Sullivan 210
Sullivan 210
D210PHKR
KOHLER DIESEL ENGINE
TIER 4 FINAL
05018730-0306 / 00
Issued: June 23, 2021
DOCUMENT INFORMATION
© Sullivan-Palatek, Inc.
ALL RIGHTS RESERVED
Part Number: 05018730-0306
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
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 without notice.
REVISION HISTORY
# DATE SECTION(S) DESCRIPTION
00 2021-06-23 Released for publication
Contents
I WARRANTY�����������������������������������������������������������������������������������������������������������������������������V
II ABOUT THIS MANUAL�������������������������������������������������������������������������������������������������������� VII
II.1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
II.2 Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
II.3 Supplemental Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
1 SAFETY ����������������������������������������������������������������������������������������������������������������������������������� 1
1.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Pressure Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Fires and Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Toxic and Irritating Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Hot Surfaces, Sharp Edges, Sharp Corners and Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Electrical Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.8 Entrapment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 TRANSPORTING AND LOCATING ��������������������������������������������������������������������������������������� 5
2.1 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Drawbars and Brake Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Preparing to Tow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 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 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.6 Sullivan-Palatek Electronic Controller (SPEC) Operational Instructions . . . . . . . . . . . . . . . . . . . . 11
3.7 Low Fuel/Adding Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.8 Operating Under Extreme Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.9 Pneumatic Tools Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.10 Jump-Starting Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 COMPONENT DESCRIPTION����������������������������������������������������������������������������������������������� 17
4.1 Portable Compressor Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Air End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4 Discharge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.6 Capacity Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.7 Electrical and Protective Circuit System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.8 Engine Shutdown Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.9 Noise Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.10 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
iii
5 MAINTENANCE��������������������������������������������������������������������������������������������������������������������� 25
5.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2 Bolt Torque Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.3 Compressor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4 WEATHER-ALL™ Compressor Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5 Oil Sample for Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6 Air Intake Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.7 Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.8 Compressor Shaft Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.9 Oil Return Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.10 Air/Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.11 Thermal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.12 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.13 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.14 Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.15 Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.16 Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.17 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.18 Service 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 Will Not Maintain Full Load Speed . . . . . . . . . . . . . . . . . . . . . . . . 38
6.10 Separator Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.11 Engine Speed Control Does Not Change to Idle Speed with Service Valves Closed . . . . . . . . . . 38
6.12 Engine Speed Control Does Not Change to Full Speed with Air Demand . . . . . . . . . . . . . . . . . . . 38
6.13 Compressor Oil Leaking in Control Lines/Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
iv Contents
I WARRANTY
WARRANTY v
vi WARRANTY
II About This Manual
WARNING! is used when death or personal injury could occur if the instruction is not followed.
CAUTION! is used when damage to property could occur if the instruction is not followed.
NOTE! is used to inform the reader of installation, operation or maintenance information that is important but not
hazardous.
SECTION 1: SAFETY
This section contains important basic information regarding general safety precautions for maintaining
and operating air compressors.
SECTION 5: MAINTENANCE
This section contains a maintenance schedule and step-by-step instructions for performing common
maintenance procedures. A list of recommended spare parts to keep on hand is also included.
SECTION 6: TROUBLESHOOTING
This section contains symptoms, causes and remedies for common air compressor malfunctions.
vii
viii About This Manual
1 SAFETY
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.
1
1.1 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:
» Only trained and authorized personnel who have read and understand this user’s manual should operate
the air compressor. Failure to follow the instructions, procedures, and safety precautions in the manual
will increase the possibility of accidents and injuries.
» Never start the air compressor unless it is safe to do so. Do not attempt to operate the air compressor
with a known unsafe condition. If an unsafe condition exists or maintenance is required, tag the air
compressor and render it inoperative by disconnecting the battery so others who may not know of the
unsafe condition cannot attempt to operate it until the unsafe condition is corrected.
» Use and operate the air compressor only in full compliance with all pertinent Federal, State and Local
codes or requirements including OSHA, EPA and other relevant agency requirements.
» Do not modify the compressor or install attachments without consulting the manufacturer.
» Known and potential hazards associated with the operating and servicing of portable air compressors
are detailed in the following pages. Not all hazards can be anticipated and the operator of the equipment
is ultimately responsible for identifying hazardous and dangerous conditions, avoiding dangerous
operation and preventing accidents.
» Refuel at a service station or from a fuel tank designed for the purpose. Ground the machine to mobile
dispensers prior to refueling.
» Immediately clean up any spills or leaking fuel, battery electrolyte, oil, or anti-freeze solution.
» Keep sparks, flames, and other sources of ignition away and do not permit smoking in the vicinity when
adding fuel, checking or adding electrolyte to batteries, checking or adding oil, or when refilling air line
anti-icing systems with anti-freeze.
» Replace damaged fuel tanks or lines. Do not store or attempt to operate the compressor with any known
leaks in the fuel system or oil lines.
» Do not permit liquids to accumulate in bottom of the compressor frame. Prevent contact with acoustical
surfaces of the air compressor. Wipe down using an aqueous industrial cleaner or steam clean as
required. If necessary, remove acoustical material, clean all surfaces and then replace acoustical
material. Do not use flammable solvents for cleaning purposes.
2 Safety
» Anti-freeze compound used in airline 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.
» Do NOT check the battery charge by placing a metal object between the terminals. Use a voltmeter or a
hydrometer.
» Do NOT charge a frozen battery. There is risk of explosion. If the battery is frozen, heat it up to at least
61°F (16°C).
» Do NOT charge a battery that is in excess of 113°F (45°C).
» Disconnect the grounded (negative) battery connection prior to attempting any repairs or cleaning
inside the enclosure. Tag the ground cable with a warning not to reconnect until servicing is complete.
» Keep electrical wiring, battery terminals and other terminals in good condition. Replace any wiring
that has cracked, cut, abraded, or otherwise degraded insulation. Replace terminals if worn, discolored
or corroded. Keep all terminals clean and tight. Turn off battery charger before making or breaking
connections to the battery. Wear a face shield whenever servicing or working on the battery.
» Keep tools and other grounded conductive objects away from exposed live electrical parts to avoid
arcing, which might serve as a source of ignition.
» Always avoid electrical parts when washing the compressor.
1.3.3 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.
» 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. Always
keep the engine and muffler clean.
» Keep oily rags, trash, leaves, litter, or other combustibles out of and away from the compressor.
» Keep a suitable fully charged class BC or ABC fire extinguisher or extinguishers nearby when servicing
and operating the compressor.
Safety 3
1.5 TOXIC AND IRRITATING SUBSTANCES
WARNING! Do not use air from this compressor for breathing air. Breathing unfiltered air from this compressor can
result in serious injury or death.
NOTE! 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.
» Operate the compressor only in open or well-ventilated areas.
» Carbon monoxide will kill. If the machine is operated indoors, discharge the engine exhaust outdoors and
be certain there are no exhaust system leaks that can discharge exhaust within the building.
» Locate the compressor so that exhaust will not be carried toward personnel, air intakes servicing
personnel areas or toward the air intake of any other portable or stationary compressor.
» Fuel, oil, coolant, lubricant, and battery electrolyte used in the compressor are typical of the industry.
Care should be taken to avoid accidental ingestion or skin or eye contact. In the event of ingestion or
contact, seek medical treatment promptly. Do not induce vomiting if fuel is ingested. Wash with soap
and water in the event of skin contact.
» Wear an acid-resistant apron and a face shield or goggles when servicing the battery. If electrolyte is
spilled on skin or clothing, immediately flush and wash with large quantities of water.
» Do not use airline anti-icing systems in airlines supplying respirators or other breathing air utilization
and equipment, and do not discharge air from these systems in unventilated or other confined areas.
» Wear goggles or a full face shield when adding anti-freeze compound to air line anti-icing systems. The
anti-freeze compound used in airline anti-icing systems contains methanol and is toxic, harmful, or
fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If contact with
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 airline anti-icing system anti-freeze compound in operator’s cabs or in unapproved
containers.
» Do not mix different types of antifreeze. The mixture may cause a chemical reaction and release harmful
substances.
1.8 ENTRAPMENT
» Make sure all personnel are out of compressor before closing and latching enclosure doors. Larger
compressors can hold a man. If it is necessary to enter the enclosure to perform service or adjustments,
secure the access door in the open position to avoid the possibility of others closing and latching the
door and inform personnel before entering the enclosure.
4 Safety
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
5
2.1 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.
NOTE! Satisfactory performance of the compressor depends upon the operator’s knowledge of the controls,
instruments, and recommended operating procedures. Consequently, the preceding sections of this manual
and also the entire Engine Operator’s Manual, located at www.kohlerpower.com, should be read and
understood before attempting to start and operate this machine.
2.2 LIFTING
» Properly drain and dispose of any fluids in the containment frame before lifting.
» This compressor is provided with a lifting bail for routine lifting and loading onto trucks, oil platforms, or
similar equipment. It is not intended for extended airlift such as via helicopter.
» Prior to lifting inspect the lifting bail and points of attachment for the following: cracked welds; cracked,
bent, corroded or degraded members; loose bolts or nuts. Do not lift machine if any of these items are
found to be defective.
» Make sure entire lifting, rigging, and supporting structure is in good condition and has a rated capacity
of at least the net weight of the compressor plus an additional 10% allowance for the weight of snow,
ice, mud, or stored 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 1910 subpart N, and other
applicable regulations.
» Do not attempt to lift in high winds.
» Keep all personnel out from under and away from the compressor when suspended.
» Lift compressor slowly and smoothly, without jerking. Tilting movements must be limited and rotation
must be prevented.
» Lift compressor no higher than necessary, use guidelines and have spotters properly located.
» Do not leave suspended compressor unattended.
» Set compressor down only on level surfaces capable of supporting at least its net weight plus an
additional 10% allowance for the weight of snow, ice, mud, or stored tools and equipment.
» If the compressor is provided with parking brakes, make sure they are set; and always block or chock
both sides of all running wheels plus drawbar stabilizer leg before disengaging the lifting hook.
2.5 TOWING
WARNING! Maintain proper torque on wheel lug nuts:
SINGLE AXLE: 85 to 95 LB-FT
TWO AND THREE AXLE: 65 to 75 LB-FT
Failure to maintain lug tightness may result in a wheel loosening and leaving the compressor and causing
injury or death or property damage.
» Non-braked compressors must be towed by a vehicle having a net weight at least 2 times higher than
the total weight of the towed compressor ready for use.
» Observe and follow all local, state, and federal traffic laws. Note and adhere to speed limits and minimum
highway speed.
WARNING! Failure to comply with maximum towing speed may cause property damage and serious bodily injury
or death.
» 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.
» Block or chock both sides of drawbar stabilizer leg or jack.
» Unhook chains and remove them from the points of attachment on the towing vehicle, then hook chains
to each other on drawbar or wrap chains around the drawbar in order to keep them off the ground.
» If provided, lower front screw jack and rear stabilizer legs. Make sure the ground is firm and capable of
supporting the weight of the compressor.
» If the compressor is provided with a swivel caster wheel, pull pin and lower caster wheel, then make sure
pin is re-engaged to secure caster wheel in the full-down and locked position.
» Disconnect coupling device, keeping hands and fingers clear of all pinch points. Do not attempt to lift
the drawbar of portable compressors by hand if the weight is more than you can safely handle - usually
weights in excess of 50 pounds. Use a lifting device such as a jack or chain hoist to lift the drawbar to
avoid injury to yourself or others.
» Keep feet clear of drawbar at all times to avoid crushing accidents in case it should slip from your hands
or otherwise fall to the ground.
NOTE! These guidelines also apply for locating and securing non-towed compressors (skid mounted and utility
models). Reference to towing may not apply.
9
3.1 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.
» Check instruments periodically during operation. If readings are abnormal, refer to Chapter 6
TROUBLESHOOTING on page 35
» Make sure that the correct type and viscosity of lubricating oils and fuel are used, especially in extreme
ambient temperatures.
» Keep batteries fully charged and properly maintained.
WARNING! Never add gasoline to diesel fuel tank - serious damage to the engine will result.
5. If necessary, add lubricating oil to the compressor sump. Refer to the Lubrication and Maintenance
section for lubricating oil specifications.
6. Check battery posts and cable clamps to assure proper contact. Connect positive cable and negative
cable battery terminals.
9. After warmup, set Start-Run valve to RUN position for full load operation.
CAUTION! If the engine stops, do not attempt to restart with the oil receiver under pressure. Wait until unit blows
down to <10 psi, then return Start-Run valve to START.
NOTE! For the first 50 hours of engine operation, it is advisable not to exceed 75% of the maximum power supplied.
10 Operation
3.4 NORMAL STOPPING
1. Position Start-Run valve to START. Close all service valves.
2. Run engine at low idle for 2 minutes.
3. Open and close the service valve to reduce pressure to approximately 75 psi or less.
4. Press ignition switch to OFF.
MAIN MENU
This screen allows the user to check user settings,
service reminders, setpoints, and the software
version.
Buttons 1 and 2 cycle between the selections;
Button 3 returns back to the Gauge screen;
Button 4 will display any faults;
Button 5 enters into the option selected with
buttons 1 and 2.
Operation 11
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.
SOFTWARE SCREEN
The current software and revision level can be found
here.
12 Operation
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.
WARNING! Do not inject ether starting fluid directly into air intake.
WARNING! Check the compressor sump oil level only when the compressor is not operating and system is completely
relieved of pressure. Open pressure relief valve to ensure relief of system air pressure when performing
maintenance on compressor air/oil system. Failure to comply with this warning may cause property
damage and serious bodily harm or death.
Operation 13
3.9 PNEUMATIC TOOLS APPLICATION
WARNING! Compressed air can be dangerous. Serious injury or death can result from the improper selection, use or
application of tools and attachments to this compressor.
Never inject compressed air into a bodily orifice. Never direct compressed air at or toward a person or
animal.
» 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.
» Provide an appropriate flow-limiting valve for each additional 75 feet of hose in runs of air hose
exceeding 0.5-inch inside diameter to reduce pressure in case of hose failure.
» Flow limiting valves are listed by pipe size and rated CFM. Select appropriate valves accordingly.
» Do not use tools that are rated below the maximum relief valve rating on this compressor. Do not exceed
manufacturer’s rated safe operating pressures for these items.
» Secure all hose connections by wire, chain, or other suitable retaining devices to prevent tools or hose
ends from being accidentally disconnected. Unrestrained disconnected hoses can flail around an cause
injury or damage.
» Vent and release all internal pressure prior to opening any line, fitting, hose, valve, drain plug or
connection. This includes components such as filters, line oilers and optional airline anti-icing systems.
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.
Air gun cleaning devices must not be used and pressures above 30 psig (2 Bars). Always use an appropriate
regulator to reduce pressure at the cleaning tool and always use with effective chip guarding and personal
protective 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!
Batteries may contain hydrogen gas which is explosive and flammable! Keep flames, sparks and any other
source of ignition away. Batteries also contain acid which is corrosive and poisonous. DO NOT allow battery
acid to contact eyes, skin, or fabrics. Serious personal injury or property damage could result! Flush any
contacted areas thoroughly with water immediately and seek medical attention.
NOTE! The following instructions are for single battery 12 VDC starting systems only. Make sure both compressor
and starting vehicle have the ignition “OFF” before connecting the jumper cables.
1. Remove all vent caps from the battery or batteries in the compressor. Do not permit dirt or foreign
matter to enter the open cells.
CAUTION! Remove vent caps on dead battery if the battery is a maintenance type and add distilled water if
needed. This is not required if the battery is a maintenance-free type that is sealed.
2. Check fluid level. If low bring to a proper level before attempting to jump-start.
14 Operation
3. Locate the starting vehicle beside the compressor, but do not permit metal-to-metal contact between
the compressor and the starting vehicle. Set the parking brakes of the compressor (if provided) and the
starting vehicle, or chock or block both sides of all wheels. Place the starting vehicle in neutral or park,
turn off nonessential accessory electrical loads and start its engine.
4. Connect one end of the RED (positive) cable to the positive (+) terminal on the dead battery in the
compressor. Make sure the other end of this cable does not touch any metal surface that would cause
arcing!
5. Connect the other end of the RED (positive ) cable to the positive (+) terminal on the good battery in the
starting vehicle.
6. Connect one end of the BLACK (negative) cable to the negative (-) post on the good battery in the
starting vehicle.
7. Connect the other end of the BLACK (negative) cable to an unpainted metal surface on the compressor
engine with the dead battery.
8. Make sure all the jumper cable clips have a good connection (good clamping force) before attempting to
start.
9. Start vehicle with the good battery first and let it run a few minutes. Then attempt to start the
compressor with the dead 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 starting motor will not crank after repeated attempts or the battery is still dead
after running the compressor for over an hour (not taking charge), then the battery must be replaced.
Operation 15
16 Operation
4 COMPONENT
DESCRIPTION
TOPICS IN THIS SECTION:
» Portable Compressor Package ������������������������������������������������������������������������������������������������������������������������������18
» Engine������������������������������������������������������������������������������������������������������������������������������������������������������������������������18
» Air End Assembly������������������������������������������������������������������������������������������������������������������������������������������������������18
» Discharge System����������������������������������������������������������������������������������������������������������������������������������������������������18
» Lubrication System��������������������������������������������������������������������������������������������������������������������������������������������������19
» Capacity Control System ����������������������������������������������������������������������������������������������������������������������������������������20
» Electrical and Protective Circuit System��������������������������������������������������������������������������������������������������������������21
» Engine Shutdown Protection����������������������������������������������������������������������������������������������������������������������������������21
» Noise Control Systems��������������������������������������������������������������������������������������������������������������������������������������������22
» Instrument Panel������������������������������������������������������������������������������������������������������������������������������������������������������23
17
4.1 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.
4.2 ENGINE
The compressor is powered by a diesel engine. For detailed information on the engine refer to the Engine
Operators Manual, located at www.kohlerpower.com.
Air at atmospheric pressure is drawn in through the inlet and compressed by the rotation of the rotors.
During the compression cycle, oil is injected into the compressor performing three important functions:
1. Lubricate the rotating parts and bearings.
2. Provide cooling for the compressed air.
3. Seal the running clearances between the rotors.
18 Component Description
4.5 LUBRICATION SYSTEM
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.
Component Description 19
4.5.2 OIL RETURN LINE
The oil that is removed by the air/oil separator gravitates to the bottom of the air/oil separator and is
returned through an orifice in the oil return scavenger line assembly. The assembly consists of a pickup tube,
return line hose, a line strainer and a sight glass/orifice. Flow can be witnessed through the sight glass. Flow
is generated via differential pressure between the high pressure sump tank and the lower pressure region of
the compressor.
5 5
LOW PRESSURE
REGULATOR HIGH/LOW
VALVE
START/RUN
VALVE
VENT DOWN TO
ATMOSPHERE
4 4
PRESSURE
INLET VALVE SENSOR
BLOWDOWN VALVE
3 3
HIGH PRESSURE
REGULATOR
2 2
RECEIVER TANK
VENT DOWN TO
ATMOSPHERE
SPEED
PRESSURE
TRANSDUCER COLD START SOLENOID
(OPTIONAL ON SOME MODELS)
VENT DOWN TO
ATMOSPHERE
RECIRCULATION
ANGLES: + OR - 1/2 DEG. DESCRIPTION
DECIMAL: X.X + OR - 0.050
X.XX + OR - 0.020 3RD ANGLE
CONTROL DIAGRAM
NOTE: VALVE MATERIAL:
X.XXX + OR - 0.005 PROJECTION
SIZE
DUAL PRESSURE
DRAWING NO: REV
1. SOLID PIPE CONNECTIONS REPRESENTED BY THIN LINES.
2. UNLESS SPECIFICALLY NOTED, INDIVIDUAL PART ORIENTATIONS ARE FOUND ON ASSEMBLY DRAWINGS
D CD-00032 00
3. UNLESS SPECIFICALLY NOTED, IMAGES OF PARTS ARE FOR REPRESENTATION ONLY, ACTUAL PARTS MAY VARY IN APPEARANCE.
FIRST USED ON: SCALE: SHEET 1 OF 1
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.
A B C D E F
FIGURE 4-3. CD-00032 DUAL PRESS CONTROL SYS (REV 00)
The following overview explains the operation of the control from a condition of “no load” to a condition of
“full capacity” at working pressure. For the working pressure range of your machine, refer to applicable data
in the Specifications section. The inlet valve cylinder pressure chamber is pneumatically connected to the
dry side of the receiver via the pressure regulator valve. When the receiver tank pressure is below the set
point of the regulator valve no pressure will exist in the inlet valve cylinder. Under these conditions, the inlet
valve will remain wide open, causing the compressor to deliver full capacity.
As the demand for air decreases, the receiver pressure will rise, and when this pressure level exceeds the set
point of the pressure regulator valve, control signal pressure will be allowed to enter the inlet valve chamber,
which in turn will move the modulating piston and the valve plate to a closed condition, thereby throttling
the incoming air.A pressure transducer separate throttle air cylinder controls engine speed. The air cylinder
is spring loaded in the full speed position when there is no air signal from the pressure regulator valve.
Whenever less than full capacity is required, receiver pressure increases, thereby opening the pressure
regulator, which allows a pressure signal to enter the throttle air cylinder and reduce the engine speed until it
matches the air requirements from 100% down to 60%. From 60% down to 0% both engine speed reduction
and inlet valve modulation act together to reduce air output.
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.
20 Component Description
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 a pressure transducer signal through the CANBUS and
the Sullivan-Palatek Electronic Controller (SPEC). From full to approximately 60% capacity, the delivery is
controlled by engine speed and a gradual closing of the inlet valve. When unloaded the inlet valve is closed
to prevent atmospheric air from entering the compressor.
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 monitors 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 amber warning light and red engine shutdown/
diagnostic light on the compressor instrument panel.
Component Description 21
4.8.2 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 shutdown the engine to protect it from
damage.
NOTE! 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.
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 and will often 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.
22 Component Description
4.10 INSTRUMENT PANEL
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:
2 3 4
2 High-Low Switch HIGH for 150 psi operation and LOW for 100 psi operation.
3 Start-Run Switch START allows compressor to be started. RUN allows full-load operation.
4 Ignition Switch START/ON position electrically energizes engine starter motor solenoid.
Component Description 23
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 pressure, engine
temperature, battery voltage and fuel level. The SPEC provides warning and shutdown information from
high compressor temperature and low fuel level. It also has complete engine diagnostic capabilities that can
read and display fault codes from the engine ECU. Multiple language options are available including English,
Spanish, French, Italian and German.
NOTE! Engine derate and derate and shutdown are controlled by the engine ECU and displayed on the SPEC. For
more information about the SPEC display, refer to page 11.
NOTE! Pages with unique button functions will display functionality with a symbol directly above the buttons.
24 Component Description
5 MAINTENANCE
25
5.1 MAINTENANCE SCHEDULE
COMPRESSOR MAINTENANCE SCHEDULE
FREQUENCY (HOURS)
1000
AS REQUIRED
250
2000
50
DAILY
PROCEDURE SEE NOTE REF.
Check oil level (before starting) x 1 5.3
Check radiator coolant level x 1
Check fuel supply (after starting) x 1
Check air filter elements x 1,7 5.6
Check for fuel, oil air and water leaks x 1
Drain water from compressor sump x 2
Drain water and sediment from fuel tank x 2,7
Change oil filter element x x 6 5.3, 5.7
Change compressor oil x x 5 5.3, 5.4
Check drawbar and bolt torque x 3 5.2
Check wheel lug nuts x 3
Check tire pressure x 3
Inspect lifting frame (before each lift) x 3
Change compressor air filter element x 4,7 5.6
Check axle 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 radiator hoses and clamps x 4
Check engine and compressor supports x 4
Replace air/oil separator element x 5
Check all door gaskets, hinges and latches x 5
Drain engine radiator coolant and replace x 5
Clean and flush cooling system x 5 5.12
Check protective circuits and verify proper function x 5
Check sump pressure relief valve x 5
Inspect and clean oil system thermostat x 6
Check control adjustment x 6 5.16
Re-pack wheel bearings x 6
NOTES
1. Or every 10 hours of operation or on rent 5. Or annually
return 6. After first 50 hours of operation
2. Or weekly 7. More frequently in extreme operating
3. Or before returning to ready line conditions (dusty, humid, low temperature)
4. Or 6 months
NOTE! For engine maintenance, please refer to the Engine Manufacturer’s Maintenance Manual.
26 Maintenance
5.2 BOLT TORQUE GUIDELINES
5.2.1 INCH FASTENERS
INCH FASTENERS TORQUE
SAE Grade 5 (ft-lb) SAE Grade 8 (ft-lb)
Size Dry Oiled Dry Oiled
1
⁄4 –20 8 6 12 9
5
⁄16 –18 17 13 25 18
3
⁄8 –16 30 23 45 35
7
⁄16 –14 50 35 70 55
1
⁄2 –13 75 55 110 80
9
⁄16 –12 110 80 150 110
5
⁄8 –11 150 110 220 170
3
⁄4 –10 260 200 380 280
5.3.1 CHECK
The oil level should be checked daily.
1. Shut down the compressor (or check before the compressor is turned on).
2. Wait two minutes after the compressor stops to allow the pressure to be relieved and the oil to settle.
3. Observe the oil level in the fluid sight glass. The fluid sight glass should be ½ to ⅔ full.
4. While the compressor is running, the oil should be visible in the sight glass.
Maintenance 27
5.3.2 FILL
Before adding or changing compressor oil, completely relieve the sump of pressure. Venting the sump tank
pressure relief valve will do this. Oil is added at the fill plug.
5.3.3 LEVEL
The proper oil level, when unit is shut down and oil has had time to settle, is across the center of the oil level
sight glass. For oil sump capacity, refer to the Parts & Specifications Manual.
WARNING! Compressor must be shut down and pressure completely relieved from system before checking fluid levels.
Open pressure relief valve to assure relief of system air pressure. Failure to comply with this warning may
cause property damage and serious bodily harm or death.
5.3.4 DRAIN
Always warm compressor thoroughly prior to changing the compressor oil. A drain valve is provided at the
bottom of the sump tank When changing the oil, make sure system is completely drained to reduce potential
contamination.
WARNING! Do not attempt to drain water, remove the oil level fill plug, or break any connection in the air or oil system
until all the pressure has been relieved. Check by manually opening the sump pressure relief valve. Serious
injury or death may result if this warning is not followed.
LUBRICANT SPECIFICATIONS
ISO Viscosity Grade 32 Normal Service Life 1000 hours*
SAE Viscosity Grade 5W-20 Viscosity Index 180
Viscosity, cst. 210°F 50 SUS Pour Point -40°C / -40°F
Viscosity, cst. 100°F 170 SUS Flash Point 199°C
NOTE! These values are not intended for use in preparing specifications.
*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.
28 Maintenance
5.5 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.
Cary, NC 27513
INTERPRET RESULTS
Once the sample is processed the laboratory will e-mail the results
of the oil analysis to the sender of the sample. The analysis report
includes customer unit information, sample data, spectrochemical
analysis, physical properties, additional test results and analysis
recommendations. If previous oil samples have been submitted for
analysis, that information will also be on the report. Information to
assist in understanding the analysis report is included on the front (1)
of the report.
Maintenance 29
5.6 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.
5.6.2 INSTALLATION
1. Insert new filter element(s)
2. Install air filter cover making sure evacuator valve is at the 6 o’clock position.
5.7.1 INSPECTION
The compressor oil filter should be checked 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 oil filter on by hand, turning it clockwise until the gasket seats. Then turn an additional ½ to
¾ turn by hand.
3. Check for leaks in operation.
5.8.1 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.
5.9.1 INSPECTION
Inspect oil return line for clogging.
5.9.2 CLEANING
If clogging is indicated, check and clean the entire line, including the orifice fitting at the compressor end,
and the siphon tube inside the separator. Blowing with a reverse flow of compressor air will clean the line.
30 Maintenance
5.10 AIR/OIL SEPARATOR
Replace the air/oil separator every 2,000 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! Prevent separator flash or fire. Maintain the separator element in proper condition and do not allow it to
become plugged with dirt and oxidized oil; be certain that the sump lid is properly grounded to the sump
when installing a new separator. DO NOT REMOVE THE GROUNDING STAPLES IN SEPARATOR GASKET.
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. Disconnect oil return line. Loosen fitting and pull siphon tube up out of separator.
3. Remove service air piping from minimum pressure valve.
4. Mark and disconnect necessary tubing at separator cover and then remove cover.
5.10.2 INSTALLATION
WARNING! Failure to properly ground the sump lid and separator can result in the build-up of an electric charge
leading to ignition inside the sump. DO NOT REMOVE THE GROUNDING STAPLES IN SEPARATOR GASKET.
Failure to comply with this warning may cause property damage and serious bodily harm or death.
WARNING! Lid and sump tank top must be clean to ensure proper grounding between element and tank. Make sure
grounding staples are in top and bottom gasket.
2. Replace separator cover; tighten bolts gradually in an opposing manner until required torque is reached.
Refer to 5.2 Bolt Torque Guidelines.
3. Clean oil return line and orifice.
4. Install service air piping and reconnect all tubing. When replacing the oil return siphon tube, allow it to
contact the bottom of the sump tank then back off no more than 1/16 inch.
NOTE! If the separator element has to be replaced frequently because it is plugged, it is an indication that dirt is
entering the inlet system, the compressor oil filter is faulty, or the oil is breaking down. The complete inlet
system, starting with the air cleaner, and all joints in piping to the inlet valve, should be checked for leaks.
5.11.1 INSPECTION
Inspect the valve by removing it from the bypass 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.
5.12.1 INSPECTION
Inspect compressor oil system for signs of varnish.
5.12.2 REMOVAL
1. Drain compressor fluid.
2. Remove oil cooler.
Maintenance 31
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.
LOWER
RAISE
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.
FIGURE 5-3. Pressure Regulating Valve
32 Maintenance
5.17 RECOMMENDED SPARE PARTS
D210PHKR
ITEM PART NUMBER DESCRIPTION QTY
1 00521-082 ELEMENT, AIR FILTER PRIMARY 2
2 00521-082s ELEMENT, AIR FILTER, SECONDARY 2
3 00543117-0026 ELEMENT, AIR/OIL SEPARATOR 1
4 05018155-0042 ELEMENT, FUEL FILTER (PRIMARY) 1
5 01900520-0327 ELEMENT, OIL FILTER (ENGINE) 1
6 01900520-0012 ELEMENT, OIL FILTER (COMPRESSOR) 1
7 00823062-0009 OIL, COMPRESSOR WEATHER-ALL, 5 GALLON 1
00823062-0010 OIL, COMPRESSOR WEATHER-ALL, DRUM, 55 GAL 1
8 05019205-0009 SENDER, PRESSURE 0-750PSI 1
9 05019415-0053 SENDER, COMPRESSOR DISCHARGE TEMP. 1
10 00600701-0406 SWITCH, IGNITION 1
11 03100-008 VALVE, SAFETY 1
12 05019820-0002 VALVE, 2-WAY 1/4 NPT (START-RUN) 1
13 09661-002 VALVE, PRESSURE REGULATOR 1
14 05019415-0053 SWITCH, TEMP SENDER 1
15 01900152-0083 BELT, FAN 1
16 00717708-0004 KIT, SERVICE, INLET VALVE 108MM 1
17 00717708-0001 KIT, REPAIR 1.25" MPV 1
18 K00031-005 KIT, OIL SAMPLE W/Q.F. 1
19 00717708-0021 KIT, DRIVE COUPLING REPLACEMENT/INSTALLATION AND DRAWING 1
NOTE! Use only service parts supplied or recommended by Sullivan-Palatek. Use of substitutes may void warranty.
See STANDARD WARRANTY for details.
Maintenance 33
34 Maintenance
6 TROUBLESHOOTING
35
6.1 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. The action which can be performed in the least
amount of time and with the removal or disassembly of the fewest parts should be performed first.
If none of the above caused the shutdown, restart the engine and observe the engine oil pressure, engine
water temperature, and compressor discharge temperature and pressure. If it is found that low engine oil
pressure or high engine water temperature is causing the shutdown, refer to the Engine Manufacturer’s
manual.
36 Troubleshooting
6.4 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.
Ice or debris in control lines Clean debris from the control lines.
Thaw out the control lines to remove the ice buildup.
Optional Heater Kit available–consult Factory for
information. Direct the lines so there is a low point to
drain any condensate.
Pressure relief valve faulty Replace the faulty relief valve.
Oil separator plugged Replace the oil separator.
Inlet valve leaks at base Replace O-ring.
Compressor shaft seal leaking Replace the compressor shaft seal and retest.
Troubleshooting 37
6.9 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.
Operating above maximum altitude rating of engine Refer to Engine Manufacturer's recommendation on
maximum altitude.
Engine fault codes present Machine not out of warm-up mode; allow machine to
complete warm-up.
If the separator element has to be replaced frequently because it is plugging up, it is an indication that
foreign material may be entering the compressor inlet or the compressor oil 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 VALVES CLOSED
POSSIBLE CAUSE ACTION
Faulty pressure transducer Replace pressure transducer.
Faulty or broken wires to SPEC or pressure Fix or replace broken wires.
transducer
Faulty SPEC Replace the SPEC or flash new program.
6.12 ENGINE SPEED CONTROL DOES NOT CHANGE TO FULL SPEED WITH
AIR DEMAND
POSSIBLE CAUSE ACTION
Start/Run valve is positioned in START instead Move the Start/Run valve to the RUN position.
of RUN
Discharge Pressure Regulator faulty or improperly set Properly adjust the regulator.
Rebuild/replace the regulator if necessary.
Faulty pressure transducer Replace pressure transducer.
Faulty or broken wires to SPEC or pressure transducer Fix or replace broken wires.
Faulty SPEC Replace the SPEC or flash new program.
Engine fault codes present Machine not out of warm-up mode; allow machine to
complete warm-up.
38 Troubleshooting
6.13 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.
High compressor discharge temperature 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.
Check MPV operation, rebuild/replace as needed.
Diaphragm in recirculation valve ruptured Inspect the diaphragm, rebuild/replace as needed.
Condensation in sump tank Drain condensation from sump tank.
Troubleshooting 39
NOTES
NOTES
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