BOSS MODEL INFINITYPTO AIR COMPRESSOR

OPERATORS, MAINTENANCEAND PARTS MANUAL

P/N: 30720006/05/2008 MCM

4

OPERATORS, MAINTENANCE, AND PARTS MANUALBOSS 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 ...................................................................................................... 27

Parts and Illustration Section ............................................................................................. 29

Recommended Spare Parts ................................................................................................ 36

Service Questionnaire........................................................................................................ 37

Instructional Procedures for Installation ........................................................................... 38

Warranty Section

Warranty Information ........................................................................................................ 43

6

SPECIFICATIONS

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SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE

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1

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2

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3

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4

5

5

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A A

B B

C C

D D

Parts ListDESCRIPTIONPART NUMBERQTYITEM

COMPR MTG SYS, INFINITY 45-60-150 SCI8G 0820035311ELEC SYS, INFINITY 45-60-150 SCI8G 08200355-999 12OIL-AIR-HYD CLNG SYS, INFINITY SCI8G 08200356-999 13CANOPY SYS, INFINITY 45-60-150 SCI8G 0820035414

SHEET

20054-0011 1 OF

REV1

INFINITY 45-60 SCI8G 08

BOSS INDUSTRIES1761 GENESIS DR.LA PORTE, IN 46350

N/APATH

MATERIAL

G:\Inventor Files\20k\20054-001.dwg

12/3/2007

12/3/2007DCLDRAWN

NDDCHECKED

1=4D

DESCRIPTION

DWG NO

R

SCALESIZE

UNMACHINED SURFACES

FRACTIONAL ` 1/16

DECIMAL .03

ANGULAR ` 1°

DO NOT SCALETOLERANCES

UNLESS NOTED

MACHINED SURFACES NOMINAL DIM.

0.000 TO 1.000 .010

1.001 TO 5.000 .015

5.001 TO 10.000 `.020

10.001 & OVER `.025

THIS DRAWING AND ALL ITS CONTENTS ARE PROPERTY OF BOSS INDUSTRIES, INC. AND MUST NOT BE COPIED OR MADE PUBLIC. IT IS LOANED AND IS SUBJECT TO RETURN UPON DEMAND. THEINFORMATION CONTAINED IN THIS DRAWING IS CONFIDENTIAL AND MUST NOT BE USED, DIRECTLY OR INDIRECTLY, IN ANY WAY DETRIMENTAL TO THE INTEREST OF BOSS INDUSTRIES, INC.

PROPRIETARY INFORMATION

34 3/4 in[882.7 mm]

32 1/4 in[819.2 mm]

17 3/4 in[450.9 mm]

6 3/8 in[163.2 mm]

5 in[127.0 mm]

19 in[481.4 mm]

20 1/4 in[514.4 mm]

DIMENSIONS OF MOUNTING HOLES

REVISION HISTORYREV DESCRIPTION DATE ENG

1 UPDATED 200353 TO REV 1, 200354 TO REV 1 5/22/2008 MCM

7

WARNING

AIR COMPRESSOR SAFETY PRECAUTIONS

Safety is basically common sense. While there are standard safety rules, each situation has its ownpeculiarities that cannot always be covered by rules. Therefore with your experience and commonsense, you are in a position to ensure your safety. Lack of attention to safety can result in:accidents, personal injury, reduction of efficiency and worst of all - Loss of Life. Watch for safetyhazards. Correct them promptly. Use the following safety precautions as a general guide to safeoperation:

Do not attempt to remove any compressor parts without first relieving the entire system ofpressure.

Do not attempt to service any part while machine is operating.

DANGER

Do not operate the compressor at pressure(s) or speed in excess of its rating as indicated in“Compressor Specifications”.

Periodically check all safety devices for proper operation.

Do not play with compressed air. Pressurized air can cause serious injury to personnel.

Exercise cleanliness during maintenance and when making repairs by covering parts and exposedopenings.

SAFETY

ALL UNITS ARE SHIPPED WITH A DETAILED OPERATORS AND PARTSMANUAL. THIS MANUAL CONTAINS VITAL INFORMATION FOR THE SAFEUSE AND EFFICIENT OPERATION OF THIS UNIT. CAREFULLY READTHE OPERATORS MANUAL BEFORE STARTING THE UNIT. FAILURE TOADHERE TO THE INSTRUCTIONS COULD RESULT IN SERIOUS BODILYINJURY OR PROPERTY DAMAGE.

CHECK THE COMPRESSOR SUMP OIL LEVEL ONLY WHEN THE COMPRESSORIS NOT OPERATING AND SYSTEM IS COMPLETELY RELIEVED OF PRESSURE.OPEN SERVICE VALVE TO ENSURE RELIEF OF SYSTEM AIR PRESSURE WHENPERFORMING MAINTENANCE ON COMPRESSOR AIR/OIL SYSTEM. FAILURETO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTYAND SERIOUS BODILY HARM.

8

SAFETY

Do not install a shut-off valve between the compressor and compressor oil sump.

DANGER

Do not disconnect or bypass safety circuit system.

Do not install safety devices other than authorized BOSS INDUSTRIES, INC. replacementdevices.

Close all openings and replace all covers and guards before operating compressor unit.

Tools, rags, or loose parts must not be left on the compressor or drive parts.

Do not use flammable solvents for cleaning parts. This can cause the unit to ignite during operation.

Keep combustibles out of and away from the Compressor/Inlet and any associated enclosures.

The owner, lessor, or operator of the Compressor are hereby notified and forewarned that anyfailure to observe these safety precautions may result in damage or injury.

BOSS INDUSTRIES, INC. expressly disclaims responsibility or liability for any injury or damagecaused by failure to observe these specified precautions or by failure to exercise that ordinarycaution and due care required when operating or handling the Compressor, even though notexpressly specified above.

DO NOT USE BOSS INDUSTRIES COMPRESSOR SYSTEMS TO PROVIDEBREATHING AIR. SUCH USAGE, WHETHER SUPPLIED IMMEDIATELY FROMTHE COMPRESSOR SOURCE, OR SUPPLIED TO BREATHING TANKS FORSUBSEQUENT USE, CAN CAUSE SERIOUS BODILY INJURY.

BOSS INDUSTRIES, INC. DISCLAIMS ANY AND ALL LIABILITIES FOR DAMAGEFOR LOSS DUE TO PERSONAL INJURIES, INCLUDING DEATH, AND/ORPROPERTY DAMAGE INCLUDING CONSEQUENTIAL DAMAGES ARISING OUTOF ANY BOSS INDUSTRIES, INC. COMPRESSORS USED TO SUPPLY BREATHINGAIR.

9

SAFETY

A compliment of warning decals is supplied with each unit. These decals must be affixed to thecomressor package in the locations noted in this manual. If for any reason a safety decal isremoved it is the owners responsibility to make sure it is replaced.

10

SAFETY

11

COMPRESSOR TERMINOLOGY

AIR/OIL COALESCER - Performs second stage separation of oil from compressed air feedingair tools. Sometimes referred to as the separator element.

CFM - Refers to the volume of compressed air being produced, expressed as cubic feet of air perminute.

COMPRESSOR LUBRICANT - DEXTRON III ATF.

GPM - Refers to the amount of gallons per minute of hydraulic fluid flowing through the pump.

OIL SUMP - The first stage of oil separation from compressed air. Also serves as reservoir areafor compressor lubricant and sometimes referred to as the receiver tank.

PSI - Refers to the operating pressure the system is set up at, expressed as pounds per squareinch.

SAFETY VALVE - A valve located on the oil sump which opens in case of excessive pressure.Sometimes referred to as the pop-off or pressure relief valve.

12

DESCRIPTION OF COMPONENTS

COMPRESSOR ASSEMBLY

The BOSS INDUSTRIES hydraulic drive compressor assembly is a positive displacement, oilflooded, rotary screw type unit employing one stage of compression to achieve the desiredpressure. Components include a housing (stator), two screws (rotors), bearings, and bearingsupports. Power from the hydraulic motor shaft is transferred to the male rotor through a drivecoupling. The female rotor is driven by the male rotor. There are five lobes on the male rotorwhile the female rotor has six roots.

PRINCIPLES OF OPERATION

In operation, two helical grooved rotors mesh to compress air. Inlet air is trapped as the malelobes roll down the female grooves, pushing trapped air along, compressing it until it reaches thedischarge port in the end of the stator and delivers smooth-flowing, pulse-free air to the receiver.

During the compression cycle, oil is injected into the compressor and serves these purposes:

1. Lubricates the rotating parts and bearings.2. Serves as a cooling agent for the compressed air.3. Seals the running clearances.

LUBRICATION SYSTEM

Oil from the compressor at discharge pressure, is directed into its integral housing, through thethermal valve and filter, and then out of the integral housing to the oil cooling system, and then backto the side of the compressor stator, where it is injected into the compressor. At the same time oilis directed internally to the bearings and shaft seal of the compressor.

OIL SUMP

Compressed, oil-laden air enters the sump from the compressor. As the oil-laden air enters thesump, most of the oil is separated from the air as it passes through a series of baffles and diffusionplates. The oil accumulates at the bottom of the sump for recirculation. However, some smalldroplets of oil remain suspended in the air and are passed on to the Coalescer.

13

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 actsas 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. When air is demanded at the service line,it passes through the coalescer which efficiently provides the final stage of oil separation.

OIL RETURN LINE

The oil that is removed by the coalescer accumulates and is returned through an internal oil returnline leading to the compressor.

MINIMUM PRESSURE VALVE

The minimum pressure valve is located at the outlet of the coalescer head and serves to maintain aminimum discharge pressure of 75 PSIG in operation, which is required to assure adequatecompressor lubrication pressure.

OIL FILTER

The compressor oil filter is a removable and cleanable screen built into the side of the compressorhousing. Screen replacement may be necessary after several cleanings.

COMPRESSOR OIL AND HYDRAULIC OIL COOLING SYSTEMS

The compressor cooling system consists of a combination hydraulic cooler and compressor coolermounted on the common frame. Compressor oil temperature is controlled by a thermal valvelocated down stream of the oil filter. The thermal valve maintains the compressor oil temperatureat 185ºF. Cool air is drawn through the vented end panel and across the combo cooler. The air isheated by the coolers and the hot air exits out the back vented panel . Allow for adequateclearance (12”) for the air to exit. Also, the package location should not be subjected to aboveambient air temperatures.

14

DESCRIPTION OF COMPONENTS

INSTRUMENTATION

The BOSS INDUSTRIES hydraulic drive compressor unit incorporates a gauge panel that monitorstemperature, pressure and hours of operation.

HOURMETER

The hourmeter records the total number of operating hours. It serves as a guide in following therecommended inspection and maintenance schedule. The hourmeter will only run when there is pressurein the system.

COMPRESSOR DISCHARGE AIR/OIL TEMPERATURE SWITCHGAUGE

This switchgauge indicates compressor air discharge temperature. The switchgauge ensures safetyshutdown in case of excessive operating temperatures, preventing compressor damage, by stoppinghydraulic flow to the compressor motor.

ELECTRICAL AND SAFETY SYSTEM

The BOSS INDUSTRIES compressor’s standard electrical system consists of:-Gauge panel with a temperature switchgauge, hourmeter and discharge pressure switchgauge.-Compressor and hydraulic oil cooler fan assembly and relay.-Compressor after cooler/oil cooler fan assembly and relay.-3-way pressure switch and relay to control hourmeter and blowdown.-12VDC N.O. hydraulic solenoid and relay.-Switch relay for customer equipment interface during compressor operation.-Differential pressure switch for air filter maintenance.-Optical oil level switch and relay.

15

DESCRIPTION OF COMPONENTS

CONTROL SYSTEM

The prime component of the compressor control system is the compressor inlet valve. The controlsystem is designed to match air supply to air demand and to prevent excessive discharge pressurewhen compressor is at idle. Control of air delivery is accomplished by the inlet valve regulationand modulation as directed by the discharge pressure regulator.

NORMALLY OPEN REGULATOR SOLENOID

A closed Furnas air pressure switch will energize the normally open regulator solenoid, thus closingit. When the normally open regulator solenoid is closed, air pressure will rise. When it is open airpressure falls only in the compressor sump.

NOTE: Most air tools operating pressure range is between 90 and 125 psi. Operatingabove the tools recommended pressures will decrease the life of the tool. Higheroperating pressure can also over torque nuts and bolts fatiguing the fastener and matingparts. Strictly adhere to tool operating pressures and torque standards set forth by thetool manufacturer and the specifications of the equipment that work is being performedon.

FURNAS SWITCH DESCRIPTION

The Furnas switch is a N.C. electrical switch set to open at 150 PSI and set to close at 115 PSI.The Furnas switch controls the N.O. regulator solenoid. If service air pressure is under 150 PSI,the Furnas switch will not trip keeping the N.O. inlet valve open and the compressor making air. Ifthe service valve is closed or the tool using the air is off, service line pressure will rise over 150PSI. This will trip the Furnas switch to open. The regulator solenoid will open and send airpressure to the inlet valve to close. With the inlet valve closed, the compressor will stop makingair. If the tool is turned on or the service valve is opened, the service line pressure will drop.When the pressure falls to 115 PSI the Furnas switch will close energizing the N.O. regulatorsolenoid closing off the air supply to the inlet valve. This will allow the inlet valve to open, and thecompressor will start making air to meet the demand.

INLET VALVE

The compressor inlet valve is a piston operated disc valve that regulates the inlet opening to controlcapacity and serves as a check valve at shutdown.

16

INSPECTION, LUBRICATION, AND MAINTENANCE

This section contains instructions for performing the inspection, lubrication, and maintenanceprocedures required to maintain the compressor in proper operating condition. The importance ofperforming the maintenance described herein cannot be over emphasized.

The periodic maintenance procedures to be performed on the equipment covered by this manualare listed below. It should be understood that the intervals between inspections specified aremaximum interval. More frequent inspections should be made if the unit is operating in a dustyenvironment, in high ambient temperature, or in other unusual conditions. A planned program ofperiodic inspection and maintenance will help avoid premature failure and costly repairs. Dailyvisual inspections should become a routine.

The LUBRICATION AND MAINTENANCE CHART lists serviceable items on this compressorpackage. The items are listed according to their frequency of maintenance, followed by thoseitems which need only “As Required” maintenance.

The maintenance time intervals are expressed in hours. The hourmeter shows thetotal number of hours your compressor has run. Use the hourmeter readings for determining yourmaintenance schedules. Perform the maintenance at multiple intervals of the hours shown. Forexample, when the hourmeter shows “100” on the dial, all items listed under “EVERY 10 HOURS”should be serviced for the tenth time, and all items under “EVERY 50 HOURS” should beserviced for the second time, and so on.

DANGER

COMPRESSOR MUST BE SHUT DOWN AND COMPLETELY RELIEVED OFPRESSURE PRIOR TO CHECKING FLUID LEVELS. OPEN SERVICE VALVE TOENSURE RELIEF OF SYSTEM AIR PRESSURE. FAILURE TO COMPLY WITH THISWARNING MAY CAUSE DAMAGE TO PROPERTY AND SERIOUS BODILY HARM.

17

LUBRICATION AND MAINTENANCE CHART

NOTE: Compressor oil and filter is to be changed after the first 50 hours of operation. After this,normal intervals are to be followed.

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18

LUBRICANT RECOMMENDATIONS

WARNING

The following are general characteristics for a rotary screw lubricant. Due to the impossibility ofestablishing limits on all physical and chemical properties of lubricants which can affect theirperformance in the compressor over a broad range of environmental influences, the responsibilityfor recommending and consistently furnishing a suitable heavy duty lubricant must rest with theindividual supplier if they choose not to use the recommended BOSS INDUSTRIES rotary screwlubricant. The lubricant supplier’s recommendation must, therefore, be based upon not only thefollowing general characteristics, but also upon his own knowledge of the suitability of therecommended lubricant in helical screw type air compressors operating in the particularenvironment involved.

CAUTION

IT IS IMPORTANT THAT THE COMPRESSOR OIL BE OF A RECOMMENDEDTYPE AND THAT THIS OIL AS WELL AS THE AIR FILTER, OIL FILTER, ANDCOALESCER ELEMENTS BE INSPECTED AND REPLACED AS STATED IN THISMANUAL.

THE COMBINATION OF A COALESCER ELEMENT LOADED WITH DIRT ANDOXIDIZED OIL PRODUCTS TOGETHER WITH INCREASED AIR VELOCITY AS ARESULT OF THIS CLOGGED CONDITION MAY PRODUCE A CRITICAL POINTWHILE THE MACHINE IS IN OPERATION WHERE IGNITION CAN TAKE PLACEAND COULD CAUSE A FIRE IN THE OIL SUMP.

FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TOPROPERTY AND SERIOUS BODILY HARM.

MIXING DIFFERENT TYPES OR BRANDS OF LUBRICANTS IS NOTRECOMMENDED DUE TO THE POSSIBILITY OF A DILUTION OF THEADDITIVES OR A REACTION BETWEEN ADDITIVES OF DIFFERENT TYPES.

19

LUBRICANT RECOMMENDATIONS

LUBRICANT CHARACTERISTICS

1. Flash point 400°F minimum.2. Pour point -40°F.3. Contains rust and corrosion inhibitors.4. Contains foam suppressors.5. Contains oxidation stabilizer.

NOTE

NOTE

DUE TO ENVIRONMENTAL FACTORS THE USEFUL LIFE OF ALL “EXTENDEDLIFE” LUBRICANTS MAY BE SHORTER THAN QUOTED BY THE LUBRICANTSUPPLIER. BOSS INDUSTRIES, INC. ENCOURAGES THE USER TO CLOSELYMONITOR THE LUBRICANT CONDITION AND TO PARTICIPATE IN AN OILANALYSIS PROGRAM WITH THE SUPPLIER.

NO LUBRICANT, HOWEVER GOOD AND/OR EXPENSIVE, CAN REPLACEPROPER MAINTENANCE AND ATTENTION. SELECT AND USE IT WISELY.

20

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 mileson an engine. Thus, eight hours operation is equal to 320 road miles, 250 hours is equal to 10,000road miles, etc.

COMPRESSOR OIL SUMP FILL, LEVEL, AND DRAIN

Before adding or changing compressor oil make sure that the compressor is completely relieved ofpressure. Oil is added at the fill cap on the side of the compressor body. A drain valve/hoseassembly is provided at the bottom of the compressor body. The proper oil level is between thetop and the midpoint 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 sump capacity isgiven in “Compressor Specifications”.

DANGER

AIR INTAKE FILTER

The air intake filter is a heavy-duty dry type high efficiency filter designed to protect thecompressor from dust and foreign objects. Optional two-stage available.

Optional filter is equipped with an evacuator cup for continuous dust ejection while operating andwhen stopped.

Frequency of maintenance of the filter depends on dust conditions at the operating site. The filterelement must be serviced when clogged (maximum pressure drop for proper operation is 15” ofwater). The filter is equipped with a pressure drop indicator, and the element should be changedbased on its reading first and then by the maintenance intervals outlined.

DO NOT ATTEMPT TO DRAIN CONDENSATE, REMOVE THE OIL LEVEL FILLPLUG, OR BREAK ANY CONNECTION IN THE AIR OR OIL SYSTEM WITHOUTSHUTTING OFF COMPRESSOR AND MANUALLY RELIEVING PRESSURE FROMTHE SUMP. FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGETO PROPERTY AND SERIOUS BODILY HARM.

21

MAINTENANCE

AIR/OIL COALESCER

The air/oil coalescer employs an element permanently housed within a spin-on canister. This is asingle piece unit that requires replacement when it fails to remove the oil from the discharge air, orpressure drop across it exceeds 15 PSI. Dirty oil clogs the element and increases the pressuredrop across it.

To replace element proceed as follows:

1. Shutdown compressor and wait for complete blow down (zero pressure).2. Turn element counterclockwise for removal (viewing element from bottom).3. Apply a film of fluid directly to seal on the new element.4. Rotate element clockwise by hand until element contacts seal (viewing element from

bottom).5. Rotate element approximately one more turn clockwise with band wrench near the top

of element.6. Run system and check for leaks.

WARNING

COALESCER OIL RETURN

This originates at the bottom of the air/oil coalescer and flows through a special recovery pipe andventuri nozzle. If the coalescer starts to fill with oil there is a good chance the venturi or pipe hasbeen plugged. Consult factory for cleaning instructions.

DO NOT SUBSTITUTE ELEMENT. USE ONLY A GENUINE BOSS INDUSTRIESREPLACEMENT ELEMENT. THIS ELEMENT IS RATED AT 200 PSI WORKINGPRESSURE. USE OF ANY OTHER ELEMENT MAY BE HAZARDOUS AND COULDIMPAIR THE PERFORMANCE AND RELIABILITY OF THE COMPRESSOR,POSSIBLY VOIDING THE WARRANTY AND/OR RESULTING IN DAMAGE TOPROPERTY AND SERIOUS BODILY HARM.

22

MAINTENANCE

OIL FILTER

The compressor oil filter is a throwaway type cartridge. It is designed with a built-in bypass so thatif there is a large restriction, due to cold oil or clogged element, the compressor will still belubricated.

To replace filter proceed as follows:1. Make sure system pressure is relieved.2. Unscrew with 14mm allen wrench.3. Remove oil filter from housing.4. Replace the oil filter screen element.5. Reinsert oil filter screen into housing and tighten with 14mm allen wrench.6. Add oil (total system takes one gallon), re-tighten filler cap.7. Check for leaks in operation.

WARNING

HYDRAULIC OIL COOLER AND COMPRESSOR OIL COOLER COMBINATION

The interior of the oil cooler should be cleaned when the pressure drop across it at full flowexceeds 25 PSI. The following procedure has been recommended by the vendor who supplies thecooler:

1. Remove cooler.2. Circulate a suitable solvent to dissolve and remove varnish and sludge.3. Flush generously with compressor lubricant (compressor oil cooler section only, use

hydraulic oil to flush the hydraulic cooler portion on the combo cooler).4. Once the coolers are reinstalled, fill the compressor and hydraulic systems with the

proper fluids to their appropriate levels.

DO NOT SUBSTITUTE ELEMENT. USE ONLY A GENUINE BOSS INDUSTRIESREPLACEMENT ELEMENT. USE OF ANY OTHER ELEMENT MAY BEHAZARDOUS AND COULD IMPAIR THE PERFORMANCE AND RELIABILITYOF THE COMPRESSOR, POSSIBLY VOIDING THE WARRANTY AND/ORRESULTING IN DAMAGE TO PROPERTY AND SERIOUS BODILY HARM.

23

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. Clean shaft surface removing all burrs from shaft where the wear sleeve gets installed.

6. Press new wear sleeve on to shaft. Oil heating new wear sleeve to 212°F approximatelyaids in the installation of this ring.

7. Press new seal into housing with seal assembly tool, until contact with snapring.

8. Temporarily install new seal installation cone over shaft to protect seal during reinstallation.

9. Reinstall cover.

10. Reinstall coupling hub to compressor shaft.

11. Reinstall adapter housing, drive coupling, and hydraulic motor to face of compressor.

24

TROUBLESHOOTING

This section contains instructions for troubleshooting the equipment following a malfunction.

The troubleshooting procedures to be performed on the equipment are listed below. Eachsymptom of trouble for a component or system is followed by a list of probable causes of thetrouble 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, althoughthe order may be varied if the need is indicated by conditions under which the trouble occurred. Inany event, the procedures which can be performed in the least amount of time and with the leastamount of removal or disassembly of parts, should be performed first.

UNPLANNED SHUTDOWNWhen the operation of the machine has been interrupted by an unexplained shutdown, check thefollowing:

1. Check the fuel level and truck dash gauges and indications for possible engineproblems.

2. Check the compressor discharge temperature/switchgauge. If the latching relay circuitis tripped the 12VDC solenoid will lose power and divert hydraulic oil back to thereservoir. The compressor blowdown pressure switch and the temperature switchgaugewill not allow power to the hydraulic solenoid until the air has blown down and thetemperature has dropped into its normal operating range and the push button has beenreset. Take compressor in for service once a high temperature shutdown has occurred.Failure to do so will void your warranty.

3. Check that the compressor oil is at proper level.4. Check oil cooler for dirt, slush, ice on the fins, or any other obstructions to the cooling

air flow.5. Make a thorough external check for any cause of shutdown such as broken hose,

broken oil lines, loose or broken wire, etc.

25

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 canproduce, air tools are free wheeling without resistance.)

B. Service valve wide open to atmosphere.C. Leaks in service line.D. Restricted compressor inlet air filter.E. Faulty control system operation (i.e.N.0. regulated air solenoid is allowing air through

all the time.)F. Furnas Switch is not closing at 115 psi.G. Low compressor oil level.

2. If discharge pressure is too high, safety valve blows, or system shuts down on high pressure,check the following:

A. Faulty discharge pressure switchgauge.B. Coalescer plugged up.C. Faulty safety valve.D. N.O. regulated air solenoid is not opening.E. Furnas switch is not opening at 150 psi.

3. Sump relief valve activates:

A. Inlet valve leaking or open.

B. Faulty relief valve.

C. Faulty Furnas switch, or N.O. regulated air solenoid, or pressure switchgauge.

SUMP PRESSURE DOES NOT BLOW DOWN

If after the compressor is shutdown, pressure does not automatically blow down, check for:

1. Normally open regulated air solenoid may be stuck closed.2. Blockage in air line from downstream of the coalescer to the inlet valve.3. Inlet valve orifice is clogged.

OIL CONSUMPTION

Abnormal oil consumption or oil in service line, check for the following:

1. Over filling of oil sump.2. Leaking oil lines or oil cooler.3. Plugged oil return line: check nozzle beneath the sightglass.4. Defective coalescer element.5. Compressor shaft seal leakage.

26

TROUBLESHOOTING

COALESCER PLUGGING

If the coalescer element has to be replaced frequently because it is plugging up, it is an indicationthat 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) usingthe improper type of oil, (4) dirty oil, (5) oil return nozzle plugged.

The complete air inlet system should be checked for leaks.

HIGH COMPRESSOR DISCHARGE TEMPERATURE

1. Check compressor oil level. Add oil if required (see Section for oil specifications).2. Check thermal valve operation.3. Clean outside of oil cooler.4. Clean oil system (cooler) internally.5. Check fan relay harness.

27

COMPRESSOR OPERATION

Before starting the compressor, read this section thoroughly. Familiarize yourself with the controls andindicators, their purpose, location, and use.

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ehtnehwlevelsihtkcehC.ssalgthgisehtsielcihevehtdnadegagnesidsirosserpmoc

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FEILERERUSSERPEVLAV

fierehpsomtaehtoterusserppmusstneV571sdeecxepmusehtedisnierusserpeht

.ISP

TELNIROSSERPMOCEVLAVLORTNOC

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28

COMPRESSOR OPERATION

OPERATING CONDITIONS

The following conditions should exist for maximum performance of the compressor. The truckshould be as close to level as possible when operating. The compressor will operate on a 15degree sideward and lengthwise tilt without any adverse problems. Operation in ambient tempera-tures above 100°F (38°C) may experience high temperature shutdown.

NOTE

NOTE

IF THE COMPRESSOR IS BEING USED TO POWER SANDBLASTING EQUIP-MENT, OR AN AIR STORAGE TANK, USE A CHECK VALVE DIRECTLY AFTERTHE MINIMUM PRESSURE VALVE TO PREVENT BACKFLOW INTO THE SUMP.THIS CHECK VALVE SHOULD HAVE A MAXIMUM PRESSURE DROP RATINGOF 2 PSIG (13.78kPa) OPERATING AND A CAPACITY RATING EQUAL TO THECOMPRESSOR.

A COMPRESSOR SERVICE VALVE SHOULD BE LOCATED TO THE HOSE REELINLET OR THE CUSTOMERS AIR CONNECTION PORT WHEN A HOSE REEL ISNOT USED. TYPICAL PLUMBING FROM THE MACHINE’S AIR OUTLET PORTOCCURS IN THE FOLLOWING ORDER:

1. MOISTURE TRAP/GAUGE/OILER COMBINATION (WHEN USED).2. AIR TANK (WHEN USED).3. HOSE REEL (WHEN USED).

29

PARTS AND

ILLUSTRATION

SECTION

30

1 1

2 2

3 3

4 4

5 5

6 6

7 7

8 8

AA

BB

CC

DD

Par

ts L

ist

DE

SC

RIP

TIO

NP

AR

T N

UM

BE

RQ

TY

ITE

M

CO

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R M

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SY

S, I

NF

INIT

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5-60

-150

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I8G

08

2003

531

1E

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S, I

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5-60

-150

SC

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08

2003

55-9

99

12

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-AIR

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D C

LNG

SY

S, I

NF

INIT

Y S

CI8

G 0

820

0356

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1

3C

AN

OP

Y S

YS

, IN

FIN

ITY

45-

60-1

50 S

CI8

G 0

820

0354

14

SH

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T

2005

4-00

11

1 O

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1761

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34 3

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[882

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m]

32 1

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[819

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17 3

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[450

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m]

6 3/

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[163

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5 in

[127

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19 in

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20 1

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36

RECOMMENDED SPARE PARTS

REBMUNTRAP NOITPIRCSED YTQ

106203 8ICSRETLIFLIO,TNEMELE 1

251703 8/7ICSRETLIFRIA,TNEMELE 1

006203 8ICSNO-NIPS,RECSELAOC 1

306203 G8ICSRIAPERLAESTFAHS,TIK 1

941703 8/7ICSTELNI,EVLAV 1

301203 GNILPUOCREDIPS 1

406203 RIAPERLAESTFAHSROTOMDYH,TIK 1

206203 8ICSLAMREHT,EVLAV 1

37

DATE:__________

1. Information given by:______________________________________________2. Information received by:____________________________________________3. Has anyone helped you: Yes______ No______4. Distributor:_____________________________________________________5. End-User:________________________________________________________6. Phone Number:___________________________________________________7. Make and Model for PTO:__________________________________________8. BOSS INDUSTRIES Serial #:_______________________________________9. Make and Model of Engine:_________________________________________10. Engine:________________________________________________________11. Transmission:___________________________________________________12. Nature of Problem:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________13. Engine RPM:_____________________________________________________14. Compressor RPM:________________________________________________15. Action Taken:__________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Additional Comments:___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

SERVICE QUESTIONNAIRE

38

Instructional Procedures for Installation of BOSS INFINITY Geared Rotary Screw Air

Compressor

This air compressor should be installed only by those who have been trained and delegated todo so and who have read and understand both the operators’ manual and the installation manual.Failure to follow the instructions, procedures, and safety precautions in this manual may result inaccidents and injuries.

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 BOSSINDUSTRIES, Inc. instructions.

Do not modify this compressor except with written factory approval.

1. MOUNTING COMPRESSORWhen mounting the compressor care should be taken to ensure that its location does not im-pede the operation of other components on the vehicle. For example, if your vehicle is equippedwith 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 enterthe air filter and the hot air from the cooler to exhaust without recirculating into the air filter. Onelast consideration in the mounting should be the routing of hoses and electrical wires. The framemounting holes are shown below and the unit should be secured to the vehicle with 3/8 inchgrade 8 bolts, washers should be used on the mounting surface. Hardware supplied with unit,may not work in all applications.

39

INSTRUCTIONAL PROCEDURES

2. INSTALLING THE WIRING & CONNECTING THE HYDRAULIC HOSES

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 BOSSINDUSTRIES compressor. (Please refer to drawing 307193 on page 35) The unit is shippedwith 4 loose wires, they need to be connected as follows:

1. Connect red wire to switched 12 vdc power. (or 24 VDC if you have this option)2. The yellow wire should be spliced into the 12 vdc switched feed for the on/off switch

per the end-users location.(or 24 VDC if you have this option)3. Connect black wire to ground.4. The orange wire is used to activate an electronic speed control circuit if required.

Please contact the factory with engine specific information for further assistance.

CONNECTING THE HOSES

The hydraulic hoses to the compressor should be connected directly to the hydraulic controlblock. The pressure “P” input line should be made from a good quality high pressure (min. 3000PSI) hydraulic hose 1/2” or 3/4” i.d. The return line to tank “T” can be made from a mediumpressure (min. 1000 PSI) hydraulic hose 3/4” i.d. Care should be taken to see that the hoses arenot installed with kinks or bends that inhibit flow of the hydraulic oil. Lack of flow could result indamage to the motor and compressor. Lastly check to make sure hoses are not in contact withsharp objects or edges that may fray, chafe or cut them over time. Secure all hoses with tiedown straps or clamps.

40

INSTRUCTIONAL PROCEDURES3. PRE-START-UP INSPECTION CHECKS

This inspection should be done prior to removing truck from bay. Final testing of the system,including checking for leaks, is to be done outside.

ALL TRUCKS SHOULD BE ROAD TESTED PRIOR TO STARTING INSTALLATION TO ISOLATE ANYPREVIOUS TRUCK PROBLEMS.

I. Check sales order to verify that all compressor related items originally ordered havebeen installed or are ready to ship with the truck. This would include any special filters,oils, hoses, options, etc.

II. Vacuum all areas that have metal or plastic shavings. Wipe all fingerprints off unit andvehicle.

III. Apply decals to proper location. Make sure that the area is cleaned prior to applyingdecals. All decals should have a professional appearance upon application.

IV. Check all assemblies, clamps, fittings, drivelines, angles, nuts, and bolts to ensure theyare 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.

V. Record all serial numbers for this installation.A. Vehicle V.I.N.B. Hydraulic Pump DataC. Air-End Serial NumberD. BOSS INDUSTRIES Serial NumberE. Receiver Tank Serial NumberF. Note any special applications relating to specific installations.

VI. Check all fluid levels (position the unit on a level surface so that proper amount of fluidscan be added).

A. Fuel to provide for three hours of operation.B. Transmission fluid and PTO box.C. Compressor. Check the compressor oil sump 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.

4. INITIAL START-UP AND TEST

A. Start power source and allow for warm-up.B. Read the operation section in the operator and parts manual carefully before proceeding onto

the initial start-up.

41

INSTRUCTIONAL PROCEDURESC. Engage hydraulic system. A direction of rotation arrow is attached to the compressor pack-

age above the hydraulic coupling. The coupling/hub must be rotating in the direction thearrow is pointing. If for any reason this arrow has been removed the correct compressorrotation is clockwise when looking directly at the compressor shaft. Check the direction ofrotation by quickly engaging and then disengaging the compressor.

CAUTIONDO NOT RUN THE COMPRESSOR IN A REVERSE ROTATION FOR PERIODS LONGER

THAN 5 SECONDS. CONTINUED OPERATION IN THIS MANNER WILL RESULT INEXTENSIVE COMPRESSOR UNIT DAMAGE.

The safety shutdown switch should be wired in series with the solenoid that opens the flow ofthe hydraulic oil to the compressor drive motor. 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. Take a screwdriver and touch the 1/16” allen head screw on the face of the tempera-ture gauge and simultaneously touch the outside ring on the face of the gauge. This should shutoff the power to the solenoid of the hydraulics. Push the button in on the shutdown switch toreset. Repeat the test with the pressure gauge if solenoid does not stop flow to compressor,check wiring.

42

WARRANTY SECTION

43

WARRANTY INFORMATION

BOSS Industries, Inc. warrants that this Rotary Screw Compressor unit conforms to applicabledrawings and specifications approved in writing by BOSS. The unit assembly will be free fromdefects in material and workmanship for a period of two (2) years from the date of initial operationor thirty (30) months from the date of shipment, whichever period first expires. All other componentsand parts of BOSS manufacture, will be free from defects in material and workmanship for aperiod of one (1) year from the date of initial operation or eighteen (18) months from the date ofshipment, whichever period first expires. If within such period BOSS receives from the Buyerwritten notice of and alleged defect in or nonconformance of the unit, all other components andparts of BOSS manufacture and if in the judgment of BOSS these items do not conform or arefound to be defective in material of workmanship, BOSS will at its option either, (a) furnish aService Representative to correct defective workmanship, or (b) upon return of the item F.O.B.BOSS original shipping point, repair or replace the item or issue credit for the replacement itemordered by Buyer, (Defective material must be returned within thirty (30) days of return shippinginstructions from BOSS. 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 alsoinclude warranty on installation for a period of one (1) year. This warranty does not cover damagecaused by accident, misuse or negligence. If the compressor unit is disassembled the warranty isvoid. BOSS’s sole responsibility and Buyer’s exclusive remedy hereunder is limited to such repair,replacement, or repayment of the purchase price. Parts not of BOSS manufacture are warrantedonly to the extent that they are warranted by the original manufacture. BOSS shall have noresponsibility for any cost or expense incurred by Buyer from inability of BOSS to repair undersaid warranty when such inability is beyond the control of BOSS or caused solely by Buyer.

There are no other warranties, express, statutory or implied, including those ofmerchantability and of fitness of purpose; nor any affirmation of fact orrepresentation which extends beyond the description of the face hereof.

This warranty shall be void and BOSS shall have no responsibility to repair, replace, or repay thepurchase price of defective or damaged parts or components resulting directly or indirectly fromthe use of repair or replacement parts not of BOSS manufacture or approved by BOSS or fromBuyer’s failure to store, install, maintain, and operate the compressor according to therecommendations contained in the Operating and Parts Manual and good engineering practice.The total responsibility of BOSS for claims, losses, liabilities or damages, whether in contract ortort, arising out of or related to its products shall not exceed the purchase price. In no event shallBOSS 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, or lost production, whether sufferedby Buyer or any third party.

BOSS Industries, Inc.

1761 Genesis Drive

LaPorte, IN 46350

44

As claims, policies and procedure are governed by the terms of the BOSS Industries, Inc. warranty, it isnecessary to outline some of the more important provisions.

The BOSS warranty applies only to new and unused products which, after shipment from the factory, havenot been altered, changed, repaired or mistreated in any manner whatsoever. Normal maintenance itemssuch as lubricants and filters are not warrantable items.

Parts not of BOSS manufacture are warranted only to the extent they are warranted by the originalmanufacturer.

Damage resulting from abuse, neglect, misapplication or overloading of a machine, accessory or part is notcovered under warranty.

Deterioration or wear occasioned by chemical and/or abrasive action or excessive heat shall not constitutedefects.

Parts replacement and/or correction of defective workmanship will normally be handled by BOSS or theirauthorized distributor.

Failure to file a detailed warranty claim/service report for each occurrence of material defect of defectiveworkmanship will cause warranty claim to be rejected.

Defective material must be returned within 30 days of receipt of shipping instructions. Failure to do sowithin specified time will result in forfeiture of claim.

The distributor is responsible for the initial investigation and write up of the warranty claim.

Distributor shall be allowed no more than 30 days from date of repair to file a warranty claim/servicereport.

Warranty for failure of BOSS replacement parts covers the net cost of the party only, not labor andmileage.

The BOSS warranty does not cover diagnostic calls and travel. That is time spent traveling to the machineto analyze the problem and returning with the proper tools and parts to correct the problem.

BOSS will deduct from allowable credits for excess freight caused by sender failing to follow returnshipping instructions.

Distributors or end-users automatically deducting the value of a warranty claim from outstanding balancesdue and payable to BOSS prior to receiving written notification of BOSS approval of the warranty claimmay be subject to forfeiture of the entire claim.

SUMMARY OF MAIN WARRANTY PROVISIONS

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WARRANTY/RETURN GOODS INSTRUCTIONS

The warranty/return procedure outlined below is provided to give the claimant the informationnecessary to file a warranty/return claim, and enable BOSS INDUSTRIES the ability to best serve its’customers.

Please see the following instructions to initiate a return:

Contact BOSS INDUSTRIES Returns Department by telephone at 219.324.7776 or via email atservice@bossair.com. You may also send a fax at 219.324.7470.

WARRANTY CLAIMS – PREPARATION OF PART RETURN

Parts returned to the factory must be properly packaged to prevent damage during shipment.Damage to a part as a result of improper handling or packing could be cause for denial. When address-ing the package for shipment, the following information must be on the outside of, or tagged clearly, tothe package.

1. Return Goods Authorization #.2. Distributor or end-users return address.3. Correct factory address.4. Number of packages pertaining to each claim.

NOTE: Our warranty requires that all defective parts be returned to BOSS INDUSTRIES freightprepaid. Items sent without RGA number will not be accepted. Unauthorized Returns Will ImmediatelyBe Refused At Dock.

RETURN OR WARRANTY CLAIMS – FILING PROCEDURES

1. Initiate through a purchase order for warranty part or request for credit.2. RGA will accompany replacement part.3. BOSS INDUSTRIES 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 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 theiranalysis/input.

6. Send Warranty Claim to:BOSS INDUSTRIES, INC.1761 Genesis DriveLaPorte, IN 46350Attn: Returns Dept.

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GENERAL

An approved claim depends on the following provision:

1. An RGA # must be issued by BOSS INDUSTRIES. (See filing procedures.)2. Failed part must be returned within 30 days of original invoice date, freight prepaid, with RGA

#.3. Part is determined to be defective.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.

1. Loss in transit:The merchandise in our kit or provided in our factory installations has been thoroughly in-spected or carefully installed and tested before leaving our plant. However, regardless of thecare taken at the factory, there is a possibility that damage may occur in shipment. For thisreason, it is recommended that the unit be carefully inspected for evidence of possible damageor malfunction during the first few hours of operation. Responsibility for the safe delivery of thekit or factory installed unit was assumed by the carrier at the time of shipment. Therefore,claims for loss or damage to the contents of the kit or factory installed unit should be madeupon the carrier.

2. Concealed loss or damage:Concealed loss or damage means loss or damage, which does not become apparent until the kitis unpacked or the factory-installed unit is run by the end-user. The contents of the kit orfactory 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 isdiscovered upon unpacking, make a written request for inspection by the carrier agent withinfifteen days of delivery date. Then file a claim with the carrier since such damage is the carrier’sresponsibility.

By following these instructions carefully, we guarantee our full support of your claims, to protectyou against loss from concealed damage.

3. Visible Loss or DamageAny external evidence of loss or damage must be noted on the Freight Bill or Express Receipt,and signed by the carrier’s agent. Failure to adequately describe such external evidence of loss,or damage may result in the carrier refusing to honor a damage claim. The carrier will supplythe form required to file such a claim.

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SCREW COMPRESSOR AIR-END EXCHANGE PROGRAM

Replacement air-ends are available from the factory. For current prices and availability, contactBOSS INDUSTRIES, Inc. or an authorized BOSS INDUSTRIES distributor. Prices are F.O.B.shipping point. Prices do not include labor for removal or installation.