25 P/N: 307167

BOSS MODEL BGPSD POWERMAX6.2 GENERATOR

OPERATORS, MAINTENANCEAND PARTS MANUAL

4/22/2009 MCM

2 P/N: 307167

OPERATORS, MAINTENANCE, AND PARTS MANUALBOSS MODEL B.G.P.S.D. POWERMAX 6.2 GENERATOR

Operation & Maintenance Section

TABLE OF CONTENTS

Operation & Maintenance Section

General Instruction ......................................................................................................... 6

Equipment Description................................................................................................... 6

Procedure for Changing Gear Drive Lubricant .............................................................. 7

Safety Rules ................................................................................................................... 9

Operating the Generator ............................................................................................... 12

Generator Maintenance ................................................................................................ 13

Parts and Illustration Section ....................................................................................... 15

Warranty Section

Warranty Information ................................................................................................... 23

3 P/N: 307167

GENERAL INSTRUCTION

Every effort has been expended to make sure that the information in this manual is both accurate and current.However, BOSS reserves the right to change, alter or otherwise improve the product at any time without priornotice.

Bold printed DANGER boxes point out important safety instructions, which if not followed, could endangerpersonal safety and/or property.

Read all safety and operations manuals for both the PTO Air Compressor and the Generator prior to operatingthis unit. Follow all instructions in both manuals.

EQUIPMENT DESCRIPTION

This generator is truck chassis mounted, revolving field, alternating current (AC) generator. The generator isdriven off a power takoff (PTO) drive shaft system. It is designed to supply electrical power for operatingcompatible electrical lighting, appliance tool and motor loads. This manual contains information for a genera-tor that operates 120 and/or 240 volts, single phase, 60 Hz devices that require up to the rated watts of yourspecific generator. The generator’s revolving field is driven by the compressor engine.Refer to the identification tag for specific rating.

CAUTION:

Do not exceed the generators wattage/amperage capacity. Add up the rated watts of alldevices you are connecting to the generator receptacles at one time. This total shouldnot be greater than the rated output watts for this generator. In most cases rated wattsof the electrical device can be found on the device nameplate. If the device nameplategives only volts and amps, multiply volts times amps to obtain watts (volts X amps =

watts).

4 P/N: 307167

PROCEDURE FOR CHANGING GEAR DRIVE LUBRICANT

1. There are three 1/4” NPT plugs on each side of the gearbox. The plug at the top of the unit covers the“fill” hole. The plug at the bottom of the unit covers the “drain” hole. The other plug, which is locatedabout 2” above the “drain” plug, covers your “level” hole.

2. Begin by draining out the old gear lubricant by removing the plug for the “drain” hole.

3. Once the lubricant has been drained, replace the “drain” hole plug and remove the “fill” plug and the“level” plug.

4. Begin filling the gearbox with 75W-90 synthetic gear lubricant in the “fill” hole.

5. Your gearbox has the correct amount of lubricant when you see it start to come out the “level” hole.

6. Replace all plugs.

Fill Hole

Level Hole

Drain Hole

5 P/N: 307167

EQUIPMENT DESCRIPTION

DANGER

OPERATORS MUST NOT TAMPER WITH ENGINE GOVERNED SPEED. HIGHOPERATING SPEEDS ARE DANGEROUS AND INCREASE RISK OF PERSONAL

INJURY OR DAMAGE TO EQUIPMENT. THE GENERATOR SUPPLIES CORRECTRATED FREQUENCY AND VOLTAGE ONLY WHEN RUNNING AT PROPERGOVERNED SPEED. INCORRECT FREQUENCY AND/OR VOLTAGE CAN

DAMAGE SOME CONNECTED ELECTRICAL LOADS. ONLY TRAINED SERVICETECHNICIANS SHOULD WORK ON THE CONTROLLER UNIT.

DANGER

ELECTRICAL SURGES AND SPIKES CAN CAUSE SERIOUS DAMAGE TO YOURSYSTEM AND EVERYTHING PLUGGED IN TO IT. PROPER SURGE

PROTECTORS SHOULD BE USED BETWEEN THE RECEPTACLES AND EVERYELECTRICAL SYSTEM BEING USED. IMPROPERLY TUNED ENGINES CANFORCE THE ELECTRONIC ENGINE SPEED CONTROL TO SPIKE AND FADE

THUS CREATING DAMAGING ELECTRICAL SURGES.

DANGER

NEVER WELD TO TRUCK CHASSIS, AS THIS WILL CAUSE DAMAGE TO MANYELECTRICAL OR ELECTRONIC COMPONENTS GROUNDED TO VEHICLES

CHASSIS.

6 P/N: 307167

SAFETY RULES

CAUTION:

THESE SAFETY RULES ARE GENERATOR SPECIFIC AND ARE TO BE USED INCONJUNCTION WITH THE PTO AIR COMPRESSOR MANUAL AND SAFETY

RULES. ALL SAFETY AND OPERATION PROCEDURES OF THE AIRCOMPRESSOR MUST BE FOLLOWED WHEN USING THE GENERATOR. THESERULES ARE NOT ALL INCLUSIVE. PLEASE REFER TO DEPARTMENTAL AND

COMPANY SAFETY PROCEDURE FOR ADDITIONAL GUIDELINES.

DANGER

THIS GENERATOR IS DESIGNED FOR OUTDOOR USE ONLY. DO NOT USE THISGENERATOR INSIDE ANY BUILDING OR ENCLOSURE. DEADLY CARBON

MONOXIDE GAS MAY CAUSE FATAL INJURIES. IN ADDITION A FIRE OR ANEXPLOSION MAY OCCUR. NO USER-PERFORMED MODIFICATIONS,

INCLUDING VENTING OF EXHAUST AND/OR COOLING VENTILATION WILLELIMINATE THE DANGER.

DANGER

IF THIS UNIT IS USED FOR BACK-UP POWER IN THE EVENT OF A UTILITYPOWER FAILURE, THE FOLLOWING STEP MUST BE TAKEN: BEFORE

CONNECTING THE GENERATOR TO AN ELECTRICAL SYSTEM, OPEN THEMAIN CIRCUIT BREAKER OR MAIN SWITCH SERVING THE SYSTEM, TO

ISOLATE THE GENERATOR SYSTEM FROM THE ELECTRIC UTILITY. FAILURETO ISOLATE THE GENERATOR AND UTILITY SYSTEMS MAY RESULT IN

DAMAGE TO THE GENERATOR AND MAY ALSO RESULT IN INJURY OR DEATHTO ELECTRIC UTILITY WORKERS, DUE TO A BACK FEED OF ELECTRICAL

ENERGY.

This generator set was designed and manufactured for specific applications. Do not attempt to modify the unitor use it for any application it was not designed for.

If you have any questions about your generator’s application, ask your Dealer/Distributor or consult the fac-tory.

7 P/N: 307167

SAFETY RULES

The manufacturer could not possibly anticipate every circumstance that might involve a hazard. For thatreason warnings in the manual and warnings on tags or decals affixed to the unit are not all inclusive. If youintend to handle, operate or service the unit by a procedure or method not specifically recommended by themanufacturer, first make sure that such a procedure or method will not render this equipment unsafe or pose athreat to you and others.

· Read this manual carefully and become familiar with your generator set. Know its applications, itslimitations and any hazards involved.

· The generator produces a very powerful voltage that can cause an extremely dangerous shock. Avoidcontact with bare wires, terminals, etc... Never permit any unqualified person to operate or service thegenerator.

· Never handle any kind of electrical cord or device while standing in water, while barefoot or whilehands or feet are wet. Dangerous electrical shock will result.

· Use a ground fault circuit interrupter in any damp or highly conductive area (such as metal decking orsteel work).

· Do not use any worn, bare, frayed or otherwise damaged electrical cord sets with the generator.Using any defective cord set may result in electrical shock or damage to equipment and/or property.

· Operate generator where it will not be exposed to excessive dirt, dust or corrosive vapors.

· Gasoline and natural gas are highly FLAMMABLE and their vapors are EXPLOSIVE. Do not permitsmoking, open flames, sparks or heat in the vicinity while exposed to these gases.

· The trucks exhaust emits DEADLY carbon monoxide gas. This dangerous gas, if breathed in sufficientconcentrations, can cause unconsciousness or even death. Operate this equipment only in the open airwhere adequate ventilation is available.

· The PTO generator requires an adequate flow of cooling air for its continued proper operation. Neveroperate the unit inside any room or enclosure where the free flow of cooling air into and out of the unitmight be obstructed. Without sufficient cooling air flow, the generator quickly overheats, damaging thegenerator or nearby property. Never operate the generator where ambient temperatures exceed100°F.

8 P/N: 307167

SAFETY RULES

· Never, engage/disengage, the engine-generator with electrical loads connected to receptacles with theconnected devices turned ON. Start the engine and let it stabilize before connecting electrical loads.Disconnect all electrical loads before disengaging the generator.

· Do not insert any object through cooling slots of the generator. You could damage the unit or injureyourself.

· Never operate generator (a) in any enclosed building, (b) if engine speed changes, (c) if connectedelectrical devices overheat, (d) if electrical output is lost, (e) if engine or generator sparks, (f) if flameor smoke is observed while unit is running, (g) if unit vibrates excessively.

GROUNDING THE GENERATOR

The National Electric Code requires the frame and external electrically conductive parts of the generator to beproperly connected to approved earth ground. Local electrical codes may also require proper grounding ofthe unit. Consult with a local electrician for ground requirements in your area.

Properly grounding the generator helps prevent electrical shock if a ground fault condition exists in the genera-tor or in connected electrical devices. The generator system has an external ground stud that should be used toproperly acquire an earth ground. A removable clamp/wire assembly that can be driven into the ground willproperly connect to earth ground. This is to be supplied by the owner of the equipment due to differentregulations regarding electrical codes from state to state. Proper grounding also helps dissipate static electric-ity, which often builds up in ungrounded devices.

9 P/N: 307167

OPERATING THE GENERATOR

CAUTION:

Never engage or disengage the PTO-generator with electrical loadsconnected to the receptacles with the connected devices turned ON.

Disconnect all electrical loads from the generator.

· Follow all safety guidelines in both the compressor and generator manuals.

· Follow all company and departmental safety procedures.

· Engage compressor PTO and allow for warm-up.

· Turn generator toggle switch to ON position and wait for engine RPM to increase and stabilize (about2-5 seconds).

Applying Electrical Loads:

· Plug in and then turn on the desired 120 or 240 volts, single phase, 60 Hertz, AC electrical load.When finished disconnect electrical load. Turn off the generator by moving the toggle switch to theOFFposition.

10 P/N: 307167

GENERAL MAINTENANCE RECOMMENDATIONS

The general maintenance of the generator must be done in conjunction with that of the air compressor. Theseunits are not independent in operation and maintenance of one unit will affect the other.

The Owner/Operator is responsible for making sure that all periodic maintenance tasks are completed on atimely basis; that all discrepancies are corrected; and that the unit is kept clean. Never operate a damaged ordefective generator.

GENERATOR MAINTENANCE

Generator maintenance consists of keeping the unit clean and dry. Cooling air slots in the generator must notbecome clogged with snow, leaves or any other foreign material.

Check the cleanliness of the generator frequently and clean when dust, dirt, oil, moisture or other foreignsubstances are visible on its exterior surface.

NOTE:

We DO NOT recommend using a garden hose to clean generator. If water entersgenerator through cooling air slots, some of the water will be retained in voids and cracks

of the rotor and stator winding insulation. Water and dirt build-up on the generatorinternal windings will eventually decrease the insulation resistance of these windings.

To clean the generator:1. Use a damp cloth to wipe exterior surfaces clean.

2. Soft bristle brush may be used to loosen caked on dirt and debris.

3. A vacuum cleaner may be used to pick up loose dirt and debris.

4. Low pressure air (not to exceed 25 PSI) may be used to blow away dirt. Inspect cooling air slots andopening on the generator. These openings must be kept clean and unobstructed.

CAUTION:

Never insert any object or tool through the air cooling slots, even if theengine is not running. Damage to the unit or personal injury may result.

CAUTION:

Never use solvents or gasoline to clean or wipe generatoror external surfaces. Explosion and/or fire can result.

11 P/N: 307167

Check all wiring for cracked, frayed or exposed sections. Replace any bad or worn sections of wire orconnectors.

GENERATOR MAINTENANCE

NOTE:

The generator’s revolving field rides on a pre-lubricated and sealed ballbearing that requires no additional lubrication for the life of the bearing.

12 P/N: 307167

PARTS AND ILLUSTRATION SECTION

13 P/N: 307167

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18 P/N: 307167

19 P/N: 307167

WARRANTY SECTION

20 P/N: 307167

BOSS Industries, Inc. warrants that this Generator unit conforms to applicable drawings and specifica-tions approved in writing by BOSS. The unit assembly will be free from defects in material and workman-ship for a period of one (1) years from the date of initial operation or eighteen (18) months from the dateof shipment, whichever period first expires. All other components and parts of BOSS manufacture, will befree from defects in material and workmanship for a period of one (1) year from the date of initial operationor eighteen (18) months from the date of shipment, whichever period first expires. If within such periodBOSS receives from the Buyer written notice of and alleged defect in or nonconformance of the unit, allother components and parts of BOSS manufacture and if in the judgment of BOSS these items do notconform or are found to be defective in material of workmanship, BOSS will at its option either, (a) furnisha Service Representative to correct defective workmanship, or (b) upon return of the item F.O.B. BOSSoriginal 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 pricefor the item without interest. Factory installed units will also include warranty on installation for a period ofone (1) year. This warranty does not cover damage caused by accident, misuse or negligence. If thegenerator unit is disassembled the warranty is void. BOSS’s sole responsibility and Buyer’s exclusiveremedy hereunder is limited to such repair, replacement, or repayment of the purchase price. Parts not ofBOSS 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 torepair 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 thoseof merchantability and of fitness of purpose; nor any affirmation of fact orrepresentation 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 purchaseprice of defective or damaged parts or components resulting directly or indirectly from the use of repair orreplacement parts not of BOSS manufacture or approved by BOSS or from Buyer’s failure to store,install, maintain, and operate the generator according to the recommendations contained in the Operatingand 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 exceedthe purchase price. In no event shall BOSS be liable for any special, indirect, incidental or consequentialdamages of any charter, including, but not limited to, loss of use of productive facilities or equipment, lossof profits, property damage, expenses incurred in reliance on the performance of BOSS, or lost produc-tion, whether suffered by Buyer or any third party.

BOSS Industries, Inc.

1761 Genesis Drive

LaPorte, IN 46352

WARRANTY INFORMATION

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SUMMARY OF MAIN WARRANTY PROVISIONS

As claims, policies and procedure are governed by the terms of the BOSS Industries, Inc. warranty, it isnecessary 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 notbeen altered, changed, repaired or mistreated in any manner whatsoever. Normal maintenance items such aslubricants and filters are not warrantable items.

Parts not of BOSS manufacture are warranted only to the extent they are warranted by the original manufac-turer.

Damage resulting from abuse, neglect, misapplication or overloading of a machine, accessory or part is notcovered under warranty.

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

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

Failure to file a detailed warranty claim/service report for each occurrence of material defect of defectiveworkmanship will cause warranty claim to be rejected.

Defective material must be returned within 30 days of receipt of shipping instructions. Failure to do so withinspecified 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 party only, not labor and mileage.

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

Distributors or end-users automatically deducting the value of a warranty claim from outstanding balances dueand payable to BOSS prior to receiving written notification of BOSS approval of the warranty claim may besubject to forfeiture of the entire claim.

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WARRANTY/RETURN GOODS INSTRUCTIONS

The warranty/return procedure outlined below is provided to give the claimant the information necessary to filea 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 atservice@bossair.com. You may also send a fax at 219.324.7470.

WARRANTY CLAIMS – PREPARATION OF PART RETURN

Parts returned to the factory must be properly packaged to prevent damage during shipment. Damage to apart as a result of improper handling or packing could be cause for denial. When addressing the package forshipment, 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 AtDock.

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 DriveLaPorte, IN 46350Attn: Returns Dept.

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GENERAL

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.

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 orcarefully installed and tested before leaving our plant. However, regardless of the care taken at thefactory, there is a possibility that damage may occur in shipment. For this reason, it is recommendedthat the unit be carefully inspected for evidence of possible damage or malfunction during the first fewhours of operation. Responsibility for the safe delivery of the kit or factory installed unit was assumedby the carrier at the time of shipment. Therefore, claims for loss or damage to the contents of the kit orfactory 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 isunpacked or the factory-installed unit is run by the end-user. The contents of the kit or factory installedunit may be damaged due to rough handling while in route to its destination, even thought the kit orfactory 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 filea claim with the carrier since such damage is the carrier’s responsibility.

By following these instructions carefully, we guarantee our full support of your claims, to protect you againstloss from concealed damage.

3. Visible Loss or DamageAny external evidence of loss or damage must be noted on the Freight Bill or Express Receipt, andsigned by the carrier’s agent. Failure to adequately describe such external evidence of loss, or damagemay result in the carrier refusing to honor a damage claim. The carrier will supply the form required tofile such a claim.

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SCREW COMPRESSOR AIR-END EXCHANGE PROGRAM

Replacement air-ends are available from the factory. For current prices and availability, contact BOSS IN-DUSTRIES, Inc. or an authorized BOSS INDUSTRIES distributor. Prices are F.O.B. shipping point.Prices do not include labor for removal or installation.