Users Manual D750-900phcu (Rev 01)

JANUARY
USER’S MANUAL
2012 Portable Air Compressors
D750PHCU D900PCU
DE750PHCU DE900PCU
DF750PHCU DF900PCU
D825PCU D900PHCU
DE825PCU DE900PHCU
DF825PCU DF900PHCU
Document: 05018730 0118 / 01

Issued: January 10, 2012
COPYRIGHT
© 2012 Sullivan-Palatek, Inc.
1201 West US Highway 20
Michigan City, IN 46360
DOCUMENT INFO
Part Number: 05018730 0118
Revision: 01
Issued: January 10, 2012
CONTACT
For replacement parts and manuals, contact us at:
Sullivan-Palatek, Inc.
1201 West US Highway 20
Tel: 800-438-6203
Fax: 219-872-5043
Web: www.sullivanpalatek.com
RECORD KEEPING
Record the model and serial number of the compressor for
future reference when contacting the factory for service or
parts.
Model Number: ___________________
Serial Number: ____________________
REVISION HISTORY
# DATE SECTION(S) DESCRIPTION
00 APR-27-2011 --- Released for publication
01 JAN-10-2012 TITLE PAGE Added models DE750PHCU, DF750PHCU, DE825PCU, DF825PCU,
DE900PCU, DF900PCU, DE900PHCU, DF900PHCU
6 Updated RECOMMENDED SPARE PARTS; Updated all
SPECIFICATIONS; Updated WD 15093 WIRING DIAGRAM (REV
00) to REV 01; Replaced “750-900 NORMALY CLOSED CONTROL
SYSTEM” (REV 00) with CD 00001 (REV 01); Updated OIL PIPING
DIAGRAM; Updated 00717796 0142 EXHAUST SYSTEM (REV 00) to
REV 01; Replaced 00717985 0033 INLET VALVE ASSEMBLY (REV 00)
with 00717985 0041 (REV 01); Updated 00717642 0157 AIR FILTER
ASSEMBLY (REV 00) to REV 01; Replaced 00717884 0120 RECEIVER
ASSEMBLY (REV 00) with 00717884 0140 (REV 00); Replaced
00717620 0067 OIL FILTER AND PIPING (REV 00) with 00717620 0077
(REV 00); Replaced 00717680 0108 INSTRUMENT PANEL ASSEMBLY
(REV 00) with 05018845 0130 (REV 02); Added 00717598 0112
(REV 01) ENCLOSURE ASSEMBLY; Replaced 05017120 0390 AXLE
ASSEMBLY (REV 00) with 05017120 0397 (REV 00); Added 05019880
0042 TIRE AND WHEEL ASSEMBLY (REV 00); Added 00717554 0090
DRAWBAR ASSEMBLY (REV 00)
WARRANTY
PORTABLE COMPRESSORS
Sullivan-Palatek, Inc. warrants its new portable air compressor products to be free from defects in material and work-
manship, subject to the following provisions:
Warranty Registration: To validate the warranty for each product the purchaser shall complete and return the war-
ranty registration form within 30 days of delivery to the first user or rental.
Warranty Period: The warranty period for applicable Sullivan-Palatek products is as follows (subject to the Exclu-
sions and Limitations noted below):
Air ends on new machines – stator and rotor assembly: Single stage compressor models: the first to expire; 42
months from shipment by Sullivan-Palatek or 36 months from delivery to the first user. Two stage high pressure
compressor models: the first to expire; 30 months from shipment by Sullivan-Palatek or 24 months from delivery to
the first user. Remainder of new portable air compressor machines: the first to expire; 18 months from shipment
by Sullivan-Palatek or 12 months from delivery to the first user.
Parts, accessories and attachments sold separately from machines, excluding warranty replacement parts
and hand tools: the first to expire; 6 months from shipment by Sullivan-Palatek or 3 months from delivery to the first
user.
Warranty replacement parts: remainder of the original warranty period of the replaced part.
Sullivan-Palatek’s Obligations: Sullivan-Palatek’s exclusive obligations with respect to breach of warranty are (i) to
repair or replace (at Sullivan-Palatek option and subject to return of defective parts) any defective part, (ii) to pay the
reasonable cost of making the repair or reinstalling the replacement part and (iii) only for air compressors having two
or more axles, to reimburse up to four hours travel labor at the travel reimbursement rate and mileage at the mileage
reimbursement rate for up to 200 miles (100 miles travel radius) per event to make repairs.
Customer’s Responsibility: As a condition to Sullivan-Palatek’s obligations under this warranty, Customer shall (i)
give Sullivan-Palatek written notice of any warrantable failure of any Sullivan-Palatek product within the applicable
warranty period, (ii) make the product available for repair at a Sullivan-Palatek authorized repair facility, (iii) pay all
costs of returning failed parts to Sullivan-Palatek, (iv) pay shipping costs for replacement parts, (v) pay reasonable
travel expenses for field repairs performed at customer’s request and (vi) pay the costs of investigating performance
complaints that are not covered by this warranty.
Exclusions and Limitations: Air end seals are not warranted. Engines, tires and batteries are not warranted by
Sullivan-Palatek and are warranted only by the manufacturers of these components. Sullivan-Palatek has no ob-
ligation for product failures or defects resulting from overloading, misuse, neglect, accident, failure to comply with
Sullivan-Palatek’s product manual or failure to install product improvements provided by Sullivan-Palatek. Use on
a product of attachments, accessories or service parts not supplied or recommended by Sullivan-Palatek may, at
Sullivan-Palatek’s option, void the warranty of that product. Sullivan-Palatek has no obligation to pay costs of return-
ing defective parts to Sullivan-Palatek or shipping replacement parts to customer.
THIS WARRANTY IS SULLIVAN-PALATEK’S ONLY WARRANTY OF ITS PORTABLE AIR COMPRESSOR PROD-
UCTS AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED. ANY IMPLIED WARRANTIES
OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED. SULLIVAN-PAL-
ATEK HAS NO OBLIGATION UNDER THIS WARRANTY OR OTHERWISE (REGARDLESS OF THE FORM OF
ACTION) FOR SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES, INCLUDING WITHOUT LIMITATION
LOST PROFITS OR LOST INCOME.
This warranty applies to all Sullivan-Palatek portable air compressors shipped after April 1, 2011 unless expressly
superseded by a later warranty. In the event of any conflict between this warranty and earlier warranty statements,
the terms of this warranty will apply.
TABLE OF CONTENTS
1 OPERATION SAFETY................................................................................................................ 1
1.1 GENERAL NOTE...........................................................................................................................................1
1.2 TOWING AND EQUIPMENT.........................................................................................................................1
1.3 DRAWBARS AND BRAKE ACTUATORS......................................................................................................1
1.4 TOWING SAFETY.........................................................................................................................................2
1.5 PARKING OR LOCATING COMPRESSOR..................................................................................................3
1.6 PRESSURE RELEASE.................................................................................................................................4
1.7 FIRES AND EXPLOSION..............................................................................................................................5
1.8 MOVING PARTS...........................................................................................................................................6
1.9 HOT SURFACES, SHARP EDGES, SHARP CORNERS, AND VACUUM....................................................6
1.10 TOXIC AND IRRITATING SUBSTANCES.....................................................................................................7
1.11 ELECTRICAL SHOCK...................................................................................................................................8
1.12 LIFTING.........................................................................................................................................................8
1.13 ENTRAPMENT..............................................................................................................................................8
1.14 JUMP STARTING..........................................................................................................................................8
2 INTRODUCTION AND DESCRIPTION......................................................................................11
2.1 GENERAL.................................................................................................................................................... 11
2.2 POWER UNIT.............................................................................................................................................. 11
2.3 COMPRESSOR ASSEMBLY....................................................................................................................... 11
2.4 PRINCIPLES OF OPERATION................................................................................................................... 11
2.5 INSTRUMENT PANEL AND OPERATING CONTROLS.............................................................................12
3 OPERATION.............................................................................................................................. 15
3.1 GENERAL....................................................................................................................................................15
3.2 PREPARATION FOR INITIAL START-UP...................................................................................................15
3.3 NORMAL STARTING..................................................................................................................................15
3.4 NORMAL STOPPING..................................................................................................................................16
3.5 EMERGENCY STOP...................................................................................................................................16
3.6 OPERATING UNDER EXTREME CONDITIONS........................................................................................16
3.7 OPERATING SUGGESTIONS....................................................................................................................17
3.8 LOW FUEL WARNING LIGHT (CUMMINS)................................................................................................17
4 INSPECTION, LUBRICATION AND MAINTENANCE.............................................................. 19
4.1 LUBRICATION AND MAINTENANCE CHART............................................................................................19
4.2 WEATHER-ALL™ COMPRESSOR FLUID.................................................................................................20
4.3 COMPRESSOR LUBRICANT USE AND SERVICING................................................................................21
4.4 COMPRESSOR OIL SUMP FILL, LEVEL AND DRAIN...............................................................................21
4.5 ENGINE LUBRICATION..............................................................................................................................21
4.6 GREASE......................................................................................................................................................21
4.7 CONTROL LINKAGE...................................................................................................................................22
4.8 AIR INTAKE FILTER....................................................................................................................................22
4.9 OIL RETURN LINE......................................................................................................................................22
4.10 COMPRESSOR OIL FILTER.......................................................................................................................22
4.11 AIR/OIL SEPARATOR.................................................................................................................................23
4.12 THERMAL BY-PASS VALVE.......................................................................................................................24
4.13 OIL COOLER...............................................................................................................................................25
SULLIVAN-PALATEK USER’S MANUAL v

Table of Contents
4.14 COMPRESSOR SHAFT OIL SEAL.............................................................................................................25
4.15 COMPRESSOR DRIVE COUPLING...........................................................................................................25
4.16 CONTROL ADJUSTMENTS........................................................................................................................25
5 TROUBLESHOOTING.............................................................................................................. 27
5.1 INTRODUCTION.........................................................................................................................................27
5.2 UNPLANNED SHUT DOWN.......................................................................................................................27
5.3 IMPROPER DISCHARGE PRESSURE......................................................................................................27
5.4 BLOWDOWN VALVE...................................................................................................................................28
5.5 OIL CONSUMPTION...................................................................................................................................28
5.6 ENGINE LUGGING.....................................................................................................................................28
5.7 SEPARATOR PLUGGING...........................................................................................................................28
5.8 IMPROPER CONTROL OPERATION.........................................................................................................29
5.9 HIGH COMPRESSOR DISCHARGE TEMPERATURE..............................................................................29
6 ILLUSTRATIONS AND PARTS................................................................................................. 31
6.1 PROCEDURE FOR ORDERING PARTS....................................................................................................31
6.2 RECOMMENDED SPARE PARTS..............................................................................................................32
6.3 DIMENSIONS AND SPECIFICATIONS.......................................................................................................33
6.4 WIRING DIAGRAM.....................................................................................................................................38
6.5 CONTROL SYSTEM DIAGRAM..................................................................................................................39
6.6 OIL PIPING DIAGRAM................................................................................................................................40
6.7 EXHAUST SYSTEM....................................................................................................................................41
6.8 COMPRESSOR AND MOUNTING PARTS.................................................................................................42
6.9 INLET VALVE ASSEMBLY...........................................................................................................................43
6.10 AIR FILTER ASSEMBLY..............................................................................................................................44
6.11 RECEIVER / SEPARATOR ASSEMBLY......................................................................................................45
6.12 COOLING ASSEMBLY................................................................................................................................48
6.13 OIL FILTER AND PIPING............................................................................................................................50
6.14 FUEL TANK AND MOUNTING PARTS........................................................................................................51
6.15 INSTRUMENT PANEL ASSEMBLY.............................................................................................................52
6.16 ENCLOSURE ASSEMBLY..........................................................................................................................53
6.17 ACOUSTICS ASSEMBLY............................................................................................................................58
6.18 CHASSIS ASSEMBLY.................................................................................................................................59
6.19 AXLE ASSEMBLY........................................................................................................................................60
6.20 TIRE AND WHEEL ASSEMBLY..................................................................................................................61
6.21 DRAWBAR ASSEMBLY..............................................................................................................................62
6.22 SAFETY CHAIN ASSEMBLY.......................................................................................................................63
vi SULLIVAN-PALATEK USER’S MANUAL

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

WARNING!
Maximum towing speeds on smooth, dry paved roads:
• Single axle compressors: 55 mph (90 kmh)
• Two and three axle compressors: 50 mph (80 kmh)
Failure to comply with this warning may cause property damage and serious bodily
injury or death.
WARNING!
Maintain proper torque on wheel lug nuts
• Single axle: 85 to 95 LB-FT
• Two and three axle: 65 to 75 LB-FT
Failure to maintain lug tightness may result in a wheel loosening and leaving the
compressor and causing injury or death or property damage.
1.3 DRAWBARS AND BRAKE ACTUATORS

WARNING!
Proper alignment and installation of mounting hardware is essential when installing
the drawbars and actuators.
Check nut threads and start attachment bolt by hand to prevent cross-threading.
harm or death.
Maintain torque within recommended ranges.
SULLIVAN-PALATEK USER’S MANUAL 1

Operation Safety
Table 2. RECOMMENDED TORQUE RANGES FOR DRAWBAR AND ACTUATOR
APPLICATION SAE Grade SCREW TORQUE (LB-FT)
DRAWBAR 5/8 UNC G8 230 DRY
175 LUBE
DRAWBAR 1 UNC G8 880 DRY
660 LUBE
ACTUATOR ASSEMBLY 7/8 UNC G5 380 DRY
285 LUBE
1.4 TOWING SAFETY

PREPARING TO TOW
Damaged or worn towing components can result in separation of the compressor from the towing vehicle during
towing. Inspect all towing components of both the compressor and towing vehicle for cracks, excessive wear or
damage. Check for loose or damaged bolts, nuts or other fasteners. Replace or repair any damaged or worn parts
before towing the compressor.
The towing vehicle and its coupling device and points of attachment must be rated for towing the wet weight of
the air compressor and the weight of stored tools, hose and other equipment plus parasitic accumulation such as
mud, snow and ice.
Always back the towing vehicle to the compressor and position it for coupling the compressor.
Use a lifting device such as a jack or chain hoist to lift or lower unit to avoid injury to yourself or others. Do not at-
tempt to raise or lower drawbar by hand if the weight is more than can be safely handled.
Avoid pinch and crushing injury. Keep hands and fingers clear of the coupling device and all other pinch points.
Keep feet clear of drawbar in case it should slip.
The coupling device must be fully engaged, closed, locked and the safety latches are engaged.
The towing restraint chains must be attached to the tow vehicle to support the drawbar in the event of accidental
uncoupling. Cross chains under front of drawbar before passing them through points of attachment on towing
vehicle. Pass each towing restraint chain through its point of attachment on the towing vehicle. Hook each chain
to by passing the grab hook over, not through, a link.
The coupling device must be free to move throughout the full range of travel while towing. Verify that other compo-
nents, wires, chains and vehicle attachments do not interfere with or restrict motion of any part of the compressor.
Make sure chain length, and if provided, brake and electrical interconnections have sufficient slack to prevent
strain when turning and maneuvering. All chains and connections must be supported so they cannot drag or rub
on road, terrain, or towing vehicle surfaces. Dragging or rubbing of this equipment will cause wear resulting in
damage, and render this equipment inoperative.
Fully retract front stabilizer screw jack and any rear stabilizer legs (if provided). If a retractable caster wheel is pro-
vided, pull the lock pin, raise and fold the caster wheel, then make sure pin is re-engaged to secure caster wheel
in full up and locked position with the wheel horizontal.
Tires must be in good condition, the correct size and load range, and be inflated to the specified pressures. Do
not change tire size or type.
Wheel lug nuts must be tightened to the specified torque.
If provided, make sure all stop, tail, directional, and clearance lights are operating properly and that lenses are
clean and unbroken. Ensure that all reflectors and reflecting surfaces including the slow moving vehicle emblem
on the compressor are clean and functional.
Make sure air delivery hoses are disconnected or fully retracted and secured on hose reels, if provided.
Make sure all access doors and toolbox covers are closed and latched. If the compressor is large enough to hold
a man, make sure all personnel are out before closing and latching access doors.
2 SULLIVAN-PALATEK USER’S MANUAL

Operation Safety
Make sure parking breaks on towing vehicle are set and that wheels are chocked or blocked before releasing the
compressor parking brakes, if provided.
Before beginning to tow the compressor, test brake operation, including breakaway switch operation if provided.
TOWING
Observe and follow all local, state and federal traffic laws. Note and adhere to speed limits and minimum highway
speed.
Do not exceed maximum towing speeds. Reduce speed accordingly, as dictated by posted signs, weather, road,
or terrain conditions.
Remember that portable air compressors may approach or exceed the weight of the towing vehicle. Maintain
increased stopping distance accordingly.
Grades in excess of 15° (27%) or any grade that would over-extend the towing or braking ability of the towing
vehicle should be avoided.
When towing the compressor, avoid potholes, rocks, rough terrain, obstructions and soft shoulders. Damage to
the undercarriage and suspension can result.
Do not permit any person to ride in or on the compressor while being towed. Serious injury can result.
Make sure the area behind and under the compressor is clear of all persons, animals and obstructions prior to
backing.
Do not permit anyone to stand or ride on the drawbar, or to stand or walk between the compressor and the towing
vehicle. Serious injury or death can result.
1.5 PARKING OR LOCATING COMPRESSOR

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

Operation Safety
1.6 PRESSURE RELEASE

WARNING!
Compressed air can be dangerous. Serious injury or death can result from the
improper selection, use or application of tools and attachments to this compressor.
WARNING!
Never inject compressed air into a bodily orifice.
WARNING!
Never direct compressed air at or toward a person or animal.
WARNING!
Do not breathe air produced by a portable air compressor.
Open the pressure relief valve at least weekly to make sure it is not blocked, obstructed, or otherwise disabled.
Install an appropriate flow-limiting valve between the compressor service air outlet and the shut-off (throttle) valve
when an air hose exceeding 1/2” inside diameter is to be connected to the shut-off (throttle) valve. This is to re-
duce pressure in case of hose or connection failure, per OSHA Standard 29 CFR 1926.302 (as) (7).
When a hose will be used to supply a manifold, install an appropriate flow-limiting valve between the manifold and
each air hose exceeding 1/2” inside diameter that is to be connected to the manifold. This will reduce pressure in
case of hose failure.
Provide an appropriate flow-limiting valve for each additional 75 feet of hose in runs of air hose exceeding 1/2”
inside diameter to reduce pressure in case of hose failure.
Flow limiting valves are listed by pipe size and rated CFM. Select appropriate valves accordingly.
Do not use tools that are rated below the maximum relief valve rating on this compressor. Do not exceed manu-
facturer’s rated safe operating pressures for these items.
Secure all hose connections by wire, chain, or other suitable retaining devices to prevent tools or hose ends from
being accidentally disconnected. Unrestrained disconnected hoses can flail around an cause injury or damage.
Do not open sump (receiver) oil filler cap when compressor is running and air system is pressurized. Shut down
the compressor and bleed the sump (receiver) pressure to zero before removing the oil filler cap.
Vent and release all internal pressure prior to opening any line, fitting, hose, valve, drain plug or connection. This
includes components such as filters, line oilers and optional airline anti-icing systems.
Serious injury can result from the direct discharge of compressed air. Do not allow personnel to be in line or
front of the discharge opening of the service valve, hoses or tools or other points of compressed air discharge.
Air gun cleaning devices must not be used and pressures above 30 psig (2 Bars). Always use an appropriate
regulator to reduce pressure at the cleaning tool and always use with effective chip guarding and personal protec-
tive equipment per OSHA Standard 29 CFR 1910.242 (b).
WARNING!
Serious injury or death may result from horseplay with air hoses and compressed air.
HORSEPLAY - DO NOT DO IT, DO NOT ALLOW IT!
Do not remove radiator cap until the coolant temperature is below its boiling point. Then loosen cap slowly to its
stop, to relieve any excess pressure. Make sure coolant is not boiling before removing cap completely.

Operation Safety
The ethyl ether in the replaceable cylinders used in diesel engine ether starting aid systems is under pressure. Do
not puncture or incinerate these cylinders. Do not attempt to remove the center valve core or side pressure relief
valve from these cylinders regardless of whether they are full or empty.
1.7 FIRES AND EXPLOSION

WARNING!
Fire or explosion can result from electrical arcing from terminal, battery connections
and improperly grounded equipment.
WARNING!
Fire or explosion can result from spilled fuel, oil and other flammable liquids.
Refuel at a service station or from a fuel tank designed for the purpose. Ground the machine to mobile dispensers
prior to refueling.
Immediately clean up any spills or leaking fuel, battery electrolyte, oil, or anti-freeze solution.
Shut off the air compressor and allow it to cool. Keep sparks, flames, and other sources of ignition away and do
not permit smoking in the vicinity when adding fuel, checking or adding electrolyte to batteries, checking or adding
oil, checking diesel engine ether starting aid systems or replacing ether cylinders, or when refilling air line anti-
icing systems with anti-freeze.
Do not permit liquids to accumulate in bottom or belly area of the compressor. Prevent contact with acoustical
surfaces of the air compressor. Wipe down using an aqueous industrial cleaner or steam clean as required. If nec-
essary, remove acoustical material, clean all surfaces and then replace acoustical material. Do not use flammable
solvents for cleaning purposes.
Disconnect the grounded (negative) battery connection prior to attempting any repairs or cleaning inside the en-
closure. Tag the ground cable with a warning not to reconnect until servicing is complete.
Keep electrical wiring, battery terminals and other terminals in good condition. Replace any wiring, which has
cracked, cut, abraded, or otherwise degraded insulation. Replace terminals, which are worn, discolored, or cor-
roded. Keep all terminals clean and tight. Turn off battery charger before making or breaking connections to the
battery. Wear a face shield whenever servicing or working on the battery.
Keep tools and other grounded conductive objects away from exposed live electrical parts to avoid arcing, which
might serve as a source of ignition.
Replace damaged fuel tanks or lines. Do not store or attempt to operate the compressor with any known leaks in
the fuel system or oil lines.
Prior to welding or making weld repairs on the compressor, remove any acoustical material or other material that
may be damaged by heat or that may support combustion, including diesel engine ether starting aid cylinders and
anti-icing system components containing anti-freeze compound.
Keep a suitable fully charged class BC or ABC fire extinguisher or extinguishers nearby when servicing and oper-
ating the compressor.
Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor.
Open all access doors and allow the enclosure to ventilate prior to attempting to start the engine. (Use this time to
check the engine and compressor oil levels, etc.).
Do not operate compressor under low overhanging leaves or permit leaves and foliage to contact hot exhaust
system surfaces when operating in forested areas.
Ethyl ether used in diesel engine ether starting aid systems is extremely flammable. Change cylinders and service
these systems only in well-ventilated areas away from heat, open flame or sparks. Do not install, store or other-
wise expose ether cylinders to temperatures above 160°F (71°C).

Operation Safety
Use only properly installed and plumbed ether starting aid systems connected to the diesel engine. Do not spray
ether into compressor air inlet filter or into an air filter that serves both the engine and the compressor. Serious
damage to the compressor or personal injury may result.
Anti-freeze compound used in airline anti-icing systems contains methanol, which is flammable. Use systems and
refill with compound only in well-ventilated areas, away from heat, open flames, or sparks. Do not expose any part
of these systems or the anti-freeze compound to temperatures above 150°F (65°C). Vapors from the anti-freeze
compound are heavier than air. Do not store compound or discharge treated air in confined or unventilated area.
Do not store containers or anti-freeze compound in direct sunlight.
1.8 MOVING PARTS

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

Avoid contact with hot oil, hot coolant, hot surfaces, and sharp edges and corners.
Keep all parts of the body away from all points of air discharge and away from hot exhaust gases.
Wear personal protective equipment, including gloves and head covering when working in, on, or around the
compressor.
Keep a first aid kit handy. Seek medical assistance promptly in case of injury. Don’t ignore small cuts and burns.
They may lead to infection.
Keep all loose clothing and parts of the body away from engine and/or compressor intakes or air filter intakes.

Operation Safety
1.10 TOXIC AND IRRITATING SUBSTANCES
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
WARNING!
Breathing unfiltered air from this compressor can result in serious injury or death.
Do not use air from this compressor for breathing air.
NOTE: NOTE: Under specific guidelines and in full compliance with OSHA Standards 29 CFR 1920 and any other fed-
eral, state, or local codes or regulations compressed air can be used for breathing air. Sullivan-Palatek does not
provide equipment and instructions for this application and its products are not produced for this application or
use.
Do not use airline anti-icing systems in airlines supplying respirators or other breathing air utilization and equip-
ment, and do not discharge air from these systems in unventilated or other confined areas.
Operate the compressor only in open or well-ventilated areas.
Carbon monoxide will kill. If the machine is operated indoors, discharge engine exhaust outdoors and be certain
that there are no exhaust system leaks that can discharge exhaust within the building.
Locate this compressor so that exhaust will not be carried toward personnel, air intakes servicing personnel ar-
eas, or toward the air intake of this or any other portable or stationary compressor.
Fuel, oil, coolant, lubricant, and battery electrolyte used in this compressor are typical of the industry. Care should
be taken to avoid accidental ingestion or skin or eye contact. In the event of ingestion or contact, seek medical
treatment promptly. Do not induce vomiting if fuel is ingested. Wash with soap and water in the event of skin con-
tact.
Wear an acid resistant apron and a face shield or goggles when servicing the battery. If electrolyte is spilled on
skin or clothing, immediately flush and wash with large quantities of water.
Ethyl ether used in diesel engine starting aid systems is toxic, harmful, and can be fatal if swallowed.
Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, do not induce vomiting but seek
medical help immediately.
Wear goggles or a full face shield when testing ether starting aid systems or adding anti-freeze compound to air
line anti-icing systems. Keep openings of valve, tube, or atomizer or ether starting aid system pointed away from
yourself and other personnel.
If ethyl ether or air line anti-icing system anti-freeze compound enters the eyes or if fumes irritate the eyes, they
should be washed with large quantities of clean water for at least 15 minutes. Medical attention should be ob-
tained immediately.
Do not store ether cylinders or airline anti-icing system anti-freeze compound in operator’s cabs or in unapproved
containers.

Operation Safety
The anti-freeze compound used in airline anti-icing systems contains methanol and is toxic, harmful, or fatal if
swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, induce vomiting by
administering a tablespoon of salt in a glass of clean, warm water until vomit is clear, then administer two tea-
spoons of baking soda in a glass of clean water. Have patient lie down and cover eyes to exclude light. Seek
medical assistance.
1.11 ELECTRICAL SHOCK

Keep the towing vehicle or equipment carrier, compressor hoses, tools, and all personnel at least 10 feet from
power lines and buried cables. Greater separation from power lines may be prudent when working around high
voltage. Contact the utility company for guidance.
Keep all parts of the body, any hand-held tools, or other conductive objects away from exposed live parts of the
compressor electrical system. Maintain dry footing, stand on insulating surfaces and do not contact any other por-
tion of the compressor when making adjustments or repairs to exposed live parts of the electrical system.
Attempt repairs only in clean, dry, well lighted, and ventilated areas.
1.12 LIFTING
This compressor is provided with a lifting bail for routine lifting and loading such as onto trucks or oil platforms. It
is not intended for extended airlift such as by helicopter. Support the compressor by slings under the main frame
with appropriate spreader bars when air lifting the machine. Lift only in full compliance with OSHA Standards 29
CFR 1910 subpart N and other applicable regulations.
Prior to lifting, inspect lifting bail and points of attachment for cracked welds and cracked, bent, corroded or other-
wise degraded members, and for loose bolts or nuts.
Make sure entire lifting, rigging, and supporting structure has been inspected, is in good condition and had a rated
capacity of at least the net weight of the compressor plus an additional 10% allowance for the weight of snow, ice,
mud, or stored tools and equipment. If you are unsure of the weight, then weigh the compressor before lifting.
Make sure lifting hook has a functional safety latch, or equivalent, and is fully engaged before lifting compressor
from the ground.
Do not attempt to lift in high winds.
Keep all personnel out from under and away from the compressor when suspended.
Lift compressor slowly and smoothly, without jerking.
Lift compressor no higher than necessary, use guidelines and have spotters properly located.
Do not leave suspended compressor unattended.
Set compressor down only on level surfaces capable of supporting at least its net weight plus an additional 10%
allowance for the weight of snow, ice, mud, or stored tools and equipment. If the compressor is provided with
parking brakes, make sure they are set; and always, block or chock both sides of all running wheels plus drawbar
stabilizer leg before disengaging the lifting hook.
1.13 ENTRAPMENT
Make sure all personnel are out of compressor before closing and latching enclosure doors. Larger compressors
can hold a man. If it is necessary to enter the enclosure to perform service or adjustments, secure the access
door in the open position to avoid the possibility of others closing and latching the door and inform personnel
before entering the enclosure.
1.14 JUMP STARTING

Observe all safety precautions mentioned elsewhere in this manual.
Batteries may contain hydrogen gas, which is flammable and explosive. Keep flames, sparks, and other sources
of ignition away.

Operation Safety
Batteries contain acid which is corrosive. Do not allow battery acid to contact eyes, fabrics, or painted surfaces.
Serious personal injury or property damage may result. Flush contacted areas thoroughly with water immediately.
Wear an acid resistant apron and face shield when jump starting the compressor.
Remove all vent caps from the battery or batteries in the compressor. Do not permit dirt or foreign matter to enter
the open cells. **
Check fluid level. If low, bring to a proper level before attempting to jump-start. **
Attempt jump-starting from another vehicle or piece of equipment with a negative ground electrical system and
with the same voltage and battery size as the battery or batteries supplied with the compressor. Do not attempt to
jump-start using motor generator sets, welders, or other sources of DC power. Serious damage may result.
Bring the starting vehicle beside the compressor, but do not permit metal-to-metal contact between the compres-
sor and the starting vehicle. Set the parking brakes of the compressor (if provided) and the starting vehicle, or
chock or block both sides of all wheels. Place the starting vehicle in neutral or park, turn off nonessential acces-
sory electrical loads and start its engine.
Use only jumper cables that are clean, in good condition, and are heavy enough to handle the starting current.
Prevent accidental contact between jumper cable terminal clips or clamps or any metallic portion of either the
compressor or the starting vehicle to eliminate the possibility of arcing, which might serve as a source of ignition.
NOTE: NOTE: Positive battery terminals are usually identified by a plus (+) sign on the terminal and the letters POS near
the terminal. A negative sign (-) or the letters NEG near the terminal usually identify the negative battery terminals.
Connect one end of a jumper cable to the positive (POS) battery terminal in the starting vehicle. When jump-
starting a 24V compressor, and if the starting vehicle is provided with two (2) 12V batteries connected in series,
connect the jumper cable to the positive (POS) (+) terminal of the ungrounded battery.
Connect one end of the other jumper cable to the grounded negative (NEG) terminal of the battery in the start-
ing vehicle. When jump starting a 24V compressor, and if the starting vehicle is provided with (2) 12V batteries
connected in series, connect the jumper cable to the negative (NEG) terminal of the grounded compressor
battery.
Check your connections. Do not attempt to start a 24V compressor with a 12V system in the starting vehicle. Do
not apply 24V to a 12V system in the compressor. Connect the other end of the same jumper cable to a clean por-
tion of the compressor engine block away from fuel lines, the crankcase breather opening, and the battery.
Start the compressor following normal procedure. Avoid prolonged cranking. Damage to the starter may occur.
Allow the compressor to warm up. When the compressor is warm and operating smoothly at normal idle RPM,
disconnect the jumper cable from the engine block on the compressor, and then disconnect the other end of the
same cable from the grounded negative (NEG) terminal of the battery on the starting vehicle. Then disconnect
the other jumper cable from the positive (POS) (+) terminal of the battery in the compressor, or if provided with (2)
12V batteries connected in series, from an ungrounded battery in the compressor, and finally disconnect the other
end of the same jumper cable from the positive (POS) (+) terminal of the battery in the starting vehicle, or from the
positive (POS) (+) terminal of the ungrounded battery in the starting vehicle if it is provided with two (2) 12V bat-
teries connected in series.
Remove and carefully dispose of the dampened cloths. They may be contaminated with acid. Replace vent caps.
**
NOTE: NOTE:
** The use of maintenance-free batteries my obviate this step.

Operation Safety

2 Introduction and Description
2.1 GENERAL
The compressor is a single stage, oil flood lubricated rotary screw
air compressor. The compressor package is available as a por-
table wheel-mounted unit, utility mounted unit or galvanized skid-
mounted unit for offshore applications. All models are enclosed in a
weather-resistant acoustical enclosure.
The complete operating unit consists of a diesel engine for power,
a compressor assembly, air/oil separator system, cooling system FEMALE ROTOR
for the engine and compressor oil, instrumentation, pneumatic con-
trol system, and acoustical enclosure.
STATOR
2.2 POWER UNIT
MALE ROTOR
The compressor is powered by a diesel engine. For detailed infor-
mation on the diesel engine refer to the Engine Operators Manual
provided with each compressor.
Figure 1. COMPRESSOR ASSEMBLY
2.3 COMPRESSOR ASSEMBLY
The compressor assembly is an oil flooded, positive displacement, single stage rotary screw unit. Components
include a stator housing, male and female rotors, bearings, and bearing supports. Engine power is transferred
to the male rotor through a coupling and, if a gear-driven unit, through gears in the gear housing. The male rotor
drives the female rotor.
2.4 PRINCIPLES OF OPERATION

AIR COMPRESSOR
Air at atmospheric pressure is drawn in through the inlet and compressed by the rotation of the rotors. During the
compression cycle, oil is injected into the compressor performing three important functions:
1. Lubricate the rotating parts and bearings.
2. Provide cooling for the compressed air.
3. Seal the running clearances between the rotors.
ENGINE TO COMPRESSOR DRIVE
The compressor and engine are connected through a non-lubricated spline coupling. It consists of a drive ring
registered and bolted directly to the engine flywheel and either a splined hub or a disc attached to the compressor
drive shaft. Because of low starting torque, no clutch is required.
LUBRICATION SYSTEM
Oil from the compressor oil sump at compressor discharge pressure is directed through the cooling system and oil
filter to a lower pressure region of the compressor stator. At the same time, oil is directed to the bearings and shaft
seal of the compressor. The oil-laden air is then discharged back into the sump.
AIR/OIL SEPARATOR AND SUMP
From the compressor discharge, oil-laden air enters the receiver/sump tank above the oil level and most of the oil
is separated from the air by gravity. The oil runs downward and accumulates for recirculation, while the remaining
oil mist passes through the separator element. The oil separator is located in the upper portion of the receiver/
sump. When air is demanded at the service line, it passes through the separator element, which provides the final
stages of air/oil separation.

Introduction and Description
OIL RETURN LINE

The oil that is removed by the separator, gravitates to the bottom of the separator and is returned through an
orifice in the oil return line, which leads to a lower pressure region of the compressor.
OIL FILTER
The compressor oil filter is of the full-flow replaceable element type. The filter has an internal by-pass valve to as-
sure adequate oil flow with cold oil or a plugged oil filter element.
THERMAL BY-PASS VALVE
The thermal by-pass valve is the center of the compressor temperature regulating system. The valve is designed
to be fully open, allowing the oil to bypass the cooler until the oil temperature reaches 110°F. Above 110°F, the
valve gradually closes down and becomes completely closed when the oil temperature reaches approximately
180° F. The valve has a built-in pressure relief feature so that a pressure drop across the valve of 50 PSI will
cause it to open. Therefore, if the cooler should become plugged the thermal valve will open regardless of temper-
ature, thus providing lubrication to the compressor until the protective circuit shuts the machine down due to high
compressor discharge temperature.
COMPRESSOR COOLING SYSTEM
The compressor cooling system consists of an oil cooler mounted adjacent to the engine radiator. Cooling air is
drawn through the cooler by the engine fan while oil is circulated through it by the receiver/sump pressure.
ENGINE COOLING SYSTEM
The engine cooling system utilizes a conventional engine radiator, thermostat, water pump, and fan to maintain
the engine coolant at a desired operating temperature. An additional charge air cooler is required for some diesel
engines in order to meet EPA emission standards under tier II regulations.
NOISE CONTROL SYSTEMS
Noise control systems incorporated in this compressor have been designed to meet the requirements of federal
noise control regulations. The principal components of the noise control systems include the enclosure, engine
exhaust system, and compressor intake system. The enclosure has been designed to provide the required noise
reduction while maintaining a good distribution of cooling airflow to the radiator and oil cooler. Additionally, low
noise emission is a key factor in selecting diesel engines to power the compressors.
2.5 INSTRUMENT PANEL AND OPERATING CONTROLS

The instrument panel contains all the necessary controls and instrumentation for operation. It is conveniently
located and enclosed by a lockable, hinged door. Following is an explanation of the principal controls and instru-
ments:
START-RUN VALVE
This valve is provided to unload the compressor for easier start-up in cold weather. When positioned on START,
this valve bypasses the pressure-regulating valve, thereby closing the inlet valve with reduced discharge pres-
sure. After the compressor is warmed up, the start-run valve can be turned to RUN position. The unit is then ready
for full-load operations. Prior to shutdown, the start-run valve must be turned to the START position and the ser-
vice valve opened and closed to reduce pressure to approximately 70 psi. Shutdown under full load can damage
the compressor and put unnecessary strain on the drive components.
VOLTMETER (OPTIONAL)
The voltmeter indicates the condition of the battery prior to start-up. When running, it tells whether the alternator
and voltage regulator are operating properly. The normal reading should be 13 to 15 volts during operation in a
12-volt system and 25 to 27 volts in a 24-volt system.
HOURMETER
The hour meter records the total number of operating hours. It serves as a guide for following the recommended
inspection and maintenance schedule as outlined in the Lubrication and Maintenance section of this manual.

ENGINE OIL PRESSURE GAUGE (OPTIONAL)

The engine oil pressure gauge shows the engine oil pressure. Do not operate the engine if oil pressure is not indi-
cated immediately after starting. For details, refer to Engine Operator and Maintenance Manual.
COMPRESSOR DISCHARGE PRESSURE GAUGE
This gauge indicates the discharge air pressure. Normal operating pressure is 70 to 115 psig or, for single stage
high-pressure compressors, 70 to 150 psig.
ENGINE WATER TEMPERATURE GAUGE (OPTIONAL)
The engine water temperature gauge shows the temperature of the engine coolant.
FUEL GAUGE
The fuel gauge indicates the fuel level of the engine fuel tank. To prevent air from entering the fuel system, the
tank should not be allowed to run empty. It should be kept filled, even when not in operation, in order to minimize
condensation. Add fuel conditioner if the compressor will be idle for an extended period. An optional low-fuel
shutdown system is available to prevent accidental fuel exhaustion.
PROTECTIVE CIRCUIT BY-PASS SWITCH
The protective circuit by-pass switch provides a means of overriding the normally open low engine oil pressure
switch at start-up. After starting, the circuit will be completed by the closing the engine oil pressure switch, when
the oil pressure reaches approximately 15 psi (1 Bar). This by-pass switch also operates the glow plug on some
models.
ENGINE SWITCH
The engine switch in the “ON” position energizes the electrical and protective circuit systems. In the “START” po-
sition it is used to electrically energize the engine starter motor solenoid. For diesel engines it also controls the en-
gine fuel solenoid. In the “ON” position, the solenoid holds the fuel valve open, allowing fuel to reach the engine.
DISCHARGE PRESSURE REGULATOR VALVE
This valve is used to select the desired discharge pressure within the operating pressure range. Turning the regu-
lator adjustment screw clockwise increases the unloaded pressure, and counter-clockwise reduces the unloaded
pressure. Observe discharge pressure gauge on the instrument panel for compressor discharge pressure.
AUTOMATIC BLOWDOWN VALVE
This valve relieves pressure in the system upon shutdown. It is closed when the compressor is in operation; how-
ever, at shutdown, the inlet valve closes, the unit becomes pressurized and sends a pressure pulse to open the
normally closed blow down valve.
MINIMUM PRESSURE VALVE
A minimum pressure valve is provided at the service air outlet (at the top of the separator). This valve serves
to maintain a minimum discharge pressure of 65 to 80 psig in operation, which is required to assure proper air/
oil separation. At normal operating pressure of 90 to 125 psig, this valve is wide open, effectively removing any
restriction to airflow.
RECIRCULATING VALVE
This valve functions automatically in response to the regulated control pressure. Receiving the unload signal to
the inlet valve, the recirculation valve is opened allowing a small quantity of pressurized sump air to be recircu-
lated through the compressor in order to hold a positive pressure signal on the inlet side of the air end to prolong
the shaft seal life.
CONTROL SYSTEM
The control system is designed to match air supply to air demand and to prevent excessive discharge pressure
when the compressor is operating but air is not being used. Control of air delivery is accomplished both by inlet
valve regulation and engine speed control as directed by the adjustable discharge pressure regulator valve.

INLET VALVE
The inlet valve assembly is the heart of the control system, which regulates the amount of air entering the com-
pressor. A separate air cylinder regulates engine speed. From full to approximately 60 percent capacity, the deliv-
ery is controlled by engine speed and a gradual closing of the inlet valve. When unloaded the inlet valve is closed
to prevent atmospheric air from entering the compressor.
CONTROL SYSTEM OPERATION
Please refer to the diagram. Before starting and with the start-run valve in the start position, the spring loaded
inlet valve is closed. When the engine is started, air entering the four small holes in the inlet valve plate cause
the pressure to rise slowly in the receiver tank. (Pressure rises to 55-60 psi in approximately 20 seconds). This
pressure becomes greater than the spring pressure in the minimum pressure valve. This air pressure will exhaust
from the attached “normally-open” running blowdown valve into the atmosphere. The compressor will reach
the discharge pressure faster. When loading the compressor, turn the start-run valve located on the instrument
panel to the “run” position. The compressor will reach the discharge pressure faster. When loading the compres-
sor, turn the start-run valve located on the instrument panel to the “run” position. The compressor will reach the
discharge pressure faster. When loading the compressor, turn the start-run valve located on the instrument panel
to the “run” position. This opens the valve. The air pressure will blow through the start-run valve and through
the “normally-open” regulator to the pilot line which closes the “normally-open” runing blowdown valve. This also
pressurizes the inlet valve, opening the inlet valve plate against spring pressure and modulates the throttle cylin-
der into the “fast” rpm position. When the demand for discharge air ceases and pressure in the receiver reaches
the set point of the pressure regulator, the regulator closes and stops the air pressure signal. The spring tension
in the inlet valve takes over and closes the valve and also stops the signal to the throttle cylinder. The spring
tension of the throttle cylinder moves the fuel lever (not shown) into the idle position. The pilot line air pressure
diminishes and returns the running blowdown valve to normal operation (normally open position). With receiver
pressure balancing the system pressure, the only air being released from the running blowdown valve is the air
that entered the system through four holes in the inlet valve plate. There is no check valve between the air end
and the receiver tank. When the machine is shut down, the screws stop turning, and the pressure made in the
receiver tank must be released. This will back pressure the discharge line, the air end, and the base of the inlet
valve. When this back pressure goes into the pilot line to the “normally-closed” automatic blowdown valve, it
opens the valve and allows the receiver tank to exhaust to the atmosphere directly, or through a 1/2” hose con-
nected to the inlet duct. This back pressure will purge the air filter as well as muffle the exhaust air. When the
compressor is shut down and there is no evidence of compressor oil coming from the inlet valve or inlet filters, this
is generally an indication of a defective inlet valve. (See troubleshooting guide).
START/RUN VALVE
The start/run valve (2) is used to by-pass the compressor pressure regulator valve. This results in reduced load
and reduced engine speed at start-up. Once the engine is warmed up, the valve is moved to the “RUN” position.
In the “Start” position, the start/run valve is open. In the “Run” position, it is closed.
ELECTRICAL AND PROTECTIVE CIRCUIT SYSTEM
The compressor electrical system is a 12-volt negative ground system used on smaller-capacity compressors and
a 24-volt negative ground system used on larger capacity compressors. It is equipped with a protective circuit to
minimize damage. This could be caused by high compressor discharge temperature, high engine water tempera-
ture, or low engine oil pressure. Refer to Wiring Diagram, Diesel Engine, as required. The following conditions
will cause automatic shutdown of the compressor.
1. Compressor discharge air temperature (CDT) approximately 265° F (129° C).
2. Low engine oil pressure (EOP) of approximately 15 psi (100 kpa).
3. High water temperature (EWT) approximately 215°F (101°C).

3 Operation
3.1 GENERAL
Each compressor is operated and tested at the factory before shipment. This testing assures that the unit is oper-
ating properly and that the compressor will deliver its rated capacity. Regardless of the care taken at the factory,
there is a possibility that adjustments may be altered or damage may occur during shipment. For this reason it is
recommended that the unit be checked for proper operation and carefully inspected before it is put in service. The
machine should be observed for any possible malfunction during the first few hours of operation.
Satisfactory performance of the compressor depends upon the operator’s knowledge of the controls, instruments,
and recommended operating procedures. Consequently, the preceding sections of this manual and also the entire
Engine Operator’s Manual should be read and understood before attempting to start and operate this machine.
3.2 PREPARATION FOR INITIAL START-UP

1. Inspect the compressor, engine, and other assemblies for damage or loose connections, which might
have occurred during shipment.
2. Check the engine’s crankcase oil level. If required, add oil as recommended in the Engine Operator’s
Manual.
3. Check the radiator coolant level. Also, if the machine will be exposed to sub-freezing temperatures,
check the specific gravity to ascertain the freezing point of the coolant.
4. Fill the fuel tank with fuel recommended in the Engine Operator’s Manual.
WARNING!
Never add gasoline to diesel fuel tank - serious damage to the engine will result.
5. If necessary, add lubricating oil to the compressor sump. Refer to the Lubrication and Maintenance
section for lubricating oil specifications.
6. Check battery posts and cable clamps to assure proper contact. Connect positive (+) cable and nega-
tive (-) cable battery terminals. Turn ignition switch to accessories position. Check gauge panel light or
voltmeter. If connections are secure light will be on, or voltmeter will register voltage. If not, the battery
may need an initial charge to activate it.
3.3 NORMAL STARTING

1. Inspect the compressor, engine, and other assemblies for damage or loose connections, which might
have occurred since the last operation.
2. Check engine water, oil, fuel, and battery fluid levels. Check compressor sump oil level.
3. Close all service valves. Move start-run valve to START position.
4. Turn ignition switch to start position, allowing starter motor to rotate compressor for a few revolutions.
(This assures that the compressor is free of residual oil). Release switch.
5. Turn ignition switch to ON position.
6. Push protective circuit by-pass switch and hold in (activates glow plug on some models).
7. Turn ignition switch to start position until engine starts, then release. If engine fails to start after 15 sec-
onds of cranking, allow starter to cool for two minutes before repeating the starting procedure.
8. Release by-pass switch when engine oil pressure is established (approximately 20 psi)
9. Allow engine to warm up. (See Engine Operator’s Manual for recommendations).
10. Position start-run valve on RUN. Compressor is now ready for full-load operation. If the engine should
stop, do not attempt to restart with the oil sump under pressure. Repeat the above procedure from step
3.

Operation
3.4 NORMAL STOPPING

1. Position start-run valve to START and close all service valves, allowing compressor to “unload.” Oper-
ate compressor in unloaded condition two to five minutes to allow machine to cool down. Open and
close the service valve to reduce pressure to approximately 70 psi.
2. Turn ignition switch to “OFF.”
3.5 EMERGENCY STOP

Turn ignition switch to “OFF.”
3.6 OPERATING UNDER EXTREME CONDITIONS

When operating the compressor in extreme conditions, perform the following service functions if applicable:
COLD WEATHER OPERATION

1. Insure that the coolant anti-freeze solution is correct for the lowest possible temperature expected.
2. When operating the compressor at ambient temperatures below 20°F lubricants suited for these condi-
tions are required. Refer to the Lubrication and Maintenance section of this manual.
3. Diesel engine starting aids are available for cold weather starting.
4. Optional starting aids and component pre-starting warming devices are available for some models.
WARNING!
Do not inject ether starting fluid directly into air intake.
HOT WEATHER OPERATION
1. Keep the engine cooling system filled with clean coolant and check the coolant level daily or before
each shift.
2. Keep the outside of the radiator and oil cooler clean.
3. Locate the unit in a well-ventilated area.
4. When operating in humid conditions, it is recommended that the compressor oil change interval be
shortened.
DUSTY OR SANDY AREAS
1. When possible, wet down the area surrounding the operating site to keep dust and blowing sand to a
minimum.
2. Inspect air filters before each operating shift or daily.
3. Keep radiator and oil cooler clean. Check daily and wash or blow clean as needed.
WARNING!
Check the compressor sump oil level only when the compressor is not operating and
system is completely relieved of pressure.
Open pressure relief valve to ensure relief of system air pressure when performing
maintenance on compressor air/oil system.
harm or death.

Operation
3.7 OPERATING SUGGESTIONS

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

If the low fuel warning light is on, the engine has shut down because of low fuel. Fuel will need to be added
before the engine can be restarted. The following steps will need to be completed before attempting to restart the
engine.
1. Turn the battery disconnect switch “OFF”.
2. Fill fuel tank with “Ultra Low Sulfer Diesel” fuel only.
3. Turn the battery disconnect switch “ON”. Low fuel light should now be off.
4. Engine can now be restarted. Follow procedures from 3.3 NORMAL STARTING.

Operation

4 Inspection, Lubrication and Maintenance
4.1 LUBRICATION AND MAINTENANCE CHART
To ensure satisfactory performance and expected productivity it is essential that a scheduled service and mainte-
nance program be established, followed and well documented. Warranty reimbursement may depend on proof of
adequate service and maintenance.
The periodic maintenance procedures are listed below. It should be understood that the intervals specified are
maximum intervals. More frequent inspections should be made if the unit is operating under extreme conditions
as described in 3.6. Daily visual inspections are recommended as routine prior to operation.
The maintenance time intervals are expressed in operating hours. An hour meter is provided on all models to help
you track operation of the compressor. In addition to the Lubrication and Maintenance Table below, refer to
the Engine Operator’s Manual for recommended engine lubrication and m aintenance.
INTERVAL ACTION
EVERY 10 □□ Check compressor oil level before starting.
OPERATING □□ Check radiator coolant level.
HOURS, DAILY OR □□ Check fuel supply after running.
ON RENT RETURN □□ Check air filter elements.
□□ Check for fuel, oil air, and water leaks.
EVERY 50 HOURS □□ Check for throttle control linkage.
OR WEEKLY □□ Drain water from compressor sump.
□□ Drain water and sediment from fuel tank.
□□ Change compressor oil filter element after first 50 hours of operation.
EVERY 250 HOURS □□ Check drawbar and bolt torque.
OR BEFORE □□ Check wheel lug nut.
RETURNING TO □□ Check tire pressure.
READY LINE □□ Inspect lifting frame (before each lift).
□□ Check engine air filter.
□□ Install new compressor air filter (shorter intervals necessary in dusty conditions).
EVERY 1000 □□ Change compressor oil and oil filter element.
HOURS OR 6 □□ More frequent oil changes will be required under extreme operating conditions such
MONTHS as high or low temperatures or high humidity. Also when using non-detergent or
turbine grade mineral oils.
□□ Install new engine air filter element (shorter intervals necessary in dusty conditions).
□□ Lubricate control linkage with light machine oil.
□□ Check axle spring shackles and mounting bolts.
□□ Clean battery terminals; check battery hold-downs, and cables, for wear.
□□ Check compressor shaft seal for leaking.
□□ Check air filter piping, fittings, and clamps.
□□ Check radiator hoses and clamps.
□□ Check engine and compressor supports.
EVERY 2000 □□ Replace separator element.
HOURS OR □□ Check all door gaskets, hinges, and latches to maintain acoustical seal.
ANNUALLY □□ Drain engine radiator coolant.
□□ Clean and flush cooling system. Refill with new coolant/anti-freeze.
□□ Check protective circuit switches and verify proper function.
□□ Check sump pressure relief valve.
PERIODICALLY OR □□ Inspect air filter elements.
AS REQUIRED □□ Inspect and clean oil system thermostat.
□□ Check control adjustment.
□□ Re-pack wheel bearings.

Inspection, Lubrication and Maintenance
4.2 WEATHER-ALL™ COMPRESSOR FLUID

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

Our Weather-All lubricant will provide extended life compared to other brand oils.
Weather-All fluid provides quick water separation which helps protect equipment in wet and humid service envi-
ronments.
Our compressor fluid has an excellent viscosity index (180), as well as, low pour point (-40°F).
This specially formulated multi-viscosity compressor fluid provides wear control for steel and brass parts when
operating at maximum pressure ratings, resulting in excellent compressor operation.
Weather-All Compressor 5W-20 Fluid combines the superior additive technology and quality hydrocarbon based
oils for Extended Life and is a custom-formulated lubricant specifically designed for long life under the severe,
demanding conditions normally encountered in recirculating systems such as rotary screw compressors.
Weather-All combines the advantages of a synthesized hydrocarbon, which results in performance improvements
beyond conventional mineral oils and many synthetic oils.
CHARACTERISTICS:
• Exceptional oxidative stability • Thermal & hydrolytic stability • Lower equipment maintenance
• Longer life • Improved performance • Extended anti-wear protection
• Low sludging tendency • Rust and corrosion inhibited
• Low evaporation loss • Viscosity stability
Table 2. Weather-All Fluid Typical Properties
ISO Viscosity Grade 32
SAE Viscosity Grade SW-20
Viscosity, cSt. 210ºF 50 SUS
100ºF 170 SUS
Normal Service Life 2000 Hrs
Viscosity Index 180
Pour Point -40°F (-40°C)
Flash Point 390°F (199°C)
Service interval may be shorter depending on operating conditions.

These values are not intended for use in preparing specifications.

4.3 COMPRESSOR LUBRICANT USE AND SERVICING

WARNING!
Never mix synthetic lubricants with hydrocarbon lubricants. Never mix synthetic
lubricants manufactured from different base products. Severe damage to the
compressor system may result.
Contamination of non-detergent mineral oils with traces of ATF, or detergent motor oils, may lead to problems
such as foaming, and plugging of filters, orifices, and lines. When ambient conditions exceed those noted, or if
conditions warrant use of “extended life” lubricants, contact Sullivan-Palatek, Inc. for a recommendation.
Lubricant manufacturers include a variety of additives in the blending process to enhance lubrication, product life
and performance. Mixing different types or brands of lubricants is not recommended due to the possibility of a
dilution of the additives or a reaction between additives of different types.
Environmental conditions in the area of compressor operation such as the presence of reactive gases or vapors
in the air may lead to chemical changes and premature degradation of the lubricant. The useful life of synthetic
lubricants may extend the normally recommended “drain and replace” period; however, the user is encouraged to
closely monitor the lubricant condition and to participate in an oil analysis program with the fluid supplier.
4.4 COMPRESSOR OIL SUMP FILL, LEVEL AND DRAIN

Change oil at least once a year, even if the normal oil change period in hours has not yet been reached. Always
warm compressor thoroughly prior to changing the compressor oil. Before adding or changing compressor oil,
ensure that the sump is completely relieved of pressure. Venting the sump tank pressure relief valve will do this. A
drain valve is provided at the bottom of the sump tank and oil cooler. When changing the oil, make sure system is
completely drained to reduce potential contamination. Oil is added at the fill plug on the side of the sump tank.
WARNING!
Do not attempt to drain water, remove the oil level fill plug, or break any connection
in the air or oil system until all the pressure has been relieved. Check by manually
opening the sump pressure relief valve. Serious injury or death may result if this
warning is not followed.
The proper oil level, when unit is shut down and oil has had time to settle, is across the center of the oil level sight
glass. For oil sump capacity, see the Compressor Specifications section.
WARNING!
Compressor must be shut down and pressure completely relieved from system
before checking fluid levels. Open pressure relief valve to assure relief of system air
pressure. Failure to comply with this warning may cause property damage and serious
bodily harm or death.
4.5 ENGINE LUBRICATION

Refer to Engine Operator’s Manual for recommended engine lubricating oil, service intervals and maintenance
practices.
4.6 GREASE
Use a multi-purpose type grease (MKG) or multi-purpose type grease with molybdenum disulfide (MPGM) con-
forming to MIL-L-7866 for all parts except wheel bearings. Use wheel-bearing grease (WBG) for lubricating the
wheel bearings.

4.7 CONTROL LINKAGE

Control linkage should be cleaned and lightly oiled at all joints.
4.8 AIR INTAKE FILTER

The air intake filters are heavy duty, two-stage dry elements to protect the engine and compressor from dust and
foreign objects. Filter maintenance frequency depends on dust conditions at the operating site. The filter element
must be serviced when clogged. (Maximum pressure drop for proper operation is 20 inches of water). Air filter ele-
ment condition indicators are available as optional equipment on most models.
4.9 OIL RETURN LINE

Check the oil return line periodically to ascertain that it does not become clogged. A clogged line results in exces-
sive oil consumption and oil in the service lines. If clogging is indicated, check and clean the entire line, including
the orifice fitting at the compressor end, and the siphon tube inside the separator. Usually, blowing with a reverse
flow of compressor air will clean the line.
4.10 COMPRESSOR OIL FILTER

The compressor oil filter is a spin-on, throwaway filter. It is designed with a built-in by-pass valve to ensure contin-
ued oil flow to the compressor. If restriction occurs, such as when the oil is cold or the filter becomes plugged, the
compressor will still receive lubrication. Depending on the compressor model, the oil filter may be a spin-on type
or a canister type.
BEFORE CHANGING EITHER TYPE OF OIL FILTER:

1. Make sure the system pressure is relieved.
2. Place oil spill pan under filter.
TO REPLACE THE SPIN-ON TYPE OF FILTER ELEMENT, PROCEED AS FOLLOWS:
1. Remove oil filter element by unscrewing it from the filter head (turn counterclockwise) and discard. The
use of a strap-type wrench may be necessary.
2. Install a new oil filter by applying a thin film of oil to the seal. Screw the oil filter on by hand, turning it
clockwise until the gasket seats. Then turn an additional 1/2 to 3/4 turn by hand.
3. Check for leaks in operation.
TO REPLACE THE CANISTER-TYPE FILTER ELEMENT, PROCEED AS FOLLOWS:
1. Remove filter canister by unscrewing center bolt at bottom of canister and discard used filter element.
2. Install new element into canister. Make sure all gaskets are in place. Seat canister into filter head. Re-
place and tighten head center bolt at bottom of canister.
3. Check for leaks in operation.

4.11 AIR/OIL SEPARATOR

WARNING!
Prevent separator flash or fire. Maintain the separator element in proper condition and
do not allow it to become plugged with dirt and oxidized oil. Be certain that the sump
lid is properly grounded to the sump when installing a new separator.
The combination of a build-up of dirt and oxidized oil can clog the element causing an
increase in air velocity at narrow points on the element media. Elevated temperatures
at these points can result in ignition of the fluid in the oil sump.
Failure to properly ground the sump lid and separator can result in the build-up of an
electric charge leading to ignition inside the sump (do not remove staples in separator
gasket).
harm or death.
The air/oil separator employs a unitized element. This is a single piece unit, which requires replacement when
it fails to remove the oil from the discharge air. Prior to replacing the separator element be sure to check the oil
return line and orifice for plugging or restrictions.To replace an element, proceed as follows:
1. Relieve sump pressure to zero pressure.
2. Disconnect oil return line. Loosen fitting and pull siphon
tube up out of separator.
3. Remove service air piping from minimum pressure valve.
4. Mark and disconnect necessary tubing at separator cover
and then remove cover.
5. Remove and replace element. Be certain lid and sump
tank top are clean to ensure proper grounding between
element and tank. Make sure grounding staples are in top
and bottom gasket.
6. Replace separator cover; tighten bolts gradually in an
opposing manner until required torque is reached. Refer
to Figure 2 BOLT TORQUE SEQUENCE and the bolt
torque tables on the following page.
7. Install service air piping and reconnect all tubing. When
replacing the oil return siphon tube, allow it to contact the Figure 2. BOLT TORQUE SEQUENCE
bottom of the sump tank then back off about 1/8 inch.
8. Clean oil return line and orifice.
If the separator element has to be replaced frequently because it is plugged, it is an indication that dirt is entering
the inlet system, the compressor oil filter is faulty, or the oil is breaking down. The complete inlet system, starting
with the air cleaner, and all joints in piping to the inlet valve, should be checked for leaks.
Table 2. BOLT TORQUE SPECIFICATIONS
BOLT THREADS GRADE 5 GRADE 5 GRADE 8 GRADE 8
DIAMETER (IN) PER INCH DRY OILED DRY OILED
1/4 20 8 6 12 9
5/16 18 17 13 25 18
3/8 16 30 23 45 35
7/16 14 50 35 70 55
1/2 13 75 55 110 80

BOLT THREADS GRADE 5 GRADE 5 GRADE 8 GRADE 8

DIAMETER (IN) PER INCH DRY OILED DRY OILED
9/16 12 110 80 150 110
5/8 11 150 110 220 170
3/4 10 260 200 380 280
7/8 9 430 320 600 460
1 8 640 480 900 680
Table 2. BOLT TORQUE FACTORS

LUBRICANT OR PLATING TORQUE CHANGES
Oil Reduce torque 15% to 25%
Dry film (Teflon or moly based) Reduce torque 50%
Dry wax (Cetyl alcohol) Reduce torque 50%
Chrome plating No change
Cadmium plating Reduce torque 25%
Zinc plating Reduce torque 15%
Table 2. BOLT TORQUE STAGES

STAGE TORQUE
1st 20-25 ft/lbs
2nd 55-60 ft/lbs
3rd 85-95 ft/lbs
The air filter element should be thoroughly inspected for holes by placing a lamp inside and carefully checking
for areas of bright light passing through the element. Inspect for dust leaking past the air filter element, seal, and
retaining bolt. The compressor oil filter should be checked making sure it has the proper element and it is properly
installed and not leaking.
4.12 THERMAL BY-PASS VALVE

The thermal by-pass valve should be inspected if the unit shuts down due to high compressor discharge air tem-
perature. Sediment particles may lodge in the valve-seating surface and prevent it from closing, thereby allowing
hot oil to pass directly to the compressor without being cooled. Inspect the valve by removing it from the by-pass
housing.
WARNING!
Shut the compressor down and relieve the valve of all pressure before attempting to
remove the valve. Serious injury or death may result if this warning is not followed.

4.13 OIL COOLER

The interior of the oil cooler should be cleaned when the pressure drop across the cooler at full load exceeds 25
psi. The following procedure is recommended.
1. Drain compressor fluid.
2. Remove oil cooler.
3. Circulate a suitable solvent to dissolve and remove varnish and sludge.
4. After oil cooler is replaced and compressor is filled with fresh oil, operate the machine normally for 50
hours, and then change compressor oil.
Should the presence of varnish be noted in the compressor oil system or air/oil separator plugging occurs, the oil
cooler and its internal “turbulators” must be cleaned. This is accomplished by adding a small amount of a special
flushing solvent-type lubricant. Contact the factory for details. After 50 hours of operation, the compressor oil con-
taining the solvent must be changed. A new oil filter element must be installed at this time, as well.
4.14 COMPRESSOR SHAFT OIL SEAL

To remove the oil seal, first remove the compressor drive coupling. Then unbolt oil seal cover. Remove oil seal
cover and pull oil seal out of housing.
On some models, the oil seal cover is installed by using a liquid gasket eliminator. It may be necessary to sepa-
rate the cover by carefully using a hammer and chisel. Use care not to damage the sealing surfaces. Inspect and
clean up gasket surface after removal is completed.
See instructions supplied with shaft seal kit.
4.15 COMPRESSOR DRIVE COUPLING

To replace the drive coupling or shaft seal it is necessary to remove the compressor from the engine. First, re-
move the upper enclosure and disconnect piping to the compressor. Support the compressor assembly securely.
Remove two bolts from the top of the compressor and replace with two studs. The studs will serve as temporary
support and guides for alignment. Remove the remaining bolts securing the compressor to the engine. Then hoist
the compressor assembly from the engine and place securely on a suitable workbench.
Refer to the parts manual for the type of drive coupling installed in your compressor or contact Sullivan-Palatek for
assistance in obtaining the appropriate components.
4.16 CONTROL ADJUSTMENTS

The engine speed governer and interconnecting linkage are preset at the factory and normally require no servic-
ing other than keeping the linkage joints clean and lubricated. However, if it becomes necessary to make adjust-
ments, use the following procedures.
DISCHARGE PRESSURE ADJUSTMENT

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

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

FULL LOAD SPEED
Open the service air valve so that the compressor “loads” then throttle as necessary to hold discharge pressure
at desired setting. Be sure there is no air leakage from the pressure regulator or control line. If speed is too high
reposition the throttle control air cylinder. If speed is too low make the opposite adjustment. Secure locknuts after
proper speed is obtained.
FOR FULL LOAD SPEED AND DISCHARGE PRESSURE SEE DIMENSION AND SPECIFICATIONS PAGES.
IDLE SPEED
Once the full load speed adjustment has been made, the idle speed should be in the rage of 1650 RPM for D185-
375 models and 1400 RPM for D750 and up. To check the idle speed, close the service air valve so that the com-
pressor “unloads.” If idle speed is too high, reposition throttle control air cylinder or lengthen linkage rod to engine
slightly. Make opposite adjustment to lower speed.
NOTE: It may be necessary to repeat both of the adjustments several times before the settings balance out, to get the
recommended idle and full load speed.

5 Troubleshooting
5.1 INTRODUCTION
This section contains instructions for troubleshooting the equipment following a malfunction. Each symptom of
trouble for a component or system is followed by a list of probably causes of the trouble and suggested proce-
dures to be followed to eliminate the cause.
The procedures listed should be performed in the order in which they are listed, although the order may be varied
if the need is indicated by conditions under which the trouble occurred. In any event, the procedures, which can
be performed in the least amount of time and with the removal or disassembly of the fewest parts, should be per-
formed first.
5.2 UNPLANNED SHUT DOWN

Check the following when the operation of the machine has been interrupted by an unexpected shutdown:
• Fuel level and fuel filter for water and contamination blockage.
• Engine coolant, engine oil, and compressor oil levels
• Fan belt tension
• Radiator and oil cooler for obstructions
• External causes such as broken hoses, broken oil lines, loose or broken wires
• Water temperature and compressor discharge temperature switches. These switches are normally
closed. Engine low oil pressure switch. This switch is a normally open switch.
If none of the above caused the shutdown, restart the engine and observe the engine oil pressure, engine water
temperature, and compressor discharge temperature and pressure gauges. Refer to the wiring diagrams and
information on the protection circuits for shutdown conditions. If it is found that low engine oil pressure or high
engine water temperature is causing the shut down, refer to the engine manufacturer’s manual.
5.3 IMPROPER DISCHARGE PRESSURE

Discharge pressure is too low.
• Start-Run valve is in “START” position.
• Too much air demand.
• Service valve open.
• Service line leaks.
• Compressor inlet air filter restricted.
• Control system operation
• Regulator valve faulty or set too low.
• Discharge pressure is too high or relief valve blows.
• Inlet valve (not closing properly).
• Discharge pressure gauge faulty.
• Control regulator valves faulty.
• Oil separator plugged.
• Pressure relief valve faulty.
• Compressor shaft seal leaking.
• Ice in control lines.
• Faulty oil line check valve
Relief valve blows with throttle lever in idle position.
• Inlet valve plate leaking.
• Discharge pressure regulator faulty or improperly set.
• Control system leaks.

Troubleshooting
5.4 BLOWDOWN VALVE

If after the compressor is shut down, pressure does not automatically blow down check for:
• Automatic blow down valve may be inoperative.
• Air line from inlet valve or sump to blow down valve may be restricted.
5.5 OIL CONSUMPTION

Check for the following if compressor oil level is decreasing excessively:
• Oil line leaking.
• Oil cooler leaking.
• Compressor shaft seal leaking.
Oil in service line check the following:
• Oil return line plugged; check entire line, especially orifice in return line.
• Separator element plugged or damaged.
• Discharge pressure below 70 psi.
5.6 ENGINE LUGGING

If engine does not accelerate or will not maintain full load speed check the following:
• Compressor discharge pressure too high.
• Improper control operation.
• Engine idle speed set too low.
• Operating above maximum altitude rating of engine.
• Engine problem. (Refer to engine manual).
5.7 SEPARATOR PLUGGING

If the separator element has to be replaced frequently because it is plugging up, it is an indication that foreign
material may be entering the compressor inlet or the compressor oil is breaking down. Compressor oil can break
down prematurely for a number of reasons: (1) extreme operating temperature, (2) failure to drain condensate
from oil sump, (3) using the improper type of oil, (4) mixing different types of oil, (5) prolonged operation at ex-
treme ambient temperatures, and (6) foreign material, gases or vapors entering compressor inlet.
• Check system for leaks.
• Check air inlet filters for dirt and dust blockage.
• Check compressor oil filter element.

Troubleshooting
5.8 IMPROPER CONTROL OPERATION

If the engine speed control lever does not move to its idle position with the service valves closed, check for:
• Pressure in control line to operate throttle cylinder is present.
• Control system is blocked between the sump and inlet valve. Also check the filter/condensate trap, if so
equipped.
• Control system leaks between sump and inlet valve.
• Engine governor speed control lever binding or throttle cylinder faulty.
• Discharge pressure regulator faulty.
• Inlet valve faulty (broken or worn rings in modulating piston).
• Modulating spring broken or loose.
If the engine speed control lever will not move to full speed when there is air demand, check for:
• Start/Run valve is positioned in “START” instead of “RUN.”
• Engine governor speed control lever binding or throttle cylinder faulty.
• Modulating spring broken.
• Control rod disconnected between the engine governor and cylinder.
• Discharge pressure regulator faulty or improperly set.
• Insufficient pressure in control line to operate throttle cylinder.
Check the following if full load speed cannot be obtained:
• Control cylinder rod to engine governor is incorrectly set or binding.
• Machine operating with excessive sump pressure.
• Inlet valve faulty; modulating spring broken.
• Engine governor incorrectly set.
• Operating above maximum altitude rating of engine.
If full load speed has been set and difficulty is encountered in setting the idle speed, check the following:
• Engine governor linkage binding or incorrectly set.
• Engine governor idle speed control lever too long.
• If the engine stalls when air demand is low, check the following:
• Idle speed may be set too low.
5.9 HIGH COMPRESSOR DISCHARGE TEMPERATURE

• Check the compressor oil level. Add oil if required.
• Clean outside of oil cooler.
• Check fan belt.
• Check thermal by-pass valve thermostat.
• Change oil and oil filter element.
• Clean oil system (cooler) internally.

Troubleshooting

6 Illustrations and Parts
6.1 PROCEDURE FOR ORDERING PARTS
Parts should be ordered from the nearest Sullivan Distributor or the Distributor from whom the machine was
purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the address
below.
When ordering parts, always indicate the SERIAL NUMBER and MODEL of the machine. This can be obtained
from the Bill of Lading for the machine or from the Serial Number Plate located on the machine.
Sullivan-Palatek, Inc.
1201 W. U.S. Highway 20
Tel: 219-874-2497
Fax: 219-872-5043
Toll Free: 800-438-6203
Web: www.sullivanpalatek.com
NOTE: When faxing, mark attention to Parts Dept.

Illustrations and Parts
6.2 RECOMMENDED SPARE PARTS

D750PHCU, D825PCU, D900PCU & D900PHCU
DESCRIPTION QTY PART NUMBER
ELEMENT, AIR FILTER (PRIMARY) 2 01900522 0082
ELEMENT, AIR FILTER (SECONDARY) 2 01900522 0083
ELEMENT, OIL FILTER (COMPRESSOR) 2 01900520 0036
ELEMENT, OIL FILTER (ENGINE) 1 01900520 0044
ELEMENT, FUEL WATER SEPARATOR 1 01900522 0086
ELEMENT, COOLANT FILTER 1 01900522 0087
ELEMENT, AIR/OIL SEPARATOR 1 05018000 0014
FLUID, COMPRESSOR WEATHER-ALL (5 GALLON) 1 00823062 0009
FLUID, COMPRESSOR WEATHER-ALL (55 GALLON) 1 00823062 0010
SWITCH, COMPRESSOR DISCHARGE TEMP. 1 05019415 0029
SWITCH, IGNITION (WITH PREHEAT) 1 00600701 0406
SWITCH, CIRCUIT BREAKER (5 AMP) 1 00602114 0005
SWITCH, CIRCUIT BREAKER - PUSH (10 AMP) 1 00602114 0010
SENDER, FUEL LEVEL 1 05019189 0007
GAUGE, FUEL LEVEL 1 05018320 0003
GAUGE, DIGITAL DIAGNOSTIC 1 05018366 0006
VALVE, SAFETY 1 05019601 0003
VALVE, 2-WAY 1/4 NPT (START-RUN) 1 05019820 0001
VALVE, PRESSURE REGULATOR 1 09661-011
KIT, REPAIR INLET VALVE 1 01140275 5073
KIT, REPAIR COMPRESSOR SHAFT SEAL 1 00701701 0298
COUPLING, FLEX 1 05017720 0031
O-RING, DISCHARGE FLEX COUPLING 2 00910659 0237
BELT, FAN 1 01900152 0055
CYLINDER, AIR (THROTTLE) 1 05017820 0028
SULLIVAN-PALATEK, INC. RECOMMENDS USE OF ONLY ORIGINAL EQUIPMENT COMPRESSOR OIL

FILTERS. USE OF A SUBSTITUTE MAY VOID WARRANTY. SEE WARRANTY FOR DETAILS.

A B C D E F
6.3
5 5
76.50in
1943.10mm
4 9.79in
4
248.68mm
(METRICS IN PARENTHESES)
4.00in 72.56in
[404.6mm]
LIFT EYE 1843.02mm
SULLIVAN-PALATEK USER’S MANUAL

3 3
56.62in
1438.14mm
DIMENSIONS AND SPECIFICATIONS
71.38in
1812.93mm
94.50in
2400.19mm
2 2
37.50in
23.12in 952.39mm
587.26mm
27.00in 33.13in 55.64in 69.27in

685.80mm 841.62mm 1413.16mm 1759.44mm
145.00in 54.48in 76.61in
3683mm 1383.69mm 1945.85mm
1 UNLESS OTHERWISE NOTED DRAWN BY: DATE:
DIMENSIONS ARE IN INCHES JPC 4/12/11 SULLIVAN-PALATEK 1
TOLERANCES AS FOLLOWS: 1201 West US Highway 20, Michigan City IN 46360
199.48in CHECKED BY: DATE: WWW.SULLIVANPALATEK.COM 1-800-438-6203
ANGLES: + OR - 1/2 DEG. MFP 4/12/11 DESCRIPTION
5066.69mm DECIMAL: X.X + OR - 0.050
X.XX + OR - 0.020 D750-900
X.XXX + OR - 0.005
MATERIAL: SIZE DRAWING NO: REV
D D750-900 00
DRAWING AND DIMENSIONS SUBJECT TO CHANGE WITHOUT NOTICE FIRST USED ON: SCALE: 1:16 SHEET 1 OF 1
THIS DRAWING AND ALL INFORMATION THEREIN IS THE PROPERTY OF SULLIVAN-PALATEK, INC. IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED.
IT IS LOANED SUBJECT TO RETURN UPON DEMAND, IS NOT TO BE USED DIRECTLY OR INDIRECTLY IN ANYWAY DETRIMENTAL TO SULLIVAN-PALATEK'S INTEREST.
A B C D E F
33
D750PHCU SPECIFICATIONS
COMPRESSOR
Model D750PHCU
Type Single Stage, Oil Flooded Rotary Screw
Rated Delivery 750 cfm (21.2 m3/min)
Rated Operating Pressure 150 psig (10.3 bar)
Rated Operating Pressure Range 70-150 psig (4.9-10.3 bar)
Ambient Temperature Range -25 to +125°F (-29 to +52°C)
Oil Capacity 30 gallons (114 L)
Total Receiver Volume 11.2 ft3 (317 L)
Air Service Connector 2-in NPT
Type Cooling System Oil to Air
Type Air Intake System Two Stage Dry
Type of Control 0-100% Demand
Tire Size 8-14.5 LT 14 Ply Rating
Estimated Weight, Serviced 9000 lbs (4082 kg)
ENGINE
Type Diesel
Engine Make Cummins
Engine Model QSC 8.3 (Tier 3)
Number of Cylinders 6
Bore and Stroke 4.49 x 5.31 in (114 x 135 mm)
Displacement 506 in3 (8.3 L)
Horsepower @ Rated RPM 275 hp (205.1 kw)
Total Oil Capacity 5.25 gallons (19.9 L)
Cooling System Capacity 10.5 gallons (40 L)
Battery Rating Volts 24 Volts
Cold Cranking Amps @ 0°F (-18°C) 1280 Amps per Battery (2)
Full Load Speed 1800 RPM
Idle Speed 1400 RPM
Fuel Tank Capacity 163.6 gallons (619.3 L)

D825PCU SPECIFICATIONS
COMPRESSOR
Model D825PCU
Air Service Connector 2-in NPT
ENGINE
Type Diesel
Engine Make Cummins
Idle Speed 1400 RPM

D900PCU SPECIFICATIONS
COMPRESSOR
Model D900PCU
Air Service Connector One 2-in NPT
ENGINE
Type Diesel
Engine Make Cummins
Idle Speed 1400 RPM

D900PHCU SPECIFICATIONS
COMPRESSOR
Model D900PHCU
Air Service Connector One 2-in NPT
ENGINE
Type Diesel
Engine Make Cummins
Idle Speed 1400 RPM

6.4 WIRING DIAGRAM
1
3
5
2
4
REVISIONS
REV. DESCRIPTION DATE APPROVED
COLOR SPECIFICATIONS 00 RELEASED 04/13/11 TGW/JAG
WIRE NO. COLOR WIRE NO. COLOR WIRE NO. COLOR CHANGED WIRE #48 (BATTERY CABLE 05017420 0048) TO #49 (05017420 0049);
01 REDREW FIGURE OF INLET AIR HEATER RELAY 05/17/11 TGW/JAG
2 WHITE 19 BLACK/YELLOW 50* WHITE
3 DARK BLUE 20* BLACK 51 BLACK
4 ORANGE 21* RED 52 BLACK WIRE INFORMATION
5 VIOLET 22* RED 53 RED
23* BLACK
6 LIGHT GREEN 54 RED WIRE NO. SULLIVAN-PALATEK
PART NUMBER DESCRIPTION
7 BROWN 24 RED 55 RED
8 YELLOW 28* BLACK 56 RED 49 05017420 0049 CABLE,BATTERY POS. 24"LG
F
F
9* WHITE 32* WHITE 57 BLACK 60 05017420 0050 CABLE, BATTERY NEG. 24"LG
10* RED 37* BLACK 58 BLACK 51 05017420 0051 CABLE,BATTERY JUMPER 27"
11 YELLOW 39* RED 59 BLACK 54 05018680 0054 LEAD WIRE, 6GA 15"LG RED
12 RED 40* RED 60 BLACK 55 05018680 0055 LEAD WIRE, 6GA 20"LG RED
13 RED 42* LIGHT BLUE 61 RED 56 05018680 0056 LEAD WIRE, 6GA 48"LG RED
14 RED 43* WHITE 62 RED 57 05018680 0057 LEAD WIRE, 6GA 21"LG BLACK
15 RED 44* WHITE 63 WHITE 58 05018680 0058 LEAD WIRE, 6GA 24"LG BLACK
16 BLACK 46* RED 64 BLACK 59 05018680 0059 LEAD WIRE, 6GA 10"LG BLACK
17 RED 47* WHITE 70 RED 70 05017420 0070 CABLE, DISCON. TO STARTER 30"LG
18 BLACK 49 RED 71 BLACK 71 05017420 0071 CABLE,STARTER GRD TO ENG GRD
* goes to 50-pin connector
39
39 39 24
39
FUSE 24 VOLT
5 AMP LAMPS
21 A
21 A LOW INST. INST.
28 B COOLANT PANEL. PANEL.
28 B LEVEL
ENGINE STOP
E
E
32 C SENSOR
32 C
43
R
24
9 A
9 A
23 B THROTTLE
23 B POSITION WARNING
22 C SENSOR
ECM 22 C 44
50 PIN Y
24
CONNECTOR 43
43
44 WAIT-TO-START
44
50 50
50 Y
24
39
40 40 56
40
CIRCUIT
42 BREAKER
42 INLET 5 AMP
D
D
INLET AIR HEATER

AIR HEATER
RELAY LOW FUEL 14
SHUTDOWN
10 20 46 47 37 42 55
FUEL LEVEL R
18 15
SWITCH
10 20 46 47 37
FUSE 19
125 AMP 2
8
7 5 6 4 3
1 3 LOW FUEL
52 53 54 SHUTDOWN
120 OHM
1/4 W
2 4 TIME DELAY
ECM 4 PIN RELAY
2 8 1
CONNECTOR
FUSE 15 2
30 AMP STARTING 15
CIRCUIT
BREAKER 15
54 14
BATTERY BATTERY MASTER 10 AMP
C
C
53 DISCONNECT CDT 11
51 49 SWITCH 5 8
ACC
39 13
BAT IGN
70
ST
60 6 IGNITION 61
60 6 SWITCH
52 12
17 2
GND. LOOP GND. LOOP 2
57
16 58
ENGINE 6
BLOCK GND. 57
B 6
G S SOL.
62 SOLENOID
2 5 2 MOTOR
63 2 71 STARTER
3 6
64 7 7 12 12
4 1 ENGINE
BLOCK GND.
POWERVIEW
GND. LOOP
J1587 J1939
DATALINK DATALINK 57
F G C D E 59 58
B
61 17 2
G B FUSE
F G C D E 100 AMP
ALTERNATOR
61
16
ECM A
9 PIN
CONNECTOR 17 17 2 2
B CDT GAUGE
FUSE CDT
1 AMP SENDER
L
G
S I
3 13
2 2
2 FUEL GAUGE
FUEL L
GND. LOOP
SENDER G
4 S I
13
REQUIRED HARNESSES FROM SIGNAL STUD
ON FUEL SENDER
A
SULLIVAN-PALATEK 2
05018395 0187 HARNESS, POWER TO ECM D750/900 UNLESS OTHERWISE NOTED DRAWN BY: DATE:
04/13/11 SULLIVAN-PALATEK
DIMENSIONS ARE IN INCHES TGW
05018395 0188 HARNESS, PRIMARY ENGINE D750-900 ANGLES: + OR - 1/2 DEG.
CHECKED BY:
GRANACKI
DATE:
04/13/11
WWW.SULLIVANPALATEK.COM
DESCRIPTION
1-800-438-6203
NOMENCLATURE: DECIMAL: X.X + OR - 0.050

PICTORAL WIRING DIAGRAM
HARNESS,SECONDARY CONTROL PANEL & ECM - ENGINE CONTROL MODULE
X.XX + OR - 0.020
05018395 0189 COMPONENTS D750-900
X.XXX + OR - 0.005
CUMMINS QSC 8.3
CDT - COMPRESSOR DISCHARGE TEMPERATURE MATERIAL: SIZE DRAWING NO: REV
05018395 0190
HARNESS,LOW FUEL SHUTDOWN RELAY & SOL - SOLENOID D WD 15093 01
SOCKET BASE D750-900 GND - GROUND FIRST USED ON: D750-900 CU SCALE: NONE SHEET 1 OF 1
1
2
3
4
5

A B C D E F
5
THROTTLE ACTUATOR
5 6.5
SAFETY VALVE
4 PRESSURE GAUGE 4
3 3

COMPRESSOR INLET
CONTROL SYSTEM DIAGRAM
INDICATOR, SEPARATOR
2 2
START/RUN VALVE
DIMENSIONS ARE IN INCHES JW 11/5/11 SULLIVAN-PALATEK 1
CHECKED BY: DATE: WWW.SULLIVANPALATEK.COM 1-800-438-6203
ANGLES: + OR - 1/2 DEG. JPC DESCRIPTION
DECIMAL: X.X + OR - 0.050
X.XX + OR - 0.020 DIAGRAM
X.XXX + OR - 0.005 CONTROL D750-900
D CD 00001 01
FIRST USED ON: 750-900 SCALE: 1: SHEET 1 OF 1
A B C D E F
39
6.6 OIL PIPING DIAGRAM

A
ITEM # PART NUMBER
B
DESCRIPTION
C
QTY
D E F
6.7
1 00519136 0009 CAP, RAIN 5.00 1
2 00900115 0001 SCREW, 1/4-20 X 3/4" LG GD 5 6 1
3 00900321 0002 WASHER, FLAT, 1/4" ZINC PLATED 6
5 5
4 00909003 0040 U-BOLT, .500-13 X 4.00 DIA 1 20 12
5 01900216 0553 BRACKET, EXHAUST TUBE BULKHEAD D750-900 1
6 01900504 0053 ELBOW, EXHAUST, 4.00 ID X 4.00 OD X 45 DEG X 6.00 RADIUS X 6.00 LEG ALUMINIZED 1
7 01901200 0026 REDUCER, TUBE 5.0 OD X 4.0 ID X 6.0 LG 1
18
8 01901569 0045 ELBOW, 90 DEG 4 ID X 4 OD 3 17 19
9 01901569 0049 TUBE, 4.00 OD X 48.00 LG 1
10 03903087 0013 CONNECTION, EXHAUST 4.00 I.D. FLEX CUMMINS QSC D750-900 1
11 05017555 0026 CLAMP, EXHAUST LAP 4" I.D. 8
16
2
EXHAUST SYSTEM
4 12 05017555 0027 CLAMP, EXHAUST LAP 4" I.D. 4

13 05018577 0010 INSULATION, EXHAUST WRAP 4.00 TUBE X 30.00 LONG X 1.00 THICK 2
15 05018755 0016 BAND, MUFFLER 10.08 ID 2
16 05018785 0047 MUFFLER, D750-900 VERTICAL 5.00 ID INLET-OUTLET 10.00 DIA 51.00 LONG 1
15
17 00900490 0081 NUT, NYLOK 3/8-16 ZINC PLATED 4
18 00900321 0004 WASHER, FLAT 3/8" ZINC PLATED 8

19 00900115 0023 SCREW,3/8-16 X 1-1/4" LG GD 5 4 12
20 01901571 0046 01901571 0046 TUBE, EXHAUST 5OD X 6LG 1
7
3 3
4 6 11
11
8
11 11 11
13 8
2 2
10
APPLY THE FOLLOWING SEALANTS TO 9 11

ALL BELOW LISTED PARTS/SURFACES
TO ALL BOLTS:
LOCTITE 242
11 5
TO ALL GASKET SURFACES:
LOCTITE 'VIPER LUBE' CLEAR
UNLESS OTHERWISE NOTED DRAWN BY: DATE:
1 HIGH PERFORMANCE SYNTHETIC DIMENSIONS ARE IN INCHES 1
JPC 3/15/11 SULLIVAN-PALATEK
1201 West US Highway 20, Michigan City IN 46360
2 3 TOLERANCES AS FOLLOWS: CHECKED BY: DATE:
GREASE WWW.SULLIVANPALATEK.COM 1-800-438-6203
X.XX + OR - 0.020 EXHAUST ASSY,
X.XXX + OR - 0.005 D750-900
TO ALL PIPE THREADS: MATERIAL: SIZE DRAWING NO: REV
13 AS NOTED 00717796 0142 01
LOCTITE 567 THREAD SEALANT 8 11 D
FIRST USED ON: D900PHCU SCALE: 1:8 SHEET 1 OF 1
A B C D E F
41
42
ITEM #
A
B
QTY
C D E F
6.8
1 00501171 1822 COMPRESSOR ASSY, 204MM, 2.026 GR 1
2 00900115 0001 SCREW, 1/4-20 X 3/4" LG GD 5 4
3 00900115 0014 SCREW, 1/2-13 X 1" LG GD 5 8
5 5
4 00900115 0275 BOLT, .4375-14 X 3.25 HEX HD GR 8 12
5 00900321 0002 WASHER, FLAT, 1/4" ZINC PLATED 4
6 00900947 0249 KEY,5/8 X 5/8 X 2 1/2" LG 1
7 01663744 0012 COVER,INSPECTION 1
8 05017375 0011 BUSHING,TAPER LOCK W/SETSCREWS 1
9 05017720 0031 COUPLING,DRIVE / D750 - D900 1
10 05019191 0007 SENDER,TEMPERATURE,1/2"-14 1 6
11 05019415 0030 SWITCH, TEMPERATURE 255 DEG F 1
4 4 4
8
3 3
3 1
COMPRESSOR AND MOUNTING PARTS
2 7 2
APPLY THE FOLLOWING SEALANTS TO 5

11
TO ALL BOLTS:
LOCTITE 242
TO ALL GASKET SURFACES: 2
LOCTITE 'VIPER LUBE' CLEAR 10
HIGH PERFORMANCE SYNTHETIC DIMENSIONS ARE IN INCHES JPC 3/14/11 SULLIVAN-PALATEK 1
GREASE ANGLES: + OR - 1/2 DEG. MFP DESCRIPTION
X.XX + OR - 0.020 COMPRESSOR ASSY,
X.XXX + OR - 0.005 204MM D750-900
TO ALL PIPE THREADS: AS NOTED 00717488 0114 01
D
SCALE: SHEET
LOCTITE 567 THREAD SEALANT FIRST USED ON: D900PHCU 1:4 1 OF 1
A B C D E F

A B C D
ITEM # PART NUMBER
E
DESCRIPTION
F
QTY
6.9
ALL BELOW LISTED PARTS/SURFACES 1 00501174 1807 VALVE, INLET 6" N.C.
2 00901091 0002 TEE, PIPE .250 #150 GALV 1
TO ALL BOLTS: 1
LOCTITE 242 3 00901160 0001 BUSHING,PIPE 1/4 X 1/8
5 11 5
4 00901161 0005 BUSHING, PIPE 1/2 X 1/4 150# GALV 1
LOCTITE 'VIPER LUBE' CLEAR 5 00901858 0036 BOLT, FLANGE 3/8-16 X 1 1/4 6
HIGH PERFORMANCE SYNTHETIC 6 00901921 0004 PLUG,PIPE 1/2" HEX SOCKET HEAD 1
GREASE
7 00903872 0027 VALVE,T HANDLE 1/8 X 1/8 1
TO ALL PIPE THREADS: 5 8 00906058 0004 NIPPLE, HEX PIPE 1/4 X 1/4 1
LOCTITE 567 THREAD SEALANT
9 00906843 0088 FITTING, BARB 1/2" HOSE, 1/2" MNPT 1
10 00915557 0064 ELBOW, 3/8" TUBE X 1/4" MNPT 1
12
4 11 00915557 0444 ELBOW, 1/4" TUBE X 1/4" MNPT 1
4 12 01663742 0055 GASKET, INLET VALVE 1 4
14 00901921 0002 PLUG, PIPE 1/4" HEX SOC HD 1
5
INLET VALVE ASSEMBLY

3 3
1
14
2 2 2
10
6.00 O.D.
AIR INLET
9 BOLT TORQUE SPECS:
3
FOR ALL OF ITEM # 00901858 0036
BOLT, FLANGE 3/8-16 X 1 1/4
1 6 UNLESS OTHERWISE NOTED DRAWN BY: DATE:
DIMENSIONS ARE IN INCHES 1
30 LB-FT DRY JRW 11/4/11 SULLIVAN-PALATEK
ANGLES: + OR - 1/2 DEG.
23 LB-FT WET JPC 11/5/11 DESCRIPTION
7 X.XX + OR - 0.020 INLET VALVE ASSY
X.XXX + OR - 0.005 D750-900
AS NOTED 00717985 0041 01
5 D
FIRST USED ON: D900PHCU SCALE: DNS SHEET 1 OF 1
A B C D E F
43
44
A B C D E F
ITEM # PART NUMBER DESCRIPTION QTY
1 01900522 0082 AIR FILTER-PRIMARY 2 17
1
2 01900522 0083 AIR FILTER - SECONDARY 2
5 3 00519398 0004 BAND, AIR FILTER D750-900 4 2 5
4 00900115 0023 SCREW,3/8-16 X 1-1/4" LG GD 5 4
5 00900115 0042 SCREW,5/16-18 X 1-3/4" LG GD 5 8
4 7
8 00900490 0062 NUT,NYLOK 5/16-18 ZINC PLATED 8 20
9 00900490 0081 NUT, NYLOK 3/8-16 ZINC PLATED 4 3
10 00910411 0010 ELBOW, RUBBER 6" X 90 DEG 2 14
11 00915557 0004 ELBOW, 1/4 TUBE X 1/8 MNPT 2
4 12 01900216 0551 BRACKET, AIR FILTER D750-900 1 4
13 01900500 0024 ELBOW, 90 DEG RUBBER 4.00 ID X 5.00 ID 1

14 01900504 0007 ELBOW, 90 DEG RUBBER 5.00 ID X 6.00 ID 1 6 8 19
6.10 AIR FILTER ASSEMBLY
15 01901571 0044 TUBE, 5.00 OD 1 6

15
16 01901572 0040 TUBE, 6.00 OD 1
5 8 6 11
17 05018174 0047 FILTER, AIR D750-900 2 5 6
13
18 92320-144 CLAMP, HOSE 4-1/2" 1
3 18
19 92320-176 CLAMP, HOSE 5-1/2" 2
3 5 3
20 92320-208 CLAMP, HOSE 6-1/2"
12
17
9
10
2 2
7
16
APPLY THE FOLLOWING SEALANTS TO

ALL BELOW LISTED PARTS/SURFACES 20
11
TO ALL BOLTS:
LOCTITE 242

GREASE ANGLES: + OR - 1/2 DEG. MFP 3/16/11 DESCRIPTION
X.XX + OR - 0.020 AIR FILTER ASSY, D750-900
X.XXX + OR - 0.005

10 D
SCALE: SHEET
LOCTITE 567 THREAD SEALANT FIRST USED ON: D900PHCU 1:8 1 OF 1
A B C D E F

A B C D E F
ITEM # PART NUMBER DESCRIPTION QTY ITEM # PART NUMBER DESCRIPTION QTY
36 00900321 0005 WASHER, FLAT 1/2 ZINC PLATE 7

1 05018485 0374 HOSE, ASSY 2.00 OD X 2.00 FSJIC AIR OUT D750-900 2
37 00900490 0103 NUT, NYLOC 1/2-13" ZINC PLATED 4
5 2 05018485 0374 HOSE, ASSY 2" X FSJIC AIR OUT D750-900 1 38 00901177 0152 NIPPLE, PIPE 1 1/2" X 5 1/2" SCH 80 GALV 1 5
39 00901091 0008 TEE, PIPE 1 1/2" #150 GALV 1
3 00901161 0005 BUSHING, PIPE 1/2 X 1/4 150# GALV 2
40 05018305 SIGHTGLASS, 1 1/2" MNPTS 1
4 95509 002 ELBOW, STREET-BRASS 1 41 01661612 BUSHING, ADAPTER 1 1/2" MNPT X 1 7/8"-12 1
5 90623-008 NIPPLE, HEX 1/2" CLOSE 1 42 01663817 0014 PLUG, 1 7/8"-12 VENTED OIL FILL 1
6 00906058 0125 NIPPLE, HEX RED 1/2 MNPT X 1/4 MNPT 1 43 03903448 0038 RECEIVER, AIR/OIL 1
ELBOW, 1/4" TUBE X 1/4" MNPT 2 44 05018000 0014 ELEMENT, SEPARATOR AIR-OIL 1
7 00915557 0444
45 01900736 0023 HEAD, RECEIVER LID 1
8 00915564 0064 TEE, MALE RUN 1/4" MNPT X 3/8" TUBE BRASS 1 46 05018485 0366 HOSE, DISCHARGE 3" FLEX D750-900 1
47 00901179 0063 NIPPLE, PIPE 2" CLOSE SEAMLESS GALV 1
9 00901177 0207 NIPPLE, PIPE 2" X 6' SCH 80 GALV 2
48 05019610 0004 VALVE,MIMIMUM PRESSURE 2" NPT 1
4 10 00519470 0001 CLAMP, EXHAUST 2.5 GM STYLE 3 49 00909753 0048 KIT, SPLIT FLANGE CODE 61 3IN 1 4
11 96363-044 CONN, CMS 1/4" MNPT X 1/4" TUBE 1 50 00915785 0032 VALVE, BALL 2" 1
12 00907254 0044 FITTING, ELBOW 90 DEG. 1/4 NPT 2 51 05019660 0022 VALVE, N/O PILOT TO CLOSE 1/2" 1
52 00901164 0005 BUSHING, PIPE 1/2" X 1/4" ZINC PLATED 1
13 00903873 0004 COCK, DRAIN 1/2" MNPT BRASS 1 53 05018785 0014 SILENCER, PNEUMATIC 1/4" 1
14 00543241 0001 GAUGE, SIGHT 1/4" 1 54 05019660 0016 VALVE, BLOWDOWN 1/2" PIPE 1
55 01901551 0046 TUBE, UPPER SCAVENGER 1
15 00906843 0088 FITTING, BARB 1/2" HOSE, 1/2" MNPT 1

56 00910659 0237 O-RING, VITON V75-237 1
16 00915557 0064 ELBOW, 3/8" TUBE X 1/4" MNPT 1 58 00915543 0444 CONNECTOR 1/4 TUBE X 1/4 NPT 1
59 00901176 0128 NIPPLE,PIPE 1/4 X 4" LG XS 1
17 00900321 0004 WASHER, FLAT 3/8 ZINC PLATE 8
3 3
18 00900115 0033 BOLT, 3/8"-16 X 1 1/2" HEX HD GR 5 4
19 00900490 0081 NUT, NYLOC 3/8-16" ZINC PLATED 5
20 00901177 0315 NIPPLE, PIPE 2" X 12" SCH 80 GALV 1
21 00901027 0009 ELBOW, PIPE 90 DEG. 2" SCH 80 GALV 3
6.11 RECEIVER / SEPARATOR ASSEMBLY
22 00907234 3232 ADAPTER, 2" MJIC X MNPT 2

23 01901520 0406 SUPPORT, PIPE D750-900 1
24 00901921 0002 PLUG, PIPE 1/4" HEX SOC HD 2
2 25 03286-003 FITTING, SIPHON 1/4" MNPT X 1/4" TUBE 1 2
26 00902239 0825 SCREW, 5/8-11" X 2 1/2" SHCS 4
27 00900115 0076 BOLT, 3/4-10 X 2-1/2" LG GD 5 12
28 05019601 0003 VALVE, SAFETY 200 PSIG 1 1/4" MNPT X 1 3/4" FNPT 1 ALL BELOW LISTED PARTS/SURFACES
29 00900115 0044 BOLT, 1/2-13" X 1-3/4" HEX GR 5 4 TO ALL BOLTS:

LOCTITE 242
30 00907254 2020 ELBOW, 1 1/4" MNPT X 1 1/4" MJIC 1
31 00901050 0008 ELBOW, STREET 1" SCH 80 GALV 1 LOCTITE 'VIPER LUBE' CLEAR
HIGH PERFORMANCE SYNTHETIC
32 00901177 0051 NIPPLE, PIPE 1" CLOSE SCH 80 GALV 1 GREASE UNLESS OTHERWISE NOTED DRAWN BY: DATE:
1 DIMENSIONS ARE IN INCHES JW 11/1/11 SULLIVAN-PALATEK 1
33 00905330 0017 TEE, REDUCING 1" X 1 1/4" X 1" 150# GALV 1 ANGLES: + OR - 1/2 DEG. JPC 11/1/11 DESCRIPTION
TO ALL PIPE THREADS: X.XX + OR - 0.020 RECEIVER ASSY
X.XXX + OR - 0.005 D750-900
34 00901161 0010 BUSHING, PIPE 1 1/4" X 1/4" 150# GALV 1 LOCTITE 567 THREAD SEALANT
AS NOTED 00717884 0140 00
D
35 09661-011 REGULATOR, NEGATIVE PRESSURE 1/4" FNPT 1
A B C D E F
45
46
A B C D E F
6 48
5 5
8 51
52 A
35
45
53
4 16 4
44
7
4
43
12
59
14
3 3
11
3
54 55
DETAIL A
25
45
2 49 2
C
3

DIMENSIONS ARE IN INCHES SULLIVAN-PALATEK 1
JW 11/1/11
ANGLES: + OR - 1/2 DEG. JPC 11/1/11 DESCRIPTION
X.XX + OR - 0.020 3RD ANGLE
RECEIVER ASSY
X.XXX + OR - 0.005 PROJECTION D750-900
DETAIL TOP MATERIAL: SIZE DRAWING NO: REV
AS NOTED 00717884 0140 00
DETAIL C D
FIRST USED ON:D900PHCU SCALE: DNS SHEET 2 OF 3
A B C D E F

A B C D E F
5 5
4 4
43

24
21 DETAIL N
3 3
33 32
DETAIL D
2
29 2
36
43
19 37 DETAIL E
50
N DIMENSIONS ARE IN INCHES 11/1/11 SULLIVAN-PALATEK 1
JW
9 TOLERANCES AS FOLLOWS: 1201 West US Highway 20, Michigan City IN 46360
X.XX + OR - 0.020 RECEIVER ASSY
18 X.XXX + OR - 0.005
3RD ANGLE
PROJECTION D750-900
10 AS NOTED 00717884 0140 00
17 D
A B C D E F
47
48
A B C D E F
1 1
2 00501016 0072 VALVE, BALL .750 NPT 2
3 00900115 0012 SCREW, 5/16-18 X 1" LG GD 5 8
5 5
4 00900115 0023 SCREW,3/8-16 X 1-1/4" LG GD 5 18
5 00900115 0055 SCREW,5/8-11 X 2" LG GD 5 4
7 00900321 0004 WASHER, FLAT 3/8" ZINC PLATED 36 17

8 00900321 0006 WASHER,FLAT,5/8" ZINC PLATED 8
9 00900490 0081 NUT, NYLOK 3/8-16 ZINC PLATED 18 7

10 00900490 0128 NUT,NYLOK 5/8-11 ZINC PLATED 4 21
11 00901161 0007 BUSHING, PIPE .750 X .250 150# GALV 1
9 6
12 00901161 0013 BUSHING, PIPE 1.00 X .750 150# GALV 1 7 3 4
4 4
13 00901177 0203 NIPPLE, PIPE .750 X 6.00 SCH 80 GALV 2

6.12 COOLING ASSEMBLY
14 00901204 0005 PLUG, PIPE SQ HEAD .750 2 19

15 00909753 0024 KIT, SPLIT FLNG CODE 61 1.5SAE 2
16 00915557 0444 ELBOW, .250 TUBE X .250 MNPT 2

9
17 01901000 0852 PANEL, COOLER SUPPORT D750-900 2 9
18 01901174 0004 SENSOR, COOLANT LEVEL 1 7

7
19 03903040 0186 BRACKET, MUFFLER D750-900 2
21 05017690 0063 COOLER ASSY, RADIATOR, OIL COOLER, ATAAC

1
9
3 D750-900 3
BARB, HOSE .250 BARB X .250 MNPT BRASS
22 05018231 0004 PARKER PUSH LOK
1
BARB, HOSE .750 BARB X .750 MNPT BRASS 7
23 05018231 0048 PARKER PUSH LOK 1
19
7
7
2
4 7 2
4
4
7 9

17
TO ALL BOLTS:
7
LOCTITE 242
TO ALL GASKET SURFACES: 7

ANGLES: + OR - 1/2 DEG.
GREASE 9 DECIMAL: X.X + OR - 0.050
MFP 3/14/11 DESCRIPTION
COOLING ASSY,
D
FIRST USED ON: SCALE: SHEET
LOCTITE 567 THREAD SEALANT D900PHCU DNS 1 OF 2
A B C D E F

A B C D E F
5 5
E 16 11
D
C
1
16
4 18 4
B
DETAIL D
ENGINE LOW
DETAIL C COOLANT LEVEL
ENGINE COOLANT SHUTDOWN SWITH
LEVEL SIGHTGLASS

4 7 7 9 13
22
3 2 3
14
A
5 8 8 10
10 8 8 5 12
DETAIL B 23
5 8 8 10 COMPRESSOR OIL
COOLER DRAIN
2 2
9 7 7 4
DETAIL E
10 8 8 5 ENGINE COOLANT
DEAERATION PORTS
13
14

DIMENSIONS ARE IN INCHES 3/14/11 SULLIVAN-PALATEK 1
JPC
2 TOLERANCES AS FOLLOWS: 1201 West US Highway 20, Michigan City IN 46360
COOLING ASSY,
DETAIL A MATERIAL: SIZE DRAWING NO: REV
AS NOTED 00717532 0124 00
ENGINE RADIATOR D
DRAIN THIS DRAWING AND ALL INFORMATION THEREIN IS THE PROPERTY OF SULLIVAN-PALATEK, INC. IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED.
A B C D E F
49
50
A B C D E F
1 00900115 0023 SCREW,3/8-16 X 1-1/4" LG GD 5 6 7
2 00900321 0004 WASHER, FLAT 3/8" ZINC PLATED 16 11
3 00900490 0081 NUT, NYLOK 3/8-16 ZINC PLATED 6 OIL FLOW
5 DIRECTION 5
4 00901177 0313 NIPPLE, PIPE 1.25 X 12.00 SCH 80 GALV 1 ARROWS
5 00906351 0006 TEE, PIPE 1.250 M X M X F SCH 40 GALV 1
6 00907234 0001 ADAPTER, 1.25 FNPT X 1.50 MSAE ORB 3 9
7 00907254 2020 ELBOW, 1.25 MNPT X 1.25 MJIC 4
8 00909003 0041 U-BOLT AND SADDLE 1.25 PIPE M10 THREADS AND NUTS 2
3 2 2 1
5
9 01900216 0550 BRACKET, OIL FILTER D750-900 2
10 01900520 0036 ELEMENT, FILTER, SPIN-ON 1
11 05018185 0038 HEAD, FILTER, SPIN-ON 1 TO
9 COMPRESSOR
4 12 05019505 0019 VALVE, THERMOSTAT 170 DEG. F. 1.500 SAE ORING 1 4
6.13 OIL FILTER AND PIPING
3 2 2 1
8
FROM COOLER
3 4 7 3
THERMAL VALVE 12
'C' PORT
6 8
7
2 THERMAL VALVE 2
'B' PORT
APPLY THE FOLLOWING SEALANTS TO THERMAL VALVE

ALL BELOW LISTED PARTS/SURFACES 'A' PORT 10
6
TO ALL BOLTS:
LOCTITE 242
7
LOCTITE 'VIPER LUBE' CLEAR TO COOLER
1
HIGH PERFORMANCE SYNTHETIC UNLESS OTHERWISE NOTED DRAWN BY: DATE:
GREASE TOLERANCES AS FOLLOWS: 1201 West US Highway 20, Michigan City IN 46360
FROM RECEIVER X.XX + OR - 0.020 OIL FILTER ASSY,
X.XXX + OR - 0.005 FPE VALVE D750-900
TO ALL PIPE THREADS: MATERIAL: SIZE DRAWING NO: REV
LOCTITE 567 THREAD SEALANT AS NOTED 00717620 0077 00
D
A B C D E F

6.14 FUEL TANK AND MOUNTING PARTS
1
3
5
2
4
TO ALL BOLTS:
LOCTITE 242 9
4
F
F
HIGH PERFORMANCE SYNTHETIC 15

GREASE 27
TO ALL PIPE THREADS: 30

LOCTITE 567 THREAD SEALANT
4 16
14
21 FUEL FROM
ENGINE
16
2
20 15
E
E
23
FUEL TO
19 ENGINE 30
11
5
13
4
11
D
D
22
26
28
16
20
18
2
C
C
3 6
19
25 7
ITEM # PART NUMBER DESCRIPTION QTY 10

1 00501016 0072 VALVE, BALL .750 NPT 1
2 00900115 0002 BOLT,5/16-18 X 3/4" LG GD 5 16
3 00900716 0033 ADAPTER UNION,MALE 1-1/2 1 12
4 00900804 0109 SCREW, #10-24 X 1/2" LG 15
5 00901068 0011 ELBOW, PIPE 45 DEG. 3.00 150# GALV 1
B
REDUCER, PIPE 3.00 FNPT X 2.00

6 00901150 0031 FNPT SCH80 GALV
1
7 00901177 1374 NIPPLE, PIPE 3.00 X 5.00 SCH 80 GALV 1
8 00901204 0005 PLUG, PIPE SQ HEAD .750 1
COUPLING, PIPE .500 FNPT 150#
9 00901288 0004 1
GALV 24
10 00901921 0004 PLUG, PIPE 1/2 HEX SOCKET 1
NIPPLE, PIPE 3.00 CLOSE SCH40
11 00902471 1510 GALV
2
12 00903686 0024 1.50 MNPT UNION 90DEG 1
13 00905850 0108 SCREW, PAN HD, 10-24 X 1-1/4 5
14 00906814 0008 HOSE, .50 ID 250PSI 1
15 00906843 0088 FITTING, 1/2 HOSE, 1/2 NPT 2
16 01225508 GASKET, FUEL SENDER 3
17 01900220 0001 BREATHER, FUEL TANK 1
18 01900220-0002 BREATHER, FUEL TANK, 2" NPT 1 1
19 01900664 0030 GASKET, SENDER MOUNT PLATE 2
20 01901000 0838 PANEL, SENDER SENSOR & INSP 2
21 03903488 0072 TUBE, FUEL RETURN D1150/350 1 29
22 03903488 0075 TUBE, FUEL PICKUP D1300 1 8
23 05017457 0028 CAP, FUEL, NON VENTED 3" NPTF 1
A
24 05017930 0019 ELBOW, .750 MNPT X .750 MNPT 1

25 05018485 0349 HOSE ASSY,1-1/2 X 31.5LG 1
SENDER, FUEL LEVEL-SWITCH D750-
UNLESS OTHERWISE NOTED
DIMENSIONS ARE IN INCHES
DRAWN BY:
JPC
DATE:
3/15/11 SULLIVAN-PALATEK
26 05019189 0007 900
1 TOLERANCES AS FOLLOWS: CHECKED BY: DATE:
1201 West US Highway 20, Michigan City IN 46360
WWW.SULLIVANPALATEK.COM 1-800-438-6203
SWITCH,LOW FUEL SHUTDOWN DECIMAL: X.X + OR - 0.050
TANK, FUEL ASSY
27 05019430 0057 1
X.XX + OR - 0.020
D750-900
27.75"LG
X.XXX + OR - 0.005

28 05019475 0065 TANK, FUEL MAIN D750-900 1 AS NOTED
D 00717972 0102 00
29 05019475 0067 TANK, FUEL D750-900 SECONDARY 1 FIRST USED ON: D900PHCU SCALE: DNS SHEET 1 OF 1
30 97254-008 ELBOW, 1/2"JIC X 1/2"MPT 2 THIS DRAWING AND ALL INFORMATION THEREIN IS THE PROPERTY OF SULLIVAN-PALATEK, INC. IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED.
1
2
3
4
5

52
A B C D E F
1 00543255 INDICATOR, RESTRICTION SEPARATOR 1
2 00600701 0406 SWITCH, KEY IGNITION 3-WAY 1
3 00900609 0011 WASHER, LOCK 5/8" INTERNALLY SERRATED ZINC 2
5 4 00902466 1200 NIPPLE, PIPE 1/8" CLOSE SCH 40 BLACK STEEL 2 5
31 5 00912141 0001 ADAPTER, BULKHEAD 1/8" FNPT 2
6 01900216 0555 BRACKET, TIMER D750-900 1
16 7 01900464 0343 DECAL, INST PANEL D750-900 1
30
8 8 01901000 0853 PANEL, INST SHELL D750-900 CUMMINS 1
17
9 05018290 0007 GAUGE, TEMPERATURE 100-280 DEG F 2.00 O.D. 1
10 05018310 0013 GAUGE, PRESSURE 0-300 PSI 3.60 O.D. 1
6
29 11 05018320 0003 GAUGE, FUEL 24V 2.00 O.D. 1
32 12 05018366 0006 GAUGE, DIAGNOSTIC, FULL FEATURE 1
7
13 05018635 0043 LAMP, YELLOW 12V 2
4 4
27 14 05018635 0044 LAMP, RED 12V 2
15 15 05018635 0070 LAMP, ILLUMINATING 24V 2
16 05019085 0017 RELAY, TIMER 24VDC-AC 1S-10MIN 1
10 17 05019085 0018 TIMER RELAY SOCKET 1
37 14 18 05019087 0003 RESISTOR 12V-24V GAUGE CONVERSION 1
28 19 05019820 0002 VALVE 2-WAY 1/4" FNPT BRASS 1
20 00901160 0001 BUSHING, PIPE 1/4 MNPT X 1/8 FNPT 1

21 00915557 0064 ELBOW, 3/8" TUBE X 1/4" MNPT 2
38 22 00915557 0444 ELBOW, 1/4" TUBE X 1/4" MNPT 1
3 27 3
23 01900930 0013 ORIFICE, .031 X 1/8" MNPT BRASS 1
12 5 24 01900930 0016 ORIFICE, .047 X 1/4" MNPT X FNPT BRASS 1
37 13
6.15 INSTRUMENT PANEL ASSEMBLY
25 96399-004 ELBOW, 1/4" MNPT X MNPT STEEL 1

26 00901108 0002 PIPE, CROSS 1/4" 150# GALV 1
37 14 21
27 00915557 0004 ELBOW, 1/4" TUBE X 1/8" MNPT 4
28 00905520 0001 COUPLING, PIPE 1/8" FNPT HEX BRASS 2
3
29 00915564 0444 TEE, MALE RUN 1/4" MNPT X 1/8" TUBE BRASS 1
33 22 30 00901023 0002 ELBOW, PIPE 1/4" FNPT BLACK SCH80 1
31 00905852 0087 SCREW, PHIL PNHEAD 8-32 X 1 2
2 32 00900490 0068 NUT, NYLOK #8-32 2 2
9
34 33 00602114 0005 CIRCUIT BREAKER, 5 AMP PUSH 1
4
19 34 01140275 6001 BOOT, DUST CIRCUIT BREAKER 1
24
35 00602114 0028 SWITCH, CIRCUIT BREAKER 10AMP 1
26 36 00519202 INDICATOR, RESTRICTION AIR CLEANER 2
37 05018634 0006 BULB, 24V 4
35 38 05019087 0008 RESISTOR, TERMINATING, 6-PIN 1
25 NS 00910082 TUBING, NYLON 1/4" BLACK (FEET) 30
20
NS 00910084 TUBING, NYLON 3/8" BLACK (FEET) 6
11 1 NS WD 15093 DIAGRAM, WIRING CUMMINS QSC8.3L 1
23 CHECKED BY: DATE: WWW.SULLIVANPALATEK.COM 1-800-438-6203
36 ANGLES: + OR - 1/2 DEG. JPC 10/21/11 DESCRIPTION
X.XX + OR - 0.020 INST PANEL ASSY.
X.XXX + OR - 0.005 D750-900 CUMMINS
3 MATERIAL: SIZE DRAWING NO: REV
AS NOTED 02
2 D 05018845 0130
FIRST USED ON: D750PHCU SCALE: NTS SHEET 1 OF 3
A B C D E F

A B C D E F
A B ITEM # PART NUMBER DESCRIPTION QTY.
1 01901000 0841 PANEL, SIDE VENTED D750-900 3

2 01901000 0845 PANEL, REAR D750-900 2
E E
5 3 01901000 0846 PANEL, LIFT BAIL HOLE D750-900 2 5
4 01901000 0855 PANEL, SIDE VENTED INVERTED VENTS D750-900 2
5 00900323 0005 WASHER, FLAT, #10 ZINC PLATED 4
6 00900389 0026 BOLT, BUTTON HEAD SCS 1/4-20 X 1 1/2 SST 143
7 00900389 0027 BOLT, BUTTON HEAD SCS 1/4-20 X 3/4 SST 36
8 00900490 0064 NUT, NYLOK #10-24 ZINC PLATED 4
9 00900490 0071 NUT, NYLOK 1/4-20 ZINC PLATE 39
10 00901560 0006 WASHER, FLAT, 1/4" 18-8 SS 39
NUT, TINNERMAN, U-STYLE 1/4-20, .18-.19 PANEL,
11 00909088 0010 .375 CENTER 149
12 00910195 0012 PLUG, HOLE LOCKING .3125 31
13 00916867 0421 RIVET,3/16" X .126 -.250 RANGE 42
4 4
14 00916867 0430 RIVET,5/32" X .126 -.1875 RANGE 16
15 01228269 0020 SPRING 3
16 01900104 0284 ANGLE, DOOR EDGE D750-900 4
D D
17 01900168 0005 BOLT,EYE 1/4-20 ZINC 3
18 01900485 0045 DOOR, ACCESS 3
6.16 ENCLOSURE ASSEMBLY
19 01900485 0054 DOOR, SIDE D750-900 4

20 01900752 0079 HINGE, ACCESS DOOR 3

21 01900752 0093 HINGE, DOOR D750-900 4
22 01901000 0840 PANEL, SIDE CENTER D750-900 3
23 01901000 0842 PANEL, SIDE DOOR HEADER D750-900 4
3 3
24 01901000 0843 PANEL, BLANK D750-900 1
25 01901000 0844 PANEL, FRONT INST PANEL D750-900 1
A B 26 01901000 0848 PANEL, TOP RECEIVER TANK ACCESS D750-900 1
C C
27 01901000 0849 PANEL, TOP ENDS D750-900 2
56.92 28 01901000 0850 PANEL, ACCESS RECEIVER TANK D750-900 1
29 01901000 0862 PANEL, CENTER COVER 2
144.87 30 03903040 0177 BRACKET, SIDE PANELS D750-900 4
F F
31 03903040 0178 BRACKET, END PANELS D750-900 2
32 03903040 0180 BRACKET, CORNER ANGLE D750-900 4
33 03903040 0181 BRACKET, PANEL BACKER D750-900 4
2 34 03903040 0182 BRACKET, TOP ANGLE FRONT STREET D750-900 1 2
35 03903040 0183 BRACKET, TOP ANGLE REAR D750-900 1
36 03903040 0184 BRACKET, TOP ANGLE FRONT CURB D750-900 1
38 05018650 0032 LATCH, T-HANDLE D750-900 4
39 05018460 0003 HOLDER,DOOR (FEMALE) 4
BRACKET, TOP ANGLE REAR CURB STREET D750-
40 03903040 0185 1
900
41 05018460 0003-2 HOLDER,DOOR (MALE) 4
42 93115-001 BOLT, WHIZLOCK 1/4-20 X 3/4 ZINC PLATED 76
43 93165-002 NUT, WHIZ HEX 1/4-20 76
131.65 44 90362-205 BOLT, 10-24 X 1.25 ZINC 4
JW 12/19/11 1201 West US Highway 20, Michigan City IN 46360
TOLERANCES AS FOLLOWS: CHECKED BY: DATE: WWW.SULLIVANPALATEK.COM 1-800-438-6203
ANGLES: + OR - 1/2 DEG. JPC DESCRIPTION
12/19/11
X.XX + OR - 0.020 3RD ANGLE ENCLOSURE ASSY.
X.XXX + OR - 0.005 PROJECTION
D 00717598 0112 01
FIRST USED ON: D750-900 SCALE: DNS SHEET 1 OF 5
A B C D E F
53
54
A B C D E F
5 16 5
19
40
A
22
38 27
3
20 35
4 16 23 4
36 20
18
27 26
38 28 C
24
34 B
29
3 3
32 23
D 38
25
18
2 16 2
30
19
F 22
38
31
E 4
1 30
39 DIMENSIONS ARE IN INCHES JW 12/19/11 SULLIVAN-PALATEK 1
16 ANGLES: + OR - 1/2 DEG. JPC 12/19/11 DESCRIPTION
19 X.XX + OR - 0.020 3RD ANGLE
ENCLOSURE ASSY.
D 00717598 0112 01
A B C D E F

A B C D E F
27 23
5 5
19
35 16
1
4
19
18
40
38
18
23 19
4
20 4
3
2
22 34
32
3 24
19
26

16
29 38
16 28
3 3
27
36
38
30
2 2
22
32
38 8
1
16
30 20
25
21
1 31 TOLERANCES AS FOLLOWS: 1201 West US Highway 20, Michigan City IN 46360
19 X.XX + OR - 0.020 3RD ANGLE
ENCLOSURE ASSY.
32 MATERIAL: SIZE DRAWING NO: REV
D 00717598 0112 01
A B C D E F
55
56
A B C D E F
5 5
4 4
SECTION A-A SECTION B-B

3 3
SECTION C-C SECTION D-D SECTION E-E
2 2

X.XX + OR - 0.020 3RD ANGLE ENCLOSURE ASSY.
D 00717598 0112 01
SECTION F-F FIRST USED ON: D750-900 SCALE: SHEET
DNS 4 OF 5
A B C D E F

A B C D E F
5 5
4 4
DETAIL A DETAIL B DETAIL C DETAIL D
42 19 3

24 33
16
3
38 11 3
14
6
44 5
26
2 2
9
DETAIL E 10 DETAIL F DETAIL H
DETAIL G
15
17
ANGLES: + OR - 1/2 DEG. DESCRIPTION
JPC 12/19/11
32 X.XX + OR - 0.020 3RD ANGLE ENCLOSURE ASSY.
18 D 00717598 0112 01
DETAIL J
A B C D E F
57
58
A B C D E F
1 01900007 0296 ACOUSTIC, 50.00 X 30.00 D750-900 4
2 01900007 0297 ACOUSTIC, 52.5 X 25.0 W HOLE D750-900 2
3 01900007 0298 ACOUSTIC, 20.00 X 20.00 D750-900 1 4
5 5
4 01900007 0295 ACOUSTIC, 52.50 X 25.00 D750-900 4 4
5 01900007 0294 ACOUSTIC, 52.50 X 10.00 D750-900 3 2
6 01900007 0293 ACOUSTIC, 25.00 X 25.00 D750-900 3
4
5
4 6 4
6.17 ACOUSTICS ASSEMBLY
3
3 3
4
5
1 1
2 2

X.XX + OR - 0.020 ACOUSTICS ASSY,
X.XXX + OR - 0.005 D750-900
AS NOTED 00717100 0010 00
D
A B C D E F

A B C D E F
1 00900016 0116 BOLT, .750-10 X 3.500 HEX HD GR 8 12
2 00900321 0007 WASHER,FLAT 3/4" ZINC PLATED 12
3 03903009 0065 LIFTING BAIL, D750-900 1
5 5
4 03903313 0087 FRAME, D750-900 1
4 4
6.18 CHASSIS ASSEMBLY

2 1
3 3
2 2
1 2
TO ALL BOLTS:
LOCTITE 242
1
LOCTITE 'VIPER LUBE' CLEAR UNLESS OTHERWISE NOTED DRAWN BY: DATE:
HIGH PERFORMANCE SYNTHETIC TOLERANCES AS FOLLOWS: 1201 West US Highway 20, Michigan City IN 46360
ANGLES: + OR - 1/2 DEG. MFP DESCRIPTION
GREASE DECIMAL: X.X + OR - 0.050
X.XX + OR - 0.020 CHASSIS ASSY, D750-900
X.XXX + OR - 0.005

D
LOCTITE 567 THREAD SEALANT FIRST USED ON: D900PHCU SCALE: DNS SHEET 1 OF 1
A B C D E F
59
60
A B C D E F
1 05017120 0400 AXLE, 6000 LBS SLIPPER SPRING UNDERSLUNG ELE & PARK BRAKES 1 NOTE:
2 05017120 0402 AXLE, 6000 LBS SLIPPER SPRING UNDERSLUNG ELE BRAKES 1 1. CONSULT SUPPLIED AXLE MANUFACTURER MANUAL FOR PROPER ASSEMBLY PROCEDURES
3 05018730 0112 MANUAL, AXLE ( NOT SHOWN) 1 AND TORQUE SPECS.
4 05017120 0393 AXLE, TANDEM SLIPPER SPRING PARTS KIT 1
5 4.1 KEEPER NUT 4 5
4.2 KEEPER BOLT 4
4.3 9/16-18 LOCKNUT 4
4.4 SPRING EYE BOLT 4
4.5 EQUALIZER NUT 2
4.6 EQUALIZER BOLT 2
4.7 EQUALIZER 2
4.2
6.19 AXLE ASSEMBLY
4 REAR OF MACHINE 4
2
4.1
4.7
4.3
4.4
4.5
4.4 4.1
3 4.6 3
4.2 4.1 4.3 4.4

4.7
4.2
4.3
4.6
2 4.5 2
4.1 4.2
4.4
4.3
3
1

DIMENSIONS ARE IN INCHES 7/25/11 SULLIVAN-PALATEK 1
JPC 1201 West US Highway 20, Michigan City IN 46360
FRONT OF MACHINE X.XX + OR - 0.020 AXLE, ASSY 12000 LBS SLIPPER
3RD ANGLE
X.XXX + OR - 0.005 PROJECTION SPRING UNDERSLUNG ELE & PARK BRAKES
(DRAWBAR END)
AS NOTED 05017120 0397 00
D
FIRST USED ON: D900PHCA SCALE: 1:5 SHEET 1 OF 2
A B C D E F

A B C D E F

1 01901704 0003 RIM, 14.50 DIA. X 8 LUG ON 6.50 B.BC 1
2 01901550 0030 TIRE 27.50 DIA. X 8.00 WIDE X 14.50 RIM 1
5
5
2
4 4

6.20 TIRE AND WHEEL ASSEMBLY
3
3
2
2
UNLESS OTHERWISE NOTED DRAWN BY: DATE:

DIMENSIONS ARE IN INCHES JPC 8/24/11 SULLIVAN-PALATEK
X.XX + OR - 0.020 WHEEL AND TIRE ASSY, 27.50 DIA. X 1
X.XXX + OR - 0.005 8.00 WIDE X 14.50 RIM, 8 LUG ON 6.50 B.C.
1
B 05019880 0042 00
FIRST USED ON: SCALE: 1: SHEET 1 OF 1
A B C D E F
61
62
A B C D E F
1 00900016 0056 BOLT, .7500-10 X 2.000 HEX HD GR 8 4
2 00900016 0076 BOLT, .7500-10 X 2.500 HEX HD GR 8 12
3 00900016 0077 BOLT, HHCS 7/8-9 X 2 1/2 GR8 ZINC PLATED 4
5 11 5
4 00900016 0095 SCREW, 5/8-11X3" LG GD8 7
5 00900305 0068 LOCKWASHER,SPRING,7/8" ZINC PL 12 1
6 00900490 0094 NUT, NYLOC 7/8-9 ZINC PLATED 4
7 00900490 0117 NUT,NYLOK 3/4-10 ZINC PLATED 4
8 00900490 0128 NUT,NYLOK 5/8-11 ZINC PLATED 7
9 01900896 0001 LUNETTE EYE, 3.0 ID 7-BOLT FLAT 1
10 03903136 0176 DRAWBAR, A-FRAME D750-900 1
11 03903263 JACK ASSY / D750Q7 - D1800QC 1
4 12 03903464 0225 SUPPORT, TOW RING 3.0 EYE 7-BOLT 1 4

10
6.21 DRAWBAR ASSEMBLY
TORQUE SPECS (FOR GRADE 8 BOLTS) SECTION OF FRAME REMOVED

BOLT SIZE LB-FT DRY LB-FT WET TO SHOW FASTENERS
5/8-11 220 170
3/4-10 380 280

7/8-9 600 460
3 3
7
4
5
2
2 2
12 3

TO ALL BOLTS: 6
5
LOCTITE 242
LOCTITE 'VIPER LUBE' CLEAR 9
HIGH PERFORMANCE SYNTHETIC TOLERANCES AS FOLLOWS: 1201 West US Highway 20, Michigan City IN 46360
GREASE DECIMAL: X.X + OR - 0.050
2 X.XX + OR - 0.020 DRAWBAR ASSY,
X.XXX + OR - 0.005 D750-900
TO ALL PIPE THREADS: 8 AS NOTED 00717554 0090 00
D
LOCTITE 567 THREAD SEALANT FIRST USED ON: D900PHCU SCALE: DNS SHEET 1 OF 1
A B C D E F

A B C D E F
ITEM DESCRIPTION QTY. PART NUMBER
1 HOOK, EYE HOIST, SZ. 26 1 00902033 0026
2 SHACKLE, CHAIN 5/8 NOMINAL 4 00902050 0006
3 CHAIN, SAFETY 5/8" PROOF 1 01900251 0003
5 5
1
4 4
2

6.22 SAFETY CHAIN ASSEMBLY
2
3 3
2
3
2 2
3
UNLESS OTHERWISE NOTED

. . . . G
DIMENSIONS ARE IN INCHES CAD BY: SWG CLAREMONT, NH
. . . . F TOLERANCES AS FOLLOWS:
ANGLES: + OR - .5
MICHIGAN CITY, IN
. . . . E DECIMAL: X.X + OR - 0.050
X.XX + OR - 0.020 THIRD ANGLE
. . . . D X.XXX + OR - 0.005 PROJECTION
1 SAFETY CHAIN ASSEMBLY 1
. . . . C MATERIAL:
SIZE DRAWING NO: REV
. . . . B
.
. . . . A . D 05017495 0022 -
PHD RELEASED FOR PRODUCTION ORIG DO NOT SCALE DRAWING SCALE: 1 : 2 SHEET 1 OF 1
APPROVED DESCRIPTION DATE E.O. NO. REV
IT IS LOANED SUBJECT TO RETURN UPON DEMAND, IS NOT TO BE USED DIRECTLY OR INDIRECTLY IN ANY WAY DETRIMENTAL TO SULLIVAN-PALATEK'S INTEREST.
A B C D E F
63

Users Manual D750-900phcu (Rev 01)

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JANUARY

Document: 05018730 0118 / 01

Model Number: ___________________

Serial Number: ____________________

SULLIVAN-PALATEK USER’S MANUAL v

vi SULLIVAN-PALATEK USER’S MANUAL

1.2 TOWING AND EQUIPMENT

1.3 DRAWBARS AND BRAKE ACTUATORS

SULLIVAN-PALATEK USER’S MANUAL 1

1.4 TOWING SAFETY

2 SULLIVAN-PALATEK USER’S MANUAL

1.5 PARKING OR LOCATING COMPRESSOR

SULLIVAN-PALATEK USER’S MANUAL 3

1.6 PRESSURE RELEASE

4 SULLIVAN-PALATEK USER’S MANUAL

1.7 FIRES AND EXPLOSION

SULLIVAN-PALATEK USER’S MANUAL 5

1.8 MOVING PARTS

1.9 HOT SURFACES, SHARP EDGES, SHARP CORNERS, AND VACUUM

6 SULLIVAN-PALATEK USER’S MANUAL

1.10 TOXIC AND IRRITATING SUBSTANCES

SULLIVAN-PALATEK USER’S MANUAL 7

1.11 ELECTRICAL SHOCK

1.14 JUMP STARTING

8 SULLIVAN-PALATEK USER’S MANUAL

SULLIVAN-PALATEK USER’S MANUAL 9

10 SULLIVAN-PALATEK USER’S MANUAL

2.4 PRINCIPLES OF OPERATION

SULLIVAN-PALATEK USER’S MANUAL 11

OIL RETURN LINE

2.5 INSTRUMENT PANEL AND OPERATING CONTROLS

12 SULLIVAN-PALATEK USER’S MANUAL

ENGINE OIL PRESSURE GAUGE (OPTIONAL)

SULLIVAN-PALATEK USER’S MANUAL 13

14 SULLIVAN-PALATEK USER’S MANUAL

3.2 PREPARATION FOR INITIAL START-UP

3.3 NORMAL STARTING

SULLIVAN-PALATEK USER’S MANUAL 15

3.4 NORMAL STOPPING

3.5 EMERGENCY STOP

3.6 OPERATING UNDER EXTREME CONDITIONS

COLD WEATHER OPERATION

16 SULLIVAN-PALATEK USER’S MANUAL

3.7 OPERATING SUGGESTIONS

3.8 LOW FUEL WARNING LIGHT (CUMMINS)

SULLIVAN-PALATEK USER’S MANUAL 17

18 SULLIVAN-PALATEK USER’S MANUAL

SULLIVAN-PALATEK USER’S MANUAL 19

4.2 WEATHER-ALL™ COMPRESSOR FLUID

PRODUCT FEATURES AND BENEFITS

Service interval may be shorter depending on operating conditions.

20 SULLIVAN-PALATEK USER’S MANUAL

4.3 COMPRESSOR LUBRICANT USE AND SERVICING

4.4 COMPRESSOR OIL SUMP FILL, LEVEL AND DRAIN

4.5 ENGINE LUBRICATION

SULLIVAN-PALATEK USER’S MANUAL 21

4.7 CONTROL LINKAGE

4.8 AIR INTAKE FILTER

4.9 OIL RETURN LINE

4.10 COMPRESSOR OIL FILTER

BEFORE CHANGING EITHER TYPE OF OIL FILTER:

22 SULLIVAN-PALATEK USER’S MANUAL

4.11 AIR/OIL SEPARATOR