Manual - Venco/Venturo Manufacturing, Inc.
Contents
1. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE 22 91 MNA UU 0000000 19 74 26 50 1 00 28 60 QUE N 20 12 M rv 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 the2. 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 26 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 J Wu N A r ue o 0088 NOUETNIB Genen LAPORTE ANM 44082060067 SERIAL 100000 27 309395 28 309395 WARRANTY SECTION 29 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
3. 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 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 AWARNING Operating the compressor at greater than 150 PSI may result in per sonal 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 Fede
4. 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 compressor 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 C 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 P 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 on the vehicle The return line to tank can be made from a medium pressure min 1000 PST hydraulic hose 3 4 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 re
5. 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 compressor 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 12VDC N 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 A CAUTION and bolts fatiguing the fastener and mating parts Strictly adhere to tool operating pressures and torque standards set forth by the tool manu facturer and the specifications of the equipment that work is being performed on
6. freely XIV Install the oil pump XV Install the connecting rods Thoroughly oil the crankshaft and rods before installing them When installing the rods make certain that the tabs are aligned on the same side of the rod see Fig 5 XVI Install the pistons rings and heads See Piston Ring Replacement on P 21 180 IN LBS e Align FIGURE 5 RODALIGNMENT 25 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 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 oillevel Loose pipe plug on oil pump cover Worn or defective oil pump Crack or scratch on oil pump cover To pa 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 Top Sai p
7. 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 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 w
8. 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 Thatis 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 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 31 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 In
9. tools rags and installation equipment from the area III Check compressor oil level and hydraulic fluid level Check all valves to ensure they are in correct operating position IV Apply decals to proper location Make sure that the area is cleaned prior to applying decals AII 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 AirTank 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 Fuelto 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 1 Read the operation section in the manual ca
10. 118885 tiiin 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 convenient 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 an 2 2 http www bossair com website 309395 Contents Revisi ist Warnings safety rules and bara ic SCCM ICAL OBS aaa 6416414141110 Description of Components 11 Installation amp Operation 12 A II o Before EA Initial o L Mai RE er Recommended Spare Parts Eile L7 Maintenance Schedule in I8 Lubrication Recommendation 19 Compressor Qil e 0 GE Hydraulic Oil Cooler E Piston Ring Replacement 2I Oil Pump Replacement en 29 Crankshaft and Bearing Replacement 4 T i roubleshooting Eur MILIEU 0 Contacting Boss Hille Where Find Spec
11. 13 CLIP 5 2 943103 025 RIVET 48 309395 Oil Drain System 309395 Mounting System Parts List ITEM PART NUMBER DESCRIPTION 1 4 308082 BUMPER 2 4 929806 200 BOLT 3 4 938206 071 WASHER 50 309395 Mounting System 51 309395 Decal System Parts List ITEM 3 lt PART NUMBER DESCRIPTION 1 1 309392 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 FAN GUARD 1 9 1 309392 09 DECAL DRIVE COUPLING 1 10 1 309392 10 DECAL OIL LEVEL 1 11 2 309392 11 DECAL RESTRICT AIRFLOW 2 1 305761 DECAL SERIAL TAG BOSS 52 309395 Decal System 309395 33 Q39V9N3 SI Old JHL N3HM AINO NNY OL 3HL MOTIV TIM 5 HOLIMS Old Ol Q3103NNOO SI 3MIM N33N9 2 Nid ONISS3HdWOO SI W31SAS JHL N3HM AINO 35384 38 TIM 33IM 39NVMO Qu Nid WON4 5 1ndino OGAZL 3HL 3 ATIVOLLVWOLNV TIM li HOIHM Lv ISd OLL OL 0344040 SVH ANVL JHL UND GVOINN TIM W31SAS JHL OSL OL ANVL JHL 34055384 ANY WALSAS 3 31VALOV TIM 3MIM MOTTSA V Nid OL SINd
12. 408 088 ELBOW 16 4 929806 100 BOLT 36 309395 Frame System 37 309395 Oil Cooler System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 300909 025 BREAKER 2 1 1301432 SUPPORT 3 1 1301433 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 960212 075 ELBOW 12 2 300211 RELAY 13 1 970512 088 CONNECTOR 14 1 970508 088 CONNECTOR 15 1 1305244 BRACKET 16 1 1301577 FAN ASSY 17 4 993204 012 RIVET 18 4 943102 038 RIVET 19 2 929105 300 BOLT 20 4 993603 025 RIVET 38 309395 Oil Cooler System FROM DISCHARGE SIDE OF HYD MOTOR USING 975412 029 Fk 9 ey amp N 7 0 7 9 TO B PORT ON VALVE 9 BLOCK N 2 PORT ON BLOCK FROM COOLER OUTLET USING 975412 021 14 A PORT ON BLOCK 6 TO PRESSURE SIDE OF HYD MOTOR USING 975508 019 gt 39 309395 Piston System Parts List Parts List PART NUMBER DESCRIPTION o 4 lt PART NUMBER DESCRIPTION 1 4 308227 ROD 29 1 902915 015 PLUG 2 4 308119 RING 30 1 902915 020 PLUG 3 8 308120 RING 31 2 900000 005 PLUG 4 4 308121 PISTON 32 9 930005 075 B
13. ET 14 2 929704 050 BOLT 15 2 929705 125 BOLT 42 309395 Air Inlet System 43 309395 Discharge System Parts List PART NUMBER DESCRIPTION QTY 1 4 938206 071 WASHER 2 2 925506 198 3 1 303202 BRACKET 4 1 1301578 SWITCH 5 1 308152 SWITCH 6 1 975104 012 ELBOW T 1 301928 125 CLAMP 8 1 934504 075 SCREW 9 1 1901142 VALVE 10 1 960112 075 CONNECTOR 11 1 960212 075 ELBOW 12 1 961912 075 TEE 13 2 960012 075 ELBOW 14 1 305268 HOSE 15 2 929806 100 BOLT 16 1 902415 020 17 1 922212 000 18 1 902203 022 19 1 922108 060 NIPPLE 20 1 961608 025 NIPPLE 21 1 922108 020 NIPPLE 22 1 1305928 HOSE 23 2 943102 038 JRIVET 44 309395 Discharge System CONNECT TO EXHAUST PORTS ON THE CYLINDER HEAD 3 0 45 309395 Canopy System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 304832 CANOPY 2 20 977004 062 WASHER 3 14 961504 090 NUT 4 1 901436 PANEL 5 1 1901495 PANEL 6 20 983904 075 BOLT 7 20 984004 071 WASHER 46 309395 Canopy System 47 309395 Oil Drain System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 3902614 HOSE 2 1 922106 035 NIPPLE 3 1 901515 015 ELBOW 4 2 3026
14. NI 20 01 AlddNS NOlivH3dO MOSS3MdWOO TWNYON HOSS3HdWOO Nid 3 3 A383LIV8 ONY 3YIM 8 Nid 3AILISOd AY3LIVE Ol A11O3BIO 43 3 38 OL 3 Nid ONY 8 Nid MOTA 2 21 HOLMS V NOI1V833dO 038 Unam OQAZI AYALIVE OQAZI 8 N3349 GNNOYD HOLIMS Old Nid 39NvHO 1 41 0 20 21 HOLMS Q ONnOMO 3 Nid 3339388 NYI NYJ HOLIMS NMOGLNHS ON NIN 154 0001 331009 NO GAH 3SOH 334 NYNI3Y SOLON GAH Wd9 OL 304 30018 33134 GION310S GAH ON NIN 154 0005 3SOH 0334 330SS3Md NIN Ql 7 SAWA 393H9 QVOINN 10114 NOLLOINNOI NOLOSNNOS AlddNS d 1 43QvoTNn M HOLMS 33nSS33d 035012 ATIVWYON 3SOH OlVAn3Nd 3SOH QN3931 oneurouos uigjs gS 309395 54
15. OLT 5 1 1308122 COLLAR 33 12 925205 273 NUT 6 1 309384 CRANKSHAFT 34 1 309388 KEY 7 1 1308123 BEARING 35 12 308141 STUD 8 1 13908124 BEARING 36 1 1308142 PIN 9 1 1908125 PIN 37 1 1309389 DIPSTICK 10 1 309385 HOUSING 38 1 308143 GASKET 11 1 308126 BEARING 39 2 308144 GASKET 12 1 308127 SEAL 40 2 308145 GASKET 13 1 1308128 HOUSING 41 1 1308149 CAP 14 1 1308129 BEARING 42 1 1308146 PUMP 15 17 929105 100 BOLT 43 4 1902915 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 308147 GASKET 20 2 308132 GASKET 48 12 938604 071 WASHER 21 3 308131 020 GASKET 49 2 308148 HEAD 22 1 308133 TUBE 50 4 308186 PIN 23 1 308134 SCREEN 51 2 308139 REED VALVE 24 1 308135 COVER 52 2 308229 CYLINDER BLOCK 25 1 308136 BUSHING 53 1 308059 CRANKCASE 26 1 308137 SPRING 54 4 1929806 175 BOLT 27 12 308138 WASHER 55 4 938206 071 WASHER 28 1 1309387 TUBE 56 4 925506 198 NUT 40 309395 Piston System 4 309395 Air Inlet System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 1300855 BAND 2 1 1301418 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 1901498 FILTER 10 2 304515 ADAPTOR 11 2 309383 CAP 12 1 1304534 TUBE 13 1 1301446 BRACK
16. amage 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 30 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 they are warranted by the original manufacturer Damage resulting from abuse neglect misapplication or overloading of a machine accessory or part is not covered under warranty Deterioration or wear occasioned by chemical and or abrasive action or excessive heat shall not constitute defects Parts replacement and or correction of defective workmanship will normally be handled by Boss Industries Inc or their authorized distributor Failure to file a detailed warranty claim service report for each occurrence of material defect of defective workmanship will cause warranty claim to be rejected Defective material must be returned within 30 days
17. arranted 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 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 d
18. arts locations 1 Piston Ring Replacement I Shut down machine and allow to cool for approximately 10 minutes II Verify entire system pressure is relieved before proceeding III Disconnect air inlet system tubes IV Disconnect 3 4 discharge jumper hose V Disconnect 3 4 discharge hose VI Unscrew the head nuts and remove the heads A rubber faced mallet will help when removing the head Tap the sides of N OTI CE the head carefully until the head is loose Lift off the heads VI Remove the cylinder bolts Tap the sides of the cylinder several times to break it loose from the gasket Rock the cylinder back and forth and lift until it is free Lift it off the pistons Useasingle edged razor blade or sharp putty knife to remove the old gasket material Do not allow the gasket material to fall into the crankcase Do not nick the head cylinder or crankcase mating faces while removing the old N E gasket Remove all of the old gasket material to provide a smooth clean surface for the new gasket Failure to follow this procedure may result in the need to reseal the unit later IX Hone the cylinder to break the glaze and to remove the buildup at the top of the cylinders X Measure the inside diameter of the cylinder for roundness and excessive wear The bore should be 2 625 0 0025 tolerance If the bore is oversized the cylinder must be replaced 2 With a ring expander remove compression and o
19. bs in 25 50 pound increments See Fig 3 22 309395 Maintenance 240 IN LBS o FIGURE 3 CYLINDER HEAD TORQUE SEQUENCE XVII Reconnect the 3 4 discharge hose and discharge jumper hose XVIII Install the compressor and connect the wiring XIX the machine N OT C E If pressure fails to build and the compressor is excessively noisy check the valve plate It may have been installed upside down 2 Oil Pump Replacement I II Shut down machine and allow to cool for approximately 10 minutes Verify entire system pressure is relieved before proceeding Remove the bolts and lift off the pump cover With a single edged razor blade or sharp putty knife remove the old gasket material Take care not to damage the machined surfaces Do not allow the gasket material to fall into the crankcase Do not nick the head cylinder or crankcase mating faces while removing the old N OTI C E gasket Remove all of the old gasket material to provide a smooth S clean surface for the new gasket Failure to follow this procedure may result in the need to reseal the unit later Lift the pump out of the cavity Position a new gasket on the rear bearing housing Insert the pump into the cavity Position the pump slightly to one side using a common screwdriver Wedge the pump into position so that it partially compresses the spring Note that the driver pin and slot in pump must be in line Place the pump c
20. c 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 requires 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 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 BossIndustries 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 32 309395 Warranty General An approved claim dep
21. checking fluid levels Open service valve to ensure relief of A e Jf system air pressure Relieve all stored air pressure energy prior to starting machine Failure 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 300854 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 As Required maintenance Lubrication and Maintenance Chart SERVICE INTERVAL MAINTENANCE OPERATION DAILY 1 Check crankcase oil level Add if needed 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 A MONTHS 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 B
22. edged razor blade or sharp putty knife Do not allow the gasket material to fall into the crankcase Do not nick the head cylinder or crankcase mating faces while removing the old N OTI C E gasket Remove all of the old gasket material to provide a smooth clean surface for the new gasket Failure to follow this procedure may result in the need to reseal the unit later N OT C E Do not gouge the machined surfaces when removing the gaskets This may cause leaks IX Press the bearing races out of the bearing housing X Press the tapered roller bearings off of the crankshaft if only the bearings are being replaced If the crankshaft is to be replaced discard the entire assembly 24 309395 Maintenance XI Press the new bearings into position Generously oil the front bearing race and install the front bearing housing with gasket Torque the bolts to 180 in Ibs See Fig 4 N OT C E The crankshaft should have new bearings installed If not press the new bearings into position on the crankshaft ams O FIGURE 4 BEARING HOUSING TORQUE SEQUENCE Slide the crankshaft into the crankcase Generously lubricate the bearing race and install the rear bearing housing and gaskets Gasket kits are supplied with two 2 each of 006 010 015 and 020 N gaskets Use these rear bearing gaskets in any combination and quantity to limit all play front to rear but still allow the crankshaft to turn
23. either temporarily or permanently Do not modify pressure switches to operate equipment at a higher pressure than specified When using a hose reel the complete system must be designed with safety valves in accordance with OSHA Regulation 1910 169 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 Ibs 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 Priorto moving vehicle to the next work site drain the air tank To prevent the collection of water in the tank drain daily Use only Boss approved replacement parts 9 309395 Specifications POWER SOURCE HYDRAULIC MOTOR OPERATING SPEED 1400 RPM MAX CYLINDER CONFIG OIL CAPACITY 113 QTS DIMENSIONS 26 1 2 Lx 19 1 8 H x 19 3 4 W WEIGHT DELIVERY 100 PSI 35 CFM ior ULIC RESERVOIR 12 GALLON MINIMUM FAN DIAMETER 14 1 8 NORMAL OPERATING PSI 1850 PSI Mams Fan Hydraulic reservoir requirement for compressor only Additional capacity will be needed to other hydraulic equipment van mx
24. ends on the following provision 1 2 A PLA 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 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 i
25. f the suitability of the recommended lubricant in piston air compressors operating in the particular environment involved jsovscosmvome __ some 4 sen vsco AT 100 C 212 F S DENSITY AT 15 C 593 FLASH POINT COC C F ASTM D92 235 455 scosso f omom _ Roms annseo AE soo 10 ROTATING PRESSURE VESSEL OXIDATION TEST ASTM D2272 2200 FAILURE FZG LOAD CARRYING TEST LOAD CEC L 07 A 95 gt 12 STAGE Mixing different types or brands of lubricants is not recommended due N OTI C 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 N OT lubricants may be shorter than quoted by the lubricant supplier Boss encourages the user to closely monitor the lubricant condition and to participate in an oil analysis program with the supplier N OT C E No lubricant however good and or expensive can replace proper main tenance 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 sh
26. ific Machine Information 17 3 309395 arrant y eweee 29 Warranty Statement ae 30 Summary of Main Warranty POIDS een 31 Return Goods Jost terra 32 Preparation of Part Rein patada aida 32 32 Other he ut 33 Transit Dama ne 33 e 35 Frame A m 36 On Cooler SYSTEM siii 38 PASTOS 40 Air uu 42 Eeer 44 Canopy Mi 46 A aqa 48 50 52 54 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 a compact strategically designed system It integrates all
27. il rings With the ring expander install the new ring kit Make certain that the oil ring is on the bottom and the beveled inside edge of the compression ring is toward the top of the piston Position the cylinder base gasket on the crankcase Use a few drops of oil to hold it in position Install the cylinder block spacer and gasket on the crankcase 21 309395 Maintenance XIV Rotate the rings so that the gaps of the three rings are 120 apart See Fig 1 Lightly lubricate the inside of the cylinder Rotate the crankshaft so that a piston is at the top of the stroke Compress the rings with aring compressor and slide the cylinder over the piston Repeat for the other piston Do not lubricate the rings Use a light lubricant such as WD 40 only on the N OTI C cylinder walls Oiling the rings will prevent them from seating and cause excessive oil consumption TOP OF PISTON FIGURE 1 PISTON RING ORIENTATION XV Slidethecylinder down until it mates with the crankcase Start all cylinder mounting bolts until they are snug Torque the bolts to 180 in Ibs in the sequence shown Do not torque to the full 180 in Ibs all at once but in 25 50 in Ib increments See Fig 2 180 IN LBS O e FIGURE 2 CYLINDER MOUNTING BOLT TORQUE SEQUENCE XVI Position the gaskets and valve plate on top of the cylinder Position the head on the cylinder and turn bolts finger tight Torque the studs nuts to 240 in I
28. 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 CFM cubic feet of air per minute at up to a maximum of 150 PSI pounds per square inch High output at relatively 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 B
29. nstalled 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 external 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 33 309395 34 309395 PARTS AND ILLUSTRATION SECTION 35 309395 Frame System Parts List o lt PART NUMBER DESCRIPTION 1 1 301405 BASE 2 2 929806 150 BOLT 3 6 925506 198 NUT 4 1 301248 BRACKET 5 1 301665 MOTOR 6 6 938206 071 WASHER 7 1 1301593 DECAL 8 1 301266 HUB 9 1 301265 HUB 10 1 301267 SPIDER 11 1 301628 WASHER 12 1 929405 100 BOLT 13 6 961504 090 NUT 14 1 970412 106 ELBOW 15 1 970
30. oss synthetic compressor oil The use of any other oil causes excessive carbon buildup and may void the warranty on the compressor NOTE 1 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 Itisimportant that the compressor oil be of a recommended type A CAUTION and that this oil as well as the air filter element be inspected 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 o
31. oss expressly disclaims responsibility or liability for any injury or damage caused by failure to observe these specified precautions or by failure to exercise the ordinary caution and due care required while operating or handling this equipment even though not expressly specified In addition to following these safety guidelines the operator should follow any company specific 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 A M 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 OTI C E 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 rv 8 reva rx Readand understand the ope
32. over into position and start two bolts bolts must be diagonally opposed Strike the pump cover with a rubber faced mallet to jar the pump loose When the tension spring can be felt against the pump cover the pump is loose 23 309395 Maintenance IX Insert the two remaining bolts and torque to 180 in Ibs The bolts should be torqued in a diagonal pattern X Install the air compressor in the vehicle Connect the air lines and wiring 3 Crankshaft and Bearing Replacement If it is necessary to replace the crankshaft related components must also be replaced Replace both bearings both races the key pump collar and pump drive pin Depending on the condition of the crankshaft bearing may be replaced N OTI C E without replacing the crankshaft Replace the bearing races whenever the bearings are replaced 1 Shut down machine and allow to cool for approximately 10 minutes II Verify entire system pressure is relieved before proceeding Remove both heads cylinders and pistons See Piston Ring Replacement on P 21 IV Remove the bolts on the connecting rods and lift them out Reassemble the connecting rods to be certain that the matched parts remain together on the same crankshaft journals lt Remove the pump cover oil pump sleeve spring and rear bearing housing 5 Remove the drive hub and the front bearing housing Pull the crankshaft from the crankcase VIII Remove all gasket material with a single
33. ral 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 C E ALL TRUCKS SHOULD BE ROAD 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 lbs Ensure that you have a sub structure to support at least that weight Be sure to follow all National Vehicle Safety Standards TRUCK MDUNTING SURFACE 7 16 DIA 4 PLACE 12 309395 Installation amp Operation 2 Installing the Wiring
34. rations 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 equipment 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 asituation 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 ADANGER ADANGER ADANGER NOTICE NOTICE Safety Never disable override or remove safeties
35. refully before proceeding onto the initial start up II Start power source and allow for warm up III Verify the compressor is disengaged IV Engage hydraulic system per company policy V Engage compressor 7 Shutdown Procedure I Disengage compressor circuit II 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 procedures required to maintain the compressor in proper operating condition The importance of performing 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
36. sult 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 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 PSI 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 NN UMW 00000000 N mmm 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 L 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 Remove all
37. ut 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 Specifications Do not attempt to drain condensate remove the oil level fill cap or A DAN G 2 4 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 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 ee 20 309395 Maintenance This following pages describe the disassembly and assembly procedures for the air compressor In all cases remove the compressor from the vehicle before proceeding with disassembly and repair within a clean environment Refer to the parts drawings in this manual for p
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