

AIN

, 3/8

" × 3

5" L

G.

1