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21

COMPONENT DESCRIPTION

4.8 

ELECTRICAL AND PROTECTIVE CIRCUIT SYSTEM

The compressor electrical system is a 12-volt negative ground system used on smaller-capacity (185–375 

CFM) compressors and a 24-volt negative ground system used on larger-capacity (750–1800 CFM) 
compressors. It is equipped with a protective circuit to minimize damage. Damage could be caused by high 
compressor discharge temperature, high engine water temperature, or low engine oil pressure. Refer to 
wiring diagrams as required. The following conditions will cause automatic shutdown of the compressor: 

 

»

Compressor discharge temperature (CDT) of approximately 265°F (129°C). A warning is shown when the 
temperature reaches 245°F (118°C) and the unit will be forced to unload.

 

»

Low engine oil pressure (EOP) dependent upon engine manufacturer’s specifications.

 

»

High water temperature (EWT) dependent upon engine manufacturer’s specifications.

4.9 

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.

WARNING! 

Failure to follow the electronic control warnings and attempts to override, bypass, or ignore these 

warnings can lead to severe engine damage. This damage will not be covered by either the engine 

manufacturer’s or 

Sullivan-Palatek’s

 warranty.

Electronically controlled engines have software that monitor engine parameters during operation. If the 
parameters exceed the normal operating threshold, the engine software will take appropriate actions to 

protect the engine from damage. There are two levels of action: derate and shutdown. If either of these 

actions are initiated, the software will also activate the yellow warning sign and red engine shutdown/

diagnostic warning sign on the Sullivan-Palatek Electronic Controller (SPEC).

4.9.1 

ENGINE DERATE

The engine will derate the power output of the engine in an attempt to correct the parameters that are out 

of range. In almost every case, power deration will result in the engine stalling, which will protect the engine 
from damage. 

NOTE! 

The yellow warning will be lit on the SPEC screen when this occurs.

4.9.2 

ENGINE SHUTDOWN

The second level of protection in the controller is engine shutdown. If the derate feature cannot correct the 

unsafe parameters or the engine does not stall, the controller will shut down the engine to protect it from 
damage. 

NOTE! 

The warning and shutdown information will be lit on the SPEC screen when this occurs.

If either of these protection features activate, the engine requires inspection by an authorized engine 
manufacturer’s Dealer before attempting to run the machine again. 

WARNING! 

Failure to inspect and correct the fault in the engine or at the point of the external sensor will result in 

repeated derates and shutdowns, which can lead to engine damage.

NOTE! 

The engine software stores all derate and shutdown information to be reviewed by the engine manufacturer’s 

representative. 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.

Operators, rental customers and anyone responsible for the operation and maintenance of this compressor 
MUST be instructed and briefed on the proper responses to control module warnings. In particular, they 
must be instructed to report warning instances and not attempt to restart the compressor until faults are 

cleared by certified personnel.

Содержание D185PKR

Страница 1: ...D185PKR D185PKRSB KOHLER DIESEL ENGINE TIER 4 FINAL OPERATION SERVICE MANUAL WHEEL MOUNTED PORTABLE COMPRESSOR 185 CFM 05018730 0287 00 Issued October 13 2020 ...

Страница 2: ...EEPING 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 wi...

Страница 3: ... 5 Towing 7 2 6 Parking or Locating Compressor 8 3 OPERATION 9 3 1 General Operating Safety 10 3 2 Preparing for Initial Start Up 10 3 3 Normal Starting 10 3 4 Normal Stopping 11 3 5 Sullivan Palatek Electronic Controller SPEC Operational Instructions 11 3 6 Operating Under Extreme Conditions 13 3 7 Pneumatic Tools Application 13 3 8 Jump Starting Battery 14 4 COMPONENT DESCRIPTION 17 4 1 Portable...

Страница 4: ...Kits 33 6 TROUBLESHOOTING 35 6 1 Introduction 36 6 2 Unplanned Shutdown 36 6 3 Discharge Pressure Is Too Low 36 6 4 Discharge Pressure is Too High or Relief Valve Blows 37 6 5 Relief Valve Blows with Throttle Lever in Idle Position 37 6 6 Pressure Does Not Blow Down After Shutdown 37 6 7 Compressor Oil Level is Decreasing Excessively 37 6 8 Oil in Service Line 37 6 9 Engine Does Not Accelerate Or ...

Страница 5: ... Purchaser 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 iv pay shipping costs for replacement parts v pay reasonable travel expenses for field repair...

Страница 6: ...vi WARRANTY ...

Страница 7: ...ng and operating air compressors SECTION 2 TRANSPORTING AND LOCATING This section contains instructions and safety guidelines for transporting and locating a portable air compressor SECTION 3 OPERATION This section contains an overview of general operating safety initial start up procedures how to start and stop the air compressor in addition to guidelines for operating under extreme conditions SE...

Страница 8: ...viii About This Manual ...

Страница 9: ...rts 3 Toxic and Irritating Substances 4 Hot Surfaces Sharp Edges Sharp Corners and Vacuum 4 Electrical Shock 4 Entrapment 4 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 ...

Страница 10: ... paper or wood to locate a suspected leakage Wear safety glasses when detecting leaks Oil fuel or compressed air can cause injuries Fluid leaking under pressure has enough force to penetrate under the skin and cause serious bodily injuries Do not open sump receiver oil filler cap when compressor is running and air system is pressurized Shut down the compressor and bleed the sump receiver pressure ...

Страница 11: ... remove any acoustical material or other material that may be damaged by heat or that may support combustion Remove and isolate negative battery cable Do not operate compressor under low overhanging leaves or permit leaves and foliage to contact hot exhaust system surfaces when operating in forested areas Do not expose dry grass grass cuttings oil or any other flammable material to exhaust gases A...

Страница 12: ... eyes wash eyes with large quantities of clean water for at least 15 minutes Medical attention should be obtained immediately 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 Lay down and cover eyes to exclude light Seek medical assistance Do not store airlin...

Страница 13: ...5 2 TRANSPORTING AND LOCATING TOPICS IN THIS SECTION Receiving 6 Lifting 6 Drawbars and Brake Actuators 6 Preparing to Tow 7 Towing 7 Parking or Locating Compressor 8 ...

Страница 14: ... tools and equipment If you are unsure of the weight then weigh the compressor before lifting Make sure lifting hook has a functional safety latch or equivalent and is fully engaged before lifting compressor from the ground Support the compressor by using slings under the main frame with appropriate spreader bars when airlifting the machine Lift only in full compliance with OSHA Standards 29 CFR 1...

Страница 15: ...ments do not interfere with or restrict motion of any part of the compressor Make sure chain length and if provided brake and electrical interconnections have sufficient slack to prevent strain when turning and maneuvering All chains and connections must be supported so they cannot drag or rub on road terrain or towing vehicle surfaces Dragging or rubbing of this equipment will cause wear resultin...

Страница 16: ...mmable material Park or locate compressor to cause the prevailing wind to direct the exhaust fumes and radiator heat away from the compressor air inlet openings and to prevent ingestion of dust and debris from the work site Set parking brakes and disconnect breakaway switch cable and all other interconnecting electrical and brake connections if provided Block or chock both sides of all wheels Bloc...

Страница 17: ...ting Safety 10 Preparing for Initial Start Up 10 Normal Starting 10 Normal Stopping 11 Sullivan Palatek Electronic Controller SPEC Operational Instructions 11 Operating Under Extreme Conditions 13 Pneumatic Tools Application 13 Jump Starting Battery 14 ...

Страница 18: ...e section for lubricating oil specifications 6 Check battery posts and cable clamps to assure proper contact Connect positive cable and negative cable battery terminals 3 3 NORMAL STARTING 1 Inspect the compressor engine and other assemblies for damage or loose connections 2 Check engine coolant oil fuel and battery fluid levels Check compressor receiver oil level 3 Close service valves 4 Set star...

Страница 19: ...ut required for each page Pages requiring custom button functionality will display button function icons directly above the buttons GAUGE HOME SCREEN The Gauge screen shows current engine and compressor conditions Additional warnings are displayed within the RPM gauge Button 2 will show any fault codes Button 3 is the Main Menu button It activates the Main Menu shown below MAIN MENU This screen al...

Страница 20: ...k 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 A warning icon will be displayed on the Gauge screen when a filter is due for replacement Buttons 1 and 2 cycle through the list of selections Button 3 returns to previous menu Buttons 4 and 5 move lef...

Страница 21: ...THER OPERATION Keep the engine cooling system filled with clean coolant Check the coolant level daily or before each shift Keep the outside of the radiator and oil cooler clean Locate the unit in a well ventilated area When operating in humid conditions change the compressor oil more frequently 3 6 3 DUSTY OR SANDY AREAS When possible wet down the area surrounding the operating site to keep dust a...

Страница 22: ...equipment per OSHA Standard 29 CFR 1910 242 b WARNING Serious injury or death may result from horseplay with air hoses and compressed air HORSEPLAY DO NOT DO IT DO NOT ALLOW IT 3 8 JUMP STARTING BATTERY WARNING Always wear an acid resistant apron face shield with goggles and gloves when working with batteries Batteries may contain hydrogen gas which is explosive and flammable Keep flames sparks an...

Страница 23: ...ead battery 10 If the compressor starts then allow it to warm up and then remove the jumper cables while keeping the compressor running Make sure not to let the clips of the cables touch while either end of the cables are attached to one of the batteries This would cause arcing 11 Replace vent caps on battery if required 12 Move starting vehicle away from compressor 13 If compressor engine startin...

Страница 24: ...16 Operation ...

Страница 25: ...N Portable Compressor Package 18 Engine 18 Air End Assembly 18 Discharge System 18 Lubrication System 19 Capacity Control System 20 Noise Control Systems 20 Electrical and Protective Circuit System 21 Engine Shutdown Protection 21 Instrument Panel 22 ...

Страница 26: ...gle stage rotary screw unit Components 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 4 3 1 COMPRESSION CYCLE FIGURE 4 1 COMPRESSION CYCLE Air at atmospheric pressure is drawn in through the inlet and comp...

Страница 27: ...rings 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 4 5 1 OIL RETURN LINE The oil that is not removed by the air oil separator gravitates...

Страница 28: ...en a larger capacity compressor or multiple compressors may be required for the customer s job needs 4 6 1 INLET VALVE The inlet valve assembly is the heart of the control system which regulates the amount of air entering the compressor The engine speed is regulated by the Sullivan Palatek Electronic Controller SPEC From full to approximately 60 capacity the delivery is controlled by engine speed ...

Страница 29: ...ted the software will also activate the yellow warning sign and red engine shutdown diagnostic warning sign on the Sullivan Palatek Electronic Controller SPEC 4 9 1 ENGINE DERATE The engine will derate the power output of the engine in an attempt to correct the parameters that are out of range In almost every case power deration will result in the engine stalling which will protect the engine from...

Страница 30: ...allows compressor to be started RUN allows full load operation 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 oil press...

Страница 31: ...e STOP button puts the machine into a mandatory cooldown state 4 10 3 START RUN VALVE The Start Run load unload valve unloads the compressor for easier start up When positioned on START this valve bypasses the pressure regulating valve so that the inlet valve closes with reduced discharge pressure After the compressor is warmed up the Start Run valve can be turned to RUN position The unit is then ...

Страница 32: ...24 Component Description ...

Страница 33: ...on 27 WEATHER ALL Compressor Lubricant 28 Oil Sample for Analysis 29 Air Intake Filter 30 Compressor Oil Filter 30 Compressor Shaft Oil Seal 30 Oil Return Line 30 Air Oil Separator 31 Thermal Valve 31 Oil Cooler 31 Grease 31 Engine Lubrication 31 Control Adjustments 32 Recommended Spare Parts 33 Service Kits 33 ...

Страница 34: ...le spring shackles and mounting bolts x 4 Clean battery terminals x 4 Check battery hold downs and cables for wear x 4 Check compressor shaft seal for leaking x 4 5 8 Check air filter piping fittings and clamps x 4 Check engine and compressor supports x 4 Replace air oil separator element x 5 5 10 Check all door gaskets hinges and latches x 5 Drain engine radiator coolant and replace x 5 9 Clean a...

Страница 35: ...e lubrication product life and performance Mixing different types or brands of lubricants is not recommended due to the possibility of a dilution of the additives or a reaction between additives of different types Environmental conditions in the area of compressor operation such as the presence of reactive gases or vapors in the air may lead to chemical changes and premature degradation of the lub...

Страница 36: ...ditions Maximum protection against scuffing and wear to bearings and rotors and wear control for steel and brass parts when operating at maximum pressure ratings results in extended compressor life Extensive testing has shown this fluid exhibits excellent resistance to foaming oil oxidation and corrosion of yellow metals and limits rust of ferrous metals This synthesized hydrocarbon based fluid pr...

Страница 37: ...vel during operation Add oil if necessary according to 5 3 2 Fill procedures Figure 5 1 OIL ANALYSIS KIT P N K00031 005 1 2 3 SUBMIT OIL SAMPLE 1 Fill out all the information on the oil sample form 3 provided with the oil analysis kit Please make sure the form is completely and legibly filled out 2 Place the oil sample bottle 2 inside the black canister and put the lid on 3 Mail the sample with th...

Страница 38: ...to ensure the correct element is properly installed and not leaking 5 7 2 REMOVAL 1 Make sure the system pressure is relieved 2 Place oil spill pan under filter 3 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 5 7 3 INSTALLATION 1 Apply a thin film of oil to the seal of a new oil filter 2 Thread the...

Страница 39: ...ermal valve if the unit shuts down because of high compressor discharge oil temperature 5 11 1 INSPECTION Inspect the valve by removing it from the manifold housing Sediment particles may lodge in the valve seating surface and prevent it from opening thereby allowing hot oil to pass directly to the compressor without being cooled 5 12 OIL COOLER The interior of the oil cooler should be cleaned whe...

Страница 40: ...r the operating pressure by turning screw counter clockwise Reset locknut after adjustment is completed See Figure 5 3 Check engine speed whenever pressure settings have been changed Only the unloaded pressure can be selected with the pressure regulating valve Full and part load pressures are a function of air usage 5 15 2 ENGINE SPEED Engine speed is controlled by the Sullivan Palatek Electronic ...

Страница 41: ...44 0001 DISPLAY 1 27 05017457 0030 RADIATOR CAP 1 28 05019310 0032 TOP SPRING 2 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 o...

Страница 42: ...34 Maintenance ...

Страница 43: ...osition 37 Pressure Does Not Blow Down After Shutdown 37 Compressor Oil Level is Decreasing Excessively 37 Oil in Service Line 37 Engine Does Not Accelerate Or Will Not Maintain Full Load Speed 38 Separator Plugging 38 Engine Speed Control Does Not Change to Idle Speed with Service Valves Closed 38 Engine Speed Control Does Not Change to Full Speed with Air Demand 38 Compressor Oil Leaking in Cont...

Страница 44: ...nd or high engine coolant temperature Check the engine coolant level Add as needed Clean the coolers Check the fan belt tension Adjust or replace as needed Refer to Engine Manufacturer s manual located at www kohlerpower com Low engine oil pressure fault code Check engine oil add as needed Verify the engine oil pressure exceeds engine manufacturer s spec with the engine running Obstruction in radi...

Страница 45: ... 185 375 CFM compressors Rebuild replace valve 6 6 PRESSURE DOES NOT BLOW DOWN AFTER SHUTDOWN POSSIBLE CAUSE ACTION Automatic blowdown valve may be faulty Check operation of the automatic blowdown valve Replace if necessary Air line from inlet valve or sump to blowdown valve may be restricted Verify the pilot signal is reaching the automatic blowdown valve Verify the blowdown valve is plumbed corr...

Страница 46: ... is breaking down Compressor oil can break down prematurely for a number of reasons Extreme operating temperature Failure to drain condensate from oil sump Using the incorrect type of oil Mixing different types of oil Prolonged operation at extreme ambient temperatures Foreign material gases or vapors entering compressor inlet 6 11 ENGINE SPEED CONTROL DOES NOT CHANGE TO IDLE SPEED WITH SERVICE VA...

Страница 47: ...erature Check the compressor oil level add oil as needed Clean the oil cooler Check the fan belt Adjust or replace as needed Check thermal bypass valve compressor oil thermostat Change compressor oil and oil filter element Clean the oil cooler internally Discharge pressure below 90 psi The air demand may be too much Add compressors or decrease the demand Adjust the discharge pressure above 90 psi ...

Страница 48: ...40 Troubleshooting ...

Страница 49: ...NOTES ...

Страница 50: ...1201 West US Highway 20 Michigan City Indiana 46360 Phone 219 874 2497 Fax 219 809 0203 info palatek com www sullivan palatek com ...

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