Service and Maintenance 250 DUS JD4045 Manual IT4 74HP Air ...bossair.com/Manuals/309663 MANUAL, 250...

This manual must be read carefully before using your Boss Industries, Inc. Air Com-

pressor. Store in a safe and convenient location for future reference.

For technical support:

Phone: (800) 635-6587 (USA)

Phone: (219) 324-7776 (Outside USA)

Fax: (877) 254-4249 (USA)

Email: [email protected]

Website: http://www.bossair.com

Service and

Maintenance

Manual

250 DUS JD4045

IT4 74HP

Air Compressor

309663

7/23/2014 KWB

2 309663

3 309663

Manual Change History................................................................................................7

1.1 Revision List....................................................................................................7

Welcome........................................................................................................................8

2.1 General Information..........................................................................................8

2.2 Overview .........................................................................................................8

Safety...................................................................................................................9-13

3.1 General Safety Overview...................................................................................9

3.2 Safety Precautions..........................................................................................10

3.3 Safety and Information Decals..........................................................................12

Specifications..............................................................................................................14

4.1 Specification Sheet........................................................................................14

Description of Components..............................................................................15-18

5.1 Engine............................................................................................................15

5.2 Drive Coupling...............................................................................................15

5.3 Compressor Airend.......................................................................................15

5.4 Separator System..........................................................................................15

Separator Tank.........................................................................................15

Separator Element......................................................................................15

5.5 Pressure Relief Valve.....................................................................................16

5.6 Engine Air Filter..........................................................................................16

5.7 Compressor Air Filter.................................................................................16

5.8 Cooling Systems...........................................................................................16

Engine Radiator..........................................................................................16

Compressor Oil Cooler...............................................................................16

5.9 Compressor Oil Filter..................................................................................16

5.10 Compressor Oil Thermal Valve......................................................................16

5.11 Compressor Inlet Valve.................................................................................17

5.12 Minimum Pressure Valve...............................................................................17

5.13 Blowdown Valve..........................................................................................17

5.14 Blowdown Switch........................................................................................17

5.15 Discharge Pressure Regulator Valve...............................................................17

5.16 Instrument Panel...........................................................................................18

Engine Oil Pressure Gauge..........................................................................18

Engine Coolant Temperature Gauge............................................................18

Compressor Discharge Pressure Gauge......................................................18

Compressor Discharge Temperature Gauge................................................18

Contents

4 309663

Contents

Description of Components (continued)............................................................15-18

5.15 Instrument Panel (continued).....................................................................18

Hourmeter.......................................................................................18

Tachometer.........................................................................................18

Voltmeter.................................................................................18

Unloader Valve...........................................................................................18

Emergency Stop Switch.............................................................................18

Bypass Switch...........................................................................................18

Ignition Switch...........................................................................................18

Installation.............................................................................................19-23

6.1 System Installation Overview...........................................................................19

6.2 Placing the Machine........................................................................................19

6.3 Connecting the System Fuel Supply.................................................................19

6.4 Fuel Specifications..........................................................................................20

High Altitude and Low Temperature Fuel....................................................20

Cold Weather Fuel.....................................................................................20

6.5 Connecting the Air Discharge Lines...............................................................20

6.6 Pre-Startup Inspection .................................................................................20

6.7 Machine Documentation...............................................................................21

6.8 Check Fluid Levels.......................................................................................21

6.9 Initial Startup Preparation..............................................................................21

6.10 Initial Startup.................................................................................................22

Operation.............................................................................................................23-24

7.1 Routine Operating Procedures........................................................................23

Routine Startup Preparation........................................................................23

Routine Startup Procedure.........................................................................23

Routine Shutdown Procedure.....................................................................23

7.2 Emergency Shutdown Procedure..........................................................24

Maintenance........................................................................................................25-36

8.1 Maintenance Overview....................................................................................25

8.2 Maintenance Schedule....................................................................................25

8.3 Recommended Spare Parts List......................................................................26

8.4 Parts and Service Contact Information............................................................26

8.5 Maintenance Log............................................................................................27

5 309663

Maintenance (continued)....................................................................................25-36

8.6 Separator Element Replacement......................................................................28

8.7 Engine Air Filter Replacement..........................................................................29

8.8 Compressor Air Filter Replacement.................................................................30

8.9 Compressor Oil..............................................................................................31

Specifications.......................................................................................31

Adding Compressor Oil.............................................................................32

Changing Compressor Oil..........................................................................32

8.10 Compressor Oil Cooler.................................................................................33

8.11 Compressor Oil Filter....................................................................................33

8.12 Engine Cooling System Maintenance..............................................................34

Engine Coolant...........................................................................................34

Engine Radiator..........................................................................................34

Engine Fan.................................................................................................35

Engine Serpentine Belt...............................................................................35

8.13 Battery..........................................................................................................35

8.14 Standby Pressure Adjustment (For 100 PSI System).....................................35

8.15 Idle Speed Adjustment..................................................................................36

8.16 Rated Speed Adjustment...............................................................................36

Troubleshooting...................................................................................................37-40

9.1 Troubleshooting Chart....................................................................................37

9.2 Parts and Service Contact Information............................................................40

Warranty..............................................................................................................41-45

10.1 Warranty Policy............................................................................................41

10.2 Summary of Main Warranty Provisions..........................................................42

10.3 Warranty/Return Goods Instructions.............................................................43

10.4 Warranty Claims - Preparation of Part Return.................................................43

10.5 Return or Warranty Claims - Filing Procedures...............................................43

10.6 Warranty Claims Provisions..........................................................................44

10.7 Damage in Transit..........................................................................................44

10.8 Screw Compressor Airend Exchange Program..............................................45

Parts and Illustration Section...........................................................................46-63

11.1 Frame System...............................................................................................46

11.2 Engine System..............................................................................................48

11.3 Compressor System.....................................................................................50

11.4 Discharge System..........................................................................................52

Contents

6 309663

Parts and Illustration Section (continued)........................................................46-63

11.5 Cooling System..........................................................................................54

11.6 Electrical System.......................................................................................56

11.7 Canopy System.......................................................................................58

11.8 Decal System..............................................................................................60

11.9 Hose System......................................................................................62

11.10 System Wiring Diagram..............................................................................63

Contents

7 309663

Manual Change History

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2102/03/8 95-85.gP metsysyponacdetadpU HRC

1.1 Revision List

8 309663

Welcome

2.2 Overview

The 250 DUS Air Compressor is a compact, strategically designed system. It integrates all major

components on a single frame, which is enclosed in a tough, weather-resistant canopy.

The 250 DUS Air Compressors rotary screw

design guarantees continuous air output of up to

250 CFM (cubic feet per minute) at 100 PSI

(pounds per square inch). With remote fluid drains

and removable doors, virtually all components are

accessible for maintenance and service. The

instrument panel clearly displays pressures,

temperatures, and hours of operation. Other

features, including a spin-on compressor oil filter

and a drop-in separator element, reduce the time

and costs associated with routine maintenance.

The 250 DUS Air Compressor also has enhanced

safety features to protect your valuable resources:

minimum pressure valve, high compressor oil

temperature shutdown, high discharge pressure

shutdown, automatic blowdown device, pressure

relief valve, high engine coolant temperature, low

engine oil pressure, and clearly displayed warning/

information decals.

2.1 General Information

Thank you for choosing the 250 DUS Air Compressor. Before operating

this system, read over this manual and become well acquainted with your

new machine. Doing this will increase your safety and maximize the life

of the machine.

While this manual is written to be as accurate as possible, Boss Indus-

tries, Inc. strives to continually improve the efficiency and performance of

its machines. As a result, sometimes there may be slight differences

between a given version of the manual and the machine.This manual must be read carefully before using your Boss Industries, Inc. Air Com-

pressor. Store in a safe and convenient location for future reference.

For technical support:

Phone: (800) 635-6587 (USA)


Fax: (877) 254-4249 (USA)



Service and

Maintenance

Manual

250 DUS JD4045

IT4 74HP

Air Compressor

309663

07/24/2012

9 309663

Safety

3.1 General Safety Overview

Indicate[s] an imminently hazardous situation, which, if

not avoided, will result in death or serious injury.

Indicate[s] a potentially hazardous situation, which, if not

avoided, could result in death or serious injury.

Indicate[s] a potentially hazardous situation, which, if not

avoided, could result in minor or moderate injury.

Indicate[s] a potentially unsafe situation or practice,

which, if not avoided, can result in property and/or

equipment damage only.

Remember, safety is basically common sense. While there are standard safety rules, each situation has

its own peculiarities that cannot always be covered by rules. Therefore with your experience and

common sense, you are in a position to ensure the safety of yourself and others. Lack of attention to

safety can result in: accidents, personal injury, reduction in efficiency, and worst of all Loss of Life.

Watch for safety hazards and correct them promptly.

Understanding the proper operation of this equipment is critical to its safe operation. The owner, lessor,

and/or operator of this equipment is hereby notified and forewarned that any failure to observe the

safety and operating guidelines may result in injury and/or damage. Boss Industries, Inc. expressly

disclaims responsibility or liability for any injury or damage caused by failure to observe these specified

precautions or by failure to exercise the ordinary caution and due care required while operating or

handling this equipment, even though not expressly specified.

In addition to following these safety guidelines, the operator should follow any company specific guide-

lines and procedures. Consult your immediate supervisor for specific company safety guidelines and/or

procedures.

The following safety symbols are used throughout this manual to draw attention to important information.

If the information is not carefully read and the instructions are not followed, severe injury, death, and/or

damage to property and equipment may occur.

10 309663

Safety

3.2 Safety Precautions

This is a pressurized system. Do not attempt to remove

any part of this machine without first completely relieving

entire system of pressure. Do not attempt to service any

part of the equipment while in operation. Never attempt

to repair or modify any pressure vessel or device.

The system is designed to compress air. Do not attempt

to compress other gases. Compression of other gases

may create a situation where an explosion or fire may

occur.

Do not use flammable solvents for cleaning system com-

ponents as this can cause the unit to ignite or explode

during operation. Keep combustibles out of and away

from system inlets and any associated enclosures.

Never disable, override, or remove safeties, either tempo-

rarily or permanently.

The following safety precautions are a general guide to safe operation of the equipment.

System contains hot oil. The system must be shut off prior

to servicing. Then permit system to cool down prior to

adding compressor oil or servicing the unit.

Do not use air from this system for breathing or food

processing. Air from this system will cause severe injury

or death if used for breathing or food processing.

Do not modify systems to operate equipment at a higher

pressure than specified.

Never operate the machine in an enclosed area.

11 309663

Safety

3.2 Safety Precautions (continued)

Read and understand this manual and all other safety

instructions before using this equipment. Failure to follow

operating instructions and/or failure to follow maintenance

procedures and intervals could result in personal injury,

death, and/or damage to equipment and property.

Use only Boss Industries, Inc. approved replacement

parts.

Check engines operator manual for required service

and maintenance intervals.

Never place machine on a grade more than 15 degrees.

Keep doors closed on the machine during operation.

This machine is equipped with safety unloading

system to prevent damage to the compressor drive

coupling. Should an attempt be made to start this

system improperly, the machine will run unloaded for

60 seconds. Likewise, if an attempt is made to

shutdown the system improperly, the unit will con-

tinue to run until the compressor system pressure

unloads below 50 PSI.

12 309663

Safety

3.3 Safety and Information Decals

Hot Exhaust Pressurized System

Electrical ShockHot Pressurized Oil

Close Doors Oil Level

This machine is supplied with a full complement of safety and identification decals. These decals are

affixed to the unit during final assembly. These decals must be clearly visible and undamaged. Should

any of these decals become illegible or damaged, immediately replace the decal.

13 309663

Safety

3.3 Safety and Information Decals (continued)

Overfill Negative Ground System

Serial Tag

Hot Coolant

Breathing Air

Ambient Temperature

Compressor Oil

14 309663

Specifications

*SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE*

4.1 Specification Sheet

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PH 15 55 16 46

ISP061@MFC 202 512 632 642

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30.00

15 309663

Description of Components

The 250 DUS Air Compressor contains a John Deere, 4 cylinder diesel engine. This engine has been

selected to handle the rugged duty required for its operation. The engine speed is regulated by a

pneumatic throttle control.

5.1Engine

5.2Drive Coupling

Power from the engine is transmitted to the compressor input shaft through a specially designed drive

coupling. The drive coupling consists of a highly torsionally flexible rubber disc that mates with an

engine flywheel flange. The coupling provides a torque limitation to protect from system overloads.

5.3 Compressor Airend

The Boss Industries, Inc. compressor airend is a positive displacement, oil flooded, rotary screw type

unit employing one stage of compression to achieve the desired pressure. Components include a

housing (stator), two screws (rotors), bearings, and bearing supports. Power from the engine flywheel

is transferred through a gear set to the male rotor. The female rotor is driven by the male rotor. There

are five lobes on the male rotor while the female rotor has six roots. 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 at the end of the stator which

delivers smooth-flowing, pulse-free air. Being an oil flooded system, the oil serves three purposes:

lubricates the rotating parts and bearings, serves as a cooling agent for the compressed air, and seals the

running clearances.

5.4 Separator System

I. Separator Tank

From the compressor airend, the compressed air and hot oil flow into a steel, ASME coded,

pressure vessel, rated at 250 PSI, that acts as an oil reservoir. This tank is the first of two stages in

separating the oil and compressed air mixture. From the bottom of the separator tank, oil is forced

to the oil filter.

II. Separator Element

At the top of the separator tank is the separator element. The separator element removes the oil

mist from the air as it is passed on to the minimum pressure valve. As the air/oil mist passes through

the outside of the media, oil gathers on the interior walls and settles to the bottom of the element.

Collected oil is returned to the compressor airend through the oil return line. The separator will filter

the oil concentration in the air to less than 3 parts per million.

16 309663

5.10 Compressor Oil Thermal Valve

The compressor oil thermal valve is a thermostatically controlled by-pass valve that allows varying

amounts of oil, depending upon the temperature, to by-pass the oil cooler. The oil thermal valve directs

oil flow back to the compressor airend until the system reaches 170F. Once at system operating

temperature, the valve shifts, directing the flow through the oil cooler before returning to the compressor

airend.


5.5 Pressure Relief Valve

This valve vents separator tank pressure to atmosphere should the pressure inside the tank exceed 200

PSI.

5.6 Engine Air Filter

The engine air filter is a two stage, dry type intake filter with a gravity evacuator and replaceable internal

element. On the outlet of the engine air filter is an air filter restriction indicator. This indicator serves as

a maintenance tool.

5.7 Compressor Air Filter

The compressor air filter is a two stage, dry type intake filter with a gravity evacuator and replaceable

internal element. On the outlet of the compressor air filter is an air filter restriction indicator. This

indicator serves as a maintenance tool.

5.8 Cooling Systems

I. Engine Radiator

The radiator is designed to dissipate the heat load of the engine and is mounted in front of the

specially selected engine fan. Hot engine coolant is passed through the interior of the radiator and

heat is transferred to the air that passes across the cooling fins.

II. Compressor Oil Cooler

The compressor oil cooler is designed to dissipate the heat created during the compression of air.

The oil cooler is mounted beside the engine radiator. This works similar to the engine radiator but is

designed to withstand the full compressor system working pressure.

5.9 Compressor Oil Filter

The compressor oil filter is a full flow, spin-on canister. It has been specially designed to handle 200

PSI. The oil filter is mounted downstream of the separator tank to ensure all contaminants are pre-

vented from being passed on to the compressor oil cooler.

17 309663


5.12 Minimum Pressure Valve

To ensure there is adequate pressure to produce proper oil flow throughout the system, a spring loaded,

normally closed minimum pressure valve is set to maintain at least 80 PSI in the separator tank.

5.11 Compressor Inlet Valve

The compressor inlet valve is a normally open air intake valve bolted to the compressor airend. When

the system is shut down, this valve also acts as a check valve that prevents the air/oil mixture within the

compressor airend from entering the inlet piping.

5.13 Blowdown Valve

The blowdown valve is a shuttle valve that vents system pressure to atmosphere when the system is shut

down. This is done to prevent the high torque load that would be required to overcome the static

pressure. The blowdown valve is stamped with an I and a P. The I side is connected to dry air

from the separator tank, and the P side is the pilot signal coming from the compressor inlet valve.

5.15 Discharge Pressure Regulator Valve

This valve, located downstream of the separator element, is used to set the desired discharge pressure.

This valve will send a pneumatic signal to the inlet valve to start closing when the pressure exceeds the

setpoint. This signal will also adjust the speed of the engine. This system has a maximum operating

pressure of 160 PSI.

Most air tools operating pressure range is between 90 and 125

PSI. Operating above the tools recommended pressures will

decrease the life of the tool. Strictly adhere to tool operating

pressures and torque standards set forth by the tool

manufacturer.

5.14 Blowdown Switch

The system is equipped with a blowdown switch. This switch will sense pressure in the pilot signal to

the blowdown valve. If the system contains pressure, the switch will prevent the machine from starting.

This will prevent premature damage to the drive coupling.

18 309663


5.16 Instrument Panel

The 250 DUS Air Compressor incorporates an instrument panel that includes numerous gauges and

controls in a single, easy to access location.

I. Engine Oil Pressure Gauge

This feature displays the oil pressure inside the engine block. When the pressure drops below 20

PSI, the system will shut down. During operation, the engine oil pressure should be approximately

60 PSI to 80 PSI.

II. Engine Coolant Temperature Gauge

This feature displays the temperature of the engine coolant. When the temperature reaches 235F,

the system will shut down. During operation, the temperature should be approximately 190F to

210F.

III. Compressor Discharge Pressure Gauge

This feature displays the pressure downstream of the airend.

IV. Compressor Discharge Temperature Gauge

This feature displays the compressor discharge temperature. When the temperature reaches 245F,

the system will shut down. During operation, the discharge temperature should be approximately

170F to 190F.

V. Hourmeter

The hourmeter records the total number of operating hours. It serves as a guide in following the

recommended maintenance schedule. The hourmeter will only run when the engine is operating.

VI. Voltmeter

This feature displays the voltage of the battery. The voltmeter will display when the ignition switch is

in the RUN position. During operation, the voltmeter should be approximately 14 VDC.

VII. Unloader Valve

This turn valve is used to limit the compressor system pressure. When the valve is in the loaded

position, the system will build to the regulator setting. If the valve is set to unloaded, the system will

build to approximately 45 PSI.

VIII. Emergency Stop Switch

The system is equipped with an emergency stop switch to immediately shutdown the machine.

IX. Bypass Switch

The bypass switch will temporarily disable the engine oil pressure shutdown during startup.

X. Ignition Switch

The ignition switch is used for starting and stopping the machine.

19 309663

6.3 Connecting the System Fuel Supply

Connect the fuel supply line to the 1/4 tube port on the starter side of the engine. Connect the fuel

return line to the 5/16 tube port, near the air inlet side of the turbo. Both tubes need to be SAE

30R7 rated fuel lines.

Installation

6.1 System Installation Overview

The 250 DUS Air Compressor should be installed only by those who have been delegated to do so,

trained, and who have read and understand this manual. Failure to follow the instructions, procedures,

and safety precautions in this manual may result in accidents and injuries.

Install, use, and operate this system only in full compliance with all pertinent O.S.H.A., Federal, State,

and Local codes or requirements, in addition to Boss Industries, Inc. and any companys regulations.

Do not modify this system except with written factory approval.

6.2 Placing The Machine

The first step in installing the 250 DUS Air Compressor is placing the system on a solid, level surface.

This machine is designed to run at up to a 15 grade maximum. The machine must be supplied ample

ambient air, as the system will overheat if the cooling air intakes temperature exceeds ambient condi-

tions.

Do not mix gasoline or alcohol with diesel fuel. This mix-

ture can cause an explosion.

Due to the precise tolerances of diesel injection systems, it is

extremely important that the fuel be kept clean and free from

dirt or water. Dirt or water in the system can cause severe

damage to both the injection pump and the injection nozzle.

5/16" TUBEFUEL RETURN

(2) 3/4" MNPT AIRSERVICE VALVE 1/4" TUBE

FUEL SUPPLY

20 309663

6.5 Connecting the Air Discharge Lines

Connect the customer supplied air discharge lines, designed to handle a minimum of 200 PSI continu-

ously, to the two 3/4 MNPT air discharge ports.

6.4 Fuel Specifications

I. High Altitude and Low Temperature Fuels

Fuels with cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient

temperatures to prevent misfires and excessive smoke.

II. Cold Weather Fuel

At operating temperatures below 32 F, use a blend of No. 1D and No. 2D fuels, also known as

Winterized No. 2D.

Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest

excepted fuel temperature. Cloud point is the temperature at which wax crystals begin to form in

diesel fuel.

The viscosity of the fuel must be kept above 1.3 centistoke to provide adequate fuel system lubrica-

tion.

Use ASTM No. 2D fuel with a minimum cetane number of 40.

No. 2 diesel fuel gives the best economy and performance

under most operating conditions. See engine manufactures

operators/instruction manual for the proper engine fuel for the

brand engine in your Boss Industries, Inc. Air Compressor.

Installation

6.6 Pre-Startup Inspection

This inspection must be done prior to initial system startup.

I. Check all assemblies, clamps, fittings, hose connections, nuts, and bolts to ensure they are properly

tied and secured.

II. Remove all tools, rags, and installation equipment from the area.

III. Verify the air discharge valves are closed.

No. 1D fuel can be used; however, fuel economy will suffer.

21 309663

HOURMETER

COOLANT

TEMPERATURE

OIL PRESSURECOMPRESSOR

TEMPERATURE

AIR PRESSURE

VOLTMETER

BYPASS SWITCH

IGNITION

SWITCH

EMERGENCY

STOP SWITCH

6.9 Initial Startup Preparation

I. Reconnect battery terminals. Ensure the red cable is connected to the batterys positive terminal,

and the black cable is connected to the batterys negative terminal.

II. Check the system for fuel, oil, and/or coolant leaks.

6.7 Machine Documentation

Record serial numbers for main components in the system.

I. Machine Serial Number __________________________________________

II. Compressor Airend Serial Number __________________________________________

III. Engine Serial Number __________________________________________

IV. Separator Tank Serial Number __________________________________________

The machine is factory filled prior to shipment. The proper fluid levels are also listed in the maintenance

section.

I. Separator Tank Oil Level = Halfway on the separator tank sightglass.

II. Engine Radiator Coolant Level = Bottom of the radiator fill neck.

III. Engine Coolant Recovery Bottle = Fill to the cold line.

IV. Engine Crankcase Oil Level = Full on the dipstick.

6.8 Check Fluid Levels

Installation

22 309663

6.10 Initial Startup

At this point the system is ready to test functionality. Be sure to have completed all of the previous steps

prior to continuing.

I. Rotate the unloader valve to UNLOAD.

II. Hold the bypass switch and turn the ignition switch to the START position. If engine fails to

start, DO NOT attempt to restart until cranking motor stops rotating and the separator tank has

blown down.

III. When engine starts, release the ignition switch. Once the oil pressure has exceeded 30 PSI

release the bypass switch. Maintain the unloader valve in the UNLOAD position until the

engine is warm and operating smoothly, then rotate the valve to LOAD.

IV. Check system for leaks.

V. Allow system to run until engine coolant temperature reaches 190F.

VI. Check for leaks again.

VII. Verify the engine speed is 1800 RPM.

VIII. Open an air service valve and verify the speed increases to 2400 RPM.

IX. Close the service valve.

X. Rotate the unloader valve to UNLOAD.

XI. Allow engine to idle until the air pressure has dropped below 50 PSI.

XII. Turn the ignition switch to the OFF position.

XIII. Initial startup testing is complete.

InstallationThis machine is equipped with safety unloading system to

prevent damage to the compressor drive coupling. Should an

attempt be made to start this system improperly, the machine

will run unloaded for 60 seconds. Likewise, if an attempt is

made to shutdown the system improperly, the unit will continue

to run until the compressor system pressure unloads below 50

PSI.

In the case of an emergency, this system is equipped with an

emergency shutdown switch. See section 7.2 for operating

instructions.

23 309663

Operation

7.1 Routine Operating Procedures

The 250 DUS Air Compressor should only be operated by those who have been delegated to do so,

trained, and who have read and understand this manual. Failure to follow the instructions, procedures,

and safety precautions in this manual may result in accidents and injuries.

Operate this system only in full compliance with all pertinent O.S.H.A., Federal, State, and Local codes

or requirements, in addition to Boss Industries, Inc. and any companys regulations.

I. Routine Startup Preparation

A. Verify machine is on a level surface. Maximum allowable tilt in any direction is 15.

B. Verify fluid levels and refill if necessary.

C. Check engine air filters indicator, element, clamps, and hoses.

D. Check compressor air filters indicator, element, clamps, and hoses.

E. Check battery cable connections for corrosion.

F. Check the condition of the engine fan belt.

G. Check for fuel, oil, and/or coolant leaks.

II. Routine Startup Procedure

A. Verify the unloader valve is in the UNLOAD position and all service valves are closed.

B. Hold down the bypass switch and turn the ignition switch to START.

C. When engine starts, release the ignition switch and continue holding bypass switch until the oil

pressure has exceeded 30PSI

D. Leave the unloader valve in the UNLOAD position for a minimum of 60 seconds and until the

engine temperature has reached 160F.

E. Turn the unloader valve to the LOAD position.

F. Check for leaks again.

G. Open service valves for air usage.

III. Routine Shutdown Procedure

A. Close all service valves.

B. Rotate the unloader turn valve to UNLOAD.

C. Allow engine to idle until the air pressure has dropped below 50 PSI.

D. Turn the ignition switch to the OFF position.

Shutting down the machine under load will damage the engine,

drive coupling, and/or the airend. Follow normal shutdown

procedure at all times.

24 309663

Operation

7.2 Emergency Shutdown Procedure

In the event of an emergency and the 250 DUS Air Compressor must be stopped suddenly without first

unloading the compressor, the machine is equipped with an emergency shutdown switch. Do not shut

the machine off loaded except in an emergency situation. Do not operate this machine again until the

problem has been properly resolved.

I. Emergency Shutdown Procedure

A. Flip up the red emergency stop switch cover on the instrument panel.

B. Flip the toggle switch up to immediately shutdown the machine.

C. Once the machine has stopped, flip the shutdown switch and cover back down.

D. Fix the problem that required the emergency shutdown.

E. Remove the side panel and replace the 20 amp fuse on the rear of the instrument panel.

Shutting down the machine under load will damage the engine,

drive coupling, and/or the airend. Follow normal shutdown

procedure at all times.

25 309663

Maintenance

This section contains instructions for performing the inspection, lubrication, and maintenance procedures

required to ensure the system is in proper operating condition. The importance of performing the

maintenance described herein cannot be over emphasized. A planned program of periodic inspection

and maintenance will help avoid premature failure and costly repairs. Keep an accurate logbook for

maintenance, service, and operating hours. The maintenance schedule intervals on this system are

maximum intervals. The factory recommended maintenance schedule is based on favorable operating

conditions. For continuous duty, extreme temperature, etc., service more frequently. Neglecting routine

maintenance can result in machine failure or permanent damage.

This system should be maintained only by those who have been delegated to do so, trained, and who

have read and understand this manual. Failure to follow the instructions, procedures, and safety

precautions in this manual may result in accidents and injuries.

8.1 Maintenance Overview

8.2 Maintenance Schedule

INTERVAL REQUIRED MAINTENANCE

1. Check separator tank oil level.

2. Check engine coolant level in coolant recovery bottle.

3. Check engine air filter maintenance indicator.

4. Check for fuel, oil, air, and coolant leaks.

5. Check compressor air filter maintenance indicator.

6. Check battery hold down for security.

1. Drain water from separator tank. More frequent draining may be required

under high humidity conditions.

2. Inspect lifting frame.

1. Change compressor oil and oil filter element.

2. Clean battery terminals.

3. Check battery hold-down and cables for wear.

4. Check engine air filter connections, fittings, and clamps.

5. Check compressor air filter connections, fittings, and clamps.

6. Check radiator hoses and clamps.

7. Check integrity of engine mounts.

1. Install new air filter elements. (compressor and engine)

2. Check all door gaskets, hinges, and latches.

3. Clean and flush engine cooling system

4. Check separator tank pressure relief valve.

5. Clean cooler fins on all coolers.

6. Install new fuel filter and water separator elements.

EVERY 10

HOURS OR

DAILY

EVERY 50

HOURS OR

WEEKLY

EVERY 500

HOURS OR 6

MONTHS

EVERY 1000

HOURS OR 1

YEAR

26 309663

Maintenance

REBMUNTIK REBMUNTRAP NOITPIRCSED

77208

39082-421 retliFliOrosserpmoC

86219-421 tnemelErotarapeS

014903 tnemelEretliFriAenignE

014903 tnemelEretliFriArosserpmoC

890703 tiKriapeRlaeStfahSG31ACS

Phone: (800) 635-6587 (USA)


Fax: (877) 254-4249 (USA)



8.3 Recommended Spare Parts List

8.4 Parts and Service Contact Information

Check engines operator manual for required service and

maintenance intervals.

Compressor oil and oil filter is to be changed after the first 50

hours of operation. After this, normal intervals are to be

followed.

27 309663

8.5 Maintenance Log

Maintenance

Accum.

Hours Date Service Performed Parts Replaced Service Work By

28 309663

Maintenance

When the oil vapor in the discharge air becomes excessive, the separator element may need replacing.

This should not be necessary more than once a year under normal operating conditions.

I. Replacement Procedure.

A. Shut down machine and allow to cool for approximately 10 minutes.

B. Verify entire system pressure is relieved before proceeding.

8.6 Separator Element Replacement

C. Disconnect the 1 hose from the minimum pressure valve.

D. Disconnect the 1/4 tube from the elbow on the separator tank lid.

E. Disconnect the 1/4 tube from the elbow on the discharge pressure regulator valve.

F. Disconnect the 1/4 tube from the elbow on the blowdown valve.

G. Disconnect the 1/4 tube from the straight connector on the oil return line.

H. Remove the eight 5/8 bolts holding the separator tank lid in place.

I. Lift and remove the lid from the package.

J. Remove the separator element.

K. Install a new element.

L. Reinstall the separator tank lid.

M. Reinstall the eight 5/8 bolts.

N. Uniformly tighten the bolts in a crisscross pattern to a torque of 220ft-lb.

O. Reconnect hose and tubes and ensure they are correctly located and tightened properly.

P. Start machine and check for any leaks.

Substitute filters may have inadequate working pressure

limits, resulting in filter leakage or rupture. Replacement

filters must be the same quality and type as the original Boss

Industries, Inc. separator element.

When disconnecting hose and tube, be sure to note the

location to ensure there is no confusion when

reconnecting.

Note the location of the separator tank lid so that it can

be reinstalled in the same orientation.

The separator element flange must have a gasket on each side

to seal the lid on one side and the vessel on the other. The

staple in each gasket acts as a static ground and must not be

removed.

The separator tank lid has a pick-up tube installed and

damaging or moving the tube will affect the machines.

29 309663

Maintenance

V. Prior to cleaning an element, check the element for damage. Damaged air filter elements must be

replaced.

A. Place a bright light inside the element to inspect for damages or leaks.

B. Inspect all seals and seal contact surfaces on the housing. Should faulty seals be evident, correct

the condition immediately.

VI. If element is undamaged, clean the air filter element.

A. The maximum number of times that an element should be cleaned is twice; however, the element

should be used no longer than a period of 1 year without changing.

C. If the cleaned element is to be stored for later use, it must be stored in a clean container.

VII. Install the air filter element.

VIII. Install the rear cover and tighten clamp.

IX. Reset the air filter restriction indicator and the machine will be ready for operation.

B. When cleaning the element with compressed air, never let the air pressure exceed 30 PSI.

Reverse flush the element by directing the compressed air up and down the pleats in the filter

media from the inside of the element. Continue reverse flushing until all dust is removed. Should

any oil or greasy dirt remain on the filter surface, the element should be replaced.

Do not strike the element against any hard surfaces for clean-

ing as it may possibly rupture the element. Do not oil element.

When cleaning an element, the element will be damaged if you

exceed the recommended maximum air pressure of 30 PSI.

I. Loosen the clamps that secure the engine air filters rear cover to the filter housing.

II. Remove and clean the rear cover.

III. Remove the air filter element.

IV. Clean the canister with a damp cloth inside and out. DO NOT blow dirt out with compressed air.

Never blow dirt out of the interior of the filter housing. This

may introduce dust downstream of the filter. Instead, use a

clean damp cloth.

8.7 Engine Air Filter Replacement

30 309663

8.8 Compressor Air Filter Replacement

Maintenance

V. Prior to cleaning an element, check the element for damage. Damaged air filter elements must be

replaced.

A. Place a bright light inside the element to inspect for damages or leaks.

B. Inspect all seals and seal contact surfaces on the housing. Should faulty seals be evident, correct

the condition immediately.

VI. If element is undamaged, clean the air filter element.

A. The maximum number of times that an element should be cleaned is twice; however, the element

should be used no longer than a period of 1 year without changing.

C. If the cleaned element is to be stored for later use, it must be stored in a clean container.

VII. Install the air filter element.

VIII. Install the rear cover and tighten clamps. Install rubber evacuator cup facing down.

IX. Reset the air filter restriction indicator and the machine will be ready for operation.

B. When cleaning the element with compressed air, never let the air pressure exceed 30 PSI.

Reverse flush the element by directing the compressed air up and down the pleats in the filter

media from the inside of the element. Continue reverse flushing until all dust is removed. Should

any oil or greasy dirt remain on the filter surface, the element should be replaced.

Do not strike the element against any hard surfaces for clean-

ing as it may possibly rupture the element. Do not oil element.

When cleaning an element, the element will be damaged if you

exceed the recommended maximum air pressure of 30 PSI.

I. Loosen the wing nut that secures the compressor air filters cover to the filter housing.

II. Remove and clean the cover.

III. Remove the air filter element.

IV. Clean the canister with a damp cloth inside and out. DO NOT blow dirt out with compressed air.

Never blow dirt out of the interior of the filter housing. This

may introduce dust downstream of the filter. Instead, use a

clean damp cloth.

31 309663

Maintenance

8.9 Compressor Oil

The following are general characteristics for a rotary screw lubricant. 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 if they choose not

to use the recommended Boss Industries, Inc. rotary screw lubricant. The lubricant suppliers

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.

Boss Recommended Compressor Lubricant: DEXRON III ATF

I. Specifications

1. Flash point 400F minimum.

2. Pour point -40F.

3. Contains rust and corrosion inhibitors.

4. Contains foam suppressors.

5. Contains oxidation stabilizer.

It is important that the compressor oil be of a recommended

type, and inspected and replaced as started in this manual.

The combination of a separator element loaded with dirt

and oxidized oil products together with increased air veloc-

ity as a result of this clogged conditions may produce a

critical point while the machine is in operation where igni-

tion can take place and could cause a fire in the separator

tank.

Mixing different types or brands of lubricants is not recom-

mended due to the possibility of a dilution of the additives

or a reaction between additives or different types.

Due to environmental factors, the useful life of all ex-

tended life lubricants may be shorter than quoted by the

lubricant supplier. Boss Industries, Inc. encourages the

user to closely monitor the lubricant condition and to par-

ticipate in an oil analysis program with the supplier.

No lubricant, however good and/or expensive, can replace

proper maintenance and attention. Select and use it wisely.

32 309663

Maintenance

F. Replace fill cap and tighten immediately.

III. Changing Compressor Oil

Initially the compressor oil and oil filter should be replaced after the first 50 hours of operation then

every 500 hours or 6 months. If the oil appears dirty or has a foul smell, it should be replaced

immediately.

A. Verify the machine is level to ensure oil level sightglass will be accurate.

B. Remove any dirt around the separator tank fill cap to prevent contamination from entering the

system.

C. Remove the separator tank fill cap.

D. Inspect and clean the fill cap. Replace if necessary.

E. Drain oil from the bottom of the separator tank.

F. If compressor oil filter change is required, proceed to section 8.11, Compressor Oil Filter.

Do not remove caps, plugs, or other components when the

system is running or pressurized. Stop system and relieve all

internal pressure before doing so. Failure to comply with this

warning will cause damage to property and serious bodily

harm.

8.9 Compressor Oil (continued)

C. Remove the separator tank fill cap.

D. Inspect and clean the fill cap. Replace if necessary.

E. Dexron III ATF can then be added until the oil level reaches halfway in the sightglass. Do not

over fill the separator tank. This will cause oil carryover in the discharge line and at blowdown.

Do not replace fill cap with a pipe cap; serious injury or dam-

age could result. Replacement filters must be the same

quality and type as the original Boss Industries, Inc. fill cap.

II. Adding Compressor Oil

A. Verify the machine is level to ensure oil level in sightglass will be accurate.

B. Remove any dirt around the separator tank fill cap to prevent contamination from entering the

system.

Do not remove caps, plugs, or other components when the

system is running or pressurized. Stop system and relieve

all internal pressure before doing so. Failure to comply

with this warning will cause damage to property and serious

bodily harm.

33 309663

Maintenance

Initially the filter should be replaced after the first 50 hours of operation, then every 500 hours or 6

months. A dirty filter can restrict oil flow, causing high oil temperature, which will result in a system

shutdown.

I. Compressor Oil Filter Replacement

A. Verify the compressor oil system is drained.

B. Using a strap wrench, remove the oil filter and o-ring.

C. Clean o-ring seating surface on the oil filter head.

D. Apply a light film of oil to the new o-ring.

E. Hand tighten new filter until o-ring is seated in o-ring groove.

F. Continue tightening filter by hand an additional 1/2 to 3/4 turn.

G. Continue with Changing the Compressor Oil steps.

8.11 Compressor Oil Filter

Substitute filters may have inadequate working pressure

limits, resulting in filter leakage or rupture. Replacement

filters must be the same quality and type as the original Boss

Industries, Inc. oil filter.

Mechanical over-tightening may distort the threads or damage

the filter element seal.

H. Replace fill cap and tighten immediately.

I. Run system briefly to see if more oil needs to be added and to ensure there are no leaks.

Do not replace fill cap with a pipe cap; serious injury or dam-

age could result. Replacement filters must be the same

quality and type as the original Boss Industries, Inc. fill cap.

8.10 Compressor Oil Cooler

Any sign of leakage from the compressor oil cooler justifies a pressure test to ensure its integrity.

Cooler leaks should only be repaired by qualified service technicians. Dirt that clogs the cooling fins of

the cooler should be removed. The use of an air stream or high-pressure steam cleaner should be done

with caution so as to not damage the delicate fins. Bent cooling fins will reduce the cooling capability of

the compressor oil cooler.

8.9 Compressor Oil (continued)

III. Changing Compressor Oil (continued)

G. Dexron III ATF can now be added until the oil level reaches halfway in the sightglass. Do not

over fill the separator tank. This will cause oil carryover in the discharge line and at blowdown.

34 309663

Maintenance

Check the coolant level only when the engine is stopped and

the temperature is below 160 F. Failure to do so can cause

personal injury from heated coolant spray.

The 250 DUS Air Compressors engine has a pressurized cooling system that contains a 50/50 mixture

of water and ethylene glycol. Maintenance of the system includes the engine coolant, belt tension, fan

integrity, and radiator. Further cooling system maintenance is defined in the engine manual.

I. Engine Coolant

A. Specifications

This diesel engine requires a balanced coolant mixture of water and ethylene glycol base

antifreeze. This protects the engine cooling system from corrosion as well as freezing damage.

The 250 DUS Air Compressor is shipped from the factory with a 50/50 mixture of water and

ethylene glycol. In tropical climates where freeze protection is not required, glycol engine

coolant should still be used to help prevent corrosion and pitting of cylinder liners.

B. Mixtures

Antifreeze concentration level should not exceed recommended levels. To do so can cause

cooling system failure.

1. A mixture of 50% antifreeze and 50% water is required for temperatures above -34 F.

2. A mixture of 60% antifreeze and 40% water is required for temperatures below -34 F.

This provides protection to -65 F.

3. Never exceed a 60% overall antifreeze mix.

C. Coolant Level

Before each start-up, when radiator is cold, the coolant level should be checked. When

needed, refill with a 50/50 solution of water and ethylene glycol, DO NOT use 100% anti-

freeze. The proper level for coolant in the system is to the bottom of the radiator fill neck and to

the cold line of the recovery bottle.

8.12 Engine Cooling System Maintenance

II. Engine Radiator

A. Radiator Core

Any sign of leakage from the engine radiator may justify a pressure test to assure its integrity.

Radiator leaks should only be repaired by qualified service technicians. Dirt that clogs the

cooling fins of the radiator should be removed. The use of an air stream or high-pressure steam

cleaner should be done with caution so as to not damage the delicate fins. Bent cooling fins will

reduce the cooling capability of the radiator.

35 309663

The battery supplied with the 250 DUS Air Compressor has been selected to have ample cold cranking

amperes for quick starts in cold weather. Keep the battery fully charged and if replacement is necessary

the new battery must be of equal or greater capacity.

Battery gas can explode causing acid burn to skin and blind-

ness. Do not overcharge or jump the battery incorrectly.

8.13 Battery

Never use the fan to rotate the engine. The blade(s) can be

damaged causing a fan failure, which can result in personal

injury or property damage.

IV. Engine Serpentine Belt

Visually inspect the engine serpentine belt. Replace belt if cracked or frayed. Check engine manual

for proper belt tension.

II. Engine Radiator (continued)

B. Radiator Pressure Cap

If coolant continually spills from radiator through the overflow, the radiator cap should be tested

and/or replaced with a 13 PSI rated cap. Be sure cap is tightened to the proper secure position.

III. Engine Fan

Check the engine fan for cracks, loose bolts, and bent or damaged blades. Replace damaged fans

immediately. Do not run system if any of the conditions exist. Make sure the hex head bolts

mounting the fan to the water pump pulley are properly torqued to 29 ft-lbs.

8.12 Engine Cooling System Maintenance (continued)

Maintenance

8.14 Standby Pressure Adjustment (For 100 PSI system)A. Close all service valves.

B. Start the machine.

C. Allow the engine to warm up.

D. The air pressure will build to 120 PSIG.

E. If the air pressure is less than 120 PSIG.

1. Adjust the discharge pressure regulator up by loosening the locknut.

2. Turn the adjusting screw clockwise.

F. If the air pressure is greater than 120 PSIG.

1. Adjust the discharge pressure regulator up by loosening the locknut.

2. Turn the adjusting screw counter-clockwise.

G. After the air pressure is set, tighten the locknut.

36 309663

MaintenanceIf your unit is rated at a higher pressure, add 20 PSI to the

working pressure for unload pressure: 160 PSI working = 180

PSI standby.

8.15 Idle Speed Adjustment

If engine speed is below 1800 RPM, contact Boss Industries, Inc.s service department for further

assistance.

8.16 Rated Speed Adjustment

I. Rotate the unloader valve to UNLOAD.

II. Turn the ignition switch to the START position. If engine fails to start, DO NOT attempt to

restart until cranking motor stops rotating and the separator tank has blown down.

III. When engine starts, release the ignition switch. Maintain the unloader valve in the UNLOAD

position until the engine is warm and operating smoothly, then rotate the valve to LOAD.

IV. Allow system to run until engine coolant temperature reaches 190F.

V. Open the air service valve until the discharge pressure gauge reads the desired working pressure.

Verify that air is not bleeding out of the bottom of the discharge pressure regulator. If air is bleed-

ing out, the standby pressure is set too high. Follow the steps in section 8.14 for reducing the

standby pressure.

VI. Loosen the adjustment locknut on the adjustment screw towards the front of the engine.

VII. Turn the adjustment screw clockwise to increase the speed.

VIII. Turn the adjustment screw counter-clockwise to decrease the speed.

IX. If the proper speed cannot be obtained with the adjustment screw, it may require loosening the

locknut on the air cylinder shaft and adjusting the clevis.

X. By turning the clevis onto the shaft, the engine speed will increase.

XI. By turning the clevis out, the engine speed will decrease.

XII. After proper speed is set, tighten all locknuts.

XIII. Close service valve and allow compressor to unload and the engine to return to idle.

DISCHARGE PRESSURE

REGULATOR BLEED HOLEAdjustment

Screw

Clevis

Locknut

Air Cylinder

Adjustment

Locknut

37 309663

Troubleshooting

9.1 Troubleshooting Chart

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38 309663

Troubleshooting

9.1 Troubleshooting Chart (continued)


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39 309663

Troubleshooting



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40 309663

Troubleshooting


9.2 Parts and Service Contact Information

When calling for technical support, please have machine

serial number and this manual available.

Phone: (800) 635-6587 (USA)


Fax: (877) 254-4249 (USA)




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41 309663

WARRANTYWarranty

10.1 Warranty Policy

BOSS INDUSTRIES, INC.

1761 GENESIS DRIVE

LAPORTE, IN 46350

(219) 324-7776 Phone

(219) 324-7470 Fax

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 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. BOSSs sole responsibility and

Buyers 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

replacement parts not of BOSS manufacture or approved by BOSS or from Buyers 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.

42 309663

As claims, policies and procedures are governed by the terms of the BOSS Industries, Inc. (BOSS)

warranty, it is necessary to outline some of the more important provisions.

The BOSS warranty applies only to new and unused products, which, after shipment from the factory,

have not been altered, changed, repaired or mistreated in any manner whatsoever. Normal maintenance

items such as lubricants and filters are not warrantable items.

Parts not of BOSS manufacture are warranted only to the extent they are warranted by the original

manufacturer.

Damage resulting from abuse, neglect, misapplication or overloading of a machine, accessory or part is

not covered under warranty.

Deterioration or wear occasioned by chemical and/or abrasive action or excessive heat shall not

constitute defects.

Parts replacement and/or correction of defective workmanship will normally be handled by BOSS

Industries, Inc. or their authorized distributor.

Failure to file a detailed warranty claim/service report for each occurrence of material defect of

defective workmanship will cause warranty claim to be rejected.

Defective material must be returned within 30 days of receipt of shipping instructions. Failure to do so

within specified time will result in forfeiture of claim.

The distributor is responsible for the initial investigation and write up of the warranty claim.

Distributor shall be allowed no more than 30 days from date of repair to file a warranty claim/service

report.

Warranty for failure of BOSS replacement parts covers the net cost of the part only, not labor and

mileage.

The BOSS warranty does not cover diagnostic calls and travel. That is time spent traveling to the

machine to analyze the problem and returning with the proper tools and parts to correct the problem.

Boss will deduct from allowable credits for excess freight caused by sender failing to follow return

shipping instructions.

Distributors or end-user automatically deducting the value of a warranty claim from outstanding balances

due and payable to BOSS prior to receiving written notification of BOSS approval of the warranty

claim may be subject to forfeiture of the entire claim.

Warranty

10.2 Summary of Main Warranty Provisions

43 309663

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

[email protected]. You may also send a fax at 219.324.7470.

Warranty

10.3 Warranty/Return Goods Instructions

10.4 Warranty Claims - Preparation of Parts Return

Parts returned to the factory must be properly packaged to prevent damage during shipment. Damage to

a part as a result of improper handling or packing could be cause for denial. When addressing the package

for shipment, the following information must be on the outside of, or tagged clearly, to the package.

1. Return Goods Authorization #.

2. Distributor or end-users return address.

3. Correct factory address.

4. 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. Unauthorized Returns Will Immediately

Be Refused At Dock.

10.5 Return or Warranty Claims - Filing Procedures

1. Initiate through a purchase order for warranty part or request for credit.

2. 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.

44 309663

An approved claim depends on the following provision:

1. An RGA # must be issued by BOSS INDUSTRIES. (See filing procedures.)

2. Failed part must be returned within 30 days of original invoice date, freight prepaid, with RGA #.

3. Part is determined to be defective.

4. Workmanship is determined to be defective.

5. Machine is within warranty period.

6. Machine has been operated within design conditions.

Claims made through distributors must be verified by distributor prior to contacting BOSS INDUSTRIES.

Warranty

10.6 Warranty Claims Provisions

10.7 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 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 carriers 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 carriers agent. Failure to adequately describe such external evidence of loss, or damage

may result in the carrier refusing to honor a damage claim. The carrier will supply the form required to

file such a claim.

45 309663

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.

Warranty

10.8 Screw Compressor Airend Exchange Program

46 309663

Parts and Illustration Section

11.1 Frame System

Parts List

ITEM QTY PART NUMBER DESCRIPTION

1 49 991204-165 INSERT

2 1 124-28093 FILTER

3 1 300599 HEAD

4 2 960212-075 ELBOW5 15 938604-071 WASHER6 7 938004-062 WASHER7 8 929104-100 BOLT

8 1 901515-030 ELBOW

9 1 960412-075 NIPPLE

10 1 922112-020 NIPPLE

11 1 309632 FRAME

12 1 306042 BRACKET

13 1 301662 VALVE14 1 120-14966 BRACKET15 2 120-26804 BOLT16 1 123-66019 BATTERY

17 1 960216-100 ELBOW

18 1 922116-040 NIPPLE

19 1 125-18146 VALVE

20 2 929104-075 BOLT21 1 150-90199 TANK

22 3 924304-145 NUT

23 3 301755-012 RELAY

24 1 961812-075 TEE

25 6 991205-150 INSERT26 1 309408 FILTER

27 1 309414 BAND

28 1 309415 INDICATOR31 2 929705-125 BOLT32 2 925305-283 NUT

47 309663

11.1 Frame System (continued)


11

16

4

24

25

25

1

5

4

12

8

13

6

20

5

21

1

96

57

22

23

19 18

17

2

3

10

765

14

15

5

7

26

28

27

FLOWDIRECTION A

BC

1

5 6

7

31

32

5

48 309663

11.2 Engine System


Parts List


1 1 309357 ENGINE

2 1 303150 SWITCH

3 1 308436 SENDER

4 1 902415-005 TEE

5 2 929808-125 BOLT

6 1 924404-145 NUT

7 2 150-90673 MOUNT

8 2 302764 ISOLATOR

9 4 120-16832 WASHER

10 2 925508-262 NUT

11 1 154-90975 COUPLING

12 2 938208-112 WASHER

13 1 120-36345 CYLINDER

14 1 158-36347 BRACKET

15 9 938812-250 WASHER

16 4 938808-200 WASHER

17 1 307333 FAN

18 6 929104-075 BOLT

19 4 938206-071 WASHER

20 4 925506-198 NUT

21 1 150-90665 MOUNT

22 1 150-90729 MOUNT

23 8 937806-094 WASHER

24 1 922102-015 NIPPLE

25 1 120-19071 BALL JOINT

26 4 929216-350 BOLT

Parts List


27 8 929212-300 BOLT

28 1 980704-012M ELBOW

29 1 924604-164 NUT

30 2 937808-125 WASHER

31 4 938816-350 WASHER

32 10 938604-071 WASHER

33 1 307055 BRACKET

34 8 929806-100 BOLT

35 1 301834 SWITCH

36 4 929806-125 BOLT

37 2 306030 ISOLATOR

38 6 924304-145 NUT

39 2 929808-300 BOLT

40 1 980100-400 CLAMP

42 2 307489 BRACKET

43 2 307490 SOLENOID

44 1 929212-250 BOLT

45 1 938912-200 WASHER

46 1 308463 SENDER

47 1 309001 ADAPTER

48 1 960112-050 CONNECTOR

49 4 938908-180 WASHER

50 4 929208-750 BOLT

51 2 120-36874 SPACER

52 1 303582 REDUCER

49 309663

11.2 Engine System (continued)


3423

2

11

40

7

165

30

9

31

26

22

36

37

19

20

465

30

9

21

38

32

33

14

18

13

6

25

28

29

35

4

1012

8

7

27

15

9

393

24

47

48

17

50

1

49

51

52

8 12

10

38

39927

15

3243

18

32

44

15

45

42

42

32

18

50 309663

11.3 Compressor System


Parts List


1 1 304936 BUSHING

2 1 303104 SWITCH3 19 938810-220 WASHER4 1 970804-025 ADAPTER

5 1 973112-075 CONNECTOR6 1 902915-020 PLUG7 1 303290-219 AIREND

8 1 980804-025 TEE

9 3 928016-500 BOLT

10 1 926102-234 O-RING

11 1 305878 FLANGE12 4 929216-100 BOLT13 3 938916-225 WASHER

14 8 938816-350 WASHER15 1 304720 VALVE

16 12 929210-400 BOLT

17 1 960224-150 ELBOW

18 1 308463 SENDER

19 1 964804-025 TEE20 1 301421 SWITCH

21 1 307682 VALVE

22 1 300112 CLAMP

23 1 301594 DECAL

24 1 308964 ADAPTER

25 1 929316-300 BOLT

26 1 922204-040 NIPPLE27 4 929212-300 BOLT28 4 938912-200 WASHER

29 4 938812-250 WASHER

30 1 304933 ADAPTER

31 7 929210-300 BOLT32 1 310076 GASKET

33 1 300036 VALVE

34 1 980704-012 ELBOW

35 1 926102-238 O-RING36 1 987304-025 ELBOW

51 309663

11.3 Compressor System (continued)


30

21

15

2

17

16

11

6

14

18

10

5

23

4

7

12

1

3

22

3

1314

9

1425

24

2729

28

29

27

20

26

819

21

AIRFLOW

31

35

343336

52 309663

11.4 Discharge System


Parts List


1 1 308087 VALVE

2 1 922220-000 NIPPLE

3 1 300023-175 RELIEF

4 1 960116-100 CONNECTOR

5 1 907605-040 BUSHING

6 1 901115-020 ELBOW

7 1 901515-040 ELBOW

8 1 960404-025 NIPPLE

9 1 980804-025 TEE

10 1 300057 VALVE

11 1 301827 VALVE

12 2 980704-025 ELBOW

13 1 902915-010M PLUG

14 1 922116-040 NIPPLE

15 1 922104-050 NIPPLE

16 1 902915-005 PLUG

17 3 938208-112 WASHER

18 1 977604-025 ELBOW

19 1 303192 TANK

20 1 902915-010 PLUG

21 1 960320-150 ELBOW

22 1 960112-100 CONNECTOR

23 3 964804-025 TEE

24 1 902915-060 PLUG

25 1 988204-025 CONNECTOR

26 3 929808-125 BOLT

27 3 937808-125 WASHER

28 1 987204-025 CONNECTOR

29 1 922224-000 NIPPLE

30 1 300107 SIGHTGLASS

31 1 960124-150 CONNECTOR

32 1 301466-150 CAP

33 1 960624-150 TEE

34 1 304210 TUBE

35 6 938206-071 WASHER

36 6 925506-198 NUT

37 3 305891 SPACER

38 6 929806-200 BOLT

39 6 938205-071 WASHER

40 1 308461 SENDER

41 2 907600-005 BUSHING

42 1 987304-025 ELBOW

43 1 988204-025M CONNECTOR

44 1 960212-075 ELBOW

45 1 307683 SWITCH

53 309663

11.4 Discharge System (continued)


22

26

24

35

6

45

41

20

28

42

8

13

23 32

30

31

34

25

43

15

9

10

12

11

23

234

5

1

16

12

3

19

2

40

714

18

41

3329

21

27

1744

38

39

37

36

I P

54 309663

11.5 Cooling System


Parts List


1 1 309283 COOLER ASSY

2 1 309303 SHROUD

3 10 938004-062 WASHER

4 14 938604-071 WASHER5 1 902915-010 PLUG6 6 929105-100 BOLT7 6 938205-071 WASHER

8 6 938005-078 WASHER

9 10 929104-075 BOLT

10 1 960212-100 ELBOW

11 2 309307 GUARD12 2 924304-145 NUT

13 2 929104-100 BOLT14 1 907604-030 BUSHING15 1 960012-075 ELBOW

55 309663

11.5 Cooling System (continued)


15

14

9

3

4

11

11

13

4

4

12

9

34

10

26

8

75

1

56 309663

11.6 Electrical System


Parts List


1 3 924304-145 NUT

2 5 943103-025 RIVET

3 1 120-16580 SPRING

4 4 938604-071 WASHER

5 1 109-9024

Service and Maintenance 250 DUS JD4045 Manual IT4 74HP Air ...bossair.com/Manuals/309663 MANUAL, 250...

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