bullet operators, maintenance and parts manual
Contents
1. 5 Number of packages pertaining to each claim NOTE Our warranty requires that all defective parts be returned to BOSS INDUSTRIES freight prepaid Items sent without RGA number will not be accepted 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 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 2 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 in stalled unit may be damaged due to rough handling while in route to its destination even though the kit or factory installed unit shows no external damage When the damage is discovered upon unpack ing make a written request for inspe2. ie Aba ey D LIRAIN CE FENT pha at EJ CT ee aT FEF feed Bei Lee ael Sep dram prm be EMI ___ ai NL PTT Sle ere Located on near Located on oil sump The start up procedure decal Near the fill cap BOSS P N 300039 BOSS P N 300038 SAFETY Cee aor 22759217 xir 11 5 E la ep death Cont Bon Aiea Vial 8 0111 3113 0 pne duas usn sting andi rect over dida Located on the control panel Located on the control panel near the near air service valve Start up procedure decal BOSS P N 300040 BOSS P N 300042 m ete Do not operate without fan quard place angers and Exallumy work Streng ep nee Located on the control panel near the Located on the exhaust panel between the Start up procedure decal Muffler and belt drive BOSS P N 300041 BOSS P N 300968 14 DECALS SHO
3. 300108 PLUG MAGNETIC 1 2 NPT 4 300072 SENSOR FAN 190 160 N 929806 100 BOLT HEX GR8 3 8 16 X 1 300017 SUMP 10 DISCHARGE 300320 SWITCH SHUTDOWN 240 DEG 31 902204 024 TEE PIPE RED 1 X 1 2 X 1 960216 100 ELBOW 1 X 1 37 FL 922216 000 NIPPLE PIPE CLOSED SCH 80 902415 040 TEE PIPE 1 300783 SIGHTGLASS OIL LEVEL 1 960116 100 1 1 37 301466 100 1 W HOLE oo 301422 SWITCH PRESSURE N O 30 PSI 960204 012 ELBOW 90 DEG 1 4 JIC X 1 8 NPT 300093 COALESCER SPIN ON ELEMENT 41 902203 023 TEE PIPE RED 3 4 X 1 2 X 3 4 IN 922112 060 NIPPLE 3 4 X 6 6 ones gt mm 960218 100 as ze mmm 300093 43 926006 337 NUT HEX 3 8 16 4 65 WARRANTY CLAIMS 66 WARRANTY Boss Industries Inc BOSS warrants that this Rotary Screw Compressor unit conforms to appli cable 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 s
4. Abnormal oil consumption or oil in service line check for the following 1 Over filling of oil sump 2 Leaking oil lines or oil cooler 3 Plugged oil return line check entire line and check valve orifice fitting at compressor port 4 Defective separator element 5 Compressor shaft seal leakage 6 Discharge pressure below 55 PSI SEPARATOR PLUGGING If the separator element has to be replaced frequently because it is plugging up 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 1 Extreme operating temperature 2 Negligence in draining condensate from oil sump 3 Using the improper type of oil 4 Dirty oil The complete inlet system should be checked for leaks 42 TROUBLESHOOTING HIGH COMPRESSOR DISCHARGE TEMPERATURE po Check compressor oil level Add oil if required see section for oil specifications Check electric fan and switch Clean outside of oil cooler Clean oil system cooler internally Plugged compressor oil filter Change element Plugged oil return line clean orifice and check valve INSUFFICIENT AIR DELIVERY Plugged air filter clean or replace Plugged air oil separator Replace separator element and also change compressor oil and oil filter at this time Defective pressure regulator adjust or repair Engine speed too low
5. Clean area inside pulley shaft where new wear ring is to be installed Apply glue loc tite 601 to wear ring inside diameter and install on inside pulley shaft until it bottoms out Do not deform wear ring and remove excess loc tite Clean seal housing inside dia Apply loctite 542 on shaft seal O D and push seal into housing Mount pulley to rotor shaft by hand and bottom pulley out by hitting slightly with brass hammer Tighten the left handed screw counter clockwise to 80Nm torque Keep pulley from rotating while tightening bolt If pulley does not rotate squarely remove and check for contamination of end of compressor shaft and the mating surfaces COMPRESSOR DRIVE BELTS The 2 belt arrangement is sized for an average life of 1000 hours This time frame can be increased or decreased depending on the end user Drive belt tension should be checked for adjustment after the first 10 hours of operation and checked for adjustment every 50 hours thereafter Failure to follow the inspection can shorten the life expectancy of the belts Belt deflection is to be checked at the midpoint between both pulleys Single belt deflection is to be 25 inches at 2 9 158 minimum to 4 1 lbs maximum 36 MAINTENANCE Both belts are to be checked separately If excessive wear is present on belts chords wear ing then belts are to be replaced If only one is worn both belts should be replaced BELT REMOVAL 1 Loosen the 5 16 18 UN
6. B lt 200032 001 gt 200032 001 55 DECAL AND IDENTIFICATION SYSTEM 200032 001 PART ITEM NUMBER DESCRIPTION orca 17 contre 56 ELECTRICAL SYSTEM 200029 27 200029 200029 zh 10 09 99 57 ELECTRICAL SYSTEM 200029 300805 HARNESS WIRE __ WIRE CH25 301140 SWITCH OVER RIDE N C EN EN RN oem eer ees 58 FRAME AND CANOPY SYSTEM 200025 001A M MA NE Ss 5y 7 CEN P 1 ES b 3 Ka MES d 10 22 99 M B 200025 0012 8 7 4 2 eo 200025 00142 FRAME AND CANOPY SYSTEM 200025 001B 06 lt trett SIF AW 0018 200025 1B C200025 00 10 22 99 60 FRAME AND CANOPY SYSTEM 200025 001 PART I I 2 61 FRAME AND CANOPY SYSTEM 200025 001 PART E UR NES oem oem poo eee mere D opem o omen oem oce S s sone eme
7. abnormalities in operation unusual noises from the engine or accessories loss of power overheating etc contact your nearest Kohler Service Center 38 MAINTENANCE ENGINE INSPECTION LUBRICATION AND MAINTENANCE CHART AFTER EACH CYCLE OF INDICATED HOURS SERVICE AIR CLEANER ELEMENT WRAPPER CHANGE CRANKCASE OIL ALL ENGINES WITHOUT FILTER CHANGE CRANKCASE OIL STANDARD WITH SERVICE THESE ITEMS eee BASE WITH FILTER seremos wes RR ERR RR RER meme LT T RER EI Check for fuel leaks With engine running visually and audibly check exhaust system for leaks 2 Perform more often when running under severe operating conditions 3 Required for initial break in only 4 For detailed maintenance contact Kohler Service Center or refer to the SERVICE MANUAL 39 TROUBLESHOOTING This section contains instructions for troubleshooting the equipment following a malfunc tion 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 proce
8. 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 or 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 SAFETY FIRE AND EXPLOSION CONT Disconnect the ground negative battery connection prior to attempting any repairs or clean ing inside the enclosure Tag the battery connection so others will not unexpectedly recon nect it Keep electrical wiring including the battery terminals and other terminals in good condi tion 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 them 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
9. devices to prevent tools or hose ends from being accidentally disconnected and expelled Open 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 connec tion 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 engage in horseplay with air hoses as serious injury or death may result 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 battery 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
10. 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 require ments 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 SAFETY 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 tends 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 circula tion The t
11. 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 exposed 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 attempting 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 SAFETY HOT SURFACES SHARP EDGES AND SHARP CORNERS VACUUM Avoid bodily contact with hot oil 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 work
12. readjust engine speed 43 RECOMMENDED SPARE PARTS LIST ENGINE MAINTENANCE PARTS DESCRIPTION BOSS P N Engine Oil Filter 300324 Engine Fuel Filter 301126 Engine Air Cleaner Element 301127 Engine Air Cleaner Wrapper 301128 Spark Plugs 301129 Fuel Shut Off Solenoid 301131 COMPRESSOR MAINTENANCE PARTS DESCRIPTION BOSS P N Drive Belts 300742 500 Compressor Air Cleaner Element 300773 Compressor Oil Filter 300324 Compressor Coalescing Element 300093 Hi Temp Compressor Shutdown Switch 300320 Fan Sensor 300072 Inlet Valve Repair Kit 300186 002 Regulator Repair Kit 300187 Compressor Shaft Seal E3 300826 Pressure Gauge 300333 Compressor Manual 300931 44 PART NUMBER amp ILLUSTRATION SECTION 45 AIR AND OIL SCHEMATIC 200030 001 PART ITEM NUMBER DESCRIPTION 1 975416 040 1 DISCHARGE HOSE AIR AND OIL 2 300964 5 32 TUBING REGULATED AIR 3 975404 042 1 4 OIL RETURN HOSE AIR AND OIL 4 300964 5 32 TUBING REGULATED AIR 5 300964 5 32 TUBING AIR AND OIL 6 975408 050 1 2 OIL FEED TO COOLER HOSE 7 975408 022 1 2 OIL RETURN TO COMPRESSOR HOSE 8 300217 TIE 15 WIRE CABLR 50 TENSILE NOT SHOWN 9 300218 TIE 24 WIRE CABLR 50 TENSILE NOT SHOWN 12 28 99 46 Mn ee E WVYOVIC SSHUNUVH 608009 85 66 62 60 WIRING HARNESS DIAGRAM 300805 WIRE WIRE NUMBER CONNECTOR END STYLES GAUGE AND CO
13. to settle is at the midpoint of the oil sightglass The package must be level when checking the DO NOT OVERFILL The oil sump capacity is given in Compres sor Specifications DANGER WHILE COMPRESSOR IS RUNNING DO NOT ATTEMPT TO DRAIN CONDEN SATE 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 COM PLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTY AND SERI OUS 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 20 29 MAINTENANCE AIR OIL COALESCER The air oil coalescer employs an element permanently housed within a spin on canister This is a single piece unit that requires replacement when it fails to remove the oil from the dis charge air See Discharge System in the illustration section To replace element proceed as follows Shutdown compressor and wait for complete blow down zero pressure Disconnect oil return line and clean out Turn element counterclockwise for removal as viewed from bottom Install n
14. 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 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 sur faces and do not contact any other portion of the compressor when making adjustments or repairs to expose live parts of the electrical system Attempt repairs only in clean dry well lighted and ventilated areas SAFETY LIFTING This compressor is 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 slin
15. 00 HOURS OR 1 YEAR 1 Install new air filter element Shorter interval may be necessary under dusty conditions 2 Check all doors gaskets hinges and latches EVERY 2000 HOURS OR 1 YEAR 1 Inspect air filter element 2 Replace spin on coalescer element if necessary 3 Inspect and clean compressor oil system cooler etc PERIODICALLY OR 4 Check engine speed control adjustment at hi low AS REQUIRED compressor settings 5 Inspect lifting frame before each lift 6 Grease wheel bearings 7 Check engine and compressor supports NOTE See Maintenance Section for clarification on above 28 COMPRESSOR INSPECTION LUBRICATION AND MAINTENANCE NOTE OBSERVE ALL GAUGE READINGS NOTE ANY CHANGE FROM THE NOR MAL 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 OIL AND OIL FILTER ELEMENT CHANGE SHOULD BE MADE AT 50 HOURS ALSO MORE FREQUENT OIL CHANGES WILL BE RE QUIRED UNDER EXTREME OPERATING CONDITIONS OF EXTREMELY HIGH OR LOW TEMPERATURES AND HIGH HUMIDITY CHANGE OIL EVERY SIX MONTHS EVEN IF THE NORMAL OIL CHANGE IN HOURS HAS NOT YET ELAPSED ALWAYS WARM UP THOROUGHLY PRIOR TO CHANGING EITHER THE EN GINE OIL OR THE COMPRESSOR OIL NOT OPEN COMPRESSOR OIL DRAIN OIL FILTER CAP OR OIL FILTER NTIL ALL PRESSURE HAS BEEN RELIEVED CHECK BY MANUALLY OPEN ING T
16. ACITY AXLE 480 x 12 RATED TUBELESS TIRES E WEIGHT SKID MOUNTED 490153 186kg 2 BALL HITCH PINTLE OP TIONAL WEIGHT w TRAILER 740163 281kg DROP DOWN JACKET FENDERS MIN EXHAUST 12 00 CLEARANCE 1 20 mal ri4131 e DOOR H 02 Sige D gt 95 4i n E bs T FA MIN EXHAUS 15 75 CLEARANCE 300 m 47 0 3 4 6 99 51004 SAFETY WARNING ALL UNITS ARE SHIPPED WITH A DETAILED OPERATORS INSTALLATION 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 accidents 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
17. BULLET OPERATORS MAINTENANCE AND PARTS MANUAL MANUAL P N 300931 REVISED 12 29 99 M B TABLE CONTENTS Operation amp Maintenance Section Page Specifications 3 Safety 4 16 Description of Components 17 22 Compressor Operation 23 27 Compressor Inspection Lubrication And Maintenance 28 40 Troubleshooting 41 44 Parts amp Illustration Section Recommended Spare Parts List 45 Parts and Illustration Section 46 64 Warranty Section Warranty Information Claims 65 70 COMPRESSOR SPECIFICATIONS MODEL TYPE DELIVERY CFM OPERATING PRESSURE RANGE AMBIENT OPERATING TEMP RANGE ENGINE SPECIFICATIONS KOHLER 4 CYCLE V TWIN OHV AIR COOLED GASOLINE MODEL CH25 POWER 3600RPM 8 HP kw 25 HP 18 7kw in 725cc 20 DEG 100 DEG F OIL SUMP CAPACITY TOTAL SYSTEM CAPACITY AIR SERVICE CONNECTION TYPE COOLING SYSTEM AIR INTAKE FILTER TYPE OF CONTROL BORE amp STROKE B 327in 83mm amp S 2 64in 67mm 2 1 QUARTS 2 LITERS 12V 375cca 32 DEGF 7 4 GALLONS 1 6 GALLONS 6 06 LITERS OIL CAPACITY w 2 2 GALLONS 8 32 LITERS FILTER BATTERY 3 4 NPT FUEL TANK CAPACITY OIL TO AIR SINGLE STAGE DRY 0 10096 DEMAND TRAILER SPECIFICATIONS OPTIONAL 1000 LBS CAP
18. C bolt at the compressor mounting pivot bracket Do not re move 2 Remove qty two 5 16 18 bolts that go through the adjuster bar adjuster bracket and air compressor flange 3 Rotate compressor up Remove belts BELT INSTALLATION 1 Place belts in pulley grooves and let weight of compressor pull belts taunt 2 Replace the two 5 16 18 screws through the adjuster bar compressor flange and adjuster bracket 3 Pull down on adjuster bar and set belts to deflection mentioned under compressor drive belts 4 While holding the correct tension tighten two 5 16 18 bolts 5 Tighten pivot bolt CONTROL ADJUSTMENTS The engine speed governor and interconnecting linkage are preset at the factory and nor mally require no servicing other than keeping the linkage joints clean and lubricated How ever in the event it becomes necessary to make adjustments use the following procedures DISCHARGE PRESSURE ADJUSTMENT The normal operating pressure as indicated by the Compressor Discharge Pressure Gauge is 80 115 PSIG To increase pressure loosen lock nut on pressure regulator adjustment screw and turn screw clockwise Lower operating pressure by turning screw counterclockwise Reset lock nut after adjustment is completed Do not adjust for operating pressure in excess of 115 PSIG or lower than 70 PSIG Check engine speed adjustments whenever pressure settings have been changed Only the unloaded pressure can be selected with the pressure regul
19. CAUTION MIXING DIFFERENT TYPES OF BRANDS OF LUBRICANTS IS NOT RECOM MENDED DUE TO THE POSSIBILITY OF A DILUTION OF THE ADDITIVES OR A REACTION BETWEEN ADDITIVES OF DIFFERENT TYPES 30 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 BULLET machines use Dextron ATF Other non detergent motor oils SAE 10W class SE or CD and SAE 30 meet these requirements 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 tempera ture range shown 40 F to 120 F 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 PRIME LUBRICANT CHARACTERISTICS 1 Flash point 400 degrees F minimum ASTM D 92 COC 2 Pour point must be at least 20 degrees F lower than the lowest expected ambient tempera ture 3 Contain rust and oxidation inhibitors 4 Contain foam suppressers SYNTHETIC DIESTER AND SYNTHESIZED HYDROCARBON LUBRICANTS OIL All elastomeric components and all metal used in the compressor are ful
20. FLOW INTO THE SUMP THIS CHECK VALVE SHOULD HAVE A MAXIMUM PRESSURE DROP RATING OF 2 PSIG 13 78 kPa OPERATING AND A CAPACITY RATING EQUAL TO THE MAXI MUM RATING OF THE COMPRESSOR 26 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 com pressor package The items are listed according to their frequency of maintenance followed by those items which need only As Required maintenance The maintenance time inter vals are expressed in hours Use the hourmeter readings for determining your maintenance schedules Perform the maintenance at multiple intervals of the hours shown For example when the h
21. HE ASME SUMP PRESSURE RELIEF VALVE 29 LUBRICATION LUBRICANT RECOMMENDATIONS WARNING IT IS IMPORTANT THAT THE COMPRESSOR FLUID BE OF A RECOM MENDED TYPE AND THAT THIS OIL AS WELL AS THE AIR FILTER OIL FIL TER 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 satis factory for use in helical screw type air compressors Due to the impossibility of establish ing limits on all physical and chemical properties of lubricants which can affect their perfor mance 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
22. 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 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 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 rep
23. LOR 6Z 1 4 5 WAY CONNECT 1 4 5 WAY CONNECT 12 GA WHITE BUTT CONNECT T 3 WAY SPLICE SLEEVE 30 RELAY SOCKET 14 GA RED RELAY JUMPER 30 TO 85 RELAY SOCKET 86 TO 1 4 DISCONNECT FAN SENSOR 16 GA WHITE 3 WAY SPLICE SLEEVE TO 10 RING STUD 14 GA RED meer __ 48 COMPRESSOR MOUNTING SYSTEM 200027 001 10 5 99 lt 200027 001 gt 5 200027 001 gt 49 COMPRESSOR MOUNTING SYSTEM 200027 001 PART 50 2 N N N ENGINE MOUNTING SYSTEM 200026 001 BOLT THROUGH THROTTLE LINKAGE MOUNTING PLATE gt CABLE FROM GAUGE PANEL HOOK TO ENGINE MOUNTED TO THROTTLE LINKAGE MOUNTING 2 d 12 28 99 8 200026 0015 19 200026 001 51 ENGINE MOUNTING SYSTEM 200026 001 PART o esee ese ee REECH 7 2 REES 2 300745 144 BUSHING 1 7 16 3 8 wem emen OIL COOLING SYSTEM 200050 OIL COOLING SYSTEM 200050 DESCRIPTION close 1 pene p 54 DECAL AND IDENTIFICATION SYSTEM 200032 001 5 SA TN 10 09 99 M
24. TS 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 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 mounted on the coalescer head and engine speed regulating cylinder operates as follows See Air Oil Schematic Discharge System and Engine Mounting System in the illustration section 1 As the 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 modu lating spring inside the valve This regulates the opening area of the inlet valve b The regulating cylinder will reduce engine speed somewhere between full load and compressor idle 2 Ifthe air demand goes to zero service valve closed the in
25. WN BOSS P N 301125 300518 300519 300649 300516 300515 300204 300913 300969 300048 300047 300046 SAFETY DESCRIPTION Decal Operating Instructions Decal 70 Decal Bullet Decal BOSS Decal Engine Oil Fill Decal Fuel Fill Decal Plate Serial N O Aluminum Decal Oil Drain Deacl Belt Tension Decal Direction of Rotation Decal Compression Fluid Decal Oil Level NOTE See canopy illustrations for these decal locations 15 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 BULLET compressor assembly is a positive displacement An 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 rotor 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 th
26. WN IN EVENT OF AUTOMATIC SHUTDOWN IT IS AL WAYS GOOD POLICY TO CHECK FOR LOOSE OR BROKEN WIRES OR COR RODED CONNECTIONS BY THE SHUTDOWN SWITCH LOCATED IN THE 1 DISCHARGE LINE AT SUMP IF THE ELECTRICAL SYSTEM CHECKS OUT PROPERLY REFER TO TROUBLESHOOTING SECTION 21 COMPRESSOR OPERATION GENERAL Every BULLET 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 opera tion the machine should be carefully observed for any possible malfunction Satisfactory performance of the machine depends on the operator s knowledge of the con trols 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 occur ring 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 Operat
27. ating valve Full and part load pressures are a function of air usage 37 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 2600 2850 RPM by moving idle stop screw at carburetor as required For operation at higher altitudes it may be desir able 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 a regular 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 mainte nance can result in engine failure or permanent damage For any
28. 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 inside or outside of canopy Keep oily rags trash leaves litter or other combustibles out of and away from the compres sor 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 SAFETY FIRE AND EXPLOSION CONT Antifreeze compound used in air line anti ice systems contains methanol which if flam mable 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 antifreeze com pound 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
29. ction 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 70 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 distributor Prices are F O B shipping point Prices do not include labor for removal or installation 71
30. d 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 con tacted 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 of 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 using 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 th
31. dures that can be performed in the least amount of time and with the least amount of removal or disassembly or parts should be performed first MACHINE WILL NOT START Check fuel level and add fuel if necessary Plugged fuel filter and replace if necessary Low battery voltage recharge if necessary Loose battery cables tighten cable dirty battery cables clean thoroughly Plugged air filter replace the element Engine problems may have developed refer to your Engine Manual Defective engine oil pressure switch check continuity and replace if necessary Blown fuse in wiring harness check continuity of fuse and replace if necessary Fuse located by engine starter solenoid Bad compressor high discharge temperature switch this switch is normally closed Check for continuity across both terminals Replace if it shows no continuity normally open 40 TROUBLESHOOTING UNPLANNED SHUTDOWN When the operation of the machine has been interrupted by an unexplained shutdown check the following 1 2 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 Make a thorough external check for any cause of shutdown such as broken hose broken oil lines loose or broken wire etc Check compressor for high discharge temperature switches it should be normally closed C D T switch located in piping on end of receiver
32. e 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 posi tive POS terminal of the battery in the compressor and finally disconnect the other end of this same jumper cable from the positive POS terminal of the battery in the starting vehicle 12 SAFETY NOTE THE OWNER LESSOR OR OPERATOR OF THE COMPRESSOR IS HEREBY NOTIFIED AND FOREWARNED THAT ANY FAILURE TO OBSERVE THESE SAFETY PRECAUTIONS MAY RESULT IN DAMAGE OR INJURY BOSS INDUSTRIES EXPRESSLY DISCLAIMS RESPONSIBILITY OR LIABILITY FOR ANY INJURY OR DAMAGE CAUSED BY FAILURE TO OBSERVE THESE SPECIFIED PRECAUTIONS OR BY FAILURE 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 x gt 1123 LE alil i Eeli H seite Ke Te I
33. e receiver During the compression cycle oil is injected into the compressor and serves these purposes 1 Lubricates the rotating parts and bearings 2 Serves as a cooling 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 in jected into the compressor At the same time oil is directed to the bearings and shaft seal of the compressor The oil laden air is then discharged back into the sump See Air Oil Sche matic in the illustration section 16 DESCRIPTION COMPONENTS OIL SUMP Compressed oil laden air enters the sump from the compressor Most of the oil is separated from the air as it passes through a series of baffles and defusing plates The oil accumulates at the bottom of the sump for re circulation Some small droplets of oil remain suspended in the air and are passed on to the coalescer See Discharge System in the illustration section 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 See Discharge System in the illustration section OIL RETURN LINE The oil that is removed by the coalescer accumulates at the bottom of the can and is returned t
34. e 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 11 SAFETY JUMP STARTING CONT 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 possibil ity 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 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 procedur
35. eck for leaks in operation WARNING 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 COMPRES SOR POSSIBLY VOIDING THE WARRANTY OIL COOLER The interior of the oil cooler should be cleaned when the pressure drop across it at full flow exceeds 15 PSI In the event the unit experiences this type of pressure drop we recommend the following Remove cooler Circulate a suitable solvent to dissolve and remove varnish and sludge Flush generously with oil After the cooler is cleaned and compressor is filled with fresh oil operate the machine normally for 50 hours then change compressor oil 5 Ifthe above procedure does not correct the problem the cooler will need to be replaced PWN 35 MAINTENANCE COMPRESSOR SHAFT OIL SEAL REMOVAL Remove all hoses 1 discharge 1 2 oil feed 1 4 oil return line 5 32 tube blow down line and one 5 32 tube inlet valve regulating air pressure line Remove compressor from mounting plate There is one 5 16 18 pivot bolt and two 5 16 18 position locking bolts Remove pulley one metric allen head bolt with left hand threads clockwise to remove Tap pulley off evenly Remove shaft seal wear ring from inside of pulley shaft Remove shaft seal with care Do not damage bore RE ASSEMBLY
36. ed by distributor prior to contracting BOSS INDUS TRIES WARRANTY CLAIMS FILING PROCEDURES Initiate through purchase order for warranty part or request for credit Warranty Claims Service Report will accompany replacement part When returning failed part to the factory for warranty credit fill out all information requested on Warranty Claims Service Report when it is returned to you with replacement part BOSS INDUSTRIES will confirm disposition of failed part within 30 days and or request additional information Claim acceptance or denial will result in release of a credit or confirmation letter of denial BOSS INDUSTRIES will consider each claim on it s own merit and reserves the right to accept or reject claim request In case of air ends these will be returned to the manufacturer for their analysis input Send Warranty Claim Service Report request to BOSS INDUSTRIES 720 BOYD BLVD 69 LA PORTE IN 46350 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 claims disallowance of credit When addressing the package for shipment the following information must be on the outside of or tagged clearly to package 1 Return Goods Authorization Number 2 Distributor or end users return address 3 Correct factory address 4 Warranty Claim Service Report Number
37. ees e oem eee eese 46 943102 038 RIVET 1 8 3 8 GRIP ALUM NOT 5 62 DISCHARGE SYSTEM 200028 001 E ES nw ES E I 12 28 99 63 DISCHARGE SYSTEM 200028 001 PART LIEM NUMBER DESCRIPTION 901515 030 ELBOW PIPE 3 4 922112 030 NIPPLE PIPE 3 4 X 3 907605 030 BUSHING REDUCING 1 1 4 X 3 4 300331 HEAD COALESCER 907602 010 BUSHING REDUCING 1 2 X 1 4 300333 GAUGE PRESSURE 1 4 NPT 300290 ORIFICE MIN PRESS 1 1 4 X 3 4 907604 030 BUSHING REDUCING 1 X 3 4 922112 020 3 4 2 300022 075 VALVE SERVICE 3 4 VENTED 1 977704 0404 TEE PIPE 1 4 X 1 4 MNPT X 1 4 MNPT 971425 025 1 4 5 32 LA 300057 VALVE REGULATOR 1 4 300020 10 VALVE BLOWDOWN 1 4 NPT 971225 025 CONNECTOR 5 32 TUBE X 1 4 NPT 301977 ORIFICE BLWDWN 1 4 W 5 64 HOLE 300023 175 VALVE RELIEF 1 2 NPT 175 929105 200 5 5 16 18 2 925305 283 NUT WHIZLOCK 5 16 18 300067 BAND SUMP MTG 10 21 907800 040 PLUG PIPE 1 w lt 22 937806 094 WASHER LOC 3 8 4 64 DISCHARGE SYSTEM 200028 001 PART ITEM NUMBER DESCRIPTION N 938206 071 WASHER FLAT 3 8 N 960008 050 ELBOW 45 DEG 1 2 X 1 2 37 FL 902715 020 TEE PIPE SIDE OUTLET 1 2
38. ew 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 Reconnect oil return line Run system and check for leaks WARNING 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 COMPRES SOR POSSIBLY VOIDING THE WARRANTY OIL RETURN LINE This line originates at the bottom of the coalescer and flows through a orifice and a check valve built into the elbow hose fitting at the compressor port If excessive oil consumption or carry over is present check to make certain this line and fittings are not clogged 34 MAINTENANCE OIL FILTER The compressor oil filter is a spin on 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 1 Make sure system pressure is relieved 2 Remove filter by unscrewing from compressor housing turn counterclockwise by hand and discard as viewed from bottom 3 Install a new filter by applying a little oil to the seal and then screw the filter on by hand turning it clockwise until hand tight plus one half turn as viewed from bottom 4 Ch
39. gs 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 and for cracked bent cor roded or otherwise degraded members and for loose bolts or nuts prior to lifting Make sure entire lifting rigging and supporting structure has been inspected is in good condition and had a rated capacity of at least the net weight of the compressor plus and 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 weight of snow ice mud or stored tools and equipment Chock both sides of wheels plus stabilizer legs before disengaging the lifting hook 10 SAFETY JUMP STARTING Observe all safety precautions mentioned elsewhere in this manual Batteries may contain an
40. hipment 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 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 negli gence 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 war ranted 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 inabilit
41. hrough an oil return line leading to the compressor The oil return line also contains an orifice and check valve located at the compressor in the elbow hose fitting See Air Oil Schematic and Compressor Mounting System in the illustration section 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 See Discharge System in the illustration section MINIMUM PRESSURE ORIFICE The minimum pressure orifice is located at the outlet of coalescer head and serves to main tain a minimum discharge pressure of 55 PSIG in operation which is required to assure adequate compressor lubrication pressure and air oil separation at the coalescer element See Discharge System in the illustration section 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 System in the illustration section 17 DESCRIPTION OF COMPONENTS COMPRESSOR COOLING SYSTEM The compressor cooling system consists of an oil cooler electric fan and motor See Oil Cooling 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 rela
42. ing in on or around the compressor Keep a first aid kit handy Seek medical assistance promptly in case of injury Don t ignore small cuts and burns as they may lead to infection Keep all loose clothing and parts of the body away from engine and or compressor intakes or 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 SAFETY TOXIC AND IRRITATING SUBSTANCES CONT Fuels oils coolants lubricants and battery electrolyte used in this compressor are typical of the industry 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
43. lacement 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 warranty 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 68 WARRANTY INTRODUCTION The warranty policy and procedures outlined here within are detailed to provide the claimant with the information necessary when filing a warranty claim and enabling BOSS INDUSTRIES the ability to serve it s customers best WARRANTY CLAIMS GENERAL An approved claim depends on the following provision 1 A warranty claim service report number must be issued by BOSS INDUSTRIES See filing procedures Failed part must be returned within 30 days freight prepaid with receipt of warranty claim service report Part is definitely defective Workmanship is definitely defective Machine is within warranty period Machine has been operating within design conditions Claims made by distributors must be verifi
44. let valve will close com pletely and the regulating cylinder will bring the engine to compressor idle 3 As the 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 cylinder retracts allowing the engine governor spring to bring the engine and compressor up to its high rpm 19 DESCRIPTION OF COMPONENTS INLET VALVE The compressor inlet valve is a piston operated disc valve that has a dual function of regulat ing the inlet opening to control capacity and serving as a check valve at shutdown See Compressor Mounting System in the illustration section DISCHARGE PRESSURE REGULATOR VALVE This valve located on the coalescer head 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 working pressure See Discharge System in the illustration section COMPRESSOR DISCHARGE PRESSURE GAUGE This gauge indicates the discharge air pressure Operate compressor with discharge pressure within 70 to 115 PSIG See Discharge System in the illustration section AUTOMATIC BLOW DOWN VALVE The automatic blow down valve is located at the coalescer head This valve will automati cally bleed the sump to zero pressure when the compressor i
45. ly 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 31 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 LUBRI CANTS MAY BE SHORTER THAN QUOTED BY THE LUBRICANT SUPPLIER BECAUSE THE NORMAL DRAIN AND REPLACE PERIOD MAY BE EX CEEDED USING SYNTHETIC LUBRICANTS DIFFERING FROM THOSE 5 FIED IN THIS MANUAL RAILS ENCOURAGES THE USER TO CLOSELY MONITOR THE LUBRICANT CONDITION AND TO PARTICIPATE IN AN OIL ANALYSIS 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 32 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 in the pipe tee on the side of the receiver sump A drain plug is provided at the bottom of the sump The proper oil level when unit is shutdown and has had time
46. opside 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 Block or chock both sides of stabilizer legs 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 ac cordingly Do not use tools that are rated below the maximum 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 4 SAFETY PRESSURE RELEASE CONT Secure all hose connections by wire chain or other suitable retaining
47. or s manual Fill fuel tank with grade of fuel recom mended in the Engine Operator s manual Connect negative battery cable to battery terminal Fill the compressor oil sump see lubricant section of the operator and parts sec tion for type of lubricant to use DO NOT OVERFILL Compressor system capacity is approximately 2 2 gallons NOTE PROPER COMPRESSOR OIL LEVEL SHOULD FILL HALF THE SIGHTGLASS WHEN THE VEHICLE IS LEVEL AND THE COMPRESSOR IS NOT RUNNING 22 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 oil sump level Close service valves Pull the choke out as required but avoid flooding the engine Operate the engine with out choking as soon after starting as possible Push override button 7 Turn engine start switch and hold until engine starts but do not hold any longer than 15 seconds at a time 8 Release override button when engine has run for 5 to 10 seconds 9 Let the engine warm up Compressor is now ready for full load operation nA BW b2 D NOTE 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 STEP 3 NORMAL STOPPING Close the service valve allowing compressor to unload Operate compres
48. ourmeter 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 MAIN TENANCE CHART refer to the Engine Operator s manual for recommended engine lubri cation 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 27 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 EVERY 10 HOURS OR DAILY Drain water from compressor oil at sump Check belt tension Drain water and sediment from fuel tank EVERY 50 HOURS OR WEEKLY Change compressor oil and oil filter Check air filter piping fittings and clamps Install new air filter element Shorter interval may be EVERY 500 HOURS necessary under dusty conditions OR 6 MONTHS 4 Check tire pressure 5 Check for excessive wear on drive belts Replace if necessary 1 Check safety circuit switches 2 Clean battery terminals 3 Check compressor shaft seal for leakage EVERY 10
49. s Check this level when the machine is shutdown Vents sump pressure to the atmosphere should pressure PRED DURE BELIEF SE inside the sump exceed 175 PSIG Regulates the amount of air intake in accordance with the amount of compressed air being used Isolates fluid in compressor unit on shutdown FAN SWITCH COMPRESSOR INLET CONTROL VALVE Senses air pressure from sump to provide automatic regulation of the compressor inlet control valve and load controller BLOW DOWN VALVE Vents sump pressure to the atmosphere at shutdown Restricts airflow to balance sump and service air MINIMUM PRESSURE ORIFICE pressure Assures a minimum of 55 PSIG to the service line PRESSURE REGULATING VALVE Orifice maintains adequate flow to compressor from OIL RETURN LINE ORIFICE AND coalescer allowing for maximum performance of the CHECK VALVE compressor Check valve stops flooding of separator element when shutdown occurs 25 COMPRESSOR OPERATION OPERATING CONDITIONS The following conditions should exist for maximum performance of the compressor 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 OR AN AIR TANK USE A CHECK VALVE DIRECTLY AFTER THE SERVICE VALVE TO PREVENT BACK
50. s stopped See Discharge Sys tem in the illustration section LIFTING BAIL Securely attached to the frame and extending to the enclosure roof is a lifting bail It is located near the machine center of gravity and provides for hoisting the compressor with a crane See specifications for compressor weight and safety section on lifting 20 DESCRIPTION OF COMPONENTS ELECTRICAL AND PROTECTIVE CIRCUIT SYSTEM The compressor electrical system is a 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 low engine oil 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 245 F This switch is normally closed and opens at 245 F 2 Low engine oil pressure EOP below approximately 10 PSI This switch is normally closed and opens when the engine is started If this pressure drops the switch closes and grounds out the spark module to shut off the engine NOTE WHENEVER THE OPERATION OF THE PROTECTIVE CIRCUIT SHUTS THE MACHINE OFF EXAMINE THE ENGINE OIL LEVEL INDICATOR STICK THEREBY PROVIDING INDICATION OF POSSIBLE CAUSE OF SHUTDOWN DUE TO THE FACT THAT THE COMPRESSOR PROTECTIVE CIRCUIT IS AN ENERGIZED TO RUN SYSTEM ANY INTERRUPTION OF CURRENT WILL SHUT THE UNIT DO
51. sor in unloaded condition for a few minutes to allow machine to cool down and engine to return to compres sor idle Turn key to OFF OPERATING UNDER EXTREME CONDITIONS When operating the compressor in extreme conditions perform the following service func tions as applicable COLD WEATHER OPERATION When operating in lower than 20 degrees F ambient perform the following service func tions as applicable 23 COMPRESSOR OPERATION 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 WARNING CHECK THE COMPRESSOR SUMP OIL LEVEL ONLY WHEN THE COMPRES SOR IS NOT OPERATING AND SYSTEM IS COMPLETELY RELIEVED OF PRESSURE OPEN SERVICE VALVE TO INSURE RELIEF OF SYSTEM AIR PRESSURE WHEN PERFORMING MAINTENANCE ON COMPRESSOR AIR OIL SYSTEM FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE PROP ERTY DAMAGE AND SERIOUS BODILY HARM OR DEATH 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 no
52. sump Check electric fan motor and wiring Check fuses in wire harness check continuity of fuse and replace if necessary Fuse located by starter solenoid Remove wire from engine oil pressure switch and try to start If unit starts add pressure gauge at pressure switch port to verify low pressure or take unit in to Kohler dealer for inspection IMPROPER DISCHARGE PRESSURE 1 2 If discharge pressure is too low check the following a Too much air demand Service valves open blowing to atmosphere Leaks in service line Restricted compressor inlet air filter Faulty control system operation regulator inlet valve etc Low engine speed If discharge pressure is too high or safety valve blows check the following a Oil separator plugged 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 41 TROUBLESHOOTING BLOW DOWN VALVE If after the compressor is shutdown pressure does not automatically blow down check for 1 Automatic blow down valve may be inoperative 2 Blockage in air line from compressor to blow down valve at coalescer head 3 Muffler at blow down clogged ENGINE OVERHEATING Low oil level refill Air blockage into engine from blower PTO side Air blockage from exhaust side of engine Dirty oil in engine Bo OIL CONSUMPTION
53. t place items under the package Engine and compressor draws a majority of its cooling air from below Check instruments periodically during operation If not in normal operating zone refer to Section 6 Troubleshooting 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 24 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 compres sor 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 The normal reading should be approximately 175 to 220 degrees F Switch closed to activate fan motor COMPRESSOR HIGH DISCHARGE Opens the electrical circuit to shut the machine down TEMPERATURE SHUTDOWN SWITCH when the discharge temperature reaches 245 degrees F Indicates the fluid level in sump Proper level should fill FLUID LEVEL SIGHTGLASS half the glas
54. y is be yond 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 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 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 720 BOYD BLVD LA PORTE IN 46350 1 800 635 6587 67 SUMMARY MAIN WARRANTY PROVISIONS As claims policies and procedure are governed by the terms of BOSS
55. y 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 oils 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 Override Button switch The normally closed override button opens the circuit of the normally closed low oil pressure switch until engine oil pressure is accomplished once engine is running Once low oil pressure switch opens it stops the circuit from grounding out the spark and stopping ignition 2 Start key The starter switch is used to electrically energize the engine starter motor solenoid to begin cranking of engine 3 Choke Gasoline Engine Only The choke is used to provide a richer fuel mixture to the engine for cold starts Pull ing 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 4 Hourmeter The hourmeter records the total number of operating hours It serves as a guide towards following the recommended inspection and maintenance schedule 18 DESCRIPTION OF COMPONEN
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