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Boss 8060 UBI Operator's Manual

Pto air compressor
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Operator
BOSS 8060 UBI
Manual
PTO Air Compressor
This manual is for operator and maintenance personnel only.
This manual must be read carefully BEFORE installing, operating, servicing and/or
maintaining your Boss Industries Air Compressor.
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)
309743
service@bossair.com (email)
KWB
http://www.bossair.com (website)
11-13-2014

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Summary of Contents for Boss 8060 UBI

  • Page 1 PTO Air Compressor This manual is for operator and maintenance personnel only. This manual must be read carefully BEFORE installing, operating, servicing and/or maintaining your Boss Industries Air Compressor. Store in a safe and convenient location for future reference. For technical support:...
  • Page 2 309743...

  • Page 3: Table Of Contents

    Table of Contents Safety ........................5-12 Safety Disclaimer ..........................6 Safety Overview ..........................6 Safety Warnings ........................7-11 Welcome ......................13-14 General Information ..........................14 System Overview ..........................14 System Specifications ........................14 Description of Components ................15-18 Subsystems ..........................16-18 Compressor Assembly ......................16 Sump Tank Assembly ......................16 Air Oil Manifold ........................17 Cooler Assembly ........................18 Air Filter Assembly .......................18 B-CAN Assembly and Harnesses ..................18...
  • Page 4 Table of Contents Maintenance ......................33-38 Overview ............................34 Recommended Spare Parts List ......................34 How to Locate a Distributor ......................34 Maintenance Schedule ........................35 Compressor Lubrication Recommendation ..................36 Proper Compressor Oil Level ......................37 Draining Moisture from the System ....................37 Warranty ......................39-44 Warranty Statement ...........................40 Summary of Main Warranty Provisions ....................41 Warranty/Return Goods Instructions ....................42 Warranty Claims - Preparation of Part Return ..................42...

  • Page 5: Safety

    Safety Safety 309743...

  • Page 6: Safety Disclaimer

    Safety Safety Disclaimer The owner, lessor, and/or operator of the Boss Industries, Inc. 8060 UBI PTO compressor system are hereby notified and forewarned that any failure to adhere to the following safety precautions may result in property damage and/or personal injury or death.

  • Page 7: Safety Warnings

    Safety Safety Warnings The following safety warnings and precautions must be observed at all times for the Boss 8060 UBI PTO compressor system: Fully read and understand this manual and all other associated documents before installing, operating, maintaining, and/or servicing this equipment. Failure to comply could result in personal injury or death and/or damage to equipment and property.
  • Page 8 Safety Safety Warnings (cont.) Do not install a shut-off valve in any oil lines throughout the Boss 8060 UBI PTO compressor system. Failure to comply will result in serious injury, death, and/or damage to equipment. Prior to every use check all safety devices for proper operation.
  • Page 9 Use only Boss Industries, Inc. approved replacement parts. Not all components have the same specifications. Only Boss approved replacement parts are safe to use when servicing a Boss 8060 UBI PTO compressor system. Failure to comply could result in personal injury or death and/or damage to equipment and property.
  • Page 10 Read the operators manual before starting this unit. Failure to adhere to instructions can result in severe personal injury. Replacement manuals can be purchased from Boss Industries, Inc. The B-CAN is not a touch screen unit. To operate, use the buttons below the screen.
  • Page 11 The Boss 8060 UBI PTO compressor system requires an adequate flow of cooling air for its continued operation. Never operate the unit inside any room or enclosure where the free flow of cooling air into and out of the unit might be obstructed.
  • Page 12 Safety 309743...

  • Page 13: Welcome

    Welcome Welcome 309743...

  • Page 14: General Information

    This manual is for operator and maintenance personnel only. and maximize the life of the compressor system. While this manual is written to be as accurate as possible, Boss strives to continu- ally improve the efficiency and performance of its products. As a result, sometimes there may be slight differences between a given version of the manual and the system.

  • Page 15: Description Of Components

    Description of Components Description of Components 309743...

  • Page 16: Subsystems

    Subsystems The Boss 8060 UBI PTO air compressor system is a group of subsystems that are shipped loose to be mounted in open spaces on the vehicle’s frame and body. The subsystems are connected using hoses and tubing that are also shipped in the kit.

  • Page 17: Air Oil Manifold

    • Minimum Pressure Orifice The spin-on coalescer is the second and final stage of oil separation in the Boss 8060 UBI PTO compressor system. As the oil laden air passes through the filter media, oil gathers on the walls and collects at the bottom of the element.

  • Page 18: Cooler Assembly

    Air Filter Assembly The air filter assembly is the entrance for ambient air to the Boss 8060 UBI PTO compressor system. Air is drawn through this assembly and into the intake valve on the compressor assembly. The air filter assembly is a two stage system that is capable of handling medium to high dust environ- ments.

  • Page 19: Operation

    Operation Operation 309743...

  • Page 20: Compressor General Overview

    Compressor General Overview Operation of the 8060 UBI PTO compressor system should only be performed by trained operators. Carefully read the entire Operation section of this manual before attempting to operate the system. Be sure to follow all company policies and procedures.

  • Page 21: Inspection Prior To Moving Vehicle

    Job Site Considerations When using the compressor all company policies and procedures should be followed along with all Boss Industries, Inc. safety procedures. The following are guidelines that should be followed when choosing the best location for running the compressor.

  • Page 22: Stopping The Compressor System

    Operation Stopping the Compressor System The following steps are for the routine shutdown of the 8060 UBI PTO compressor system. This process is in addition to any company policies and procedures. 1. Ensure all service valves are closed. 2. Press the red STOP COMPR button and the compressor system will disengage.

  • Page 23: Shutdowns

    Operation Shutdowns There are two compressor parameters that are constantly being monitored and are logged in an event history. If the compressor system reaches a point outside of the monitored parameters, the compressor will shutdown. The two compressor shutdowns are: •...

  • Page 24: System Safeties

    Operation System Safeties Numerous safeties must be met before and during system operation. If you are unable to satisfy all necessary safeties by performing the suggested fix, the vehicle should be taken in for service. The following 2 charts list these safeties with a description of what is wrong and possible ways to fix them.
  • Page 25 Operation System Safeties (cont.) t a r t l u . y l c i l t l u . y l c i l t l u . y l t a r . r o 309743...
  • Page 26 Operation 309743...

  • Page 27: B-Can

    B-CAN B-CAN 309743...

  • Page 28: B-Can Overview

    B-CAN Basic Display The Boss B-CAN is designed to emulate the analog gauge systems of the past while improving the ease of operation. The B-CAN provides only the information required for the operator to use the unit. Whenever the vehicle is running, the B-CAN system is active.

  • Page 29: Hour Meter

    B-CAN B-CAN Basic Display (cont.) Hour Meter The Hour Meter records and displays the total number of hours the compressor has been engaged. The hour meter will flash when the system is running, signifying increasing hours. Compressor Status The Compressor Status display gives vital information about the current state of the compressor system.

  • Page 30: B-Can Basic Menu

    If Information is selected from the main menu, this will display the System Information tab. This screen will display the following: • Boss Serial Number - This is used for quick access to the serial number. • Last Service Access By - This will tell you who worked on the compressor last and how to contact them for service and maintenance.

  • Page 31: Display Options

    B-CAN B-CAN Basic Menu (cont.) Display Options The Display Options selection will take you to a new menu that allows you to change the following: • Button Beep - Indicates whether or not the B-CAN beeps every time a button is pressed. Available options are ON (default) and OFF.

  • Page 32: Switch To Service Mode

    B-CAN B-CAN Basic Menu (cont.) Service Menu (cont.) Active Faults All active faults are listed here. The fault will automati- cally be removed from this list when the problem has been fixed. Fault Summary The fault summary will list the total count of each type of fault.

  • Page 33: Maintenance

    Maintenance Maintenance 309743...

  • Page 34: Overview

    How To Locate a Distributor Service and maintenance must be performed by your local distributor. For a listing of distributors in your area contact Boss Industries, Inc. Phone: (800) 635-6587 (USA) Phone: (219) 324-7776 (Outside USA) Local Fax: (877) 254-4249 service@bossair.com (email)

  • Page 35: Maintenance Schedule

    Maintenance Maintenance Schedule † The Maintenance Schedule lists serviceable items in the compressor system. The items are listed according to their frequency of maintenance, followed by those items which need only “As Required” maintenance. r e t o i r y l l i r u s r i...

  • Page 36: Compressor Lubrication Recommendation

    Review safety section prior to performing any compressor service. Boss recommends Dexron III ATF. Choose your rotary screw lubricant carefully. Due to the impossibility of establishing limits on all physical and chemical properties of...

  • Page 37: Proper Compressor Oil Level

    Maintenance Proper Compressor Oil Level (Daily) Review safety section prior to performing any compressor service. Checking and maintaining the proper compressor oil level will extend the life of the system and minimize down time. 1. Turn the vehicle off and ensure the system is relieved of all air pressure. 2.
  • Page 38 Maintenance 309743...

  • Page 39: Warranty

    Warranty Warranty 309743...

  • Page 40: Warranty Statement

    Industries, Inc. receives from the Buyer written notice of and alleged defect in or nonconformance of the unit, all other components and parts of Boss Industries, Inc. manufacture and if in the judgment of Boss Industries, Inc. these items do not conform or are found to be defective in material of workmanship, Boss Industries, Inc.

  • Page 41: Summary Of Main Warranty Provisions

    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, Inc. replacement parts covers the net cost of the part only, not labor and mileage.

  • Page 42: Warranty/Return Goods Instructions

    4. Claim denial will result in issuance of a letter of denial. 5. Boss Industries, Inc. will consider each claim on its own merit and reserves the right to accept or reject claim request. In case of airends, these will be returned to the manufacturer for their analysis/ input.

  • Page 43: General

    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, Inc. Damage in Transit Do not return damaged merchandise to Boss Industries, Inc., please follow claim procedure.

  • Page 44: Screw Compressor Airend Exchange Program

    Screw Compressor Airend Exchange Program Replacement airends are available from the factory. For current prices and availability, contact Boss Industries, Inc. or an authorized Boss Industries, Inc. distributor. Prices are F.O.B. shipping point. Prices do not include labor for removal or installation.

  • Page 45: Drawings

    Drawings Drawings Multiple drawings are included in this section. Ensure you are looking at the proper drawing for your system. If you need help determining the proper drawing please contact your local distributor. 309743...

  • Page 46: Compressor Assembly

    Drawings 10G Compressor Assembly Parts List ITEM PART NUMBER DESCRIPTION 301677-305 AIREND 301703 FLANGE 301917 FLANGE 932206-050 SCREW 926102-145 O-RING 301594 DECAL 938206-071 WASHER 973112-075 CONNECTOR 960024-150 ELBOW 902915-020 PLUG 929212-350 BOLT 929212-800 BOLT 938912-200 WASHER 938812-250 WASHER 938208-112 WASHER 970804-025 ADAPTER 987305-012...
  • Page 47 Drawings 10G Compressor Assembly (cont.) 309743...

  • Page 48: Rsc9 Compressor Assembly

    Drawings RSC9 Compressor Assembly Parts List ITEM PART NUMBER DESCRIPTION 308894 AIREND 300629 VALVE 303820 FLANGE 301549 FLANGE 932206-050 SCREW 126-64754 GASKET 926102-140 O-RING 301594 DECAL 973112-075 CONNECTOR 960024-150 ELBOW 902915-020 PLUG 929212-300 BOLT 929212-800 BOLT 938912-200 WASHER 938812-250 WASHER 938208-112 WASHER 987305-025M...
  • Page 49 Drawings RSC9 Compressor Assembly (cont.) 309743...

  • Page 50: Compressor Assembly

    Drawings 14D Compressor Assembly Parts List ITEM PART NUMBER DESCRIPTION 301690 AIREND 304100 FOOT 301733 FLANGE 932206-050 SCREW 126-64754 GASKET 970804-025 ADAPTER 929212-350 BOLT 300629 VALVE 902915-020 PLUG 938916-225 WASHER 938816-350 WASHER 929216-450 BOLT 304720 VALVE 929216-100 BOLT 938812-250 WASHER 301694 GASKET 938208-112...
  • Page 51 Drawings 14D Compressor Assembly (cont.) 309743...

  • Page 52: Rsc9 Sump Tank Assembly

    Drawings 10G/RSC9 Sump Tank Assembly Parts List ITEM PART NUMBER DESCRIPTION 304619 BRACKET 300225 SUMP 300234 BAND 304629 J-BOLT 937806-094 WASHER 938206-071 WASHER 902415-060 902915-020 PLUG 961912-075 907603-020 BUSHING 960112-075 CONNECTOR 301466-150 300107 SIGHTGLASS 300108 PLUG 925506-198 929806-100 BOLT 300023-175 RELIEF 929806-125 BOLT...
  • Page 53 Drawings 10G/RSC9 Sump Tank Assembly (cont.) 309743...

  • Page 54: Sump Tank Assembly

    Drawings 14D Sump Tank Assembly Parts List ITEM PART NUMBER DESCRIPTION 304619 BRACKET 300225 SUMP 300234 BAND 304629 J-BOLT 937806-094 WASHER 938206-071 WASHER 902415-060 902915-020 PLUG 961912-075 907603-020 BUSHING 960116-075 CONNECTOR 301466-150 300107 SIGHTGLASS 300108 PLUG 925506-198 929806-100 BOLT 300023-175 VALVE 929806-125 BOLT...
  • Page 55 Drawings 14D Sump Tank Assembly (cont.) 309743...

  • Page 56: B-Can Assembly

    Drawings B-CAN Assembly Parts List ITEM PART NUMBER DESCRIPTION 309228 CONTROLLER 309639 BRACKET 924304-145 929104-150 BOLT 938604-071 WASHER 309643 DECAL 310071 DECAL 301713 SPACER 309702 CABLE 992304-100 SCREW 938904-090 WASHER 938804-090 WASHER 40062 HARNESS 309452 HARNESS 309451 HARNESS 929104-075 BOLT 309743...
  • Page 57 Drawings B-CAN Assembly (cont.) OPTIONAL MOUNTING CONFIGURATIONS 309743...

  • Page 58: Air Filter Assembly

    Drawings Air Filter Assembly Parts List ITEM PART NUMBER DESCRIPTION 309408 ASSY 309413 309414 BAND 938205-071 WASHER 925505-273 309415 INDICATOR 929105-150 BOLT 10FT 301785-300 HOSE 301786-300 CLAMP 309743...
  • Page 59 Drawings Air Filter Assembly (cont.) 309743...

  • Page 60: Air Oil Manifold

    Drawings 10G Air Oil Manifold Parts List ITEM QTY PART NUMBER DESCRIPTION 1 301421 SWITCH 1 300057 VALVE VALVE 1 301827 1 993504-141 PLUG 1 961902-012 1 977704-0404 1 304121 HEAD 1 300599 HEAD 1 907603-010 BUSHING 1 304814 BRACKET 1 304122 COALESCER 1 300005...
  • Page 61 Drawings 10G Air Oil Manifold (cont.) 309743...

  • Page 62: Rsc9 Air Oil Manifold

    Drawings RSC9 Air Oil Manifold Parts List ITEM PART NUMBER DESCRIPTION 301421 SWITCH 300057 VALVE 301827 VALVE 993504-141 PLUG 961902-012 977704-0404 304121 HEAD 300599 HEAD 907603-010 BUSHING 304814 BRACKET 304122 COALESCER 300005 ELEMENT 300022-075 VALVE 300605 ORIFICE 907604-030 BUSHING 960412-075 NIPPLE 960112-075 CONNECTOR...
  • Page 63 Drawings RSC9 Air Oil Manifold (cont.) 309743...

  • Page 64: Air Oil Manifold

    Drawings 14D Air Oil Manifold Parts List ITEM PART NUMBER DESCRIPTION 301421 SWITCH 300057 VALVE 301827 VALVE 993504-141 PLUG 961902-012 977704-0404 304121 HEAD 300599 HEAD 907603-010 BUSHING 304814 BRACKET 304122 COALESCER 300005 ELEMENT 300022-075 VALVE 300605 ORIFICE 907604-030 BUSHING 960412-075 NIPPLE 987302-012 ELBOW...
  • Page 65 Drawings 14D Air Oil Manifold (cont.) 309743...

  • Page 66: Rsc9 Cooler Assembly

    Drawings 10G/RSC9 Cooler Assembly Parts List ITEM PART NUMBER DESCRIPTION 300014 COOLER 304454 VENTURI 310077 FAN ASSY 925305-283 929705-100 BOLT 960212-075 ELBOW 961505-140 943104-038 RIVET 301755-012 RELAY 301784-L BRACKET 301784-R BRACKET 307862 HARNESS 309743...
  • Page 67 Drawings 10G/RSC9 Cooler Assembly (cont.) 309743...

  • Page 68: Cooler Assembly

    Drawings 14D Cooler Assembly Parts List ITEM PART NUMBER DESCRIPTION 300014 COOLER 304454 VENTURI 310077 FAN ASSY 925305-283 929705-100 BOLT 960216-075 ELBOW 961505-140 943104-038 RIVET 301755-012 RELAY 301784-L BRACKET 301784-R BRACKET 307862 HARNESS 309743...
  • Page 69 Drawings 14D Cooler Assembly (cont.) 309743...

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