Service and
Maintenance
User Manual
BOSS
K36BP 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)
http://www.bossair.com (website)
308528
9/02/2014 KWB
2 308528
Contents
Revision List........................................................................................................5
Welcome........................................................................................................6
Safety Information...............................................................................................7
Specifications...............................................................................................10
Description of Components...............................................................................11
Installation & Operation...................................................................................12
Warnings, safety rules, and hazards...............................................................7
Installation............................................................................................12
Before Starting...........................................................................................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.........................................................................................27
Where To Find Specific Machine Information.............................................27
3 308528
Warranty..............................................................................................................29
Warranty Statement....................................................................................30
Summary of Main Warranty Points..............................................................31
Return Goods Instructions.........................................................................32
Preparation of Part Return..........................................................................32
Filing Procedures.......................................................................................32
Other Info..................................................................................................33
Transit Damage..........................................................................................33
Drawings.....................................................................................................35
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
4 308528
Revision List
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5 308528
Welcome
This manual must be read carefully before using your Boss Industries Air Compressor.
Store in a safe and convenient location for future reference.
308528
07/16/2010 MCM
Service and
Maintenance
User Manual
Hydraulic Air Compressor
BOSS
K36BP PISTON
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)
General Information
Thank you for choosing the Boss K36BP 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 K36BP Hydraulic Air Compressor
The Boss K36BP is a compact, strategically designed system. It integrates all major components on a single
frame, which is enclosed in a tough, weather-resistant canopy.
The K36BP 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 K36BP 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 308528
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
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 procedures.
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.
Indicate[s] an imminently hazardous situation, which, if
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,
which, if not avoided can result in property and/or
equipment damage only.
7 308528
Safety
The following safety precautions are a general guide to safe operation of the equipment.
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 procedures 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 processing. 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 308528
Safety
Never disable, override, or remove safeties, either temporarily or permanently.
Connect air hoses only in full compliance with OSHA Standard 29 CFR
1926:302 (b)(7). The required safety devices (velocity fuses) should be
tested in accordance with their manufacturer’s recommendations to verify that
they reduce pressure in case of hose failure and will not nuisance trip with the
hose and tool combinations in use. Failure to comply could result in personal
injury and/or damage to equipment and property.
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. Operating 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 200 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.
Prior to 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 308528
Specifications
1/2 in
[12.7 mm]
17 3/4 in
[450.5 mm]
28 1/2 in
[723.9 mm]
31 3/8 in
[797.4 mm]
21 3/8 in
[542.0 mm]
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SNOISNEMID W"8/312xH"4/371xL"8/313 THGIEW .SBL081
ISP001@YREVILED MFC63
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*.QER
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RETEMAIDNAF "8/141 ISPGNITAREPOLAMRON ISP0581
ISPMUMIXAM ISP0042
* Hydraulic reservoir requirement for compressor only. Additional capacity will be needed for other hydraulic
equipment.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE
– K36BP system is to run intermittently.
– When the K36BP 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 20 GAL for the K36BP plus all the
other manufacturer’s requirements.
– Mounting surface must be capable of 180 lbs. 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 308528
Description of Components
Compressor Assembly - The Boss K36BP 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 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
(10”) for the air to exit. Also, the package location should not be subjected to air temperatures above
ambient.
Fluid Level Sight Glass - This sight glass indicates the fluid level in the crank case. Proper level should be
in the middle of the sight glass. 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
and bolts 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 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, energizing 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.
Operating the compressor at greater than 150 PSI may result in personal injury and property damage.
11 308528
Installation & 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.
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.
12 308528
HYDRAULIC
TANK OUT
HYDRAULIC
PRESSURE
IN
AIR
OUT
Installation & 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 compressor.
The unit is shipped with a 5 pin connector, they need to be connected as follows:
1. Pin “A” and Pin “E” are to be connected directly to battery positive (Pin “A”) and battery
negative (Pin “E”).
2. Compressor Only: for normal compressor operation, supply 12VDC inputs to Pin “C”. 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” will be present only when the system is compressing.
3. Tool Circuit: To operate the tool circuit, supply 12VDC input to Pin “B”. This will interrupt the
signal to the compressor’s hydraulic solenoid and speed control output, disengage the compressor while allowing the cooler fan to continue to operate. This will continue cooling the hydraulic
fluid while the tool circuit is in operation.
3. Connecting the Hydraulic Hoses
The hydraulic hoses to the compressor should be connected directly to the hydraulic fittings. The fittings are
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 hyraulic 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
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 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 3/4” female NPT. The
air line should be made from a good quality (min. 200 PSI) hydraulic hose 1/2” or 3/4” I.D. 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.
13 308528
Installation & 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.
I. 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 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. 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 308528
Installation & Operation
V. Record all serial numbers for this installation.
A. Vehicle V.I.N.
___________________________________________________________________________
B. Hydraulic Pump Data
___________________________________________________________________________
C. Compressor Serial Number
___________________________________________________________________________
D. 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 half the sightglass when
finished with the test.
D. Any other applicable fluids.
E. Transmission fluid and PTO box.
15 308528
Installation & Operation
6. Operating Procedure
I. Read the operation section in the manual carefully before proceeding onto the initial start-up.
II. Start power source and allow for warm-up.
III. Engage hydraulic system per company policy.
IV. Verify the compressor and tool circuits are both disengaged.
V. Engage compressor. If the tool circuit is needed, engage the tool circuit. The compressor will stop,
but the cooler fan will continue to run. When the tool circuit is no longer required, disengage the
tool circuit and the compressor will automatically start.
7. Shutdown Procedure
I. Disengage tool circuit (if engaged).
II. Disengage compressor circuit.
III. 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 308528
Maintenance
PART NUMBER DESCRIPTION
80186 KIT, REPAIR REED VALVE
308157 ELEMENT, AIR FILTER
301267 SPIDER, CURVED JAW
302936 KIT, REPAIR HYD MOTOR SEAL
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 checking fluid levels. Open service valve to ensure relief of
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
For Parts and/or Service 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)
How To Order Parts
17 308528
Maintenance
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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
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.
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-lbs plus or minus 10 in-lbs.
18 308528
Maintenance
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Lubrication Recommendations
It is important that the compressor oil be of a recommended type
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 of the suitability of the
recommended lubricant in piston air compressors operating in the particular environment involved.
Mixing different types or brands of lubricants is not recommended due
to the possibility of a dilution of the additives or a reaction between
additives or different types.
19 308528
Maintenance
Due to environmental factors, the useful life of all “extended life”
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.
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 the side of the compressor body. A drain line is located opposite
the service door. The proper oil level is in the middle of the oil sightglass, 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 Specifications”.
Do not attempt to drain condensate, remove the oil level fill cap, or
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 308157)
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.
1. Remove cooler.
2. Circulate a suitable solvent to dissolve and remove varnish and sludge.
3. Flush generously with hydraulic oil.
4. Once the cooler is reinstalled, fill the hydraulic system with the proper fluid to their appropriate levels.
20 308528
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 parts locations.
1. Piston Ring Replacement
I.
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.
VII. Remove the cylinder bolts. Tap the sides of the cylinder several times to break it loose from
VIII. Use a single edged razor blade, or sharp putty knife, to remove the old gasket material.
Shut down machine and allow to cool for approximately 10 minutes.
A rubber faced mallet will help when removing the head. Tap the sides of
the head carefully until the head is loose. Lift off the heads.
the gasket. Rock the cylinder back and forth and lift until it is free. Lift it off the pistons.
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
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.
XI. With a ring expander, remove the compression and oil rings.
XII. 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.
XIII. 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 308528
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 a ring 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
cylinder walls. Oiling the rings will prevent them from seating and cause
excessive oil consumption.
FIGURE 1. PISTON RING ORIENTATION
XV. Slide the cylinder down until it mates with the crankcase. Start all cylinder mounting bolts, until they
are snug. Torque the bolts to 180 in-lbs in the sequence shown. Do not torque to the full 180 in-lbs
all at once, but in 25-50 in-lb increments. See Fig. 2.
180 IN-LBS
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-lbs in 25-50 pound increments. See Fig. 3.
22 308528
Maintenance
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. Test the machine.
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. Shut down machine and allow to cool for approximately 10 minutes.
II. Verify entire system pressure is relieved before proceeding.
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 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
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.
V. Lift the pump out of the cavity.
VI. Position a new gasket on the rear bearing housing.
VII. 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.
VIII. Place the pump cover 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 308528
Maintenance
IX. Insert the two remaining bolts and torque to 180 in-lbs. 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
without replacing the crankshaft. Replace the bearing races whenever the
bearings are replaced.
I. Shut down machine and allow to cool for approximately 10 minutes.
II. Verify entire system pressure is relieved before proceeding.
III. 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.
V. Remove the pump cover, oil pump, sleeve, spring, and rear bearing housing.
VI. Remove the drive hub, and the front bearing housing.
VII. Pull the crankshaft from the crankcase.
VIII. Remove all gasket material with a single 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
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.
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 308528
Maintenance
XI. Press the new bearings into position.
XII. Generously oil the front bearing race and install the front bearing housing with gasket. Torque the
bolts to 180 in-lbs. See Fig. 4.
The crankshaft should have new bearings installed. If not, press the new
bearings into position on the crankshaft.
FIGURE 4. BEARING HOUSING TORQUE SEQUENCE
XIII. 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
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.
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.
FIGURE 5. ROD ALIGNMENT
25 308528
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
1. Low oil level.
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. Defective oil pump
2. Blocked oil passage.
3. Damage oil pump drive pin.
COMPRESSOR WILL NOT ENGAGE
1. No power supplied to compressor.
2. Internal circuit breaker tripped.
3. Hydraulic system not engaged.
4. Defective pressure switch.
COMPRESSOR ENGAGES BUT WILL NOT PRESSURIZE TANK
1. Air leak in plumbing.
2. Worn piston rings or valve plates.
COMPRESSOR DOES NOT RECOVER PRESSURE AS FAST AS IT SHOULD
1. Dirty filter.
2. Air leak in plumbing.
3. Worn valve plates or piston rings.
26 308528
Troubleshooting
Contacting Boss
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)
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.
27 308528
28 308528
WARRANTY SECTION
29 308528
Boss warrants that this Piston Compressor unit conforms to applicable drawings and specifications
approved in writing by Boss. 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 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 receives from the Buyer written notice of and alleged defect in or nonconformance of
the unit, all other components and parts of Boss manufacture and if in the judgment of Boss these items
do not conform or are found to be defective in material of workmanship, Boss 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 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. 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’ sole
responsibility and Buyer’s exclusive remedy hereunder is limited to such repair, replacement, or repayment
of the purchase price. Parts not of Boss manufacture are warranted only to the extent that they are
warranted by the original manufacture. Boss shall have no responsibility for any cost or expense
incurred by Buyer from inability of Boss to repair under said warranty when such inability is beyond the
control of Boss or caused solely by Buyer.
There are no other warranties, express, statutory or implied, including 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 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 manufacture or approved by Boss 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 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 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, or lost production, whether suffered by Buyer or any third party.
Boss Industries, Inc.
1761 Genesis Drive
LaPorte, IN 46350
Warranty
30 308528
Warranty
Summary of Main Warranty Provisions
As claims, policies and procedure are governed by the terms of the Boss warranty, it is necessary to outline
some of the more important provisions.
The Boss warranty applies only to new and unused products which, after shipment from the factory, have 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 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 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 replacement parts covers the net cost of the party only, not labor and mileage.
The Boss warranty does not cover diagnostic calls and travel. That is time spent traveling to the machine to
analyze the problem and returning with the proper tools and parts to correct the problem.
Boss will deduct from allowable credits for excess freight caused by sender failing to follow return shipping
instructions.
Distributors or end-users automatically deducting the value of a warranty claim from outstanding balances
due and payable to Boss prior to receiving written notification of Boss approval of the warranty claim may be
subject to forfeiture of the entire claim.
31 308528
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 the ability to best serve its’ customers.
Please see the following instructions to initiate a return:
Contact Boss 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.
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 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
1. Initiate through a purchase order for warranty part or request for credit.
2. RGA will accompany replacement part.
3. Boss 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 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 308528
Warranty
General
An approved claim depends on the following provision:
1. An RGA # must be issued by Boss. (See filing procedures.)
2. Failed part must be returned within 30 days of original invoice date, freight prepaid, with
RGA #.
3. Part is determined to be defective.
4. Workmanship is determined to be defective.
5. Machine is within warranty period.
6. Machine has been operated within design conditions.
Claims made through distributors must be verified by distributor prior to contacting Boss.
Damage in Transit
Do not return damaged merchandise to Boss, 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 shipment. 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 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 Receipt, and signed by the carrier’s agent. Failure to adequately describe such external evidence 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 308528
34 308528
PARTS AND
ILLUSTRATION
SECTION
35 308528
Parts List
ITEM
QTY
PART NUMBER
DESCRIPTION
1 1 308221
FRAME, BASE
2 6 961504-090 NUT, TINNERMAN
3 1 308244 NIPPLE, HYD
4 1 985612-075 ADAPTER
5
1 938206-071 WASHER, FLAT
6 1 308216
ADAPTER, NYLON
7
1 308217
FILTER, AIR
8 1 929806-100
BOLT, HEX
9 3 931702-050
SCREW, MACH
10 3 300211 RELAY
11 1 304957
CLAMP, HOSE
12 1 937806-094 WASHER, LOC
13 1 308287
BRACKET, RELAY
14 2 938604-071 WASHER, FLAT
15 2 938004-062
WASHER, LOC
16 2 929104-075
BOLT, HEX
17 1 308223 BRACKET, HYD BLOCK
18 4 938605-071
WASHER, FLAT
19
4
938005-078 WASHER, LOC
20 2 929105-300
BOLT, HEX
21 1 80061-12
BLOCK, HYD VALVE
22 1 970512-088
CONNECTOR
23 1 970408-088
ELBOW
24 1 970412-088 ELBOW
25 1 983012-088 ADAPTER
26 1 983512-075
ADAPTER
27 2 929105-100
BOLT, HEX
28 1 943103-025 RIVET
29 1 302613
CLIP
Frame System
36 308528
1
13
10
16
14
15
6
7
11
12
8
5
18
26
25
20
19
24
21
23
22
27
19
18
17
2
4
3
9
29
28
Frame System
37 308528
Parts List
ITEM QTY PART NUMBER DESCRIPTION
1
4
902915-030 PLUG, PIPE
2 1 300783
SIGHTGLASS, OIL
3 1 907604-030 BUSHING, REDUCING
4 1 960212-075
ELBOW, HYD
5 2 902915-040 PLUG, PIPE
6 1 906030-020 CAP, PIPE
7
1 902203-032 TEE
8 1 901115-020 ELBOW, PIPE
9 1 906915-040 TEE
10 1 40020 ASSY, PISTON
11 1 960816-100 ELBOW, HYD
12 1.5 FT 302636
HOSE
13 4 938206-071 WASHER, FLAT
14 4 929806-150
BOLT, HEX
15 4 937806-094 WASHER, LOC
16 2 922212-000 NIPPLE, PIPE
17 1 308149
CAP, BREATHER
18 1 301142
VALVE, CHECK
19 1 975104-012 ELBOW, COMPRSN
20 1 301578 SWITCH, TEMP
21 1 961912-075 TEE
22 1 902615-030 ELBOW, PIPE
23 2 308214
ELBOW, NYLON
24 1 308215 ADAPTER, NYLON
25 2 960012-075 ELBOW, HYD
26 1 990512-075
ELBOW, HYD
27 2 307440 FITTING
Piston System
38 308528
10
8
6
9
19
14
15
13
25
4
1
20
13
15
14
2
11
3
17
16
18
26
21
25
1
5
24
22
16
1
23
23
1
7
27
12
27
Piston System
39 308528
Piston Assembly
Parts List
ITEM QTY PART NUMBER DESCRIPTION
1 4 308336 ROD
2 4 308119
RING
3 8 308120 RING
4 4 308121 PISTON
5 1 308122
COLLAR
6 1 308123 BEARING
7 1 308124 BEARING
8 1 308125 PIN
9 1 308126 BEARING
10 1 308127
SEAL
11 1 308128 HOUSING
12 1 308129 BEARING
13 5 929105-100 BOLT
14
5
938005-078 WASHER
15 1 308130 CLAMP
16 1 308131-006 GASKET
17 1 308131-010 GASKET
18 2 308132 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
30 12 925805-273 NUT
31 12 308140 STUD
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 CRANKSHAFT
41 1 308058 CRANKCASE
42 2 308148 HEAD
43 1 308162
HOUSING
44 2
308139-MOD REED VALVE ASSY
45 2 308064 CYLINDER BLOCK
46 4 308186 PIN
47 1 921103-100 KEY
40 308528
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
41
1
1
4
4
2
3
3
38
31
25
30
35
44
36
46
46
42
32
39
29
45
Piston Assembly
41 308528
Parts List
DESCRIPTIONPART NUMBERQTYITEM
NUT, TINNERMAN961505-14081
BOLT, WHIZLOCK929705-07582
ELBOW, HYD960212-07513
FAN, PUSHER30157714
RIVET, SPLIT993204-0124
5
WASHER, FLAT
938604-07146
WASHER, LOC
938004-06247
BOLT, HEX
929104-07548
SHROUD, CLR
30822219
COOLER, OIL300836110
ELBOW, HYD960712-075111
CONNECTOR
990612-075112
Cooler System
42 308528
4
9
5
6
7
8
2
3
1
10
11
12
Cooler System
43 308528
Parts List
ITEM QTY PART NUMBER DESCRIPTION
1 2 929806-125
BOLT, HEX
2 1 301665 MOTOR
3 1 301593
DECAL, TEMP
4 1 301266 HUB
5
1 308166
HUB
6 1 301267
SPIDER
7 1 970412-106
ELBOW, HYD
8 1 970508-088
CONNECTOR
9 1 308085
ADAPTER
10 2 937806-094 WASHER, LOC
11
5
938604-071 WASHER, FLAT
12 5 938004-062
WASHER, LOC
13
5
929104-100
BOLT, HEX
Hydraulic Drive System
44 308528
5
13
2
3
1
10
7
4
6
12
11
8
9
Hydraulic Drive System
45 308528
Parts List
DESCRIPTION
PART NUMBER
QTY
ITEM
SWITCH, PRESSURE
30815211
TEE, PIPE902415-03013
ELBOW, HYD
960012-0751
4
BUSHING, REDUCING
907603-0101
5
ELBOW, HYD
960704-02516
NIPPLE, PIPE922104-0201
7
NIPPLE, PIPE922112-03518
Discharge System
46 308528
5
7
6
1
4
3
8
Discharge System
47 308528
Parts List
ITEM QTY PART NUMBER DESCRIPTION
1 1 301383
LATCH
2 6 943103-025
RIVET, POP
3 1 306891
HINGE, ALU
4 18 961504-090 NUT, TINNERMAN
5
24 981504-075 SCREW
6 24 977004-062
WASHER, NYLON
7
24 984004-071 WASHER, FLAT
8 1 306944 SPACER, AIR FILTER PANEL
9 1 308078 PANEL, TOP
10 1 308079
PANEL, ACCESS
11 1 308077
PANEL, REAR
12 1 308226
PANEL, FRONT
13 1 302011-013 GROMMET
NS .75 ft 300574-012 SLEEVE
NS
1 308238
HARNESS
NS 3 ft 300444 TAPE FOAM
Canopy System
48 308528
11
9
3
8
12
4
7
6
4
2
2
10
1
13
5
Canopy System
49 308528
Decal System
Parts List
DESCRIPTION
PART NUMBER
QTY
ITEM
DECAL, SERIAL TAG
30576111
DECAL, VALVE BLOCK30837112
DECAL, SHEET30835314
DECAL, DRIVE COUPLING308353-0114A
DECAL, DANGER BREATHING
308353-0214B
DECAL, WARNING CONNECT AIR
308353-031
4C
DECAL, WARNING READ MANUAL308353-0414D
DECAL, DO NOT BLOCK AIR INTAKE
308353-0514E
DECAL, WARNING FAN GUARD
308353-0714F
DECAL, AIR308353-0814G
DECAL, OIL DRAIN308353-091
4H
DECAL, COMPR SIGHT GLASS308353-1024I
50 308528
Decal System
4G
4B
4C
4I
4D
4I
1
4H
4E
4F
4A
2
51 308528
System Schematic
52 308528
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