Compressor Drive Coupling

Compressor Drive Coupling - Removal and Replacement

The compressor is driven off the rear of the engine via a Torsional Drive Coupling (fig 4-4). The cou-
pling consists of a rubber element, flange, and taper lock bushing. Usually no service is required other than
replacement when the rubber element is worn out. You can inspect the coupling through the opening in the
side of the bell housing / adapter plate (fig. 4-10).

WARNING:
Be sure to relieve pressure from hydraulic and pneumatic
systems before loosening parts or connections.

Compressor Unit - Removal:

1. Support the compressor unit with a suitable lifting device.
2. Remove bolts that attach compressor to engine and lower compressor mounting bolts (fig's. 4-10,
4-11 and 4-11a).
NOTE Be sure not to lose shims at lower mounting.

NOTE Some couplings have a negative reaction to thread lock chemicals.

3. Loosen main air connection so compressor unit can be moved back far enough to allow access to
drive coupling.
4. Inspect drive coupling and taper lock bushing. Normally the rubber element is the only part that
requires replacement. Refer to parts manual for part numbers.
5. Repair or replace as required.

Fig. 4-9 Torsional Drive Coupling

1. Rubber Element
2. Flange
3. Taper Lock Bushing

Drive Train / Compressor 4-107

 
Compressor Installation

Before Installation and Start-Up of New or Rebuilt Compressor:

1. Drain all lubricant from receiver tank and system.
2. Replace compressor oil filter element.
3. Remove separator and check receiver tank for foreign material, metal cuttings, varnish and sludge.
The system must be completely cleaned out.
4. Flush out compressor oil cooler.
5. Check all valves for foreign material and proper operation.
6. Install new filter elements and separator element. Install compressor unit (see "Compressor Unit -
Installation" below).
7. Reconnect all hoses and valves that were removed.
8. Fill system with new, clean lubricant (see section 9 for lubricant specifications) and pour 2 quarts
(1.9 liters) of lubricant down the inlet.
9. Start compressor and set the full load RPM and the idle RPM (refer to Sullair service manuals in this
section).
10. Set the controls at the rated pressure and RPM.
11. Checks engine and compressor operating temperature. The engine water temperature should not
be above 200o F (93.3o C) in radiator top tank. Compressor discharge temperature should not be
above 210o F (98.9o C).
12. Check all shutdown devices for proper operation and temperature range.

Compressor Unit - Installation:

1. Move compressor unit back into place with a suitable lifting device. Keep weight of compressor sus-
pended with lifting device until all bolts and shims are installed.
2. Tighten mounting bolts to engine flywheel housing (fig. 4-10).
3. Be sure to install the same number of shims that were removed from the rear compressor mounts
and install bolts (fig.4-11). If a new or rebuilt compressor is being installed, install as many shims
that will fit between the rear compressor mount and frame pads. This must be done to keep weight
of compressor off the engine flywheel housing, which can lead to premature bearing and seal failure.
Tighten all bolts according to standard torque specifications listed in section 9 of this manual.
4. Reconnect any hoses or fittings that were removed.

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Compressor Installation

Fig. 4-10 Compressor Mounting Bolts (engine adapter)

and Inspection hole

Fig. 4-11 Rear Compressor Mounting Bolts

and Shims.

Fig. 4-11a Front Compressor Mounting Bolts

and Shims.

Drive Train / Compressor 4-109

 
Main and Auxiliary Air

The physical and functional aspects of the compressed air system are described briefly in the following
paragraphs. However, you should refer to the parts manual for installation details and to the Sullair manual
for technical information and troubleshooting.

Compressed Air Subsystem Components (low pressure)

Fig. 4-12 Low Pressure Compressor Cooling and Lubrication System Functional Diagram.

The compressed air subsystem consists of an engine driven air compressor, a separator tank, and
the miscellaneous control and plumbing elements required to control the operation of the subsystem and
to direct the air flow as desired. Figure 4-12 illustrates the compressor lubrication and cooling functions.
Although the following topics briefly describe the functions of the compressor and separator tank, you
should refer to the Sullair manual for functional details of these units.

1. Air Compressor - A single-stage, positive-displacement, oil-flood-lubricated type air compressor

is located behind the engine. The compressor operates in association with the separator tank to
provide compressed air at a given CFM to the rotary drill and to other air operated components as
required. The air compressor is engine driven by means of a torsional drive coupling.
In operation, the compressor unit receives oil from the separator tank sump. Besides acting as
a coolant for the compressor, the oil seals the leakage paths between the rotor and stator and
between the rotor meshes. Forming a lubricating film between the rotors, the oil allows one rotor to
directly drive the other. As the air is compressed, it becomes mixed with oil which must be sepa-
rated out before the air is used.
2. Separator Tank - The separator tank is both a sump for the compressor oil and a reservoir for
the compressed air. The tank serves to separate the cooling and lubricating oil from the air in the
air/oil mixture delivered by the compressor. A built-in filter in the separator tank filters the oil from
the air, and the recovered oil is returned to the compressor. A sight gauge in the return line enables
the operator to see that oil is flowing in the line. A blow-down valve is located in a common line
between the compressor and tank.

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Main and Auxiliary Air

Compressed Air Functions

The main function of the compressed air system is to provide air to the drill bit to propel the particles
out of the hole. A secondary function of the system is to provide auxiliary air for control functions and for
operation of air tools, etc.

An air cleaner assembly on the intake to the air compressor cleans the air before it goes into the
compressor. Similar to the air cleaner for the diesel engine, the unit has the same type of filter elements.
The lower element traps the larger particles and a double filter unit that filters out the fine particles. Both
the safety (inner) element and the primary (outer) element are disposable. The lower permanent element is
designed to be removed for cleaning, while the upper safety (inner) element and the primary (outer) element
are disposable. Although cleaning of these elements is possible, replacement is recommended. Refer to the
parts manual for installation and assembly details and to the beginning of this section for service instructions.

1. Main Air System - Filtered air to the drill bit passes through a check valve and the butterfly
control valve, then through the main air header to an air hose that connects with a stand pipe. From
the stand pipe the air is applied through a hose and swivel connector to the rotary element where it
passes into the drill stem to emerge from the drill bit, blowing out the particles from the blast hole.
Water is injected into the main air manifold by means of an air loop to the water injection system.
2. Auxiliary Air - The auxiliary air is used to control the main air butterfly valve, and is also available
for special tool applications such as indexing the optional pipe rack and operating the automatic
tool wrench.
3. Air subsystem Control Functions - The main air control valve, controlled by a switch on the
control console, can be operated in two directions.
4. Air System Indicators - Three pressure gauges indicate the various air pressures in the system.
The air "T" tank pressure gauge indicates the pressure in the tank itself, while the filter pressure
gauge indicates the air pressure on the delivery side of the filter. The difference between the filter
pressure gauge and the "T" pressure gauge readings indicates the condition of the filter. A pressure
differential greater than ten PSI indicates incomplete air/oil separation, and thus indicates the need
to service the air compressor. The bit pressure gauge indicates the pressure at the main air header,
and hence the air pressure of the air delivered to the drill bit.
A pressure switch on the main air header completes the circuit to the drill hour meter. Thus, when
air is applied for drill operation the hour meter begins to count, measuring the time of operation.
When the air is cut-off, the hour meter ceases to run, thereby indicating the number of hours the
engine has operated (as indicated on the engine hour meter).

Drive Train / Compressor 4-111

 
Sulliscrew Compressor Unit

Functional Description
This unit provides continuous pulse-free compression to meet your needs. With a Sullair Compressor,
no internal inspection of the compressor unit is required.

Fluid is injected into the compressor unit and mixes directly with the air as the rotors turn, compress-
ing the air. As a coolant, it controls the rise of air temperatures normally associated with the heat of com-
pression. The fluid also seals the leakage paths between the rotors and the stator and also between the
rotors themselves. It acts as a lubricating film between the rotors allowing one rotor to directly drive the
other, which acts as an idler. After the air/fluid mixture is discharged from the compressor unit, the fluid is
separated from the air. At this time, the air flows to your service line and the fluid is cooled in preparation
for reinjection.

Control System
The purpose of the compressor control system is to regulate the compressor air intake to match the
amount of compressed air being used. The inlet valve consists of a butterfly valve controlled by an air
cylinder as shown in fig. 4-13. For high pressure machines refer to Sullair Drill Compressor manual for high
pressure units in this section. Fig. 4-12a shows the high pressure control circuit.

Fig. 4-12a High Pressure Compressor Control System.

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Butterfly Inlet Control System (high pressure)

Refer to Sullair Drill Compressor Model 20/12 500 - 1350 CFM (high pressure 250 -
500 PSIG) Operator's Manual #02250136-659 in this section.
This manual covers instructions for compressor set-up and inlet valve adjustment.

Drive Train / Compressor 4-113

 
Butterfly Inlet Control System (low pressure)

Butterfly System Initial Set-up Procedure

Perform steps 1 - 6 with machine shutdown and pressure relieved.
1. Align air cylinder (item 1, fig. 4-13). Be sure cylinder is in line and rods are not bent or damaged.
2. Using shop air at the base of the cylinder, extend the large rod all the way out.
3. With cylinder extended place a wrench on the butterfly lever and move back to fully closed position
(the small cylinder rod has a spring behind it). You should be able to close the butterfly valve before
the spring bottoms out. If not, adjust cylinder base or stop screw (2).
4. Shut off shop air supply and remove hose from cylinder. Push the butterfly lever all the way back so
large cylinder rod is fully retracted and butterfly valve is closed. Install hose from return manifold to
base of cylinder.
5. Using the stop screw (2), adjust butterfly inlet so it is just barely open, just enough to build 50 - 60
PSI (3.5 to 4.1 bar) after starting machine.
6. Back out the reducing regulator, and the system regulator (fig. 4-13a).
7. Place compressor Start/Run valve in START position, and start machine and leave in low idle and watch
pressure build. Loosen running blowdown outlet to muffler (fig. 4-13a) and verify when blowdown
opens. Pressure should build to approx. 50 to 60 PSI (3.5 to 4.1 bar). This should be a steady pres-
sure. If not, adjust butterfly open or closed to get 50 to 60 PSI (3.5 to 4.1 bar). Check at high idle
and re-adjust if necessary.
8. Return to low idle and turn compressor vStart/Run valve to RUN position.
9. Adjust the system regulator to approx. 90 to 100 PSI (6.2 to 6.9 bar).
10. Shift to high idle and check, re-adjust if necessary.

Fig. 4-13 Butterfly Inlet Valve

1. Air Cylinder 2. Stop Screw 3. Butterfly Valve 4. Return Manifold 5. Grease Fitting (2)

4-114 Drive Train / Compressor


Butterfly Inlet Control System (low pressure)

11. Open main air partially and let the butterfly open and close.
12. Adjust reducing regulator (fig. 4-13a) to 20 PSI (1.4 bar).

Maintenance
1. Keep linkage and area around inlet clean.
2. Be sure clamps are tight and rubber inlet boot has no tears or holes.
3. Grease the butterfly valve weekly at the grease fittings (5) located at each end of the shaft.

Fig. 4-13a Low Pressure Air Control Piping (ref. 425365)

Drive Train / Compressor 4-115
 
Compressor Maintenance

Please refer to the following Sullair manuals for proper operation and maintenance of the compressor:

250 to 2000 CFM Single Stage Low Pressure Manual No. 02250150-154
or
500 to 1350 CFM High Pressure (250 - 500 PSI) Manual No. 02250136-569

4-116 Drive Train / Compressor


Notes

Drive Train / Compressor 4-117

 
Compressor Oil Filter

Fig. 4-14 Compressor Oil Filter Assembly

1. Visual Service Indicator
2. O-Ring
3. Locking Screw
4. Cannister Assembly
5. Filter Element
6. Filter Bowl
7. Filter Head

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Compressor Oil Filter

Routine Maintenance
Compressor Filters do not normally require special attention except for periodic monitoring of the
differential pressure warning device.

1. If external leakage is noted, replace o-ring at leak. For bowl seal leaks, replace o-ring (2). If leakage
persists, check sealing surfaces for scratches or cracks; replace any defective parts.
2. Differential pressure devices actuate when the element needs changing or because of high fluid
viscosity in "cold start" conditions. If visual indicator is fitted and actuates during "cold start", reset
by depressing the rubber button when the normal operating temperature is reached. If indicator
actuates after resetting, replace element.

Changing Filter Elements

WARNING:
Relieve pressure on hydraulic and pneumatic systems before
loosening connections or parts.
Failure to depressurize system before proceeding could result in
explosive loss of fluid, damage to equipment, or possible per-
sonal injury.

1. Turn off and depressurize the system. Open bleed plug (if fitted) one and one half turns.
2. Unscrew and remove filter cover bowl (6) from head assembly (7), counterclockwise when viewed
from above. It may be necessary to use a lever on the "Rotolok Ring" of the filter bowl (6) to loosen
the bowl initially.
3. Remove filter element (5) and carefully inspect the surface for visible contamination. Normally no
dirt should show, but visible dirt or particles can be an early warning of system component break-
down and can indicate potential failure. Discard both the filter element and its o-ring. The filter
element is not cleanable. Any attempt to clean the filter element can cause degradation of the filter
medium and allow contaminated fluid to pass through the filter element.

CAUTION:
DO NOT attempt to clean or reuse element.

Drive Train / Compressor 4-119

 
Compressor Oil Filter

Fig. 4-14 Compressor Oil Filter Assembly

1. Visual Service Indicator
2. O-Ring
3. Locking Screw
4. Cannister Assembly
5. Filter Element
6. Filter Bowl
7. Filter Head

Fig. 4-15 Compressor Oil Filter Assembly - may be mounted on either side.
1. Compressor Oil Filter
4-120 Drive Train / Compressor

Compressor Oil Filter

Changing Filter Elements (continued)

4. DO NOT run the system without a filter element (5) installed. Check that the o-ring (2) on the head
assembly (7) is not damaged. Use replacement filter element part number called for on the element
change label or in the parts book.
5. Lubricate element o-ring (2) with clean system fluid and push open end of filter element (5) straight
onto the nipple in the head assembly (7). Clean out filter bowl (6) and lightly lubricate threads of
filter cover assembly with clean system fluid. Screw cover assembly onto head assembly until it
bottoms. O-ring sealing in not improved by overtightening.

CAUTION:
DO NOT use pipe wrench, hammer , or any other tool to tighten
bowl.

6. Bleed the system and check for leaks. To bleed filter, open bleed plug, if fitted, one and one half
turns. Jog system and fill filter until all air bleeds through plug, then tighten plug. Pressurize system
fully and check for leaks; if leaks occur, check o-rings and sealing surfaces.
7. After element change, ensure differential pressure device is reset by pushing in the button; electri-
cal switches reset automatically. When system reaches normal operating temperature, check that
the electrical switch has not actuated and/or the visual warning button has remained depressed. If
visual indicator rises due to a cold start condition, reset again as outlined in "Routine Maintenance".

Fig. 4-15a Compressor Oil Filter Assembly - may be mounted on either side
depending on compressor installation.
1. Compressor Oil Filter

Drive Train / Compressor 4-121

 
Compressor Oil Filter Service Bulletin

4-122 Drive Train / Compressor