309831 BA502 - Boss Industries, Inc.
Contents
1. _ Service and Maintenance User Manual BOSS BA502 PISTON Hydraulic Air Compressor This manual must be read carefully before using your Boss Industries Air Compressor Store in a safe and conventent 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 N E http www bossair com website 309831 Contents Revisi ist Warnings safety rules and B3Z3rdS ic Specificati 10 PESOS ee nea Description of Installation amp Operation a ana ee a L2 Mounting the OMI BTS SOF ae Installing the Connecting the Hydraulic Hs ana L4 Connecting the Air Hose 14 Pre Start Up Inspection Checks una A Operaune Pros die nee Mai SS Esa aises OVERVIEW O Recommended Spare Parts Et nee L7 Maintenance Schedule LS Lubrication 19 Air Intake Filtfer ona Hydraulic Oil Coole aaa T leshooti 22 General Tips nunus Contacting Boss dun sia Where To Find Specific Machine Inform2. 7 309831 Safety The following safety precautions are a general guide to safe operation of the equipment AWARNING 2 ENTE reva ADANGER Readand 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 Pressurized System Do not attempt to remove any compressor parts without first completely relieving entire system of pressure Do not attempt to service any part of the equipment while in operation Never attempt to repair or modify any pressure 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 Air from this compressor will cause severe injury if used for breathing or food processing The compressor is designed to compress air only Do not attempt to compress other gases Compression of other gases may create a situation where an explosion or fire may occur Do not use flammable solvents for cleaning compressor parts as this can cause the unit to ignite or explode during operation Kee
3. 164 000 3SOH 0334 3unSS33d NIN AI EL 304 35078 331134 29 QION310S GAH NOILO3NNOO SIWOLSNI NOILO3NNOO 5 33qvo1Nn 93 079 ATIVWYON 1NI UV 3SOH 5 w 9 309831 46
4. 7 1 960216 075 ELBOW 8 1 80061 12 BLOCK 9 2 924305 166 NUT 10 2 929105 300 BOLT 11 1 970516 088 CONNECTOR 12 2 938605 071 WASHER 13 2 1300211 RELAY 14 2 309788 BRACKET 15 4 938206 071 WASHER 16 4 937806 094 WASHER 17 4 929806 125 BOLT 18 1 1960016 075 ELBOW 19 2 993603 025 RIVET 20 1 970412 088 ELBOW 40 309831 Cooler System FROM DISCHARGE SIDE OF HYD MOTOR B PORT ON BLOCK FROM COOLER OUTLET FAN WIRE LOCATION 18 TO B PORT ON VALVE BLOCK 41 309831 Canopy System Parts List PART NUMBER DESCRIPTION 1 1 1309790 PANEL 2 1 309791 PANEL 3 1 309792 PANEL 4 1 309793 PANEL 5 1 309794 HOOD 6 28 961504 090 NUT 7 34 977004 062 WASHER 8 34 984004 071 WASHER 9 1 302011 013 10 34 981504 075 SCREW 11 2 943103 025 RIVET 12 2 1302613 CLIP 42 309831 6 SS 309831 Canopy System 43 Decal System Parts List lt DESCRIPTION 1 1 1305761 DECAL SERIAL TAG BOSS 2 1 1301593 DECAL TEMP HYD 140 F30 3 1 1308353 DECAL 36 BHP SHEET 3A 1 308353 01 DECAL DRIVE COUPLING 3B 1 1308353 02 DECAL DANGER BREATHING 1 308353 03 DECAL WARNING AIR 3D 1 308353 04 DECAL WARNING READ MANUAL 3E 1 308353 06 DECAL HYD PRESS amp TANK 3F 1 308353 07 D
5. 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 Normal maintenance items such as lubricants and filters are not warrantable items Parts not of Boss Industries Inc manufacture are warranted only to the extent they are warranted by the original manufacturer Damage resulting from abuse neglect misapplication or overloading of a machine accessory or part is not covered under warranty Deterioration or wear occasioned by chemical and or abrasive action or excessive heat shall not constitute defects Parts replacement and or correction of defective workmanship will normally be handled by Boss Industries Inc or their authorized distributor Failure to file a detailed warranty claim service report 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 mor
6. compliance with OSHA standards 29 CFR 1910 subpart N Inspect lifting provision for cracked welds and for cracked bent corroded or otherwise degraded members prior to lifting Make sure entire lifting rigging and supporting structure has been inspected is in good condition and had a rated capacity of at least the net weight of the compressor plus and additional 10 allowance for the weight of snow ice mud or stored tools and equipment If you are unsure of the weight then weigh the compressor before lifting Make sure lifting hook has a functional safety latch or equivalent and is fully engaged once it has been lifted clear of the ground Do not attempt to lift in high winds Keep all personnel out from under and away from the compressor when suspended Lift compressor slowly and smoothly without jerking Lift compressor no higher than necessary Keep lift operators in constant attendance whenever compressor is suspended Set compressor down only on level surfaces capable of supporting at least its net weight plus an additional 10 allowance for the weight of snow ice mud or stored tools and equipment 12 309831 Installation amp Operation 2 Mounting the Compressor When mounting the compressor care should be taken to ensure that its location does 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 th
7. specific installations 15 309831 Installation amp Operation 6 Pre Start up Inspection Checks Continued VI Checkallfluid levels position the unit on a level surface so that proper amount of fluids can be added Fuelto provide three hours of operation Hydraulic fluid levels may have to be topped off after test Compressor Check the compressor oil level see lubricant section of the operator and parts section for type of lubricant to use 1 Add oil if needed 2 Additional oil may need to be added after test 3 Top off oil level to half the sightglass when finished with the test D Any other applicable fluids E Transmission fluid and PTO box O gt 7 Operating Procedure L Read the operation section in the manual carefully before proceeding onto the initial start up II Start power source and allow for warm up MI Verify the compressor is disengaged IV Engage hydraulic system per company policy V Engage compressor 8 Shutdown Procedure L Disengage compressor circuit II Relieve system of stored air Operating Conditions The following conditions should exist for maximum performance of the compressor The truck should be as close to levelas possible when operating Operation in ambient temperatures above 100 F 38 C may experience high temperature shutdown 16 309831 Maintenance This section contains instructions for performing the inspection lubrication and maintenance pro
8. types 19 309831 Maintenance Due to environmental factors the useful life of all extended life lubricants may be shorter than quoted by the lubricant supplier Boss N OT C E encourages the user to closely monitor the lubricant condition and to participate in an oil analysis program with the supplier Nolubricant however 2004 and or expensive can replace proper maintenance and attention Select and use it wisely 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 the side of the compressor body A drain line is located opposite the service door The proper oil level is in the middle of the oil sightglass when the unit is shut down and has had time to settle The truck must be level when checking the oil DO NOT OVERFILL The oil capacity is given in Compressor Specifications Do not attempt to drain condensate remove the oil level fill cap or A DANG 354 break any connection in the air or oil system without shutting off the compressor and relieve the system of all stored air pressure Air Intake Filter P N 309867 The air intake filter is a heavy duty dry type high efficiency filter designed to protect the compressor from dust and foreign objects Frequency of maintenance of the filter depends on dust conditions at
9. B 14 1 1309785 SLEEVE 34 309831 Motor System 309831 Piston System Parts List lt DESCRIPTION 1 1 309786 PISTON 2 1 309787 PULLEY 3 1 300747 217 BUSHING 4 1 907605 030 BUSHING 5 1 922112 075 NIPPLE 6 4 938208 112 WASHER 7 4 925508 262 NUT 8 4 929808 250 BOLT 9 1 960212 075 ELBOW 10 1 922106 060 NIPPLE 11 1 307439 CAP 12 1 307440 FITTING 13 1 901515 015 ELBOW 14 1 120 91269 BARB 15 1 300033 075 CLAMP 16 1 1 2 ft 302636 HOSE 17 1 906030 030 CAP 18 1 309904 LIFTBAIL 36 309831 Piston System 309831 Discharge System Parts List ITEM PART NUMBER DESCRIPTION 1 1 1301578 SWITCH 2 1 1301142 VALVE 3 2 922212 000 NIPPLE 4 1 961608 025 NIPPLE 5 902203 032 6 1 1309718 VALVE 7 4 938605 071 WASHER 8 2 924305 166 NUT 9 2 1929105 125 BOLT 10 1 309789 BRACKET 11 1 960212 075 ELBOW 12 1 922212 030 NIPPLE 13 1 975104 012 ELBOW 14 2 943102 038 RIVET 38 309831 Discharge System 39 309831 Cooler System Parts List PART NUMBER DESCRIPTION 1 1 1301434 SHROUD 2 8 1961505 140 NUT 3 8 929705 075 BOLT 4 1 300836 COOLER 5 1 301577 FAN ASSY 6 4 1993204 062 RIVET
10. ECAL WARNING FAN GUARD 3G 1 308353 08 DECAL AIR LEXAN 3H 1 308353 09 DECAL OIL DRAIN 31 1 308353 10 DECAL COMPR SIGHT GLASS 44 309831 Decal System 2 IN Os lt N N s QK VA UNITS A AAN 3 NN UN KT N 309831 45 N31SAS NMOGLNHS OL 0351 38 NYO SIHL SI YOLOW 3HL NAHM SINIL 1N3S33d 38 Nid WO33 WNOIS LNdLNO JHL SLVAILOWSY ATIVOLLVAOLNV TUM LNIOd HOIHM ISd 071 OL SVH ANVL JHL INN GVOINN WALSAS 3HL 15 641 01 ANVL 3HL 3ZIVNSS IYA 5 SLVAILOV SIHL wu OL SINANI AlddNS NOLLWVYSdO YOSSAYdWOD IVAYON YOSSIYANOI 3 Nid JALVIIN 3AHISOd OL 1 38 OL 3 ONY NOLLWYAdO 20 21 ANALLVE DOAZL 90AZ1 0 HOLIMS Q 9 3 E 1 L p K csi Y3AV3Y8 LINDYID ER RO E EI ae eae Saas PS E eee IEEE SIR SOC a NMOGLNHS 154 0001 231009 10 04h 20 ISOH 0333 NIN dl L YOLOW GAH
11. Industries Inc or caused solely by Buyer There are no other warranties express statutory or implied including those of merchantability and of fitness of purpose nor any affirmation of fact or representation which extends beyond the description of the face hereof This warranty shall be void and Boss Industries Inc shall have no responsibility to repair replace or repay the purchase price of defective or damaged parts or components resulting directly or indirectly from the use of repair or replacement parts not of Boss Industries Inc manufacture or approved by Boss Industries Inc or from Buyer s failure to store install maintain and operate the compressor according to the recommendations contained in the Operating and Parts Manual and good engineering practice The total responsibility of Boss Industries Inc for claims losses liabilities or damages whether in contract or tort arising out of or related to its products shall not exceed the purchase price In no event shall Boss Industries Inc be liable for any special indirect incidental or consequential damages of any charter including but not limited to loss of use of productive facilities or equipment loss of profits property damage expenses incurred in reliance on the performance of Boss Industries Inc or lost production whether suffered by Buyer or any third party Boss Industries Inc 1761 Genesis Drive LaPorte IN 46350 25 309831 Warranty
12. art as a result of improper handling or packing could be cause for denial When addressing the package for shipment the following information must be on the outside of or tagged clearly to the package Return Goods Authorization Distributor or end users return address Correct factory address 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 RGA number will not be accepted Unauthorized Returns Will Immediately Be Refused At Dock Return or Warranty Claims Filing Procedures 1 Initiate through a purchase order for warranty part or request for credit RGA will accompany replacement part 3 Boss Industries Inc 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 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 1761 Genesis Drive LaPorte IN 46350 27 309831 Warranty General An approved claim depends on the following provision 1 2 UPA An RGA must be issued by Boss Industries Inc See filing procedures Failed part must be returned within 30 days of original invoice date freight prepaid with RGA Part is determined to
13. ation 23 3 309831 arrant y eee eee eee eee eee eee eee eee eee eee eee eee eee 2 Warranty Statement z tt 25 Summary of Main Warranty 26 Return Goods NStrUCHONS zen earan 27 Preparation of Part Rein een 27 Filino Proc dE au un canneries 27 e 28 Transit Dan aiii 28 Dra wint S A A 30 Meere 32 A 34 Piston SSL o e E 36 38 Cooler Deere 40 Canopy SVEN Ao 42 Decal SSE 44 Winns s usus A 46 4 309831 Revision List LOCATION DESCPRIPTION OF CHANGE INITIALS 6 3 2013 12 Added lifting section Updated Piston System with lift bail 5 309831 Welcome General Information 22 Thank you for choosing the Boss BA502 Hydraulic Air Compressor inne Before operating this compressor read over this manual and become wellacquainted with your new machine Doing this willincrease your safety and maximize the life of the machine While this manual is written to be as accurate as possible Boss strives to continually improve the efficiency and performance of its machines Asa result sometimes there may be slight difference
14. be defective Workmanship is determined to be defective Machine is within warranty period 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 1 Loss in transit The merchandise in our kit or provided in our factory installations has been thoroughly inspected or carefully installed and tested before leaving our plant However regardless of the care taken at the factory there is a possibility that damage may occur in shipment For this reason it is recommended that the unit be carefully inspected for evidence of possible damage or malfunction during the first few hours of operation Responsibility for the safe delivery of the 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 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 installed unit may be damaged due to rough handling while in route to its destination even thought the kit or factory installed unit shows no external damage When the damage is d
15. ce 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 It should be understood that the intervals between inspections specified are maximum interval More frequent inspections should be made if the unit is operating in a dusty environment in high ambient temperature or in other unusual conditions A planned program of periodic inspection and maintenance will help avoid premature failure and costly repairs Daily visual inspections should become a routine Compressor must be shut down and completely relieved of pressure prior to checking fluid levels Open service valve to ensure relief of A p W 2 2 system air pressure Relieve all stored air pressure energy prior to starting machine Failure to comply with this warning will cause damage to property and serious bodily harm Recommended Spare Parts List PART NUMBER DESCRIPTION 80331 KIT REPAIR REED VALVE 309867 ELEMENT AIR FILTER 309785 SLEEVE NEOPRENE COUPLING 302030 KIT REPAIR HYD MOTOR SEAL 308245 LUBRICANT 2QT BOX SYNTH 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 Obossair com email http www bossair com web
16. e 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 clearance is needed The compressor air filter is mounted on the frame Cool ambient air is drawn in from under the frame One last consideration in the mounting should be the routing of hoses and electrical wires The frame mounting holes are shown below and the unit should be secured to the vehicle with 3 8 inch grade 8 bolts and washers Hardware supplied with unit may not work in all applications The compressor weighs 500 lbs Ensure that you have a sub structure to support at least that weight Be sure to follow all National Vehicle Safety Standards TRUCK MOUNTING SURFACE 7 16 DIA 6 PLACES 3 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 The unit is shipped with a 5 pin connector they need to be connected as follows 1 Pin A and Pin E are to be connected directly to battery positive Pin and battery negative Pin E 2 Compressor Only for normal compressor operation supply 12VDC inputs to Pin C This will activate the system and pressurize the tank to 175 PSI The system will then unload u
17. e than 30 days from date of repair to file a warranty claim service report Warranty for failure of Boss Industries Inc replacement parts covers the net cost of the part only not labor and mileage The Boss Industries Inc warranty does not cover diagnostic calls and travel That is time spent traveling to the machine to analyze the problem and returning with the proper tools and parts to correct the problem Boss Industries Inc will deduct from allowable credits for excess freight caused by sender failing to follow return shipping instructions Distributors or end users automatically deducting the value of a warranty claim from outstanding balances due and payable to Boss Industries Inc prior to receiving written notification of Boss Industries Inc approval of the warranty claim may be subject to forfeiture of the entire claim 26 309831 Warranty 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 customers Please see the following instructions to initiate a return Contact Boss Industries Inc Returns Department by telephone at 800 635 6587 You may also send a fax at 877 254 4249 Warranty Claims Preparation of Part Return Parts returned to the factory must be properly packaged to prevent damage during shipment Damage to a p
18. el inlet or the customer s air connection port when a hose reel is not used Typical plumbing from machine s air outlet port occurs in the following order 1 Air tank 2 OSHA valve 3 Service valve 4 Moisture trap gauge oiler combination when used 5 Hose reel when used 6 Pre Start up Inspection Checks This inspection should be done prior the compressor test Check all assemblies clamps fittings hose connections nuts and bolts to ensure they properly tied and secured to the vehicle This is a very critical area of inspection The vehicle should not be moved until this inspection has been completed II Remove all tools rags and installation equipment from the area Check compressor oil level and hydraulic fluid level Check all valves to ensure they correct operating position 14 309831 Installation amp Operation 6 Pre Start up Inspection Checks Continued 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 Vacuum all areas that have metal or plastic shavings Wipe all fingerprints off unit and vehicle VI Record all serial numbers for this Installation A Vehicle B Hydraulic Pump Data C Compressor Serial Number D Boss Serial Number E Tank Serial Number F Note any special applications relating to
19. fications POWER SOURCE HYDRAULIC MOTOR OPERATING SPEED 830 RPM MAX CYLINDER CONFIG 2 Stage 2 Piston OIL CAPACITY 3 QTS DIMENSIONS 37 1 8 L x 28 x 23 1 4 W WEIGHT 590 LBS DELIVERY 175 PSI 50 CFM ULIC RESERVOIR 25 GALLON MINIMUM COOLING NORMAL GPM 800 RPM 13 GPM FAN DIAMETER NORMAL OPERATING PSI 2200 PSI IAS Hydraulic reservoir requirement for compressor only Additional capacity will be needed to other hydraulic equipment SPECIFICATIONS SUbJECT TO CHANGE WITHOUT PRIOR NOTICE 502 system is to run intermittently When the BA502 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 25 GAL for the BA502 plus all the other manufacturer s requirements Mounting surface must be capable of 590 Ibs load spread over the four mounting holes Cooling air intake must not see air temperatures above ambient Cooling air discharge must have 10 clearance from any obstructions Ambient running conditions 20 to 100 F 20 maximum operating slope 10 309831 Description of Components Compressor Assembly The Boss BA502 hydraulic drive piston compressor assembly is a positive displacement intermittent flow two stage reciprocating unit The piston compressor consists of a crank shaft oil filter oil pump two connecting rods pistons cyl
20. inders and valve assemblies As the crankshaft rotates the pistons move up and down As the first stage piston move down a vacuum is created above the piston which allows the reed valve to open and fill the area above the piston with air When the piston move back up this air is discharged into a storage tank mounted on the side As the second stage piston move down a vacuum is created above the piston which allows the reed valve to open and fill the area above the piston with air from the first stage storage tank When the piston move back up this air is discharged from the compressor Oil lubricates the bearings and cylinder walls as the crankshaft rotates ensuring that the system stays cool Hydraulic Oil Cooling Systems The compressor cooling system consists of a hydraulic cooler mounted on the compressor frame Cool air is drawn through the hydraulic cooler and flows over the compressor surface exiting out the rear vented panel Allow for adequate clearance 10 for the air to exit Also the package location should not be subjected to air temperatures above ambient Fluid Level Sight Glass This sight glass indicates the fluid level in the crank case Proper level should be in the middle of the sight glass Check this level when the compressor is disengaged and the vehicle is parked on level ground Fluid level should be checked prior to each use Electrical System The Boss compressor s standard electrical system consists of H
21. iscovered upon unpacking make a written request for inspection by the carrier agent within fifteen days of delivery date Then file a claim with the carrier since such damage is the carrier s responsibility following these instructions carefully we guarantee our full support of your claims to protect you against loss from concealed damage Visible Loss Any external evidence of loss damage must be noted on the Freight Bill or Express ceipt and signed by the carrier s agent Failure to adequately describe such external evi dence of loss or damage may result in the carrier refusing to honor a damage claim The carrier will supply the form required to file such a claim 28 309831 29 309831 PARTS AND ILLUSTRATION SECTION 30 309831 31 309831 Frame System Parts List PART NUMBER DESCRIPTION 1 1 1309780 BASE 2 4 1309781 ISOLATOR 3 8 938908 180 WASHER 4 8 925406 063 NUT 32 309831 Frame System 309831 Motor System Parts List ITEM PART NUMBER DESCRIPTION 1 1 309719 MOTOR 2 1 970416 188 ELBOW 3 1 970512 162 CONNECTOR 4 4 938208 112 WASHER 5 2 925508 262 NUT 6 2 929808 200 BOLT 7 8 1938206 071 WASHER 8 4 1929806 125 BOLT 9 4 925506 198 NUT 10 1 309782 CRADLE 11 1 1309783 BRACKET 12 1 1309784 HUB 13 1 306079 HU
22. ntil the tank has dropped to 140 PSI at which point it will automatically reactivate The 12VDC output signal from Pin D will be present at all times when the motor is running This can be used to shutdown the hydraulic system 13 309831 Installation amp Operation 4 Connecting the Hydraulic Hoses The hydraulic hoses to the compressor should be connected directly to the hydraulic fittings The pressure input line should be made from a good quality high pressure hydraulic hose 3 4 rated to handle the hydraulic systems on the vehicle The return line to tank can be made from a medium pressure min 1000 PSD hydraulic hose 1 Care should be taken to see that the hoses are not installed with kinks or bends that inhibit flow of the hydraulic oil Lack of flow could result in damage to the motor and compres sor Lastly check to make sure hoses are not in contact with sharp objects or edges that may fray chafe or cut them over time Secure all hoses with tie down straps or clamps 5 Connecting the Air Hose The air discharge hose should be connected directly to the AIR port The fitting is a 3 4 female NPT The air line should be made from a good quality min 200 PSI air hose 3 4 Care should be taken to see that the hose is not installed with kinks When adding an air hose ensure OSHA Regulation 1910 169 is followed compressor service valve should be located at the hose re
23. operation The owner lessor or operator of this equipment is hereby notified and forewarned that any failure to observe the safety and operating guidelines may result in injury and or damage 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 In addition to following these safety guidelines the operator should follow any company specific guidelines and procedures Consult your immediate supervisor for specific company safety guidelines and or proce dures The following safety symbols are used throughout the manual to draw attention to important information If the information is not carefully read and the instructions are not followed severe injury death and or damage to property and equipment may occur A D G E Indicate s imminently hazardous situation which if 2 not avoided will result in death or serious injury Indicate s a potentially hazardous situation which if not avoided could result in death or serious injury Indicate s a potentially hazardous situation which if not avoided could result in minor or moderate injury Indicate s a potentially unsafe situation or practice N OTI C E which if not avoided can result in property and or equipment damage only
24. p combustibles out of and away from compressor inlet and any associated enclosures 8 309831 A DANGER A DANGER A DANGER NOTICE NOTICE Safety Never disable override or remove safeties either temporarily or permanently Connect air hoses only in full compliance with OSHA Standard 29 CFR 1926 302 b 7 The required safety devices velocity fuses should be tested in accordance with their manufacturer s recommendations to verify that they reduce pressure in case of hose failure and will not nuisance trip with the hose and tool combinations in use Failure to comply could result in personal injury or death and or damage to equipment and property Never leave 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 unloader to a setting of greater than 175 PSI Operating the compressor at greater than 175 PSI may result in personal injury and property damage Mount the compressor in a stable location capable of supporting 500 lbs Slight vibration may occur during operation and the machine may move if not securely mounted 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 9 309831 Speci
25. ponents 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 Boss Industries Inc original shipping point repair or replace the item or issue credit for the replacement item ordered by Buyer Defective material must be returned within thirty 30 days of return shipping instructions from Boss Industries Inc Failure to do so within specified time will result in forfeiture of claim or c refund the full purchase price for the item without interest Factory installed units will also include warranty on installation for a period of one 1 year This warranty does not cover damage caused by accident misuse or negligence If the compressor unit is disassembled the warranty is void Boss Industries Inc sole responsibility and Buyer s exclusive remedy hereunder is limited to such repair replacement or repayment of the purchase price Parts not of Boss Industries Inc manufacture are warranted only to the extent that they are warranted by the original manufacture Boss Industries Inc shall have no responsibility for any cost or expense incurred by Buyer from inability of Boss Industries Inc to repair under said warranty when such inability is beyond the control of Boss
26. s between a given version of the manual and the machine Boss BA502 Hydraulic Air Compressor The Boss BA502 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 BA502 Piston design provides output of up to 50 CFM cubic feet of air per minute at up to maximum of 175 PSI pounds per square inch High output at relatively low GPM gallons per minute translates into the most efficient quiet and reliable system in its class designed to handle virtually any application The BA502 Piston also has enhanced safety features offering applications designed to protect your most valuable resource your operating crew To prevent overheating a high temperature switch will shut down the machine in the event of high discharge temperatures 6 309831 Safety 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 experience and common sense you are in a position to ensure your and others safety Lack of attention to safety can result in accidents personal injury reduction in efficiency and worst of all Loss of Life Watch for safety hazards and correct them promptly Understanding the proper operation of this equipment is critical to its safe
27. site 17 309831 Maintenance 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 need only Required maintenance Lubrication and Maintenance Chart SERVICE INTERVAL MAINTENANCE OPERATION 1 Check crankcase oil level Add if needed DAILY 2 Drain condensation from air receiver 1 Inspect the air intake 2 Check the cylinder head stud torque see NOTE 2 3 Check the operation of the receiver safety valves 4 Inspect lifting frame 1 Change the crankcase oil see NOTE 1 eee 2 Check cooler fins for dirt and obstruction Clean if needed EVERY 6 MONTHS 1 Inspect the drive coupling for wear 2 Change the air cleaner 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 Compressor oil capacity is 3 quarts NOTE 2 Cylinder head stud torque MUST be checked after the initial day of operation The compressor must be cold room temperature before re torquing of studs Torque studs to 1 418 in Ibs plus or minus 10 in Ibs 18 309831 Maintenance Lubrica
28. the operating site The filter element must be serviced when clogged A clogged air filter element will reduce compressor performance and cause premature wear of components 20 309831 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 Remove cooler Circulate a suitable solvent to dissolve and remove varnish and sludge Flush generously with hydraulic oil Once the cooler is reinstalled fill the hydraulic system with the proper fluid to their appropriate levels Bun 21 309831 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 In any event the procedures which can be performed in the least amount of time and with the least amount of removal or disassembly of parts should be performed first COMPRESSOR WILL NOT ENGAGE 1 No power supplied to compressor 2 Internal circuit breaker tripped 3 Hydraulic system not engaged COMPRESSOR ENGAGES BUT WILL NOT PRESSURIZE TANK 1 Airleak in plumbing 2 Worn piston rings or
29. tion Recommendations It is important that the compressor oil be of a recommended ACAUTION type and that this oil as well as the air filter element be in spected and replaced as started in this manual 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 range of environmental influences the responsibility for recommending and consistently furnishing a suitable heavy duty lubricant must rest with the individual supplier if they choose not to use the recommended 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 RATING some amupa Tawo wae ______ arca onos s RUST PREVENTION PROPERTIES Pass WATER SEPERABILTY ROTATING PRESSURE VESSEL OXIDATION TEST ASTM D2272 FZG LOAD CARRYING TEST CEC L 07 A 95 Mixing different types or brands of lubricants is not recommended OTI C a due to the possibility of a dilution of the additives or a reaction between additives or different
30. valve plates COMPRESSOR DOES NOT RECOVER PRESSURE AS FAST AS IT SHOULD 1 Dirty filter 2 Airleak in plumbing 3 Worn valve plates or piston rings 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 Description of the problem 22 309831 Troubleshooting How To Find Specific Machine Information The machine serial number can be found on the Boss serial tag located on the base in the rear of the machine near the oil sightgalss 23 309831 WARRANTY SECTION 24 309831 Warranty 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 for a period of one 1 years from the date of initial operation or eighteen 18 months from the date of shipment whichever period first expires All other components and parts of Boss Industries Inc manufacture will be free from defects in material and workmanship for a period of one 1 year from the date of initial operation or eighteen 18 months from the date of shipment whichever period first expires If within such period Boss Industries Inc receives from the Buyer written notice of and alleged defect in or nonconformance of the unit all other com
31. ydraulic oil cooler fan assembly and relay 12VDCN O hydraulic solenoid Most air tools operating pressure range is between 90 and 125 psi Operating above the tools recommended pressures will decrease the life ACAUTION of the tool Higher operating pressure can also over torque nuts and bolts fatiguing the fastener and mating parts Strictly adhere to tool operating pressures and torque standards set forth by the tool manufacturer and the specifications of the equipment that work is being performed on 11 309831 Installation amp 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 precautions in this manual may result in accidents and injuries 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 N OT C E ALL TRUCKS SHOULD BE ROAD TESTED PRIOR TO STARTING INSTALLATION TO ISOLATE ANY PREVIOUS TRUCK PROBLEMS 1 Lifting Boss Industries Inc offers a lifting bail for routine lifting loading onto trucks etc Compressors to be air lifted by helicopter must not be supported by the lifting provision but by slings with appropriate spreader bars Lift only in full
Download Pdf Manuals
Related Search