TWISTER - Airworks Compressors

- A division of Airworks Compressors and Mobile Equipment Corp -

TWISTER

T100 – T235

INSTALLATION

&

OPERATION MANUAL

REVISED 05/18

Unit Serial Number __________________________

Engine SN _________________________

Compressor SN ____________________

Control Box SN _____________________

Table of Contents

Operating Instructions ................................................................................................................................. 1

Basic Installation/Operation ..................................................................................................................... 1

Safety ........................................................................................................................................................ 2

Maintenance ............................................................................................................................................. 4

Starting/Shutdown Procedures ................................................................................................................. 5

Coolant Fill Instructions (Cold Weather Kit) ............................................................................................. 6

Troubleshooting ........................................................................................................................................ 8

Caring For Your Twister ........................................................................................................................... 11

Warranty Policy ....................................................................................................................................... 12

Drawings ..................................................................................................................................................... 14

Wiring ...................................................................................................................................................... 14

Control Box .............................................................................................................................................. 15

Control Box Mounting Template............................................................................................................. 16

Bulkhead ................................................................................................................................................. 17

Body ........................................................................................................................................................ 18

Base Pan .................................................................................................................................................. 19

Mounting Instructions – Air Flow............................................................................................................ 20

Engine ...................................................................................................................................................... 21

Compressor ............................................................................................................................................. 22

Warnings ................................................................................................................................................. 23

Optional Equipment and Tie In Kits ........................................................................................................... 24

1

Basic Twister Installation and Operation

Important: Read and understand operation manual before installation.

1. a) Trace base size and mount hole locations onto cardboard and use as template to drill holes to mount compressor in suitable location. Use caution when drilling; check below for obstacles.

b) Allow for proper fitting, hose, wire routing. Allow for proper ventilation and service access.

2. Mount compressor to service body using 4 holes provided in base. Securely fasten. Use locking fasteners.

3. a) Run supply and return fuel lines to truck diesel fuel tank. Use the auxiliary pick up provisions on tank. Note: Do not cut into the truck engine lines. Consult vehicle manufacturer for proper procedure, use kit part number ATA013.

b) Use caution to prevent rubbing/pinching on fuel line when vehicle in motion and any contact with hot or moving parts.

c) Electric fuel pump on Twister may need to be relocated near to fuel tank on long fuel line runs or with for high lifts (over 3 feet) and long runs (over 6 feet).

d) An electric auxiliary fuel pump is available for long fuel line runs for long fuel line runs Part Number AOF003

4. Run battery cable from Twister to truck battery. Install a 150 amp circuit breaker (Electric tie in kit Part Number ATA012) in system, near battery; size cable properly for length of run. Protect from rubbing and damage.

5. Mount Twister control panel in accessible location. For extended length location use extension P/N AOCBH10

6. If connecting truck cooling system to Twister, use Airworks’ Cold Weather Package, P/N ATO112. NOTE: Any alteration to Twister cooling system will result in a void warranty!

7. Operating unit with low coolant level will cause damage not covered by Warranty!

8. Avoid cooling air flow restriction, air must flow freely into unit and exit from unit without restriction. Ensure hot air is not redirected into cooling air stream.

Installation Notes

The electric fuel pump on the Twister is not capable of drawing fuel from long distances. If the installation of the Twister is more than 6 feet from the fuel tank, the pump should be relocated closer to the fuel tank. An auxiliary fuel pump is available from Airworks, part number ATO110 for long runs (more than 6 feet) or high lift (more than 3 feet).

Restrictions in the air line such as 45 degree and 90 degree fittings should be limited to 3 or less. Too many direction changes or elbows will lead to loss of air flow. Size fittings at least the same size as twister air outlet or larger.

When installing the Twister in a confined location, direction of airflow through the unit should be considered. A source of fresh air in and a place to vent the warm air is critical to the proper operation of the compressor and engine. Do not allow or cause warm air to recirculate back into compressor.

When connecting the battery cables to the Twister, it is recommended to use a minimum 4 gauge welding cable with a 150 amp breaker in line. Due to the rubber mounting bases on the Twister, it is recommended that the unit is grounded, using supplied ground lead from Twister to chassis battery.

*for installation at a distance over 12’ from battery, heavier cable is recommended.

2

Safety Precautions

Observe the Following General Safety Rules

a) Read and understand operation manual and all related safety materials, before operating machine. Installer to ensure manual and all safety decals are delivered with unit on completion of product installation.

b) Follow safe work practices and wear the appropriate safety equipment when operating air-power equipment.

c) Avoid contact with the drive system. Do not operate with panels removed. d) Avoid skin contact with pressurized air. Injury or death may result. e) Make sure the air entering the compressor is free of flammable vapours that could cause an

explosion. f) Vaporized oil propelled by high pressure air is an explosive mixture. g) Do not breathe the compressor air. Vaporized oil is a respiratory hazard. h) Components are hot during and following operation; use caution. i) Disconnect all power before any servicing. j) Do not attempt to service compressor while under pressure; remove fill cap and filters slowly,

drain reservoir, before opening system. k) Never refuel unit while running or hot. l) Avoid sparks and flame when refuelling m) Fuel in a well ventilated area only. n) If using electric generator or welder options ensure all components in good condition, use in

dry location only, refer to manual.

When operating the compressor:

Ensure all users are familiar with safe operation and have read this manual.

a) Do not bypass any of the units safety shut down devices. b) Do not expose the unit to extreme heat. c) Do not repair or service a pressurized system. d) Maintenance and repairs are to be performed by qualified personnel only. e) Do not tamper with the pressure relief valve (PSV). f) Do not attempt to modify any component. g) Do not operate with cover or doors removed. h) Do not use replacement or service parts other than Airworks recommended components. i) Compressor may start at any time discount power before serving.

Safety Features

a) 200 psi relief valve (PSV) b) Temperature safety shut down on engine and compressor c) Rapid blow down valve to discharge system pressure on compressor side of system after unit

is shut down d) Low oil pressure shut down on engine e) Outer enclosure prevents contact with hot and moving parts. f) Optional low coolant sensor (include in all cold weather kits) g) Warning decals

3

Lubrication and Filters

a) Use only Airworks certified and approved fluids and filters b) Compressor may be under pressure; ensure pressure is released and unit is switched off

and unloaded before servicing, remove fill cap slowly – stop if pressure is present until compressor unloads.

c) Oil filters are spin-on type

d) Air filters are paper element replaceable

e) Spin on coalescing separator element

Operating Principals

The system uses a flooded lobe, rotary screw compressor. The oil filled compressor contains two synchronous rotors turning at a variable speed.

When air at atmospheric pressure is introduced into the housing, by the inlet control valve it is trapped between the rotors allowing for compression.

A lubricated pitch line provides sealing. As the lobes on the rotors mesh, they reduce the volume of air, compressing it to the desired pressure.

Oil separation occurs in two stages.

1. Mechanical; where the air/oil is first separated through a series of baffles 2. The coalescing filter.

A liquid to liquid cooling system is used to maintain compressor oil temperature. This system uses the cooling system of the prime mover to act as a heat sink for heat transfer and may also use an air to oil cooler.

Rotary screw compressors are machined to close tolerances and ingestion of foreign objects into the system will rapidly damage or shorten the life expectancy of the unit.

Direct coupled engine and compressor drive improves efficiency and reduces moving parts.

Important

Driving on rough terrain while your unit is running may cause damage to be incurred. Shut your unit off prior to moving your vehicle to prevent this.

4

Routine Maintenance

You must follow the maintenance schedule and use only Airworks genuine replacement parts to maintain your system and warranty.

The most critical aspect of maintenance is proper air filtration and clean oil. If any particulate matter enters the compressor through the air inlet or other means, they can contaminate roller bearings, gears and rotors in the compressor. Contamination will cause severe and rapid damage to components.

Ensure compressor is completely unloaded before servicing. Clean Areas to be serviced. Remove fill cap and filters slowly.

Damage caused by contamination not covered by warranty.

Maintenance Schedule

The following maintenance schedule should be observed to assure good performance and long service life. The hours indicated are displayed on the unit’s hour meter. To maintain warranty it is recommended to service Twister minimum once per year regardless or hour used.

For replacement parts please order the indicated part numbers from an authorized dealer.

250 Hours – Change engine oil and oil filter. Change compressor oil, oil filter, and air filter.

Inspect unit coupler assembly, check for leaks, loose fasteners, fittings, wire and hoses chaffing as above. T40/T60 - Airworks Service Kit P/N ATS425 T100/T185 - Airworks Service Kit P/N ATS125

500 Hours – Change engine oil, oil filter, fuel element, fan belt and air cleaner element. Change

compressor oil, oil filter, coalescing filter and air filter. Replace fan belt. Replace coupler insert. Set valve lash.

T40/T60 - Airworks Service Kit P/N ATS450 T100/T185 - Airworks Service Kit P/N ATS150 500 HR Service Kit Instructions

NOTE: Fuel filter housing requires bleeding after fuel filter change.

a) Turn unit on without starting engine.

b) Loosen screw on top of fuel filter housing until a steady flow of fuel is seen.

c) Tighten screw, start unit, check for leaks.

Clean up any spilt fuel or oil and dispose of properly.

Inspect all components for loose or rubbing parts and adjust valve lash. Inspect all items for wear, including drive coupler. Check for fluid and air leaks. Check air pressure and engine speed settings.

5

Value Lash Settings Cold

Kobota Z482 Intake 0.007 / Exhaust 0.007

Yanmar 3TNV Intake 0.008 / Exhaust 0.008

Twister Starting Procedure

Diesel Engines

* Turn ignition key to the left and hold for 15 seconds. This primes the fuel pump and engages the pre-heater. In cold temperatures (below -10 degrees C), hold pre-heater for up to ONE minute if required NOTE: NEVER USE STARTING FLUIDS * Now turn the key to the right (crank position). When engine has started release key. * When engine has “reached operating temperature”, engage the compressor switch; this will allow the compressor to start. * When pressure reaches preset pressure (150 to 170 psi) unit will idle down. * System is now ready for use.

Twister Shutdown Procedure Diesel Engines

* Switch compressor button off. * Compressor will disengage and bleed off pressure. * Allow engine to idle 30 seconds * Turn key to off position. * Engine will stop

* Never shut the engine off with compressor under load. This may result in compressor damage.

6

Coolant Fill Instructions – For Use with Cold Weather Kit

Cold weather option ties chassis cooling system into Twister cooling system.

NEVER OPEN THE COOLING SYSTEM WHILE HOT!

Perform a visual check of both the chassis engine and the Twister coolant expansion bottle with both engines cold. The Twister expansion bottle should be 1/3 full or less. Consult the chassis owner’s manual for the correct chassis coolant level.

Check the coolant level in the Chassis reservoir

• Coolant should be at the manufacturer’s suggested level. If low, open cap very slowly, if coolant

remains in Twister, it will flow into chassis reservoir as the air lock is broken. Allow to fill to

manufacturer’s suggested level from Twister or if required add additional coolant. Once

suggested level is reached, close system and DO NOT OPEN AGAIN.

Check the coolant level in the Twister

• SLOWLY open the Twister radiator cap. Correct coolant level is ½ inch above radiator core when

cold and chassis at proper level. If level is not above the core of the radiator, add coolant using

the same coolant as suggested by the chassis manufacturer. Do not fill upper radiator tank to

top as room is required for expansion as truck and/or Twister heat up. Overfilling will cause

coolant overflow at the Twister.

Test the system by running the Twister or the chassis engine. Let engine(s) cool and check for correct level and fill (AT THE TWISTER) as necessary until the coolant is at the correct level.

TIP: If chassis reservoir has been overfilled by opening the cap and breaking the air lock or by simply adding too much coolant while performing the above checks, ensure that the Twister coolant level is LOW. The coolant levels will then balance themselves as the Twister/truck runs. After running, allow to cool down and recheck levels at both the chassis and Twister. Coolant level should be correct in chassis reservoir. If low at the Twister, add coolant to the Twister to bring to correct level – ½ inch above core.

If coolant is pushed out at chassis cap, the cap is weak. Test and replace as required.

7

Pressure Regulation and Engine Speed Control

The system uses two control systems. One, an air pressure control switch and the other, an engine speed control. This allows for instant response to air demands based on air flow and reduction of load on the engine and reduces fuel usage. These items are set at the factory and should not require adjustment.

Adjusting the System

If insufficient airflow is developed under high demand conditions, check the engine RPM.

The throttle control is preset for maximum delivery by the system at all airflow demands within the unit’s abilities, but in some instance may require adjustment by the user. This is done by adjusting the linkage on the throttle control to increase or decrease the engine RPM.

The cut out and cut in pressure of the compressor can be adjusted on the pressure switch (clockwise to increase pressure). Consult your Airworks dealer if you have any questions before attempting adjustment.

Airflow and system pressure are related. As the cfm requirements increase, the pressure produced during flow, as with any air system, diminishes. The Twister is designed to efficiently run instruments requiring air at 90 psi or less (manufacturer’s standard psi rating).

If you must set up a system without knowing the demands on the system, you can make adjustments by using an orifice in the outlet to stimulate tool use. A system testing and adjustment tool is available from Airworks (ATT001).

If unit cycles rapidly during tool/equipment use, this indicates the compressor is producing more air than tool/equipment requires. Engine rpm may be decreased to lower air volume produced. Contact dealer for proper procedure.

8

Trouble Shooting the System

Quick accurate diagnosis of problems will help to effect repairs in a timely fashion and should involve the following:

a) Understand the operational characteristics of the system to better determine the problem. b) Run the system, if possible, to determine the problem. c) Do not perform test procedures that are harmful to people or equipment. d) Perform repairs using the correct parts and procedures. e) Consult your local dealer or Airworks Compressors Corp.

Symptom:

Compressor does not produce adequate air

Check and correct the following:

a) Compressor oil level is correct b) Coupling between engine and compressor is intact c) Pressure switch is operational d) Air filters are clean e) Engine RPM is set to spec, adjust as required f) Blockage downstream of compressor g) No air produced - minimum pressure valve sticking or misadjusted.

Symptom:

Frequent over-temperature shut downs


a) Check engine and compressor oil levels b) Check engine coolant level, while unit is cool c) Check engine and compressor hoses for kinks d) Check engine and compressor over temp shut down temp probes e) Check for adequate air circulation around unit, hot air shall not be drawn into unit. f) Check oil filters not plugged g) Fan belt is properly adjusted h) Radiator core dirty/blocked, clean with caution using compressed air. Do not damage fins. i) Faulty over temp switch on engine (240°F) or compressor (270°F)

Symptom:

Excessive air pressure


a) Check pressure switch for correct operation b) System pressure line leaking (from compression to pressure switch) c) Inlet valve functioning and power to solenoid valve

9

Symptom:

Engine stalls when compressor starts


a) Engine fuel filter or air filter plugged - replace b) Fuel pump functioning c) Air compressor is under pressure – allow to unload d) Operating speed is too low – adjust as required (1800 rpm) e) Blow down valve operating properly f) Compressor switched on, building pressure (should be off to start) g) Positive air shut off valve tripping (optional – not on all units)

Symptom:

Low air pressure


a) Air flow capacity exceeded – reduce load demand on compressor b) Engine speed too low – adjust as required c) Pressure regulator/switch not operating properly – adjust or replace as required d) Restricted flow - kinked or collapsed air line, ice blockage.

Symptom:

Excessive oil in the air produced


a) Check compressor oil level – ensure correct level b) Check oil scavenging line is clear – clear and inspect c) Check coalescing filter – replace as required

Symptom:

Diesel engine turns but will not start

Check and correct the following

a) Adequate fuel supply (min 4psi running) b) Glow plugs - test c) Compressor switch on/turn off d) Fuel filter restricted/valve off – bleed air from filter housing e) Positive air shut off valve tripped (optional – not on all units) f) Fuel pump operation – check flow g) Bleed air from fuel filter through screw at top of filter.

10

Symptom:

Oil blows out of compressor air filter on shut down


a) Unit shut down while compressor under load b) check inlet control valve seal – repair as required

Symptom:

Engine Smoking Lack of Power


a) Check coolant level b) Air in fuel filter c) Operating in hot environment (air intake can be routed to outside fresh air) d) High air pressure check e) Low fuel pressure/delivery (min 4psi running)

Symptom:

Compressor builds air while engine cranking and overpressures when running


a) Compressor switch is off while cranking b) Inlet check valve stuck – (18) on page 22 c) Inlet solenoid valve faulty – (19) on page 22 d) Damaged leaking inlet valve seal, usually resulting in oil on inside of air filter

Symptom:

No air production


a) Listen for air unloading when engine shut down. If no air unloading, check drive hub, remove rubber plug in bell housing, check for drive disk failure/debris

b) Check minimum pressure valve operation by removing compressor top cover and compressor air filter lid. Depress the black valve using a blunt object and slight pressure downward while unit running and compressor switch on. If air pressure builds and holds valve open on its own, suspect minimum pressure valve issue – (13) on page 22

c) If above checks yield no results check inlet valve. Check valve function, loosen steel tube between check valve and top of compressor case, have someone start unit, if air builds check valve is faulty. Tighten check valve tube immediately and before shutting unit off or over pressure and oil loss may result.

11

Caring for Your Twister

Your Twister is designed to provide many thousands of hours of working life. By following the listed procedures you will ensure this happens and protect your investment, up time and warranty.

Every 25 hours

• Check fluid levels

• Check for loose or rubbing components, leaks, air and fluid

Every 100 hours

• As above plus

• Check air filter elements condition

• Check fan belt tension

• Check fuel filter

Every 250 hours

• As above plus

• Service engine and compressor oil and filters

• Check radiator hoses and clamps

• Check air intake hose

• Check hoses for rubbing and/or wear

• Check replace belts as required

Every 500 hours

• As above plus

• Service engine oil and filters

• Check radiator hoses and clamps

• Check air intake lines

• Replace coupler on engine and compressor

• Replace the fuel filter element

• Clean the radiator external fins

• Replace the fan belt/replace generator belt if required

• Check valve lash (see page 5)

500 HR Service Kit Instructions

NOTE: Fuel filter housing requires bleeding after fuel filter change.

a) Turn unit on without starting engine, to run fuel pump

b) Loosen screw on top of fuel filter housing until a steady flow of fuel is seen.

c) Tighten screw, start unit, check for leaks.

Clean up any spilt fuel and dispose of properly

Every 2 years

• Replace radiator hoses and clamps

• Change radiator coolant

• Replace air intake hose

12

Warranty Policy

General Provisions and Limitations

1. Airworks Compressor Corp. warrants to each original retail purchaser (here after the buyer) of its new air compressor system from Airworks or its authorized dealers that such products are free from manufacturer’s defects in material and workmanship.

2. No warranty is made with respect to: a) Any products which in Airworks judgment have been subject to negligence, accident

or improper storage, installation, application, operation or maintenance, or have been altered or repaired in such a way that effects the product adversely.

b) Operation of unit with low coolant level will cause damage not covered by warranty. c) Components or accessories manufactured, warranted and serviced by other than

authorized dealer. d) Consequential damage(s) caused by Products failure. e) Any product(s) if other than Airworks genuine components are used in the Product

and/or installation f) Normal wear and tear g) Paint and cosmetic items h) Any modifications whatsoever, including operation without body panels

3. The warranty period will commence upon installation of the product. The returned warranty

registration form marks the date of installation. If the warranty registration form has not been received by Airworks within 2 months from the date of purchase then the warranty period will be deemed to commence 30 days from date of shipment from Airworks.

4. a) T40/T60 Air end has a limited life time warranty providing original service schedule and parts are utilized.

b) The units are warranted for two (2) years or two thousand (2000) hours, whichever occurs first, against manufactures defects in materials and workmanship.

5. Replacement parts, electrical components and cosmetic items (at Airworks discretion) shall be

warranted for a period of six (6) months or three hundred (300) hours, whichever occurs first.

6. Airworks Obligation a) Airworks obligation is limited to repairing or at Airworks option, replacing; during normal

business hours at an authorized service facility of Airworks, any component, which in Airworks judgment is proven to be defective as warranted.

b) Airworks obligation is limited to Product(s) proven to be warranted. No liability is accepted for any consequential damages, injuries or expenses directly or indirectly related to the Products failure.

c) Airworks is not responsible for any costs incurred due to lost time, travel or lost revenue related to warranty issues.

d) Airworks is not responsible for time required to service or repair product due to mounting location.

e) Airworks is not responsible for return shipping to Airworks of failed components. f) Airworks will be responsible for ground shipment or replacement of validated warranty parts. g) Airworks is to be contacted prior to any possible warranty repairs are undertaken for warranty

consideration.

13

Buyers Obligations

a) You, the buyer, are obligated to notify your dealer within 10 days of any defect and return defective part within 30 days of notification.

b) The buyer must prepay all the costs associated with the warranty claim and submit receipts/invoices to your dealer for evaluation.

c) The buyer must return components returned under this agreement to your dealer, designated by Airworks, for evaluation, to establish a claim under this warranty.

d) Buyer shall maintain and service Airworks products in accordance with this manual.

Warranty Registration Validations * A warranty registration is supplied to the buyer with the product that must be returned to Airworks at time of installation. Disclaimer and Warranty Service

a) Any labour costs incurred in excess of Airworks set labour rates are not covered. b) Any travel time or labour costs incurred by unauthorized personnel are not covered by this

warranty. c) Any related service/repair costs incurred due to mounting location and accessibility are not

covered by this warranty. d) This warranty is in lieu of all other warranties expressed or implied e) All warranty claims must be pre-authorised by Airworks and components returned prepaid

using the assigned RGA number.

(16) Secondary Fuel Filter(17) Fuel Inlet(18) Fuel Return(19) Top Filler Cap (Engine Oil)(20) Rocker Arm Cover(21) Air Intake Port (From Air Cleaner)(22) Flywheel Drive Plate(23) Starter Motor(24) Exhaust Manifold(25) Alternator 40 Amp(25A) Alternator 80 Amp(26) Engine Air Filter(27) Fuel Primary Filter(28) Idle Solenoid

(1) Lifting Eye (Flywheel End)(2) Turbocharger(3) Lifting Eye (Engine Cooling Fan End)(4) Engine Coolant Pump(5) Engine Cooling Fan(6) Crankshaft V-Pulley(7) V-Belt(8) Side Filler Cap (Engine Oil)(9) Drain Plug (Engine Oil)(10) Fuel Injection Pump(11) Engine Oil Cooler(12) Engine Oil Filter(13) Dipstick (Engine Oil)(14) Governor Lever(15) Intake Manifold

(26)

(28)

(27)

ATE104

ATE151ATE138ATE152ATB102ATE126

ATE106ATE153ATE154ATE125ATE111ATE113ATE121

ATE107ATE115ATE116ATE150

ATE119ATE120

ATE155ATB101ATE133ATB128ATB080ATE027ATE117ATB006

T100 - T235 ENGINE

06/18

TWISTER

Copyright Airworks Compressors Corp. 21#4024-01

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18 19

21

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ϤϤCopyright Airworks Compressors Corp. #4027-01

(T100)(T150)(T185)(T235)

-T235)(T235)

(T185

06/18

(1) Air End Complete

(2) Air Filter(3) Inlet Valve Assembly(4) Oil Filter Cartridge(5) Coalessing Filter(6) Pressure Maintaining Valve(7) Safety Valve 200 PSI Std.(8) Oil Out Fitting(9) Oil Return Fitting(10) Oil Fill Plug(11) Oil Drain(12) Discharge Fitting(13) Minimum Pressure Valve(14) Pressure Switch(16) Fan Cooler(17) Aux. Cooler(18) Inlet Check Valve(19A) Inlet Control Solenoid 12V(19B) Inlet Control Block(20) Compressor Drive Hub(21) Thermal Valve

ATC101-AATC101-BATC101-CATC101-DATC102ATC129ATC103ATC104ATC125ATC109ATC133ATC134ATC167ATC123ATC122ATC112ATC006ATB147ATB148ATC186ATC127ATC126ATC118-03ATC188

TWISTERT100 - T235 COMPRESSOR

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TWISTER - Airworks Compressors