Omega 185-210 DUS, JD 4045 User Manual
185-210 DUS
JD 4045
OMEGA TOOL
OPERATORS, MAINTENANCE,
AND PARTS MANUAL
SERIAL NUMBER_________________________________________
MODEL NUMBER_________________________________________
P/N: 307271
06/17/2008 MCM
TABLE OF CONTENTS
INTRODUCTION .............................................................................................................................. 6
SECTION 1 SAFETY......................................................................................................................... 9
1.1 PARKING .......................................................................................................................................9
1.2 BEFORE STARTING THE COMPRESSOR ................................................................................ 9
1.3 COMPRESSOR USE AND COMPRESSED AIR ........................................................................ 9
1.4 SERVICING ..................................................................................................................................10
1.5 LIFTING .......................................................................................................................................10
SECTION 2 DESCRIPTION...........................................................................................................11
2.1 INTRODUCTION......................................................................................................................... 11
2.2 ROTARY COMPRESSOR COMPONENTS ..............................................................................11
2.3 ENGINE COMPONENTS ...........................................................................................................12
2.4 CHASSIS ......................................................................................................................................13
2.5 ENCLOSURE ...............................................................................................................................13
2.6 INSTRUMENT PANEL DOOR ................................................................................................... 1 3
SECTION 3 OPERA TION.............................................................................................................. 14
3.1 START UP PREPARATION ........................................................................................................14
3.2 STARTING PROCEDURE .......................................................................................................... 14
3.3 EMERGENCY SHUTDOWN PROCEDURE ............................................................................1 4
3.4 ROUTINE SHUTDOWN PROCEDURE ....................................................................................14
SECTION 4 MAINTENANCE ....................................................................................................... 15
4.1 ENGINE FUEL SPECIFICATIONS.............................................................................................15
4.2 ENGINE OIL AND FILTER.........................................................................................................16
4.3 ENGINE COOLING SPECIFICATIONS.....................................................................................1 6
4.4 FAN ...............................................................................................................................................17
4.5 RADIATOR PRESSURE CAP ....................................................................................................1 7
4.6 RADIATOR...................................................................................................................................17
4.7 COMPRESSOR OIL ....................................................................................................................17
4.8 COMPRESSOR & ENGINE AIR FILTER MAINTENANCE ................................................... 2 0
4.9 COMPRESSOR OIL THERMOSTATIC VALVE .......................................................................21
4.10 COMPRESSOR AIR/OIL SEPARATOR................................................................................... 21
4.11 BELTS & BELT ADJUSTMENT ..............................................................................................21
4.12 CONTROLS-OPERATION AND ADJUSTMENTS.................................................................22
4.13 INSTRUMENTS ........................................................................................................................23
4.14 BATTERY ...................................................................................................................................23
4.15 MAINTENANCE SCHEDULE ................................................................................................. 2 4
4.16 DAILY OPERATION .................................................................................................................24
4.17 MAINTENANCE SCHEDULE CHART...................................................................................25
4.18 RECOMMENDED SPARE PARTS LIST .................................................................................26
4.19 PROCEDURE FOR ORDERING PARTS.................................................................................2 6
SECTION 5 TROUBLESHOOTING ............................................................................................ 27
5.1 TROUBLESHOOTING................................................................................................................27
5.2 TROUBLESHOOTING CHART ................................................................................................. 2 8
WARRANTY ..................................................................................................................................... 31
SECTION 6 ASSEMBLY_DRAWINGS......................................................................................... 37
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INTRODUCTION
OWNER’S RESPONSIBILITY
Your new Boss air compressor was engineered, built and tested to ensure the user both dependable and
economical service. This compressor has also been certified as conforming to the applicable Noise Emission
standards of the Environmental Protection Agency .
Continuation of this unit’s performance depends upon the care it receives during use. Therefore, operation
and maintenance procedures described in this manual should be followed carefully. The operator and
service personnel responsible for the care of this unit should be thoroughly familiar with this information.
It is the owner’s and/or operator’s responsibility to perform all safety checks and to ensure that all lubrication,
maintenance instruction and recommended practices are followed for safe operation. If disassembly or
replacement is required, particularly of internal parts, we recommend the owner see his dealer and not
attempt the repair himself.
It is owner’s responsibility to ensure that the preventive maintenance program is followed at the recommended
intervals. Proper care and service will assure long service life with a minimum of problems and operating
expenses.
W e recommend that the owner and operator be thoroughly familiar with the contents of the manual.
If you encounter difficulties which you cannot diagnose our service personnel are prepared to help you.
Our toll free number is 1-800-635-6587. Outside the continental United States and Canada our number is
219-324-7776.
The model and serial number information is requested on all correspondence. This information can be
found on the Model Number Identification Plate. The information contained on the identification plate
should be transferred to the cover page of the manual for future reference.
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WARNING
ALL UNITS ARE SHIPPED WITH A DET AILED OPERA TORS AND P ARTS MANUAL.
THIS MANUAL CONTAINS VITAL INFORMATION FOR THE SAFE USE AND
EFFICIENT OPERATION OF THIS UNIT. CAREFULLY READ THE OPERATORS
MANUAL BEFORE STARTING THE UNIT. FAILURE TO ADHERE TO THE
INSTRUCTIONS COULD RESULT IN SERIOUS BODILY INJURY OR PROPERTY
DAMAGE.
AIR COMPRESSOR SAFETY PRECAUTIONS
Safety is basically common sense. There are standard safety rules but each situation has its own peculiarities,
which cannot always be covered by rules. Therefore with your experience and common sense, you are in
a position to do something about safety. Lack of attention to safety can result in: accidents, personal
injury, reduction of efficiency and worst of all - Loss of Life. Watch for safety hazards. Correct them
promptly . Use the following safety precautions as a general guide to safe operation:
Do not attempt to remove any compressor parts without first relieving the entire system of pressure.
Do not attempt to service any part while machine is operating.
DANGER
CHECK THE COMPRESSOR SUMP OIL LEVEL ONL Y WHEN THE COMPRESSOR
IS NOT OPERATING AND SYSTEM IS COMPLETELY RELIEVED OF PRESSURE.
OPEN SERVICE VALVE TO ENSURE RELIEF OF SYSTEM AIR PRESSURE WHEN
PERFORMING MAINTENANCE ON COMPRESSOR AIR/OIL SYSTEM. FAILURE
TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTY AND
SERIOUS BODILY HARM.
Do not operate the compressor at pressures or speeds in excess of its rating.
Periodically check all safety devices for proper operation.
Do not play with compressed air . Pressurized air can cause serious injury to personnel.
Exercise cleanliness during maintenance and when making repairs by covering parts and exposed openings.
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USER MODIFICATION
This Boss compressor incorporates numerous features to minimize noise emissions from the unit during
operation. This configuration has been tested for noise emissions at conditions specified by the U.S.
Environmental Protection Agency . Conformance to regulations requires the incorporation of the following
notification and definition in the OPERA TION AND MAINTENANCE MANUAL.
T AMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following act:
1. The removal, rendering inoperative, other than for purposes of maintenance, repair or replacement
of any device or element of design incorporated into any new compressor for the purpose for noise
control prior to its sale or delivery to the ultimate purchaser .
2. The use of the compressor after such device or element of design has been removed or rendered
inoperative by any person.
Among the acts included in the prohibition against tampering are those listed:
1. Removal or rendering inoperative any of the following:
a. The engine exhaust system including the manifold, muffler or tailpipe.
b. Any of the enclosure components and associated sound barrier materials.
c. The sound baffles in the intake, exhaust and cooling system gas paths.
d. The air intake system including the air cleaner, the intake ducting, valve cover and gaskets.
2. Removal of any of the following:
a. Engine mounts or other sound isolating barriers in the system.
b. Fan shrouding and sound hood.
3. Operation of the compressor with any of the enclosure doors open.
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SECTION 1 SAFETY
1.1 PARKING
CHOOSING A P ARKING SITE
1. Park the compressor on a level firm area. Never park on a grade of more than 15 degrees (27%).
If you must park on any grade, park across the grade so that the compressor does not tend to roll.
2. Park so that the wind carries exhaust fumes and radiator heat away from the compressor inlet.
3. Park away from work site dust.
4. Stay clear of electrical power lines. Keep the towing vehicle or equipment carrier , compressor,
hoses, tools and all personnel at least 10 feet from power lines and buried cables.
1.2 BEFORE STARTING THE COMPRESSOR
1. Check fluids levels and for possible leaks.
2. Use adequate hose and couplings with safety locks or pins.
3. Remove all tools and/or loose items from engine compartment.
4. Relieve any pressure in receiver tank.
5. Use proper eye and ear protection.
1.3 COMPRESSOR USE AND COMPRESSED AIR
1. Air from this machine is not fit for human breathing or food processing.
2. Never operate in an enclosed area.
3. Never use compressed air to clean your clothes and never direct it at another person, it can kill.
4. Always wear eye protection.
5. Install velocity fuse (“OSHA”) upstream of hose to prevent hose whip in case of a rupture.
6. Keep doors or hoods closed on machines in operation.
7. Do not touch hot surfaces or moving parts, such as exhaust or fans.
8. Do not adjust or restrict relief valves.
9. Do not refuel while machine is running; shut down and allow to cool before refueling.
10. Do not jump-start with cable connections directly on battery .
12. Do not use air at pressure higher than 30 PSIG (207 KP A) for cleaning purposes. Use of higher air
pressure can cause injury to the operator .
13. Keep compressor panels closed except when making repairs, adjustments, or servicing the
compressor .
14. Make sure all personnel are out of and clear of the compressor before starting or operating it.
15. Do not use either cylinder or air line antifreeze compound in confined area.
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1.4 SERVICING
1. Before servicing compressor, relieve receiver pressure and allow to cool.
2. Be sure all access panels are opened and/or removed.
3. Wipe up all spills resulting from servicing.
4. Disconnect the grounded (negative) battery connection before making repairs or cleaning inside
the enclosure.
5. Do not use flammable solvents for cleaning the compressor .
6. Radiator coolant is under pressure. Do not remove radiator cap quickly, it may cause spray of
scalding coolant and severe burns to operator.
7. Make repairs only in clean, dry and well-lighted and well-ventilated areas.
8. Keep all parts of the body and any hand held tools or other metal objects away from exposed live
parts of the electrical system.
9. Replace damaged fuel tanks or lines immediately . DO NOT WELD on or near fuel tanks or lines.
10. Make sure all personnel are out of the compressor before closing and/or replacing panels.
1.5 LIFTING
1. If the compressor is provided with a lifting bail, then lift by the bail. If no bail is provided, then lift
by sling.
2. When lifting by helicopter , use a sling. Do not lift by unit lifting bail.
3. Inspect the entire lifting, rigging and supporting structure to ensure it is in good condition and has
a rated capacity of at least the gross weight of the compressor plus 50%.
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SECTION 2 DESCRIPTION
2.1 INTRODUCTION
Your Boss compressor is a gas/diesel driven Rotary Screw Compressor unit that provides superior
performance and reliability along with a minimal amount of required maintenance.
2.2 ROTARY COMPRESSOR COMPONENTS
COMPRESSOR DESCRIPTION
The compressor assembly is a positive displacement, oil flood lubricated, screw type unit employing one
stage of compression to achieve the desired pressure. Components include a housing (stator), two screws
(rotors), gears, bearings and bearing supports.
In operation, two helical grooved rotors mesh to compress air. Inlet air entering the casing is compressed
as the male lobes roll down the female grooves, pushing trapped atmospheric air along and compressing it
in one stage of compression. This process delivers smooth-flowing air at full pressure to the receiver .
T o illustrate the compression sequence, consider the action of the male lobe as similar to a ball. As a helix
rotates, the ball (male lobe) meshes with the groove to start a compression cycle with trapped atmospheric
air. As the ball moves down the groove, air is compressed. Atmospheric air fills in behind the ball preparing
the groove for another compression cycle as rotation continues and the male lobe again meshes with the
groove.
During the compression cycle, oil is injected into the compressor for the purpose of lubrication, cooling
and sealing. Compressed air laden with oil leaves the compressor unit through a discharge port, which is
designed to give optimum performance within the desired discharge pressure range.
AIR FIL TER
The Rotary Screw Compressor unit and engine are protected by a high efficiency , two-stage air filtering
system. This is a dry filter that requires maintenance when the air filter restriction gauge says it is time.
OIL COOLING
The compressor is an “oil flooded” compressor . The oil lubricates, seals and cools the internals of the
compressors as it is injected into the compressor. The oil goes through the compressor with the air where
it picks up the heat generated by the compression process then seals the spaces between moving parts and
lubricates bearings. The hot oil must be cooled. It is separated from the air, passed through the oil cooler
(mounted next to the engine radiator), through a thermostatic valve (that helps to rapidly warm cold oil at
start-up), then through a full flow oil filter and then back into the compressor. See instructions 4.10 and
4.13 for oil filter element and air/oil separating element servicing.
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AIR/OIL SEP ARATOR
At the compressor discharge the compressed air and the hot oil flow into a steel ASME coded pressure
vessel (rated at 175 psig-250psig) that acts as a reservoir for the air and separates out the oil. From the
bottom of this oil sump the oil leaves the vessel on its way to the oil cooler . The air and the slight oil mist
still entrained in the air flow through the separator element, which removes the last of the oil from the air.
The air passes on out to its final use and the separated oil goes through the scavenge line to the compressor
to re-enter the system.
As the compressor air leaves the receiver it goes through a minimum pressure valve that is set to maintain
at least 80 psig (55kpa) in the receiver when the compressor is running. The purpose of this pressure is to
ensure that there is pressure to force the oil out of the bottom of the receiver, through the oil cooling system,
so that sufficient oil is injected into the compressor .
CONTROL SYSTEM
The Boss compressor system is simple to operate. Starting procedure is explained in section 3 and on the
instrument panel door of the compressor. Each machine has an On/Of f switch and a safety bypass switch
that bypasses the safety shutdowns. Once the machine is “on line” and in the run position, control is
automatic. The control system senses the need for air and adjusts the speed of the engine and compressor
as well as the opening of the compressor inlet valve to supply the amount of air needed. If the air demand
is zero, the engine and compressor “idle” and the inlet valve is shut to control the air entering the compressor.
If the demand is maximum, the opposite happens, full speed and wide-open inlet valve. Intermediate air
demands give intermediate speeds and valve openings for maximum operating efficiency . Service and
adjustments are in section 4.14.
2.3 ENGINE COMPONENTS
ENGINE DESCRIPTION
The engine in each Boss compressor system is selected to have reserve horsepower and speed necessary to
drive the compressor and all accessories when operating up to a discharge pressure 100 psig (686kpa) to
220 psig (1509kpa).
RADIATOR
The radiator is selected to handle the heat load of the engine. Mounted next to the compressor oil cooler.
Cooling air is moved through these two coolers with a specially selected engine fan. The system is designed
to handle extreme heat conditions.
FUEL SYSTEM
All units are supplied with fuel tank capacity adequate for a day’ s normal operation, fuel filtering system
and optional low fuel shutdown. See section 4.3 for fuel servicing.
MUFFLER
Engine noise is reduced by a durable, low restriction engine muffler .
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2.4 CHASSIS
FRAME
The entire compressor frame and body is “utilized” and constructed of 3/16" or 10 gauge steel plate,
resulting in light weight while providing a much stronger body than conventional designs of light sheet
metal over structural members.
2.5 ENCLOSURE
Enclosure is 14 gauge metal with powder coat finish. Each access panel has lockable handles with mechanical
props.
2.6 INSTRUMENT PANEL DOOR
Lockable instrument panel doors provide access to all controls and gauges.
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SECTION 3 OPERA TION
3.1 START UP PREPARATION
1. Check engine and compressor oil levels. Do not overfill.
2. Check coolant level in radiator (Fill at coolant recovery bottle).
3. Check for fuel, oil and coolant leaks.
4. Check air cleaner, clamps and hoses.
5. Check battery connections.
6. Check and adjust tension of fan belts.
NOTE: This unit has minimum air pressure valve to assure compressor oil flow . There will be no airflow
from the compressor if receiver pressure is less that 80 PSIG.
3.2 STARTING PROCEDURE
1. Close service valves and move unloader valve to “ST AR T” position
2. Press and hold bypass button and turn starter switch to “ST AR T” position. If engine fails to start.
DO NOT attempt to restart until cranking motor stops rotating. Before restarting, starter switch
must be returned to “OFF” position
3. When engine starts, release starter switch and hold bypass button down until oil pressure reaches
15PSI then release. Maintain unloader valve at “START” position until engine is warm and
operating smoothly , then move unloader valve to “RUN” position.
3.3 EMERGENCY SHUTDOWN PROCEDURE
Turn start stop switch to “OFF” position
3.4 ROUTINE SHUTDOWN PROCEDURE
1. Move unloader to start position
2. Allow compressor to run 2 to 3 minutes to cool.
3. Move on/off switch to “OFF” position
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SECTION 4 MAINTENANCE
4.1 ENGINE FUEL SPECIFICATIONS
WARNING
DO NOT MIX GASOLINE OR ALCOHOL WITH DIESEL FUEL. THIS MIXTURE
CAN CAUSE AN EXPLOSION.
CAUTION
DUE TO THE PRECISE TOLERANCES OF DIESEL INJECTION SYSTEMS, IT IS
EXTREMEL Y IMPROTANT THA T THE FUEL BE KEPT CLEAN AND FREE OF DIRT
OR WA TER. DIRT OR W ATER IN THE SYSTEM CAN CAUSE SEVERE DAMAGE T O
BOTH THE INJECTION PUMP AND THE INJECTION NOZZLE.
USE ASTM NO.2D FUEL WITH A MINIMUM CET ANE NUMBER OF 40. NO.2 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 COMPRESSOR.
HIGH AL TITIDE 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.
COLD WEA THER FUEL
At opening temperatures below 0 degrees C (32 degrees F) use a blend of No.1D and No.2D fuels, also
know as “winterized” No.2D. NOTE: No.1D fuel can be used; however, fuel economy will suffer .
Use low sulfur content fuel having a cloud point that is at least 10 degrees below the lower expected 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 1.3 centistokes to provide adequate fuel system lubrication.
ENGINE FUEL FIL TER
See engine manufactures operator/instruction manual for the proper fuel filter replacement changing intervals
for the brand engine in your Boss compressor.
WARNING
KEEP HANDS AND FINGERS CLEAR OF FUEL FITTINGS. HIGH PRESSURE OF
THE FUEL CAN CAUSE PENETRA TION OF THE SKIN. SEEK IMMDIA TE MEDICAL
A TTENTION IF SKIN IS BROKEN BY THE FUEL SPRA Y.
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4.2 ENGINE OIL AND FILTER
See engine manufactures operator/instruction manual for the proper engine oil and filter changing intervals
for the brand engine in your Boss compressor.
OIL FIL TER REPLACEMENT
1. Clean the area around the lubricating filter head.
2. Remove the filter.
3. Clean the o-ring surface of the filter head.
NOTE: The o-ring can stick on the filter head. Make sure it is removed.
4. Apply a light film of lubricating oil to the o-ring-sealing surface before installing.
5. Install the filter as specified by the filter manufacturer.
CAUTION
MECHANICAL OVER-TIGHTENING MAY DIST ORT THE THREADS OR DAMAGE
THE FIL TER ELEMENT SEAL.
4.3 ENGINE COOLING SPECIFICATIONS
Diesel engines require a balanced coolant mixture of water and ethylene glycol base antifreeze. This
protects the engine cooling system from corrosions as well as freezing damage. The Boss 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. It will help prevent corrosion
and pitting of cylinder liners. See engine manufactures operator/instruction manual for the proper engine
coolant for the brand engine in your Boss compressor.
MIXTURES:
Antifreeze concentration level should not exceed recommended levels. Doing so can cause cooling system
failure.
· Use a high quality , low silicate antifreeze
· A mixture of 50% antifreeze and 50% water is required for temperatures above –37 º C (-34 ºF).
· A mixture of 60% antifreeze and 40% water us required for environments below –37 ºC (-34 ºF). This
provides protection to –54 ºC (-65 ºF).
· Never exceed a 60% antifreeze and 40% water mix.
ENGINE COOLING SYSTEM
All engines have a pressurized cooling system that contains a 50/50 mixture of water and ethylene glycol.
Daily maintenance of the system includes a check of the coolant level, proper belt adjustment of fan and
water pump drives, soundness of fan and cleanliness of the radiator and oil cooler to permit airflow . Further
cooling system maintenance is defined in the engine maintenance manual.
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