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Boss 210 DUS JD4045 - User Manual

Boss 210 DUS JD4045
63 pages
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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
Service and
Maintenance
Manual
210 DUS JD4045
IT4 74HP
Air Compressor
309416
05-03-2013 ARB

Table of Contents

Questions and Answers

  • D
    Derek KellerAug 15, 2025
    How to fix a Boss 210 DUS JD4045 that will not crank?
    • E
      ellisjohnAug 16, 2025
      If your Boss Air Compressor won't crank, several issues could be the cause. First, check the battery terminals for tightness and any signs of corrosion, clean and tighten them. Also, ensure the battery has sufficient voltage, and charge or replace it if necessary. Inspect the ignition switch and replace it if faulty. Examine the starter solenoid connections for looseness or corrosion, clean and tighten them. Finally, the starter solenoid or starter itself may be faulty, requiring repair or replacement.
  • C
    Cathy MoralesAug 19, 2025
    What to do if my Boss 210 DUS JD4045 is overheating?
    • T
      Teresa FernandezAug 19, 2025
      If your Boss Air Compressor is overheating, several factors could be responsible. Ensure the unit is positioned in an area with adequate fresh air or open up the confined space. Check the fan belt for looseness or breakage, and tighten or replace it as needed. Clean any dirt buildup on the coolers, being careful not to damage the fins. Verify that the compressor oil level is correct and add oil if low. Replace a dirty compressor oil filter. If the thermostatic valve is malfunctioning, clean or replace the element. Address any restrictions in the compressor oil lines or oil cooler by cleaning or replacing the lines and cleaning the internal tubes of the cooler. Make sure that the doors are on. Add coolant to the proper level if the engine coolant level is low.
  • R
    Ronald QuinnAug 21, 2025
    Why does my Boss 210 DUS JD4045 crank but not start?
    • K
      Karen FisherAug 22, 2025
      If your Boss Air Compressor cranks but doesn't start, it could be due to several reasons. First, ensure there is enough fuel in the unit and add fuel if necessary, priming the fuel system if the unit has run out of fuel. Check for air in the fuel system by inspecting fuel line connections, tightening or repairing them as needed, and priming the fuel system. Lastly, check if the fuel solenoid is inoperative by checking for voltage at the solenoid while cranking the engine, and check the safety switches.
  • D
    deanthomasAug 25, 2025
    How to troubleshoot insufficient air delivery from Boss 210 DUS JD4045?
    • J
      jennifercannonAug 26, 2025
      If your Boss Air Compressor isn't delivering enough air, start by rechecking the maximum air requirement to ensure the compressor isn't undersized. Verify the engine speed and adjust it as needed. Inspect the air intake for restrictions, checking the air filter for dirt and ensuring the indicator is working, looking for obstructions in the filter and inlet piping, and confirming that the inlet valve is opening fully. Replace the drive coupling if it’s faulty.
  • D
    daltoncoleAug 27, 2025
    What to do if my Boss Air Compressor shuts down with air demand?
    • S
      Scott WellsAug 27, 2025
      If your Boss Air Compressor shuts down when there's air demand, the following could be the cause. Make sure the unit has enough fuel, adding more if necessary and priming the fuel system if it ran out. Replace a restricted fuel filter. Also, a safety shutdown might be activated. Check the compressor oil filter for restrictions and replace it if needed. Clean the radiator/oil cooler fins if there's a high engine coolant/discharge temperature shutdown. Repair or replace a slipping or broken fan belt. Add oil if the compressor or engine oil level is low.
  • P
    Patricia RamosAug 30, 2025
    Why won't my Boss 210 DUS JD4045 build up pressure?
    • J
      jonathanmitchellAug 30, 2025
      If your Boss Air Compressor isn't building up pressure, start by replacing the gauge if it's defective. Check service lines for leaks or open valves if the air demand is too great. If the blowdown valve is open, check to see if it’s getting a pilot signal and repair or service the valve. Replace the coupling if the drive coupling is faulty.
  • M
    michaelhernandezSep 2, 2025
    What causes excessive oil consumption in a Boss 210 DUS JD4045 Air Compressor?
    • T
      Teresa ScottSep 2, 2025
      Excessive oil consumption in your Boss Air Compressor can stem from several sources. If the separator tank is overfilled, drain it to the proper level. Check all piping lines and connections for leaks in the compressor oil system and repair as necessary. Inspect the oil return line and its check valve for restrictions, clearing them as needed, and ensure the oil return line reaches the bottom of the separator element. Replace the separator element if it's damaged. Consider that operating at low pressures increases oil carryover; recheck the load requirements if the compressor is undersized for the air requirement.
  • J
    John HernandezSep 5, 2025
    What causes excessive pressure buildup in a Boss 210 DUS JD4045 Air Compressor with no demand?
    • K
      Krista SimmonsSep 6, 2025
      If your Boss Air Compressor builds excessive pressure when there is no demand, it could be due to a defective gauge, which would need to be replaced. It may also be caused by the discharge pressure regulator not being properly adjusted or being faulty; try adjusting the regulator, or repair or replace it if necessary.
  • J
    Jeremy DavisSep 8, 2025
    Why does my Boss Air Compressor have high fuel consumption?
    • L
      latkinsonSep 8, 2025
      High fuel consumption in your Boss Air Compressor can be attributed to a couple of reasons. Check all the fuel lines and connections for leaks in the fuel system, repairing or replacing them as needed. Also, ensure the engine is operating at the correct speed by adjusting it to its proper speed.
  • E
    Erika WilliamsSep 12, 2025
    What to check if my Boss 210 DUS JD4045 continues to have high fuel consumption?
    • W
      William RangelSep 12, 2025
      If your Boss Air Compressor continues to have high fuel consumption, there are a few things to inspect. Check if the pressure to the inlet valve is set too high and adjust the regulator to the correct pressure for the unit. Inspect the engine air intake system for any restrictions, cleaning, repairing, or replacing components as necessary. Also, incorrect injection timing can cause this issue, so adjust it to the specifications in the engine manual.

Summary

Manual Change History

Revision List

Details changes made to the manual over time.

Welcome

General Information

Introduces the compressor and emphasizes reading the manual for safety and longevity.

Overview

Provides a general description of the 210 DUS Air Compressor's features and design.

Safety

General Safety Overview

Emphasizes the importance of common sense and awareness for safe operation.

Safety Precautions

Lists specific safety warnings and precautions to prevent injury and damage.

Safety and Information Decals

Identifies and explains the purpose of various safety decals on the machine.

Specifications

Specification Sheet

Provides detailed technical specifications, dimensions, and operating parameters.

Description of Components

Engine

Describes the John Deere 4-cylinder diesel engine powering the compressor.

Drive Coupling

Explains the function of the flexible disc drive coupling.

Compressor Airend

Details the rotary screw compressor's design and operation.

Separator System

Covers the separator tank and element for oil/air separation.

Pressure Relief Valve

Explains the valve that vents excess pressure from the separator tank.

Engine Air Filter

Describes the two-stage dry type engine air filter system.

Compressor Air Filter

Details the two-stage dry type compressor air filter system.

Cooling Systems

Covers the engine radiator and compressor oil cooler.

Compressor Oil Filter

Describes the spin-on canister compressor oil filter.

Compressor Oil Thermal Valve

Explains the valve that regulates oil flow to the oil cooler.

Compressor Inlet Valve

Details the normally open air intake valve.

Minimum Pressure Valve

Explains the valve that maintains minimum pressure in the separator tank.

Blowdown Valve

Describes the valve that vents system pressure upon shutdown.

Blowdown Switch

Explains the switch that prevents starting if system pressure is present.

Discharge Pressure Regulator Valve

Details the valve used to set desired discharge pressure.

Instrument Panel

Describes the panel containing gauges and controls for monitoring operation.

Installation

System Installation Overview

Provides general guidelines for safely installing the air compressor.

Placing The Machine

Details instructions for positioning the compressor on a level surface.

Connecting the System Fuel Supply

Explains how to connect the fuel supply and return lines.

Fuel Specifications

Discusses fuel types, cetane numbers, and cold weather considerations.

Connecting the Air Discharge Lines

Instructions for connecting customer-supplied air discharge lines.

Pre-Startup Inspection

Lists essential checks to perform before the initial system startup.

Machine Documentation

Guides on recording serial numbers for main components.

Check Fluid Levels

Details how to check and refill essential fluid levels like oil and coolant.

Initial Startup Preparation

Outlines steps to prepare the compressor for its first startup.

Initial Startup

Provides a step-by-step procedure for the initial startup of the compressor.

Operation

Routine Startup Preparation

Lists pre-operation checks for routine startup procedures.

Routine Startup Procedure

Provides a step-by-step guide for starting the machine normally.

Routine Shutdown Procedure

Outlines the correct procedure for shutting down the machine safely.

Emergency Shutdown Procedure

Details the steps for performing an emergency shutdown.

Maintenance

Maintenance Overview

Explains the importance of planned maintenance and record-keeping.

Maintenance Schedule

Provides a schedule of required maintenance tasks based on operating hours.

Recommended Spare Parts List

Lists essential spare parts and their kit numbers for the unit.

Parts and Service Contact Information

Provides contact details for obtaining parts and technical service.

Maintenance Log

A template for recording details of maintenance performed on the unit.

Separator Element Replacement

Step-by-step instructions for replacing the separator element.

Engine Air Filter Replacement

Detailed procedure for replacing the engine air filter element.

Compressor Air Filter Replacement

Detailed procedure for replacing the compressor air filter element.

Compressor Oil

Discusses compressor oil characteristics, recommendations, and warnings.

Adding Compressor Oil

Guide on how to add compressor oil to the system safely.

Changing Compressor Oil

Detailed steps for changing the compressor oil and filter.

Compressor Oil Cooler

Information on inspecting and maintaining the compressor oil cooler.

Compressor Oil Filter

Instructions for replacing the compressor oil filter.

Engine Cooling System Maintenance

Covers maintenance of the engine coolant and radiator.

Engine Fan

Instructions for checking the engine fan for damage or loose components.

Engine Serpentine Belt

Guidance on inspecting the engine serpentine belt for wear.

Battery

Information regarding the unit's battery specifications and care.

Standby Pressure Adjustment

Procedure for adjusting the standby air pressure setting.

Idle Speed Adjustment

Instructions on how to adjust the engine's idle speed.

Rated Speed Adjustment

Procedure for adjusting the engine's rated operating speed.

Troubleshooting

Troubleshooting Chart

A guide to diagnose and resolve common machine issues by symptom.

Troubleshooting Chart

Continues the guide with more common issues and their solutions.

Troubleshooting Chart

Further details on diagnosing and resolving operational problems.

Troubleshooting Chart

Final section of the troubleshooting chart covering more issues.

Parts and Service Contact Information

Contact details for obtaining parts and technical service.

Warranty

Warranty Policy

Details the terms and conditions of the product warranty.

Summary of Main Warranty Provisions

Outlines key provisions, exclusions, and procedures for warranty claims.

Warranty;Return Goods Instructions

Provides instructions for initiating a warranty or return claim.

Warranty Claims - Preparation of Parts Return

Guidance on packaging parts correctly for warranty claims.

Return or Warranty Claims - Filing Procedures

Steps for properly filing warranty or return claims.

Warranty Claims Provisions

Lists conditions that must be met for an approved warranty claim.

Damage in Transit

Procedures for reporting and claiming damages that occur during shipping.

Screw Compressor Airend Exchange Program

Information regarding the availability of replacement compressor airends.

Parts and Illustration Section

Frame System

Lists and illustrates parts related to the compressor's frame structure.

Frame System

Continues the illustration and part breakdown of the frame components.

Engine System

Lists and illustrates all parts associated with the engine.

Engine System

Continues the illustration and part breakdown of the engine system.

Compressor System

Lists and illustrates all parts of the compressor unit itself.

Compressor System

Continues the illustration and part breakdown of the compressor system.

Discharge System

Lists and illustrates parts of the air discharge system.

Discharge System

Continues the illustration and part breakdown of the discharge system.

Cooling System

Lists and illustrates parts of the engine and oil cooling systems.

Cooling System

Continues the illustration and part breakdown of the cooling system.

Electrical System

Lists and illustrates components of the electrical system.

Electrical System

Continues the illustration and part breakdown of the electrical system.

Canopy System

Lists and illustrates parts related to the compressor's canopy.

Canopy System

Continues the illustration and part breakdown of the canopy system.

Decal System

Lists and identifies the various safety and information decals on the machine.

Decal System

Continues the illustration showing the locations of decals.

Hose System

Lists all hoses, their sizes, types, and installation locations.

System Wiring Diagram

Provides the complete electrical wiring diagram for the compressor system.

Boss 210 DUS JD4045 Specifications

General IconGeneral
BrandBoss
Model210 DUS JD4045
CategoryAir Compressor
LanguageEnglish

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