Sullivan-Palatek D260PDKR Installation and operating instructions

OPERATION & SERVICE MANUAL
WHEEL-MOUNTED PORTABLE COMPRESSOR \ 260 CFM
D260PDKR
KOHLER DIESEL ENGINE
TIER 4 FINAL
Document: 05018730 0308 / 00
Issued: March,2022

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: [phone]
Fax: [phone]
Toll Free: [phone]
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 2022 -03Released for publication

III
I WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
II ABOUT THIS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
II.1 Safety Instructions .................................................................iii
II.2 Manual Organization ................................................................iii
II.3 Supplemental Documents............................................................iii
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
  .............................................................................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 Sullivan-Palatek Electronic Controller (SPEC) Operational Instructions ....................11
3.6 Operating Under Extreme Conditions .................................................13
3.7 Pneumatic Tools Application.........................................................13
3.8 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
CONTENTS

IV
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 Compressor Oil Filter ...............................................................30
5.7 Engine Lubrication .................................................................30
5.8 Grease ...........................................................................30
5.9 Air Intake Filter ....................................................................30
5.10 Oil Return Line.....................................................................30
5.11 Air/Oil Separator...................................................................31
5.12 Thermal Valve .....................................................................31
5.13 Oil Cooler .........................................................................31
  ...........................................................32
5.15 Control Adjustments ...............................................................32
5.16 Recommended Spare Parts .........................................................33
5.17 Service Kits .......................................................................33
6 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1 Introduction ......................................................................36
6.2 Unplanned Shutdown ..............................................................36
6.3 Discharge Pressure Is Too Low.......................................................37
6.4 Discharge Pressure is Too High or Relief Valve Blows ...................................37
6.5 Relief Valve Blows with Throttle Lever in Idle Position ..................................37
  ........................................37
6.7 Compressor Oil Level is Decreasing Excessively ........................................38
6.8 Oil in Service Line ..................................................................38
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...........39
6.12 Engine Speed Control Does Not Change to Full Speed with Air Demand....................39
  .......................................39

IWARRANTY
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

pay the 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.
I WARRANTY
10.31.15

II WARRANTY

III
II AbOUT ThIS MANUAL
II.1 SAFETY INSTRUCTIONS
Instructions for the safe operation and maintenance of the Sullivan-Palatek air compressor are located

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: TRANSPORTING AND LOCATING
This section contains instructions and safety guidelines for transporting and locating a portable air
compressor.
SECTION 3: 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 4: COMPONENT DESCRIPTION

compressor.
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.
II.3 SUPPLEMENTAL DOCUMENTS

The Engine
manual can be accessed at www.kohlerpower.com.

IV ABOUT THIS MANUAL

1
1 SAFETY
TOPICS IN THIS SECTION:
» General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
» Pressure Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
» Fires and Explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
» Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
» Toxic and Irritating Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
» Hot Surfaces, Sharp Edges, Sharp Corners and Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
» Electrical Shock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
» Entrapment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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 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
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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.
1.2 PRESSURE RELEASE
» 
items. Pay attention to the possible residual pressure when you disconnect a device from a pressurized
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.
1.3 FIRES AND EXPLOSION
1.3.1 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
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» Immediately clean up any spills or leaking fuel, battery electrolyte, oil, or anti-freeze solution.
» 
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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
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» 

Do not expose any part of these systems or the anti-freeze compound to temperatures above 150°F