Sullivan-Palatek D110PKU User Manual
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Sullivan-Palatek D110PKU User Manual

Wheel-mounted portable compressor 110 cfm
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USER MANUAL
WHEEL-MOUNTED PORTABLE COMPRESSOR \ 110 CFM
D110PKU
KUBOTA DIESEL ENGINE
TIER 4 FINAL
Document: 05018730 0249 / 01
Issued: January 31, 2019

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  • Page 1 USER MANUAL WHEEL-MOUNTED PORTABLE COMPRESSOR \ 110 CFM D110PKU KUBOTA DIESEL ENGINE TIER 4 FINAL Document: 05018730 0249 / 01 Issued: January 31, 2019...
  • Page 2 DOCUMENT INFORMATION © Sullivan-Palatek, Inc. ALL RIGHTS RESERVED Part Number: 05018730 0249 Revision: 01 CONTACT INFORMATION Sullivan-Palatek, Inc. 1201 West US Highway 20 Michigan City, Indiana 46360 Phone: (219) 874-2497 Fax: (219) 872-5043 Toll Free: (800) 438-6203 Website: www.sullivan-palatek.com RECORD KEEPING...
  • Page 3 12 months from delivery to the first user. Parts, Accessories and Attachments Sold Separately From Machines, Excluding Warranty Replacement Parts and Hand Tools: the first to expire; 6 months from shipment by Sullivan-Palatek or 3 months from delivery to the first user.

  • Page 5: About This Manual

    MANUAL ORGANIZATION NOTE! Anyone operating or servicing the Sullivan-Palatek air compressor should read this entire manual and be familiar with its information. The following is a quick guide to the contents in this manual: SECTION 1: SAFETY This section contains important basic information regarding general safety precautions for maintaining and operating air compressors.
  • Page 6 AboUT ThIS MAnUAL...

  • Page 7: Table Of Contents

    CONTENTS AbOUT THIS MANUAL � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � V Safety Instructions .
  • Page 8 Compressor Oil Filter ............. . .27 Air/Oil Separator .

  • Page 9: Safety

    SAFETY TOPICS IN THIS SECTION: » General Safety ................2 »...

  • Page 10: General Safety

    GENERAL SAFETY Safety is a prime consideration in the design and manufacture of the compressor. Ultimately, the responsibility for safe operation rests with the individuals who use and maintain the compressor. The following safety precautions are offered as a guide for the safe operation and maintenance of this machinery: »...

  • Page 11: Moving Parts

    » Anti-freeze compound used in airline anti-icing systems contains methanol, which is flammable. Use systems and refill with compound only in well-ventilated areas, away from heat, open flames, or sparks. Do not expose any part of these systems or the anti-freeze compound to temperatures above 150°F (65°C).

  • Page 12: Toxic And Irritating Substances

    Under specific guidelines and in full compliance with OSHA Standards 29 CFR 1920 and any other federal, state, or local codes or regulations compressed air can be used for breathing air. Sullivan-Palatek does not provide equipment and instructions for this application and its products are not produced for this application or use.

  • Page 13: Specifications

    SPECIFICATIONS TOPICS IN THIS SECTION: » Technical Data................6 »...

  • Page 14: Technical Data

    TECHNICAL DATA D110PKU COMPRESSOR Rated Delivery 110 cfm (3.11 m /min) Maximum Pressure 110 psig (7.6 bar) Working Pressure 100 psig (6.9 bar) Minimum Separator Pressure 51 psig (3.5 bar) Max. Sound Power Level 74 dBA Safety Valve Opening Pressure...

  • Page 15: Dimensions

    DIMENSIONS 29.5 inches 46.6 inches (1185 mm) (750 mm) 113.7 inches (2888 mm) 60 inches (1514 mm) Figure 2-1. WHEEL-MOUNTED AND SKID-MOUNTED DIMENSIONS SPECIFICATIONS...
  • Page 16 SPECIFICATIONS...

  • Page 17: Component Description

    COMPONENT DESCRIPTION TOPICS IN THIS SECTION: » Compressor Package ............... .10 »...

  • Page 18: Compressor Package

    Safety Relief Valve Compressor Oil Fill Figure 3-1. D110PKU COMPRESSOR COMPONENTS ENGINE SHUTDOWN PROTECTION The Safety Relief Valve (15) is located on the Separator/Receiver Tank (6). When a fault occurs the engine will shut down when one of three safety devices are triggered by the Engine Stop Solenoid (14).

  • Page 19: Compressor Cooling

    COMPRESSOR COOLING The compressor cooling and lubrication system is designed to provide adequate lubrication as well as maintain the proper operating temperature of the compressor. The Fan (16) vents the heat coming from the compression of the air with the oil, which flows through the Cooler (4) and cooled due to the air issued from the Fan.
  • Page 20 COMPONENT Separator/Receiver Tank Pressure Regulator Inlet Valve Engine Speed Cylinder Inlet Valve Cylinder Blowdown Valve Start-Stop/Run Valve Minimum Pressure Valve (MPV) Figure 3-1. CAPACITY CONTROL SYSTEM 3.6.1 reguLATOr VALVe (DiSCHArge PreSSure) The regulator valve is used to select the desired discharge pressure within the operating pressure range. Turning the regulator adjustment screw clockwise increases the unloaded pressure, and counter-clockwise reduces the unloaded pressure.

  • Page 21: Transporting And Locating

    TRANSPORTING AND LOCATING TOPICS IN THIS SECTION: » Receiving ................. .14 »...

  • Page 22: Receiving

    RECEIVING Each compressor is operated and tested at the factory before shipment. This testing assures that the unit is operating properly and that the compressor will deliver its rated capacity. Regardless of the care taken at the factory, there is a possibility that adjustments may be altered or damage may occur during shipment. For this reason it is recommended that the unit be checked for proper operation and carefully inspected before it is put in service.

  • Page 23: Preparing To Tow

    PREPARING TO TOW » Properly drain and dispose of any fluids in the containment cage before towing. » before beginning to tow the compressor, test brake operation, including breakaway switch operation if provided. » Damaged or worn towing components can result in separation of the compressor from the towing vehicle during towing.

  • Page 24: Parking Or Locating Compressor

    » Do not exceed maximum towing speeds. Reduce speed accordingly, as dictated by posted signs, weather, road, or terrain conditions. » Remember that portable air compressors may approach or exceed the weight of the towing vehicle. Maintain increased stopping distance accordingly. »...

  • Page 25: Operation

    OPERATION TOPICS IN THIS SECTION: » General Operating Safety ..............18 »...

  • Page 26: General Operating Safety

    GENERAL OPERATING SAFETY » Allow at least ten feet of unobstructed area in front of cooling air inlets and outlets to ensure good airflow. » Do not start the engine by shorting the starter connections–the compressor could start and run. »...

  • Page 27: Normal Starting

    Pressure Gauge Key Ignition Switch Hourmeter Figure 5-1. D110PKU INSTRUMENT PANEL NORMAL STARTING Inspect the compressor, engine, and other assemblies for damage or loose connections. Check engine water, oil, fuel, and battery fluid levels. Check compressor receiver oil level. Close Service Valve (2). Turn Start-Stop/Run Valve (1) to START position.

  • Page 28: Low Fuel

    LOW FUEL If the engine has shut down because of low fuel, fuel will need to be added before the engine can be restarted. The following steps will need to be completed before attempting to restart the engine: Turn the ignition switch to OFF. Fill fuel tank with Ultra Low Sulfur Diesel fuel only.

  • Page 29: Jump-Starting Battery

    » Provide an appropriate flow-limiting valve for each additional 75 feet of hose in runs of air hose exceeding 0.5-inch inside diameter to reduce pressure in case of hose failure. » Flow limiting valves are listed by pipe size and rated CFM. Select appropriate valves accordingly. »...
  • Page 30 Replace vent caps on battery if required. If compressor engine starting motor will not crank after repeated attempts or the battery is still dead after running the compressor for over an hour (not taking charge), then the battery must be replaced. Move starting vehicle away from compressor.

  • Page 31: Maintenance

    MAINTENANCE TOPICS IN THIS SECTION: » Maintenance ................24 ™...

  • Page 32: Maintenance

    The maintenance procedures indicated in this manual are given for normal conditions of use. In difficult conditions, temperatures extremes, high hygrometry, atmospheric pollution, high elevation, etc. some maintenance must be performed more frequently and particular precautions must be taken. 6.1.1 MAINTENANCE SCHEDULE D110PKU RECOMMENDED MAINTENANCE FREQUENCY (HOURS) PROCEDURE REFERENCE Check oil level (before starting) 6.3.1...

  • Page 33: Weather-All Compressor Lubricant

    Sullivan-Palatek recommends oil sampling as the best guide for your fluid change interval. Changing fluid once a year my not be adequate or it can be excessive. For this reason an hourly service on lubricants is merely a guide.

  • Page 34: Oil Sample For Analysis

    Wait two minutes after the compressor stops to allow the pressure to be relieved and the oil to settle. Observe the oil level in the fluid sight glass. The fluid sight glass should be no more than ⅔ full. While the compressor is running, the oil should be visible in the sight glass. 6.3.2 FILL Before adding or changing compressor oil, completely relieve the sump of pressure.

  • Page 35: Compressor Oil Filter

    Venting the sump tank pressure relief valve will do this. Place oil spill pan under filter. Remove filter canister by unscrewing the Figure 6-3. D110PKU OIL FILTER disposable element and discarding used filter element. 6.5.3 INSTALLATION Install a new element after slightly greasing the seal.

  • Page 36: Air/Oil Separator

    Make sure the Filter Cap (3) is properly closed. If the filter envelope is not sealed, dust and dirt may be sucked in, reducing engine life, and resulting in engine or compressor failure. Figure 6-5. D110PKU AIR FILTER REPLACEMENT MAINTENANCE...

  • Page 37: Radiator

    RADIATOR 6.8.1 INSPECTION Remove the radiator cap and check if engine coolant reaches the supply hole. Check the level of coolant in expansion tank. If the level is below the “LOW” mark, add as needed. Do not overfill. Close the cap firmly. If the cap is loose or improperly tightened coolant can flow out and the engine may overheat.

  • Page 38: Compressor Belts

    Replace the belts if damaged. If the belt is loose or damaged it could result in overheating or insufficient load. BELT TENSION NUT Figure 6-6. D110PKU COMPRESSOR DRIVE BELT MAINTENANCE...

  • Page 39: Troubleshooting

    TROUbLESHOOTING TOPICS IN THIS SECTION: » Introduction................32 »...

  • Page 40: Introduction

    INTRODUCTION This section contains instructions for troubleshooting the equipment following a malfunction. Each issue or problem is followed by a list of probable causes and suggested actions to be followed in order to eliminate the cause. The actions listed should be performed in the order listed, although the order may be varied if the need is indicated by conditions under which the problem occurred.

  • Page 41: Discharge Pressure Is Too Low

    DISCHARGE PRESSURE IS TOO LOW POSSIbLE CAUSE ACTION Start/Run valve in the START position Move the Start/Run valve to the RUN position and retest. Too much air demand Add additional compressor to handle the demand or decrease the air demand. Service valve open Close service valve and retest.

  • Page 42: Oil In Service Line

    Compressor discharge pressure too high Adjust the pressure to the maximum operating pressure for the machine. Engine idle speed set too low Adjust the idle speed to the Sullivan-Palatek recommended RPM. Operating above maximum altitude rating of engine Refer to Engine Manufacturer's recommendation on maximum altitude.

  • Page 43: Engine Speed Control Lever Does Not Move To Full Speed With Air Demand

    Engine governor linkage binding or incorrectly set Inspect governor linkage and adjust, lubricate, or replace as necessary. Engine governor idle speed control lever too long Adjust the idle speed to the Sullivan-Palatek recommended RPM. 7.15 ENGINE STALLS WHEN AIR DEMAND IS LOW...
  • Page 44 TROUBLESHOOTING...

  • Page 45: Parts Catalog

    PARTS CATALOG TOPICS IN THIS SECTION: » ordering Parts................38 »...

  • Page 46: Ordering Parts

    Use the space provided on the inside cover of the manual to record the model and serial number of the compressor for future reference. 8.1.1 CONTACT INFORMATION For replacement parts and manuals contact: Sullivan-Palatek, Inc. 1201 West US highway 20 Michigan City, Indiana 46360 Phone: (219) 874-2497 Fax: (219) 872-5043 Toll Free: (800) 438-6203 www.sullivan-palatek.com...

  • Page 47: Recommended Spare Parts

    00823062 0009 OIL, WEATHER-ALL, 5 GALLON PAIL NOTE! Use only service parts supplied or recommended by Sullivan-Palatek. Use of substitutes may void warranty. See WARRANTY for details. SERVICE KIT A service kit is available for basic servicing of the compressor and engine. Buying a kit offers savings over buying individual parts.

  • Page 48: Engine Assembly

    ENGINE ASSEMBLY PARTS CATALOG...
  • Page 49 PARTS CATALOG...

  • Page 50: Engine Mounting Assembly

    ENGINE MOUNTING ASSEMBLY PARTS CATALOG...
  • Page 51 PARTS CATALOG...

  • Page 52: Engine To Frame Assembly

    ENGINE TO FRAME ASSEMBLY PARTS CATALOG...
  • Page 53 ENGINE TO FRAME ASSEMbLY ITEM PART NUMbER DESCRIPTION 01903000 0683 FRAME 01903000 0907 SCREW HM12x70 01903000 0896 WASHER L12 EP2,5 01903000 0898 WASHER PLATE M16 01903000 0883 SELF LOCKING NUT HM16 01903000 0896 WASHER L12 EP2,5 01903000 0882 SELF LOCKING NUT HM12 01903000 0633 BELT 01903000 0935...

  • Page 54: Battery Assembly

    BATTERY ASSEMBLY PARTS CATALOG...
  • Page 55 — BATTERY 01903000 0747 BRACKET, HOLDOWN 01903000 0870 WASHER, FLAT M8 01903000 0912 SCREW HM8X20 01903000 0972 01903000 0973 CABLE, BATTERY POS. (NOT SHOWN) 01903000 0974 CABLE, BATTERY NEG. (NOT SHOWN) *Batteries not available for purchase through Sullivan-Palatek. PARTS CATALOG...

  • Page 56: Exhaust Assembly

    8.10 EXHAUST ASSEMBLY PARTS CATALOG...
  • Page 57 PARTS CATALOG...

  • Page 58: Compressor Assembly

    8.11 COMPRESSOR ASSEMBLY PARTS CATALOG...
  • Page 59 PARTS CATALOG...

  • Page 60: Inlet Valve Assembly

    8.12 INLET VALVE ASSEMBLY PARTS CATALOG...
  • Page 61 INLET VALVE ASSEMbLY ITEM PART NUMbER DESCRIPTION 01903000 0637 VALVE, INLET 01903000 0938 O-RING 01903000 0900 SCREW CHC M8X20 01903000 0939 O-RING 01903000 0870 WASHER, FLAT M8 01903000 0914 SCREW HM8X30 01903000 0874 01903000 0941 FITTING, STR TUBE 01903000 1581 ORIFICE PARTS CATALOG...

  • Page 62: Air Filter Assembly

    8.13 AIR FILTER ASSEMBLY PARTS CATALOG...
  • Page 63 AIR FILTER ASSEMBLY ITEM PART NUMBER DESCRIPTION 01903000 0908 SCREW HM4X16 01903000 0894 WASHER, FLAT M4 01903000 0964 ELBOW, TUBE 01903000 0648 REGULATOR, AIR PRESSURE 01903000 0719 BRACKET, ANGLE 01903000 0964 ELBOW, TUBE 01903000 0871 SELF LOCKING NUT HM8 ZB 01903000 0884 SELF LOCKING NUT HM4 01903000 0870...

  • Page 64: Receiver Assembly

    8.14 RECEIVER ASSEMBLY PARTS CATALOG...
  • Page 65 RECEIVER ASSEMbLY ITEM PART NUMbER DESCRIPTION 01903000 1604 TANK, SEPARATOR 01903000 0638 ELEMENT, SEPARATOR TANK LID (INCLUDED WITH 01903000 1604) 01903000 0879 WASHER, FLAT M12 01903000 0880 SCREW HM12X30 01903000 0942 SEAL, OIL FILL 01903000 0698 CAP, OIL FILL 01903000 1595 NIPPLE 01903000 0699 VALVE...

  • Page 66: Receiver Assembly To Frame

    8.15 RECEIVER ASSEMBLY TO FRAME PARTS CATALOG...
  • Page 67 PARTS CATALOG...

  • Page 68: Control Tubing Assembly

    8.16 CONTROL TUBING ASSEMBLY PARTS CATALOG...
  • Page 69 PARTS CATALOG...

  • Page 70: Cooling Assembly

    8.17 COOLING ASSEMBLY PARTS CATALOG...
  • Page 71 PARTS CATALOG...

  • Page 72: Cooling Assembly Attachment To Frame

    8.18 COOLING ASSEMBLY ATTACHMENT TO FRAME PARTS CATALOG...
  • Page 73 PARTS CATALOG...

  • Page 74: Cooling System, Hoses And Recovery Tank Installation

    8.19 COOLING SYSTEM, HOSES AND RECOVERY TANK INSTALLATION PARTS CATALOG...
  • Page 75 PARTS CATALOG...

  • Page 76: Oil Filter And Discharge Hose Assembly

    8.20 OIL FILTER AND DISCHARGE HOSE ASSEMBLY PARTS CATALOG...
  • Page 77 PARTS CATALOG...

  • Page 78: Fuel Tank Assembly

    8.21 FUEL TANK ASSEMBLY PARTS CATALOG...
  • Page 79 FUEL TANK ASSEMbLY ITEM PART NUMbER DESCRIPTION 01903000 0912 SCREW HM8X20 01903000 0870 WASHER, FLAT M8 01903000 0870 WASHER, FLAT M8 01903000 0963 01903000 0954 BRACKET, FUEL TANK 01903000 0956 STRAP, FUEL TANK 01903000 0870 WASHER, FLAT M8 01903000 0912 SCREW HM8X20 01903000 0955 BRACKET, ANGLE...

  • Page 80: Instrument Panel Assembly

    8.22 INSTRUMENT PANEL ASSEMBLY PARTS CATALOG...
  • Page 81 INSTRUMENT PANEL ASSEMbLY ITEM PART NUMbER DESCRIPTION 01903000 0741 BOX, INSTRUMENT PANEL CABLE HARNESS SUPPLY RELAY SUPPORT 01903000 0895 WASHER, FLAT M5 01903000 0909 SCREW HM5X16 01903000 1638 SAFETY RELAY 01903000 1639 TIMER RELAY 01903000 0866 WASHER, FLAT M6 01903000 0911 SCREW HM6X20 CABLE HARNESS SUPPLY FUSE HOLDER CLIP...

  • Page 82: Canopy Assembly

    8.23 CANOPY ASSEMBLY PARTS CATALOG...
  • Page 83 PARTS CATALOG...

  • Page 84: Canopy Installation

    8.24 CANOPY INSTALLATION PARTS CATALOG...
  • Page 85 CANOPY INSTALLATION ITEM PART NUMbER DESCRIPTION 01903000 1640 SCREW 01903000 1644 GRATE 01903000 0912 SCREW HM8X20 01903000 0870 WASHER, FLAT M8 01903000 0759 SUPPORT, GAS SPRING 01903000 0760 RODEND, THREADED SWIVEL 01903000 0871 SELF-LOCKING NUT HM8 ZB PARTS CATALOG...

  • Page 86: Lifting Bail Assembly

    8.25 LIFTING BAIL ASSEMBLY PARTS CATALOG...
  • Page 87 LIFTING bAIL ASSEMbLY ITEM PART NUMbER DESCRIPTION 01903000 0735 SUPPORT 01903000 0736 BRACE 01903000 0737 BRACE 01903000 0916 SCREW M8X40 DOME HEAD SQ COL 01903000 0915 SCREW M8X25 DOME HEAD SQ COL 01903000 0871 SELF LOCKING NUT HM8 ZB 01903000 0888 NUT HM8 01903000 0870 WASHER, FLAT M8...

  • Page 88: Front Crossmember Assembly

    8.26 FRONT CROSSMEMBER ASSEMBLY PARTS CATALOG...
  • Page 89 PARTS CATALOG...

  • Page 90: Light Package

    8.27 LIGHT PACKAGE PARTS CATALOG...
  • Page 91 PARTS CATALOG...

  • Page 92: Fender Installation

    8.28 FENDER INSTALLATION PARTS CATALOG...
  • Page 93 PARTS CATALOG...

  • Page 94: Axle And Wheel Assembly

    8.29 AXLE AND WHEEL ASSEMBLY PARTS CATALOG...
  • Page 95 PARTS CATALOG...

  • Page 96: Option] Skid Assembly

    8.30 [OPTION] SKID ASSEMBLY PARTS CATALOG...
  • Page 97 PARTS CATALOG...
  • Page 98 NOTES...
  • Page 99 NOTES...
  • Page 100 1201 Wes t US highway 20 Michigan Cit y, Indiana 46360 Phone: 219.874.2497 Fax: 219.809.0203 info@palatek .com w w w.sullivan-palatek .com...

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