BOSSCO BA440 PISTON User manual

310969
3/20/18 DJH
http://www.bossair.com
Pක඗ඌඝඋග Mඉඖඝඉඔ
BA440 PISTON
Hydraulic Air Compressor
This manual must be read carefully before using your Boss Industries, LLC BA440 PISTON. Store in a
safe and convenient location for future reference.

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Contents
Welcome...............................................4
General Information.........................................4
Safety....................................................5
General Safety Overview.................................5
Safety Precautions...........................................6
Specifications......................................8
Specification Sheet..........................................8
Installation & Operation......................9
Mounting the Compressor................................9
Installation of Wiring.......................................10
Connecting the Hydraulic Hoses....................10
Connecting the Air Hoses..............................10
Pre-Start-up Inspection Checks.....................11
Check All Fluid Levels....................................11
Machine Documentation................................11
Operating Procedure......................................12
Shutdown Procedure.....................................12
Operating Conditions.....................................12
Maintenance.......................................13
Lifetime Warranty Information........................13
Recommended Spare Parts List....................13
Maintenance Chart.........................................14
Compressor Oil..............................................15
Compressor Oil Fill, Level, and Drain............16
Changing the Air Intake Filter........................16
Changing the Hydraulic Oil Cooler.................16
Piston Ring Replacement..............................16
Oil Pump Replacement..................................18
Crankshaft and Bearing Replacement...........18
Troubleshooting................................20
Low Oil Pressure............................................20
No Oil Pressure..............................................20
Compressor Will Not Engage.........................20
Compressor Engages But Will Not Pressurize
Tank............................................................20
Compressor Does Not Recover Pressure as
Fast as it Should..........................................20
Contacting Boss Industries, LLC....................20
Warranty.............................................21

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Welcome
General Information
Thank you for choosing the Boss Industries, LLC
BA440 PISTON Hydraulic Air Compressor. Before
operating, carefully read this manual and become well
acquainted with your new machine. Doing this will
increase your safety and maximize the life of the
machine.
While this manual is written to be as accurate as
possible, Boss Industries, LLC strives to continually
improve the efficiency and performance of its
machines. As a result, sometimes there may be slight
differences between a given version of the manual
and the machine.

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Safety
General Safety Overview

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Safety
Safety Precautions
The following safety precautions are a general guide to safe operation of the equipment.

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Safety
Safety Precautions (continued)

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Specifications
Specification Sheet
COMPRESSOR SPECIFICATIONS
Model BA440 PISTON
Type Hydraulic Air Compressor
Output Compressor RPM Hyd Flow Hyd Pressure
Delivery 40 CFM @ 100 PSI 1650 12.18 GPM 2100 PSIG
35 CFM @ 100 PSI 1400 10.16 GPM 2100 PSIG
30 CFM @ 100 PSI 1150 8.35 GPM 2100 PSIG
Operating Pressure
Range 90 - 150 PSIG
Ambient Operating
Temperature Range -20°- 100°F
Oil Capacity
(Compressor) 1 1/3 quarts
Air Service Connection 1/2” NPT
Overall Dimensions 26.50” L X 23 ” W X 19.75” H
Weight 180 lbs.
*CALCULATIONS PERFORMED @ 85% EFFICIENCY MECHANICAL AND 96% EFFICIENCY
VOLUMETRIC.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE
●BA440 system is to run intermittently.
●When the BA440 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 20 GAL for the BA440 plus all the other
manufacturer’s requirements.
●Cooling air intake must not see air temperatures above ambient.
●Cooling air discharge must have 10” clearance from any obstructions.
●20° maximum operating slope.

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Installation & Operation
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 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 machine. A
minimum of 10” of clearance is needed for the hot
discharge air from the cooler. Cool ambient air is
drawn in from under the frame. One last
consideration in the mounting should be the routing
of hydraulic hoses. Be sure these can be safely run
to the hydraulic manifold on the machine. The unit
should be secured to the vehicle with four 3/8” grade
8 bolts, flat washers, and loc washers. Ensure that
you have a sub structure that will support the weight
of the compressor. Be sure to follow all National
Vehicle Safety Standards.

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Installation of 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 1 end of a 5 pin
connector. They need to be connected as follows:
Pin A (Yellow) - 12VDC power supply
(24VDC if equipped)
Pin B (Red) - Battery (Positive Terminal)
Pin C (Green) - PTO Ground
Pin D(Orange) - 12VDC output signal
(24VDC if equipped)
Pin E (Black) - Battery (Negative Terminal)
Connecting the Hydraulic Hoses
The hydraulic hoses to the compressor should be
connected directly to the hydraulic manifold with
appropriately sized fittings. The input line should be
made from a good quality high pressure (min. 3000
PSI) hydraulic hose 1/2" or 3/4” i.d. The return line
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 with kinks or bends
that inhibit flow of the hydraulic oil. Lack of flow
could result in damage to the motor and compressor.
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.
Installation & Operation
Connecting the Air Hoses
The air discharge hose should be connected directly
to the “AIR” port. The fitting is a 1/2” female NPT.
The air line should be made from a good quality (min
200 Psi) hydraulic hose 1/2” or 3/4” i.d. 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.

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Installation & Operation
Pre-Start-up Inspection Checks
This inspection should be done prior to the
compressor test.
I. Check all assemblies, clamps, fittings, hose
connections, nuts, and bolts to ensure they are
properly tied and secured to the vehicle. This
is a very critical area of inspection. The
vehicle should not be moved until this
inspection has been completed.
II. Remove all tools, rags, and installation
equipment from the area.
III. Check all valves to ensure they are in correct
operating position.
IV. Vacuum all areas that have metal or plastic
shavings. Wipe all fingerprints off unit and
vehicle.
Check All Fluid Levels
Position the unit on a level surface so that proper
amount of fluids can be added.
I. Fuel to provide three hours of operation
II. Hydraulic fluid levels may have to be topped
off after test.
III. Compressor
A. Add oil if needed.
B. Additional oil may need to be added after
test.
C. Top off oil level to the “FULL” line on
the dipstick when finished with test.
II. Any other applicable fluids
III. Transmission fluid and PTO box.
Machine Documentation
Record all serial numbers for this installation.
A. Vehicle V.I.N.
_________________________________________
B. Hydraulic Pump Data
_________________________________________
C. Compressor Serial Number
_________________________________________
D. BOSS Serial Number
_________________________________________
E. Air Tank Serial Number
_________________________________________
F. Note any special applications relating to specific
installations.
_________________________________________

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Operating Procedure
I. Read this manual carefully before proceeding.
II. Start power source and allow for warm-up.
III. Verify the compressor is disengaged.
IV. Engage hydraulic system per company policy.
V. Engage compressor
Installation & Operation
Shutdown Procedure
I. Disengage compressor circuit.
II. Relieve system of stored air.
Operating Conditions
The following conditions should exist for maximum
performance of the compressor:
●The machine should be as close to level as
possible when operating.
●Ambient temperature for operation should be
below 100°F (38°C). The machine may
experience high temperature shutdown above
this level.

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Maintenance
Lifetime Warranty Information
In order to maintain the lifetime warranty status on
your BA440 PISTON, the required maintenance
intervals listed on the following page must be obeyed.
Recommended Spare Parts List
PART
NUMBER DESCRIPTION
80279 Kit, Repair Reed Valve
300854 Element, Air Filter
301267 Spider, Curved Jaw
302936 Kit, Repair HYD Motor
Seal
310610-2Q Lubricant, ShieldWorks
2Q

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Maintenance Chart
The MAINTENANCE CHART lists serviceable items on this compressor package. The items are listed
according to their frequency of maintenance.
Maintenance
INTERVAL REQUIRED MAINTENANCE
DAILY
1. Check crankcase oil level.
2. Drain Condensation from air receiver.
WEEKLY
1. Inspect the air intake.
2. Check the cylinder head stud torque (See NOTE 2)
3. Check the operation of the receiver safety values.
EVERY 3 MONTHS
1. Change the crankcase oil (See NOTE 1)
2. Check cooler fins for dirt and obstructions. Clean if needed.
EVERY 6 MONTHS
1. Inspect the drive coupling for wear.
2. Change the air cleaner.

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Maintenance
Compressor Oil
The following are general characteristics for a rotary
screw 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 Industries, LLC ShieldWorks rotary screw
lubricant. The lubricant supplier’s recommendation
must, therefore, be based upon not only the following
general characteristics, but also upon his or her own
knowledge of the suitability of the recommended
lubricant in helical screw type air compressors
operating in the particular environment involved.
Recommended Compressor Lubricant: BOSS
ShieldWorks
1. Specifications
1. Flash point 496°F minimum.
2. Pour point -40°F.
3. Contains rust and corrosion inhibitors.
4. Contains foam suppressors.
5. Contains oxidation stabilizer.

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Maintenance
Compressor Oil Fill, Level, and
Drain
Before adding or changing compressor oil, make sure
that the compressor is completely relieved of pressure.
Oil is added at the fill cap on a pipe on the rear of the
crankcase. A drain line is located on the rear panel of
the machine. Proper oil level is to the “FULL” line
on the dipstick, when the unit is shut down and has
had time to settle. The machine must be level when
checking the oil. DO NOT OVERFILL. The oil
capacity is given in “Compressor Specifications”.
Changing the Air Intake Filter
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 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.
Changing the Hydraulic Oil Cooler
The interior of the oil cooler should be cleaned when
the pressure drop across it at full flow exceeds 25 PSI.
First, remove the cooler. Then, circulate a suitable
solvent to dissolve and remove varnish and sludge.
Then flush the cooler generously with hydraulic oil.
Reinstall the cooler. Once the cooler is reinstalled,
fill the hydraulic system with the proper fluid to their
appropriate levels.
Piston Ring Replacement
Shut down the machine and allow to cool for
approximately 10 minutes. Next, verify entire system
pressure is relieved before proceeding. Then,
disconnect air inlet system tubes. Now disconnect
3/4” discharge jumper hose and 3/4” discharge hose.
Unscrew the head nuts and remove the heads.
Remove the cylinder bolts and tap the sides of the
cylinder several times to break it loose from the
gasket. Next, rock the cylinder back and forth and lift
until it is free. Lift it off of the pistons. To remove the
old gasket material, just a single edged razor blade or
putty knife.

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Maintenance
Now hone the cylinder to break the glaze and remove
the buildup at the top of the cylinders. 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. Next, with a ring expander, remove the
compression and oil rings. After the old rings have
been removed, with the ring expander, install the new
ring kit. Make certain that the oil ring is on the bottom
and the beveled edge of the compression ring is
toward the top of the piston. Now position the
cylinder base gasket on the crankcase, using a few
drops of oil to hold it in position. Install the cylinder
block spacer and gasket on the crankcase. Next you
will rotate the rings so that the gaps of the three rings
are 120 degrees apart. Lightly lubricate the inside of
the cylinder and 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 this step for the other piston.
Now slide the cylinder down until it mates with the
crankcase. Start all cylinder mounting bolts until they
are snug, then torque the bolts to 180 in-lbs in the
sequence shown below. Do not torque the full 180
in-lbs all at once, but in 25 - 50 in-lbs increments.
Position the gaskets and valve plate on top of the
cylinder. Then position the head on the cylinder and
turn bolts finger tight. After tightening with hands,
torque the studs/nuts to 240 in-lbs in 25 - 50 in-lb
increments in the sequence shown below.
Now reconnect the 3/4” discharge hose and discharge
jumper hose. Next, install the compressor and connect
the wiring and test the machine.

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Maintenance
Oil Pump Replacement
First, shut down the machine and allow it to cool for
at least 10 minutes. Verify that the entire system is
pressure relived before proceeding. Next, remove the
bolts and lift off the pump cover. Use a single edged
razor blade or putty knife to remove the old gasket
material, but make sure not to damage the machined
surfaces.
Lift the pump out of the cavity and position a new
gasket on the rear bearing housing. Next, insert the
pump into the cavity and position it slightly to one
side using a common screwdriver. Wedge the pump
into he piston so that it partially compresses the
spring. Note that the driver pin and slot in pump must
be in line. Next place the pump cover into position
and start two bolts. Strike the pump cover with a
rubber mallet to jar the pump loose. When the tension
spring can be felt against the pump cover, the pump
is lose. Now you can insert the two remaining bolts
and torque to 180 in-lbs. The bolts should be torqued
in a diagonal pattern. Finally, install the air
compressor in the vehicle and connect air lines and
wiring.
Crankshaft and Bearing
Replacement
If it is necessary to replace the crankshaft, related
components must also be replaced. Replace both
bearings, both races, the key, pump collar, and
pump drive pin.
First, shut down the machine and allow it to cool for
at least 10 minutes. Verify that the entire system is
pressure relived before proceeding. Remove both
heads, cylinders, and pistons (See Piston Ring
Replacement on pg. 16). Next, remove the bolts on
the connecting rods and lift them out. Reassemble the
connecting rods to be certain that the matched parts
remain together on the same crankshaft journals. Now
remove the pump cover, oil pump, sleeve, spring, and
rear bearing housing. Next remove the drive hub and
the front bearing housing. Next pull the crankshaft
from the crankcase and remove all gasket material
with a razor blade or putty knife.

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Maintenance
Next, press the bearing races out of the bearing
housing. Only push the tapered roller bearings off the
crankshaft if they’re being replaced. If you're
replacing the crankshaft, discard the whole assembly.
Now press new bearings into the piston and
generously oil the front bearing race and install the
front bearing housing with gasket. Torque the bolts
to 180 in-lbs as shown below.
Slide the crankshaft into the crankcase and generously
lubricate the bearing race and install rear bearing
housing and gaskets.
Next install the oil pump and then the connecting
rods. Thoroughly oil the crankshaft rods before
installing them. When installing the rods, make
certain that the tabs are aligned on the same side of
the rod as shown below. Finally, install the pistons,
rings, and heads (See Piston Ring Replacement on
pg. 16)

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Troubleshooting
Low Oil Pressure
If the oil pressure is too low, check the following:
I. Oil level in machine
II. Loose pipe plug on oil pump cover
III. Worn or defective oil pump
IV. Crack or scratch on oil pump cover
No Oil Pressure
If the oil pressure is nonexistent, check the following:
I. Defective oil pump
II. Blocked oil passage
III. Damaged oil pump drive pin
Compressor Will Not Engage
If the compressor will not start, check the following:
I. No power supplied to compressor
II. Internal circuit breaker tripped
III. Hydraulic system not engaged
IV. Defective pressure switch
Compressor Engages But Will Not
Pressurize Tank
If the compressor starts but the tank does not become
pressurized, check the following:
I. Air leak in plumbing
II. Worn piston rings or valve plates
Compressor Does Not Recover
Pressure as Fast as it Should
If the compressor is not recovering pressure at normal
speeds, check the following:
I. Dirty filter
II. Air leak in plumbing
III. Worn valve plates or piston rings
Contacting Boss Industries, LLC