Boss 36 BHP PISTON, Service And Maintenance User Manual

Page 1: ...e 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 http www bossair com website 309150 10 29 2014 KWB Service and Maintenance User Manual Hydraulic Air Compressor BOSS 36 BHP PISTON ...

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Page 3: ...rting 14 Initial Start up Test 16 Maintenance 17 Overview 17 Recommended Spare Parts List 17 Maintenance Schedule 18 Lubrication Recommendation 19 Compressor Oil 20 Air Intake Filter 20 Hydraulic Oil Cooler 20 Piston Ring Replacement 21 Oil Pump Replacement 23 Crankshaft and Bearing Replacement 24 Troubleshooting 26 General Tips 26 Contacting Boss Ind 27 WhereTo Find Specific Machine Information 2...

Page 4: ...n Goods Instructions 32 Preparation of Part Return 32 Filing Procedures 32 Other Info 33 Transit Damage 33 Drawings 34 Frame System 36 Piston System 38 Piston Assembly 40 Cooler System 42 Hydraulic Drive System 44 Discharge System 46 Canopy System 48 Decal System 50 Wiring Diagram 52 ...

Page 5: ...5 309150 Revision List E T A D N O I T A C O L E G N A H C F O N O I T P I R P C S E D S L A I T I N I ...

Page 6: ...ossible Boss strives to continuallyimprovetheefficiencyandperformanceofitsmachines Asa result sometimestheremaybeslightdifferencesbetweenagivenversion ofthemanualandthemachine Boss 36 BHP Hydraulic Air Compressor The Boss 36 BHP is a compact strategically designed system It integrates all major components on a single frame which is enclosed in a tough weather resistantcanopy The 36 BHP Piston desi...

Page 7: ...erve these specified precautions or by failure to exercise theordinarycautionandduecarerequiredwhileoperatingorhandlingthisequipment eventhoughnot expresslyspecified Inadditiontofollowingthesesafetyguidelines theoperatorshouldfollowanycompanyspecificguidelines and procedures Consult your immediate supervisor for specific company safety guidelines and or proce dures Thefollowingsafetysymbolsareused...

Page 8: ...ressure 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 Airfromthiscompressorwillcausesevereinjuryifused...

Page 9: ...ve 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 Slightvibrationm...

Page 10: ...S SUBJECT TO CHANGE WITHOUT PRIOR NOTICE E C R U O S R E W O P R O T O M C I L U A R D Y H D E E P S G N I T A R E P O X A M M P R 0 0 4 1 G I F N O C R E D N I L Y C n o t s i P 4 V Y T I C A P A C L I O S T Q 3 1 1 S N O I S N E M I D W 8 7 0 2 x H 4 3 7 1 x L 2 1 8 2 T H G I E W S B L 0 8 1 I S P 0 0 1 Y R E V I L E D M F C 6 3 R I O V R E S E R C I L U A R D Y H Q E R M U M I N I M N O L L A G...

Page 11: ...system consists of Hydraulicoilcoolerfanassemblyandrelay 12VDC N O hydraulic solenoid Switchrelayforcustomerequipmentinterfaceduringcompressoroperation 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 fatiguing the fastenerand mating part...

Page 12: ...oes 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 clearan...

Page 13: ...aulicfittings Thefittingsare 3 4 JIC 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 T can be made from a medium pressure min 1000 PSI hydraulic hose 3 4 I D Care should be taken to see that the hosesarenotinstalledwithkinksorbendsthatinhibitflowofthehydraulicoil La...

Page 14: ...are in correct operatingposition 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 Vacuumallareasthathavemetalorplasticshavings Wipeallfingerprintsoffunitandvehicle Installation Operation 5 Pre Start up Inspection Checks Acompressor service valve should be located at the hose reel inlet...

Page 15: ...______________________ 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 th...

Page 16: ... Engagehydraulicsystempercompanypolicy V Engagecompressor 7 Shutdown Procedure I Disengagecompressorcircuit II Relievesystemofstoredair Installation Operation Operating Conditions Thefollowingconditionsshouldexistformaximumperformanceofthecompressor Thetruckshouldbeas close to level as possible when operating Operation in ambient temperatures above 100 F 38 C may experiencehightemperatureshutdown ...

Page 17: ...d program of periodic inspection and maintenance will help avoid premature failure and costly repairs Daily visualinspectionsshouldbecomearoutine Maintenance Recommended Spare Parts List 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 bossair com email http www bossair com website PART NUMBER DESCRIPTION 80186...

Page 18: ...d after the initial day of operation The compressor must be cold room temperature before re torquing of studs Torque studs to 240 in lbs plus or minus 10 in lbs L A V R E T N I E C I V R E S N O I T A R E P O E C N A N E T N I A M Y L I A D d e d e e n f i d d A l e v e l l i o e s a c k n a r c k c e h C 1 r e v i e c e r r i a m o r f n o i t a s n e d n o c n i a r D 2 Y L K E E W e k a t n i r...

Page 19: ...O C S I V C I T A M E N I K 5 4 4 D M T S A F 4 0 1 C 0 4 T A s 2 m m 6 4 F 2 1 2 C 0 0 1 T A s 2 m m 7 7 F 9 5 C 5 1 T A Y T I S N E D L m g 8 9 2 1 D M T S A 3 4 8 C O C T N I O P H S A L F F C 2 9 D M T S A 5 5 4 5 3 2 T N I O P R U O P F C 7 9 D M T S A 9 4 5 4 I V X E D N I Y T I S O C S I V 9 0 9 2 O S I N I D 5 3 1 S E I T R E P O R P N O I T N E V E R P T S U R B 5 6 6 D M T S A S S A P Y ...

Page 20: ...oggedairfilterelementwillreducecompressorperformance 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 1 Removecooler 2 Circulateasuitablesolventtodissolveandremovevarnishandsludge 3 Flushgenerouslywithhydraulicoil 4 Oncethecoolerisreinstalled fillthehydraulicsystemwiththeproperf...

Page 21: ...ylinder to break the glaze and to remove the buildup at the top of the cylinders XI 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 XII Witharingexpander removethecompressionandoilrings XIII With the ring expander install the new ring kit Make certain that the oil ring is o...

Page 22: ... cylinder Rotate the crankshaft so that a piston is at the top of the stroke Compress the rings with a ring compressor and slide the cylinder over the piston Repeat for the other piston XVII 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 lbs in 25 50 pound increments See Fig 3 FIGURE 2 CYLIND...

Page 23: ...hose XIX Reconnect the 1 4 furnace switch tube XX Installthecompressorandconnectthewiring XXI Testthemachine 2 Oil Pump Replacement I Shutdownmachineandallowtocoolforapproximately10minutes II Verifyentiresystempressureisrelievedbeforeproceeding III Remove the bolts and lift off the pump cover IV With a single edged razor blade or sharp putty knife remove the old gasket material Take care not to da...

Page 24: ...lt against the pump cover the pump is loose IX Insert the two remaining bolts and torque to 180 in lbs The bolts should be torqued in a diagonal pattern X Installtheaircompressorinthevehicle Connecttheairlinesandwiring 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 p...

Page 25: ... and 020 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 freely FIGURE 4 BEARING HOUSING TORQUE SEQUENCE 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 XI Press the new bearings into position...

Page 26: ...east amount of time and with the least amount of removal or disassembly of parts should be performed first Troubleshooting LOW OIL PRESSURE 1 Lowoillevel 2 Loose pipe plug on oil pump cover 3 Worn or defective oil pump 4 Crack or scratch on oil pump cover NO OIL PRESSURE 1 Defectiveoilpump 2 Blocked oil passage 3 Damageoilpumpdrivepin COMPRESSOR WILL NOT ENGAGE 1 No power supplied to compressor 2 ...

Page 27: ... Fax 877 254 4249 http www bossair com Whencallingfortechnicalsupport havethefollowinginformationavailable 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 ...

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Page 29: ...29 309150 WARRANTY SECTION ...

Page 30: ...Boss Industries Inc sole responsibility and Buyer s exclusive remedyhereunderislimitedtosuchrepair replacement orrepaymentofthepurchaseprice Partsnot of Boss Industries Inc manufacture are warranted only to the extent that they are warranted by the originalmanufacture BossIndustries Inc shallhavenoresponsibilityforanycostorexpenseincurred by Buyer from inability of Boss Industries Inc to repair un...

Page 31: ...t 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...

Page 32: ...r 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 Inc freight prepaid Items sent without RGAnumber will not be accepted Unauthorized Returns Will ImmediatelyBeRefusedAtDock Return or Warranty ...

Page 33: ...he 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 2 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 content...

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Page 35: ...35 309150 PARTS AND ILLUSTRATION SECTION ...

Page 36: ...VET 943103 025 1 3 CLIP 302613 1 4 WASHER 938206 071 1 5 ADAPTER 308216 1 6 FILTER 308217 1 7 BOLT 929806 100 1 8 SCREW 931702 050 2 9 RELAY 300211 2 10 CLAMP 304957 1 11 WASHER 937806 094 1 12 BRACKET 308218 1 13 WASHER 938604 071 2 14 WASHER 938004 062 2 15 BOLT 929104 075 2 16 Frame System ...

Page 37: ...37 309150 16 15 13 14 10 1 2 5 11 12 8 6 7 9 4 3 Frame System ...

Page 38: ... 2 307440 FITTING 9 1 901115 020 ELBOW 10 1 902203 032 TEE 11 1 961912 075 TEE 12 1 40020 PISTON ASSY 13 1 960816 100 ELBOW 14 1 990512 075 ELBOW 15 4 938206 071 WASHER 16 4 929806 150 BOLT 17 4 937806 094 WASHER 18 2 922212 000 NIPPLE 19 1 308149 CAP 20 1 301142 VALVE 21 1 975104 012 ELBOW 22 1 301578 SWITCH 24 1 902615 030 ELBOW 25 2 308214 ELBOW 26 1 308215 ADAPTER 27 2 960012 075 ELBOW 28 1 5 ...

Page 39: ...39 309150 Piston System 7 21 18 4 14 20 22 27 13 3 2 27 12 19 1 11 1 26 24 18 25 1 16 17 15 6 25 1 5 9 10 8 8 28 ...

Page 40: ...32 GASKET 19 3 308131 020 GASKET 20 1 308133 TUBE 21 1 308134 SCREEN 22 1 308135 COVER 23 1 308136 BUSHING 24 1 308137 SPRING 25 12 308138 WASHER 26 1 902915 015 PLUG 27 2 900000 005 PLUG 28 9 930005 075 BOLT 29 12 925205 273 NUT 32 12 308141 STUD 33 1 308142 PIN 34 1 308143 GASKET 35 2 308144 GASKET 36 2 308145 MOD GASKET 37 1 308146 PUMP 38 2 308147 GASKET 39 12 938604 071 WASHER 40 1 308038 CRA...

Page 41: ...41 309150 28 22 34 27 13 14 11 19 19 17 16 19 33 37 8 5 12 6 23 24 26 20 15 21 40 47 7 9 18 18 43 28 10 48 49 41 1 1 4 4 2 3 3 38 25 35 44 36 46 46 42 32 39 29 45 13 PistonAssembly ...

Page 42: ...5 075 8 2 COOLER 308086 1 3 ELBOW 960212 075 2 4 FAN 301577 1 5 RIVET 993204 012 4 6 BLOCK 80061 12 1 7 CONNECTOR 970512 088 1 8 ELBOW 970408 088 1 9 WASHER 938604 071 4 10 WASHER 938004 062 4 11 BOLT 929104 075 4 12 SHROUD 308202 1 13 WASHER 938005 078 1 14 NUT 925505 273 1 15 BOLT 929105 275 2 16 ...

Page 43: ...43 309150 13 6 5 3 7 1 4 4 2 10 11 12 9 8 16 14 15 16 Cooler System ...

Page 44: ...R QTY ITEM BOLT 929806 125 2 1 MOTOR 301665 1 2 DECAL 301593 1 3 HUB 301266 1 4 HUB 308166 1 5 SPIDER 301267 1 6 ELBOW 970412 106 1 7 CONNECTOR 970508 088 1 8 ADAPTER 308085 1 9 WASHER 937806 094 2 10 WASHER 938604 071 5 11 WASHER 938004 062 5 12 BOLT 929104 100 5 13 ...

Page 45: ...45 309150 3 1 10 7 2 4 6 5 13 12 11 9 8 Hydraulic Drive System ...

Page 46: ...50 Discharge System Parts List DESCRIPTION PART NUMBER QTY ITEM SWITCH 308152 1 1 NIPPLE 922112 030 1 2 ELBOW 960012 075 1 3 BUSHING 907603 010 1 4 ELBOW 960704 025 1 5 NIPPLE 922104 020 1 6 TEE 902415 030 1 7 ...

Page 47: ...47 309150 2 3 4 6 5 1 7 Discharge System ...

Page 48: ...1 RIVET 943103 025 6 2 HINGE 306891 1 3 NUT 961504 090 18 4 SCREW 981504 075 24 5 WASHER 977004 062 24 6 WASHER 984004 071 24 7 SPACER 306944 1 8 GROMMET 302011 013 1 9 PANEL 308076 1 10 PANEL 308078 1 11 PANEL 308079 1 12 PANEL 308077 1 13 HARNESS 309138 1 NS TAPE FOAM 300444 3 ft NS ...

Page 49: ...49 309150 Canopy System 11 13 4 6 7 1 12 2 2 8 3 4 10 9 5 ...

Page 50: ...OUPLING 2B 1 308353 02 DECAL DANGER BREATHING 2C 1 308353 03 DECAL WARNING CONNECT AIR 2D 1 308353 04 DECAL WARNING READ MANUAL 2E 1 308353 05 DECAL DO NOT BLOCK AIR INTAKE 2F 1 308353 06 DECAL HYD PRESS TANK 2G 1 308353 07 DECAL WARNING FAN GUARD 2H 1 308353 08 DECAL AIR LEXAN 2I 1 308353 09 DECAL OIL DRAIN 2J 2 308353 10 DECAL COMPR SIGHT GLASS ...

Page 51: ...51 309150 2J 2B 2C 2D 2J 2H 2E 1 2I 2G 2A 2F Decal System ...

Page 52: ...52 309150 System Schematic ...