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Sullivan-Palatek D185PKR - User Manual

Sullivan-Palatek D185PKR
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D185PKR
D185PKRSB
KOHLER DIESEL ENGINE
TIER 4 FINAL
OPERATION & SERVICE MANUAL
WHEEL-MOUNTED PORTABLE COMPRESSOR \ 185 CFM
05018730-0287 / 00
Issued: October 13, 2020

Table of Contents

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Summary

Sullivan-Palatek Portable Air Compressor Standard Warranty

Warranty Registration

Details on validating warranty coverage by registering the product within 30 days of delivery.

Warranty Period

Specifies the duration of warranty for different components like air ends and machines.

Sullivan-Palateks Obligations

Outlines manufacturer's responsibilities for repairing or replacing defective parts.

Purchasers Responsibility

Lists duties of the purchaser, including notice of failure and product availability for repair.

Exclusions and Limitations

Lists conditions, parts, or damages not covered by the warranty, such as engine seals or consequential damages.

About This Manual

Safety Instructions

Guidelines for safe operation and maintenance of the compressor, with risk level labels.

Manual Organization

Overview of the manual's structure and content, guiding the reader through its sections.

Supplemental Documents

Information on additional resources for specific components, like the Engine Manual.

Safety Precautions

General Safety Precautions

Basic safety rules for operating and maintaining the compressor, emphasizing trained personnel.

Pressure Release Procedures

Steps for safely releasing pressure from air, oil, and cooling circuits before maintenance.

Fire and Explosion Hazards

Information on flammable liquids, fuel handling, and preventing fires and explosions.

Moving Parts Safety

Warnings and precautions regarding keeping clear of belts, pulleys, and other moving components.

Toxic and Irritating Substances

Guidance on handling hazardous materials like fuel, oil, and anti-freeze, and avoiding exposure.

Hot Surfaces, Sharp Edges, and Vacuum Hazards

Precautions for dealing with hot parts, sharp edges, and potential vacuum hazards.

Electrical Shock Prevention

Safety measures to avoid electrical hazards, including keeping clear of live parts.

Entrapment Hazards

Safety advice to prevent entrapment by machine parts or enclosures, especially doors.

Transporting and Locating

Receiving and Inspection

Procedures for checking the compressor upon delivery for damage or operational issues.

Safe Lifting and Handling

Guidelines for properly lifting and moving the compressor using appropriate rigging.

Drawbars and Brake Systems

Details on drawbar and brake actuator installation, including torque specifications.

Towing Preparations

Steps to ensure the compressor and towing vehicle are ready for safe towing operations.

Towing Procedures and Speed Limits

Best practices and speed recommendations for towing the compressor safely.

Parking and Location Guidelines

Instructions for safely parking and positioning the compressor at the work site.

Operation

General Operating Safety

Essential safety guidelines to follow during normal compressor operation.

Preparing for Initial Start-Up

Steps to ensure the compressor and engine are ready for their first operation.

Normal Starting and Stopping

Step-by-step instructions for starting and stopping the compressor under normal conditions.

SPEC Controller Operational Instructions

How to use the Sullivan-Palatek Electronic Controller interface for monitoring and control.

Operation in Extreme Conditions

Guidance for using the compressor in challenging environments like cold, heat, or dusty areas.

Pneumatic Tools Application

Safe practices for using compressed air with pneumatic tools, avoiding misuse.

Jump-Starting the Battery

Procedures for safely jump-starting the compressor's battery system.

Component Description

Compressor Package Overview

Description of the compressor unit's design, including its single-stage rotary screw configuration.

Engine Details

Details on the diesel engine, its cooling system, and the drive mechanism to the compressor.

Air End Assembly Details

Explanation of the rotary screw compression mechanism, rotors, and the compression cycle.

Discharge System Components

Components like the receiver/sump tank and the minimum pressure valve.

Lubrication System Overview

Details on oil flow, the oil filter, return lines, and the thermal bypass valve.

Capacity Control System Explained

How the compressor regulates air output based on demand using inlet valve and engine speed.

Noise Control System Components

Components and design features aimed at reducing operational noise levels.

Electrical System and Protection

Explanation of the electrical system and safety shutdown features like high temperature or low oil pressure.

Engine Shutdown Protection Features

Overview of the engine's protective measures against damage through derate or shutdown.

Instrument Panel and Controls

Explanation of the main controls and displays on the instrument panel.

Maintenance

Maintenance Schedule

Periodic maintenance tasks and their recommended intervals for the compressor.

Bolt Torque Guidelines

Recommended torque specifications for various fastener sizes and grades.

Compressor Lubrication Procedures

How to check, fill, and drain the compressor oil, including level checks.

WEATHER-ALL Compressor Lubricant

Information on the recommended synthetic compressor fluid for optimal performance.

Oil Sample Analysis

Instructions for collecting and submitting oil samples for laboratory analysis.

Air Intake Filter Maintenance

Procedures for inspecting and replacing air intake filters for optimal air supply.

Compressor Oil Filter Service

Steps for replacing the compressor oil filter element to ensure clean lubrication.

Shaft Seal and Oil Return Line Maintenance

Checking shaft seals for leaks and oil return lines for clogs to prevent oil issues.

Separator and Thermal Valve Service

Replacing the separator element and inspecting the thermal valve's function.

Oil Cooler and Lubrication

Cleaning the oil cooler and applying grease and engine lubrication guidelines.

Control Adjustments

How to adjust discharge pressure and engine speed settings for optimal performance.

Recommended Spare Parts

A list of essential spare parts for the D185PKR model to ensure readiness.

Service Kits Information

Information on available service kits for routine compressor and engine maintenance.

Troubleshooting

Troubleshooting Introduction

How to use this section to diagnose and resolve equipment issues effectively.

Unplanned Shutdowns

Potential causes and corrective actions for unexpected compressor shutdowns.

Low Discharge Pressure

Steps to diagnose and fix issues resulting in low air pressure output from the compressor.

High Discharge Pressure or Relief Valve Activation

Troubleshooting high pressure conditions and relief valve blow-off events.

Relief Valve Blows at Idle Position

Addressing relief valve issues that occur specifically when the engine is idling.

Pressure Blowdown Issues After Shutdown

Solutions for systems that fail to depressurize properly post-shutdown.

Excessive Compressor Oil Level Decrease

Diagnosing and correcting rapid oil loss from the compressor system.

Oil in Service Line

Identifying and rectifying oil contamination in the air service lines.

Engine Speed and Load Performance

Troubleshooting issues with engine speed not accelerating or maintaining full load.

Separator Plugging

Identifying causes and solutions for a plugged air/oil separator element.

Engine Speed Control to Idle

Resolving issues where the engine fails to reach idle speed after operation.

Engine Speed Control to Full Load

Troubleshooting problems with the engine not reaching full speed under air demand.

Oil Leaking in Control Lines;Orifices

Identifying and fixing oil leaks within the compressor's control system.

Summary

Sullivan-Palatek Portable Air Compressor Standard Warranty

Warranty Registration

Details on validating warranty coverage by registering the product within 30 days of delivery.

Warranty Period

Specifies the duration of warranty for different components like air ends and machines.

Sullivan-Palateks Obligations

Outlines manufacturer's responsibilities for repairing or replacing defective parts.

Purchasers Responsibility

Lists duties of the purchaser, including notice of failure and product availability for repair.

Exclusions and Limitations

Lists conditions, parts, or damages not covered by the warranty, such as engine seals or consequential damages.

About This Manual

Safety Instructions

Guidelines for safe operation and maintenance of the compressor, with risk level labels.

Manual Organization

Overview of the manual's structure and content, guiding the reader through its sections.

Supplemental Documents

Information on additional resources for specific components, like the Engine Manual.

Safety Precautions

General Safety Precautions

Basic safety rules for operating and maintaining the compressor, emphasizing trained personnel.

Pressure Release Procedures

Steps for safely releasing pressure from air, oil, and cooling circuits before maintenance.

Fire and Explosion Hazards

Information on flammable liquids, fuel handling, and preventing fires and explosions.

Moving Parts Safety

Warnings and precautions regarding keeping clear of belts, pulleys, and other moving components.

Toxic and Irritating Substances

Guidance on handling hazardous materials like fuel, oil, and anti-freeze, and avoiding exposure.

Hot Surfaces, Sharp Edges, and Vacuum Hazards

Precautions for dealing with hot parts, sharp edges, and potential vacuum hazards.

Electrical Shock Prevention

Safety measures to avoid electrical hazards, including keeping clear of live parts.

Entrapment Hazards

Safety advice to prevent entrapment by machine parts or enclosures, especially doors.

Transporting and Locating

Receiving and Inspection

Procedures for checking the compressor upon delivery for damage or operational issues.

Safe Lifting and Handling

Guidelines for properly lifting and moving the compressor using appropriate rigging.

Drawbars and Brake Systems

Details on drawbar and brake actuator installation, including torque specifications.

Towing Preparations

Steps to ensure the compressor and towing vehicle are ready for safe towing operations.

Towing Procedures and Speed Limits

Best practices and speed recommendations for towing the compressor safely.

Parking and Location Guidelines

Instructions for safely parking and positioning the compressor at the work site.

Operation

General Operating Safety

Essential safety guidelines to follow during normal compressor operation.

Preparing for Initial Start-Up

Steps to ensure the compressor and engine are ready for their first operation.

Normal Starting and Stopping

Step-by-step instructions for starting and stopping the compressor under normal conditions.

SPEC Controller Operational Instructions

How to use the Sullivan-Palatek Electronic Controller interface for monitoring and control.

Operation in Extreme Conditions

Guidance for using the compressor in challenging environments like cold, heat, or dusty areas.

Pneumatic Tools Application

Safe practices for using compressed air with pneumatic tools, avoiding misuse.

Jump-Starting the Battery

Procedures for safely jump-starting the compressor's battery system.

Component Description

Compressor Package Overview

Description of the compressor unit's design, including its single-stage rotary screw configuration.

Engine Details

Details on the diesel engine, its cooling system, and the drive mechanism to the compressor.

Air End Assembly Details

Explanation of the rotary screw compression mechanism, rotors, and the compression cycle.

Discharge System Components

Components like the receiver/sump tank and the minimum pressure valve.

Lubrication System Overview

Details on oil flow, the oil filter, return lines, and the thermal bypass valve.

Capacity Control System Explained

How the compressor regulates air output based on demand using inlet valve and engine speed.

Noise Control System Components

Components and design features aimed at reducing operational noise levels.

Electrical System and Protection

Explanation of the electrical system and safety shutdown features like high temperature or low oil pressure.

Engine Shutdown Protection Features

Overview of the engine's protective measures against damage through derate or shutdown.

Instrument Panel and Controls

Explanation of the main controls and displays on the instrument panel.

Maintenance

Maintenance Schedule

Periodic maintenance tasks and their recommended intervals for the compressor.

Bolt Torque Guidelines

Recommended torque specifications for various fastener sizes and grades.

Compressor Lubrication Procedures

How to check, fill, and drain the compressor oil, including level checks.

WEATHER-ALL Compressor Lubricant

Information on the recommended synthetic compressor fluid for optimal performance.

Oil Sample Analysis

Instructions for collecting and submitting oil samples for laboratory analysis.

Air Intake Filter Maintenance

Procedures for inspecting and replacing air intake filters for optimal air supply.

Compressor Oil Filter Service

Steps for replacing the compressor oil filter element to ensure clean lubrication.

Shaft Seal and Oil Return Line Maintenance

Checking shaft seals for leaks and oil return lines for clogs to prevent oil issues.

Separator and Thermal Valve Service

Replacing the separator element and inspecting the thermal valve's function.

Oil Cooler and Lubrication

Cleaning the oil cooler and applying grease and engine lubrication guidelines.

Control Adjustments

How to adjust discharge pressure and engine speed settings for optimal performance.

Recommended Spare Parts

A list of essential spare parts for the D185PKR model to ensure readiness.

Service Kits Information

Information on available service kits for routine compressor and engine maintenance.

Troubleshooting

Troubleshooting Introduction

How to use this section to diagnose and resolve equipment issues effectively.

Unplanned Shutdowns

Potential causes and corrective actions for unexpected compressor shutdowns.

Low Discharge Pressure

Steps to diagnose and fix issues resulting in low air pressure output from the compressor.

High Discharge Pressure or Relief Valve Activation

Troubleshooting high pressure conditions and relief valve blow-off events.

Relief Valve Blows at Idle Position

Addressing relief valve issues that occur specifically when the engine is idling.

Pressure Blowdown Issues After Shutdown

Solutions for systems that fail to depressurize properly post-shutdown.

Excessive Compressor Oil Level Decrease

Diagnosing and correcting rapid oil loss from the compressor system.

Oil in Service Line

Identifying and rectifying oil contamination in the air service lines.

Engine Speed and Load Performance

Troubleshooting issues with engine speed not accelerating or maintaining full load.

Separator Plugging

Identifying causes and solutions for a plugged air/oil separator element.

Engine Speed Control to Idle

Resolving issues where the engine fails to reach idle speed after operation.

Engine Speed Control to Full Load

Troubleshooting problems with the engine not reaching full speed under air demand.

Oil Leaking in Control Lines;Orifices

Identifying and fixing oil leaks within the compressor's control system.

Sullivan-Palatek D185PKR Specifications

General IconGeneral
BrandSullivan-Palatek
ModelD185PKR
CategoryAir Compressor
LanguageEnglish

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