IMT CAS40PL Manuel utilisateur

Iowa Mold Tooling Co., Inc.

500 Highway 18 West

Garner, Iowa 50438

Phone: 641.923.3711

Fax: 641.923.2424

www.imt.com

KEEP THE MANUAL

WITH THE VEHICLE

P/N 99906549 rev 00

Eﬀective Date:

FEBRUARY - 2020

CAS40PL, CAS40PL-CW,

CAS40PLE, CAS40PLE-CW

40 CFM/100 PSIG HYDRAULIC ALL WEATHER

CLOSED OR OPEN CIRCULATION RECIPROCATING COMPRESSOR

OPERATION MANUAL AND PARTS LIST

Read this manual before install-

ing, operating or servicing this

equipment. Failure to comply with

the operation 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

eﬀort has been made to ensure

accuracy.

Iowa Mold Tooling Co., Inc.

reserves the right to make

design change modiﬁcations

or improvements without prior

notiﬁcation.

NOTE

Use only IMT Reciprocating

Compressor Oil and Genuine

IMT Parts. Inspect and replace

damaged components before

operation. Substituting non-IMT

oil or non-genuine IMT ﬁlter

components WILL VOID THE

COMPRESSOR WARRANTY!

NOTE

Making unauthorized modiﬁca-

tions to the system components

WILL VOID THE WARRANTY!

Always inform IMT before

beginning any changes to the

CAS40PL systems.

BLANK PAGE

TABLE OF

CONTENTS

99906549 rev 00 (JANUARY-2020) TOC - I

TABLE OF CONTENTS

IOWA MOLD TOOLING CO., INC.

(641) 923-3711

CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW

TABLE OF CONTENTS ................................................................ TOC - I

Section 1: SAFETY .................................................................... 1 - 1

1.1 GENERAL INFORMATION ..................................................................................... 1 - 1

1.2 INTERNATIONAL SAFETY SYMBOL ..................................................................... 1 - 1

1.3 DANGERS, WARNINGS, CAUTIONS, AND NOTES.............................................. 1 - 1

1.3.1 DANGERS........................................................................................................ 1 - 1

1.3.2 WARNINGS...................................................................................................... 1 - 1

1.3.3 CAUTIONS ....................................................................................................... 1 - 2

1.3.4 NOTES ............................................................................................................. 1 - 3

1.4 SAFETY 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 TIGHTENING TORQUE VALUES................................................. 2 - 3

TABLE 2C: COMPRESSOR TORQUE VALUES................................................................... 2 - 3

SECTION 3: INSTALLATION ........................................................... 3 - 1

3.1 MACHINE PACKAGE RECEIPT/INSPECTION ......................................................... 3 - 1

3.2 GENERAL INSTRUCTIONS....................................................................................... 3 - 1

3.3 DETERMINING THE CAS40PL UNIT MOUNTING LOCATION................................... 3 - 2

3.4 HYDRAULIC SYSTEM OVERVIEW............................................................................. 3 - 2

3.4.1 HYDRAULIC SYSTEM FILTRATION................................................................... 3 - 2

Figure 3-1: Installation and Dimensions Diagram - Open Center 12VDC ...................... 3 - 3

Continued on next page...

TOC - II 99906549 rev 00 (JANUARY-2020)

TABLE OF CONTENTS

IOWA MOLD TOOLING CO., INC.

(641) 923-3711

CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW

SECTION 3: INSTALLATION (CONTINUED)

Figure 3-2: Installation and Dimensions Diagram - Open Center 12V,

No Thermal Valve .................................................................................................... 3 - 4

Figure 3-3: Installation and Dimensions Diagram - Open Center 12V,

With Thermal Valve & Gauges................................................................................ 3 - 5

3.4.2 HYDRAULIC OIL RESERVOIR ........................................................................... 3 - 6

3.4.2.1 DETERMINING RESERVOIR SIZE........................................................... 3 - 6

3.4.2.2 DETERMINING RESERVOIR SHAPE....................................................... 3 - 6

3.4.2.3 MANDATORY RESERVOIR FEATURES................................................... 3 - 6

3.4.2.4 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 LOCATION ......................................................................................... 3 - 8

3.5.2 CLEARANCES..................................................................................................... 3 - 8

3.5.3 MACHINE STABILIZATION AND GROUNDING ................................................. 3 - 8

3.5.4 SERVICE CONNECTIONS.................................................................................. 3 - 8

3.5.5 ELECTRICAL CONNECTIONS ........................................................................... 3 - 8

3.5.6 HYDRAULIC SUPPLY CIRCUIT.......................................................................... 3 - 9

3.5.7 ROUTING ............................................................................................................ 3 - 9

3.5.8 HYDRAULIC SYSTEM REQUIREMENTS .......................................................... 3 - 9

3.6 CONNECTING THE HYDRAULIC SUPPLY AND RETURN.................................. 3 - 9

3.7 CONNECTING THE AIR SUPPLY ......................................................................... 3 - 9

3.7.1 AIR RESERVOIR TANK INSTALLATION .......................................................... 3 - 10

SECTION 4: OPERATION ................................................................ 4 - 1

4.1 GENERAL INFORMATION......................................................................................... 4 - 1

4.2 OPERATING CONDITIONS ....................................................................................... 4 - 1

4.3 INITIAL (FIRST-TIME) START-UP................................................................................ 4 - 1

Continued on next page...

99906549 rev 00 (JANUARY-2020) TOC - III

TABLE OF CONTENTS

IOWA MOLD TOOLING CO., INC.

(641) 923-3711

CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW

SECTION 4: OPERATION (CONTINUED)

Figure 4-1: Instrumentation............................................................................................. 4 - 2

4.3.1 ROUTINE START-UP FROM MACHINE ............................................................. 4 - 2

4.3.2 ROUTINE SHUTDOWN PROCEDURE (FIRST AND ROUTINE) ....................... 4 - 2

Figure 4-2: Controller Screen Identiﬁcation and Navigation ........................................... 4 - 3

4.4 EXTREME CONDITION OPERATION ....................................................................... 4 - 4

SECTION 5: MAINTENANCE........................................................... 5 - 1

5.1 GENERAL INFORMATION......................................................................................... 5 - 1

5.2 MACHINE MAINTENANCE SCHEDULE ................................................................... 5 - 1

5.3 REPLACEMENT PARTS .............................................................................................. 5 - 2

TABLE 5A: ROUTINE MAINTENANCE SCHEDULE............................................................ 5 - 3

TABLE 5B: ROUTINE REPLACEMENT 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 REPLACING LONG-SIDE PANELS........................................................... 5 - 6

5.4.2 CHECKING PRESSURE READING.................................................................... 5 - 6

5.4.3 COMPRESSOR SYSTEM LUBRICATION .......................................................... 5 - 6

5.4.3.1 CHECKING THE OIL LEVEL ..................................................................... 5 - 6

5.4.3.2 CHANGING THE COMPRESSOR OIL...................................................... 5 - 6

5.4.4 AIR FILTER MAINTENANCE............................................................................... 5 - 7

5.4.4.1 INSPECTING THE AIR FILTER ................................................................. 5 - 7

5.4.4.2 REPLACING THE AIR FILTER ELEMENT................................................. 5 - 8

5.4.5 COOLER CORE MAINTENANCE ........................................................................ 5 -8

5.4.6 COUPLING ALIGNMENT .................................................................................... 5 - 9

5.4.7 REPLACING THE DRIVE COUPLING ................................................................ 5 - 9

5.4.7.1 REPLACING THE DRIVE COUPLING ELEMENT................................... 5 - 10

5.4.7.2 COUPLING ASSEMBLY........................................................................... 5 - 10

5.4.7.3 HUB ALIGNMENT CHECK ...................................................................... 5 - 11

5.4.7.4 COUPLING MAINTENANCE ................................................................... 5 - 11

Continued on next page...

TOC - IV 99906549 rev 00 (JANUARY-2020)

TABLE OF CONTENTS

IOWA MOLD TOOLING CO., INC.

(641) 923-3711

CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW

SECTION 5: MAINTENANCE (CONTINUED)

5.4.8 CHECKING HOSES AND WIRING ................................................................... 5 - 11

5.5 SERVICING THE SYSTEM FUSE ............................................................................. 5 - 12

5.6 PRESSURE (SAFETY) RELIEF VALVES .................................................................. 5 - 12

5.7 LONG TERM STORAGE............................................................................................ 5 - 13

SECTION 6: TROUBLESHOOTING................................................. 6 - 1

6.1 GENERAL INFORMATION......................................................................................... 6 - 1

6.2 TROUBLESHOOTING GUIDE ................................................................................... 6 - 2

SECTION 7: ILLUSTRATED PARTS LIST....................................... 7 - 1

7.1 PARTS ORDERING INFORMATION.......................................................................... 7 - 1

TABLE 7A: RECOMMENDED SPARE PARTS LIST............................................................. 7 - 2

7.2 COMPRESSOR AND PARTS..................................................................................... 7 - 4

7.3 COMPRESSOR PARTS............................................................................................. 7 - 6

7.4 DISPLAY AND CONTROLLER................................................................................... 7 - 8

7.5 DISPLAY AND GAUGE ASSEMBLY (MECHANICAL 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

7.9 FRAME AND CANOPY - 2 OF 3 (ASSEMBLY PARTS B - C) .................................. 7 - 16

7.9 FRAME AND CANOPY - 3 OF 3 (ASSEMBLY PARTS D - F) .................................. 7 - 17

7.10 HYDRAULIC MANIFOLD ASSEMBLY - 12VDC OPEN CENTER

(STANDARD & COLD WEATHER)........................................................................... 7 - 18

7.11 HYDRAULIC MANIFOLD ASSEMBLY - CLOSED CENTER (24V)

(STANDARD & COLD WEATHER)........................................................................... 7 - 20

7.12 DECAL IDENTIFICATION/LOCATIONS - 1 OF 2..................................................... 7 - 22

7.12 DECAL IDENTIFICATION/LOCATIONS - 2 OF 2..................................................... 7 - 23

7.13 HOSE AND TUBE ROUTING - OPEN CENTER 12V, NO THERMAL ..................... 7 - 24

7.14 HOSE AND TUBE ROUTING - OPEN CENTER 12V, WITH THERMAL ................. 7 - 25

7.15 HOSE AND TUBE ROUTING - OPEN CENTER 12V, NO THERMAL,

WITH GAUGES ........................................................................................................ 7 - 26

7.16 HOSE AND TUBE ROUTING - OPEN CENTER 12V, THERMAL & GAUGES........ 7 - 27

Continued on next page...

99906549 rev 00 (JANUARY-2020) TOC - V

TABLE OF CONTENTS

IOWA MOLD TOOLING CO., INC.

(641) 923-3711

CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW

SECTION 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 VALVE .......................................................................................... 7 - 31

7.21 HYDRAULIC OIL FLOW SCHEMATIC DIAGRAM - OPEN CENTER...................... 7 - 32

7.22 HOSE INSTALLATION GUIDE ................................................................................. 7 - 33

TABLE 7B: MAINTENANCE TRACKING LOG.................................................................... 7 - 34

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

SECTION 1:

SAFETY

99906549 rev 00 (JANUARY-2020) 1 - 1

SECTION 1: SAFETY

IOWA MOLD TOOLING CO., INC.

(641) 923-3711

CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW

1.1 GENERAL INFORMATION

The products provided by IMT®Mfg., Inc. are de-

signed and manufactured for safe operation and

maintenance. But it is ultimately the responsibility

of the users and maintainers for safe use of this

equipment. Part of this responsibility is to read

and be familiar with the contents of this manual

before operation or performing maintenance ac-

tions.

1.2 INTERNATIONAL

WARNING SYMBOL

The international warning symbol (shown above)

is used on all decals, labels and signs that con-

cern information pertaining to bodily harm. When

you see the international warning symbol, pay

extremely careful attention, and follow the given

instructions or indications to avoid any possible

hazard.

1.3 DANGERS, WARNINGS,

CAUTIONS AND NOTES

These boxes are labeled clearly with the title

block listing either Danger, Warning, Caution, or

other non-safety issue. They draw attention to

speciﬁc issues that are pertinent to the safe and

correct operation of the machine.

The symbols shown and deﬁned in Section 1:

Safety are used throughout this manual and on

the machine to call attention to, and identify, pos-

sible hazards.

1.3.1 DANGERS

DANGER

Identiﬁes actions or conditions which will cause

death, 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 operating. They can be

sources of electrical shock.

1.3.2 WARNINGS

WARNING

Identiﬁes actions or conditions which may

cause death, severe injury, or equipment dam-

age or destructive malfunctions.

• DO NOT EVER use this compressor as a

breathing air source. IMT disclaims any and all

liabilities for damage or loss due to fatalities,

personal injuries resulting from the use of a

IMT compressor to supply breathing air.

• DO NOT perform any modiﬁcations to this

equipment without prior factory approval.

• DO NOT operate the compressor 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

personnel.

• DO NOT operate the compressor with any by-

pass or other safety systems disconnected or

rendered inoperative.

• DO NOT operate the equipment while you are

under the inﬂuence of alcohol or drugs.

• DO NOT operate the equipment while you are

feeling ill.

• DO NOT attempt to service the equipment

while it is operating.

• Before performing maintenance, or replacing

parts, relieve the entire system pressure, af-

ter the system has blown down, by opening a

service valve which will vent all pressure to the

atmosphere. After that, remove any remaining

residual pressure by slowly opening the ﬁll

cap. Remove all electrical power.

1 - 2 99906549 rev 00 (JANUARY-2020)

SECTION 1: SAFETY

IOWA MOLD TOOLING CO., INC.

(641) 923-3711

CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW

NOTE

Slowly remove ﬁll cap to vent compressor

sump pressure.

• DO NOT use the compressor for purposes oth-

er than for which it is intended. High pressure

air can cause serious and even fatal injuries.

• DO NOT operate the compressor outside of its

speciﬁed pressure and speed ratings. (See

Section 2: Speciﬁcations or refer to the equip-

ment data plate.).

• DO NOT use ﬂammable solvents or cleaners

for cleaning the compressor or its parts.

• DO NOT operate the compressor in areas

where ﬂammable, toxic, corrosive fumes, or

other damaging substance can be ingested by

the compressor intake.

• Keep arms, hands, hair and all other body parts,

and clothing away from fans, drive shafts, and

other moving parts.

• DO NOT wear jewelry, unbuttoned cuﬀs, ties,

or loose-ﬁtting clothing when you are working

near moving/rotating parts.

• ALWAYS conﬁne long hair when working near

moving/rotating parts.

• NEVER operate the equipment while wearing a

headset to listen to music or the radio.

• Wear personal protective equipment such as

gloves, work shoes, and eye and hearing pro-

tection as required for the task at hand.

• DO NOT operate the compressor with any

guards removed or damaged, or other safety

devices inoperative.

• DO NOT operate the compressor in enclosed

or conﬁned spaces where ventilation is re-

stricted or closed-oﬀ.

• Ensure that hoses connected to service valves

are ﬁtted with correctly sized and rated ﬂow

limiting devices which comply with applicable

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, and other conductive objects

away from live electrical components.

• Before performing maintenance or repair oper-

ations on the compressor, ensure that all pow-

er has been removed and been locked out to

prevent accidental application.

• DO NOT assume that because the compressor

is in a STOPPED condition that hydraulic pow-

er has been removed.

• Use this compressor only to compress atmo-

spheric air. Use of this equipment as a booster

pump and/or to compress any other gaseous

or aerosol substance constitutes improper

use. It can also cause damage or injuries.

Such misuse will also void the warranty.

• Install, operate, and maintain this equipment in

full compliance with all applicable OSHA, oth-

er Federal, state, local codes, standards, and

regulations.

• When lifting objects, be aware of proper lifting

techniques to avoid injury.

• ALWAYS read and follow safety related pre-

cautions found on containers of hazardous

substances.

1.3.3 CAUTIONS

CAUTION

Identiﬁes actions or conditions which will or

can cause injuries, equipment damage or mal-

functions.

• Check all safety devices for proper operation

on a routine basis.

• Ensure that no tools, rags, or other objects are

left on compressor drive systems or near in-

takes.

• Keep the equipment clean when performing

maintenance or service actions. Cover open-

ings to prevent contamination.

• DO NOT operate the compressor if cooling air

is not available (fan/cooler not operating) or if

lubricant levels are below their speciﬁed min-

imum levels.

• Ensure all plugs, hoses, connectors, covers,

and other parts removed for maintenance ac-

Ce manuel convient aux modèles suivants

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