Boss 210 DUS JD4045, IT4 74HP Service And Maintenance Manual

Service and

Maintenance

Manual

210 DUS JD4045

IT4 74HP

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: [phone] (USA)
Phone: [phone] (Outside USA)
Fax: [phone] (USA)
Email: [e-mail]
Website:

http://www.bossair.com

309416

05-03-2013 ARB

01/31/2012

2 309416

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

5.5 Pressure Relief Valve.....................................................................................16

5.6 Engine Air Filter..........................................................................................16

5.7 Compressor Air Filter.................................................................................16

5.8 Cooling Systems...........................................................................................16

Engine Radiator..........................................................................................16

Compressor Oil Cooler...............................................................................16

5.9 Compressor Oil Filter..................................................................................16

5.10 Compressor Oil Thermal Valve......................................................................16

5.11 Compressor Inlet Valve.................................................................................17

5.12 Minimum Pressure Valve...............................................................................17

5.13 Blowdown Valve..........................................................................................17

5.14 Blowdown Switch........................................................................................17

5.15 Discharge Pressure Regulator Valve...............................................................17

5.16 Instrument Panel...........................................................................................18

Engine Oil Pressure Gauge..........................................................................18

Engine Coolant Temperature Gauge............................................................18

Compressor Discharge Pressure Gauge......................................................18

Compressor Discharge Temperature Gauge................................................18

01/31/2012

3 309416

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

6.7 Machine Documentation...............................................................................21

6.8 Check Fluid Levels.......................................................................................21

6.9 Initial Startup Preparation..............................................................................21

6.10 Initial Startup.................................................................................................22

Operation.............................................................................................................23-24

7.1 Routine Operating Procedures........................................................................23

Routine Startup Preparation........................................................................23

Routine Startup Procedure.........................................................................23

Routine Shutdown Procedure.....................................................................23

7.2 Emergency Shutdown Procedure..........................................................24

Maintenance........................................................................................................25-36

8.1 Maintenance Overview....................................................................................25

8.2 Maintenance Schedule....................................................................................25

8.3 Recommended Spare Parts List......................................................................26

8.4 Parts and Service Contact Information............................................................26

8.5 Maintenance Log............................................................................................27

01/31/2012

4 309416

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

Engine Serpentine Belt...............................................................................35

8.13 Battery..........................................................................................................35

8.14 Standby Pressure Adjustment (For 100 PSI System).....................................35

8.15 Idle Speed Adjustment..................................................................................36

8.16 Rated Speed Adjustment...............................................................................36

Troubleshooting...................................................................................................37-40

9.1 Troubleshooting Chart....................................................................................37

9.2 Parts and Service Contact Information............................................................40

Warranty..............................................................................................................41-45

10.1 Warranty Policy............................................................................................41

10.2 Summary of Main Warranty Provisions..........................................................42

10.3 Warranty/Return Goods Instructions.............................................................43

10.4 Warranty Claims - Preparation of Part Return.................................................43

10.5 Return or Warranty Claims - Filing Procedures...............................................43

10.6 Warranty Claims Provisions..........................................................................44

10.7 Damage in Transit..........................................................................................44

10.8 Screw Compressor Airend Exchange Program..............................................45

Parts and Illustration Section...........................................................................46-63

11.1 Frame System...............................................................................................46

11.2 Engine System..............................................................................................48

11.3 Compressor System.....................................................................................50

11.4 Discharge System..........................................................................................52

01/31/2012

5 309416

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

01/31/2012

6 309416

Manual Change History

ETAD NOITACOL EGNAHCFONOITPIRCSED SLAITINI

1.1 Revision List

01/31/2012

7 309416

Welcome

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: [phone] (USA)
Phone: [phone] (Outside USA)
Fax: [phone] (USA)
Email: [e-mail]
Website:

http://www.bossair.com

Service and

Maintenance

Manual

210 DUS JD4045

IT4 74HP

Air Compressor

309416

01/31/2012

2.1 General Information

Thank you for choosing the 210 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.

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.

2.2 Overview

The 210 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 210 DUS Air Compressor’s rotary screw
design guarantees continuous air output of up to
210 CFM (cubic feet per minute) at 100 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 210 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.

01/31/2012

8 309416

Safety

3.1 General Safety Overview

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.

01/31/2012

9 309416

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. 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.

01/31/2012

Never operate the machine in an enclosed area.

10 309416

3.2 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 15 degrees.

Keep doors closed on the machine during operation.

Check engine’s operator manual for required service
and maintenance intervals.

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.

01/31/2012

11 309416

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

Electrical ShockHot Pressurized Oil

Close Doors Oil Level

12 309416

01/31/2012

Safety

3.3 Safety and Information Decals (continued)

Overfill Negative Ground System

Compressor Oil

Hot Coolant

Serial Tag

Breathing Air

01/31/2012

13 309416

4.1 Specification Sheet

yticapaC

ISP001@

MFC 571 581 002 012

PH 83 14 54 74

ISP521@

MFC 471 481 991 902

PH 44 74 25 55

ISP061@

MFC 071 181 891 402

PH 84 15 65 75

deepStupnIrosserpmoC

MPR 0002 5212 5232 0042

dneriArosserpmoC oitaRraeG50.3htiwG01ACS

enignE

47

PH

DJ

5404

MIRTNI

REIT

4

EAS/W

B

EVIRDXUA

metsySlacirtcelEenignE CDV21

snoisnemiDesaB "2/107X"03X"8/548

knaTleuFleseiDlanoitpO

PAC L041,.LAG73

MID "5.6X"03X"87

elgnAgnitarepOenihcaM mumixam°51

elcyCytuD suounitnoC

snoitidnoCtneibmA F°521otF°04-

66.77

48.07

78.00

84.55

30.00

Specifications

*SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE*

01/31/2012

14 309416

Description of Components

5.1Engine

The 210 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.

5.2Drive 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.

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 which
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.

In operation, two helical grooved

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 250 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.

15 309416

01/31/2012

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. 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 beside the engine radiator. This works similar to the engine radiator but is
designed to withstand the full compressor system working pressure.

5.9 Compressor Oil Filter

The compressor oil filter is a full flow, spin-on canister. It has been specially designed to handle 200
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.

5.10 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 170°F. Once at system operating
temperature, the valve shifts, directing the flow through the oil cooler before returning to the compressor
airend.

01/31/2012

16 309416

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.

5.12 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.

5.13 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.

5.14 Blowdown Switch

The system is equipped with a blowdown switch. This switch will sense pressure in the pilot signal to
the blowdown valve. If the system contains pressure, the switch will prevent the machine from starting.
This will prevent premature damage to the drive coupling.

5.15 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 exceeds the
setpoint. This signal will also adjust the speed of the engine. This system has a maximum operating
pressure of 160 PSI.

Most air tools operating pressure range is between 90 and 125
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.

01/31/2012

17 309416

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. 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 235°F,
the system will shut down. During operation, the temperature should be approximately 190°F to
210°F.

III. Compressor Discharge Pressure Gauge

This feature displays the pressure downstream of the airend.

IV. Compressor Discharge Temperature Gauge

This feature displays the compressor discharge temperature. When the temperature reaches 245°F,
the system will shut down. During operation, the discharge temperature should be approximately
170°F to 190°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 display when the ignition switch is
in the “RUN” position. During operation, the voltmeter should be approximately 14 VDC.

VII. Unloader Valve

This turn valve is used to limit the compressor system pressure. When the valve is in the loaded
position, the system will build to the regulator setting. If the valve is set to unloaded, the system will
build to approximately 45 PSI.

VIII. Emergency Stop Switch

The system is equipped with an emergency stop switch to immediately shutdown the machine.

IX. Bypass Switch

The bypass switch will temporarily disable the engine oil pressure shutdown during startup.

X. Ignition Switch

The ignition switch is used for starting and stopping the machine.

01/31/2012

18 309416

Installation

1/4" TUBE

FUEL SUPPLY

(2) 3/4" MNPT AIR

SERVICE VALVES

5/16" TUBE
FUEL RETURN

6.1 System Installation Overview

The 210 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.

6.2 Placing The Machine

The first step in installing the 210 DUS Air Compressor is placing the system on a solid, level surface.
This machine is designed to run at up to a 15° 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

Connect the fuel supply line to the 1/4” tube port on the starter side of the engine. Connect the fuel
return line to the 5/16” tube port, near the air inlet side of the turbo. Both tubes need to be SAE
30R7 rated fuel lines.

01/31/2012

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.

Do not mix gasoline or alcohol with diesel fuel. This mix­ture can cause an explosion.

19 309416