€.SULLAIR. PORTABLE AIR COMPRESSOR 375, 375H & 425 DPQ JOHN DEERE 375 CATERPILLAR STANDARD AFTERCOOLED/FILTERED OPERATOR’S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE mber Siar CorporationAIR CARE SEMINAR TRAINING Sullair Air Care Seminars are 2—-day courses that provide hands —on instruction in the proper operation, maintenance and service of Sullair equipment. Individual seminars on Portable compressors are presented at regular intervals throughout the year at a dedicated training facility at Sullair's corporate headquarters in Michigan City, Indiana. Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of the most common problems, and actual equipment operation. The seminars are recommended for rental house and Contractor jaintenance and service personnel. For detailed course outlines, schedule and cost information contact: Sullair Corporate Training Department 1—800—SULLAIR or 219-879-5451 (ext. 5630) — Or Write — Sullair Corporation 3700 E. Michigan Blvd. Michigan City, IN 46360 Attn: Service Training DepartmentSection 1 SAFETY Section 2 DESCRIPTION Section 3 SPECIFICATIONS Section 4 OPERATION TABLE OF CONTENTS. OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL Noooanneet © eee 14 14 15 15 7 18 19 B88 14 GENERAL, 1.2 TOWING 1.3 PRESSURE RELEASE 1.4 FIRE AND EXPLOSION {5 MOVING PARTS 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS 1.7 TOXIC AND IRRITATING SUBSTANCES 1.8 ELECTRICAL SHOCK 1.9 UFTING 4.40 ENTRAPMENT 1.11 JUMP STARTING 24 INTRODUCTION 2.2 DESCRIPTION OF COMPONENTS. 2.3 SULLAIR COMPRESSOR UNIT, "FUNCTIONAL DESCRIPTION 2.4 COMPRESSOR COOLING AND LUBRICATION ‘SYSTEM, FUNCTIONAL DESCRIPTION. 2.5 COMPRESSOR DISCHARGE SYSTEM, "FUNCTIONAL DESCRIPTION 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION 2:7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION 2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION 2.9 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION 2.10 AFTERCOOLED AND FILTERED AIR SYSTEM, FUNCTIONAL DESCRIPTION. ‘SPECIFICATIONS 975, 37SH AND 425 JOHN DEERE ‘SPECIFICATIONS 375 CATERPILLAR, LUBRICATION GUIDE 4.1 GENERAL 4.2 PURPOSE OF CONTROLSSection 4 OPERATION (cont) Section 5 MAINTENANCE Section 6 NOISE CONTROL Section 7 ILLUSTRATIONS AND PARTS LIST 24 24 22 22 BESBISRBRBEBRB BS TABLE OF CONTENTS (CONTINUED) 43 START-UP PROCEDURE 44 SUBSEQUENT START-UP PROCEDURE 45 SHUTDOWN PROCEDURE 15.1. GENERAL 52 DAILY OPERATION ‘5.3 MAINTENANCE AFTER INITIAL 50 HOURS. ‘OF OPERATION '5.3A MAINTENANCE EVERY 50 HOURS ‘5.4 MAINTENANCE AFTER INITIAL 100 HOURS OF OPERATION '5.4A MAINTENANCE EVERY 100 HOURS. ‘555 MAINTENANCE EVERY 200 HOURS. ‘56 MAINTENANCE EVERY 250 HOURS. 57 MAINTENANCE EVERY 300 HOURS ‘5.8 MAINTENANCE EVERY 500 HOURS. ‘59 MAINTENANCE EVERY 600 HOURS. 5.10 MAINTENANCE EVERY 1000 HOURS. 5.11. MAINTENANCE EVERY 1200 HOURS: 5.11A MAINTENANCE EVERY YEAR OR 12,000 MILES 65.12 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES 5.13 TROUBLESHOOTING 6.1 NOISE EMISSIONS WARRANTY {62 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED 163 NOISE EMISSIONS MAINTENANCE AND ‘MAINTENANCE RECORD LOG 71 PROCEDURE FOR ORDERING PARTS 7.2 RECOMMENDED SPARE PARTS LST 7.3 ENGINE, COMPRESSOR AND PARTS ~ JOHN DEERE ‘7.4 ENGINE, COMPRESSOR AND PARTS ~ CATERPILLAR ‘7 RADIATOR AND COMPRESSOR FLUID COOLING SYSTEM ~ JOHN DEERE & CATERPILLAR,Section 7 ILLUSTRATIONS AND PARTS LIST (cont.) 8 72 74 78 se TABLE OF CONTENTS (CONTINUED) 176 AIR INLET SYSTEM & EXHAUST SYSTEM — JOHN DEERE & ‘CATERPILLAR 177 CONTROL PARTS AND DISCHARGE PARTS — JOHN DEERE & ‘CATERPILLAR, ‘7.7R ASSEMBLIES ~ REGULATOR VALVE (H AND STANDARD MODELS) AND CONTROL ORIFICE (H MODELS) 7.78 ASSEMBLIES — SERVICE VALVE, PNEUMATIC CONTROL VALVE ‘AND RECEIVER FLUID FILL — ALL MODELS 7.8 OPTIONAL AFTERCOOLERJFILTER AND PARTS—JOHN DEERE & CATERPILLAR’ 7.9 ELECTRICAL PARTS-JOHN DEERE AND CATERPILLAR. 7.40 INSTRUMENT PANEL AND PARTS-JOHN DEERE AND CATERPILLAR, 741 FUEL TANK AND CONNECTIONS ~ JOHN DEERE & CATERPILLAR 7.42 FRAME, AXLE & PARTS AND AXLE ASSEMBLY — JOHN DEERE ‘AND CATERPILLAR 7.49 FRAME, LESS RUNNING GEAR AND PARTS ~ JOHN DEERE AND (CATERPILLAR. 7.14 CANOPY, ACOUSTICAL PANELS AND PARTS-JOHN DEERE AND ‘CATERPILLAR 7.15 DECALS 7.16 DECAL LOCATIONSNOTES4.1 GENERAL Salat Corporation designs and manufactures all Of its products so they can be operated safely. However, the responsiblity for safe operation rests with those who use and maintain these products. ‘The following safety precautions are offered as a Quide which, if conscientiously followed, will mini- mz the possibly of accidents throughout the Useful feof this equipment. Read the CIMA Safety Manual prior to compressor operation and towing, if applicable in your area. The air compressor should be operated only by those who have been trained and delegated to do 0, and who have read and understood this Opera~ tor's Manual, Failure tofollow the instructions, pro- cedures and safety precautions in this manual can resuit in accidents and injuries. NEVER start the air compressor unless its safe to doso. DO NOT attemptto operate the air compres- sor with a known unsafe condition. Tag the air com- pressor and render it inoperative by disconnecting the battery so others who may not know of the un- safe condition will not attempt to operate it unti the Condition is corrected. Use and operate the air compressor only in full compliance with all pertinent OSHA requirements and/or all pertinent Federal, State and Local codes or requirements, DO NOT modity the compressor except with writ ten factory approval Each day walk around the air compressor and in- spect for leaks, loose or missing parts, damaged parts or parts out of adjustment. Perform all recom mended daily maintenance. Inspect for tom, frayed, blistered or otherwise dete- fiorated and degraded hoses. Replace as re- quired, Pei Estimated hose life based on a 5-day 8—hour ‘work week Is 3 years. These conditions exist on fan 8-hour shit only. Any ether operation ofthe ‘equipment other than 8-hour shifie would short- ‘en the hose Ite based on hours of operation. 1.2 TOWING (1D) A. PREPARING TO TOW PSG DO NoTtow the compressor should ts weightex- ‘ceed the rated limit ofthe tow vehicle, as the veh ‘ele may not brake safely with excess weight See Fated limitin ow vehicle Operator's Marval, and Feviewits instructions and ether requirements for tafe towing. 1. Prior to hitching the air compressor to the tow vehicle, inspect all attachment parts and equip- ment, checking for () signs of excessive wear or corrosion, (i) parts that are cracked, bent, Section 1 SAFETY dented or otherwise deformed or degraded, and {ii) loose nuts, bolts or other fasteners. Should any such condition be present, DO NOT TOW Until the problem is corrected. 2. Back the tow vehicle to the compressor and Position it in preparation for coupling the com- pressor. 3. If the compressor is provided with a drawbar latched in the vertical upright position, carefully unlatch drawbar and lower ito engage the cou- pling device. If not, raise drawbar to engage coupling device or otherwise couple the com- pressor to the towing vehicle, EOE ‘This equipment may be tongue heavy, DO NOT attempt to raise or wer tne crawoaby hand i ihe weight fe more than you can safely Bando. Use the screw jack provided or a chain fal ityou ‘cannot lft or lower it without avoiding injury to yourself orothers. Keep hands and fingers clear ofthe coupling device and all other pinch points. Keep feet clear of drawbarto avoid injury incase it should slip from your hands. 4, Make sure the coupling device is fully en- gaged, closed and locked 5, If chains are provided, pass each chain through its point of attachment on the towing ve- hicle; then hook each chain to itself by passing the grab hook over (not through) a link. Cross chains under front of drawbar before passing them through points of attachment on towing Vehicle to support front of drawbar in case it should accidentally become uncoupled. 6, Make sure that the coupling device and adja- centstructures on the towing vehicle (and also, it utilized, chain adjustment, brake andor electr- cal interconnections) DO NOT interfere with or restrict motion of any part of the compressor, in- cluding its coupling device, with respect to the towing vehicle when maneuvering over any an- ticipated terrain. 7. If provided, make sure chain length, brake and electrical interconnections provide suffi cient slack to prevent strain when cornering and ‘maneuvering, yet are supported so they cannot drag or rub on road, terrain or towing vehicle sur- faces which might cause wear that could render them inoperative ENG Retract the front screw jack only after attaching {the compressor to the tow vehicle. Ralse the serew jack ois full up position and pull the pin ‘connecting the jack to the drawbar. Potato tho Serow jack o te stowed postion, 1 the DESCRIPTION OF COMPONENTS performance and reliability along with @ minimal amount of maintenance requirements. ‘Te compressor is equipped with a Sulla rotary ‘screw compressor unit. Compared to other com- pressors, the Sulairis unique in mechanical reliabil- ity and compressor durability. No inspection is re- quired of the working parts within the compressor unit ‘As you continue reading this manual and come to lear how the compressor operates andis cared for, you will see how surprisingly easy itis to keep a Sull- air compressor in top operating condition. Read Section 5 (Maintenance) and learn how to keep your compressor in top operating condition. ‘Should any problem or question arise which cannot be answered inthis text, contact your nearest Sullair Referto Figures 2-1, The components and assem- blies of the Sulair375, 375H, and 425 Standard and Afteroooled Portable ‘air compressors are clearly shown, The package includes @ heavy duty rotary ‘screw air compressor, a diesel engine, fuel tank, ‘compressor inlet system, compressor cooling and lubrication system, compressor discharge system, capacity control system, instrument panel and electrical system. A low profile canopy offers improved handling and mobility. Large side service doors provide easy ac- cess to all serviceable components, This model meets EPA regulations for 76dbA at 7 meters (23 feet). Sul alr compressors are capable of deliver ing capacities as follows: Figure 2—1 Sullair Rotary Screw Portable Air Compressor — John Deere Standard & Aftercooler Models ENGINE AIR FILTER COMPRESSOR FILTER w AIR INLET VALVE. FUEL TANK ‘OPTIONAL, GRAWEAR AFTERCOOLED MODEL \ Moisture SEPARATOR STANDARD MODEL MINIMUM PRESSURE) (CHECK VALVE opmioNaL, oe ENGINE AIR pee! FILTER COMPRESSOR 2 FLTER AIRINLET VALVE a ‘SUMP TANK23 24 Model 375 375CFM @ 100 PSIG (6.9 bar) Model 37SH | 375CFM @ 150 PSIG (10.3 ban) Model 425 425CFM @ 100 PSIG (6.9 bar) The control system can easily be adjusted for pres- sures from 70 to 125 PSIG (4.8 to 8.6 bar) for stan- dard machines and from 70 to 150 PSIG (4.80 10.3. bar) for “H” machines. The compressor unit is driven by an industrial diesel engine designed to provide enough horsepower for more than ade~ Quate reserve at rated conditions. Refer to the En- gine Operator's Manual for a more detailed descrip- tion of the engine. The engine cooing tor, high capacity fan and thermostat. The high c pacity fan pushes air through the radiator, keeping the engine at the proper operating temperature. ‘The same fan also cools the fluid in the compressor cooling and lubrication system. The engine radiator and the compressor fluid cooler sit side by side which allows the fan air to push through both simul- taneously. As air passes through the fluid cooler, the heat of compression is removed from the fluid. ‘The compressor is supplied with a large capacity fuel tank which will keep the compressor running through one (1) eight hour shift under normal oper ating conditions. SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION Sulair compressors feature the Sullair compressor Unit, a single-stage, positive displacement, flood lubricated=type compressor. This unit provides continuous (pulse —free) compression to meet your needs. With a Sullair compressor, no maintenance or inspection of the internal parts of the compressor unit is required Fluid is injected into the compressor unit where it mixes directly with the air as the rotors turn, com- pressing the air. The fluid flow has three main funo- tions: 1. As coolant, it controls the rise of air temperature normally associated with the heat of compres- sion. 2, Seals the leakage paths between the rotors and ‘the stator and also between the rotors them- selves. 8, Acts as a lubricating flm between the rotors allow- ing one rotor to directly drive the other. After the airfiuid moture is discharged from the Compressor unit, the fluid is separated from the air. Atthis time, the air flows to your serve line and the fluid is cooled in preparation for reinjection. COMPRESSOR COOLING AND LUBRICATION ‘SYSTEM, FUNCTIONAL DESCRIPTION Section 2 DESCRIPTION Refer to Figure 2-2. The compressor cooling and lubrication system is designed to provide adequate lubrication as well as maintain the proper operating temperature of the compressor. In addition to the fluid cooler and interconnecting piping, the sys- tem consists also of three other components: a fluid filter, thermal valve, and a fan which perform the following function: + The fluid fiter fitters the fluid +The thermal valve functions as a temperature requ- lator directing fiuid either to the cooler orto the com- pressor unit, bypassing the cooler as will be ex- plained later * The fan pushes air through the cooler removing the heat of compression from the fluid. ‘The functions of the lubrication system are ex- plained in more detail below. Fluid is used in the sys- tem as a coolant and as a lubricant. Itis housed in the receiver/sump which, will from this time forward, be referred to as the SUMP. Upon startup, fluid flows fromthe sump to the fluid thermal valve, Fluid circulation is achieved by forc- ing the fluid from the high pressure region of the sump to a lower pressure area in the compressor unt minimum pressure device (see Section 25 ‘Compressor Discharge System) is provided to as- sure adequate fluid flow under all conditions. When entering the thermal valve upon start—up, the fluid temperature is cool and thus itis not necessary to route it through the cooler, Hence the fluid flows through the fluid fer and on to the compressor unit bypassing the cooler. As the compressor continues to.operate, the temperature of the fluid rises and the thermostatic control_ opens, allowing a portion of the fluid to the cooler. When the temperature reaches 140°F (60°C), the thermostat is fully oper allowing all fluid entering the thermal vaive to be di rected fo the cooler. The cooler isa radiator type that works in conjune- tion with the engine fan. The fan pushes air through the cooler removing the heat of compression from the fiuid. From the cooler, the fiuid is then routed back through the fluid fiter. All fluid flowing to the ‘compressor unit passes through this fit. The fluid leaving the fier flows to the compressor unit where it lubricates, seals and cools the compression chamber as well as lubricates the bearings and gears, 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNC- TIONAL DESCRIPTION Refer to Figures 2-3 and 2-4, The Sullair co pressor unit discharges compressed air/fluid mix- ture into the sump. The sump has three functions: 1. tacts as a primary fluid separator. 2. Serves as the compressor fluid sump. 8, Houses the airifluid separator.Section 2 DESCRIPTION Figure 2-2 Compressor Cooling and Lubrication System COMPRESSOR. ‘The compressed airfiuid mixture enters the sump and is directed against the side of the sump. By change of direction and reduction of velocity, large droplets of fluid separate and fallto the bottom ofthe ‘sump. The fractional percentage of fluid remaining in the compressed air collects on the surface of the final separator element as the compressed air lows through the separator. As more and more fluid col- lects on the element surface, the fluid descends to the bottom of the separator. A return line (or scav- enge tube) leads from the bottom of the separator ‘element to the inlet region of the compressor unit. Fluid collecting on the bottom of the separator ele- menttis returned to the compressor by the pressure difference between the area surrounding the sepa- fator element and the compressor inlet, An orifice (protected by a strainer) is included in this return line to assure proper flow. The sump is ASME code rated at 200 psig (13.8 bar) working pressure. A minimum pressure device o- 10 ‘cated downstream from the separator, assures a minimum receiver pressure of 55 psig (8.8 bar) dur- ing all conditions. This pressure is necessary for proper air/fluid separation and proper fluid circula- tion A pressure relief valve (located on the wet side ofthe ‘separator Is set to open if the sump pressure ex- ‘ceeds 165 psig (11.4 bar) oF 200 PSIG (13.8 bar) for “H machines. A temperature switch willshut down the compressor, the. dscharge temperature feaches the speciiedimit gwen in Sections, Spec- fications. Fluid is added to the sump via a capped fluid filer. PIS DO NOT remove caps, plugs, andlor other compo- ‘ents whan comprouecr le rning or preseurized, Stop compressor and relieve alinfornal pressure. Be- fore doing 20.2.6 CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figures 2-3 and 2—4 or 2—4A. The pur- pose of the control systems to regulate the amount Of air intake in accordance with the amount of com- pressed air being used. The control system con- sists of a pressure regulating valve(s), air inlet valve, system blowdown valve, and tubing con- necting the various components to the compres- sor and engine governor. The functional descr tions of the control system are given in four distinct phases of operation. Itapplies to any controlsystem with the exception of those with stated pressures Which are dependent on pressure requirements. The pressures stated will be in accordance with a compressor having an operating pressure range of 100 to 110 psig (6.9 to 7.6bar). START — 0 TO 40 PSIG (0 to 2.8 BAR) Section 2 DESCRIPTION COLD START When the compressors started, the sump pressure will icky rse from 0 0 40 psig (0 to 2.8 bar). Dur- ing this period the pressure regulator valve is inac- tive. At this pressure range the idle warm—up con- ‘rol maintains a closed inlet valve for engine idle op- eration. After. sufficient machine warm—up_ is achieved, turn the handle of the selector valve- warm-up control (located on the instrument panel) from the ‘start’ to the “run” position. The inlet valve is fully open due to inlet air pressure, and the com- pressor operates at full capacity operation. As the compressor operates at full capacity, the engine runs at full speed. NORMAL OPERATION — 5510 100 PSIG (3.8TO 6.9 BAR) OR 55 TO 150 PSIG (3.8 TO 10.3 BAR) FOR “H” MACHINES ‘When the warm-up control selector valve handle is, moved to the “run” position, the sump pressure Figure 2~3 Compressor Discharge System — Standard and Aitercooled Models MINIMUM PRESSURE/ oo ‘CHECK VALVE ENGINE AFTERCOOLER SEPARATOR ELEMENT STANDARD MODEL NON-AFTERCOOLED AFTERCOOLED SERVICE JAVALVE MINIMUM PRESSURE VALVE ‘SERVICE AIR __oumier, \ ‘OPTIONAL DISCHARGE ARFILTERS SUMP TANK MOISTURE. SEPARATOR "Section 2 DESCRIPTION Figure 2-4 Control System with Piping and Instrumentation — 375 and 425 Models AR PRESSURE GAUGE ‘AIR FILTER, INSTRUMENT PANEL ENGINE SPEED CONTROL CYLINDER oO-r @-Awomar FLUID y A FLUID COOLER AFTERCOOLED MACHINES: ‘ONLY ORIFICE BLOWDOWN VALVE STRAINER IMUM PRESSURE) (CHECK VALVE Ke —. PRESSURE REEF || valve fl BE Mot SEPARATOR, JAFTERCOOLERSection 2 Figure 2—4A Control System with Piping and Instrumentation — 375H Models once SEC sxovoown wre J srmanen va abet, aneurer | [> CHECKVANE oe AeSOLATOR = er must || RM : ; fusyeen | ragssune 7 ea _ Valve (\aow_ | wesralmenrt | PRESSURE _ ) mae | eae | son ) Ry) a { b coi SEE ibe A, coupdesson sa EE N. A ND FILL/PLUID oun Cees ess -FLUID/AIR. f -nwo 4 oxtowa, Sees aan Le wostire me Ott S SSNS srrencooten RUDCOOLER srencoouep aes suSection 2 DESCRIPTION Figure 2~5 Air Inlet System — John Deere ENGINE AIR FILTER ENGINE fises above 5 psig (8.8 bar. At this time, the net valve remains fully open for maximum air output The engine will continue to run at full speed during this phase of operation. MODULATION — 100 TO 110 PSIG (6.9 T0 7.6 2.7 BAR) OR 150 TO 165 PSIG (10.3 TO 11.4 BAR) FOR “H” MACHINES ‘Should less than the rated capacity of ar be used, the service line pressure will rise above 100 psig (6.9 bar) low or single pressure rating, 150 psig (103 bar) dual or high pressure rating. The pressure reg- uleting valve gradually opens, abpiying pressure fo the inlet valve piston and speed control cylinder. This causes the inlet valve to partially close and re- duces the speed of the engine. As the pressure in- creases, the inlet valve piston will further close the inlet valve and continue reducing the speed unti it reaches a pre—set idle speed. Now as air demand increases, the sump pressure will fall below the 110 Ps (7.6 bar) or 165 psig (11.4 bar) for "H” ma- chines. ‘The pressure regulating valve will close, the air inlet valve wil uly open and the engine wil once again run at a pre-set full load speed. Between the pressure regulating valve and inlet valve, a small orifice is installed which vents a small amount ofa tothe atmosphere, when the pressure regulating valve is open. This aliows variance of air output to match air demand. The orifice also bleeds any accumulated moisture from the regulator. 14 COMPRESSOR ‘AR FILTER ‘COMPRESSOR SHUTDOWN The blowdown valve is normally closed, Upon shut down, the back pressure in the compressor inlet signals the blowdown valve to vent the sump pres- sure to the atmosphere. AIR INLET SYSTEM, FUNCTIONAL DESCRIP- Refer to Figure 2—5. The air inlet system consists of two airfilters, a compressor air inlet valve and in- terconnecting piping to the engine and compres- sor. ‘The airfiters are single-stage dry element—type fi- ters. These filters are capable of cleaning extremely dirty air. However, in such cases, frequent checks of the air fiter will be required, ‘See Section 5 for Air Filter Maintenance Procedures. INSTRUMENT PANEL GROUP, FUNCTIONAL DE- ‘SCRIPTION Refer to Figure 2—6. The instrument panel group Consists of a molded panel containing an air pres- ‘sure gauge, hourmeter, ignition/start switch, cir- cuit breaker, idle warm-up control, and on Cat- erpillar engines a cold weather starting aid but- ton. A high-low pressure selector valve is lo- cated on the panel for "H” compressors. Refer to Figure 2—6 for locations of the folowing in- dicators and controls: + The air pressure gauge continually monitors the sump pressure at various load or unload conditions. + The hourmeter indicates the accumulative hours of compressor operation. This is useful for planningFigure 2~6 Instrument Panel! Group ‘AIR PRESSURE CONTROL CONTROL GAUGE SELECTOR IanmowsTaRT VALVE. HOURMETER ‘SWITCH | circurt BREAKER | rl Lf HIGH/LOW PRESSURE SELECTOR (HIGH PRESSURE MACHINES ONLY) and logging service operations. * The Ignition/start switch is used to energize the electrical system and start the compressor. The starter switch is rotated to the ignition position to en- ergize the electrical system and momentarily ro- tafed to the start position to engage the starter and start the compressor. + The idle warm—up valve control is turned from start to run after suficient warm-up is achieved for full compressor operation. +The Pressure selector valve on “H” compressors allows the selection of the compressor operating pressure range, 55 to 110 psig (8.8to 7.6 bar) or 55 40160 psig (3.8 to 11.0 bar). + The cold weather starting aid (on Caterpilar en- gines) should be used when starting in cold ami ents, Press the button and hold for 10-30 seconds (depending upon temperature), release prior to starting + Discharge alrite differential pressure gauges (located on top of the discharge air fers of after- ‘cooled and fitered compressors only) are provided to monitor the air fiers (‘st and 2nd stage) condi- tion. Areading over 10 psig (0.7 bar) inthe red zone indicates time to service the air fiter. Section 2 DESCRIPTION 2.9 ELECTRICAL SYSTEM, FUNCTIONAL DE- SCRIPTION Refer to Figure 27 . The electrical system is com- prised of not only the necessary equipment re- Quired to operate the compressor, butalsoasystem Which shuts down the compressor in the event of a matfunction. The components of the electrical sys- temare an engine starter, a battery, an alternator witha builtin voltage regulator «fuel solenoid, a compressor discharge temperature switch, which will shut down the compressor should the compressor temperature exceed 250°F (121°C), an engine water temperature switch set to shut down the compressor when water temperature Teaches 239°F (115°C) for John Deere and 225° (107°C) for Caterpilar, and an engine oil pressure switch. The engine oii pressure switch is provided to shut down the compressor when the engine oil pressure becomes insufficient. 2.10 AFTERCOOLED AND FILTERED AIR SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figure 2-3. The purpose for the atter cooled system is to operate the air compressor in conditions when compressed air temperatures re- quired tobe 15° to 20°F (9to 13°C) over ambient temperature. selector valve is provided on all aftercooled com- ppressors. Choosing the aftercooled air completely forces the airflow from the receiver tanktto the after- cooler, The ambient air which is drawn thru the af- tercooler by the engine fan, cools the compressed air as it passes thru the aftercooler core. Cooled air enters the moisture separator where condensation is temoved from the cooler air and discharged. This condensate does carry some oil and it should be glsposed of propery in accordance wth local regu: lations. From the moisture separator the air enters the (op- tional) frst stage iter. Particles and additional water are removed bythe first stage fter which are stored in automatic drain traps. Upon reaching a preset level the drain trap opens and discharges the con- densate. The condensate should be drained and stored in a suitable container. From the first stage filter the air enters the (optional) second stage filter. This fiter removes smaller particles and any addi- tional water which are collected in the drain trap. ‘When the preset ievelis reached the automatic con- densate trap discharges the condensate. The con- densate should be drained and stored in a suitable container. Upon compressor shutdown, the moisture separa- tor trap will drain to clear condensate from the sys- tem. This will prevent freezing in cold climates. Note:_After—cooler system should not be operated in ambient conditions below 32° F (0°C). ‘To operate in the non—aftercooled mode close the aftercooler service valve completely. 18Section 2 DESCRIPTION Figure 2~7 Electrical System ~ JOHN DEERE and CATERPILLAR oie RT sore | tt rae | @ ow oe = TAUTERWATORS 25 THRU 426] [ETARTEL Tae EET) aoe eee aed é} bem eebag 16Section 3 SPECIFICATIONS SPECIFICATIONS — 375, 375H and 425 JOHN DEERE DIMENSIONS Model Series. Length it) Wiath Heiant Wetaht (wet in om in mm in on ib kg 375, 375H, 425, 2—Wheei 151 (3835.4) 78.9 (2004) 68.5 (1740) 4150" (1882.5) 375, 375H, 425DLQ 95.7 (2413) 58.2 (1478) 57.5 (1460.5) 4020* (1823.5) () Length over drawbar for 2-wheel version *Add 70 Ibs (32 kg) for Aftercooled Version COMPRESSOR: 375 Type Rotary Screw Maximum Operating Pressure 125 psig (8,6 bar) Delivery 375 Free CFM (7745) Rated Pressure 100 psig (7 bar) Cooling Pressurized Compressor Fluid Lubricating Compressor Fluid See Table 1 ‘Sump Capacity 7US. gallons (26.5" liters) Track Width 675" (1714.5 mm) Tire Size (Load Range) H78 x 18ST (0) Tire Pressure 65 psig (4.4 bar) Wheel Size 15x 6H Lug Nut Torque 60 ft.—Ibs. (81 Nm) Operating Tilt (maximum) 15° Electrical System 42 Volt Compressor Discharge Temp, Shutdown 250° Service Valves. (23/4) Maximum Towing Speed 55 MPH (88 KMPH) ‘Axle Rating 5000 pounds (2268 Ka) ‘Sound Level 76 GBA at 7 meters ENGINE: Type Diese! fake sohn Deere Model yD 4045TF 150 Displacement 276.cu. in. (4.5L) Cylinders 4 Bore x Stroke 4.19 x 5.00 (106mm x 127mm) Rated Speed 2250 RPM Rated Power SATHPIBSKW Type of Motor Oil See Engine Operator Manual Fuel Tank Capacity 48 gallons (181.7 liters) Radiator Capacity 4 gallons (15 Liters) Engine Water Temperature Shutdown 208°F (115°C) Minimum Idle Speed 4600 RPM (11) Alternator Rating 65 amp 375H Rotary Screw £130 pig (10-bar) 875 Free CFI (7 4) 150 psig (10.3 bar) Pressurized Compressor Fluid See Table 1 7US. gallons 26.5 ters) 2 (1714.5 mm) psig (6 ban si a ikaw 60 ft.—Ibs. (81 Nm) 18 12 Vott Shutdown 250° (121°C) (23/4) 55 MPH (88 KMPH) 5000 pounds (2268 Ka) 76 dBA at 7 meters Diesel John Deere UD 4045TF250 276 cu. in. (4.5L) 4 4.19 x 5.00 (108mm x 127mm) 2250 RPM ‘123HP/S2KW See Engine Operator Manual 48 gallons (181.7 liters) 4 galions (15 Liters) ‘Shutdown 239°F (115°C) 1600 RPM (II) 65 amp 425 Rotary Screw 125 psig (8.6 bar) 425 Free (201L/s) }00 psig (6.9 bar) Pressurized Compressor Fluid See Table 1 7 US. gallon (2635 ters) 67.5 (1714.5 mm) H78 x 15ST (0) 65 psig (4.4 bar) 18 x6 0 fips. (1 Nm) 12 Volt ‘Shutdown 250° (121°C) 2.3/4) 55 MPH (88 KMPH) ‘5000 pounds (2268 Kg) 76 dBA at 7 meters Diesel John Deere YD 4045TF250 276 cu. in. (4.51) 4.19 x 5.00 (106mm x 127mm) 2300 RPM 424HP/S3kW See Engine Operator Manual 48 gallons (181.7 liters) 4 gallons (15 Liters) Shutdown239°F (115°C) 4600 RPM (11) 65 amp (1D) DO NOT allow engine idle rpm to drop below minimum idle speed. Compressor and/or coupling damage will occur. 7Section 3 SPECIFICATIONS SPECIFICATIONS ~ 375 CATERPILLAR DIMENSIONS Model Series Length ch Width Height Weight (wet) in om in mn io om ib ko 375 2—Wheel 151 (3835.4) 78.9 (2004) 68.5 (1740) -4240* (1923.3) 375 DLQ 95.7 (2413) 58.2 (1478) 87.5 (1460.5) 4120" (1869) (0 Length over drawbar. *Add 70 Ibs (32 kg) for Aftercooled Version ‘COMPRESSOR: 375 Type Rotary Screw Maximum Operating Pressure 125 psig (10 bar) Delivery 875 Free (1774/5) Rated Pressure 100 psig (7 bar) Cooling Pressurized ‘Compressor Fluid Compressor Fluid Lubricating Compressor Fluid See fable 1 ‘Sump Capacity 7US. gallons (2635 iters) Track Width 67.5" (1714.5mm) Tite Size (Load Range) H78 x 18ST (0) Tire Pressure 85 psi (4.4 bat) Wheel Size 15x Lug Nut Torque 60 ft.—Ibs. (61 Nm) Operating Tit (maximum) 15° Electrical System 42 Vot Compressor Discharge Temp. Shutdown 250 (121°C) Service Valves Q 3/4 Maximum Towing Speed 55 MPH (88 Kmph) Axle Rating 5000 lbs (2268 Kg) Sound Level 76 dBA at 7 meters ENGINE: Type Diesel Mike Caterpilar Mode! Cata054—T Displacement 243 cubic in. (4.0 Liter) Cylinders 4 Bore x Stroke 8.94 x 5.00 (106mm x 127mm) Rated Speed 2250 RPM. Rated Power 408HP/81.5kW ‘Type of Motor Oil See Engine Fuel Tank Capacity Radiator Capacity’ Engine Water Temperature Minimum Idle Speed ‘Alternator Rating Operator's Manual 48 gallons (181.7 liters) 4 gallons (15 Liters) Shutdown 225°F (107°F) 1600 RPM (1) 55 amp (1) DO NOT allow engine idle rpm to drop below minimum idle speed. Compressor and/or coupling damage will occur, 18LUBRICATION GUIDE - COMPRESSOR FLUID TYPE Sullair AWF () 1200 D=A Torque Fluid 300 SAE10W SE, SF, SG, CD 300 MIL-L-2104E 10W 300 CHANGE PERIOD, HOURS, Section 3 SPECIFICATIONS AMBIENT TEMPERATURE RANGE °F (°C) 20 to 120 (~29 to 49) 1010 110 (12 to 43) Oto 100 (~18 to 98) Oto 100 (18 to 38) () Sullair part numbers for Sullair AWF are 250030~757 (6 gallons/20 iters) and 250080768 (5S gallon drum/208 iters) ‘APPLICATION GUIDE Sullair Air Compressors are supplied with Sullair AWE which is heavy duty multi—viscosity, all— ‘weather fluid, Sullair AWF also allows an extended change interval. Detergent motor oils (SAE 10W Class SE,SF, SG or CD) can also be used. Any of these oils are suitable under conditions where se- vere oil oxidations can occur. Water must be drained from the receiver periodical- ly. In high ambient temperature and high humidity conditions, condensed moisture may emulsify with the oilforming a“milky” color. SAE 10Wis especially prone to this condition, The fluid should be changed if this condition develops. DO NOT mix types of fluids. Combinations of differ- ent fiuids may lead to operational problems such as foaming, fer plugging, orifice or line plugging, When ambient conditions exceed those noted or if conditions warrant use of other extended life lubri- ccants, contact Sullair for recommendations. Sullair encourages the user to participate in a fluid analysis program. This could result ina fluid change interval differing from that stated in the manual. Sul- lair Corporation offers a fluid analysis program for Sullair AWF. Contact your local Sullair representa- tive for details. D~A Lubricant? Company Inc. offers an analysis program for users of D—A products and Sullair AWF. Contact your D—A lubricant supplier or Sullair rep- resentative for details. LUBRICATION GUIDE - ENGINE For engine oil specifications, refer to the Engine Op- erator’s Manual. 194a 42 Section 4 OPERATION GENERAL While Sullair has built into this compressor a compre- hensive array of controls and indicators to assure you that itis operating properly, you will want o rec- service or indicate the beginning of a matfunction. Before starting your Sullair compressor, read this, section thoroughly and familiarize yourself with the Controls and indicators — their purpose, location and ‘ognize and interpret the reading which will call for use. PURPOSE OF CONTROLS CONTROL OR INDICATOR PURPOSE IGNITION/START SWITCH COLD WEATHER STARTING AID BUTTON AIR PRESSURE GAUGE HOURMETER FLUID LEVEL SIGHT GLASS COMPRESSOR DISCHARGE TEMPERATURE SWITCH ‘THERMAL VALVE MINIMUM PRESSURE DEVICE PRESSURE RELIEF VALVE AIR INLET VALVE PRESSURE REGULATOR (8) DISCHARGE AIR FILTER DIFFERENTIAL PRESSURE GAUGE Turn this switch to the * IGN" (ignition) position to energize the electrical system of the compressor. Turn the switch to the "START" position to momentarily engage the starter and stan the compressor Tum to the “OFF” postion to shutthe compressor down. This switch is located on the in- strument panel, (For Caterpillar engines) Push this button, prior to com= pressor start—up, to allow the engine to warm—up for easy starting, Continually monitors the pressure inside the receiver sump at various load and unload conditions. Indicates the accumulated hours of operation. Useful for planning and logging service schedules. Monitors the fluid level in the sump. Proper level is visible halfway up the sight glass. Check the level when the com- pressor is shut down and on level ground. Opens the electrical circuit to shut down the compres— sor when the discharge temperature reaches a specific value (see Section 8, Specifications). Functions as a temperature regulator directing the com- pressor fluid either to the cooler or to the compressor unit Maintains the minimum of 55 psig (3.8 bar) in the compres- sor sump. Opens sump pressure to the atmosphere should pressure inside the sump exceed 165 psig (11.4 bar) or 200 psig (13.8 bar) on “H" models. Regulates the amount of air allowed to enter the air inlet valve. This regulation is determined by a pressure signal from the pressure regulator. Allows a pressure signal to reach the engine speed control cylinder and the air inlet valve to control air delivery accord- ing to demand. (For Optional Discharge Air Fitter models only) Monitors the airfiter (first and second stage) condition. A reading over {0psia (0.7bar) inthe redzoneindicatestimeto sence ar (ers,4.2 PURPOSE OF CONTROLS (Continued) Section 4 OPERATION ‘CONTROL OR INDICATOR PURPOSE BLOWDOWN VALVE IDLE WARM-UP CONTROL Vents sump pressure to the atmosphere at shutdown, Maintains a closed air inlet valve for reduced compressor load on start-up. When sufficient warm—up is reached turn the handle from the “start” to the “run” position for full operation. PRESSURE SELECTOR SWITCH ("H" MODELS) Allows compressor operation in t low” range from 55 to 110 psig (3.8 to 7.6 bar) or in the "high" range from 55 to 160 psig (3.8 to 11 bar), 4.3 START-UP PROCEDURE The following procedure should be used to make the initial start—up of your compressor: 1. Position the compressor on a level surface so that proper amounts of liquid can be added if neces- sary. () 2. Check oil and fluid levels both in the engine and the cooling system(s). Maintain the proper level; add if necessary. Fill the fuel tank. Drain water from the fuel/water separator. Crack open one service line. Bleed fuel injection lines if necessary (see Engine Operator's Manual). Place the warm—up control in the start position, Place the pressure selector switch in the “low” position (’H" models). On Caterpillar engines in cold weather, engage cold weather starting aid button. Hold button for 40-30 seconds and then release. 8 Tum ignitonjstat switch to the “IGN" poston (0. Turn the ignition/start switch to the “START” posi- tion momentarily to engage starter, when engine starts release switch, 11, Allow for sufficient warm—up of compressor, then tum idle warm-up switch from start to run for fll ‘compressor operation. 412. Ciose all doors in order to maintain proper noise control. 418. After the intial run, shut the compressor down and refi the radiator and compressor fluid sump as re~ quired. Tighten any loose fittings and check fan belt tension @ 12 on o -(D The radiator is filed with a 50/50 mixture of ethyi- ene glycol and water. All engines receive Suppie- ‘mental Coolant Additive (SCA) at the factory before shipment. Refer to your Engine Operator's Manual for details and specific engine requirements. 4.4 SUBSEQUENT START-UP PROCEDURE ‘On subsequent starts, follow the procedure ex- plained below: 1. Check engine oil, water and fuel levels. 2. Check compressor fluid level (should be visible in sight glass). Drain water rom the fuel water sep arator. . Check dust collectors and clean if necessary. Crack open service valve. . Bleed fue jection nes if necessary (see Engine Operator's Manual). . Place the warm-up control in the start position Place the pressure selector switch in the "low" position ("H” models). On Caterpillar engines in cold weather, enga ‘cold weather stating ald Dutton. Hold button for 410-30 seconds and then release. ‘9, Tur ignition/start switch to the “IGN” position 410. Turn the ignition/start switch to the “START” posi- tion momentarily to engage starter, when engine starts release switch. 11. Allow for sulficient warm up of compressor before operating. 12, After warm—up, tum idle warm—up switch from the start to run position for full operation, 4.5. SHUTDOWN PROCEDURE To shut the compressor down, close the service valves and run compressor for approximately 5 min- utes to allow the compressor to cool down and turn the ignition/start switch to the OFF position. Incase of emergency where immediate, shutdown i re quired, this procedure is not necessary. The igni- flonistat switch should be put in the OFF postion immediately. 21Section 5 MAINTENANCE 5.1 GENERAL AA,good maintenance program is the key to long ‘compressor life, Below is a program that, when hered to, should keep the compressor in top operat- ing condition. Formaintenance requirements on en- gine, refer tothe Engine Operator's Manual for ade- tailed description of service instructions. See Sec- tion 5.12, Parts Replacement and Adjustment Pro- cedures for a detailed description of specific com- pressor system components. Prior to performit maintenance, read the CIMA Safety Manual, ifap cable in your area. PMG DO NOT remove caps, plugs and/or other compo- ania when compressor fe running or press Stop compressor and relioveallinternal pressure before doing 80. DAILY OPERATION Prior ta starting the compressor, itis necessary to check the fluid level in the sump. Should the level be low, simply add the necessary amount. f the addi- tion offluid becomes too frequent, a simple problem has developed which is causing this excessive loss. See the Troubleshooting Section (6.13) under Ex- cessive Fluid Consumption for a probable cause and remedy. Also check the engine oil level and the radiator coolant level prior to starting. Drain water from the engine fuel—water separator. ‘The radiator and engine cooling systom must be rained and flushed every 1200 hours. Replace ‘coolant with a solution of ane glycol 52 Reeumemude ime miscorercigiere eiogeeea mar aupiaeanet ‘Additive (SCA) added to system. Refer to your Engine Operator's Manual {ordetaile and specific ongine requirements. ‘After a routine start has been made, observe the in- sstrument panel gauge and be sure it monitors the correct reading for that particular phase of opera- tion. After the Compressor has warmed up, itis reo- ‘ommended that a general check on the overall com- pressor and instrument panel be made to assure that the compressor is running properly. Also check the air fiter maintenance indicators if supplied. 5.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION ‘After the initial 50 hours of operation, a few mainte nance requirements are needed to rid the system of any foreign materials. Perform the following mainte- hance operations to prevent unnecessary prob- lems. 1. Clean the return line orifice and strainer. 2, Change compressor fluid filter. 22 8. Check Engine Operator's Manual for required service. 4, Check fue! filter for water. 5.3A MAINTENANCE EVERY 50 HOURS 1. Inspect and replace air filter elements (if re- quired). 2. Check fuel filter for water. 5.4 MAINTENANCE AFTER INITIAL 100 HOURS ‘OF OPERATION 1. Change engine oil and fier (John Deere engine). 5.4A MAINTENANCE EVERY 100 HOURS ‘After 100 hours of operation, it will be necessary to perform the following: 4, Clean the radiator and cooler exteriors, 2. Check Engine Operator's Manual for required service. MAINTENANCE EVERY 200 HOURS Perform the following after every 200 hours of opera- tion: 4. Check fan belt tension. 2. Clean the radiator and cooler exterior. Depending ‘on how contaminated the atmosphere may be, ‘more frequent cooler and radiator cleaning may be necessary. 8. Check Engine Operator's Manual for required service. MAINTENANCE EVERY 250 HOURS 1. Change engine oil and filter (John Deere and Cat- erpillar engines). MAINTENANCE EVERY 300 HOURS Fuld change period will vary according to fuld brand: Hetero Lubrication Guide in Section 3. Perform the folowing after every 300 hours ofopers- ion: 1. Change the compressor fluid and fluid fier, if not using Sullair AWF. Run the compressor for 5 to 40 minutes to warm the fluid. Shut the compres- sor off and relieve all internal pressure before proceeding. Drain the fluid sump by removing the plug af the bottom ofthe sump tank. For fluid filter element replacement, see Filter Element Replacement under the Maintenance Section 5.12 Parts Replacement and Adjustment Proce- dures. Fill he sump with fluid according to speci- fications in Section 3, Remove any accumulated dirt from the fluid filer cap prior to filing the sump. 2. Clean return line strainer. 3. Check Engine Operator's Manual for required service, MAINTENANCE EVERY 500 HOURS Perform th fllowing after every 800 hours of pera- jon: 55 5.6 571. Change the fuel filer (John Deere engines). Should persistent clogging be evident, change the fuel filter more frequently. 2. Change engine fuel-water separator (Caterpillar engines) 8, Check the engine RPM. Idle speeds should never be allowed to fall below the minimums (see Sec- tion 3 Specifications). Operation at speeds below. the minimum, ile peeds shown inthe Table in Section 3, Specifica- ions will damage the compressor. Exended op- ion se speeds will induce coupling jor compressor falures. 4, Lubricate the control linkage. 5. Check Engine Manual for required service. 5.9 MAINTENANCE EVERY 600 HOURS 1. Change the fuel filter (Caterpillar engines). ‘Should persistant clogging be evident, change the fuel filter more frequently. 2. Change the compressor fluid fiter. 3. Change engine fuel-water separator (John Deere engines). 5.10 MAINTENANCE EVERY 1000 HOURS Perform the following after every 1000 hours of op- eration: 4. Clean the return line orifice. 5.11. MAINTENANCE EVERY 1200 HOURS ‘When using Sullair AWF, change the compressor fluid and replace the fluid filter element (See mainte- nance procedures in Section 5.12). 5.11 MAINTENANCE EVERY YEAR OR 12,000 MILES 1. Lubricate axle bearings on wheel-mounted units, 5.12 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES: COMPRESSOR FLUID CHANGE PROCEDURE Warm-up compressor for 5 to 19 minutes to warm the fluid. Shut the compressor off and relieve all in- ternal pressure before proceeding. Drain the ud sump by removing the plug at the bottom of the sump tank, Change the compressor fluid and re- place the fiuid fiter element. For element replace- ment see procedure for servicing the fluid iter in this section. Fill the sump with fluid according to specifications in Section 8, COMPRESSOR FLUID FILTER ELEMENT RE- PLACEMENT 4. Using a strap wrench, remove the old element. 2. Clean the gasket seating surface. ‘8. Apply a light film of fluid to the new gasket. Section 5 MAINTENANCE 4, Hand tighten the new element (P/N 250026-982) nti the new gasket is seated on the gasket seat 5. Continue tightening the element by hand an addi- tional 1/2 to 3/4 turn, 6. Restart the compressor and check for leaks. AIR FILTER MAINTENANCE Refer to Figure 5-2. Air filter maintenance should be performed as often as conditions require. If the filters are equipped with an optional maintenance indicator, maintenance should be done when the indicator shows red. The following procedure will ‘explain how to replace the air fier element. AIR FILTER ELEMENT REPLACEMENT 41. Loosen and remove the air fiter end cover. 2, Remove element. 3. Clean the body and cover with a damp cloth in- side and out. 4, Replace the new fier element. 5. Reposition the cover and lock into position. 6. Reset the air filter restriction indicator if so equipped, and the unit will be ready for opera- tion ELEMENT INSPECTION 1. Place a bright light inside the element to inspect ‘for damage or leak holes. Concentrated light will shine through the element and disclose any holes. 2. Inspect all gaskets and gasket contact sulaces ofthe housing. Should fully gaskets be evident, correct the condition immediately. 3. Ifthe clean element is to be stored for later use, it must be stored in a clean container. Figure 5-1 Compressor Fluid Filter FILTER HEAD SY FLUID FILTER, * Replacement Element P/N 250025~525 23Section 5 MAINTENANCE Figure 5~2 Air Fitter FLTER, = AIR FILTER ELEMENT. *Filter Element P/N 02250051 -136 (2 reg’d.) 4. After the element has been installed, inspect and tighten all ir inlet connections prior to resuming operation. ‘SEPARATOR ELEMENT REPLACEMENT Refer to Figure 5-3. When fluid carry over is evident after the fluid retum line strainer and orfice as well 23s the blowdown valve seal has been inspected and found to be in satisfactory condition, separator ele- ment replacement is necessary. Use element no. 250034—087 and follow the procedure explained below. 41. Remove all piping connected to the sump cover to allow removal (return line, service line, ete.) 2, Remove the fluid return line from the fiting in the cover. 8, Remove the eight (8) cover bolts and washers and lift the cover from the sump. 4, Remove the separator element. 5. Scrape the old gasket material from the cover and the flange on the sump. Be sure to keep all scrapings from falling inside tank. 6. Install the new element. 24 Figure 5-8 Air/Fluid Separator carscrew——__g WASHES oe oe SepaRaTOR ELEMENT. WITH GASKETS *Replacement Separator P/N 250034—087 7. Replace the sump cover and bolts. Run the cover bolts in finger tight, then gradually tighten in a crisscross pattern in 4 to 5 steps. Always tighten the bolts alternately at opposite sides. of the ‘cover. Never tighten bolts adjacent to each other. Torque bolts to 60 ft.—Ibs. (81 Nm). 8 Reconnect all piping. The fluid return line tube should extend to the bottom ofthe separator ele- ‘ment. This will assure the proper fluid return flow. ©. Clean the fluid return tine strainer and clear the Orifice prior to restarting the compressor. 10. After 24 hours of operation, tighten sump cover bolt to torque specification listed in step number 7 PROCEDURE FOR SETTING SPEED AND PRESSURE CONTROLS ON PORTABLE COM- PRESSORS WITH POPPET VALVE Refer to Figures 5~4A and 5—4B. Prior to adjusting the Control System, itis necessary to determine the rated full load pressure and the high/low RPM set- tings for your particular compressor. This informa- tion can be obtained from the Operator's Manual (Specifications Section) or by contacting your local authorized Sullair Representative. The following ex-planation applies to compressor wth 100 psi (6.9 ar) rated full load pressure. 1, Start the compressor and allow the engine to warm—up to normal operating temperature with the service valve closed 2. With the service valve closed, set the engine low speed (idle) to its specified setting with the idle stop screw on the engine injector pump. Operation at speeds below the minimum ile SBeods shown fe Section under Spectentions ‘nl damage the compressor. Extended operation slow hate apse wil nace coupling andor ‘Compressor falures- 3. Adjust the pressure regulator so that the com- [pressor maintains 115 psig (8 bar). Section 5 MAINTENANCE 4, Gradually open the service valve to atmosphere Until the engine comes up in speed and sump pressure is held at 100 psig (6.9 bar). At this Point, set the engine high speed fo ts specified ‘setting by adjusting the high idle threaded rodo- ‘cated on the engine speed control. To raise or lower the speed, lengthen or shorten the rod re- spectively. 5. Open the service valve to 100 psig (6.9 bar) (rated Tull oad. pressure) and. recheox top engine speed and control response. Close the service valve and allow the compressor to cycle and re- check low engine speed (idle). ‘The following explanation applies to “H” compres- sor with dual pressure controls. 4, Start the compressor and allow the engine to ‘warm-up to normal operating temperature with Control System Adjustment _— Standard Pressure AIR INLET BLOWDOWN VALVE ‘VALVE \. IDLE WARM-UP ENGINE SPEED ‘CONTROL, CYLINDER ENGINE MINIMUM PRESSURE PRESSURE/SPEED REGULATOR VALVE. (CHECK VALVE 25Section 5 MAINTENANCE Figure §-4A Control System Adjustment ~ Dual Pressure AIRINLET ‘VALVE ENGINE SPEED ‘CONTROL, CYLINDER ENGINE IDLE WARM—UP- VALVE BLOWDOWN PRESSURE PRESSURE/SPEED ‘REGULATOR PRESSURE/SPEED "REGULATOR ‘Minium PRESSURE) (CHECK VALVE, the service valve closed and the pressure selec- tor valve set to the “low” position. 2. Follow the procedure for setting the controls at 100 psig (6.9 bar) rated full load pressure as de- scribed in Steps 2 through 5 above. 3. Tum the pressure selector valve to the “high position with the service valve closed. 4. Adjust the high pressure regulator so that the Compressor maintains 165 psig (11.4 bar) 5. Gradually open the service valve to atmosphere Until the engine, comes up in speed and sump pressure is held at 150 psig (10.3 bar), At this point the engine should be at rated speed. ifneo- essary, to raise or lower the speed, lengthen or shorten the rod respectively. OPERATING ADJUSTMENTS ‘The first step isto start the compressor according to the instructions in Section 4, Subsequent Start-up. 26 ‘Allow the engine to operate until it reaches the nor- mal operating temperature. Open the service valve until the engine speed increases to, or close to, the maximum specified operating speed. BEARING LUBRICATION Refer to Figure 5~5. Proper lubrication is essential to the proper functioning and reliability of your por- table compressor axle. Wheel bearings should be lubricated at least once every 12 months, or more frequently to help insure proper performance. Use wheel bearing grease that conforms to military specification MIL—G- 10824 or a high temperature whee! bearing grease such as ithium complex NLGI Consistency #2. I your axle is equipped with the E-Z Lube feature, the bearings can be periodical lubricated without removing the hubs from the axle. This feature con- sists of axle spindles that have been specially drilled and fitted with a grease zerk in their ends. WhenFigure 5-5 Typical E~Z Lube Axle om RUBBER PLUG OUTER BEARING GREASE Flow GREASE ZERK’ METAL END CAP om Section 5 MAINTENANCE INNER BEARING SPRING LOADED DOUBLE LIP SEAL greases pumped into the zerk itis channeled to the inner bearing and then flows back to the outer bearing and eventually back out of the grease cap hold (see Figure 5-5). The procedure is as follows: 1. Remove the rubber plug from the end of the grease cap. 2, With a standard grease gun filed wih a qualty wheel bearing grease, place the gun onto the grease zerk located in the end of the spindle. Make sure the grease gun nozzle is fully en gaged on the fitting. 3. Pump grease into the zerk., The old, displaced (tease ill begin to low back outthe cap around ie grease gun nozzle. 4, When the new, clean grease is observed, remove the grease gun, wipe off any excess, and replace the rubber plug in the cap. FIRST STAGE DISCHARGE AIR FILTER MAINTE- NANCE — AFTERCOOLED & FILTERED MODELS GENERAL Refer to Figure 5-6. By familiarizing yourself with the fitration process and the monitoring system of the unit (consisting of a complete set of gauges) you can easily analyze and determine the location of any ‘matfunction The first stage fitter element should be changed when the pressure drop of the fier reaches the red band on the pressure differential gauge (differential pressure of 10 to 15 psid (0,7 to 1.03 bar). First Stage Discharge Air Fitter (Optional) Figure FILTER HOUSING. Replacement element kit PIN 250024—428 27Section 5 MAINTENANCE DAILY OPERATION Check the automatic drain trap on a regular basis to insure that itis operating properly. FIRST STAGE ELEMENT REPLACEMENT 1. Depressurize fiter and remove the filter housing. 2 Remove the element 3, Clean inside of the fiter housing, it necessary. 4. Install new element and gaskets. 5. After unit is reassembled, check for air leaks. 6. Record initial pressure drop upon compressor re- start SAFETY TOXIC AND IRRITATION SUBSTANCES use airflow from this fiter for respiration (breathing) except in full compliance with OHSA. Standards 29 CFR 1910 and any other Federal, State or Local Codes or Regulations. PT Dat or srs in an ret tom nag Compressed air wit sin ‘Squipment: see osha standards of safely equip: ‘ment, This fiter will not remove water vapor, oll vapor, car- bon monoxide or other toxic gases. This fitter is efficient in removing contaminating par- ticles such as ash, dust, water aerosols, lubricant mist, carbon, rust and other polutants of 0.3 micron and larger. DESIGN RATINGS: SECOND STAGE DISCHARGE AIR FILTER MAINTENANCE ~ AFTERCOOLED & FILTERED MODELS, GENERAL, Refer to Figure 5-7. By familiarizing yourself with the filtration process and the monitoring system of the unit (consisting ofa complete set of gauges) you ‘can easily analyze and determine the location of any malfunction. ‘The second stage fter element should be changed when the presure drop offiter reaches this band on the pressure differential gauge (differential pressure of 10 to 15 psid (7 to 1.08 bar) DAILY OPERATION ‘Check the automatic drain trap on a regular basis to insure that they are operating properly. SECOND STAGE ELEMENT REPLACEMENT 1. Depressurize fiter and remove the fier housing, 2, Remove the filter element and clean inside of housing, if necessary. 8, Install the new element and gaskets. 28 Figure 5-7 Second Stage Discha oe Ow air Fiter (Optional) a ELEMENT FILTER HOUSING Replacement element kit P/N 250024—436 4, After unit is reassembled, check for air leaks. 5. Record intial pressure drop upon compressor re- ‘SAFETY TOXIC AND IRRITATION SUBSTANCES DO NOT use air flow from this fier for respiration (breathing) except in full compliance with OHSA Standards 29 CFR 1910 and any other Federal, State or Local Codes or Regulations. PSG DEATH OR SERIOUS INJURY CAN RESULT FROM INHALING COMPRESSED AIR WITHOUT USING PROPER SAFETY EQUIPMENT. SEE OSHASTAN- DARDS ON SAFETY EQUIPMENT. The second stage fiter will not remove water vapor, oll vapor, carbon monoxide or other toxic gases.‘The second stage filter can remove particulate and eliminate all lubricants aerosols of 0.01 micron in size and larger. DESIGN RATINGS: Design ratings aro 150°F (68°C) maximum init ai temperature. All welded fiter housings are ASME code stamped for 200 PSIG (14 bar) maximum working pressure. 5.13 TROUBLESHOOTING ‘The following Troubleshooting Chart is based upon the data obtained both from testing at the factory and from applied situations in the field. It contains symptoms and usual causes for the described problems, however DO NOT assume that these are the only problems that may occur. All available data Section 5 MAINTENANCE concerning the trouble should be systematically analyzed before undertaking any repairs or compo- nent replacement procedures. ‘A detailed visual inspection is worth performing for almost all problems. Doing so may prevent unnec- essary additional damage to the compressor. ‘Always remember to: 4. Check for loose wiring, 2. Check for damaged piping 8. Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or ‘a but odor. ‘Should the problem(s) persist after making the rec- ‘ommended check, consult your nearest Sullair rep- resentative or the Sullair Corporation. TROUBLESHOOTING ‘SYMPTOM PROBABLE CAUSE. REMEDY ‘COMPRESSOR WILLNOT START No Fuel (Check fuel level and ade fuel if necessary. Plugged Fuel Fier Low Battory Votage Plugged Air Flor Engine Problems May Have Developed, Detective Engine Oil Pressure Switch Blown Fuse In Wiring Harness CoMPresson SHUTS DOWN No Fuel WITH AIR DEMAND PRESENT Compressor Discharge Tony Engin Wor tornpotaue Sa Detective Engine Ol Pressure Switch Blown Fuse In Whing Hamess (Check fuel shut-off valve, Replace the element. Recharge or replace if necessary. Loose battery cables; tighten cables. Dity battery cables; clean thoroughly. ‘Clean or replace the element. Refer to Engine Operator's Manual. ‘Check continuity flow and replace fho-swicn tnecessay. (Chock continuity and replace it necessary. (Check fuel level and ada fuel necessary. tue or Cooling ai ow is insufficient; clean cooler fn Open and check for proper venation, Low fuid sump level acd fi. Low engine coolant; ade uid Goaged compressor Rid ter; change ‘The tomperature regulating section of the {ld contr centr fe not inctoning properly; change the tremmosia elament. Detective discharge or engine temperature switch: hock fora shor open tout t tho {gine fel rack soleroid. Should this chock Sut normally could be possible that the fomporature switch iol defective. (Check continuity and replace itnecessary. Check continuity and replace itnecessary.Section 5 MAINTENANCE TROUBLESHOOTING (continued) ‘SYMPTOM PROBABLE CAUSE. REMEDY COMPRESSOR WILL. NOT. BUILD UP FULL DISCHARGE PRESSURE IMPROPER UNLOADING. WITH AN EXCESSIVE PRESSURE EUILD~UP CAUSING PRESSURE RELIEF VALVE TO OPEN ‘At Demand le Too Great Dirty Air itor Pressure Regulator Out Of Adjustment Detective Pressure Regulator Detective idle Warm-up Contot Pressure Regulating Valve Is Set Seorign “airs Leak Ia Cont Systom Cau tos OrPressure Sgn Inet Vato Jammed Restction In The Cont! Systm Defective Pressure Ral Vane Gponing At Too Low OF Prosbice Defective Pressure Regulator For compressors, with dle warm—up contros, Sitch toggle 10 "run" for hill operation: (Check service lines for leaks or open valves Check the fiter indicator and change element required Adjust regulator according to conto! fahustmentinsvuctons ithe Maintenance Becton Check siapheagm and replace i neces att ‘valable) " ay Replace contol Readjust. Check contol tines. Detective pressure regulating vane; repair valve fet avalobie). Free or replace valve. ‘Check al control lines and components. toe andfor other contaminants could cause restrtons, Replace pressure roliot valve ‘Check diaphragm and replace it necessary (it avaliable) INSUFFICIENT AIR DELIVERY EXCESSIVE COMPRESSOR FLUID CONSUMPTION Engage idle Warm—up Control n “Run” Postion For Full Compressor Operation. Plugged Air Fiter Plugged AirFluid Separator Detective Pressure Regulator Engine Speed Too Low Detective ele Warmup Control Clogged Retum Lino ‘Leak In The Lubrication Systom Replace. Replace separator element and also change Compressor ful and Mud or at tis mo. Adjust or ropa Readust engine speed. Replace contol (ica oii and rtum ine strane. Check all pipes, connections and components ‘Separator Elomont Damaged Or Not Change separator element. Functioning Properly ‘COMPRESSOR OVERHEATING Low Sump Fuld Lovel Fi Loose Or Broken Fan Belt Dirty Fluid Cooler Coro Plugged Compressor Fluid Fite Tighton of change bet, Clean core thoroughly {Change element 30TROUBLESHOOTING (continued) Section 5 MAINTENANCE ‘SYMPTOM PROBABLE CAUSE. REMEDY COMPRESSOR OVERHEATING Faulty Thermostat ‘Change thermostat (CONTINUED) Plugged Fluid Cooler Tube (Interna) _—_~Replace cooler ENGINE OVERHEATING Loose Or Broken Fan Belt Tighten or change bet. Dirty Rector Core Low Fd Lovet Fauty Water Pump Plugged Rachator Defective Engine Thermostat (Clean thoroughly. Poll ‘Change pump. (Clean and fush thoroughly Replace engine thermostat 316.1 NOISE EMISSIONS WARRANTY Sullair Corporation warrants to the ultimate pur- Chaser and each subsequent purchaser that this air compressor was designed, built and equipped to conform at the time of sale to the first retail pur- chaser, with all applicable U.S. E.PA. and/or any Federal, State or Local noise control regulations. This warranty is not limited to any particular part, component, or system of the air compressor. De fects in the design, assembly, orin any part, compo- rent, orsystem ofthe compressor which, atthe time of sale to the first retail purchaser, caused noise emissions to exceed Federal standards are covered by this warranty for the life of the air compressor. 6.2 TAMPERING WITH THE NOISE CONTROL SYS- TEM IS PROHIBITED Federal Law prohibits the following acts or the caus ing thereof: 1. The removal or rendering inoperative by any per- ‘sons, other than for purposes of maintenance, repair, or replacement, of any device or element ‘of design incorporated into any new compressor for the purpose of noise control prior tots sale or delivery to the ultimate purchaser or while itis in use Section 6 NOISE CONTROL 2. The use of the compressor after such device or element of design has been removed or ren- dered inoperative by any person, ‘Among those acts included in the prohibition ‘against tampering are the acts listed below: 1. Removal or rendering inoperative any ofthe fol lowing: a, Engine exhaust system or parts thereof b. Compressor ar intake system or part thereot ¢. Enclosure of part there 2, Removal of any of the following: ‘a. Vibration isolators b. Control silencer ¢. Floor panel di Fan shroud . Acoustical materials includit or foam tape 8, Operation with canopy doors open for any pur- pose other than starting, stopping, adjustment, repair, replacement of parts of maintenance. 6.3 NOISE EMISSIONS MAINTENANCE AND MAIN- TENANCE RECORD LOG The following instructions and maintenance record log book, for the proper maintenance, use and re- pair of this compressor, is intended to prevent noise emission degradation (refer to Figure 6—1) \g fiberglass foam Figure 6~1 Noise Emission Maintenance and Maintenance Record Log 1. ANNUAL MUFFLER AND EXHAUST SYSTEM INSPECTION ‘Atleast annually inspect muffer(s) and engine exhaust system to make sure all parts are securely mounted, thataljints and connections are tight, anctha he mfr sin good condition. DONOT operate compres sor with defective exhaust system. indicated in the Parts List. lemove and replace any de ctive parts by ordering with part numbers Maintenance Performed By Location Date Maintenance Performed By Location 32Section 6 NOISE CONTROL 2. ANNUAL AIR FILTER(S) AND AIR INLET SYSTEM INSPECTION In addition to the instructions in the Maintenance section of the Operator's Manual, the airfiter(s) and entire air inlet system should be inspected at least annually, to make sure all parts are securely mounted, that al joints and connections are tight, that there are no other leaks in the system, and that the fter element(s) are intact. DO NOT operate compressor with detective air inlet system. Remove and replace defective parts by ordering with part numbers indicated in the Parts List. Maintenance Performed By Location Date Maintenance Performed By Location Date 3. ANNUAL ENGINE VIBRATION MOUNT INSPECTION At least annually inspect engine vibration mounts for security of attachment and to make sure the resilient parts are intact. DO NOT operate compressor with defective engine mounting system. Remove and replace defective parts by ordering with part numbers indicated in Parts List. Maintenance Performed By Location Date Maintenance Performed By Location DateSection 6 NOISE CONTROL 4. ANNUAL FRAME, CANOPY, AND PARTS INSPECTION Atleast annually inspect rame, canopy and parts, or securiy of attachment. Make sure there are not an missing or deformed members, including all hinged doors, covers and their fastening devices. DO NO’ operate compressor with defective frame, canopy and parts. Remove and replace defective parts by order- ing with part numbers indicated in Parts List. Maintenance Performed By Location Date Maintenance Performed 5, ANNUAL ACOUSTICAL MATERIALS INSPECTION Atleast annually inspect all acoustical materials, if any, for security ofattachment. Make sure that there is not ‘any material missing or damaged (refer to Parts List). Clean or replace, ifnecessary. DO NOT operate com- pressor with defective acoustical material. Remove and replace defective parts by ordering with part num- bers indicated in the Parts List Maintenance Performed By Location Date Maintenance PerformedSection 6 NOISE CONTROL 6. ANNUAL INSPECTIONS FOR PROPER OPERATION OF ALL SYSTEMS. In addition to other instructions in the Operator's Manual, atleast annually, operate compressor and inspect tomake sure all systems are operating properly and that engine runs at rated speed and pressure. DO NOT operate maifunctioning or improperly adjusted compressor. Repair or adjust, per instructions in Operator's Manual, as required. Maintenance Performed By Location Date Maintenance Performed By Location Date 3536 NOTESSection 7 ILLUSTRATIONS AND PARTS LIST 7.1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative or the Representative from whom the com- pressor was purchased. Iffor any reason parts cannot be obtained in this manner, contact the factory directly at the address, phone or fax numbers below. When ordering parts always incloate the Seral Number ofthe compressor. This can be obiained from the Bill cf Lading for the compressor or from the Serial Number Plate located on the compressor. SULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City, Indiana 46360 U.S.A. Telephone: 1-800~SULLAIR (U.S.A. Oniy) or 41-218-879-! FAX: (218) 874-1273 FAK (210) 874-1895 (Parts) FAX: (219) 874-1205 (Service) SULLAIR ASIA, LTD. SULLAIR EUROPE, S.A. Sullair Road, No. + Zone Des Granges BP 82 Chiwan, Shekou 42602 Montbrison Cedex, France ‘Shenzhen, Guangdong PRV. ‘Telephone: 33-477968470 PR.C. Post Code 51 ‘ax: 33-477968499, Telephone: 755— 6851686 "AX: 755~6853473 7.2 RECOMMENDED SPARE PARTS LIST Desoription Kit Number Quantity element for air fier assy. 02250114—170 02250051~136 2 ‘element for main compressor fluid filer 250025~521 250025-525 1 ‘element for ainfluid separator 250034087 1 ‘element for fuel-water separator 02250118495 1 element for 1st stage discharge fier (aftercooled) 250024~-428 1 element for 2nd stage discharge fiter(aftercooled) 250024-436 1 3 oil fiter (John Deere) 02250100-288 1 02250083-017 1 02250100-289 1 element for engine fuel fiter (Caterpillar) 02250083-016 1 repair kit for blowdown valve 02250049-634 (02250049-634 1 repair kit for thermal valve 02250113-796 044583, 1 repair kit for lange SAE o-ring (02250099-416 1 repair kit for pressure regulator valve 250017—280 250019-453 1 repair kit for pressure regulator valve 041517 (375H) 041742 1 repair kt for inlet valve 250026-779 250029-249 1 repair kit for return line strainer 241771 2a1772 1 repair kit for minimum pressure/check valve 02250084-294 250019-444 1 repair kit for shaft seal 602541 -002 1 repair coupling assemblies (JD & CAT 375) 250031 -586 1 repair coupling assemblies (JD 375H & 425) 250024-470 1 Sullair AWE (6 gallons/20 liters) 250030-757 1 Sullair AWF (65 gallon drum/208 liters) 250030-758 1 manual, CIMA safety 250023-146 1 manual, Portable Component Service 02250056-343 1 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSORSection 7 ILLUSTRATIONS AND PARTS LIST 7.3 ENGINE, COMPRESSOR AND PARTS ~ JOHN DEERE ENGINE SPEED CYLINDER ITEM 5 Reference Page 43Section 7 ILLUSTRATIONS AND PARTS LIST 7.3 ENGINE, COMPRESSOR AND PARTS ~ JOHN DEERE key part number description number quantity 1 bushing, taperlock (375) 02250049-415 1 sbushing,taperlock (375H & 425) 407848 1 2 elbow,check valve 1/4t x 1/8 02250058-275, 1 3 support (375) 02250061 ~551 1 + angle (375H & 425) 02250116-372 1 4 ‘spacer, brake lever 02250064-504 2 5 ‘sub assembly,control cylinder (375) 02250085-731 1 *sub assembly,control cylinder (375H & 425) 022501 16-373 1 6 spacer, fan 02250094-984 1 7 switch, temp 239 deg. t 02250098-484 1 8 spring, extension .31 x 7.5#/in (02250112337 1 9 fan (02250115-567 1 10 unit (375)(0) 02250116-147 1 + unit (875H) (0) 02250118-239, 1 + unit (425)(1) 02250116-146 1 1" angle 02250116-343 1 12 engine Consult Factory 1 13 support 022501 18-851 2 14 mount, vibration 022501 18-869, 4 15 switch, temp 02250119-047 1 16 shield, heat 02250120-958 1 7 drainlock, 1/4” 040061 1 18 gasket, inlet viv 5.25 od x 4.12 id 040708 1 19 tube.ss 1/4" fuel return 250011-577 1 20 connector.1/4t x 1/4 npt str 250018-428 2 21 adapter 250022-732 1 22 spacer, coupling 250023-218 1 23 key,shatt (375) 250023-340 1 + key,shatt (375H & 425) 02250053-263, 1 24 valve, air inlet 4” 250026-779 1 25 spacer, brake lever 250028-681 2 26 coupling assy (375) 250031 -586 1 scoupling assy (375H & 425) 250024-470 1 (D There is an exchange program whereby a remanufactured compressor unitcan be obtained from Sullait distributors or the factory at less cost than the owner could repair the unit. For information regarding the unit exchange program, contact your nearest Sullair representative or the Sullair Corporation. ‘The shaft seal is not considered pat ofthe compressor unin regard tothe two year warranty, The normal Sullair parts warranty applies. For shaft seal repairs consult factory. (Continued on Page 41) PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR: 39Section 7 ILLUSTRATIONS AND PARTS LIST 7.3 ENGINE, COMPRESSOR AND PARTS - JOHN DEERE a ENGINE SPEED CYLINDER 5 ITEM 5 Reference Page 43 40Section 7 ILLUSTRATIONS AND PARTS LIST 7.3 ENGINE, COMPRESSOR AND PARTS - JOHN DEERE (continued) key description: engine, compressor & parts part number (continued) number quantity 27 nut,hex f pitd 5/16-18 825905-283, 2 28 rnut,hex locking 1/4-20 825504—145 2 29 rnut,hex locking 3/816 825506-198 8 30 rnut.hex locking 5/8—11 825510-329 2 31 capser, hex 8.8 m8 x 55mm 828008-055 1 32 capser, hex 8.8 m10 x 16mm 828010-016 1 33 ccapser, hex 8.8 m10 x 35mm 828010-035 12 34 capscr, hex 8.8 m10 x 75mm 1828010075 4 35 ‘capscr, hex 8.8 m12 x 30mm. 1828012-030 6 36 capscr, hex gr5 3/8-16 x 1 829106-100 8 37 capscr, hex gt5 1/2-13 x1 829108100 10 38 capscr, hex gt5 1/2-13x 1 1/2 829108-150 4 39 capser, hex gr5 1/2-13 x3 1/4 829108-325 2 40 capscr, hex 915 5/8—11 x3 1/2 829110-350 2 a screw, hex ser washer 5/16-18 x 3/4 829705-075 2 42 washer, spr lock reg pltd 1/2 837808-125 6 43 washer, pI-b reg pltd 3/8 838206-071 20 44 washer, pl-b reg pltd 1/2 838208-112 2 45 washer, pl-b reg pltd 5/8 838210-112 2 46 washer, spr lock—metric pltd m8 838808-200 1 47 washer, spr lock—metric pltd m10 838810-220 17 48 washer, spr lock—metric pltd m12 838812-250 6 49 elbow, 37f1 90m 1 x 1 860216-100 1 50 bushing,red pltd 1/4 x 1/8 867100-005 1 51 capscrew, ferry head hd pltd 1/4-20x 1 1/4 867804—125 1 52 capscrew, ferry head hd pitd 1/4-20 x1 1/2 867304-150 1 53 capscrew, ferry head hd pitd 3/8-16 x 1 (375) 867306-100 8 scapscrew (375H & 425) 829106-225, 8 (Continued on Page 43) PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR: atSection 7 ILLUSTRATIONS AND PARTS LIST 7.3 ENGINE, COMPRESSOR AND PARTS ~ JOHN DEERE > ENGINE SPEED CYLINDER ITEM 5. Reference Page 43Section 7 ILLUSTRATIONS AND PARTS LIST 7.3 ENGINE, COMPRESSOR AND PARTS - JOHN DEERE (continued) description: 375 Cylinder Assy ~ part ITEM 5 part no. 02250085-731 number quantity 1 rod 250011590 1 2 cylinder, speed 250021405 1 38 joint, ball 250011—597 1 4 elbow 250018-429 1 5 joint, bait 250011-578 1 6 rnut,nex jam rh untfin 4/4” 824604-164 2 7 rhut,hex jam th unfin 1/4" 824704-164 1 8 spring 250022-782 1 9 washer, pl br 1/4" 837204-071 1 key description: 375H & 425 Cylinder Assy — part number ITEM 5 part no. 02250116-373 number quantity 1 rod 02250064-593, 1 2 cylinder, speed 250021405 1 3 joint, ball, 250011-597 1 4 elbow 250018-429 1 5 joint, bal 25001-5878 1 6 nu hex jam rh unfin 1/4” 866604—164 2 7 niu hex jam th unfin 1/4" 868204-164 1 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR: 43Section 7 ILLUSTRATIONS AND PARTS LIST 7.4 ENGINE, COMPRESSOR AND PARTS ~ CATERPILLAR, ENGINE SPEED CYLINDER ITEM 5 (Reference Page 47) aSection 7 ILLUSTRATIONS AND PARTS LIST 7.4 ENGINE, COMPRESSOR AND PARTS - CATERPILLAR, key part number description number quantity 1 bushing taperiock 2012 02250049-415 1 2 elbow,check valve 1/4t x 1/8 02250058-275 1 3 spacer 02250064-594 2 4 switch, engine hi temp 225 deg nc 02250084—094 1 5 sub assembly,control cy! 02250086-890 1 6 support 02250105-279 1 7 spring, extension .31 x 7.5#/in 02250112-337 1 8 fant 02250115-570 1 9 unit, 16 series 375(1) 02250116-147 1 10 engine Consult Factory 1 1 support, eng frt th 02250118-852 1 12 support, eng ft rh 02250118-853, 1 13 ‘mount, vibration 02250118-869 4 14 switch, temp sht dn 250 deg f 02250119-047 1 15 drainlock, 1/4” ‘040061 1 16 gasket, inlet viv 5.25 od x 4.12 id 040708 1 17 tube,ss 1/4” fuel return 250011877 1 18 connector, 1/4t x 1/4 npt str 250018428, 2 19 adapter 25002-7382 1 20 spacer, coupling 250023-218 1 21 key.shatt 250023-340 1 22 valve, air inlet 4 250026-779 1 23 coupling assy 250031 -586 1 24 capscrew, ferry 3/8-24 x 1" 405131 8 25 rnut.hex locking 1/4-20 825504-145, 2 26 nut,hex locking 3/8-16 825506-198, 8 27 rnut,hex locking 5/8—11 825510-329 2 (D There is an exchange program whereby a remanufactured compressor unitcan be obtained from Sullair distributors or he factory at less cost than the owner could repair the unit. For information regarding the unit exchange program, contact your nearest Sullair representative or the Sullair Corporation. ‘The shaft seal is not considered part of the compressor unit in regard to the two year warranty. The normal Sullair parts warranty applies. For shaft seal repairs consult factory. (Continued on Page 47) PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 45Section 7 ILLUSTRATIONS AND PARTS LIST 7.4 ENGINE, COMPRESSOR AND PARTS - CATERPILLAR 1 - Fa ENGINE SPEED CYLINDER 7 ITEM 5 (Reference Page 47) aSection 7 ILLUSTRATIONS AND PARTS LIST 7.4 ENGINE, COMPRESSOR AND PARTS — CATERPILLAR (continued) key number 28 29 30 31 32 33 34 35 36 37 38 39 40 a 42 43 44 45 Noansens PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR: description: engine, compressor & parts (continued) capscr, hex 8.8 m8 x 70mm capscr, hex 8.8 m10 x 35mm ccapscr, hex 8.8 m12x 25mm ccapscr, hex gr5 3/8~16 x 1 ccapscr, hex gr5 1/2—13.x1 capscr, hex grS 1/2—13.x 1 1/2 capscr, hex gr5 1/2-13x3 1/4 capscr, hex gt5 5/8-11 x3 1/2 washer, spr lock reg pitd 1/2 washer, pi-b reg pltd 3/8 washer, pl-b reg pltd 1/2 washer, pl—b reg pltd 5/8 washer, spr lock—metric pitd m8 washer, spr lock—metric ptd m10 washer, spr lock—metric pita m12 bushing,red pitd 1/4 x 1/8 capscrew, fery head hd pltd 1/420 x 1 1/4 capscrew, ferry head hd pltd 1/4~20 x 1 1/2 description: speed cylinder - item 5 rod, threaded speed control 1/4—28 joint, ball female 1/4” Lh. joint, ball female 1/4” rh. elbow, 90 1/4"tube x 1/8"npt cylinder, speed air 3/4” bore x 1"str ‘ut, hex jam th pitd 1/4—28 nut, hex jam rh pltd 1/4-28 part number 828008-070 828010-035 828012025 829106-100 829108-100 829108-150 829108-325 829110-350 837808 —125 938206-071 938208—112 838210-112 838808~200 838810-220 838812250 867100-005 867304—125 867304-150 02250064-593 250011 -578 250011 -597 250018429 250024~272 866604-164 868204-164 quantity etee tet ratrot rs eee 0 a7ILLUSTRATIONS AND PARTS LIST Section 7 7.5 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM — JOHN DEERE & CATERPILLARSection 7 ILLUSTRATIONS AND PARTS LIST 7.5 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM ~ JOHN DEERE & CATERPILLAR key part number description number quantity 1 bucket, radiator fluid recovery 02250083-466 1 scap, bucket (02250097-021 1 2 filter, uid 02250096-783, 1 3 clip buckle for ins. strapping 02250110-229 6 4 housing() 02250113-796 1 5 support, oil fiter 02250114—008 1 6 radiator 02250114-934 1 scap, radiator 02250099-019 1 7 cooler, oll (JD &CAT) 02250114-935 1 8 hose,radiator upper (JD) 02250114-999 1 shose,radiator upper (CAT) 02250115-004 1 8 hose,radiator lower (JD) 02250115-002 1 hose radiator lower (CAT) 02250115-006, 1 10 guard 02250115~433, 1 14 baffle, cooler rh 02250115-491 1 12 baffle, cooler h 02250115~492 1 13 baffie, cooler bottom 02250115-493, 1 14 baffie, cooler top 02250115-494 1 15 support, cir end baffle 02250115-709 2 16 shroud, fan (JD) 02250115-877, 1 + shroud, fan (CAT) 02250115-878 1 17 hose, hydraulic parkrimp 1 x 40 02250116-469, 3 18 hose, hydraulic parkrimp 1 x 39 02250116-472 1 18 panel, acst rear baf 975 1.5° 02250117-110, 1 20 baffle, rear lower 02250118-165, 1 21 baffle, rear upper 02250118-166 1 22 panel, acoustical baf rear up 1.5" 375 02250118-350 1 23 tank, air—oil 02250118-422 1 24 panel 02250118-951 1 25 support, cooler assy 02250119-030, 2 26 clamp, hose 1 5/16" to 2 1/4” adi 040014 2 27 drainlock, 1/4” 040061 1 (D) For maintenance on thermal valve no. 02250113-796 order kit no. 044583. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 49Section 7 ILLUSTRATIONS AND PARTS LIST 7.5 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM - JOHN DEERE & CATERPILLAR (continued) ke part number description number quantity 28 clamp, hose 1 19/16" x 2.9/4" adj, 040083 2 29 element, thrm vlv (155 deg f) 044583 1 30 clamp, hose 3/8” 047235 1 31 strapping, 1/2" wide (tt) 047829 73 32 weatherstrip, 1"thick x 1"wide (ft) 250041174 6 33 nutjhex f pitd 5/16—18 1825305-283 32 34 ccapscr, hex gr5 5/16-18 x 3/4 829105-075 4 35 sorew, hex ser washer 1/4—20 x 1/2 829704-050 6 36 sorew, hex ser washer 1/4-20 x 3/4 829704-075 2 37 sorew, hex ser washer 5/16—18 x 3/4 829705-075 23, 38 sorew, hex ser washer 5/16—18 x 1 829705-100 16 39 washer, spr lock reg pltd 5/16 837805-078 4 40 washer, pl—b reg pid 5/16 838205-071 49 at washer, pl—b wide pltd 5/16 838305-071 2 42 hose,fuel line 1/4” (ft) 842315-025 3 43 reducersstr thrd viton 1 1/4 x1 870020-016 2 44 connector, straight x jie 1 5/16 x1 5/16 870116-016 2 45 connector, 45 deg str x jic 1 5/16 x 1 5/ 870516-016 1 46 connector,90d str x/ic 1 5/16 x 1 5/16 870616-016 2 47 union, straight thrd 1 1/16—12 871316-131 1 48 tee,run 37fl str thd 1 5/16~12 871916-131 1 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 5tSection 7 ILLUSTRATIONS AND PARTS LIST 7.6 AIR INLET SYSTEM & EXHAUST SYSTEM — JOHN DEERE & CATERPILLAR CATERPILLARS. ONLY JOHN DEERES ONLYSection 7 ILLUSTRATIONS AND PARTS LIST 7.6 AIR INLET SYSTEM & EXHAUST SYSTEM - JOHN DEERE & CATERPILLAR key part number description number quantity 1 gasket, exht (CAT) (02250110-425 1 2 elbow, red rub 5" to 4” 02250113-942 1 3 hose, a inlet (JD) 02250113956 1 4 hose, air inlet (CAT) 02250113-974 1 5 support 02250114-010 1 6 filter, air (D) 02250114-170 2 7 tube,exhaust (JD) 02250115-008, 1 8 tube,exhaust (CAT) 02250115-010 1 9 muffler, exhaust 02250115-201 1 10 plate, heat shield (CAT) 02250119-942 1 "1 clamp, hose 4.28/4.59 040842 2 12 ‘clamp. exhaust 3” 043713 1 13 ‘cap, rain exhaust 3° 047208 1 14 ‘lamp, hose 2—19/16 to 3-3/4"(CAT) 250018-550 1 15 ‘olamp, hose 4.25/3.31 (JD) 250031—415 1 16 ‘olamp, exhaust (JD) 250081-771 1 7 ‘clamp, hose 6” dia worm drive 408153 1 18 clamp, hose 23/8" id. (CAT) 408300-010 1 19 nut,hex f pltd 5/1618 825905-283, 3 20 ccapsor, hex 8.8 m10 x 25mm(CAT) 828010-025 3 21 ‘capsor, hex gr5 S/8—16 x1 829108-100 7 22 screw, hex ser washer 5/16~18 x 1 829705-100 3 23 washer, spr lock reg pltd 3/8 837806-094 7 24 washer, pl—b reg pitd 3/8 838206-071 4 25 washer, spr lock—metric pitd m1o(CAT) 838810-220 3 (D For maintenance on fiter part no. 022501 14-170 order kit no, 02250051 -136, PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR: 53‘ROMMECTION_EXPL ANATION SMTG START-RUN VALVE (PRESS SIDE) 2 TOIT ier FLANGE + 19 TNter'Vatve’ 219 sheep eye) >TO Bi-Lo VALVE - Low side >TO HILO VALVE = HI" ste 21 HIZLO VALVE > “ComON poRT) 278 Starr. Section 7 ILLUSTRATIONS AND PARTS LIST 7.7 CONTROL PARTS & DISCHARGE PARTS ~ JOHN DEERE & CATERPILLAR ON / SEE COOLING SYSTEM 1 '=RUN VALVE (COMMON PORT) 54Section 7 ILLUSTRATIONS AND PARTS LIST 7.7 CONTROL PARTS & DISCHARGE PARTS ~ JOHN DEERE & CATERPILLAR ‘oti part mber description number quantity 1 insert, nylon tubing 1/4"od 02250052-841 2 2 tube,nyl 25 od x 040w wht(t) (02250054~860 4 3 tube,nyl 25 od x .040w bik (ft) (02250054—861 18 4 sub assembly,receiver oi fill (1) 02250085-729 1 5 sub assembly,control orice (1) 02250122-099 1 6 valve, 1 1/2" npt min pressure check 02250094-204 1 7 flange,kitsae spit 2 1/2" — viton 02250099-416 2 8 ‘manifold, ~1/2 fnpt 375 serv air 02250114-390 1 9 sub assembly,blowdown valve std (11) 02250118-381 1 10 tank, airfoil sep 02250118-422 1 1 hose,discharge 02250118-423, 1 12 sub assembly,feg viv assy (1) 02250118-560 1 13 sub assembly,hi press reg viv assy (1) 02250118-562 1 14 sub assembly.service valves std (II) 02250118-603, 1 15 ‘connector, tube oil return 5/16x1/4 02250118-809 1 16 hose, air service 02250119-080, 1 7 strainer, v—type 300psix1/4(111) 2ai771 1 18 tube,steel 5/16"od oil siphon 250009-253, 1 19 connector, 1/4t x 1/4 npt str 250018-428 1 20 valve, press rif 165# 3/4” 250022—458 1 24 elemental sep 8.81 x 11.18 250034—087 1 22 washer, .625 hardened 250040100 8 23 plug.straight thread 3/4—16 viton 250042-623 1 24 connector tube—male 5/16 x 1/4 1812205025 1 25 rnut,hex fpitd 5/16-18 1825305—283 4 26 capscr, hex gr8 1/2-13 x1 1/2 1828208-150 4 27 capscr, hex gr5 5/8—11 x1 3/4 829110-175 8 28 screw, hex ser washer 5/16-18 x 1 1829705100 4 29 washer, pl—b reg untin 1/2 837208-112 4 30 washer, spr lock 1/2 837508-125 4 (1) See section 7.7A for details. (Ul) See section 7.78 for details. (111) For maintenance on strainer part no, 241771, order kit number 24172, (Continued on Page 57) PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSORSection 7 ILLUSTRATIONS AND PARTS LIST 7.7 CONTROL PARTS & DISCHARGE PARTS ~ JOHN DEERE & CATERPILLAR HIGH PRESSURE MACHINES ONLY 7 ‘SEE COOLING ‘SYSTEM 56Section 7 ILLUSTRATIONS AND PARTS LIST 7.7 CONTROL PARTS & DISCHARGE PARTS ~ JOHN DEERE & CATERPILLAR (continued) key part number description number quantity 3t washer, pl-b reg pltd 5/16 838205-071 8 32 elbow, 37f1 90m 1 1/2x 1 1/2 860224-150 1 33 elbow, pipe 45 deg pit 1 1/2” 866115-060 1 34 nipple,pipe pltd 1 1/2x 2.1/2 (866324—-025 1 35 nipple,pipe—xs pit 1 1/2x cl 1866424—-000 2 36 nipple,pipe—xs pit 1 1/2 x 4 1966424—040 1 37 plug, pipe 1/2" 3000# stl pit '866900-020 2 38 bushing,ted pltd 1/2x 1/4 867102—010 1 39 bushing,ted pltd 1 x 3/4 867104—030 1 40 connector,90d str x jie 1 5/16 x1 5/16 870616-016 1 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 87Section 7 ILLUSTRATIONS AND PARTS LIST 7.7A Assemblies - Regulator Valve (“H” and “Standard") & Control Orifice ("H” Models) REGULATOR VALVE ASSEMBLY “H" Models REGULATOR VALVE ASSEMBLY Standard Models CONTROL ORIFICE ASSEMBLY “H” Models 58Section 7 ILLUSTRATIONS AND PARTS LIST 7.7K Assemblies ~ Regulator Valve (“H” and “Standard”) & Control Orifice ("H” Models) key description: “H” Model Regulator Assy part number art no. 022501 18-561 number quantity 1 support, reg viv sa’s 375 02250118-558 1 2 valve, regulator back press(I) 041517 1 3 valve, pressure regulator(I1) 250017280 1 4 elbow, 90 1/4t pls x 1/4 npt m 250018-430 3 5 washer, spr lock reg pltd 1/4 837804—062 1 6 tee, pipe 150# pit 1/4 866815-010 1 7 u=bot1/4" x 1" pipe pltd 868304—100 1 8 nipple,pipe—hx pit 1/4 x 1/4 868504025 2 kes description: “Standard” Model Regulator Assy | part number part no. 022501185: number quantity 1 oriice,.078" 1/8 tpt x 1/8 mnpt oz250069-264 1 2 support, reg viv sa’s 375 02250118-558 1 3 silencer, air ejection 1/8"npt-male 248755 1 4 valve, pressure regulator (Il) 250017280 1 5 elbow, 90 1/4t pls x 1/4 npt m 250018-430 2 6 tee,male 1/4 tube x 1/4 npt 250028-582 1 7 washer, spr lock reg pltd 5/16 1837805-078 2 8 bushing,red pltd 1/4 x 1/8 .867100-005 1 9 cross, pipe 1/4” pit 867615—010 1 10 u=bott.5/16" x 1 1/4” pipe pitd (868305—125 1 4 nipple pipe—hx pitd 1/4 x 1/4 1868504—025 1 key description: Control Orifice Assy “H” Models _ part number part no. 02250122-099 number quantity 1 otifice, .078" 1/8 fnpt x 1/8 mnpt 02250069-264 1 2 silencer, air ejection 1/8°npt-male 248755 1 3 tee,male 1/4 tube x 1/4 npt 250028-582 1 4 tee,pipe 150# pit 1/4 (866815-010 1 5 bushing, red pltd 1/4 x 1/8 1867100005 1 6 nipple, pipe—hx pltd 1/4 x 1/4 1868504—025 1 (1) For maintenance on pressure valve no. 041517, order repair kit no. 041742, (I) For maintenance on regulator valve no. 250017—280, order repair kit no. 250019-453. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 59Section 7 ILLUSTRATIONS AND PARTS LIST 7.7B Assemblies ~ Service Valve, Pneumatic Control Valve, & Receiver Fluid Fill — All Models gee are 6 oem PNEUMATIC CONTROL _. All Models RECEIVER FLUID FILL ASSEMBLY All ModelsSection 7 ILLUSTRATIONS AND PARTS LIST 7.7B Assemblies — Service Valve, Pneumatic Control Valve, & Receiver Fluid Fill — All Models description: Service Valve Assembly part part no. 02250118-602 number quantity valve, ball 3/4” service 250019-865 2 nipple,pipe—xs pit 3/4 x ol 866412-000 2 bushing,red pitd 1 1/2 x9/4 867108-030 2 tee, pipe pltd 11/2 868430-060 1 key description: Pneumatic Control Assy part number part no. 02250118-380 number quantity 1 valve, blowdown 1/4 npt hi prs 02250049-634 1 2 silencer, alr ejection 1/8°npt—male 248755 1 3 orifice, 099 x .125m x .125F 250014-060 1 4 elbow, 90 1/4t pls x 1/4 npt m 250018-430 1 5 tee,male 1/4 tube x 1/4 npt 250028-582 1 6 nipple,pipe—xs pit 1/4 x2 1/2 1966404-025 1 7 tee, pipe 150# pit 1/4 866815010 1 8 bushing,red pltd 1/4 x 1/8 '867100-005 1 9 nipple,pipe—hx pit 1/4 x 1/4 1868504—025 1 key description: Fluid Fill Assembly part number art no, 02250085-729 number quantity 1 adapter.receiver fluid 02250064-595 1 2 glass, sight 02250081-779 1 3 plug.o-ring boss sae 1 1/4 040029 1 4 tee, pipe 150# pit 1 1/2 866815-060 1 (D For maintenance on pneumatic valve no. 02250049-634, order repair kit no. 02250049-634 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR: etSection 7 ILLUSTRATIONS AND PARTS LIST 7.8 OPTIONAL AFTERCOOLER/FILTER AND PARTS - JOHN DEERE & CATERPILLAR, MANIFOLD 62Section 7 ILLUSTRATIONS AND PARTS LIST 7.8 OPTIONAL AFTERCOOLER/FILTER AND PARTS ~ JOHN DEERE & CATERPILLAR key part number description number quantity 1 tube,nyl.25 od x .040w bik (ft) 02250054-861 25 2 cooler, arto air 02250114-996 1 3 shroud, fan (JD) 02250115-611 1 shroud, fan (CAT) 02250115-612 1 4 plate, access: 02250116-321 1 5 valve, ball 3—wat 1-1/2 tnpt 02250118-872 1 6 panel, acst aftr clr 02250118-952 1 7 hose, air 3—way to aftr cir 02250119-082 1 8 hose, air fit to manifold 02250051-446 1 9 hose, alr 3—-way to manifold 02250119-083, 1 10 hose, air separ to filters 02250119-083 1 1" panel, aftr cir baffle 02250119-175, 1 12 shield, heat (JD only) 02250120-958 1 13 support 02250121-077 1 4 separator, water 02250121 -166 1 15 hose, air srv 1/1-2 x54" Ig (02250119079 1 16 ofifice,.081 .125m .125f hrs 025690 2 7 grommet,rubber 1” hole oao162 2 18 connector, 1/4t x 1/8 npt str 250018-427 5 19 kitminni fit mntg 420-700 250024—284 1 20 fiter, mpf—420n 250024-363 1 a1 fiter, mph—420n 250024-374 1 22 clamp, hose 1 3/8" id. -408300-008 1 23 rnut.hex fpitd 5/16-18 1825305-283 10 24 screw, hex ser washer 1/4~20 x 9/4 1829704-075 14 25 screw, hex ser washer 5/16-18 x 1 828705-100 10 26 washer, pl—b reg pltd 5/16 838205-071 4 27 elbow, 87fl 45m 1 1/2x1 1/2 860024—150 3 28 connector 37 fimpt pitd 1 1/2x 1 1/2 860124-150 2 29 elbow, 87f1 90m 1 1/2x1 1/2 860224—150 4 30 nipple,pipe—xs plt 1 1/2x cl 866424—000 2 (@ For maintenance on fiter no, 250024—363, order repair kit no, 250024~428. (UD) For maintenance on filter no. 250024—374, order repair kit no. 250024—436, (Continued on Page 65) PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSORSection 7 ILLUSTRATIONS AND PARTS LIST 7.8 OPTIONAL AFTERCOOLER/FILTER AND PARTS - JOHN DEERE & CATERPILLAR VANE © ‘MANIFOLDSection 7 ILLUSTRATIONS AND PARTS LIST 7.8 OPTIONAL AFTERCOOLER/FILTER AND PARTS ~ JOHN DEERE & CATERPILLAR (continued) key part number description number quantity 31 nipple,pipe—xs pit 1 1/2x3 1/2 866424—035 1 32 nipple;pipe—xs plt 1 1/2x6 866424~-060 1 33 nipple,pipe—xs pit 1 1/2x8 866424—080 1 34 elbow, pipe 90 deg 300# pit 1 1/2" 867030060 1 35 bushing,red pitd 3/8 x 1/8 867101 -005 1 36 u=bot1/2" x 4 pipe pd 868308~400 1 a7 tee, pipe pltd 11/2 868430-060 1 38 elbow, pipe 45 deg 300# pit 1 1/2" 869430-060 1 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 65Section 7 ILLUSTRATIONS AND PARTS LIST 7.9 ELECTRICAL PARTS — JOHN DEERE & CATERPILLAR, FOR CATERPILLAR MACHINES 250030-047 CABLE, BATT 0 GA x 54 Rid @Section 7 ILLUSTRATIONS AND PARTS LIST 7.9 ELECTRICAL PARTS ~ JOHN DEERE & CATERPILLAR, hey , part number description number quantity 1 channel, extruded rubber "u” .25"w 02250086-448 2 2 ‘clamp, tube 3/8” 02250091-103, 38 3 washer, external serrated m10 02250092—169 2 4 connector female pipe 1/8-27 npt 02250097-138 1 5 cable,ground 4—gauge strap 02250101-258 1 6 tray,battery 02250114-232 1 7 cchni, batt hold dwn 02250114-233 1 8 battery, grp 31 hi cap taper post 02250114-276 1 9 panel, frame rear (02250115-719 1 10 frame, assembly (022501 18-932 1 14 hamess, wire std light 4—wire (02250119-646 1 12 bumper.std 875 with lights (02250119-652 1 13 lamp,license plate std (02250119-658 1 14 bracket, license plate lamp 02250119-678 1 15 grommet,fubber 1” hole o4o162 1 16 boot,battery terminal 041561 2 17 clip,cord holder self adhesive 041632 6 18 rnutplastic square license plate 250008-076 4 19 support, starter relay 250007668 1 20 grommet,rubber 1-3/4" hole 250020-358 1 21 fuse, blade type ate 30amp 250023-996 1 22 lamp tailfturnistop (shock mtg) 250028-415 2 23 ‘cable, battery 18"lg black 250029-839 1 24 cable, battery red 1/0 x 78" elp(JD) 250023-025 1 + cable, battery red (CAT) 250030-047 1 25 switch, engine oil pressure 250041-638 1 26 solenoid, starter no 12vde 407567 1 27 clamp, hose 9/16"id 408300-001 1 28 clamp, hose 9/16"i.d. (JD) 408300-001 3 29 nnut,hex fpitd 1/4-20 825904-236 2 30 nutyhex fpltd 5/16-18 825905-283, 9 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR: e77.9 ELECTRICAL PARTS — JOHN DEERE & CATERPILLAR ILLUSTRATIONS AND PARTS LIST Section 7 FOR CATERPILLAR MACHINES 250030-047 CABLE, BATT 0 GA x 54 Réd @Section 7 ILLUSTRATIONS AND PARTS LIST 7.9 ELECTRICAL PARTS ~ JOHN DEERE & CATERPILLAR (continued) key number 31 32 33 34 35 36 37 38 39 40 a 42 43 44 45 46 a7 48 description nut,hex locking #1024 nut,hex locking §/16-18(JD) ‘capscr, hex 8.8 m10 x 25mm(JD) sorew, hex ser washer 1/4~20 x 3/4 sorew, hex ser washer 5/16~18 x 3/4(JD) screw, hex ser washer 5/16—18 x 1 sorew, hex ser washer 5/16—18 x1 1/ screw, mach—rd hd #1024 x 3/4 screw, self—drill 1/4 x 3/4 washer, pl-b reg unfin 7/16(JD) washer, spr lock reg pltd 5/16 washer, pl-b reg pltd 5/16 washer, pl-b wide pitd 5/16 washer, lock ext tooth 1/4 washer, spr lock—metric pltd m10(JD) wrap,tie plastic ty25 fod.threaded .31 x9 nipple, pipe—xs pit 1/8 x cl part number 1825502083 825505-166 1828010-025 1829704-075 1829705-075 1829705-100 1829705—125 831602-075 1834504—075 837207-071 837805-078 838205-071 .838305-071 838404-028 938810-220 1843200-025 843505-090 ‘866402—000 quantity PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 6Section 7 ILLUSTRATIONS AND PARTS LIST 7.10 INSTRUMENT PANEL & PARTS ~ JOHN DEERE AND CATERPILLAR HANDLES MUST POINT TOWARD OPEN PORTS. 70Section 7 ILLUSTRATIONS AND PARTS LIST 7.9 INSTRUMENT PANEL & PARTS ~ JOHN DEERE AND CATERPILLAR key part number description number quantity 1 ‘gauge, pressure air 0-300 2° (02250044-361 1 2 gauge, voltmeter 12 volt 2"() 02250044-366 1 3 gauge, temp (1) 02250050-514 1 4 ‘gauge, pressure mech 0-100psi 2°(1) 02250050-516 1 5 hour-meter, 12~24vde 10000hr 2° 02250050-517 1 6 tube,nylon .25°od x .04w black (ft) 02250054-861 2 7 circuitbreaker, 10. amp o2250084-284 1 8 panel, instrument molded 02250099-928, 1 9 decal. group gauge panel 02250100-088 1 10 decal.group std panel 02250100-089 1 1 adapter, m14 x 1.5 to 5/8-18 unt 02250101-345, 1 2 hares, wiring (JD) 02250101-462 1 8 plug,plastic 1/2" black 02250101-613, 2 4 ‘gauge, temp (1) 02250102-619 1 15 harness, wiring (CAT) 02250103230, 1 16 ‘o-ring,strtthrd metric m14x1.5 02250111—856 1 17 harness, e&c—panel (JD) 02250116-329, 1 18 harness, e&o-panel (CAT) 02250116-330 1 19 valve, ball Sway 1/8" npt 02250117-385 2 20 clipe—ring 1/2" 02250118-240, 2 a switch, starter push—button 040038 1 22 elbow, 90 1/4"tube x 1/8"npt 250018-429 3 23 switch, ignition anti—restart 250034—601 1 24 tee,m run 1/4t plsx 1/8npt 250041 -088 2 25 elbow, 90 deg 1/4" tube x 1/8"inpt 250041 -286 1 26 o-ring,str thd 70 vit 1/2"—908 250042-643 1 a plug, pipe 1/8” 3000# st! pit '866900-005 1 (@ Optional gauges PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR: nmSection 7 ILLUSTRATIONS AND PARTS LIST 7.11 FUEL TANK & CONNECTIONS ~ JOHN DEERE AND CATERPILLAR MOUNTED AT ENG INE/COMPRESSOR: AIR FILTER BRACKET CATERPILLAR ENGINES ONLY SHOWN TO ENGINE FUEL 4 3 oq Zz Go Z im c a a * 90 90 o> vAD com =-4 tm Za or4 es 24 mc 4_G am ac cm or PUMP INLET (CAT)Section 7 ILLUSTRATIONS AND PARTS LIST 7.11 FUEL TANK & CONNECTIONS — JOHN DEERE AND CATERPILLAR key part number description number quantity 1 adaptor, 1/2str oring x 1/4 fnpt 02250075-714 2 2 ‘cap, fuel fill buttress thread 02250004-781 1 3 tube, fuel pump 90 deg 02250110-586 1 4 tank, fuel piste 47 gal 02250115~685 1 5 strap, fue! tank Lh 02250115~702 1 6 strap, fuel tank rh 02250115-703 1 7 flange,fuel pick—up retrn 02250116-337 1 8 filter, ass'y fuel/water sep (1) 02250118-494 1 9 connector, hose 5/16"hose x 1/4"npt 043258 2 10 clamp, hose 3/8" 047295 7 4 elbow, 1/4” hose x 1/4” pipe 250003-573 1 12 gasket, fuel gauge neoprene 250004~752 1 13 screw, mach phill #10—24 x 1/2 250025~-692 5 14 insert, 1/4~20 thrd blind 250034-538 2 18 nut.hex f pitd §/16-18 825905~283, 2 16 nut,hex locking 5/16-18 82505-1668 2 7 ‘screw, hex ser washer 1/4-20 x 1/2 829704-050 2 18 ‘screw, hex ser washer 5/16~18 x 1 829705-100 2 19 washer, spr lock reg pltd #10 837802-047 5 20 washer, pl-b reg pltd 5/16 838205-071 2 21 hose,fuel line 1/4" (t) 842315-025 5 22 hose,fuel line 5/16” (A) 842815-031 6 () For maintenance on fter part number 02250118494, order kit number 022501 18-495. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSORSection 7 ILLUSTRATIONS AND PARTS LIST 7.12 FRAME, AXLE & PARTS and AXLE ASSEMBLY — JOHN DEERE & CATERPILLAR FRAME, AXLE & PARTS ITEM 13 AXLE ASSEMBLY P/N 02250116-323 (Reference page 77) 74.Section 7 ILLUSTRATIONS AND PARTS LIST 7.12 FRAME, AXLE & PARTS and AXLE ASSEMBLY - JOHN DEERE & CATERPILLAR key part number description number quantity 1 nut,shackle 02250058-263 2 2 bott, shackle (02250058-267 2 3 washer fi hard 53 x 1.12x.188 02250064—266 8 4 tire,assembly h78-15 st d 02250100-518 2 5 plug,4” round black plastic 02250106-068 2 6 bail ting 875 new style 02250114-011 1 7 fender w/hd brakes 02250114-765 2 8 panel, tool box 02250115-704 1 9 panel, frame side rh 02250115-717 1 10 panel, frame side Lh. 02250115-718, 1 1" panel, frame rear 02250115-719 1 12 panel, frame frt 02250115-721 1 13 axle, assembly 02250116-323, 1 14 battle, frm bottom mid 02250116-413, 1 15 drawbar assy, std wedge style 02250116-793 1 16 jack, hd wipad 02250116-794 1 7 panel, acst frm fr 1" 02250117-109 1 18 battle, frm bottom rear 02250118-117, 1 19 panel, acoustical frm side rh 1” 02250118-951 1 20 panel, acoustical frm side Ih 1” 022501 18-352 1 21 panel, acoustical frm rear th 1” 02250118-353, 1 22 panel, acoustical baff bot rear 1” 022501 18-355, 1 23 panel, acoustical batf bot mid 1” 022501 18-356 1 24 angle, baffle frm rear 02250118-877 1 25 frame, assembly 02250118-932 1 26 panel, acst toolbox 02250118-950 1 27 ott, Keeper 040116 2 28 nut.keeper bolt 040117 2 29 hanger, front mount 045194 2 30 hanger, rear slipper dexter #030-028 045195 2 31 plug,plastic 1" dia 234114 1 32 eye, 3” lunette demountable 250002-221 1 33 link, quick 3/8" 250017-836 1 34 chain, 3/8” x 71"w/2 hks pltd 250018-492 1 35 Weatherstrip, 9/16 x 3/8 ft 25002-4396 16 36 nut,hex f pitd 5/16-18 825305283, 20 (Continued on Page 77) PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 75ILLUSTRATIONS AND PARTS LIST Section 7 7.12 FRAME, AXLE & PARTS and AXLE ASSEMBLY ~ JOHN DEERE & CATERPILLAR FRAME, AXLE & PARTS ITEM 13 ‘AXLE ASSEMBLY PIN 02250116323 (Reference page 77) 76Section 7 ILLUSTRATIONS AND PARTS LIST 7.12 FRAME, AXLE & PARTS and AXLE ASSEMBLY — JOHN DEERE & CATERPILLAR (continued) key part number description number quantity 37 nut,hex locking 1/2—18 1825508-262 1 38 nut,hex locking 5/811 1825510329 2 38 capscr, hex gr6 1/2-13 x1 1828608-100 1 40 capscr, hex gr5 1/2-13 x1 1/2 829108-150 13 a capscr, hex gr5 1/2—13 x 1 3/4 829108-175 6 42 capscr, hex gtS 1/2-13 x4 1/2 829108450 1 43 ‘capscrew, hex gt5 5/8—11 x 43/4 829110-475 2 44 screw, hex ser washer 5/16~18 x 3/4 829705-075 59 45 screw, hex ser washer 5/16—18 x 1 829705-100 5 46 washer, spr lock reg pltd 1/2 837808125 19 a7 washer, pl—b reg pltd 5/16 838205-071 52 48 washer, pl—b reg pltd 1/2 938208-112 7 49 washer, pl-b reg pitd 5/8 838210-112 4 50 washer, pl—b wide pitd 5/16 838305-071 12 51 nut,retainer 5/16-18 861405-092 18 part description: axle assembly — tem 13 number quantity spring, leaf 2500 250010-112 2 plate, tie dexter#12—2 045197 2 u-boltaxle spring mtg. 3° 242486 4 ‘ut,hex 1/220 plated 047881 8 hub,6 on 5-1/2" bolt center 250025-527 2 cap, grease axle assy dexter#21—042 250040-788, 2 plug,rubber axle assy ez—lube — 2 fiting, grease—str 1/4°npt 1861000-025 2 ‘nut,wheel 1/220 plated 250023-470 12 stud, wheel hub axle assy 250023-468 12 washer, tang axle assy 250040-784 2 washer, spindle dexter#5-023 047874 2 bearing, inner dexter#31-30 040118 2 nut.spindle dexter#6—001 047875 2 bearing, outer dexter#31-32 040119 2 seal, ol axle assy dexter#10-10 250040-787 2 beam, axle 49.92sc 67.5hf - 1 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR, 77.13 FRAME, LESS RUNNING GEAR, & PARTS ~ JOHN DEERE & CATERPILLAR ILLUSTRATIONS AND PARTS LIST Section 7 78Section 7 ILLUSTRATIONS AND PARTS LIST 7.13 FRAME, LESS RUNNING GEAR, & PARTS - JOHN DEERE & CATERPILLAR key ; part number description number quantity 1 plug.4” round black plastic 02250106-068, 2 2 bailifting 02250114-011 1 3 panel, tool box 02250115~704 1 4 panel, frame side rh. 02250115-717 1 5 panel, frame side Ih 02250115-718 1 6 panel, frame rear 02250115-719 1 7 panel, frame frt 02250115-721 1 8 baffle, frm bottom mid 02250116-413, 1 9 panel, acst frm ft 1" 022501 17-109 1 10 baffle, frm bottom rear 02250118-117, 1 1" panel, acoustical frm side rh 1” 02250118-351 1 12 panel, acoustical frm side th 1° 02250118-352 1 13 panel, acoustical frm rear th 1” 02250118-353, 1 14 panel, acoustical baff bot rear 1” 02250118-355 1 18 panel, acoustical baff bot mid 1" 02250118-356 1 16 angle, baffie frm rear 02250118-877 1 17 frame, assembly 02250118932 1 18 panel, acst toolbox 02250118-950 1 19 channel, less run-gear mtg 02250119-501 2 20 panel, frm front 175h serv mant 02250119-552 1 a4 plug,plastic 1.75" dia 02250119-699 1 22 plate, cover license plate hole 02250119849 1 23 plug,plastic 1" dia 234114 1 24 weatherstrip, 3/16 x 9/8 ft 250022—436 16 25 nnut.hex f pltd 5/16—18 1825305-283, 22 26 nut,hex locking #10-24 1825502—083 2 27 capser, hex gr5 1/2—13x 1 1/2 829108-150 1 28 ccapscr, hex gr 1/2-13x 1 9/4 829108-175 6 29 screw, hex ser washer 5/16—18 x 1/2 829705050 4 30 screw, hex ser washer 5/1618 x 3/4 1829705-075 69 31 screw, hex ser washer 5/16—18 x1 829705-100 1 32 screw, mach=rd hd #10—24 x 3/4 831602-075 2 33 washer, spr lock reg pltd 1/2 1837808—125 17 34 washer, pl-b reg pitd 5/16 838205-071 66 35 washer, pl-b reg pltd 1/2 838208-112 11 36 washer, pl-b wide pitd 5/16 838305-071 4 37 nutyretainer 5/16—18 1861405092 18 38 battle 02250119-502 1 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSORSection 7 ILLUSTRATIONS AND PARTS LIST 7.14 CANOPY, ACOUSTICAL PANELS & PARTS ~ JOHN DEERE & CATERPILLAR Instrument Panel and Parts Reference page 83Section 7 ILLUSTRATIONS AND PARTS LIST 7.14 CANOPY, ACOUSTICAL PANELS & PARTS ~ JOHN DEERE & CATERPILLAR key part number description number quantity 1 seal,weatherstrip 1/2" x 1/2" o2250101-614 12 2 catch pivot slam pad Ick bik 02250107-837 2 3 clip,buckle for ins. strapping 02250110-228 2 4 lip,insulation retaining 02250112-005 7 5 panel, canopy fit rh. 02250115-722 1 6 panel, canopy frt th 02250115-723 1 7 panel, canopy rear rh 02250115-724 1 8 panel, canopy rear h (02250115-725 1 8 panel, canopy rear access 02250115-727 1 10 door,canopy r.h. 02250115728 1 1" door,canopy Lh. 02250115-729 1 12 hinge, canopy door 1&r 02250115-790 2 13 baffle, canopy top 02250115~781 1 14 panel, acst fit rh 1” 02250117-098 1 15 panel, acst frt ih 1” 02250117-099 1 16 panel, acst side frt rh 1” 02250117-100 1 7 panel, acst side frth 1" 02250117-101 1 18 panel, acst door rh 1” 02250117-102 1 19 panel, acst door ih 1” 02250117-103 1 20 panel, acst side rh 1.5" 02250117-104 1 21 panel, acst side rth 1.5” 02250117-105 1 22 panel, acst rear rh 1” 02250117-106 1 23 panel, acst rear ih 1” 02250117-107 1 24 panel, acst rear access 1” 02250117-108 1 25 panel, acst canopy top 2” 02260117-111 1 26 channel, insull supt ‘rt 02250117-316 2 27 channel, insul supt rear 02250117-317 2 28 panel, acoustical can top rear 2” 02250118-349 1 29 panel, canopy top 02250118-907 1 30 grille, wire canopy top 022501 18-908 1 31 grommet,rubber 040125 2 32 strapping, 1/2" wide (t) 047829 10 (Continued on Page 83) PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 81Section 7 ILLUSTRATIONS AND PARTS LIST 7.14 CANOPY, ACOUSTICAL PANELS & PARTS ~ JOHN DEERE & CATERPILLAR Instrument Panel and Parts Reference page 83Section 7 ILLUSTRATIONS AND PARTS LIST 7.14 CANOPY ACOUSTICAL PANELS & PARTS - JOHN DEERE & CATERPILLAR (continued) key part number description number quantity 33 weatherstrip, 3/16 x 9/8 ft 250022—496 44 34 ‘screw, mach phill #10—24 x 1/2 250025-692 24 35 hook,door latch male ss 250033-828 2 36 catch, door latch female ss 250033-829 2 37 insert, 1/4~20 thd blind 250034—538 14 38 bumper.ubber 1/2 dia 250035-095 4 39 nut.hex f pitd §/16-18 1825305 -263 30 40 nut.hex locking #10-24 1825502-083 24 at rnut.hex locking 1/4—20 1825504—145 14 42 nut,hex locking 5/16-18 825505—166 1 43 capscr, hex gt5 1/4—20 x 3/4 829104-075 26 44 screw, hex ser washer 1/4—20 x 3/4 829704075 2 45 screw, hex ser washer 5/16—18 x 3/4 829705-075 7 46 washer, pI-b reg pltd 1/4 838204-071 40 47 washer, pl-b reg pitd 5/16 838205-071 3t 48 eyebott,reg cp 5/16—18x1 1/8 839105-112 1 key description: part number instrument panel & parts number quantity 1 door access, instrument pane! o2250103-622 1 2 hinge, instrument panel door 02250103-623 1 3 sctew,phil pan hd #6-32 x3/8 02250112-009 4 4 panel.instr std 022501 16-332 1 5 pecetheretip, sie care 250022—436 3 6 ‘screw, mach phill #10-24 x 1/2 250025-692 8 7 bumper,ubber 1/2 dia 250035-095 1 8 nnut,hex locking #6-32 825500-102 4 8 washer, pl-b reg pitd #6 838200-045, 4 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSORSection 7 ILLUSTRATIONS AND PARTS LIST 7.45 DECALS , 3 = OIL FOR COMPRESSOR @ A\ (a WEATHER Pui) RHUEUNTIBRUNNNEONPRESOMae €=>SULLAIR 6 375 ~ SULLAIR. a Corea WATER p> DRAIN COETurTcey Perris SCs Pee) aed CEES? CAUTION | DIESEL FUEL ONLY " SHUT ENGINE OFF BEFORE REFUELING a4 A WARNING ‘e pean io brig oss \ 13Section 7 ILLUSTRATIONS AND PARTS LIST 7.15 DECALS ke part number description number quantity 1 decal, ISO 9001 02250057-624 1 2 decal, noise emission control 049463 1 (US. compressors only) 3 decal, Sullair AWF 250032—902 1 4 decal, Sullair logo ~ black 02250059-058, 3 5 decal, “975 Sullar" front (D 02250117-349 1 decal “375H Sulla front (1) 02250117352 1 decal "425 Sulair front (I) 02250118-606 1 6 decal, “375 Sullair” RH. side 02250117-348, 1 decal, “375H Sulla” RLH. side () 02250117-351 1 sdecal, “425 Sullair” RLH. side (I) 02250118-605 1 7 decal, “375 Sullair” LH. side() 02250117-347 1 «decal, “375H Sulla” LH. side (1) 02250117-350 1 sdecal, “425 Sulla” LH. side (I) 02250118-604 1 8 sign, warning hot surfaces 407408 2 9 sign, warning crush/sever 408919 1 10 decal, water drain 040345, 2 1 decal, diesel fuel 040248 1 12 decal, doors closed 250038-030 4 13 decal, warning pressurized cig sys 02250051 -826 1 (Continued on Page 87) (@ Not shown NOTE: SEE SECTION 7.16 FOR DECAL LOCATIONS PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 85Section 7 ILLUSTRATIONS AND PARTS LIST 7.15 DECALS AAWARNING | AWARNING AWARNING 2 7 PUI emir rials eee Lit) Cen eras naka Presta t) Sees Pema eel anette Derek elite te AWARNING' RATED SPEED 2300 RPM TC Real Do not operate unguarded PU ScUn CL} MIN IDLE SPEED 1600 RPM Ray acd ces 86Section 7 ILLUSTRATIONS AND PARTS LIST 7.15 DECALS (continued) key part number description number quantity 14 decal, warming 100/1600 (11) 250028258 1 15 sign, warning compressor flu fil cap 049685 1 16 reflector, 2" x 8" red stripe 040108 4 17 reflector, amber 250034-319 2 18 decal, rated 2300 Idle 1600 02250104—474 1 sdecal, rated 2250 Idle 1600 (1) 02250119-118 1 19 sign, warming sever fan port o4s965 2 20 sign, warning sever bett drive o4s964 1 (Continued on Page 89) (1) Not Shown (I) OSHA guidelines are superceded by any Federal, State or Local regulations whenever applicable. NOTE: SEE SECTION 7.16 FOR DECAL LOCATIONS PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 87Section 7 ILLUSTRATIONS AND PARTS LIST 7.15 DECALS ‘START ~ STOP PROCEDURE 22. ® in iy TE i AFTERCOOLED AND FILYERED Alk| a1 88Section 7 ILLUSTRATIONS AND PARTS LIST 7.15 DECALS (continued) key part number description number quantity 21 decal, operation instructions (John Deere) 02250102—251 1 ‘decal, operation instructions (CAT) () 02250103-130 1 22 sign, caution towing 85mph 250005-578 1 23 decal, general maintenance (John Deere)(1) 02250120-498 1 decal, general maintenance (CAT) 02250120-497 1 24 decal, axle lube 250042-543 2 25 decal, PE designation 02250075-540 1 26 decal, earth ground (02250075-046 3 2 decal, warning tougue heavy 02250077-929 1 28 decal, warning proposition 65 02250118-638, 1 (US. compressors ony) 29 decal, AWF warranty 02250097-455 1 30 decal, Deere Power 02250109-529 1 sdecal, Cat Power (1) 02250103-130, 1 31 decal, aftercooled & fitered air 02250075-506 1 32 decal, aftercooled air flow 02250119-385, 1 33 tag, rpm warranty void (1) 250025-437 1 34 seal, wire wilead disc (1) 250026-962 1 35 nameplate, Sullair serial no. (1) 02250108-078 1 36 decal, wiring diagram (1) 02250120-060 1 (@ Not shown NOTE: SEE SECTION 7.16 FOR DECAL LOCATIONS PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSORSection 7 ILLUSTRATIONS AND PARTS LIST 7.16 DECAL LOCATIONS Decal Location Key Numbers on this page are cross-referenced to Section 7.15 Decal Key Numbers TTB 25 & 26 LocareD ov FRE FAILS NEAR BATTERY GON CORECTION ltems 22, 9, 24, 81, 27, 16, 17 are not used on less running gear models. For aftercooled air only option, configure item 31 to read ‘Aftercooled Air" DECAL LOCATION REFERENCE Ref. [QUANTITY DESCRPTION LOCATION wo z DEEL _WATER CAAT ‘GUERSTNE TEAR DRATCOOKTCLRBSTOET GE AT REAR GALE 17 T EDA WARING 100-1600 ‘Som 15 r ‘Som 2 n S00 [ie z 2 T SIGN, WARNS SEVER BELT DANE [VALTER T SIGN, CAUTION TORRE SS WT ‘SOM TOT TEED OV LESS RANINO GEAR OPTION z z SIGN, WARNING HOT SURFACES ‘SOW ION LIFTING GAIL BOTH SIDESI z T SIN, WARNS CSVSET ‘SOW T_TNOT SED OV LESS RANINE GEAR_OPTTONT 2 2 DECAL CNTION OOORS CLOSED” ‘SOWNTINSIDE OW BAQC OF DOOR LATOHEST GE OECAL NOT USED. a z DECAL ALE LOBE TRSTRLETIONS | SHOWN TROT USED ON LESS RUNNING GEAR OPTION? cr T DECAL, WARRING PRESSURIZED CLS STS | ON TOP COOLER BAFFLE ABOVE RADTATOR CAFAX WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some ofits constituents are known to the State of California to cause cancer, birth defects ‘and other reproductive harm. Battery posts, terminals and ‘elated accessories contain lead and lead compounds known to the State of California to cause cancer ‘and birth defects and other feproductive harm. Wash hands after handing.WORLDWIDE SALES AND SERVICE SULLAIR ASIA, LTD. SULLAIR EUROPE, S.A. Sullair Road, No. 1 Zone a Grang jes BP'82 cnet a ne of iaie eee mera RRS” fe ria Telephone: 785~ 6851686 "AX: 7556853473 SULLAIR CORPORATION ‘00 East Michigan Boulevard ichigen cl Indiana 46360 USA. Telephone! 1-80 7 SULA (USA. Only) or FAK: (219) 874=1273 FAX. (Bis) 874~1695 (Parts) FAX: (219) 874-1205 (Service) ce Printed in U.S.A. Specifications Subject To (Change Without Prior Notice 00