307239 24HP RX-70 - Boss Industries, Inc.
Contents
1. 2 Y 8 9 2 i 30 1 5 etal AHOISIHNOISIA3H ar 395007 N suioiwiamnuao NOLLdIHOSSG ar herr m 286206 gt 1 066408 261 05 SLHYd 28 4 WOW L OL 066205 non TEHA SOV 0569 N auod vT o Ed me p y D TUE MESE WOW OL 7500 d31vadn H31000 110 WOH HOSSIHANOO 37009 OL 13110 HOSS3HdWOO 2 2 14 X 0 0 X GO 7 X3riavavd SNL SZ0 096L0 U 9 SN SZ SVE 39N1 97196068 YE SN Z L H3HSVM 1 36 925805 1 92 2O1 H3HSVM 060 708866 v Sz Y IHL 9 L L X GO 55 6 X dl 26 5 ONIH O 2862706 2 2 LSNI 183415 X GAH 8 0 70 096 dunsSdud OL LN v L X HVd v L 381 HOLO3NNOO 5 0 709086 6 22 WINS2 8011 9 6v2L0 Z 300 T H3dVL 82 872 08 1 02 X TAMS 381 MOT 520 70 086 6l X Wr L HIN 620 0896 812. 15 Pp NO L dio 1109 om is 91 MN LINN GION3IOS xus 7109 Gene 1M3lV Ind 71303 YALYWLS VOZ ALINNILNOD HOLIMS NOLLVNIBWOO 1331 1331 HOLIMS TONINO HOLIMS NOLLVNIBWOO TA 39 39 110 1 lt M 14 M5 1 T o lt 7 NOLLINOI E gt 2 A 18 Y31411938 YOLVINOSY 30010 18 GIONF1OS HOLIMS 4015 3NI9NI M 031910933 1MVIS 0100 ng M na m A 4 48 39nvo 3onvo T 34055344 JYNIVIIANZL 35 M5 l Y SSS NMOGLONHS 53 P N 307239
3. NOILdIHOS3G INON 7 97 006 cLL SPZ00 dQ3OV Id3d 0 Xu SLHYd 3NION3 quvno HV31O OL 279 861 gt 0 1SAVHX3 MOST3 406 06 OOSXAE Q3QNV8 1799 920206 3NION3 1v23d 919006 2 1HOIH LIN 401 VONOH 0687081 9 ATINA 9660061 AJA SLE X S V SAS 5 7 98 006 ININ8 H3HSVM 002 808866 X ININ8 60 9 17108 092 802626 NOLSId ONIHdS 08691 05 82 v L WYF LAN 91 09726 196708 0 HIV 1339VH8 9 0 8 L X TAMS 1 T3 10 0 086 SUD 1V14 H3HSVM 140 09866 9 02 1 SYD 1709 001 v01626 S LOAId L3340VH8 7598 8981 6 Oc v L SUD DOTAN LAN Svl vOEre6 9 8 82 1 14061 02 9334 3NION3 37598 06 1 _ 9 2 91 8 6 8HO 17109 002 908606 7 8 91 8 849 DOTAN LAN 861 9099026 7 v 8 5 849 1 14 H3HSVM 140 9028 6 8 2 1 LO9LL OZL L 009 dH 72 3NION3 960 06 L YAEWAN LHVd ALO 1511 L 6 5 307239
4. 27 P N 307239 LUBRICATION LUBRICANT RECOMMENDATIONS WARNING IT IS IMPORTANT THAT THE COMPRESSOR FLUID BE OF A RECOMMENDED TYPE AND THAT THIS OIL AS WELL AS THE AIR FILTER OIL FILTER AND SEPARATOR ELEMENTS BE INSPECTED AND REPLACED AS STATED IN THIS MANUAL THE COMBINATION OF A SEPARATOR ELEMENT LOADED WITH DIRT AND OXIDIZED OIL PRODUCTS TOGETHER WITH INCREASED AIR VELOCITY AS A RESULT OF THIS CLOGGED CONDITION MAY PRODUCE A CRITICAL POINT WHILE THE MACHINE IS IN OPERATION WHERE IGNITION CAN TAKE PLACE AND COULD CAUSE A FIRE IN THE OIL SUMP FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTY AND SERIOUS BODILY HARM The following general characteristics categorize lubricants that have been found to be satisfactory for use in helical screw type air compressors Due to the impossibility of establishing limits on all physical and chemical properties 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 The lubricant supplier s recommendation must therefore be based upon not only the following general characteristics but also upon his own knowledge of the suitability of the recommended lubricant in helical screw type air compressors operating in the particular environment involved CAUTION MIX
5. 157 Sued 52 P N 307239 30 maus 23125 1014 9 ASSV SS3NQMVH ON 1 3002 991 IF 5508 30 1S333l me NI 3HL OL VIIN3NIBIL 30 NI AULO3YIO 532 48 5 GSNIHOVANIT NI YO 035 YVININV 49 ONIS VEO nit SE xs 5 dAVOc YONOH Of Xa 10409 Gios OL covo ama 1H9n an 3m8 SSOS NVJIVIO 1 5 1 MO NON O MOTHA 4 OSC9v NI 31404 1 S3lMISnaNI 5509 NO9 SI ONI S3RISQONI S3OVI8NS G3NIHOYN NMOSS 19 5508 40 AlH3dOHd JHL GION SSSTN NI3H3HL NOILVAHOJNI TW ONY SIH 29 wo 31 25 LON 09 a z YOSNIS 1515 9102 HOLIMS 03007 20 2 0 l 3univar3dw3l NNINN3L azaay 60 20 60 z ON 4 SLI 8 iv8 ald A 431005 ANVWISd GION310S ama S 1S NW 105 112 3334 1 y 7 annoxo 9 3 H3 iv3ug 5 1 1
6. HHO 0102 02 OL 996002 Q31vadn St ovweroNoan mantas WON 0102 91 9 8 OL 596002 d31v dn 91 T HYO OLOZ ZL Z 6 A3H OL 596002 1 21 2 42 052 NI 31HOd iago aa iovis WOW 0102 02 6 01 596002 GaLvadn 81 ul 8 6 81 V sauisnant paese gases WON 01028401 Qi 196002 1 AJH OL 996002 WOW 0102 8 11 21 OL 596002 d31vadn 02 T 9921 ug 21 ul v L 62 7 68 SE g be Y O gt 25 17667 Le 23 0 A 506 Ul 8 5 BL LATING ONIddlHS SLVYO ZOseoe SN 5509 IVANVIA 662206 SN 0 S1uVd ONY ISOH 912002 9 a 0 SLYVd 8 991009 oseood S 0 S1HVd Y 3NION3 99 002 v 9 0 SLHYd Y HOSSdHdWOO 996002 6 0 S1uvd Y 196002 4 0 519 TINVA 16 18 003 1uvd Wall sued 5 v 9 4 8 47 307239 P N 09597 NI 31HOd V1 SSS 5 15 5508 E qawo3Ho D rd SODZEVZ WOW TIV ONV _ z y y 1 i388 oa AYOLSIH NOISIASY 2
7. 23 P N 307239 COMPRESSOR OPERATION While BOSS Industries has built into its compressor several controls and indicators to assure you that it is running properly you will want to recognize and interpret the readings which will call for service or indicate the beginning of a malfunction Before starting the compressor read this section thoroughly Familiarize yourself with the controls and indicators their purpose location and use CONTROL OR INDICATOR PURPOSE AIR PRESSURE GAUGE Continually monitors the sump pressure at various load and unload conditions Monitors the temperature of the air fluid mixture leaving the compressor unit FAN SWITCH The normal reading should be approximately 140 to 220 Fahrenheit Switch closes to activate fan motor COMPRESSOR HIGH DISCHARGE TEMPERATURE SHUTDOWN Opens the electrical circuit to shut the machine down when the discharge SWITCH temperature reaches 250 Fahrenheit FLUID LEVEL SIGHTGLASS Indicates the fluid level in sump Proper level should fill half of the top sight glass Check this level when the machine is shutdown PRESSURE RELIEF VALVE Vents sump pressure to the atmosphere should pressure inside the sump exceed 175 PSIG COMPRESSOR INLET CONTROL Regulates the amount of air intake in accordance with the amount of VALVE compressed air being used Isolates fluid in compressor unit on shutdown PRESSURE REGULATING VALVE Senses air pressure from sump to provide automatic reg
8. 1 3O L33HS DAP 1920027 Sr SAU E eee eae ANY NI ATLOSHIGNI E ON OMA ANOS 321 8002 022 38 LON 8002 2 2 g SAN 1VILN3GIJNOO AYOLSIH NOISIA3H NOLLdIHOS3G OL 570505 Q31vadn SLUWd USNI 9999997 0 6002 8 6 G3IONSSTING S3ONVHSIOI AO 10001 31955 10N OG oh FUVINONY 020 00001 OL 1003 7210 70186 lt 20 06 86 090 912106 010 61 106 00 9 0006 00 1 1206 G 000 271206 Q39v 1ddH OLOZ 0L y OL 5709505 1 0529 STANOW fowr sesos 999 BO SIS3N39 19 1 t ororo saiuisnanissog oU en TY ESO SIH HOLIMS 3NION3 AAV L WOOT 0S L 68020 0 XH SSdNHVH 670406 1040 N39 4 319901 HOLIMS 999008 930 082 1544002 SEN 1 X LANN 8 1 10 706 86 154091 Y9 8 1 Adid 600 512106 91 6 SYD 1 14 H3HSVM 1 0 409866 0 TANVd LSNI 1VO3d 9 0 3 18v9 666006 3unssaud 8 0006 44 NMOGLNHS HOLIMS 620008 YALAWYNOH 39nvo 720006 062 107 39nvVOHO LIMS 700 9 000
9. 1vO3d O0v0O00 8 L 8c LOH H39Nvd 1v93d 860006 660006 L 92 LO3NNOO 1v23d 27000 Sc 08 2 21 IvO30 c 006 vOL ve Qquvno 1139 896006 c EM mia 7903 1vo3d 918008 ce 226 2 LSNYHX LOH 1V93d 42006 701 le TvO3d el600 02 SSV1D LHDIS 71 030 896206 61 Orr TSAIMS 4100079 1SSHM H31S VO 5517081 81 3N3HdO3N 2 1 YL 2 1 8X v L HOLVIOSI 176105 HL 91 211519 dVO 210908 SL 2 1 X 05 MOOTZIHM 1108 050 70 626 S pl 002 54 H3ONIJ 796708 L E 31aNVH 0ZX8 49 696708 c 97 ak X 1 6 8 60 706 2 8 8 5 849 H3HSVM 1Z0 9078 6 91 v v X 90 X 8 5 NOTAN H3HSVM 290 900 46 9 122 T3604 199 0 MOHUVGT33HM 0 161708 99 83 1 8 AYLLY 155708 0 002 54 TANVd S96v0 9 8 1 9 OL wy NMOG 67305 4 LAVHS v WIH 9 X amp X 221 133HM 381L e69v0 c 6 91 8 6 849 DOTAN LAN 861 905636 OL 8 4909 T33HM OLLVIAN3Nd 31XV 216906 c GANAN LUV WALI wai Y3AWNN Lave 1517 Sued 1517 Sled L v 8 9 4 8
10. 6 0189 X WW GH 208 17109 066 706626 v Zt 30018 GION31OS DNIE O 8106 066 08 91 3NION3 NO 8 1 X TAMS SEN b 1 MOT 210 0 086 St OL 8 1 X ddS8N 8 1 H31dvGV 210 2080 6 2 vi 2 1 X ddS8W 2 1 GAH MOS T3 050 809076 2 El 8 1 038 GAH Idd IN 10 09196 OPHOS 1VO Z X 271 3dld 020 801226 8 ONIZ 2 1 VO 020 060906 2 W9 133818 3dld M0913 020 611106 1 9 ddS8 8 1 3dld 29506 5 LAN X ddS8 2 1 H3ldvav 169 06 y 31 V8931NI 081205 QN3UIV ASSV vEO0P v L HOLVTQO3H 3ATVA 750006 2 1HOd Q3IN3A 30IAH3S ANYA 050 220008 NOLLdIHOS30 LHVd AO Wall L 6 49 307239 30 133HS 3161 0 SSO8 JO 159931 NI HL OL IVILN3WIHLL My OLXY SLYVd 8 491009 30 NI A1LO38IO NI HO 5 39 OL LON SI INVW30 G3NVOT SI LI O31dOD 3avWaa SLL LON LSNW ONY 02 SI SIIHLSNANI 0659 NI 31HOd V1 Ya SISINZO 1941 O Apo et 1 55089 e 800270270 ANY SIHL ED NA VU funy N3 163 pesespsu ed ASU UMN 01139 0935010 Z I X 91 1 777005 N v L LX 91L 8 1108 Sc 1 908626 91 8 5 849 OO TAN LA
11. 93N 318V9 AH3LLV8 9 1106 SN 4 SOd 318V9 AH3LLV8 YLLLOE HL SN D guva 8 5 X 3NIHVIN 1903 ONLLLIJ 299 06 1 SN WO ASSY 31EVO 66659 56611 SN Q MOVIE DAN AY311V8 318 1080065 SN SQN3 7 1 13N3 8118 L0vSOE SN lt lt ISOH 198108 H SN SS 1903 1839 guvo ISOH 520 20 06 Y L SN 9 7913 1430 8uv9 ISOH 1 0 00 0 Y L SN e ut OL 02 NMOQ JIL dYHLS 11705 SN 2 1 8 201 H3HSVM 521 808 66 Lv ININOL 1913 H3HSVM 005 016856 7 9v WINOL 0O1 H3HSVM 055 018856 v Sv WINSZ X NINO 6 0L89 1709 0S2 012626 v by L 2 L 849 DOTAN LAN 29c 80SSc6 111 X l 2 1 889 1108 09 70 1 ev L X 91 8 889 1108 921 908626 v Hr 8106 07XH 3SV8 31V 1d 6 80 0 gt 8106 31v 1d 1964061 65 1 7 1 X guva 2 1 H3 1dOO vc Z0 86 ANVL 1905 07X8 ASSY 1007 46 L X 91 8 889 1108 001 908626 v 96 31 28 02 7 1 NVINH3NNLL LAN 060 v0S196 S se 0 379708 ve V vlad X 9L 950 801576 V 55 5809 DVL 1 5 IVIO30 1925081 26 31 28 2 1 X 91 8 889 17109 056 908626 2 Le 9 SSO8 1930 6 9006 L 06 1 0901 02X4 c29vOE 6c ONIHIV3H8
12. For example when the hourmeter shows 100 on the dial all items listed under EVERY 10 HOURS should be serviced now for the tenth time and all items under EVERY 50 HOURS should be served for the second time In addition to the following LUBRICATION AND MAINTENANCE CHART refer to the Engine Operator s manual for recommended engine lubrication and maintenance DANGER COMPRESSOR MUST BE SHUT DOWN AND COMPLETELY RELIEVED OF PRESSURE PRIOR TO CHECKING FLUID LEVELS OPEN SERVICE VALVE TO ASSURE RELIEF OF SYSTEM AIR PRESSURE FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTY AND SERIOUS BODILY HARM 25 P N 307239 COMPRESSOR INSPECTION LUBRICATION AND MAINTENANCE CHART INTERVAL ACTION Check compressors oil level Check air filter Check for oil and air leaks Check fuel supply after running Check for fuel oil and compressor fluid leaks Drain water from compressor oil at sump Check belt tension Drain water and sediment from fuel tank Change compressor oil and oil filter Check air filter piping fittings and clamps EVERY 500 HOURS 3 Install new air filter element Shorter interval may be necessary under dusty OR 6 MONTHS conditions 4 Check tire pressure 5 Check for excessive wear on drive belts Replace if necessary EVERY 1000 HOURS 1 Check safety circuit switches 2 Clean battery terminals R1 YEAR E 3 Check compressor shaft seal fo
13. clean or replace the screen Reinsert filter and gasket into housing and tighten with 14mm allen wrench Add oil re tighten filler cap Check for leaks in operation Uu dm LI WARNING DO NOT SUBSTITUTE ELEMENT USE ONLY A GENUINE BOSS INDUSTRIES REPLACEMENT ELEMENT THIS ELEMENT IS RATED AT 200 PSI WORKING PRESSURE USE OF ANY OTHER ELEMENT MAY BE HAZARDOUS AND COULD IMPAIR THE PERFORMANCE AND RELIABILITY OF THE COMPRESSOR POSSIBLY VOIDING THE WARRANTY OIL FILL UPPER SIGHT GLASS LOWER SIGHT GLASS HI Le OIL FILTER THERMAL VALVE OIL DRAIN 33 P N 307239 MAINTENANCE NOTE PARTS REQUIRED FOR ENGINE MAINTENANCE MAY BE FOUND IN THE ENGINE PARTS MANUAL A COPY OF WHICH IS PROVIDED WITH EACH UNIT FULL LOAD SPEED Using an air flow silencer open service air valve until 100 PSI is being held on receiver pressure gauge Be sure there is no air leakage from pressure regulator vent hole With the use of an electronic photo tachometer set the full load speed at 3500 3600 RPM The governor spring tension held by an anchor bolt allows adjustments to be made IDLE SPEED To adjust idle speed close service air valve and set idle speed to 2000 2500 RPM by moving id
14. devices should be tested in accordance with their manufacturer s recommendations to verify that they reduce pressure in case of hose failure and will not nuisance trip with the hose and tool combinations in use 300042 P N 300042 Drivebelts in rotation Switch off engine and disconnect battery or power supply before attempting to work or perform maintenance on the compressor package P N 300968 DESCRIPTION OF COMPONENTS POWER UNIT The power unit used to drive the compressor is a gasoline engine that has been carefully selected for its ability to provide an efficient and reliable source of power For detailed information on the power unit refer to the Engine Operator s Manual provided separately COMPRESSOR ASSEMBLY The RX70 compressor assembly is a positive displacement oil flooded rotary screw type unit employing one stage of compression to achieve the desired pressure Components include a housing stator two screws rotors bearings and bearing supports The power source drives the male rotor through the inlet housing The male rotor drives the female rotor PRINCIPLES OF OPERATION In operation two helical grooved rotors mesh to compress air Inlet 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 and delivers smooth flowing pulse free air to the receiver During the compression c
15. 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 damage 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 which extends beyond the description of the face hereof This warranty shall 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 replace
16. the Engine Operator s manual Connect negative battery cable to battery terminal Check the compressor oil sump level If oil level is low add ATF Dexron III See below for fill plug and sight glass locations DO NOT OVER FILL NOTE PROPER COMPRESSOR OIL LEVEL SHOULD FILL HALF OF THE UPPER SIGHTGLASS WHEN THE COMPRESSOR IS LEVEL AND THE COMPRESSOR IS NOT RUNNING OIL FILL z UPPER SIGHT GLASS Y LOWER SIGHT GLASS OIL FILTER y THERMAL VALVE OIL DRAIN 21 P N 307239 COMPRESSOR OPERATION NORMAL STARTING GASOLINE ENGINE 1 Inspect the compressor engine and other assemblies for loose connections or damage that might have occurred since the last operation Check engine oil and fluid levels Check compressor oil sump level Ensure service valves are closed Verify cold start switch is in the ON position Pull the choke out as required but avoid flooding the engine Release the choke as soon after starting as possible Turn engine start switch and hold until engine starts but do not hold any longer than 10 seconds at a time Let the machine run for 3 5 minutes to allow the engine to warm up Toggle the cold start switch to the OFF position The system is now ready for f
17. BOSS RX70 24HP OPERATORS MAINTENANCE AND PARTS MANUAL Difference is 1761 Genesis Dr LaPorte IN 46350 800 635 6587 Fax 219 324 7470 P N 307239 11 29 2010 MCM TABLE OF CONTENTS Operation amp Maintenance Section Page A A 6 T Description Of Components votes isa e rue 17 Compressor Ol GT AUG tao 21 Compressor Inspection Lubrication and Maintenance 25 Iroubleshooting mee a iai 36 Recommended Spare Parts sisecsccecsccsasecaccactsecececdeeccessecnscctssentsessccentsacecsecdsesseecsctacexss 39 Warranty Information C alils cities 40 Parts Illustration Section scooters 46 4 P N 307239 SPECIFICATIONS HONDA 4 CYCLE V MODEL RX 70 TWIN OHV AIR COOLED GASOLINE 70 CFM mu 93 100 PSIG DELIVERY DELIVERY CFM 3 moot o GX670 DELIVERY rw 0 mu 93 MIN OPERATING 3600 RPM PRESSURE RANGE 80 115 PSIG 24 HP 15 8kw AMBIENT OPERATING TEMPERATURE 20 TO 105 DISPLACEMENT 40 9 cubic inches RANGE FAHRENHEIT cubic inches cc 670cc 75 GALLONS 2 83 3 0 77MM amp OIL SUMP CAPACITY LITERS BORE amp STROKE TOTAL SYSTEM 1 0 GALLONS 3 80 OIL CAPACITY WITH 1 69 QUARTS 1 6 CAPACITY LITERS FILTER LITERS AIR SERVICE 12V 227 O CONNECTIONS FAHRENHEIT TYPE
18. COOLING 5 2 GALLONS 20 OIL TO AIR FUEL TANK CAPACITY zz pg AIR INTAKE FILTER SINGLE STAGE DRY TYPE OF CONTROL 0 100 DEMAND WEIGHT 430165 195kg PART NUMBER 1200381 INST PANEL amp PARTS 24HP RX70 200367 IFRAME amp PARTS 24HP RX70 200365 COMPRESSOR amp PARTS 24HP RX70 200366 ENGINE amp PARTS 24HP RX70 200380 COOLER amp PARTS 24HP RX70 200215 HOSE AND PARTS RX70 307239 MANUAL BOSS 24 RX70 303807 CRATE SHIPPING BULLET 36X50X45 al 5 co 31 1 2 in 799 1 mm Jf OOO ve 35 1 4 in 894 7 mm lo 1 e o 0 9 29 1 4 in 743 8 mm 5in 126 5 mm 18 5 8 in 471 7 mm 58 3 4 in 1491 3 mm 8 7 6 5 4 3 2 1 P N 307239 SAFETY WARNING ALLUNITS ARE SHIPPED WITH A DETAILED OPERATORS INSTALLATIONS AND PARTS MANUAL THIS MANUAL CONTAINS VITAL INFORMATION FOR SAFE AND EFFICIENT OPERATION OF THIS UNIT CAREFULLY READ THE OPERATORS MANUAL BEFORE STARTING THE UNIT FAILURE TO READ AND COMPREHEND THE INSTRUCTIONS COULD RESULT IN SERIOUS BODILY INJURY OR PROPERTY DAMAGE GENERAL The compressor is designed and manufactured to operate with relative safety However the responsibility for safe operation rests with those who use and maintain these products The following safety precautions are offered as a guide which if conscientiously followed will minimize the possibility of a
19. ILURE TO EXERCISE THAT ORDINARY CAUTION AND DUE CARE REQUIRED WHEN OPERATING OR HANDLING THE COMPRESSOR EVEN THOUGH NOT EXPRESSLY SPECIFIED ABOVE Compliments of warning decals are supplied with each unit These decals are affixed to the unit after it has been painted prior to being put into service The decals are placed so as to be clearly visible to the user and service personnel Read the operators manual before starting this unit Failure to adhere to instructions can result in severe personal injury Replacement manuals can be purchased from Boss Industries Inc 1761 Genesis Dr LaPorte IN 46350 300039 P N 300039 15 P N 307239 HOT OIL UNDER PRESSURE Will cause SEVERE PERSONAL INJURY OR DEATH Do not remove valves caps plugs or piping when com pressor is running or pressurized Shut down com pressor and relieve system of all pressure before removing valves caps iping Give OF ng 300038 P N 300038 Discharge air used for breathing will cause severe injury or death Consult filtration specialist for additional filtration and treat ment equipment to meet occupational safety and health administration standards P N 300040 AE Do not operate without in place 300041 P N 300041 SAFETY 16 P N 307239 22 Connect air hoses only in full compliance with OSHA Standard 29 CFR 1926 b 7 The required safety
20. ING DIFFERENT TYPES OF BRANDS OF LUBRICANTS IS NOT RECOMMENDED DUE TO THE POSSIBILITY OF A DILUTION OF THE ADDITIVES OR A REACTION BETWEEN ADDITIVES OF DIFFERENT TYPES 28 P N 307239 LUBRICATION APPLICATION GUIDE Not all lubricating oils are suitable for rotary screw compressor use The most satisfactory oils are the non detergent types that contain high levels of corrosion oxidation and foam inhibitors Your RX70 compressor is factory filled with Dexron III ATF Other non detergent motor oils SAE 10W class SE or CD and SAE 30 that meet the requirements below can be used However BOSS recomends you to use Dexron III ATF The viscosity of the oil chosen depends largely on the ambient operating temperature range The oil must provide sufficient lubrication for bearings and rotors at operating temperature and it must have a pour point low enough to provide fluidity at low starting temperatures In general the viscosity range represented by these SAE grades is satisfactory for the temperature range shown 40 to 120 SAE 30 10 F to 75 F SAE 10 W 20 F Pour Point 40 F to 100 F Auto Trans Fluid 50 F Pour Point PRIMELUBRICANT CHARACTERISTICS 1 Flash point 400 F minimum ASTM D 92 COC 2 point must be at least 20 lower than the lowest expected ambient temperature 3 Contain rust and oxidation inhibitors 4 Contain foam suppressers SYNTHETIC DIESTER AND SYNTHESIZED HYDROCA
21. MPLETELY RELIEVED OF PRESSURE OPEN SERVICE VALVE TO ENSURE RELIEF OF SYSTEM AIR PRESSURE WHEN PERFORMING MAINTENANCE ON COMPRESSOR AIR OILSYSTEM FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE PROPERTY DAMAGE AND SERIOUS BODILY HARM OR DEATH OPERATING CONDITIONS For maximum compressor performance the compressor should be as close to level as possible when operating The compressor will operate on a 15 degree sideward lengthwise tilt without any adverse problems Fluid carryover and oil starvation may occur if operated beyond this tilt NOTE IF THE COMPRESSOR IS BEING USED TO POWER SANDBLASTING EQUIPMENT ORAN AIR TANK USE A CHECK VALVE DIRECTLY AFTER THE SERVICE VALVE TO PREVENT BACK FLOW INTO THE SUMP THIS CHECK VALVE SHOULD HAVE A MAXIMUM PRESSURE DROP RATING OF 2 PSIG 13 78 kPa OPERATING AND CAPACITY RATING EQUAL TO THE MAXIMUM RATING OF THE COMPRESSOR OPERATING SUGGESTIONS Replace any faulty gauge immediately Allow at least ten feet of unobstructed area in front of the engine muffler to assure good airflow Do not place items under the package Check instruments periodically during operation If not in normal operating zone refer to Section 6 Trouble shooting Make sure that correct type and viscosity lubricating oils and fuel are used especially in extreme ambient temperatures Keep batteries fully charged and properly maintained Keep control linkage clean and lightly lubricated
22. N 861 909926 8 5 849 1 14 140 90 8 6 NNOO d WM ON 4 SZ dIN31 HOSN3S 698206 2 X 8 6 Tamana 280206 X OIFIN 2 1 HOLO3NNOO 0S0 801096 154091 1 9 2 1 3dld 33 1 0c0 SLvc06 O8HOS 1VO 35010 X 2 1 3 1ddIN 000 0 ISOH 49670 9 1 H31009 00 HOV3 DLW 10 H3N3ISVJ 218006 60v 9 HOLOW M ASSY 696608 3 151 sued P N 307239 2 v y 9 4 8 51 307239 P N T 30 TEIS TH RETO HOUR TS IUSTUS AHOISIH NOISIASH 5 795002 VN anion vamo ONS NOLLdIHOSG mwos azs TM ee oam ONT ASE 8002 9171 SONILLIJ ONVANVL 13NJ Q3ONVHO SLUVd 10 20220 SYM s20 202 06 lt 190 SEVA H3NOISN3L 1138 0569 NI 1 4 V1 com RON TETUR 3ilvid 3015 v aav co ERES aoe q ecu S RO
23. O CHECK FOR LOOSE OR BROKEN WIRES OR CORRODED CONNECTIONS BY THE SHUTDOWN SWITCH LOCATED IN THE DISCHARGE LINE AT SUMP IF THE ELECTRICAL SYSTEM CHECKS OUT PROPERLY REFER TO TROUBLESHOOTING SECTION 20 P N 307239 COMPRESSOR OPERATION GENERAL Every RX70 compressor has been operated and tested at the factory before shipment This testing assures that the unit is operating properly and that the compressor will deliver its rated capacity Regardless of the care taken at the factory there still exists a possibility that damage may occur during shipment For this reason it is recommended that the unit be carefully inspected for evidence of damage in shipment During the first few hours of operation the machine should be carefully observed for any possible malfunction Satisfactory performance of the machine depends on the operator s knowledge of the controls instruments and recommended operating procedures Consequently the preceding sections of this manual should be read and understood before attempting to start and operate this machine PREPARATION FOR INITIAL START UP Inspect the compressor engine and other assemblies for loose connections or damage occurring during shipment Position the compressor package on a level surface so the proper amounts of fluids can be added Check the engine crankcase oil level If required add oil as recommended in the Engine Operator s manual Fill fuel tank with grade of fuel recommended in
24. RBON LUBRICANTS OIL All elastomeric components and all metal used in the compressor are fully compatible with synthetic diester and synthesized hydrocarbon lubricants The viscosity grade chosen for synthetic diester base or SHC lubricants should be based upon the suggested viscosity ranges listed under prime lubricant characteristics and the lubricant supplier 29 P N 307239 LUBRICATION NOTE UNKNOWN INFLUENCES OF ENVIRONMENTAL FACTORS SUCH AS THE INTAKE OF REACTIVE GASES OR VAPORS IN THE AIR MAY LEAD TO CHEMICAL CHANGES IN ANY OIL CAUSING PREMATURE FAILURE OF THE LUBRICANT AND THE USEFUL LIFE OF ALL EXTENDED LIFE LUBRICANTS MAY BE SHORTER THAN QUOTED BY THE LUBRICANT SUPPLIER BECAUSE THE NORMAL DRAIN AND REPLACE PERIOD MAY BE EXCEEDED USING SYNTHETIC LUBRICANTS DIFFERING FROM THOSE SPECIFIED IN THIS MANUAL BOSS ENCOURAGES THE USER TO CLOSELY MONITOR THE LUBRICANT CONDITION AND TO PARTICIPATE IN AN OILANALYSIS PROGRAM WITH THE SUPPLIER NOTE NO LUBRICANT HOWEVER GOOD AND OR EXPENSIVE CAN REPLACE PROPER MAINTENANCE AND ATTENTION SELECT AND USE IT WISELY ENGINE LUBRICATION Refer to Engine Operator s manual for recommended engine lubricating oil 30 P N 307239 MAINTENANCE COMPRESSOR OIL SUMP FILL LEVEL AND DRAIN Before adding or changing compressor oil make sure that the sump is completely relieved of pressure Oil is added at the fill cap on the side of the compressor A dr
25. ain plug is provided at the bottom of the sump The proper oil level when unit is shutdown and has had time to settle is at the midpoint of the upper oil sightglass The package must be level when checking the oil DO NOT OVERFILL The oil sump capacity is given in Compressor Specifications OIL FILL UPPER SIGHT GLASS LOWER SIGHT GLASS OIL FILTER THERMAL VALVE OIL DRAIN DANGER WHILE COMPRESSOR IS RUNNING DO NOT ATTEMPT TO DRAIN CONDENSATE REMOVE THE OIL LEVEL FILL PLUG OR BREAK ANY CONNECTION IN THE AIR OR OIL SYSTEM WITHOUT SHUTTING OFF COMPRESSOR AND MANUALLY RELIEVING PRESSURE FROM THE SUMP FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTY AND SERIOUS BODILY HARM AIR INTAKE FILTER The air intake filter is a heavy duty single stage high efficiency filter designed to protect the compressor from dust and foreign objects See compressor mounting system in illustration section Frequency of maintenance of the filter depends on dust conditions at the operating site The filter element must be serviced when clogged maximum pressure drop for proper operation is 15 31 P N 307239 MAINTENANCE AIR OIL COALESCER The air oil coalescer employs an element per
26. anty claim from outstanding balances due and payable to BOSS INDUSTRIES prior to receiving written notification of BOSS INDUSTRIES approval of the warranty claim may be subject to forfeiture of the entire claim 42 P N 307239 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 WARRANTY CLAIMS PREPARATION OF PART 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 Jc DUE NOTE Our warranty requires that all defective parts be returned to BOSS INDUSTRIES freight prepaid Items sent without RGA number will not be accepted Unauthorized Returns Will Immediately Be Refused At Dock RETURN OR WARRANTY CLAIMS FILING PROCEDURES 1 Ini
27. ates as follows 1 As demand for air decreases the receiver pressure rises and when this pressure exceeds the set point of the pressure regulator the regulator opens sending a pressure signal to the inlet valve and to the regulating cylinder a The inlet valve disc moves towards the valve inlet against the force of the modulating spring inside the valve This regulates the opening area of the inlet valve b Theregulating cylinder will reduce engine speed somewhere between full load and compressor idle 2 Ifthe air demand goes to zero service valve closed the inlet valve will close completely and the regulating cylinder will bring the engine to compressor idle 3 Asthe demand for air increases receiver pressure drops slightly below the set point of the pressure regulator eliminating the signal to the inlet valve and regulator cylinder a Inlet valve disc opens fully b Regulating cylinderretracts allowing the engine governor spring to bring the engine and compressor up to its high rpm INLET VALVE The compressor inlet valve is a piston operated disc valve that has a dual function of regulating the inlet opening to control capacity and serving as a check valve at shutdown DISCHARGE PRESSURE REGULATOR VALVE This valve is used to select the desired discharge pressure within the operating pressure range Turning the regulator screw clockwise increases the working pressure a counter clockwise movement of the screw reduces
28. cable to the positive POS battery terminal in the starting vehicle Connect one end of the other jumper cable to the grounded negative NEG terminal of the battery in the starting vehicle Check you connections Do not apply 24V to a 12V system in the compressor Connect the other end of this same jumper cable to a clean portion of the compressor engine block away from fuel lines the crank case breather opening and the battery Start the compressor in accordance with normal procedure Avoid prolonged cranking Allow the compressor to warm up When the compressor is warm and operating smoothly at normal ideal RPM disconnect the jumper cable from the engine block on the compressor then disconnect the other end of this same cable from the grounded negative NEG terminal of the battery in the starting vehicle Then disconnect the other jumper cable from the positive POS terminal of the battery in the compressor and finally disconnect the other end of this same jumper cable from the positive POS 4 terminal of the battery in the starting vehicle 14 P N 307239 SAFETY NOTE THE OWNER LEASER OR OPERATOR OF THE COMPRESSOR IS HEREBY NOTIFIED AND FOREWARNED THAT ANY FAILURE TO OBSERVE THESE SAFETY PRECAUTIONS MAY RESULT IN DAMAGE OR INJURY NOTE BOSS INDUSTRIES EXPRESSLY DISCLAIMS RESPONSIBILITY OR LIABILITY FOR ANY INJURY OR DAMAGE CAUSED BY FAILURE TO OBSERVE THESE SPECIFIED PRECAUTIONS OR BY FA
29. ccidents throughout the useful life of this equipment Only those who have read and understand this operator s manual should operate this air compressor Failure to follow the instructions procedures and safety precautions in this manual may increase the possibility of accidents and injuries Never start this air compressor unless it is safe to do so Do not attempt to operate the air compressor with a known unsafe condition Tag the air compressor and render it inoperative by disconnecting the battery so others who may not know of the unsafe condition will not attempt to operate it until the unsafe condition is corrected Use and operate this air compressor only in full compliance with all pertinent OSHA requirements and all pertinent Federal State and Local codes or requirements Do not modify this compressor except with written factory approval Any unauthorized modification automatically voids the factory warranty The operation of engine powered equipment will always be somewhat dangerous Do not consider this section to be complete but always continue to be alert for hazards PARKING OR LOCATING COMPRESSOR Locate compressor on level areas if possible If not locate compressor across grade so the compressor does not tend to roll down hill Do not locate compressor on grades exceeding 15 degrees 27 Make sure compressor is parked or located on a firm surface that can support its weight Locate compressor so the wind if any t
30. ce 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 44 P N 307239 SCREW COMPRESSOR AIR END 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 are F O B shipping point Prices do not include labor for removal or installation 45 P N 307239 PARTS amp ILLUSTRATION SECTION 46 P N 307239 L v 9 L 8 1140 1335 ABOLSIH NOISIASH 52 100717009 aton vnen ONA AIVA uu 6 socis NES SEOSES WOW OL GIVOSR FL ul y 89 18vieod 80021
31. d compressor air filter clean or replace 2 Plugged air oil separator Replace separator element and also change compressor oil and oil filter at this time 3 Defective pressure regulator adjust or repair 4 Engine speed too low readjust engine speed 38 P N 307239 RECOMMENDED SPARE PARTS 39 P N 307239 WARRANTY INFORMATION CLAIMS 40 P N 307239 WARRANTY 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 two 2 years from the date of initial operation or thirty 30 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 non conformance 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 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
32. e 15 16 bolt on the front of the tensioner use the 9 16 wrench to loosen the bolt on the backside of the tensioner bracket Turn the 15 16 bolt counter clockwise until the tension is fully released from the belt 3 Remove the old belt 4 Install new belt 5 Usea9 16 wrench and a 15 16 socket wrench to set the tension on the belt Turn the 15 16 bolt on the front of the tensioner clockwise to set the tension Use the 9 16 wrench to tighten the bolt on the backside of the tensioner bracket to hold the tensioner arm in place 6 Useabelttensiometer to properly tension the belt 7 Proper tension is 1 4 deflection with a deflection force of 9 4 16 minimum to 13 8 16 maximum 34 P N 307239 MAINTENANCE ENGINE INSPECTION LUBRICATION AND MAINTENANCE CHART AFTER EACH CYCLE OF INDICATED SERVICE THESE ITEMS HOURS HOURS INSPECT ENGINE GENERALLY CHECK OIL LEVEL SERVICE AIR CLEANER ELEMENT WRAPPER CHANGE CRANKCASE OIL ALL ENGINES WITHOUT FILTER CHANGE CRANKCASE OIL STANDARD WITH FILTER 2 5 X X X X X REPLACE OIL FILTER CHECK BATTERY ELECTROLYTE LEVEL CLEAN COOLING FANS REPLACE AIR CLEANER ELEMENT REPLACE FUEL FILTER CHECK OR REPLACE SPARK PLUGS CHANGE CRANKCASE OIL HIGH CAPACITY BASE WITH FILTER A eeh e e eee rt CONAN Check for fuel leaks With engine running visually and audibly check exhaust system for leaks Perform more often when running under seve
33. eeze compound are heavier than air Do not store compound or discharge treaded air in confined or unventilated area Do not store containers or antifreeze compound in direct sunlight MOVING PARTS Keep hands arms and other parts of the body and also clothing away from belts pulleys and other moving parts Do not attempt to operate the compressor with the fan guard or other guards removed Wear snug fitting clothing and confine long hair when working around this compressor especially when ex posed to hot or moving parts inside the enclosure Keep access doors closed except when making repairs adjustments or performing service Make sure all personnel are clear of the compressor prior to attempting to start to operate it or shutting it off Shut off engine before adding fuel oil lubrications air line anti freeze compound or battery electrolyte Disconnect the grounded negative battery connection to prevent accidental engine operation prior to attempt ing repair or make adjustments Tag the battery connection so others won t unexpectedly reconnect it Use appropriate lockout tag out procedures Make adjustments only when the engine is shut off When necessary make adjustment and then start engine to check adjustment If adjustment is incorrect shut off engine readjust and then restart engine to recheck adjustment 10 P N 307239 SAFETY HOT SURFACES SHARP EDGES AND SHARP CORNERS VACUUM Avoid bodily contact with hot oil
34. ends to carry the engine exhaust fumes and radiator heat away from the compressor air inlet openings and also where the compressor will not be exposed to excessive dust from the work site Muffler side of package must have 12 inches of clearance so engine cooling air can escape from package without restriction or re circulation The topside of package at the compressor oil cooling fan must also have 12 inches of clearance so cooling air can escape from package without restriction or re circulation Block or chock both sides of all wheels 7 P N 307239 SAFETY PRESSURE RELEASE Install the appropriate flow limiting valves between the compressor service air outlet and the shut off throttle valve Air hoses exceeding 1 4 inside diameter are to be connected to the shut off throttle valve to reduce pressure in case of hose or connection failure per OSHA Standard 29 CFR 1926 302 as 7 When the hose is to be used to supply a manifold install an additional appropriate flow limiting valve between the manifold and each air hose exceeding 1 4 inside the diameter that is to be connected to the manifold to reduce pressure in case of hose failure Provide a flow limiting valve every 75 feet of hose in runs of air hose exceeding 1 4 inside diameter to reduce pressure in case of hose failure Flow limiting valves are listed by pipe size and rated CFM Select appropriate valves accordingly Do not use tools that are rated below the maximum
35. er 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 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 INDUSTRIES replacement parts covers the net cost of the party only not labor and mileage The BOSS INDUSTRIES 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 correct the problem BOSS INDUSTRIES will deduct from allowable credits for excess freight caused by sender failing to follow return shipping instructions Distributors or end users automatically deducting the value of a warr
36. ged up b Faulty safety valve c Faulty regulator or set to high d Inlet valve leaking or partially open Loss of pressure signal to inlet valve from regulator causing inlet valve to stay open COMPRESSOR Abnormal compressor oil consumption or oil in service line check for the following Over filling of oil sump Leaking oil lines or oil cooler Plugged oil return line check entire line and check valve orifice fitting at compressor port Defective separator element Compressor shaft seal leakage Discharge pressure below 55 PSI Ov tA or SEPARATOR PLUGGING Ifthe separator element has to be replaced frequently because it is plugging up itis 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 1 Extreme operating temperature 2 Negligence in draining condensate from oil sump 3 Usingthe impropertype of oil 4 Dirtyoil The complete inlet system should be checked for leaks 37 P N 307239 TROUBLESHOOTING HIGH COMPRESSOR DISCHARGE TEMPERATURE 1 Check compressor oil level Add oil if required see section for oil specifications 2 Check electric fan and switch 3 Clean outside of oil cooler 4 Clean oil system cooler internally 5 Plugged compressor oil filter Change element 6 Plugged oil return line clean orifice and check valve INSUFFICIENT AIR DELIVERY 1 Plugge
37. ght of snow ice mud or stored tools and equipment Chock both sides of wheels plus stabilizer legs before disengaging the lifting hook 12 P N 307239 SAFETY JUMP STARTING Observe all safety precautions mentioned elsewhere in this manual Batteries may contain and or generate gases that are flammable and explosive Keep flames sparks and other sources of ignition away Batteries contain acid that is corrosive Do not allow battery acid to contact eyes fabrics or painted surfaces as serious personal injury or property damage may result Flush any contacted areas thoroughly with water immediately Wear an acid resistant apron and face shield when attempting to jump start the compressor Remove all vent caps from the battery in the compressor Do not permit dirt or foreign matter to enter the open cells Do not attempt to open sealed maintenance free batteries Check fluid level If low bring fluid to proper level before attempting to jump start Do not attempt to jump start if fluid is frozen or slushy Bring batteries up to at least 40 degrees F 5 degrees C before attempting to jump start Cover open cells of all compressor batteries with clean dampened cloths before attempting to jump start Attempt to jump start only with a vehicle with a negative ground electrical system with the same voltage and which is equipped with a battery of comparable size or larger than supplied with the compressor Do not attempt to jump start by u
38. hem Do not store or attempt to operate the compressor with any known leaks in the fuel system or any oil lines Remove any other material that may be damaged by heat or that may support combustion including anti ice system components containing antifreeze compound prior to attempting weld repairs Keep a suitable fully charged class BC or ABC fire extinguisher or extinguishers nearby when servicing and operating the compressor Do not store any type of containers with fuel or lubricants inside or outside of canopy Keep oily rags trash leaves litter or other combustibles out of and away from the compressor Open all access doors and allow the enclosure to ventilate prior to attempting to start the engine Use this time to check the engine and compressor oil levels etc Do not operate compressor under low overhanging leaves or permit such leaves to contact hot exhaust system surfaces when operating in forested areas Do not attempt to use ether as a starting aid in gasoline engines as serious personal injury or property damage may result 9 P N 307239 SAFETY FIRE AND EXPLOSION CONT Antifreeze compound used in air line anti ice systems contains methanol which if flammable Use systems and refill with compound only in well ventilated areas away from heat open flames or sparks Do not expose any part of these systems or the antifreeze compound to the temperatures above 150 degrees F 65 degrees C Vapors from the antifr
39. hot coolant hot surfaces and sharp edges and corners Keep all parts of the body away from all points of air discharge and away from hot exhaust gases Wear personal protective equipment including gloves and head covering when working in on or around the compressor Keep a first aid kit handy Seek medical assistance promptly in case of injury Do not ignore small cuts and burns as they may lead to infection Keep all loose clothing and parts of the body away from engine compressor and air filter intakes TOXIC AND IRRITATING SUBSTANCES Do not use air from this compressor for breathing except in full compliance with OSHA Standards 29 CFM 1920 and any other Federal State or Local Codes or Regulations Do not use air line anti ice systems in air lines supplying respirators or other breathing air utilization equipment and do not discharge air from these systems in non ventilated or other confined areas Operate the compressor only in open or well ventilated areas If the machine is operated indoors discharge engine exhaust outdoors being certain that there are no exhaust system leaks Locate this compressor so that exhaust is not apt to be carried towards personnel air intakes servicing personnel areas or towards the air intake of this or any other portable or stationary compressor TOXIC AND IRRITATING SUBSTANCES CONT Fuels oils coolants lubricants and battery electrolyte used in this compressor are typical of the ind
40. ity of fuse and replace if necessary Fuse located by engine starter solenoid UNPLANNED SHUTDOWN When the operation of the machine has been interrupted by an unexplained shutdown check the following 1 Check to determine if compressor oil is at proper level Check oil cooler for dirt slush ice on the fins or any other obstructions to cooling airflow 3 Make a thorough external check for any cause of shutdown such as broken hose broken oil lines loose or broken wire etc 4 Checkelectric fan motor and wiring 5 Check fuses in wire harness check continuity of fuse and replace if necessary Fuse located by starter solenoid 6 Checktheengine oil level with the engine stopped and in a level position If the oil level is low remove the oil filler cap and fill to the upper limit mark on the dipstick with the recommended oil ENGINE OVERHEATING 1 Lowoillevel refill 2 Air blockage into engine from blower PTO side 3 Airblockage from exhaust side of engine 4 Dirty oil inengine 36 P N 307239 TROUBLESHOOTING IMPROPER DISCHARGE PRESSURE 1 Ifdischarge pressure is too low check the following a Too much air demand b Service valves open blowing to atmosphere c Leaks in service line d Restricted compressor inlet air filter e Faulty control system operation regulator inlet valve etc f Low engine speed 2 If discharge pressure is too high or safety valve blows check the following Oil separator plug
41. le stop screw at carburetor as required For operation at higher altitudes it may be desirable to raise the idle speed to improve part load response and acceleration High altitude engine kits are available ENGINE INSPECTION LUBRICATION AND MAINTENANCE The following is aregular schedule of inspection and servicing for the engine based on operating hours Use the factory recommended Periodic Maintenance Schedule based on favorable operating conditions to serve as a guide to get long and efficient engine life Regular service periods are recommended for normal service and operating conditions For severe duty extreme temperature etc service more frequently Neglecting routine maintenance can result in engine failure or permanent damage For any abnormalities in operation unusual noises from the engine or accessories loss of power overheating etc contact your nearest Honda Service Center BELT TENSIONING PROCEDURE 1 Usea9 16 wrench and a 15 16 socket wrench to set the tension on the belt Turn the 15 16 bolt on the front of the tensioner clockwise to set the tension Use the 9 16 wrench to tighten the bolt on the backside of the tensioner bracket to hold the tensioner arm in place 2 Proper tension is 1 4 deflection with a deflection force of 9 4 16 minimum to 13 8 16 maximum BELT REPLACEMENT PROCEDURE 1 Remove compressor belt guard 2 Usea9 16 wrench and a 15 16 socket wrench to release the tension on the belt Hold th
42. manently housed within a spin on canister This is a single piece unit that requires replacement when it fails to remove the oil from the discharge air To replace element P N 302600 proceed as follows Shutdown compressor and wait for complete blow down zero pressure Turn element counterclockwise for removal as viewed from bottom Install new rubber seal in head and supply a film of fluid directly on the seal Rotate element clockwise by hand until element contact seal as viewed from bottom Rotate element at top edge of can one more turn clockwise with band wrench Run system and check for leaks OV Oe WARNING DO NOT SUBSTITUTE ELEMENT USE ONLY A GENUINE BOSS INDUSTRIES REPLACEMENT ELEMENT THIS ELEMENT IS RATED AT 200 PSI WORKING PRESSURE USE OF ANY OTHER ELEMENT MAY BE HAZARDOUS AND COULD IMPAIR THE PERFORMANCE AND RELIABILITY OF THE COMPRESSOR POSSIBLY VOIDING THE WARRANTY COALESCER REGULATOR VALVE 40 1 2 FNPT SERVICE VALVE MINIMUM PRESSURE VALVE 32 P N 307239 MAINTENANCE OIL FILTER The compressor oil filter is a cartridge throw away type It is designed with a built in by pass so that if there is a large restriction due to cold oil or clogged element the compressor will still be lubricated To replace filter proceed as follows Make sure system pressure is relieved Unscrew with 14mm allen wrench Remove oil filter from housing Remove gasket and
43. ment 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 Inno event shall BOSS be liable for any special indirect incidental or consequential damages of any charter 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 1761 GENESIS DRIVE LA PORTE IN 46350 1 800 635 6587 41 P N 307239 SUMMARY OF MAIN WARRANTY PROVISIONS As claims policies and procedure are governed by the terms of BOSS Industries warranty it is necessary to outline some of the more important provisions The BOSS INDUSTRIES 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 maintenance items such as lubricants filters and shaft seals are not warrantable items Parts not of BOSS INDUSTRIES manufacture are warranted only to the extent they are warranted by the original manufactur
44. ommended inspection and maintenance schedule 4 Pressure Meter The pressure meter displays compressor discharge air pressure This meter also has a shutdown feature and will shutdown the engine if the discharge air pressure reaches 150 psi 5 Temperature Meter The temperature meter displays compressor discharge air temperature This meter also has a shutdown feature and will shutdown the engine if the discharge air reaches 250 F Note If the compressor shuts down on high discharge air pressure or high discharge air temperature find and fix the problem before restarting Also the shutdown relay reset button must be reset before the engine can be restarted CONTROL SYSTEM The prime components of the compressor control system include the compressor inlet valve and an air cylinder The control system is designed to match air supply to air demand and to prevent excessive discharge pressure when compressed air is not being used Control of air delivery is accomplished by the inlet valve regulation as directed by the discharge pressure regulator 18 P N 307239 DESCRIPTION OF COMPONENTS CONTROL SYSTEM OPERATION The following discussion explains the operation of the control system from a condition of no load to a condition of full capacity at working pressure For the working pressure range of your machine refer to applicable data in the specification sections The pressure Regulator and engine speed regulating cylinder oper
45. r leakage EVERY 2000 HOURS 1 Install new air filter element Shorter interval may be necessary under OR 1 YEAR dusty conditions Inspect air filter element Replace spin on coalescer element if necessary Inspect and clean compressor oil system cooler etc Check engine speed control adjustment at hi low compressor settings Inspect lifting frame before each lift Grease wheel bearings Check engine and compressor supports EVERY 50 HOURS OR WEEKLY PERIODICALLY OR AS REQUIRED NOTE See Maintenance Section for clarification on above 26 P N 307239 COMPRESSOR INSPECTION LUBRICATION AND MAINTENANCE NOTE OBSERVE ALL GAUGE READINGS NOTE ANY CHANGE FROM THE NORMAL READING AND DETERMINE THE CAUSE HAVE NECESSARY REPAIRS MADE NORMAL IS THE USUAL GAUGE READING WHEN OPERATING AT SIMILAR CONDITIONS ON A DAY TO DAY OPERATION FIRST COMPRESSOR OILAND OIL FILTER ELEMENT CHANGE SHOULD BE MADE AT 50 HOURS ALSO MORE FREQUENT OIL CHANGES WILL BE REQUIRED UNDER EXTREME OPERATING CONDITIONS OF EXTREMELY HIGH OR LOW TEMPERATURES AND HIGH HUMIDITY CHANGE OIL EVERY SIX MONTHS EVEN IF THE NORMAL OIL CHANGE PERIOD IN HOURS HAS NOT YET ELAPSED ALWAYS WARM UP THOROUGHLY PRIOR TO CHANGING EITHER THE ENGINE OIL OR THE COMPRESSOR OIL DO NOT OPEN COMPRESSOR OIL DRAIN OIL FILTER CAP OR OIL FILTER UNTIL ALL PRESSURE HAS BEEN RELIEVED CHECK BY MANUALLY OPENING THE ASME SUMP PRESSURE RELIEF VALVE
46. re operating conditions Required for initial break in only For detailed maintenance refer to the HONDA SERVICE MANUAL 35 P N 307239 TROUBLESHOOTING This section contains instructions for troubleshooting the equipment following a malfunction The troubleshoot ing 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 or disas sembly or parts should be performed first MACHINE WILL NOT START 1 High pressure or high temperature safety trip Reset safety relay Push button in on control panel 2 Check fuel level and add fuel if necessary 3 Plugged fuel filter and replace if necessary 4 Low battery voltage recharge if necessary 5 Loose battery cables tighten cable dirty battery cables clean thoroughly 6 Plugged air filter replace the element 7 Engine problems may have developed refer to your Engine Manual 8 Defective engine oil level switch check continuity and replace if necessary 9 Blown fuse in wiring harness check continu
47. 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 enduser 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 against loss from concealed damage 3 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 eviden
48. relief valve rating on this compressor Select tools air hoses pipes valves filters and fittings accordingly Do not exceed manufacturer s rated safe operating pressures for these items Secure all hose connections by wire chain or other suitable retaining devices to prevent tools or hose ends from being accidentally disconnected and expelled Open compressor oil filler cap only when compressor is not running and is not pressurized Shut down the compressor and bleed the sump open service valve pressure to zero before removing the oil filler cap Vent all internal pressure prior to opening any line fitting hose valve drain plug connection or other components such as filters or line oilier and before attempting to refill optional air line anti ice systems with antifreeze compound Keep personnel out of line with and away from the discharge opening of hoses or tools or other points of compressed air discharge Do not use air pressures higher than 30 PSIG 207kPa for cleaning purposes and then only with effective chip guarding and personal protective equipment per OSHA Standard 29 CFR 1910 242 b Do not play with air hoses as serious injury or death may result 8 P N 307239 SAFETY FIRE AND EXPLOSION Refuel at a service station or from a fuel tank designed for its intended purpose If this is not possible then ground the machine to the dispenser prior to refueling Immediately clean up any spills or leaking fuel batte
49. repairs only in clean dry well lighted and ventilated areas LIFTING This compressor 15 provided with a lifting bail for routine lifting loading onto trucks etc Compressors to be air lifted by helicopter must not be supported by the lifting bail but by slings with appropriate spreader bars instead In any event lift only in full compliance with OSHA standards 29 CFR 1910 subpart N Inspect lifting bail and points of attachment for cracked welds for cracked bent corroded or otherwise degraded members and for loose bolts or nuts prior to lifting Make sure entire lifting rigging and supporting structure has been inspected and is in good condition Verify the rated capacity is at least the net weight of the compressor plus an additional 10 allowance for the weight of snow ice mud or stored tools and equipment If you are unsure of the weight then weigh the compressor before lifting Make sure lifting hook has a functional safety latch or equivalent and is fully engaged once it has been lifted clear of the ground Do not attempt to lift in high winds Keep all personnel out from under and away from the compressor when suspended Lift compressor slowly and smoothly without jerking Lift compressor no higher than necessary Keep lift operators in constant attendance whenever compressor is suspended Set compressor down only on level surfaces capable of supporting at least its net weight plus an additional 10 allowance for the wei
50. ry electrolyte oil or antifreeze solution Shut off the air compressor and allow it to cool Then keep sparks flames and other sources of ignition away and do not permit smoking in the vicinity when adding fuel when checking or adding electrolyte to batteries when checking or adding oil or when refilling air line anti ice systems with antifreeze compound Do not permit liquids including air line anti ice system antifreeze compound or oil film to accumulate on bottom covers or on under or around any external or internal surfaces of the air compressor Wipe down using an industrial cleaner or steam clean as required Do not use flammable solvents for cleaning purposes Disconnect the ground negative battery connection prior to attempting any repairs or cleaning inside the enclosure Tag the battery connection so others will not unexpectedly reconnect it Keep electrical wiring including the battery terminals and other terminals in good condition Replace any wiring that has cracked cut abraded or otherwise degraded insulation or terminals that are worn discolored or corroded Keep all terminals clean and tight Turn off battery charger before making or breaking connections to the battery Keep grounded conductive objects such as tools away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition Replace damaged fuel tanks or lines immediately rather than attempting to repair t
51. sing motor generator sets welders or other sources of DC power as serious damage may result Bring the starting vehicle alongside the compressor but do not permit metal to metal contact between the compressor and the starting vehicle Set the parking brakes of the starting vehicle chock compressor wheels and stabilizer legs on both sides The use of maintenance free batteries may eliminate this step Place the starting vehicle in neutral or park turn off all nonessential accessory electrical loads and start its engine Use only jumper cables that are clean in good condition and are heavy enough to handle the starting current Avoid accidental contact between jumper cable terminal clips or clamps and each other or any metallic portion of either the compressor or the starting vehicle to minimize the possibility of uncontrolled arcing which might serve as a source of ignition Positive battery terminals are usually identified by a plus sign on the terminal and the letters POS adjacent to the terminal Negative battery terminals are usually identified by a minus sign on the terminal and the letters NEG adjacent to the terminal Connect one end of a jumper cable to the positive POS battery terminal in the starting vehicle Connect one end of the other jumper cable to the grounded negative NEG terminal of the battery in the starting vehicle 13 P N 307239 SAFETY JUMP STARTING CONT Connect one end of a jumper
52. tem in the illustration section 17 P N 307239 DESCRIPTION OF COMPONENTS COMPRESSOR COOLING SYSTEM The compressor cooling system consists of an oil cooler and electric fan assembly See Cooler and Parts System in the illustration section An automated thermostatic control system maintains a continuous temperature check of the lubricant The fan sensor trips a normally open relay which sends power to the fan motor once compressor oil temperature reaches 190 F The fan sensor stops power to the fan motor once the compressor oil temperature drops to 160 F INSTRUMENT PANEL AND OPERATING CONTROLS The instrument panel contains all the necessary gauges and instruments for operation and is located outside of the main enclosure The following is an explanation of their use See Electrical System amp Wiring Diagram in the illustration section 1 Start key The starter switch is used to electrically energize the engine starter motor solenoid to begin cranking of engine 2 Choke Gasoline Engine Only The choke is used to provide a richer fuel mixture to the engine for cold starts Pulling the choke cable out increases the fuel mixture As the engine warms up the choke should be pushed inward The engine should operate without choking as soon as possible after starting to avoid flooding or dilution of lubricating oil 3 Hourmeter The hourmeter records the total number of operating hours It serves as a guide towards following the rec
53. tiate through a purchase order for warranty part or request for credit RGA 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 43 P N 307239 GENERAL An approved claim depends on the following provision MD Qv Ux de to 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 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 inspected or carefully installed and tested before leaving our plant However
54. ulation of the compressor inlet control valve and load controller MINIMUM PRESSURE VALVE Restricts airflow to balance sump and air pressure Assures a minimum of 60 PSIG to the service line 24 P N 307239 COMPRESSOR INSPECTION LUBRICATION AND MAINTENANCE This section contains instructions for performing the inspection lubrication and maintenance procedures required in maintaining the compressor in proper operating condition The importance of performing the maintenance described herein cannot be over emphasized Periodic maintenance procedures to be performed on the equipment covered by this manual are listed below 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 to avoid premature failure and costly repairs Daily visual inspections should become a routine The LUBRICATION AND MAINTENANCE CHART lists serviceable items on this compressor package The items are listed according to their frequency of maintenance followed by those items which need only As Required maintenance The maintenance time intervals are expressed in hours Use the hourmeter readings for determining your maintenance schedules Perform the maintenance at multiple intervals of the hours shown
55. ull load operation 0 Service valves can now be opened QUA de 220190221 IF ENGINE SHOULD STOP DO NOT ATTEMPT TO RESTART WITH THE OIL SUMP UNDER PRESSURE ALLOW BLOW DOWN OF SUMP TO END REPEAT THE ABOVE PROCEDURE FROM STEP3 NORMAL STOPPING 1 Close the service valves 2 Toggle cold start switch to the ON position 3 Letthe compressor run for a few minutes to allow machine to cool down an for system pressure to unload 4 Turn key to OPERATING UNDER EXTREME CONDITIONS When operating the compressor in extreme conditions perform the following service functions as applicable COLD WEATHER OPERATION When operating in lower than 20 degrees F ambient change engine oil per engine owner s manual and let the engine and compressor warm up before opening the service valve HOT WEATHER OPERATION Keep the engine filled with clean oil and check the oil level more frequently than usual Keep the outside of the compressor oil cooler clean Locate the unit in a well ventilated area When operating in humid conditions it is recommended that the compressor oil change interval be shortened DUSTY OR SANDY AREAS When possible wet down the area surrounding the operating site to keep dust and blowing sand to a minimum Inspect air filters more frequently 22 P N 307239 COMPRESSOR OPERATION WARNING CHECK THE COMPRESSOR SUMP OIL LEVEL ONLY WHEN THE COMPRESSOR IS NOT OPERATING AND SYSTEM IS CO
56. ustry Care should be taken to avoid accidental ingestion and or skin or eye contact In the event of indigestion seek medical treatment promptly Do not induce vomiting if fuel is ingested Wash with soap and water in the event of skin contact Wear an acid resistant apron and a face shield or goggles when servicing the battery If electrolyte is spilled on skin or clothing immediately flush with large quantities of water If air line anti ice system antifreeze compound enters the eyes or if fumes irritate the eyes they should be washed with large quantities of clean water for 15 minutes A physician preferably an ophthalmologist or eye specialist should be contacted immediately The antifreeze compound used in air line anti ice systems contains methanol and is toxic harmful or fatal if swallowed Avoid contact with the skin or eyes and avoid breathing the fumes Call a physician immediately expose live parts of the electrical system 11 P N 307239 SAFETY ELECTRICAL SHOCK Keep the compressor or equipment carrier compressor hoses tools and all personnel at least 10 feet from power lines and buried cables Keep all parts of the body and any hand held tools or other conductive objects away from exposed live parts of the electrical system Maintain dry footing stand on insulating surfaces and do not contact any other portion of the compressor when making adjustments or repairs to expose live parts of the electrical system Attempt
57. working pressure Do not set pressure over 125 psi Normal set pressure is 80 to 120 psig COMPRESSOR DISCHARGE PRESSURE GAUGE This gauge indicates the discharge air pressure Operate compressor with discharge pressure within 80 to 120 PSIG AUTOMATIC BLOW DOWN VALVE The automatic blow down valve This valve will automatically bleed the sump to zero pressure when the compressor is stopped 19 P N 307239 DESCRIPTION OF COMPONENTS ELECTRICAL AND PROTECTIVE CIRCUIT SYSTEM The compressor electrical system is 12 volt negative ground type It is equipped with a protective circuit to minimize damage which could be caused by high compressor discharge temperature or high discharge pressure See wiring diagram and electrical system in the illustrations section The following conditions will cause automatic shutdown of the compressor 1 Compressor discharge temperature switch exceeds approximately 250 F 2 Compressor discharge pressure that exceeds 150 psi NOTE WHENEVER THE OPERATION OF THE PROTECTIVE CIRCUIT SHUTS THE MACHINE OFF THE RESET BUTTON ON THE CONTROL PANEL MUST BE RESET PUSHED IN BEFORE YOU CAN RESTART THE COMPRESSOR DO NOT RESTART THE COMPRESSOR UNTIL THE CAUSE OF THE SHUTDOWN IS FOUND AND FIXED DUE TO THE FACT THAT THE COMPRESSOR PROTECTIVE CIRCUIT IS AN ENERGIZED TO RUN SYSTEM ANY INTERRUPTION OF CURRENT WILLSHUT THE UNIT DOWN IN EVENT OF AUTOMATIC SHUTDOWN IT IS ALWAYS GOOD POLICY T
58. ycle oil is injected into the compressor and serves these purposes 1 Lubricates the rotating parts and bearings 2 Serves as acooling agent for the compressed air 3 Seals the running clearances LUBRICATION SYSTEM Oil from the compressor oil sump at the compressor discharge pressure is directed through the oil cooling system then the oil filter and back to the compressor stator where it is injected into the compressor At the same time oil is directed to the bearings and shaft seal of the compressor SAFETY VALVE The pop safety valve is set at 175 PSI and is located at the top of the air oil sump This valve acts as a backup to protect the system from excessive pressure that might result from a malfunction AIR OIL COALESCER The coalescer is self contained within a spin on housing and is separate of the sump When air is demanded at the service line it passes through the coalescer which efficiently provides the final stage of oil separation MINIMUM PRESSURE VALVE The minimum pressure valve is located at the outlet of the compressor and serves to maintain a minimum discharge pressure of 60 PSIG in operation which is required to assure adequate compressor lubrication pressure and air oil separation at the coalescer element OIL FILTER The compressor oil filter is the full flow replaceable element type and has a safety by pass built into it This element screws directly to the compressor stator housing See Compressor Mounting Sys
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