Airworks – Twister Series Compressors

Models

Twister T40
Twister T40 Diablo
Twister T60
Twister T60 GH
Twister T100
Twister T185
Twister Hybrid

Optional Equipment

• BOOSTER PAK – 12/24 volt D.C. booster/alternator package for boost starting equipment.
• HYDRAULIC PUMP OUTPUT – Direct drive hydraulic pump supplies hydraulic power for pickers, bucket lifts, hydraulic tools etc.
• GENERATOR – Generators from 4-6.5 kw, 120 and 220 volts, belt and direct drive available.
• AUTO START – Monitors compressor demand and will shut unit down when selected time elapses without air demand; unit restarts when air demand is sensed.
• RADIO REMOTE CONTROL – Allows starting, stopping and idle control from up to 200 foot range.
• COLD WEATHER PACKAGE – Allows cooling system of unit to tie into chassis, warming unit on the way to job site. Keeps cab/chassis warm while unit is working with vehicle shut off.
• SUMMER PACKAGE – Air conditioning package keeps the cab cool with vehicle shut off.
• ALTERNATOR UPGRADE – 100 to 200 amp alternator upgrade allows operation of inverters, lights etc. 40 amp alternator is standard.
• STAND ALONE PACKAGING – Units can be skid mounted and left on site or moved from truck to truck. Package includes battery box, fuel tank and fork lift skid.

Features and Benefits

• World’s first diesel compact air compressor
• Rotary screw compressor
• Less weight; less fuel; more power; easy to transfer
• Tier 4 certified
• Safety shut down procedure
• Over temperature protection
• Continuous duty
• Integral oil cooler
• Powder coated finish
• Wired remote controls
• Multi-positional exhaust
• Reduced chassis idle time

Hybrid Option Additional Features and Benefits

• One of a kind truck mounted air compressor
• Cleaner burning fuel extends engine life
• Suitable for any chassis; reduced chassis run time
• Decreased fuel usage: Kubota powered
• Encapsulated rotary screw air compressor
• Direct coupled engine/compressor (no belt drive)

T60GH Additional Standard Features

• Generator
• Hydraulic Pump

Operating Principles

• The system uses a flooded lobe, rotary screw compressor. The oil filled compressor contains two rotors turning at a variable speed.
• When air at atmospheric pressure is introduced into the housing, 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.
• 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.
• Oil separation occurs in two stages
  • One: the mechanical; where the air/oil is first separated through a series of baffles
  • Two: by the coalescing filter.

System Operation

Important: Read and understand operation manual before installation.

1. 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.
2. Allow for proper fitting, hose wire routing. Allow for proper ventilation and service access.
3. Mount compressor to service body. Securely fasten.
4. Run supply and return 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.
5. Use caution to prevent rubbing/pinching on hose when vehicle in motion.
6. Electric fuel pump on Twister may need to be relocated near to fuel tank on long hose runs.
7. An electric auxiliary fuel pump is available for high lifts and long runs (see parts lists).
8. Run battery cable from Twister to truck battery. Install a 150 amp circuit breaker in system, near battery; size cable properly for length of run.
9. Mount Twister control panel in accessible location.
10. If connecting truck cooling system to Twister, use Airworks’ Cold Weather Package, P/N ATA020.
11. An auxiliary booster water pump is available for long run and high mounting locations. Use Airworks’ P/N ATA015.

Installation Notes

The stock fuel pump on the Twister is not capable of drawing fuel from long distances. If the installation of the Twister is more than 6 (six) feet from the fuel tank, the pump should be relocated closer to the fuel tank. An auxillary fuel pump is available from Airworks, part number ATA014 for long runs or high lift.

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 may lead to loss of flow.

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 out is critical to the proper operation of the compressor and engine.

When connecting the battery cables to the Twister, it is recommended to use a minimum 4 gauge wire with a 150 amp breaker in line. Due to the rubber mounting bases on the Twister, it is recommended that the unit is grounded to a clean, paint free spot on the Twister engine and to battery.

Twister Starting Procedure

Turn ignition key to the left and hold for 15 seconds. This primes the fuel pump and engages the glow plugs. Never hold key in this position for longer than 15 seconds as damage to the glow plugs could result.
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 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

Switch compressor button off.
Compressor will shut down and bleed off pressure.
Turn key to off position.
Engine will stop

Observe the Following General Safety Rules

Read and understand operation manual, before operating machine. Installer to ensure manual and all safety decals are delivered with unit on completion of product installation.
Follow safe work practices and wear the appropriate safety equipment when operating air-power equipment.
Avoid contact with the drive system. Do not operate with panels removed.
Avoid skin contact with pressurized air. Injury or death may result.
Make sure the air entering the compressor is free of flammable vapours that could cause an explosion.
Vaporized oil propelled by high pressure air is an explosive mixture.
Do not breathe the compressor air. Vaporized oil is a respiratory hazard.
Components are hot during and following operation; use caution.
Disconnect all power before any servicing.
Do not attempt to service compressor while under pressure; remove fill cap and filters slowly.

When operating the compressor

Do not bypass any of the units safety shut down devices.
Do not expose the unit to extreme heat.
Do not repair or service a pressurized system.
Maintenance and repairs are to be performed by qualified personnel only.
Do not tamper with the pressure relief valve.
Do not attempt to modify any component.
Do not operate with cover or doors removed.

Safety Features

200 psi relief valve
Temperature safety shut down on engine and compressor
Rapid blow down valve to discharge system pressure on compressor side of system after unit is shut down
Low oil pressure shut down on engine

Lubrication and Filters

Use only Airworks certified and approved engine and compressor oils and filters
Compressor may be under pressure; ensure pressure is released and unit is unloaded before servicing, remove fill cap slowly – stop if pressure is present
Oil filters are spin-on type
Air filters are paper type replaceable
Spin on coalescing separator element

Routine Maintenance

During the warranty period 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 particles enter the compressor through the air inlet, 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.

Maintenance Schedule

The following maintenance schedule should be observed to assure good performance and long service life. The hours indicated are those displayed on the unit’s hour meter.

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.

T40 – Airworks Service Kit P/N ATA40250
T100 – Airworks Service Kit P/N ATA00250
T185 – Airworks Service Kit P/N ATA85250
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.

T40 – Airworks Service Kit P/N ATA40500
T100 – Airworks Service Kit P/N ATA00500
T185 – Airworks Service Kit P/N ATA85500
Inspect all components for loose or rubbing parts and repair as required.

Pressure Regulation and Engine Speed Control

The system uses two control systems. One, a factory set air pressure 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 cooling system.

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 at the factory, but in some instance may require minute adjustment by the user. This is done by adjusting the linkage on the throttle control to increase or decrease the diesel RPM.

The cut out and cut in pressure of the compressor can be adjusted on the pressure switch. Consult your Airworks dealer before attempting adjustment.

Airflow and system pressure are related. As the cfm requirements increase, the pressure produced, as with any air system, diminishes. The Twister is designed to efficiently run tools requiring air at 90 psi (tool manufacturer’s standard psi rating). If you must set up a system with out 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).

Troubleshooting

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

1. Understand the operational characteristics of the system to better determine the problem.
2. Run the system, if possible, to determine the problem.
3. Do not perform test procedures that are harmful to people or equipment.
4. Perform repairs using the correct parts and procedures.
5. Consult your local dealer or Airworks Compressors Corp.

Symptom:

Compressor does not produce adequate air
Check and correct the following:

1. Compressor oil level is correct
2. Coupling between engine and compressor is intact
3. Pressure switch is operational
4. Air filter is clean
5. Engine RPM is set to spec.

Symptom:

Frequent over-temperature shut downs
Check and correct the following:

1. Check engine and compressor oil levels
2. Check engine coolant level, while unit is cool
3. Check engine and compressor hoses for kinks
4. Check engine and compressor over temp shut down temp probes
5. Check for adequate air circulation around unit
6. Check heat exchanger not fouled
7. Check oil filters not plugged
8. Fan belt is properly adjusted

Symptom:

Excessive air pressure
Check and correct the following:

1. Check pressure switch for correct operation
2. System pressure line blocked or frozen (from compression to pressure switch)
3. Inlet valve functioning and no oil in compressor air filter

Symptom:

Engine stalls when compressor starts
Check and correct the following:

1. Engine fuel filter plugged
2. Fuel pump functioning
3. Air compressor is under pressure
4. Operating speed is too low
5. Blow down valve operating properly
6. Compressor switched on, building pressure (should be off to start)
7. Positive air shut off tripping (optional – not on all units)

Symptom:

Low air pressure
Check and correct the following:

1. Air flow capacity exceeded
2. Engine speed too low
3. Pressure regulator not operating properly

Symptom:

Excessive oil in the air produced
Check and correct the following:

1. Check compressor oil level
2. Check oil scavenging line is clear
3. Check coalescing filter

Symptom:

Oil blows out of compressor air filter on shut down
Check and correct the following:

1. Unit shut down while compressor under load
2. Check inlet control valve seal

Symptom:

Diesel engine turns but will not start
Check and correct the following

1. Adequate fuel supply
2. Glow plugs not used/faulty
3. Compressor switch on
4. Fuel filter restricted/valve off
5. Positive air shut off tripped (optional – not on all units)
6. Fuel pump operation

Caring for Your Twister

Every 25 hours

Check fluid level
Check for loose or rubbing components

Every 100 hours

As above plus
Clean air filter element
Check fan belt tension
Check fuel filter

Every 250 hours

As above plus
Service engine oil and filters
Check radiator hoses and clamps
Check air intake hose
Inspect coupler on engine and compressor, replace if required
Check hoses for rubbing and/or wear

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

Every 750 hours

Check the valve clearance

Every 2 years

Replace radiator hoses and clamps
Change radiator coolant
Replace air intake hose

Warranty Policy

General Provisions and Limitations

• Airworks Compressor Corp. warrants to each original retail purchaser (here after the buyer) of its new diesel drive air compressor system from Airworks or its authorized dealers that such products are free from manufacturers defects in material and workmanship.
• No warranty is made with respect to:
• 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.
• Components or accessories manufactured, warranted and serviced by other than authorized dealer.
• Consequential damage(s) caused by Products failure.
• Any product(s) if other than Airworks genuine components are used in the Product and/or installation
• Normal wear and tear
• Paint and cosmetic items

• 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.
• The units are warranted for two (2) years or two thousand (2000) hours, whichever occurs first, against manufactures defects in materials and workmanship.
• 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.
• Airworks Obligation
• 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.
• 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.
• Airworks is not responsible for any costs incurred due to lost time or travel related to warranty issues.
• Airworks is not responsible for time required to service or repair product die to mounting location.
• Airworks is not responsible for return shipping to Airworks of failed components.
• Airworks will be responsible for ground shipment or replacement of validated warranty parts.
• Airworks is to be contacted prior to any possible warranty repairs are undertaken for warranty consideration.

• Buyers Obligations
• You, the buyer, are obligated to notify your dealer within 10 days of any defect and return defective part within 30 days of notification.
• The buyer must prepay all the costs associated with the warranty claim and submit receipts/invoices to your dealer for evaluation.
• The buyer must return components returned under this agreement to your dealer, designated by Airworks, for evaluation, to establish a claim under this warranty.
• 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

• Any labour costs incurred in excess of Airworks set labour rates are not covered.
• Any travel time or labour costs incurred by unauthorized personnel are not covered by this warranty.
• Any related service/repair costs incurred due to mounting location and accessibility are not covered by this warranty.
• This warranty is in lieu of all other warranties expressed or implied
• All warranty claims must be pre-authorised by Airworks and components returned prepaid using the assigned RGA number.