RynoWorx AirBoss 575 Operator's Manual

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Skid Systems

AirBoss575 Pro

AirBoss575 Elite

AirBoss750 Pro

AirBoss750 Elite

AirBoss 575 / 750-V1

Operator's Manual

RA-SSY-0032

RA-SSY-0033

RA-SSY-0035

RA-SSY-0036

RC-SUM-0015 - Rev 1

Trailer Packages

AirBoss575 Pro

AirBoss575 Elite

AirBoss750 Pro

AirBoss750 Elite

*AirBoss750 Elite

RA-TSY-0040

PKG A

RA-TSY-0041

PKG B

RA-TSY-0046

PKG A

RA-TSY-0047

PKG B

RA-TSY-0048

PKG C

RA-TSY-0058

PKG A

RA-TSY-0059

PKG B

RA-TSY-0064

PKG A

RA-TSY-0065

PKG B

RA-TSY-0066

PKG C

*Shown

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Summary of Contents for RynoWorx AirBoss 575

Page 1 AirBoss 575 / 750-V1 Operator's Manual Skid Systems Trailer Packages AirBoss575 Pro RA-SSY-0032 AirBoss575 Pro RA-TSY-0040 PKG A AirBoss575 Elite RA-SSY-0033 AirBoss575 Pro RA-TSY-0041 PKG B AirBoss750 Pro RA-SSY-0035 AirBoss575 Elite RA-TSY-0046 PKG A AirBoss750 Elite RA-SSY-0036 AirBoss575 Elite RA-TSY-0047...
Page 2: Safety And General Information
⚠ Failure to follow all safety precautions can result in serious injury or death ⚠ RynoWorx Inc. assumes no liability for any accident or injury incurred through improper use of machine ⚠ CHECK ENGINE, COMPRESSOR, FRL, AND HYDRAULIC OIL LEVELS BEFORE FIRST USE ⚠...
Page 3: Factory Calibrations
Factory Calibrations: Your AirBoss was calibrated using: • 2.0 GPM tips with water • 50 psi in the expansion tank • Compressor regulator set to 90psi • FRL regulator set to 90psi • *Pneumatic hose reel regulator set to 10psi *if equipped •...
Page 4 *Trailers *if equipped Towing Best Practices: 1. Stay Within Your Limits. Review the towing capacity of your specific vehicle and ensure it’s capable of handling the weight of your trailer. Exceeding the maximum towing capacity can result in dangerous handling, insufficient braking performance, or serious damage to the vehicle’s suspension, engine and drivetrain.
Page 5 Trailer Specifications: AirBoss trailers are fabricated by Weberlane. 750 Elite Spray System with Extended Trailer Package C: RA-TSY-0066 (RA-SSY-0036) (RA-TRL-5012) RA-TSY-0066 System Dimensions: 244 x 88 x 93” GVWR: 15,600 lbs ✔ Safety Break-Away System and Chains Axle Capacity 2 x 7,225 lbs E-Z Lube ✔...
Page 6: Required Tools
Required Tools Your AirBoss spray system should arrive completely assembled. No tools are required to begin operation. Suggested tools to have on hand: • 12" Pipe Wrench (with 2.5" Jaw) • Adjustable wrench (1.5” width) or Channel Lock pliers • Ratchet set •...
Page 7: Engine Details
Engine Details All AirBoss 575 and 750 systems are equipped with a Kohler CH440 engine. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To find a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).
Page 8: Part Diagrams
2 PART DIAGRAMS RC-SUM-0015 - Rev 1...
Page 11 RC-SUM-0015 - Rev 1...
Page 12: Operation
3 OPERATION 3.1 Operation Guidelines • The AirBoss system was pre-tested for leaks before shipping, however, we recommend that you test the system using WATER to ensure you do not have leaks before moving onto sealant • The air-pump is self-priming •...
Page 13 Filter baskets Your system comes with 2 sizes of filter baskets. 4 mm (approx. 5/32”) and 5.5 mm (approx. 7/32”). We recommend using the larger basket for emulsion and sealers with more solid, and the smaller filter for coal tar sealers.
Page 14: Compressor Operation
3.2 Compressor Operation Auto Idle Throttle Control (kick-down) Your AirBoss Spray system is equipped with an auto idle kickdown to lower engine RPM when the compressor tanks are full. This hose runs from the brass valve to the throttle on your engine. This sensor is attached between the compressor and the tank.
Page 15 Compressor & Air Tanks: NOTE: You must fully open the pressure relief valve at the bottom of the tank at the end of each day. Condensation and sediment can form and shorten the life of the tanks. It is normal for this water to be brown in colour.
Page 16 Setting the desired pressure: **NOTE: These regulators do NOT control any of the AirBoss equipment. There is another regulator on the FRL that controls the equipment. These regulators are only for extra air lines / tools connected to the compressor directly. 1.
Page 17 Expansion tank: Your AirBoss is equipped with an expansion tank that helps to minimize pulses created by the diaphragm pump. This expansion tank has a bladder inside that can be charged with air to help dial in the perfect amount a dampening.
Page 18 Airline Valve: The AirBoss unit is equipped with a ball valve to control the air flow to the diaphragm pump. This valve should be closed when not in use, and open during all operations. THE PUMP CANNOT WORK WITH THE VALVE CLOSED. OPEN CLOSED...
Page 19 FRL (Filter, Regulator, Lubricator): The FRL filters water, regulates the air pressure, and provides a small amount of oil to lubricate pneumatic parts. 1. During normal operation, water will collect in the reservoir and will need to be emptied. It must be emptied daily by pushing upwards on the bottom of the vial.
Page 20 “SIDES” of the AirBoss – INPUT & OUTPUT There are two “sides” to your AirBoss plumbing. 1. Input - The input side of the AirBoss contains 2 valves • Primary input valve controls flow from the main tank • Secondary input valve controls flow from a 3 party source such as a barrels, totes, or other containers •...
Page 21 Valves: Your AirBoss uses ball valves. Ball valves have several advantages: • Resistant to high pressure • Easy to operate, only needing a quarter turn • Easy to see if it’s open or closed, or somewhere in between • Easy to partially open, if needed Ball valves are open when the handle is parallel with the plumbing and are closed when the handle is perpendicular to the plumbing.
Page 22 Powered Hose Reel (If Equipped) The RA-SSY-0033 (575 Elite) and RA-SSY-0036 (750 Elite) come with a pneumatic powered hose reel. The Hose Reel regulator should be set to 10-15psi max. Setting the regulator higher could result in damage to the reel, hose, or injury to operators. Valve Closed Valve open...
Page 23 Hydraulic Agitation: Forward Reverse...
Page 24 Muffler Drain Valve The muffler generates moisture during operation. This moisture is collected in the plumbing below the muffler. This need to be drained regularly (see maintenance schedule) Closed: Open:...
Page 25 *If equipped – Water Pump & Water Tanks Depending on which trailer unit you have you may have 30 or 60 gallons of water storage. You will also have an Air Operated Double Diaphragm (AODD) pump. This water pump will come with 50’ of water line. The pump is controlled by the valve on the FLR: Closed (Off) Open (On)
Page 26 Regulator is located on the water pump. It should be set to 20psi. The pump is located next at the rear of the trailer, next to the sealer pump, under the input valves.
Page 27 3.3 System Modes Input Modes 1) Main Tank This is going to be the way you will be operating most of the time. Feeding from your main tank. 1. Close the valve at the at the middle of the AirBoss, valve on top, closest to the rear of the unit 2.
Page 28 3) Manual Emptying of main tank (controlled via both input valves) Opening BOTH input valves will allow you to drain the contents main tank out the back of the unit. 1) Open the valve at the at the middle of the AirBoss, valve on top, closest to the rear of the unit 2) Open the valve at the bottom middle of the tank, valve on the bottom...
Page 29 Output Modes 1) Traveling Mode We recommend closing ALL valves before traveling. All 3 output valves are closed 1. Recirculation valve closed 2. Secondary output valve closed 3. Spray output valve closed...
Page 30 2) Recirculation Mode This will output back into the main tank to help mix your product before beginning work. Recirculating and activating the hydraulic agitation is the best way to mix your sealer and ensure uniform consistency. 1. Open the recirculation output valve (with the blue hose running to the tank) 2.
Page 31 3) Secondary Output This mode will allow you to use your AirBoss to fill 3 party containers such as barrels, totes, tanks, or other AirBoss. This is the fastest way to transfer the contents of your tank elsewhere. 1. Close the recirculation output valve (with the blue hose running to the tank) 2.
Page 32 4) Spray Mode This is how you will be operating your system most of the time. Spraying through your spray wand. 1. Close the recirculation output valve (with the blue hose running to the tank) 2. Close the secondary output valve (Pointing downwards at 5 o’clock with a metal cam lock cap) 3.
Page 33 3.3.1 Spray Wand Operation The spray wand included with this system has a ball valve handle to accurately control the flow of sealer. Please refer to the following diagram for the valve positions. 3.4 Transferring Sealer from a Drum (Transfer kit sold separately) Mix the sealer with a drum mixer for several minutes before transferring 1.
Page 34 4. Set up the valves on the unit to prepare for transfer. 1. Open the recirculation output valve (with the blue hose running to the tank) 2. Close the secondary output valve (Pointing downwards at 5 o’clock with a metal cam lock cap) 3.
Page 35 3.5 Transferring Sealer from a Tote (Transfer kit sold separately) 1. Mix the sealer with a drum mixer for several minutes before transferring 2. Connect the 2” female cam lock on the 15’ transfer hose to outlet port on the tote. 3.
Page 36 Quick Start Guide...
Page 38 3.6 Starting the Engine Kohler – CH440 1. Engine RPM (automatically controlled) 2. Choke  ON ➔ OFF 3. Fuel ➔ ON  OFF...
Page 39 CH440 Starting: **MAKE SURE YOUR HYDRAULIC LINES ARE CONNECTED** Failure to connect hydraulic lines will burn out the starter 1. OFF / KILL 2. RUN 3. START 1. Turn the fuel shut-off valve to ON position 2. Turn the engine on/off switch to ON position 3.
Page 40: Maintenance
4 MAINTENANCE Table A: Maintenance Schedule Before After Every Every Every Every Every Maintenance Procedure Each Each 1000 Hours Hours hours hours Check Engine Oil Level Check Compressor Oil Level Check Hydraulic Oil Level Check FRL Oil level Check Fuel Level Close compressor tank drain valves (both) Check all connections for hoses, spray wands, belts, and transfer kits.
Page 41: Changing Engine Oil
4.1 Changing Engine Oil Place the engine on a level surface and place a suitable container under the drain plug bolt 1. Remove the oil filler cap 2. Remove the drain plug bolt and drain plug washer 3. Drain the oil into a suitable container Please dispose of used oil in a manner that is compatible with the environment.
Page 42: End Of Season Maintenance
4.3 End of season maintenance *If Equipped (Trailer) 60 Gallon (dual tanks) 1. Drain the water tanks by removing the drain plug 2. Run the water pump until no more fluid come out of the spray hose. There is no risk running the water pump dry.
Page 43: Spray Tank
Spray Tank: *See manual for valve configurations 1. Drain as much sealant from the tank into long term storage containers. This can be completed several ways (fastest to slowest): • Using the secondary output and a transfer hose, pump the sealer into the container •...
Page 44 8. Initiate the hydraulic agitation system to rotate the mixing paddles forward and backward for several minutes to remove as much built up material as possible from the side walls of the tank. 9. Recirculate for about 10 minutes.
Page 45 10. Flush any sealer out of the spray hose by switching to spray mode and spraying into the storage container until you see water coming out of the spray wand. 11. Aim the spray wand into the top of the main tank and spray for roughly 10 minutes.
Page 46 12. Drain all the water from the tank - leave these 2 valves open for now 13. Drain the water from the filter pot by opening the filter pot drain valve 14. Remove and clean the filter basket 15. Replace the filter basket 16.
Page 47 20. Clean the tips and quick connect fitting with a NYLON bristle brush (not brass or any other metal brush). 21. Close both the primary and secondary input valves 22. Pour 5-10 gallons of washer fluid into the tank 23. Run the system in spray mode to flush the water out of the spray hose. Once you see washer fluid coming out of the spray tip, point the spray wand back into the main tank for 1 minute.
Page 48 Koeler Engine: 1. Add fuel stabilizer to the gas tank. 1. Run the engine for 2-3 minutes to circulate the stabilizer. 2. Remove the air filter cover.
Page 49 4. Spray engine fogger into the air intake until you see heavy smoke. While continuing to spray, turn off the engine. Stop spraying once the engine has completely stopped 5. Clean the air filter 6. Re-install the air filter.
Page 50 Compressor: 1. Drain all the air from the compressor unit. 2. Close the vale once the air is expelled 3. Perform an oil change on the compressor pump.
Page 51 5. Detach the battery wires from the compressor’s battery pack and remove it from the system, store it in a dry warm place. 6. Inspect the compressor’s flywheel belts for any wear and tear.
Page 52 8. Drain the collected water from the moisture separator. 9. Release any pressure from the moisture separator by pulling the emergency pressure release valve located next to it.
Page 53 11. Lubricate the chain 12. Lubricate the bearings on the tank (2) and the hose reel (2). 13. If possible, store equipment and sealing materials out of weather in a shed or garage. If this is not possible, cover it with a tarp and store it somewhere safe from external damage such as falling trees.
Page 54 Troubleshooting: My engine stalls when I slide the choke to off: • The engine is cold, leave the choke on full for a minute or two, then slowly slide it to the off position Switching the choke suddenly may stall the engine My engine stalls randomly, but then works again after a few minutes: •...
Page 55 The system will not build all the way to full pressure: • Make sure the air line valve is closed on the diaphragm pump • Turn off the engine, wait for the kickdown and listen for any air leaking noises •...
Page 56 Recirculating: Recirculating is the best way to keep your sealant mixed and prevent settling of aggregate. Many of the steps outlined in this document refer back to the quick start guide. The reason for this is that it is designed to highlight all of the possible failure points in trying to get your AirBoss up and running. Being able to recirculate requires all of the steps from the quick start to be confirmed as working.
Page 57 I keep getting clogs in my spray tips, or incomplete fan patterns while spraying • Mix your sealer more before spraying Put your unit into recirculation mode for 10-15 minutes • This may also be caused by excessively thick sealers Your sealer should be the consistency of tomato soup.
Page 58 I’m getting low pressure while I’m in spray mode • Thin material to a better working consistency • Check the regulator pressure • Check for blockages in the wand or hose • Check the filter put is clean and full •...
Page 59 How do I grease the pins in the diaphragm pump? • Open top of the pump and grease the pins, follow the YouTube video Should I charge my tanks up before spraying? • Compressor tanks should be charged to 120 psi and the expansion tank should be at 50 psi Contact Customer Support •...

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