Oshkosh Corporation IMT CAS80R Installation, Operation, Maintenance & Parts Manual Download Page 27 | Manualshive

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CAS80R

SECTION 4: OPERATION

Manual # 99905932 (February 2016)

PAGE - 21

®

IOWA MOLD TOOLING CO., INC.

(641) 923-3711 • www.imt.com

2. Ensure there are no obstructions of

cooling air intakes and outlets
around the unit.

3. Do not leave anything resting on top

of the machine. Hot cooling air will
generate high heat and must not be
restricted.

4. Be sure to leave sufficient room

around the unit for cooling air
circulation. A minimum of ten (10)
inches clearance is needed for the
cooler intake and sides, and ten (10)
inches for the rear of the unit.
Heated air must be able to vent
away from the intake.

5. Operate machine with top cover

closed.

6. Refer to specifications for operating

parameters.

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Summary of Contents for IMT CAS80R

Page 1: ...1 923 6063 www imt com KEEP THE MANUAL WITH THE VEHICLE Read this manual before installing operating or servicing this equipment Failure to comply with the operation and maintenance instructions in th...

Page 2: ...NOTICE TO CUSTOMER This manual is the final version and some of the information and specifications are subject to change without notice...

Page 3: ...NT CHARACTERISTICS 6 TABLE 2C BOLT AND TORQUE SPECIFICATIONS 6 SECTION 3 INSTALLATION 7 3 1 MACHINE PACKAGE RECEIPT INSPECTION 7 3 2 GENERAL INSTRUCTIONS 7 3 3 DETERMINING THE IMT UNIT MOUNTING LOCATI...

Page 4: ...ROUTING 14 SECTION 4 OPERATION 17 4 1 GENERAL INFORMATION 17 4 2 PURPOSE OF CONTROLS 17 4 3 INITIAL START UP PROCEDURE 19 4 4 ROUTINE START UP PROCEDURE 19 4 5 COLD WEATHER START UP PROCEDURE 20 4 6 R...

Page 5: ...6B FRAME AND CANOPY ACCESS DOOR 43 7 6C FRAME AND CANOPY ROOF PANEL 43 7 6D FRAME AND CANOPY BACK SIDE PANEL 44 7 6E FRAME AND CANOPY COMPRESSOR SIDE PANEL 44 7 6F FRAME AND CANOPY HYDRAULIC DRIVE FRA...

Page 6: ...TABLE OF CONTENTS CAS80R PAGE IV Manual 99905932 February 2016 BLANK PAGE IOWA MOLD TOOLING CO INC 641 923 3711 www imt com...

Page 7: ...ssor or any of its systems if there is a known unsafe condition Disable the equipment by disconnecting it from its power source Install a lock out tag to identify the equipment as inoperable to other...

Page 8: ...ssume that because the compressor is in a STOPPED condition that hydraulic power has been removed Use this compressor only to compress atmospheric air Use of this equipment as a booster pump and or to...

Page 9: ...n present a hazard to operators or service personnel All pertinent decals listed in Section 7 9 Decal Locations are located near a component which is subject to respect in terms of safety precautions...

Page 10: ...SECTION 1 SAFETY CAS80R PAGE 4 Manual 99905932 February 2016 BLANK PAGE IOWA MOLD TOOLING CO INC 641 923 3711 www imt com...

Page 11: ...Standard 24V Optional Electrical connections 4 pin Deutsch Supply connections customer hook up Hydraulic Oil In 3 4 in 37 JIC Hydraulic Oil Out 1 in 37 JIC Electrical 12V DC Positive and Ground Standa...

Page 12: ...arks No markings 3 lines 5 lines 6 lines Allen head Material Low carbon S S Medium carbon tempered Medium carbon quenched tempered Medium carbon quenched tempered High carbon quenched tempered Tensile...

Page 13: ...ection 3 10 The location must allow for the machine dimensions Figure 3 4 and additional space requirements for minimum cooling access and maintenance Refer to Figure 3 4 to determine the minimum spac...

Page 14: ...re two types of mounting locations to consider open mounting and enclosed mounting Figure 3 1 Open mounting refers to machine placement location on the service body whereby the machine is directly exp...

Page 15: ...LIC REQUIREMENTS The hydraulic pump must be rated for 2 900 psi consistent operation and 3 300 psi for pressure spikes The compressor capacity will depend on hydraulic oil flow If the compressor is be...

Page 16: ...or case drain flow onto main return line Pump failure caused by cavitation of the circulating fluid and motor seal breakdown due to excess return line pressure can occur if proper allowances are not t...

Page 17: ...ERVOIR SHAPE The reservoir structure should be tall and narrow rather than shallow and broad Figure 3 3 A tall narrow tank is recommended because 1 The oil level is well above suction line opening avo...

Page 18: ...ptor or housing which does not protrude above the inner surface of the floor of the tank It should be visible and accessible for removal with sufficient space available for catching the waste oil If t...

Page 19: ...with the main reservoir oil volume A reservoir heater For those systems that are exposed to cold climate ambients having the ability to preheat the hydraulic oil prior to start up will make for easie...

Page 20: ...12V DC or 24V DC negative ground Refer to Section 7 10 Wiring Diagram 3 10 6 HYDRAULIC SUPPLY CIRCUIT It is recommended that the compressor unit possesses a separate pump flow return hydraulic circui...

Page 21: ...CAS80R SECTION 3 INSTALLATION Manual 99905932 February 2016 PAGE 15 IOWA MOLD TOOLING CO INC 641 923 3711 www imt com Figure 3 4 Dimensions 051168_r0...

Page 22: ...SECTION 3 INSTALLATION CAS80R PAGE 16 Manual 99905932 February 2016 BLANK PAGE IOWA MOLD TOOLING CO INC 641 923 3711 www imt com...

Page 23: ...ly monitors service line discharge air temperature Will activate shut down if over pressure occurs Discharge Air Temperature Temperature Gauge Continuously monitors service line discharge temperature...

Page 24: ...W X A B G M G F B L K J H E C A ITEM DESCRIPTION J COMPRESSOR OIL LEVEL SIGHT GLASS K CIRCUIT BREAKERS L INSTRUMENT PANEL M COOLER N COOLER FAN ITEM DESCRIPTION P COMPRESSOR OIL DRAIN A AIR FILTER HO...

Page 25: ...ture gauge for ideal operating temperature which should be between 165 F and 190 F 11 Cycle compressor on off with service valve to ensure proper operation 12 Close the service valve 13 Disengage hydr...

Page 26: ...oil time to warm up for proper lubrication of the compressor and to allow the moisture to be evacuated from the compressor and compressed air lines 4 At this time the compressor unit can be used as i...

Page 27: ...on top of the machine Hot cooling air will generate high heat and must not be restricted 4 Be sure to leave sufficient room around the unit for cooling air circulation A minimum of ten 10 inches clear...

Page 28: ...SECTION 4 OPERATION CAS80R PAGE 22 Manual 99905932 February 2016 BLANK PAGE IOWA MOLD TOOLING CO INC 641 923 3711 www imt com...

Page 29: ...TE It is important to keep in mind that operating the compressor package in a severe environment may require more frequent service intervals than prescribed in the periodic maintenance schedule WARNIN...

Page 30: ...your local IMT representative or where the compressor system was purchased If for any reason parts are not available in this manner they can be purchased through IMT directly 5 4 PARTS REPLACEMENT AN...

Page 31: ...if necessary 3 After starting check pressure gauge for correct operating pressure 4 Check for leaks WARNING When tightening hoses or fittings make sure unit it shut off WARNING Never use hand to check...

Page 32: ...itched OFF since electrical terminals inside pressure regulator will be exposed and opening the canopy exposes the belt drive system WARNING Before performing maintenance Shut down machine relieve all...

Page 33: ...cation Although the pressure relief valve has a reset ring at the cap DO NOT test the pressure relief valve by pulling on the reset ring The pressure relief valve requires no safety testing 5 4 3 LONG...

Page 34: ...SECTION 5 MAINTENANCE CAS80R PAGE 28 Manual 99905932 February 2016 BLANK PAGE IOWA MOLD TOOLING CO INC 641 923 3711 www imt com...

Page 35: ...hould be performed first Always remember to 1 Check for loose wiring 2 Check for damaged piping 3 Check for parts damaged by heat or an electrical short circuit usually noticeable by discoloration or...

Page 36: ...nes for leaks or open valves Too much air demand Dirty air filter Check the filter and clean or change element if required Pressure regulator out of adjustment DO NOT ATTEMPT TO ADJUST Contact the IMT...

Page 37: ...pressure valve and adjust Replace if necessary Defective coalescer Replace coalescer element Overspeeding Readjust speed Incorrect oil used Drain and replace with proper oil Compressor overheating Che...

Page 38: ...a momentary drop in supply hydraulic supply pressure flow may initiate compressor blowdown to commence Check setting on supply pressure system relief valve Check to ensure adequate pressure flow Check...

Page 39: ...y at the address or phone numbers below When ordering parts always indicate the Serial Number of the machine package This can be obtained from the Bill of Lading for the machine package or from the co...

Page 40: ...ter 1 coalescer 1 PLEASE NOTE WHEN ORDERING PARTS ALWAYS INDICATE MACHINE SERIAL NUMBER IMPORTANT IMPORTANT IMPORTANT NOTE Use only approved oil and genuine IMT parts Inspect damaged components before...

Page 41: ...PARTS LIST Manual 99905932 February 2016 PAGE 35 IOWA MOLD TOOLING CO INC 641 923 3711 www imt com TABLE 7B MAINTENANCE TRACKING LOG DATE DESCRIPTION OF MAINTENANCE PART S REPLACED DATE DESCRIPTION OF...

Page 42: ...CAS80R SECTION 7 ILLUSTRATED PARTS LIST PAGE 36 Manual 99905932 February 2016 IOWA MOLD TOOLING CO INC 641 923 3711 www imt com 7 2A COMPRESSOR ASSEMBLY AND REPLACEMENT PARTS 6180007ID_r0...

Page 43: ...PSI 77041959 1 29 CAPSCREW HX SOC 5 16 18 x 3 3 9 ELBOW 1 4T x 1 8P PUSH ON 1 30 VALVE INLET 1 5 VMC RH38 1 10 ELBOW 90 DEG PUSH ON 1 4T x 1 4P 1 31 TUBE SCAVANGE 0 25 COMPRESSOR 1 11 CONNECTOR 1 8P x...

Page 44: ...3711 www imt com 7 2B COMPRESSOR AND MOUNTING PARTS KEY NO DESCRIPTION PART NUMBER QTY 1 AIREND ATT VSE075GD22 70734925 1 2 PLUG PIPE 1 2 1 3 NUT HEX LOCKING 3 8 16 3 4 CAPSCREW HEX GR 9 3 8 16 x 1 3...

Page 45: ...HEX GR8 1 2 13 1 75 2 5 WASHER LOCK 1 2 2 PLEASE NOTE WHEN ORDERING PARTS INDICATE MACHINE SERIAL NUMBER 7 3B CLOSED CENTER AND HYDRAULIC THERMAL VALVE KEY NO DESCRIPTION PART NUMBER QTY 1 ELBOW 90 DE...

Page 46: ...2VDC 24VDC KEY NO DESCRIPTION PART NUMBER QTY 1 CONNECTOR 12 MSAE x 12 MJIC 2 2 ELBOW 90 DEG 16 MJIC x 16 MSAE 2 3A COOLER COMPR AND HYD WITH FAN 12V DC 73052172 1 3B COOLER COMPR AND HYD WITH FAN 24V...

Page 47: ...UTDOWN 70734663 1 3 ELBOW 90 DEG PUSH ON 1 4T x 1 4P 2 4 CONNECTOR 1 4P x 1 4T PUSH ON 1 5 GAUGE AIR PRESSURE w SWITCH 70048247 1 6 BOOT RUBBER RESET SWITCH 77040596 1 7 GAUGE TEMP MURPHY 6 1 2 714171...

Page 48: ...ER QTY 1 WASHER NYLON 5 16 18 26 2 SCREW TRUSS HD 5 16 18 x 3 4 SS 26 3 PANEL END COOLER SIDE NEW IMT 71416165 1 4 PANEL GAUGE SIDE 71416166 1 5 DOOR ACCESS 71416167 1 6 PANEL ROOF CANOPY CAS80R 71416...

Page 49: ...S INDICATE MACHINE SERIAL NUMBER 6030089ID A_r0 6030089ID C_r0 6030089ID B_r0 7 6B FRAME AND CANOPY ACCESS DOOR KEY NO DESCRIPTION PART NUMBER QTY 1 LATCH SENTRY PANEL 51724525 1 2 DOOR ACCESS IMT CAS...

Page 50: ...ERIAL NUMBER KEY NO DESCRIPTION PART NUMBER QTY 1 WASHER NYLON FLAT 1 4 2 2 ROD ROOF SUPPORT NEW ADHD 71416179 1 3 CLIP PROP ROD 72661754 1 4 PANEL 1 ACOUSTICAL FOAM 11 75 x 15 75 71416160 1 5 PANEL 1...

Page 51: ...2 3 FRAME IMT CAS80R 71416177 1 4 BAIL LIFTING IMT 70734926 1 5 BRACKET SERV AIR ASSY 70734927 1 6 BRACKET MOUNTING RELAY BREAKER IMT 71416178 1 7 NUT HEX LOCKING 3 8 16 4 8 CAPSCREW HEX GR8 3 8 16 x...

Page 52: ...2 PLUG SAE O RING HOLLOW HEX 8 1 3 PLUG SAE O RING HOLLOW HEX 16 1 4 TEE RUN 16 MSAE x 16 MJIC 1 5 MANIFOLD HYD OPEN CENTER 25 GPM 3000PSI COMPLETE 73540547 1 5A BLOCK 71416181 1 5B RELIEF 71416182 1...

Page 53: ...WIVEL 16 1 6 MANIFOLD HYD OPEN CENTER 25 GPM 3000 PSI COMPLETE 1 6A BLOCK 1 6B RELIEF 1 6C SOLENOID 1 6D 12V COIL 1 6E 24V COIL 1 7 FLAT SHIM HYDRAULIC MANIFOLD IMT 1 8 MANIFOLD HYDRAULIC THERMAL RELI...

Page 54: ...ESCRIPTION PART NUMBER QTY 1 ELBOW 90 DEG 12 MJIC x 12 MSAE 1 2 TEE JIC JIC SAE 12 1 3 VALVE THERMAL 180 DEGREE ALUM BODY 3 4 SAE 73540546 1 4 BRACKET SUPPORT THERMAL VALVE 71416180 1 5 NUT HEX LOCKIN...

Page 55: ...that becomes damaged or illegible KEY NO DESCRIPTION PART NUMBER QTY 1 DECAL CAP AND PLUG REMOVAL 1 2 DECAL ROTATING PARTS 1 3 DECAL DO NOT USE AIR 1 4 DECAL HOT PARTS 1 5 DECAL AIR HOSE 1 6 DECAL RE...

Page 56: ...ety decal that becomes damaged or illegible KEY NO DESCRIPTION PART NUMBER QTY 10 DECAL HYDRAULIC RETURN 1 11 DECAL FAN GUARD 1 12 DECAL 12V DC 1 13 DECAL HYDRAULIC SUPPLY 1 14 DECAL AIR DISCHARGE 1 1...

Page 57: ...CAS80R SECTION 7 ILLUSTRATED PARTS LIST Manual 99905932 February 2016 PAGE 51 IOWA MOLD TOOLING CO INC 641 923 3711 www imt com 7 10 WIRING DIAGRAM 273632_r0...

Page 58: ...CAS80R SECTION 7 ILLUSTRATED PARTS LIST PAGE 52 Manual 99905932 February 2016 IOWA MOLD TOOLING CO INC 641 923 3711 www imt com 7 11 SCHEMATIC HYDRAULIC OIL FLOW OPEN CENTER 273630_r1...

Page 59: ...ww imt com 7 12 SCHEMATIC HYDRAULIC OIL FLOW OPEN CENTER COLD WEATHER 274602_r0 TRUCK SYSTEM COMPRESSOR HYDRAULICS MACHINE END PANEL RETURN PRESSURE SOLENOID VALVE PRESSURE RELIEF VALVE PRESSURE MOTOR...

Page 60: ...016 IOWA MOLD TOOLING CO INC 641 923 3711 www imt com 7 13 SCHEMATIC COMPRESSOR OIL AIR FLOW 1 OF 2 274445_r3 1 of 2 MACHINE CANOPY PANEL ROTARY SCREW COMPRESSOR COMPRESSOR COOLER THERMAL VALVE COMPRE...

Page 61: ...ED PARTS LIST Manual 99905932 February 2016 PAGE 55 IOWA MOLD TOOLING CO INC 641 923 3711 www imt com 7 13 SCHEMATIC COMPRESSOR OIL AIR FLOW 2 OF 2 274445_r3 2 of 2 REGULATOR VALVE BLOWDOWN VALVE P DI...

Page 62: ...N 7 ILLUSTRATED PARTS LIST PAGE 56 Manual 99905932 February 2016 IOWA MOLD TOOLING CO INC 641 923 3711 www imt com 7 14 HOSE AND TUBING OPEN CENTER SYSTEM 6130110ID_r1 3 1 5 9 8 6 7 4 10 12 19 14 11 1...

Page 63: ...TO MOTOR IN 71416186 1 7 TUBE 3 4 O D COMP OIL PICK UP TO THERMAL 71416187 1 8 TUBE MANIFOLD TO MOTOR RETURN 71416188 1 9 TUBE 1 00 O D HYD COOLER RETURN TO BULKHEAD 71416189 1 10 TUBE 3 4 AIR DISCHA...

Page 64: ...LUSTRATED PARTS LIST PAGE 58 Manual 99905932 February 2016 IOWA MOLD TOOLING CO INC 641 923 3711 www imt com 7 15 HOSE AND TUBING OPEN CENTER COLD WEATHER SYSTEM 6130116ID_r1 3 8 6 7 5 1 9 2 4 17 16 1...

Page 65: ...IN 71416186 1 6 TUBE 3 4 O D COMP OIL PICK UP TH THERMAL 71416187 1 7 TUBE 3 4 AIR DISCHARGE 71416190 1 8 TUBE 3 4 THERMAL VALVE TO OIL FILTER INJECTION 71416191 1 9 TUBE 1 00 O D THERMAL BLOCK TO COO...

Page 66: ...BLANK PAGE...

Page 67: ...BLANK PAGE...

Page 68: ...cations Subject to Change Without Prior Notice 051168 051282 051283 051284 090079 OP_r0 An Oshkosh Corporation Company IOWA MOLD TOOLING CO INC 500 Highway18 West Garner Iowa 50438 Phone 641 923 3711...

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