Sullivan-Palatek DC185P3JD User manual

User Manual
Portable Air Compressors
2013
AUGUST
185 cfm (P3)
John Deere Diesel Engine
Wheel-Mounted
DC185P3JD
DE185P3JD
DF185P3JD
Document: 05018730 0157 / 02
Issued: August 27, 2013

DOCUMENT INFORMATION:
© Sullivan-Palatek, Inc.
ALL RIGHTS RESERVED
Part Number: 05018730 0157
Revision: 02
CONTACT INFORMATION:
Sullivan-Palatek, Inc.
1201 West US Highway 20
Michigan City, IN 46360
Tel: [phone]
Fax: [phone]
Toll Free: 800-438-6203
Website: www.sullivanpalatek.com
RECORD KEEPING:
Record the model and serial number of the compressor for
future reference when contacting the factory for service or
parts.
Model Number:
Serial Number:
DISCLAIMER:
Although this manual is checked for conformity with the
machines described, we cannot guarantee that all errors will
be excluded. Necessary corrections will be made in future
editions of this manual. This manual is subject to change
without notice.
REVISION HISTORY:
# DATE SECTION(S) DESCRIPTION
00 2013-04-26 --- Released for publication
01 2013-07-10 8.13 Replaced RECEIVER ASSEMBLY 00717884 0130 with 00717884 0143 (REV 01)
8.14 Updated DISCHARGE HOSE 00717886 0001 to (REV 01)
8.15 Updated COOLING ASSEMBLY 00717532 0117 to (REV 02)
02 2013-08-27 3.6 Replaced FIGURE 3-6. CD 00006 with CD 00008 (REV 00)
8.6 Added drawing for ENGINE ASSEMBLY, FLEX & CANADIAN 00717585 0223 (REV 00)
8.7 Added drawing for ENGINE ASSEMBLY, EXPORT 00717585 0224 (REV 00)
8.11 Replaced INLET VALVE ASSEMBLY 00717985 0032 with 00717985 0044 (REV 00)
8.13 Replaced RECEIVER ASSEMBLY 00717884 0043 with 00717884 0170 (REV 00)
8.15 Added CONTROL TUBING CD 00008 (REV 00)
8.16 Replaced INSTRUMENT PANEL ASSEMBLY 00717680 0116 and INSTRUMENT PANEL
05018845 0123 with 05018845 0135 (REV 00)

WARRANTY
Portable Compressors
Sullivan-Palatek, Inc. warrants its new portable air compressor products to be free from defects in material and workmanship,
subject to the following provisions:
Warranty Registration: To validate the warranty for each product the purchaser shall complete and return the warranty
UHJLVWUDWLRQIRUPZLWKLQGD\VRIGHOLYHU\WRWKHÀUVWXVHURUUHQWDO
Warranty Period: The warranty period for applicable Sullivan-Palatek products is as follows (subject to the Exclusions and
Limitations noted below):
Air ends on new machines – stator and rotor assembly: Single stage FRPSUHVVRU PRGHOV WKH ÀUVW WR H[SLUH
42 months from shipment by Sullivan-Palatek RUPRQWKV IURPGHOLYHU\ WRWKHÀUVW XVHUTwo stage high pressure
FRPSUHVVRUPRGHOVWKHÀUVWWRH[SLUHPRQWKVIURPVKLSPHQWE\Sullivan-Palatek RUPRQWKVIURPGHOLYHU\WRWKHÀUVW
user. Remainder of new portable air compressor machines:WKHÀUVWWRH[SLUHPRQWKVIURPVKLSPHQWE\Sullivan-
Palatek RUPRQWKVIURPGHOLYHU\WRWKHÀUVWXVHU
Parts, accessories and attachments sold separately from machines, excluding warranty replacement parts
and hand tools:WKHÀUVWWRH[SLUHPRQWKVIURPVKLSPHQWE\Sullivan-Palatek RUPRQWKVIURPGHOLYHU\WRWKHÀUVWXVHU
Warranty replacement parts: remainder of the original warranty period of the replaced part.
Sullivan-Palatek’s Obligations: Sullivan-Palatek’s exclusive obligations with respect to breach of warranty are (i) to repair
or replace (at Sullivan-Palatek option and subject to return of defective parts) any defective part, (ii) to pay the reasonable
cost of making the repair or reinstalling the replacement part and (iii) only for air compressors having two or more axles, to
reimburse up to four hours travel labor at the travel reimbursement rate and mileage at the mileage reimbursement rate for
up to 200 miles (100 miles travel radius) per event to make repairs.
Customer’s Responsibility: As a condition to Sullivan-Palatek’s obligations under this warranty, Customer shall (i) give
Sullivan-Palatek written notice of any warrantable failure of any Sullivan-Palatek product within the applicable warranty
period, (ii) make the product available for repair at a Sullivan-Palatek authorized repair facility, (iii) pay all costs of returning
failed parts to Sullivan-PalatekLYSD\VKLSSLQJFRVWVIRUUHSODFHPHQWSDUWVYSD\UHDVRQDEOHWUDYHOH[SHQVHVIRUÀHOG
repairs performed at customer’s request and (vi) pay the costs of investigating performance complaints that are not covered
by this warranty.
Exclusions and Limitations: Air end seals are not warranted. Engines, tires and batteries are not warranted by Sullivan-
Palatek and are warranted only by the manufacturers of these components. Sullivan-Palatek has no obligation for product
failures or defects resulting from overloading, misuse, neglect, accident, failure to comply with Sullivan-Palatek’s product
manual or failure to install product improvements provided by Sullivan-Palatek . Use on a product of attachments, accessories
or service parts not supplied or recommended by Sullivan-Palatek may, at Sullivan-Palatek’s option, void the warranty of
that product. Sullivan-Palatek has no obligation to pay costs of returning defective parts to Sullivan-Palatek or shipping
replacement parts to customer.
THIS WARRANTY IS SULLIVAN-PALATEK’S ONLY WARRANTY OF ITS PORTABLE AIR COMPRESSOR
PRODUCTS AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED. ANY IMPLIED
WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED.
SULLIVAN-PALATEK HAS NO OBLIGATION UNDER THIS WARRANTY OR OTHERWISE (REGARDLESS OF
THE FORM OF ACTION) FOR SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES, INCLUDING WITHOUT
LIMITATION LOST PROFITS OR LOST INCOME.
This warranty applies to all Sullivan-Palatek portable air compressors shipped after April 1, 2011 unless expressly superseded
E\DODWHUZDUUDQW\,QWKHHYHQWRIDQ\FRQÁLFWEHWZHHQWKLVZDUUDQW\DQGHDUOLHUZDUUDQW\VWDWHPHQWVWKHWHUPVRIWKLV
warranty will apply.

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State
of California to cause cancer, birth
defects and other reproductive harm.

V
I ABOUT THIS MANUAL
I.I SAFETY INSTRUCTIONS
Instructions for the safe operation and maintenance of the Sullivan-Palatek air compressor are located
throughout this manual. These instructions are presented with different labels according to the level of risk
involved, described as follows.
WARNING! is used when death or personal injury could occur if the instruction is not followed.
CAUTION! is used when damage to property could occur if the instruction is not followed.
NOTE! is used to inform the reader of installation, operation or maintenance information that is important but not
hazardous.
I.II MANUAL ORGANIZATION
Anyone operating or servicing the Sullivan-Palatek air compressor should read this entire manual and be
familiar with its information. The chart below is a quick guide to the contents in this manual.
SECTION 1: SAFETY
This section contains important basic information regarding the compressor such as general safety precau-
tions for maintaining and operating portable air compressors.
SECTION 2: SPECIFICATIONS
7KLVVHFWLRQFRQWDLQVDOOWKHHQJLQHHULQJLQIRUPDWLRQUHODWHGWRWKHVSHFLÀFDLUFRPSUHVVRUVXFKDVDSSOLFD-
tion data, dimensional drawings and wiring diagrams.
SECTION 3: COMPONENT DESCRIPTION
This section contains information about how the different systems and components function within an air
compressor.
SECTION 4: TRANSPORTING AND LOCATING
This section contains instructions and safety guidelines for transporting and locating a portable air
compressor.
SECTION 5: OPERATION
This section contains an overview of the compressor controls, initial start-up procedures, and how to start
and stop the air compressor.
SECTION 6: MAINTENANCE
This section contains a maintenance schedule and step-by-step instructions for performing common main-
tenance procedures.
SECTION 7: TROUBLESHOOTING
This section contains symptoms, causes and remedies for common air compressor malfunctions.
SECTION 8: PARTS CATALOG
This section contains procedures for ordering parts, a list of recommended spare parts to keep on hand,
and exploded assembly drawings with corresponding parts lists of all the parts on the air compressor.
I.III SUPPLEMENTAL DOCUMENTS
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supplemental documents are provided in addition to the standard compressor manual.

VI ABOUT THIS MANUAL

VII
II CONTENTS
I ABOUTTHISMANUAL...................................................................V
I.I Safety Instructions ......................................................................v
I.II Manual Organization ....................................................................v
I.III Supplemental Documents ................................................................v
1 SAFETY...............................................................................1
1.1 GeneralSafety ........................................................................ 2
1.2 PressureRelease...................................................................... 2
1.3 FiresandExplosion .................................................................... 2
1.4 MovingParts.......................................................................... 3
1.5 HotSurfaces,SharpEdges,SharpCornersandVacuum...................................... 3
1.6 ToxicandIrritatingSubstances........................................................... 4
1.7 ElectricalShock ....................................................................... 4
1.8 Entrapment........................................................................... 4
2 SPECIFICATIONS.......................................................................5
2.1 TechnicalData ........................................................................ 6
2.2 DimensionalDrawing................................................................... 7
2.3 WiringDiagram........................................................................ 8
3 COMPONENTDESCRIPTION..............................................................9
3.1 PortableCompressorPackage ..........................................................10
3.2 Engine..............................................................................10
3.3 AirendAssembly......................................................................10
3.4 DischargeSystem.....................................................................10
3.5 LubricationSystem.................................................................... 11
3.6 CapacityControlSystem ...............................................................12
3.7 NoiseControlSystems.................................................................13
3.8 InstrumentPanel.....................................................................13
3.9 ElectricalandProtectiveCircuitSystem...................................................14
3.10 Engine Shutdown Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 TRANSPORTINGANDLOCATING.........................................................17
4.1 Lifting ..............................................................................18
4.2 DrawbarsandBrakeActuators..........................................................18
4.3 PreparingtoTow......................................................................18
4.4 Towing..............................................................................19
4.5 ParkingorLocatingCompressor.........................................................20
5 OPERATION..........................................................................21
5.1 InstrumentPanel.....................................................................22
5.2 Receiving............................................................................23
5.3 PneumaticToolsApplication............................................................23
5.4 PreparingforInitialStart-Up ............................................................23
5.5 NormalStarting ......................................................................24
5.6 NormalStopping...................................................................... 24
5.7 EmergencyStop......................................................................24
5.8 OperatingUnderExtremeConditions..................................................... 24
5.9 OperatingSuggestions.................................................................25
5.10 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6 MAINTENANCE........................................................................27
6.1 MaintenanceSchedule ................................................................28
6.2 BoltTorqueGuidelines.................................................................29
 &RPSUHVVRU/XEULFDQW6SHFLÀFDWLRQV .....................................................29
6.4 CompressorLubrication................................................................30
6.5 CompressorOilFilter.................................................................. 31
6.6 EngineLubrication.................................................................... 31

VIII CONTENTS
6.7 Grease.............................................................................. 31
6.8 ControlLinkage....................................................................... 31
6.9 AirIntakeFilter....................................................................... 31
6.10 OilReturnLine ....................................................................... 31
6.11 Air/OilSeparator......................................................................32
6.12 ThermalBy-PassValve.................................................................32
6.13 OilCooler............................................................................32
6.14 CompressorShaftOilSeal..............................................................33
6.15 ControlAdjustments...................................................................33
7 TROUBLESHOOTING.................................................................. 35
7.1 Introduction..........................................................................36
7.2 UnplannedShutdown..................................................................36
7.3 DischargePressureIsTooLow.......................................................... 37
7.4 DischargePressureisTooHighorReliefValveBlows........................................ 37
7.5 ReliefValveBlowsWithThrottleLeverInIdlePosition ....................................... 37
7.6 PressureDoesNotBlowDownAfterShutdown............................................. 37
7.7 CompressorOilLevelIsDecreasingExcessively............................................38
7.8 OilInServiceLine.....................................................................38
7.9 EngineDoesNotAccelerateOrWillNotMaintainFullLoadSpeed.............................38
7.10 SeparatorPlugging....................................................................38
7.11 EngineSpeedControlLeverDoesNotMoveToIdlePositionWithServiceValvesClosed...........39
7.12 EngineSpeedControlLeverDoesNotMoveToFullSpeedWithAirDemand.....................39
7.13 FullLoadSpeedCannotBeObtained.....................................................39
 ,GOH6SHHG'LIÀFXOW7R6HW$IWHU)XOO/RDG6SHHG+DV%HHQ6HW ................................39
7.15 EngineStallsWhenAirDemandIsLow ...................................................40
 &RPSUHVVRU2LO/HDNLQJLQ&RQWURO/LQHV2ULÀFHV ...........................................40
8 PARTSCATALOG......................................................................41
8.1 Ordering Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.2 Parts Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.3 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.4 Recommended Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.5 Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.6 Engine Assembly, Flex & Canadian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.7 Engine Assembly, Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.8 Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.9 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.10 Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
8.11 Inlet Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
8.12 Air Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.13 Receiver Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.14 Discharge Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
8.15 Control Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8.16 Cooling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.17 Oil Filter and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
8.18 Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
8.19 Instrument Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.20 Enclosure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
8.21 Machine Dress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
8.22 Chassis Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
8.23 Lifting Bail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
8.24 Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
8.25 Tire and Wheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
8.26 Fender Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8.27 Drawbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
8.28 Swivel Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
8.29 Safety Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

1
1 SAFETY
TOPICS IN THIS SECTION:
»General Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
»Pressure Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
»Fires and Explosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
»Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
»Hot Surfaces, Sharp Edges, Sharp Corners and Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
»Toxic and Irritating Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
»Electrical Shock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
»Entrapment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2SAFETY
1.1 GENERAL SAFETY
Safety is a prime consideration in the design and manufacture of the compressor. Ultimately, the respon-
sibility for safe operation rests with the individuals who use and maintain the compressor. The following
safety precautions are offered as a guide for the safe operation and maintenance of this machinery.
Only trained and authorized personnel who have read and understand this operator’s manual should
operate the air compressor. Failure to follow the instructions, procedures, and safety precautions in this
manual will increase the possibility of accidents and injuries.
Never start the air compressor unless it is safe to do so. Do not attempt to operate the air compressor with
a known unsafe condition. If an unsafe condition exists or maintenance is required, tag the air compressor
and render it inoperative by disconnecting the battery so others who may not know of the unsafe condition
cannot attempt to operate it until the unsafe condition is corrected.
Use and operate the air compressor only in full compliance with all pertinent Federal, State and Local
codes or requirements including OSHA, EPA and other relevant agency requirements.
Do not modify this compressor or install attachments without consulting the manufacturer.
Known and potential hazards associated with the operating and servicing of portable air compressors are
detailed in the following paragraphs. Not all hazards can be anticipated and the operator of the equipment
is ultimately responsible for identifying hazardous and dangerous conditions, avoiding dangerous opera-
tion and preventing accidents.
1.2 PRESSURE RELEASE
'RQRWRSHQVXPSUHFHLYHURLOÀOOHUFDSZKHQFRPSUHVVRULVUXQQLQJDQGDLUV\VWHPLVSUHVVXUL]HG6KXW
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Do not remove radiator cap until the coolant temperature is below its boiling point. Then loosen cap slowly
to its stop, to relieve any excess pressure. Make sure coolant is not boiling before removing cap completely.
The ethyl ether in the replaceable cylinders used in diesel engine ether starting aid systems is under pres-
sure. Do not puncture or incinerate these cylinders. Do not attempt to remove the center valve core or side
pressure relief valve from these cylinders regardless of whether they are full or empty.
1.3 FIRES AND EXPLOSION
WARNING! Fire or explosion can result from electrical arcing from terminal, battery connections and improperly
grounded equipment.
WARNING! )LUHRUH[SORVLRQFDQUHVXOWIURPVSLOOHGIXHORLODQGRWKHUÁDPPDEOHOLTXLGV
Refuel at a service station or from a fuel tank designed for the purpose. Ground the machine to mobile
dispensers prior to refueling.
Immediately clean up any spills or leaking fuel, battery electrolyte, oil, or anti-freeze solution.
6KXWRIIWKHDLUFRPSUHVVRUDQGDOORZLWWRFRRO.HHSVSDUNVÁDPHVDQGRWKHUVRXUFHVRILJQLWLRQDZD\
and do not permit smoking in the vicinity when adding fuel, checking or adding electrolyte to batteries,
checking or adding oil, checking diesel engine ether starting aid systems or replacing ether cylinders, or
ZKHQUHÀOOLQJDLUOLQHDQWLLFLQJV\VWHPVZLWKDQWLIUHH]H
Do not permit liquids to accumulate in bottom of the compressor frame. Prevent contact with acoustical
surfaces of the air compressor. Wipe down using an aqueous industrial cleaner or steam clean as required.
If necessary, remove acoustical material, clean all surfaces and then replace acoustical material. Do not
XVHÁDPPDEOHVROYHQWVIRUFOHDQLQJSXUSRVHV
Disconnect the grounded (negative) battery connection prior to attempting any repairs or cleaning inside
the enclosure. Tag the ground cable with a warning not to reconnect until servicing is complete.
Keep electrical wiring, battery terminals and other terminals in good condition. Replace any wiring, which
has cracked, cut, abraded, or otherwise degraded insulation. Replace terminals, which are worn, discol-
ored, or corroded. Keep all terminals clean and tight. Turn off battery charger before making or breaking
connections to the battery. Wear a face shield whenever servicing or working on the battery.
Keep tools and other grounded conductive objects away from exposed live electrical parts to avoid arcing,
which might serve as a source of ignition.

3SAFETY
Replace damaged fuel tanks or lines. Do not store or attempt to operate the compressor with any known
leaks in the fuel system or oil lines.
Prior to welding or making weld repairs on the compressor, remove any acoustical material or other mate-
rial that may be damaged by heat or that may support combustion, including diesel engine ether starting
aid cylinders and anti-icing system components containing anti-freeze compound.
.HHSDVXLWDEOHIXOO\FKDUJHGFODVV%&RU$%&ÀUHH[WLQJXLVKHURUH[WLQJXLVKHUVQHDUE\ZKHQVHUYLFLQJDQG
operating the compressor.
Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor.
Open all access doors and allow the enclosure to ventilate prior to attempting to start the engine. Use this
time to check the engine and compressor oil levels, etc.
Do not operate compressor under low overhanging leaves or permit leaves and foliage to contact hot
exhaust system surfaces when operating in forested areas.
(WK\OHWKHUXVHGLQGLHVHOHQJLQHHWKHUVWDUWLQJDLGV\VWHPVLVH[WUHPHO\ÁDPPDEOH&KDQJHF\OLQGHUVDQG
VHUYLFHWKHVHV\VWHPVRQO\LQZHOOYHQWLODWHGDUHDVDZD\IURPKHDWRSHQÁDPHRUVSDUNV'RQRWLQVWDOO
store or otherwise expose ether cylinders to temperatures above 160°F (71°C).
WARNING! Use only properly installed and plumbed ether starting aid systems connected to the diesel engine. Do
QRWVSUD\HWKHULQWRFRPSUHVVRUDLULQOHWÀOWHURULQWRDQDLUÀOWHUWKDWVHUYHVERWKWKHHQJLQHDQGWKH
compressor. Serious damage to the compressor or personal injury may result.
$QWLIUHH]HFRPSRXQGXVHGLQDLUOLQHDQWLLFLQJV\VWHPVFRQWDLQVPHWKDQROZKLFKLVÁDPPDEOH8VH
V\VWHPVDQGUHÀOOZLWKFRPSRXQGRQO\LQZHOOYHQWLODWHGDUHDVDZD\IURPKHDWRSHQÁDPHVRUVSDUNV'R
not expose any part of these systems or the anti-freeze compound to temperatures above 150°F (65°C).
Vapors from the anti-freeze compound are heavier than air. Do not store compound or discharge treated
DLULQFRQÀQHGRUXQYHQWLODWHGDUHD'RQRWVWRUHFRQWDLQHUVRUDQWLIUHH]HFRPSRXQGLQGLUHFWVXQOLJKW
1.4 MOVING PARTS
Keep hands, arms, and other parts of the body as well as clothing away from belts, pulleys, and other
moving parts.
Do not attempt to operate the compressor with the fan guard or other guards removed.
:HDUVQXJÀWWLQJFORWKLQJDQGFRQÀQHORQJKDLUZKHQZRUNLQJDURXQGFRPSUHVVRUVRUDQ\PDFKLQHU\
Keep access doors closed except when repairing, adjusting or performing service, or when starting or stop-
ping the compressor.
Make sure all personnel are clear of the compressor prior to starting, operating, or shutting the compres-
sor off.
Shut off engine before servicing. This includes, but is not limited to, adding fuel, oil, coolant, lubricants,
airline anti-freeze compound, or battery electrolyte, or before replacing ether starting aid cylinders.
Disconnect the grounded negative battery connection to prevent accidental engine operation prior to
attempting repair of adjustments. Tag the battery connection so others will not unexpectedly reconnect it.
Shut down the engine before making adjustments. Make adjustment, and then start engine to check
adjustment. If adjustment is incorrect, shut off the engine, readjust, then restart engine to recheck the
adjustment.
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surfaces clean and free of oil, water, anti-freeze, or other liquids to minimize the possibility of slips or falls.
Use extreme caution when ground is covered with ice or snow.
1.5 HOT SURFACES, SHARP EDGES, SHARP CORNERS AND VACUUM
Avoid contact with hot oil, hot coolant, hot surfaces, and sharp edges and corners.
Keep all parts of the body away from all points of air discharge and away from hot exhaust gases.
Wear personal protective equipment, including gloves and head covering when working in, on, or around
the compressor.
.HHSDÀUVWDLGNLWDYDLODEOH6HHNPHGLFDODVVLVWDQFHSURPSWO\LQFDVHRILQMXU\'RQRWLJQRUHVPDOOFXWV
and burns. They may lead to infection.

4SAFETY
.HHSDOOORRVHFORWKLQJDQGSDUWVRIWKHERG\DZD\IURPHQJLQHDQGRUFRPSUHVVRULQWDNHVRUDLUÀOWHU
intakes.
1.6 TOXIC AND IRRITATING SUBSTANCES
WARNING! 'RQRWXVHDLUIURPWKLVFRPSUHVVRUIRUEUHDWKLQJDLU%UHDWKLQJXQÀOWHUHGDLUIURPWKLVFRPSUHVVRUFDQ
result in serious injury or death.
NOTE! 8QGHUVSHFLÀFJXLGHOLQHVDQGLQIXOOFRPSOLDQFHZLWK26+$6WDQGDUGV&)5DQGDQ\RWKHUIHGHUDO
VWDWHRUORFDOFRGHVRUUHJXODWLRQVFRPSUHVVHGDLUFDQEHXVHGIRUEUHDWKLQJDLU6XOOLYDQ3DODWHNdoes
QRWSURYLGHHTXLSPHQWDQGLQVWUXFWLRQVIRUWKLVDSSOLFDWLRQDQGLWVSURGXFWVDUHQRWSURGXFHGIRUWKLV
application or use.
Do not use airline anti-icing systems in airlines supplying respirators or other breathing air utilization and
HTXLSPHQWDQGGRQRWGLVFKDUJHDLUIURPWKHVHV\VWHPVLQXQYHQWLODWHGRURWKHUFRQÀQHGDUHDV
Operate the compressor only in open or well-ventilated areas.
Carbon monoxide will kill. If the machine is operated indoors, discharge engine exhaust outdoors and be
certain that there are no exhaust system leaks that can discharge exhaust within the building.
Locate this compressor so that exhaust will not be carried toward personnel, air intakes servicing person-
nel areas, or toward the air intake of this or any other portable or stationary compressor.
Fuel, oil, coolant, lubricant, and battery electrolyte used in this compressor are typical of the industry. Care
should be taken to avoid accidental ingestion or skin or eye contact. In the event of ingestion or contact,
seek medical treatment promptly. Do not induce vomiting if fuel is ingested. Wash with soap and water in
the event of skin contact.
Wear an acid resistant apron and a face shield or goggles when servicing the battery. If electrolyte is
VSLOOHGRQVNLQRUFORWKLQJLPPHGLDWHO\ÁXVKDQGZDVKZLWKODUJHTXDQWLWLHVRIZDWHU
WARNING! Ethyl ether used in diesel engine starting aid systems is toxic, harmful, and can be fatal if swallowed.
$YRLGFRQWDFWZLWKWKHVNLQRUH\HVDQGDYRLGEUHDWKLQJWKHIXPHV,IVZDOORZHGGRQRWLQGXFHYRPLWLQJ
EXWVHHNPHGLFDOKHOSLPPHGLDWHO\
Wear goggles or a full face shield when testing ether starting aid systems or adding anti-freeze compound
to air line anti-icing systems. Keep openings of valve, tube, or atomizer or ether starting aid system pointed
away from yourself and other personnel.
If ethyl ether or air line anti-icing system anti-freeze compound enters the eyes or if fumes irritate the eyes,
they should be washed with large quantities of clean water for at least 15 minutes. Medical attention
should be obtained immediately.
Do not store ether cylinders or airline anti-icing system anti-freeze compound in operator’s cabs or in unap-
proved containers.
The anti-freeze compound used in airline anti-icing systems contains methanol and is toxic, harmful, or
fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, induce
vomiting by administering a tablespoon of salt in a glass of clean, warm water until vomit is clear, then
administer two teaspoons of baking soda in a glass of clean water. Have patient lie down and cover eyes to
exclude light. Seek medical assistance.
1.7 ELECTRICAL SHOCK
Keep the towing vehicle or equipment carrier, compressor hoses, tools, and all personnel at least 10 feet
from power lines and buried cables. Greater separation from power lines may be prudent when working
around high voltage. Contact the utility company for guidance.
Keep all parts of the body, any hand-held tools, or other conductive objects away from exposed live parts
of the compressor electrical system. Maintain dry footing, stand on insulating surfaces and do not contact
any other portion of the compressor when making adjustments or repairs to exposed live parts of the
electrical system.
1.8 ENTRAPMENT
Make sure all personnel are out of compressor before closing and latching enclosure doors. Larger
compressors can hold a man. If it is necessary to enter the enclosure to perform service or adjustments,
secure the access door in the open position to avoid the possibility of others closing and latching the door
and inform personnel before entering the enclosure.

5
2 SPECIFICATIONS
TOPICS IN THIS SECTION:
»2.1 TechnicalData...................................................................6
»2.2 DimensionalDrawing.............................................................7
»2.3 WiringDiagram..................................................................8

6SPECIFICATIONS
2.1 TECHNICAL DATA
2.1.1 D185P3JD
COMPRESSOR
Type Single Stage, Oil Flooded Rotary Screw
Rated Delivery cfm (m3/min) 185 (5.2)
Rated Operating Pressure psig (bar) 100 (6.9)
Rated Operating Pressure Range psig (bar) 70-125 (4.9-8.6)
Ambient Temperature Range °F (°C) -20 to +125 (-29 to +52)
Oil Capacity gallons (L) 5.5 (21)
Total Receiver Volume ft3(L) 1.7 (48)
Air Service Connector NPT Two 3/4-in
Type Cooling System Oil to Air
Type Air Intake System Two Stage Dry
Type of Control 0-100% Demand
Tire Size 175/80D13
Estimated Weight, Serviced lbs (kg) 1980 (898)
ENGINE
Type Diesel
Engine Make John Deere
Engine Model 4024TF (Tier 4 Interim)
Number of Cylinders 4
Bore and Stroke in (mm) 3.39 x 4.13 (86 x 105)
Displacement in3(L) 149 (2.4)
Horsepower @ Rated RPM hp (kW) 49 (36.5)
Total Oil Capacity qts (liters) 8.5 (8)
Cooling System Capacity qts (liters) 14 (13.2)
Battery Rating Volts volts 12
Cold Cranking Amps @ 0°F (-18°C) amps 700
Full Load Speed rpm 2650
Idle Speed rpm 1650
Fuel Tank Capacity gallons (L) 20 (75.7)

7SPECIFICATIONS
2.2 DIMENSIONAL DRAWING
46.50in
TRACK WIDTH
1181.13mm
56.51in
1435.30mm
61.87in
EXHAUST HEIGHT
1571.41mm
TO OPEN DOOR
236.23mm
MIN. REQ'D
9.30in
HEIGHT
74.93in
OPEN DOOR
1903.18mm
16.97in
431.04mm
59.15in
1502.51mm
9.09in
231mm
54.69in
MACHINE WIDTH
1389.08mm
36.50in
ENCLOSURE WIDTH
927.08mm
NOTE: SPECIFICATIONS SUBJECT TO
CHANGE WITHOUT NOTICE
1/11/10
1343.29mm
52.89in
36.91in
IN SHIPPING POSITION
SHIPPING POSITION
3.00in
937.64mm
AIR OUTLET
121.92in
1706.57mm
MACHINE LENGTH WITH DRAWBAR
WITH DRAWBAR IN
MACHINE HEIGHT
3096.84mm
66.50in
MACHINE LENGTH
1689.02mm
LIFT EYE
76.20mm
1783.99mm
ENCLOSURE LENGTH
67.19in
70.24in
39.53in
ENCLOSURE HEIGHT
1004.12mm
EST. WEIGHT (DRY)
2020 LBS
916 KG
FIGURE 2-1. D185P3 PORTABLE DIMENSIONAL SPECS 1-11-10

8SPECIFICATIONS
2.3 WIRING DIAGRAM
FIGURE 2-2. WD 15067 DIAGRAM, WIRING D185-210 JD (REV B)

9
3 COMPONENT
DESCRIPTION
TOPICS IN THIS SECTION:
»Portable Compressor Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
»Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
»Airend Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
»Discharge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
»Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
»Capacity Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
»Noise Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
»Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
»Electrical and Protective Circuit System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
»Engine Shutdown Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

10 COMPONENT DESCRIPTION
3.1 PORTABLE COMPRESSOR PACKAGE
7KHFRPSUHVVRULVDVLQJOHVWDJHRLOÁRRGOXEULFDWHGURWDU\VFUHZDLUFRPSUHVVRU7KHFRPSUHVVRUSDFNDJH
is available as a portable wheel-mounted unit, utility mounted unit or galvanized skid-mounted unit for
offshore applications. All models are enclosed in a weather-resistant acoustical enclosure.
The complete operating unit consists of a diesel engine for power, a compressor assembly, air/oil separator
system, cooling system for the engine and compressor oil, instrumentation, pneumatic control system, and
acoustical enclosure.
3.2 ENGINE
The compressor is powered by a diesel engine. For detailed information on the diesel engine refer to the
Engine Operators Manual provided with each compressor.
3.2.1 ENGINE COOLING SYSTEM
The engine cooling system utilizes a conventional engine radiator, thermostat, water pump, and fan to
maintain the engine coolant at a desired operating temperature. An additional charge air cooler is required
for some diesel engines in order to meet EPA emission standards under tier II regulations.
3.2.2 ENGINE TO COMPRESSOR DRIVE
The compressor and engine are connected through a non-lubricated spline coupling. It consists of a drive
ULQJUHJLVWHUHGDQGEROWHGGLUHFWO\WRWKHHQJLQHÁ\ZKHHODQGHLWKHUDVSOLQHGKXERUDGLVFDWWDFKHGWRWKH
compressor drive shaft. Because of low starting torque, no clutch is required.
3.3 AIREND ASSEMBLY
7KHFRPSUHVVRUDVVHPEO\LVDQRLOÁRRGHGSRVLWLYHGLVSODFHPHQWVLQJOHVWDJHURWDU\VFUHZXQLW&RPSR-
nents include a stator housing, male and female rotors, bearings, and bearing supports. Engine power
is transferred to the male rotor through a coupling and, if a gear-driven unit, through gears in the gear
housing. The male rotor drives the female rotor.
3.3.1 COMPRESSION CYCLE
FIGURE 3-1. DIAGRAM, COMPRESSION CYCLE
Air at atmospheric pressure is drawn in through the inlet and compressed by the rotation of the rotors.
During the compression cycle, oil is injected into the compressor performing three important functions:
1. Lubricate the rotating parts and bearings.
2. Provide cooling for the compressed air.
3. Seal the running clearances between the rotors.
3.4 DISCHARGE SYSTEM
3.4.1 RECEIVER/SUMP
From the compressor discharge, oil-laden air enters the receiver/sump tank above the oil level and most of
the oil is separated from the air by gravity. The oil runs downward and accumulates for recirculation, while
the remaining oil mist passes through the separator element. The oil separator is located in the upper
portion of the receiver/sump. When air is demanded at the service line, it passes through the separator
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3.4.2 MINIMUM PRESSURE VALVE
A minimum pressure valve is provided at the service air outlet (at the top of the separator). This valve
serves to maintain a minimum discharge pressure of 65 to 80 psig in operation, which is required to
assure proper air/oil separation. At normal operating pressure of 90 to 125 psig, this valve is wide open,
HIIHFWLYHO\UHPRYLQJDQ\UHVWULFWLRQWRDLUÁRZ

11COMPONENT DESCRIPTION
3.5 LUBRICATION SYSTEM
FIGURE 3-3. AS-804-185 OIL HOSES D185P2 FLEX AIR JD4024 (REV 0)
Oil from the compressor oil sump at compressor discharge pressure is directed through the cooling system
DQGRLOÀOWHUWRDORZHUSUHVVXUHUHJLRQRIWKHFRPSUHVVRUVWDWRU$WWKHVDPHWLPHRLOLVGLUHFWHGWRWKH
bearings and shaft seal of the compressor. The oil-laden air is then discharged back into the sump.
The compressor cooling system consists of an oil cooler mounted adjacent to the engine radiator. Cooling
air is drawn through the cooler by the engine fan while oil is circulated through it by the receiver/sump
pressure.
3.5.1 OIL RETURN LINE
The oil that is removed by the separator, gravitates to the bottom of the separator and is returned through
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3.5.2 THERMAL BY-PASS VALVE
The thermal by-pass valve is the center of the compressor temperature regulating system. The valve is
designed to be fully open, allowing the oil to bypass the cooler until the oil temperature reaches 110°F.
Above 110°F, the valve gradually closes down and becomes completely closed when the oil tempera-
ture reaches approximately 140°F. The valve has a built-in pressure relief feature so that a pressure
drop across the valve of 50 PSI will cause it to open. Therefore, if the cooler should become plugged the
thermal valve will open regardless of temperature, thus providing lubrication to the compressor until the
protective circuit shuts the machine down due to high compressor discharge temperature.
3.5.3 OIL FILTER
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12 COMPONENT DESCRIPTION
3.6 CAPACITY CONTROL SYSTEM
The control system is designed to match air supply to air demand and to prevent excessive discharge pres-
sure when the compressor is operating but air is not being used. Control of air delivery is accomplished
both by inlet valve regulation and engine speed control as directed by the adjustable discharge pressure
regulator valve.
COLD START SOLENOID
(OPTIONAL ON SOME MODELS)
PRESSURE
REGULATOR
NOTE:
VENT DOWN TO
2. UNLESS SPECIFICALLY NOTED, INDIVIDUAL PART ORIENTATIONS ARE FOUND ON ASSEMBLY DRAWINGS
1. SOLID PIPE CONNECTIONS REPRESENTED BY THIN LINES.
ATMOSPHERE
VENT DOWN TO
ATMOSPHERE
VENT DOWN TO
ATMOSPHERE
VENT DOWN TO
VALVE
START/RUN
ATMOSPHERE
BLOWDOWN VALVE
GAUGE
PRESSURE
RECEIVER TANK
INLET VALVE
THROTTLE CYLINDER
ATMOSPHERE
VENT DOWN TO
3. UNLESS SPECIFICALLY NOTED, IMAGES OF PARTS ARE FOR REPRESENTATION ONLY, ACTUAL PARTS MAY VARY IN APPEARANCE.
MATERIAL:
DECIMAL: X.X + OR - 0.050
IT IS LOANED SUBJECT TO RETURN UPONDEMAND, IS NOT TO BE USED DIRECTLY OR INDIRECTLY
DRA
D
PROJECTION
1201 West
SCALE:
TOLERANCES AS FOLLOWS:
DESCRIPTION
THIS DRAWING ANDALL INFORMATIONTHEREINIS THE PROPERTYOF SULLIVAN-PALATEK, INC. I
WWW.SUL
SUL
CHECKED BY: DATE:
DATE:DRAWN BY :
FIRST USED ON:
ANGLES: + OR - 1/2 DEG.
DIMENSIONS A RE IN INCHES
UNLESS OTHERWISE NOTED
X.XXX + OR - 0.005
X.XX + OR - 0.020
3RD ANGLE
SIZE
LOW PR
3/28/13
1D185P2JD
MFP
AS NOTED
3/28/13 DIAG
JPC
FIGURE 3-6. CD 00008 DIAGRAM, CONTROL D185P2-P3 SINGLE PRESSURE PNEUMATIC CONTROL (REV 00)
The following discussion explains the operation of the control from a condition of “no load” to a condition
of “full capacity” at working pressure. For the working pressure range of your machine, refer to applicable
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the dry side of the receiver via the pressure regulator valve that when the separator pressure is below the
set point of the regulator valve no pressure will exist in the inlet valve cylinder, and the modulating piston
will be held at the fully-opened position by the pre-load of the modulating spring. Under these conditions,
the inlet valve will remain wide open, causing the compressor to deliver full capacity. As the demand for air
decreases, the receiver pressure will rise, and when this pressure level exceeds the set point of the pres-
sure regulator valve, control signal pressure will be allowed to enter the inlet valve chamber which in turn
will move the modulating piston and the valve plate to a closed condition, thereby throttling the incoming
air. A separate throttle air cylinder controls engine speed. The air cylinder is spring loaded in the full speed
position when there is no air signal from the pressure regulator valve. Whenever less than full capacity is
required, receiver pressure increases, thereby opening the pressure regulator, which allows a pressure
signal to enter the throttle air cylinder and reduce the engine speed until it matches the air requirements
from 100% down to 60%. From 60% down to 0% both engine speed reduction and inlet valve modulation
act together to reduce air output.
3.6.1 INLET VALVE
The inlet valve assembly is the heart of the control system, which regulates the amount of air entering the
compressor. A separate air cylinder regulates engine speed. From full to approximately 60 percent capacity,
the delivery is controlled by engine speed and a gradual closing of the inlet valve. When unloaded the inlet
valve is closed to prevent atmospheric air from entering the compressor.