Series 60 PTO Air Compressor - Iowa Mold Tooling Co., Inc.

PN:301420: 20070329
PG-1: SERIES 60 ROTARY SCREW AIR COMPRESSOR
Series 60
PTO Air Compressor
OPERATORS AND PARTS MANUAL
P/N: 301420
03/23/99
Iowa Mold Tooling Co., Inc. is an Oshkosh Truck Corporation company.
PN:301420: 19991221
PG-2: SERIES 60 ROTARY SCREW AIR COMPRESSOR
TABLE OF CONTENTS
GENERAL ARRANGEMENT ................................................................................................................................... 4
SPECIFICATIONS ................................................................................................................................................... 5
TYPICAL INSTALLATION ....................................................................................................................................... 6
SAFETY INFORMATION ......................................................................................................................................... 7
AIR COMPRESSOR SAFETY PRECAUTIONS ....................................................................................................... 7
SAFETY INFORMATION ......................................................................................................................................... 8
COMPRESSOR TERMINOLOGY .......................................................................................................................... 12
ATF ....................................................................................................................................................................... 12
AIR/OIL COALESCER ........................................................................................................................................... 12
CFM ...................................................................................................................................................................... 12
LOAD CONTROLLER ............................................................................................................................................ 12
OIL SUMP ............................................................................................................................................................. 12
PSI ........................................................................................................................................................................ 12
SAFETY VALVE .................................................................................................................................................... 12
SHUTDOWN SWITCH ........................................................................................................................................... 12
SIDE MOUNT PTO ................................................................................................................................................ 12
COMPRESSOR ASSEMBLY ................................................................................................................................. 13
PRINCIPLES OF OPERATION ............................................................................................................................. 13
LUBRICATION SYSTEM ....................................................................................................................................... 13
OIL SUMP ............................................................................................................................................................. 13
ELECTRICAL AND SAFETY CIRCUIT SYSTEM .................................................................................................. 15
AUTOMATIC BLOW DOWN VALVE ....................................................................................................................... 15
CONTROL SYSTEM ............................................................................................................................................. 15
DISCHARGE PRESSURE REGULATOR VALVE ................................................................................................... 15
INLET VALVE ........................................................................................................................................................ 15
CONTROL SYSTEM OPERATION ........................................................................................................................ 16
INSPECTION, LUBRICATION, AND MAINTENANCE ............................................................................................ 17
LUBRICATION AND MAINTENANCE CHART ....................................................................................................... 18
LUBRICANT RECOMMENDATIONS ..................................................................................................................... 19
LUBRICANT CHARACTERISTICS ........................................................................................................................ 20
MAINTENANCE .................................................................................................................................................... 21
COMPRESSOR OIL SUMP FILL, LEVEL, AND DRAIN ........................................................................................ 21
GREASE ............................................................................................................................................................... 21
AIR INTAKE FILTER ............................................................................................................................................. 21
AIR/OIL COALESCER ........................................................................................................................................... 22
OIL RETURN LINE ................................................................................................................................................ 22
OIL FILTER ........................................................................................................................................................... 23
OIL COOLER ........................................................................................................................................................ 23
SHAFT SEAL INSTALLATION INSTRUCTIONS ................................................................................................... 24
PTO ....................................................................................................................................................................... 24
HYDRAULIC PUMP OPTION ................................................................................................................................ 25
TROUBLESHOOTING ........................................................................................................................................... 26
TRUCK ENGINE WILL NOT START ...................................................................................................................... 26
UNPLANNED SHUTDOWN .................................................................................................................................... 26
IMPROPER DISCHARGE PRESSURE ................................................................................................................. 27
SUMP PRESSURE DOES NOT BLOW DOWN ...................................................................................................... 27
OIL CONSUMPTION ............................................................................................................................................. 27
ENGINE LUGGING ............................................................................................................................................... 28
COALESCER PLUGGING ..................................................................................................................................... 28
HIGH COMPRESSOR DISCHARGE TEMPERATURE .......................................................................................... 28
COMPRESSOR OPERATION ............................................................................................................................... 29
STARTING/STOPPING ......................................................................................................................................... 29
COMPRESSOR OPERATION ............................................................................................................................... 30
OPERATING CONDITIONS ................................................................................................................................... 31
FlLASH RECOVERY PROCEDURE FOR ROTARY COMPRESSORS ................................................................... 32
AIR/OIL SCHEMATIC-20019 & 20031-DWG .......................................................................................................... 33
AIR/OIL SCHEMATIC-20021-DWG ........................................................................................................................ 34
PN:301420: 19991221
PG-3: SERIES 60 ROTARY SCREW AIR COMPRESSOR
TABLE OF CONTENTS, CONTINUED
AIR/OIL SCHEMATIC-20028 & 20032 .................................................................................................................... 35
AIR/OIL SCHEMATIC-PARTS ............................................................................................................................... 36
CONTROL HOSE PORT CALL OUTS ................................................................................................................... 37
AIR INLET SYSTEM .............................................................................................................................................. 38
OIL COOLING SYSTEM-20019 & 20031 ............................................................................................................... 39
OIL COOLING SYSTEM-20021, 20028 & 20032 .................................................................................................... 39
OIL COOLING SYSTEM-PARTS ........................................................................................................................... 40
COMPRESSOR MOUNTING SYSTEM-DWG ........................................................................................................ 41
COMPRESSOR MOUNTING SYSTEM-PARTS ..................................................................................................... 42
DISCHARGE SYSTEM-20019 & 20031-DWG ........................................................................................................ 43
DISCHARGE SYSTEM-20021-DWG ...................................................................................................................... 44
DISCHARGE SYSTEM-20028 & 20032-DWG ........................................................................................................ 45
DISCHARGE SYSTEM-PARTS .............................................................................................................................. 46
DISCHARGE SYSTEM-PARTS (cont) ................................................................................................................... 47
PTO AND DRIVELINE SYSTEM-DWG .................................................................................................................. 48
PTO AND DRIVELINE SYSTEM-DWG .................................................................................................................. 49
PTO AND DRIVELINE SYSTEM-PARTS ............................................................................................................... 50
HARNESS-ELECTRICAL SYSTEM ( F-SUPERDUTY DIESEL/MNL & AUTO TRANS ) ......................................... 51
ELECTRICAL SYSTEM (F-SUPERDUTY DIESEL/MNL TRANS) ........................................................................... 52
ELECTRICAL SYSTEM (F-SUPERDUTY DIESEL/AUTO TRANS) ......................................................................... 53
MISC PARTS-BOX (6X6X12) F-450 ‘97’ DIESEL MNL TRANS ............................................................................. 54
BOLT BAG PARTS LOCATED IN BOX ................................................................................................................. 55
5, & 10 GPM PUMP OPTIONS FOR CRANE PACKAGES-DWG ........................................................................... 56
5, & 10 GPM PUMP OPTIONS FOR CRANE PACKAGES-PARTS ........................................................................ 57
RECOMMENDED SPARE PARTS LIST ................................................................................................................. 58
SERVICE QUESTIONNAIRE ................................................................................................................................. 59
REVISIONS LIST
DATE
20020326
20020429
20020708
20030131
20070329
LOCATION
42,45
32
42
8
COVER
DESCRIPTION OF CHANGE
CHANGES TO DISCHARGE SYSTEM
ADDED FLASH RECOVERY PROCEDURE
ITEM #18 - 926102-223 WAS 926102-222
ADDED SUB-ZERO TEMP. OPERATION
UPDATED OWNERSHIP STATEMENT
PN:301420: 19990129
PG-4: SERIES 60 ROTARY SCREW AIR COMPRESSOR
GENERAL ARRANGEMENT
IMT Underdeck PTO Compressors are shipped in kit form for field installation. These kits
include:
1. Rotary Screw Compressor and Mounting Bracket.
2. Oil Sump with Mounting Brackets.
3. Spin-on Coalescer/Air Manifold Assembly.
4. Compressor Oil Cooler.
5. Air Inlet Filtration System.
6. Hoses and Fittings.
7. All Necessary Safety and Informational Decals.
8. Wiring Harness.
9. PTO and Drivelines.
10. Parts, Service, and Maintenance Manual.
IMT offers factory installation by qualified technicians, as well as a nationwide network of
authorized distributors for field installations, parts and service.
PN:301420: 19990129
PG-5: SERIES 60 ROTARY SCREW AIR COMPRESSOR
SPECIFICATIONS
IMT SERIES 60 (SIDE-MOUNT) COMPRESSOR
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE
PN:301420: 19990129
PG-6: SERIES 60 ROTARY SCREW AIR COMPRESSOR
TYPICAL INSTALLATION
PN:301420: 19990129
PG-7: SERIES 60 ROTARY SCREW AIR COMPRESSOR
SAFETY INFORMATION
CONTINUED
WARNING
ALL UNITS ARE SHIPPED WITH A DETAILED OPERATORS AND PARTS MANUAL. THIS
MANUAL CONTAINS VITAL INFORMATION FOR THE SAFEUSE 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.
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
CHECK THE COMPRESSOR SUMP OIL LEVEL ONLY WHEN THE COMPRESSOR IS NOT
OPERATING AND SYSTEM IS COMPLETELY RELIEVED OF PRESSURE. OPEN SERVICE
VALVE TO ENSURE RELIEF OF SYSTEM AIR PRESSURE WHEN PERFORMING MAINTENANCE
ON COMPRESSOR AIR/OIL SYSTEM. FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE
DAMAGE TO PROPERTY AND SERIOUS BODILY HARM.
Do not operate the compressor at pressure 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. Keep dirt away from parts by
covering parts and exposed openings.
SAFETY INFORMATION
Do not install a shut-off valve between the compressor and compressor oil sump.
DANGER
DO NOT USE IMT COMPRESSOR SYSTEMS TO PROVIDE BREATHING AIR.SUCH USAGE,
WHETHER SUPPLIED IMMEDIATELY FROM THE COMPRESSOR SOURCE, OR SUPPLIED TO
BREATHING TANKS FOR SUBSEQUENT USE, CAN CAUSE SERIOUS BODILY INJURY.
PN:301420: 20030131
PG-8: SERIES 60 ROTARY SCREW AIR COMPRESSOR
DANGER
CONTINUED
IMT DISCLAIMS ANY AND ALL LIABILITIES FOR DAMAGE FOR LOSS DUE TO PERSONAL
INJURIES, INCLUDING DEATH, AND/OR PROPERTY DAMAGE INCLUDING CONSEQUENTIAL
DAMAGES ARISING OUT OF ANY IMT COMPRESSORS USED TO SUPPLY BREATHING AIR.
•
•
•
•
•
•
Do not disconnect or bypass safety circuit system.
Do not install safety devices other than authorized IMT 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.
Keep combustibles out of and away from the Compressor 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.
IMT 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.
SUB-ZERO TEMPERATURE OPERATION INSTRUCTIONS
CAUTION
READ AND UNDERSTAND THE SUB-ZERO TEMPERATURE OPERATION INSTRUCTIONS BELOW.
DO NOT OPERATE COMPRESSOR WITH THE OIL TEMPERATURE BELOW 0º F.
Sub-Zero Operation
For IMT rotary screw compressors (both shaft driven and hydraulically driven) sub-zero temperature
operation is defined as operation of the compressor when the oil temperature is below 0º F. It is possible
to operate an IMT rotary screw compressor when the ambient temperature is below 0º F, but only by
adhering to the following guidelines:
Maintenance Requirements
If the IMT rotary screw compressor is expected to operate at temperatures below 0º F, the oil filter,
coalescer, air filter, and oil should be changed before the compressor is ran in sub-zero temperatures
(ex: late fall, but this may vary by location and environment). Performing this maintenance will improve
the performance of the system during sub-zero temperature operation. Use only IMT approved rotary
screw compressor oils and filters.
Storage Requirements
The IMT rotary screw compressor should be stored at or above 0º F. If the ambient temperature is below
0º F the vehicle should be stored inside, preferably in a heated environment. After moving the vehicle
from the heated environment, the compressor system should be operated for 15 minutes before
proceeding to a job site. During this time, the service valve must be slightly ajar, such that the pressure
gauge reads between 100 and 140 psi. This ensures that the oil temperature has had adequate time to
come up to operating temperature, and that most of the water in the system has been removed. This will
PN:301420: 19990129
PG-9: SERIES 60 ROTARY SCREW AIR COMPRESSOR
allow for approximately one hour of travel time before the oil cools to ambient temperature. CONTINUED
If an extended driving time is expected, the operator may need to stop driving and run the
system for 15 minutes every hour to ensure that the oil temperature does not cool to below 0º F. The
operator should use his/her judgment when deciding what interval is needed between running the
compressor to warm the oil. Lower ambient temperature will require more frequent warming of the
compressor oil.
Failure to Follow Maintenance & Storage Requirements
At temperatures below 0º F, failure to follow the above guidelines may result overheating of the
compressor due to the oil’s inability to circulate through the compressor system. The lack of circulation
leads to rapid warming of the compressor air end, and eventually the compressor air end will exceed the
maximum operating temperature. If the system shuts down due to high temperature during sub-zero
temperature operation, the oil will need to be warmed before restarting. This may require moving the
vehicle to a heated location or waiting for the ambient temperature (and therefore the oil temperature) to
exceed 0º F.
CAUTION
FAILURE TO ADHERE TO THESE GUIDELINES, AND REPEATED RUNNING OF THE COMPRESSOR
TO HIGH TEMPERATURE SHUTDOWN, MAY RESULT IN PERMANENT DAMAGE TO THE AIR END.
SAFETY INFORMATION
A compliment of warning decals is supplied with each unit. These decals must be affixed to the
vehicle after it has been painted, trimmed, and undercoat, etc. and prior to being put into service.
The decals shall be placed so as to be clearly visible to the user and service personnel. (Figures 1
through 6.)
Figure 1. To be placed on visor
or dash near start-up procedure
decal.
Figure 2. To be placed on body
near oil sump filler cap.
PN:301420: 19990129
PG-10: SERIES 60 ROTARY SCREW AIR COMPRESSOR
SAFETY INFORMATION
Figure 3. To be placed on body
near air service valve.
CONTINUED
Figure 4. To be placed on
body near compressor
mounting foot.
PN:301420: 20020121
PG-11: SERIES 60 ROTARY SCREW AIR COMPRESSOR
SAFETY INFORMATION
COMPRESSOR FLUID
301475
Figure 5. To be placed on body near oil sump filler cap.
Figure 6. Serial number and name plate to be placed on door jam.
FILL OIL TO THIS
LEVEL IN
SIGHTGLASS
70396127
Figure 7. To be placed on body near oil sump filler cap.
PN:301420: 19990129
PG-12: SERIES 60 ROTARY SCREW AIR COMPRESSOR
COMPRESSOR TERMINOLOGY
ATF
Automatic transmission fluid.
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.
LOAD CONTROLLER
Sometimes referred to as the engine speed control.
OIL SUMP
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.
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.
SHUTDOWN SWITCH
Works in conjunction with a power relay, sending a signal to stop the compressor power source in
cases of high temperature. Power relay incorporates an additional wire for remote engine/speed
control kill.
SIDE MOUNT PTO
Power take off gearbox that bolts to the side of the transmission. The PTO input gear meshes with
one of the gears in the vehicle’s transmission. The rotation developed by the engine drives the
transmission which turns the PTO gear box and rotates the PTO output shaft.
PN:301420: 19990129
PG-13: SERIES 60 ROTARY SCREW AIR COMPRESSOR
DESCRIPTION OF COMPONENTS
CONTINUED
COMPRESSOR ASSEMBLY
The IMT PTO 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 engine is
transferred to the male rotor through a drive shaft and gears in the gear housing. The female
rotor is driven by the male rotor. There are four lobes on the male rotor while the female rotor
has five 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 oil sump, at compressor discharge pressure, is directed through the oil
filter, cooling system, and 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. The oil-laden air is then discharged back into the sump.
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 defusion 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.
PN:301420: 19990129
PG-14: SERIES 60 ROTARY SCREW AIR COMPRESSOR
DESCRIPTION OF COMPONENTS
CONTINUED
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 and is independent of the sump. 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 at the bottom of the can and is returned
through an oil return line leading to the compressor. The oil return line is 1/4 and goes to elbow
hose fitting which is located at the compressor.
MINIMUM PRESSURE ORIFICE
The minimum pressure orifice is located at the outlet of the coalescer head and serves to
maintain a minimum discharge pressure of 65 PSIG in operation, which is required to assure
adequate compressor lubrication pressure.
OIL FILTER
The compressor oil filter is the full-flow replaceable element type and has a safety bypass built
into it.
COMPRESSOR COOLING SYSTEM
The compressor cooling system consists of an oil cooler mounted in front of the truck’s radiator.
Oil temperature is controlled by a thermal valve located down stream of the oil filter. This valve
maintains compressor oil temperature of 180°F in ambient temperatures less than 100°F.
PN:301420: 19990129
PG-15: SERIES 60 ROTARY SCREW AIR COMPRESSOR
DESCRIPTION OF COMPONENTS
CONTINUED
ELECTRICAL AND SAFETY CIRCUIT SYSTEM
The IMT PTO unit is supplied with a hourmeter, wire harness and a high compressor discharge
temperature switch. Engine shutdown occurs in the event of high compressor temperature, on
compressor trucks with cable shift PTO’s. Compressor trucks with hot shift PTO’s will disengage
the PTO in the event of high compressor temperature.
AUTOMATIC BLOW DOWN VALVE
There is one blow down valve in the compressor system. It is located at the downstream side of
the coalescer head and will automatically bleed the sump to zero pressure when the compressor
is disengaged. Blow down time interval takes between 30 to 60 seconds.
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.
DISCHARGE PRESSURE REGULATOR VALVE
This valve, located on the coalescer head is used to set the desired discharge pressure within
the operating pressure range. Turning the regulator screw clockwise increases the working
pressure, a counterclockwise movement of the screw reduces the working pressure. This
system has a maximum operating pressure of 175 psi.
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 nut 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.
INLET VALVE
The compressor inlet valve is a piston operated disc valve that regulates the inlet opening to
control capacity and serving as a check valve at shutdown.
PN:301420: 19990129
PG-16: SERIES 60 ROTARY SCREW AIR COMPRESSOR
DESCRIPTION OF COMPONENTS
CONTROL SYSTEM OPERATION
The following discussion explains the operation of the control system from a condition of “no
load” to a condition of “full capacity” at working pressure. For the working pressure range of your
machine, refer to applicable data in “Specifications”.
The pressure regulator, mounted on the coalescer head, operates as follows:
1. As the demand for air decreases, the receiver pressure rises. When this pressure
exceeds the set point of the pressure regulator, the regulator opens sending a
secondary pressure signal to the inlet valve. The poppet valve moves towards the
valve inlet against the force of the modulating spring inside the valve. This regulates
the opening area of the inlet valve.
2. If the air demand goes to zero, (service valve closed or air dead headed at tool) the
inlet valve will close completely.
3. As the demand for air increases, the secondary pressure signal to the inlet valve is
removed and the inlet valve poppet modulates to full open.
PN:301420: 19990129
PG-17: SERIES 60 ROTARY SCREW AIR COMPRESSOR
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. 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. A planned program of
periodic inspection and maintenance will help avoided premature failure and costly repairs. Daily
visual inspections should become a routine.
The LUBRICATION AND 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 “EVERY 10
HOURS” should be serviced for the tenth time, and all items under “EVERY 50 HOURS” should
be serviced for the second time, and so on.
DANGER
COMPRESSOR MUST BE SHUT DOWN AND COMPLETELY RELIEVED OF PRESSURE PRIOR
TO CHECKING FLUID LEVELS. OPEN SERVICE VALVE TO ENSURE RELIEF OF SYSTEM AIR
PRESSURE. FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO
PROPERTY AND SERIOUS BODILY HARM.
PN:301420: 19991026
PG-18: SERIES 60 ROTARY SCREW AIR COMPRESSOR
LUBRICATION AND MAINTENANCE CHART
EVERY 1000
HOURS
NOTE
Compressor oil and filter is to be changed after the first 50 hours of operation. After this, normal
intervals are to be followed.
PN:301420: 19990129
PG-19: SERIES 60 ROTARY SCREW AIR COMPRESSOR
LUBRICANT RECOMMENDATIONS
CONTINUED
WARNING
IT IS IMPORTANT THAT THE COMPRESSOR OIL BE OF A RECOMMENDED TYPE AND THAT
THIS OIL AS WELL AS THE AIR FILTER, OIL FILTER, AND COALESCER ELEMENTS BE
INSPECTED AND REPLACED AS STATED IN THIS MANUAL.
THE COMBINATION OF A COALESCER ELEMENT LOADED WITH DIRT AND OXIDIZED OIL
PRODUCTS TOGETHER WITH INCREASED AIR VELOCITY AS A RESULT OF THIS CLOGGED
CONDITION MAY PRODUCE A CRITICAL POINT WHILE THE MACHINE IS IN OPERATION
WHERE IGNITION CAN TAKE PLACE AND COULD CAUSE A FIRE IN THE OIL SUMP.
FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTY AND
SERIOUS BODILY HARM.
The following are general characteristics for IMT rotary screw lubricant. Due to the impossibility of
establishing limits on all physical and chemical properties of lubricants which can affect their performance
in the compressor over a broad range of environmental influences, the responsibility for recommending
and consistently furnishing a suitable heavy duty lubricant must rest with the individual supplier if they
choose not to use the recommended IMT 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 PTO helical screw type air compressors
operating in the particular environment involved. The owner of this equipment should contact the factory
if IMT rotary screw lubricant is not used as supplied with this equipment.
CAUTION
MIXING DIFFERENT TYPES OR BRANDS OF LUBRICANTS IS NOT RECOMMENDED DUE TO
THE POSSIBILITY OF A DILUTION OF THE ADDITIVES OR A REACTION BETWEEN
ADDITIVES OF DIFFERENT TYPES.
IMT ‘Cool Blue’ rotary screw lubricant shipped with your kit contains additives for rust, corrosion and
anti-wear inhibitors. Use of any other lubricant is not recommended and may forfeit the warranty.
PN:301420: 19990129
PG-20: SERIES 60 ROTARY SCREW AIR COMPRESSOR
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
DUE TO ENVIRONMENTAL FACTORS THE USEFUL LIFE OF ALL “EXTENDED LIFE”
LUBRICANTS MAY BE SHORTER THAN QUOTED BY THE LUBRICANT SUPPLIER. IMT
ENCOURAGES THE USER TO CLOSELY MONITOR THE LUBRICANT CONDITION AND TO
PARTICIPATE IN AN OIL ANALYSIS PROGRAM WITH THE SUPPLIER.
NOTE
NO LUBRICANT, HOWEVER GOOD AND/OR EXPENSIVE, CAN REPLACE PROPER
MAINTENANCE AND ATTENTION. SELECT AND USE IT WISELY.
PN:301420: 19990129
PG-21: SERIES 60 ROTARY SCREW AIR COMPRESSOR
MAINTENANCE
CONTINUED
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 OIL SUMP FILL, LEVEL, AND DRAIN
Before adding or changing compressor oil make sure that the sump is completely relieved of
pressure. Oil is added at the fill cap on the side of the receiver/sump. A drain plug is provided at
the bottom of the sump. The proper oil level, when unit is shut down and has had time to settle,
is at the midpoint of the oil sightglass. The truck must be level when checking the oil. DO NOT
OVERFILL. The oil sump capacity is given in “Compressor Specifications”.
DANGER
DO NOT ATTEMPT TO DRAIN CONDENSATE, REMOVE THE OIL LEVEL FILL PLUG, OR
BREAK ANY CONNECTION IN THE AIR OR OIL SYSTEM WITHOUT SHUTTING OFF
COMPRESSOR AND MANUALLY RELIEVING PRESSURE FROM THE SUMP. FAILURE TO
COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTY AND SERIOUS BODILY
HARM.
GREASE
Lubricate the compressor drive shaft universal joints every time the truck is lubricated or every
100 hours of compressor operation, whichever comes first.
AIR INTAKE FILTER
The air intake filter is a heavy-duty two-stage dry type high efficiency filter designed to protect
the compressor from dust and foreign objects.
The 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” H2O). The filter is equipped with a pressure drop indicator, and the element should be
changed based on it’s reading first and then by the maintenance intervals outlined.
PN:301420: 19990129
PG-22: SERIES 60 ROTARY SCREW AIR COMPRESSOR
MAINTENANCE
CONTINUED
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. Disconnect drain line.
3. Turn element counterclockwise for removal (viewing element from bottom).
4. Install new rubber seal in head and supply a film of fluid directly to seal.
5. Rotate element clockwise by hand until element contacts seal (viewing element from
bottom).
6. Rotate element approximately one more turn clockwise with band wrench near the top
of element.
7. Reconnect drain line.
8. Run system and check for leaks.
NOTE
When connecting drain line care must be taken to hold onto canister nut securely when tightening
the hose fitting.
WARNING
DO NOT SUBSTITUTE ELEMENT. USE ONLY A GENUINE IMT REPLACEMENT ELEMENT.
THIS ELEMENT IS RATED AT 200 PSI WORKING PRESSURE. 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.
OIL RETURN LINE
This line originates at the bottom of the air/oil coalescer and flows through a 1/4 hose elbow
located at the air-end.
PN:301420: 19990129
PG-23: SERIES 60 ROTARY SCREW AIR COMPRESSOR
MAINTENANCE
CONTINUED
OIL FILTER
The compressor oil filter is a spin-on, throw away type.
To replace filter proceed as follows:
1. Make sure system pressure is relieved.
2. Remove filter by unscrewing from filter head (turn counterclockwise by hand viewing
from bottom) and discard.
3. Install a new filter by applying a little oil to the seal and then screw the filter on by hand
(turning it clockwise until hand tight, plus one - third turn viewing from bottom). Do not
use tools to tighten the filter.
4. Check for leaks in operation.
WARNING
DO NOT SUBSTITUTE ELEMENT. USE ONLY A GENUINE IMT REPLACEMENT ELEMENT.
THIS ELEMENT IS RATED AT 200 PSI WORKING PRESSURE. 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.
OIL COOLER
The interior of the oil cooler should be cleaned when the pressure drop across it at full flow
exceeds 25 PSI. The following procedure has been recommended by the vendor who supplies
the cooler:
1. Remove cooler.
2. Circulate a suitable solvent to dissolve and remove varnish and sludge.
3. Flush generously with IMT compressor lubricant.
4. After cooler is reinstalled and compressor is filled with fresh oil, change compressor oil
after 50 hours of normal operation.
PN:301420: 19990129
PG-24: SERIES 60 ROTARY SCREW AIR COMPRESSOR
MAINTENANCE
CONTINUED
SHAFT SEAL INSTALLATION INSTRUCTIONS
1. Remove pto drive shaft, companion flange and key.
2. Remove (4) socket head metric bolts on cover and slide cover off shaft.
3. Pull seal wear sleeve off shaft with puller, adding heat to one area only on wear sleeve will
help enlarge and aid in it’s removal.
4. Clean shaft and surface of bearing remove all burrs from shaft where the wear sleeve gets
installed.
5. Press new wear sleeve on to shaft. Oil heating new wear sleeve to 212°F approximately
aids in the installation of this ring.
6. Press old shaft seal out of cover and clean cover for assembly of new seal.
7. Press new seal into cover (included in repair kit).
8. Apply silicone to outside diameter of assembly tool and slide assembly onto drive shaft
until it touches the wear sleeve (tool and silicone included in repair kit).
9. Install cover, new o-ring, new seal assembly, over shaft and assembly tool. Note:
Assembly tool is slip fit on shaft and allows new seal in cover to slide on to wear sleeve
without cutting the lip of shaft seal. One new cover is on the assembly tool.
10.Bolt cover on squarely and slide off assembly tool.
11. Reinstall drive line assembly.
NOTE
THE SEAL COVER IS INSTALLED USING A O-RING GASKET. CARE SHOULD BE TAKEN TO
NOT PINCH THE O-RING OUT OF IT’S GROOVE UPON REINSTALLATION.
PTO
The PTO should be serviced in accordance with the PTO manual. The SAE side-mount type of
PTO is lubricated by the transmission oil and thus requires little maintenance. It is strongly
recommended that you periodically torque the fasteners in accordance with the PTO manual.
PN:301420: 19990129
PG-25: SERIES 60 ROTARY SCREW AIR COMPRESSOR
HYDRAULIC PUMP OPTION
The single cog belt arrangement is sized for an average life of 1000 hours. This time frame can
be increased or decreased depending on the end users periodic maintenance schedule. Drive
belt tension should be checked for adjustment every 100 hours there after. Belt deflection is to be
checked at midpoint between both pulleys. Belt deflection is to be 1/8” at 3.5 lbs. Minimum to 5.0
lbs. Maximum.
BELT TENSION - Belt tension is accomplished as follows:
1. Loosen the 3/8” bolts that attaches the hydraulic pump to mounting plate. Pump should
now pivot free on bottom mounting bolt.
2. Pivot hydraulic pump until the correct deflection is accomplished. Hold pump in the
position until the two 3/8” bolts are retightened.
NOTE
Over-tensing belt can damage compressor and hydraulic pump. When tensing belt all hardware
should be broken loose only to the point in which the hydraulic pump can pivot.
PN:301420: 19990129
PG-26: SERIES 60 ROTARY SCREW AIR COMPRESSOR
TROUBLESHOOTING
CONTINUED
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.
In general, the procedures listed should be performed in the order in which they are listed,
although the order may be varied if the need is indicated by conditions under which the trouble
occurred. In any event, the procedures which can be performed in the least amount of time and
with the least amount of removal or disassembly of parts, should be performed first.
TRUCK ENGINE WILL NOT START
Most problems in this area will not be connected with the compressor, and should therefore be
checked out with the engine manual.
Manual transmissions require our safety shutdown switch to shut off the engine in
cases of high temperature. If this occurs the truck can be restarted once the high temperature
condition is not present or by disengaging the PTO. In most cases this switch is located in the 1”
discharge line between the compressor and the receiver tank. If the compressor hi-temperature
switch has shut off the engine the compressor truck should be taken in for service/
troubleshooting.
UNPLANNED SHUTDOWN
When the operation of the machine has been interrupted by an unexplained shutdown, check the
following:
1. Check the fuel level and truck dash gauges and indications for possible engine
problems.
2. Check that the compressor oil is at proper level.
3. Check oil cooler for dirt, slush, ice on the fins, or any other obstructions to the cooling
air flow.
4. Compressor Hi-Temp Switch is normally open until the 240° F shutdown temperature is
reached. At this time the switch closes sending power to relay thus interrupting the
engine operation. Check continuity across this switch. If it shows a normally closed
state when the oil is below 240°, then the switch is defective. Compressors installed on
the FORD 4R100 automatic do not kill the truck motor in the event of high discharge
temperature. The shutdown switch and relay, control the power to the hot shift PTO
only. In situations of high compressor discharge temperature, the PTO will disengage.
5. Make a thorough external check for any cause of shutdown such as broken hose,
broken oil lines, loose or broken wire, etc.
PN:301420: 19990129
PG-27: SERIES 60 ROTARY SCREW AIR COMPRESSOR
TROUBLESHOOTING
CONTINUED
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. Leaks in service line.
d. Restricted compressor inlet air filter.
e. Faulty control system operation (i.e. regulator is sending a signal to close inlet valve at
all times.)
2. If discharge pressure is too high or safety valve blows, check the following:
a.
b.
c.
d.
Faulty discharge pressure gauge.
Coalescer plugged up.
Faulty safety valve.
Faulty regulator (regulator air pressure signal is not getting to inlet valve).
SUMP PRESSURE DOES NOT BLOW DOWN
If after the compressor is shutdown, pressure does not automatically blow down, check for:
1. Automatic blow down valve may be inoperative at coalescer head.
2. Blockage in air line from side of inlet valve to blow down valve.
3. Muffler at blow down clogged.
OIL CONSUMPTION
Abnormal oil consumption or oil in service line, check for the following:
1.
2.
3.
4.
5.
6.
Over filling of oil sump.
Leaking oil lines or oil cooler.
Plugged oil return line: check entire line, to the compressor.
Defective coalescer element.
Compressor shaft seal leakage.
Discharge pressure below 65 PSI or above 175 PSI.
PN:301420: 19990129
PG-28: SERIES 60 ROTARY SCREW AIR COMPRESSOR
TROUBLESHOOTING
ENGINE LUGGING
If engine
1.
2.
3.
4.
does not accelerate or will not maintain full load speed, check the following:
Engine problem (refer to engine manual).
Compressor discharge pressure too high.
Improper compressor speed. (Compressor running at truck idle.)
Operating at above maximum altitude rating of compressor and truck.
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 line 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.
PN:301420: 19990129
PG-29: SERIES 60 ROTARY SCREW AIR COMPRESSOR
COMPRESSOR OPERATION
CONTINUED
STARTING/STOPPING
An operating procedure decal is furnished with every PTO Compressor. The decal should be
attached to the dashboard or visor of the truck where it will be visible to the driver. Cable shift
PTO’s require the use of decal 301476. Hot shift PTO’s are to use decal 301661. Both decals are
supplied with your kit. Install the appropriate decal based on the type of PTO used.
The following decal is a sample.
PN:301420: 19990129
PG-30: SERIES 60 ROTARY SCREW AIR COMPRESSOR
COMPRESSOR OPERATION
CONTINUED
Before starting the PTO/compressor, read this section thoroughly. Familiarize yourself with the controls and indicators, their purpose, location, and use.
PN:301420: 19990129
PG-31: SERIES 60 ROTARY SCREW AIR COMPRESSOR
COMPRESSOR OPERATION
OPERATING CONDITIONS
The following conditions should exist for maximum performance of the PTO/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. Fluid carry over and/or oil
starvation may occur if operated beyond this tilt.
NOTE
IF THE COMPRESSOR IS BEING USED TO POWER SANDBLASTING EQUIPMENT, OR AN AIR
STORAGE TANK, USE A CHECK VALVE DIRECTLY AFTER THE MINIMUM PRESSURE
ORIFICE TO PREVENT BACKFLOW INTO THE SUMP. THIS CHECK VALVE SHOULD HAVE A
MAXIMUM PRESSURE DROP RATING OF 2 PSIG (13.78kPa) OPERATING AND A CAPACITY
RATING EQUAL TO THE COMPRESSOR.
NOTE
THE COMPRESSOR SERVICE VALVE SHOULD BE RELOCATED TO THE HOSE REEL INLET
OR BE THE CUSTOMERS AIR CONNECTION PORT WHEN A HOSE REEL IS NOT USED.
TYPICAL PLUMBING FROM MINIMUM PRESSURE ORIFICE SHOULD FLOW IN THE
FOLLOWING ORDER:
1.
MINIMUM PRESSURE ORIFICE.
2.
CHECK VALVE.
3.
AIR TANK (WHEN USED).
4.
SERVICE VALVE.
5.
MOISTURE TRAP/GAUGE/OILER COMBINATION (WHEN USED).
6.
HOSE REEL (WHEN USED).
PN:301420:
20020429
PG-32: SERIES 60 ROTARY SCREW AIR COMPRESSOR
FLASH RECOVERY PROCEDURE FOR ROTARY COMPRESSORS
The following highlights the steps required to flush system when it has flashed.
1. Flush air compressor and check for rotor grinding.
(a) Remove 2½” inlet hose from inlet valve and remove the driveshaft.
(b) Drain sump tank.
(c) Remove 1” hose from side of oil sump tank.
(d) Place the 1” hose at same height of inlet valve and fill inlet of compressor with clean synthetic cool blue oil.
Once full, lower hose into bucket and rotate compressor by hand to evacuate any remaining oil. Repeat until
oil is clean. Make sure the compressor turns freely by hand and that there is no grinding present.
(e) Reinstall drive shaft.
2. Flush oil sump tank
(a) Leave the 1” hose from the compressor flush procedure off. Loosen tank-mounting bands, disconnect and
mark all hoses and remove oil tank. Remove tank.
(b) Fill tank with synthetic cool blue oil, until about half full. Slosh oil from end to end, then drain out oil at drain
plug in bottom of tank. Check drain-plug and tee for any restrictions, (i.e. chunks of hose).
(c) Reinstall tank and install the filler tube.
(d) Replace the ½” hose from oil tank to oil filter head. Verify that plastic bypass valve is intact in filter head.
3. Flush oil cooler
(a) Replace both hoses from cooler to thermal valve.
(b) Inspect that the plastic shroud and fan blades are intact. Put power direct to red lead (ground black lead) at
fan motor to verify that motor works. Do not run the motor outside of the shroud. Leave package assembled. Fan is a puller style, verify that air from fan blows out towards cab of truck.
(c) Replace 1” hose from compressor to oil sump tank.
(d) Replace all filters, air, oil and coalescer.
(e) Re-connect all hoses and add synthetic cool blue oil to proper level in tank.
4. Test safety circuit
(a) Start truck. Do not start air compressor, go to Murphy switch gauge and short across the post to the metal
bezel of the gauge and truck should kill.
(b) You should be ready to start air compressor for testing. Start truck; engage PTO, run compressor for five
minutes. Drain oil, change oil filter, fill oil to proper level, and finish testing.
PN:301420: 19990129
PG-33: SERIES 60 ROTARY SCREW AIR COMPRESSOR
AIR/OIL SCHEMATIC-20019 & 20031-DWG
CONTINUED
PN:301420: 19990129
PG-34: SERIES 60 ROTARY SCREW AIR COMPRESSOR
AIR/OIL SCHEMATIC-20021-DWG
CONTINUED
PN:301420: 19991124
PG-35: SERIES 60 ROTARY SCREW AIR COMPRESSOR
AIR/OIL SCHEMATIC-20028 & 20032
CONTINUED
PN:301420: 19990129
PG-36: SERIES 60 ROTARY SCREW AIR COMPRESSOR
20
AIR/OIL SCHEMATIC-PARTS
01
20
9
02
20
1
02
20
8
03
20
1
03
2
ITEM
PART
NUMBER
DESCRIPTION
QTY
QTY
1
975408-108
HOSE, COOLER FEED 1/2
1
1
2
301261
VA LV E , T H E R M A L 3 / 8 - 1 8 0 D E G
1
1
1
1
1
3
300005
E L E M E N T, O I L F I LT E R 8 0 6 0
1
1
1
1
1
4
300783
SIGHT GLASS, OIL LEVEL 1 SAE
1
1
1
1
1
5
301466
C A P, J I C 1 W / H O L E
1
1
1
1
1
6
300108
PLUG, MAGNETIC 1/2 NPT
1
1
1
1
1
7
301040
SWITCH, SAFETY SHUTDOWN N.O.
1
1
1
1
1
8
975416-156
HOSE, COMPRESSOR DICHARGE 1
1
9
301670
COALESCER, SPIN-ONELEMENT I MT SHORT
1
1
1
1
1
10
301331
COMPRESSOR, R.S. D.D. B101
1
1
1
1
1
11
975404-175
HOSE, COALESCER OILRETURN 1/4
1
12
301421
SWITCH, PRESSURE 5# N.C.
1
1
1
1
1
13
301587
VA L V E , 1 - 1 / 4 T E E I N L E T
1
1
1
1
1
14
301404
ORFICE, MINIMUM PRESSURE 1/2
1
1
1
1
1
15
300331
HEAD, COALESCER
1
1
1
1
1
16
301422
SWITCH, PRESSURE 30# N.O.
1
1
1
1
1
17
300023-200
VA L V E , R E L I E F 1 / 2 N P T 2 0 0 L B S .
1
1
1
1
1
18
300017
S U M P, 1 0 D I S C H A R G E
1
1
1
1
1
19
975508-030
HOSE, COMPRESSOR OIL FEED 1/2
1
20
975508-090
HOSE, COOLER RETURN 1/2
1
1
21
301400
COOLER, FRONT MOUNT IMT
1
1
22
975404-168
H O S E , R E G U L AT O R O U T L E T 1 / 4
1
1
23
975404-168
HOSE, BLOWDOWN PILOT 1/4
1
1
24
300057
VA L V E , R E G U L AT O R 1 / 4
1
1
1
1
1
25
300918
A S S Y, A I R F I LT E R 4 . 8
1
1
1
1
1
26
300715
VA LV E , B L O W D O W N 1 / 8 N P T
1
1
1
1
1
27
300716
MUFFLER, EXHAUST 1/8
1
1
1
1
1
28
300022-050
VA LV E , S E RV I C E 1 / 2 W / V E N T
1
1
1
1
1
29
975408-144
H O S E , O I L F I LT E R F E E D 1 / 2
1
30
975416-027
HOSE, COMPRESSOR DISCHARGE 1
1
31
975404-044
HOSE, COALESCER OIL RETURN
1
32
975404-041
HOSE, BLOWDOWN PILOT 1/4
1
33
975404-040
H O S E , R E G U L AT O R O U T L E T 1 / 4
1
34
975508-044
HOSE, COMPRESSOR OIL FEED 1
1
35
975408-120
36
QTY
QTY
QTY
1
1
1
1
1
1
1
1
1
1
1
HOSE, COOLER FEED 1/2
1
1
975408-103
HOSE, COOLER RETURN 1/2
1
1
37
975508-015
HOSE, COMPRESSOR OIL FEED
1
1
38
975404-048
HOSE, BLOWDOWN PILOT 1/4
1
1
39
975404-050
H O S E , R E G U L AT O R O U T L E T 1 / 4
1
1
40
975404-056
HOSE,COALESCER OIL RETURN
1
1
PN:301420: 19990129
PG-37: SERIES 60 ROTARY SCREW AIR COMPRESSOR
CONTROL HOSE PORT CALL OUTS
PN:301420: 19990129
PG-38: SERIES 60 ROTARY SCREW AIR COMPRESSOR
AIR INLET SYSTEM
2
0
03
2
1
8
1
9
03
02
02
01
0
0
0
0
2
2
2
2
* REPLACEMENT AIR FILTER ELEMENT P/N 300854
PN:301420: 19990129
PG-39: SERIES 60 ROTARY SCREW AIR COMPRESSOR
OIL COOLING SYSTEM-20019 & 20031
OIL COOLING SYSTEM-20021, 20028 & 20032
CONTINUED
PN:301420: 19990129
PG-40: SERIES 60 ROTARY SCREW AIR COMPRESSOR
OIL COOLING SYSTEM-PARTS
2
0
01
2
9
0
0
2
21
0
02
8
2
0
03
2
1
0
03
2
PN:301420: 19990129
PG-41: SERIES 60 ROTARY SCREW AIR COMPRESSOR
COMPRESSOR MOUNTING SYSTEM-DWG
CONTINUED
PN:301420: 20020708
PG-42: SERIES 60 ROTARY SCREW AIR COMPRESSOR
COMPRESSOR MOUNTING SYSTEM-PARTS
2
0
2
01
0
9
2
02
0
1
02
2
8
0
2
03
0
1
03
2
ITEM
PART
NUMBER
DESCRIPTION
QTY
QTY
QTY
QTY
QTY
1
929808-200
BOLT, HEX GR8 1/2-13 X 2
4
4
4
4
4
2
937808-125
WASHER, LOC 1/2
4
4
4
4
4
3
301558
GASKET, .062 INLET VALVE ELBOW
1
1
1
1
1
4
938208-112
WASHER, PLAIN 1/2 PLATED
4
4
4
4
4
5
922220-000
NIPPLE, PIPE 1 1/4 X CLOSE SCH
1
1
1
1
1
6
926008-448
NUT, HEX GR8 1/2-13
4
4
4
4
4
7
301568
ADAPTER, INLET VALVE
1
1
1
1
1
8
301587
VALVE,1 1/4 TEE INLET
1
1
1
1
1
9
929308-300
BOLT, SOC HD 8MM X 30MM
4
4
4
4
4
10
938908-180
WASHER, FLAT M8
4
4
4
4
4
11
974700-025
PLUG, 1/4 BSPP
1
1
1
1
1
12
938808-200
WASHER, LOC M8
4
4
4
4
4
13
970608-050
ELBOW, 1/2 BSPP M X 1/2 37 DEG FL
1
1
1
1
1
14
929312-300
BOLT, 12MM X 30MM
3
3
3
3
3
15
938812-250
WASHER, LOC M12
7
7
7
7
7
16
938912-200
WASHER, FLAT M12
3
3
3
3
3
17
960216-100
ELBOW, 1 X 1 37 DEG FL
1
1
1
1
1
18
926102-223
O-RING, B101 DISCHARGE
1
1
1
1
1
19
301538
FLANGE, DISC B101 1"
1
1
1
1
1
20
929312-800
BOLT, SOC HD GR12.8 12MM X 80M
4
4
4
4
4
21
301422
SWITCH, PRESSURE N.O. 30 PSI W
1
1
1
1
1
22
301331
COMPRESSOR, R.S. DD B101 NON G
1
1
1
1
1
23
301040
SWITCH, SAFETY SHUTDOWN N.O.
1
1
1
1
1
24
301421
SWITCH, PRESSURE N.C.
1
1
1
1
1
25
960204-025M
ELBOW, 1/4 X 1/4 37 DEG FL WITH H
1
1
1
1
1
26
960204-012
ELBOW, 1/4 JIC 90 DEG X 1/8 NPT
2
2
2
2
2
27
943102-038
RIVET, 1/8 X 3/8 LONG
4
4
4
4
4
28
301480
PLATE, SERIAL NO# - IMT SERIES
1
1
1
1
1
29
301401
FLANGE, COMPANION B101 IMT
1
1
1
1
1
30
932206-050
SCREW, SET 3/8 X 1/2
1
1
1
1
1
31
907602-005
BUSHING, REDUCING 1/2 X 1/8
1
1
1
1
1
32
301600
PLATE, SPACER COMP. MOUNTING I
1
1
1
1
1
33
301565
FOOT, COMP MTG B 101S
1
1
1
1
1
PN:301420: 20020328
PG-43: SERIES 60 ROTARY SCREW AIR COMPRESSOR
CONTINUED
20020328
18
17
28
27
37
DISCHARGE SYSTEM-20019 & 20031-DWG
PN:301420: 19991124
PG-44: SERIES 60 ROTARY SCREW AIR COMPRESSOR
DISCHARGE SYSTEM-20021-DWG
CONTINUED
PN:301420: 19991124
PG-45: SERIES 60 ROTARY SCREW AIR COMPRESSOR
DISCHARGE SYSTEM-20028 & 20032-DWG
CONTINUED
PG-46: SERIES 60 ROTARY SCREW AIR COMPRESSOR
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
PART NO.
937806-094
926006-337
938206-071
300023-200
906703-023
922212-100
907605-030
902915-010
300057
960204-025
961604-012
300716
960204-012
300715
960404-025
964804-025
960216-100
72053680
301466
300022-050
960408-050
301404
300331
301670
929806-125
906530-040
300108
DESCRIPTION
WASHER, LOCK 3/8 GRADE 8
NUT, HEX GR8 3/8-16
WASHER, FLAT 3/8
VALVE, RELIEF 1/2 NPT 200 LG
TEE, PIPE RED 3/4 X 1/2
NIPPLE, PIPE 3/4 X 10 SCH80
BUSHING, RED 1-1/4 X 3/4
PLUG, PIPE 1/4 RECESSED
VALVE, REGULATOR 1/4
ELBOW, 1/4 X 1/4 37° FL
NIPPLE, HEX RED 1/4 X 1/8
MUFFLER, EXHAUST 1/8
ELBOW, 1/4 JIC 90° X 1/8 NPT
VALVE, BLOWDOWN 1/8 NPT
NIPPLE, HEX 1/4 HYD
TEE, PIPE 1/4F X 1/4M X 1/4F
ELBOW, 1 x 1 37°
STRAIGHT 1 X 1 37°
CAP JIC 1” W/HOLE
VALVE, SERVICE 1/2 W/VENT
NIPPLE, HEX 1/2”
ORIFICE, MIN PRESSURE 1/2”
HEAD, COALESCER
COALESCER, SPIN-ON ELEMENT IMT
BOLT, HEX 3/8-16 X 1-1/4
ELBOW, PIPE 90° 1 X 1 HEA
PLUG, MAGNETIC 1/2 NPT
QTY QTY QTY
4
6
8
2
4
4
6
8
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
6
4
1
1
2
1
1
1
20031
20028
CONTINUED
20021
20019
DISCHARGE SYSTEM-PARTS
20032
PN:301420: 20020328
QTY QTY
4
8
4
4
8
1
1
1
1
1
1
1
1
4
4
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
4
2
1
PN:301420: 19990129
PG-47: SERIES 60 ROTARY SCREW AIR COMPRESSOR
DISCHARGE SYSTEM-PARTS (cont)
20
20
03
03
02
2
1
8
9
1
01
02
20
20
20
ITEM
PART
NUMBER
DESCRIPTION
QTY
QTY
QTY
QTY
QTY
27
906630-040
TEE, PIPE 1" HEAVY
1
1
1
1
1
28
300783
SIGHTGLASS, OIL LEVEL 1
1
1
1
1
1
29
300017
SUMP, 10 DISCHARGE
1
1
1
1
1
30
902915-040
PLUG, 1 HEX SOCKET
1
1
1
1
1
31
925305-283
NUT, WHIZLOCK 5/16-18
2
2
4
2
4
32
929105-250
BOLT, HEX GR5 5/16-18 X 2 1/2
2
2
2
2
2
33
300067
BAND, SUMP MTG 10
2
2
2
2
2
34
906530-030
ELBOW, PIPE 90 DEG 3/4" X 3/4" H
1
35
960116-100
CONNECTOR, 1 X 37 DEG FL
1
36
907603-015
BUSHING, REDUCING 3/4 X 3/8
1
1
37
922216-000
NIPPLE, PIPE 1 X CLOSE SCH80
1
1
38
960108-038
CONNECTOR, 3/8 NPT X 1/2 JIC M
1
1
39
301402
BRACKET, TANK TO FRAME IMT
2
40
300599
HEAD, OIL FILTER
1
1
1
41
300005
ELEMENT, OIL FILTER 8060
1
1
1
42
301487
GUARD, OIL FILTER
1
1
1
43
929104-050
BOLT, HEX GR5 1/4-20 X 1/2
2
2
2
44
938004-062
WASHER, LOC 1/4
2
2
2
45
922216-040
NIPPLE, 1 X 4 HVY
1
1
1
46
301601
SPACER, .44IN X 2.75 LG
4
4
47
929806-400
BOLT, HEX GR8 3/8-16 X 4
4
4
48
300625
BRACKET, COALESCER/OIL
1
1
49
929705-100
BOLT, WHIZLOCK GR5 5/16-18 X 1
2
2
50
922216-230
NIPPLE, PIPE 1" X 23
1
1
51
300068-1541
BRACKET, TANK MTG 15.41
2
2
52
929004-100
U-BOLT, W/1/1"-20 HEX NUTS X 1
1
1
1
1
2
1
2
PN:301420: 19990129
PG-48: SERIES 60 ROTARY SCREW AIR COMPRESSOR
PTO AND DRIVELINE SYSTEM-DWG
20019
20031 & 20032
20021
(200121, 200107, 200090)
CONTINUED
PN:301420: 19990129
PG-49: SERIES 60 ROTARY SCREW AIR COMPRESSOR
PTO AND DRIVELINE SYSTEM-DWG
20028
20028-05P
20028-10P
CONTINUED
PN:301420: 19990304
PG-50: SERIES 60 ROTARY SCREW AIR COMPRESSOR
PTO AND DRIVELINE SYSTEM-PARTS
2
0
01
2
9
0
0
2
21
0
0
2
28
0
2
0
2
0
0
02
02
31
8810
05
P
P
2
0
0
32
PN:301420: 19991124
PG-51: SERIES 60 ROTARY SCREW AIR COMPRESSOR
HARNESS-ELECTRICAL SYSTEM ( F-SUPERDUTY DIESEL/MNL & AUTO TRANS )
PN:301420: 19991124
PG-52: SERIES 60 ROTARY SCREW AIR COMPRESSOR
ELECTRICAL SYSTEM (F-SUPERDUTY DIESEL/MNL TRANS)
PN:301420: 19990129
PG-53: SERIES 60 ROTARY SCREW AIR COMPRESSOR
ELECTRICAL SYSTEM (F-SUPERDUTY DIESEL/AUTO TRANS)
PN:301420: 19990129
PG-54: SERIES 60 ROTARY SCREW AIR COMPRESSOR
MISC PARTS-BOX (6X6X12) F-450 ‘97’ DIESEL MNL TRANS
20019, 20031, & 20032
20021
PN:301420: 19990129
PG-55: SERIES 60 ROTARY SCREW AIR COMPRESSOR
BOLT BAG PARTS LOCATED IN BOX
20019 & 20031
20021
20028 & 20032
PN:301420: 19991221
PG-56: SERIES 60 ROTARY SCREW AIR COMPRESSOR
5, & 10 GPM PUMP OPTIONS FOR CRANE PACKAGES-DWG
PN:301420: 19991221
PG-57: SERIES 60 ROTARY SCREW AIR COMPRESSOR
5, & 10 GPM PUMP OPTIONS FOR CRANE PACKAGES-PARTS
ITEM
PART NO.
DESCRIPTION
QTY (5GPM)
QTY (10GPM)
1
301388
BELT GUARD
1
1
2
934502-050
SCREW, SELF TAP #10X1/2
4
4
3
301389
GUARD, TOP/BOTTOM BELT
2
2
4
939806-150
BOLT, 3/8-16X1-1/2 HHGR8
2
2
5
938206-071
WASHER 3/8 FLAT GR8
2
2
6
301393-036
SPROCKET 36T POLYCHAIN
1
7
301394-720
BELT 720MMX22MM POLYCHAIN
1
8
301029-075
BUSHING 3/4 SH
1
9
9301366
BRACKET-HYD PUMP MTG
1
1
10
301375
HYD PUMP .67CIR
1
1
11
937806-094
WASHER 3/8 LOCK GR8
2
2
12
926006-337
NUT 3/8-16 HEX GR8
2
2
13
972710-300
BOLT 10MMX30MM SH
4
4
14
938810-220
WASHER M10 LOCK
4
4
15
301393-056
SPROCKET 56T POLYCHAIN
16
300745-350
BUSHING 35MM X 10MM SDS
1
18
301393-048
SPROCKET 48T POLYCHAIN
1
19
300745-075
BUSHING 3/4 SDS
1
20
301393-064
SPROCKET 64T POLYCHAIN
1
21
301393-800
BELT 800MM X 22MM POLYCHAIN
1
22
80009
KIT-HYD BLOCK N.O. SOLENOID
1
1
23
929104-200
BOLT 1/4-20X2 HHGR5
2
2
24
938004-062
WASHER 1/4 LOCK GR5
2
2
25
938604-071
WASHER 1/4 FLAT
2
2
26
925204-226
NUT 1/4-20 HEX GR5
2
2
1
1
PN:301420: 19991124
PG-58: SERIES 60 ROTARY SCREW AIR COMPRESSOR
RECOMMENDED SPARE PARTS LIST
PART NUMBER
DESCRIPTION
QTY
300005
OIL FILTER ELEMENT
1
300854
AIR FILTER ELEMENT
1
301670
SPIN ON COALESCER
1
300187
REGULATOR REPAIR KIT
1
301409
SHAFT SEAL REPAIR KIT
1
300186-003 (used on 301010)
INLET VALVE REPAIR KIT
1
300186-004 (used on 301587)
INLET VALVE REPAIR KIT
1
PN:301420: 19990129
PG-59: SERIES 60 ROTARY SCREW AIR COMPRESSOR
SERVICE QUESTIONNAIRE
DATE: _______________
1. Information given by:
2. Information received by:
3. Has anyone helped you:
4.
5.
6.
7.
8.
Distributor:
End-User:
Phone Number:
Make and Model for PTO:
IMT 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:
Yes
No
PN:301420:
PG-60: SERIES 60 ROTARY SCREW AIR COMPRESSOR