Table of Contents
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Service and
Maintenance
This manual must be read carefully before using your Boss Industries, Inc. Air Com-
pressor. Store in a safe and convenient location for future reference.
For technical support:
Phone: (800) 635-6587 (USA)
Phone: (219) 324-7776 (Outside USA)
Fax: (877) 254-4249 (USA)
Email: service@bossair.com
Website: http://www.bossair.com
Manual
210 DUS JD4045
IT4 74HP
Air Compressor
309416
05-03-2013 ARB
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Table of Contents
Related Manuals for Boss 210 DUS JD4045
Summary of Contents for Boss 210 DUS JD4045
- Page 1 Maintenance IT4 74HP Manual Air Compressor This manual must be read carefully before using your Boss Industries, Inc. Air Com- pressor. Store in a safe and convenient location for future reference. For technical support: Phone: (800) 635-6587 (USA) Phone: (219) 324-7776 (Outside USA) Fax: (877) 254-4249 (USA) Email: service@bossair.com...
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Page 3: Table Of Contents
Contents Manual Change History....................7 1.1 Revision List....................7 Welcome........................8 2.1 General Information..................8 2.2 Overview ......................8 Safety........................9-13 3.1 General Safety Overview...................9 3.2 Safety Precautions..................10 3.3 Safety and Information Decals................12 Specifications......................14 4.1 Specification Sheet..................14 Description of Components................15-18 5.1 Engine......................15 5.2 Drive Coupling....................15 5.3 Compressor Airend..................15 5.4 Separator System..................15 Separator Tank..................15 Separator Element..................15... - Page 4 Contents Description of Components (continued)............15-18 5.15 Instrument Panel (continued)..............18 Hourmeter..................18 Tachometer..................18 Voltmeter.................18 Unloader Valve...................18 Emergency Stop Switch................18 Bypass Switch...................18 Ignition Switch...................18 Installation.....................19-23 6.1 System Installation Overview................19 6.2 Placing the Machine..................19 6.3 Connecting the System Fuel Supply..............19 6.4 Fuel Specifications..................20 High Altitude and Low Temperature Fuel............20 Cold Weather Fuel..................20 6.5 Connecting the Air Discharge Lines...............20 6.6 Pre-Startup Inspection .................20...
- Page 5 Contents Maintenance (continued)..................25-36 8.6 Separator Element Replacement..............28 8.7 Engine Air Filter Replacement................29 8.8 Compressor Air Filter Replacement..............30 8.9 Compressor Oil....................31 Specifications..................31 Adding Compressor Oil................32 Changing Compressor Oil................32 8.10 Compressor Oil Cooler.................33 8.11 Compressor Oil Filter..................33 8.12 Engine Cooling System Maintenance..............34 Engine Coolant...................34 Engine Radiator..................34 Engine Fan....................35...
- Page 6 Contents Parts and Illustration Section (continued)............46-63 11.5 Cooling System..................54 11.6 Electrical System..................56 11.7 Canopy System..................58 11.8 Decal System....................60 11.9 Hose System..................62 11.10 System Wiring Diagram................63 309416 01/31/2012...
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Page 7: Manual Change History
Manual Change History 1.1 Revision List 309416 01/31/2012... -
Page 8: Welcome
Inc. strives to continually improve the efficiency and performance of its machines. As a result, sometimes there may be slight differences This manual must be read carefully before using your Boss Industries, Inc. Air Com- between a given version of the manual and the machine. -
Page 9: Safety
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. -
Page 10: Safety Precautions
Safety 3.2 Safety Precautions 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. - Page 11 Use only Boss Industries, Inc. approved replacement parts. Never place machine on a grade more than 15 degrees.
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Page 12: Safety And Information Decals
Safety 3.3 Safety and Information Decals 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... -
Page 13: Safety
Safety 3.3 Safety and Information Decals (continued) Hot Coolant Overfill Negative Ground System Compressor Oil Serial Tag Breathing Air 309416 01/31/2012... -
Page 14: Specifications
Specifications 4.1 Specification Sheet h t i o i t " 8 " 0 " 2 " 8 " 0 " 5 ° 5 n i t F ° F ° *SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE* 66.77 48.07 78.00 30.00 84.55... -
Page 15: Description Of Components
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. -
Page 16: Pressure Relief Valve
Description of Components 5.5 Pressure Relief Valve This valve vents separator tank pressure to atmosphere should the pressure inside the tank exceed 200 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. -
Page 17: Compressor Inlet Valve
Description of Components 5.11 Compressor Inlet Valve 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. -
Page 18: Instrument Panel
Description of Components 5.16 Instrument Panel The 210 DUS Air Compressor incorporates an instrument panel that includes numerous gauges and controls in a single, easy to access location. I. Engine Oil Pressure Gauge This feature displays the oil pressure inside the engine block. When the pressure drops below 20 PSI, the system will shut down. -
Page 19: Installation
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. -
Page 20: Fuel Specifications
See engine manufactures operators/instruction manual for the proper engine fuel for the brand engine in your Boss Industries, Inc. Air Compressor. No. 1D fuel can be used; however, fuel economy will suffer. 6.5 Connecting the Air Discharge Lines Connect the customer supplied air discharge lines, designed to handle a minimum of 200 PSI continu- ously, to the two 3/4”... -
Page 21: Machine Documentation
Installation 6.7 Machine Documentation 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. -
Page 22: Initial Startup
Installation This machine is equipped with safety unloading system to prevent damage to the compressor drive coupling. Should an attempt be made to start this system improperly, the machine will run unloaded for 60 seconds. Likewise, if an attempt is made to shutdown the system improperly, the unit will continue to run until the compressor system pressure unloads below 50 PSI. -
Page 23: Operation
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. -
Page 24: Emergency Shutdown Procedure
Operation 7.2 Emergency Shutdown Procedure In the event of an emergency and the 210 DUS Air Compressor must be stopped suddenly without first unloading the compressor, the machine is equipped with an emergency shutdown switch. 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. -
Page 25: Maintenance
Maintenance 8.1 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. -
Page 26: Recommended Spare Parts List
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 l i F r e t t a r... -
Page 27: Maintenance Log
Maintenance 8.5 Maintenance Log Accum. Hours Date Service Performed Parts Replaced Service Work By 309416 01/31/2012... -
Page 28: Separator Element Replacement
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. -
Page 29: Engine Air Filter Replacement
Maintenance 8.7 Engine Air Filter Replacement Loosen the clamps 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. Never blow dirt out of the interior of the filter housing. -
Page 30: Compressor Air Filter Replacement
Maintenance 8.8 Compressor Air Filter Replacement 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. Never blow dirt out of the interior of the filter housing. -
Page 31: Compressor Oil
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. -
Page 32: Adding Compressor Oil
Do not replace fill cap with a pipe cap; serious injury or dam- age 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. -
Page 33: 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. -
Page 34: Engine Cooling System Maintenance
Maintenance 8.12 Engine Cooling System Maintenance 210 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. Engine Coolant A. -
Page 35: Engine Fan
Maintenance 8.12 Engine Cooling System Maintenance (continued) Engine Radiator (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 13 PSI rated cap. Be sure cap is tightened to the proper secure position. III. -
Page 36: Idle Speed Adjustment
160 PSI working = 180 PSI standby. 8.15 Idle Speed Adjustment If engine speed is below 1800 RPM, contact Boss Industries, Inc.’s service department for further assistance. 8.16 Rated Speed Adjustment Rotate the unloader valve to “UNLOAD”. -
Page 37: Troubleshooting
Troubleshooting 9.1 Troubleshooting Chart e t t r e t y t l e t t i t c g i t e t t t l o e t t . y r t l u i t i c t i c t i r a t... - Page 38 Troubleshooting 9.1 Troubleshooting Chart (continued) l i o l i f r e t c i r i t c n i t t l i f . r e h t i r i a i t c n i t c i t c i t f l a...
- Page 39 Troubleshooting 9.1 Troubleshooting Chart (continued) e l l i . l e i p i n i l i t c r i a . y r l i o s t i c i r o i t . y r l i o l i o .
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Page 40: Parts And Service Contact Information
Troubleshooting 9.1 Troubleshooting Chart (continued) t a l t e l . t i r i a i t p r i a c i r c i r o i t , r i n i t . y r c i f i t a j n i... -
Page 41: Warranty
BOSS manufacture and if in the judgment of BOSS these items do not conform or are found to be defective in material of workmanship, BOSS will at its option either, (a) furnish a Service Representative to correct defective workmanship, or (b) upon return of the item F.O.B. -
Page 42: Summary Of Main Warranty Provisions
Distributor shall be allowed no more than 30 days from date of repair to file a warranty claim/service report. Warranty for failure of BOSS replacement parts covers the net cost of the part only, not labor and mileage. The BOSS warranty does not cover diagnostic calls and travel. That is time spent traveling to the machine to analyze the problem and returning with the proper tools and parts to correct the problem. -
Page 43: Warranty/Return Goods Instructions
4. Claim denial will result in issuance of a letter of denial. 5. BOSS INDUSTRIES will consider each claim on its’ own merit and reserves the right to accept or reject claim request. In case of air-ends, these will be returned to the manufacturer for their analysis/ input. -
Page 44: Warranty Claims Provisions
5. Machine is within warranty period. 6. Machine has been operated within design conditions. Claims made through distributors must be verified by distributor prior to contacting BOSS INDUSTRIES. 10.7 Damage in Transit Do not return damaged merchandise to BOSS INDUSTRIES, please follow claim procedure. -
Page 45: Screw Compressor Airend Exchange Program
Warranty 10.8 Screw Compressor Airend 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. -
Page 46: Parts And Illustration Section
Parts and Illustration Section 11.1 Frame System Parts List ITEM PART NUMBER DESCRIPTION 48 120-36992 INSERT 124-28093 FILTER 300599 HEAD 960212-075 ELBOW 16 938604-071 WASHER 938004-062 WASHER 929104-100 BOLT 901515-030 ELBOW 960412-075 NIPPLE 922112-020 NIPPLE 309279 FRAME 306042 BRACKET 301662 VALVE 120-14966 BRACKET... - Page 47 Parts and Illustration Section 11.1 Frame System (continued) FLOW DIRECTION 309416 01/31/2012...
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Page 48: Engine System
Parts and Illustration Section 11.2 Engine System Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 309357 ENGINE 120-19071 BALL JOINT 303150 SWITCH 929216-350 BOLT 308436 SENDER 929212-300 BOLT 902415-005 980704-012M ELBOW 929808-125 BOLT 924604-164 924404-145 937808-125 WASHER 150-90673 MOUNT... - Page 49 Parts and Illustration Section 11.2 Engine System (continued) 309416 01/31/2012...
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Page 50: Compressor System
Parts and Illustration Section 11.3 Compressor System Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 1 301677-305 BUSHING 4 929212-350 BOLT 1 302244 SWITCH 4 938912-200 BOLT 19 929210-400 BOLT 1 902915-020 PLUG 1 120-90607 1 960224-150 ELBOW BUSHING 1 303104 SWITCH... - Page 51 Parts and Illustration Section 11.3 Compressor System (continued) FLOW 309416 01/31/2012...
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Page 52: Discharge System
Parts and Illustration Section 11.4 Discharge System Parts List ITEM PART NUMBER DESCRIPTION 1 308087 VALVE 1 922220-000 NIPPLE 1 300023-175 RELIEF 1 960116-100 CONNECTOR 1 907605-040 BUSHING 1 901115-020 ELBOW 1 901515-040 ELBOW 1 960404-025 NIPPLE 1 980804-025 1 300057 VALVE 1 301827 VALVE... - Page 53 Parts and Illustration Section 11.4 Discharge System (continued) 309416 01/31/2012...
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Page 54: Cooling System
Parts and Illustration Section 11.5 Cooling System Parts List ITEM PART NUMBER DESCRIPTION 309283 COOLER ASSY 309303 SHROUD 10 938004-062 WASHER 14 938604-071 WASHER 902915-010 PLUG 929105-100 BOLT 938205-071 WASHER 938005-078 WASHER 10 929104-075 BOLT 960212-100 ELBOW 309307 GUARD 924304-145 929104-100 BOLT 907604-030... - Page 55 Parts and Illustration Section 11.5 Cooling System (continued) 309416 01/31/2012...
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Page 56: Electrical System
Parts and Illustration Section 11.6 Electrical System Parts List ITEM PART NUMBER DESCRIPTION 924304-145 943103-025 RIVET 120-16580 SPRING 938604-071 WASHER 109-90240 DOOR 120-65681 EYEBOLT 983904-075 BOLT 40032 ASSY 977004-062 WASHER 309416 01/31/2012... - Page 57 Parts and Illustration Section 11.6 Electrical System (continued) 309416 01/31/2012...
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Page 58: Canopy System
Parts and Illustration Section 11.7 Canopy System Parts List ITEM PART NUMBER DESCRIPTION 307259 PANEL 120-62264 LATCH 307896 PANEL 977004-062 WASHER 983904-075 BOLT 984004-071 WASHER 309267 ROOF 307263 COVER 120-36992 INSERT 307255 PANEL 307260 PANEL 307256 PANEL 307257 COVER 980100-300 CLAMP 307708 MUFFLER... - Page 59 Parts and Illustration Section 11.7 Canopy System (continued) DETAIL A DETAIL B 309416 01/31/2012...
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Page 60: Decal System
Parts and Illustration Section 11.8 Decal System Parts List ITEM PART NUMBER DESCRIPTION 305761 DECAL, SERIAL TAG BOSS 302568 DECAL, COMPR SIGHT GLASS 104-90114 DECAL, FLUID 104-90190 DECAL, DIESEL ASSORTMENT 104-90029 DECAL, DOORS CLOSED 104-90040 DECAL, HOT COOLANT 104-90027 DECAL, HOT EXHAUST... - Page 61 Parts and Illustration Section 11.8 Decal System (continued) DETAIL A 309416 01/31/2012...
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Page 62: Hose System
Parts and Illustration Section 11.9 Hose System 309416 01/31/2012... -
Page 63: System Wiring Diagram
Parts and Illustration Section 11.10 System Wiring Diagram 309416 01/31/2012...