PORTABLE

AIR COMPRESSOR
185H, 210H, 260 CFM
CATERPILLAR & JOHN DEERE

OPERATORS
MANUAL AND
PARTS LIST
KEEP FOR
FUTURE
REFERENCE
Part Number

02250156---375
Sullair Corporation

The information in this document is

correct at the time of printing for
Portable Compressor Serial Number

004 150300
and all subsequent Serial Numbers.
 AIR CARE
SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands---on instruction in the
proper operation, maintenance and service of Sullair equipment. Individual
seminars on Portable compressors are presented at regular intervals
throughout the year at a dedicated training facility at the Sullair corporate
headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service
parts, troubleshooting of the most common problems, and actual equipment
operation. The seminars are recommended for rental house and Contractor
Maintenance and service personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department
1---888---SULLAIR or 219---879---5451 (ext. 5363)
www.sullair.com
--- Or Write ---
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department
 TABLE OF CONTENTS

OPERATOR IS REQUIRED TO READ

ENTIRE INSTRUCTION MANUAL

Section 1
SAFETY 1 1.1 GENERAL

1 1.2 TOWING
3 1.3 PRESSURE RELEASE
4 1.4 FIRE AND EXPLOSION
5 1.5 MOVING PARTS
5 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
5 1.7 TOXIC AND IRRITATING SUBSTANCES
6 1.8 ELECTRICAL SHOCK
6 1.9 LIFTING
6 1.10 ENTRAPMENT
7 1.11 JUMP STARTING

Section 2
DESCRIPTION 9 2.1 INTRODUCTION

9 2.2 DESCRIPTION OF COMPONENTS

10 2.3 SULLAIR COMPRESSOR UNIT,
FUNCTIONAL DESCRIPTION
11 2.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
11 2.5 COMPRESSOR DISCHARGE SYSTEM,
FUNCTIONAL DESCRIPTION
12 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
15 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
15 2.8 INSTRUMENT PANEL GROUP,
FUNCTIONAL DESCRIPTION
15 2.9 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION
16 2.10 SHUTDOWN SYSTEM, FUNCTIONAL DESCRIPTION

Section 3
SPECIFICATIONS 21 3.1A SPECIFICATIONS --- JOHN DEERE

22 3.1B SPECIFICATIONS --- CATERPILLAR

23 3.2 LUBRICATION GUIDE
23 3.3 APPICATION GUIDE
23 3.4 LUBRICATION GUIDE --- ENGINE
 TABLE OF CONTENTS

Section 4
OPERATION 25 4.1 GENERAL

25 4.2 PURPOSE OF CONTROLS

26 4.3 START--- UP PROCEDURE
26 4.4 SUBSEQUENT START--- UP PROCEDURE
26 4.5 SHUTDOWN PROCEDURE

Section 5
MAINTENANCE 27 5.1 GENERAL

27 5.2 DAILY OPERATION

27 5.3 MAINTENANCE AFTER INITIAL 50 HOURS
OF OPERATION
27 5.3A MAINTENANCE EVERY 50 HOURS
27 5.4 MAINTENANCE EVERY 100 HOURS
27 5.5 MAINTENANCE EVERY 250 HOURS
28 5.6A MAINTENANCE EVERY 1500 HOURS OR ANUALLY
28 5.6B MAINTENANCE EVERY YEAR OR 12,000 MILES
28 5.7 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
28 COMPRESSOR FLUID CHANGE PROCEDURE
28 COMPRESSOR FLUID FILTER ELEMENT REPLACEMENT
28 AIR FILTER MAINTENANCE
29 SPEARATOR ELEMENT REPLACEMENT
29 PROCEDURE FOR SETTING SPEED AND PRESSURE CONTROLS
ON PORTABLE COMPRESSOR WITH POPPET VALVE
31 BEARING LUBRICATION
31 5.8 TROUBLESHOOTING --- INTRODUCTION
32 5.9 TROUBLESHOOTING --- GUIDE

Section 6
NOISE CONTROL 37 6.1 NOISE EMISSIONS WARRANTY

37 6.2 TAMPERING WITH NOISE CONTROL

SYSTEM PROHIBITED
37 6.3 NOISE EMISSIONS MAINTENANCE AND
MAINTENANCE RECORD LOG

Section 7
ILLUSTRATIONS AND
PARTS LIST 41 7.1 PROCEDURE FOR ORDERING PARTS

42 7.2 RECOMMENDED SPARE PARTS LIST

44 7.3A ENGINE, COMPRESSOR & PARTS--- 185H & 210H CATERPILLAR
48 7.3B ENGINE, COMPRESSOR & PARTS--- 260 CATERPILLAR
52 7.3C ENGINE, COMPRESSOR & PARTS--- 185H & 210H JOHN DEERE
56 7.3D ENGINE, COMPRESSOR & PARTS--- 260 JOHN DEERE
60 7.4A AIR INLET AND EXHAUST --- ALL CATERPILLAR MODELS
62 7.4B AIR INLET AND EXHAUST --- ALL JOHN DEERE MODELS
 TABLE OF CONTENTS

Section 7
ILLUSTRATIONS AND
PARTS LIST (CONT) 64 7.5 AIR INLET VALVE ASSEMBLY --- 260 JOHN DEERE
AND CATERPILLAR
66 7.6 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM ---
ALL MODELS

70 7.7A FRAME, RUNNING GEAR & PARTS --- ALL MODELS

74 7.7B FRAME, LESS RUNNING GEAR & PARTS --- ALL MODELS
78 7.8 DISCHARGE SYSTEM AND PARTS --- ALL MODELS
82 7.9A REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY ---
ALL 185H & 210H MODELS
82 7.9B REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY ---
ALL 260 MODELS
84 7.10 ELECTRIC PARTS --- ALL MODELS
86 711A FUEL TANK AND PARTS --- ALL CATERPILLAR MODELS
88 7.11B FUEL TANK AND PARTS --- ALL JOHN DEERE MODELS
90 7.12 CANOPY, ACOUSTICAL PANELS & PARTS--- ALL MODELS
94 7.13 INSTRUMENT PANEL & PARTS--- ALL MODELS
96 7.14A INSTRUMENT PANEL AND PARTS --- 185H AND 210H
CATERPILLAR (STANDARD GAUGE)
98 7.14B INSTRUMENT PANEL AND PARTS --- --- 260 CATERPILLAR
(STANDARD GAUGE)
100 7.14C INSTRUMENT PANEL AND PARTS --- 185H AND 210H
JOHN DEERE (STANDARD GAUGE)
102 7.14D INSTRUMENT PANEL AND PARTS --- 260 JOHN DEERE
(STANDARD GAUGE)
104 7.14E INSTRUMENT PANEL AND PARTS --- 185H AND 210H
CATERPILLAR (FULL GAUGE)
106 7.14F INSTRUMENT PANEL AND PARTS --- 260 CATERPILLAR
(FULL GAUGE)
108 7.14G INSTRUMENT PANEL AND PARTS --- 185H AND 210H
JOHN DEERE (FULL GAUGE)
110 7.14H INSTRUMENT PANEL AND PARTS --- 260 JOHN DEERE
(FULL GAUGE)
112 7.15 SINGLE HOSE REEL OPTION --- ALL MODELS
114 7.16 DUAL HOSE REEL OPTION--- ALL MODELS
116 7.17 ONE PINT OILER OPTION--- ALL MODELS
118 7.18 ONE QUART OILER / MOISTURE SEPARATOR OPTION ---
ALL MODELS
120 7.19 CANADIAN TAIL / CLEARANCE LIGHTS --- ALL MODELS
122 7.20 DECALS
132 7.21 DECAL LOCATIONS
134 7.22 DRAWBAR AND PARTS--- ALL MODELS
 Section 1
SAFETY

1.1 GENERAL dented or otherwise deformed or degraded, and

Sullair Corporation designs and manufactures all (iii) loose nuts, bolts or other fasteners. Should
of its products so they can be operated safely. any such condition be present, DO NOT TOW
However, the responsibility for safe operation rests until the problem is corrected.
with those who use and maintain these products. 2. Back the tow vehicle to the compressor and
The following safety precautions are offered as a position it in preparation for coupling the com-
guide which, if conscientiously followed, will mini- pressor.
mize the possibility of accidents throughout the
useful life of this equipment. Read the CIMA Safety 3. If the compressor is provided with a drawbar
Manual prior to compressor operation and towing, latched in the vertical upright position, carefully
if applicable in your area. unlatch drawbar and lower it to engage the cou-
pling device. If not, raise drawbar to engage
The air compressor should be operated only by coupling device or otherwise couple the com-
those who have been trained and delegated to do pressor to the towing vehicle.
so, and who have read and understood this Opera-
tors Manual. Failure to follow the instructions, pro- ! WARNING
cedures and safety precautions in this manual can
result in accidents and injuries. This equipment may be tongue heavy. DO NOT
attempt to raise or lower the drawbar by hand if
NEVER start the air compressor unless it is safe to the weight is more than you can safely handle.
do so. DO NOT attempt to operate the air compres-
sor with a known unsafe condition. Tag the air com- Use the screw jack provided or a chain fall if you
pressor and render it inoperative by disconnecting cannot lift or lower it without avoiding injury to
the battery so others who may not know of the un- yourself or others. Keep hands and fingers clear
safe condition will not attempt to operate it until the of the coupling device and all other pinch points.
condition is corrected. Keep feet clear of drawbar to avoid injury in case
Use and operate the air compressor only in full it should slip from your hands.
compliance with all pertinent OSHA requirements 4. Make sure the coupling device is fully en-
and/or all pertinent Federal, State and Local codes gaged, closed and locked.
or requirements. 5. If chains are provided, pass each chain
DO NOT modify the compressor except with writ- through its point of attachment on the towing ve-
ten factory approval. hicle; then hook each chain to itself by passing
Each day walk around the air compressor and in- the grab hook over (not through) a link. Cross
spect for leaks, loose or missing parts, damaged chains under front of drawbar before passing
parts or parts out of adjustment. Perform all recom- them through points of attachment on towing
mended daily maintenance. vehicle to support front of drawbar in case it
should accidentally become uncoupled.
Inspect for torn, frayed, blistered or otherwise dete-
riorated and degraded hoses. Replace as re- 6. Make sure that the coupling device and adja-
quired. cent structures on the towing vehicle (and also, if
utilized, chain adjustment, brake and/or electri-
cal interconnections) DO NOT interfere with or
NOTE restrict motion of any part of the compressor, in-
Estimated hose life based on a 5---day 8---hour cluding its coupling device, with respect to the
work week is 3 years. These conditions exist on towing vehicle when maneuvering over any an-
an 8---hour shift only. Any other operation of the ticipated terrain.
equipment other than 8---hour shifts would short-
en the hose life based on hours of operation. 7. If provided, make sure chain length, brake
and electrical interconnections provide suffi-
cient slack to prevent strain when cornering and
1.2 TOWING (I) maneuvering, yet are supported so they cannot
A. PREPARING TO TOW drag or rub on road, terrain or towing vehicle sur-
faces which might cause wear that could render
! WARNING them inoperative.
DO NOT tow the compressor should its weight ex-
ceed the rated limit of the tow vehicle, as the vehi- ! WARNING
cle may not brake safely with excess weight. See
rated limit in tow vehicle Operators Manual, and Retract the front screw jack only after attaching
review its instructions and other requirements for the compressor to the tow vehicle. Raise the
safe towing. screw jack to its full up position and pull the pin
connecting the jack to the drawbar. Rotate the
screw jack to its stowed position, parallel to the
drawbar, and reinsert the pin. Make sure the jack
1. Prior to hitching the air compressor to the tow is secured in place prior to towing.
vehicle, inspect all attachment parts and equip- If a caster wheel is provided on the screw jack it is
ment, checking for (i) signs of excessive wear or part of the screw jack and can not be removed.
corrosion, (ii) parts that are cracked, bent, Follow the same procedure for stowing away the

1
Section 1
SAFETY

wheeled jack as you would for the standard screw 17. DO NOT load this equipment with accesso-
jack. Pull the pin connecting the jack to the draw- ries or tools such that it is unbalanced from side
bar and raise the screw jack to its full up position.
Rotate the screw jack to its stowed position, par- to side or front to back. Such unbalance will re-
allel to the drawbar, and reinsert the pin. Make duce the towability of this equipment and may
sure the jack is secured in place prior to towing. increase the possibility of tipping, rolling over,
jackknifing, etc. Loss of control of the towing ve-
! WARNING hicle may result.
This equipment may be tongue heavy. DO NOT B. TOWING
attempt to raise or lower the drawbar by hand if 1. Observe all Federal, State, and Local laws
the weight is more than you can safely handle.
while towing this equipment (including those
specifying minimum speed).
8. On two---wheeled models, fully retract front 2. DO NOT exceed the towing speeds listed be-
screw jack and any rear stabilizer legs. If a cast- low under ideal conditions. Reduce your speed
er wheel is provided on the screw jack it is part of according to posted speed limits, weather, traf-
the screw jack and can not be removed. Follow fic, road or terrain conditions.
the same procedure for stowing away the a. Two axle four---wheel steerable models:
wheeled jack as you would for the standard 15MPH (24KMPH).
screw jack. Pull the pin connecting the jack to
the drawbar and raise the screw jack to its full up b. All other models: 55 MPH (88KMPH).
position. Rotate the screw jack to its stowed 3. Remember that the portable air compressor
position, parallel to the drawbar, and reinsert the may approach or exceed the weight of the tow-
pin. Make sure the jack is secured in place prior ing vehicle. Maintain increased stopping dis-
to towing. tances accordingly. DO NOT make sudden lane
changes, U ---turns, or other maneuvers. Such
9. Make sure tires are in good condition and are maneuvers can cause the compressor to tip, roll
the size (load range) specified and are inflated to over, jackknife or slide and cause loss of control
the specified pressures. DO NOT change the of the towing vehicle. Tipping, rolling over, etc.
tire size or type. Also, make sure wheel bolts, can occur suddenly without warning. U ---turns
lugs or nuts are tightened to the specified especially should be made slowly and carefully.
torques.
4. Avoid grades in excess of 15_ (27%).
10. If provided, make sure all dual stop, tail direc-
tional and clearance lights are operating prop- 5. Avoid potholes, rocks and other obstructions,
erly and that their lenses are clean and func- and soft shoulders or unstable terrain.
tional. Also, make sure all reflectors and reflect- 6. Maneuver in a manner that will not exceed the
ing surfaces, including the slow moving vehicle freedom of motion of the compressors drawbar
emblem on compressors provided with same, and/or coupling device, in or on the towing ve-
are clean and functional. hicles coupling device and/or adjacent struc-
ture whether towing forward or backing up, re-
11. Make sure all service air hoses (not air brake gardless of the terrain being traversed.
hoses) are disconnected or are fully stowed and
secured on hose reels, if provided. 7. DO NOT permit personnel to ride in or on the
compressor.
12. Make sure all access doors and tool box cov- 8. Make sure the area behind, in front of, and un-
ers are closed and latched. If the compressor is der the compressor is clear of all personnel and
large enough to hold a man, make sure all per- obstructions prior to towing in any direction.
sonnel are out before closing and latching ac-
cess doors. 9. DO NOT permit personnel to stand or ride on
the drawbar, or to stand or walk between the
13. Make sure parking brakes in towing vehicle compressor and the towing vehicle.
are set, or that its wheel are chocked or blocked,
or that it is otherwise restrained from moving. C. PARKING OR LOCATING COMPRESSOR
Then, release the compressor parking brakes, if 1. Park or locate compressor on a level surface,
provided. if possible. If not, park or locate compressor
across grade so the compressor does not tend
14. Make sure the compressor wheels are not to roll downhill. DO NOT park or locate com-
chocked or blocked, and that all tie---downs, if pressor on grades exceeding 15_ (27%).
any, are free.
2. Make sure compressor is parked or located
15. Test running brake operation, including on a firm surface than can support its weight.
breakaway switch operation if provided, before 3. Park or locate compressor so the wind, if any,
attempting to tow the compressor at its rated
speed or less when conditions prevail. tends to carry the exhaust fumes and radiator
heat away from the compressor air inlet open-
16. DO NOT carry loose or inappropriate tools, ings, and also where the compressor will not be
equipment or supplies on or in the compressor. exposed to excessive dust from the work site.

2
 Section 1
SAFETY

4. On four---wheel models, park compressor curely latched in the vertical upright position.
with front wheels in straight ahead position. Keep feet clear of drawbar at all times to avoid
5. Set parking brakes and disconnect crushing accidents in case it should slip from
breakaway switch cable and all other intercon- your hands or otherwise fall to the ground.
necting electrical and/or brake connections, if 12. Move the towing vehicle well clear of the
provided. parked compressor and erect hazard indica-
6. Block or chock both sides of all wheels. tors, barricades and/or flares (if at night) if com-
pressor is parked on or adjacent to public roads.
7. If provided, unhook chains and remove them Park so as not to interfere with traffic.
from the points of chain attachment on the tow-
ing vehicle, then hook chains to bail on drawbar
or wrap chains around the drawbar and hook (I) While not towed in the usual sense of the word,
them to themselves to keep chains off the many of these instructions are directly applica-
ground which might accelerate rusting. ble to skid---mounted portable air compressors
as well.
8. Lower front screw jack and/or any front and
rear stabilizer legs. Make sure the surface they 1.3 PRESSURE RELEASE
contact has sufficient load bearing capability to A. Open the pressure relief valve at least weekly to
support the weight of the compressor. make sure it is not blocked, closed, obstructed or
otherwise disabled.
! WARNING
B. Install an appropriate flow ---limiting valve be-
Retract the front screw jack only after attaching tween the compressor service air outlet and the
the compressor to the tow vehicle. Raise the shutoff (throttle) valve, when an air hose exceed-
screw jack to its full up position and pull the pin
connecting the jack to the drawbar. Rotate the
ing 1/2 (13mm) inside diameter is to be connected
screw jack to its stowed position, parallel to the to shut ---off (throttle) valve, to reduce pressure in
drawbar, and reinsert the pin. Make sure the jack case of hose failure, per OSHA Standard 29 CFR
is secured in place prior to towing. 1926.302 (b) (7) or any applicable Federal, State
If a caster wheel is provided on the screw jack it is and Local codes, standards and regulations.
part of the screw jack and can not be removed.
Follow the same procedure for stowing away the C. When the hose is to be used to supply a mani-
wheeled jack as you would for the standard screw fold, install an additional appropriate flow ---limiting
jack. Pull the pin connecting the jack to the draw-
bar and raise the screw jack to its full up position. valve between the manifold and each air hose ex-
Rotate the screw jack to its stowed position, par- ceeding 1/2 (13mm) inside diameter that is to be
allel to the drawbar, and reinsert the pin. Make connected to the manifold to reduce pressure in
sure the jack is secured in place prior to towing. case of hose failure.
! WARNING D. Provide an appropriate flow ---limiting valve for
This equipment may be tongue heavy. DO NOT
each additional 75 feet (23 meters) of hose in runs
attempt to raise or lower the drawbar by hand if of air hose exceeding 1/2 (13mm) inside diameter
the weight is more than you can safely handle. to reduce pressure in case of hose failure.
E. Flow ---limiting valves are listed by pipe size and
9. If a caster wheel is provided on the screw jack rated CFM. Select appropriate valve accordingly.
it is part of the screw jack and can not be re-
moved. Follow the same procedure for stowing F. DO NOT use tools that are rated below the maxi-
away the wheeled jack as you would for the mum rating of this compressor. Select tools, air
standard screw jack. Raise the screw jack to its hoses, pipes, valves, filters and other fittings ac-
full up position and pull the pin connecting the cordingly. DO NOT exceed manufacturers rated
jack to the drawbar. Rotate the screw jack to its safe operating pressures for these items.
stowed position, parallel to the drawbar, and re- G. Secure all hose connections by wire, chain or
insert the pin. Make sure the jack is secured in other suitable retaining device to prevent tools or
place prior to towing. hose ends from being accidentally disconnected
10. Disconnect coupling device, keeping hands and expelled.
and fingers clear of all pinch points. If the com-
pressor is provided with a drawbar, DO NOT at- H. Open fluid filler cap only when compressor is
tempt to lift the drawbar or if hinged, to raise it to not running and is not pressurized. Shut down
the upright position, by hand, if the weight is the compressor and bleed the sump (receiver) to
more than you can safely handle. Use a screw- zero internal pressure before removing the cap.
jack or chain fall if you cannot lift or raise the I. Vent all internal pressure prior to opening any
drawbar without avoiding injury to yourself or line, fitting, hose, valve, drain plug, connection or
others. other component, such as filters and line oilers,
11. When possible, stow hinged drawbar in the and before attempting to refill optional air line anti---
vertical upright position. Make certain it is se- icer systems with antifreeze compound.

3
Section 1
SAFETY

J. Keep personnel out of line with and away from D. DO NOT permit liquids, including air line anti---
the discharge opening of hoses, tools or other icer system antifreeze compound or fluid film to ac-
points of compressed air discharge. cumulate on bottom covers or on, under or around
acoustical material, or on any external or internal
K. DO NOT use air at pressures higher than 30 surfaces of the air compressor. Wipe down using
psig (2.1 bar) for cleaning purposes, and then only an aqueous industrial cleaner or steam clean as re-
with effective chip guarding and personal protec- quired. If necessary remove acoustical material,
tive equipment per OSHA Standard 29 CFR clean all surfaces and then replace acoustical ma-
1910.242 (b) or any applicable Federal, State and terial. Any acoustical material with a protective cov-
Local codes, standards and regulations. ering that has been torn or punctured should be re-
placed immediately to prevent accumulation of liq-
L. DO NOT engage in horseplay with air hoses as uids or fluid film within the material. DO NOT use
death or serious injury may result. flammable solvents for cleaning purposes.
M. This equipment is supplied with an ASME de- E. Disconnect the grounded (negative) battery
signed pressure vessel protected by an ASME connection prior to attempting any repairs or clean-
rated relief valve. Lift the handle once a week to ing inside the enclosure. Tag the battery connec-
make sure the valve is functional. DO NOT lift the tions so others will not unexpectedly reconnect it.
handle while machine is under pressure. F. Keep electrical wiring, including the battery ter-
minals and other terminals, in good condition. Re-
N. If the machine is installed in an enclosed area it is place any wiring that has cracked, cut abraded or
necessary to vent the relief valve to the outside of otherwise degraded insulation or terminals that are
the structure or to an area of non---exposure. worn, discolored or corroded. Keep all terminals
O. DO NOT remove radiator filler cap until the cool- clean and tight.
ant temperature is below its boiling point. Then G. Turn off battery charger before making or break-
loosen cap slowly to its stop to relieve any excess ing connections to the battery.
pressure and make sure coolant is not boiling be-
fore removing cap completely. Remove radiator H. Keep grounded conductive objects such as
filler cap only when cool enough to touch with a tools away from exposed live electrical parts such
bare hand. as terminals to avoid arcing which might serve as a
source of ignition.
P. The ethyl ether in the replaceable cylinders used I. Replace damaged fuel tanks or lines immediately
in diesel ether starting aid systems (optional) is un- rather than attempt to weld or otherwise repair
der pressure. DO NOT puncture or incinerate them. DO NOT store or attempt to operate the
those cylinders. DO NOT attempt to remove the compressor with any known leaks in the fuel sys-
center valve core or side pressure relief valve from tem. Tag the compressor and render it inoperative
these cylinders regardless of whether they are full until repair can be made.
or empty.
J. Remove any acoustical material or other material
Q. If a manual blowdown valve is provided on the that may be damaged by heat or that may support
receiver, open the valve to insure all internal pres- combustion prior to attempting weld repairs. Re-
sure has been vented prior to servicing any pres- move diesel engine ether starting aid cylinders and
surized component of the compressor air/fluid sys- air line anti---icer system components containing
tem. antifreeze compound, prior to attempting weld re-
pairs in any place other than the fuel system. DO
1.4 FIRE AND EXPLOSION NOT weld on or near the fuel system.
A. Refuel at a service station or from a fuel tank de-
signed for its intended purpose. If this is not possi- K. Keep a suitable fully charged class BC or ABC
ble, ground the compressor to the dispenser prior fire extinguisher or extinguishers nearby when
to refueling. servicing and operating the compressor.
L. Keep oily rags, trash, leaves, litter or other com-
B. Clean up spills of fuel, fluid, battery electrolyte or bustibles out of and away from the compressor.
coolant immediately if such spills occur.
M. Open all access doors and allow the enclosure
C. Shut off air compressor and allow it to cool. to ventilate thoroughly prior to attempting to start
Then keep sparks, flames and other sources of ig- the engine.
nition away and DO NOT permit smoking in the vi- N. DO NOT operate compressor under low over-
cinity when adding fuel, or when checking or add- hanging leaves or permit such leaves to contact hot
ing electrolyte to batteries, or when checking or exhaust system surfaces when operating the com-
adding fluid, or when checking diesel engine ether pressor in forested areas.
starting aid systems or replacing cylinders, or
when refilling air line anti---icer systems antifreeze O. Ethyl ether used in diesel engine ether starting
compound. aid systems is extremely flammable. Change cylin-

4
 Section 1
SAFETY

ders, or maintain or troubleshoot these systems battery connection so others will not unexpectedly
only in well---ventilated areas away from heat, open reconnect it.
flame or sparks. DO NOT install, store or otherwise
expose ether cylinders to temperatures above H. When adjusting the controls, it may require op-
160_F (71_C). Remove ether cylinder from the eration of the equipment during adjustment. DO
compressor when operating in ambient tempera- NOT come in contact with any moving parts while
tures above 60_F (16_C). adjusting the control regulator and setting the en-
gine RPM. Make all other adjustments with the en-
P. DO NOT attempt to use ether as a starting aid in gine shut off. When necessary, make adjustment,
gasoline engines or diesel engines with glow plugs other than setting control regulator and engine
as serious personnel injury or property damage RPM, with the engine shut off. If necessary, start the
may result. engine and check adjustment. If adjustment is in-
correct, shut engine off, readjust, then restart the
Q. DO NOT spray ether into compressor air filter or engine to recheck adjustment.
into an air filter that serves both the engine and the
compressor as serious damage to the compressor I. Keep hands, feet, floors, controls and walking
or personal injury may result. surfaces clean and free of fluid, water, antifreeze or
other liquids to minimize possibility of slips and
R. Antifreeze compound used in air line anti---icer falls.
systems contains methanol which is flammable.
Use systems and refill with compound only in well--- 1.6 HOT SURFACES, SHARP EDGES AND SHARP
ventilated areas away from heat, open flames or CORNERS
sparks. DO NOT expose any part of these systems A. Avoid bodily contact with hot fluid, hot coolant,
or the antifreeze compound to temperatures above hot surfaces and sharp edges and corners.
150_F (66_C). Vapors from the antifreeze com- B. Keep all parts of the body away from all points of
pound are heavier than air. DO NOT store com- air discharge and away from hot exhaust gases.
pound or discharge treated air in confined or un-
ventilated areas. DO NOT store containers or anti- C. Wear personal protective equipment including
freeze compound in direct sunlight. gloves and head covering when working in, on or
around the compressor.
S. Store flammable fluids and materials away from
your work area. Know where fire extinguishers are D. Keep a first aid kit handy. Seek medical assis-
and how to use them, and for what type of fire they tance promptly in case of injury. DO NOT ignore
are intended. Check readiness of fire suppression small cuts and burns as they may lead to infection.
systems and detectors if so equipped.
1.7 TOXIC AND IRRITATING SUBSTANCES
1.5 MOVING PARTS A. DO NOT use air from this compressor for respi-
A. Keep hands, arms and other parts of the body ration (breathing) except in full compliance with
and also clothing away from belts, pulleys and OSHA Standards 29 CFR 1920 and any other Fed-
other moving parts. eral, State or Local codes or regulations.
B. DO NOT attempt to operate the compressor
with the fan or other guards removed. ! DANGER
Death or serious injury may occur from inhaling
C. Wear snug---fitting clothing and confine long hair compressed air without using proper safety
when working around this compressor, especially equipment. See OSHA standards, and/or any
when exposed to hot or moving parts inside the en- Federal, State or Local codes or regulations on
safety equipment.
closure.
D. Keep access doors closed except when making B. DO NOT use air line anti---icer systems in air
repairs or adjustments, performing service or when lines supplying respirators or other breathing air
starting or stopping the compressor. utilization equipment and DO NOT discharge air
E. Make sure all personnel are out of and clear of from these systems into unventilated or other con-
the compressor prior to attempting to start or oper- fined areas.
ate it. C. Operate the compressor only in open or well---
ventilated areas.
F. Shut off engine before adding fuel, fluid, coolant
lubricants, air line antifreeze compound or battery D. If the compressor is operated indoors, dis-
electrolyte, or before replacing ether starting aid charge engine exhaust fumes outdoors.
cylinders.
E. Locate the compressor so that exhaust fumes
G. Disconnect the grounded negative battery con- are not apt to be carried towards personnel, air in-
nection to prevent accidental engine operation takes servicing personnel areas or towards the air
prior to attempting repairs or adjustments. Tag the intake of any portable or stationary compressor.

5
Section 1
SAFETY

F. Fuels, fluids, coolants, lubricants and battery D. Stay clear of the compressor during electrical
electrolyte used in the compressor are typical of the storms! It can attract lightning.
industry. Care should be taken to avoid accidental
ingestions and/or skin contact. In the event of in- 1.9 LIFTING
gestion seek medical treatment promptly. DO NOT A. If the compressor is provided with a lifting bail,
induce vomiting if fuel is ingested. Wash with soap then lift by the bail provided. If no bail is provided,
and water in the event of skin contact. then lift by sling. Compressors to be air lifted by
helicopter must not be supported by the lifting bail,
G. Wear an acid---resistant apron and a face shield but by slings instead. In any event, lift only in full
or goggles when servicing the battery. If electrolyte compliance with OSHA Standards 29 CFR 1910
is spilled on skin or clothing, immediately flush with subpart N or any other Local, State, Military and
large quantities of water. Federal regulations that may apply.
H. Ethyl ether used in diesel engine ether starting B. Inspect lifting bail and points of attachment for
aid systems is toxic, harmful or fatal if swallowed. cracked welds and for cracked, bent, corroded or
Avoid contact with the skin or eyes and avoid otherwise degraded members and for loose bolts
breathing the fumes. If swallowed, DO NOT induce or nuts prior to lifting.
vomiting, but call a physician immediately.
C. Make sure entire lifting, rigging and supporting
I. Wear goggles or a full face shield when testing structure has been inspected, is in good condition
ether starting aid systems or when adding anti- and has a rated capacity of at least the net weight of
freeze compound to air line anti---icer systems. the compressor plus an additional 10% allowance
Keep openings of valve or atomizer tube of ether for weight of snow, ice, mud or stored tools and
starting aid system pointed away from yourself and equipment. If your are unsure of the weight, then
other personnel. weigh compressor before lifting.
J. If ethyl ether or air line anti---icer system anti- D. Make sure lifting hook has a functional safety
freeze compound enters the eyes or if fumes irritate latch or equivalent, and is fully engaged and
the eyes, they should be washed with large quanti- latched on the bail.
ties of clean water for 15 minutes. A physician,
preferably any eye specialist, should be contacted E. Use guide ropes or equivalent to prevent twisting
immediately. or swinging of the compressor once it has been
lifted clear of the ground.
K. DO NOT store ether cylinders or air line anti---
icer system antifreeze compound in operators F. DO NOT attempt to lift in high winds.
cabs or in other similar confined areas.
G. Keep all personnel out from under and away
L. The antifreeze compound used in air line anti--- from the compressor whenever it is suspended.
icer systems contains methanol and is toxic, harm-
ful or fatal if swallowed. Avoid contact with the skin H. Lift compressor no higher than necessary.
or eyes and avoid breathing the fumes. If swal-
lowed, induce vomiting by administering a table- I. Keep lift operator in constant attendance when-
spoon of salt in each glass of clean warm water un- ever compressor is suspended.
til vomit is clear, then administer two tablespoons of
baking soda in a glass of clean water. Have patient J. Set compressor down only on a level surface ca-
lay down and cover eyes to exclude light. Call a pable of supporting at least its net weight plus an
physician immediately. additional 10% allowance for the weight of snow,
ice, mud or stored tools and equipment.
1.8 ELECTRICAL SHOCK
A. Keep the towing vehicle or equipment carrier, K. If the compressor is provided with parking
compressor hoses, tools and all personnel at least brakes, make sure they are set, and in any event,
10 feet (3 meters) from power lines and buried ca- block or chock both sides of all running wheels be-
bles. fore disengaging the lifting hook.
B. Keep all parts of the body and any hand---held 1.10 ENTRAPMENT
tools or other conductive objects away from ex- A. Make sure all personnel are out compressor be-
posed live parts of electrical system. Maintain dry fore closing and latching enclosure doors.
footing, stand on insulating surfaces and DO NOT
contact any other portion of the compressor when B. If the compressor is large enough to hold a man
making adjustments or repairs to exposed live and if it is necessary to enter it to perform service
parts of the electrical system. adjustments, inform other personnel before doing
so, or else secure the access door in the open posi-
C. Attempt repairs only in clean, dry and well--- tion to avoid the possibility of others closing and
lighted and ventilated areas. possibly latching the door with personnel inside.

6
 Section 1
SAFETY

1.11 JUMP STARTING N. Positive battery terminals are usually identified

A. Observe all safety precautions mentioned else- by a plus (+) sign on the terminal and the letters
where in this manual. POS adjacent to the terminal. Negative battery ter-
minals are usually identified by the letters NEG ad-
B. Batteries may contain hydrogen gas which is jacent to the terminal or a negative (---) sign.
flammable and explosive. Keep flames, sparks and
other sources of ignition away. O. Connect one end of a jumper cable to the posi-
tive (POS) (+) battery terminal in the starting vehi-
C. Batteries contain acid which is corrosive and cle. When jump starting 24V compressors and if
poisonous. DO NOT allow battery acid to contact the starting vehicle is provided with two (2) 12V bat-
eyes, skin, fabrics or painted surfaces as serious teries connected in series, connect the jumper ca-
personal injury or property damage could result. ble to the positive (POS) (+) terminal of the un-
Flush any contacted areas thoroughly with water grounded battery.
immediately. Always wear an acid---resistant apron
and face shield when attempting to jump start the P. Connect the other end of the same jumper cable
compressor. to the positive (POS) (+) terminal of the starter mo-
tor battery in the compressor, or when jump start-
D. Remove all vent caps (if so equipped) from the ing 24V compressor, to the positive (POS) (+) ter-
battery or batteries in the compressor. DO NOT minal of the ungrounded battery in the compressor.
permit dirt or foreign matter to enter the open cells.
Q. Connect one end of the other jumper cable to
E. Check fluid level. If low, bring fluid to proper level the grounded negative (NEG) (---) terminal of the
before attempting to jump start (not applicable to battery in the starting vehicle. When jump starting
maintenance---free batteries). 24V compressors and if the starting vehicle is pro-
vided with two (2) 12V batteries connected in se-
F. DO NOT attempt to jump start if fluid is frozen or ries, connect the jumper cable to the negative
slushy. Bring batteries up to at least 60_F (16_C) (NEG) (---) terminal of the grounded battery.
before attempting to jump start or it may explode.
R. Check your connections. DO NOT attempt to
G. Cover open cells of all compressor batteries with start a 24V compressor with one 12V battery in the
clean dampened cloths before attempting to jump starting vehicle. DO NOT apply 24V to one 12V bat-
start. tery in the compressor.

S. Connect the other end of this same jumper cable

H. Attempt to jump start only with a vehicle having a to a clean portion of the compressor engine block
negative ground electrical system with the same away from fuel lines, the crank case breather open-
voltage, and is also equipped with a battery or bat- ing and the battery.
teries of comparable size or larger than supplied in
the compressor. DO NOT attempt to jump start us- T. Start the compressor in accordance with normal
ing motor generator sets, welders or other sources procedure. Avoid prolonged cranking.
of DC power as serious damage may result.
U. Allow the compressor to warm up. When the
I. Bring the starting vehicle alongside the compres- compressor is warm and operating smoothly at
sor, but DO NOT permit metal to metal contact be- normal idle RPM, disconnect the jumper cable
tween the compressor and the starting vehicle. from the engine block in the compressor, then dis-
connect the other end of this same cable from the
J. Set the parking brakes of both the compressor ( if grounded negative (NEG) (---) terminal of the bat-
provided) and the starting vehicle or otherwise tery in the starting vehicle. Then disconnect the
block both sides of all wheels. other jumper cable from the positive (POS) (+) ter-
minal of the battery in the compressor, or if pro-
K. Place the starting vehicle in neutral or park, turn vided with two (2) 12V batteries connected in se-
off all non---essential accessory electrical loads ries, from the ungrounded battery in the compres-
and start its engine. sor, and finally, disconnect the other end of this
same jumper cable from the positive (POS) (+)
L. Use only jumper cables that are clean, in good terminal of the battery in the starting vehicle or
condition and are heavy enough to handle the from the positive (POS) (+) terminal of the un-
starting current. grounded battery in the starting vehicle, if it is pro-
vided with two (2) 12V batteries connected in se-
M. Avoid accidental contact between jumper cable ries.
terminal clips or clamps and any metallic portion of
either the compressor or the starting vehicle to V. Remove and carefully dispose of the dampened
minimize the possibility of uncontrolled arcing cloths, as they may now be contaminated with
which might serve as a source of ignition. acid, then replace all vent caps.

7
 NOTES

8
 Section 2
DESCRIPTION

2.1 INTRODUCTION 2.2 DESCRIPTION OF COMPONENTS

The Sullair 185H, 210H and 260 CFM Portable Air Refer to Figures 2---1. The components and assem-
Compressors offer superior performance and reli- blies of the Sullair Portable Air compressor are
ability along with a minimal amount of maintenance clearly shown. The package includes a heavy duty
requirements. rotary screw air compressor, a diesel engine,
fuel tank, compressor inlet system, compressor
The compressor is equipped with a Sullair rotary cooling and lubrication system, compressor dis-
screw compressor unit. Compared to other com- charge system, capacity control system, instru-
pressors, the Sullair is unique in mechanical reliabil- ment panel and electrical system.
ity and compressor durability. No inspection is re- A low profile canopy offers improved handling and
quired of the working parts within the compressor mobility. Large side service doors provide easy ac-
unit. cess to all serviceable components.
As you continue reading this manual and come to This model meets EPA regulations for 76dbA at 7
learn how the compressor operates and is cared for, meters (23 feet).
you will see how surprisingly easy it is to keep a Sull- The Sullair air compressors are capable of deliver-
air compressor in top operating condition. ing capacities as follows:
Read Section 5 (Maintenance) and learn how to
keep your compressor in top operating condition. Model 185H: 185 CFM @ 150 psig (10.3 bar)
Should any problem or question arise which cannot Model 210H: 210 CFM @ 150 psig (10.3 bar)
be answered in this text, contact your nearest Sullair Model 260: 260 CFM @ 100 psig (6.9 bar)
representative or the Sullair Corporation Service
Department. The control system can easily be adjusted for pres-

Figure 2 ---1 Sullair Rotary Screw Portable Air Compressor --- General Arrangement All Models

9
 Section 2
DESCRIPTION

Figure 2 ---2 Compressor Cooling and Lubrication System

185H & 210 MODELS

260 MODELS

sures from 80 to 125 psig (5.5 to 8.6 bar) for stan- The same fan also cools the fluid in the compressor
dard machines and from 80 to 150 psig (5.5 to 10.3 cooling and lubrication system. The engine radiator
bar) for H machines. The compressor unit is and the compressor fluid cooler sit side by side
driven by an industrial diesel engine designed to which allows the fan air to push through both simul-
provide enough horsepower for more than ade- taneously. As air passes through the fluid cooler,
quate reserve at rated conditions. Refer to the En- the heat of compression is removed from the fluid.
gine Operators Manual for a more detailed descrip-
tion of the engine. The compressor is supplied with a large capacity
fuel tank which will keep the compressor running
through one (1) eight hour shift under normal oper-
The engine cooling system is comprised of a radia- ating conditions.
tor, high capacity fan and thermostat. The high ca- 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL
pacity fan pushes air through the radiator, keeping DESCRIPTION
the engine at the proper operating temperature. Sullair compressors feature the Sullair compressor

10
 Section 2
DESCRIPTION

unit, a single---stage, positive displacement, flood thermostatic control opens, allowing a portion of
lubricated---type compressor. This unit provides the fluid to the cooler. When the temperature
continuous (pulse---free) compression to meet your reaches 140_F (60_C), the thermostat is fully open
needs. With a Sullair compressor, no maintenance allowing all fluid entering the thermal valve to be di-
or inspection of the internal parts of the compressor rected to the cooler.
unit is required.
The cooler is a radiator---type that works in conjunc-
Fluid is injected into the compressor unit where it tion with the engine fan. The fan pushes air through
mixes directly with the air as the rotors turn, com- the cooler removing the heat of compression from
pressing the air. The fluid flow has three main func- the fluid. From the cooler, the fluid is then routed
tions: back through the fluid filter. All fluid flowing to the
compressor unit passes through this filter. The fluid
1. As coolant, it controls the rise of air temperature leaving the filter flows to the compressor unit where
normally associated with the heat of compres- it lubricates, seals and cools the compression
sion. chamber as well as lubricates the bearings and
2. Seals the leakage paths between the rotors and gears.
the stator and also between the rotors them- 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNC-
selves. TIONAL DESCRIPTION
3. Acts as a lubricating film between the rotors allow-
ing one rotor to directly drive the other. Refer to Figures 2---3, 2---4A, and 2---4B. The Sullair
compressor unit discharges compressed air/fluid
After the air/fluid mixture is discharged from the mixture into the sump. The sump has three func-
compressor unit, the fluid is separated from the air. tions:
At this time, the air flows to your service line and the 1. It acts as a primary fluid separator.
fluid is cooled in preparation for re---injection.
2. Serves as the compressor fluid sump.
2.4 COMPRESSOR COOLING AND LUBRICATION 3. Houses the air/fluid separator.
SYSTEM, FUNCTIONAL DESCRIPTION The compressed air/fluid mixture enters the sump
Refer to Figure 2---2. The compressor cooling and
lubrication system is designed to provide adequate and is directed against the side of the sump. By
lubrication as well as maintain the proper operating change of direction and reduction of velocity, large
temperature of the compressor. In addition to the droplets of fluid separate and fall to the bottom of the
fluid cooler and interconnecting piping, the sys- sump. The fractional percentage of fluid remaining
tem consists also of three other components: a in the compressed air collects on the surface of the
fluid filter, thermal valve, and a fan which perform final separator element as the compressed air flows
the following functions: through the separator. As more and more fluid col-
lects on the element surface, the fluid descends to
S The fluid filter filters the fluid. the bottom of the separator. A return line (or scav-
S The thermal valve functions as a temperature regu- enge tube) leads from the bottom of the separator
lator directing fluid either to the cooler or to the com- element to the inlet region of the compressor unit.
pressor unit, bypassing the cooler as will be ex- Fluid collecting on the bottom of the separator ele-
plained later. ment is returned to the compressor by the pressure
S The fan pushes air through the cooler removing difference between the area surrounding the sepa-
the heat of compression from the fluid. rator element and the compressor inlet. An orifice
(protected by a strainer) is included in this return line
The functions of the lubrication system are ex- to assure proper flow.
plained in more detail below. Fluid is used in the sys-
tem as a coolant and as a lubricant. It is housed in The sump is ASME code rated at 200 psig (13.8 bar)
the receiver/sump which, will from this time forward, working pressure. A minimum pressure device lo-
be referred to as the SUMP. cated downstream from the separator, assures a
minimum receiver pressure of 85 psig (5.9 bar) dur-
Upon start ---up, fluid flows from the sump to the fluid ing all conditions. This pressure is necessary for
thermal valve. Fluid circulation is achieved by forc- proper air/fluid separation and proper fluid circula-
ing the fluid from the high pressure region of the tion.
sump to a lower pressure area in the compressor A pressure relief valve (located on the wet side of the
unit. A minimum pressure device (see Section 2.5 separator) is set to open if the sump pressure ex-
Compressor Discharge System) is provided to as- ceeds 200 psig (13.8 bar). A temperature switch will
sure adequate fluid flow under all conditions. shut down the compressor if the discharge tem-
When entering the thermal valve upon start ---up, the perature reaches the specified limit given in Section
fluid temperature is cool and thus it is not necessary 3, Specifications.
to route it through the cooler. Hence the fluid flows Fluid is added to the sump via a capped fluid filler.
through the fluid filter and on to the compressor unit
! WARNING
bypassing the cooler. As the compressor continues
to operate, the temperature of the fluid rises and the DO NOT remove caps, plugs, and/or other compo-

11
 Section 2
DESCRIPTION

Figure 2 ---3 Compressor Discharge System

nents when compressor is running or pressurized. tions of the control system are given in four distinct
Stop compressor and relieve all internal pressure be- phases of operation. It applies to any control system
fore doing so. with the exception of those with stated pressures
which are dependent on pressure requirements.
2.6 CAPACITY CONTROL SYSTEM, FUNCTIONAL The pressures stated will be in accordance with a
DESCRIPTION compressor having an operating pressure range of
Refer to Figures 2---3, 2---4A or 2---4B. The purpose 100 to 110 psig (6.9 to 7.6bar).
of the control system is to regulate the amount of air
intake in accordance with the amount of com- START -- 0 TO 40 PSIG (0 TO 2.8 BAR)
pressed air being used. The control system con- COLD WEATHER
sists of a pressure regulating valve(s), air inlet To minimize problems in cold weather, starting aids,
valve, system blowdown valve, and tubing con- engine coolant heaters and dry---side receiver relief
necting the various components to the compres- valves should be used. Refer to the engine opera-
sor and engine governor. The functional descrip- tors manual for additional information.

12
 Section 2
DESCRIPTION

Figure 2 ---4A Control System with Piping and Instrumentation --- 185H & 210H Models

13
Section 2
DESCRIPTION

Figure 2 ---4B Control System with Piping and Instrumentation --- 260 Models

14
 Section 2
DESCRIPTION

COLD START terconnecting piping to the engine and compres-

When the compressor is started, the sump pressure sor.
will quickly rise from 0 to 40 psig (0 to 2.8 bar). Dur-
ing this period the pressure regulator valve is inac- The air filters are two---stage dry element ---type fil-
tive. At this pressure range the idle warm---up con- ters. These filters are capable of cleaning extremely
trol maintains a closed inlet valve for engine idle op- dirty air. However, in such cases, frequent checks of
eration. After engine start ---up, turn the handle of the air filter will be required.
the selector valve warm---up control (located on the See Section 5 for Air Filter Maintenance Procedures.
instrument panel) from the start to the run posi-
tion within the first 30 seconds of operation. The in- 2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL DE-
strument panel annunciator light will go off after 30 SCRIPTION
seconds. The inlet valve is fully open due to inlet air Refer to Figure 2---6. The instrument panel group
pressure, and the compressor operates at full ca- consists of a molded panel containing an air pres-
pacity operation. As the compressor operates at full sure gauge, hourmeter, ignition/start switch, an-
capacity, the engine runs at full speed. nunciator light, idle warm-- up control, and a
cold weather starting aid button. A high-- low
NORMAL OPERATION -- 55 TO 100 PSIG (3.8 TO pressure selector switch is located on the panel
6.9 BAR) OR 55 TO 150 PSIG (3.8 TO 10.3 BAR) for 185H and 210H compressors.
FOR H MACHINES
When the warm---up control selector valve handle is
moved to the run position, the sump pressure Refer to Figure 2---6 for locations of the following in-
rises above 85 psig (5.9 bar). At this time, the inlet dicators and controls:
valve remains fully open for maximum air output. S The air pressure gauge continually monitors the
The engine will continue to run at full speed during sump pressure at various load or unload conditions.
this phase of operation. S The hourmeter indicates the accumulative hours
MODULATION -- 100 TO 110 PSIG (6.9 TO 7.6 of compressor operation. This is useful for planning
BAR) OR 150 TO 165 PSIG (10.3 TO 11.4 BAR) and logging service operations.
FOR H MACHINES S The engine switch is used to energize the electri-
Should less than the rated capacity of air be used, cal system and start the compressor. The starter
the service line pressure will rise above 100 psig (6.9 switch is pressed to the on position to energize the
bar) low or single pressure rating, 150 psig (10.3 electrical system and momentarily pressed to the
bar) dual or high pressure rating. The pressure reg- start position to engage the starter and start the
ulating valve gradually opens, applying pressure to compressor.
the inlet valve piston and speed control cylinder . S The idle warm-- up valve control is turned from
This causes the inlet valve to partially close and re- start to run after engine start is achieved for full com-
duces the speed of the engine. As the pressure in- pressor operation.
creases, the inlet valve piston will further close the S The Pressure selector switch (185H & 210H
inlet valve and continue reducing the speed until it Models) allows the selection of the compressor op-
reaches a pre---set idle speed. Now as air demand erating pressure range, 85 to 110 psig (5.9 to 7.6
increases, the sump pressure will fall below the 110 bar) or 85 to 160 psig (5.9 to 11.0 bar).
psig (7.6 bar) or 165 psig (11.4 bar) for H ma- S The cold weather starting aid should be used
chines. when starting in cold amibients. Press the button
and hold for 10---30 seconds (depending upon tem-
The pressure regulating valve will close, the air inlet perature).
valve will fully open and the engine will once again S The annunciator light indicates compressor safe-
run at a pre---set full load speed. ty shutdown status.
Between the pressure regulating valve and inlet
valve, a small orifice is installed which vents a small 2.9 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIP-
amount of air to the atmosphere, when the pressure TION
regulating valve is open. This allows variance of air Refer to Figure 2---6 . The electrical system is com-
output to match air demand. The orifice also bleeds prised of not only the necessary equipment re-
any accumulated moisture from the regulator. quired to operate the compressor, but also a system
which shuts down the compressor in the event of a
SHUTDOWN malfunction. The components of the electrical sys-
The blowdown valve is normally closed. Upon shut- tem are an engine starter, a battery, an alternator
down, the back pressure in the compressor inlet with a built-- in voltage regulator, a fuel solenoid,
signals the blowdown valve to vent the sump pres- a compressor discharge temperature switch,
sure to the atmosphere. which will shut down the compressor should the
compressor temperature exceed 250_F (121_C),
2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIP- an engine water temperature switch set to shut
TION down the compressor when water temperature
Refer to Figure 2---5. The air inlet system consists of reaches 225_F (107_C) and an engine oil pres-
two air filters, a compressor air inlet valve and in- sure switch. The engine oil pressure switch is

15
 Section 2
DESCRIPTION

Figure 2 ---5 Air Inlet System (typical)

provided to shut down the compressor when the en- 3 flashes: low engine oil pressure
gine oil pressure becomes insufficient. The low 4 flashes: low engine speed
speed switch is provided to shutdown the compres-
sor if engine speed falls below 1500 RPM. 5 flashes: low fuel level (optional)
2.10 SHUTDOWN SYSTEM DESCRIPTION The SSAM also provides startup logic for the com-
The Shutdown System and Annunciation Module pressor. When the ignition switch is placed in the
(SSAM) continually monitors the status of the com- ON position, the annunciator light will come on for
pressor . In the event of a shutdown condition, the 30 seconds. During this 30 second period, ignition
SSAM will shutdown the compressor and flash the switch activation to the START position will engage
appropriate code on the instrument panel annun- the engine starter. The low engine oil pressure
ciator light. The flash code will remain active (flash- switch and the low engine speed switch will remain
ing) until the ignition switch is turned OFF. The flash inactive during the this 30 second period. At the end
codes are as follows: of the 30 second period, the annunciator light will
go off and the engine START cycle will be disabled.
1 flash : high compressor temperature At this time, all safety system checks become ac-
2 flashes: high engine coolant temperature tive including low fuel level (if equipped).

16
 Section 2
DESCRIPTION

Figure 2 ---6 Instrument Panel Group

17
 Section 2
DESCRIPTION

Figure 2 ---7 Electrical System --- JOHN DEERE

02250144--- 446R05

18
 Section 2
DESCRIPTION

Figure 2 ---7A Electrical System --- CATERPILLAR

P02250144--- 395R04

19
 NOTES

20
 Section 3
SPECIFICATIONS

3.1A SPECIFICATIONS -- JOHN DEERE

Model Series Length (I) Width Height Weight (wet)(II)

in mm in mm in mm lb kg

185H,210H,260 2Wheel 143.3 3640 65.4 1661 59.9 1522 2840 1288
185H,210H,260 LRG 85.1 2162 47.5 1207 49 1245 2585 1173

(I) Length over drawbar.

(II)Weight shown is for 260 models. Deduct 120 lbs.(55kg) for 185H and 210H models.

COMPRESSOR: 185H 210H 260

Type Rotary Screw Rotary Screw Rotary Screw
Maximum Operating 150 psig (10.3 bar) 150 psig (10.3bar) 100 psig (6.9bar)
Pressure
Delivery 185 Free CFM (87 L/S) 210 Free CFM (99L/S) 260 Free CFM (122L/S)
Fluid Compressor Fluid Compressor Fluid Compressor Fluid
Lubricating Compressor See Lubrication Guide See Lubrication Guide See Lubrication Guide
Sump Capacity 3 U.S. Gallons 3 U.S. Gallons 3 U.S. Gallons
(11 Liters) (11 Liters) (11 Liters)
Track Width 55 in. (1397 mm) 55 in. (1397 mm) 55 in. (1397 mm)
Tire Size (Load Range)
Tire Pressure 50 psig (3.5 bar) 50 psig (3.5 bar) 50 psig (3.5 bar)
Lug Nut Torque 60 ft. ---lbs. (81 Nm) 60 ft. ---lbs. (81 Nm) 60 ft. ---lbs. (81 Nm)
Wheel Size 15 X 5 15 X 5 15 X 5
Operating Tilt (maximum) 15 Degrees 15 Degrees 15 Degrees
Electrical System 12 Volt 12 Volt 12 Volt
Compressor Discharge Shutdown 250_F Shutdown 250_F Shutdown 250_F
Temp. (121_C) (121_C) (121_C)
Service Valves (2) 3/4 (2) 3/4 (2) 3/4
Maximum Towing Speed 55 mph (88 kmph) 55 mph (88 kmph) 55 mph (88 kmph)
Axle Rating 3500 lbs. (1588 kg) 3500 lbs. (1588 kg) 3500 lbs. (1588 kg)
Rated Pressure 150 psig (10.3 bar) 150 psig (10.3 bar) 100 psig (7 bar)
Sound Level 76 dBA at 7 meters 76 dBA at 7 meters 76 dBA at 7 meters

ENGINE:
Type Diesel Diesel Diesel
Make John Deere John Deere John Deere
Model 5030T 5030T 5030T
Displacement 186 cu. in. (3.0L) 186 cu. in. (3.0L) 186 cu. in. (3.0L)
Cylinders 5 5 5
Bore x Stroke 3.39 x 4.13 in. 3.39 x 4.13 in. 3.39 x 4.13 in.
(86mm x 105mm) (86mm x 105mm) (86mm x 105mm)
Rated Speed 2600 RPM 2500 RPM 2500 RPM
Rated Power 82 HP ( 61 kW) 82 HP ( 61 kW) 82 HP ( 61 kW)
Type of Motor Oil See Engine See Engine See Engine
Operators Manual Operators Manual Operators Manual
Fuel Tank Capacity 35 Gallons (132 liters) 35 Gallons (132 liters) 35 Gallons (132 liters)
Radiator Capacity 3 U.S. Gallons 3 U.S. Gallons 3 U.S. Gallons
(11.4 liters) (11.4 liters) (11.4 liters)
Engine Water Shutdown 225_F Shutdown 225_F Shutdown 225_F
Temperature (107_C) (107_C) (107_C)
Minimum Idle Speed 1800 RPM (II) 1800 RPM (II) 1800 RPM (II)
Alternator Rating 70 amp 70 amp 70 amp
(II) DO NOT allow engine idle rpm to drop below minimum idle speed. Compressor and/or coupling damage will occur. The compressor
is equipped with a Low Speed Shutdown System that will shutdown the compressor if engine speed falls below 1500 rpm.

21
 Section 3
SPECIFICATIONS

3.1B SPECIFICATIONS -- CATERPILLAR

Model Series Length (I) Width Height Weight (wet)(II)

in mm in mm in mm lb kg

185H,210H,260 2Wheel 143.3 3640 65.4 1661 59.9 1522 2760 1251
185H,210H,260 LRG 85.1 2162 47.5 1207 49.0 1245 2505 1136

(I) Length over drawbar.

(II) Weight shown is for 260 models. Deduct 120 lbs.(55kg) for 185H and 210H models.

COMPRESSOR: 185H 210H 260

Type Rotary Screw Rotary Screw Rotary Screw
Maximum Operating 150 psig (10.3 bar) 150 psig (10.3 bar) 100 psig (6.9 bar)
Pressure
Delivery 185 Free CFM (87 L/S) 210 Free CFM (99 L/S) 260 Free CFM (122 L/S)
Fluid Compressor Fluid Compressor Fluid Compressor Fluid
Lubricating Compressor See Lubrication Guide See Lubrication Guide See Lubrication Guide
Sump Capacity 3 U.S. Gallons 3 U.S. Gallons 3 U.S. Gallons
(11 Liters) (11 Liters) (11 Liters)
Track Width 55 in. (1397 mm) 55 in. (1397 mm) 55 in. (1397 mm)
Tire Size (Load Range)
Tire Pressure 50 psig (3.5 bar) 50 psig (3.5 bar) 50 psig (3.5 bar)
Lug Nut Torque 60 ft. ---lbs. (81 Nm) 60 ft. ---lbs. (81 Nm) 60 ft. ---lbs. (81 Nm)
Wheel Size 15 X 5 15 X 5 15 X 5
Operating Tilt (maximum) 15 Degrees 15 Degrees 15 Degrees
Electrical System 12 Volt 12 Volt 12 Volt
Compressor Discharge Shutdown 250_F Shutdown 250_F Shutdown 250_F
Temp. (121_C) (121_C) (121_C)
Service Valves (2) 3/4 (2) 3/4 (2) 3/4
Maximum Towing Speed 55 mph (88 kmph) 55 mph (88 kmph) 55 mph (88 kmph)
Axle Rating 3500 lbs. (1588 kg) 3500 lbs. (1588 kg) 3500 lbs. (1588 kg)
Rated Pressure 150 psig (10.3 bar) 150 psig (10.3 bar) 100 psig (7 bar)
Sound Level 76 dBA at 7 meters 76 dBA at 7 meters 76 dBA at 7 meters

ENGINE:
Type Diesel Diesel Diesel
Make Caterpillar Caterpillar Caterpillar
Model 3044T 3044T 3044T
Displacement 201 cu. in. ( 3.3 L) 201 cu. in. ( 3.3 L) 201 cu. in. ( 3.3 L)
Cylinders 4 4 4
Bore x Stroke 3.70 x 4.72 in. 3.70 x 4.72 in.. 3.70 x 4.72 in..
( 94 mm x 120 mm) ( 94 mm x 120 mm) ( 94 mm x 120 mm)
Rated Speed 2600 RPM 2500 RPM 2500 RPM
Rated Power 80 HP (60 kW) 80HP ( 60 kW) 80HP ( 60 kW)
Type of Motor Oil See Engine See Engine See Engine
Operators Manual Operators Manual Operators Manual
Fuel Tank Capacity 35 Gallons (132 liters) 35 Gallons (132 liters) 35 Gallons (132 liters)
Radiator Capacity 3 U.S. Gallons 3 U.S. Gallons 3 U.S. Gallons
(11.4 liters) (11.4 liters) (11.4 liters)
Engine Water Shutdown 225_F Shutdown 225_F Shutdown 225_F
Temperature (107_C) (107_C) (107_C)
Minimum Idle Speed 1800 RPM (III) 1800 RPM (III) 1800 RPM (III)
Alternator Rating 90 amp 90 amp 90 amp
(III) DO NOT allow engine idle rpm to drop below minimum idle speed. Compressor and/or coupling damage will occur. The compressor
is equipped with a Low Speed Shutdown System that will shutdown the compressor if engine speed falls below 1500 rpm.

22
 Section 3
SPECIFICATIONS

3.2 LUBRICATION GUIDE -- COMPRESSOR

AMBIENT TEMPERATURE
FLUID TYPE CHANGE PERIOD, HOURS RANGE _F (_C)

Sullair AWF (I) 1200 ---20 to 125 (---29 to 52)

D ---A Torque Fluid 300 10 to 110 (---12 to 43)
SAE10W SE, SF, SG, CD 300 0 to 100 (---18 to 38)
MIL---L---2104E 10W 300 0 to 100 (---18 to 38)

(I) Sullair part numbers for Sullair AWF are 250030---757 (5 gallons/20 liters) and 250030---758 (55 gallon drum/208 liters).

3.3 APPLICATION GUIDE When ambient conditions exceed those noted or if

Sullair Air Compressors are supplied with Sullair conditions warrant use of other extended life lubri-
AWF which is heavy duty multi---viscosity, all--- cants, contact Sullair for recommendations.
weather fluid. Sullair AWF also allows an extended
change interval. Detergent motor oils (SAE 10W Sullair encourages the user to participate in a fluid
Class SE,SF, SG or CD) can also be used. Any of analysis program. This could result in a fluid change
these oils are suitable under conditions where se- interval differing from that stated in the manual. Sul-
vere oil oxidations can occur. lair Corporation offers a fluid analysis program for
Sullair AWF. Contact your local Sullair representa-
Water must be drained from the receiver periodical- tive for details.
ly. In high ambient temperature and high humidity
conditions, condensed moisture may emulsify with D ---A Lubricantr Company Inc. offers an analysis
the oil forming a milky color. SAE 10W is especially program for users of D ---A products and Sullair AWF.
prone to this condition. The fluid should be changed Contact your D ---A lubricant supplier or Sullair rep-
if this condition develops. resentative for details.
DO NOT mix types of fluids. Combinations of differ- 3.4 LUBRICATION GUIDE -- ENGINE
ent fluids may lead to operational problems such as For engine oil specifications, refer to the Engine Op-
foaming, filter plugging, orifice or line plugging. erators Manual.

23
 NOTES

24
 Section 4
OPERATION
4.1 GENERAL service or indicate the beginning of a malfunction.
While Sullair has built into this compressor a compre- Before starting your Sullair compressor, read this
hensive array of controls and indicators to assure section thoroughly and familiarize yourself with the
you that it is operating properly, you will want to rec- controls and indicators --- their purpose, location and
ognize and interpret the reading which will call for use.
4.2 PURPOSE OF CONTROLS

CONTROL OR INDICATOR PURPOSE

ENGINE SWITCH Press this switch to the ON (ignition) position to energize

the electrical system of the compressor. Press the switch to
the START position to momentarily engage the starter
and start the compressor. Pressthe switch to the OFF
position to shut the compressor down. This switch is lo-
cated on the instrument panel.
COLD WEATHER STARTING AID BUTTON Push this button, prior to compressor start ---up, to allow the
engine to warm---up for easy starting.
AIR PRESSURE GAUGE Continually monitors the pressure inside the receiver sump
at various load and unload conditions.
HOURMETER Indicates the accumulated hours of operation. Useful for
planning and logging service schedules.
FLUID LEVEL SIGHT GLASS Monitors the fluid level in the sump. Proper level is visible
halfway up the sight glass. Check the level when the com-
pressor is shut down and on level ground.
COMPRESSOR DISCHARGE TEMPERATURE Opens the electrical circuit to shut down the compres---
SWITCH sor when the discharge temperature reaches a specific
value (see Section 3, Specifications).
THERMAL VALVE Functions as a temperature regulator directing the com-
pressor fluid either to the cooler or to the compressor unit.
MINIMUM PRESSURE DEVICE Maintains the minimum of 85 psig (5.9 bar) in the compres-
sor sump.
PRESSURE RELIEF VALVE Opens sump pressure to the atmosphere should pressure
inside the sump exceed 200 psig (13.8 bar) .
AIR INLET VALVE Regulates the amount of air allowed to enter the air inlet
valve. This regulation is determined by a pressure signal
from the pressure regulator.
PRESSURE REGULATOR (S) Allows a pressure signal to reach the engine speed control
cylinder and the air inlet valve to control air delivery accord-
ing to demand.
SHUTDOWN SYSTEM/ANNUNCIATOR MODULE (SSAM) Monitors the compressor safety system for shut-
down conditions. The annunciator module on the instru-
ment panel will flash a code indicating the reason for com-
pressor shutdown.

25
 Section 4
OPERATION

4.2 PURPOSE OF CONTROLS (Continued)

CONTROL OR INDICATOR PURPOSE

BLOWDOWN VALVE Vents sump pressure to the atmosphere at shutdown.

IDLE WARM---UP CONTROL Maintains a closed air inlet valve for reduced compressor
load on start ---up. After engine starts, turn the handle of the
selector valve from the start to the run position for full
operation within the first minute of operation.

4.3 START-- UP PROCEDURE shipment. Refer to your Engine Operators Manual

The following procedure should be used to make the for details and specific engine requirements.
initial start ---up of your compressor:
1. Position the compressor on a level surface so that 4.4 SUBSEQUENT START-- UP PROCEDURE
proper amounts of liquid can be added if neces- On subsequent starts, follow the procedure ex-
sary. (I) plained below:
2. Check oil and fluid levels both in the engine and 1. Check engine oil, water and fuel levels.
the cooling system(s). Maintain the proper level; 2. Check compressor fluid level (should be visible in
add if necessary. sight glass). Drain water from the fuel---water
3. Fill the fuel tank. Drain water from the fuel---water separator.
separator. 3. Check dust collectors and clean if necessary.
4. Crack open one service line. 4. Crack open service valve.
5. Bleed fuel injection lines if necessary (see Engine 5. Bleed fuel injection lines if necessary (see Engine
Operators Manual). Operators Manual).
6. Turn the warm---up control selector valve to the 6. Turn the warm---up control selector valve to the
start position. start position.
7. In cold weather, engage cold weather starting aid 7. In cold weather, engage cold weather starting aid
button. Hold button for 5---10 seconds and then button. Hold button for 5---10 seconds and then
release. release.
8. Press the engine switch to the ON position. 8. Press the engine switch to the ON position.
9. Press the engine switch to the START position 9. Press the engine switch to the START position
momentarily to engage starter, when engine momentarily to engage starter, when engine
starts release switch. starts release switch.
10. After the engine starts, turn the idle warm---up se- 10. Allow for sufficient warm up of compressor before
lector valve from start to run for full compressor operating.
operation within the first 30 seconds of operation. 11. After the engine starts, turn the idle warm---up se-
After 30 seconds, the annunciator light will go off. lector valve from the start to run position for full
11. Close canopy in order to maintain proper noise operation within the first 30 seconds of operation.
control. 4.5 SHUTDOWN PROCEDURE
12. After the initial run, shut the compressor down and To shut the compressor down, close the service
refill the radiator and compressor fluid sump as re- valves and run compressor for approximately 5 min-
quired. Tighten any loose fittings and check fan utes to allow the compressor to cool down and
belt tension. press the engine switch to the OFF position. In
case of emergency where immediate shutdown is
(I) The radiator is filled with a 50/50 mixture of ethyl- required, this procedure is not necessary. The en-
ene glycol and water. All engines receive Supple- gine switch should be pressed to the OFF position
mental Coolant Additive (SCA) at the factory before immediately.

26
 Section 5
MAINTENANCE

5.1 GENERAL 4. Check fuel filter for water.

A good maintenance program is the key to long 5.3A MAINTENANCE EVERY 50 HOURS
compressor life. Below is a program that, when ad-
hered to, should keep the compressor in top operat- 1. Inspect and replace air filter elements (if re-
ing condition. For maintenance requirements on en- quired).
gine, refer to the Engine Operators Manual for a de- 2. Check fuel filter for water.
tailed description of service instructions. See Sec-
tion 5.7, Parts Replacement and Adjustment Proce- 5.4 MAINTENANCE EVERY 100 HOURS
dures for a detailed description of specific compres- After 100 hours of operation, it will be necessary to
sor system components. Prior to performing main- perform the following:
tenance, read the CIMA Safety Manual, if applicable 1. Clean the radiator and cooler exteriors.
in your area. 2. Check Engine Operators Manual for required
service.
! WARNING
5.5 MAINTENANCE EVERY 250 HOURS
DO NOT remove caps, plugs and/or other compo- Perform the following after every 250 hours of opera-
nents when compressor is running or pressur- tion:
ized.
1. Check fan belt tension.
Stop compressor and relieve all internal pressure
before doing so. 2. Clean the radiator and cooler exterior. Depending
on how contaminated the atmosphere may be,
5.2 DAILY OPERATION more frequent cooler and radiator cleaning may
Prior to starting the compressor, it is necessary to be necessary.
check the fluid level in the sump. Should the level be 3. Change engine oil and filter.
low, simply add the necessary amount. If the addi-
tion of fluid becomes too frequent, a simple problem NOTE
has developed which is causing this excessive loss.
See the Troubleshooting Sections (5.8 and 5.9) un- Fluid change period will vary according to fluid
brand. Refer to Lubrication Guide in Section 3.
der Excessive Fluid Consumption for a probable
cause and remedy. Also check the engine oil level Perform the following after every 250 hours of opera-
and the radiator coolant level and drain water from tion:
the engine fuel/water separator prior to starting. 4. Change the compressor fluid and fluid filter, if not
using Sullair AWF. Run the compressor for 5 to
NOTE 10 minutes to warm the fluid. Shut the compres-
sor off and relieve all internal pressure before
The radiator and engine cooling system must be proceeding. Drain the fluid sump by removing
drained and flushed every two (2) years. Replace
the coolant with a solution of 50% ethylene glycol the plug at the bottom of the sump tank. For fluid
and 50% water or as required for your geographic filter element replacement, see Filter Element
location. DO NOT use a leak sealing type of anti--- Replacement under the Maintenance Section
freeze. All engines must have Supplemental Cool- 5.7 Parts Replacement and Adjustment Proce-
ant Additive (SCA) added to the engine coolant
system. Refer to your Engine Operators Manual
dures. Fill the sump with fluid according to speci-
for details and specific engine requirements. fications in Section 3. Remove any accumulated
dirt from the fluid filler cap prior to filling the
After a routine start has been made, observe the in- sump.
strument panel gauge and be sure it monitors the 5. Replace return line strainer.
correct reading for that particular phase of opera- 6. Check the engine RPM. Idle speeds should never
tion. After the compressor has warmed up, it is rec- be allowed to fall below the minimums (see Sec-
ommended that a general check on the overall com- tion 3 Specifications).
pressor and instrument panel be made to assure 7. Change the fuel filter . Should persistant clogging
that the compressor is running properly. Also check be evident, change the fuel filter more frequently.
the air filter maintenance indicators if supplied.
8. Change engine fuel---water separator.
5.3 MAINTENANCE AFTER INITIAL 50 HOURS 9. Change the air filter (s) primary elements.
OF OPERATION 10.Change compressor fuild filter.
After the initial 50 hours of operation, a few mainte-
nance requirements are needed to rid the system of NOTE
any foreign materials. Perform the following mainte-
nance operations to prevent unnecessary prob- Operation at speeds below the minimum idle
lems. speeds shown in the Table in Section 3, Specifica-
tions will damage the compressor. Extended op-
1. Clean the return line orifice and strainer. eration below those speeds will induce coupling
2. Change compressor fluid filter. and/or compressor failures.
3. Check Engine Operators Manual for required 11. Lubricate the control linkage.
service. 12. Check Engine Manual for required service.

27
 Section 5
MAINTENANCE
Figure 5 ---1 Compressor Fluid Filter ment see procedure for servicing the fluid filter in
this section. Fill the sump with fluid according to
specifications in Section 3.
COMPRESSOR FLUID FILTER ELEMENT RE-
PLACEMENT
Refer to Figure 5---1.
1. Using a strap wrench, remove the old element.
2. Clean the gasket seating surface.
3. Apply a light film of fluid to the new gasket.
4. Hand tighten the new element (from kit P/N
250028---032) until the new gasket is seated on
the gasket seat.
5. Continue tightening the element by hand an addi-
tional 1/2 to 3/4 turn.
6. Restart the compressor and check for leaks.
AIR FILTER MAINTENANCE
Refer to Figure 5---2. Air filter maintenance should
be performed as often as conditions require. If the
filters are equipped with an optional maintenance
indicator, maintenance should be done when the in-
dicator shows red. The following procedure will ex-
plain how to replace the air filter element.
AIR FILTER ELEMENT REPLACEMENT
1. Loosen and remove the air filter end cover.
2. Remove element.
3. Clean the body and cover with a damp cloth in-
side and out.
4. Replace the new filter element.
5. Reposition the cover and lock into position.
6. Reset the air filter restriction indicator if so
equipped, and the unit will be ready for opera-
* Replacement Element Kit P/N 250028---032 tion.
ELEMENT INSPECTION
13. Clean the return line orifice. 1. Place a bright light inside the element to inspect
for damage or leak holes. Concentrated light will
5.6A MAINTENANCE EVERY 1500 HOURS OR
ANNUALLY Figure 5 ---2 Air Filter
1. When using Sullair AWF, change the compressor
fluid and replace the fluid filter element (See
maintenance procedures in Section 5.7).
2. Service engine cooling system.

5.6B MAINTENANCE EVERY YEAR OR 12,000

MILES
1. Lubricate axle bearings on wheel---mounted
units.
5.7 PARTS REPLACEMENT AND ADJUSTMENT
PROCEDURES
COMPRESSOR FLUID CHANGE PROCEDURE
Warm---up compressor for 5 to 10 minutes to warm
the fluid. Shut the compressor off and relieve all in-
ternal pressure before proceeding. Drain the fluid
sump by opening the valve at the bottom of the
sump tank. Change the compressor fluid and re- *Filter Element P/N 02250122---816 (2 reqd)
place the fluid filter element. For element replace-

28
 Section 5
MAINTENANCE

Figure 5 ---3 Air/Fluid Separator 4. Remove the separator element.

5. Scrape the old gasket material from the cover and
the flange on the sump. Be sure to keep all
scrapings from falling inside tank.
6. Install the new element.
7. Replace the sump cover and bolts. Run the cover
bolts in finger tight, then gradually tighten in a
crisscross pattern in 4 to 5 steps. Always tighten
the bolts alternately at opposite sides of the
cover. Never tighten bolts adjacent to each other.
Torque bolts to 60 ft. ---lbs. (81 Nm).
8. Reconnect all piping. The fluid return line tube
should extend to the bottom of the separator ele-
ment. This will assure the proper fluid return flow.
9. Clean the fluid return line strainer and clear the
orifice prior to restarting the compressor.
10. After 24 hours of operation, tighten sump cover
bolt to torque specification listed in step number
7.

PROCEDURE FOR SETTING SPEED AND

PRESSURE CONTROLS ON PORTABLE COM-
PRESSORS WITH POPPET VALVE
Refer to Figure 5---4. Prior to adjusting the Control
System, it is necessary to determine the rated full
load pressure and the high/low RPM settings for
your particular compressor. This information can be
obtained from the Operators Manual (Specifica-
tions Section) or by contacting your local authorized
Sullair Representative. The following explanation
applies to a compressor with 100 psig (6.9 bar)
rated full load pressure.
*Replacement Separator Kit P/N 02250078---031

1. Start the compressor and allow the engine to

shine through the element and disclose any warm---up to normal operating temperature with
holes. the service valve closed.
2. With the service valve closed, set the engine low
2. Inspect all gaskets and gasket contact surfaces speed (idle) to its specified setting with the idle
of the housing. Should faulty gaskets be evident, stop screw on the engine injector pump.
correct the condition immediately.
3. If the clean element is to be stored for later use, it
must be stored in a clean container. NOTE
4. After the element has been installed, inspect and
tighten all air inlet connections prior to resuming Operation at speeds below the minimum idle
speeds shown in Section 3 under Specifications
operation. will damage the compressor. Extended operation
below those speeds will induce coupling and/or
SEPARATOR ELEMENT REPLACEMENT compressor failures.
Refer to Figure 5---3. When fluid carry over is evident
after the fluid return line strainer and orifice as well 3. Adjust the pressure regulator so that the com-
as the blowdown valve seal has been inspected and pressor maintains 115 psig (8 bar).
found to be in satisfactory condition, separator ele- 4. Gradually open the service valve to atmosphere
ment replacement is necessary. Use separator ele- until the engine comes up in speed and sump
ment part number no. 250034---112 and follow the pressure is held at 100 psig (6.9 bar). At this
procedure explained below. point, set the engine high speed to its specified
setting by adjusting the high idle threaded rod lo-
1. Remove all piping connected to the sump cover cated on the engine speed control (where appli-
to allow removal (return line, service line, etc.). cable). To raise or lower the speed, lengthen or
2. Remove the fluid return line from the fitting in the shorten the rod respectively.
cover. 5. Open the service valve to 100 psig (6.9 bar) (rated
3. Remove the eight (8) cover bolts and washers full load pressure) and recheck top engine
and lift the cover from the sump. speed and control response. Close the service

29
 Section 5
MAINTENANCE

Figure 5 ---4 Control System Adjustment

185H & 210 MODELS

260 MODELS

30
 Section 5
MAINTENANCE

Figure 5 ---5 Typical E ---Z Lube Axle

valve and allow the compressor to cycle and re- frequently to help insure proper performance. Use
check low engine speed (idle). wheel bearing grease that conforms to military
The following explanation applies to H compres- specification MIL---G---10924 or a high temperature
sor with dual pressure controls. wheel bearing grease such as lithium complex NLGI
1. Start the compressor and allow the engine to Consistency #2.
warm---up to normal operating temperature with If your axle is equipped with the E---Z Lube feature,
the service valve closed and the pressure selec- the bearings can be periodically lubricated without
tor switch set to the low position. removing the hubs from the axle. This feature con-
2. Follow the procedure for setting the controls at sists of axle spindles that have been specially drilled
100 psig (6.9 bar) rated full load pressure as de- and fitted with a grease zerk in their ends. When
scribed in Steps 2 through 5 above. grease is pumped into the zerk, it is channeled to
3. Switch the pressure selector switch to the high the inner bearing and then flows back to the outer
position with the service valve closed. bearing and eventually back out of the grease cap
hold (see Figure 5---5). The procedure is as follows:
4. Adjust the high pressure regulator so that the
compressor maintains 165 psig (11.4 bar). 1. Remove the rubber plug from the end of the
5. Gradually open the service valve to atmosphere grease cap.
until the engine comes up in speed and sump 2. With a standard grease gun filled with a quality
pressure is held at 150 psig (10.3 bar). At this wheel bearing grease, place the gun onto the
point the engine should be at rated speed. If nec- grease zerk located in the end of the spindle.
essary, to raise or lower the speed, lengthen or Make sure the grease gun nozzle is fully en-
shorten the rod respectively. gaged on the fitting.
3. Pump grease into the zerk. The old, displaced
OPERATING ADJUSTMENTS grease will begin to flow back out the cap around
The first step is to start the compressor according to the grease gun nozzle.
the instructions in Section 4, Subsequent Start ---up. 4. When the new, clean grease is observed, remove
Allow the engine to operate until it reaches the nor- the grease gun, wipe off any excess, and replace
mal operating temperature. Open the service valve the rubber plug in the cap.
until the engine speed increases to, or close to, the
maximum specified operating speed. 5.8 TROUBLESHOOTING -- INTRODUCTION
The following Troubleshooting Chart is based upon
BEARING LUBRICATION the data obtained both from testing at the factory
Refer to Figure 5---5. Proper lubrication is essential and from applied situations in the field. It contains
to the proper functioning and reliability of your por- symptoms and usual causes for the described
table compressor axle. Wheel bearings should be problems, however DO NOT assume that these are
lubricated at least once every 12 months, or more the only problems that may occur. All available data

31
 Section 5
MAINTENANCE
concerning the trouble should be systematically 2. Check for damaged piping.
analyzed before undertaking any repairs or compo- 3. Check for parts damaged by heat or an electrical
nent replacement procedures. short circuit, usually apparent by discoloration or
A detailed visual inspection is worth performing for a burnt odor.
almost all problems. Doing so may prevent unnec- Should the problem(s) persist after making the rec-
essary additional damage to the compressor. ommended check, consult your nearest Sullair rep-
Always remember to: resentative or the Sullair Corporation.
1. Check for loose wiring.

5.9 TROUBLESHOOTING GUIDE

SYMPTOM PROBABLE CAUSE REMEDY

ENGINE DOES NOT CRANK OR CRANKS ONLY WITHOUT STARTING:

NO FLASH CODE: Low Voltage or Battery disconnected Check battery cables and tighten if necessary.

Check ground wire for proper attachment to frame.

Tighten as required.

Low Voltage or Battery disconnected Recharge or replace battery if required.

Blown fuse in wiring harness Remove and inspect fuse. Replace if necessary.

Instrument panel connectors loose or Checked instrument panel connectors and

disconnected reattach if required.

Check instrument panel wires for broken

connections or corrosion. Clean and/or replace if
required

Faulty SSAM module Replace the SSAM Module.

FLASH CODE: ONE FLASH Compressor temperature switch is open Check wiring connection to switch and tighten as
required.

Check switch continuity to ground and replace if

necessary.

If the compressor feels hot --- see symptom

COMPRESSOR OVERHEATING.

FLASH CODE: TWO FLASHES Engine coolant temperature switch is open Check wiring connection to switch and tighten as
required.

Check switch continuity to ground and replace if

necessary.

If the compressor feels hot --- see symptom

ENGINE OVERHEATING.

FLASH CODE: FOUR FLASHES Did not attempt to start compressor within When starting the compressor, immediately
30 seconds of turning ignition switch ON. turn the Ignition Switch to the START position
and begin the engine cycle.

Low Battery Voltage Loose battery cables and tighten if necesssary.

Recharge or replace battery if necessary.

No fuel Check fuel level and fuel if necessary.

Water/dirt in fuel and/or fuel filter Drain water from fuel water separators on fuel
filters. Siphon water from fuel tank and clean
fuel tank if necessary.

Plugged fuel filter Replace fuel filter if necessary.

32
 Section 5
MAINTENANCE

5.9 TROUBLESHOOTING GUIDE (CONTINUED)

SYMPTOM PROBABLE CAUSE REMEDY

FLASH CODE: FOUR FLASHES (cont) Plugged air filter Clean and replace if necessary.

Engine problems may have developed Refer to Engine Operators Manual.

Starter solenoid relay does not engage Check wiring and tighten all connections.

Replace relay.

Alternator failure Check output of alternator frequency terminal

COMPRESSOR SHUTS DOWN:

NO FLASH CODE: Blown fuse in wiring harness Remove/Inspect fuse and replace if necessary.

Instrument panel connectors loose or Check instrument panel connectors and reattach if
disconnected. required

Instrument panel connectors loose or Check instrument panel wires for broken connec
disconnected. tions or corrosion. Clean and/or replace if required.

Faulty SSAM module Replace the SSAM Module

FLASH CODE: ONE FLASH Faulty compressor temperature switch Check wiring connection to switch and tighten as
required.

Check switch continuity when cool and replace if

necessary.

Cooling air flow is insufficient Clean cooler and check for proper ventilation.

Low compressor fluid sump level Add fluid as required.

Clogged compressor fluid filter Change filter element.

Faulty thermostat Change the thermostat element.

Loose or broken fan belt Check fan belt and tighten/replace as necessary.

Plugged fluid cooler tube (internal) Replace cooler.

FLASH CODE: TWO FLASHES Faulty Engine coolant temperature switch Check wiring connection to switch and tighten as
necessary.

Check switch continuity to ground when cool and

replace if necessary.

Cooling air flow is insufficient Clean cooler and check for proper ventilation.

Loose or broken fan belt Check fan belt and tighten/replace as necessary.

Engine problems may have developed. Refer to engine operators manual.

No engine coolant Check engine coolant level and fill with proper wa
ter/glycol mixture as required.

FLASH CODE: THREE FLASHES Faulty engine oil pressure switch Check wiring connection to switch and tighten as
required.

Install gauge in parallel with switch. Replace switch

if pressure exceeds 15 psig and switch stays
open. If pressure is less than 15 psig, refer to En
gine Operators Manual.

33
 Section 5
MAINTENANCE

5.10 TROUBLESHOOTING GUIDE (CONTINUED)

SYMPTOM PROBABLE CAUSE REMEDY

FLASH CODE: FOUR FLASHES No/Low fuel Check fuel level and add fuel if necessary.

Plugged fuel filter Replace and clean as required.

Plugged air filter Replace and clean as required.

Water/Dirt in fuel and/or fuel filter Drain water from fuel water separators on fuel filters
Siphon water from fuel tank and clean fuel tank it.
necessary.
COMPRESSOR WILL NOT For compressors with idle warm--- up controls,
BUILD UP FULL DISCHARGE switch toggle to run for full operation.
PRESSURE
Air Demand Is Too Great. Check service lines for leaks or open valves.

Dirty Air Filter Check the filter indicator and change element
if required.
Defective Pressure Regulator Check diaphragm and replace if necessary
(kit available).
Defective Idle Warm--- up Control Replace control.

IMPROPER UNLOADING WITH AN

EXCESSIVE PRESSURE BUILD--- UP
CAUSING PRESSURE RELIEF VALVE
TO OPEN Pressure Regulating Valve Is Set Readjust.
Too High

Leak In Control System Causing Check control lines.

Loss Of Pressure Signal
Defective pressure regulating valve;
repair valve (kit available).
Inlet Valve Jammed Free or replace valve.

FLASH CODE: FIVE FLASHES (option) No/low fuel Check fuel level & add fuel if necessary.
IMPROPER UNLOADING WITH AN
EXCESSIVE PRESSURE BUILD--- UP
CAUSING PRESSURE RELIEF VALVE
TO OPEN (continued) Restriction In The Control System Check all control lines and components.
Ice and/or other contaminants could cause
.

Defective Pressure Relief Valve Replace pressure relief valve.

Opening At Too Low Of Pressure

Defective Pressure Regulator Check diaphragm and replace if necessary

(kit available).

INSUFFICIENT AIR DELIVERY Engage Idle Warm--- up Control In Run

Position For Full Compressor Operation.

Plugged Air Filter Replace.

Plugged Air/Fluid Separator Replace separator element and also change

compressor fluid and fluid filter at this time.

Defective Pressure Regulator Adjust or repair.

Engine Speed Too Low Readjust engine speed.

Defective Idle Warm--- up Control Replace control.

34
 Section 5
MAINTENANCE

5.9 TROUBLESHOOTING GUIDE (CONTINUED)

SYMPTOM PROBABLE CAUSE REMEDY

EXCESSIVE COMPRESSOR Clogged Return Line Clear orifice and return line strainer.
FLUID CONSUMPTION
Leak In The Lubrication System Check all pipes, connections and
components.
Separator Element Damaged Or Not Change separator element.
Functioning Properly

COMPRESSOR OVERHEATING Low Sump Fluid Level Fill.

Loose Or Broken Fan Belt Tighten or change belt.

Dirty Fluid Cooler Core Clean core thoroughly.

Plugged Compressor Fluid Filter Change element.

Faulty Thermostat Change thermostat element.

Plugged Fluid Cooler Tube (Internal) Replace cooler.

ENGINE OVERHEATING Loose Or Broken Fan Belt Tighten or change belt.

Dirty Radiator Core Clean thoroughly.

Low Fluid Level Refill.

Faulty Water Pump Change pump.

Plugged Radiator Clean and flush thoroughly.

Defective Engine Thermostat Replace engine thermostat.

35
 NOTES

36
 Section 6
NOISE CONTROL
6.1 NOISE EMISSIONS WARRANTY 2. The use of the compressor after such device or
Sullair Corporation warrants to the ultimate pur- element of design has been removed or ren-
chaser and each subsequent purchaser that this air dered inoperative by any person.
compressor was designed, built and equipped to Among those acts included in the prohibition
conform at the time of sale to the first retail pur- against tampering are the acts listed below:
chaser, with all applicable U.S. E.P.A. and/or any
Federal, State or Local noise control regulations. 1. Removal or rendering inoperative any of the fol-
lowing:
This warranty is not limited to any particular part, a. Engine exhaust system or parts thereof
component, or system of the air compressor. De- b. Compressor air intake system or part thereof
fects in the design, assembly, or in any part, compo- c. Enclosure of part thereof
nent, or system of the compressor which, at the time 2. Removal of any of the following:
of sale to the first retail purchaser, caused noise a. Vibration isolators
emissions to exceed Federal standards are covered b. Control silencer
by this warranty for the life of the air compressor. c. Floor panel
d. Fan shroud
6.2 TAMPERING WITH THE NOISE CONTROL SYS- e. Acoustical materials including fiberglass foam
TEM IS PROHIBITED or foam tape
Federal Law prohibits the following acts or the caus- 3. Operation with canopy doors open for any pur-
ing thereof: pose other than starting, stopping, adjustment,
1. The removal or rendering inoperative by any per- repair, replacement of parts or maintenance.
sons, other than for purposes of maintenance, 6.3 NOISE EMISSIONS MAINTENANCE AND MAIN-
repair, or replacement, of any device or element TENANCE RECORD LOG
of design incorporated into any new compressor The following instructions and maintenance record
for the purpose of noise control prior to its sale or log book, for the proper maintenance, use and re-
delivery to the ultimate purchaser or while it is in pair of this compressor, is intended to prevent noise
use. emission degradation (refer to Figure 6---1).

Figure 6 ---1 Noise Emission Maintenance and Maintenance Record Log

1. ANNUAL MUFFLER AND EXHAUST SYSTEM INSPECTION

At least annually inspect muffler(s) and engine exhaust system to make sure all parts are securely mounted,
that all joints and connections are tight, and that the muffler is in good condition. DO NOT operate compres-
sor with defective exhaust system. Remove and replace any defective parts by ordering with part numbers
indicated in the Parts List.

Maintenance
Performed
By
Location
Date

Maintenance
Performed
By
Location
Date

DDDDDDDDDDDDDDDDD

37
Section 6
NOISE CONTROL

2. ANNUAL AIR FILTER(S) AND AIR INLET SYSTEM INSPECTION

In addition to the instructions in the Maintenance section of the Operators Manual, the air filter(s) and entire
air inlet system should be inspected at least annually, to make sure all parts are securely mounted, that all
joints and connections are tight, that there are no other leaks in the system, and that the filter element(s) are
intact. DO NOT operate compressor with defective air inlet system. Remove and replace defective parts by
ordering with part numbers indicated in the Parts List.

Maintenance
Performed
By
Location
Date

Maintenance
Performed
By
Location
Date

DDDDDDDDDDDDDDDDD

3. ANNUAL ENGINE VIBRATION MOUNT INSPECTION

At least annually inspect engine vibration mounts for security of attachment and to make sure the resilient
parts are intact. DO NOT operate compressor with defective engine mounting system. Remove and replace
defective parts by ordering with part numbers indicated in Parts List.

Maintenance
Performed
By
Location
Date

Maintenance
Performed
By
Location
Date

DDDDDDDDDDDDDDDDD

38
 Section 6
NOISE CONTROL

4. ANNUAL FRAME, CANOPY, AND PARTS INSPECTION

At least annually inspect frame, canopy and parts, for security of attachment. Make sure there are not any
missing or deformed members, including all hinged doors, covers and their fastening devices. DO NOT
operate compressor with defective frame, canopy and parts. Remove and replace defective parts by order-
ing with part numbers indicated in Parts List.

Maintenance
Performed
By
Location
Date

Maintenance
Performed
By
Location
Date

DDDDDDDDDDDDDDDDD

5. ANNUAL ACOUSTICAL MATERIALS INSPECTION

At least annually inspect all acoustical materials, if any, for security of attachment. Make sure that there is not
any material missing or damaged (refer to Parts List). Clean or replace, if necessary. DO NOT operate com-
pressor with defective acoustical material. Remove and replace defective parts by ordering with part num-
bers indicated in the Parts List.

Maintenance
Performed
By
Location
Date

Maintenance
Performed
By
Location
Date

DDDDDDDDDDDDDDDDD

39
Section 6
NOISE CONTROL

6. ANNUAL INSPECTIONS FOR PROPER OPERATION OF ALL SYSTEMS.

In addition to other instructions in the Operators Manual, at least annually, operate compressor and inspect
to make sure all systems are operating properly and that engine runs at rated speed and pressure. DO NOT
operate malfunctioning or improperly adjusted compressor. Repair or adjust, per instructions in Operators
Manual, as required.

Maintenance
Performed
By
Location
Date

Maintenance
Performed
By
Location
Date

DDDDDDDDDDDDDDDDD

40
 Section 7
ILLUSTRATIONS AND PARTS LIST
7.1 PROCEDURE FOR ORDERING PARTS
Parts should be ordered from the nearest Sullair Representative or the Representative from whom the com-
pressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly
at the address, phone or fax numbers below.

When ordering parts always indicate the Serial Number of the compressor. This can be obtained from the Bill
of Lading for the compressor or from the Serial Number Plate located on the compressor (see Figure 7---1).

Figure 7 ---1 Serial Number Plate Location

NOTE: For future convenience, write the machine serial number below:
Serial Number ____________________________________________________________________

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

3700 East Michigan Boulevard Zone Des Granges BP 82 Sullair Road, No. 1
Michigan City, Indiana 46360 U.S.A. 42602 Montbrison Cedex, France Chiwan, Shekou
Telephone: 1-- 800-- SULLAIR (U.S.A.) Telephone: 33-- 477968470
Shenzhen, Guangdong PRV.
or 1-- 219-- 879-- 5451 Fax: 33-- 477968499
PRC POST CODE 518068
Telephone: 86-- 755-- 2-- 6851686
Fax: (219) 874-- 1273 www.sullaireurope.com
Fax: 86-- 755-- 2-- 6853473
www.sullair.com www.sullair- asia.com
Parts Department
Telephone: 1-- 888-- SULLAIR (U.S.A.)
Fax:(219) 874-- 1835 CHAMPION COMPRESSORS, LTD.
www.sullair.com 11 -- 15 Mario Place
Princes Highway
Service Department Hallam, Victoria 3803
1-- 888-- 775-- 1604 (U.S.A.)
Telephone:
Australia
Telephone: 61-- 3-- 9-- 796-- 4000
Fax: (219) 874-- 1205
Fax: 61-- 3-- 9-- 703-- 8053
www.sullaircompressors.com www.championcompressors.com.au/

41
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.2 RECOMMENDED SPARE PARTS LIST

KEY DESCRIPTION PART QUANTITY

NUMBER NUMBER

ELEMENTS:
1 element, replacement for air/fluid separator 02250078-- 031 1
2 element for engine oil filter (Caterpillar ) 02250150-- 119 1
3 element for engine fuel filter (Caterpillar ) 02250150-- 120 1
4 element for engine oil filter (John Deere ) 02250144-- 815 1
5 element for engine fuel filter (John Deere ) 02250144-- 814 1
6 element, replacement for air filter 8 primary 02250122-- 816 2
7 element for thermal valve 130F 02250104-- 907 1
KITS:
8 kit, element fuel manager 02250153-- 904 1
9 kit, element for main compressor fluid filter 250028-- 032 1
10 kit, repair for regulator/blowdown valve manifold 02250147-- 737 1
11 kit, repair for pressure regulator valve 250017---280 250019-- 453 1
12 maintenance for minimum pressure/check valve
no. 02250088---349:
S repair kit 250026-- 758 1
S repair kit, cap 1 1/4 02250046-- 397 1
S repair kit, piston 02250051-- 338 1
13 repair kit for return line strainer 241771 241772 1
14 kit, coupling lord (185H, 210H) 02250103-- 596 1
15 kit, coupling lord (260) 02250099-- 930 1
16 repair kit for inlet valve (185H, 210H) 02250109-- 684 1
17 repair kit for inlet valve no. 02250088---348 2---1/2 (260) 250019-- 451 1
18 kit, spring replacment for inlet valve
no. 02250088---348 2---1/2 (260) 250029-- 315 1
LUBRICATION:
19 Sullair AWF---5 gallons (18.9 liter) 250030-- 757 1
20 Sullair AWF---55 gallon drum (208 liter) 250030-- 758 1
MISCELLANEOUS:
21 manual, portable air compressor CIMA 250023-- 146 1

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

42
 Section 7
ILLUSTRATIONS AND PARTS LIST

NOTES

43
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3A ENGINE, COMPRESSOR & PARTS -- 185H & 210H CATERPILLAR

02250149--- 637R02

44
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3A ENGINE, COMPRESSOR & PARTS -- 185H & 210H CATERPILLAR

key part
number description number quantity

1 spacer, brake lever 250p 02250064---594 1

2 conn, female pipe 1/8---27 npt 02250097---138 1
3 elbow, 90 3/8tube x 1/4npt m 02250099---626 1
4 bshg, tpr qd sd 38mm bore 185q 02250103---559 1
5 spring, extension 3.0lg 4.52lb/in .313od 02250124---065 1
6 washer, snubbing vibration mount 02250125---471 6
7 mount, vibration isolator 185 02250125---472 4
8 tee, male branch 3/8tube x 1/8npt 02250138---698 1
9 hose, parkrimp 3/4 x 32 02250139---776 1
10 valve, check 1/8 female --- male 02250142---248 1
11 engine, diesel ca 804---33t 185h/260 (I) 02250146---013 1
12 support, engine l&r 185h---260 pe 02250146---146 2
13 spacer, fan 1.5 lg 185h---260 pe 02250146---479 1
14 fan, 18 blower 185h---260 pe 02250146---549 1
15 rod, speed ctl 185dpq jd 02250148---086 1
16 support, speed cyl 185h---260 ca/pe 02250149---240 1
17 cover, eng pto 185h---260 cat 02250150---197 1
18 gasket, eng pto 185h---260 cat 02250150---198 1
19 orifice, .062 x .25m x .25m nptf 027443 1
20 clamp, hose 13/16 to 1---1/2 040513 1
21 joint, ball female 1/4 l.h. 250011---578 1
22 joint, ball female 1/4 r.h. 250011---597 1
23 elbow, 90 1/4tube x 1/8npt 250018---429 1
24 cylinder, speed 3/4 x 1 stroke 250024---272 1
25 coupling, eng---compr lord 250 (II) 250034---921 1
26 pin, drive coupling 250 jd 250035---041 8
27 elbow, 90d 1/4 tube x 1/4fnpt 250041---287 1
28 nut, hex locking 1/4---20 825504---145 2
29 nut, hex locking 1/2---13 825508---262 2
30 capscrew, hex 8.8 m6 x 16mm 828006---016 1
31 capscrew, hex 8.8 m8 x 65mm 828008---065 4
32 capscrew, hex 8.8 m10 x 25mm 828010---025 2

(Continued on page 47)

(I) For in depth coverage of the engine, consult the Engine Operators Manual. For maintenance on Cater-
pillar engine oil filter, order replacement filter no. 02250150---119. For maintenance on Caterpillar engine
fuel filter, order replacment filter no. 02250150---120.
(II) For maintenance on coupling, order repair kit no. 02250103---596.

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

45
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3A ENGINE, COMPRESSOR & PARTS -- 185H & 210H CATERPILLAR

02250149--- 637R02

46
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3A ENGINE, COMPRESSOR & PARTS -- 185H & 210H CATERPILLAR (continued)

key part
number description number quantity

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

34 capscrew, hex 8.8 m12 x 25mm 828012---025 8
35 capscrew, hex 8.8 m12 x 75mm 828012---075 2
36 capscrew, hex gr5 1/2---13 x 3 1/4 829108---325 2
37 screw, socket iso 4762 m10 x 40mm 829310---040 8
38 washer, pl---b reg pltd 1/2 838208---112 2
39 washer, spr lock ---metric pltd m8 838808---200 4
40 washer, spr lock ---metric pltd m10 838810---220 14
41 hose, heater 3/4 842115---075 5 ft
42 key, paral iso r773 10x8x40 865210---040 1
43 nut, hex jam lh pltd 1/4---28 866604---164 1
44 capscrew, ferry head hd pltd 1/4---20 x 1 867304---100 1
45 capscrew, ferry head hd pltd 1/4---20 x 1 1/2 867304---150 1
46 nut, hex jam rh pltd 1/4---28 868204---164 2
47 connector, 45 deg str x jic 1 7/8 x 1 7/8 870524---024 1
48 connector, 90d str x jic 1 1/16 x 1 1/16 870612---012 1
49 adapter, pipe male 7/16 orng x 1/8 877202---012 1
50 washer, nord---lock pl 1/2 878608---077 8
51 compressor & part, dxx102147e (III) 1
52 washer, rtnr ctl cyl spring 5/16 02250078---842 1

(III) There is an exchange program whereby a remanufactured compressor unit can be obtained from Sullair
distributors or the factory at less cost than the owner could repair the unit. For information regarding the
unit exchange program, contact your nearest Sullair representative or the Sullair Corporation.
The shaft seal is not considered part of the compressor unit in regard to the two year warranty. The normal
Sullair parts warranty applies. For shaft seal repairs consult factory.

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

47
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3B ENGINE, COMPRESSOR & PARTS -- 260 CATERPILLAR

02250149--- 631R02

48
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3B ENGINE, COMPRESSOR & PARTS -- 260 CATERPILLAR

key part
number description number quantity

1 key, .375 x .312 x 1.80 class #2 02250060---568 1

2 spacer, brake lever 250p 02250064---594 1
3 valve, air inlet 2 1/2 black (I) 02250088---348 1
4 elbow, 90 3/8tube x 1/4npt m 02250099---626 1
5 spring, extension 3.0lg 4.52lb/in .313od 02250124---065 1
6 washer, snubbing vibration mount 02250125---471 4
7 mount, vibration isolator 185 02250125---472 4
8 hose, parcrimp 3/4 x 26 02250126---680 1
9 tee, male branch 3/8tube x 1/4npt m 02250136---998 1
10 support, compressor 12s 260dpq 02250146---142 1
11 support, engine l&r 185h---260 pe 02250146---146 2
12 spacer, fan 1.5 lg 185h---260 pe 02250146---479 1
13 fan, 18 blower 185h---260 pe 02250146---549 1
14 hose, 1---1/2---18 185h---260dpq 02250146---978 1
15 rod, speed ctl 185dpq jd 02250148---086 1
16 support, speed cyl 185h---260 ca/pe 02250149---240 1
17 cover, eng pto 185h---260 cat 02250150---197 1
18 gasket, eng pto 185h---260 cat 02250150---198 1
19 orifice, .062 x .25m x .25m nptf 027443 1
20 clamp, hose 13/16 to 1---1/2 040513 1
21 compr model, 12series unit (II) 1
22 joint, ball female 1/4 l.h. 250011---578 1
23 joint, ball female 1/4 r.h. 250011---597 1
24 elbow, 1/4 tube x 1/4 npt 250018---430 1
25 spacer, air conn vlv 250q 250022---950 1
26 cylinder, speed 3/4 x 1 stroke 250024---272 1
27 housing, adapter (250034---402c) 250034---403 1

(Continued on page 51)

NOTE: For in depth coverage of the engine, consult the Engine Operators Manual. For maintenance on
Caterpillar engine oil filter, order replacement filter no. 02250150---119. For maintenance on Caterpillar
engine fuel filter, order replacment filter no. 02250150---120.
(I) See Section 7.5 for breakdown of the inlet filter. For maintenance on air inlet valve no. 02250088---348,
order repair kit no. 250019---451, or spring replacement kit no. 250029---315.
(II) There is an exchange program whereby a remanufactured compressor unit can be obtained from Sullair
distributors or the factory at less cost than the owner could repair the unit. For information regarding the
unit exchange program, contact your nearest Sullair representative or the Sullair Corporation.
The shaft seal is not considered part of the compressor unit in regard to the two year warranty. The
normal Sullair parts warranty applies. For shaft seal repairs consult factory.

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

49
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3B ENGINE, COMPRESSOR & PARTS -- 260 CATERPILLAR

02250149--- 631R02

50
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3B ENGINE, COMPRESSOR & PARTS -- 260 CATERPILLAR (continued)

key part
number description number quantity

28 bushing, taper wood---sd 1.75 250034---920 1

29 coupling, eng---compr lord 250 (III) 250034---921 1
30 pin,drive coupling 250 jd 250035---041 8
31 elbow, 90d 1/4 tube x 1/4fnpt 250041---287 1
32 nut, hex locking 1/4---20 825504---145 2
33 nut, hex locking 1/2---13 825508---262 4
34 o---ring, neoprene 3 1/2 x 1/8 826202---238 1
35 capscrew, hex 8.8 m6 x 16mm 828006---016 1
36 capscrew, hex 8.8 m8 x 65mm 828008---065 4
37 capscrew, hex 8.8 m10 x 25mm 828010---025 2
38 capscrew, hex 8.8 m10 x 35mm 828010---035 12
39 capscrew, hex 8.8 m12 x 25mm 828012---025 8
40 capscrew, hex gr5 1/2---13 x 1 829108---100 14
41 capscrew, hex gr5 1/2---13 x 1 1/4 829108---125 4
42 capscrew, hex gr5 1/2---13 x 3 1/4 829108---325 4
43 capscrew, hex gr5 5/8---11 x 1 1/4 829110---125 4
44 screw, socket iso 4762 m10 x 40mm 829310---040 8
45 washer, spr lock reg pltd 1/2 837808---125 8
46 washer, spr lock reg pltd 5/8 837810---156 4
47 washer, pl---b reg pltd 1/2 838208---112 4
48 washer, spr lock ---metric pltd m8 838808---200 4
49 washer, spr lock ---metric pltd m10 838810---220 14
50 hose, heater 3/4 842115---075 1 ft
51 nut, hex jam lh pltd 1/4---28 866604---164 1
52 plug, pipe 1/8 3000# stl plt 866900---005 1
53 capscrew, ferry head hd pltd 1/4---20 x 1 867304---100 1
54 capscrew, ferry head hd pltd 1/4---20 x 1 1/2 867304---150 1
55 nut, hex jam rh pltd 1/4---28 868204---164 2
56 connector, 90d str x jic 1 7/8 x 1 7/8 870624---024 1
57 washer, nord---lock pl 1/2 878608---077 8

(III) For maintenance on coupling, order repair kit no. 02250099---930.

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

51
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3C ENGINE, COMPRESSOR & PARTS -- 185H & 210H JOHN DEERE

02250149--- 639R02

52
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3C ENGINE, COMPRESSOR & PARTS -- 185H & 210H JOHN DEERE

key part
number description number quantity

1 spacer, brake lever 250p 02250064---594 1

2 conn, female pipe 1/8---27 npt 02250097---138 1
3 elbow, 90 3/8tube x 1/4npt m 02250099---626 1
4 bshg, tpr qd sd 38mm bore 185q 02250103---559 1
5 washer, snubbing vibration mount 02250125---471 6
6 mount, vibration isolator 185 02250125---472 4
7 tee, male branch 3/8tube x 1/8npt 02250138---698 1
8 hose, parkrimp 3/4 x 32 02250139---776 1
9 valve, check 1/8 female --- male 02250142---248 1
10 engine, diesel jd5030tf270 83hp (I) 02250145---523 1
11 support, eng frt rh 185h---260 jd 02250146---143 1
12 support, eng frt lh 185h---260 jd 02250146---144 1
13 rod, speed ctl 185dpq jd 02250148---086 1
14 cylinder, speed air 1---1/16 bore 1 stk 02250148---089 1
15 support, low rpm stop 185 jd 02250148---091 1
16 spring, extension spd ctl 185 jd 02250148---166 1
17 fan, 18 blwr cw 185h---260 jd 02250148---498 1
18 valve, eng oil drain m22x1.5 02250148---791 1
19 spacer, fan 3.50lg 2.5bc 185h jd 02250148---826 1
20 clip, spring spd ctl 185---260 02250152---418 1
21 support, spd ctl 185---260 jd 02250152---439 1
22 orifice, .062 x .25m x .25m nptf 027443 1
23 rod end, spherical rh 5/16 040136 1
24 clamp, hose 1/2 043197 1
25 joint, ball female 1/4 l.h. 250011---578 1
26 elbow, 90 1/4tube x 1/8npt 250018---429 1
27 coupling, eng---compr lord 250 (II) 250034---921 1
28 pin, drive coupling 250 jd 250035---041 8
29 elbow, 90d 1/4 tube x 1/4fnpt 250041---287 1
30 nut, hex pltd 1/4---20 825204---226 1
31 nut, hex locking 1/4---20 825504---145 1
32 nut, hex locking 1/2---13 825508---262 2
33 capscrew, hex 8.8 m8 x 20mm 828008---020 3

(Continued on page 55)

(I) For in depth coverage of the engine, consult the Engine Operators Manual. For maintenance on John
Deere engine oil filter, order replacement filter no. 02250144---815. For maintenance on John Deere en-
gine fuel filter, order replacment filter no. 02250144---814.
(II) For maintenance on coupling, order repair kit no. 02250103---596.

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

53
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3C ENGINE, COMPRESSOR & PARTS -- 185H & 210H JOHN DEERE

02250149--- 639R02

54
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3C ENGINE, COMPRESSOR & PARTS -- 185H & 210H JOHN DEERE (continued)

key part
number description number quantity

34 capscrew, hex 8.8 m8 x 120mm 828008---120 4

35 capscrew, hex 8.8 m10 x 35mm 828010---035 12
36 capscrew, hex 8.8 m12 x 75mm 828012---075 2
37 capscrew, hex 8.8 m16 x 30mm 828016---030 4
38 capscrew, hex gr5 1/4---20 x 1 829104---100 1
39 capscrew, hex gr5 1/2---13 x 3 1/4 829108---325 2
40 washer, pl---b reg pltd 5/16 838205---071 3
41 washer, pl---b reg pltd 1/2 838208---112 2
42 washer, spr lock ---metric pltd m8 838808---200 6
43 washer, spr lock ---metric pltd m10 838810---220 12
44 hose, heater 5/8 842115---062 1 ft
45 key, paral iso r773 10x8x40 865210---040 1
46 nut, hex jam lh pltd 1/4---28 866604---164 1
47 capscrew, ferry head hd pltd 1/4---20 x 1 867304---100 1
48 capscrew, ferry head hd pltd 1/4---20 x 1 1/2 867304---150 1
49 capscrew, ferry head hd pltd 3/8---16 x 1 1/2 867306---150 8
50 nut, hex jam rh pltd 1/4---28 868204---164 1
51 nut, hex jam rh pltd 5/16---24 868205---195 1
52 connector, 45 deg str x jic 1 7/8 x 1 7/8 870524---024 1
53 connector, 90d str x jic 1 1/16 x 1 1/16 870612---012 1
54 adapter, pipe male 7/16 orng x 1/8 877202---012 1
55 washer, nord---lock pl 5/8 878610---100 4
56 compressor & part, dxx102147e (III) 1

(III) There is an exchange program whereby a remanufactured compressor unit can be obtained from Sull-
air distributors or the factory at less cost than the owner could repair the unit. For information regarding
the unit exchange program, contact your nearest Sullair representative or the Sullair Corporation.
The shaft seal is not considered part of the compressor unit in regard to the two year warranty. The
normal Sullair parts warranty applies. For shaft seal repairs consult factory.

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

55
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3D ENGINE, COMPRESSOR & PARTS -- 260 JOHN DEERE

02250149--- 634R02

56
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3D ENGINE, COMPRESSOR & PARTS -- 260 JOHN DEERE

key part
number description number quantity

1 key, .375 x .312 x 1.80 class #2 02250060---568 1

2 spacer, brake lever 250p 02250064---594 1
3 vlv, air inlet 2 1/2 black (I) 02250088---348 1
4 elbow, 90 3/8tube x 1/4npt m 02250099---626 1
5 washer, snubbing vibration mount 02250125---471 4
6 mount, vibration isolator 185 02250125---472 4
7 hose, parcrimp 3/4 x 26 02250126---680 1
8 tee, male branch 3/8tube x 1/4npt m 02250136---998 1
9 engine, diesel jd5030tf270 83hp (II) 02250145---523 1
10 support, compressor 12s 260dpq 02250146---142 1
11 support, eng frt rh 185h---260 jd 02250146---143 1
12 support, eng frt lh 185h---260 jd 02250146---144 1
13 rod, speed ctl 185dpq jd 02250148---086 1
14 cylinder, speed air 1---1/16 bore 1 stk 02250148---089 1
15 support, low rpm stop 185 jd 02250148---091 1
16 spring, extension spd ctl 185 jd 02250148---166 1
17 fan, 18 blwr cw 185h---260 jd 02250148---498 1
18 valve, eng oil drain m22x1.5 02250148---791 1
19 spacer, fan 3.50lg 2.5bc 185h jd 02250148---826 1
20 clip, spring spd ctl 185---260 02250152---418 1
21 support, spd ctl 185---260 jd 02250152---439 1
22 orifice, .062 x .25m x .25m nptf 027443 1
23 rod end, spherical rh 5/16 040136 1
24 clamp, hose 1/2 043197 1
25 compr model, 12 series unit (III) 1
26 joint, ball female 1/4 l.h. 250011---578 1
27 elbow, 90 1/4t pls x 1/4 npt m 250018---430 1
28 spacer, air conn vlv 250q 250022---950 1

(I) See Section 7.5 for breakdown of the inlet filter. For maintenance on air inlet valve no. 02250088---348,
order repair kit no. 250019---451, or spring replacement kit no. 250029---315.
(II) For in depth coverage of the engine, consult the Engine Operators Manual. For maintenance on John
Deere engine oil filter, order replacement filter no. 02250144---815. For maintenance on John Deere en-
gine fuel filter, order replacment filter no. 02250144---814.
(III) There is an exchange program whereby a remanufactured compressor unit can be obtained from Sullair
distributors or the factory at less cost than the owner could repair the unit. For information regarding the
unit exchange program, contact your nearest Sullair representative or the Sullair Corporation.
The shaft seal is not considered part of the compressor unit in regard to the two year warranty. The
normal Sullair parts warranty applies. For shaft seal repairs consult factory.
(Continued on page 59)

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

57
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ILLUSTRATIONS AND PARTS LIST

7.3D ENGINE, COMPRESSOR & PARTS -- 260 JOHN DEERE (continued)

02250149--- 634R02

58
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.3D ENGINE, COMPRESSOR & PARTS -- 260 JOHN DEERE (continued)

key part
number description number quantity

29 housing, adapter (250034---402c) 250034---403 1

30 bushing, taper wood---sd 1.75 250034---920 1
31 coupling, eng---compr lord 250 (IV) 250034---921 1
32 pin, drive coupling 250 jd 250035---041 8
33 elbow, 90d 1/4 tube x 1/4fnpt 250041---287 1
34 nut, hex pltd 1/4---20 825204---226 1
35 nut, hex locking 1/4---20 825504---145 1
36 nut, hex locking 1/2---13 825508---262 4
37 o---ring, neoprene 3 1/2 x 1/8 826202---238 1
38 capscrew, hex 8.8 m8 x 20mm 828008---020 3
39 capscrew, hex 8.8 m8 x 120mm 828008---120 4
40 capscrew, hex 8.8 m10 x 35mm 828010---035 12
41 capscrew, hex 8.8 m16 x 30mm 828016---030 4
42 capscrew, hex gr5 1/4---20 x 1 829104---100 1
43 capscrew, hex gr5 1/2---13 x 1 829108---100 14
44 capscrew, hex gr5 1/2---13 x 1 1/4 829108---125 4
45 capscrew, hex gr5 1/2---13 x 3 1/4 829108---325 4
46 capscrew, hex gr5 5/8---11 x 1 1/4 829110---125 4
47 washer, spr lock reg pltd 1/2 837808---125 8
48 washer, spr lock reg pltd 5/8 837810---156 4
49 washer, pl---b reg pltd 5/16 838205---071 3
50 washer, pl---b reg pltd 1/2 838208---112 4
51 washer, spr lock ---metric pltd m8 838808---200 6
52 washer, spr lock ---metric pltd m10 838810---220 12
53 hose, heater 5/8 842115---062 1 ft
54 nut, hex jam lh pltd 1/4---28 866604---164 1
55 plug, pipe 1/8 3000# stl plt 866900---005 1
56 capscrew, ferry head hd pltd 1/4---20 x 1 867304---100 1
57 capscrew, ferry head hd pltd 1/4---20 x 1 1/2 867304---150 1
58 capscrew, ferry head hd pltd 3/8---16 x 1 1/2 867306---150 8
59 nut, hex jam rh pltd 1/4---28 868204---164 1
60 nut, hex jam rh pltd 5/16---24 868205---195 1
61 connector, 90d str x jic 1 7/8 x 1 7/8 870624---024 1
62 washer, nord---lock pl 5/8 878610---100 4

(IV) For maintenance on coupling, order repair kit no. 02250099---930.

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

59
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.4A AIR INLET AND EXHAUST -- ALL CATERPILLAR MODELS

02250149--- 632R00

60
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.4A AIR INLET AND EXHAUST -- ALL CATERPILLAR MODELS

key part
number description number quantity

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

2 muffler, exhaust 185---8f cat 02250116---163 1
3 clamp, muffler 3/8 bent rod 02250116---227 1
4 filter, air 8 plastic 250q (I) 02250122---797 1
5 hose, hump red 3 x 3.5 x 4.00lg 02250123---376 1
6 support, filter compr 185h---260dpq 02250146---126 1
7 support, filter engs 185h---260dpq 02250146---127 1
8 hose, air inl unit 185hdpq 02250146---129 1
9 hose, air inlet 185h---260dpq pe 02250146---134 1
10 filter, air 8 plastic 185h---260 (II) 02250146---137 1
11 tube, exhaust 185h---260dpq pe 02250146---155 1
12 supt, muffler 185h---260dpq pe 02250146---416 1
13 shield, heat exht 185h---260 pe/ca 02250149---252 1
14 gasket, exhaust 185h---260 pe/cat 02250149---406 1
15 shield, heat fuel tank 185h cat 02250151---050 1
16 clamp, hose 1 13/16 x 2 3/4 adj. 40083 1
17 clamp, exhaust 2---1/2 43203 1
18 clamp, exhaust 2 44135 1
19 clamp, hose 2---13/16 to 3---3/4 250018---550 3
20 clamp, hose 5/8 i.d. 408300---005 1
21 nut, hex f pltd 5/16---18 825305---283 3
22 nut, hex locking 3/8---16 825506---198 1
23 nut, hex metric m8 x 1.25 825908---125 1
24 capscr, hex 8.8 m8 x 20mm 828008---020 2
25 screw, hex ser washer 5/16---18 x 3/4 829705---075 2
26 washer, pl---b reg pltd 3/8 838206---071 1
27 washer, spr lock ---metric pltd m8 838808---200 3
28 washer, metric---iso7089--- 8 865408---170 3
29 plug, pipe 1/8 3000# stl plt 866900---005 1

(I) For maintenance on air filter no. 02250122---797, order replacement element no. 02250122---816.
(II) For maintenance on air filter no. 02250146---137, order replacement element no. 02250122---816 .

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

61
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.4B AIR INLET AND EXHAUST -- ALL JOHN DEERE MODELS

02250149--- 636R00

62
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.4B AIR INLET AND EXHAUST -- ALL JOHN DEERE MODELS

key part
number description number quantity

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

2 clamp, muffler 3/8 bent rod 02250116---227 1
3 filter, air 8 plastic 250q (I) 02250122---797 1
4 hose, hump red 3 x 3.5 x 4.00lg 02250123---376 1
5 clp, v---band jd 4024t 185dpq 02250137---896 1
6 support, filter compr 185h---260dpq 02250146---126 1
7 support, filter engs 185h---260dpq 02250146---127 1
8 hose, air inl unit 185hdpq 02250146---129 1
9 hose, air inlet 185h---260 jd 02250146---131 1
10 filter, air 8 plastic 185h---260 (II) 02250146---137 1
11 muffler, exhaust 185h---260 jd 02250146---159 1
12 support, muffler 185h---260dpq jd 02250146---429 1
13 tube, exhaust 185h---260 jd 02250150---280 1
14 clamp, hose 1 13/16 x 2 3/4 adj. 40083 1
15 clamp. exhaust 3 43713 1
16 clamp, hose 2---13/16 to 3---3/4 250018---550 3
17 clamp, hose 5/8 i.d. 408300---005 1
18 nut, hex f pltd 5/16---18 825305---283 4
19 nut, hex locking 3/8---16 825506---198 2
20 capscr, hex 8.8 m8 x 20mm 828008---020 8
21 screw, hex ser washer 5/16---18 x 3/4 829705---075 4
22 washer, pl---b reg pltd 3/8 838206---071 2
23 washer, spr lock ---metric pltd m8 838808---200 8
24 washer, metric---iso7089--- 8 865408---170 8
25 plug, pipe 1/8 3000# stl plt 866900---005 1

(I) For maintenance on air filter no. 02250122---797, order replacement element no. 02250122---816.
(II) For maintenance on air filter no. 02250146---137, order replacement element no. 02250122---816 .

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

63
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.5 AIR INLET VALVE ASSEMBLY -- 260 JOHN DEERE AND CATERPILLAR

02250088--- 348R01

64
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.5 AIR INLET VALVE ASSEMBLY -- 260 JOHN DEERE AND CATERPILLAR

key part
number description number quantity

1 control vlv sa 250035---309 1

2 cast body--- painted iron p/n/alum. 250039---716 1
3 disc seal 250039---717 1
4 hex ret. cap 250039---669 1
5 spring for piston 250039---718 1
6 piston 250039---670 1
7 piston o---ring viton 250039---671 1
8 spring for cont. vlv. 250039---719 1
9 retaining ring (split) 250039---720 1

NOTE 1: For maintenance on inlet valve (185H, 210H John Deere), order repair kit no. 02250109---684.
NOTE 2: O---ring no. 826202---238 is used to seal off the inlet valve assembly with the compressor unit.
NOTE 3: For maintenane on inlet valve (260 John Deere), order repair kit no. 250019---451, or spring replace-
ment kit no. 250029---315.

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

65
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.6 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM -- ALL MODELS

02250149--- 629R00

66
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.6 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM -- ALL MODELS

key part
number description number quantity

1 container, radiator fluid recovery 02250083---466 1

2 element, thermal valve 130 deg f 185q (I) 02250104---907 1
3 hose, parkrimp 3/4 x 26 02250107---492 1
4 hose, hydparkrimp 3/4 x 88 02250107---494 1
5 guard, fan 20 (110---130 & 185h) 02250112---141 1
6 hose, parcrimp 3/4 x 26 02250126---680 1
7 hose, parkrimp 3/4 x 66 02250126---681 1
8 manifold, thrm by---pass 185 bdr 02250132---254 1
9 seal, clip---on baffles 185 60hp 02250137---297 7
10 hose, parkrimp 3/4 x 32 02250139---776 1
11 cooler, oil 185h---260 t2 02250142---907 1
12 hose, radiator lower 185h jd 5030 02250143---199 1
13 hose, radiator upper 185h jd 02250143---200 1
14 hose, radiator upper 185h---260 pe/cat 02250146---070 1
15 baffle, clr/rad lower 185h---260dpq 02250146---074 1
16 supt, clr/rad mid 185h---260dpq 02250146---075 1
17 support, thermo valve 185h---260 02250146---140 1
18 shroud, rad/oil clr 185h---260 cat 02250146---478 1
19 hose, radiator low 185h---260 pe 02250146---566 1
20 shroud, rad/oil clr 185h---260jd 02250148---825 1
21 radiator, eng. 185h---260 t2 02250149---985 1
22 baffle, clr/rad rh 185h---260 02250149---990 1
23 baffle, clr/rad lh 185h---260dpq 02250149---991 1
24 baffle, clr/rad top 185h---260dpq 02250149---992 1
25 clamp, hose 1 5/16 to 2 1/4 adj. 40014 3
26 drainlock, 1/4 40061 1
27 clamp, hose 1 13/16 x 2 3/4 adj. 40083 1
28 adapter, oil filter .970---20 x 3/4---16 250025---914 1
29 elem, fluid filter (ref 250025---523 tab) (II) 250026---982 1
30 weatherstrip, 1 thick x 1 wide 250041---174 2 ft
31 plug, straight thread 3/4---16 viton 250042---623 1
32 clamp, hose 5/8 i.d. 408300---005 1
33 clamp, hose 1 13/16 i.d. 408300---009 1
34 nut, hex f pltd 1/4---20 825304---236 6

(Continued on page 69)

(I) For maintenance on thermal valve assembly, order erplacement element no. 02250104---907 .

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

67
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.6 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM -- ALL MODELS

02250149--- 629R00

68
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.6 RADIATOR & COMPRESSOR FLUID COOLING SYSTEM -- ALL MODELS (continued)

key part
number description number quantity

35 nut, hex f pltd 5/16---18 825305---283 30

36 o---ring, viton 1 1/2 x 3/32 826502---128 1
37 capscr, hex gr5 3/8---16 x 3/4 829106---075 2
38 screw, hex ser washer 1/4---20 x 3/4 829704---075 20
39 screw, hex ser washer 5/16---18 x 3/4 829705---075 22
40 screw, hex ser washer 5/16---18 x 1 829705---100 8
41 washer, spr lock reg pltd 3/8 837806---094 2
42 washer, pl---b reg pltd 1/4 838204---071 2
43 hose, fuel line 1/4 842315---025 4 ft
44 plug, pipe 1/2 3000# stl plt 866900---020 1
45 rdc, str thrd viton 1 x 3/4 870016---012 1
46 conn, str x jic 1 1/16 x 1 1/16 870112---012 3
47 conn, 45 deg str x jic 1 1/16 x 1 1/16 870512---012 1
48 conn, 90d str x jic 1 1/16 x 1 1/16 870612---012 2

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

69
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.7A FRAME, RUNNING GEAR & PARTS -- ALL MODELS

02250155--- 667R00

70
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.7A FRAME, RUNNING GEAR & PARTS -- ALL MODELS

key part
number description number quantity

1 refl, red 3 truck ---lite 02250052---701 2

2 refl, yellow 3 truck ---lite 02250052---702 2
3 tire, assembly f78---15 (c) 02250101---234 1
4 anl, can supt lift bail 185q8e 02250101---983 1
5 supt, lifting bail l&r 185q 8f 02250105---978 2
6 plate, lifting bail eye 185h---260 02250105---981 1
7 plug, 4 round black plastic 02250106---068 1
8 axle, assy 3500# 55tr x 41.5sc 02250107---053 1
9 jack, hd w/pad 185---425 std 02250116---794 1
10 drawbar, std pivot 185dpq 02250133---864 1
11 supt, shipping 185 pivot drbar 02250133---984 1
12 support, dr---bar swivel 185q 02250141---183 1
13 frame, assembly 185h---260dpq 02250146---077 1
14 fender, 15 wheel 185h---260dpq 02250146---111 2
15 baffle, front inlet 185h---260dpq 02250146---123 1
16 insul, frm frt rh 185h---260 02250147---120 1
17 insul, frm frt 185h---260 02250147---121 1
18 insul, frm rear 185h---260 02250147---122 1
19 insul,toolbox rear 185h---260 02250147---123 1
20 insul, frm side out r&l 185h 02250147---125 2
21 insul, clr baff fill 185h 02250147---126 2
22 insul, toolbox pnl 185h---260 02250147---127 1
23 insul, baff frt 185h---260 02250147---129 1
24 supt, lifting bail 185h---260 02250149---137 1
25 striker, latch frt ---bk ---sides 185h---260 02250149---684 3
26 panel, toolbox w/cut 185h---260dpq 02250150---086 1
27 panel, filter access 185h---260 02250150---087 1
28 bumper, baf 185h---260 dpq tab 02250150---221 1
29 pnl, frm frt 185h tab w/cutouts 02250151---338 1
30 pnl, frm lh w/outlet 185h tab 02250151---341 1
31 pnl, frm rh w/outlet 185h tab 02250151---398 1
32 pnl, frm rear 185h---260 dpq tab 02250151---921 1
33 bracket, spring hanger rear 250002---070 2
34 bracket, spring hanger front 250002---071 2
35 eye, 3 lunette demountable 250002---221 1
36 kit, hdwr 175/185 running gear 250002---968 1
37 weatherstrip, 3/16 x 3/8 250022---436 16 ft
38 screw, #12 wing head 407514 2

(Continued on page 73)

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

71
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.7A FRAME, RUNNING GEAR & PARTS -- ALL MODELS

02250155--- 667R00

72
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.7A FRAME, RUNNING GEAR & PARTS -- ALL MODELS (continued)

key part
number description number quantity

39 retainer, screw assy 407515 2

40 recepticle, clip on 407516 2
41 nut, hex f pltd 5/16---18 825305---283 22
42 nut, hex locking #8---32 825501---070 4
43 nut, hex locking #10---24 825502---083 6
44 nut, hex locking 5/16---18 825505---166 2
45 nut, hex locking 1/2---13 825508---262 8
46 nut, hex locking 5/8---11 825510---329 2
47 capscr, hex gr5 5/16---18 x 1 829105---100 5
48 capscr, hex gr5 1/2---13 x 1 1/4 829108---125 22
49 capscr, hex gr5 1/2---13 x 1 3/4 829108---175 4
50 capscr, hx gr5 5/8---11 x 4 3/4 829110---475 2
51 screw, hex ser washer 5/16---18 x 3/4 829705---075 56
52 washer, spr lock reg pltd 1/2 837808---125 18
53 washer, pl---b reg pltd 5/16 838205---071 42
54 washer, pl---b reg pltd 1/2 838208---112 20
55 washer, pl---b reg pltd 5/8 838210---112 4
56 washer, pl---b wide pltd 5/16 838305---071 1
57 nut, retainer 5/16---18 .092 861405---092 13
58 capscr, hx gr5 1/2---13 x 1 1/4 plt 875608---125 8
59 screw, flt phillips 8---32 x 3/4 875901---075 4
60 screw, rnd phillips 10---24 x 3/4 876002---075 6
61 washer, nord---lock pl 1/2 878608---077 8

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

73
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.7B FRAME LESS RUNNING GEAR & PARTS -- ALL MODELS

02250151--- 314R00

74
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.7B FRAME LESS RUNNING GEAR & PARTS -- ALL MODELS

key part
number description number quantity

1 latch, pivot slam pad lck blk 02250107---837 3

2 grommet, rub 5.75 od 185 60hp 02250138---688 1
3 hinge, side doors 185h---260dpq 02250146---104 2
4 baffle, canopy frt rh 185h---260 02250146---684 1
5 baffle, canopy frt lh 185h---260 02250146---685 1
6 insul, clr baff fill 185h 02250147---126 2
7 insul, air fltr brkt 185h 02250147---128 1
8 insul, can door frt 185h---260 02250147---130 1
9 insul, can door sides 185h---260 02250147---131 1
10 insul can roof lh 185h---260 02250147---136 1
11 insul, can rear lh 185h---260 02250147---138 1
12 insul, baff frt rear l&r 185h 02250147---139 2
13 insul, baff frt side l&r 185h 02250147---140 2
14 insul, roof frt 185h---260 02250147---141 1
15 insul, roof rear 185h---260 02250147---142 1
16 insul, can side rear rh 185h 02250147---157 1
17 hng, can door frt 185h---260dpq 02250149---691 1
18 support, insullation roof 185h 02250150---056 2
19 support, insull roof mid 185h 02250150---057 1
20 pnl,can door sides 185hdpq tab 02250150---225 2
21 door, can frt 185h---260 dpq tab 02250150---227 1
22 pnl, can rear lh 185h---260 tab 02250151---316 1
23 pnl, can frt 185h---260dpq tab 02250151---348 1
24 panel, canopy frt rh 185h---260dpq tab 02250151---402 1
25 pnl, can rear rh 185h---260dpq tab 02250151---407 1
26 pnl, can roof 185h---260 dpq tab 02250151---830 1
27 pnl, can rear bolt ---on 185h tab 02250151---835 1
28 insul, can door rear 185h---260 02250151---906 1
29 weatherstrip, 3/16 x 3/8 250022---436 31 ft
30 screw, mach phill #10---24 x 1/2 250025---692 36
31 hook, door latch male ss 250033---828 3
32 catch, door latch female ss 250033---829 3
33 insert, 1/4---20 blind 250034---538 10
34 bumper, rubber 1/2 dia 250035---095 5
35 nut, hex f pltd 1/4---20 825304---236 6
36 nut, hex locking #10---24 825502---083 36
37 nut, hex locking 1/4---20 825504---145 12

(Continued on page 77)

Note: Consult factory when ordering exterior panels for specific color panel part numbers.

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

75
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.7B FRAME LESS RUNNING GEAR & PARTS -- ALL MODELS

02250151--- 314R00

76
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.7B FRAME LESS RUNNING GEAR & PARTS -- ALL MODELS (continued)

key part
number description number quantity

38 capscr, hex gr5 1/4---20 x 1/2 829104---050 22

39 screw, hex ser washer 5/16---18 x 3/4 829705---075 32
40 washer, pl---b reg pltd 1/4 838204---071 34
41 washer, pl---b reg pltd 5/16 838205---071 6
42 nut, retainer 5/16---18 .092 861405---092 13

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

77
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.8 DISCHARGE SYSTEM AND PARTS -- ALL MODELS

02250149--- 638R01

78
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.8 DISCHARGE SYSTEM AND PARTS -- ALL MODELS

key part
number description number quantity

1 insert, nylon tubing 1/4 od 02250052---841 2

2 tube, nyl .25 od x 040w wht 02250054---860 3 ft
3 tube, nylon .25 od x .04w black 02250054---861 4 ft
4 adpt, receiver oil fill 185dpq 02250064---595 1
5 elem, sep 100---250/100, 185/150 (I) 02250078---029 1
6 tube, 5/16 od x .040 wall 02250081---220 4
7 gl, sight oil level 1---1/2 pltd 02250081---779 1
8 vlv, 1---1/4 npt min press chk (II) 02250083---049 1
9 insert, nyl tubing 3/8 od 02250099---052 4
10 elbow, 90 3/8 tube x 1/4 npt m 02250099---626 1
11 connector, tube oil return 1/4 x 1/4 02250108---700 1
13 tube, oil siphon 1/4 od 110---185 02250114---091 1
14 tbg, nylon---11 3/8 od red 02250139---950 5
15 tbg, nylon---11 3/8 od yellow 02250139---951 4
16 tbg ,nylon---11 3/8 od green 02250139---952 5
17 tbg, nylon---11 3/8 od blue 02250139---953 5
18 tbg, nylon---11 3/8 od orange 02250139---954 6
19 valve, drain 1---1/16---12unf o---ring 02250142---844 1
20 tank, air/oil sep 185h---260dpq 02250142---908 1
21 hose, 1---1/2---18 185h---260dpq 02250146---978 1
22 hose, 1 x 18 w/37deg swvls 02250146---980 1
23 sa, reg/bd manifold 260dpq (III) 02250149---628 1
24 sa, reg/bd vlv 185h---210h (IV) 02250150---360 1
26 plug, o---ring boss sae 1 1/4 40029 1
27 clamp, hose 13/16 to 1---1/2 40513 1
28 strainer, v---type 300psix1/4 (V) 241771 1

(Continued on page 81)

(I) For maintenance on separator, order replacement element no. 02250078---031.

(II) For maintenance on minimum pressure / check valve no. 02250083---049, order as follows:
repair kit 250026---758 1
repair kit, cap 1 1/4 02250046---397 1
repair kit, piston 02250051---338 1
(III) For a breakdown of this sub---assemblys parts, consult Section 7.9B.
(IV) For a breakdown of this sub---assemblys parts, consult Section 7.9A.
(V) For maintenance on v---type strainer no. 241771, order repair kit no. 241772.

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

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7.8 DISCHARGE SYSTEM AND PARTS -- ALL MODELS

02250149--- 638R01

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ILLUSTRATIONS AND PARTS LIST

7.8 DISCHARGE SYSTEM AND PARTS -- ALL MODELS (continued)

key part
number description number quantity

29 valve, relief 140psi 1/2 npt 249807 1

30 conn, 1/4t x 1/4 npt str 250018---428 1
31 valve, ball 3/4 service 250019---865 2
32 coupling, 3/4 male npt am7 250031---648 2
33 washer, .500 hardened 250040---099 8
34 conn, tube---m 1/4 x 1/4 810204---025 1
35 nut, hex locking 1/2---13 825508---262 3
36 capscr, hex gr8 1/2---13 x 1 1/2 828208---150 8
37 capscr, hex gr5 1/2---13 x 1 1/2 829108---150 3
38 screw, hex ser washer 3/8---16 x 1/2 829706---050 2
39 washer, pl---b reg unfin 1/2 837208---112 6
40 washer, spr lock reg pltd 3/8 837806---094 2
41 washer, pl---b reg pltd 3/8 838206---071 2
42 hose, heater 3/4 842115---075 1 ft
43 elbow, 37fl 45m 1 x 1 860016---100 1
44 conn, 37 fl/mpt pltd 1 x 1 860116---100 1
45 nipple, pipe---xs plt 3/4 x cl 866412---000 2
46 nipple, pipe---xs plt 1 x cl 866416---000 2
47 nipple, pipe---xs plt 1 1/4 x cl 866420---000 1
48 nipple, pipe---xs plt 1 1/2 x cl 866424---000 1
49 elbow, pipe 90 deg 300# plt 1 867030---040 1
50 bushing, red pltd 1 1/4 x 1 867105---040 1
51 tee, pipe pltd 1 1/2 868430---060 1
52 tee, red pltd 1 x 3/4 x 3/4 868604---033 1
53 conn, 90d str x jic 1 1/16 x 1 1/16 870612---012 1
54 conn, 90d str x jic 1 7/8 x 1 7/8 870624---024 1
55 tee, str thd m---rn viton 1 1/16 871800---106 1

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

81
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ILLUSTRATIONS AND PARTS LIST

7.9A REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY-- ALL 185H & 210H MODELS
7.9B REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY-- ALL 260 MODELS

02250150--- 361R00 / 022500149--- 098R00

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ILLUSTRATIONS AND PARTS LIST

7.9A REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY-- ALL 185H & 210H MODELS

key part
number description number quantity

1 connector, 5/16tube x 1/4npt 02250081---219 1

2 tee, m run 3/8tube x 1/4npt 02250099---615 1
3 elbow, 90 3/8tube x 1/4npt m 02250099---626 2
4 connector, 3/8 tube x 1/4npt 02250148---188 1
5 manifold, press reg/bd 150psi 185h 02250151---201 1
6 valve, pressure regulator (I) 250017---280 1
7 connector, 1/4tube x 1/4npt 250018---428 1
8 tee, pipe 150# plt 1/4 866815---010 1
9 bushing, red pltd 1/2 x 1/4 867102---010 1
10 nipple, pipe---hx pltd 1/4 x 1/4 868504---025 2

(I) For maintenance on pressure regulator valve no. 250017---280, order repair kit no. 250019---453.

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

7.9B REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY-- ALL 260 MODELS

key part
number description number quantity

1 conn, 5/16 tube x 1/4 npt 02250081---219 1

2 tee, m run 3/8 tube x 1/4 npt 02250099---615 1
3 conn, 3/8tube x 1/2npt 02250129---957 1
4 manifold, regulator blowdown 185 (I) 02250146---046 1
5 conn, 3/8 tube x 1/4npt 02250148---188 1
6 conn, 1/4 tube x 1/4 npt 250018---428 1

(I) For maintenance on regulator blowdown manifold no. 02250147---046, order repair kit no.
02250147---737.

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

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ILLUSTRATIONS AND PARTS LIST

7.10 ELECTRICAL PARTS-- ALL MODELS

02250148--- 897R00

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ILLUSTRATIONS AND PARTS LIST

7.10 ELECTRICAL PARTS-- ALL MODELS

key part
number description number quantity

1 channel, extruded rubber u .25 w 02250086---448 1ft

2 washer, external serrated m10 02250092---169 2
3 cable, ground 4---gauge strap 02250101---258 1
4 battery, grp 31 760 cca 02250104---192 1
5 hold---down, battery 11 j ---bolt 02250104---193 2
6 harn, wrg std light 4---wire 185 02250119---646 1
7 lamp, license plate std 02250119---658 1
8 bracket, license plate lamp 02250119---678 1
9 switch, engine oil pressure n.o. 02250130---668 1
10 switch, temp n.c. 250f, single pole 02250133---513 1
11 sw, engine hi---temp, 225f nc 02250138---107 1
12 support, battery hold 185h---260dpq 02250146---116 1
13 sw, eng hi---temp, 225f nc m16 02250150---295 1
14 boot, battery terminal 041561 2
15 adapter, 1/8npt x 1/8jap pt 250004---618 1
16 nut, plastic square license plate 250006---076 4
17 angle, hold---down battery 250019---104 1
18 cable, batt 0 ga x 15 black 250019---480 1
19 fuse, blade type atc 30amp 250023---996 1
20 lamp, tail/turn/stop (shock mtg) 250028---415 2
21 cable, batt 0 ga x 54 red 250030---047 1
22 nut, hex f pltd 5/16---18 825305---283 1
23 nut, hex locking #10---24 825502---083 2
24 screw, hex ser washer 5/16---18 x 3/4 829705---075 4
25 wrap, tie nylon tf4---8 843200---025 8
26 wrap, tie nylon ty 272mx 843201---272 2
27 nipple, pipe---xs plt 1/8 x cl 866402---000 1
28 tee, pipe 150# plt 1/8 866815---005 1
29 plug, pipe 1/8 3000# stl plt 866900---005 1
30 screw, rnd phillips 10---24 x 3/4 876002---075 2

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

85
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ILLUSTRATIONS AND PARTS LIST

7.11A FUEL TANK AND PARTS -- ALL CATERPILLAR MODELS

02250148--- 847R01

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ILLUSTRATIONS AND PARTS LIST

7.11A FUEL TANK AND PARTS -- ALL CATERPILLAR MODELS

key part
number description number quantity

1 adpt, 1/2str oring x 1/4 fnpt 02250075---714 4

2 cap, fuel fill buttress thread 02250094---791 1
3 tube, fuel return 1/4 jd 185q 02250102---573 1
4 connector, tube oil return 1/4 x 1/4 02250108---700 1
5 filter, assy fuel/water sep (I) 02250118---494 1
6 plug, fuel/water sep 1/2---20 unf 02250118---524 4
7 conn, tube oil return 5/16x1/4 02250118---809 1
8 support, fuel filter mtg. 250 02250123---128 1
9 adpt, fuel pick ---up 185 60hp 02250137---526 1
10 tube, fuel pick ---up 185dpq 60hp 02250139---885 1
11 tank, fuel 34 gallon 185h---260dpq 02250146---112 1
12 strap, fuel tnk hold 185h---260 02250146---113 2
13 support, fuel fltr 185h---260 pe/ca 02250149---381 1
14 connector, hose 5/16 hose x 1/4 npt 043258 2
15 clamp, hose 3/8 047235 9
16 gasket, fuel gauge neoprene 250004---752 1
17 elbow, 5/16 hose x 1/4 npt 406615 2
18 clamp, hose 1 13/16 i.d. 408300---009 1
19 nut, hex f pltd 5/16---18 825305---283 10
20 nut, hex locking 5/16---18 825505---166 4
21 screw, hex ser washer 5/16---18 x 3/4 829705---075 6
22 screw, hex ser washer 5/16---18 x 1 829705---100 4
23 washer, spr lock reg pltd #10 837802---047 5
24 washer, pl---b reg pltd 5/16 838205---071 4
25 hose, fuel line 1/4 842315---025 4 ft
26 hose, fuel line 5/16 842315---031 3 ft
27 plug, pipe 1/8 3000# stl plt 866900---005 1
28 screw, rnd phillips 10---24 x 3/4 876002---075 5

(I) For maintenance on fuel/water assembly filter no. 02250118---494, order repair kit no. 02250153---904.

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

87
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ILLUSTRATIONS AND PARTS LIST

7.11B FUEL TANK AND PARTS -- ALL JOHN DEERE MODELS

02250149--- 635R01

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ILLUSTRATIONS AND PARTS LIST

7.11B FUEL TANK AND PARTS -- ALL JOHN DEERE MODELS

key part
number description number quantity

1 tube, nyl .25 od x .040w blk 02250054---861 2 ft

2 adapter, 1/2str oring x 1/4 fnpt 02250075---714 2
3 cap, fuel fill buttress thread 02250094---791 1
4 conn, female pipe 1/8---27 npt 02250097---138 1
5 tube, fuel return 1/4 jd 185q 02250102---573 1
6 connector, tube oil return 1/4 x 1/4 02250108---700 1
7 filter, assy fuel/water sep (I) 02250118---494 1
8 plug, fuel/water sep 1/2---20 unf 02250118---524 2
9 connector, tube oil return 5/16x1/4 02250118---809 1
10 support, fuel filter mtg. 250 02250123---128 1
11 tube, fuel pick ---up 185dpq 60hp 02250139---885 1
12 tank, fuel 34 gallon 185h---260dpq 02250146---112 1
13 strap, fuel tank hold 185h---260 02250146---113 2
14 adapter, fuel pickup 185 60hp 02250152---163 1
15 silencer, exhaust 1/8npt tm---18w70 micron 02250152---316 1
16 connector, hose 5/16hose x 1/4npt 043258 1
17 clamp, hose 3/8 047235 7
18 gasket, fuel gauge neoprene 250004---752 1
19 conn, 1/4 tube x 1/8 npt 250018---427 1
20 elbow, 90 1/4tube x 1/8npt 250018---429 1
21 elbow, 5/16hose x 1/4npt 406615 1
22 clamp, hose 9/16id 408300---001 1
23 nut, hex f pltd 1/4---20 825304---236 1
24 nut, hex f pltd 5/16---18 825305---283 6
25 nut, hex locking 5/16---18 825505---166 4
26 screw, hex ser washer 1/4---20 x 3/4 829704---075 1
27 screw, hex ser washer 5/16---18 x 3/4 829705---075 4
28 screw, hex ser washer 5/16---18 x 1 829705---100 2
29 washer, spr lock reg pltd #10 837802---047 5
30 washer, pl---b reg pltd 1/4 838204---071 1
31 washer, pl---b reg pltd 5/16 838205---071 4
32 hose, fuel line 1/4 842315---025 4 ft
33 hose, fuel line 5/16 842315---031 3 ft
34 screw, rnd phillips 10---24 x 3/4 876002---075 5

(I) For maintenance on fuel/water assembly filter no. 02250118---494, order repair kit no. 02250153---904.

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

89
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ILLUSTRATIONS AND PARTS LIST

7.12 CANOPY, ACOUSTICAL PANELS & PARTS -- ALL MODELS

02250151--- 313R00

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ILLUSTRATIONS AND PARTS LIST

7.12 CANOPY, ACOUSTICAL PANELS & PARTS -- ALL MODELS

key part
number description number quantity

1 channel, utility mount 100---250 02250044---205 2

2 anl, can supt lift bail 185q8e 02250101---983 1
3 supt, lifting bail l&r 185q 8f 02250105---978 2
4 plate, lifting bail eye 185h---260 02250105---981 1
5 plug, 4 round black plastic 02250106---068 1
6 frame, assembly 185h---260dpq 02250146---077 1
7 baffle, front inlet 185h---260dpq 02250146---123 1
8 insul, frm frt rh 185h---260 02250147---120 1
9 insul, frm frt 185h---260 02250147---121 1
10 insul, frm rear 185h---260 02250147---122 1
11 insul,toolbox rear 185h---260 02250147---123 1
12 insul, frm side out r&l 185h 02250147---125 2
13 insul, clr baff fill 185h 02250147---126 2
14 insul, toolbox pnl 185h---260 02250147---127 1
15 insul, baff frt 185h---260 02250147---129 1
16 supt, lifting bail 185h---260 02250149---137 1
17 striker, latch frt ---bk ---sides185h---260 02250149---684 3
18 panel, toolbox w/cut 185h---260dpq 02250150---086 1
19 panel, filter access 185h---260 02250150---087 1
20 bumper, baf 185h---260 dpq tab 02250150---221 1
21 pnl, frm frt 185h tab w/cutouts 02250151---338 1
22 pnl, frm lh w/outlet 185h tab 02250151---341 1
23 pnl, frm rh w/outlet 185h tab 02250151---398 1
24 pnl, frm rear 210h---260 dlq tab 02250155---687 1
25 weatherstrip, 3/16 x 3/8 250022---436 16 ft
26 screw, #12 wing head 407514 2
27 retainer, screw assy 407515 2
28 recepticle, clip on 407516 2
29 nut, hex f pltd 5/16---18 825305---283 22
30 nut, hex locking #10---24 825502---083 6
31 nut, hex locking 5/16---18 825505---166 2
32 nut, hex locking 1/2---13 825508---262 4
33 capscr, hex gr5 5/16---18 x 1 829105---100 5
34 capscr, hex gr5 1/2---13 x 1 1/4 829108---125 12
35 capscr, hex gr5 1/2---13 x 1 3/4 829108---175 4
36 screw, hex ser washer 5/16---18 x 3/4 829705---075 50
37 washer, spr lock reg pltd 1/2 837808---125 12
38 washer, pl---b reg pltd 5/16 838205---071 36

(Continued on page 93)

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

91
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7.12 CANOPY, ACOUSTICAL PANELS & PARTS -- ALL MODELS

02250151--- 313R00

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ILLUSTRATIONS AND PARTS LIST

7.12 CANOPY, ACOUSTICAL PANELS & PARTS -- ALL MODELS (continued)

key part
number description number quantity

39 washer, pl---b reg pltd 1/2 838208---112 8

40 washer, pl---b wide pltd 5/16 838305---071 1
41 nut, retainer 5/16---18 .092 861405---092 13
42 screw, rnd phillips 10---24 x 3/4 876002---075 6

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

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7.13 INSTRUMENT PANEL & PARTS -- ALL MODELS

02250151--- 313R00

PART NUMBER MODEL GAUGE REFER TO SECTION

REFERENCE CONFIGURATION
02250154-- 335 185H & 210H Caterpillar Standard 7.14A
02250154-- 337 260 Caterpillar Standard 7.14B
02250154-- 440 185H & 210H Standard 7.14C
John Deere
02250154-- 442 260 John Deere Standard 7.14D
02250154-- 336 185H & 210H Caterpillar Full 7.14E
02250154-- 338 260 Caterpillar Full 7.14F
02250154-- 441 185H & 210H Full 7.14G
John Deere
02250154-- 443 260 John Deere Full 7.14H

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7.13 INSTRUMENT PANEL & PARTS -- ALL MODELS

key part
number description number quantity

1 hinge, instrument panel door 185q---8f 02250103---623 1

2 scrw, phil pan hd #6---32 x3/8 02250112---009 4
3 latch, locking instrument panel 02250125---511 1
4 door, instrument panel 185 60hp 02250138---181 1
5 pnl,inst std 185h dpq jd t2 02250147---486 1
6 pnl,can frt 185h---260dpq tab 02250151---348 1
7 weatherstrip, 3/16 x 3/8 250022---436 3 ft
8 screw, mach phill #10---24 x 1/2 250025---692 8
9 bumper, rubber 1/2 dia 250035---095 2
10 nut, hex locking #6---32 825500---102 4
11 nut, hex locking #8---32 825501---070 1
12 nut, acorn pltd #8---32 825615---002 2
13 washer, pl---b reg pltd #6 838200---045 4
14 screw, flt phillips 8---32 x 3/4 875901---075 1
15 screw, rnd phillips 8---32 x 3/8 876001---038 2

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

95
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ILLUSTRATIONS AND PARTS LIST

7.14A INSTRUMENT PANEL AND PARTS -- 185H AND 210H CATERPILLAR (STANDARD GAUGE)

02250154--- 335R01

96
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ILLUSTRATIONS AND PARTS LIST

7.14A INSTRUMENT PANEL AND PARTS -- 185H AND 210H CATERPILLAR (STANDARD GAUGE)

key part
number description number quantity

1 gauge, pressure air 0---300 2 02250044---361 1

2 hour---meter, 12---24vdc 10000hr 2 02250050---517 1
3 tee, m run 3/8tube x 1/4npt 02250099---615 2
4 elbow, 90 3/8tube x 1/4npt m 02250099---626 2
5 tube, nylon .375od x .050w black 02250099---630 2 ft
6 controller, 185/375 shutdown
module (ssam) 02250126---682 1
7 lense, cliplite led 02250129---189 1
8 panel, instrument plastic ssam 02250129---190 1
9 decal, dual pressure 185---375 ssam 02250130---630 1
10 decal, starting aid 185---375 cat 02250130---631 1
11 decal, group std panel (ssam) 02250131---485 1
12 switch, engine ignition 12---volt 02250132---883 1
13 valve, ball 2---way 1/4npt 02250136---999 2
14 elbow, 90 f 3/8tube x 1/4npt 02250137---033 1
15 cover, access ssam molded abs 02250137---265 1
16 harness, wiring 210h---260 cat t2 02250154---334 1
17 switch, starter push---button 040038 1
18 screw, tc---f rd hd #6---32 x 1/2 835700---050 2
19 washer, pl---b reg pltd #6 838200---045 2
20 bushing, red pltd 1/4 x 1/8 867100---005 1

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

97
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7.14B INSTRUMENT PANEL AND PARTS -- 260 CATERPILLAR (STANDARD GAUGE)

02250154--- 337R01

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ILLUSTRATIONS AND PARTS LIST

7.14B INSTRUMENT PANEL AND PARTS -- 260 CATERPILLAR (STANDARD GAUGE)

key part
number description number quantity

1 gauge, pressure air 0---300 2 02250044---361 1

2 hour---meter, 12---24vdc 10000hr 2 02250050---517 1
3 elbow, 90 3/8tube x 1/4npt m 02250099---626 1
4 tube,nylon .375od x .050w black 02250099---630 1 ft
5 controller, 185/375 shutdown
module (ssam) 02250126---682 1
6 lense, cliplite led 02250129---189 1
7 panel, instrument plastic ssam 02250129---190 1
8 decal ,starting aid 185---375 cat 02250130---631 1
9 decal, group std panel (ssam) 02250131---485 1
10 switch, engine ignition 12---volt 02250132---883 1
11 tee, male branch 3/8tube x 1/4npt m 02250136---998 1
12 valve, ball 2---way 1/4npt 02250136---999 1
13 elbow, 90 f 3/8tube x 1/4npt 02250137---033 1
14 cover, access ssam molded abs 02250137---265 1
15 harness, wiring 210h---260 cat t2 02250154---334 1
16 switch, starter push---button 040038 1
17 screw, tc---f rd hd #6---32 x 1/2 835700---050 2
18 washer, pl---b reg pltd #6 838200---045 2
19 bushing, red pltd 1/4 x 1/8 867100---005 1

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

99
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ILLUSTRATIONS AND PARTS LIST

7.14C INSTRUMENT PANEL AND PARTS -- 185H AND 210H JOHN DEERE (STANDARD GAUGE)

02250154--- 440R01

100
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ILLUSTRATIONS AND PARTS LIST

7.14C INSTRUMENT PANEL AND PARTS -- 185H AND 210H JOHN DEERE (STANDARD GAUGE)

key part
number description number quantity

1 gauge, pressure air 0---300 2 02250044---361 1

2 hour---meter, 12---24vdc 10000hr 2 02250050---517 1
3 tee, m run 3/8tube x 1/4npt 02250099---615 2
4 elbow, 90 3/8tube x 1/4npt m 02250099---626 2
5 tube, nylon .375od x .050w black 02250099---630 2 ft
6 lense, cliplite led 02250129---189 1
7 panel, instrument plastic ssam 02250129---190 1
8 decal, dual pressure 185---375 ssam 02250130---630 1
9 decal, starting aid 185---375 cat 02250130---631 1
10 decal, group std panel (ssam) 02250131---485 1
11 switch, engine ignition 12---volt 02250132---883 1
12 valve, ball 2---way 1/4npt 02250136---999 2
13 elbow, 90 f 3/8tube x 1/4npt 02250137---033 1
14 cover, access ssam molded abs 02250137---265 1
15 controller, ssam 185---60hp 02250139---296 1
16 harness, wiring 210h---260 jd t2 02250154---439 1
17 switch, starter push---button 040038 1
18 screw, tc---f rd hd #6---32 x 1/2 835700---050 2
19 washer, pl---b reg pltd #6 838200---045 2
20 bushing, red pltd 1/4 x 1/8 867100---005 1

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

101
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7.14D INSTRUMENT PANEL AND PARTS -- 260 JOHN DEERE (STANDARD GAUGE)

02250154--- 442R01

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ILLUSTRATIONS AND PARTS LIST

7.14D INSTRUMENT PANEL AND PARTS -- 260 JOHN DEERE (STANDARD GAUGE)

key part
number description number quantity

1 gauge, pressure air 0---300 2 02250044---361 1

2 hour---meter, 12---24vdc 10000hr 2 02250050---517 1
3 elbow, 90 3/8tube x 1/4npt m 02250099---626 1
4 tube, nylon .375od x .050w black 02250099---630 1 ft
5 lense, cliplite led 02250129---189 1
6 panel, instrument plastic ssam 02250129---190 1
7 decal, starting aid 185---375 cat 02250130---631 1
8 decal, group std panel (ssam) 02250131---485 1
9 switch, engine ignition 12---volt 02250132---883 1
10 tee, male branch 3/8tube x 1/4npt m 02250136---998 1
11 valve, ball 2---way 1/4npt 02250136---999 1
12 elbow, 90 f 3/8tube x 1/4npt 02250137---033 1
13 cover, access ssam molded abs 02250137---265 1
14 controller, ssam 185---60hp 02250139---296 1
15 harness, wiring 210h---260 jd t2 02250154---439 1
16 switch, starter push---button 040038 1
17 screw, tc---f rd hd #6---32 x 1/2 835700---050 2
18 washer, pl---b reg pltd #6 838200---045 2
19 bushing, red pltd 1/4 x 1/8 867100---005 1

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

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7.14E INSTRUMENT PANEL AND PARTS -- 185H AND 210H CATERPILLAR (FULL GAUGE)

02250154--- 336R02

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ILLUSTRATIONS AND PARTS LIST

7.14E INSTRUMENT PANEL AND PARTS -- 185H AND 210H CATERPILLAR (FULL GAUGE)

key part
number description number quantity

1 gauge, pressure air 0---300 2 02250044---361 1

2 gauge, volt ---meter 12 volt 2 02250044---366 1
3 gauge, pressure mech 0---100psi 2 02250050---516 1
4 hour---meter, 12---24vdc 10000hr 2 02250050---517 1
5 tee, m run 3/8tube x 1/4npt 02250099---615 2
6 elbow, 90 3/8tube x 1/4npt m 02250099---626 2
7 tube, nylon .375od x .050w black 02250099---630 2 ft
8 gauge, temp mech 48 140---300$sf 02250102---619 1
9 controller, 185/375 shutdown
module (ssam) 02250126---682 1
10 lense, cliplite led 02250129---189 1
11 panel, instrument plastic ssam 02250129---190 1
12 decal, dual pressure 185---375 ssam 02250130---630 1
13 decal, starting aid 185---375 cat 02250130---631 1
14 harness, voltmeter 125---425 jd/cat 02250130---635 1
15 decal, group full gauge (ssam) 02250131---486 1
16 switch, engine ignition 12---volt 02250132---883 1
17 valve, ball 2---way 1/4npt 02250136---999 2
18 elbow, 90 f 3/8tube x 1/4npt 02250137---033 1
19 cover, access ssam molded abs 02250137---265 1
20 gauge, temp mech 8ft 140---300$sf 02250143---278 1
21 harness, wiring 210h---260 cat t2 02250154---334 1
22 adapter, red 1/2---14 npt murphy thrd 02250155---384 1
23 switch, starter push---button 040038 1
24 screw, tc---f rd hd #6---32 x 1/2 835700---050 2
25 washer, pl---b reg pltd #6 838200---045 2
26 bushing, red pltd 1/4 x 1/8 867100---005 1

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

105
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ILLUSTRATIONS AND PARTS LIST

7.14F INSTRUMENT PANEL AND PARTS -- 260 CATERPILLAR (FULL GAUGE)

02250154--- 338R02

106
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ILLUSTRATIONS AND PARTS LIST

7.14F INSTRUMENT PANEL AND PARTS -- 260 CATERPILLAR (FULL GAUGE)

key part
number description number quantity

1 gauge, pressure air 0---300 2 02250044---361 1

2 gauge, volt ---meter 12 volt 2 02250044---366 1
3 gauge, pressure mech 0---100psi 2 02250050---516 1
4 hour---meter, 12---24vdc 10000hr 2 02250050---517 1
5 elbow, 90 3/8tube x 1/4npt m 02250099---626 1
6 tube, nylon .375od x .050w black 02250099---630 1 ft
7 gauge, temp mech 48 140---300f 02250102---619 1
8 controller, 185/375 shutdown
module (ssam) 02250126---682 1
9 lense, cliplite led 02250129---189 1
10 panel, instrument plastic ssam 02250129---190 1
11 decal, starting aid 185---375 cat 02250130---631 1
12 harness, voltmeter 125---425 jd/cat 02250130---635 1
13 decal, group full gauge (ssam) 02250131---486 1
14 switch, engine ignition 12---volt 02250132---883 1
15 tee, male branch 3/8tube x 1/4npt m 02250136---998 1
16 valve, ball 2---way 1/4npt 02250136---999 1
17 elbow, 90 f 3/8tube x 1/4npt 02250137---033 1
18 cover, access ssam molded abs 02250137---265 1
19 gauge, temp mech 8ft 140---300f 02250143---278 1
20 harness, wiring 210h---260 cat t2 02250154---334 1
21 adapter, red 1/2---14 npt murphy thrd 02250155---384 1
22 switch, starter push---button 040038 1
23 screw, tc---f rd hd #6---32 x 1/2 835700---050 2
24 washer, pl---b reg pltd #6 838200---045 2
25 bushing, red pltd 1/4 x 1/8 867100---005 1

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

107
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ILLUSTRATIONS AND PARTS LIST

7.14G INSTRUMENT PANEL AND PARTS -- 185H AND 210H JOHN DEERE (FULL GAUGE)

02250154--- 441R02

108
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.14G INSTRUMENT PANEL AND PARTS -- 185H AND 210H JOHN DEERE (FULL GAUGE)

key part
number description number quantity

1 gauge, pressure air 0---300 2 02250044---361 1

2 gauge, volt ---meter 12 volt 2 02250044---366 1
3 gauge, pressure mech 0---100psi 2 02250050---516 1
4 hour---meter, 12---24vdc 10000hr 2 02250050---517 1
5 tee,m run 3/8tube x 1/4npt 02250099---615 2
6 elbow, 90 3/8tube x 1/4npt m 02250099---626 2
7 tube, nylon .375od x .050w black 02250099---630 2 ft
8 gauge, temp mech 48 140---300f 02250102---619 1
9 lense, cliplite led 02250129---189 1
10 panel, instrument plastic ssam 02250129---190 1
11 decal, dual pressure 185---375 ssam 02250130---630 1
12 decal, starting aid 185---375 cat 02250130---631 1
13 harness, voltmeter 125---425 jd/cat 02250130---635 1
14 decal, group full gauge (ssam) 02250131---486 1
15 switch, engine ignition 12---volt 02250132---883 1
16 valve, ball 2---way 1/4npt 02250136---999 2
17 elbow, 90 f 3/8tube x 1/4npt 02250137---033 1
18 cover, access ssam molded abs 02250137---265 1
19 controller, ssam 185---60hp 02250139---296 1
20 gauge, temp mech 8ft 140---300f 02250143---278 1
21 harness, wiring 210h---260 jd t2 02250154---439 1
22 adapter, red 1/2---14 npt murphy thrd 02250155---384 1
23 switch, starter push---button 040038 1
24 screw, tc---f rd hd #6---32 x 1/2 835700---050 2
25 washer, pl---b reg pltd #6 838200---045 2
26 bushing, red pltd 1/4 x 1/8 867100---005 1

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

109
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ILLUSTRATIONS AND PARTS LIST

7.14H INSTRUMENT PANEL AND PARTS -- 260 JOHN DEERE (FULL GAUGE)

02250154--- 443R02

110
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ILLUSTRATIONS AND PARTS LIST

7.14H INSTRUMENT PANEL AND PARTS -- 260 JOHN DEERE (FULL GAUGE)

key part
number description number quantity

1 gauge, pressure air 0---300 2 02250044---361 1

2 gauge, volt ---meter 12 volt 2 02250044---366 1
3 gauge, pressure mech 0---100psi 2 02250050---516 1
4 hour---meter, 12---24vdc 10000hr 2 02250050---517 1
5 elbow, 90 3/8tube x 1/4npt m 02250099---626 1
6 tube, nylon .375od x .050w black 02250099---630 1 ft
7 gauge, temp mech 48 140---300f 02250102---619 1
8 lense, cliplite led 02250129---189 1
9 panel, instrument plastic ssam 02250129---190 1
10 decal, starting aid 185---375 cat 02250130---631 1
11 harness, voltmeter 125---425 jd/cat 02250130---635 1
12 decal, group full gauge (ssam) 02250131---486 1
13 switch, engine ignition 12---volt 02250132---883 1
14 tee, male branch 3/8tube x 1/4npt m 02250136---998 1
15 valve, ball 2---way 1/4npt 02250136---999 1
16 elbow, 90 f 3/8tube x 1/4npt 02250137---033 1
17 cover, access ssam molded abs 02250137---265 1
18 controller, ssam 185---60hp 02250139---296 1
19 gauge, temp mech 8ft 140---300f 02250143---278 1
20 harness, wiring 210h---260 jd t2 02250154---439 1
21 adapter, red 1/2---14 npt murphy thrd 02250155---384 1
22 switch, starter push---button 040038 1
23 screw, tc---f rd hd #6---32 x 1/2 835700---050 2
24 washer, pl---b reg pltd #6 838200---045 2
25 bushing, red pltd 1/4 x 1/8 867100---005 1

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

111
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ILLUSTRATIONS AND PARTS LIST

7.15 SINGLE HOSE REEL OPTION -- ALL MODELS

02250151--- 192R01

112
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.15 SINGLE HOSE REEL OPTION -- ALL MODELS

key part
number description number quantity

1 support, manifold single hose reel 02250054---447 1

2 hose, medium pressure 1jic x 32long 02250054---969 1
3 draw ---bar, long pivot 185dpq 02250136---247 1
4 reel, hose 100ft 3/4hose x 3/4npt 040170 1
5 hose, assembly 5/8id x 18long 040885 1
6 valve, air velocity flow 3/4npt 043480 1
7 adapter, swivel 90deg 3/4h x 3/4p 045241 1
8 support, service manifold 250002---145 1
9 oiler, 1qt microfog nogren 250005---016 1
10 u---bolt, hose reel mount 110---250 250008---322 2
11 valve, ball 3/4 service 250019---865 2
12 coupling, 3/4 male npt am7 250031---648 2
13 lubricator, cf 1 pt 1 30cf 251315 1
14 oiler, line 2---quart 1 npt 405403 1
15 nut, hex f pltd 1/4---20 825304---236 4
16 nut, hex f pltd 5/16---18 825305---283 4
17 nut, hex locking 3/8---16 825506---198 8
18 capscrew, hex gr5 3/8---16 x 1 829106---100 4
19 screw, hex ser washer 5/16---18 x 3/4 829705---075 2
20 washer, pl---b reg pltd 1/4 838204---071 4
21 washer, pl---b reg pltd 5/16 838205---071 4
22 washer, pl---b reg pltd 3/8 838206---071 8
23 connector, 37 fl/mpt pltd 1 x 1 860116---100 1
24 elbow, 37fl 90m 1 x 1 860216---100 1
25 nipple, pipe---xs plt 3/4 x cl 866412---000 4
26 nipple, pipe---xs plt 1 x cl 866416---000 5
27 nipple, pipe---xs plt 1 x 2 866416---020 1
28 nipple,pipe---xs plt 1 x 7 866416---070 1
29 plug, pipe 1 3000# stl plt 866900---040 1
30 elbow, pipe 90 deg 300# plt 3/4 867030---030 1
31 elbow, pipe 90 deg 300# plt 1 867030---040 1
32 bushing, red pltd 1 x 3/4 867104---030 2
33 coupling, pipe 1 300# plt 867430---040 1
34 union, pipe---brs seat 1 300# plt 868030---040 1
35 u---bolt, 1/4 x 1 pipe pltd 868304---100 2
36 u---bolt, 5/16 x 1 1/4 pipe pltd 868305---125 1
37 tee, pipe pltd 1 868430---040 2

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

113
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ILLUSTRATIONS AND PARTS LIST

7.16 DUAL HOSE REEL OPTION -- ALL MODELS

02250141--- 690R02

114
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ILLUSTRATIONS AND PARTS LIST

7.16 DUAL HOSE REEL OPTION -- ALL MODELS

key part
number description number quantity

1 support, hose reel manifold 110---250 02250048---573 1

2 support, hose reel 110---250 portables 02250048---574 1
3 hose, medium pressure 1jic x 32long 02250054---969 2
4 draw ---bar, long pivot 185dpq 02250136---247 1
5 support, dr---bar swivel 185q 02250141---183 1
6 reel, hose 100ft 3/4hose x 3/4npt 040170 2
7 hose, assembly 5/8id x 18long 040885 2
8 valve, air velocity flow 3/4npt 043480 2
9 adapter, swivel 90deg 3/4h x 3/4p 045241 2
10 support, service manifold 250002---145 1
11 oiler, 1qt microfog nogren 250005---016 1
12 u---bolt, hose reel mount 110---250 250008---322 2
13 valve, ball 3/4 service 250019---865 3
14 coupling, 3/4 male npt am7 250031---648 3
15 lubricator, cf 1 pt 1 30cf 251315 1
16 oiler, line 2---quart 1 npt 405403 1
17 nut, hex f pltd 1/4---20 825304---236 4
18 nut, hex f pltd 5/16---18 825305---283 4
19 nut, hex locking 3/8---16 825506---198 12
20 capscrew, hex gr5 3/8---16 x 1 829106---100 8
21 screw, hex ser washer 5/16---18 x 3/4 829705---075 2
22 washer, pl---b reg pltd 1/4 838204---071 4
23 washer, pl---b reg pltd 5/16 838205---071 4
24 washer, pl---b reg pltd 3/8 838206---071 12
25 connector, 37 fl/mpt pltd 1 x 1 860116---100 1
26 elbow, 37fl 90m 1 x 1 860216---100 1
27 nipple, pipe---xs plt 3/4 x cl 866412---000 7
28 nipple, pipe---xs plt 1 x cl 866416---000 5
29 nipple, pipe---xs plt 1 x 2 866416---020 1
30 plug, pipe 1 3000# stl plt 866900---040 1
31 elbow, pipe 90 deg 300# plt 3/4 867030---030 2
32 bushing, red pltd 1 x 3/4 867104---030 3
33 coupling, pipe 1 300# plt 867430---040 1
34 cross, pipe 1 plt 867830---040 1
35 union, pipe---brs seat 1 300# plt 868030---040 1
36 u---bolt, 1/4 x 1 pipe pltd 868304---100 2
37 u---bolt, 5/16 x 1 1/4 pipe pltd 868305---125 1
38 tee, pipe pltd 1 868430---040 1
39 coupling, pipe 1 150# plt 869015---040 1

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

115
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7.17 ONE PINT OILER OPTION -- ALL MODELS

02250151--- 189R00

116
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ILLUSTRATIONS AND PARTS LIST

7.17 ONE PINT OILER OPTION -- ALL MODELS

key part
number description number quantity

1 support, service manifold 250002---145 1

2 valve, ball 3/4 service 250019---865 2
3 coupling, 3/4 male npt am7 250031---648 2
4 lubricator, cf 1 pt 1 30cf 251315 1
5 nut, hex f pltd 1/4---20 825304---236 1
6 nut, hex f pltd 5/16---18 825305---283 1
7 screw, hex ser washer 5/16---18 x 3/4 829705---075 1
8 washer, pl---b reg pltd 1/4 838204---071 1
9 washer, pl---b reg pltd 5/16 838205---071 1
10 nipple, pipe---xs plt 3/4 x cl 866412---000 2
11 nipple, pipe---xs plt 1 x cl 866416---000 2
12 nipple, pipe---xs plt 1 x 2 866416---020 1
13 nipple, pipe---xs plt 1 x 4 866416---040 1
14 nipple, pipe---xs plt 1 x 7 866416---070 1
15 elbow, pipe 90 deg 300# plt 1 867030---040 1
16 bushing, red pltd 1 x 3/4 867104---030 1
17 union, pipe---brs seat 1 300# plt 868030---040 1
18 elbow, red 1 x 3/4 plt 868104---075 1
19 u---bolt, 1/4 x 1 pipe pltd 868304---100 1
20 tee, pipe pltd 1 868430---040 1

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

117
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ILLUSTRATIONS AND PARTS LIST

7.18 ONE QUART OILER / MOISTURE SEPARATOR OPTIONS -- ALL MODELS

02250151--- 191R00

118
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ILLUSTRATIONS AND PARTS LIST

7.18 ONE QUART OILER / MOISTURE SEPARATOR OPTIONS -- ALL MODELS

key part
number description number quantity

1 separator, moisture 02250127---121 1

2 support, service manifold 250002---145 1
3 oiler, 1qt microfog nogren 250005---016 1
4 valve, ball 3/4 service 250019---865 2
5 coupling, 3/4 male npt am7 250031---648 2
6 nut, hex f pltd 1/4---20 825304---236 2
7 nut, hex f pltd 5/16---18 825305---283 2
8 screw, hex ser washer 5/16---18 x 3/4 829705---075 2
9 washer, pl---b reg pltd 1/4 838204---071 2
10 washer, pl---b reg pltd 5/16 838205---071 2
11 nipple, pipe---xs plt 3/4 x cl 866412---000 2
12 nipple, pipe---xs plt 1 x cl 866416---000 3
13 nipple, pipe---xs plt 1 x 2 866416---020 1
14 nipple, pipe---xs plt 1 x 4 866416---040 1
15 nipple, pipe---xs plt 1 x 7 866416---070 1
16 elbow, pipe 90 deg 300# plt 1 867030---040 1
17 bushing, red pltd 1 x 3/4 867104---030 1
18 union, pipe---brs seat 1 300# plt 868030---040 1
19 elbow, red 1 x 3/4 plt 868104---075 1
20 u---bolt, 1/4 x 1 pipe pltd 868304---100 1
21 tee, pipe pltd 1 868430---040 1

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

119
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ILLUSTRATIONS AND PARTS LIST

7.19 CANADIAN TAIL / CLEARANCE LIGHTS -- ALL MODELS

02250150--- 874R00

120
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.19 CANADIAN TAIL / CLEARANCE LIGHTS -- ALL MODELS

key part
number description number quantity

1 nameplate, vin can dual lang 02250101---371 1

2 cover, vin canada 02250101---403 1
3 harness, wirinr clearance lts 02250122---197 1
4 reflector, 3 dia adhs mtg red 02250129---278 4
5 reflector, 3 dia yellow 02250129---279 2
6 lamp, side clearance red 02250139---569 2
7 lamp, side clearance yellow 02250139---570 2
8 holder, lamp side clearance blk 02250139---571 4
9 nut, hex locking #10---24 825502---083 8
10 screw, rnd phillips 10---24 x 3/4 876002---075 8

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

121
Section 7
ILLUSTRATIONS AND PARTS LIST

7.20 DECALS

122
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.20 DECALS

key part
number description number quantity

1 sign, caution towing 55mph 250005---578 1

2 sign, warning compressor fluid fill cap 049685 1
3 sign, warning crush/sever 408919 1
4 decal, side door t ---latch 02250136---670 2
5 sign, warning sever fan port 049965 2
6 decal, doors closed 250038---030 4
7 decal, PE designation 02250075---540 1
8 decal, earth ground 02250075---046 3

(Continued on page 125)

NOTE: SEE SECTION 7.21 FOR MOST DECAL LOCATIONS

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

123
Section 7
ILLUSTRATIONS AND PARTS LIST

7.20 DECALS

124
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.20 DECALS (continued)

key part
number description number quantity

9 decal, warning 100/1600 (I) 250028---258 1

10 decal, warning tougue heavy 02250077---929 1
11 sign, warning hot surfaces 407408 2
12 decal, warning pressurized clg sys 02250051---826 1
13 sign, warning sever belt drive 049964 1
14 decal, diesel fuel 040248 1
15 decal, overfill 02250142---530 2

(Continued on page 127)

(I) OSHA guidelines are superceded by any Federal, State or Local regulations whenever applicable.

NOTE: SEE SECTION 7.21 FOR MOST DECAL LOCATIONS

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

125
Section 7
ILLUSTRATIONS AND PARTS LIST

7.20 DECALS

126
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.20 DECALS (continued)

key part
number description number quantity

16A decal, rated speed 2600/1800 RPM 02250149---907 1

16B decal, rated speed 2500/1800 RPM 02250149---908 1
17A decal, 185H side 02250150---039 2
Sdecal, 185H front 02250109---740 2
17B decal, 210H side 02250150---040 2
Sdecal, 210H front 02250136---964 2
17C Sdecal,260 side 02250150---041 2
decal, 260 front 02250127---644 2
18 decal, noise emission control
(U.S. compressors only) 049463 1
19 decal, operation start/stop 02250133---511 1
20 decal, warning proposition 65
(U.S. compressors only) 02250118---638 1
21 decal, Sullair logo --- black 02250059---054 2

(Continued on page 129)

NOTE: SEE SECTION 7.21 FOR MOST DECAL LOCATIONS

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

127
Section 7
ILLUSTRATIONS AND PARTS LIST

7.20 DECALS

128
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.20 DECALS (continued)

key part
number description number quantity

22A decal, maintenance 210H---260 Cat 02250154---3747 1

22B decal, maintenance 210H---260 JD 02250154---348 1
23 reflector, red 040103 2
24 reflector, amber 250034---319 2
25 decal, water drain 040345 2
26 decal, Sullair AWF 250032---902 1
27 decal, axle lub instructions 250042---543 2

(Continued on page 131)

NOTE: SEE SECTION 7.21 FOR MOST DECAL LOCATIONS

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

129
Section 7
ILLUSTRATIONS AND PARTS LIST

7.20 DECALS

130
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.20 DECALS (continued)

key part
number description number quantity

28 decal, Need An Air Tool 02250140---925 1

29 decal, Sullair AWF 02250097---455 1
30 decal, ISO 9001 02250057---624 1
31 decal, drawbar installation 02250142---050 1
32 decal, wiring diagram 02250144---447 1
33 nameplate, Sullair serial no. (II) 02250108---078 1
34 tag, rpm (II) 250025---437 1
35 seal, wire (II) 250026---962 1
36 nut, hex locking (II) 825501---070 4
37 rivet, pop (II) 843102---038 1
38 screw (II) 875901---075 4

(II) Not shown.

NOTE: SEE SECTION 7.21 FOR MOST DECAL LOCATIONS

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

131
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.21 DECAL LOCATIONS

02250149--- 633R01

132
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.21 DECAL LOCATIONS

key part
number description number quantity

1 decal,iso 9001 blk 3.44x5.75 02250057---624 1

2 decal,sullair 2.50 x 20.0 02250059---054 3
3 decal,earth ground 02250075---046 2
4 decal,pe designation 02250075---540 1
5 decal, warning tongue heavy 100---375 02250077---929 1
6 decal,5 year warranty 02250097---455 1
7 nameplate, sullair serial no. 185q---8f 02250108---078 1
8 decal,185h sullair front 02250109---781 1
9 decal,lead warning proposition 65 02250118---638 1
10 decal,260 sullair front 02250127---644 1
11 decal, operator procedure start stop 185 02250133---511 1
12 decal, warning side door t ---latch 02250136---670 4
13 decal,210h sullair front 02250136---964 1
14 decal,need an air tool? sml 02250140---925 1
15 decal,drwbr instl 185q pe std 02250142---050 1
16 decal,caution--- do not overfill 02250142---530 1
17 decal, wiring diagram 375 cat tier ii w/ssam 02250144---396 1
18 decal, wiring diagram 185 pe/cat/jd tier ii 02250144---447 1
19 decal,rated 2600 odle 1800 (I) 02250149---907 1
20 decal,rated 2500 idle 1800 (II) 02250149---908 1
21 decal,185h 2.5 tall black 02250150---039 2
22 decal,210h 2.5 tall black 02250150---040 2
23 decal,260 2.5 tall black 02250150---041 2
24 decal,maintenance 210h---260 catterpillar 02250154---347 1
25 decal,maintenance 210h---260 john deere 02250154---348 1
26 reflector, red 1.68 x 4.25 040103 4
27 decal diesel fuel 040248 1
28 decal,noise emission control 049463 1
29 reflector, amber 1.68 x 4.25 250034---319 2
30 rivet, pop 1/8 x 3/8 843102---038 4

(I) For 185H and 210 models.

(II) For 260 models.

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

133
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ILLUSTRATIONS AND PARTS LIST

7.22 DRAWBAR INSTALLATION -- ALL MODELS

02250141--- 874R00

134
 Section 7
ILLUSTRATIONS AND PARTS LIST

7.22 DRAWBAR INSTALLATION -- ALL MODELS

key part
number description number quantity

1 washer, pl---b reg plted 1/2 (I) 838208---112 8

2 capscr, hx gr5 1/2---13 x 1 1/4 plt (I) 875608---125 8
3 washer, nord---lock pl 1/2 (I) 878608---077 8

(I) These items shipped as loose parts.

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

135
 WORLDWIDE SALES AND SERVICE

SULLAIR CORPORATION
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 1-- 800-- SULLAIR (U.S.A.)
or 1-- 219-- 879-- 5451
Fax: (219) 874-- 1273
SULLAIR EUROPE, S.A. www.sullair.com SULLAIR ASIA, LTD.
Zone Des Granges BP 82 Sullair Road, No. 1
Chiwan, Shekou
42602 Montbrison Cedex, France Parts Department Shenzhen, Guangdong PRV.
Telephone: 33-- 477968470
Telephone: 1-- 888-- SULLAIR (U.S.A.) PRC POST CODE 518068
Fax: 33-- 477968499 Telephone: 86-- 755-- 2-- 6851686
www.sullaireurope.com (219) 874-- 1835
Fax:
Fax: 86-- 755-- 2-- 6853473
www.sullair.com
www.sullair-- asia.com
Service Department
1-- 888-- 775-- 1604 (U.S.A.)
Telephone:
Fax: (219) 874-- 1205

www.sullaircompressors.com

CHAMPION COMPRESSORS, LTD.

11-- 15 Mario Place
Princes Highway
Hallam, Victoria 3803
Australia
Telephone: 61-- 3-- 9-- 796-- 4000
Fax: 61-- 3-- 9-- 703-- 8053
www.championcompressors.com.au/

The information in this document is

correct at the time of printing for
Portable Compressor Serial Number

004 150300
and all subsequent Serial Numbers.

Printed in U.S.A.
Specifications Subject To
Change Without Prior Notice
E05EP