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IMT CAS40PL, Инструкция по эксплуатации и список запасных частей

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SECTION 7: ILLUSTRATED PARTS LIST

7 - 30 

 99906549 rev 00 (JANUARY-2020)

 

CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW

IOWA MOLD TOOLING CO., INC.

(641) 923-3711

WIRING DIAGRAM TO BE USED
WITH HARNESS (CONSULT
SERVICE DEPT.)

11

10 AMP

INLINE FUSE

1

1

30

87

N.O.

87A N.C.

85

86

2

FAN

RELAY

3

FAN

M OTOR

BLUE
BLACK

LIVE FEED MUST BE
CONNECTED TO "A"
TERM INAL ON CONN ECTOR

17

5

HO UR METER

14

4

7

+

-

16

PRESS URE SWITCH

6 PIN

CONNECTOR

9

6

30

87

N.O.

87A N.C.

85

86

SAFETY

RELAY

NC

NO

C

1

2

4

N

G

20

21

3A

19

12

15

8

16A

MANIFOLD BLOCK

VALVE (ON - OFF )

N.O. HYDRAULIC SOLENOID

1

2

A

B

GROUND STUD

F

B

C

D

E

A

30 AMP JCASE STYLE FUSE

12/24 VDC BATTERY SUPPLY

F

B

C

D

E

A

18

MACHINE

ACTIVATION

CIRCUIT

SYSTEM GROUND

AUXILIARY CIRCUIT

SYSTEM GROUND

6 PIN

CONNECTOR

DIODE 6AMP IN-LINE

1

22

13

10

3

5

18

17

7.19   WIRING DIAGRAM

279501_r1

Ref Harness: 279500_r1

Содержание CAS40PL

Страница 1: ...and maintenance in structions in this manual will VOID THE EQUIPMENT WARRANTY NOTE This publication contains the latest information available at the time of preparation Every e ort has been made to en...

Страница 2: ...BLANK PAGE...

Страница 3: ...DECALS 1 3 1 5 DISPOSING OF MACHINE FLUIDS 1 3 SECTION 2 SPECIFICATIONS 2 2 Figure 2 1 Machine Main Component Locations 2 1 2 1 GENERAL INTRODUCTION 2 2 TABLE 2A SPECIFICATIONS 2 2 TABLE 2B CAPSCREW...

Страница 4: ...4 RECOMMENDED RESERVOIR OPTIONS 3 7 3 4 2 5 RESERVOIR FEATURES TO AVOID 3 8 3 4 2 6 RECOMMENDED HYDRAULIC SYSTEM SPECIFICATIONS 3 8 3 4 3 STANDARDS GUIDELINES 3 8 3 5 INSTALLATION 3 8 3 5 1 MACHINE LO...

Страница 5: ...LACEMENT KITS 5 3 5 4 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES 5 5 5 4 1 REMOVING PANELS FOR MACHINE MAINTENANCE ACCESS 5 5 5 4 1 1 REMOVING LONG SIDE PANELS FOR MAINTENANCE ACCESS 5 5 5 4 1 2 REPL...

Страница 6: ...CONTROL 7 8 7 6 MOTOR AND DRIVE PARTS 7 9 7 7 HYDRAULIC COOLER PARTS 12V WITH THRML GAUGES 7 10 7 8 HYDRAULIC COOLER PARTS 24V WITH THRML GAUGES 7 12 7 9 FRAME AND CANOPY 1 OF 3 ASSEMBLY PART A 7 14 7...

Страница 7: ...ILLUSTRATED PARTS LIST CONTINUED 7 17 HYDRAULIC THERMAL VALVE ASSEMBLY 7 28 7 18 ELECTRICAL SCHEMATIC 7 29 7 19 WIRING DIAGRAM 7 30 7 20 HYDRAULIC OIL FLOW SCHEMATIC DIAGRAM OPEN CENTER WITH THERMAL V...

Страница 8: ...TOC VI 99906549 rev 00 JANUARY 2020 TABLE OF CONTENTS IOWA MOLD TOOLING CO INC 641 923 3711 CAS40PL CAS40PL CW CAS40PLE CAS40PLE CW BLANK PAGE...

Страница 9: ...severe injury or equipment damage or destructive malfunctions Keep tools or other conductive objects away from live electrical parts Never touch electrical wires or components while the machine is ope...

Страница 10: ...icable codes Pressurized broken or disconnected hoses can whip causing injuries or damage DO NOT use tools hoses or equipment that have maximum ratings below that of this com pressor Keep metal tools...

Страница 11: ...box titled with an IMPORTANT banner as shown below and may also contain the WARNING symbol should the information be linked to a safety issue IMPORTANT Additional CRUCIAL information or existing infor...

Страница 12: ...PRESSOR OIL DRAIN HOSE Z RELIEF VALVE J COOLER FAN FAN MOTOR AA SOLENOID K CONTROLLER BB1 INSTRUMENT PANEL DIGITAL DISPLAY L HYDRAULIC MOTOR BB2 INSTRUMENT PANEL GAUGE DISPLAY M1 CLOSED CENTER functio...

Страница 13: ...0 2575 2600 2300 2470 2550 2600 NOTE Compressor adjustment should be set in accordance with rated RPMs I 30 CFM 690 COMPRESSOR RPM II 40 CFM 1100 COMPRESSOR RPM COMPRESSOR GENERAL SYSTEM INFORMATION S...

Страница 14: ...omatic load control 12 or 24V Air pressure switch for automatic load control Pre set at factory TABLE 2B CAPSCREW TIGHTENING TORQUE VALUES SIZE GRADE LUBRICATED 1 4 20 UNC 5 6 ft bs 5 16 18 UNC 5 13 f...

Страница 15: ...such as electrical and hydraulic power supply availability and location DISCLAIMER DO NOT install in any enclosed space without first contacting IMT WARNING Install operate and maintain this equipmen...

Страница 16: ...EW IMPORTANT IMT highly recommends consulting a hydraulic supply expert for specifying the correct hydrau lic supply components for vehicle side integra tion including oil reservoir size hydraulic pre...

Страница 17: ...17 12 09 6 54 7 45 1 2 13 UNC NU T 8 PLACES 3 51 23 48 21 25 1 00 30 50 18 44 NOTES 1 DECAL AREA SHOWN IN DASHED LINES Figure 3 1 Installation and Dimensions Diagram Open Center 12VDC 051665ID_r0 DISC...

Страница 18: ...OWN IN SINGLE LENGTH DASHED LINES PRESSURE GAUGE HOUR METER OR CONTROLLER DISPLAY 1 2 13 UNC NUT 8 PLACES Figure 3 2 Installation and Dimensions Diagram Open Center 12V No Thermal Valve 051787_r2 DISC...

Страница 19: ...ALTERNATE LID HINGE DIRECTION 21 00 3 51 23 48 18 44 1 40 1 00 1 2 13 UNC NUT 8 PLACES 30 50 NOTES 1 DECAL AREA SHOWN IN SINGLE LENGTH DASHED LINES Figure 3 3 Installation and Dimensions Diagram Open...

Страница 20: ...turn flow well below the surface so it does not break the surface and cause aer ation cavitation of the oil 3 4 2 3 MANDATORY RESERVOIR FEATURES The reservoir should incorporate the following design f...

Страница 21: ...e is needed to protect the system against contaminants be ing introduced into the oil The filter should be mounted externally from the reservoir in a lo cation that allows for easy of service access A...

Страница 22: ...ne so that there is no restriction of cooling air through the enclosure Refer to Figure 3 3 Cooling air enters the en closure at the rear cooler package end of the machine passes through the cooler an...

Страница 23: ...stem schematic layouts and components The following requirements should be taken into con sideration before installing the hydraulic system The hydraulic flow and pressure requirements of the air comp...

Страница 24: ...pliant to applicable stan dards 200 psig minimum Supplied with an adequately rated relief valve Supplied with moisture drain CONNECTION HOSING AND SERVICE VALVE SPECIFICATIONS Hose must be flexible st...

Страница 25: ...ified operating settings The crankcase has been factory filled but the oil needs to be checked in order to ensure propper level before initial start up Note also that vehilce needs to be parked on lev...

Страница 26: ...ly or return leaks and correct if required 5 Allow air pressure to build up in the receiver tank 6 Move the PTO ON OFF switch to the OFF position NOTE Ensure that the service valve is closed and compr...

Страница 27: ...his screen shows the preset cut in and cut out pressures for the range of operation These pres sures can be adjusted by pressing the Up or Down arrows Note that when adjusting the Cut in Cut out press...

Страница 28: ...utes 3 Shut o hydraulic power supply 4 4 EXTREME CONDITION OPERATION When operating in extreme hot or cold conditions extra attention should be given to any indications that could lead to a serious pr...

Страница 29: ...ment while it is operating WARNING DO NOT touch electrical wires wire harnesses terminals or other components when power is applied to the compressor unit WARNING Keep metal tools and other conductive...

Страница 30: ...ne maintenance or replacement parts consult Section 7 1 Parts Ordering Pro cedure and Table 7A Recommended Spare Parts List 5 3 REPLACEMENT PARTS Replacement parts should be purchased through your loc...

Страница 31: ...e 7A for full replacement parts listing including separate components non routine items and options PLEASE NOTE WHEN ORDERING PARTS INDICATE MACHINE SERIAL NUMBER Daily Maintenance Weekly Maintenance...

Страница 32: ...ing including separate components non routine items and options PLEASE NOTE WHEN ORDERING PARTS INDICATE MACHINE SERIAL NUMBER Daily Maintenance Weekly Maintenance Every 500 Hours or Annually KEY TASK...

Страница 33: ...ent clean when performing maintenance or service actions Cover open ings to prevent contamination NOTE When using compressed air to clean the com ponents the nozzle pressure should not exceed 15 PSIG...

Страница 34: ...cting the oil level ensure that the oil fill sight glass does not contain any cracks or pits The compressor is fully charged at the facto ry with IMT Reciprocating Compressor Oil This section gives de...

Страница 35: ...ately every 500 operating hours or sooner depending upon inspection Plugged air filters can cause high oil consumption and reduced delivery quantity Change the filter more often when running in dusty...

Страница 36: ...nt element available within kit no 71417220 Once obtained refer to Figure 5 3 and the following procedure to service the air filter 1 Review the safety guidelines in Section 5 4 4 then follow steps 1...

Страница 37: ...ring the motor to the unit via the motor adapter However in the case where the coupling ele ment needed to be replaced or if the alignment is such that there is excessive machine vibration etc there i...

Страница 38: ...oupling assembly 4 Remove the spider coupling element 5 Carefully wipe the coupling halves with a clean cloth and place the new element into position on the compressor coupling half 6 Re insert the mo...

Страница 39: ...Figure 5 6 5 4 7 3 HUB ALIGNMENT CHECK To ensure alignment refer to Figure 5 6 and the following procedure 1 Place a straight edge square on the outer di ameter of both halves in locations 90 apart T...

Страница 40: ...always be aware of the safety warnings given in Section 1 Safety WARNING Before performing maintenance Shut down machine relieve all system pres sure and lock out all power as per the Safety Section o...

Страница 41: ...ain valve on the tank Cover with a waterproof secured tarp or plastic sheet to prevent the accumulation of dust but leave the bottom open for air circulation The covering should allow for easy removal...

Страница 42: ...5 14 99906549 rev 00 JANUARY 2020 SECTION 5 MAINTENANCE IOWA MOLD TOOLING CO INC 641 923 3711 CAS40PL CAS40PL CW CAS40PLE CAS40PLE CW BLANK PAGE...

Страница 43: ...The procedures which can be performed in the least amount of time and with the least amount of re moval or disassembly of parts should be per formed first Always remember to 1 Check for loose wiring 2...

Страница 44: ...ion 7 18 and 7 19 Low hydraulic flow pressure Check and reset Refer to Sections 7 11 and 7 12 for flow regulator location and replacement info Hydraulic motor or pump worn Replace Low hydraulic oil le...

Страница 45: ...relief valve s open con tinuously Defective air pressure gauge Refer to Section 5 4 2 and Section 7 5 Replace if neces sary Damaged worn or leaking valve Replace valve Pressure switch set too high Ma...

Страница 46: ...r Worn piston rings Replace rings Piston rings incorrectly installed Reinstall Worn or scored cylinder Replace cylinder and rings Knocking sound from compressor Crankcase oil level low Check refill to...

Страница 47: ...ct the factory directly at the address or phone numbers below When ordering parts always indicate the Serial Number of the machine package This can be obtained form the Bill of Lading for the machine...

Страница 48: ...f 65 PSI low pressure 71417228 1 13 Valve Relief 200 PSI high pressure 73540467 1 14 Element Drive Coupling Replacement 71417229 1 15 Kit Isolator 71417230 1 16 Valve Solenoid Replacement IV 1 17 Regl...

Страница 49: ...ide to replacement parts damage may occur to the machine beyond the scope of this listing Should any part of the compressor package that is not listed in Table 7A become damaged or inoperable use the...

Страница 50: ...RICATE ALL ELASTOMERIC SEALS GASKETS O RINGS BEFORE TIGHTENING 3 ALL BOLTS TO BE TORQUED TO THEIR RESPECTIVE SAE TORQUE SPECIFICATIONS FOR THEIR GRADES AND SIZES UNLESS OTHERWISE SPECIFIED HIGH PRESSU...

Страница 51: ...EE 1 4 NPT MALE BRANCH 1 4 ORIFICE FILTER 032 DIA 1 4 FPT X 1 4 MPT 1 5 WASHER LOCK 1 2 GRADE 8 4 6 VALVE CHECK MANIFOLD 60CFM 450F 1 7 COMPRESSOR PARTS DD AL 1 8 EYE LIFTING COMPRESSOR 1 9 HOSE COMPR...

Страница 52: ...ED PARTS LIST 7 6 99906549 rev 00 JANUARY 2020 CAS40PL CAS40PL CW CAS40PLE CAS40PLE CW IOWA MOLD TOOLING CO INC 641 923 3711 PRESSURE RELIEF 200 TO 217 PSIG 15 BAR PRESSURE RELIEF 65 PSIG 7 3 COMPRESS...

Страница 53: ...N559 1 14 TUBE MID STAGE COOLING 1 5 HOUSING BELL HYD MOTOR TO COMPRESSOR 1 15 GASKET DISCHARGE AFTERCOOLER 1 6 HUB COUPLING COMPRESSOR DD 1 16 VALVE RELIEF 65 PSI 1 4 NPT MALE 1 7 SPIDER COUPLING DD...

Страница 54: ...IC 1 6 PANEL GAUGE ELECTRONIC REAR 1 PLEASE NOTE WHEN ORDERING PARTS INDICATE MACHINE SERIAL NUMBER POS AND NEG ARE INTERCHANGEABLE NOTES 1 USE LOCTITE 567 THREAD SEALANT WITH PTFE OR EQUIVALENT SEALA...

Страница 55: ...T SCREW SUPPLIED WITH COMPRESSOR ASSEMBLY 7 6 MOTOR AND DRIVE PARTS 6100242ID_r1 ITEM DESCRIPTION PART NUMBER QTY 1 ELBOW 90 DEG 8 MJIC x 12 MSAE 1 2 ELBOW 90 DEG 4 MJIC x 6 MSAE 1 3 TEE JIC JIC SAE 1...

Страница 56: ...RAME CANOPY DRAWING 6020235 12V W THRML SHOWN TABULATED ASSEMBLIES PART NUMBER DESCRIPTION ITEM A DESCRIPTION ITEM B DESCRIPTION ITEM C DESCRIPTION HYDRAULIC COOLER PARTS 12V W THRML RELAY NO NC WEATH...

Страница 57: ...T SENSOR MOUNTING 1 5 BRACKET COOLER MOUNTING LEFT 1 6 KIT ACOUSTICAL INSULATION 2 7 BUSHING PIPE BRASS 1 4 x 1 8 1 8 NUT HEX FLANGE 1 4 20 2 9 NUT HEX FLANGE 5 16 18 6 10 NUT HEX LOCKING 5 16 18 4 11...

Страница 58: ...LR PRTS 12V W THRML GAUGES RELAY NO NC WHTRPRF 12V w BKT RSTR TEE MJIC MJIC ORNG RUN 3 4 CLR OIL ASSY HYD CLR PRTS 24V W THRML GAUGES RELAY NO NC 24V WHTRPRF 20 AMP TEE MJIC MJIC ORNG RUN 3 4 CLR OIL...

Страница 59: ...1 4 NPT 1 5 BRACKET COOLER MOUNTING RIGHT 1 6 BRACKET SENSOR MOUNTING 1 7 BRACKET COOLER MOUNTING LEFT 1 8 KIT ACOUSTICAL INSULATION 2 9 ELBOW PIPE STREET 1 4 1 10 NUT HEX FLANGE 1 4 20 3 11 NUT HEX F...

Страница 60: ...99906549 rev 00 JANUARY 2020 CAS40PL CAS40PL CW CAS40PLE CAS40PLE CW IOWA MOLD TOOLING CO INC 641 923 3711 NOTE THIS END TO LID FASTEN WITH BLUE LOCTITE ZIP TIE HARNESS HERE 7 9 FRAME AND CANOPY 1 OF...

Страница 61: ...SPACER 313ID X 0 75OD X 0 375L 2 2 WASHER NYLON FLAT 1 4 22 3 SCREW TRUSS 1 4 20 X 3 4 SS 22 4 GAS SPRING 6 STROKE 20 1 5 CAPSCREW HEX GR5 1 4 20 x 0 75 3 6 CAPSCREW HEX GR5 1 4 20 x 1 2 7 SCREW SER...

Страница 62: ...ASKET SEAL AND TRIM 1 333 ft PLEASE NOTE WHEN ORDERING PARTS INDICATE MACHINE SERIAL NUMBER INSTALL FOR MODELS USING MECHANICAL GAUGES ONLY 2x DEFAULT INSTRUMENT PANEL LOCATION 2x 2x 4x 4x 2x ITEM DES...

Страница 63: ...3 4 1 PLEASE NOTE WHEN ORDERING PARTS INDICATE MACHINE SERIAL NUMBER ITEM DESCRIPTION PART NUMBER QTY 1 PANEL COOLER SIDE 1 2 KIT ACOUSTICAL INSULATION 1 3 NUT HEX LOCKING 5 16 18 UNC 1 4 STUD BALL 39...

Страница 64: ...3 3711 NOTES 1 LUBRICATE ALL ELASTOMERIC SEALS GASKETS O RINGS BEFORE TIGHTENING 2 ALL BOLTS TO BE TORQUED TO THEIR RESPECTIVE SAE TORQUE SPECIFICATIONS FOR THEIR GRADES AND SIZES UNLESS OTHER WISE SP...

Страница 65: ...DRAULIC SOFT SHIFT 1 6 CAP FEMALE JIC SHIPPING 6 9 16 18 1 7 CAP FEMALE JIC SHIPPING 12 1 1 16 12 1 8 CAP FEMALE JIC SHIPPING 16 1 5 16 12 1 9 BRACKET HYD OIL OP CTR MNFLD 1 10 NUT HEX LOCKING 3 8 16...

Страница 66: ...SEALS GASKETS O RINGS BEFORE TIGHTENING 2 ALL BOLTS TO BE TORQUED TO THEIR RESPECTIVE SAE TORQUE SPECIFICATIONS FOR THEIR GRADES AND SIZES UNLESS OTHERWISE SPECIFIED 3 ADD DROPS OF RED LOCTITE TO ALL...

Страница 67: ...SHIPPING 6 9 16 18 279109 002 1 8 CAP FEMALE JIC SHIPPING 12 1 1 16 12 279109 005 1 9 CAP FEMALE JIC SHIPPING 16 1 5 16 12 279109 006 1 10 BRACKET HYD OIL CLSD CTR MNFLD 279469 1 11 NUT HEX LOCKING 5...

Страница 68: ...R HOSE I 1 5 DECAL IMT SERVICE REPAIR 70392962 1 6 DECAL CAUTION AUTO START I 1 7 DECAL HYDRAULIC HIGH PRESSURE I 1 8 DECAL DO NOT REMOVE CAPS I 1 9 DECAL DO NOT USE AIR I 1 11 DECAL IMT OIL RECIPROCA...

Страница 69: ...l that becomes damaged or illegible ITEM DESCRIPTION PART NUMBER QTY 13 DECAL LOGO IMT CAS40PL I 2 14 DECAL AIR DISCHARGE 1 15 DECAL 12VDC 1 16 DECAL HYDRAULIC RETURN 1 17 DECAL HYDRAULIC CASE DRAIN 1...

Страница 70: ...AND TUBE ROUTING INSTRUCTIONS ITEM PART NUMBER DESCRIPTION QTY START END 1 HOSE HYDRAULIC MOTOR IN DD 1 A A 2 HOSE HYDRAULIC MANF TO MOTOR OUT DD 1 B B 3 HOSE HYDRAULIC MOTOR TO COOLER DD 1 C C 4 HOSE...

Страница 71: ...SCRIPTION QTY START END 1 HOSE HYDRAULIC MOTOR IN DD 1 A A 2 HOSE HYDRAULIC MANF TO MOTOR OUT DD 1 B B 3 HOSE HYDRAULIC COOLER OUT 1 C C 3 HOSE HYDRAULIC MOTOR CASE DRAIN DD 1 D D 5 HOSE HYDR MOTOR TO...

Страница 72: ...NSTRUCTIONS ITEM PART NUMBER DESCRIPTION QTY START END 1 HOSE HYDRAULIC MOTOR IN DD 1 A A 2 HOSE HYDRAULIC MANF TO MOTOR OUT DD 1 B B 3 HOSE HYDRAULIC MOTOR TO COOLER DD 1 C C 4 HOSE HYDRAULIC COOLER...

Страница 73: ...N QTY START END 1 HOSE HYDRAULIC MOTOR IN DD 1 A A 2 HOSE HYDRAULIC MANF TO MOTOR OUT DD 1 B B 3 HOSE HYDRAULIC COOLER OUT 1 C C 3 HOSE HYDRAULIC MOTOR CASE DRAIN DD 1 D D 5 HOSE HYDR MOTOR TO THERM V...

Страница 74: ...923 3711 7 17 HYDRAULIC THERMAL VALVE ASSEMBLY ITEM DESCRIPTION PART NUMBER QTY 1 ELBOW 90 DEG 12 MJIC x 16 MSAE 3 2 VALVE THERMAL BYPASS 1 SAE 50PSI 100 DEG 1 PLEASE NOTE WHEN ORDERING PARTS INDICAT...

Страница 75: ...OF KEYED IGNITION C VBBS IN8 IN9 GND GND IN10 IN11 VBBS E OUT0 GND OUT1 GND OUT2 GND OUT3 GND N2 VBBS CAN2H CAN2L GND HMI 60 OHM RESISTOR FUSE 3 2 30 AMP JCASE STYLE FUSE VANAIR 279301 FOR 12V AND 24V...

Страница 76: ...CONNECTED TO A TERMINAL ON CONNECTOR 17 5 HOUR METER 14 4 7 16 PRESS URE SWITCH 6 PIN CONNECTOR 9 6 30 87 N O 87A N C 85 86 SAFETY RELAY NC NO C 1 2 4 N G 20 21 3A 19 12 15 8 16A MANIFOLD BLOCK VALVE...

Страница 77: ...RAULIC OIL COOLER DIRECTION HYDRAULIC OIL ROTATION RESERVOIR PUMP TRUCK SYSTEM FILTER PRESSURE RETURN MACHINE END PANEL THERMAL VALVE W PRESSURE RELIEF IN COOLER TANK CASE DRAIN SOLENOID RELIEF VALVE...

Страница 78: ...OLD TOOLING CO INC 641 923 3711 HYDRAULIC OIL COOLER RELIEF VALVE ROTATION RESERVOIR PUMP TRUCK SYSTEM FILTER PRESSURE RETURN MACHINE END PANEL SOLENOID VALVE CASE DRAIN P T A B TRUCK SYSTEM MACHINE H...

Страница 79: ...e motion produces bending rather than twisting 4 Use elbows or other adapters as necessary to eliminate excess hose length and to insure neater installation for easier main tenance 2 Ample bend radius...

Страница 80: ...USTRATED PARTS LIST 7 34 99906549 rev 00 JANUARY 2020 CAS40PL CAS40PL CW CAS40PLE CAS40PLE CW IOWA MOLD TOOLING CO INC 641 923 3711 TABLE 7B MAINTENANCE TRACKING LOG DATE DESCRIPTION OF MAINTENANCE PA...

Страница 81: ...BLANK PAGE...

Страница 82: ...oling Co Inc 500 Highway 18 West Garner Iowa 50438 Phone 641 923 3711 Fax 641 923 2424 www imt com 051731 051829 051830 051831 Printed in the U S A Specifi cations subject to change without prior noti...

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