BOSSCO Infinity User manual

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

4
OPERATORS, MAINTENANCE, AND PARTS MANUAL
BOSS INDUSTRIES INFINITY
Operation & Maintenance Section
TABLEOFCONTENTS
Operation& Maintenance Section
Specifications...................................................................................................................... 6
Safety .................................................................................................................................. 7
CompressorTerminology .................................................................................................. 11
Description of Components............................................................................................... 12
Inspection,Lubrication,andMaintenance.......................................................................... 16
Troubleshooting................................................................................................................. 24
Compressor Operation ...................................................................................................... 27
Parts and Illustration Section ............................................................................................. 29
RecommendedSpare Parts ................................................................................................ 36
ServiceQuestionnaire........................................................................................................ 37
Instructional Procedures for Installation ........................................................................... 38
Warranty Section
WarrantyInformation ........................................................................................................ 43

6
SPECIFICATIONS
GISP051@YREVILEDMFC5406
rosserpmoCotdeepStupnI MPR MPG
0051 @01 ISP0742 1591 @31 ISP0742
rosserpmoC-yticapaCdiulF )
ciluardyhton( metsySsnollaG0.1 pmuSrosserpmoC57.
metsySrosserpmoC-stnenopmoC )snoisnemiDllarevO( wolebees
)
yrd(thgieW .sbl003
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
A A
B B
C C
D D
Parts List
DESCRIPTIONPART NUMBERQTYITEM
COMPR MTG SYS, INFINITY 45-60-150 SCI8G 0820035311
ELEC SYS, INFINITY 45-60-150 SCI8G 08200355-99912
OIL-AIR-HYD CLNG SYS, INFINITY SCI8G 08200356-99913
CANOPY SYS, INFINITY 45-60-150 SCI8G 0820035414
SHEET
20054-001
11
OF
REV
1
INFINITY 45-60 SCI8G 08
BOSS INDUSTRIES
1761 GENESIS DR.
LA PORTE, IN 46350
N/A
PATH
MATERIAL
G:\Inventor Files\20k\20054-001.dwg
12/3/2007
12/3/2007
DCL
DRAWN
NDD
CHECKED
1=4
D
DESCRIPTION
DWG NO
R
SCALE
SIZE
UNMACHINEDSURFACES
FRACTIONAL ` 1/16
DECIMAL
` .03
ANGULAR
` 1°
DO NOT SCALE
TOLERANCES
UNLESS NOTED
MACHINEDSURFACES
NOMINALDIM.
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 AN D IS SUBJEC T TO
RETURN UPON DEMAND . THE
INFORMATION CONTAINED IN
THIS DRAWING IS
CONFIDEN TIAL AND MUST
NOT BE USED, DIRECTLY OR
INDIRECTLY, IN ANY WA Y
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 HISTORY
REV DESCRIPTION DATE ENG
1UPDATED 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 own
peculiarities that cannot always be covered by rules. Therefore with your experience and common
sense, 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 safety
hazards. Correct them promptly. Use the following safety precautions as a general guide to safe
operation:
Do not attempt to remove any compressor parts without first relieving the entire system of
pressure.
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 exposed
openings.
SAFETY
ALLUNITSARE SHIPPEDWITHADETAILEDOPERATORSAND PARTS
MANUAL. THISMANUALCONTAINSVITALINFORMATION FORTHE SAFE
USEANDEFFICIENTOPERATIONOFTHISUNIT. CAREFULLYREAD
THEOPERATORSMANUALBEFORESTARTINGTHEUNIT. FAILURETO
ADHERE TO THE INSTRUCTIONS COULD RESULT IN SERIOUS BODILY
INJURYORPROPERTYDAMAGE.
CHECKTHECOMPRESSORSUMPOILLEVELONLYWHENTHECOMPRESSOR
ISNOTOPERATINGAND SYSTEMISCOMPLETELYRELIEVEDOFPRESSURE.
OPENSERVICEVALVETOENSURERELIEFOFSYSTEMAIRPRESSUREWHEN
PERFORMINGMAINTENANCEONCOMPRESSORAIR/OILSYSTEM. FAILURE
TOCOMPLYWITHTHISWARNINGMAYCAUSEDAMAGETOPROPERTY
AND SERIOUS BODILYHARM.

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. replacement
devices.
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 any
failure to observe these safety precautions may result in damage or injury.
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.
DO NOT USE BOSS INDUSTRIES COMPRESSOR SYSTEMS TO PROVIDE
BREATHINGAIR. SUCHUSAGE,WHETHERSUPPLIEDIMMEDIATELYFROM
THE COMPRESSOR SOURCE, OR SUPPLIED TO BREATHING TANKS FOR
SUBSEQUENTUSE,CANCAUSE SERIOUSBODILYINJURY.
BOSSINDUSTRIES,INC.DISCLAIMSANYANDALLLIABILITIESFORDAMAGE
FOR LOSS DUE TO PERSONAL INJURIES, INCLUDING DEATH, AND/OR
PROPERTYDAMAGEINCLUDINGCONSEQUENTIALDAMAGESARISINGOUT
OFANYBOSSINDUSTRIES,INC.COMPRESSORSUSEDTOSUPPLYBREATHING
AIR.

9
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.

10
SAFETY

11
COMPRESSOR TERMINOLOGY
AIR/OILCOALESCER- 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.
COMPRESSOR LUBRICANT - DEXTRON IIIATF.
GPM- Refers to the amount of gallons per minute of hydraulic fluid flowing through the pump.
OILSUMP - The first stage of oil separation from compressed air. Also serves as reservoir area
for 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 square
inch.
SAFETYVALVE-Avalve 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
COMPRESSORASSEMBLY
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. Power from the hydraulic motor shaft is transferred to the male rotor through a drive
coupling. The female rotor is driven by the male rotor. There are five lobes on the male rotor
while 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 male
lobes roll down the female grooves, pushing trapped air along, compressing it until it reaches the
discharge 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 the
thermal valve and filter, and then out of the integral housing to the oil cooling system, and then back
to the side of the compressor stator, where it is injected into the compressor. At the same time oil
is 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 the
sump, most of the oil is separated from the air as it passes through a series of baffles and diffusion
plates. The oil accumulates at the bottom of the sump for recirculation. However, some small
droplets of oil remain suspended in the air and are passed on to the Coalescer.

13
DESCRIPTION OF COMPONENTS
SAFETYVALVE
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. 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 return
line leading to the compressor.
MINIMUM PRESSUREVALVE
The minimum pressure valve is located at the outlet of the coalescer head and serves to maintain a
minimum discharge pressure of 75 PSIG in operation, which is required to assure adequate
compressor lubrication pressure.
OILFILTER
The compressor oil filter is a removable and cleanable screen built into the side of the compressor
housing. Screen replacement may be necessary after several cleanings.
COMPRESSOR OILAND HYDRAULIC OIL COOLING SYSTEMS
The compressor cooling system consists of a combination hydraulic cooler and compressor cooler
mounted on the common frame. Compressor oil temperature is controlled by a thermal valve
located down stream of the oil filter. The thermal valve maintains the compressor oil temperature
at 185ºF. Cool air is drawn through the vented end panel and across the combo cooler. The air is
heated by the coolers and the hot air exits out the back vented panel . Allow for adequate
clearance (12”) for the air to exit. Also, the package location should not be subjected to above
ambient air temperatures.

14
DESCRIPTION OF COMPONENTS
INSTRUMENTATION
TheBOSSINDUSTRIEShydraulic drivecompressorunitincorporates agaugepanelthat monitors
temperature,pressure and hoursof operation.
HOURMETER
Thehourmeterrecords thetotalnumberof operatinghours. Itserves as aguidein following the
recommendedinspectionandmaintenanceschedule. Thehourmeterwillonly run when thereis pressure
inthesystem.
COMPRESSORDISCHARGEAIR/OILTEMPERATURESWITCHGAUGE
Thisswitchgaugeindicatescompressorairdischargetemperature. Theswitchgauge ensures safety
shutdownincaseof excessive operatingtemperatures,preventingcompressor damage, bystopping
hydraulicflowtothecompressor motor.
ELECTRICALANDSAFETYSYSTEM
TheBOSSINDUSTRIES compressor’s standardelectricalsystem consistsof:
-Gaugepanelwithatemperatureswitchgauge, hourmeterand dischargepressure switchgauge.
-Compressorandhydraulicoil coolerfanassemblyand relay.
-Compressoraftercooler/oil coolerfanassemblyand relay.
-3-waypressure switch andrelay tocontrolhourmeter andblowdown.
-12VDCN.O. hydraulic solenoidand relay.
-Switchrelayforcustomerequipmentinterface during compressoroperation.
-Differentialpressureswitchforairfiltermaintenance.
-Opticaloillevelswitchandrelay.

15
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.
NORMALLYOPEN REGULATOR SOLENOID
A closed Furnas air pressure switch will energize the normally open regulator solenoid, thus closing
it. When the normally open regulator solenoid is closed, air pressure will rise. When it is open air
pressure falls only in the compressor sump.
NOTE: Most air tools operating pressure range is between 90 and 125 psi. Operating
above the tools recommended pressures will decrease the life of the tool. Higher
operating pressure can also over torque nuts and bolts fatiguing the fastener and mating
parts. Strictly adhere to tool operating pressures and torque standards set forth by the
tool manufacturer and the specifications of the equipment that work is being performed
on.
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. If
the service valve is closed or the tool using the air is off, service line pressure will rise over 150
PSI. This will trip the Furnas switch to open. The regulator solenoid will open and send air
pressure to the inlet valve to close. With the inlet valve closed, the compressor will stop making
air. 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. regulator
solenoid closing off the air supply to the inlet valve. This will allow the inlet valve to open, and the
compressor will start making air to meet the demand.
INLETVALVE
The compressor inlet valve is a piston operated disc valve that regulates the inlet opening to control
capacity and serves as a check valve at shutdown.

16
INSPECTION, LUBRICATION, AND MAINTENANCE
Thissection contains instructionsfor performing theinspection, 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. It should be understood that the intervals between inspections specified are
maximum interval. More frequent inspections should be made if the unit is operating in a dusty
environment, in high ambient temperature, or in other unusual conditions. Aplanned program of
periodic inspection and maintenance will help avoid premature failure and costly repairs. Daily
visual inspections should become a routine.
The LUBRICATIONAND MAINTENANCE CHART lists serviceable items on this compressor
package. The items are listed according to their frequency of maintenance, followed by those
items which need only “As Required” maintenance.
The maintenance time intervals are expressed in hours. The hourmeter shows the
total number of hours your compressor has run. Use the hourmeter readings for determining your
maintenance schedules. Perform the maintenance at multiple intervals of the hours shown. For
example, when the hourmeter shows “100” on the dial, all items listed under “EVERY10 HOURS”
should be serviced for the tenth time, and all items under “EVERY50 HOURS” should be
serviced for the second time, and so on.
DANGER
COMPRESSOR MUST BE SHUT DOWN AND COMPLETELY RELIEVED OF
PRESSUREPRIOR TOCHECKINGFLUID LEVELS. OPEN SERVICEVALVETO
ENSURERELIEFOFSYSTEMAIRPRESSURE. FAILURETOCOMPLYWITHTHIS
WARNINGMAYCAUSEDAMAGETOPROPERTYANDSERIOUSBODILYHARM.

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.
LAVRETNINOITCA
YLLACIDOIREP GNIRUD NOITAREPO
egnahcynaetoN.sgnidaereguagllaevresbO.1 ehtenimreteddnasgnidae
rlamronehtmorf :ETON(.edamsriaperyrassecenevaH.esuac nehwgnidaereguaglausuehtsi"LAMRON" yadotyadanosnoit
idnocralimistagnitarepo ).sisab
YLIAD
.levelliorosserpmocehtkcehC.1 rotacidniporderusserP.retlifriakcehC.
2.gnitareposirosserpmocelihw .skaelriadnaliorofkcehC.3 .sehctiwstiucricytefaskcehC.4
SRUOH52YREVE YLHTNOM
RO .liorosserpmocmorfretawniarD.1
005YREVE 6ROSRUOH SHTNOM
neercsecalperdnaliorosserpmocegnahC.1 .egakaelro
flaestfahsrosserpmockcehC.2 .spmalcdnasgnittif,gnipipretlifriakcehC.3 .stroppusrosserpmockcehC.4 retrohS
(.tnemeleretlifriawenllatsnI.5 ytsudrednuyrassecenebyamlavretni ).snoitidnoc .evlavytefaspmuskcehC.6
0001
YREVE 1ROSRUOH RAEY .tnemelegnicselaocegnahC.1
ROYLLACIDOIREP DERIUQERSA
.tnemeleretlifrianaelcdnatcepsnI.1 recselaocno-nipsecalperdnatcepsnI.2 .yrassecenfitnemele .snifrelooclionaelcdnatcepsnI.3

18
LUBRICANT RECOMMENDATIONS
WARNING
The following are general characteristics for a rotary screw lubricant. Due to the impossibility of
establishinglimits on allphysical and chemicalproperties of lubricants which canaffect their
performance in the compressor over a broad range of environmental influences, the responsibility
forrecommending and consistentlyfurnishing a suitableheavy dutylubricant must restwith the
individual supplier if they choose not to use the recommended BOSS INDUSTRIES rotary screw
lubricant. The lubricant supplier’s recommendation must, therefore, be based upon not only the
following general characteristics, but also upon his own knowledge of the suitability of the
recommended lubricant in helical screw type air compressors operating in the particular
environmentinvolved.
CAUTION
IT IS IMPORTANT THAT THE COMPRESSOR OIL BE OF A RECOMMENDED
TYPE AND THAT THIS OILAS WELLAS THE AIR FILTER, OIL FILTER, AND
COALESCERELEMENTS BEINSPECTEDANDREPLACEDASSTATED INTHIS
MANUAL.
THE COMBINATION OFACOALESCER ELEMENT LOADED WITH DIRTAND
OXIDIZEDOILPRODUCTSTOGETHERWITHINCREASEDAIRVELOCITYASA
RESULTOFTHISCLOGGEDCONDITIONMAYPRODUCEACRITICALPOINT
WHILETHEMACHINEISINOPERATIONWHEREIGNITIONCANTAKEPLACE
ANDCOULDCAUSEAFIRE INTHE OILSUMP.
FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO
PROPERTYAND SERIOUS BODILYHARM.
MIXING DIFFERENT TYPES OR BRANDS OF LUBRICANTS IS NOT
RECOMMENDED DUE TO THE POSSIBILITY OF A DILUTION OF THE
ADDITIVESORAREACTIONBETWEENADDITIVESOFDIFFERENTTYPES.

19
LUBRICANT RECOMMENDATIONS
LUBRICANT CHARACTERISTICS
1. Flashpoint 400°Fminimum.
2. Pour point -40°F.
3. Contains rust and corrosion inhibitors.
4. Contains foam suppressors.
5. Containsoxidation stabilizer.
NOTE
NOTE
DUETOENVIRONMENTALFACTORSTHE USEFULLIFEOFALL“EXTENDED
LIFE”LUBRICANTSMAYBE SHORTERTHAN QUOTEDBYTHELUBRICANT
SUPPLIER. BOSS INDUSTRIES, INC. ENCOURAGES THE USER TO CLOSELY
MONITOR THE LUBRICANT CONDITION AND TO PARTICIPATE IN AN OIL
ANALYSISPROGRAM WITHTHE SUPPLIER.
NO LUBRICANT, HOWEVER GOOD AND/OR EXPENSIVE, CAN REPLACE
PROPERMAINTENANCEANDATTENTION. SELECTANDUSE ITWISELY.

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 miles
on an engine. Thus, eight hours operation is equal to 320 road miles, 250 hours is equal to 10,000
road miles, etc.
COMPRESSOR OILSUMPFILL, LEVEL,AND DRAIN
Before adding or changing compressor oil make sure that the compressor is completely relieved of
pressure. Oil is added at the fill cap on the side of the compressor body. Adrain valve/hose
assembly is provided at the bottom of the compressor body. The proper oil level is between the
top 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 is
givenin “Compressor Specifications”. DANGER
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. Optional two-stage available.
Optional filter is equipped with an evacuator cup for continuous dust ejection while operating and
when stopped.
Frequency of maintenance of the filter depends on dust conditions at the operating site. The filter
element must be serviced when clogged (maximum pressure drop for proper operation is 15” of
water). The filter is equipped with a pressure drop indicator, and the element should be changed
based on its reading first and then by the maintenance intervals outlined.
DO NOTATTEMPT TO DRAIN CONDENSATE, REMOVE THE OILLEVELFILL
PLUG,OR BREAKANYCONNECTIONINTHEAIR OROILSYSTEMWITHOUT
SHUTTINGOFFCOMPRESSORANDMANUALLYRELIEVINGPRESSUREFROM
THESUMP. FAILURETOCOMPLYWITHTHISWARNINGMAYCAUSEDAMAGE
TOPROPERTYAND SERIOUSBODILYHARM.

21
MAINTENANCE
AIR/OIL COALESCER
The air/oil coalescer employs an element permanently housed within a spin-on canister. This is a
single piece unit that requires replacement when it fails to remove the oil from the discharge air, or
pressure drop across it exceeds 15 PSI. Dirty oil clogs the element and increases the pressure
drop across it.
To replace element proceed as follows:
1. Shutdown compressor and wait for complete blow down (zero pressure).
2. Turn element counterclockwisefor removal (viewingelement 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
ofelement.
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 and
venturi nozzle. If the coalescer starts to fill with oil there is a good chance the venturi or pipe has
been plugged. Consult factory for cleaning instructions.
DO NOT SUBSTITUTE ELEMENT. USE ONLYA GENUINE BOSS INDUSTRIES
REPLACEMENT ELEMENT. THIS ELEMENT IS RATEDAT 200 PSI WORKING
PRESSURE. USEOFANYOTHERELEMENTMAYBEHAZARDOUSANDCOULD
IMPAIR THE PERFORMANCE AND RELIABILITY OF THE COMPRESSOR,
POSSIBLY VOIDING THE WARRANTYAND/OR RESULTING IN DAMAGE TO
PROPERTYAND SERIOUS BODILYHARM.