Boss BA435 Piston Instruction manual

Air Compressor Manual
Models: 824252PAT
824253PAT
824256VAT
824276VAT
Service and Support: 866-869-3114
Pt# 1312100710
Rev0411
TABLE OF CONTENTS
PAGE
1
Safety Guidelines - Definitions
Before Using the Air Compressor
2
When Installing or Moving the Compressor
Before Each Use
3
Follow Safety Precautions for Electrical Connection
Plan Ahead to Protect Your Eyes, Hands, Face & Ears
When Operating
4
Spraying Precautions
Perform These Maintenance Operations
5
Warning Labels
Glossary
6
Wiring
Starting the Compressor
7-8
Troubleshooting
9-11
Parts
12
Warranty Statement
SAFETY GUIDELINES - DEFINITIONS
Safety is a combination of common sense, staying alert and knowing how your compressor works.
Read this manual to understand this compressor.
DANGER
means if safety information is not followed someone will be seriously injured or killed
WARNING
means if safety information is not followed someone could be seriously injured or killed
CAUTION
means if safety information is not followed someone may be seriously injured or killed
IMPORTANT SAFETY INSTRUCTIONS
Save these instructions
Improper operation or maintenance of this product could result in serious injury and property
damage. Read and understand all warnings and operation instructions before using this compressor.
Before using the air compressor
Things you should know
Inspect your work area
Air compressors are utilized in a variety of air
1. Keep work area clean.
system applications. Because air compressors
and other components (hoses, connectors, air
2. Cluttered areas and benches invite accidents.
tools, spray guns, etc.) make up a high pressure
Floors must not be slippery from wax or dust.
pumping system, the following safety precautions should be observed at all times.
Inspect your compressor
Only persons familiar with these rules of
safe operation should use the air
compressor.
1. To reduce the risk of injury from accidental
starting, turn switch off and disconnect the
power before checking it.
1. Read the instruction manual carefully before
attempting to assemble, disassemble or
operate your system. Be thoroughly familiar
with the controls and the proper use of the
equipment.
2. If any part is missing, bent or broken in any
way, or any electrical part does not work properly, keep the compressor off and disconnected.
3. Check hoses for weak or worn condition
before each use, making certain all connections
2. Review and understand all safety instructions
are secure. Do Not use if defect is found.
and operating procedures in this manual.
WARNING
3. Review the maintenance methods for this
compressor (See “Maintaining Your
Compressor” section).
Do not operate compressor if damaged during
shipping, handling or use. Damage may result
in bursting and cause injury or property damage.
DANGER
This compressor is Not designed for and should
not be used in breathing air applications.
Page 1
When installing or moving the compressor
WARNING
6. A minimum clearance of 18 inches between
the compressor and a wall is required
because objects could obstruct airflow.
This compressor is extremely top heavy. The
compressor must be bolted to the floor with
vibration pads before operating to prevent
equipment damage, injury or death. Do Not
tighten bolts completely as this may
cause stress to the tank welds.
7. The compressor should be located where it can
be directly wired to a circuit breaker. The
compressor should be wired by a qualified
electrician.
To reduce the risk of a dangerous
environment
8. Never store flammable liquids or gases in
the vicinity of an operating compressor.
1. Keep work area well lit.
2. Operate compressor in a well-ventilated
area free from flammable liquids and vapors.
3. Operate compressor in a ventilated area so
that compressor may be properly cooled and
the surrounding air temperature will not be
more than 100°F.
9. Do Not locate the compressor air inlet near
steam, paint spray, sandblasting areas or
any other source of contamination. The
debris could damage the motor and pump.
WARNING
Never use plastic (PVC) pipe for compressed
air. Serious injury or death could result.
4. Never use a compressor in a wet
environment.
CAUTION
5. Protect material lines and air lines from
damage or puncture. Keep hose and
wires away from sharp objects, chemical
spills, oil, solvents and wet floors.
Never use the shipping skid for mounting the
compressor.
WARNING
This compressor is not intended for outdoor
installation.
NOTICE
Do Not secure compressor with toggle bolts
into drywall. Drywall sheeting or plaster will not
support the weight of the compressor.
WARNING
Never install a shut off valve between the compressor pump and tank. Personal injury and/or
equipment damage could occur.
Note: Tank Outlet Size: 1/4” NPT for Models 824252PAT & 824253PAT
½” NPT for Models 824256VAT & 824276VAT
Before each use
Inspect your work area
Inspect your compressor
1. Keep work area clean. Cluttered areas and
benches invite accidents.
1. To reduce the risk of injury from accidental
starting, turn the switch off and disconnect
power.
2. The floor must not be slippery from wax or
dust.
2. If any part is missing, bent or broken in any
way, or any electrical part does not work
properly, keep the compressor off and disconnect power. Do Not use if defect is found.
3. Check hoses for weak or worn condition
before each use, making certain all connections are secure. Do Not use if a defect is
found.
Page 2
Follow the safety precautions for electrical connections
1. Follow all local electrical and safety codes,
as well as the National Electric Code (NEC)
and the Occupational Safety and Health
Act (OSHA).
3. Protect wires from contact with sharp objects.
CAUTION
2. Wiring and fuses should follow electrical
codes, current capacity and be properly
grounded.
All electrical connections should be made by
a qualified electrician.
Plan ahead to protect your eyes, hands, face and ears
Dress for safety
1. Wear safety glasses (meeting ANSI Z87.1 or
in Canada CSA Z94.3-99) and use hearing
protection when operating the unit. Everyday
glasses are not safety glasses.
WARNING
Be careful when touching the exterior of compressor, pump, motor and air lines; they may
become hot enough to cause injury.
2. Wear shoes to prevent shock hazards.
WARNING
3. Tie back long hair.
Never operate the compressor without a
beltguard. The compressor can start automatically without warning. Personal injury or
property damage could occur from contact
with moving parts.
Pay attention to your hands
WARNING
Keep fingers away from running compressor.
Fast moving and hot parts may cause injury
and/or burns.
CAUTION
The compressor may be hot even if the unit is
stopped.
WARNING
Use of a mask or respirator per chemical
manufacturers’ instructions may be necessary if there is a chance of inhaling toxic fumes.
Read mask and respirator instructions carefully. Consult a safety expert if you are not
sure about the use of certain masks or
respirators.
When operating
WARNING
1. Do not exceed the pressure rating of any
component of the system.
2. Release pressure within the system slowly
to prevent flying dust and debris.
3. If the equipment starts to abnormally vibrate,
STOP the compressor immediately and
check for the cause.
Never change the safety valve or pressure
switch settings. Keep safety valve free from
paint and other accumulations. See compressor
specification decal for maximum operating
pressure. Do not operate with the pressure
switch set higher than the maximum operating
pressure.
Page 3
Spraying precautions
WARNING
1. Do Not spray in the vicinity of open flames
or other places where a spark can cause
ignition. Do Not smoke when spraying
paint, insecticides, or other flammable
substances.
Never point a spray gun at yourself or any
other person or animal. Accidental discharge
may result in serious injury.
Reduce the risk of dangerous
environment
Be informed about the materials you use
1. When spraying with solvents or toxic chemicals, follow the instructions provided by the
chemical manufacturer. Consult a safety
expert if unsure about the use of masks or
respirators.
WARNING
Extreme caution should be taken when
spraying flammable liquids as the spark from
a motor or pressure switch may cause a fire
or explosion. Ample ventilation must be
provided.
2. If the material you intend to spray contains
trichloreoethane and methylene chloride, do
not use accessories that contain aluminum or
galvanized materials, as these chemicals can
react with galvanized components causing
corrosion and weakening equipment. Use
stainless steel accessories.
WARNING
Spray in a well ventilated area to keep fumes
from collecting and causing serious injury and
fire hazards.
Perform these maintenance operations
1. Do regular maintenance; keep all nuts, bolts,
and screws tight, to be sure equipment is in
safe working condition.
2. Inspect tank yearly for rust, pin holes or any
other imperfections that could cause it to
become unsafe.
4. Drain tanks of moisture after each day’s use.
If unit will not be used for awhile, it is best to
leave the drain cock open until such time as it
is to be used. This will allow moisture to
completely drain out and help prevent
corrosion of inside of tank.
5. Always disconnect from power source before
working on or near a motor, or its connected
load. If power disconnect point is out-ofsight, secure it in the “OFF” position and tag it
to prevent unexpected application of power.
WARNING
NEVER attempt to repair or modify a tank!
Welding, drilling or any other modification will
weaken the tank resulting in damage from
rupture or explosion. Always replace worn,
cracked or damaged tanks.
WARNING
3. Clean electrical equipment with an approved
cleaning agent, such as a dry, non-flammable cleaning solvent.
Disconnect power and depressurize system
before servicing air compressor. Slightly open
drain cock after shutting off compressor.
Daily
Monthly
(Make sure the main power is off.) Check the belts
for tension. Belts should not move up and down
when the compressor runs and when stopped,
should not have more than ½ in of play when
depressed. Be careful not to over tighten belts
during adjustment.
Check oil level at sight glass. Oil should be
1/2 way to slightly above in oil sight glass.
Drain moisture from tank.
Verify the pressure switch unloader is
working by listening for a brief hissing sound
when the compressor shuts off.
Visually check the compressor for loose parts,
excessive noise or vibration.
Remove and check air filter, replace if necessary.
Change oil every 3 months or 300 hours. A
compressor grade 40 wt. non-detergent oil
should be used.
Page 4
WARNING LABELS
WIRING
Find and read all warning labels found on the air compressor.
Sample Warning Labels shown.
Your decals may vary.
GLOSSARY OF TERMS
Air Filter
Pressure Switch
Porous element contained within a metal or
plastic housing attached to the compressor
cylinder head which removes impurity from the
intake air of the compressor.
Device which automatically controls the on/off
cycling of the compressor. It stops the
compressor when the cut-off pressure in
the tank is reached and starts the compressor
when the air pressure drops below the cut-in
pressure.
Air Tank
PSI (Pounds per Square Inch)
Cylindrical component which contains the
compressed air.
Check Valve
Measurement of the pressure exerted by the
force of air. The actual psi is measured by a
pressure gauge on the compressor.
Device which prevents compressed air from
flowing back from the air tank to the compressor pump.
Pump
Electric Motor
Device which produces the compressed air
with a reciprocating piston contained within a
cylinder.
Device which provides the rotational force
necessary to operate the compressor pump.
Safety Valve
Pressure Gauge
Device which prevents air pressure in the air
tank from rising over a predetermined limit.
Device which shows the tank or regulated
pressure of the compressed air.
Thermal Overload Switch
Device, integrated into the electric motor winding,
which automatically “shuts off” the compressor
if the temperature of the electric motor exceeds
a predetermined limit.
Page 5
WIRING
WIRING
WARNING
ALL ELECTRICAL WIRING SHOULD BE DONE
BY A QUALIFIED ELECTRICIAN
Incoming power
should be connected
to the posts
marked (LINE)
General Information
Adequate wiring and motor protection
should be provided for all stationary
compressors. Wiring used for other
machinery should not be used. A
qualified electrician familiar with local
electrical codes in your area should be
used.
Do Not Make
Connections On
Prewired Posts
Marked (MOTOR)!
WARNING
To reduce the risk of electrical hazards, fire
hazards or damage to the compressor, use
proper circuit protection. Your compressor
is wired at the factory for operation using
the voltage shown. Connect the compressor
to a power source with the correct breaker
size.
WARNING
Electrical connections must be properly
grounded. Ground connections should be
connected at the grounding screw.
CAUTION
Overheating, short circuiting and fire damage
will result from inadequate wiring.
Model
824252PAT
824253PAT
824256VAT
82476VAT
Voltage
115V / 1 ph
208-230V / 1 ph
15
FLA
Breaker Size 20 amp
Electrical connections
must be properly
grounded. Ground
connections should be
connected at a
grounding screw.
16
30 amp
The motor is equipped with a manual,
resetable overload device to protect it from
overheating. In the event the compressor will
not run and power is properly connected and
on, press the motor overload reset button
located on the non drive end of the motor.
STARTING THE COMPRESSOR
STARTING THE COMPRESSOR
Prior to actually running the compressor,
check the following items:
Crankcase oil - Make sure the sight glass
shows ½ full or slightly above.
Make sure all rags, tools, oil, etc. are away
from the unit.
Open the air system to free it of any pressure.
Switch the compressor on for a few
revolutions to make sure the rotation is
correct. Correct rotation is clockwise
when facing the sight glass on the pump.
Operate the compressor for a few minutes
unloaded (air system open) then allow the
compressor to pump up. Make sure the
electrical pressure switch properly switches
off the compressor according to the setting
desired.
CAUTION
Make sure the pressure in the tank does
not exceed its rating. Single stage compressors should operate at a maximum of
135 psi. If the pressure gauge indicates
a pressure thatis higher than these
maximum pressures, shut off compressor
immediately and call 1-866-869-3114.
Page 6
TROUBLESHOOTING GUIDE
Low discharge pressure 1. Compressor too small for
application
2. Air leaks
3. Restricted intake air
4. Blown gasket(s)
5. Broken or misaligned valves
1. Reduce air demand or use a compressor
with more air capacity.
2. Listen for air leaks. Apply a soap solution
to all fittings and connections. Bubbles
will form at points of leakage. Tighten
or replace fittings or connections.
3. Clean or replace air filter.
4. Replace necessary gaskets.
5. Remove head and inspect for broken or
misaligned valves. Replace valves, if
necessary.
!
Excessive noise
“knocking”
1. Loose drive pulley or flywheel
2. Low on oil
3. Worn connecting rod or
connecting rod bearing
4. Noisy check valve
CAUTION
Install a new head gasket
each time head is removed
1. Tighten drive pulley or flywheel bolt.
2. Check for proper oil level. Low or dirty
oil may cause bearing damage.
3. Replace connecting rod and/or connecting
rod bearings.
4. Replace check valve.
!
DANGER
Do not remove check valve
with air pressure in tank
Excessive oil carryover
1. Worn piston rings
2. Restricted intake air
3. Too much oil in compressor
4. Incorrect oil viscosity
1. Replace with new piston rings.
2. Clean or replace air filter.
3. Drain oil to proper oil level.
4. Use a quality non-detergent 30 or 40wt
oil specified for each model (Page 4).
Water in tank and/or
discharge line
1. Normal. Amount of water will
increase as humidity in the
air increases.
1. Drain tank at least once per day.
2. Add an inline filter to reduce moisture in
in the air line.
Will not run or motor
hums
1. Low voltage
1. Check voltage with volt meter across both
legs of incoming power. Check reset button
on motor.
2. Malfunctioning pressure switch 2. Repair or replace pressure switch.
3. Malfunctioning check valve
3. Replace check valve or pressure switch.
!
Breaker or reset
repeatedly trips
Do not remove check valve
with air pressure in tank
1. Make sure the breaker is sized properly.
See page 6 in this manual.
2. Check voltage with volt meter across both
2. Low voltage
legs of incoming power.
3. Replace motor.
3. Malfunctioning motor
4. Check all electrical connections.
4. Loose electrical connections
5. Malfunctioning pressure switch 5. Adjust or replace pressure switch.
6. Replace check valve.
6. Malfunctioning check valve
1. Incorrect breaker size
!
Tank does not hold
pressure when not
running and shut off
valve is closed
DANGER
1. Malfunctioning check valve
Page 7
Do not remove check valve
with air pressure in tank
1. Replace check valve.
!
2. Loose fittings or connections
3. Crack or pin hole in tank
DANGER
not remove check valve
DANGER Do
with air pressure in tank
2. Tighten or replace fittings or connections.
3. Replace tank. Do not attempt to repair tank.
TROUBLESHOOTING GUIDE (Continued)
Pressure switch unloader constantly
leaking air
1. Malfunctioning check valve
Pressure switch not
unloading
1. Malfunctioning pressure
switch
1. Replace check valve if unloader bleeds
constantly.
!
1. Replace pressure switch if it does not release
air pressure briefly when unit shuts off.
!
Excessive vibration
1. Improper installation
2. Loose belts
3. Misaligned flywheel or
drive pulley
Overheating
1. Compressor too small for
application
2. Cooling surfaces dirty
3. Improper cooling
Page 8
not remove check valve
DANGER Do
with air pressure in tank
DANGER
Do not remove pressure
switch with air pressure in
tank
1. Make sure unit is mounted on a level surface
with vibration pads.
2. Replace belts. Align and tighten properly.
3. Align flywheel and drive pulley.
1. Reduce air demand or use a compressor
with more air capacity.
2. Clean all cooling surfaces of dirt and dust.
3. Install compressor in an area with adequate
cool dry air.
Pump 82-1312100119
Beltguard
82-6214343100 & 82-2236110472
Motor
82-1312100388
Handle
82-2236107285
Regulator
82-1312100002
Discharge Tube
Pressure Switch
82-1312100213
82-1312100455
Tank
824252PAT
82-1312100474
Drive Pulley 82-1312100440
Safety Valve 82-1312100005
Gauge
82-1312100006
Belt
82-1312100129
Check Valve 82-1312100168
Unloader Line 82-1312100026
Power Cord 82-1312100007
Pump
82-1312100119
Wheel
Drain
82-1312100060
82-1312100360
Discharge Tube
82-1312100213
Motor
Beltguard
82-6214343100 &
82-2236110472
82-1312100388
Pressure Switch
82-1312100455
Regulator
82-1312100002
Handle
82-2236107294
Tank
82-1312100476
824253PAT
Drive Pulley 82-1312100440
Safety Valve 82-1312100005
Gauge
82-1312100006
Belt
82-1312100129
Check Valve 82-1312100168
Unloader Line 82-1312100026
Power Cord 82-1312100007
Wheel
82-1312100029
Drain
82-1312100360
02
01
09
03
10
08
05
06
04
07
1. Compressor
2. Air Filter
3. Electric Motor
4. Safety Valve
5. Pressure Switch
6. Pressure Gauge
7. Tank Drain
8. Check Valve
9. Discharge Tube
10. Belt Guard
11. Unloader Line (Not Visible)
12. Drive Belt (Not Visible)
13. Drive Pulley (Not Visible)
824256VAT
824276VAT
82-1312100119
82-2236102108
82-1312100388
82-1312100005
82-1312100455
82-1312100006
82-1312100360
82-1312100168
82-1312100216
82-6214343100 (Front)
82-2236110472 (Back)
82-1312100026
82-1312100129
82-1312100440
82-1312100123
82-2236102108
82-1312100390
82-1312100005
82-1312100455
82-1312100006
82-1312100360
82-1312100168
82-1312100215
82-6214343100 (Front)
82-2236110472 (Back)
82-1312100026
82-1312100134
82-1312100448
Page 9
Compressor Pump
82-1312100119
11
09
07
01
10
05
12
06
02
08
03
Page 10
04
Compressor Pump
82-1312100119
01
02
03
04
05
06
07
08
09
10
11
12
Valve Assembly Kit
Conrod Kit
Crankshaft Kit
Crankcase Bottom Kit
Cylinder Kit
Shaft Seal Kit
Head Kit
Flywheel Kit
Top Gasket Kit
Oil Level Kit
Air Filter Kit
Ring Kit (2 Required)
82-6229024900
82-9428010
82-9428020
82-6229022500
82-6229022900
82-9428050
82-6229023900
82-6229023400
82-6229023600
82-9428100-KIT
82-6229020500
82-9428120
Compressor Pump
82-1312100123
01
02
03
04
05
06
07
08
09
10
11
12
Valve Assembly Kit
Conrod Kit
Crankshaft Kit
Crankcase Bottom Kit
Cylinder Kit
Shaft Seal Kit
Head Kit
Flywheel Kit
Top Gasket Kit
Oil Level Kit
Air Filter Kit
Ring Kit (2 Required)
Page 11
82-6229024900
82-6229021800
82-6229022800
82-9428031
82-6229023100
82-9428050
82-6229023900
82-9428071
82-6229023600
82-9428100-KIT
82-6229020500
82-9428120
AIR COMPRESSOR WARRANTY POLICY
Atlas Copco Compressors, LLC makes every effort to assure that its products meet
high quality and durability standards, and warrants to the original purchaser that this
product is free from defects in materials and workmanship for a period of one year
from date of purchase.
(90 days if used by a professional contractor or if used as rental equipment).
This warranty does not apply to damage due directly or indirectly to misuse, abuse,
negligence or accidents; repairs or alterations outside our facilities; or lack of
maintenance. We shall in no event be liable for death, injuries to persons or
property, or for incidental, contingent, special or consequential damages arising
from the use of our product.
Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation of exclusion may not apply to you. To take
advantage of this warranty, the product or part must be returned to us with
transportation charges prepaid. Proof of purchase date and an explanation of the
complaint must accompany the merchandise. If our inspection verifies the defect,
we will either repair or replace the product at our election or we may elect to refund
the purchase price if we cannot readily and quickly provide you with a replacement.
We will return the repaired products at our expense, but if we determine there is no
defect, or that the defect resulted from causes not within the scope of our warranty,
then you must bear the cost of returning the product. This warranty gives you
specific legal rights and you may also have other rights which vary from state to
state.
Altas Copco Compressors, LLC
1800 Overview Drive
Rock Hill, SC 29730
Service and Support: 866-869-3114