309872 MANUAL, 80201 AHBI.pmd
Contents
1. 11 229 Compressor Af Filter asiater REN E EEEE 11 5 6 450 151 12 Ded Compressor 12 Installation amp Operation 13 16 6 1 System Installation Over vie wos 13 62 Mounting the Compressor 13 6 3 Installation of Air Storage Tanks 13 64 Installation of WIFIn8 14 65 Connecting the Hydraulic Hoses 15 66 Pre Start up Inspection Checks 15 57 Checkallfiumdl velsuuu u us 15 0 8 Machine DocumentatiI9n 16 69 sorberne 16 6 10 Shutdown 16 6 11 Safety 011091 9 ean ciate 16 6 12 Oper tins ConditI nS ua aaswassssssassasssiyssqassahaysapawanpuykaqaysasapsssisqs 16 Maintenance sussie 7 2 J J RON2. S 2 3SOH 0S X L 44 309872
3. 17 7 2 Recommended 0 1 1191 9 0 17 T Howto Order 17 TA Maintenance Chart uu u 18 3 309872 Contents Maintenance cont 17 21 T Compressor 19 7 6 Compressor Oil Fill Level and 20 Jef hanging th 20 7 8 Changing the Air Oil Coalescer 21 7 9 Changing the Air Intake Filter 21 a uuu oer nee 22 24 qasa awaykunaqa 22 8 2 Improper Discharge 22 8 3 Sump Pressure Does Not Blow Down 23 8 4 TS STAI 23 Coalescer PIUS 22550235 u uum 23 8 6 High Compressor Discharge Temperature 23 8 7 Contacting Boss Industries Inc 24
4. 044 25 30 Warranty POC u uba uu b iu E E 26 92 Summary of Main Warranty Provisions 24 9 3 Warranty Return Goods Instructions 28 9 4 Warranty Claims Preparation of Part Return 28 9 5 Return or Warranty Claims Piling Procedures 28 9 6 Warranty Claims 29 9 D magein 29 98 Screw Compressor Airend Exchange Pro ram 30 31 44 10 1 sens te bek neden 32 33 TORE GOERE SV 34 35 1013 Air Filter SYSTEM 36 37 10 4 Canopy SYSTEM 38 39 TOS Eleetrical cents 40 41 10 6 Decal uuu p 42 43 10 7 Hose SYSTE 44 4 309872 Manual Change History 1 1 Revision List INITIALS m 2 Q Z x NR LOCATION DATE 309
5. Wo 2 309872 29 10 5 Electrical System Electrical System Parts List ITEM 3 PART NUMBER DESCRIPTION 1 1 1300074 GAUGE 2 1 1300076 004 SWITCHGAUGE 3 1 1300075 SWITCHGAUGE 4 1 1300079 SWITCH 5 1 1987325 012 ELBOW 6 1 308299 PLUG 7 1 960602 012 TEE 8 1 01422 SWITCH 9 1 970808 050 10 1 308525 SEAL 11 1 302011 013 40 309872 Electrical System 10 5 Electrical System continued 309872 4 10 6 Decal System Decal System Parts List ITEM PART NUMBER DESCRIPTION 1 1 302035 DECAL 1 1300038 DECAL 1 1 300039 1 1 300040 DECAL 1D 1 300042 1E 1 1300672 2 1 1305761 DECAL 3 1 300649 DECAL 4 1 1300913 _ DECAL 5 1 1302568 DECAL 6 1 1302443 7 1 1302444 42 309872 Decal System 10 6 Decal System continued 43 309872 Hose System 10 7 Hose System DINA OC ASOH alt X ab DINA 9 ASOH X L CL CL ASOH S X N O ASOH 09 E gt N O m 92491 ASOH alt X ab ONILNOH ASOH ASOH S X lt VA
6. 025 ELBOW 19 1 970612 075 ELBOW 20 1 980704 012 ELBOW 21 1 0 2134 SPIDER 22 1 970416 162 ELBOW 23 1 970420 188 ELBOW 24 1 962220 125 UNION 25 1 309834 ADAPTER 26 1 309857 27 1 970820 125 ADAPTER 28 1 993504 141 PLUG 29 1 309847 BASE 30 1 987325 012 ELBOW 31 2 929808 200 BOLT 32 4 938208 112 WASHER 33 6 937808 125 WASHER 34 7 929210 350 BOLT 35 7 938810 220 WASHER 36 7 1938910 200 WASHER 37 2 1306186 BRACKET 38 4 929808 150 BOLT 39 2 970808 050 ADAPTER 40 1 922208 000 NIPPLE 41 1 302633 VALVE 42 1 902915 020 PLUG 43 2 1308525 SEAL 44 1 977515 100 CAP 45 1 977515 125 46 2 929312 250 BOLT 47 2 970802 012 ADAPTER 48 1 973112 075 CONNECTOR 49 1 981612 075 ELBOW 50 1 300112 CLAMP 51 1 907605 030 BUSHING 52 1 300022 075 VALVE 53 1 309856 305 AIREND 54 1 960712 075 ELBOW 55 1 922112 020 NIPPLE 56 2 974700 012 PLUG 57 1 300111 CLAMP 58 1 1962116 100 UNION 32 309872 Compressor System 10 1 Compressor System continued SY 0 NY 0 Gy 2224 lt Z amp Z _ 2 309872 33 10 2 Cooler System Cooler System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 20 929705 100 BOLT 2 18 961505 140 NUT 3 2 306174 BRACKET 4 1 1306180 LOUVER 5 1 1300014 COOLER 6 1 1306159 SHROUD 7 1 1302622 ASSY 8 4 961504 090 NUT 9 4 938004 062 WASHER 10 4
7. 4249 USA Email service Website http www bossair com 17 309872 Maintenance 7 4 Maintenance Chart The MAINTENANCE CHART lists serviceable items on this compressor package The items are listed according to their frequency of maintenance 1 Drain liquid from compressor sump More frequent draining may EVERY 50 HOURS required under high humidity conditions Inspect compressor mounting bolts 1 Change compressor oil and oil filter element EVERY 500 HOURS 2 Check compressor shaft seal for leakage OR 6 MONTHS 3 Check compressor air filter connections fittings and clamps 1 hi Compressor oil and oil filter is to be changed after the first 50 O hours of operation After this normal intervals are to be followed 2 4 Install new air filter element 18 309872 Maintenance 7 5 Compressor Oil It is important that the compressor oil be of a recommended type and inspected and replaced as stated in this manual The combination of a coalescer element loaded with dirt and oxidized oil products together with increased air veloc ity as a result of this clogged condition may produce critical point while the machine is in operation where igni tion can take place and could cause a fire in the separator tank The following are general characteristics for a rotary screw lubricant Due to the impossibility of establishing limits on all physical and chemical pr
8. Number B Compressor Serial Number C Note any special applications relating to specific installations 6 9 Operating Procedure I Read this manual carefully before proceeding 1 Verify the service valve is closed Engage hydraulic system IV Allow hydraulic system to run on bypass for 3 5 minutes to warm up V Engage hydraulic flow to compressor VI Allow compressor speed to stabilize before opening service valve for use 6 10 Shutdown Procedure I Close service valve H If equipped for a 2 speed system allow engine speed to throttle down to low speed Disengage hydraulic flow to compressor IV Disengage hydraulic system 6 11 Safety Circuit Testing To perform safety circuit testing follow the operating procedure in section 6 9 above Use a screwdriver or other metal object to touch the 1 16 allen head screw on the face of the temperature gauge and simulta neously touch the outside ring on the face of the gauge This should shut off power to the solenoid of the hydraulics Push the button in on the shutdown switch to reset Repeat the test with the pressure gauge If the solenoid does not stop flow to the compressor check wiring 6 12 Operating Conditions The following conditions should exist for maximum performance of the compressor The machine should be as Close to level as possible when operating Operation in ambient temperatures above 100 F 38 C may experience high temperature shutdow
9. REV 2 24 2014 UPDATED 101112 TO REV 5 11 25 UPDATED 101115 REV 2 101112 TO REV 4 11 19 2013 UPDATED 101112 TO REV 3 AND 101116 TO REV 1 10 11 2013 101112 2 AND 101116 REV 15 25 2013 UPDATED 101112 AND 101114 REV 1 7726 2013 DESCI DATE 24 2 1 8 RIPTION REVISION HISTORY 4 3 10 309872 Description of Components 5 1 Compressor Airend The Boss Industries Inc compressor airend is a positive displacement oil flooded rotary screw type unit employing one stage of compression to achieve the desired operating pressure In operation two helically grooved rotors mesh to compress air Intake air is trapped as the male lobes roll down the female grooves pushing trapped air along compressing it until it reaches the discharge port in the end of the stator This delivers smooth flowing pulse free air The oil in a rotary screw airend serves three purposes e Lubricates the rotating parts and bearings Serves as a cooling agent to remove the heat from compression Seals the running clearances The airend supplied with the 80201 AHBI is an integrated type which means the oil reservoir and many other components are all integrated into the airend casting design 5 2 Drive System Hydraulic power turns a hydraulic gear motor that is mounted to the front of the compressor airend There is
10. a shaft to shaft coupling that transfers this power to the compressor input shaft An internal gear set provides higher speeds to the compressor male rotor for increased output with conservative hydraulic requirements Hydraulic bulkhead fittings are provided for easily interfacing an existing hydraulic system 5 3 Coalescer Element The coalescer element is a spin on canister style filter that removes the oil mist from the air as it is passed on to the minimum pressure valve As the air oil mist passes through the outside of the media oil gathers on the interior walls and settles to the bottom of the element Collected oil is returned to the compressor airend through the oil return line The coalescer will filter the oil concentration in the air to less than 3 parts per million 5 4 Pressure Relief Valve This valve vents sump tank pressure to atmosphere should the pressure inside the tank exceed 220 PSI 5 5 Compressor Air Filter The compressor air filter is a two stage dry type intake filter with a gravity evacuator and replaceable internal element On the outlet of the compressor air filter is an air filter restriction indicator This indicator serves as a maintenance tool 11 309872 Description of Components 5 6 Compressor Oil Filter The compressor oil filter is a spin on type 25 micron filter located on the rear of the airend Located in the same block as the oil filter is a thermal valve which allows the compressor oil to heat
11. against loss from concealed damage Visible Loss or Damage Any 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 of loss or damage may result in the carrier refusing to honor a damage claim The carrier will supply the form required to file such a claim 29 309872 Warranty 9 8 Screw Compressor Airend Exchange Program Replacement air ends are available from the factory For current prices and availability contact BOSS INDUSTRIES Inc or an authorized BOSS INDUSTRIES distributor Prices shipping point Prices do not include labor for removal or installation 30 309872 5 ILLUSTRATION SECTION 31 309872 Compressor System 10 1 Compressor System Parts List PART NUMBER DESCRIPTION 1 1 309858 MOTOR 2 1 1300629 VALVE 3 1 301694 4 8 929212 350 BOLT 5 10 938812 250 WASHER 6 12 938912 200 WASHER 7 1 01421 SWITCH 8 1 301422 SWITCH 9 1 300057 VALVE 10 1 301827 VALVE 11 1 964804 025 MOD 12 1 960404 025 NIPPLE 13 1 907600 005 BUSHING 14 1 961604 012 NIPPLE 15 1 980804 025 16 1 960702 012 ELBOW 17 1 902915 010 PLUG 18 1 980704
12. bolts securing it Directly below the opening you will find the air oil coalescer To remove the old element turn it counter clockwise until it is loose and then lift it off of the stem and out of the access panel It is normal for this filter to drip when it is removed If necessary you may want to remove the oil filter access panel as well to gain better access to the air oil coalescer You may need the assistance of a band wrench to remove the old element but new elements should be installed by hand tightening only Once the old element is out put a film of oil on the rubber ring of the new element and place it onto the stem and turn clockwise with your hands until it is tight The element should spin on freely until the last full turn Make sure the threads are engaging properly if it does not spin freely Once the new element has been installed reinstall the coalescer access panel and the oil filter access panel if necessary using the 3 bolts that were previously removed Do not substitue element Use only a Boss Industries Inc approved replacement element This element is rated at 290 PSI working pressure Use of any non approved elements may be hazardous and could impair the perfor mance and reliability of the compressor possibly voiding the warranty and or resulting in damage to property and serious bodily harm 7 9 Changing the Air Intake Filter The air intake filter is a heavy duty dry type high efficiency filter designed
13. compressor idle L Inlet valve leaking or open 1 Faulty regulator 22 309872 Troubleshooting 8 3 Sump Pressure Does Not Blow Down If after the compressor is shutdown pressure does not automatically blow down check for 1 Blowdown valve may be inoperative located at the inlet valve Blow down valve exhaust port plugged Blowdown valve should have a 9 64 orifice drilled into a 1 4 pipe plug that is installed in the exhaust port 8 4 Oil Consumption Abnormal oil consumption or oil in service line can be caused by the following L Overfilling of oil sump 1 Leaking oil lines or oil cooler Defective coalescer element IV Compressor shaft seal leakage V Discharge pressure below 65 PSI or above 175 PSI 8 5 Coalescer Plugging If the coalescer element has to be replaced frequently because it is plugging it is an indication that foreign material may be entering the compressor inlet or the compressor oil is breaking down Compressor oil can break down prematurely for a number of reasons I Extreme operating temperature 1 Negligence in draining condensate from oil sump Using the improper type of oil IV Dirty oil 8 6 High Compressor Discharge Temperature If the compressor shuts down on high temperature check the following I Check compressor oil level Add oil if required 1 Clean outside of oil cooler Clean oil system cooler internally IV Check fan switch relay harness 23 309872 Tr
14. to protect the compressor from dust and foreign objects Frequency of maintenance of the filter depends on dust conditions at the operating site The filter element must be serviced when clogged Aclogged air filter element will reduce compressor performance and cause premature wear of components To change the air filter element first open the air filter access panel located on the front of the machine by turning the latch counter clockwise and allowing the door to gently fall open Make sure the machine is not running when you perform this or any other maintenance Inside the access panel you will find an air filter assembly with 3 latches Disengage each latch and pull the end cover off of the air filter assembly Inside you will find the air filter element Remove the air filter element by pulling and gently twisting Install the new filter element in reverse fashion Reinstall the air filter assembly end cover and latch all 3 latches to ensure a tight seal on the element inside Relatch the air filter access panel in the closed position Do not substitue element Use only a Boss Industries Inc approved replacement element Use of any non approved elements may be hazardous and could impair the perfor mance and reliability of the compressor possibly voiding the warranty and or resulting in damage to property and serious bodily harm 21 309872 Troubleshooting 8 1 Overview This section contains instructions for troubleshooting the
15. verify that they reduce pressure in case of hose failure and will not nuisance trip with the hose and tool combinations in use Failure to comply could result in personal injury or death and or damage to equipment and property Never leave the machine running unattended or leave a tool connected to an air hose when not using Relieve system of all stored air pressure after use Using a compressor in an enclosed area WILL KILL YOU Engine exhaust contains carbon monoxide This is a poison you cannot see or smell Contact manufacturer for body mounting recommendations Never adjust the pressure switch to a setting of greater than 150 PSI Oper ating the compressor at greater than 150 PSI may result in personal injury and property damage Mount the compressor in a stable location capable of supporting 600 Ibs Slight vibration may occur during operation and the machine may move if not securely mounted When using tools maintain secure footing at all times Do not overreach or awkwardly use air tools Use only Boss Industries Inc approved replacement parts or equivalent 9 309872 Specifications 4 1 Specification Sheet COMPRESSOR SPECIFICATIONS 80201 AHBI Model Oil flooded Rotary Screw Hydraulic Flow 2200 PSI GPM Input RPM CFM Output 1010 1200 100 1450 125 1875 160 2160 185 Delivery Operating Pressure 80 110 PSIG Range Ambient Operating 209 1109 Temperature Range Oil Capacity Compressor S ga
16. 872 Welcome 2 1 General Information agg Bess 457 evolutionary Service and 80201 AHBI Maintenance Hydraulically Driven Thank you for choosing the Boss Industries Inc 80201 AHBI Air Com User Manual Air Compresso pressor Before operating this compressor carefully read this manual and become well acquainted with your new machine Doing this will increase your safety and maximize the life of the machine While this manual is written to be as accurate as possible Boss Industries Inc strives to continually improve the efficiency and performance of its for future reference machines As a result sometimes there may be slight differences between a Tn te cay nur ese AC given version of the manual and the machine 2 2 Overview The Boss Industries Inc 80201 AHBI is a compact strategically designed system It integrates all major components on a single frame which is enclosed in a tough weather resistant aluminum canopy The 80201 AHBI design provides output of up to 185 CFM cubic feet of air per minute at up to a maximum of 110 PSI pounds per square inch Three maintenance doors make virtually all components accessible for maintenance and service Instrumentation clearly displays temperature pressure and hours of operation Other features including a spin on compressor oil filter and a spin on coalescer element reduce the time and costs associated with routi
17. 938604 071 WASHER 11 4 929104 075 BOLT 12 411 300444 13 2 960212 075 ELBOW 14 2 925305 283 NUT 34 309872 Cooler System 10 2 Cooler System continued 309872 35 Air Filter System 10 3 Air Filter System Parts List ITEM PART NUMBER DESCRIPTION 1 1 1309414 2 4 938205 071 WASHER 3 2 925505 273 NUT 4 2 929105 150 BOLT 5 1 1309415 INDICATOR 6 2 301786 300 CLAMP 7 1 1309870 ASSY NS 2 FT 301785 300 HOSE 36 309872 Air Filter System 10 3 Air Filter System continued ah nO AS 4 Ova AY Qo TH 37 309872 10 4 Canopy System Canopy System Parts List ITEM PARTNUMBER DESCRIPTION 1 30 961504 090 2 1 309850 PANEL 3 1 309851 PANEL 4 1 309849 5 1 09852 PANEL 6 1 09853 PANEL 7 1 306944 SPACER 8 1 306891 HINGE 9 6 943103 025 10 1 306943 11 1 09848 PANEL 12 1 309854 PANEL 13 52 984004 071 WASHER 14 1 309855 PANEL 15 16 991204 260 INSERT 16 6 991204 165 INSERT 17 52 981504 075 SCREW 18 3 300444 010 38 309872 Canopy System 10 4 Canopy System continued SE AN 2 2 N LNBs
18. The Service and 80201 AHBI Maintenance Hydraulically Driven User Manual Air Compressor This manual must be read carefully before using your Boss Industries Inc Air Com pressor Store in a safe and convenient location for future reference For technical support Phone 800 635 6587 USA Phone 219 324 7776 Outside USA Fax 877 254 4249 USA Email service bossair com Website http www bossair com 309872 08 13 2014 KWB 309872 Contents Manual Change HiS fOKrY a auasissiasqqassssassqisqsaqsassqakasaaysasckassasas asaqsasassassssasaassssssqa sa y uu 5 E S 2 1 WSS 6 22 R am u 23 6 SSCL Vos gt Sel General Safety 7 8 9 LO AT Specification aar 10 Description of Components 11 12 1 Compressor Arrendar 11 52 11 53 C alescer Element 11 54 Pressure Relief ValV uu ua
19. al of workmanship BOSS will at its option either a furnish a Service Representative to correct defective workmanship b upon return of the item BOSS original shipping point repair or replace the item or issue credit 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 result in forfeiture of claim or c refund the full purchase price for the item without interest Factory installed units will also include warranty on installation for a period of one 1 year This warranty does not cover damaged caused by accident misuse or negligence If the compressor unit is disassembled the warranty is void BOSS s sole responsibility and Buyer s exclusive remedy hereunder is limited to such repair replacement or repayment of the purchase price Parts not of BOSS manufacture are warranted only to the extent that they are warranted by the original manufacture BOSS shall have no responsibility for any cost or expense incurred by Buyer from inability of BOSS to repair under said warranty 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 of merchantability and of fitness of purpose nor any affirmation of fact or representation that extends beyond the description of the face hereof This warranty sh
20. all be void and BOSS shall have no responsibility to repair replace or repay the purchase price of defective or damaged parts or components resulting directly or indirectly from the use of repair or replacement parts not of BOSS manufacture or approved by BOSS or from Buyer s failure to store install maintain and operate the compressor according to the recommendations contained in the Operating and Parts Manual and good engineering practice The total responsibility of BOSS for claims losses liabilities or damages whether in contract or tort arising out of or related to its products shall not exceed the purchase price In no event shall BOSS be liable for any special indirect incidental or consequential damages of any character including but not limited to loss of use of productive facilities or equipment loss of profits property damage expenses incurred in reliance on the performance of BOSS or lost production whether suffered by Buyer or any third party BOSS INDUSTRIES INC 1761 GENESIS DRIVE LAPORTE IN 46350 219 324 7776 Phone 219 324 7470 Fax 26 309872 Warranty 9 2 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
21. chandise 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 inspected or carefully installed and tested before leaving our plant However regardless of the care taken 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 or malfunction during the first few hours of operation Responsibility for the safe delivery of the kit 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 made upon the carrier Concealed loss or damage Concealed loss or damage means loss or damage which does not become apparent until the kit is unpacked or the factory installed unit is run by the end user The contents of the kit or factory 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 is discovered upon unpacking make a written request for inspection by the carrier agent within fifteen days of delivery date Then file a claim with the carrier since such damage is the carrier s responsibility By following these instructions carefully we guarantee our full support of your claims to protect you
22. correct the problem Boss will deduct from allowable credits for excess freight caused by sender failing to follow return shipping instructions Distributors or end user automatically deducting the value of a warranty claim from outstanding balances due and payable to BOSS prior to receiving written notification of BOSS approval of the warranty claim may be subject to forfeiture of the entire claim 27 309872 Warranty 9 3 Warranty Return Goods Instructions The warranty return procedure outlined below is provided to give the claimant the information necessary to file a warranty return claim and enable BOSS INDUSTRIES the ability to best serve its customers Please see the following instructions to initiate a return Contact BOSS INDUSTRIES Returns Department by telephone at 219 324 7776 or via email at service bossair com You may also send a fax at 219 324 7470 9 4 Warranty Claims Preparation of Parts Return Parts returned to the factory must be properly packaged to prevent damage during shipment Damage to a part as a result of improper handling or packing could be cause for denial When addressing the package for shipment the following information must be on the outside of or tagged clearly to the package Return Goods Authorization Distributor or end users return address Correct factory address Number of packages pertaining to each claim Pen NOTE Our warranty requires that all defective parts be re
23. enance and attention Select and use it wisely 19 309872 Maintenance 7 6 Compressor Oil Fill Level and Drain Before adding or changing compressor oil make sure that the compressor is completely relieved of pressure The drain is located on the front of the machine towards the bottom of the airend To drain the oil remove the plug from the end of the drain Then rotate the valve to the open position to release all of the oil from the compressor sump When oil has been drained rotate the valve to the closed position and reinstall the plug into the end of the drain Oil is added at the fill cap on the front of the machine above the sightglass The proper oil level is in the middle of the oil sightglass when the unit is shut down and has had time to settle The machine must be level when checking the oil DO NOT OVERFILL The oil capacity is given in Compressor Specifications Do not attempt to drain condensate remove the oil level fill T D A N G R cap or break any connection in the air or oil system without shutting off the compressor and relieving the system of all stored air pressure 7 7 Changing the Oil Filter The oil filter is a spin on type element that is easily replaced through the oil filter access panel First remove the oil filter access panel from the right side by the air outlet of the machine by removing the 4 bolts securing it Inside the access panel will be 2 filter elements the oil filter and the air
24. equipment following a malfunction The troubleshooting procedures to be performed on the equipment are listed below Each symptom of trouble for a component or system is followed by a list of probable causes of the trouble and suggested procedures to be followed to eliminate the cause In general the procedures listed should be performed in the order in which they are listed although the order may be varied if the need is indicated by conditions under which the trouble occurred In any event the procedures that can be performed in the least amount of time and with the least amount of removal disassembly or parts should be performed first 8 2 Improper Discharge Pressure If discharge pressure is too low check the following I Too much air demand Air tools require more air than what the compressor can produce air tools are free wheeling without resistance II Service valve is wide open to atmosphere Leaks in service line IV Restricted compressor inlet air filter V Faulty control system operation i e regulator is sending a signal to close the inlet valve at all times If discharge pressure is too high safety valve blows or system shuts down on high pressure check the following I Faulty discharge pressure switchgauge or improper shutdown setting Coalescer plugged or blocked Faulty safety valve IV Faulty regulator regulator air pressure signal is not getting to inlet valve High pressure shutdown at
25. he motor and compressor Lastly check to make sure hoses are not in contact with sharp objects or edges that may fray chafe or cut them over time Secure all hoses with tie down straps or clamps ELECTRICAL CONNECTION s l HYD PRESSURE HYD RETURN PORT 1 JIC PORT 1 1 4 JIC 6 6 Pre Start up Inspection Checks This inspection should be done prior to the compressor test I Check all assemblies clamps fittings hose connections nuts and bolts to ensure they are properly tied and secured to the vehicle This is a very critical area of inspection The vehicle should not be moved until this inspection has been completed 1 Remove all tools rags and installation equipment from the area Check compressor oil level Check all valves to ensure they are in correct operating position IV Vacuum all areas that have metal or plastic shavings Wipe all fingerprints off unit and vehicle 6 7 Check all fluid levels Position the unit on a level surface so that proper amount of fluids can be added I Check the compressor oil level A Add oil if needed B Additional oil may need to be added after test C Top off oil level to half the sightglass when finished with the test 1 Check hydraulic system oil level 15 309872 Installation amp Operation 6 8 Machine Documentation Record all serial numbers for this installation A Boss Industries Inc Serial
26. hese safety guidelines the operator should follow any company specific guidelines and procedures Consult your immediate supervisor for specific company safety guidelines and or proce dures The following safety symbols are used throughout the manual to draw attention to important information If the information is not carefully read and the instructions are not followed severe injury death and or damage to property and equipment may occur A D A N G R Indicate s an imminently hazardous situation which if not avoided will result in death or serious injury Indicate s a potentially hazardous situation which if not avoided could result in death or serious injury Indicate s a potentially hazardous situation which if not avoided could result in minor or moderate injury Indicate s a potentially unsafe situation or practice N which if not avoided can result in property and or equipment damage only 7 309872 3 2 Safety Precautions Safety The following safety precautions are a general guide to safe operation of the equipment gt AWARNING S 28 UNE FUN Read and understand the operations manual and all other safety instructions before using this equipment Failure to follow operating instructions and or failure to follow maintenance proce dures and intervals could result in personal injury death and or damage to equipment and property Pressurized System Do no
27. llons Air Service Connection 3 4 Overall Dimensions 36 x 28 x 31 Weight Wet 700 105 CALCULATIONS PERFORMED 85 EFFICIENCY MECHANICAL AND 96 EFFICIENCY VOLUMETRIC SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE 4 1 3 2 1 1 Paris List AIR FILTER ACCESS ITEM OTY PART NUMBER DESCRIPTION 40 54 1 1 1101112 SYS 80201 2 1 101113 COOLER SYS 80201 36 00 3 1 101114 __ AIR FILTER SYS 80201 D 4 1 101115 SYS 80201 AHBI D 5 1 101116 ELECTRICAL SYS 80201 AHBI 6 1 101117 DECAL SYS 80201 7 1 101118 _ HOSE SYS 80201 AHBI 9 1101117 DECAL SYS 80201 COALESCER ACCESS H OIL FILTER ACCESS MINIMUM CLEARANCE HOT DISCHARGE AIR FROM FRONT 10 MINIMUM CLEARANCE 12 ELECTRICAL CONNECTION ple 1 OIL DRAIN 2122 F 2 73 M HYDRAULIC PRESSURE gt INLE JIC FRESH INTAKE COOLING AIR FROM BOTTOM HYDRAULIC RETURN 7 OUTLET 1 1 4 BOSS INDUSTRIES 18898 2222 LA PORTE 46350 DESCRIPTION 80201 AHBI e B UPDATED 101117 REV 8 27 2014 PDATED 101112 7 57472014 BSN GAUGE PANEL AND SAFETY SHUTDOWN SWITCH UPDATED 101112 REV 6 AND 101116 TO
28. n 16 309872 Maintenance 7 1 Overview This section contains instructions for performing the inspection lubrication and maintenance procedures required to maintain the compressor in proper operating condition The importance of performing the maintenance described herein cannot be over emphasized The periodic maintenance procedures to be performed on the equipment covered by this manual are listed on the following page It should be understood that the intervals between inspections specified are maximum intervals More frequent inspections should be made if the unit is operating in a dusty environment in high ambient temperature or in other unusual conditions A planned program of periodic inspection and maintenance will help avoid premature failure and costly repairs Daily visual inspections should become a routine Compressor must be shut down and completely relieved of pressure prior to checking fluid levels Open service valve to A D A N G F R ensure relief of system air pressure Relieve all stored air pressure energy prior to starting machine Failure to comply with this warning will cause damage to property and serious bodily harm 7 2 Recommended Spare Parts List PART NUMBER DESCRIPTION 300005 Spin On Oil Filter Element 304122 Spin On Air Oil Separator Element 309410 Air Filter Element 7 3 How To Order Parts For technical support Phone 800 635 6587 USA Phone 219 324 7776 Outside USA Fax 877 254
29. ne maintenance The 80201 AHBI also has enhanced safety features to protect your valuable resources minimum pressure valve high compressor oil temperature shutdown high compressor pressure shutdown automatic blowdown device pressure relief valve and clearly displayed warning information decals 309872 Safety 3 1 General Safety Overview IMPORTANT READ BEFORE OPERATING EQUIPMENT Remember safety is basically common sense While there are standard safety rules each situation has its own peculiarities that cannot always be covered by rules Therefore with your experience and common sense you are in a position to ensure the safety of yourself and those around you Lack of attention to safety can result in accidents personal injury reduction in efficiency and worst of all Loss of Life Watch for safety hazards and correct them promptly Understanding the proper operation of this equipment is critical to its safe operation The owner lessor or operator of this equipment is hereby notified and forewarned that any failure to observe the safety and operating guidelines may result in injury and or damage Boss Industries Inc expressly disclaims responsi bility or liability for any injury or damage caused by failure to observe these specified precautions or by failure to exercise the ordinary caution and due care required while operating or handling this equipment even though not expressly specified In addition to following t
30. oil coalescer The oil filter will be on the left side and is the smaller of the 2 filters To remove the old element turn it counter clockwise until it is loose and then lift it off of the stem and out of the access panel It is normal for this filter to drip oil when it is removed You may need the assistance of a band wrench to remove the old element but new elements should be installed by hand tightening only Once the old element is out put a film of oil on the rubber ring of the new element and place it onto the stem and turn clockwise with your hands until it is tight The element should spin on very freely until the last full turn Make sure the threads are engaging properly if it does not spin freely Once the new element has been installed reinstall the oil filter access panel using the 4 bolts that were previously removed Do not substitue element Use only a Boss Industries Inc approved replacement element This element is rated at 200 PSI working pressure Use of any non approved ele AWARNING ments may be hazardous and could impair the performance and reliability of the compressor possibly voiding warranty and or resulting in damage to property and serious bodily harm 20 309872 Maintenance 7 8 Changing the Air Oil Coalescer The air oil coalescer is a spin on type element that is easily replaced through the coalescer access panel First remove the coalescer access panel from the top of the machine by removing the 3
31. operties of lubricants which can affect their performance in the compressor over a broad range of environmental influences the responsibility for recommending and consistently furnishing a suitable heavy duty lubricant must rest with the individual supplier if they choose not to use the recommended Boss Industries Inc rotary screw lubricant The lubricant supplier s recommendation must therefore be based upon not only the following general characteristics but also upon his or her own knowledge of the suitability of the recommended lubricant in helical screw type air compressors operating in the particular environment involved Mixing different types or brands of lubricants is not recom N mended due to possibility of a dilution of additives or a reaction between additives of different types Recommended Compressor Lubricant DEXRON 11 ATF I Specifications 1 Flash point 400 F minimum Pour point 40 F Contains rust and corrosion inhibitors Contains foam suppressors Contains oxidation stabilizer Due to environmental factors useful life of all tended lubricants may be shorter than quoted by the N lubricant supplier Boss Industries Inc encourages user to closely monitor the lubricant condition and to par ticipate in an oil analysis program with the supplier No lubricant however good and or expensive can replace N O proper maint
32. oubleshooting 8 7 Contacting Boss Industries Inc If you need assistance with any of the preceding steps or cannot find the solution to your problem call the Boss Industries Inc Service Department Phone 800 635 6587 USA Phone 219 324 7776 Outside USA Fax 877 254 4249 USA Email service bossair com Website http www bossair com When calling for technical support have the following information available Machine Serial Number Description of the problem 24 309872 WARRANTY SECTION 25 309872 Warranty 9 1 Warranty Policy Boss Industries Inc BOSS warrants that this Rotary Screw Compressor unit conforms to applicable drawings and specifications approved in writing by BOSS The unit assembly will be free from defects in 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 and parts 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 whichever period first expires If within such period BOSS receives from the Buyer written notice of and alleged defect in or nonconformance of the unit all other components and parts of BOSS manufacture and if in the judgment of BOSS these items do not conform or are found to be defective in materi
33. r to exhaust without recirculating into the machine A minimum of 12 of clearance is needed for the hot discharge air from the cooler Aminimum of 10 of clearance is required from the front of the compressor to allow for proper air intake Cool ambient air is drawn in from below the machine One last consideration in the mounting should be the routing of hydraulic hoses Be sure these can be safely run to the bulkhead fittings on the machine The unit should be secured to the vehicle with four 1 2 grade 8 bolts washers and nyloc nuts Ensure that you have a sub structure that will support the weight of the compressor Be sure to follow all National Vehicle Safety Standards 6 3 Installation of Air Storage Tanks This Rotary screw air compressor system is designed to provide continuous volume and constant pressure without the use of an air storage tank Within a few seconds of engagement the compressor will produce full volume and pressure needed to run corresponding air operated equipment without waiting for air tanks to fill Air storage tanks are not utilized as standard equipment on vehicle mounted rotary screw compressors The installation of air storage tanks if not done properly will hinder the performance of the rotary screw compressor Boss Industries Inc strongly discourages the use of an air storage tank as standard equipment for vehicle mounted rotary screw air compressors In the rare event air usage is required without ope
34. rating the vehicle an air storage tank can be added to your system When adding an air storage tank be sure to follow all state and federal DOT regulations regarding air storage tank usage 13 309872 Installation amp Operation 6 4 Installation of Wiring This unit is shipped from the factory with all necessary internal wiring installed The only remaining wiring necessary is the wiring needed to interface your vehicle power source with the Boss compressor The unit is shipped with 1 end of a6 pin connector They need to be connected as follows PinA Battery Power PinB Battery Ground PinC 12vdc switch power for operation PinD Power Out to hydraulic system solenoid through safeties PinE Regulated Pressure Signal In PinF Regulated Pressure Signal Out Pin D should be used to direct hydraulic flow to the compressor This wire can also be used with a relay to signal the engine speed to increase if additional hydraulic flow is required during compressor operation The regulated pressure signal wires are used in conjunction with a 2 speed system for engine speed control The regulated pressure signal In wire should be connected to a signal wire This may be a power or ground In example below this wire is connected to pin D for switched power through the compressor safeties This signal will be returned on the regulated pressure signal wire when your regulated pressure switch is closed To put this ano
35. repaired or mistreated in any manner whatsoever Normal maintenance items 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 original manufacturer Damage resulting from abuse neglect misapplication or overloading of a machine accessory or part is not covered under warranty Deterioration or wear occasioned by chemical and or abrasive action or excessive heat shall not constitute defects Parts replacement and or correction of defective workmanship will normally be handled by BOSS Industries Inc or their authorized distributor Failure to file a detailed warranty claim service report for each occurrence of material defect of defective workmanship will cause warranty claim to be rejected Defective material must be returned within 30 days of receipt of shipping instructions Failure to do so within 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 service report Warranty for failure of BOSS replacement parts covers the net cost of the part only not labor and mileage The BOSS warranty does not cover diagnostic calls and travel That is time spent traveling to the machine to analyze the problem and returning with the proper tools and parts to
36. t attempt to remove any compressor parts without first completely relieving entire system of pressure Do not attempt to service any part of the equipment while in operation Never attempt to repair or modify any pressure vessel or device System contains hot oil The compressor system must be shut off prior to servicing Open the service valve to ensure complete relief of system air pressure and stored energy Then permit system to cool down prior to adding compressor oil or servicing the unit Do not use air from this compressor for breathing or food process ing Air from this compressor will cause severe injury if used for breathing or food processing The compressor is designed to compress air only Do not attempt to compress other gases Compression of other gases may create a situation where an explosion or fire may occur Do not use flammable solvents for cleaning compressor parts as this can cause the unit to ignite or explode during operation Keep combustibles out of and away from compressor inlet and any associated enclosures 8 309872 Safety 3 2 Safety Precautions continued A DANGER A DANGER A DANGER A DANGER NOTICE Never disable override or remove safeties either temporarily or permanently Connect air hoses only in full compliance with O S H A Standard 29 CFR 1926 302 b 7 The required safety devices velocity fuses should be tested in accordance with their manufacturer s recommendations to
37. ther way pin is connected to pin when air supply is exceeding air demand and this can be used to tell your engine to slow down This circuit has a5 Amp maximum rating ENGINE SPEED SIGNAL WIRE COULD BE POWER OR GROUND DEPENDING ON ENGINE 30 87a a 287 30 872 54 ENGINE SPEED LOW 86 85 86 85 16GA PURPLE WIRE 16 GREEN WIRE 16 BLACK WIRE 16GA BLUE WIRE 126 BLACK WIRE 12GA RED WIRE D 1 HYDRAULIC SOLENOID A BATTERY POWER B BATTERY GROUND SWITCHED POWER D SWITCHED POWER OUT THROUGH SAFETIES REGULATED PRESSURE IN F REGULATED PRESSURE OUT ee 12VDC SWITCHED IGNITION POWER COMPRESSOR ON OFF SWITCH BATTERY 11226 BSM 4 16 13 14 309872 Installation amp Operation 6 5 Connecting the Hydraulic Hoses The hydraulic hoses to the compressor should be connected directly to the bulkhead fittings The input line on the left should be made from a good quality high pressure min 3000 PSI hydraulic hose 1 1 4 The return line on right can be made from a medium pressure min 1500 psi hydraulic hose 1 1 4 i d Care should be taken to see that the hoses are not installed with kinks or bends that inhibit flow of the hydraulic oil Lack of flow could result in damage to t
38. turned to BOSS INDUSTRIES freight prepaid Items sent without RGA number will not be accepted Unauthorized Returns Will Immediately Be Refused At Dock 9 5 Return or Warranty Claims Filing Procedures 1 Initiate through a purchase order for warranty part or request for credit 2 will accompany replacement part 3 BOSS INDUSTRIES will confirm disposition of failed part within 30 days of receipt and or request additional information 4 Claim denial will result in issuance of a letter of denial 5 BOSS INDUSTRIES will consider each claim on its 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 to BOSS INDUSTRIES INC 1761 Genesis Drive LaPorte IN 46350 Attn Returns Dept 28 309872 Warranty 9 6 Warranty Claims Provisions An approved claim depends on the following provision Oy ia An RGA must be issued by BOSS INDUSTRIES See filing procedures Failed part must be returned within 30 days of original invoice date freight prepaid with RGA Part is determined to be defective Workmanship is determined to be defective Machine is within warranty period Machine has been operated within design conditions Claims made through distributors must be verified by distributor prior to contacting BOSS INDUSTRIES 9 7 Damage in Transit Do not return damaged mer
39. up before being directed to the oil cooler The oil travels through the oil filter and then based on temperature either goes to the oil cooler or is returned directly to the airend sump 5 7 Compressor Oil Cooler The compressor oil cooler is designed to dissipate the heat created during the compression of air The compressor oil flows through the tubes of the cooler transferring heat to the air that flows over the fins 12 309872 Installation amp Operation 6 1 System Installation Overview This air compressor should be installed only by those who have been trained and delegated to do so and who have read and understand the manual Failure to follow the instructions procedures and safety precautions in this manual may result in accidents and injuries Install use and operate this air compressor only in full compliance with all pertinent O S H A Federal State and Local codes or requirements in addition to any company s regulations Do not modify this compressor except with written factory approval 6 2 Mounting the Compressor When mounting the compressor care should be taken to ensure that its location does not impede the operation of other components on the vehicle For example if your vehicle is equipped with a crane you must make sure the compressor will not interfere with the swing of the crane In addition the compressor should be installed in an area that permits cool ambient air to enter the air filter and the hot ai
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