Boss Infinity Operator, Maintenance And Parts Manual

Pto air compressor

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BOSS MODEL INFINITY
PTO AIR COMPRESSOR
OPERATORS, MAINTENANCE
AND PARTS MANUAL
P/N: 307200
06/05/2008 MCM

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Summary of Contents for Boss Infinity

  • Page 1 BOSS MODEL INFINITY PTO AIR COMPRESSOR OPERATORS, MAINTENANCE AND PARTS MANUAL P/N: 307200 06/05/2008 MCM...
  • Page 3: Table Of Contents

    OPERATORS, MAINTENANCE, AND PARTS MANUAL BOSS INDUSTRIES INFINITY Operation & Maintenance Section TABLE OF CONTENTS Operation & Maintenance Section Specifications ........................6 Safety ..........................7 Compressor Terminology ....................11 Description of Components....................12 Inspection, Lubrication, and Maintenance ................16 Troubleshooting ......................... 24 Compressor Operation ......................
  • Page 5: Specifications

    SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE Parts List ITEM PART NUMBER DESCRIPTION 200353 COMPR MTG SYS, INFINITY 45-60-150 SCI8G 08 200355-999 ELEC SYS, INFINITY 45-60-150 SCI8G 08 200356-999 OIL-AIR-HYD CLNG SYS, INFINITY SCI8G 08 200354 CANOPY SYS, INFINITY 45-60-150 SCI8G 08 19 in [481.4 mm]...
  • Page 6: Safety

    SAFETY WARNING ALL UNITS ARE SHIPPED WITH A DETAILED OPERATORS AND PARTS MANUAL. THIS MANUAL CONTAINS VITAL INFORMATION FOR THE SAFE USE AND EFFICIENT OPERATION OF THIS UNIT. CAREFULLY READ THE OPERATORS MANUAL BEFORE STARTING THE UNIT. FAILURE TO ADHERE TO THE INSTRUCTIONS COULD RESULT IN SERIOUS BODILY INJURY OR PROPERTY DAMAGE.
  • Page 7 BOSS INDUSTRIES, INC. expressly disclaims responsibility or liability for any injury or damage caused by failure to observe these specified precautions or by failure to exercise that ordinary caution and due care required when operating or handling the Compressor, even though not expressly specified above.
  • Page 8 SAFETY A compliment of warning decals is supplied with each unit. These decals must be affixed to the comressor package in the locations noted in this manual. If for any reason a safety decal is removed it is the owners responsibility to make sure it is replaced.
  • Page 9 SAFETY...
  • Page 10: Compressor Terminology

    COMPRESSOR TERMINOLOGY AIR/OIL COALESCER - Performs second stage separation of oil from compressed air feeding air tools. Sometimes referred to as the separator element. CFM - Refers to the volume of compressed air being produced, expressed as cubic feet of air per minute.
  • Page 11: Description Of Components

    DESCRIPTION OF COMPONENTS COMPRESSOR ASSEMBLY The BOSS INDUSTRIES hydraulic drive compressor assembly is a positive displacement, oil flooded, rotary screw type unit employing one stage of compression to achieve the desired pressure. Components include a housing (stator), two screws (rotors), bearings, and bearing supports.
  • Page 12 DESCRIPTION OF COMPONENTS SAFETY VALVE The pop safety valve is set at 200 PSI and is located at the top of the air/oil sump. This valve acts as a backup to protect the system from excessive pressure that might result from a malfunction. AIR/OIL COALESCER The coalescer is self-contained within a spin-on housing.
  • Page 13 DESCRIPTION OF COMPONENTS INSTRUMENTATION The BOSS INDUSTRIES hydraulic drive compressor unit incorporates a gauge panel that monitors temperature, pressure and hours of operation. HOURMETER The hourmeter records the total number of operating hours. It serves as a guide in following the recommended inspection and maintenance schedule.
  • Page 14 DESCRIPTION OF COMPONENTS CONTROL SYSTEM The prime component of the compressor control system is the compressor inlet valve. The control system is designed to match air supply to air demand and to prevent excessive discharge pressure when compressor is at idle. Control of air delivery is accomplished by the inlet valve regulation and modulation as directed by the discharge pressure regulator.
  • Page 15: Inspection, Lubrication, And Maintenance

    INSPECTION, LUBRICATION, AND MAINTENANCE This section contains instructions for performing the inspection, lubrication, and maintenance procedures required to maintain the compressor in proper operating condition. The importance of performing the maintenance described herein cannot be over emphasized. The periodic maintenance procedures to be performed on the equipment covered by this manual are listed below.
  • Page 16 LUBRICATION AND MAINTENANCE CHART N " " L l i f . l i t l i t t i t l i t l i NOTE: Compressor oil and filter is to be changed after the first 50 hours of operation. After this, normal intervals are to be followed.
  • Page 17 BOSS INDUSTRIES rotary screw lubricant. The lubricant supplier’s recommendation must, therefore, be based upon not only the...
  • Page 18 DUE TO ENVIRONMENTAL FACTORS THE USEFUL LIFE OF ALL “EXTENDED LIFE” LUBRICANTS MAY BE SHORTER THAN QUOTED BY THE LUBRICANT SUPPLIER. BOSS INDUSTRIES, INC. ENCOURAGES THE USER TO CLOSELY MONITOR THE LUBRICANT CONDITION AND TO PARTICIPATE IN AN OIL ANALYSIS PROGRAM WITH THE SUPPLIER.
  • Page 19 MAINTENANCE If some of the maintenance intervals in the schedule outlined in this manual seem to be rather short, it should be considered that one hour’s operation of a compressor is equal to about 40 road miles on an engine. Thus, eight hours operation is equal to 320 road miles, 250 hours is equal to 10,000 road miles, etc.
  • Page 20 6. Run system and check for leaks. WARNING DO NOT SUBSTITUTE ELEMENT. USE ONLY A GENUINE BOSS INDUSTRIES REPLACEMENT ELEMENT. THIS ELEMENT IS RATED AT 200 PSI WORKING PRESSURE. USE OF ANY OTHER ELEMENT MAY BE HAZARDOUS AND COULD...
  • Page 21 6. Add oil (total system takes one gallon), re-tighten filler cap. 7. Check for leaks in operation. WARNING DO NOT SUBSTITUTE ELEMENT. USE ONLY A GENUINE BOSS INDUSTRIES REPLACEMENT ELEMENT. USE OF ANY OTHER ELEMENT MAY BE HAZARDOUS AND COULD IMPAIR THE PERFORMANCE AND RELIABILITY OF THE COMPRESSOR, POSSIBLY VOIDING THE WARRANTY AND/OR RESULTING IN DAMAGE TO PROPERTY AND SERIOUS BODILY HARM.
  • Page 22 MAINTENANCE SHAFT SEAL SHAFT SEAL INSTALLATION INSTRUCTIONS: 1. Remove hydraulic motor, drive coupling and adapter housing from face of compressor. 2. Remove coupling hub from compressor shaft. 3. Remove 4 screws from shaft seal cover and press seal out. 4. Pull seal wear sleeve off shaft with puller. 5.
  • Page 23: Troubleshooting

    TROUBLESHOOTING This section contains instructions for troubleshooting the equipment following a malfunction. 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.
  • Page 24 TROUBLESHOOTING IMPROPER DISCHARGE PRESSURE 1. If discharge pressure is too low, check the following: A. Too much air demand. (Air tools require more air than what the compressor can produce, air tools are free wheeling without resistance.) B. Service valve wide open to atmosphere. C.
  • Page 25 TROUBLESHOOTING COALESCER PLUGGING If the coalescer element has to be replaced frequently because it is plugging up, it is an indication that foreign material may be entering the compressor inlet or the compressor oil is breaking down. Compressor oil can break down prematurely for a number or reasons. (1) Extreme operating temperature, (2) negligence in draining condensate from oil sump, (3) using the improper type of oil, (4) dirty oil, (5) oil return nozzle plugged.
  • Page 26: Compressor Operation

    COMPRESSOR OPERATION Before starting the compressor, read this section thoroughly. Familiarize yourself with the controls and indicators, their purpose, location, and use.
  • Page 27 COMPRESSOR OPERATION OPERATING CONDITIONS The following conditions should exist for maximum performance of the compressor. The truck should be as close to level as possible when operating. The compressor will operate on a 15 degree sideward and lengthwise tilt without any adverse problems. Operation in ambient tempera- tures above 100°F (38°C) may experience high temperature shutdown.
  • Page 28: Parts And Illustration Section

    PARTS AND ILLUSTRATION SECTION...
  • Page 35: Recommended Spare Parts

    RECOMMENDED SPARE PARTS...
  • Page 36: Service Questionnaire

    No______ Distributor:_____________________________________________________ End-User:________________________________________________________ Phone Number:___________________________________________________ Make and Model for PTO:__________________________________________ BOSS INDUSTRIES Serial #:_______________________________________ Make and Model of Engine:_________________________________________ Engine:________________________________________________________ Transmission:___________________________________________________ Nature of Problem:________________________________________________ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...
  • Page 37: Instructional Procedures For Installation

    Install, use, and operate this air compressor only in full compliance with all pertinent O.S.H.A. requirements and all pertinent Federal, State, and Local codes or requirements and with BOSS INDUSTRIES, Inc. instructions. Do not modify this compressor except with written factory approval.
  • Page 38 This unit is shipped from the factory with all necessary internal wiring installed. The only remain- ing wiring necessary is the wiring needed to interface your vehicle/power source with the BOSS INDUSTRIES compressor. (Please refer to drawing 307193 on page 35) The unit is shipped with 4 loose wires, they need to be connected as follows: 1.
  • Page 39 A. Vehicle V.I.N. B. Hydraulic Pump Data C. Air-End Serial Number D. BOSS INDUSTRIES Serial Number E. Receiver Tank Serial Number F. Note any special applications relating to specific installations. Check all fluid levels (position the unit on a level surface so that proper amount of fluids can be added).
  • Page 40 In cases of high temperature and/or pressure, the closing of the valve will stop the compressor operation. Safety circuit testing for INFINITY Safety circuit testing can be done in the following manner. Start the truck. Engage the com- pressor.
  • Page 41: Warranty Section

    WARRANTY SECTION...
  • Page 42: Warranty Information

    BOSS manufacture and if in the judgment of BOSS these items do not conform or are found to be defective in material of workmanship, BOSS will at its option either, (a) furnish a Service Representative to correct defective workmanship, or (b) upon return of the item F.O.B.
  • Page 43: Summary Of Main Warranty Provisions

    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 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.
  • Page 44 4. Claim denial will result in issuance of a letter of denial. 5. BOSS INDUSTRIES will consider each claim on its’ own merit and reserves the right to accept or reject claim request. In case of air-ends, these will be returned to the manufacturer for their analysis/input.
  • Page 45 4. Workmanship is determined to be defective. 5. Machine is within warranty period. 6. Machine has been operated within design conditions. Claims made through distributors must be verified by distributor prior to contacting BOSS IN- DUSTRIES. DAMAGE IN TRANSIT Do not return damaged merchandise to BOSS INDUSTRIES, please follow claim procedure.
  • Page 46 SCREW COMPRESSOR AIR-END EXCHANGE PROGRAM Replacement air-ends are available from the factory. For current prices and availability, contact BOSS INDUSTRIES, Inc. or an authorized BOSS INDUSTRIES distributor. Prices are F.O.B. shipping point. Prices do not include labor for removal or installation.

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