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Boss Industries BA435 Piston Service And Maintenance User Manual

Hydraulic air compressor
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Service and
Maintenance
User Manual
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)
BOSS
BA435 PISTON
Hydraulic Air Compressor
309395
09/17/2013 ARB

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  • Page 1 Maintenance BA435 PISTON User Manual 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)
  • Page 2 309395...

  • Page 3: Table Of Contents

    Contents Revision List....................5 Welcome.......................6 Safety Information....................7 Warnings, safety rules, and hazards............7 Specifications....................10 Description of Components................11 Installation & Operation...................12 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................21 Troubleshooting....................22 General Tips....................22...
  • Page 4 Warranty.....................25 Warranty Statement.................26 Summary of Main Warranty Points............27 Return Goods Instructions..............28 Preparation of Part Return..............28 Filing Procedures...................28 Other Info....................29 Transit Damage..................29 Drawings.....................31 Frame System................32 Piston System..................34 Piston Assembly..................36 Cooler System.................38 Hydraulic Drive System..............40 Discharge System................42 Canopy System................44 Decal System.................46 Wiring Diagram................48 309395...

  • Page 5: Revision List

    Revision List 309395...

  • Page 6: Welcome

    As a result, sometimes there may be slight differences between a given version This manual must be read carefully before using your Boss Industries Air Compressor. Store in a safe and convenient location for future reference.
  • Page 7 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 –...
  • Page 8 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 proce- dures and intervals could result in personal injury, death, and/or damage to equipment and property.
  • Page 9 Safety Never disable, override, or remove safeties, 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.

  • Page 10: Specifications

    Specifications t s i L " H " " 4 " 8 * Hydraulic reservoir requirement for compressor only. Additional capacity will be needed to other hydraulic equipment. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE 22.91 20.12 19.74 26.50 1.00 28.60 –...

  • Page 11: Description Of Components

    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.

  • Page 12: Installation & Operation

    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.
  • Page 13 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.
  • Page 14 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.
  • Page 15 Installation & Operation 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. ___________________________________________________________________________ Check all fluid levels (position the unit on a level surface so that proper amount of fluids can be added).
  • Page 16 Installation & Operation 6. Operating Procedure Read the operation section in the manual carefully before proceeding onto the initial start-up. Start power source and allow for warm-up. III. Verify the compressor is disengaged. Engage hydraulic system per company policy. Engage compressor. 7.

  • Page 17: Maintenance

    Maintenance This section contains instructions for performing the inspection, lubrication, and maintenance proce- dures required to maintain the compressor in proper operating condition. The importance of per- forming the maintenance described herein cannot be over emphasized. The periodic maintenance procedures to be performed on the equipment covered by this manual are listed on the following page.
  • Page 18 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 l l i .

  • Page 19: Lubrication Recommendation

    Maintenance 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 in- spected and replaced as started in this manual. The following are general characteristics for a piston lubricant. Due to the impossibility of establishing limits on all physical and chemical properties of lubricants which can affect their performance in the compressor over a broad range of environmental influences, the responsibility for recommending and consistently furnishing a suitable heavy duty lubricant must rest with the individual supplier if they choose not to use the...

  • Page 20: Compressor Oil

    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.

  • Page 21: Hydraulic Oil Cooler

    Maintenance HYDRAULIC OIL COOLER The interior of the oil cooler should be cleaned when the pressure drop across it at full flow exceeds 25 PSI. Remove cooler. 2. Circulate a suitable solvent to dissolve and remove varnish and sludge. 3. Flush generously with hydraulic oil. 4.

  • Page 22: Troubleshooting

    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.

  • Page 23: Contacting Boss Ind

    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.
  • Page 24 309395...
  • Page 25 WARRANTY SECTION 309395...

  • Page 26: Warranty

    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.
  • Page 27 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.

  • Page 28: Return Goods Instructions

    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.
  • Page 29 5. Machine is within warranty period. 6. Machine has been operated within design conditions. Claims made through distributors must be verified by distributor prior to contacting Boss Industries, Inc.. Damage in Transit Do not return damaged merchandise to Boss Industries, Inc., please follow claim procedure.
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  • Page 31 PARTS AND ILLUSTRATION SECTION 309395...

  • Page 32: Frame System

    Frame System Parts List ITEM PART NUMBER DESCRIPTION 301405 BASE 929806-150 BOLT 925506-198 301248 BRACKET 301665 MOTOR 938206-071 WASHER 301593 DECAL 301266 301265 301267 SPIDER 301628 WASHER 929405-100 BOLT 961504-090 970412-106 ELBOW 970408-088 ELBOW 929806-100 BOLT 309395...
  • Page 33 Frame System 309395...
  • Page 34 Oil Cooler System Parts List ITEM PART NUMBER DESCRIPTION 300909-025 BREAKER 301432 SUPPORT 301433 BRACKET 301434 SHROUD 80061-12 BLOCK 924305-166 938605-071 WASHER 961505-140 929705-075 BOLT 300836 COOLER 960212-075 ELBOW 300211 RELAY 970512-088 CONNECTOR 970508-088 CONNECTOR 305244 BRACKET 301577 FAN ASSY 993204-062 RIVET 943102-038...
  • Page 35 Oil Cooler System FROM DISCHARGE SIDE OF HYD. MOTOR USING 975412-029 TO "B" PORT ON VALVE BLOCK "B" PORT ON BLOCK FROM COOLER OUTLET USING 975412-021 "A" PORT ON BLOCK TO PRESSURE SIDE OF HYD. MOTOR USING 975508-019 309395...

  • Page 36: Piston System

    Piston System Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 308227 902915-015 PLUG 308119 902915-020 RING PLUG 308120 RING 900000-005 PLUG 308121 930005-075 PISTON BOLT 308122 COLLAR 12 925205-273 309384 CRANKSHAFT 309388 308123 BEARING 12 308141 STUD 308124 BEARING...
  • Page 37 Piston System 309395...
  • Page 38 Air Inlet System Parts List ITEM PART NUMBER DESCRIPTION 300855 BAND 301418 SLEEVE 301417 SLEEVE 301602 ISOLATOR 304566 TUBE 300857 938605-071 WASHER 924305-166 301438 FILTER 304515 ADAPTOR 309383 304534 TUBE 301446 BRACKET 929704-050 BOLT 929705-125 BOLT 309395...
  • Page 39 Air Inlet System 309395...

  • Page 40: Discharge System

    Discharge System Parts List ITEM PART NUMBER DESCRIPTION 938206-071 WASHER 925506-198 303202 BRACKET 301578 SWITCH 308152 SWITCH 975104-012 ELBOW 301928-125 CLAMP 934504-075 SCREW 301142 VALVE 960112-075 CONNECTOR 960212-075 ELBOW 961912-075 960012-075 ELBOW 305268 HOSE 929806-100 BOLT 902415-020 922212-000 NIPPLE 902203-022 922108-060 NIPPLE 961608-025...
  • Page 41 Discharge System CONNECT TO EXHAUST PORTS ON THE CYLINDER HEAD FLOW 309395...

  • Page 42: Canopy System

    Canopy System Parts List ITEM PART NUMBER DESCRIPTION 304832 CANOPY 977004-062 WASHER 961504-090 301436 PANEL 301435 PANEL 983904-075 BOLT 984004-071 WASHER 309395...
  • Page 43 Canopy System 309395...
  • Page 44 Oil Drain System Parts List ITEM PART NUMBER DESCRIPTION 302614 HOSE 922106-035 NIPPLE 901515-015 ELBOW 302613 CLIP 943103-025 RIVET 309395...
  • Page 45 Oil Drain System 309395...
  • Page 46 Mounting System Parts List ITEM PART NUMBER DESCRIPTION 308082 BUMPER 929806-200 BOLT 938206-071 WASHER 309395...
  • Page 47 Mounting System 309395...

  • Page 48: Decal System

    Decal System Parts List ITEM PART NUMBER DESCRIPTION 309392 DECAL, BA435 SHEET 309392-01 DECAL, BA435 LOGO 309392-02 DECAL, OIL DRAIN 309392-03 DECAL, VALVE BLOCK 309392-04 DECAL, AIR 309392-05 DECAL, WARNING CONNECT AIR 309392-06 DECAL, DANGER BREATHING 309392-07 DECAL, WARNING READ MANUAL 309392-08 DECAL, WARNING FAN GUARD 309392-09...
  • Page 49 Decal System 1.11 1.11 1.10 309395...
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