In the world of firewood processing, efficiency and innovation are key. Blockbuster firewood processors have integrated an air return system that simplifies operations and enhances overall performance. This blog will explore the components, benefits, and troubleshooting tips for this air system, ensuring operators can maximize their machine’s potential.

Key Components of the Air System

The air system in Blockbuster processors (18-20, 18-20+, 22-20 and 22-22) consists of several essential components that work together to optimize functionality. Understanding these components is crucial for effective operation and maintenance.

  • • Compressor: The heart of the air system, responsible for generating the necessary air pressure (135psi shut-off, 115psi turn-on).
  • • 2-Chamber Air Tank: Stores compressed air for use in various functions within the processor.
  • • Splitting Cylinder: Utilizes air pressure for returning/retracting the cylinder and this is plumbed into the small section of the air tank and can see pressures of 300-500psi when the cylinder is extended.
  • • Dump Tray (22-22 only): Utilizes air to extend the dump tray cylinder so it automatically returns to the “up” position when the dump tray lever is released – also plumbed into the small section of the air tank.
  • • Saw Cylinder: Utilizes air to automatically retract the saw cylinder so it returns to its upright position after the saw lever is released – this is the only cylinder plumbed into the large section of the air tank.
  • • Auto Stop/Measuring Stop (Standard feature on the 22-22, an option on the 18-20+ & 22-20) Uses air to automatically retract the stop cylinder to avoid “pinching” the log when being cut and is plumbed into the small side of the air tank.

How the Air System Works

The air system operates under pressure, filling the air tank to approximately 135 pounds. This pressure is crucial for the various functions of the processor. Regular checks for oil or moisture in the air tank are essential to maintain optimal performance. A small amount of oil or moisture is normal, but excessive amounts could indicate an internal bypass issue in one of the cylinders (more than a mist or a few tablespoons).

Key operations of the air system include:

  • • Automatic return of the splitting cylinder after it completes its stroke.
  • • Automatic saw cylinder return (to the upright position) when the saw lever is released.
  • • Automatic retract of the Auto Stop/Measuring Stop cylinder.
  • • Automatic return on the dump tray (on the 22-22 model only).

Benefits of the Air System

The air return system in Blockbuster processors offers numerous advantages that enhance user experience and operational efficiency:

  • • Autocycle Functionality: The system allows for a more automated operation, freeing the operator from additional manual tasks.
  • • User-Friendly Design: With no electric solenoid valves or complex wiring, the air system is straightforward and easy to service.
  • • Efficiency in Operations: By running the same pump section for both the splitting cylinder and saw motor, users can cut and split wood simultaneously.
  • • Reduced Maintenance Needs: The simplicity of the air system means less potential for electrical faults, leading to easier maintenance and repairs.
  • • Helpful to have compressed air at the worksite to inflate tires and blow/clean off the machine at the end of the day.

Troubleshooting the Air System

While the air system is generally reliable, issues can arise. Here are some common troubleshooting tips to ensure smooth operation:
Low Air Pressure
If the air pressure is low, check the following:

  • • Ensure the key is on to activate the pressure switch and compressor power.
  • • Inspect the 80-amp fuse; a blown fuse will prevent the compressor from turning on.
  • • Check for power at the compressor; if it doesn’t turn on, there may be a relay issue.

 

Identifying Leaks

If air pressure doesn’t maintain (during operation or while shut off), you may have a leak. To identify it:

  • • Use soapy water to spray fittings on the air tank, hose ends, compressor, and cylinders. Look for bubbles indicating leaks.
  • • Listen for gurgling sounds in the hydraulic tank, which could suggest bad packing in a cylinder.

Testing Cylinders

To determine which cylinder might be causing issues:

  • • After running for a few hours, drain the air tank on the smaller chamber, if oil is present (more than a mist or a few tablespoons), check the splitting cylinder, dump tray cylinder and then the auto-stop cylinder (if equipped).
    • • Cap off the air hose to one of the cylinders that has air going to it, turn on the compressor and see if air pressure stabilizes, which can help pinpoint the issue to a specific cylinder. Do this one cylinder at a time.
  • • After running for a few hours, drain the air tank on the larger chamber, if oil is present (more than a mist or a few tablespoons), check the saw cylinder.
    • • Cap off the air hose to one of the cylinders that has air going to it, turn on the compressor and see if air pressure stabilizes, which can help pinpoint the issue to a specific cylinder. Do this one cylinder at a time.

Conclusion

The air return system is an innovation that helps set Blockbuster firewood processors apart. The simple yet effective design combines reliable performance with easy maintenance, allowing operators to maximize productivity while minimizing downtime. Whether you’re running an 18-20 model or the larger 22-22, understanding and properly maintaining your processor’s air system is key to ensuring years of efficient operation.
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