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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)
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 Where To Find Specific Machine Information..........27 309150...
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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.....................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 309150...
(website) 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-resistant canopy. The 36 BHP Piston design provides output of up to 36 CFM (cubic feet of air per minute) at up to a maximum of 150 PSI (pounds per square inch).
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.
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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.
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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. 309150...
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 [451.5 mm] 20 7/8 in 28 1/2 in 1/2 in...
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.
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.
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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.
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.
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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).
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.
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.
. r a r i a . r e 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.
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.
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.
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.
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Maintenance 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.
Maintenance FIGURE 3. CYLINDER HEAD TORQUE SEQUENCE XVIII. Reconnect the 3/4" discharge hose and discharge jumper hose. XIX. Reconnect the 1/4" furnace switch tube. Install the compressor and connect the wiring. XXI. Test the machine. If pressure fails to build and the compressor is excessively noisy, check the valve plate.
Maintenance 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. Insert the two remaining bolts and torque to 180 in-lbs.
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Maintenance 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. 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.
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.
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. 309150...
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.
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.
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.
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.
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...
Decal System Parts List ITEM PART NUMBER DESCRIPTION 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 &...
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