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Sullivan-Palatek D185PDKR Operation & Service Manual
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Sullivan-Palatek D185PDKR Operation & Service Manual

Wheel-mounted portable compressor/185 cfm
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OPERATION & SERVICE MANUAL
WHEEL-MOUNTED PORTABLE COMPRESSOR \ 185 CFM
D185PDKR
KOHLER DIESEL ENGINE
TIER 4 FINAL
Document: 05018730-0310 / 00
Issued: January, 2024

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  • Page 1 OPERATION & SERVICE MANUAL WHEEL-MOUNTED PORTABLE COMPRESSOR \ 185 CFM D185PDKR KOHLER DIESEL ENGINE TIER 4 FINAL Document: 05018730-0310 / 00 Issued: January, 2024...
  • Page 2 DOCUMENT INFORMATION: © Sullivan-Palatek, Inc. ALL RIGHTS RESERVED Part Number: 05018730-0310 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:...
  • Page 3 Normal Stopping..............11 Sullivan-Palatek Electronic Controller (SPEC) Operational Instructions ....11 Operating Under Extreme Conditions .
  • Page 4 MAINTENANCE ............25 Maintenance Schedule .
  • Page 5 Sullivan-Palatek or 36 months from delivery to the first user. Two stage high pressure compressor models: the first to expire; 30 months from shipment by Sullivan-Palatek or 24 months from delivery to the first user. Remainder of new portable air compressor machines: the first to expire; 18 months from shipment by Sullivan-Palatek or 12 months from delivery to the first user.
  • Page 6 WARRANTY...
  • Page 7 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...
  • Page 9 SAFETY TOPICS IN THIS SECTION: » General Safety ................2 »...
  • Page 10 GENERAL SAFETY Safety is a prime consideration in the design and manufacture of the compressor components. 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 » Anti-freeze compound used in air line anti-icing systems contains methanol, which is flammable. Use systems and refill with compound only in well-ventilated areas, away from heat, open flames, or sparks. Do not expose any part of these systems or the anti-freeze compound to temperatures above 150°F (65°C). Vapors from the anti-freeze compound are heavier than air. Do not store compound or discharge treated air in confined or unventilated area. Do not store containers or anti-freeze compound in direct sunlight. » Store flammable liquids in suitable containers and cabinets, away from sources of sparks and heat. 1.3.2 BATTERIES AND WIRING WARNING! Fire or explosion can result from electrical arcing from terminal, battery connections and improperly...
  • Page 12 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 TRANSPORTING AND LOCATING TOPICS IN ThIS SECTION: » Receiving ................. . . 6 »...
  • Page 14 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 15 PREPARING TO TOW » Properly drain and dispose of any fluids in the containment frame before towing. » Before beginning to tow the compressor, test brake operation, including breakaway switch operation if provided or if equipped. » Damaged or worn towing components can result in separation of the compressor from the towing vehicle during towing.
  • Page 16 » Observe and follow all local, state, and federal traffic laws. Note and adhere to speed limits and minimum highway speed. » Do not exceed maximum towing speeds. Reduce speed accordingly, as dictated by posted signs, weather, road, or terrain conditions. » Remember that portable air compressors may approach or exceed the weight of the towing vehicle. Maintain increased stopping distance accordingly.
  • Page 17 Normal Stopping ................11 » Sullivan-Palatek Electronic Controller (SPEC) Operational Instructions ......11 »...
  • Page 18 GENERAL OPERATING SAFETY » 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 19 Run engine at low idle for 2 minutes. Open and close the service valve to reduce pressure to approximately 75 psi or less. Press ignition switch to OFF. SULLIVAN-PALATEK ELECTRONIC CONTROLLER (SPEC) OPERATIONAL INSTRUCTIONS The buttons for operation will be referred to numerically based upon the image at right.
  • Page 20 USER SETTINGS SCREEN Brightness, contrast, language, units, and time and date can be accessed in this screen. Buttons 1 and 2 cycle between the selections; Button 3 returns back to the Menu screen; Buttons 4 and 5 adjust the setting of the selected item.
  • Page 21 DIAGNOSTIC MESSAGE SCREEN This screen will pop up when the machine encounters a Fault/SPN/FMI code. The specific fault will be displayed, as well as an indication if a shutdown will occur. If a diagnostic fault is hidden, a warning icon will be displayed on the Gauge screen.
  • Page 22 » Install an appropriate flow-limiting valve between the compressor service air outlet and the shut-off (throttle) valve when an air hose exceeding 0.5-inch inside diameter is to be connected to the shut-off (throttle) valve. This is to reduce pressure in case of hose or connection failure, per OSHA Standard 29 CFR 1926.302 (as) (7). » When a hose will be used to supply a manifold, install an appropriate flow-limiting valve between the manifold and each air hose exceeding 0.5-inch inside diameter that is to be connected to the manifold. This will reduce pressure in case of hose failure.
  • Page 23 Connect the other end of the BLACK (negative) cable to an unpainted metal surface on the compressor engine with the dead battery. Make sure all the jumper cable clips have a good connection (good clamping force) before attempting to start. Start vehicle with the good battery first and let it run a few minutes. Then attempt to start the compressor with the dead battery.
  • Page 24 OPERATION...
  • Page 25 COMPONENT DESCRIPTION TOPICS IN ThIS SECTION: » Portable Compressor Package ..............18 »...
  • Page 26 PORTABLE COMPRESSOR PACKAGE The compressor is a single-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 27 RECEIVER TANK COMPRESSOR OIL COOLER ENGINE FUEL TANK LUBRICATION SYSTEM REV. DESCRIPT 200 PSI @ 500°F 185 CFM @ 100 PSI 217 PSI @ 300°F KDI 193 30 GALLON 49 HP @ 2800 RPM RELEASED FOR P MADE LINES DARKER FILTER INLET VENT...
  • Page 28 3. UNLESS SPECIFICALLY NOTED, IMAGES OF PARTS ARE FOR REPRESENTATION ONLY, ACTUAL PARTS MAY VARY IN APPEARANCE. THIS DRAWING AND ALL INFORMATION THEREIN IS THE PROPERTY OF SULLIVAN-PALATEK, INC. IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED. IT IS LOANED SUBJECT TO RETURN UPON DEMAND, IS NOT TO BE USED DIRECTLY OR INDIRECTLY IN ANYWAY DETRIMENTAL TO SULLIVAN-PALATEK'S INTEREST.
  • Page 29 Low Fuel warning at 11% of capacity. Shutdown will occur at 5-8%. ENGINE SHUTDOWN PROTECTION Sullivan-Palatek uses electronically controlled engines in the 185-1800 CFM line of compressors. Personnel operating and maintaining these compressors MUST be familiar with and understand the operation and protection features available with these engines.
  • Page 30 The warning and shutdown lights will be lit on the control panel when this occurs. If either of these protection features activate, the engine requires inspection by an authorized distributor of Sullivan-Palatek products or an authorized engine manufacturer’s dealer before attempting to run the machine again.
  • Page 31 The instrument panel contains all the necessary controls and instrumentation for operation. It is conveniently located at the right rear of the unit, and enclosed by a lockable, hinged door. Following is an explanation of the principal controls and instruments: Figure 4-4. INSTRUMENT PANEL, D185PDKR ITEM NAME DESCRIPTION...
  • Page 32 4.10.1 SuLLiVAN-PALATeK eLeCTrONiC CONTrOLLer (SPeC) The Sullivan-Palatek Electronic Controller (SPEC) 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 temperature, battery voltage and fuel level.
  • Page 33 MAINTENANCE TOPICS IN ThIS SECTION: » Maintenance Schedule ...............26 »...
  • Page 34 MAINTENANCE SCHEDULE MAINTENANCE SChEDULE FREQUENCY (hOURS) PROCEDURE 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 35 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. 5.3.1 CHECK The oil level should be checked daily.
  • Page 36 *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 37 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 38 AIR INTAKE FILTER Check daily, every 10 hours of operation or on rent return. Replace filter element every 1,000 hours or 6 months. Replace more frequently in dusty conditions. Empty the evacuator valve (dust boot) daily. 5.6.1 REMOVAL AND INSPECTION Unscrew wingnut on air filter cover and remove cover. Unscrew primary air filter element wingnut; pull used element to remove. Remove and inspect the secondary filterby unscrewing wingnut and pulling element. The air filter elements should be thoroughly inspected for holes by placing a lamp inside the element and carefully checking for areas of bright light passing through the element and seal. 5.6.2 INSTALLATION Insert new filter element(s) and tighten wingnut(s).
  • Page 39 5.10 AIR/OIL SEPARATOR Replace the air/oil separator every 1,000 hours, annually, or when differential exceeds 10 psi. The air/oil separator employs a unitized element. The separator element is a single piece unit, which requires replacement when it fails to remove the oil from the discharge air. Prior to replacing the separator element be sure to check the oil return line and orifice for plugging or restrictions. WARNING! The combination of a build-up of dirt and oxidized oil can clog the element causing an increase in air velocity at narrow points on the element media.
  • Page 40 5.15.2 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 Figure 5-3.
  • Page 41 05017457-0030 RADIATOR CAP 05019310-0032 TOP SPRING NOTE! Use only service parts supplied or recommended by Sullivan-Palatek. Use of substitutes may void warranty. See STANDARD WARRANTY for details. 5.17 SERVICE KITS Service kits are available for basic servicing of the compressor and engine. Buying kits offers savings over buying individual parts. There are annual kits (wet or dry) for a year’s worth of compressor and engine servicing and line service kits for a single compressor and engine service.
  • Page 42 MAINTENANCE...
  • Page 43 TROUbLEShOOTING TOPICS IN ThIS SECTION: » Introduction................36 »...
  • Page 44 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 45 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 46 COMPRESSOR OIL LEVEL IS DECREASING EXCESSIVELY POSSIbLE CAUSE ACTION Oil line leaking Repair or replace any leaking lines and retest. Oil cooler leaking Repair or replace the leaking oil cooler and retest. Compressor shaft seal leaking Replace the compressor shaft seal and retest. Oil in service line See “6.8 Oil in Service Line”section.
  • Page 47 6.11 ENGINE SPEED CONTROL DOES NOT CHANGE TO IDLE SPEED WITH SERVICE VALVES CLOSED POSSIbLE CAUSE ACTION Bad or broken wires to SPEC or pressure transducer Fix or replace broken wires. Discharge pressure regulator faulty Properly adjust the regulator. Rebuild/replace the regulator if necessary. Bad pressure transducer Replace pressure transducer.
  • Page 48 TROUBLESHOOTING...
  • Page 49 NOTES...
  • Page 50 NOTES...
  • Page 53 1201 West 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...