Boss Industries BA435 Piston Service And Maintenance User Manual

[Page 1] Boss Industries BA435 Piston

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) 254-4...

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2 309395 ...

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3 309395 Contents Revision List....................................................................................................5 Welcome.......................................................................................................6...

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4 309395 Warranty.....................................................................................................25 Warranty Statement.................................................................................26 Summary of Mai...

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5 309395 Revision List ETAD NOITACOL EGNAHCFONOITPIRPCSED SLAITINI ...

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6 309395 Welcome General Information Thank you for choosing the Boss BA435 Hydraulic Air Compressor. Before operating this compressor, read over this manual and become well acquainted with your new machine. Doing this will increase your safet...

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7 309395 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 experie...

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8 309395 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 instr...

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9 309395 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 d...

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10 309395 – BA435 system is to run intermittently. – When the BA435 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 12 GAL...

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11 309395 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, ...

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12 309395 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 p...

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13 309395 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. T...

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14 309395 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 inspe...

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15 309395 V. Record all serial numbers for this installation. A. Vehicle V.I.N. ___________________________________________________________________________ B. Hydraulic Pump Data _________________________________________________________________...

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16 309395 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. Verify the compressor is disengaged. IV. Engage hydraulic sy...

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17 309395 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 h...

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18 309395 Maintenance Lubrication and Maintenance Chart 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 n...

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19 309395 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...

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20 309395 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 a pipe on the rear of the crankcase. A drain line is l...

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21 309395 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. 1. Remove cooler. 2. Circulate a suitable solvent to dissolve and remove varnish and sludg...

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22 309395 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 id...

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23 309395 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 Descrip...

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24 309395 ...

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25 309395 WARRANTY SECTION ...

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26 309395 Boss Industries, Inc. warrants that this Piston Compressor unit conforms to applicable drawings and specifications approved in writing by Boss Industries, Inc.. The unit assembly will be free from defects in material and workmanship...

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27 309395 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. warrant...

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28 309395 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 Industries, Inc. the ability to best serve its...

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29 309395 General An approved claim depends on the following provision: 1. An RGA # must be issued by Boss Industries, Inc.. (See filing procedures.) 2. Failed part must be returned within 30 days of original invoice date, freight prepaid, wit...

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30 309395 ...

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31 309395 PARTS AND ILLUSTRATION SECTION ...

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32 309395 Frame System Parts List DESCRIPTIONPART NUMBERQTYITEM BASE 30140511 BOLT 929806-15022 NUT925506-19863 BRACKET 30124814 MOTOR3016651 5 WASHER 938206-07166 DECAL 30159317 HUB301266 18 HUB30126519 SPIDER301267110 WASHER 301628111 BOLT ...

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33 309395 Frame System 15 2 16 8 10 11 16 6 14 6 9 4 5 6 3 7 1 3 13 12 ...

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34 309395 Oil Cooler System Parts List DESCRIPTION PART NUMBER QTY ITEM BREAKER 300909-02511 SUPPORT 301432 12 BRACKET 30143313 SHROUD 301434 14 BLOCK 80061-12 1 5 NUT924305-16666 WASHER938605-0716 7 NUT961505-14088 BOLT 929705-075129 COOLER 3...

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35 309395 Oil Cooler System 10 11 8 9 4 17 16 13 5 14 6 6 7 2 3 9 1 11 12 TO "B" PORT ON VALVE BLOCK "A" PORT ON BLOCK TO PRESSURE SIDE OF HYD. MOTOR USING 975508-019 "B" PORT ON BLOCK FROM COOLER OUTLET USING 975...

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36 309395 Piston System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 4 308227 ROD 2 4 308119 RING 3 8 308120 RING 4 4 308121 PISTON 5 1 308122 COLLAR 6 1 309384 CRANKSHAFT 7 1 308123 BEARING 8 1 308124 BEARING 9 1 308125 PIN 10 1 309385 HOUSI...

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37 309395 Piston System 33 48 35 43 49 50 40 51 39 15 52 27 47 3 3 2 4 1 53 30 23 17 22 6 34 8 11 20 20 10 32 12 28 37 29 26 25 7 14 5 9 42 36 21 18 19 21 21 41 46 45 44 13 16 15 24 32 31 13 38 56 55 54 ...

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38 309395 Air Inlet System Parts List DESCRIPTION PART NUMBER QTY ITEM BAND30085511 SLEEVE 30141812 SLEEVE30141713 ISOLATOR30160224 TUBE30456615 CAP30085716 WASHER 938605-0712 7 NUT924305-16628 FILTER30143819 ADAPTOR 304515210 CAP309383211 TUB...

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39 309395 Air Inlet System 12 8 7 1 11 10 4 15 10 11 13 14 2 5 3 9 6 ...

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40 309395 Discharge System Parts List DESCRIPTIONPART NUMBERQTYITEM WASHER 938206-07141 NUT925506-19822 BRACKET303202 13 SWITCH 30157814 SWITCH3081521 5 ELBOW 975104-012 16 CLAMP 301928-12517 SCREW934504-07518 VALVE30114219 CONNECTOR960112-075...

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41 309395 Discharge System 7 6 2 1 3 1 15 19 4 16 21 5 20 18 17 9 8 13 22 13 12 10 14 11 CONNECT TO EXHAUST PORTS ON THE CYLINDER HEAD AIR FLOW 23 23 ...

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42 309395 Canopy System Parts List DESCRIPTIONPART NUMBERQTYITEM CANOPY 30483211 WASHER 977004-062202 NUT961504-090143 PANEL30143614 PANEL3014351 5 BOLT983904-075206 WASHER 984004-071207 ...

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43 309395 Canopy System 7 2 6 3 3 5 4 6 7 2 1 ...

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44 309395 Oil Drain System Parts List DESCRIPTION PART NUMBER QTY ITEM HOSE30261411 NIPPLE922106-03512 ELBOW901515-01513 CLIP 30261324 RIVET943103-0252 5 ...

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45 309395 Oil Drain System 3 4 1 2 5 ...

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46 309395 Mounting System Parts List DESCRIPTION PART NUMBER QTY ITEM BUMPER30808241 BOLT 929806-20042 WASHER 938206-07143 ...

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47 309395 Mounting System 1 2 3 ...

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48 309395 Decal System Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 309392 DECAL, BA435 SHEET 1.1 2 309392-01 DECAL, BA435 LOGO 1.2 1 309392-02 DECAL, OIL DRAIN 1.3 1 309392-03 DECAL, VALVE BLOCK 1.4 1 309392-04 DECAL, AIR 1.5 1 309392-05 D...

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49 309395 Decal System 1.11 1.10 2 1.1 1.11 1.3 1.4 1.5 1.6 1.7 1.2 1.1 1.9 1.8 ...

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50 309395 System Schematic ...