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Summary of Contents for Sullivan-Palatek D185UIZ
- Page 1 OPERATION & SERVICE MANUAL PORTABLE UTILITY COMPRESSOR \ 185 CFM D185UIZ ISUZU DIESEL ENGINE TIER 4 FINAL 05018730-0304 / 00 Issued: June 18, 2021...
- Page 2 DOCUMENT INFORMATION © Sullivan-Palatek, Inc. ALL RIGHTS RESERVED Part Number: 05018730-0304 Revision: 00 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...
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Page 3: Table Of Contents
Emergency Stop ..............8 Sullivan-Palatek Electronic Controller (SPEC) Operational Instructions ..... 9 Operating Under Extreme Conditions . - Page 4 Air Intake Filter ..............26 Compressor Oil Filter .
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Page 5: Warranty
Sullivan-Palatek’s Obligations: Sullivan-Palatek’s exclusive obligations under its warranty are (i) to repair or replace any defective part at Sullivan-Palatek’s option and subject to return of defective parts, (ii) to pay the reasonable cost of making the repair or reinstalling the replacement part, and (iii) for air compressors having two or more axles, reimbursement of up to four hours travel labor and up to 200 miles (100 miles travel radius) per event to make repairs. - Page 6 WARRANTY...
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Page 7: About This Manual
II.2 MANUAL ORGANIZATION 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 8 VIII ABOUT THIS MANUAL...
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Page 9: Safety
SAFETY TOPICS IN THIS SECTION: » Receiving ................. . . 2 »... -
Page 10: 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. The machine should be observed for any possible malfunction during the first few hours of operation. -
Page 11: Fires And Explosion
circuit. » Do NOT try to detect pressure leaks with your hands. It is not always possible to identify a leak from a tiny hole. Use a piece of paper or wood to locate a suspected leakage. Wear safety glasses when detecting leaks. -
Page 12: Moving Parts
» Always avoid electrical parts when washing the compressor. 1.5.3 COMBUSTIBLES » Prior to welding or making weld repairs on the compressor, remove any acoustical material or other material that may be damaged by heat or that may support combustion. Remove and isolate negative battery cable. -
Page 13: Hot Surfaces, Sharp Edges, Sharp Corners And Vacuum
clean, warm water until vomit is clear, then administer two teaspoons of baking soda in a glass of clean water. Lay down and cover eyes to exclude light. Seek medical assistance. » Do not store airline anti-icing system anti-freeze compound in operator’s cabs or in unapproved containers. - Page 14 SAFETY...
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Page 15: Operation
Emergency Stop � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8 » Sullivan-Palatek Electronic Controller (SPEC) Operational Instructions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9 »... -
Page 16: General Operating Safety
GENERAL OPERATING SAFETY » Replace any faulty gauge immediately� » allow at least ten feet of unobstructed area in front of cooling air inlets and outlets to assure good airflow. » If compressor is connected to a common header with one or more compressors, a check valve must be provided between each compressor and header�... -
Page 17: Sullivan-Palatek Electronic Controller (Spec) Operational Instructions
SULLIVAN-PALATEK ELECTRONIC CONTROLLER (SPEC) OPERATIONAL INSTRUCTIONS The buttons for operation will be referred to numerically based upon the image at right� Button functionality can vary depending on the operator input required for each page� Pages requiring custom button functionality will display button function icons directly above the buttons�... - Page 18 SHUTDOWN SETPOINTS SCREEN This screen indicates the setpoints at which shutdowns will occur� Button 3 returns back to the Menu screen; Buttons 4 and 5 cycle through the a list of warnings associated with the shutdown setpoints� SERVICE REMINDER SCREEN This screen indicates when certain filters should be replaced�...
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Page 19: Operating Under Extreme Conditions
OPERATING UNDER EXTREME CONDITIONS 2.7.1 COLD WEATHER OPERATION Use the correct coolant anti-freeze solution and engine oil for the lowest possible temperature expected� CAUTION! Make sure coolant and engine oil are approved by the engine manufacturer. When operating the compressor at ambient temperatures below 20°F, use lubricants suited for these conditions�... -
Page 20: Jump-Starting Battery
WARNING! Serious injury can result from the direct discharge of compressed air. Do not allow personnel to be in line or front of the discharge opening of the service valve, hoses or tools or other points of compressed air discharge. »... -
Page 21: Component Description
COMPONENT DESCRIPTION TOPICS IN THIS SECTION: » Portable Compressor Package ..............14 »... -
Page 22: Portable Compressor Package
PORTABLE COMPRESSOR PACKAGE The compressor is asingle stage, oil flood lubricated rotary screw air compressor. The compressor package 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, compressor assembly, air/oil separator system, cooling system for the engine and compressor oil, instrumentation, pneumatic control system, and acoustical enclosure. -
Page 23: Lubrication System
LUBRICATION SYSTEM Figure 3-2. DIAGRAM, OIL PIPING 185-375 (REV 00) Oil from the compressor oil sump at compressor discharge pressure is directed through the cooling system and oil filter to a lower pressure region of the compressor stator. At the same time, oil is directed to the bearings and shaft seal of the compressor. The oil-laden air is then discharged back into the sump. The compressor cooling system consists of an oil cooler mounted adjacent to the engine radiator. Cooling air is pushed through the cooler by the engine fan while oil is circulated through it by the receiver/sump pressure. -
Page 24: Capacity Control System
3.5.2 THERMAL BYPASS VALVE The thermal bypass valve is the center of the compressor temperature regulating system. The valve is designed to be fully open, allowing the oil to bypass the cooler until the oil temperature reaches 110°F. Above 110°F, the valve gradually closes down and becomes completely closed when the oil temperature reaches approximately 140°F. -
Page 25: Noise Control Systems
NOTE! The compressor can only produce its maximum rating of air flow at rated pressure (rated CFM at rated psig). If the tank pressure continues to decrease when the machine is at full speed and the inlet valve fully open, a larger capacity compressor or multiple compressors may be required for the customer’s job needs. -
Page 26: Instrument Panel
INSTRUMENT PANEL ITEM NAME DESCRIPTION Discharge Air Pressure Gauge Displays discharge air pressure of compressor. Sullivan-Palatek Electronic Monitors the engine and compressor parameters, displays warning and Controller (SPEC) shutdown information, and displays engine diagnostic information from the engine ECU. Ignition Switch START position electrically energizes engine starter motor solenoid. - Page 27 3.8.2 SuLLiVAN-PALATeK eLeCTrONiC CONTrOLLer (SPeC) MODEL PV380 The Sullivan-Palatek Electronic Controller (SPEC) Model PV380 monitors all critical compressor and engine parameters, provides warning and shutdown information and has complete engine diagnostic capabilities. Parameters monitored by the SPEC include engine speed, compressor temperature, engine oil pressure, engine temperature, battery voltage and fuel level.
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Page 28: Electrical And Protective Circuit System
Attempts to restart the compressor without repairing the fault sensed by the protection system will be recorded in the engine software and will void the engine manufacturer’s warranty. The Sullivan-Palatek warranty DOES NOT COVER the engine. The engine and its components are warranted only by the engine manufacturer. -
Page 29: Maintenance
MAINTENANCE TOPICS IN THIS SECTION: » Maintenance Schedule ...............22 »... -
Page 30: Maintenance Schedule
MAINTENANCE SCHEDULE COMPRESSOR MAINTENANCE SCHEDULE FREQUENCY (HOURS) PROCEDURE SEE NOTE REF� Check oil level (before starting) Check radiator coolant level Check fuel supply (after starting) Check air filter elements Check for fuel, oil air and water leaks Drain water from compressor sump Drain water and sediment from fuel tank Change oil filter element Change compressor oil... -
Page 31: Bolt Torque Guidelines
The useful life of synthetic lubricants may extend the normally recommended drain and replace period; however, the user is encouraged to closely monitor the lubricant condition and to participate in an oil analysis program with the fluid supplier. When ambient conditions exceed those noted, or if conditions warrant use of “extended life” lubricants, contact Sullivan-Palatek for a recommendation. 4.3.1 CHECK The oil level should be checked daily. -
Page 32: Weather-All ™ Compressor Lubricant
*Service life is only a guideline for typical oil life if temperature is the only variable to be considered. Many variables affect the oil life, i.e. environmental impact from various gases, dust and dirt, compressor short cycling, etc. 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. Please consult your factory-trained servicing distributor for questions concerning your lubricant life and Sullivan-Palatek’s lubricant sampling program. -
Page 33: Oil Sample For Analysis
OIL SAMPLE FOR ANALYSIS The first oil sample should be drawn after the compressor has run for 500 hours or 3 months. Intervals for following oil samples will be determined by the analysis results. SAMPLE OIL FROM SUMP TANK Run the compressor long enough to reach normal operating temperatures. Turn compressor OFF and allow pressure to blow down to 0 psi. Remove the drain plug from the end of the drain line at the bottom of the sump tank. -
Page 34: Curbside Service Access
CURBSIDE SERVICE ACCESS Most maintenance points and the SPEC controller display are conveniently located behind the curbside access door. Fuel fill and serviceable parts such as filters can be accessed from this location, with the exception of the engine oil filter, which is accessible from the side panel. The sump and fuel drains are located below the curbside access door, while the engine and cooler drains are located streetside. FUEL FILL AIR FILTERS FUEL FILTER OIL FILTER SPEC DISPLAY... -
Page 35: Compressor Shaft Oil Seal
Place oil spill pan under filter. Remove oil filter element by unscrewing it from the filter head (turn counter-clockwise) and discard. The use of a strap-type wrench may be necessary. 4.8.3 INSTALLATION Apply a thin film of oil to the seal of a new oil filter. Thread the oil filter on by hand, turning it clockwise until the gasket seats. Then turn an additional ½ to ¾ turn by hand. Check for leaks in operation. COMPRESSOR SHAFT OIL SEAL Check the compressor shaft seal for leaking oil every 1,000 hours or 6 months. 4.9.1 INSPECTION Inspect the compressor shaft seal for signs of leaking oil. NOTE! If replacement is necessary, removal and installation instructions will be provided with the shaft seal kit. 4.10 OIL RETURN LINE Check the oil return line periodically to make sure that it does not become clogged. -
Page 36: Thermal Valve
4.15.2 ENGINE SPEED Engine speed is controlled by the Sullivan-Palatek Electronic Controller (SPEC). The full load and idle speeds are programmed at the Factory and there should be no need for adjustment. If the machine is experiencing speed problems please contact our Service Department. -
Page 37: Troubleshooting
TROUBLESHOOTING TOPICS IN THIS SECTION: » Introduction................30 »... -
Page 38: 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 39: Discharge Pressure Is Too High Or Relief Valve Blows
DISCHARGE PRESSURE IS TOO HIGH OR RELIEF VALVE BLOWS POSSIBLE CAUSE ACTION Regulator valve faulty or mis-adjusted Properly adjust the regulator. Rebuild/replace the regulator if necessary. Inlet valve not closing properly Check the white sealing ring for the poppet valve, to ensure it is intact and not damaged. -
Page 40: Engine Does Not Accelerate Or Will Not Maintain Full Load Speed
ENGINE DOES NOT ACCELERATE OR WILL NOT MAINTAIN FULL LOAD SPEED POSSIBLE CAUSE ACTION Compressor discharge pressure too high Adjust the pressure to the maximum operating pressure for the machine. Engine problem Have an authorized engine repair facility inspect the engine. -
Page 41: Compressor Oil Leaking In Control Lines/Orifices
5.13 COMPRESSOR OIL LEAKING IN CONTROL LINES/ORIFICES POSSIBLE CAUSE ACTION Compressor oil level in sump tank too full Check and adjust compressor oil as needed. Oil return line (scavenger tube) plugged or restricted Remove the oil return line and clean. Separator element plugged or damaged Replace the separator element and change compressor oil. - Page 42 NOTES...
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- Page 44 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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