Sullivan-Palatek D110PKU User manual
D110PKU
KUBOTA DIESEL ENGINE
TIER 4 FINAL
USER MANUAL
WHEEL-MOUNTED PORTABLE COMPRESSOR \ 110 CFM
Document: 05018730 0249 / 01
Issued: January 31, 2019
DOCUMENT INFORMATION
© Sullivan-Palatek, Inc.
ALL RIGHTS RESERVED
Part Number: 05018730 0249
Revision: 01
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 2018-09-20 Released for publication
01 2019-01-31 8.4, 5 Updated Recommended Spare Parts list and Service Kit
8.13 Updated Air Filter Assembly Recommended Spare Parts list
Sullivan-Palatek D110PKU Air Compressor
WARRANTY
Sullivan-Palatek warrants its new D110PKU air compressor to be free from defects in material and workmanship,
subject to the following provisions:
Warranty Registration: To validate the warranty for each product the purchaser shall complete and return the
Warranty Period: The warranty period for applicable Sullivan-Palatek products is as follows (subject to the
Exclusions and Limitations noted below):
Air Ends, Stator and Rotor Assembly:
Remainder of New Air Compressor Machines:
Parts, Accessories and Attachments Sold Separately From Machines, Excluding Warranty Replacement Parts
and Hand Tools:
Warranty Replacement Parts:
Sullivan-Palatek’s Obligations: Sullivan-Palatek’s exclusive obligations under its warranty are (i) to repair or
replace any defective part at Sullivan-Palatek’s option and subject to return of defective parts, and (ii) to pay the
Purchaser’s Responsibility: 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
Exclusions and Limitations:
obligation for product failures or defects resulting from overloading, misuse, neglect, accident, failure to comply
Use of attachments, accessories or service parts not supplied or recommended by Sullivan-Palatek may void the
THIS WARRANTY IS SULLIVAN-PALATEK’S ONLY WARRANTY OF ITS D110PKU AIR COMPRESSOR PRODUCTS
AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED. ANY IMPLIED WARRANTIES OF
MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED. SULLIVAN-PALATEK HAS NO
OBLIGATION UNDER THIS WARRANTY OR OTHERWISE (REGARDLESS OF THE FORM OF ACTION) FOR SPECIAL,
CONSEQUENTIAL OR INCIDENTAL DAMAGES, INCLUDING WITHOUT LIMITATION LOST PROFITS OR LOST INCOME.
THE TOTAL RESPONSIBILITY OF SULLIVAN-PALATEK FOR CLAIMS, LOSSES, LIABILITIES OR DAMAGES, WHETHER
IN CONTRACT OR TORT ARISING OUT OF OR RELATED TO ITS PRODUCTS SHALL NOT EXCEED THE PURCHASE
PRICE OF THE COVERED PRODUCT.
V
I AbOUT THIS MANUAL
I.1 SAFETY INSTRUCTIONS
Instructions for the safe operation and maintenance of the Sullivan-Palatek air compressor are located
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.
I.2 MANUAL ORGANIZATION
NOTE! Anyone operating or servicing the Sullivan-Palatek air compressor should read this entire manual and be
familiar with its information. The following is a quick guide to the contents in this manual:
SECTION 1: SAFETY
This section contains important basic information regarding general safety precautions for maintaining and
SECTION 2: SPECIFICATIONS
SECTION 3: COMPONENT DESCRIPTION
SECTION 4: TRANSPORTING AND LOCATING
This section contains instructions and safety guidelines for transporting and locating a portable air
SECTION 5: OPERATION
This section contains an overview of general operating safety, initial start-up procedures, how to start and
SECTION 6: MAINTENANCE
This section contains a maintenance schedule and step-by-step instructions for performing common
SECTION 7: TROUbLESHOOTING
SECTION 8: PARTS CATALOG
This section contains procedures for ordering parts, a list of recommended spare parts to keep on hand, and
I.3 SUPPLEMENTAL DOCUMENTS
VI ABOUT THIS MANUAL
VII
I CONTENTS
I AbOUT THIS MANUAL � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � V
v
v
v
1 SAFETY � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1
2
2
2
3
4
4
4
4
2 SPECIFICATIONS � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
7
3 COMPONENT DESCRIPTION � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
10
10
11
11
11
11
4 TRANSPORTING AND LOCATING � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13
14
14
14
15
15
5 OPERATION � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 17
18
18
19
19
19
19
20
20
20
21
6 MAINTENANCE � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 23
24
™25
25
VIII
27
28
28
29
29
29
30
7 TROUbLESHOOTING� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 31
32
32
33
33
33
33
33
34
34
34
34
35
35
35
35
35
8 PARTS CATALOG � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 37
38
38
38
39
39
40
42
44
48
50
52
54
58
70
72
74
78
80
82
84
88
1
1 SAFETY
TOPICS IN THIS SECTION:
» 2
» Pressure Release 2
» Fires and Explosion 2
» Moving Parts 3
» Toxic and Irritating Substances 4
» 4
» Electrical Shock 4
» Entrapment 4
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State
2SAFETY
1.1 GENERAL SAFETY
machinery:
» Only trained and authorized personnel who have read and understand this user’s manual should operate
»
compressor and render it inoperative by disconnecting the battery so others who may not know of the
» Use and operate the air compressor only in full compliance with all pertinent Federal, State and Local
»
» Known and potential hazards associated with the operating and servicing of portable air compressors
is ultimately responsible for identifying hazardous and dangerous conditions, avoiding dangerous
1.2 PRESSURE RELEASE
»
»
»
»
»
the coolant temperature is below its boiling point, then loosen cap slowly to its stop to relieve any
1.3 FIRES AND EXPLOSION
1.3.1 FUEL & LIQUIDS
WARNING! Fire or explosion can result from spilled fuel, oil and other ammable liquids.
»
»
»
»
»
3SAFETY
»
Do not expose any part of these systems or the anti-freeze compound to temperatures above 150°F
»
1.3.2 BATTERIES AND WIRING
WARNING! Fire or explosion can result from electrical arcing from terminal, battery connections and improperly
grounded equipment.
»
»
»
» Disconnect the grounded (negative) battery connection prior to attempting any repairs or cleaning
»
» Keep tools and other grounded conductive objects away from exposed live electrical parts to avoid
»
1.3.3 COMBUSTIBLES
» Prior to welding or making weld repairs on the compressor, remove any acoustical material or other
» Do not operate compressor under low overhanging leaves or permit leaves and foliage to contact hot
»
»
»
1.4 MOVING PARTS
»
» Keep hands, arms, and other parts of the body, as well as clothing, away from belts, pulleys, and other
»
»
walking surfaces clean and free of oil, water, anti-freeze, or other liquids to minimize the possibility of
»
doors closed except when repairing, adjusting or performing service, or when starting or stopping the
» Shut down engine before servicing, especially when adding fuel, oil, coolant, lubricants, airline
4SAFETY
1.5 TOXIC AND IRRITATING SUBSTANCES
WARNING! Do not use air from this compressor for breathing air. Breathing unltered air from this compressor can
result in serious injury or death.
NOTE! Under specic 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.
»
»
» Locate the compressor so that exhaust will not be carried toward personnel, air intakes servicing
»
»
» Do not use airline anti-icing systems in airlines supplying respirators or other breathing air utilization
» The
anti-freeze compound used in airline anti-icing systems contains methanol and is toxic, harmful, or
clean, warm water until vomit is clear, then administer two teaspoons of baking soda in a glass of clean
» Do not store airline anti-icing system anti-freeze compound in operator’s cabs or in unapproved
»
1.6 HOT SURFACES, SHARP EDGES, SHARP CORNERS AND VACUUM
»
»
» Wear personal protective equipment, including gloves, safety glasses and head covering when working
»
»
1.7 ELECTRICAL SHOCK
» Keep the towing vehicle or equipment carrier, compressor hoses, tools, and all personnel at least 10 feet
» Keep all parts of the body, any hand-held tools, or other conductive objects away from exposed live
contact any other portion of the compressor when making adjustments or repairs to exposed live parts
1.8 ENTRAPMENT
»
secure the access door in the open position to avoid the possibility of others closing and latching the
5
2 SPECIFICATIONS
TOPICS IN THIS SECTION:
» Technical Data
» Dimensions 7
6
2.1 TECHNICAL DATA
D110PKU
COMPRESSOR
Rated Delivery 110 cfm (3.11 m3/min)
Maximum Pressure 110 psig (7.6 bar)
Working Pressure 100 psig (6.9 bar)
Minimum Separator Pressure 51 psig (3.5 bar)
Max. Sound Power Level 74 dBA
Safety Valve Opening Pressure 145 psig (10 bar)
Air Service Connector ¾"inches FNPT
Total Oil Capacity 1.7 gallons (6.5 L)
Total Volume of Receiver Tank 4 gallons (15 L)
ENGINE
Type Diesel
Engine Make Kubota
Engine Model D1105
Number of Cylinders 3
Horsepower @ Rated RPM 24.3 hp (18.1 kW)
Maximum Operating Speed 3000 RPM (0+50)
Minimum Operating Speed 1750 RPM
Engine Oil Sump Capacity 1 gallons (3.78 L)
Fuel Tank Capacity 6.3 gallons (23.8 L)
Cooling System Capacity 2 gallons (7.5 L)
WEIGHTS
AXLE-MOUNTED
Total weight ready for use 1237 lbs (561 kg)
Total authorized loaded weight 1653 lbs (750 kg)
SKID
Total weight ready for use 1058 lbs (480 kg)
7
2.2 DIMENSIONS
(750 mm)
52 inches (1320 mm)
52 inches (1320 mm)
8
9
3 COMPONENT
DESCRIPTION
TOPICS IN THIS SECTION:
» 10
» Engine Shutdown Protection10
» 11
» Separator11
» 11
» 11
10
3.1 COMPRESSOR PACKAGE
This package includes a diesel KUBOTA 3-cylinder engine (type D1105), an air end, a capacity control system,
which is common to both radiators, is used to exhaust air and to maintain both engine and air end at the
D110PKU COMPRESSOR COMPONENTS
3.2 ENGINE SHUTDOWN PROTECTION
15) is located on the Separator/Receiver Tank (6
When a fault occurs the engine will shut down when one of three safety devices are triggered by the Engine
Stop Solenoid (14
safety devices protect the engine and compressor against the risk of:
1. Engine oil pressure drop: pressure switch on the Engine (1)
2. 7)
3. Engine overheating: water temperature switch on the Engine (1)
#COMPONENT #COMPONENT
1Engine 9Engine Oil Fill
2Compressor Oil Filter 10 Engine Speed Cylinder
3Air Filter compressor / motor 11 Engine Oil Dipstick
4Cooler compressor / motor 12 Engine Oil Filter
5Inlet Valve 13 Fuel Filter
6Separator / Receiver Tank 14 Engine Stop Solenoid
7Compressor / Air End 15 Safety Relief Valve
8Compressor Oil Fill 16 Fan
11
3.3 COMPRESSOR COOLING
The compressor cooling and lubrication system is designed to provide adequate lubrication as well as
The Fan (16
416)
64
6) high pressure and the low pressure zone of the
Air End (72
3.4 SEPARATOR
The separator has four main functions:
1.
2.
3. Fluid tank
4. Air reserve for the regulation
A calibrated port, located downstream from the separator, helps maintain a minimum receiver pressure of 51
15) located on the separator is set to open if the sump pressure exceeds
3.5 COMPRESSOR FLUID
1.
2.
3.
3.6 CAPACITY CONTROL SYSTEM
The control system is designed to match air supply to air demand and to prevent excessive discharge
both by inlet valve regulation and engine speed control as directed by the adjustable discharge pressure
inlet valve cylinder pressure chamber is pneumatically connected to the dry side of the receiver via the
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 air cylinder is spring loaded in the full speed position when there is no air signal from the pressure
the pressure regulator, which allows a pressure signal to enter the throttle air cylinder and reduce the engine
12
CAPACITY CONTROL SYSTEM
3.6.1
Turning the regulator adjustment screw clockwise increases the unloaded pressure, and counter-clockwise
3.6.2 INLET VALVE
The inlet valve assembly is the heart of the control system, which regulates the amount of air entering the
3.6.3 AUTOMATIC BLOWDOWN VALVE
3.6.4
RUN
START RUN
3.6.5 MINIMUM PRESSURE VALVE
#COMPONENT
1Separator/Receiver Tank
2Pressure Regulator
3Inlet Valve
4Engine Speed Cylinder
5Inlet Valve Cylinder
6Blowdown Valve
Start-Stop/Run Valve
8Minimum Pressure Valve (MPV)
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