Boss BA435 PISTON, Service And Maintenance Manual

Page 1: ...e 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 309395 02 08 2013 ARB Service and Maintenance User Manual Hydraulic Air Compressor BOSS BA435 PISTON ...

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Page 3: ...tion 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 Contacting Boss Ind 23 Where To Find Specific Machine Information 23 ...

Page 4: ...n 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 ...

Page 5: ...5 309395 Revision List E T A D N O I T A C O L E G N A H C F O N O I T P I R P C S E D S L A I T I N I ...

Page 6: ...n 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 High output at relativelylowGPM gallonsperminute translatesinto themostefficient quiet andreliablesysteminitsclass designedtohandlevirtuallyanyapplication The BA435 Piston also has enhanced safety features offeringapplicationsdesignedtoprotectyourmost valuable resource your operating...

Page 7: ...erve these specified precautions or by failure to exercise theordinarycautionandduecarerequiredwhileoperatingorhandlingthisequipment eventhoughnot expresslyspecified Inadditiontofollowingthesesafetyguidelines theoperatorshouldfollowanycompanyspecificguidelines and procedures Consult your immediate supervisor for specific company safety guidelines and or proce dures Thefollowingsafetysymbolsareused...

Page 8: ...ressure vessel or device System contains hot oil The compressor system must be shut off prior to servicing Open the service valve to ensure complete relief of system air pressure and stored energy Then permit system to cool down prior to adding compressor oil or servicing the unit Do not use air from this compressor for breathing or food process ing Airfromthiscompressorwillcausesevereinjuryifused...

Page 9: ...tem of all stored air pressure after use Never adjust the pressure switch to a setting of greater than 150 PSI Oper ating the compressor at greater than 150 PSI may result in personal injury and property damage Mount the compressor in a stable location capable of supporting 180 lbs Slightvibrationmayoccurduringoperationandthemachinemaymoveifnot securelymounted Whenusingtools maintainsecurefootinga...

Page 10: ...tions SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE E C R U O S R E W O P R O T O M C I L U A R D Y H D E E P S G N I T A R E P O X A M M P R 0 0 4 1 G I F N O C R E D N I L Y C n o t s i P 4 V Y T I C A P A C L I O S T Q 3 1 1 S N O I S N E M I D W 4 3 9 1 x H 8 1 9 1 x L 2 1 6 2 T H G I E W S B L 0 8 1 I S P 0 0 1 Y R E V I L E D M F C 5 3 R I O V R E S E R C I L U A R D Y H Q E R M U M ...

Page 11: ...ystem consists of Hydraulicoilcoolerfanassemblyandrelay 12VDC N O hydraulic solenoid Switchrelayforcustomerequipmentinterfaceduringcompressoroperation Most air tools operating pressure range is between 90 and 125 psi Operating above the tools recommended pressures will decrease the life of the tool Higher operating pressure can also over torque nuts and bolts fatiguing the fastener and mating part...

Page 12: ...oes not impede the operation of other components on the vehicle For example if your vehicle is equipped with a crane you must make sure the compressor will not interfere with the swing of the crane In addition the compressor should be installed in an area that permits cool ambient air to enter the air filter and the hot air to exhaust without recirculating into the air filter 10 of exhaust clearan...

Page 13: ...e connected directly to the hydraulic block The port sizes in the blocke are 10 SAE The pressure P input line should be made from a good quality high pressure hydraulic hose 1 2 or 3 4 I D rated to handle the hydraulic systems on the vehicle The return line to tank T can be made from a medium pressure min 1000 PSI hydraulic hose 3 4 I D Care should be taken to see that the hoses are not installed ...

Page 14: ...are in correct operatingposition IV Apply decals to proper location Make sure that the area is cleaned prior to applying decals All decals should have a professional appearance upon application V Vacuumallareasthathavemetalorplasticshavings Wipeallfingerprintsoffunitandvehicle Installation Operation 5 Pre Start up Inspection Checks Acompressor service valve should be located at the hose reel inlet...

Page 15: ..._________________ F Note any special applications relating to specific installations ___________________________________________________________________________ VI Check all fluid levels position the unit on a level surface so that proper amount of fluids can be added A Fuel to provide three hours of operation B Hydraulic fluid levels may have to be topped off after test C Compressor Check the com...

Page 16: ... Engagehydraulicsystempercompanypolicy V Engagecompressor 7 Shutdown Procedure I Disengagecompressorcircuit II Relievesystemofstoredair Installation Operation Operating Conditions Thefollowingconditionsshouldexistformaximumperformanceofthecompressor Thetruckshouldbeas close to level as possible when operating Operation in ambient temperatures above 100 F 38 C may experiencehightemperatureshutdown ...

Page 17: ...d program of periodic inspection and maintenance will help avoid premature failure and costly repairs Daily visualinspectionsshouldbecomearoutine Maintenance Recommended Spare Parts List How To Order Parts For Parts and or Service Support Phone 800 635 6587 USA Phone 219 324 7776 Outside USA Local Fax 877 254 4249 service bossair com email http www bossair com website Compressor must be shut down ...

Page 18: ...d after the initial day of operation The compressor must be cold room temperature before re torquing of studs Torque studs to 240 in lbs plus or minus 10 in lbs L A V R E T N I E C I V R E S N O I T A R E P O E C N A N E T N I A M Y L I A D d e d e e n f i d d A l e v e l l i o e s a c k n a r c k c e h C 1 r e v i e c e r r i a m o r f n o i t a s n e d n o c n i a r D 2 Y L K E E W e k a t n i r...

Page 19: ... dilution of the additives or a reaction between additives or different types T I N U D O H T E M G N I T A R E D A R G Y T I S O C S I V O S I 8 4 4 3 O S I 6 4 Y T I S O C S I V C I T A M E N I K 5 4 4 D M T S A F 4 0 1 C 0 4 T A s 2 m m 6 4 F 2 1 2 C 0 0 1 T A s 2 m m 7 7 F 9 5 C 5 1 T A Y T I S N E D L m g 8 9 2 1 D M T S A 3 4 8 C O C T N I O P H S A L F F C 2 9 D M T S A 5 5 4 5 3 2 T N I O ...

Page 20: ...ressor from dust and foreign objects Frequency of maintenance of the filter depends on dust conditions at the operating site The filter elementmustbeservicedwhenclogged Acloggedairfilterelementwillreducecompressorperformance and cause premature wear of components Do not attempt to drain condensate remove the oil level fill cap or break any connection in the air or oil system without shutting off t...

Page 21: ...hen 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 sludge 3 Flush generously with hydraulic oil 4 Once the cooler is reinstalled fill the hydraulic system with the proper fluid to their appropriate levels ...

Page 22: ...east amount of time and with the least amount of removal or disassembly of parts should be performed first Troubleshooting LOW OIL PRESSURE 1 Lowoillevel 2 Loose pipe plug on oil pump cover 3 Worn or defective oil pump 4 Crack or scratch on oil pump cover NO OIL PRESSURE 1 Defectiveoilpump 2 Blocked oil passage 3 Damageoilpumpdrivepin COMPRESSOR WILL NOT ENGAGE 1 No power supplied to compressor 2 ...

Page 23: ... Fax 877 254 4249 http www bossair com Whencallingfortechnicalsupport havethefollowinginformationavailable 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 ...

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Page 25: ...25 309395 WARRANTY SECTION ...

Page 26: ...Boss Industries Inc sole responsibility and Buyer s exclusive remedyhereunderislimitedtosuchrepair replacement orrepaymentofthepurchaseprice Partsnot of Boss Industries Inc manufacture are warranted only to the extent that they are warranted by the originalmanufacture BossIndustries Inc shallhavenoresponsibilityforanycostorexpenseincurred by Buyer from inability of Boss Industries Inc to repair un...

Page 27: ...t for each occurrence of material defect of defective workmanship will cause warranty claim to be rejected Defective material must be returned within 30 days of receipt of shipping instructions Failure to do so within specified time will result in forfeiture of claim The distributor is responsible for the initial investigation and write up of the warranty claim Distributor shall be allowed no more...

Page 28: ...r tagged clearly to the package 1 Return Goods Authorization 2 Distributor or end users return address 3 Correct factory address 4 Number of packages pertaining to each claim NOTE Our warranty requires that all defective parts be returned to Boss Industries Inc freight prepaid Items sent without RGAnumber will not be accepted Unauthorized Returns Will ImmediatelyBeRefusedAtDock Return or Warranty ...

Page 29: ...he kit or factory installed unit was assumed by the carrier at the time of ship ment Therefore claims for loss or damage to the contents of the kit or factory installed unit should be made upon the carrier 2 Concealed loss or damage Concealed loss or damage means loss or damage which does not become apparent until the kit is unpacked or the factory installed unit is run by the end user The content...

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Page 31: ...31 309395 PARTS AND ILLUSTRATION SECTION ...

Page 32: ...OLT 929806 150 2 2 NUT 925506 198 6 3 BRACKET 301248 1 4 MOTOR 301665 1 5 WASHER 938206 071 6 6 DECAL 301593 1 7 HUB 301266 1 8 HUB 301265 1 9 SPIDER 301267 1 10 WASHER 301628 1 11 BOLT 929405 100 1 12 NUT 961504 090 6 13 ELBOW 970412 106 1 14 ELBOW 970408 088 1 15 BOLT 929806 100 4 16 ...

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

Page 34: ...34 1 4 BLOCK 80061 12 1 5 NUT 924305 166 6 6 WASHER 938605 071 6 7 NUT 961505 140 8 8 BOLT 929705 075 12 9 COOLER 300836 1 10 ELBOW 960212 075 2 11 RELAY 300211 2 12 CONNECTOR 970512 088 1 13 CONNECTOR 970508 088 1 14 BRACKET 305244 1 15 FAN ASSY 301577 1 16 RIVET 993204 062 4 17 RIVET 943102 038 4 18 BOLT 929105 300 2 19 RIVET 993603 025 4 20 ...

Page 35: ...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 975412 021 FROM DISCHARGE SIDE OF HYD MOTOR USING 975412 029 20 20 ...

Page 36: ...EN 24 1 308135 COVER 25 1 308136 BUSHING 26 1 308137 SPRING 27 12 308138 WASHER 28 1 309387 TUBE Parts List ITEM QTY PART NUMBER DESCRIPTION 29 1 902915 015 PLUG 30 1 902915 020 PLUG 31 2 900000 005 PLUG 32 9 930005 075 BOLT 33 12 925205 273 NUT 34 1 309388 KEY 35 12 308141 STUD 36 1 308142 PIN 37 1 309389 DIPSTICK 38 1 308143 GASKET 39 2 308144 GASKET 40 2 308145 GASKET 41 1 308149 CAP 42 1 30814...

Page 37: ...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 ...

Page 38: ...ND 300855 1 1 SLEEVE 301418 1 2 SLEEVE 301417 1 3 ISOLATOR 301602 2 4 TUBE 304566 1 5 CAP 300857 1 6 WASHER 938605 071 2 7 NUT 924305 166 2 8 FILTER 301438 1 9 ADAPTOR 304515 2 10 CAP 309383 2 11 TUBE 304534 1 12 BRACKET 301446 1 13 BOLT 929704 050 2 14 BOLT 929705 125 2 15 ...

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

Page 40: ... 975104 012 1 6 CLAMP 301928 125 1 7 SCREW 934504 075 1 8 VALVE 301142 1 9 CONNECTOR 960112 075 1 10 ELBOW 960212 075 1 11 TEE 961912 075 1 12 ELBOW 960012 075 2 13 HOSE 305268 1 14 BOLT 929806 100 2 15 TEE 902415 020 1 16 NIPPLE 922212 000 1 17 TEE 902203 022 1 18 NIPPLE 922108 060 1 19 NIPPLE 961608 025 1 20 NIPPLE 922108 020 1 21 HOSE 305328 1 22 RIVET 943102 038 2 23 ...

Page 41: ...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 ...

Page 42: ... 309395 Canopy System Parts List DESCRIPTION PART NUMBER QTY ITEM CANOPY 304832 1 1 WASHER 977004 062 20 2 NUT 961504 090 14 3 PANEL 301436 1 4 PANEL 301435 1 5 BOLT 983904 075 20 6 WASHER 984004 071 20 7 ...

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

Page 44: ...44 309395 Oil Drain System Parts List DESCRIPTION PART NUMBER QTY ITEM HOSE 302614 1 1 NIPPLE 922106 035 1 2 ELBOW 901515 015 1 3 CLIP 302613 2 4 RIVET 943103 025 2 5 ...

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

Page 46: ...46 309395 Mounting System Parts List DESCRIPTION PART NUMBER QTY ITEM BUMPER 308082 4 1 BOLT 929806 200 4 2 WASHER 938206 071 4 3 ...

Page 47: ...47 309395 Mounting System 1 2 3 ...

Page 48: ... 3 1 309392 03 DECAL VALVE BLOCK 1 4 1 309392 04 DECAL AIR 1 5 1 309392 05 DECAL WARNING CONNECT AIR 1 6 1 309392 06 DECAL DANGER BREATHING 1 7 1 309392 07 DECAL WARNING READ MANUAL 1 8 1 309392 08 DECAL WARNING FAN GUARD 1 9 1 309392 09 DECAL DRIVE COUPLING 1 10 1 309392 10 DECAL OIL LEVEL 1 11 2 309392 11 DECAL RESTRICT AIRFLOW 2 1 305761 DECAL SERIAL TAG BOSS ...

Page 49: ...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 ...

Page 50: ...50 309395 System Schematic ...