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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
K36BP PISTON
Hydraulic Air Compressor
308528
9/02/2014 KWB
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Table of Contents
Related Manuals for Boss K36BP PISTON
Summary of Contents for Boss K36BP PISTON
- Page 1 Maintenance K36BP 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) Fax: (877) 254-4249 (USA) service@bossair.com (email)
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Page 3: Table Of Contents
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 308528... - Page 4 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 308528...
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Page 5: Revision List
Revision List e l f & c i l c i l . s l 308528... -
Page 6: Welcome
07/16/2010 MCM 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). -
Page 7: Safety Information
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. - 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 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. 308528...
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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 for other hydraulic equipment. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE 17 3/4 in [450.5 mm] 1/2 in 21 3/8 in 28 1/2 in... -
Page 11: Description Of Components
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. -
Page 12: Installation & Operation
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. - Page 13 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.
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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 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. Engage hydraulic system per company policy. Verify the compressor and tool circuits are both disengaged. Engage compressor. -
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
. 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. -
Page 19: Lubrication Recommendation
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. -
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. -
Page 21: Piston Ring Replacement
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. - Page 22 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.
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Page 23: Oil Pump Replacement
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. -
Page 24: Crankshaft And Bearing Replacement
Maintenance Insert the two remaining bolts and torque to 180 in-lbs. The bolts should be torqued in a diagonal pattern. 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. - Page 25 Maintenance 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.
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Page 26: 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 27: Contacting Boss
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. 308528... - Page 28 308528...
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Page 29: Warranty
WARRANTY SECTION 308528... -
Page 30: Warranty Statement
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. -
Page 31: Summary Of Main Warranty Points
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. -
Page 32: Return Goods Instructions
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. -
Page 33: 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. Damage in Transit Do not return damaged merchandise to Boss, please follow claim procedure. - Page 34 308528...
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Page 35: Drawings
PARTS AND ILLUSTRATION SECTION 308528... -
Page 36: Frame System
Frame System Parts List ITEM PART NUMBER DESCRIPTION 308221 FRAME, BASE 961504-090 NUT, TINNERMAN 308244 NIPPLE, HYD 985612-075 ADAPTER 938206-071 WASHER, FLAT 308216 ADAPTER, NYLON 308217 FILTER, AIR 929806-100 BOLT, HEX 931702-050 SCREW, MACH 300211 RELAY 304957 CLAMP, HOSE 937806-094 WASHER, LOC 308287 BRACKET, RELAY... - Page 37 Frame System 308528...
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Page 38: Piston System
Piston System Parts List ITEM PART NUMBER DESCRIPTION 902915-030 PLUG, PIPE 300783 SIGHTGLASS, OIL 907604-030 BUSHING, REDUCING 960212-075 ELBOW, HYD 902915-040 PLUG, PIPE 906030-020 CAP, PIPE 902203-032 901115-020 ELBOW, PIPE 906915-040 40020 ASSY, PISTON 960816-100 ELBOW, HYD 1.5 FT 302636 HOSE 938206-071 WASHER, FLAT... - Page 39 Piston System 308528...
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Page 40: 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 929105-100 BOLT 938005-078 WASHER 308130 CLAMP 308131-006 GASKET 308131-010 GASKET 308132 GASKET 308131-020... - Page 41 Piston Assembly 308528...
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Page 42: Cooler System
Cooler System Parts List ITEM PART NUMBER DESCRIPTION 961505-140 NUT, TINNERMAN 929705-075 BOLT, WHIZLOCK 960212-075 ELBOW, HYD 301577 FAN, PUSHER 993204-012 RIVET, SPLIT 938604-071 WASHER, FLAT 938004-062 WASHER, LOC 929104-075 BOLT, HEX 308222 SHROUD, CLR 300836 COOLER, OIL 960712-075 ELBOW, HYD 990612-075 CONNECTOR 308528... - Page 43 Cooler System 308528...
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Page 44: Hydraulic Drive System
Hydraulic Drive System Parts List ITEM PART NUMBER DESCRIPTION 929806-125 BOLT, HEX 301665 MOTOR 301593 DECAL, TEMP 301266 308166 301267 SPIDER 970412-106 ELBOW, HYD 970508-088 CONNECTOR 308085 ADAPTER 937806-094 WASHER, LOC 938604-071 WASHER, FLAT 938004-062 WASHER, LOC 929104-100 BOLT, HEX 308528... - Page 45 Hydraulic Drive System 308528...
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Page 46: Discharge System
Discharge System Parts List ITEM PART NUMBER DESCRIPTION 308152 SWITCH, PRESSURE 902415-030 TEE, PIPE 960012-075 ELBOW, HYD 907603-010 BUSHING, REDUCING 960704-025 ELBOW, HYD 922104-020 NIPPLE, PIPE 922112-035 NIPPLE, PIPE 308528... - Page 47 Discharge System 308528...
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Page 48: Canopy System
Canopy System Parts List ITEM PART NUMBER DESCRIPTION 301383 LATCH 943103-025 RIVET, POP 306891 HINGE, ALU 961504-090 NUT, TINNERMAN 981504-075 SCREW 977004-062 WASHER, NYLON 984004-071 WASHER, FLAT 306944 SPACER, AIR FILTER PANEL 308078 PANEL, TOP 308079 PANEL, ACCESS PANEL, REAR 308077 308226 PANEL, FRONT... - Page 49 Canopy System 308528...
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Page 50: Decal System
Decal System Parts List ITEM PART NUMBER DESCRIPTION 305761 DECAL, SERIAL TAG 308371 DECAL, VALVE BLOCK 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 308353-07 DECAL, WARNING FAN GUARD 308353-08... - Page 51 Decal System 308528...
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Page 52: Wiring Diagram
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