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31

MAINTENANCE

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. Elevated temperatures at these points can result in

ignition of the fluid in the oil sump.

5.10.1 REMOVAL

1.

Relieve sump pressure to zero pressure.

2.

Unscrew air/oil separator element by turning counter-clockwise.

3.

Remove the old element and discard in accordance to local codes.

5.10.2 INSTALLATION

1.

Apply a thin film of oil to the seal of a new element.

2.

Thread the element on by hand, turning it clockwise until the gasket seats. Then turn an additional
¼ turn by hand.

5.11

THERMAL VALVE

Inspect and clean the thermal 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 when the pressure drop across the cooler at full load exceeds

25 psi.

5.12.1 INSPECTION

Inspect compressor oil system for signs of varnish.

5.12.2 REMOVAL

1.

Drain compressor fluid.

2.

Remove oil cooler.

5.12.3 CLEANING

Circulate a suitable solvent to dissolve and remove varnish and sludge.

5.12.4 INSTALLATION

1.

Replace oil cooler and fill compressor with fresh oil.

2.

Operate the machine normally for 50 hours. After 50 hours, change compressor oil and install a new oil
filter element.

5.13

GREASE

Use a multi-purpose type grease (MKG) or multi-purpose type grease with molybdenum disulfide (MPGM)

conforming to MIL-L-7866 for all parts except wheel bearings. Use wheel-bearing grease (WBG) for

lubricating the wheel bearings.

5.14

ENGINE LUBRICATION

Refer to Engine Operation and Maintenance Manual, located at www.kohlerpower.com for recommended
engine lubricating oil, service intervals, and maintenance practices.

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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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