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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
36 BHP PISTON
Hydraulic Air Compressor
309150
2/8/2013 ARB
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Table of Contents
Related Manuals for Boss Industries 36 BHP PISTON
Summary of Contents for Boss Industries 36 BHP PISTON
- Page 1 Maintenance 36 BHP 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)
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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 309150...
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Page 5: Revision List
Revision List 309150... -
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 Information
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. 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.
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Page 10: Specifications
Specifications t s i L " H " " 8 " 8 * Hydraulic reservoir requirement for compressor only. Additional capacity will be needed to other hydraulic equipment. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE 17 3/4 in [450.5 mm] 20 7/8 in 28 1/2 in 1/2 in... -
Page 11: Description Of Components
Description of Components Compressor Assembly - The Boss 36 BHP 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 4 pin connector, they need to be connected as follows: 1.
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Page 14: Before Starting
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).
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Page 16: Initial Start-Up & Test
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 Schedule
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 309150...
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Page 25: Warranty
WARRANTY SECTION 309150... -
Page 26: Warranty Statement
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: Summary Of Main Warranty Points
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: Other Info
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. - Page 30 309150...
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Page 31: Drawings
PARTS AND ILLUSTRATION SECTION 309150... -
Page 32: Frame System
Frame System Parts List ITEM PART NUMBER DESCRIPTION 308081 FRAME 961504-090 943103-025 RIVET 302613 CLIP 938206-071 WASHER 308216 ADAPTER 308217 FILTER 929806-100 BOLT 931702-050 SCREW 300211 RELAY 304957 CLAMP 937806-094 WASHER 308218 BRACKET 938604-071 WASHER 938004-062 WASHER 929104-075 BOLT 309150... - Page 33 Frame System 309150...
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Page 34: Piston System
Piston System Parts List ITEM PART NUMBER DESCRIPTION 902915-030 PLUG 300783 SIGHTGLASS 907604-030 BUSHING 960212-075 ELBOW 906915-040 902915-040 PLUG 906030-020 307440 FITTING 901115-020 ELBOW 902203-032 961912-075 40020 PISTON ASSY 960816-100 ELBOW 990512-075 ELBOW 938206-071 WASHER 929806-150 BOLT 937806-094 WASHER 922212-000 NIPPLE 308149 301142... - Page 35 Piston System 309150...
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Page 36: Piston Assembly
Piston Assembly Parts List ITEM PART NUMBER DESCRIPTION 308336 308119 RING 308120 RING 308121 PISTON 308122 COLLAR 308123 BEARING 308124 BEARING 308125 308126 BEARING 308127 SEAL 308128 HOUSING 308129 BEARING 17 929105-100 BOLT 938005-078 WASHER 308130 CLAMP 308131-006 GASKET 308131-010 GASKET 308132 GASKET... - Page 37 Piston Assembly 309150...
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Page 38: Cooler System
Cooler System Parts List ITEM PART NUMBER DESCRIPTION 961505-140 929705-075 BOLT 308086 COOLER 960212-075 ELBOW 301577 993204-062 RIVET 80061-12 BLOCK 970512-088 CONNECTOR 970408-088 ELBOW 938604-071 WASHER 938004-062 WASHER 929104-075 BOLT 308202 SHROUD 938005-078 WASHER 925505-273 929105-275 BOLT 309150... - Page 39 Cooler System 309150...
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Page 40: Hydraulic Drive System
Hydraulic Drive System Parts List ITEM PART NUMBER DESCRIPTION 929806-125 BOLT 301665 MOTOR 301593 DECAL 301266 308166 301267 SPIDER 970412-106 ELBOW 970508-088 CONNECTOR 308085 ADAPTER 937806-094 WASHER 938604-071 WASHER 938004-062 WASHER 929104-100 BOLT 309150... - Page 41 Hydraulic Drive System 309150...
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Page 42: Discharge System
Discharge System Parts List ITEM PART NUMBER DESCRIPTION 308152 SWITCH 922112-030 NIPPLE 960012-075 ELBOW 907603-010 BUSHING 960704-025 ELBOW 922104-020 NIPPLE 902415-030 309150... - Page 43 Discharge System 309150...
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Page 44: Canopy System
Canopy System Parts List ITEM PART NUMBER DESCRIPTION 301383 LATCH 943103-025 RIVET 306891 HINGE 961504-090 981504-075 SCREW 977004-062 WASHER 984004-071 WASHER 306944 SPACER 302011-013 GROMMET 308076 PANEL 308078 PANEL 308079 PANEL 308077 PANEL 309138 HARNESS 3 ft 300444 TAPE, FOAM 309150... - Page 45 Canopy System 309150...
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Page 46: Decal System
Decal System Parts List ITEM PART NUMBER DESCRIPTION 300649 DECAL, BOSS 305761 DECAL, SERIAL TAG 308353 DECAL, SHEET 308353-01 DECAL, DRIVE COUPLING 308353-02 DECAL, DANGER BREATHING 308353-03 DECAL, WARNING CONNECT AIR 308353-04 DECAL, WARNING READ MANUAL 308353-05 DECAL, DO NOT BLOCK AIR INTAKE 308353-06 DECAL, HYD PRESS &... - Page 47 Decal System 309150...
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Page 48: Wiring Diagram
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