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Sullivan-Palatek D300PDKR - User Manual

Sullivan-Palatek D300PDKR
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OPERATION & SERVICE MANUAL
WHEEL-MOUNTED PORTABLE COMPRESSOR
D300PDKR
KOHLER DIESEL ENGINE
TIER 4 FINAL
Document: 05018730-0319 / 00
Issued: January, 2024

Table of Contents

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Summary

About This Manual

Safety Instructions

Instructions for the safe operation and maintenance of the air compressor.

Manual Organization

Guide to the structure and contents of the manual.

Supplemental Documents

Location of supplemental documents for specific compressor components.

Safety

General Safety

Essential safety precautions for operating and maintaining the air compressor.

Pressure Release

Procedures for safely releasing pressure from air, oil, and cooling circuits.

Fires and Explosion

Hazards and precautions related to fuel, liquids, batteries, and wiring.

Moving Parts

Safety guidelines to avoid injury from rotating components and machinery.

Toxic and Irritating Substances

Precautions when handling fuels, oils, coolants, and anti-freeze compounds.

Hot Surfaces, Sharp Edges, Sharp Corners and Vacuum

Awareness of burn and cut hazards from hot components and sharp edges.

Electrical Shock

Safety measures to prevent electrical shock from the compressor system.

Entrapment

Precautions to avoid being trapped inside the compressor enclosure during service.

Transporting and Locating

Receiving

Procedures for inspecting the compressor upon arrival and before service.

Lifting

Guidelines for safely lifting and rigging the compressor unit.

Drawbars and Brake Actuators

Information on proper alignment and installation of drawbars and actuators.

Preparing to Tow

Steps to take before towing the compressor, including safety checks.

Towing

Best practices and safety precautions for towing the compressor.

Parking or Locating Compressor

Instructions for safely parking and positioning the compressor unit.

Operation

General Operating Safety

General safety rules to follow during compressor operation.

Preparing for Initial Start-Up

Checks and procedures before starting the compressor for the first time.

Normal Starting

Step-by-step guide for starting the compressor engine and system.

Normal Stopping

Procedures for safely shutting down the compressor.

Sullivan-Palatek Electronic Controller (SPEC) Operational Instructions

How to operate the compressor using the SPEC electronic control system.

Operating Under Extreme Conditions

Guidelines for operating the compressor in cold, hot, or dusty environments.

Pneumatic Tools Application

Safety and application guidelines for using pneumatic tools with the compressor.

Jump-Starting Battery

Instructions for safely jump-starting the compressor's battery.

Component Description

Portable Compressor Package

Overview of the compressor unit, its configuration, and components.

Engine

Description of the diesel engine powering the compressor.

Air End Assembly

Details about the rotary screw air end assembly and compression cycle.

Discharge System

Explanation of the receiver/sump and minimum pressure valve components.

Lubrication System

Overview of the oil circulation, cooling, and return systems.

Capacity Control System

How the compressor adjusts air output based on demand.

Electrical and Protective Circuit System

Description of the electrical system and protective shutdown features.

Engine Shutdown Protection

Explanation of engine derate and shutdown safety features.

Noise Control Systems

Components and design for meeting federal noise control regulations.

Instrument Panel

Explanation of the controls and instruments on the compressor's panel.

Maintenance

Maintenance Schedule

A schedule of required maintenance tasks and frequencies.

Bolt Torque Guidelines

Recommended torque values and sequences for fasteners.

Compressor Lubrication

Procedures for checking, filling, and draining compressor oil.

WEATHER-ALL Compressor Lubricant

Information on the specific lubricant used and its specifications.

Oil Sample for Analysis

Steps for taking an oil sample for laboratory analysis.

Compressor Oil Filter

Procedures for inspecting, removing, and installing the oil filter.

Engine Lubrication

Reference to the engine manufacturer's manual for engine lubrication.

Grease

Types of grease recommended for various components.

Air Intake Filter

Procedures for inspecting, removing, and installing the air intake filter.

Oil Return Line

Inspection and cleaning procedures for the oil return line.

Air;Oil Separator

Replacement intervals and procedures for the air/oil separator elements.

Thermal Valve

Inspection and cleaning of the thermal valve for temperature regulation.

Oil Cooler

Procedures for cleaning and maintaining the oil cooler.

Compressor Shaft Oil Seal

Inspection for leaks of the compressor shaft oil seal.

Control Adjustments

Procedures for adjusting discharge pressure and engine speed.

Recommended Spare Parts

List of common spare parts with part numbers and descriptions.

Service Kits

Information on available service kits for compressor and engine maintenance.

Troubleshooting

Introduction

Guidance for using the troubleshooting section to identify and resolve issues.

Unplanned Shutdown

Possible causes and actions for unexpected compressor shutdowns.

Discharge Pressure Is Too Low

Troubleshooting steps for low discharge air pressure.

Discharge Pressure is Too High or Relief Valve Blows

Causes and solutions for high discharge pressure or relief valve activation.

Relief Valve Blows with Throttle Lever in Idle Position

Diagnosing relief valve issues when the throttle is at idle.

Pressure Does Not Blow Down After Shutdown

Troubleshooting why system pressure remains after shutting down.

Compressor Oil Level is Decreasing Excessively

Identifying causes for a rapidly dropping compressor oil level.

Oil in Service Line

Troubleshooting oil found in the air service line.

Engine Does Not Accelerate Or Will Not Maintain Full Load Speed

Diagnosing issues with engine acceleration or maintaining speed.

Separator Plugging

Causes and solutions for a plugged air/oil separator element.

Engine Speed Control Does Not Change to Idle Speed with Service Valves Closed

Troubleshooting engine speed control when service valves are closed.

Engine Speed Control Does Not Change to Full Speed with Air Demand

Diagnosing engine speed control issues with air demand.

Compressor Oil Leaking in Control Lines;Orifices

Identifying and resolving oil leaks in control lines and orifices.

Summary

About This Manual

Safety Instructions

Instructions for the safe operation and maintenance of the air compressor.

Manual Organization

Guide to the structure and contents of the manual.

Supplemental Documents

Location of supplemental documents for specific compressor components.

Safety

General Safety

Essential safety precautions for operating and maintaining the air compressor.

Pressure Release

Procedures for safely releasing pressure from air, oil, and cooling circuits.

Fires and Explosion

Hazards and precautions related to fuel, liquids, batteries, and wiring.

Moving Parts

Safety guidelines to avoid injury from rotating components and machinery.

Toxic and Irritating Substances

Precautions when handling fuels, oils, coolants, and anti-freeze compounds.

Hot Surfaces, Sharp Edges, Sharp Corners and Vacuum

Awareness of burn and cut hazards from hot components and sharp edges.

Electrical Shock

Safety measures to prevent electrical shock from the compressor system.

Entrapment

Precautions to avoid being trapped inside the compressor enclosure during service.

Transporting and Locating

Receiving

Procedures for inspecting the compressor upon arrival and before service.

Lifting

Guidelines for safely lifting and rigging the compressor unit.

Drawbars and Brake Actuators

Information on proper alignment and installation of drawbars and actuators.

Preparing to Tow

Steps to take before towing the compressor, including safety checks.

Towing

Best practices and safety precautions for towing the compressor.

Parking or Locating Compressor

Instructions for safely parking and positioning the compressor unit.

Operation

General Operating Safety

General safety rules to follow during compressor operation.

Preparing for Initial Start-Up

Checks and procedures before starting the compressor for the first time.

Normal Starting

Step-by-step guide for starting the compressor engine and system.

Normal Stopping

Procedures for safely shutting down the compressor.

Sullivan-Palatek Electronic Controller (SPEC) Operational Instructions

How to operate the compressor using the SPEC electronic control system.

Operating Under Extreme Conditions

Guidelines for operating the compressor in cold, hot, or dusty environments.

Pneumatic Tools Application

Safety and application guidelines for using pneumatic tools with the compressor.

Jump-Starting Battery

Instructions for safely jump-starting the compressor's battery.

Component Description

Portable Compressor Package

Overview of the compressor unit, its configuration, and components.

Engine

Description of the diesel engine powering the compressor.

Air End Assembly

Details about the rotary screw air end assembly and compression cycle.

Discharge System

Explanation of the receiver/sump and minimum pressure valve components.

Lubrication System

Overview of the oil circulation, cooling, and return systems.

Capacity Control System

How the compressor adjusts air output based on demand.

Electrical and Protective Circuit System

Description of the electrical system and protective shutdown features.

Engine Shutdown Protection

Explanation of engine derate and shutdown safety features.

Noise Control Systems

Components and design for meeting federal noise control regulations.

Instrument Panel

Explanation of the controls and instruments on the compressor's panel.

Maintenance

Maintenance Schedule

A schedule of required maintenance tasks and frequencies.

Bolt Torque Guidelines

Recommended torque values and sequences for fasteners.

Compressor Lubrication

Procedures for checking, filling, and draining compressor oil.

WEATHER-ALL Compressor Lubricant

Information on the specific lubricant used and its specifications.

Oil Sample for Analysis

Steps for taking an oil sample for laboratory analysis.

Compressor Oil Filter

Procedures for inspecting, removing, and installing the oil filter.

Engine Lubrication

Reference to the engine manufacturer's manual for engine lubrication.

Grease

Types of grease recommended for various components.

Air Intake Filter

Procedures for inspecting, removing, and installing the air intake filter.

Oil Return Line

Inspection and cleaning procedures for the oil return line.

Air;Oil Separator

Replacement intervals and procedures for the air/oil separator elements.

Thermal Valve

Inspection and cleaning of the thermal valve for temperature regulation.

Oil Cooler

Procedures for cleaning and maintaining the oil cooler.

Compressor Shaft Oil Seal

Inspection for leaks of the compressor shaft oil seal.

Control Adjustments

Procedures for adjusting discharge pressure and engine speed.

Recommended Spare Parts

List of common spare parts with part numbers and descriptions.

Service Kits

Information on available service kits for compressor and engine maintenance.

Troubleshooting

Introduction

Guidance for using the troubleshooting section to identify and resolve issues.

Unplanned Shutdown

Possible causes and actions for unexpected compressor shutdowns.

Discharge Pressure Is Too Low

Troubleshooting steps for low discharge air pressure.

Discharge Pressure is Too High or Relief Valve Blows

Causes and solutions for high discharge pressure or relief valve activation.

Relief Valve Blows with Throttle Lever in Idle Position

Diagnosing relief valve issues when the throttle is at idle.

Pressure Does Not Blow Down After Shutdown

Troubleshooting why system pressure remains after shutting down.

Compressor Oil Level is Decreasing Excessively

Identifying causes for a rapidly dropping compressor oil level.

Oil in Service Line

Troubleshooting oil found in the air service line.

Engine Does Not Accelerate Or Will Not Maintain Full Load Speed

Diagnosing issues with engine acceleration or maintaining speed.

Separator Plugging

Causes and solutions for a plugged air/oil separator element.

Engine Speed Control Does Not Change to Idle Speed with Service Valves Closed

Troubleshooting engine speed control when service valves are closed.

Engine Speed Control Does Not Change to Full Speed with Air Demand

Diagnosing engine speed control issues with air demand.

Compressor Oil Leaking in Control Lines;Orifices

Identifying and resolving oil leaks in control lines and orifices.

Sullivan-Palatek D300PDKR Specifications

General IconGeneral
BrandSullivan-Palatek
ModelD300PDKR
CategoryAir Compressor
LanguageEnglish

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