309395 BA435 - Boss Industries, Inc.
Contents
1. BA435 system is to run intermittently When the BA435 is installed with other hydraulic drive equipment it will require a dedicated flow line If other hydraulics are required the reservoir size should be at least 12 GAL for the BA435 plus all the other manufacturer s requirements Mounting surface must be capable of 180 Ibs load spread over the four mounting holes Cooling air intake must not see air temperatures above ambient Cooling air discharge must have 10 clearance from any obstructions Ambient running conditions 20 to 100 F 20 maximum operating slope 10 309395 Description of Components Compressor Assembly The Boss BA435 hydraulic drive piston compressor assembly is a positive displacement intermittent flow reciprocating unit The piston compressor consists of a crankshaft oil filter oil pump four connecting rods pistons cylinders and valve assemblies As the crankshaft rotates the pistons move up and down As they move down a vacuum is created above the piston which allows the reed valve to open and fill the area above the piston with air When the pistons move back up this air is discharged from the compressor Oil lubricates the bearings and cylinder walls as the crankshaft rotates ensuring that the system stays cool Hydraulic Oil Cooling Systems The compressor cooling system consists of a hydraulic cooler mounted on the co2. Under normal operating conditions oil changes are required every 3 months When operating in a dirty environment change the oil and air filter more frequently as your particular operating conditions dictate Compressor oil capacity is 1 1 3 quarts NOTE 2 Cylinder head stud torque MUST be checked after the initial day of operation The compressor must be cold room temperature before re torquing of studs Torque studs to 240 in Ibs plus or minus 10 in Ibs 18 309395 Maintenance Lubrication Recommendations It is important that the compressor oil be of a recommended A CAUTION type and that this oil as well as the air filter element be in spected and replaced as started in this manual The following are general characteristics for a piston 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 Piston lubricant The lubricant supplier s recommendation must therefore be based upon not only the following general characteristics but also upon his own knowledge of the suitability of the recommended lubricant in piston air compressors operating in the particular environment involved RATI
3. expressly specified In addition to following these safety guidelines the operator should follow any company specific guidelines and procedures Consult your immediate supervisor for specific company safety guidelines and or proce dures The following safety symbols are used throughout the 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 A D G E R Indicate s an imminently hazardous situation which if d d 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 N which if not avoided can result in property and or equipment damage only 7 309395 Safety The following safety precautions are a general guide to safe operation of the equipment AWARNING K 28 ENTE 8 ME ADANGER Read and understand the operations manual and all other safety instructions before using this equipment Failure to follow operating instructions and or failure to follow maintenance proce dures and intervals could result in personal injury death and or damage to equipmen
4. gt 5 TO B PORT ON VALVE 9 BLOCK PORT ON BLOCK FROM COOLER OUTLET USING 975412 021 A PORT ON BLOCK 6 TO PRESSURE SIDE OF HYD MOTOR USING 975508 019 35 309395 Piston System Parts List Parts List PART NUMBER DESCRIPTION o 4 lt PART NUMBER DESCRIPTION QTY 1 4 1308227 ROD 29 1 902915 015 PLUG 2 4 308119 RING 30 1 902915 020 PLUG 3 8 1308120 RING 31 2 1900000 005 PLUG 4 4 1308121 PISTON 32 9 1930005 075 BOLT 5 1 1308122 COLLAR 33 12 925205 273 NUT 6 1 309384 CRANKSHAFT 34 1 309388 7 1 308123 BEARING 35 12 308141 STUD 8 1 308124 BEARING 36 1 1308142 PIN 9 1 1308125 PIN 37 1 309389 DIPSTICK 10 1 1309385 HOUSING 38 1 308143 GASKET 11 1 308126 BEARING 39 2 1308144 GASKET 12 1 308127 SEAL 40 2 308145 GASKET 13 1 308128 HOUSING 41 1 308149 CAP 14 1 1308129 BEARING 42 1 308146 PUMP 15 17 929105 100 BOLT 43 4 902915 030 PLUG 16 5 938005 078 WASHER 44 1 903315 020 ELBOW 17 1 308130 CLAMP 45 1 922108 070 NIPPLE 18 1 308131 006 GASKET 46 1 971612 050 BUSHING 19 1 308131 010 GASKET 47 2 1308147 20 2 308132 GASKET 48 12 938604 071 WASHER 21 3 1308131 020 GASKET 49 2 308148 HEAD 22 1 1308133 TUBE 50 4 1308186 PIN 23 1 308134 SCREEN 51 2 1308139 REED VALVE 24 1 1308135 COVER 52 2 130822
5. 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 ship ment Therefore claims for loss or damage to the contents of the kit or factory installed unit should be made upon the carrier 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 carrier s 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 Re ceipt and signed by the carrier s agent Failure to adequately describe such externa
6. 150 PSI the pressure switch will remain in its normally closed state keeping the N O hydraulic solenoid closed and the compressor producing air If the service valve is closed or the tool using the air is off service line pressure will rise to 150 PSI This will cause the pressure switch to open and deactivate the hydraulic solenoid The compressor will stop making air If the tool is turned on or the service valve is opened the service line pressure will drop When the pressure falls to 115 PSI the pressure switch will close energiz ing the N O hydraulic solenoid forcing flow to the motor and the compressor will start producing air to meet the demand Never adjust the pressure switch to a setting of greater than 150 PSI Oper AWARNING ating the compressor at greater than 150 PSI may result in personal injury and property damage 11 309395 Installation amp Operation This air compressor should be installed only by those who have been trained and delegated to do so and who have read and understand the manual Failure to follow the instructions procedures and safety precautions in this manual may result in accidents and injuries Install use and operate this air compressor only in full compliance with all pertinent O S H A Federal State and Local codes or requirements in addition to Boss and any company s regulations Do not modify this compressor except with written factory approval N OT ALL TRUCKS SHOULD BE ROAD
7. Dock Return or Warranty Claims Filing Procedures Initiate through a purchase order for warranty part or request for credit 2 RGA will accompany replacement part 3 Boss Industries Inc 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 Inc will consider each claim on its own merit and reserves the right to accept or reject claim request 6 Send Warranty Claim to Boss Industries Inc 1761 Genesis Drive LaPorte IN 46350 28 309395 Warranty General An approved claim depends on the following provision 1 2 A dm t9 An RGA must be issued by Boss Industries Inc See filing procedures Failed part must be returned within 30 days of original invoice date freight prepaid with RGA Part is determined to be defective Workmanship is determined to be defective Machine is within warranty period 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 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
8. TESTED PRIOR TO STARTING INSTALLATION TO ISOLATE ANY PREVIOUS TRUCK PROBLEMS 1 Mounting the Compressor When mounting the compressor care should be taken to ensure that its location does not impede the operation of other components on the vehicle For example if your vehicle is equipped with a crane you must make sure the compressor will not interfere with the swing of the crane In addition the compressor should be installed in an area that permits cool ambient air to enter the air filter and the hot air to exhaust without recirculating into the air filter 10 of exhaust clearance is needed The compressor air filter is mounted on the frame Cool ambient air is drawn in from under the frame One last consideration in the mounting should be the routing of hoses and electrical wires The frame mounting holes are shown below and the unit should be secured to the vehicle with 3 8 inch grade 8 bolts and washers Hardware supplied with unit may not work in all applications The compressor weighs 180 Ibs Ensure that you have a sub structure to support at least that weight Be sure to follow all National Vehicle Safety Standards TRUCK MOUNTING SURFACE 7 16 DIA 4 PLACE 12 309395 Installation amp Operation 2 Installing the Wiring This unit is shipped from the factory with all necessary internal wiring installed The only remaining wiring necessary is the wiring needed to interface your vehicle power source with the Boss compre
9. down straps or clamps 4 Connecting the Air Hose The air discharge hose should be connected directly to the AIR port The fitting is a 1 2 female NPT The air line should be made from a good quality min 200 PSD hydraulic hose 1 2 or 3 4 LD Care should be taken to see that the hose is not installed with kinks When adding an air hose ensure OSHA Regulation 1910 169 is followed HYDRAULIC TANK OUT 000080000 IY UMW 00000000 MYM TN omme an 13 309395 Installation amp Operation A compressor service valve should be located at the hose reel inlet or the customer s air connection port when a hose reel is not used Typical plumbing from the machine s air outlet port occurs in the following order 1 Air tank 2 OSHA valve 3 Service valve 4 Moisture trap gauge oiler combination when used 5 Hose reel when used 5 Pre Start up Inspection Checks This inspection should be done prior the compressor test 1 Check all assemblies clamps fittings hose connections nuts and bolts to ensure they are properly tied and secured to the vehicle This is a very critical area of inspection The vehicle should not be moved until this inspection has been completed II Removeall tools rags and installation equipment from the area Check compressor oil level and hydraulic fluid level Check all valves to ensure they in correct operating positi
10. may be varied if the need is indicated by conditions under which the trouble occurred In any event the procedures which can be performed in the least amount of time and with the least amount of removal or disassembly of parts should be performed first LOW OIL PRESSURE Low oil level Loose pipe plug on oil pump cover Worn or defective oil pump Crack or scratch on oil pump cover BOO p os NO OIL PRESSURE 1 Defective oil pump 2 Blocked oil passage 3 Damage oil pump drive pin COMPRESSOR WILL NOT ENGAGE No power supplied to compressor Internal circuit breaker tripped Hydraulic system not engaged Defective pressure switch Te COMPRESSOR ENGAGES BUT WILL NOT PRESSURIZE TANK 1 Airleakin plumbing 2 Worn piston rings or valve plates COMPRESSOR DOES NOT RECOVER PRESSURE AS FAST AS IT SHOULD 1 Dirty filter 2 Airleakin plumbing 3 Worn valve plates or piston rings 22 309395 Troubleshooting Contacting Boss Industries Inc Local Phone 800 635 6587 Local Fax 877 254 4249 http www bossair com When calling for technical support have the following information available Machine Serial Number Description of the problem How To Find Specific Machine Information The machine serial number can be found on the Boss serial tag located on the side of machine B Wu N am r LO 0088 NOUETNIB 44082060067 PAVN BO
11. 0 309395 Discharge System CONNECT TO EXHAUST PORTS ON THE CYLINDER HEAD Ce 9 QOO 4 309395 Canopy System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 304832 2 20 977004 062 WASHER 3 14 961504 090 NUT 4 1 301496 PANEL 5 1 301435 PANEL 6 20 983904 075 BOLT 7 20 984004 071 WASHER 42 309395 Canopy System 43 309395 Oil Drain System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 1302614 HOSE 2 1 1922106 035 3 1 901515 015 ELBOW 4 2 302613 CLIP 5 2 943103 025 RIVET 44 309395 Oil Drain System 309395 Mounting System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 4 308082 BUMPER 2 4 929806 200 BOLT 3 4 938206 071 WASHER 46 309395 Mounting System 47 309395 Decal System Parts List ITEM lt PART NUMBER DESCRIPTION 1 1 1309392 DECAL BA435 SHEET 1 1 2 309392 01 DECAL BA435 LOGO 1 2 1 309392 02 DECAL OIL DRAIN 1 3 1 309392 03 DECAL VALVE BLOCK 1 4 1 309392 04 DECAL AIR 1 5 1 309392 05 DECAL WARNING CONNECT AIR 1 6 1 309392 06 DECAL DANGER BREATHING 1 7 1 309392 07 DECAL WARNING READ MANUAL 1 8 1 309392 08 DECAL WARNING GUARD 1 9 1 309392 0
12. 118885 uu Service and Maintenance User Manual BOSS BA435 PISTON Hydraulic Air Compressor This manual must be read carefully before using your Boss Industries Air Compressor Store in a safe and conventent location for future reference For technical support Phone 800 635 6587 USA Phone 219 324 7776 Outside USA Fax 877 254 4249 USA service bossair com email gt Se 2 http www bossair com website 309395 Contents Revisi ist Warnings safety rules and hazards EE SP CCI CANONS aria Description of Components 11 Installation Tostalla On mem 2 e Initial Start up Te osa L Mai AA 17 1 7 Recommended Spare Parts Litunia Maintenance Schedule 18 Lubrication Recommendaton 19 Compressor Oil ee Air Intake Filter sus ie Hydraulic Oil Conte leshooti General Ip E Contacting Boss Ind 23 Where To Find Specific Machine Information 23 3 309395 arrant y DEELER 25 KEN E E 26 Summary of Main Warranty Points nee 27 Return Goods Instruectiohnssssss 28 Preparation Or E 28 i
13. 9 CYLINDER BLOCK 25 1 1308136 BUSHING 53 1 308059 CRANKCASE 26 1 1308137 SPRING 54 4 1929806 175 BOLT 27 12 308138 WASHER 55 4 938206 071 WASHER 28 1 1309387 TUBE 56 4 925506 198 NUT 36 309395 Piston System 37 309395 Air Inlet System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 1300855 BAND 2 1 301418 SLEEVE 3 1 1301417 SLEEVE 4 2 301602 ISOLATOR 5 1 1304566 TUBE 6 1 1300857 CAP 7 2 938605 071 WASHER 8 2 924305 166 NUT 9 1 301438 FILTER 10 2 304515 ADAPTOR 11 2 309383 12 1 1304534 TUBE 13 1 301446 BRACKET 14 2 929704 050 BOLT 15 2 929705 125 BOLT 38 309395 Air Inlet System 2 5 lt ZC 5 309395 Discharge System Parts List PART NUMBER DESCRIPTION QTY 1 4 938206 071 WASHER 2 2 925506 198 NUT 3 1 1303202 BRACKET 4 1 1301578 SWITCH 5 1 1308152 SWITCH 6 1 975104 012 ELBOW 7 1 301928 125 CLAMP 8 1 934504 075 SCREW 9 1 1901142 VALVE 10 1 960112 075 CONNECTOR 11 1 1960212 075 ELBOW 12 1 961912 075 TEE 13 2 960012 075 ELBOW 14 1 1305268 HOSE 15 2 1929806 100 16 1 902415 020 17 1 1922212 000 NIPPLE 18 1 902203 022 19 1 922108 060 NIPPLE 20 1 961608 025 NIPPLE 21 1 1922108 020 NIPPLE 22 1 1305328 HOSE 23 2 943102 038 mRIVET 4
14. 9 DECAL DRIVE COUPLING 1 10 1 309392 10 DECAL OIL LEVEL 1 11 2 309392 11 DECAL RESTRICT AIRFLOW 2 1 1305761 DECAL SERIAL TAG BOSS 48 309395 Decal System 309395 49 Q39V9N3 SI Old JHL N3HM AINO NNY OL 3HL MOTIV TIM SIHL HOLIMS Old Ol Q3103NNOO SI 3MIM 3359 2 Nid ONISS3HdWOO SI W31SAS JHL N3HM AINO IN3S34d 38 38 39NVMO Qu Nid WON4 5 INdLNO OGAZL 3HL 3 ATIVOLLVWOLNV TIM ANIOd HOIHM Lv ISd OLL OL 0344040 SVH ANVL JHL UND GVOINN TIIM WILSAS JHL OSL OL ANVL JHL 3YNSSIYA ANY WALSAS 3 31VALOV TIM 3YIM MOTTSA AR Nid OL SINdNI 20 01 AlddNS NOlivH3dO MOSS3MdWOO TWNYON 303 UOSSIU4WOI Nid 3 3 ANILIVA ONY 3YIM 8 Nid 3AILISOd AY3LIVE Ol 43 3 38 OL 3 Nid ONY 8 Nid MOTTA 2 21 4018390 038 Unam OQAZI AYALIVE OQAZI 8 N3349 GNNOYD HOLMS Old Nid 39NY80 INdLNO 20 21 HOLMS Q ONNOYO AMiLIVH 3 Nid 3339388 NYI NYJ HOLIMS NMOGLNHS dW3l ON NIN ISd OOOL 331009 GAH 3SOH 334 NYNI3Y SOLON GAH Wd9 304 30018 33134 QION310S GAH ON NIN 154 0008 3SOH 0334 330SS3Md NIN Ql 7 JAVA 23 2
15. DAR OOM SERIAL NO 100000 23 309395 24 309395 WARRANTY SECTION 25 309395 Warranty Boss Industries Inc warrants that this Piston Compressor unit conforms to applicable drawings and specifications approved in writing by Boss Industries Inc The unit assembly will be free from defects in material and workmanship for a period of one 1 years from the date of initial operation or eighteen 18 months from the date of shipment whichever period first expires All other components and parts of Boss Industries Inc 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 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 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 Industries Inc 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
16. Distributors or end users automatically deducting the value of a warranty claim from outstanding balances due and payable to Boss Industries Inc prior to receiving written notification of Boss Industries Inc approval of the warranty claim may be subject to forfeiture of the entire claim 27 309395 Warranty Warranty Return Goods Instructions 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 Inc the ability to best serve its customers Please see the following instructions to initiate a return Contact Boss Industries Inc Returns Department by telephone at 800 635 6587 You may also send a fax at 877 254 4249 Warranty Claims Preparation of Part Return Parts returned to the factory must be properly packaged to prevent damage during shipment Damage to a part as a result of improper handling or packing could be cause for denial When addressing the package for shipment the following information must be on the outside of or tagged clearly to the package Return Goods Authorization Distributor or end users return address Correct factory address Number of packages pertaining to each claim pe NOTE Our warranty reguires that all defective parts be returned to Boss Industries Inc freight prepaid Items sent without RGA number will not be accepted Unauthorized Returns Will Immediately Be Refused At
17. E R Never leave the machine running unattended or leave a tool connected to an air hose when not using Relieve system of all stored air pressure after use Never adjust the pressure switch to a setting of greater than 150 PSI Oper ating the compressor at greater than 150 PSI may result in personal injury and property damage Mount the compressor in a stable location capable of supporting 180 lbs Slight vibration may occur during operation and the machine may move if not securely mounted When using tools maintain secure footing at all times Do not overreach or awkwardly use air tools N Prior to moving vehicle to the next work site drain the air tank To prevent the collection of water in the tank drain daily N OTI Use only Boss approved replacement parts 9 309395 Specifications POWER SOURCE HYDRAULIC MOTOR OPERATING SPEED 1400 RPM MAX CYLINDER CONFIG OIL CAPACITY 118 QTS DIMENSIONS 26 1 2 Lx 19 1 8 H x 19 3 4 W WEIGHT DELIVERY 100 PSI 35 CFM ei ULIC RESERVOIR 12 GALLON MINIMUM FAN DIAMETER 14 1 8 NORMAL OPERATING PSI 1850 PSI ped Hydraulic reservoir requirement for compressor only Additional capacity will be needed to other hydraulic equipment van mx ke SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE 22 91 MNA UU 0000000 19 74 26 50 1 00 28 60 VEN N Y 20 12 M rv
18. NG name eos amupa mecum mx meon ns RUST PREVENTION PROPERTIES _ ASTM Deos B Pass WATER SEPERABILTY ROTATING PRESSURE VESSEL OXIDATION TEST ASTM D2272 FZG LOAD CARRYING TEST CEC L 07 A 95 Mixing different types or brands of lubricants is not recommended N OTI due to the possibility of a dilution of the additives or a reaction between additives or different types 19 309395 Maintenance Due to environmental factors the useful life of all extended life lubricants may be shorter than quoted by the lubricant supplier Boss N E encourages the user to closely monitor the lubricant condition and to participate in an oil analysis program with the supplier N OT No lubricant however good and or expensive can replace proper maintenance and attention Select and use it wisely Compressor Oil Fill Level and Drain Before adding or changing compressor oil make sure that the compressor is completely relieved of pressure Oil is added at the fill cap on a pipe on the rear of the crankcase A drain line is located on the rear panel of the machine The proper oil level is to the FULL line on the dipstick when the unit is shut down and has had time to settle The truck must be level when checking the oil DO NOT OVERFILL The oil capacity is given in Compressor Speci
19. QVOINN 10114 NOLLOINNOI NOLOSNNOS AlddNS on 43QvoTNn M HOLMS JYNSSIYA 035012 ATIVWYON ONIYIM 3SOH OLUVNNINd 3SOH QN3931 oneurouos ULOJS A 309395 50
20. approved by Boss Industries Inc or from Buyer s failure to store install maintain and operate the compressor according to the recommendations contained in the Operating and Parts Manual and good engineering practice The total responsibility of Boss Industries Inc 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 Industries Inc 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 Industries Inc or lost production whether suffered by Buyer or any third party Boss Industries Inc 1761 Genesis Drive LaPorte IN 46350 26 309395 Warranty Summary of Main Warranty Provisions As claims policies and procedure are governed by the terms of the Boss Industries Inc warranty it is necessary to outline some of the more important provisions The Boss Industries Inc 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 Industries Inc manufacture are warranted only to the extent th
21. ely low GPM gallons per minute translates into the most efficient quiet and reliable system in its class designed to handle virtually any application The BA435 Piston also has enhanced safety features offering applications designed to protect your most valuable resource your operating crew To prevent overheating a high temperature switch will shut down the machine in the event of high discharge temperatures 6 309395 Safety IMPORTANT READ BEFORE OPERATING EQUIPMENT 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 your and others safety 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 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 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
22. ey 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 Industries Inc replacement parts covers the net cost of the part only not labor and mileage The Boss Industries Inc warranty does not cover diagnostic calls and travel That is time spent traveling to the machine to analyze the problem and returning with the proper tools and parts to correct the problem Boss Industries Inc will deduct from allowable credits for excess freight caused by sender failing to follow return shipping instructions
23. fications Do not attempt to drain condensate remove the oil level fill cap or A DANG 2 2 break any connection in the air or oil system without shutting off the compressor and relieve the system of all stored air pressure Air Intake Filter P N 300854 The air intake filter is a heavy duty dry type high efficiency filter designed to protect the compressor from dust and foreign objects Frequency of maintenance of the filter depends on dust conditions at the operating site The filter element must be serviced when clogged A clogged air filter element will reduce compressor performance and cause premature wear of components 20 309395 Maintenance HYDRAULIC OIL COOLER The interior of the oil cooler should be cleaned when the pressure drop across it at full flow exceeds 25 PSI Remove cooler Circulate a suitable solvent to dissolve and remove varnish and sludge Flush generously with hydraulic oil Once the cooler is reinstalled fill the hydraulic system with the proper fluid to their appropriate levels AYN 21 309395 Troubleshooting The troubleshooting procedures to be performed on the equipment are listed below Each symptom of trouble for a component or system is followed by a list of probable causes of the trouble and suggested procedures to be followed to identify the cause In general the procedures listed should be performed in the order in which they are listed although the order
24. from Boss Industries Inc 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 Boss Industries Inc sole responsibility and Buyer s exclusive remedy hereunder is limited to such repair replacement or repayment of the purchase price Parts not of Boss Industries Inc manufacture are warranted only to the extent that they are warranted by the original manufacture Boss Industries Inc shall have no responsibility for any cost or expense incurred by Buyer from inability of Boss Industries Inc to repair under said warranty when such inability is beyond the control of Boss Industries Inc 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 Industries Inc 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 Industries Inc manufacture or
25. l el 28 Other IO 29 Transit Dama jo A 29 N 31 er era 32 Pistons 34 Piston Assembly 36 Cooler VS Le ee 38 Hydraulic Drive System A YP YE 40 DPi chatge ytte 42 Canopy e 44 Decal SS OM aus ee HM 46 Wiring 48 4 309395 Revision List INITIALS 2 Q 2 Ge Q E LOCATION DATE 309395 Welcome General Information BOSS 25 Thank you for choosing the Boss BA435 Hydraulic Air Compressor Mamas Hydraulic Air Compressor Before operating this compressor 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 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 Boss BA435 Hydraulic Air Compressor The Boss BA435 is acompact strategically designed system It integrates all major components on a single frame which is enclosed in a tough weather resistant canopy The BA435 Piston design provides output of up to 35 cubic feet of air per minute at up to a maximum of 150 PSI pounds per square inch High output at relativ
26. l evi dence 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 29 309395 30 309395 PARTS AND ILLUSTRATION SECTION 31 309395 Frame System Parts List o lt PART NUMBER DESCRIPTION 1 1 301405 2 2 929806 150 BOLT 3 6 925506 198 NUT 4 1 301248 BRACKET 5 1 301665 MOTOR 6 6 1938206 071 WASHER 7 1 301593 DECAL 8 1 301266 HUB 9 1 301265 HUB 10 1 301267 SPIDER 11 1 301628 WASHER 12 1 929405 100 BOLT 13 6 1961504 090 NUT 14 1 970412 106 ELBOW 15 1 970408 088 ELBOW 16 4 929806 100 BOLT 32 309395 Frame System 33 309395 Oil Cooler System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 300909 025 BREAKER 2 1 301432 SUPPORT 3 1 301433 BRACKET 4 1 301434 SHROUD 5 1 80061 12 BLOCK 6 6 924305 166 NUT 7 6 938605 071 WASHER 8 8 961505 140 NUT 9 12 929705 075 BOLT 10 1 1300836 COOLER 11 2 1960212 075 ELBOW 12 2 300211 RELAY 13 1 1970512 088 14 1 1970508 088 CONNECTOR 15 1 1305244 BRACKET 16 1 1301577 FAN ASSY 17 4 1993204 062 RIVET 18 4 943102 038 RIVET 19 2 1929105 300 20 4 993603 025 RIVET 34 309395 Oil Cooler System FROM DISCHARGE SIDE OF HYD MOTOR USING 975412 029 lt
27. mpressor frame Cool air is drawn through the vented end panel and flows over the compressor surface and through the hydraulic cooler exiting out the front vented panel Allow for adequate clearance 107 for the air to exit Also the package location should not be subjected to air temperatures above ambient Dipstick The dipstick indicates the fluid level in the crank case Proper level should be at the FULL line on the dipstick Check this level when the compressor is disengaged and the vehicle is parked on level ground Fluid level should be checked prior to each use Electrical System The Boss compressor s standard electrical system consists of Hydraulic oil cooler fan assembly and relay 12VDCN O hydraulic solenoid Switch relay for customer equipment interface during compressor operation 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 Higher operating pressure can also over torque nuts and bolts A CAUTION fatiguing the fastener and mating parts Strictly adhere to tool operating pressures and torque standards set forth by the tool manufacturer and the specifications of the equipment that work is being performed on Pressure Switch The pressure switch is a N C electrical switch set to open at 150 PSI and set to close at 115 PSI The pressure switch controls the N O hydraulic solenoid If service air pressure is under
28. ompany policy V Engage compressor 7 Shutdown Procedure L Disengage compressor circuit Relieve system of stored air Operating Conditions The following conditions should exist for maximum performance of the compressor The truck should be as close to level as possible when operating Operation in ambient temperatures above 100 F 38 C may experience high temperature shutdown 16 309395 Maintenance This section contains instructions for performing the inspection lubrication and maintenance proce dures required to maintain the compressor in proper operating condition The importance of per forming the maintenance described herein cannot be over emphasized The periodic maintenance procedures to be performed on the equipment covered by this manual are listed on the following page It should be understood that the intervals between inspections specified are maximum interval More frequent inspections should be made if the unit is operating in a dusty environment in high ambient temperature or in other unusual conditions A planned program of periodic inspection and maintenance will help avoid premature failure and costly repairs Daily visual inspections should become a routine Compressor must be shut down and completely relieved of pressure prior to checking fluid levels Open service valve to ensure relief of A p W gt system air pressure Relieve all stored air pressure energy prior to starting machine Fail
29. on IV Apply decals to proper location Make sure that the area is cleaned prior to applying decals All decals should have a professional appearance upon application V Vacuum all areas that have metal or plastic shavings Wipe all fingerprints off unit and vehicle 14 309395 Installation amp Operation V Record all serial numbers for this installation A Vehicle V LN B Hydraulic Pump Data C Compressor Serial Number J Boss Serial Number E Air Tank Serial Number F Note any special applications relating to specific installations VI Check all fluid levels position the unit on a level surface so that proper amount of fluids can be added A Fuel to provide three hours of operation B Hydraulic fluid levels may have to be topped off after test C Compressor Check the compressor oil level see lubricant section of the operator and parts section for type of lubricant to use 1 Add oil if needed 2 Additional oil may need to be added after test 3 Top off oil level to the FULL line on the dipstick when finished with the test D Any other applicable fluids E Transmission fluid and PTO box 15 309395 Installation amp Operation 6 Operating Procedure I Read the operation section in the manual carefully before proceeding onto the initial start up IL Start power source and allow for warm up Verify the compressor is disengaged IV Engage hydraulic system per c
30. ssor The unit is shipped with a 5 pin connector they need to be connected as follows 1 Pin and Pin E are to be connected directly to battery positive Pin red wire and battery negative Pin E black wire 2 Compressor Only for normal compressor operation supply 12VDC inputs to Pin A yellow wire This will activate the system and pressure the tank to 150 PSI The system will then unload until the tank has dropped to 110 PSI at which point it will automatically activate The 12VDC output signal from Pin D orange wire will be present only when the system is compressing 3 Pin green wire is connected to PTO ground 3 Connecting the Hydraulic Hoses The hydraulic hoses to the compressor should be connected directly to the hydraulic block The port sizes in the blocke are 10 SAE The pressure input line should be made from a good quality high pressure hydraulic hose 1 2 or 3 4 I D rated to handle the hydraulic systems the vehicle The return line to tank be made from a medium pressure min 1000 PSD hydraulic hose 3 4 I D Care should be taken to see that the hoses are not installed with kinks or bends that inhibit flow of the hydraulic oil Lack of flow could result in damage to the motor and compressor Lastly check to make sure hoses are not in contact with sharp objects or edges that may fray chafe or cut them over time Secure all hoses with tie
31. t and property Pressurized System Do not attempt to remove any compressor parts 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 System contains hot oil The compressor system must be shut off prior to servicing Open the service valve to ensure complete relief of system air pressure and stored energy Then permit system to cool down prior to adding compressor oil or servicing the unit Do not use air from this compressor for breathing or food process ing Air from this compressor will cause severe injury if used for breathing or food processing The compressor is designed to compress air only 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 compressor parts as this can cause the unit to ignite or explode during operation Keep combustibles out of and away from compressor inlet and any associated enclosures 8 309395 Safety A D G E R Never disable override or remove safeties either temporarily or permanently Do not modify pressure switches to operate equipment at a higher pressure A D E R than specified When using a hose reel the complete system must be designed with safety valves in accordance with OSHA Regulation 1910 169 A A N G
32. ure to comply with this warning will cause damage to property and serious bodily harm Recommended Spare Parts List PART NUMBER DESCRIPTION 80279 KIT REPAIR REED VALVE 308157 ELEMENT AIR FILTER 301267 SPIDER CURVED JAW 302936 KIT REPAIR HYD MOTOR SEAL 308245 LUBRICANT 2QT BOX SYNTH How To Order Parts For Parts and or Service Support Phone 800 635 6587 USA Phone 219 324 7776 Outside USA Local Fax 877 254 4249 service Obossair com email http www bossair com website 17 309395 Maintenance The LUBRICATION AND MAINTENANCE CHART lists serviceable items on this compressor package The items are listed according to their frequency of maintenance followed by those items which need only Required maintenance Lubrication and Maintenance Chart SERVICE INTERVAL MAINTENANCE OPERATION 1 Check crankcase oil level Add if needed DAILY 2 Drain condensation from air receiver 1 Inspect the air intake WEEKLY 2 Check the cylinder head stud torque see NOTE 2 3 Check the operation of the receiver safety valves 1 Change the crankcase oil see NOTE 1 EVERY AMON TS 2 Check cooler fins for dirt and obstruction Clean if needed EVERY 6 MONTHS 1 Inspect the drive coupling for wear 2 Change the air cleaner Use only Boss synthetic compressor oil The use of any other oil causes excessive carbon buildup and may void the warranty on the compressor NOTE 1
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