Boss K36BP PISTON Service And Maintenance User Manual Download Page 1

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This manual must be read carefully before using your Boss Industries Air Compressor.
Store in a safe and convenient location for future reference.

308528

9/02/2014 KWB

Service and

Maintenance

User Manual

Hydraulic Air Compressor

BOSS

K36BP PISTON

For technical support:

Phone: (800) 635-6587 (USA)
Phone: (219) 324-7776 (Outside USA)
Fax: (877) 254-4249 (USA)
[email protected] (email)
http://www.bossair.com (website)

Summary of Contents for K36BP PISTON

Page 1: ...fe and convenient location for future reference 308528 9 02 2014 KWB Service and Maintenance User Manual Hydraulic Air Compressor BOSS K36BP PISTON 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 ...

Page 2: ...2 308528 ...

Page 3: ...tarting 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 20 Piston Ring Replacement 21 Oil Pump Replacement 23 Crankshaft and Bearing Replacement 24 Troubleshooting 26 General Tips 26 Contacting Boss 27 WhereTo Find Specific Machine Information 27 ...

Page 4: ...n 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 ...

Page 5: ... 1 1 5 3 2 3 g P e b u t e l b i x e l f o t g n i b m u l p n i a r d l i o d e t a d p U M C M 1 1 4 8 5 4 4 4 g P m e t s y s y p o n a c d e t a d p U M C M 1 1 9 9 1 4 0 4 g P 7 4 6 4 c i l u a r d y H d n a r e t p a d A r o t o M c i l u a r d y H o t n o t s i P d e t a d p U s l a c e D k c o l B M C M ...

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 K36BP 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: ...ave the machine running unattended or leave a tool connected to an air hose when not using Relieve system 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 200 lbs Slightvibration...

Page 10: ...O CHANGE WITHOUT PRIOR NOTICE 1 2 in 12 7 mm 17 3 4 in 450 5 mm 28 1 2 in 723 9 mm 31 3 8 in 797 4 mm 21 3 8 in 542 0 mm 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 8 3 1 2 x H 4 3 7 1 x L 8 3 1 3 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...

Page 11: ...system 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 fastenerand 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: ...hecoolerfantocontinuetooperate Thiswillcontinuecoolingthehydraulic fluidwhilethetoolcircuitisinoperation 3 Connecting the Hydraulic Hoses Thehydraulichosestothecompressorshouldbeconnecteddirectlytothehydraulicfittings Thefittingsare 3 4 JIC 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 hyraulic systems on the vehicle Th...

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 c...

Page 16: ...compressor will stop but the cooler fan will continue to run When the tool circuit is no longer required disengage the toolcircuitandthecompressorwillautomaticallystart 7 Shutdown Procedure I Disengagetoolcircuit ifengaged II Disengagecompressorcircuit III Relievesystemofstoredair Installation Operation Operating Conditions Thefollowingconditionsshouldexistformaximumperformanceofthecompressor Thet...

Page 17: ...ditions A planned 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 Fax 877 254 4249 USA service bossair com Email http www bossair com Website PART NUMBER DES...

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: ...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 P R U O P F C 7 9 D M T S A 9 4 5 4 I V X E D N I Y T I S O C S I V 9 0 9 2 O S I N I D 5 3 1 S E I T R E P O R P N O I T N E V E R P T S U R B 5 6 6 D M T S A S S A P Y ...

Page 20: ...element will reduce compressor performance and cause premature wear of components 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 Removecooler 2 Circulateasuitablesolventtodissolveandremovevarnishandsludge 3 Flushgenerouslywithhydraulicoil 4 Oncethecoolerisreinstalled fillthehydraulicsystemwiththeproperfluidtothei...

Page 21: ... the glaze and to remove the buildup at the top of the cylinders X Measure the inside diameter of the cylinder for roundness and excessive wear The bore should be 2 625 0 0025 tolerance If the bore is oversized the cylinder must be replaced XI Witharingexpander removethecompressionandoilrings XII With the ring expander install the new ring kit Make certain that the oil ring is on the bottom and th...

Page 22: ... 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 Repeat for the other piston XVI Position the gaskets and valve plate on top of the cylinder Position the head on the cylinder and turn bolts finger tight Torque the studs nuts to 240 in lbs in 25 50 pound increments See Fig 3 FIGURE 2 CYLINDE...

Page 23: ... excessively noisy check the valve plate It may have been installed upside down XVII Reconnect the 3 4 discharge hose and discharge jumper hose XVIII Installthecompressorandconnectthewiring XIX Testthemachine 2 Oil Pump Replacement I Shutdownmachineandallowtocoolforapproximately10minutes II Verifyentiresystempressureisrelievedbeforeproceeding III Remove the bolts and lift off the pump cover IV Wit...

Page 24: ...ecting rods to be certain that the matched parts remain together on the same crankshaft journals V Removethepumpcover oil pump sleeve spring and rear bearing housing VI Removethedrivehub andthefrontbearinghousing VII Pullthecrankshaftfromthecrankcase VIII Remove all gasket material with a single edged razor blade or sharp putty knife IX Insert the two remaining bolts and torque to 180 in lbs The b...

Page 25: ...Piston Ring Replacement on P 21 Maintenance Gasket kits are supplied with two 2 each of 006 010 015 and 020 gaskets Use these rear bearing gaskets in any combination and quantity to limit all play front to rear but still allow the crankshaft to turn freely FIGURE 4 BEARING HOUSING TORQUE SEQUENCE XI Press the new bearings into position XII Generouslyoilthefrontbearingraceandinstallthefrontbearingh...

Page 26: ...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 27: ...4249 USA service bossair com email http www bossair com website Whencallingfortechnicalsupport havethefollowinginformationavailable MachineSerialNumber Descriptionoftheproblem 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 28: ...28 308528 ...

Page 29: ...29 308528 WARRANTY SECTION ...

Page 30: ...edthewarrantyisvoid Boss sole responsibilityandBuyer sexclusiveremedyhereunderislimitedtosuchrepair replacement orrepayment of the purchase price Parts not of Boss manufacture are warranted only to the extent that they are warranted by the original manufacture Boss shall have no responsibility for any cost or expense incurredbyBuyerfrominabilityofBosstorepairundersaidwarrantywhensuchinabilityisbey...

Page 31: ...r 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 tha...

Page 32: ...t be on the outside of or 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 freight prepaid Items sent withoutRGAnumberwillnotbeaccepted UnauthorizedReturnsWillImmediatelyBeRefusedAtDock Return or Warranty...

Page 33: ...nit 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 contents of the kit or factory insta...

Page 34: ...34 308528 ...

Page 35: ...35 308528 PARTS AND ILLUSTRATION SECTION ...

Page 36: ...Y 11 1 304957 CLAMP HOSE 12 1 937806 094 WASHER LOC 13 1 308287 BRACKET RELAY 14 2 938604 071 WASHER FLAT 15 2 938004 062 WASHER LOC 16 2 929104 075 BOLT HEX 17 1 308223 BRACKET HYD BLOCK 18 4 938605 071 WASHER FLAT 19 4 938005 078 WASHER LOC 20 2 929105 300 BOLT HEX 21 1 80061 12 BLOCK HYD VALVE 22 1 970512 088 CONNECTOR 23 1 970408 088 ELBOW 24 1 970412 088 ELBOW 25 1 983012 088 ADAPTER 26 1 983...

Page 37: ...37 308528 1 13 10 16 14 15 6 7 11 12 8 5 18 26 25 20 19 24 21 23 22 27 19 18 17 2 4 3 9 29 28 Frame System ...

Page 38: ...0 TEE 10 1 40020 ASSY PISTON 11 1 960816 100 ELBOW HYD 12 1 5 FT 302636 HOSE 13 4 938206 071 WASHER FLAT 14 4 929806 150 BOLT HEX 15 4 937806 094 WASHER LOC 16 2 922212 000 NIPPLE PIPE 17 1 308149 CAP BREATHER 18 1 301142 VALVE CHECK 19 1 975104 012 ELBOW COMPRSN 20 1 301578 SWITCH TEMP 21 1 961912 075 TEE 22 1 902615 030 ELBOW PIPE 23 2 308214 ELBOW NYLON 24 1 308215 ADAPTER NYLON 25 2 960012 075...

Page 39: ...39 308528 10 8 6 9 19 14 15 13 25 4 1 20 13 15 14 2 11 3 17 16 18 26 21 25 1 5 24 22 16 1 23 23 1 7 27 12 27 Piston System ...

Page 40: ...32 GASKET 19 3 308131 020 GASKET 20 1 308133 TUBE 21 1 308134 SCREEN 22 1 308135 COVER 23 1 308136 BUSHING 24 1 308137 SPRING 25 12 308138 WASHER 26 1 902915 015 PLUG 27 2 900000 005 PLUG 28 9 930005 075 BOLT 29 12 925205 273 NUT 30 12 925805 273 NUT 31 12 308140 STUD 32 12 308141 STUD 33 1 308142 PIN 34 1 308143 GASKET 35 2 308144 GASKET 36 2 308145 MOD GASKET 37 1 308146 PUMP 38 2 308147 GASKET ...

Page 41: ...41 308528 28 22 34 27 13 14 11 19 19 17 16 19 33 37 8 5 12 6 23 24 26 20 15 21 40 47 7 9 18 18 43 28 10 41 1 1 4 4 2 3 3 38 31 25 30 35 44 36 46 46 42 32 39 29 45 PistonAssembly ...

Page 42: ...T WHIZLOCK 929705 075 8 2 ELBOW HYD 960212 075 1 3 FAN PUSHER 301577 1 4 RIVET SPLIT 993204 012 4 5 WASHER FLAT 938604 071 4 6 WASHER LOC 938004 062 4 7 BOLT HEX 929104 075 4 8 SHROUD CLR 308222 1 9 COOLER OIL 300836 1 10 ELBOW HYD 960712 075 1 11 CONNECTOR 990612 075 1 12 Cooler System ...

Page 43: ...43 308528 4 9 5 6 7 8 2 3 1 10 11 12 Cooler System ...

Page 44: ... 301665 MOTOR 3 1 301593 DECAL TEMP 4 1 301266 HUB 5 1 308166 HUB 6 1 301267 SPIDER 7 1 970412 106 ELBOW HYD 8 1 970508 088 CONNECTOR 9 1 308085 ADAPTER 10 2 937806 094 WASHER LOC 11 5 938604 071 WASHER FLAT 12 5 938004 062 WASHER LOC 13 5 929104 100 BOLT HEX Hydraulic Drive System ...

Page 45: ...45 308528 5 13 2 3 1 10 7 4 6 12 11 8 9 Hydraulic Drive System ...

Page 46: ...TION PART NUMBER QTY ITEM SWITCH PRESSURE 308152 1 1 TEE PIPE 902415 030 1 3 ELBOW HYD 960012 075 1 4 BUSHING REDUCING 907603 010 1 5 ELBOW HYD 960704 025 1 6 NIPPLE PIPE 922104 020 1 7 NIPPLE PIPE 922112 035 1 8 Discharge System ...

Page 47: ...47 308528 5 7 6 1 4 3 8 Discharge System ...

Page 48: ...0 NUT TINNERMAN 5 24 981504 075 SCREW 6 24 977004 062 WASHER NYLON 7 24 984004 071 WASHER FLAT 8 1 306944 SPACER AIR FILTER PANEL 9 1 308078 PANEL TOP 10 1 308079 PANEL ACCESS 11 1 308077 PANEL REAR 12 1 308226 PANEL FRONT 13 1 302011 013 GROMMET NS 75 ft 300574 012 SLEEVE NS 1 308238 HARNESS NS 3 ft 300444 TAPE FOAM Canopy System ...

Page 49: ...49 308528 11 9 3 8 12 4 7 6 4 2 2 10 1 13 5 Canopy System ...

Page 50: ...53 1 4 DECAL DRIVE COUPLING 308353 01 1 4A DECAL DANGER BREATHING 308353 02 1 4B DECAL WARNING CONNECT AIR 308353 03 1 4C DECAL WARNING READ MANUAL 308353 04 1 4D DECAL DO NOT BLOCK AIR INTAKE 308353 05 1 4E DECAL WARNING FAN GUARD 308353 07 1 4F DECAL AIR 308353 08 1 4G DECAL OIL DRAIN 308353 09 1 4H DECAL COMPR SIGHT GLASS 308353 10 2 4I ...

Page 51: ...51 308528 Decal System 4G 4B 4C 4I 4D 4I 1 4H 4E 4F 4A 2 ...

Page 52: ...52 308528 System Schematic ...

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