Sullivan-Palatek D185UIZ Installation and operating instructions
OPERATION & SERVICE MANUAL
PORTABLE UTILITY COMPRESSOR \ 185 CFM
D185UIZ
ISUZU DIESEL ENGINE
TIER 4 FINAL
05018730-0304 / 00
Issued: June 18, 2021
DOCUMENT INFORMATION
© Sullivan-Palatek, Inc.
ALL RIGHTS RESERVED
Part Number: 05018730-0304
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 2021-06-18 Released for publication
III
I WARRANTY � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � VII
II ABOUT THIS MANUAL � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �IX
II.1 Safety Instructions ................................................................ ix
II.2 Manual Organization ............................................................... ix
II.3 Supplemental Documents........................................................... ix
1 SAFETY � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1
1.1 Receiving ..........................................................................2
.............................................................................2
1.3 General Safety .....................................................................2
1.4 Pressure Release ...................................................................2
1.5 Fires and Explosion .................................................................3
1.6 Moving Parts .......................................................................4
1.7 Toxic and Irritating Substances .......................................................4
1.8 Hot Surfaces, Sharp Edges, Sharp Corners and Vacuum ..................................5
1.9 Electrical Shock.....................................................................5
1.10 Entrapment ........................................................................5
2 OPERATION � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
2.1 General Operating Safety ............................................................8
2.2 Preparing for Initial Start-Up .........................................................8
2.3 Normal Starting ....................................................................8
2.4 Normal Stopping....................................................................8
2.5 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Sullivan-Palatek Electronic Controller (SPEC) Operational Instructions .....................9
2.7 Operating Under Extreme Conditions .................................................11
2.8 Pneumatic Tools Application.........................................................11
2.9 Jump-Starting Battery .............................................................12
3 COMPONENT DESCRIPTION � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13
3.1 Portable Compressor Package .......................................................14
3.2 Engine............................................................................14
3.3 Air End Assembly ..................................................................14
3.4 Discharge System..................................................................14
3.5 Lubrication System ................................................................15
3.6 Capacity Control System............................................................16
3.7 Noise Control Systems..............................................................17
3.8 Instrument Panel ..................................................................18
3.9 Electrical and Protective Circuit System...............................................20
3.10 Engine Shutdown Protection ........................................................20
4 MAINTENANCE � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21
4.1 Maintenance Schedule ..............................................................22
4.2 Bolt Torque Guidelines..............................................................23
4.3 Compressor Lubrication ............................................................23
4.4 WEATHER-ALL™Compressor Lubricant................................................24
4.5 Oil Sample for Analysis .............................................................25
4.6 Curbside Service Access ............................................................26
CONTENTS
IV CONTENTS
4.7 Air Intake Filter ....................................................................26
4.8 Compressor Oil Filter ...............................................................26
...........................................................27
4.10 Oil Return Line.....................................................................27
4.11 Air/Oil Separator ...................................................................27
4.12 Thermal Valve .....................................................................28
4.13 Oil Cooler .........................................................................28
4.14 Engine Lubrication .................................................................28
4.15 Control Adjustments ...............................................................28
5 TROUBLESHOOTING� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 29
5.1 Introduction ......................................................................30
5.2 Unplanned Shutdown ..............................................................30
5.3 Discharge Pressure Is Too Low.......................................................30
5.4 Discharge Pressure is Too High or Relief Valve Blows ...................................31
5.5 Relief Valve Blows with Throttle Lever in Idle Position ..................................31
........................................31
5.7 Compressor Oil Level is Decreasing Excessively ........................................31
5.8 Oil in Service Line ..................................................................31
5.9 Engine Does Not Accelerate Or Will Not Maintain Full Load Speed.........................32
5.10 Separator Plugging ................................................................32
5.11 Engine Speed Control Does Not Change to Idle Speed with Service Valves Closed...........32
5.12 Engine Speed Control Does Not Change to Full Speed with Air Demand....................32
.......................................33
VWARRANTY
Sullivan-Palatek Portable Air Compressor
STANDARD WARRANTY
Sullivan-Palatek warrants its new portable air compressor products 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
Warranty Period: The warranty period for applicable Sullivan-Palatek products is as follows (subject to the Exclusions and
Limitations noted below):
Air ends on new machines – stator and rotor assembly: Single stage
Two stage high pressure compressor
Remainder of new portable air compressor machines:
Parts, accessories and attachments sold separately from machines, excluding warranty replacement parts and hand
tools:
Warranty replacement parts: remainder of the original warranty period of the replaced part.
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, (ii) to pay the reasonable cost of making
the repair or reinstalling the replacement part, and (iii) for air compressors having two or more axles, reimbursement of up
to four hours travel labor and up to 200 miles (100 miles travel radius) per event to make repairs. Reimbursement rates for
travel and mileage are set at the discretion of Sullivan-Palatek and are subject to change without notice.
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 shipping costs for
costs of investigating performance complaints that are not covered by this warranty.
Exclusions and Limitations: Air end seals are not warranted. Engines, tires and batteries are not warranted by Sullivan-
Palatek but are warranted only by the manufacturers of these components. Sullivan-Palatek has no obligation for product
failures or defects resulting from overloading, misuse, neglect, accident, failure to comply with Sullivan-Palatek’s product
manual, or failure to install product improvements provided by Sullivan-Palatek. Use of attachments, accessories or service
parts not supplied or recommended by Sullivan-Palatek may void the warranty of that product. Sullivan-Palatek has no
obligation to pay costs of returning defective parts to Sullivan-Palatek or shipping replacement parts to purchaser.
THIS WARRANTY IS SULLIVAN-PALATEK’S ONLY WARRANTY OF ITS PORTABLE 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.
terms of this warranty will apply.
10.31.15
I WARRANTY
VI WARRANTY
vii
II About this MAnuAl
II.1 SAFETY INSTRUCTIONS
Instructions for the safe operation and maintenance of the Sullivan-Palatek air compressor are located
throughout this manual. These instructions are presented with dierent labels according to the level of risk
involved, described as follows:
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.
II.2 MANUAL ORGANIZATION
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 operating air compressors.
sECtion 2: oPERAtion
This section contains an overview of general operating safety, initial start-up procedures, how to start and
stop the air compressor, SPEC instructions, in addition to guidelines for operating under extreme conditions
and procedures for pneumatic tool applications.
sECtion 3: CoMPonEnt DEsCRiPtion
This section contains information about how the dierent systems and components function within an air
compressor.
sECtion 4: 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 5: tRoublEshootinG
This section contains symptoms, causes and remedies for common air compressor malfunctions.
II.3 SUPPLEMENTAL DOCUMENTS
For more detailed information on certain components or optional equipment specic to this compressor,
supplemental documents are provided, including the and the Parts & Specications Manual.
VIII ABOUT THIS MANUAL
1
1 SAFETY
TOPICS IN THIS SECTION:
» Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
» . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
» General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
» Pressure Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
» Fires and Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
» Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
» Toxic and Irritating Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
» Hot Surfaces, Sharp Edges, Sharp Corners and Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
» Electrical Shock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
» Entrapment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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.
2SAFETY
1.1 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
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 should be read and understood before attempting to start and
operate this machine.
1.2 LIFTING
»
with OSHA Standards 29 CFR 1910 subpart N, and other applicable regulations.
»
these items are found to be defective.
»
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
»
»
» Keep all personnel out from under and away from the compressor when suspended.
»
»
» 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.
1.3 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.
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.
1.4 PRESSURE RELEASE
»
items. Pay attention to the possible residual pressure when you disconnect a device from a pressurized
3SAFETY
circuit.
» Do NOT try to detect pressure leaks with your hands. It is not always possible to identify a leak from
a tiny hole. Use a piece of 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.
»
»
the coolant temperature is below its boiling point, then loosen cap slowly to its stop to relieve any
excess pressure. Make sure coolant is not boiling before removing cap completely, and protect yourself
by wearing safety glasses.
1.5 FIRES AND EXPLOSION
1.5.1 FUEL & LIQUIDS
WARNING! Fire or explosion can result from spilled fuel, oil and other ammable liquids.
» 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.
»
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
»
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
sunlight.
»
1.5.2 BATTERIES AND WIRING
WARNING! Fire or explosion can result from electrical arcing from terminal, battery connections and improperly
grounded equipment.
» 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
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.
4SAFETY
» Always avoid electrical parts when washing the compressor.
1.5.3 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.
»
» Keep oily rags, trash, leaves, litter, or other combustibles out of and away from the compressor.
»
and operating the compressor.
1.6 MOVING PARTS
»
compressor.
» Keep hands, arms, and other parts of the body, as well as clothing, away from belts, pulleys, and other
moving parts.
»
»
walking surfaces clean and free of oil, water, anti-freeze, or other liquids to minimize the possibility of
slips or falls. Use extreme caution when ground is covered with ice or snow.
» Do not attempt to operate the compressor with the fan guard or other guards removed. Keep access
doors closed except when repairing, adjusting or performing service, or when starting or stopping the
compressor.
» Shut down engine before servicing, especially when adding fuel, oil, coolant, lubricants, airline
anti-freeze compound, or battery electrolyte. The engine must also be shut down before making
adjustments. Restart engine to check adjustment. If adjustment is incorrect, shut down the engine
again, readjust, then restart engine to recheck the adjustment.
1.7 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. 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
» Do not use airline anti-icing systems in airlines supplying respirators or other breathing air utilization
» 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
5SAFETY
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.
»
substances.
1.8 HOT SURFACES, SHARP EDGES, SHARP CORNERS AND VACUUM
» Avoid contact with hot oil, hot coolant, hot surfaces, and sharp edges and corners.
» Keep all parts of the body away from all points of air discharge and away from hot exhaust gases.
» Wear personal protective equipment, including gloves, safety glasses and head covering when working
in, on, or around the compressor.
»
and burns–these may lead to infection.
»
intakes.
1.9 ELECTRICAL SHOCK
» Keep the towing vehicle or equipment carrier, compressor hoses, tools, and all personnel at least 10 feet
from power lines and buried cables. Greater separation from power lines may be prudent when working
around high voltage. Contact the utility company for guidance.
» Keep all parts of the body, any hand-held tools, or other conductive objects away from exposed live
parts of the compressor electrical system. Maintain dry footing, stand on insulating surfaces and do not
contact any other portion of the compressor when making adjustments or repairs to exposed live parts
of the electrical system.
1.10 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.
6SAFETY
7
2 OPERATION
TOPICS IN THIS SECTION:
» General Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
» Preparing for Initial Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
» Normal Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
» Normal Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
» Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
» Sullivan-Palatek Electronic Controller (SPEC) Operational Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
» Operating Under Extreme Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
» Pneumatic Tools Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
» Jump-Starting Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
8OPERATION
2.1 GENERAL OPERATING SAFETY
» Replace any faulty gauge immediately.
» Allow at least ten feet of unobstructed area in front of cooling air inlets and outlets to assure good
airow.
» 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 31 .
» 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.
2.2 PREPARING FOR INITIAL START-UP
1. Inspect the compressor, engine, and other assemblies for damage or loose connections which might
have occurred during shipment.
2. Check the engine’s crankcase oil level. If required, add oil as recommended in the Engine Manual.
3. Check the radiator coolant level. Also, if the machine will be exposed to sub-freezing temperatures,
check the specic gravity to ascertain the freezing point of the coolant.
4. Fill the fuel tank with fuel recommended in the Engine Manual.
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 4.3 Compressor Lubrication on page
23 for lubricating oil specications.
6. Check battery posts and cable clamps to assure proper contact. Connect positive cable and negative
cable battery terminals.
2.3 NORMAL STARTING
1. Inspect the compressor, engine and other assemblies for damage or loose connections.
2. Check engine coolant, oil, fuel, and battery uid levels. Check compressor receiver oil level.
3. Close service valves.
4. Set start-run valve to START position.
5. Turn engine start switch to allow unit to rotate a few revolutions so that the unit will turn freely.
6. Turn ignition switch to ON position. Allow display to boot up and show gauges.
7. Turn ignition switch to START position and hold until engine starts.
8. Let engine warm up to 140°F. Set start-run valve to RUN position. Compressor is now ready for full load
operation.
NOTE! If the engine stops, do not attempt to restart with the oil receiver under pressure.
2.4 NORMAL STOPPING
1. Position start-run valve to START. Close all service valves.
2. Run engine at low idle for 1 to 2 minutes.
3. Open and close the service valve to reduce pressure to approximately 60 psi or less.
4. Turn ignition switch to OFF.
2.5 EMERGENCY STOP
In case of emergency turn the ignition switch to the OFF position.
9OPERATION
2.6 SULLIVAN-PALATEK ELECTRONIC CONTROLLER (SPEC)
OPERATIONAL INSTRUCTIONS
The buttons for operation will be referred to
numerically based upon the image at right.
Button functionality can vary depending on the
operator input 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 allows the user to check user settings,
service reminders, setpoints, and the soware
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.
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.
10 OPERATION
SHUTDOWN SETPOINTS SCREEN
This screen indicates the setpoints at which
shutdowns will occur.
Button 3 returns back 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 lters should be
replaced. A warning icon will be displayed on the
Gauge screen when a lter 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 le and right between lters.
Password for resetting is 0473.
SOFTWARE SCREEN
The current soware and revision level can be found
here.
Button 3 returns back to the Menu screen.
DIAGNOSTIC MESSAGE SCREEN
This screen will pop up when the machine
encounters a Fault/SPN/FMI code. The specic
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.
Buttons 3 or 5 will hide the message;
Button 4 will show other stored fault codes that are
still active.
11OPERATION
2.7 OPERATING UNDER EXTREME CONDITIONS
2.7.1 COLD WEATHER OPERATION
Use the correct coolant anti-freeze solution and engine oil for the lowest possible temperature expected.
CAUTION! Make sure coolant and engine oil are approved by the engine manufacturer.
When operating the compressor at ambient temperatures below 20°F, use lubricants suited for these
conditions. Refer to the 4.3 Compressor Lubrication on page 23.
Optional starting aids and component pre-starting warming devices are available for some models for cold
weather starting.
WARNING! Do not inject ether starting uid directly into air intake.
2.7.2 HOT WEATHER OPERATION
» Keep the engine cooling system lled with clean coolant.
» Check the coolant level daily or before each shi.
» 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.
2.7.3 DUSTY OR SANDY AREAS
» When possible, wet down the area surrounding the operating site to keep dust and blowing sand to a
minimum.
» Inspect air lters before each operating shi or daily.
» Keep radiator and oil cooler clean. Check daily and wash or blow clean as needed.
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.
2.8 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 orice.
Never direct compressed air at or toward a person or animal.
Do not breathe air produced by a portable air compressor.
» Install an appropriate ow-limiting valve between the compressor service air outlet and the shut-o
(throttle) valve when an air hose exceeding ½-inch inside diameter is to be connected to the shut-o
(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 ow-limiting valve between the
manifold and each air hose exceeding ½-inch inside diameter that is to be connected to the manifold.
This will reduce pressure in case of hose failure.
» Provide an appropriate ow-limiting valve for each additional 75 feet of hose in runs of air hose
exceeding ½-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 ail around an cause
injury or damage.
» Vent and release all internal pressure prior to opening any line, tting, hose, valve, drain plug or
connection. This includes components such as lters, line oilers and optional airline anti-icing systems.
12 OPERATION
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 eective 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!
2.9 JUMP-STARTING BATTERY
WARNING! Always wear an acid-resistant apron, face shield with goggles and gloves when working with batteries!
WARNING! Batteries may contain hydrogen gas which is explosive and ammable! Keep ames, 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 uid level. If low bring to a proper level before attempting to jump-start.
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 o 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 rst 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 aer repeated attempts or the battery is still dead
aer running the compressor for over an hour (not taking charge), then the battery must be replaced.
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