Service and Maintenance Manual

Transcription

1 Service and Maintenance Manual 0 DUS JD4045 T3 80HP Air Compressor This manual must be read carefully before using your Boss Industries, Inc. Air Compressor. Store in a safe and convenient location for future reference. For technical support: Phone: (800) (USA) Phone: (9) (Outside USA) Fax: (877) (USA) service@bossair.com Website: /3/04 KWB

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3 Contents Manual Change History...7. Revision List...7 Welcome...8. General Information...8. Overview...8 Safety General Safety Overview Safety Precautions Safety and Information Decals... Specifications Specification Sheet...4 Description of Components Engine Drive Coupling Compressor Airend Separator System...5 Separator Tank...5 Separator Element Pressure Relief Valve Engine Air Filter Compressor Air Filter Cooling Systems...6 Engine Radiator...6 Compressor Oil Cooler Compressor Oil Filter Compressor Oil Thermal Valve Compressor Inlet Valve Minimum Pressure Valve Blowdown Valve Discharge Pressure Regulator Valve Instrument Panel...7 Engine Oil Pressure Gauge...7 Engine Coolant Temperature Gauge...7 Compressor Discharge Pressure Gauge...8 Compressor Discharge Temperature Gauge...8 Hourmeter...8 Voltmeter

4 Contents Installation System Installation Overview Placing the Machine Connecting the System Fuel Supply Fuel Specifications...0 High Altitude and Low Temperature Fuel...0 Cold Weather Fuel Connecting the Air Discharge Lines Pre-Startup Inspection Machine Documentation Check Fluid Levels Initial Startup Preparation Safety Shutdown Verification Initial Startup... Operation Routine Operating Procedures...3 Routine Startup Preparation...3 Routine Startup Procedure...3 Routine Shutdown Procedure Emergency Shutdown Procedure...4 Maintenance Maintenance Overview Maintenance Schedule Recommended Spare Parts List Parts and Service Contact Information Maintenance Log Separator Element Replacement Engine Air Filter Replacement Compressor Air Filter Replacement Compressor Oil...3 Specifications...3 Adding Compressor Oil...3 Changing Compressor Oil Compressor Oil Cooler Compressor Oil Filter Engine Cooling System Maintenance...34 Engine Coolant

5 Contents Maintenance (continued) Engine Radiator...34 Engine Fan...35 Engine Serpentine Belt Battery Standby Pressure Adjustment (For 00 PSI System) Idle Speed Adjustment Rated Speed Adjustment...36 Troubleshooting Troubleshooting Chart Parts and Service Contact Information...40 Warranty Warranty Policy Summary of Main Warranty Provisions Warranty/Return Goods Instructions Warranty Claims - Preparation of Part Return Return or Warranty Claims - Filing Procedures Warranty Claims Provisions Damage in Transit Screw Compressor Airend Exchange Program...45 Parts and Illustration Section Frame System Engine System Compressor System Discharge System Cooling System Electrical System Canopy System Decal System Hose System...6. System Wiring Diagram

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7 Manual Change History. Revision List DATE LOCATIO N DESCRIPTION OF CHANGE INITIALS 8/9/ Pg /9/ Pg Updated cooler system Updated canopy system CRH CRH

8 . General Information Welcome Thank you for choosing the 0 DUS Air Compressor. Before operating this system, read over this manual and become well acquainted with your new machine. Doing this will increase your safety and maximize the life of the machine. Service and Maintenance Manual 0 DUS JD4045 T3 80HP Air Compressor While this manual is written to be as accurate as possible, Boss Industries, Inc. strives to continually improve the efficiency and performance of its machines. As a result, sometimes there may be slight differences between a given version of the manual and the machine. This manual must be read carefully before using your Boss Industries, Inc. Air Compressor. Store in a safe and convenient location for future reference. For technical support: Phone: (800) (USA) Phone: (9) (Outside USA) Fax: (877) (USA) service@bossair.com Website: /7/03 ARB. Overview The 0 DUS Air Compressor is a compact, strategically designed system. It integrates all major components on a single, frame, which is enclosed in a tough, weather-resistant canopy. The 0 DUS Air Compressor s rotary screw design guarantees continuous air output of up to 0 CFM (cubic feet per minute) at 0 PSI (pounds per square inch). With remote fluid drains and removable doors, virtually all components are accessible for maintenance and service. The instrument panel clearly displays pressures, temperatures, and hours of operation. Other features, including a spin-on compressor oil filter and a drop-in separator element, reduce the time and costs associated with routine maintenance. The machine also has a 5 (foot) harness extension for the ignition switch, high speed override, and the unload switch. The 0 DUS Air Compressor also has enhanced safety features to protect your valuable resources: minimum pressure valve, high compressor oil temperature shutdown, high discharge pressure shutdown, automatic blowdown device, pressure relief valve, high engine coolant temperature, low engine oil pressure and clearly displayed warning/information decals

9 3. General Safety Overview Safety Remember, safety is basically common sense. While there are standard safety rules, each situation has its own peculiarities that cannot always be covered by rules. Therefore with your experience and common sense, you are in a position to ensure the safety of yourself and others. Lack of attention to safety can result in: accidents, personal injury, reduction in efficiency, and worst of all Loss of Life. Watch for safety hazards and correct them promptly. Understanding the proper operation of this equipment is critical to its safe operation. The owner, lessor, and/or operator of this equipment is hereby notified and forewarned that any failure to observe the safety and operating guidelines may result in injury and/or damage. Boss Industries, Inc. expressly disclaims responsibility or liability for any injury or damage caused by failure to observe these specified precautions or by failure to exercise the ordinary caution and due care required while operating or handling this equipment, even though not expressly specified. In addition to following these safety guidelines, the operator should follow any company specific guidelines and procedures. Consult your immediate supervisor for specific company safety guidelines and/or procedures. The following safety symbols are used throughout this manual to draw attention to important information. If the information is not carefully read and the instructions are not followed, severe injury, death, and/or damage to property and equipment may occur. Indicate[s] an imminently hazardous situation, which, if not avoided, will result in death or serious injury. Indicate[s] a potentially hazardous situation, which, if not avoided, could result in death or serious injury. Indicate[s] a potentially hazardous situation, which, if not avoided, could result in minor or moderate injury. Indicate[s] a potentially unsafe situation or practice, which, if not avoided, can result in property and/or equipment damage only

10 3. Safety Precautions Safety The following safety precautions are a general guide to safe operation of the equipment. This is a pressurized system. Do not attempt to remove any part of this machine without first completely relieving entire system of pressure. Do not attempt to service any part of the equipment while in operation. Never attempt to repair or modify any pressure vessel or device. System contains hot oil. The system must be shut off prior to servicing. Then permit system to cool down prior to adding compressor oil or servicing the unit. Do not use air from this system for breathing or food processing. Air from this system will cause severe injury or death if used for breathing or food processing. The system is designed to compress air. Do not attempt to compress other gases. Compression of other gases may create a situation where an explosion or fire may occur. Do not use flammable solvents for cleaning system components as this can cause the unit to ignite or explode during operation. Keep combustibles out of and away from system inlets and any associated enclosures. Never disable, override, or remove safeties, either temporarily or permanently. Do not modify systems to operate equipment at a higher pressure than specified. Never operate the machine in an enclosed area

11 3. Safety Precautions (continued) Safety Read and understand this manual and all other safety instructions before using this equipment. Failure to follow operating instructions and/or failure to follow maintenance procedures and intervals could result in personal injury, death, and/or damage to equipment and property. Use only Boss Industries, Inc. approved replacement parts. Never place machine on a grade more than 5 degrees. Keep doors closed on the machine during operation. Check engine s operator manual for required service and maintenance intervals

12 3.3 Safety and Information Decals Safety This machine is supplied with a full complement of safety and identification decals. These decals are affixed to the unit during final assembly. These decals must be clearly visible and undamaged. Should any of these decals become illegible or damaged, immediately replace the decal. Hot Exhaust Pressurized System Hot Pressurized Oil Electrical Shock Close Doors Oil Level

13 Safety 3.3 Safety and Information Decals (continued) Overfill Negative Ground System Hot Coolant Compressor Oil Serial Tag Breathing Air

14 4. Specification Sheet Specifications 00 5 PSI COMPRESSOR INPUT SPEED Compressor Airend CFM HP CFM HP RPM SCA0G with 3.05 Gear Ratio ENGINE 80 HP DEERE 4045 TIER 3 ENGINE ELECTRICAL SYSTEM BASE DIMENSIONS Machine Duty Ambient Cycle Operating Angle Conditions V DC 89 /4" X 30" X 73 5 maximu m Continuou s -40 F to 5 F 3/8" *SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE*

15 Description of Components 5.Engine The 0 DUS Air Compressor contains a John Deere, 4 cylinder diesel engine. This engine has been selected to handle the rugged duty required for its operation. The engine speed is regulated by a pneumatic throttle control. 5.Drive Coupling Power from the engine is transmitted to the compressor input shaft through a specially designed drive coupling. The drive coupling consists of a highly torsionally flexible rubber disc that mates with an engine flywheel flange. The coupling provides a torque limitation to protect from system overloads. 5.3 Compressor Airend The Boss Industries, Inc. compressor airend is a positive displacement, oil flooded, rotary screw type unit employing one stage of compression to achieve the desired pressure. Components include a housing (stator), two screws (rotors), bearings, and bearing supports. Power from the engine flywheel is transferred through a gear set to the male rotor. The female rotor is driven by the male rotor. There are five lobes on the male rotor while the female rotor has six roots. In operation, two helical grooved rotors mesh to compress air. Inlet air is trapped as the male lobes roll down the female grooves, pushing trapped air along, compressing it until it reaches the discharge port at the end of the stator and delivers smooth-flowing, pulse-free air. Being an oil flooded system, the oil serves three purposes: lubricates the rotating parts and bearings, serves as a cooling agent for the compressed air, and seals the running clearances. 5.4 Separator System I. Separator Tank From the compressor airend, the compressed air and hot oil flow into a steel, ASME coded, pressure vessel, rated at 50 PSI, that acts as an oil reservoir. This tank is the first of two stages in separating the oil and compressed air mixture. From the bottom of the separator tank, oil is forced to the oil filter. II. Separator Element At the top of the separator tank is the separator element. The separator element removes the oil mist from the air as it is passed on to the minimum pressure valve. As the air/oil mist passes through the outside of the media, oil gathers on the interior walls and settles to the bottom of the element. Collected oil is returned to the compressor airend through the oil return line. The separator will filter the oil concentration in the air to less than 3 parts per million

16 5.5 Pressure Relief Valve Description of Components This valve vents separator tank pressure to atmosphere should the pressure inside the tank exceed 70 PSI. 5.6 Engine Air Filter The engine air filter is a two stage, dry type intake filter with a gravity evacuator and replaceable internal element. On the outlet of the engine air filter is an air filter restriction indicator. This indicator serves as a maintenance tool. 5.7 Compressor Air Filter The compressor air filter is a two stage dry type intake filter with a gravity evacuator and replaceable internal element. On the outlet of the compressor air filter is an air filter restriction indicator. This indicator serves as a maintenance tool. 5.8 Cooling Systems I. Engine Radiator The radiator is designed to dissipate the heat load of the engine and is mounted in front of the specially selected engine fan. Hot engine coolant is passed through the interior of the radiator and heat is transferred to the air that passes across the cooling fins. II. Compressor Oil Cooler The compressor oil cooler is designed to dissipate the heat created during the compression of air. The oil cooler is mounted behind to the engine radiator. This works similar to the engine radiator but is designed to withstand the full compressor system working pressure of 60 PSI. 5.9 Compressor Oil Filter The compressor oil filter is a full flow, spin-on canister. It has been specially designed to handle the full system pressure of 60 PSI. The oil filter is mounted downstream of the separator tank to ensure all contaminants are prevented from being passed on to the compressor oil cooler. 5.0 Compressor Oil Thermal Valve The compressor oil thermal valve is a thermostatically controlled by-pass valve that allows varying amounts of oil, depending upon the temperature, to by-pass the oil cooler. The oil thermal valve directs oil flow back to the compressor airend until the system reaches 70 F. Once at system operating temperature, the valve shifts directing the flow through the oil cooler before returning to the compressor airend

17 5. Compressor Inlet Valve Description of Components The compressor inlet valve is a normally open air intake valve bolted to the compressor airend. When the system is shut down, this valve also acts as a check valve that prevents the air/oil mixture within the compressor airend from entering the inlet piping. 5. Minimum Pressure Valve To ensure there is adequate pressure to produce proper oil flow throughout the system, a spring loaded, normally closed minimum pressure valve is set to maintain at least 80 PSI in the separator tank. 5.3 Blowdown Valve The blowdown valve is a shuttle valve that vents system pressure to atmosphere when the system is shut down. This is done to prevent the high torque load that would be required to overcome the static pressure. The blowdown valve is stamped with an I and a P. The I side is connected to dry air from the separator tank, and the P side is the pilot signal coming from the compressor inlet valve. 5.4 Discharge Pressure Regulator Valve This valve, located downstream of the separator element, is used to set the desired discharge pressure. This valve will send a pneumatic signal to the inlet valve to start closing when the pressure excessed the setpoint. This signal will also adjust the speed of the engine. This system has a maximum operating pressure of 60 PSI. 5.5 Instrument Panel Most air tools operating pressure range is between 90 and 5 PSI. Operating above the tools recommended pressures will decrease the life of the tool. Strictly adhere to tool operating pressures and torque standards set forth by the tool manufacturer. The 0 DUS Air Compressor incorporates a digital control panel that monitors numerous gauges. I. Engine Oil Pressure Gauge This feature displays the oil pressure inside the engine block. When the pressure drops below 0 PSI, the system will shut down. During operation, the engine oil pressure should be approximately 60 PSI to 80 PSI. II. Engine Coolant Temperature Gauge This feature displays the temperature of the engine coolant. When the temperature reaches 35 F, the system will shut down. During operation, the temperature should be approximately 90 F to 0 F

18 5.5 Instrument Panel (continued) Description of Components III. Compressor Discharge Pressure Gauge This feature displays the pressure downstream of the airend. When the pressure reaches 45 PSI, the system will shut down. IV. Compressor Discharge Temperature Gauge This feature displays the compressor discharge temperature. When the temperature reaches 45 F, the system will shut down. During operation, the discharge temperature should be approximately 70 F to 90 F. V. Hourmeter The hourmeter records the total number of operating hours. It serves as a guide in following the recommended maintenance schedule. The hourmeter will only run when the engine is operating. VI. Voltmeter This feature displays the voltage of the battery. The voltmeter will only display when the ignition switch is in the RUN position. During operation, the voltmeter should be approximately 4 VDC

19 Installation 6. System Installation Overview The 0 DUS Air Compressor should be installed only by those who have been delegated to do so, trained, and who have read and understand this manual. Failure to follow the instructions, procedures, and safety precautions in this manual may result in accidents and injuries. Install, use, and operate this system only in full compliance with all pertinent O.S.H.A., Federal, State, and Local codes or requirements, in addition to Boss Industries, Inc. and any company s regulations. Do not modify this system except with written factory approval. 6. Placing The Machine The first step in installing the 0 DUS Air Compressor is placing the system on a solid, level surface. This machine is designed to run at up to a 5 grade maximum. The machine must be supplied ample ambient air, as the system will overheat if the cooling air intake s temperature exceeds ambient conditions. 6.3 Connecting the System Fuel Supply " MNPT AIR DISCHARGE Connect the fuel supply line to the /4 tube port on the starter side of the engine. Connect the fuel return line to the 5/6 tube port, near the air inlet side of the turbo. Both tubes need to be SAE 30R7 rated fuel lines. Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free from dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and the injection nozzle

20 Installation Use ASTM No. D fuel with a minimum cetane number of 40. No. diesel fuel gives the best economy and performance under most operating conditions. See engine manufactures operators/instruction manual for the proper engine fuel for the brand engine in your Boss Industries, Inc. Air Compressor. Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion. 6.4 Fuel Specifications I. High Altitude and Low Temperature Fuels Fuels with cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent misfires and excessive smoke. II. Cold Weather Fuel At operating temperatures below 3 degrees F, use a blend of No. D and No. D fuels, also known as Winterized No. D. Use a low sulfur content fuel having a cloud point that is at least 0 degrees below the lowest excepted fuel temperature. Cloud point is the temperature at which wax crystals begin to form in diesel fuel. The viscosity of the fuel must be kept above.3 centistoke to provide adequate fuel system lubrication. No. D fuel can be used; however, fuel economy will suffer. 6.5 Connecting the Air Discharge Lines Connect the customer supplied air discharge line, designed to handle a minimum of 00 PSI continuously, to the MNPT air discharge port. 6.6 Pre-Startup Inspection This inspection must be done prior to initial system startup. I. Check all assemblies, clamps, fittings, hose connections, nuts, and bolts to ensure they are properly tied and secured. II. Remove all tools, rags, and installation equipment from the area. III. Check the air discharge valve is closed

21 6.7 Machine Documentation Installation Record serial numbers for main components in the system. I. Machine Serial Number II. Compressor Airend Serial Number III. Engine Serial Number IV. Separator Tank Serial Number 6.8 Check Fluid Levels The machine is factory filled prior to shipment. The proper fluid levels are also listed in the maintenance section. I. Separator Tank Oil Level = Halfway on the separator tank sightglass. II. Engine Radiator Coolant Level = Bottom of the radiator fill neck. III. Engine Coolant Recovery Bottle = Fill to the cold line. IV. Engine Crankcase Oil Level = Full on the dipstick. 6.9 Initial Startup Preparation I. Reconnect battery terminals. Ensure the red cable is connected to the battery s positive terminal, and the black cable is connected to the battery s negative terminal. II. Check the system for fuel, oil, and/or coolant leaks. HOURMETER ANNUNCIATOR PANEL ENGINE COOLANT TEMPERATURE ENGINE OIL PRESSURE COMPRESSOR DISCHARGE TEMPERATURE COMPRESSOR DISCHARGE PRESSURE VOLTMETER HIGH SPEED OVERRIDE TOGGLE SWITCH LOAD/UNLOAD TOGGLE SWITCH IGNITION SWITCH

22 6.0 Safety Shutdown Verification Installation I. Turn the ignition switch to the RUN position. II. Touch the Engine Coolant Temperature switch gauge adjustment screw to the bezel with a screw driver. Do this within the first 0 seconds of turning the ignition switch to the RUN position. By doing this, the corresponding indicator on the annuciator panel will illuminate. If the light does not come on, verify the mating harnesses are connected properly. The annuciator panel is equipped with a by-pass timer at startup for the Engine Oil Pressure safety shutdown. III. Press the RESET button on the annuciator panel. The indicator light for Engine Coolant Temperature will turn off. IV. Turn the ignition switch to the OFF position. This will reset the bypass timer. V. Repeat these steps for the rest of the switch gauges: A. Compressor Discharge Temperature B. Compressor Discharge Pressure C. Engine Coolant Temperature VI. For the Engine Oil Pressure switch gauge, just let the by-pass timer run out. 6. Initial Startup At this point the system is ready to test for functionality. Be sure to have completed all of the previous steps prior to continuing. I. Flip the load/unload toggle switch to UNLOAD. II. Turn the ignition switch to the START position. If engine fails to start, DO NOT attempt to restart until cranking motor stops rotating and the separator tank has blown down. III. When engine starts, release the ignition switch. Maintain the load/unload toggle switch in the UNLOAD position until the engine is warm and operating smoothly, then flip the switch to LOAD. IV. Check system for leaks. V. Allow system to run until engine coolant temperature reaches 90 F. VI. Check for leaks again. VII. Verify the engine speed is 800 RPM. VIII. Open the air discharge valve and verify the speed increases to 400 RPM. IX. Close the service valve. X. Flip the load/unload toggle switch to UNLOAD. XI. Flip the high speed override toggle switch to HIGH SPEED. XII. Verify the speed increases to 400 RPM. XIII. Flip the high speed override toggle switch to OFF. XIV. Allow engine to idle for a few minutes. XV. Turn the ignition switch to the OFF position. XVI. Initial startup testing is complete

23 7. Routine Operating Procedures Operation The 0 DUS Air Compressor should only be operated by those who have been delegated to do so, trained, and who have read and understand this manual. Failure to follow the instructions, procedures, and safety precautions in this manual may result in accidents and injuries. Operate this system only in full compliance with all pertinent O.S.H.A., Federal, State, and Local codes or requirements, in addition to Boss Industries, Inc. and any company s regulations. I. Routine Startup Preparation A. Verify fluid levels and refill if necessary. B. Check engine air filter s indicator, element, clamps, and hoses. C. Check compressor air filter s indicator, element, clamps, and hoses. D. Check battery cable connections for corrosion. E. Check the condition of the engine fan belt. F. Check for fuel, oil, and/or coolant leaks. G. Test the shutdown function for each switchgauge. II. Routine Startup Procedure A. Flip the load/unload toggle switch to UNLOAD. B. Turn the ignition switch to the START position. If engine fails to start, DO NOT attempt to restart until cranking motor stops rotating and the separator tank has blown down. C. When engine starts, release the ignition switch. Maintain the load/unload toggle switch in the UNLOAD position until the engine is warm and operating smoothly, then flip the switch to LOAD. D. Check system for leaks. E. Allow system to run until engine coolant temperature reaches 90 F. F. Check for leaks again. G. Open the air discharge valve. III. Routine Shutdown Procedure A. Close service valves. B. Flip the load/unload toggle switch to UNLOAD. C. Allow engine to idle for a few minutes. D. Turn the ignition switch to the OFF position. Shutting down the machine under load will damage the engine, drive coupling, and/or the airend. Follow normal shutdown procedure at all times

24 7. Emergency Shutdown Procedure Operation In the event of an emergency and the 0 DUS Air Compressor must be stopped suddenly without first unloading the compressor, the machine s ignition switch can be used. Do not shut the machine off loaded except in an emergency situation. Do not operate this machine again until the problem has been properly resolved. I. Emergency Shutdown Procedure A. Turn the ignition switch to Off. B. Correct source of emergency situation prior to operating this machine again. Shutting down the machine under load will damage the engine, drive coupling, and/or the airend. Follow normal shutdown procedure at all times

25 Maintenance 8. Maintenance Overview This section contains instructions for performing the inspection, lubrication, and maintenance procedures required to ensure the system is in proper operating condition. The importance of performing the maintenance described herein cannot be over emphasized. A planned program of periodic inspection and maintenance will help avoid premature failure and costly repairs. Keep an accurate logbook for maintenance, service, and operating hours. The maintenance schedule intervals on this system are maximum intervals. The factory recommended maintenance schedule is based on favorable operating conditions. For continuous duty, extreme temperature, etc., service more frequently. Neglecting routine maintenance can result in machine failure or permanent damage. This system should be maintained only by those who have been delegated to do so, trained, and who have read and understand this manual. Failure to follow the instructions, procedures, and safety precautions in this manual may result in accidents and injuries. 8. Maintenance Schedule INTERVAL EVERY 0 HOURS OR DAILY EVERY 50 HOURS OR WEEKLY EVERY 500 HOURS OR 6 MONTHS EVERY 000 HOURS OR YEAR REQUIRED MAINTENANCE. Check separator tank oil level.. Check engine coolant level in coolant recovery bottle. 3. Check engine air filter maintenance indicator. 4. Check for fuel, oil, air, and coolant leaks. 5. Check compressor air filter maintenance indicator 6. Check battery hold down for security.. Drain water from separator tank. More frequent draining may be required under high humidity conditions.. Inspect lifting frame.. Change compressor oil and oil filter element.. Clean battery terminals 3. Check battery hold-down and cables for wear. 4. Check engine air filter connections, fittings, and clamps. 5. Check compressor air filter connections, fittings, and clamps 6. Check radiator hoses and clamps. 7. Check integrity of engine mounts.. Install new air filter elements. (compressor and engine). Check all door gaskets, hinges, and latches. 3. Clean and flush engine cooling system 4. Check separator tank pressure relief valve. 5. Clean cooler fins on all coolers. 6. Install new fuel filter

26 Maintenance Compressor oil and oil filter is to be changed after the first 50 hours of operation. After this, normal intervals are to be followed. Check engine s operator manual for required service and maintenance intervals. 8.3 Recommended Spare Parts List KIT NUMBER PART NUMBER DESCRIPTIO N Compressor Oil Filte r Separator Elemen t Engine & Compressor Air Filter Element SCA0G Shaft Seal Repair Kit 8.4 Parts and Service Contact Information Phone: (800) (USA) Phone: (9) (Outside USA) Fax: (877) service@bossair.com Website:

27 Maintenance 8.5 Maintenance Log Accum. Hours Date Service Performed Parts Replaced Service Work By

28 8.6 Separator Element Replacement Maintenance When the oil vapor in the discharge air becomes excessive, the separator element may need replacing. This should not be necessary more than once a year under normal operating conditions. I. Replacement Procedure. A. Shut down machine and allow to cool for approximately 0 minutes. B. Verify entire system pressure is relieved before proceeding. C. Disconnect the hose from the minimum pressure valve. D. Disconnect the /4 tube from the straight connector on normally open (N.O.) solenoid valve. E. Disconnect the /4 tube from the tee on the discharge pressure regulator valve. F. Disconnect the /4 tube from the elbow on the blowdown valve. G. Disconnect the /4 tube from the elbow on the oil return line. H. Remove the eight 5/8 bolts holding the separator tank lid in place. I. Lift and remove the lid from the package. J. Remove the separator element. When disconnecting hose and tube, be sure to note the location to ensure there is no confusion when reconnecting. Note the location of the separator tank lid so that it can be reinstalled in the same orientation. The separator tank lid has a pick-up tube installed and damaging or moving the tube will affect the machines Substitute filters may have inadequate working pressure limits, resulting in filter leakage or rupture. Replacement filters must be the same quality and type as the original Boss Industries, Inc. separator element. The separator element flange must have a gasket on each side to seal the lid on one side and the vessel on the other. The staple in each gasket acts as a static ground and must not be removed. K. Install a new element. L. Reinstall the separator tank lid. M. Reinstall the eight 5/8 bolts. N. Uniformly tighten the bolts in a crisscross pattern to a torque to 0ft-lb. O. Reconnect hose and tubes and ensure they are correctly located and tightened properly. P. Start machine and check for any leaks

29 8.7 Engine Air Filter Replacement Maintenance I. Loosen the clamp that secure the engine air filter s rear cover to the filter housing. II. Remove and clean the rear cover. III. Remove the air filter element. IV. Clean the canister with a damp cloth inside and out. DO NOT blow dirt out with compressed air. V. Prior to cleaning an element, check the element for damage. Damaged air filter elements must be replaced. A. Place a bright light inside the element to inspect for damages or leaks. B. Inspect all seals and seal contact surfaces on the housing. Should faulty seals be evident, correct the condition immediately. VI. If element is undamaged, clean the air filter element. Never blow dirt out of the interior of the filter housing. This may introduce dust downstream of the filter. Instead, use a clean damp cloth. A. The maximum amount of times that an element should be cleaned is times; however, the element should be used no longer than a period of year without changing. Do not strike the element against any hard surfaces for cleaning as it may possibly rupture the element. Do not oil element. B. When cleaning the element with compressed air, never let the air pressure exceed 30 PSI. Reverse flush the element by directing the compressed air up and down the pleats in the filter media from the inside of the element. Continue reverse flushing until all dust is removed. Should any oil or greasy dirt remain on the filter surface, the element should be replaced. When cleaning an element, the element will be damaged if you exceed the recommended maximum air pressure of 30 PSI. C. If the cleaned element is to be stored for later use, it must be stored in a clean container. VII. Install the air filter element. VIII. Install the rear cover and tighten clamp. IX. Reset the air filter restriction indicator and the machine will be ready for operation

30 8.8 Compressor Air Filter Replacement Maintenance I. Loosen the wing nut that secures the compressor air filter s cover to the filter housing. II. Remove and clean the cover. III. Remove the air filter element. IV. Clean the canister with a damp cloth inside and out. DO NOT blow dirt out with compressed air. V. Prior to cleaning an element, check the element for damage. Damaged air filter elements must be replaced. A. Place a bright light inside the element to inspect for damages or leaks. B. Inspect all seals and seal contact surfaces on the housing. Should faulty seals be evident, correct the condition immediately. VI. If element is undamaged, clean the air filter element. Never blow dirt out of the interior of the filter housing. This may introduce dust downstream of the filter. Instead, use a clean damp cloth. A. The maximum amount of times that an element should be cleaned is times; however, the element should be used no longer than a period of year without changing. Do not strike the element against any hard surfaces for cleaning as it may possibly rupture the element. Do not oil element. B. When cleaning the element with compressed air, never let the air pressure exceed 30 PSI. Reverse flush the element by directing the compressed air up and down the pleats in the filter media from the inside of the element. Continue reverse flushing until all dust is removed. Should any oil or greasy dirt remain on the filter surface, the element should be replaced. When cleaning an element, the element will be damaged if you exceed the recommended maximum air pressure of 30 PSI. C. If the cleaned element is to be stored for later use, it must be stored in a clean container. VII. Install the air filter element. VIII. Install the rear cover and tighten clamps. Install rubber evacuator cup down. IX. Reset the air filter restriction indicator and the machine will be ready for operation

31 Maintenance 8.9 Compressor Oil It is important that the compressor oil be of a recommended type, inspected and replaced as started in this manual. The combination of a separator element loaded with dirt and oxidized oil products together with increased air velocity as a result of this clogged conditions may produce a critical point while the machine is in operation where ignition can take place and could cause a fire in the separator tank. The following are general characteristics for a rotary screw lubricant. Due to the impossibility of establishing limits on all physical and chemical properties of lubricants which can affect their performance in the compressor over a broad range of environmental influences, the responsibility for recommending and consistently furnishing a suitable heavy duty lubricant must rest with the individual supplier if they choose not to use the recommended Boss Industries, Inc. rotary screw lubricant. The lubricant supplier s recommendation must, therefore, be based upon not only the following general characteristics, but also upon his own knowledge of the suitability of the recommended lubricant in helical screw type air compressors operating in the particular environment involved. Boss Recommended Compressor Lubricant: DEXRON III ATF I. Specifications. Flash point 400 F minimum.. Pour point -40 F. 3. Contains rust and corrosion inhibitors. 4. Contains foam suppressors. 5. Contains oxidation stabilizer. Mixing different types or brands of lubricants is not recommended due to the possibility of a dilution of the additives or a reaction between additives or different types. Due to environmental factors, the useful life of all extended life lubricants may be shorter than quoted by the lubricant supplier. Boss Industries, Inc. encourages the user to closely monitor the lubricant condition and to participate in an oil analysis program with the supplier. No lubricant, however good and/or expensive, can replace proper maintenance and attention. Select and use it wisely

32 Maintenance 8.9 Compressor Oil (continued) II. Adding Compressor Oil A. Verify the machine is level to assure oil level in sightglass will be accurate. B. Remove any dirt around the separator tank fill cap to prevent contamination from entering the system. Do not remove caps, plugs, or other components when the system is running or pressurized. Stop system and relieve all internal pressure before doing so. Failure to comply with this warning will cause damage to property and serious bodily harm. C. Remove the separator tank fill cap. D. Inspect and clean the fill cap. Replace if necessary. E. Dexron III ATF can then be added until the oil level reaches halfway in the sightglass. Do not over fill the separator tank. This will cause oil carryover in the discharge line and at blowdown. Do not replace fill cap with a pipe cap; serious injury or damage could result. Replacement filters must be the same quality and type as the original Boss Industries, Inc. fill cap. F. Replace fill cap and tighten immediately. III. Changing Compressor Oil Initially the compressor oil and oil filter should be replaced after the first 50 hours of operation then every 500 hours or 6 months. If the oil appears dirty or has a foul smell, it should be replaced immediately. A. Verify the machine is level to assure oil level sightglass will be accurate. B. Remove any dirt around the separator tank fill cap to prevent contamination from entering the system. Do not remove caps, plugs, or other components when the system is running or pressurized. Stop system and relieve all internal pressure before doing so. Failure to comply with this warning will cause damage to property and serious bodily harm. C. Remove the separator tank fill cap. D. Inspect and clean the fill cap. Replace if necessary. E. Drain oil from the bottom of the separator tank. F. If compressor oil filter change is required, proceed to section 8., Compressor Oil Filter

33 Maintenance 8.9 Compressor Oil (continued) III. Changing Compressor Oil (continued) G. Dexron III ATF can now be added until the oil level reaches halfway in the sightglass. Do not over fill the separator tank. This will cause oil carryover in the discharge line and at blowdown. H. Replace fill cap and tighten immediately. I. Run system briefly to see if more oil needs to be added and to ensure there are no leaks. 8.0 Compressor Oil Cooler 8. Compressor Oil Filter Initially the filter should be replaced after the first 50 hours of operation, then every 500 hours or 6 months. A dirty filter can restrict oil flow, causing high oil temperature, which will result in a system shutdown. I. Compressor Oil Filter Replacement A. Verify the compressor oil system is drained. B. Using a strap wrench, remove the oil filter and o-ring. C. Clean o-ring seating surface on the oil filter head. Do not replace fill cap with a pipe cap; serious injury or damage could result. Replacement filters must be the same quality and type as the original Boss Industries, Inc. fill cap. Any sign of leakage from the compressor oil cooler justifies a pressure test to assure its integrity. Cooler leaks should only be repaired by qualified service technicians. Dirt that clogs the cooling fins of the cooler should be removed. The use of an air stream or high-pressure steam cleaner should be done with caution so as to not damage the delicate fins. Bent cooling fins will reduce the cooling capability of the compressor oil cooler. Substitute filters may have inadequate working pressure limits, resulting in filter leakage or rupture. Replacement filters must be the same quality and type as the original Boss Industries, Inc. oil filter. D. Apply a light film of oil to the new o-ring. E. Hand tighten new filter until o-ring is seated in o-ring groove. Mechanical over-tightening may distort the threads or damage the filter element seal. F. Continue tightening filter by hand an additional / to 3/4 turn. G. Continue with Changing the Compressor Oil steps

34 8. Engine Cooling System Maintenance Maintenance The 0 DUS Air Compressor s engine has a pressurized cooling system that contains a 50/50 mixture of water and ethylene glycol. Maintenance of the system includes the engine coolant, belt tension, fan integrity, and radiator. Further cooling system maintenance is defined in the engine manual. I. Engine Coolant A. Specifications This natural gas engine requires a balanced coolant mixture of water and ethylene glycol base antifreeze. This protects the engine cooling system from corrosion as well as freezing damage. The 0 DUS Air Compressor is shipped from the factory with a 50/50 mixture of water and ethylene glycol. In tropical climates where freeze protection is not required, glycol engine coolant should still be used to help prevent corrosion and pitting of cylinder liners. B. Mixtures Antifreeze concentration level should not exceed recommended levels. To do so can cause cooling system failure.. A mixture of 50% antifreeze and 50% water is required for temperatures above -34 F.. A mixture of 60% antifreeze and 40% water is required for temperatures below -34 F. This provides protection to -65 F. 3. Never exceed a 60% overall antifreeze mix. C. Coolant Level Before each start-up, when radiator is cold, the coolant level should be checked. When needed, refill with a 50/50 solution of water and ethylene glycol, DO NOT use 00% antifreeze. The proper level for coolant in the system is to the bottom of the radiator fill neck and to the cold line of the recovery bottle. Check the coolant level only when the engine is stopped and the temperature is below 60 F. Failure to do so can cause personal injury from heated coolant spray. II. Engine Radiator A. Radiator Core Any sign of leakage from the engine radiator may justify a pressure test to assure its integrity. Radiator leaks should only be repaired by qualified service technicians. Dirt that clogs the cooling fins of the radiator should be removed. The use of an air stream or high-pressure steam cleaner should be done with caution so as to not damage the delicate fins. Bent cooling fins will reduce the cooling capability of the radiator

35 II. Engine Radiator (continued) 8.3 Battery Maintenance 8. Engine Cooling System Maintenance (continued) B. Radiator Pressure Cap If coolant continually spills from radiator through the overflow, the radiator cap should be tested and/or replaced with a 3 PSI rated cap. Be sure cap is tightened to the proper secure position. III. Engine Fan Check the engine fan for cracks, loose bolts, and bent or damaged blades. Replace damaged fans immediately. Do not run system if any of the conditions exist. Make sure the hex head bolts mounting the fan to the water pump pulley are properly torqued to 9 ft-lbs. Never use the fan to rotate the engine. The blade(s) can be damaged causing a fan failure, which can result in personal injury or property damage. IV. Engine Serpentine Belt Visually inspect the engine serpentine belt. Replace belt if cracked or frayed. Check engine manual for proper belt tension. The battery supplied with the 0 DUS Air Compressor has been selected to have ample cold cranking amperes for quick starts in cold weather. Keep the battery fully charged and if replacement is necessary the new battery must be of equal or greater capacity. Battery gas can explode causing acid burn to skin and blindness. Do not overcharge or jump the battery incorrectly. 8.4 Standby Pressure Adjustment (For 0 PSI system) A. Close all service valves. B. Start the machine. C. Allow the engine to warm up. D. The air pressure will build to 5 PSIG. E. If the air pressure is less than 5 PSIG.. Adjust the discharge pressure regulator up by loosing the locknut.. Turning the adjusting screw clockwise. F. If the air pressure is greater than 5 PSIG.. Adjust the discharge pressure regulator up by loosing the locknut.. Turning the adjusting screw counter-clockwise. G. After the air pressure is set, tighten the locknut

36 Maintenance 8.5 Idle Speed Adjustment If your unit is rated at a higher pressure, add 0 PSI to the working pressure for unload pressure: 00 PSI working = 0 PSI standby. If engine speed is below 800 RPM, contact Boss Industries, Inc. s service department for further assistance. 8.6 Rated Speed Adjustment I. Flip the load/unload toggle switch to UNLOAD. II. Turn the ignition switch to the START position. If engine fails to start, DO NOT attempt to restart until cranking motor stops rotating and the separator tank has blown down. III. When engine starts, release the ignition switch. Maintain the load/unload toggle switch in the UNLOAD position until the engine is warm and operating smoothly, then flip the switch to LOAD. IV. Allow system to run until engine coolant temperature reaches 90 F. V. Open the air discharge valve until the discharge pressure gauge reads the desired working pressure. Verify that air is not bleeding out of the bottom of the discharge pressure regulator. If air is bleeding out, the standby pressure is set to high. Follow the steps in section 8.4 for reducing the standby pressure. VI. Loosen the adjustment locknut on the adjustment screw towards the front of the engine. VII. Turn the adjustment screw clockwise to increase the speed. VIII. Turn the adjustment screw counter-clockwise to decrease the speed. IX. If the proper speed cannot be obtained with the adjustment screw, it may require loosing the locknut on the air cylinder shaft and adjusting the clevis. X. By turning the clevis onto the shaft, the engine speed will increase. XI. By turning the clevis out, the engine speed will decrease. XII. After proper speed is set, tighten all locknuts. XIII. Close service valve and allow compressor to unload and the engine to return to idle. Adjustment Screw Air Cylinder Clevis Locknut DISCHARGE PRESSURE REGULATOR BLEED HOLE Adjustment Locknut

37 9. Troubleshooting Chart SYMPTOM Troubleshooting CAUSE REMEDY Faulty battery connections. Check the battery terminals for tightness and corrosion. L ow battery voltage. Charge or replace the battery. Machine will not crank F aulty ignition switch. Replace the switch. Starter solenoid connections are loose or corroded. Clean and tighten connections. Machine cranks, but will not start Faulty starter solenoid or starter. No fuel. Air in the fuel system. Fuel solenoid inoperative. Out of fuel. Repair or replace the faulty components. Add fuel. If unit has run out of fuel it may be necessary to prime the fuel system. a. Check fuel line connections and tighten or repair. b. Prime the fuel system. a. While cranking the engine; check for voltage at the solenoid. b. Check safety switch gauges. Add fuel. If unit has run out of fuel it may be necessary to prime the fuel system. F uel filter restricted. Change fuel filter. Machine shuts down with air demand present Safety shutdown activated. a. Low engine coolant shutdown; add coolant. b. High engine coolant/discharge temperature shutdown; clean radiator/oil cooler fins. c. Fan belt slipping or broken; repair or replace. d. e. Compressor oil level low; add oil. Engine oil level low; add oil

38 9. Troubleshooting Chart (continued) Troubleshooting SYMPTOM CAUSE REMEDY Machine shuts down with air demand present (continued) f. Compressor oil filter restricted; change the filter. Safety shutdown activated. (continued) g. Engine oil filter restricted; change filter. D efective safety shutdown gauge. Check the shutdown gauge. Thermostatic valve malfunctioning. Clean or element. replace the thermostatic D efective gauge. Replacethe gauge. Machine will not build up pressure Air demand too great. Blowdown valve open. Check service lines for leaks or open valves. a. Check to see if the blowdown valve is getting a pilot signal. b. Repair or service vlave. F aulty drive coupling. Replace the coupling. With no demand, the compressor builds excessive pressure D efective gauge. Replace the gauge. Discharge pressure regulator not a. Adjust the regulator. properly adjusted or faulty. b. Repair or replace the regulator. Compressor undersized for the air requirement. Recheck maximum air requirement. E ngine speed low. Check speed and adjust as necessary. Insufficient air delivery Air intake restricted. a. Check air filter for dirt and make sure the indicator is working. b. Look for obstructions in the filter and inlet piping. c. Check that the inlet valve is opening fully. Faulty drive coupling. F aulty drive coupling. Replace the coupling