85-210 DUS JD 4045 OMEGA TOOL OPERATORS, MAINTENANCE, AND PARTS MANUAL SERIAL NUMBER_________________________________________ MODEL NUMBER_________________________________________ P/N: 307271 06/17/2008 MCM
TABLE OF CONTENTS INTRODUCTION .............................................................................................................................. 6 SECTION 1 SAFETY ......................................................................................................................... 9 1.1 1.2 1.3 1.4 1.5 PARKING ....................................................................................................................................... 9 BEFORE STARTING THE COMPRESSOR .............
INTRODUCTION OWNER’S RESPONSIBILITY Your new Boss air compressor was engineered, built and tested to ensure the user both dependable and economical service. This compressor has also been certified as conforming to the applicable Noise Emission standards of the Environmental Protection Agency. Continuation of this unit’s performance depends upon the care it receives during use. Therefore, operation and maintenance procedures described in this manual should be followed carefully.
WARNING ALL UNITS ARE SHIPPED WITH A DETAILED OPERATORS AND PARTS MANUAL. THIS MANUAL CONTAINS VITAL INFORMATION FOR THE SAFE USE AND EFFICIENT OPERATION OF THIS UNIT. CAREFULLY READ THE OPERATORS MANUAL BEFORE STARTING THE UNIT. FAILURE TO ADHERE TO THE INSTRUCTIONS COULD RESULT IN SERIOUS BODILY INJURY OR PROPERTY DAMAGE. AIR COMPRESSOR SAFETY PRECAUTIONS Safety is basically common sense.
USER MODIFICATION This Boss compressor incorporates numerous features to minimize noise emissions from the unit during operation. This configuration has been tested for noise emissions at conditions specified by the U.S. Environmental Protection Agency. Conformance to regulations requires the incorporation of the following notification and definition in the OPERATION AND MAINTENANCE MANUAL. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following act: 1.
SECTION 1 SAFETY 1.1 PARKING CHOOSING A PARKING SITE 1. Park the compressor on a level firm area. Never park on a grade of more than 15 degrees (27%). If you must park on any grade, park across the grade so that the compressor does not tend to roll. 2. Park so that the wind carries exhaust fumes and radiator heat away from the compressor inlet. 3. Park away from work site dust. 4. Stay clear of electrical power lines.
1.4 SERVICING 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Before servicing compressor, relieve receiver pressure and allow to cool. Be sure all access panels are opened and/or removed. Wipe up all spills resulting from servicing. Disconnect the grounded (negative) battery connection before making repairs or cleaning inside the enclosure. Do not use flammable solvents for cleaning the compressor. Radiator coolant is under pressure.
SECTION 2 DESCRIPTION 2.1 INTRODUCTION Your Boss compressor is a gas/diesel driven Rotary Screw Compressor unit that provides superior performance and reliability along with a minimal amount of required maintenance. 2.2 ROTARY COMPRESSOR COMPONENTS COMPRESSOR DESCRIPTION The compressor assembly is a positive displacement, oil flood lubricated, screw type unit employing one stage of compression to achieve the desired pressure.
AIR/OIL SEPARATOR At the compressor discharge the compressed air and the hot oil flow into a steel ASME coded pressure vessel (rated at 175 psig-250psig) that acts as a reservoir for the air and separates out the oil. From the bottom of this oil sump the oil leaves the vessel on its way to the oil cooler. The air and the slight oil mist still entrained in the air flow through the separator element, which removes the last of the oil from the air.
2.4 CHASSIS FRAME The entire compressor frame and body is “utilized” and constructed of 3/16" or 10 gauge steel plate, resulting in light weight while providing a much stronger body than conventional designs of light sheet metal over structural members. 2.5 ENCLOSURE Enclosure is 14 gauge metal with powder coat finish. Each access panel has lockable handles with mechanical props. 2.6 INSTRUMENT PANEL DOOR Lockable instrument panel doors provide access to all controls and gauges.
SECTION 3 OPERATION 3.1 START UP PREPARATION 1. Check engine and compressor oil levels. Do not overfill. 2. Check coolant level in radiator (Fill at coolant recovery bottle). 3. Check for fuel, oil and coolant leaks. 4. Check air cleaner, clamps and hoses. 5. Check battery connections. 6. Check and adjust tension of fan belts. NOTE: This unit has minimum air pressure valve to assure compressor oil flow. There will be no airflow from the compressor if receiver pressure is less that 80 PSIG. 3.
SECTION 4 MAINTENANCE 4.1 ENGINE FUEL SPECIFICATIONS WARNING DO NOT MIX GASOLINE OR ALCOHOL WITH DIESEL FUEL. THIS MIXTURE CAN CAUSE AN EXPLOSION. CAUTION DUE TO THE PRECISE TOLERANCES OF DIESEL INJECTION SYSTEMS, IT IS EXTREMELY IMPROTANT THAT THE FUEL BE KEPT CLEAN AND FREE OF DIRT OR WATER. DIRT OR WATER IN THE SYSTEM CAN CAUSE SEVERE DAMAGE TO BOTH THE INJECTION PUMP AND THE INJECTION NOZZLE. USE ASTM NO.2D FUEL WITH A MINIMUM CETANE NUMBER OF 40. NO.2 DIESEL.
4.2 ENGINE OIL AND FILTER See engine manufactures operator/instruction manual for the proper engine oil and filter changing intervals for the brand engine in your Boss compressor. OIL FILTER REPLACEMENT 1. Clean the area around the lubricating filter head. 2. Remove the filter. 3. Clean the o-ring surface of the filter head. NOTE: The o-ring can stick on the filter head. Make sure it is removed. 4. Apply a light film of lubricating oil to the o-ring-sealing surface before installing. 5.
COOLANT LEVEL Before each start-up, when radiator is cold, the coolant should be checked. When needed, refill with a 50/ 50 solution of water and ethylene glycol, DO NOT use 100% antifreeze for “topping off”. WARNING CHECK THE COOLANT LEVEL ONLY WHEN THE ENGINE IS STOPPED AND THE TEMPERATURE IS BELOW 160ºF (70ºC) FAILURE TO DO SO CAN CAUSE PERSONAL INJURY FROM HEATED COOLANT SPRAY. 4.4 FAN Check the fan for cracks, loose rivets, and bent or loose blades. Make sure it is securely mounted.
COMPRESSOR OIL SPECIFICATIONS It is permissible to use oils other than the ATF shown above; such as Hydraulic oil. If they are used then they must have at least the following minimum properties: • ISO grade 32 • CPS No. 255675 • API Gravity • Viscosity, Kinematic cst at 40 degrees C 33.6 cst at 100 degrees C 5.5 • Viscosity saybolt SUS at 100 degrees F 173 SUS at 210 degrees F 45 • Viscosity index 98 • Pour point deg. C(deg F) -33(-27) • Flash point deg.C(deg.F) 204(399) • Oxidation stability • Hours to 2.
CAUTION DO NOT REPLACE FILL CAP WITH A PIPE CAP; SERIOUS INJURY OR DAMAGE COULD RESULT. THE THREADS ARE DIFFERENT. ALWAYS ENSURE A STRAIGHT THREAD FILL CAP IS USED. CHANGING COMPRESSOR OIL 1. Oil and air filter will help prolong oil life. If the oil appears dirty or it has a foul smell it should be replaced. 2. Change compressor oil and filter every 500 hours. 3. Remove fill cap and drain oil from the bottom of the air/oil receiver. Oil will drain more quickly and completely if it is warm from operation.
4.8 COMPRESSOR & ENGINE AIR FILTER MAINTENANCE ELEMENT REPLACEMENT 1. Loosen the clamps that secure the dust cup to the body and remove the cover. 2. Empty the dirt from the dust cup. 3. Remove the element. 4. Clean the canister and dust cap with a damp cloth inside and out. DO NOT blow dirt out with compressor air. 5. At this time clean or replace the element. 6. Replace the element. 7. Reposition the cover and tighten the clamp, INSTALL WITH “TOP” UP. 8.
4.9 COMPRESSOR OIL THERMOSTATIC VALVE The oil thermostatic valve acts as a thermostatically controlled by-pass valve and allows varying amounts of oil, depending upon the temperature, to by-pass cooler during the warm up period. When circulated oil reaches a temperature of 140 º F, the valve closes the by-pass completely and all the oil is circulated though the cooler.
4.12 CONTROLS-OPERATION AND ADJUSTMENTS The compressor system is designed to match air supply and engine performance with the demand. The components of the control system are, the blowdown valve, start-run solenoid, compressor inlet valve, pressure regulator and an engine air cylinder. The start-run valve that is open in the start run position.
PRESSURE REGULATOR ADJUSTMENT After setting idle speed and compressor is in run position, the pressure regulator adjustment can be checked and adjusted if required. The air cylinder receives an air signal from the pressure regulator. This air cylinder controls engine speed with air demand. To adjust pressure regulator, with compressor in the run position, open service valve slightly to allow air to bleed out.
4.15 MAINTENANCE SCHEDULE A good maintenance program is the key to long machine life. Follow a regular schedule of inspection and servicing, based on operating hours. Keep an accurate logbook for maintenance, servicing and operating hours. Use the factory recommended Periodic Maintenance schedule (based on favorable operating conditions) to serve as a guide to get long and efficient machine life. Regular service periods are recommended for normal service and operating conditions.
4.17 MAINTENANCE SCHEDULE CHART INTERVAL EVERY 10 HOURS OR DAILY EVERY 50 HOURS OR WEEKLY EVER 500 HOURS EVERY 1000 HOURS REQUIRED MAINTENANCE 1. Check compressor system fluid level. 2. Check radiator coolant level in coolant recovery tank. 3. Check fuel supply after running. 4. Check air filter maintenance indicator (if equppied). 5. Check for fuel, oil, air, and water leaks. 6. Check battery mounting for security. 7. Drain water and sediment from fuel tank. 1.
4.18 RECOMMENDED SPARE PARTS LIST ENGINE ENGINE AIR FILTER ELEMENT JD4045 3 0 2 0 14 COMPRESSOR OIL FILTER ELEMENT 124- 28093 SEPARATOR AIR/OIL ELEMENT 124- 25700 COMPRESSOR AIR FILTER ELEMENT 302014 COMPLETE KITS ARE ALSO AVAILABLE THAT INCLUDE ALL THE ABOVE PARTS. KIT FOR JOHN DEERE 4045 WITH 10G COMPRESSOR...............................................................80114 4.19 PROCEDURE FOR ORDERING PARTS Parts can be ordered directly from the factory.
SECTION 5 TROUBLESHOOTING 5.1 TROUBLESHOOTING If the unit will not crank when a “START” is attempted, DO NOT jump-start without first considering the following: • If there is obvious battery damage such as a cracked or broken case, replace battery • Check for loose battery cables. Tighten if necessary • Check terminals for corrosion, clean if necessary 1. 2. 3.
5.2 TROUBLESHOOTING CHART The information contained in the troubleshooting chart has been compiled from field report data and factory experience. It contains symptoms and usual causes for the report data and factory experience. It contains symptoms and usual causes for the described problems; however, do not assume that these are the only problems that may occur. All available data concerning the trouble should be systematically analyzed.
SYMPTOM CAUSE Out of fuel Check fuel level and add fuel if necessary. Fuel filter restricted. Change fuel filter. a. Engine collant level low; add coolant. b. Compressor oil and radiator flow restricted; clean coolers. c. Fan belts slipping or broken; repair or replace. d. Compressor oil low; add oil. e. Engine oil level low; add oil. f. Compressor oil filter restricted; change the filter. g. Engine oil filter restricted; change the filter.
SYMPTOM Excessive compressor oil consumption. CAUSE Oil reserve over filled. Leak in the compressor oil system. REMEDY Drain to the proper level. Check all piping lines and connections; repair as necessary. a. Check scavenge line and its check Oil scavenge line not removing valve for restrictions; clear as necessary. the oil from the separator. b. Make sure that the scavenge line reaches the bottom of the separator. Separator element damaged. Replace the element.
WARRANTY Boss Industries, Inc. (BOSS) warrants that this Rotary Screw Compressor unit conforms to applicable drawings and specifications approved in writing by BOSS. The unit assembly will be free from defects in material and workmanship for a period of three (3) years from the date of initial operation or fortytwo (42) months from the date of shipment, whichever period first expires.
SUMMARY OF MAIN WARRANTY PROVISIONS As claims, policies and procedures are governed by the terms of the BOSS Industries, Inc. (BOSS) warranty, it is necessary to outline some of the more important provisions. The BOSS warranty applies only to new and unused products, which, after shipment from the factory, have not been altered, changed, repaired or mistreated in any manner whatsoever. Normal maintenance items such as lubricants and filters are not warrantable items.
WARRANTY/RETURN GOODS INSTRUCTIONS The warranty/return procedure outlined below is provided to give the claimant the information necessary to file a warranty/return claim, and enable BOSS INDUSTRIES the ability to best serve its’ customers. Please see the following instructions to initiate a return: Contact BOSS INDUSTRIES Returns Department by telephone at 219.324.7776 or via email at service@bossair.com. You may also send a fax at 219.324.7470.
GENERAL An approved claim depends on the following provision: 1. 2. 3. 4. 5. 6. An RGA # must be issued by BOSS INDUSTRIES. (See filing procedures.) Failed part must be returned within 30 days of original invoice date, freight prepaid, with RGA #. Part is determined to be defective. Workmanship is determined to be defective. Machine is within warranty period. Machine has been operated within design conditions.
SCREW COMPRESSOR AIR-END EXCHANGE PROGRAM Replacement air-ends are available from the factory. For current prices and availability, contact BOSS INDUSTRIES, Inc. or an authorized BOSS INDUSTRIES distributor. Prices are F.O.B. shipping point. Prices do not include labor for removal or installation.
NOTES 36 P/N: 307271
SECTION 6 ASSEMBLY_DRAWINGS 37 P/N: 307271
38 P/N: 307271 A B C D 8 8 2 7/8 in [73.0 mm] 2 in [50.8 mm] 24 1/8 in [612.8 mm] 7 7 15 7/8 in [403.2 mm] 6 75 in [1905.0 mm] 79 in [2006.6 mm] 31 5/8 in [803.1 mm] 85 in [2160.4 mm] 6 4 1/4 in [108.0 mm] 5 5 3 in [76.2 mm] 24 in [609.6 mm] 8 - PLACES n1 in THRU 31 in [787.4 mm] 4 3 2 1 REV 1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 NS NS 3 6/5/2008 4/18/2008 DATE MCM MCM ENG MCM Parts List 2 DESCRIPTION 1 2 THIS DRAWING AND ALL ITS NOMINAL DIM.
39 P/N: 307271 A B C D 4 5 4 3 4 7 1 2 6 7 8 10 9 1 REV 11 13 15 14 2 1 1 DATE 6/16/2008 ENG MCM Parts List 1 2 1 R 2 THIS DRAWING AND ALL ITS NOMINAL DIM. FRACTIONAL ` 1/16 CONTENTS ARE PROPERTY 0.000 TO 1.000 ` .010 DECIMAL ` .03 OF BOSS INDUSTRIES, INC. 1.001 TO 5.000 ` .015 ANGULAR ` 1° AND MUST NOT BE COPIED 5.001 TO 10.000 `.020 OR MADE PUBLIC. IT IS DO NOT SCALE DESCRIPTION TOLERANCES LOANED AND IS SUBJECT TO 10.001 & OVER `.025 UNLESS NOTED RETURN UPON DEMAND.
8 7 6 5 4 3 2 Parts List ITEM 1 2 3 4 5 6 7 8 D 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 C 25 26 27 28 29 30 31 32 33 34 35 36 37 QTY 1 1 1 2 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 2 2 4 1 1 1 1 4 8 8 5 4 PART NUMBER 307207 150-90729 150-90665 150-90673 302764 154-90975 980100-250 302423-100 158-65476 150-90666 302015 158-65921 158-65875 120-34188 303150 123-33230 123-19735 907602-015 922102-015 901115-005 902415-005 929808-125 924404-145 305891 DESCRIPTION ENGINE, JD4045 W SAE-A AUX DR
41 P/N: 307271 A B C D 3 8 8 9 4 "D" PORT 8 17 20 15 13 19 7 7 14 16 9 "E" PORT 3 "G" PORT 26 5 21 10 22 5 24 6 5 NOTE: PORT CALLOUTS REFRENCED ON HOSE SYSTEM & PARTS DRAWING 6 2 6 13 4 11 23 4 1 12 7 21 18 25 3 3 `.020 `.025 5.001 TO 10.000 10.001 & OVER `1/ 16 `.03 `1~ FRACTIONAL DECIMAL ANGULAR U MA ED D S SU RFA S UN NM ACH C CH HIIIIN NE UR F FA AC CE ES `.015 `.010 1.001 TO 5.000 0.000 TO 1.000 NOMINAL DIM.
42 P/N: 307271 A B C D 8 8 16 15 5 7 7 5 15 16 5 5 15 6 15 16 6 16 "Q" Port 11 17 NOTES: PORT CALLOUTS REFRENCED ON HOSE SYSTEM & PARTS DRAWING 3 1 5 2 5 12 10 7 18 7 14 9 3 4 7 13 4 4 2 1 REV REPLACED 901415-030 WITH 901215-030 REPLACED 158-62952 WITH 307364 DESCRIPTION REVISION HISTORY 9 8 6 2 3 3 1 2 6 1 14 12 12 2 4 1 1 2 2 1 14 14 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 6/13/2008 4/18/2008 DATE QTY ITEM MCM MCM ENG Parts List DESCRIPTION
43 P/N: 307271 A B C D 8 8 24 15 "K" PORT 35 1 7 25 7 7 7 34 9 29 32 22 3 5 29 11 12 11 28 26 20 8 15 16 27 6 14 6 34 31 7 13 14 35 2 "N" PORT 33 21 10 7 30 4 17 19 23 6 5 4 4 NOTE: PORT CALLOUTS REFRENCED ON HOSE SYSTEM & PARTS DRAWING "P" PORT 18 "M" PORT 5 3 29 30 31 32 33 34 35 NS 3 3 1 1 1 1 3 3 1 `.015 `.020 `.025 5.001 TO 10.000 10.001 & OVER `1/ 16 `.
44 P/N: 307271 A B C D 8 8 12 DETAIL A SCALE 1 / 2 PORT "V" 7 13 7 7 3 14 PORT "S" 2 1 PORT "T" 10 4 11 A 8 9 16 B 6 5 5 6 5 NOTE: PORT CALLOUTS REFRENCED ON HOSE SYSTEM & PARTS DRAWING 6 17 15 11 13 4 4 10 DETAIL B SCALE 1 / 4 12 3 3 `.015 `.020 `.025 1.001 TO 5.000 5.001 TO 10.000 10.001 & OVER `1/ 16 `.03 `1~ FRACTIONAL DECIMAL ANGULAR U UN NM MA D S SU RFA S ACH C CH HIIIIN NE ED UR F FA AC CE ES `.010 0.000 TO 1.000 NOMINAL DIM.
45 P/N: 307271 ITEM QTY PART NUMBER 1 1 304024 2 1 300071-200 3 6 304785-075 4 2 304784-075 5 2 304785-100 6 1 301786-300 7 2 FT 304783-100 8 1 120-65471 4 9 120-11555 10 1 303823 11 2 120-11563 12 1 302907 13 21 FT 301960-025 14 23 FT 304783-075 15 18 1/2 FT 89034176 3 1 DESCRIPTION KIT, HOSE 1 1/2 X 60 2-CRIMP ST.
46 P/N: 307271 A B C D 1 7 8 8 6 2 2 4 4 3 3 10 7 7 2 8 4 3 5 6 6 1 2 4 3 5 11 5 1 9 1 4 4 3 2 4 2 3 1 UPDATED 307260 TO REV 1 REV DESCRIPTION REVISION HISTORY 3 4 6/5/2008 DATE MCM ENG 7 1 1 2 THIS DRAWING AND ALL ITS NOMINAL DIM. FRACTIONAL ` 1/16 CONTENTS ARE PROPERTY 0.000 TO 1.000 ` .010 DECIMAL ` .03 OF BOSS INDUSTRIES, INC. 1.001 TO 5.000 ` .015 ANGULAR ` 1° AND MUST NOT BE COPIED 5.001 TO 10.000 `.020 OR MADE PUBLIC.
47 P/N: 307271 A B C D 8 8 7 4 5 6 7 7 3 2 6 6 5 5 7 4 4 4 5 10 1 2 1 1 2 1 1 1 4 FT 2 FT -1 1 2 3 4 5 6 7 8 9 10 NS 2 1 3 6 3 2 Parts List 2 DESCRIPTION 1 2 THIS DRAWING AND ALL ITS NOMINAL DIM. FRACTIONAL ` 1/16 CONTENTS ARE PROPERTY 0.000 TO 1.000 ` .010 DECIMAL ` .03 OF BOSS INDUSTRIES, INC. 1.001 TO 5.000 ` .015 ANGULAR ` 1° AND MUST NOT BE COPIED 5.001 TO 10.000 `.020 OR MADE PUBLIC. IT IS DO NOT SCALE TOLERANCES 10.001 & OVER `.
S GND I+ Air Pressure 16 GA. RED GND S S Oil Pressure 16 GA. BLACK I+ I+ Over Ride Button 16 GA. RED Optional Fuel Gauge 20 GA. BLACK BAT ST GND _ S + _ Hourmeter 16 GA. BLACK 16 GA. RED + Circuit Breaker 16 GA. RED Temperature Coolant I+ 16 GA. RED ACC GND IGN Ignition Switch INSTRUMENT PANEL WIRING SCHEMATIC 16 GA. RED S 20 GA. LT. BLUE Ammeter S + 16 GA. RED Battery 12V 10 GA. RED 10 GA. ORANGE I 14 AWG PURPLE 20 GA. ORANGE 20 GA. DK. GREEN 20 GA. WHITE 14 GA.
