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Sullivan-Palatek D300PD2KR Operation & Service Manual
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Sullivan-Palatek D300PD2KR Operation & Service Manual

Wheel-mounted portable compressor
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OPERATION & SERVICE MANUAL
WHEEL-MOUNTED PORTABLE COMPRESSOR
D300PD2KR
KOHLER DIESEL ENGINE
TIER 4 FINAL
Document: 05018730-0321 / 00
Issued: November, 2024

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Summary of Contents for Sullivan-Palatek D300PD2KR

  • Page 1 OPERATION & SERVICE MANUAL WHEEL-MOUNTED PORTABLE COMPRESSOR D300PD2KR KOHLER DIESEL ENGINE TIER 4 FINAL Document: 05018730-0321 / 00 Issued: November, 2024...
  • Page 2 DOCUMENT INFORMATION: © Sullivan-Palatek, Inc. ALL RIGHTS RESERVED Part Number: 05018730 0308 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:...
  • Page 3 Normal Stopping..............13 Sullivan-Palatek Electronic Controller (SPEC) Operational Instructions ....13 Operating Under Extreme Conditions .
  • Page 4 MAINTENANCE ............27 Maintenance Schedule .
  • Page 5 Sullivan-Palatek or 36 months from delivery to the first user. Two stage high pressure compressor models: the first to expire; 30 months from shipment by Sullivan-Palatek or 24 months from delivery to the first user. Remainder of new portable air compressor machines: the first to expire; 18 months from shipment by Sullivan-Palatek or 12 months from delivery to the first user.
  • Page 6 WARRANTY...
  • Page 7 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.
  • Page 8 VIII ABOUT THIS MANUAL...
  • Page 9 SAFETY TOPICS IN THIS SECTION: » General Safety ..............2 »...
  • Page 10 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: »...
  • Page 11 replace acoustical material. Do not use flammable solvents for cleaning purposes. » Anti-freeze compound used in air line 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. 1.3.2 BATTERIES AND WIRING WARNING! Fire or explosion can result from electrical arcing from terminal, battery connections and improperly grounded equipment.
  • Page 12 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.
  • Page 13 » 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.
  • Page 14 SAFETY...
  • Page 15 TRANSPORTING AND LOCATING TOPICS IN ThIS SECTION: » Receiving ................. . . 8 »...
  • Page 16 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.
  • Page 17 PREPARING TO TOW » Properly drain and dispose of any fluids in the containment frame before towing. » Before beginning to tow the compressor, test brake operation, including breakaway switch operation if provided or if equipped. » Damaged or worn towing components can result in separation of the compressor from the towing vehicle during towing.
  • Page 18 » Observe and follow all local, state, and federal traffic laws. Note and adhere to speed limits and minimum highway speed. » Do not exceed maximum towing speeds. Reduce speed accordingly, as dictated by posted signs, weather, road, or terrain conditions. » Remember that portable air compressors may approach or exceed the weight of the towing vehicle. Maintain increased stopping distance accordingly.
  • Page 19 Normal Stopping ................13 » Sullivan-Palatek Electronic Controller (SPEC) Operational Instructions ......13 »...
  • Page 20 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.
  • Page 21 Run engine at low idle for 2 minutes. Open and close the service valve to reduce pressure to approximately 75 psi or less. Press ignition switch to OFF. SULLIVAN-PALATEK ELECTRONIC CONTROLLER (SPEC) OPERATIONAL INSTRUCTIONS The buttons for operation will be referred to numerically based upon the image at right.
  • Page 22 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.
  • Page 23 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.
  • Page 24 » 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.
  • Page 25 Connect the other end of the BLACK (negative) cable to an unpainted metal surface on the compressor engine with the dead battery. Make sure all the jumper cable clips have a good connection (good clamping force) before attempting to start. Start vehicle with the good battery first and let it run a few minutes. Then attempt to start the compressor with the dead battery.
  • Page 26 OPERATION...
  • Page 27 COMPONENT DESCRIPTION TOPICS IN ThIS SECTION: » Portable Compressor Package ..............20 »...
  • Page 28 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.
  • Page 29 LUBRICATION SYSTEM RECEIVER TANK COMPRESSOR OIL COOLER ENGINE FUEL TANK REV. DESC 200 PSI @ 500°F 150 PSI / 100 PSI 217 PSI @ 300°F KDI 2504 30 GALLON RELEASED F 79 HP @ 2400 RPM FILTER INLET VENT VALVE ORIFICE 5/16"...
  • Page 30 SHEET 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.
  • Page 31 Low Fuel warning at 11% of capacity. Shutdown will occur at 5-8%. ENGINE SHUTDOWN PROTECTION Sullivan-Palatek uses electronically controlled engines in the 185-1800 CFM line of compressors. Personnel operating and maintaining these compressors MUST be familiar with and understand the operation and protection features available with these engines.
  • Page 32 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.
  • Page 33 UNLESS OTHERWISE NOTED DRAWN BY: DIMENSIONS ARE IN INCHES Figure 4-4. INSTRUMENT PANEL, DUAL PSI, D300PD2KR TOLERANCES AS FOLLOWS: CHECKED BY: ANGLES: + OR - 1/2 DEG. DECIMAL: X.X + OR - 0.050 X.XX + OR - 0.020...
  • Page 34 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 temperature, battery voltage and fuel level.
  • Page 35 MAINTENANCE TOPICS IN ThIS SECTION: » Maintenance Schedule ...............28 »...
  • Page 36 MAINTENANCE SCHEDULE COMPRESSOR MAINTENANCE SChEDULE FREQUENCY (hOURS) PROCEDURE SEE NOTE REF. Check oil level (before starting) 65.3 Check radiator coolant level Check fuel supply (after starting) Check air filter elements Check for fuel, oil air and water leaks Drain water from compressor sump Drain water and sediment from fuel tank Change oil filter element Change compressor oil...
  • Page 37 The useful life of synthetic lubricants may extend the normally recommended drain and replace period; however, the user is encouraged to closely monitor the lubricant condition and to participate in an oil analysis program with the fluid supplier. When ambient conditions exceed those noted, or if conditions warrant use of “extended life” lubricants, contact Sullivan-Palatek for a recommendation. 5.3.1 CHECK The oil level should be checked daily.
  • Page 38 *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.
  • Page 39 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. SAMPLE OIL FROM SUMP TANK Run the compressor long enough to reach normal operating temperatures. Turn compressor OFF and allow pressure to blow down to 0 psi. Open the drain pet cork valve and drain any water from the sump tank.
  • Page 40 COMPRESSOR OIL FILTER Replace the oil filter element once after the first 50 hours of operation, then every 1,000 hours. Replace more frequently in extreme operating conditions. 5.6.1 INSPECTION The compressor oil filter should be checked to ensure the correct element is properly installed and not leaking. 5.6.2 REMOVAL Make sure the system pressure is relieved. Place oil spill pan under filter.
  • Page 41 5.11 AIR/OIL SEPARATOR Replace the (2) air/oil separator filter elements every 2,000 hours, annually, or when differential exceeds 10 psi. The air/oil separator employs a unitized element. The separator filter elements require replacement when they fail to remove the oil from the discharge air. Prior to replacing the separator element be sure to check the oil return line and orifice for plugging or restrictions. WARNING! The combination of a build-up of dirt and oxidized oil can clog the element causing an increase in air velocity at narrow points on the element media. Elevated temperatures at these points can result in ignition of the fluid in the oil sump.
  • Page 42 5.15.2 ENGINE SPEED Engine speed is controlled by the Sullivan-Palatek Electronic Controller (SPEC). 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.
  • Page 43 00717708-0027 KIT, DRIVE COUPLING D210-260 KB09147-362 KIT,SHAFT SEAL 3LIP,CW Use only service parts supplied or recommended by Sullivan-Palatek. Use of substitutes may void warranty. See STANDARD WARRANTY for details. 5.17 SERVICE KITS Service kits are available for basic servicing of the compressor and engine. There are annual kits (wet or dry) for a year’s worth of compressor and engine servicing and line service kits for a single compressor and...
  • Page 44 MAINTENANCE...
  • Page 45 TROUbLEShOOTING TOPICS IN ThIS SECTION: » Introduction................38 »...
  • Page 46 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.
  • Page 47 DISCHARGE PRESSURE IS TOO LOW POSSIbLE CAUSE ACTION Run/Start valve in the START position Move the Run/Start valve to the RUN position and retest. Too much air demand Add additional compressor to handle the demand or decrease the air demand. Service valve open Close service valve and retest.
  • Page 48 COMPRESSOR OIL LEVEL IS DECREASING EXCESSIVELY POSSIbLE CAUSE ACTION Oil line leaking Repair or replace any leaking lines and retest. Oil cooler leaking Repair or replace the leaking oil cooler and retest. Compressor shaft seal leaking Replace the compressor shaft seal and retest. Oil in service line See “6.8 Oil in Service Line”section.
  • Page 49 6.11 ENGINE SPEED CONTROL DOES NOT CHANGE TO IDLE SPEED WITH SERVICE VALVES CLOSED POSSIbLE CAUSE ACTION Bad or damaged wires to SPEC Fix/replace broken wires. Discharge pressure regulator faulty Properly adjust the regulator. Rebuild/replace the regulator if necessary. Bad pressure transducer Replace pressure transducer.
  • Page 50 TROUBLESHOOTING...
  • Page 51 NOTES...
  • Page 52 NOTES...
  • Page 54 1201 West 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...