250 dus aux-drive 13g - home - boss air
TRANSCRIPT
30727212/02/2009 MCM
250 DUSAUX-DRIVE 13G
OPERATORS, MAINTENANCE,AND PARTS MANUAL
SERIAL NUMBER________________________________
MODEL NUMBER________________________________
4P/N:307272
TABLE OF CONTENTS
SPECIFICATIONS ............................................................................................................................. 6
INTRODUCTION .............................................................................................................................. 7
SECTION 1 SAFETY ....................................................................................................................... 101.1 BEFORE STARTING THE COMPRESSOR ............................................................................................... 101.2 COMPRESSOR USE AND COMPRESSED AIR ....................................................................................... 101.3 SERVICING ................................................................................................................................................... 111.4 LIFTING ......................................................................................................................................................... 11
SECTION 2 DESCRIPTION ........................................................................................................... 122.1 INTRODUCTION ......................................................................................................................................... 122.2 ROTARY COMPRESSOR COMPONENTS ............................................................................................... 122.3 ENGINE COMPONENTS ............................................................................................................................ 132.4 CHASSIS ...................................................................................................................................................... 142.5 ENCLOSURE ............................................................................................................................................... 142.6 INSTRUMENT PANEL DOOR .................................................................................................................... 14
SECTION 3 OPERATION............................................................................................................... 153.1 START UP PREPARATION .......................................................................................................................... 153.2 STARTING PROCEDURE ........................................................................................................................... 153.3 EMERGENCY SHUTDOWN PROCEDURE.............................................................................................. 153.4 ROUTINE SHUTDOWN PRODEDURE ..................................................................................................... 15
SECTION 4 MAINTENANCE ....................................................................................................... 164.1 ENGINE FUEL SPECIFICATIONS.............................................................................................................. 164.2 ENGINE OIL AND FILTER .......................................................................................................................... 174.3 ENGINE COOLING SPECIFICATIONS: .................................................................................................... 174.4 FAN ............................................................................................................................................................... 184.5 RADIATOR PRESSURE CAP ..................................................................................................................... 184.6 RADIATOR ................................................................................................................................................... 184.7 COMPRESSOR OIL .................................................................................................................................... 194.8 COMPRESSOR & ENGINE AIR FILTER MAINTENANCE ..................................................................... 214.9 COMPRESSOR OIL THERMOSTATIC VALVE ......................................................................................... 224.10 COMPRESSOR AIR/OIL SEPARATOR .................................................................................................... 234.11 BELTS & BELT ADJUSTMENT ................................................................................................................ 234.12 CONTROLS-OPERATION AND ADJUSTMENTS .................................................................................. 244.13 INSTRUMENTS ......................................................................................................................................... 254.14 BATTERY ................................................................................................................................................... 264.15 MAINTENANCE SCHEDULE .................................................................................................................. 264.16 DAILY OPERATION .................................................................................................................................. 264.17 MAINTENANCE SCHEDULE CHART .................................................................................................... 274.18 RECOMMENDED SPARE PARTS LIST .................................................................................................. 284.19 PROCEDURE FOR ORDERING PARTS.................................................................................................. 28
SECTION 5 TROUBLESHOOTING ............................................................................................. 295.1 TROUBLESHOOTING ................................................................................................................................. 295.2 TROUBLESHOOTING CHART ................................................................................................................... 30
WARRANTY ..................................................................................................................................... 33
SECTION 6 ASSEMBLY DRAWINGS ........................................................................................... 39
6P/N: 307272
SPECIFICATIONSBOSS INDUSTRIES 250 DUS
YTICAPACISP001@ MFC 022 032 042 052 062
PH 05 25 45 65 85
ISP521@ MFC 812 822 832 842 XPH 65 85 06 36 X
DEEPSTUPNIROSSERPMOC MPR 5222 0132 0142 0052 0062
ENIGNE EVIRDXUA/W5404EREEDPH08
METSYSLACIRTCELEENIGNE CDV21
SNOISNEMIDESAB 06X03X08
LEUFLESEIDLANOITPO PAC L89,.LAG62MID "5.6X"03X"08
CG66 3/4 in
[1696.0 mm]
5 1/2 in[139.7 mm]
4 3/4 in[120.6 mm]
39 3/8 in[1000.2 mm]
7P/N: 307272
INTRODUCTION
OWNER’S RESPONSIBILITY
Your new Boss Air Compressor was engineered, built and tested to ensure the user both dependable andeconomical service. This compressor has also been certified as conforming to the applicable NoiseEmission standards of the Environmental Protection Agency.
Continuation of the performance built into this unit depends upon the care it receives in use. Therefore,operation and maintenance procedures described in this manual should be followed carefully. Theoperator and service personnel responsible for the care of this unit should be thoroughly familiar withthis information.
It is the owner’s and/or operator’s responsibility to perform all safety checks and to ensure that alllubrication, maintenance instruction and recommended practices are followed for safe operation. Ifdisassembly or replacement is required, particularly of internal parts, we recommend the owner see hisdealer and not attempt the repair himself.
It is owner’s responsibility to ensure that the preventive maintenance program is followed at therecommended intervals. Proper care and service will assure long service life with a minimum ofproblems and operating expenses.
We recommend that the owner and operator be thoroughly familiar with the contents of the manual.
If you encounter difficulties which you cannot diagnose our service personnel are prepared to help you.Our toll free number is 1-800-635-6587. Outside the continental United States and Canada our numberis 219-324-7776.
The model and serial number information is requested on all correspondence. This information can befound on the Model Number Identification Plate/Serial Tag. The information contained on theidentification plate/serial tag should be transferred to the cover page of the manual for future reference.
8P/N: 307272
WARNING
AIR COMPRESSOR SAFETY PRECAUTIONS
Safety is basically common sense. There are standard safety rules but each situation has its ownpeculiarities, which cannot always be covered by rules. Therefore with your experience and commonsense, you are in a position to do something about safety. Lack of attention to safety can result in:accidents, personal injury, reduction of efficiency and worst of all - Loss of Life. Watch for safetyhazards. Correct them promptly. Use the following safety precautions as a general guide to safeoperation:
Do not attempt to remove any compressor parts without first relieving the entire system of pressure.
Do not attempt to service any part while machine is operating.
DANGER
Do not operate the compressor at pressuresor speeds in excess of its rating.
Periodically check all safety devices for proper operation.
Do not play with compressed air. Pressurized air can cause serious injury to personnel.
Exercise cleanliness during maintenance and when making repairs. Keep dirt away from parts bycovering parts and exposed openings.
ALL UNITS ARE SHIPPED WITH A DETAILED OPERATORS AND PARTS MANUAL.THIS MANUAL CONTAINS VITAL INFORMATION FOR THE SAFE USE ANDEFFICIENT OPERATION OF THIS UNIT. CAREFULLY READ THE OPERATORSMANUAL BEFORE STARTING THE UNIT. FAILURE TO ADHERE TO THEINSTRUCTIONS COULD RESULT IN SERIOUS BODILY INJURY OR PROPERTYDAMAGE.
CHECK THE COMPRESSOR SUMP OIL LEVEL ONLY WHEN THE COMPRESSORIS NOT OPERATING AND SYSTEM IS COMPLETELY RELIEVED OF PRESSURE.OPEN SERVICE VALVE TO ENSURE RELIEF OF SYSTEM AIR PRESSURE WHENPERFORMING MAINTENANCE ON COMPRESSOR AIR/OIL SYSTEM. FAILURETO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTY ANDSERIOUS BODILY HARM.
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USER MODIFICATION
This Boss Air Compressor incorporates numerous features to minimize noise emissions from the unitduring operation. This configuration has been tested for noise emissions at conditions specified by theU.S. Environmental Protection Agency. Conformance to regulations requires the incorporation of thefollowing notification and definition in the OPERATION AND MAINTENANCE MANUAL.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following act:
1. The removal, rendering inoperative, other than for purposes of maintenance, repair orreplacement of any device or element of design incorporated into any new compressor for the purposefor noise control prior to its sale or delivery to the ultimate purchaser.
2. The use of the compressor after such device or element of design has been removed or renderedinoperative by any person.
Among the acts included in the prohibition against tampering are those listed:
1. Removal or rendering inoperative any of the following:a. The engine exhaust system including the manifold, muffler or tailpipe.b. Any of the enclosure components and associated sound barrier materials.c. The sound baffles in the intake, exhaust and cooling system gas paths.d. The air intake system including the air cleaner, the intake ducting, valve cover and
gaskets.2. Removal of any of the following:
a. Engine mounts or other sound isolating barriers in the system.b. Fan shrouding and sound hood.
3. Operation of the compressor with any of the enclosure doors open.
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SECTION 1 SAFETY
1.1 BEFORE STARTING THE COMPRESSOR1. Check fluids levels and for possible leaks.2. Use adequate hose and couplings with safety locks or pins.3. Remove all tools and/or loose items from engine compartment.4. Relieve any pressure in receiver tank.5. Use proper eye and ear protection.
1.2 COMPRESSOR USE AND COMPRESSED AIR1. Air from this machine is not fit for human consumption-do not use air for breathing or food
processing.2. Never operate in an enclosed area.3. Never use compressed air to clean your clothes and never direct it at another person, it can kill.4. Always wear eye protection.5. Install check valve (“OSHA”) upstream of hose to prevent hose whip in case of a rupture.6. Keep doors or hoods closed on machines in operation.7. Do not touch hot surfaces or moving parts, such as exhaust or fans.8. Do not adjust or restrict relief valves.9. Do not refuel while machine is running; shut down and allow to cool before refueling.10. Do not jump-start with cable connections directly on battery.11. To prevent back strain, only the smallest air compressors should be unhitched by hand.
Drawbars on all other units must be raised and lowered by a jack, chain fall or other liftingdevice.
12. Do not use air at pressure higher than 30 PSIG (207 KPA) for cleaning purposes. Use of higherair pressure can cause injury to the operator.
13. Keep compressor hoods closed except when making repairs, adjustments, or servicing thecompressor.
14. Make sure all personnel are out of and clear of the compressor before starting or operating it.15. Do not use ether cylinders or air line antifreeze compound in confined area.
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1.3 SERVICING1. Before servicing compressor, relieve receiver pressure and allow to cool.2. Be sure all opened doors and hoods are propped and secured.3. Disconnect battery before any work is to be performed.4. Wipe up all spills resulting from servicing.5. Disconnect the grounded (negative) battery connection before making repairs or cleaning inside
the enclosure.6. Do not use flammable solvents for cleaning the compressor.7. Do not remove radiator cap quickly, it may cause spray of scalding coolant and severe burns to
operator.8. Make repairs only in clean, dry and well-lighted and well-ventilated areas.9. Keep all parts of the body and any hand held tools or other metal objects away from exposed live
parts of the electrical system.10. Replace damaged fuel tanks or lines immediately. DO NOT WELD on or near fuel tanks or
lines.11. Make sure all personnel are out of the compressor before closing and latching hoods.12. Radiator coolant is under pressure. When checking coolant in radiator, loosen cap slowly first,
to relieve pressure before removing cap completely.
1.4 LIFTING1. If the compressor is provided with a lifting bail, then lift by the bail. If no bail is provided, then
lift by sling.2. When lifting by helicopter, use a sling. Do not lift by unit lifting bail.3. Inspect the entire lifting, rigging and supporting structure to ensure it is in good condition and
has a rated capacity of at least the gross weight of the compressor plus 50%.
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SECTION 2 DESCRIPTION
2.1 INTRODUCTIONYour Boss Air Compressor portable is a gas/diesel driven Rotary Screw Compressor unit that providessuperior performance and reliability along with a minimal amount of required maintenance.
2.2 ROTARY COMPRESSOR COMPONENTSCOMPRESSOR DESCRIPTIONThe compressor assembly is a positive displacement, oil flood lubricated, screw type unit employing onestage of compression to achieve the desired pressure. Components include a housing (stator), two screws(rotors), gears, bearings and bearing supports.
In operation, two helical grooved rotors mesh to compress air. Inlet air entering the casing is compressedat the male lobes roll down the female grooves, pushing trapped atmospheric air along and compressing itin one stage of compression. This process delivers smooth-flowing air at full pressure to the receiver.
To illustrate the compression sequence, consider the action of the male lobe as similar to a ball. As a helixrotates, the ball (male lobe) meshes with the groove to start a compression cycle with trapped atmosphericair. As the ball moves down the groove, air is compressed. Atmospheric air fills in behind the ball preparingthe groove for another compression cycle as rotation continues and the male lobe again meshes with thegroove.
During the compression cycle, oil is injected into the compressor for the purpose of lubrication, coolingand sealing. Compressed air laden with oil leaves the compressor unit through a discharge port, which isdesigned to give optimum performance within the desired discharge pressure range.
AIR FILTERThe Rotary Screw Compressor unit and engine are protected by a high efficiency, two-stage air filteringsystem. This is a dry filter that requires maintenance when the air filter restriction gauge indicates so.
OIL COOLINGThe compressor is an “oil flooded” compressor. The oil lubricates, seals and cools the internals of thecompressors as it is injected into the compressor. The oil goes through the compressor with the air whereit picks up the heat generated by the compression process then seals the spaces between moving parts andlubricates bearings. The hot oil must be cooled. It is separated from the air, passed through the oil cooler(mounted next to the engine radiator), through a thermostatic valve (that helps to rapidly warm cold oil atstart-up), then through a full flow oil filter and back into the compressor.
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AIR/OIL SEPARATORAt the compressor discharge the compressed air and the hot oil flow into a steel ASME coded pressurevessel (rated at 175 psig-250psig) that acts as a reservoir for the air and separates out the oil. From thebottom of this oil sump the oil leaves the vessel on its way to the oil cooler. The air and the slight oil miststill entrained in the air flow through the separator element, which removes the last of the oil from the air.The air passes on out to its final use and the separated oil goes through the scavenge line to the compressorto re-enter the system.
As the compressor air leaves the receiver it goes through a minimum pressure valve that is set to maintainat least 80 psig (55kpa) in the receiver when the compressor is running. The purpose of this pressure is toensure that there is pressure to force the oil out of the bottom of the receiver, through the oil cooling systemso that sufficient oil is injected into the compressor.
CONTROL SYSTEMThe Boss Air Compressor portable is simple to operate. Starting procedure is explained in section 3 and onthe instrument panel door of the compressor. Each machine has an On/Off switch and a safety bypassswitch that bypasses the safety shutdowns. Once the machine is “on line” and in the run position, controlis automatic. The control system senses the need for air and adjusts the speed of the engine and compressoras well as the opening of the compressor inlet valve to supply the amount of air needed. If the air demandis zero, the engine and compressor “idle” and the inlet valve is shut to control the air entering the compressor.If the demand is maximum, the opposite happens, full speed and wide-open inlet valve. Intermediate airdemands give intermediate speeds and valve openings for maximum operating efficiency. Service andadjustments are in section 4.12.
2.3 ENGINE COMPONENTSENGINE DESCRIPTIONThe engine in each Boss Air Compressor portable compressor is selected to have reserve horsepower andspeed necessary to drive the compressor and all accessories when operating up to a discharge pressure 100psig (686kpa) to 220 psig (1509kpa).
RADIATORThe radiator is selected to handle the heat load of the engine and mounted next to the compressor oil cooler.Cooling air is moved through these two coolers with a specially selected engine fan. The system is designedto handle extreme heat conditions.
FUEL SYSTEMAll units are supplied with fuel tank capacity adequate for a day’s normal operation, fuel filtering systemand optional low fuel shutdown. See section 4.3 for fuel servicing.
MUFFLEREngine noise is reduced by a durable, low restriction engine muffler.
14P/N: 307272
2.4 CHASSISFRAMEThe 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 sheetmetal over structural members.
2.5 ENCLOSUREEnclosure is 14 gauge metal with powder coat finish. Each access panel has lockable handles with mechanicalprops.
2.6 INSTRUMENT PANEL DOORLockable instrument panel doors provide access to all controls and gauges.
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SECTION 3 OPERATION
3.1 START UP PREPARATION1. 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.7. NOTE: This unit has minimum air pressure valve to assure compressor oil flow. There will be
no airflow from the compressor if receiver pressure is less that 80 PSIG.
3.2 STARTING PROCEDURE1. Close service valves and move unloader valve to “START” position.2. Press and hold bypass button and turn starter switch to “START” position. If engine fails to
start. DO NOT attempt to restart until cranking motor stops rotating. Before restarting, starterswitch must be returned to “OFF” position.
3. When engine starts, release starter switch and hold bypass button down until oil pressure reaches15PSI then release. Maintain unloader valve at “START” position until engine is warm andoperating smoothly, then move unloader valve to “RUN” position.
3.3 EMERGENCY SHUTDOWN PROCEDURETurn start stop switch to “OFF” position.
3.4 ROUTINE SHUTDOWN PRODEDURE1. Move unloader to start position.2. Allow compressor to run 2 to 3 minutes to cool.3. Move on/off switch to “OFF” position.
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SECTION 4 MAINTENANCE
4.1 ENGINE FUEL SPECIFICATIONS
WARNING
CAUTION
HIGH ALTITIDE AND LOW TEMPERATURE FUELSFuels with cetane numbers higher than 40 may be needed in high altitudes or extremely low ambienttemperatures to prevent misfires and excessive smoke.
COLD WEATHER FUELAt operating temperatures below 8 degrees C (32 degrees F) use a blend of No.1D and No.2D fuels,also know as “winterized” No.2D. NOTE: No.1D fuel can be used; however, fuel economy will suffer.
Use low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expectedfuel temperature. Cloud point is the temperature at which wax crystals begin to form in diesel fuel.
The viscosity of the fuel must be kept above 1.3 centistokes to provide adequate fuel system lubrication.
ENGINE FUEL FILTERSee engine manufactures operator/instruction manual for the proper fuel filter replacement changingintervals for the brand engine in your BOSS compressor.
DO NOT MIX GASOLINE OR ALCOHOL WITH DIESEL FUEL. THIS MIXTURECAN CAUSE AN EXPLOSION.
DUE TO THE PRECISE TOLERANCES OF DIESEL INJECTION SYSTEMS, IT ISEXTREMELY IMPROTANT THAT THE FUEL BE KEPT CLEAN AND FREE OF DIRTOR WATER. DIRT OR WATER IN THE SYSTEM CAN CAUSE SEVERE DAMAGE TOBOTH THE INJECTION PUMP AND THE INJECTION NOZZLE.USE ASTM NO.2 D FUEL WITH A MINIMUM CETANE NUMBER OF 40. NO.2 DIESELFUEL GIVES THE BEST ECONOMY AND PERFORMANCE UNDER MOSTOPERATING CONDITIONS. SEE ENGINE MANUFACTURES OPERATORS/INSTRUCTION MANUAL FOR THE PROPER ENGINE FUEL FOR THE BRANDENGINE IN YOUR BOSS AIR COMPRESSOR.
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4.2 ENGINE OIL AND FILTERSee engine manufactures operator/instruction manual for the proper engine oil and filter changingintervals for the brand engine in your BOSS compressor.
OIL FILTER REPLACEMENT1. Clean the area around the lubricating filter head.2. Remove the filter.3. Clean the o-ring surface of the filter head.NOTE: The o-ring can stick on the filter head. Make sure it is removed.4. Apply a light film of lubricating oil to the o-ring-sealing surface before installing.5. Install the filter as specified by the filter manufacturer.
CAUTION
4.3 ENGINE COOLING SPECIFICATIONS:Diesel engines require a balanced coolant mixture of water and ethylene glycol base antifreeze. Thisprotects the engine cooling system from corrosions as well as freezing damage. The Boss AirCompressor portables are shipped form the factory with a 50/50 mixture of water and ethylene glycol.In tropical climates where freeze protection is not required, glycol engine coolant should still be used. Itwill help prevent corrosion and pitting of cylinder liners. See engine manufactures operator/instructionmanual for the proper engine coolant for the brand engine in your BOSS compressor.
MIXTURES:Antifreeze concentration level should not exceed recommended levels. To do so can cause coolingsystem failure.· Use a high quality, low silicate antifreeze· A mixture of 50% antifreeze and 50% water is required for temperatures above –37 º C (-34 ºF).· A mixture of 60% antifreeze and 40% water us required for environments below –37 ºC (-34 ºF).
This provides protection to –54 ºC (-65 ºF).· Never exceed a 60% antifreeze and 40% water mix.
ENGINE COOLING SYSTEMAll engines have a pressurized cooling system that contains a 50/50 mixture of water and ethyleneglycol. Daily maintenance of the system includes a check of the coolant level, proper belt adjustment offan and water pump drives, soundness of fan and cleanliness of the radiator and oil cooler to permitairflow. Further cooling system maintenance is defined in the engine maintenance manual.
MECHANICAL OVER-TIGHTENING MAY DISTORT THE THREADS OR DAMAGETHE FILTER ELEMENT SEAL.
KEEP HANDS AND FINGERS CLEAR OF FITTING. HIGH PRESSURE OF THEFUEL CAN CAUSE PENETRATION OF THE SKIN. SEEK IMMEDIATE MEDICALATTENTION IF SKIN IS BROKEN BY THE FUEL SPRAY.
WARNING
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COOLANT LEVELBefore each start-up, when radiator is cold, the coolant should be checked. When needed, refill with a50/50 solution of water and ethylene glycol, DO NOT use 100% antifreeze for “topping off”.
WARNING
4.4 FANCheck the fan for cracks loose rivets and bent or loose blades. Make sure it is securely mounted.Tighten the cap screws if loose. Replace damaged fans.
WARNING
4.5 RADIATOR PRESSURE CAPIf coolant continually spills from radiator through the overflow then the radiator cap should be testedand/or replaced with a cap of the same pressure rating, generally 13 PSI. Be sure cap is turned to theproper secure position.
4.6 RADIATORAny sign of leakage from the radiator may justify a pressure test to assure its soundness. Radiator leaksshould only be repaired by qualified service people. Dirt that clogs the cooling fins of the radiatorshould be removed. The use of an air stream of high-pressure steam cleaner should be done withcaution so as to not damage the delicate fins. Bent cooling fins will reduce the cooling capability of theradiator.
CHECK THE COOLANT LEVEL ONLY WHEN THE ENGINE IS STOPPED ANDTHE TEMPERATURE IS BELOW 160 º F (70 ºC) FAILURE TO DO SO CAN CAUSEPERSONAL INJURY FROM HEATED COOLANT SPRAY.
NEVER USE THE FAN TO ROTATE THE ENGINE. THE BLADE(S) CAN BEDAMAGED CAUSING A FAN FAILURE, WHICH CAN RESULT IN PERSONAL INJURYOR PROPERTY DAMAGE.
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BOSS AIR COMPRESSORS DOES NOT RECOMMEND MIXING DIFFERENT TYPESOF OILS. WHEN CHANGING TO A DIFFERENT TYPE OIL, CLEAN COOLER, AIR/OIL RECEIVER AND LINES THOROUGHLY.
4.7 COMPRESSOR OILThe life and proper operation of the compressor is dependent on adequate and clean compressor oil.DEXRON®- III Automatic Transmission Fluid is supplied with the new machine and should be usedfor proper level maintenance and for oil changes. We recommend that you use DEXRON®- IIIAutomatic Transmission Fluid.
WARNING
COMPRESSOR OIL SPECIFICATIONSIt is permissible to use oils other than the ATF shown above; such as Hydraulic oil. If they are used thenthey must have at least the following minimum properties:· ISO grade 32· CPS No. 255675· API Gravity -· Viscosity, Kinematic
cst at 40 degrees C 33.6cst at 100 degrees C 5.5
· Viscosity sayboltSUS at 100 degrees F 173SUS at 210 degrees F 45
· Viscosity index 98· Pour point deg. C(deg F) -33(-27)· Flash point deg.C(deg.F) 204(399)· Oxidation stability· Hours to 2.0 mg KOH/g
acid no., ASTM D 943 >600
The advantage in using DEXRON® -III in the compressor is that it is good lubricant suitable to itsapplication and it is readily available. There are other oils that may be used that have longer life. Theyare better able to stand the extreme operating conditions. Whether or not to use these oils is a decisionthat depends upon the operating conditions. Very frequent oil changes are necessary in extremely hot,dirty operating conditions and if the compressor is operating in a remote, difficult-to-reach servicelocation then perhaps it would be better to use the DEXRON® -III because of availability and cost. If,however service is convenient and attentive so that the oil can be used for as long as it will provide goodprotection; then higher quality oils may be used that will extend the life of the compressor.
WARNING
DO NOT REMOVE CAPS OR OTHER COMPONENTS WHEN COMPRESSOR ISRUNNING OR PRESSURIZED. BEFORE DOING SO STOP COMPRESSOR ANDRELIEVE ALL INTERNAL PRESSURE.
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ADDING COMPRESSOR OIL1. Level the compressor to assure oil level indicator will be accurate.2. Remove any dirt around fill cap, which is located on or near the air/oil receiver and then remove
the fill cap itself.3. Inspect the fill cap for damage and cleanliness. Replace if necessary.4. Proper oil can then be added until the oil level reaches halfway in the sight-level tube or the
“bullseye”.5. Replace fill cap securely-never put cap on without tightening immediately.6. Do not over fill the sump tank. This will cause oil to spray out of the blowdown valve and/or
service valve.
CAUTION
CHANGING COMPRESSOR OIL1. 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 warm from operation.4. Close all drains and replace oil with fresh oil to proper level. Replace fill cap and run the unit
briefly to see if more oil needs to be added and to ensure there or no leaks.
COMPRESSOR OIL FILTERThe oil filter in the compressor lubrication system is of the full flow spin-on canister type. Initially thefilter should be replaced after the first 50 hours, then every 500 hours or sooner if indicated. A dirtyfilter can restrict oil flow, causing high oil temperature condition, which will result in a unit shutdown.
CAUTION
SUBSTITUTE FILTERS MAY HAVE INADEQUATE WORKING PRESSURE LIMITS,RESULTING IN ELEMENT LEAKAGE OR RUPTURE. REPLACEMENT FILTERSMUST BE THE SAME QUALITY AND TYPES AS THE ORIGINAL BOSS AIRCOMPRESSORS FILTER.
DO NOT REPLACE FILL CAP WITH A PIPE CAP; SERIOUS INJURY OR DAMAGECOULD RESULT. THE THREADS ARE DIFFERENT. ALWAYS ENSURE A STRAIGHTTHREAD FILL CAP IS USED.
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DO NOT STRIKE THE ELEMENT AGAINST ANY HARD SURFACES AND POSSIBLYRUPTURE THE ELEMENT. NEVER BLOW DIRT OUT OF THE INTERIOR OF THEFILTER HOUSING. THIS MAY INTRODUCE DUST DOWNSTREAM OF THE FILTER.INSTEAD, USE A CLEAN DAMP CLOTH. DO NOT OIL ELEMENT.
COMPRESSOR OIL FILTER REPLACEMENT1. Using a strap wrench, remove the old element and o-ring.2. Clean o-ring seating surface.3. Apply a light film of oil to the new o-ring.4. Hand tighten new element until new o-ring is seated in the o-ring groove.5. Continue tightening element by hand an additional ½ to ¾ turn.6. Restart machine and check for leaks.
CAUTION
4.8 COMPRESSOR & ENGINE AIR FILTER MAINTENANCEELEMENT REPLACEMENT1 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 time clean or replace the element.6. Replace the element.7. Reposition the cover and tighten the clamp, INSTALL WITH “TOP” UP.8. Reset the air filter restriction indicator (if supplied) and the machine will be ready for operation.
CAUTION
CAUTION
MECHANICAL OVER-TIGHTENING MAY DISTORT THE THREADS OR DAMAGETHE FILTER ELELMENT SEAL.
WHEN CLEANING AN ELEMENT, THE ELEMENT WILL BE DAMAGED IF YOUEXCEED THE RECOMMENDED MAXIMUM PRESSURE FOR COMPRESSED AIR.(30 PSI/200 KPA)
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AIR FILTER ELEMENT CLEANINGThe air filter element is cleaned by using compressed air. The maximum amount of times that anelement should be cleaned is (2) times; however the element should be used no longer than a period ofone(1) year without changing.
Prior to cleaning an element, check the element for damage. Damaged elements must be replaced.
When cleaning the element with compressed air, never let the air pressure exceed 30 PSIG (200 kpa).Reverse flush the element by, directing the compressed air up and down the pleats in the filter mediafrom the “clean side” of the element. Continue reverse flushing until all dust is removed. Should anyoil or greasy dirt remain on the filter surface, the element should then be replaced.
ELEMENT INSPECTION:1. Place a bright light inside the element to inspect for damaged or leak.2. Inspect all gaskets and gasket contact surfaces of the housing. Should faulty gaskets be evident,
correct the condition immediately. If the clean element is to be stored for later use, it must bestored in a clean container.
3. After the element has been installed, inspect and tighten all air inlet connections prior toresuming operation.
4.9 COMPRESSOR OIL THERMOSTATIC VALVEThe oil thermostatic valve acts as a thermostatically controlled by-pass valve and allows varyingamounts of oil depending upon the temperature, to by-pass cooler during the warm up period. Whencirculated oil reaches a temperature of 140 º F, the valve closes the by-pass completely and all the oil iscirculated though the cooler. The oil cooler by-pass is restricted enough to cause some warm oil to flowthrough the cooler during the warm-up period, maintaining a higher average compressor oiltemperature. This reduces condensation in the oil system and also reduces the possibility of a slug ofcold oil from the cooler, causing a momentary high restriction and a temporary reduction in the oilpressure, hence oil flow.
CLEANING OIL THERMOSTAT1. If it becomes necessary to take the thermostat apart and clean it, disassemble at the bolted flange
and remove the element.2. If coated or dirty, clean as necessary. The element and rubber seal ring should be cleaned only
with hot water.3. Inspect the element for bent or dented parts.4. Replace any damage part during cleaning and assembling the pipe openings should be closed
with tape or plugs until pipe connections made.
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4.10 COMPRESSOR AIR/OIL SEPARATOR
WARNING
The separator element is located in the top of the air-oil receiver/separator tank. Here the oil mistcontained in the air is removed prior to the final discharge of air. Air should be taken only from theoutlet service valves on the center of the top end of the separator-never directly from the receiver/separator fittings on the side of the tank. When the oil vapor in the discharge air becomes excessive, theseparator element may need replacing. This should not be necessary more than once a year undernormal operating conditions.
SEPARATOR ELEMENT REPLACEMENT1. The element may be replaced by removing the head from the top of separator and pulling the
element out. Only a factory element should be used as a replacement.2. The separator element flange must have a gasket on each side to seal the head on one side and
the vessel on the other. The staple in each gasket must be left in the gasket, it acts as a staticground.
3 Re-torque the head bolts uniformly to a specification of 220ft-1b.(dry) or 170ft-lb. (wet) whenreplacing the separator head.
4.11 BELTS & BELT ADJUSTMENTVisually inspect the belts. Replace belts if cracked or frayed. Check engine manual for proper belttension.
DO NOT REMOVE CAPS, PLUGS OR OTHER COMPONENTS WHEN COMPRESSORIS RUNNING OR PRESSURIZED. PERSONAL INJURY WILL RESULT. BEFOREDOING SO, STOP COMPRESSOR AND RELIEVE ALL INTERNAL PRESSURE.
24P/N: 307272
4.12 CONTROLS-OPERATION AND ADJUSTMENTSThe compressor system is designed to match air supply and engine performance with the demand. Thecomponents 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 is open in the start run position. This allows air to by-pass the pressure regulatorand go directly to the compressor inlet valve, closing it and to the engine air cylinder, holding thethrottle at idle. When switched to the run position, shutting off the by-pass air, control air now has to gothrough the pressure regulator.
The pressure regulator is referred to as a positive type and its operation is proportional to systempressure. As pressure increases it opens, allowing air to pressurize the inlet valve and air cylinder.When there is an air demand, the pressure decreases and the regulator starts to close, relieving thepressure in the inlet valve and air cylinder. An orifice in the regulator bleeds the air out of control linebetween regulator, engine air cylinder and inlet valve supplies a signal proportional to the systempressure the inlet valve will modulate. With no air demand the pressure rises, the signal air from theregulator closes the inlet valve. When an air demand is present or the pressure falls, the air signal isremoved allowing the inlet valve to open to match air demand.
The blowdown valve has two functions in the system. First it prevents excessive pressure in the startand unload modes by bleeding off the small amount of air being drawn in during idle. Secondly itrelieves or blows down the system on shutdown. This valve is not adjustable.
ADJUSTMENTWhen performing control adjustments care must be taken in regard to safety as the compressor must berunning. Be aware of moving parts, as well as, hot items, such as fans, belts and exhaust components.
IDLE OR UNLOAD SPEED ADJUSTMENT (For 100 PSI System)With the compressor warmed up and all service valves closed, move start-run switch to run position. Airpressure will build to 120 psig. If air pressure is less than 120 psig, adjust regulator up by turning theadjusting screw clockwise. If air pressure is greater than 120 psig, adjust regulator down by turning theadjusting screw counter-clockwise.
Note: If your unit is rated at a higher pressure add 20psi to the working pressure for unload pressure; ex:150 PSI working = 170 unload.
25P/N: 307272
IDLE SPEED ADJUSTMENT PROCEDURESOn the injection pump throttle arm, there are two adjusting screws. The air cylinder connected to thethrottle arm, this air cylinder moves throttle to increase and decrease engine speed with air demand.When adjusting idle speed, the air cylinder should be fully extended moving throttle arm towards frontof engine. To adjust idle speed, loosen locknut on adjusting screw towards rear of engine. Turningadjustment screw clockwise will increase speed. If proper speed cannot be obtained with the adjustmentscrews, it may require loosing the locknut on air cylinder shaft and adjusting clevis. By turning clevisonto shaft speed will increase, by turning clevis out, speed will decrease. After proper speed is set,tighten all locknuts.
PRESSURE REGULATOR ADJUSTMENTAfter setting idle speed and compressor is in run position, the pressure regulator adjustment can bechecked and adjusted if required. The air cylinder receives an air signal from the pressure regulator.This air cylinder controls engine speed with air demand. To adjust pressure regulator, with compressorin the run position, open service valve slightly to allow air to bleed out. By watching air pressure gaugenote when air cylinder starts to retract, this should be approximately 105 psig. If cylinder does not startto retract until at a lower pressure, the regulator is set to low. The regulator has a locknut andadjustment screw. Loosen the locknut and turn adjustment screw clockwise to increase the pressure.Turning screw counter clockwise decreases pressure. After adjustment is complete, tighten locknut.Note: If you unit is rated a higher pressure add 5 PSI to the working pressure; ex: 150 PSI working =155 retract pressure.
RATED SPEED ADJUSTMENTWith the compressor in a run position open service valve slowly until pressure gauge is reading 100 PSI(working pressure). Check that air cylinder is fully retracted, moving throttle arm to full speed andcheck the engine speed. Adjust the speed to within the specifications in the front of this manual.To adjust there are two adjusting screws on throttle arm; the adjusting screw towards rear of engine isthe high-speed adjustment. Loosen locknut on adjustment screw by turning screw counter clockwise,speed increases, after setting speed to specifications, tighten locknut, close service valve and allowcompressor to unload and return to idle.
4.13 INSTRUMENTSThe standard control panel has gauges for air pressure, oil pressure, coolant temperature, ammeter andhourmeter. Also included is an ignition switch, start/run valve and safety bypass switch. The safetybypass switch cuts out the low oil pressure switch to permit starting. The low oil pressure switch isnormally open and closes upon activation. Safety shutdowns are also provided for high compressor oiltemperature and high engine coolant temperature. These switches are normally closed and uponactivation open. If the compressor will not start or shuts down while in operation without an obviousmalfunction, each switch can be checked individually by connecting a jumper wire across the terminalposts one switch at a time. The defective switch must be replaced.NOTE: the existing wiring harness must be connected to the safety switches while making the abovecheck.
26P/N: 307272
4.14 BATTERYBatteries supplied with Boss Air Compressor are selected to have ample cold cranking amperes forquick starts in inclement weather. Keep them fully charged and if replacement is necessary thereplacement must be of equal capacity.
WARNING
4.15 MAINTENANCE SCHEDULEA good maintenance program is the key to long machine life. Follow a regular schedule of inspectionand servicing, based on operating hours. Keep an accurate logbook for maintenance, servicing andoperating hours. Use the factory recommended Periodic Maintenance schedule (based on favorableoperating conditions) to serve as a guide to get long and efficient machine life. Regular service periodsare recommended for normal service and operating conditions. For engine maintenance, refer to theengine manual where a detailed description of service instructions is given. For continuous duty,extreme temperature, etc., service more frequently. Neglecting routine maintenance can result inmachine failure or permanent damage.
WARNING
4.16 DAILY OPERATIONPrior to starting the machine, it is necessary to check the oil level in the sump. Should the level be low,add the necessary amount. If the addition of oil become too frequent, a simple problem may havedeveloped which is causing this excessive loss. See the troubleshooting section under Excessive OilConsumption for a probable cause and remedy. Also check the linkage prior to starting.
NOTE: the radiator and engine cooling system should be drained and flushed every two years. Replacethe coolant with a mixture of 50% ethylene glycol and 50% water. Do not use a leak sealing type ofantifreeze. Should a 100% water solution be used, a rust inhibitor must be added.
After a routine start has been made, observe the instrument panel gauges. After the machine haswarmed up, it its recommended that general check on the overall machine and instrument panel be madeto assure the compressor is running properly. Also check the air filter maintenance indicator (ifsupplied). Should the indicators show red, clean or replace the elements immediately (see enginemanual).
BATTERY GAS CAN EXPLODE CAUSING ACID BURN TO SKIN AND BLINDNESS.DO NOT OVERCHARGE OR JUMP THE BATTERY INCORRECTLY.
DO NOT REMOVE CAPS, PLUGS OR OTHER COMPONENTS WHEN COMPRESSORIS RUNNING OR PRESSURIZED. SEVERE PERSONAL INJURY MAY RESULT. STOPCOMPRESSOR AND RELIEVE ALL INTERNAL PRESSURE BEFORE DOING SO.
27P/N: 307272
INTERVAL REQUIRED MAINTENANCE REFERENCE1. Check air end f luid level2. Check radiator coolant recovery tank3. Check fuel supply after running4. Check air f ilter maintenance indicator5. Check for fuel, oil, air, and w ater leaks6. Check battery mounting for security7. Drain w ater and sediment from fuel tank Drain at bottom of tank1. Clean return line orif ice after initial start only2. Drain w ater from compressor oil reservior. More frequent draining may be required under high humidity conditions.
Drain at bottom of reservoir
3. Inspecting lif ting frame (and before each lif t).
1. Change air end f luid and fluid f ilter elements.
2. Clean battery terminals, check battery hold-dow ns and cables for w ear.3. Check air f ilter piping, f ittings, and clamps.4. Check radiator hoses and clamps.5. Check engine and air end mounts.6. Check fan belt tension.1. Install new air f ilter elements (shorter interval may be necessary under dusty conditions).2. Check all door gaskets, hinges, and latches to maintain acoustics seal.3. Drain engine radiator coolant. Clean and f lush cooling system. Refill w ith coolant.4. Check engine and compressor shut dow n sw itches.5. Check reservoir pressure relief valve.6. Install new fuel f ilter and w ater separator elements.
EVERY 10 HOURS OR
DAILY
EVERY 50 HOURS OR WEEKLY
EVERY 500 HOURS
EVERY 1000 HOURS
4.17 MAINTENANCE SCHEDULE CHART
NOTICE: Check engine operator’s manual for requred service and service intervals.
28P/N: 307272
4.18 RECOMMENDED SPARE PARTS LIST
COMPLETE KITS ARE ALSO AVAILABLE THAT INCLUDE ALL THE ABOVE PARTS.
KIT FOR JOHN DEERE 4045 with 13G Compressor......................................................80115
4.19 PROCEDURE FOR ORDERING PARTSParts can be ordered directly from the factory. When ordering parts always indicate the serial number ofthe unit. For parts call 1-800-635-6587.
TNEMELERETLIFRIAENIGNE 410203
TNEMELERETLIFLIOROSSERPMOC 39082-421
TNEMELELIO/RIAROTARAPES 86219-421
TNEMELERETLIFRIAROSSERPMOC 148203
29P/N: 307272
SECTION 5 TROUBLESHOOTING
5.1 TROUBLESHOOTINGIf the unit will not crank when a “START” is attempted, DO NOT jump-start without first consideringthe following:· If there is obvious battery damage such as a cracked or broken case, replace battery· Check for loose battery cables. Tighten if necessary· Check terminals for corrosion, clean if necessary
1. Connect the first jumper cable from positive “+” (red) terminal of the discharged battery to thepositive “+” (red) terminal on the booster battery. NEVER connect “+” (red) to “-” (black). DONOT PERMIT vehicles to touch each other as this could establish a ground connection andcounteract the benefits of this procedure.
2. Connect one end of second jumper cable to the ground negative “-” (black) terminal of the boosterbattery. Connect the other end of this jumper cable to a solid, stationary metallic point on thecompressor with the discharged battery but at a point AWAY from the battery (at least 18 inches ormore) if possible. DO NOT connect directly to the negative post of the discharged battery.
3. Disconnect positive battery terminal whenever using a high rate charge. Start the compressor inaccordance with normal procedure. When the engine is operating smoothly disconnect the jumpercable end at the engine block before disconnecting the jumper cables from the other position.
Your Boss Air Compressor has safety switches that protect the engine and compressor from permanentdamage. The safety switches are as follows:1. Engine Oil Pressure: This is a normally open switch that closes with 15 PSI of engine oil pressure.2. Engine Coolant Temperature: This is a normally closed that opens a 220° F.3. Compressor Oil Temperature: This is a normally closed switch that opens at 245°F.
All above switches are in series with the power feed to the engine fuel solenoid. If any of the switchesopen, power is lost and the engine shuts down.
WARNING
OPERATING WITHOUT SAFETY SWITCHES COULD CAUSE SEVERE PERSONALINJURY OR DEATH AND CAUSE SIGNIFICANT PROPERTY DAMAGE. IT WILLVOID EXISTING WARRANTIES. ALWAYS ENSURE THAT ALL SAFETY SYSTEMSARE FUNCTIONAL.
30P/N: 307272
5.2 TROUBLESHOOTING CHART
The information contained in the troubleshooting chart has been compiled from field report data and factoryexperience. It contains symptoms and usual causes for the described problems; however, do not assumethat these are the only problems that may occur. All available data concerning the trouble should besystematically analyzed. Before undertaking any repairs or component replacement procedures, a detailedvisual inspection is worth performing for almost all problems and may avoid unnecessary additional damageto the machine.· Check for loose wiring.· Check for damaged piping.· Check for parts damaged by ear or an electrical short circuit, usually apparent by discoloration ora burnt odor.
Should your problem persist after making the recommended checks, consult your nearest Boss AirCompressor distributor or the Boss Air Compressor factory by calling 1-800-635-6587 or (219) 324-7776.
SYMPTOM CAUSE REMEDY
Faulty battery connections Check the battery terminals for tightness and corrosion.a. Check voltage and charge or replace the battery.b. Unit may be jump started.
Faulty ignition switch Replace the switchStarter solenoid connections are loose or corroded.
Clean and tighten connections.
Faulty starter solenoid or starter. Repair or replace the faulty components.a. Check fuel level and add if necessary.b. If the unit has run out of fuel it may be necessary to prime the fuel system.a. Check fuel line connections and tighten or repair.b. Prime the fuel system.
Defective safety bypass switch Replace the switcha. With ignition and safety bypass on; check for voltage at the solenoid.b. Check safety switches.
Machine will not crank
Low battery voltage
Machine cranks, but will not start
No fuel
Air in the fuel system
Fuel solenoid inoperative.
31P/N: 307272
SYMPTOM CAUSE REMEDY
Out of fuel Check fuel level and add fuel if necessary
Fuel filter restricted Change fuel filter.a. Engine coolant level low; add coolant.b. Compressor oil and radiator flow restricted; clean coolers.c. Fan belts slipping or broken; repair or replace.d. Compressor oil low; add oil.e. Engine oil level low; add oil.f. Compressor oil filter restricted; change the filter.g. Engine oil filter restricted; change the filter
Defective safety shutdown switch Check the shutdown switches.
Thermostatic valve malfunctioning Clean or replace the thermostatic element.
Defective gauge Replace the gauge.
Air demand too great Check service lines for leaks or open valves.a. Check to see if the blowdown valve is getting a pilot signal.b. Repair or service valve.
Faulty coupling Replace the coupling.Defective gauge Replace the gauge.
a. Check for restrictions in the control lines.b. Repair or place control air cylinder.c. Check that the inlet valve is closing.a. Adjust the regulator.b. Repair or replace the regulator.
Compressor undersized for the air requirement
Recheck maximum air requirement.
Engine speed low Check speed and adjust as necessary.a. Check air filter for dirt and make sure the indicator is working.b. Look for obstructions in the filter and inlet piping.c. Check that the inlet valve is opening fully.
Faulty drive coupling Replace the coupling.
Machine shuts down with air
demand presentSafety shutdown switches activated.
Machine will not build up pressure Blowdown valve open
With no demand the compressor builds excessive
pressure
Air cylinder not fully extending
Pressure regulator not properly adjusted or faulty.
Insufficient air delivery
Air intake restricted
32P/N: 307272
SYMPTOM CAUSE REMEDY
Oil reserve over filled Drain to the proper level.
Leak in the compressor oil system Check all piping lines and connections; repair as necessary.a. Check scavenge line and its check valve for restrictions; clear as necessary.
b. Make sure that the scavenge line reaches the bottom of the separator.
Separator element damaged Replace the element.
Compressor undersized for the air requirement
Operating at low pressures increases the oil carry over; recheck the load requirements
Unit being operated in an area with limited fresh air
Reposition the unit or open up the confinement.
Fan belts are loose or broken Tighten or replace.
Dirt build up on the coolers Clean the cooler thoroughly. Be careful not to damage the fins.
Compressor level low Check and fill to proper level.Compressor oil filter dirty Replace the filter.
Thermostatic valce malfunctioning Clean or replace the element.Restriction in the compressor oil
linesClean or replace the lines.
Restriction in the oil cooler Clean internal tubes of the cooler.Operating the compressor with the
hood openClose the hood.
Coolant level low Add coolant to the proper level.
Leaks in the fuel systemCheck all the fuel lines and connection; repair or replace as necessary.
Engine not at correct operating speed
Adjust the engine to its proper speed.
Pressure to regulator set too high Adjust regulator to correct pressure for the unit.
Engine air intake is restrictedInspect the air intake system checking for any restriction; clean repair or replace as necessary.
Incorrect injection timing Adjust to specifications in the engine manual.
Excessive compressor oil consumption
Oil scavenge line not removing the oil from the separator
Compressor overheating
High fuel consumption
33P/N: 307272
WARRANTY
Boss Industries, Inc. (BOSS) warrants that this Rotary Screw Compressor unit conforms to applicabledrawings and specifications approved in writing by BOSS. The unit assembly will be free from defectsin material and workmanship for a period of three (3) years from the date of initial operation or forty-two (42) months from the date of shipment, whichever period first expires. All other components andparts of BOSS manufacture will be free from defects in material and workmanship for a period of one(1) year from the date of initial operation or eighteen (18) months from the date of shipment, whicheverperiod first expires. If within such period BOSS receives from the Buyer written notice of and allegeddefect in or nonconformance of the unit, all other components and parts of BOSS manufacture and if inthe judgment of BOSS these items do not conform or are found to be defective in material of workmanship,BOSS will at its option either, (a) furnish a Service Representative to correct defective workmanship,or (b) upon return of the item F.O.B. BOSS original shipping point, repair or replace the item or issuecredit for the replacement item ordered by Buyer, (Defective material must be returned within thirty(30) days of return shipping instructions from BOSS. Failure to do so within specified time will resultin forfeiture of claim), or (c) refund the full purchase price for the item without interest. Factoryinstalled units will also include warranty on installation for a period of one (1) year. This warranty doesnot cover damaged caused by accident, misuse or negligence. If the compressor unit is disassembledthe warranty is void. BOSS’s sole responsibility and Buyer’s exclusive remedy hereunder is limited tosuch repair, replacement, or repayment of the purchase price. Parts not of BOSS manufacture arewarranted only to the extent that they are warranted by the original manufacture. BOSS shall have noresponsibility for any cost or expense incurred by Buyer from inability of BOSS to repair under saidwarranty when such inability is beyond the control of BOSS or caused solely by Buyer.
There are no other warranties, express, statutory or implied, including those ofmerchantability and of fitness of purpose; nor any affirmation of fact or representationthat extends beyond the description of the face hereof.
This warranty shall be void and BOSS shall have no responsibility to repair, replace, or repay thepurchase price of defective or damaged parts or components resulting directly or indirectly from the useof repair or replacement parts not of BOSS manufacture or approved by BOSS or from Buyer’s failureto store, install, maintain, and operate the compressor according to the recommendations contained inthe Operating and Parts Manual and good engineering practice. The total responsibility of BOSS forclaims, losses, liabilities or damages, whether in contract or tort, arising out of or related to its productsshall not exceed the purchase price. In no event shall BOSS be liable for any special, indirect, incidentalor consequential damages of any character, including, but not limited to, loss of use of productivefacilities or equipment, loss of profits, property damage, expenses incurred in reliance on the performanceof BOSS, or lost production, whether suffered by Buyer or any third party.
BOSS INDUSTRIES, INC.1761 GENESIS DRIVELAPORTE, IN 46350(219) 324-7776 Phone(219) 324-7470 Fax
34P/N: 307272
SUMMARY OF MAIN WARRANTY 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, changed, repaired or mistreated in any manner whatsoever. Normal maintenanceitems such as lubricants and filters are not warrantable items.
Parts not of BOSS manufacture are warranted only to the extent they are warranted by the originalmanufacturer.
Damage resulting from abuse, neglect, misapplication or overloading of a machine, accessory or part isnot covered under warranty.
Deterioration or wear occasioned by chemical and/or abrasive action or excessive heat shall notconstitute defects.
Parts replacement and/or correction of defective workmanship will normally be handled by BOSSIndustries, Inc. or their authorized distributor.
Failure to file a detailed warranty claim/service report for each occurrence of material defect ofdefective workmanship will cause warranty claim to be rejected.
Defective material must be returned within 30 days of receipt of shipping instructions. Failure to do sowithin specified time will result in forfeiture of claim.
The distributor is responsible for the initial investigation and write up of the warranty claim.
Distributor shall be allowed no more than 30 days from date of repair to file a warranty claim/servicereport.
Warranty for failure of BOSS replacement parts covers the net cost of the part only, not labor andmileage.
The BOSS warranty does not cover diagnostic calls and travel. That is time spent traveling to themachine to analyze the problem and returning with the proper tools and parts to correct the problem.
Boss will deduct from allowable credits for excess freight caused by sender failing to follow returnshipping instructions.
Distributors or end-user automatically deducting the value of a warranty claim from outstandingbalances due and payable to BOSS prior to receiving written notification of BOSS approval of thewarranty claim may be subject to forfeiture of the entire claim.
35P/N: 307272
WARRANTY INTRODUCTION
The warranty policy and procedures outlined here within are detailed to provide the claimant with theinformation necessary when filing a warranty claim, and enabling BOSS the ability to serve it’scustomers best.
WARRANTY CLAIMS - GENERAL
An approved claim depends on the following provision:
1. A warranty claim/service report # must be issued by BOSS. (See filing procedures).2. Failed part must be returned within 30 days, freight prepaid, with receipt of warranty claim/
service report.3. Part is definitely defective.4. Workmanship is definitely defective.5. Machine is within warranty period.6. Machine has been operating within design conditions.
Claims made by distributors must be verified by distributor prior to contacting BOSS.
WARRANTY CLAIMS - INSTRUCTIONS FOR SUBMITTING CLAIM
When making a warranty claim, study the situation that led up to the failure carefully. Verify that thefailure wan not the result of abuse or negligence. Warranty claims are not considered under normalmachine maintenance.
WARRANTY CLAIMS - FILING PROCEDURES
1. Initiate through purchase order for warranty part or request for credit.2. Warranty Claims/Service Report will accompany replacement part. When returning failed part
to the factory for warranty credit, fill out all information requested on Warranty Claims/ServiceReport when it is returned to you with replacement part.
3. BOSS will confirm disposition of failed part within 30 days, and or request additionalinformation.
4. Claim acceptance or denial will result in release of a credit or confirmation letter of denial.5. BOSS will consider each claim on it’s own merit and reserves the right to accept or reject claim
request. In case of air-ends, these will be returned to the manufacturer for their analysis/input.6. Send Warranty Claim/Service Report request to:
BOSS INDUSTRIES, INC.1761 GENESIS DRIVELAPORTE, IN 46350ATTN: WARRANTY CLAIM ENCLOSED
36P/N: 307272
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. Workmanship is determined to be defective.5. Machine is within warranty period.6. Machine has been operated within design conditions.
Claims made through distributors must be verified by distributor prior to contacting BOSSINDUSTRIES.
DAMAGE IN TRANSIT
Do not return damaged merchandise to BOSS INDUSTRIES, please follow claim procedure.
1. Loss in transit:The merchandise in our kit or provided in our factory installations has been thoroughly inspectedor carefully installed and tested before leaving our plant. However, regardless of the caretaken at the factory, there is a possibility that damage may occur in shipment. For this reason,it is recommended that the unit be carefully inspected for evidence of possible damage ormalfunction during the first few hours of operation. Responsibility for the safe delivery of thekit or factory installed unit was assumed by the carrier at the time of shipment. Therefore,claims for loss or damage to the contents of the kit or factory installed unit should be madeupon the carrier.
2. Concealed loss or damage:Concealed loss or damage means loss or damage, which does not become apparent until thekit is unpacked or the factory-installed unit is run by the end-user. The contents of the kit orfactory installed unit may be damaged due to rough handling while in route to its destination,even thought the kit or factory installed unit shows no external damage. When the damage isdiscovered upon unpacking, make a written request for inspection by the carrier agent withinfifteen days of delivery date. Then file a claim with the carrier since such damage is thecarrier’s responsibility.
By following these instructions carefully, we guarantee our full support of your claims, to protectyou against loss from concealed damage.
3. Visible Loss or DamageAny external evidence of loss or damage must be noted on the Freight Bill or Express Receipt,and signed by the carrier’s agent. Failure to adequately describe such external evidence ofloss, or damage may result in the carrier refusing to honor a damage claim. The carrier willsupply the form required to file such a claim.
37P/N: 307272
SCREW COMPRESSOR AIR-END EXCHANGE PROGRAM
Replacement air-ends are available from the factory. For current prices and availability, contact BOSSINDUSTRIES, Inc. or an authorized BOSS INDUSTRIES distributor. Prices are F.O.B. shipping point.Prices do not include labor for removal or installation.
38P/N: 307272
NOTES
39P/N: 307272
SECTION 6 ASSEMBLY DRAWINGS
40P/N: 307272
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