PTO AIR COMPRESSOR OPERATORS, INSTALLATION AND …

1 1 BOSS Industries, Air COMPRESSOR (IBI Split-Shaft)Operators, INSTALLATION and Parts ManualPTO AIR COMPRESSOROPERATORS, INSTALLATIONAND PARTS manual (IBI SPLIT-SHAFT)301367 Revised 6/5/01 BOSS Industries, Air COMPRESSOR (IBI Split-Shaft)Operators, INSTALLATION and Parts Manual2 OPERATORS, INSTALLATION , AND PARTS MANUALTABLE OF CONTENTSO peration & Maintenance SectionGeneral Arrangement ..3 Specifications ..4 Safety ..10 COMPRESSOR Terminology ..11 Description of Components ..12-17 Inspection, Lubrication, and Maintenance ..25 Troubleshooting ..26-30 COMPRESSOR Operation ..31-33 INSTALLATION SectionInstallation Instructions ..34-46 Parts & Illustration SectionParts and Illustration Section ..47-62 Warranty Section & Recommended Spare Parts ListWarranty Information.

2 63-68 Recommended Spare Parts List ..693 BOSS Industries, Air COMPRESSOR (IBI Split-Shaft)Operators, INSTALLATION and Parts ManualGENERAL ARRANGEMENTBoss Underdeck PTO Compressors are shipped in kit form for field INSTALLATION . Thesekits include:1. Rotary Screw COMPRESSOR , Split-shaft Gear Box, and Mounting Bracket. Page 592. Oil Sump with Mounting Brackets. Page 563. Spin-on Coalescer/Air Manifold Assembly. Page 564. COMPRESSOR Oil Cooler/Fan Assembly or Optional Front Mount Cooler Without Fan Assembly. Page 60 and 615. Load Controller. Page 546. Air Inlet Filtration System. Page 527. Hoses and Fittings 8. All Necessary Safety and Informational Decals 9. Instrument Panel Assembly/Wiring. Page 50 10. Oil Filter Assembly. Page 60- 11. PTO and Drivelines (Optional accessories).

3 12. Parts, Service, and Industries offers factory INSTALLATION by qualified technicians, as well as anationwide network of authorized distributors for field installations, parts and Industries, Air COMPRESSOR (IBI Split-Shaft)Operators, INSTALLATION and Parts Manual4 SPECIFICATIONSMODEL 80200-IBI (SPLIT-SHAFT)COMPRESSORD elivery @ 110 PSIG*125 CFM150 CFM175 CFMI nput Speed975 RPM1165 RPM1333 RPMF luid Capacity (gallons) GALCOMPONENTS(Overall Dimensions) W x H x DIA x LSpin-On DIA x HCooler/Fan W x H x LEngine Speed W x H x LGauge W x H x LAir Inlet DIA x LWeight (dry)est 675 LBS.*125 & 150 PSIG options available. Consult SUBJECT TO CHANGE WITHOUT PRIOR NOTICE5 BOSS Industries, Air COMPRESSOR (IBI Split-Shaft)Operators, INSTALLATION and Parts ManualSAFETYWARNINGALL UNITS ARE SHIPPED WITH A DETAILED OPERATORS, INSTALLATION ANDPARTS manual .

4 THIS manual CONTAINS VITAL INFORMATION FOR THE SAFEUSE AND EFFICIENT OPERATION OF THIS UNIT. CAREFULLY READ THEOPERATORS manual BEFORE STARTING THE UNIT. FAILURE TO ADHERE TOTHE INSTRUCTIONS COULD RESULT IN SERIOUS BODILY INJURY OR COMPRESSOR SAFETY PRECAUTIONSS afety is basically common sense. There are standard safety rules but eachsituation has its own peculiarities which cannot always be covered by with your experience and common sense, you are in a position to dosomething about 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 generalguide to safe operation:Do not attempt to remove any COMPRESSOR parts without first relieving the entiresystem of not attempt to service any part while machine is THE COMPRESSOR SUMP OIL LEVEL ONLY WHEN THE COMPRESSOR ISNOT OPERATING AND SYSTEM IS COMPLETELY RELIEVED OF PRESSURE.

5 OPENSERVICE VALVE TO INSURE RELIEF OF SYSTEM AIR PRESSURE WHENPERFORMING MAINTENANCE ON COMPRESSOR AIR/OIL SYSTEM. FAILURE TOCOMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTY AND SERIOUSBODILY not operate the COMPRESSOR at pressures or speeds in excess of its rating asindicated in COMPRESSOR Specifications .Periodically check all safety devices for proper not play with compressed air. Pressurized air can cause serious injury cleanliness during maintenance and when making repairs. Keep dirt awayfrom parts by covering parts and exposed Industries, Air COMPRESSOR (IBI Split-Shaft)Operators, INSTALLATION and Parts Manual6 SAFETYDo not install a shut-off valve between the COMPRESSOR and COMPRESSOR oil NOT USE BOSS INDUSTRIES, INC. COMPRESSORS TO PROVIDE BREATHINGAIR. SUCH USAGE, WHETHER SUPPLIED IMMEDIATELY FROM THE COMPRESSORSOURCE, OR SUPPLIED TO BREATHING TANKS FOR SUBSEQUENT USE, CANCAUSE SERIOUS BODILY INDUSTRIES, INC.

6 DISCLAIMS ANY AND ALL LIABILITIES FOR DAMAGE ORLOSS DUE TO PERSONAL INJURIES, INCLUDING DEATH, AND/OR PROPERTYDAMAGE INCLUDING CONSEQUENTIAL DAMAGES ARISING OUT OF ANY BOSSCOMPRESSORS USED TO SUPPLY BREATHING not disconnect or by-pass safety circuit not install safety devices other than authorized Boss replacement all openings and replace all covers and guards before operating , rags, or loose parts must not be left on the COMPRESSOR or drive not use flammable solvents for cleaning combustibles out of and away from the COMPRESSOR and any owner, lessor, or operator of the COMPRESSOR are hereby notified andforewarned that any failure to observe these safety precautions may result indamage or Industries, Inc. expressly disclaims responsibility or liability for any injury and/ordamage caused by failure to observe these specified precautions or by failure toexercise that ordinary caution and due care required when operating or handlingthe COMPRESSOR , even though not expressly specified Industries, Air COMPRESSOR (IBI Split-Shaft)Operators, INSTALLATION and Parts ManualSAFETYA compliment of warning decals are supplied with each unit.

7 These decals shouldbe affixed to the vehicle after it has been painted, trimmed, and undercoated, prior to being put into service. The decals should be placed so as to be clearlyvisible to the user and service personnel. (Figures 1thru 8)Figure 1. To be placed Figure 2. To be placedon visor or dash near on body near oil sumpstart-up procedure decal. filler Industries, Air COMPRESSOR (IBI Split-Shaft)Operators, INSTALLATION and Parts Manual8 SAFETYF igure 3. To be placed Figure 4. To be placedon body near air service on body near air servicevalve.` Industries, Air COMPRESSOR (IBI Split-Shaft)Operators, INSTALLATION and Parts manual SAFETYF igure 5. To be placed Figure 6.

8 To be placedon frame near COMPRESSOR on fan Industries, Air COMPRESSOR (IBI Split-Shaft)Operators, INSTALLATION and Parts Manual10 SAFETYF igure 7. To be placed on body near oil sump filler cap. Figure 8. Serial number/name plate to be placed on drivers side door Industries, Air COMPRESSOR (IBI Split-Shaft)Operators, INSTALLATION and Parts ManualCOMPRESSOR TERMINOLOGYATF: Automatic transmission COALESCER: Performs second stage separation of oil from compressed airfeeding air tools. Sometimes referred to as the separator : Refers to the volume of compressed air being produced expressed as cubicfeet of air per CONTROLLER: Sometimes referred to as the engine speed SUMP: The first stage of oil separation from compressed air. Also serves asreservoir area for COMPRESSOR lubricant and sometimes referred to as the : Refers to the operating pressure the system is set up at, expressed as poundsper square VALVE: A valve located on the oil sump which opens in case of excessivepressure.

9 Sometimes referred to as the pop-off or pressure relief SWITCH: Works in conjunction with temperature and pressureswitchgauges, sending a signal to stop the COMPRESSOR power source in cases ofhigh temperature or PTO: Transfer case gear box with integrally mounted compressortransmits engine power and torque from the main driveshaft. The PTO gear box ismounted to the frame rail sides with special mounting brackets behind thetransmission. With the PTO engaged, the rear driveline is stationary while the frontdriveline rotates into the gear box automatically starting operation of the integrallymounted air COMPRESSOR . With the PTO disengaged, the front driveshaft transmitspower through the box to the rear driveshaft and rear Industries, Air COMPRESSOR (IBI Split-Shaft)Operators, INSTALLATION and Parts Manual12 DESCRIPTION OF COMPONENTSPRINCIPLES OF OPERATIONIn operation, two helically grooved rotors mesh to compress air.

10 Inlet air is trappedas 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 anddelivers smooth-flowing, pulse-free air to the the compression cycle, oil is injected into the COMPRESSOR and serves thesepurposes: 1. Lubricates the rotating parts and bearings. 2. Serves as a cooling agent for the compressed air. 3. Seals the running SYSTEMOil from the COMPRESSOR oil sump, at COMPRESSOR discharge pressure, is directedthrough the oil filter, cooling system, and to the side of the COMPRESSOR stator, whereit is injected into the COMPRESSOR . At the same time oil is directed internally to thebearings and shaft seal of the COMPRESSOR . The oil-laden air is then dischargedback into the SUMPC ompressed, oil-laden air enters the sump from the COMPRESSOR .