Omega Engineering JD 4045 manual

185-210 DUS JD 4045 OMEGA T OOL OPERA TORS, MAINTENANCE, AND P AR TS MANUAL P/N: 307271 06/1 7 /2008 MCM SERIAL NUMBER_________________________________________ MODEL NUMBER_________________________________________[...]

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4 P/N: 307271 TABLE OF CONTENTS INTRODUCTION .............................................................................................................................. 6 SECTION 1 SAFETY ............................................................................................................... .......... 9 1.1 P ARKING .....................[...]

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6 P/N: 307271 OWNER’S RESPONSIBILITY Y our 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 [...]

7 P/N: 307271 W ARNING 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[...]

8 P/N: 307271 USER MODIFICA TION 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 notificat[...]

9 P/N: 307271 SECTION 1 SAFETY 1.1 P ARKING 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 compr[...]

10 P/N: 307271 1.4 SER VICING 1. Before servicing compressor , relieve receiver pressure and allow to cool. 2. Be sure all access panels are opened and/or removed. 3. W ipe 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 [...]

11 P/N: 307271 SECTION 2 DESCRIPTION 2.1 INTRODUCTION Y our 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 ROT ARY COMPRESSOR COMPONENTS COMPRESSOR DESCRIPTION The compressor assembly is a positive displacement, oil flood[...]

12 P/N: 307271 AIR/OIL SEP ARA TOR 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 oi[...]

13 P/N: 307271 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 [...]

14 P/N: 307271 SECTION 3 OPERA TION 3.1 ST AR T UP PREP ARA TION 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. N[...]

15 P/N: 307271 SECTION 4 MAINTENANCE 4.1 ENGINE FUEL SPECIFICA TIONS W ARNING CAUTION HIGH AL TITIDE AND LOW TEMPERA TURE 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 degre[...]

16 P/N: 307271 4.2 ENGINE OIL AND FIL TER 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[...]

17 P/N: 307271 COOLANT LEVEL Before each start-up, when radiator is cold, the coolant should be checked. When needed, refill with a 50/ 50 solution of water and ethylene glycol, DO NOT use 100% antifreeze for “topping of f”. W ARNING 4.4 F AN Check the fan for cracks, loose rivets, and bent or loose blades. Make sure it is securely mounted. T i[...]

18 P/N: 307271 COMPRESSOR OIL SPECIFICA TIONS It is permissible to use oils other than the A TF shown above; such as Hydraulic oil. If they are used then they must have at least the following minimum properties: • ISO grade 3 2 • CPS No. 255675 • API Gravity - • V iscosity , Kinematic cst at 40 degrees C 33.6 cst at 100 degrees C 5.5 • V [...]

19 P/N: 307271 CAUTION CHANGING COMPRESSOR OIL 1. Oil and air filter will help prolong oil life. If the oil appears dirty or it has a foul smell it should be replaced. 2. Change compressor oil and filter every 500 hours. 3. Remove fill cap and drain oil from the bottom of the air/oil receiver . Oil will drain more quickly and completely if it is wa[...]

20 P/N: 307271 4.8 COMPRESSOR & ENGINE AIR FIL TER MAINTENANCE ELEMENT REPLACEMENT 1. Loosen the clamps that secure the dust cup to the body and remove the cover . 2. Empty the dirt from the dust cup. 3. Remove the element. 4. Clean the canister and dust cap with a damp cloth inside and out. DO NOT blow dirt out with compressor air . 5. At this[...]

21 P/N: 307271 4.9 COMPRESSOR OIL THERMOST A TIC V AL VE The oil thermostatic valve acts as a thermostatically controlled by-pass valve and allows varying amounts of oil, depending upon the temperature, to by-pass cooler during the warm up period. When circulated oil reaches a temperature of 140 º F , the valve closes the by-pass completely and al[...]

22 P/N: 307271 4.12 CONTROLS-OPERA TION AND ADJUSTMENTS The compressor system is designed to match air supply and engine performance with the demand. The components of the control system are, the blowdown valve, start-run solenoid, compressor inlet valve, pressure regulator and an engine air cylinder . The start-run valve that is open in the start [...]

23 P/N: 307271 PRESSURE REGULA TOR ADJUSTMENT After setting idle speed and compressor is in run position, the pressure regulator adjustment can be checked and adjusted if required. The air cylinder receives an air signal from the pressure regulator . This air cylinder controls engine speed with air demand. T o adjust pressure regulator , with compr[...]

24 P/N: 307271 4.15 MAINTENANCE SCHEDULE A good maintenance program is the key to long machine life. Follow a regular schedule of inspection and servicing, based on operating hours. Keep an accurate logbook for maintenance, servicing and operating hours. Use the factory recommended Periodic Maintenance schedule (based on favorable operating conditi[...]

25 P/N: 307271 I NT ERV AL REQUI RED M AI NT E NA NCE REFERENCE 1. C hec k c om pres s or s y s t em flui d l ev el . 2. Chec k radi at or c oolant l ev el i n c oolant rec ov ery t ank . 3. C hec k f uel s upply af t er r unni ng. 4. C hec k air fil ter m aint enanc e i ndic at o r (if equppied). 5. C hec k f or fuel, oil , air, and wat er leak s [...]

26 P/N: 307271 4.18 RECOMMENDED SP ARE P AR TS LIST COMPLETE KITS ARE ALSO A V AILABLE THA T INCLUDE ALL THE ABOVE P AR TS. KIT FOR JOHN DEERE 4045 WITH 10G COMPRESSOR...............................................................8011 4 4.19 PROCEDURE FOR ORDERING P AR TS Parts can be ordered directly from the factory . When ordering parts always i[...]

27 P/N: 307271 SECTION 5 TROUBLESHOOTING 5.1 TROUBLESHOOTING If the unit will not crank when a “ST AR T” is attempted, DO NOT jump-start without first considering the following: • If there is obvious battery damage such as a cracked or broken case, replace battery • Check for loose battery cables. T ighten if necessary • Check terminals f[...]

28 P/N: 307271 5.2 TROUBLESHOOTING CHART The information contained in the troubleshooting chart has been compiled from field report data and factory experience. It contains symptoms and usual causes for the report data and factory experience. It contains symptoms and usual causes for the described problems; however , do not assume that these are th[...]

29 P/N: 307271 SY MPT O M C A U SE R E M E D Y O ut of fuel Chec k fuel l ev e l an d add fuel i f nec es s ary . Fuel f i lt er re s t ri c t ed. C han ge f u el f i lt er. a. E n gi ne c oll ant l ev el l ow; a dd c ool an t . b. Com p res s or oi l a nd r adi at or fl ow res t ri c t ed; c l ean c ool ers . c . F an bel t s s l i pp i ng or b ro[...]

30 P/N: 307271 S YM P T OM CAUS E RE M E DY Oi l res erv e o v e r f i l l ed. Drai n t o t he p rope r l ev el . Leak i n t he c om pres s or oi l sys te m. Chec k al l pi pi ng l i nes an d c o nnec t i on s ; repai r as n ec e s s a ry . a. Chec k s c av eng e l i ne a nd i t s c h ec k v al v e for res t ri c t i o ns ; c l ea r as n ec e s s a[...]

31 P/N: 307271 W ARRANTY Boss Industries, Inc. (BOSS) warrants that this Rotary Screw Compressor unit conforms to applicable drawings and specifications approved in writing by BOSS. The unit assembly will be free from defects in material and workmanship for a period of three (3) years from the date of initial operation or forty- two (42) months fro[...]

32 P/N: 307271 SUMMAR Y OF MAIN W ARRANTY PROVISIONS As claims, policies and procedures are governed by the terms of the BOSS Industries, Inc. (BOSS) warranty , it is necessary to outline some of the more important provisions. The BOSS warranty applies only to new and unused products, which, after shipment from the factory , have not been altered, [...]

33 P/N: 307271 W ARRANTY/RETURN GOODS INSTRUCTIONS The warranty/return procedure outlined below is provided to give the claimant the information necessary to file a warranty/return claim, and enable BOSS INDUSTRIES the ability to best serve its’ customers. Please see the following instructions to initiate a return: Contact BOSS INDUSTRIES Returns[...]

34 P/N: 307271 GENERAL An approved claim depends on the following provision: 1. An RGA # must be issued by BOSS INDUSTRIES. (See filing procedures.) 2. Failed part must be returned within 30 days of original invoice date, freight prepaid, with RGA #. 3. Part is determined to be defective. 4. W orkmanship is determined to be defective. 5. Machine is[...]

35 P/N: 307271 SCREW COMPRESSOR AIR-END EXCHANGE PROGRAM Replacement air-ends are available from the factory . For current prices and availability , contact BOSS INDUSTRIES, Inc. or an authorized BOSS INDUSTRIES distributor . Prices are F .O.B. shipping point. Prices do not include labor for removal or installation.[...]

36 P/N: 307271 NOTES[...]

37 P/N: 307271 SECTION 6 ASSEMBL Y _ DRA WINGS[...]

38 P/N: 307271 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 A A B B C C D D Parts Lis t DESCRI PTIO N PART NU MBER QTY ITEM FRAME & PART S, OMEGA 185-210 DUS 100633 1 1 ENGINE & PART S, OMEGA 185-210 DUS 100634 1 2 COMPRESSOR & PARTS, OMEGA 185-21 0 DUS 100635 1 3 COOLERS & PA RTS, OMEGA 185-210 DU S 100636 1 4 SUMP TANK & P ARTS, OMEGA 185-[...]

39 P/N: 307271 Parts List DESCRI PTION PART NUMBER QTY ITEM FRAME, OM EGA 185-21 0 DUS 307252 1 1 INSERT, 1/4-20UNC AKS4-4 20-165 120-36992 40 2 HEA D, OIL FI LTER 3/ 4 FNPT 1 5-PSI BY PASS 300599 1 3 FILTER, COM PR OIL 185/210 POR T 124-28093 1 4 ELBOW, HYD 3/4 MJIC X 3/4 MNPT 960212-075 1 5 BRACKET, COALESCER/OIL FILTER 306042 1 6 WASHER, FLAT GR[...]

40 P/N: 307271 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 A A B B C C D D SIZE DWG NO REV SCALE SHEET OF DRAWN PATH TITL E CHECKED MATERIA L THIS DRA WING AN D ALL INFORMATION THEREIN IS THE PROPE RTY OF BOSS INDUSTRIES, INC., IS CON - FIDENT IAL AND MU ST NOT BEMADE PUBLIC OR COPIED . IT IS LOAN ED SUBJEC T TO RETURN UPON DEMAND, IS NOT TO BE USED DIR ECTLY [...]

41 P/N: 307271 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 A A B B C C D D SIZE DWG NO REV SCALE SHEET OF DRAWN PATH TITL E CHECKED MATERI AL THIS D RAWING AND ALL INFORMA TION THER EIN IS THE PRO PERTY OF BOSS INDUSTRIES , INC. , IS CON- FIDE NTIAL AND MUST NOT BEMAD E PUBLI C OR COPIED. IT IS LOANED SUBJ ECT TO RETU RN UPON DEMAND, IS NOT TO BE USED DIRECTLY[...]

42 P/N: 307271 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 A A B B C C D D Parts List DESCRIPT ION PART NU MBER QTY ITEM TANK, COOLAN T RECOVERY 150-90199 1 1 SUPPORT COO LER MTG 307253 2 2 INSERT, 1/4-20U NC AKS4-420-165 120-36992 6 3 COOLER, OIL 1 8.6 X 27 SUPERIOR185 1 " 301992 1 4 BOLT, HEX GR5 1/4-20 X 3/4 929104-075 14 5 BOLT, WHIZLOC K GR5 5/16-18 [...]

43 P/N: 307271 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 A A B B C C D D SIZE DWG NO REV SCALE SHEET OF DRAWN PATH TITL E CHECKED MATERI AL THIS DRAWING AND A LL INFORMA TION THER EIN IS THE PRO PERTY OF BOSS INDUSTRIES, INC., IS CO N- FIDE NTIAL AND MUST NOT BEMAD E PUBLI C OR COPIED. IT IS LOANED SUBJ ECT TO RETU RN UPON DEMAND, IS NOT TO BE USED DIRECTLY [...]

44 P/N: 307271 DETA IL A SCALE 1 / 2 DETA IL B SCALE 1 / 4 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 A A B B C C D D SIZE DWG NO REV SCALE SHEET OF DRAWN PATH TITL E CHECKED MATERI AL THIS DRAWING AND A LL INFORMA TION THER EIN IS THE PR OPERTY OF B OSS INDUSTRIES, INC., IS C ON- FIDE NTIAL AND MUST NOT BEMAD E PUBLI C OR COPIED. IT IS LOANED SUBJ ECT TO RET[...]

45 P/N: 307271 1 1 2 2 3 3 4 4 A A B B C C D D SIZ E DWG NO REV SCAL E SHEET OF DRAWN PAT H TITLE CHECKED MAT ERIAL THIS DRAWING AND ALL INFORMAT ION THEREIN IS THE P ROPER TY OF BO SS INDUSTRI ES, INC., IS C ON- FIDENTIA L AND MUST NO T BEMADE PUBLIC OR COPI ED. IT IS LOA NED SUBJECT T O RETURN UPON DEMAND, I S NOT TO BE USED DIRECT LY OR IN- DIRE[...]

46 P/N: 307271 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 A A B B C C D D Parts List DESCRIPTION PART NUMBE R QTY ITEM LATCH ADJ LE VER C2-33-35 120-62264 8 1 BOLT, BTNHD S S STAR-DRIVE 1/4-20 X 3/4 983904 -075 38 2 WASHER, NYLO N 1/4 X .06 X .62 977004-062 38 3 WASHER, FLAT WIDE 1/4 SS 984004-071 38 4 ROOF, 185-210 DUS JD4045 OMEGA TO OL 307254 1 5 PANEL, DU[...]

47 P/N: 307271 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 A A B B C C D D SHEET 60417 1 1 OF REV 2 OPT, O IL/F LUID DRAINS INS T-PANEL END BOSS INDUSTR IES 1761 GENESIS DR. LA PORTE, IN 46350 N/A PATH MATE RIAL G:Inventor Files60k 60417.dwg 6/3/2008 MCM DRAWN CHECKED 1=6 D DESCRIPTION DWG NO R SCALE SIZE UNMACHIN ED SURFACES FRACTIONAL ` 1/16 DECIMAL ` .03[...]

48 P/N: 307271 Optional Fuel Gauge Sender Oil Pressure Gauge Sender Coolant Temp. Gauge Sender Fuel Solenoid Low Oil Pressure Safety Switch (N.O.) High Oil Temperature Safety Switch (N.C.) High Coolant Temperature Safety Switch (N.C.) Diode + _ AC Tap Bat. Alt. + Field Exec. W/ Internal Regulator Starter Battery 12V + _ Optional Tachometer Circuit [...]