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CAS440HT Air Compressor
Copyright © 2012 Iowa Mold Tooling Co., Inc.
All rights reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise without the
prior written permission of Iowa Mold Tooling Co., Inc.
Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation Company.
Printed on 23 January, 2012
Manual Part # 99900838
IOWA MOLD TOOLING CO., INC.
Tel: 641-923-3711
Website: http://www.imt.com
Revised 20120124
PO Box 189
Garner, IA 50438
FAX: 641-923-2424
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Summary of Contents for IMT CAS440HT
- Page 1 Manual Part # 99900838 CAS440HT Air Compressor Revised 20120124 IOWA MOLD TOOLING CO., INC. PO Box 189 Garner, IA 50438 Tel: 641-923-3711 FAX: 641-923-2424 Website: http://www.imt.com Copyright © 2012 Iowa Mold Tooling Co., Inc. All rights reserved No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior written permission of Iowa Mold Tooling Co., Inc.
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Page 3: Table Of Contents
Contents Revisions ..............................ii Compressor Introduction Compressor Precautions ..........................5 Compressor Safety............................6 Compressor Information Record........................7 CAS440HT Recommended Spare Parts .......................8 CAS440HT Compressor Specifications Installation PTO & Pump Installation ...........................11 PTO Installation............................11 Driveline and Pump Installation .........................13 Topdeck Compressor Installation .......................15 Oil Cooler (optional)...........................17 Operation Operation ..............................19... -
Page 4: Revisions
Contents Revisions DATE LOCATION DESCRIPTION 20070817 MAINTENAN CHANGED MAINTENANCE SCHEDULE COMPRESSOR OIL CHANGE DURATION; ECN 10523 – CHANGED #28 72066516 SCHEDULE, TO 72661642 2300080 20071127 MAINT. ECN 10612 - CHANGED NOTE IN MAINTENANCE SCHEDULE TO 6 SCHEDULE MONTHS 20090409 23000080 ADDED CALLOUT FOR ITEM #9 - MOTOR;... -
Page 5: Compressor Introduction
Modifications to your equipment must be performed with IMT approved accessories, parts and optional equipment. If in doubt, contact IMT prior to making any modifications. DO NOT alter or modify any safety device! All safety devices must be inspected, tested and maintained in proper working condition. - Page 6 CAS440HT Air Compressor Manual Part # 99900838 WARNING READ YOUR MANUAL!! FAILURE TO READ, UNDERSTAND AND FOLLOW ANY SAFETY PROCEDURES APPLICABLE TO YOUR EQUIPMENT MAY RESULT IN EQUIPMENT DAMAGE, SERIOUS INJURY, OR DEATH. MANUAL STRUCTURE Throughout this manual, three means are used to draw the attention of personnel. They are...
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Page 7: Compressor Precautions
Section 1 Compressor Introduction Compressor Precautions Failure to follow operating and maintenance Do not use air from this compressor for procedures as outlined in this manual could result breathing or food processing. Air from this in equipment damage, personal injury or death. compressor will cause severe injury or death if Follow all maintenance procedures and intervals. -
Page 8: Compressor Safety
Do not install a shut-off valve between the compressor and compressor oil sump. DANGER AVOID DEATH OR SERIOUS INJURY! 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. -
Page 9: Compressor Information Record
Section 1 Compressor Introduction 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. -
Page 10: Cas440Ht Recommended Spare Parts
CAS440HT Air Compressor Manual Part # 99900838 CAS440HT Recommended Spare Parts Recommended Spare Parts for one-year for CAS440HT Top-deck Compressor: NOTE: This spare parts list does not necessarily indicate that the items can be expected to fail in the course of a year. It is intended to provide the user with a stock of parts sufficient to keep the unit operating with the minimal down-time waiting for parts. -
Page 11: Cas440Ht Compressor Specifications
E C T I O N CAS440HT Compressor Specifications CAS440HT DELIVERY AT 175 PSI 46 cfm (1300 lpm) FLUID CAPACITY 32 gal (121 l) FILTER - HYDRAULIC SUCTION 100 mesh FILTER - HYDRAULIC RETURN 10 microns PRESSURE SWITCH 175 psi off / 150 psi on (12 psi off/ 10... -
Page 13: Installation
E C T I O N Installation PTO & Pump Installation In some cases the customer or his agent may have to install a compressor, PTO, and pump. These instructions will provide general information to assist with installation. The pump may be installed either directly on the PTO or may be driven by a driveline. - Page 14 CAS440HT Air Compressor Manual Part # 99900838 Run the engine and transmission in a well ventilated area. Listen for noises which indicate any engine/transmission problems. The engine and transmission should be in good operating condition before the installation of the PTO.
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Page 15: Driveline And Pump Installation
Installation Driveline and Pump Installation The pump may be driven using a driveline rather than directly mounting to the PTO. The following steps are a guide in this application. NOTE Before installing driveline, refer to instructions for proper driveline installation techniques. Install the PTO (see instructions). - Page 16 CAS440HT Air Compressor Manual Part # 99900838 DANGER Rotating Shaft Hazard Keep body, hands, hair, clothes away. Do not work around shafts with engine on. Rotating parts will injure or kill. 70392891 WARNING AVOID DEATH OR SERIOUS INJURY! The driveline installer must inspect the final position of the driveline to determine whether an operator or other personnel are protected from rotating driveline hazards.
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Page 17: Topdeck Compressor Installation
Installation Topdeck Compressor Installation The topdeck compressor is mounted on an oil reservoir which is bolted to the deck of the carrier vehicle. Due to variations, use these instructions only as a guide. Locate compressor position on the deck. Layout mounting hole pattern per figure. Drill six 1/2"... - Page 18 CAS440HT Air Compressor Manual Part # 99900838 Connect the wiring to the compressor where applicable. 10 Fill the oil tank and open suction gate valve. Disconnect pressure hose at hydraulic pump. Engage the PTO and turn the engine with starter until oil comes out the pressure side of the pump.
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Page 19: Oil Cooler (Optional)
Installation Oil Cooler (optional) Oil coolers vary in their installation dependent on available space and other considerations. Install the oil cooler in front of the carrier vehicle's radiator, or, as an alternative, in a protective structure which is cooled by an electric fan. See figure for general location within the hydraulic system. -
Page 21: Operation
E C T I O N Operation Operation The compressor has an operating time limit of approximately three hours depending upon ambient air temperature (outside air temperature), weather conditions and whether an oil cooler has been installed. Oil coolers will extend the three hour limit. CAUTION THE HYDRAULIC OIL TEMPERATURE MUST NOT BE ALLOWED TO EXCEED 190°F (88°C). -
Page 22: Shutdown
CAS440HT Air Compressor Manual Part # 99900838 1000 RPM MAXIMUM! Operating this unit in excess of 1000 RPM, measured at the compressor flywheel, will void your warranty. Engine RPM may be different. The flow required to the compressor is 16 GPM. -
Page 23: Maintenance & Repair
E C T I O N Maintenance & Repair 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. -
Page 24: Maintenance Schedule
CAS440HT Air Compressor Manual Part # 99900838 Maintenance Schedule ITEM MAINTENANCE DESCRIPTION SERVICE INTERVAL (Hours/Months) DAILY WEEKLY EVERY 500/3 1000/6 1500/9 2000/12 HOURS COMPRESSOR Air intake - inspect and clean. Compressor oil level - check, add if needed. Compressor oil - change. -
Page 25: Compressor Hydraulic Oil
Maintenance & Repair Compressor Hydraulic Oil The hydraulic oil is the power transmission medium, system lubricant, and coolant. Under normal operating conditions, the hydraulic oil must meet the following viscosity and grade specifications: AMBIENT TEMPERATURE RANGE 0 - 90º BELOW 32 - 90º... -
Page 26: Hydraulic Fluid Deterioration
CAS440HT Air Compressor Manual Part # 99900838 Hydraulic Fluid Deterioration Contamination of the hydraulic fluid by solvents, water, dust or other abrasives will cause deterioration of the fluid. Sustained presence of the impurities will result in premature breakdown of antifoam, lubrication, anti-rust and viscosity properties. Introduction of water to the system and operation at high temperatures (above 180°F) will result in an increase in the oil... -
Page 27: Compressor Hydraulic Oil Change
Maintenance & Repair Compressor Hydraulic Oil Change Check the oil in the hydraulic reservoir quarterly, and replace the oil on an annual basis. Purging the system requires a new oil supply sufficient to completely fill the reservoir, lines, cylinders, etc., and an extra quantity for loss during this procedure. To minimize oil loss during this process, operate the truck engine at low RPM. -
Page 28: Compressor Filter Element Replacement
CAS440HT Air Compressor Manual Part # 99900838 Compressor Filter Element Replacement To avoid residue accumulation in the reservoir and to protect the hydraulic components (valves, pumps,motors, etc.), the filters must be serviced on a regular basis. They must be changed after the initial 50-hours of new unit operation and every 200-hours thereafter.To change filter elements:... -
Page 29: Compressor Hydraulic System Precautions
Maintenance & Repair Compressor Hydraulic System Precautions To avoid malfunction of the compressor hydraulic system, follow these steps whenever a hydraulic component is removed from the system. ALWAYS relieve internal hydraulic pressure before proceeding with a repair. Carefully loosen a fitting and allow the pressure to bleed off. NEVER allow foreign matter (dirt, water, metal particles, etc.) to enter the system through the open connections. -
Page 30: Troubleshooting Guide
CAS440HT Air Compressor Manual Part # 99900838 Troubleshooting Guide Compressor Troubleshooting Guide Symptom Probable Cause Relief valve bypassing oil. Adjust relief valve. Turn clockwise to Air compressor slows increase bypass pressure. If this does not correct the problem, return down as air pressure the relief valve to the original position. -
Page 31: Parts
E C T I O N Parts... -
Page 32: Cas440Ht Compressor Parts (23000080)
CAS440HT Air Compressor Manual Part # 99900838 CAS440HT Compressor Parts (23000080) ORIGINAL PART OF COMPRESSOR TO SPEED TANK CONTROL (IDLE PRESSURE) TANK PART OF COMPRESSOR PUMP 11,12 FRONT OF TRUCK 34,60,... - Page 33 Parts 23000080 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 70073051 COMPRESSOR 52719724 RESERVOIR 52720047 BASE WELDMENT 52724369 BRACKET (WAS 52070749) 70058486 BELT-POWER V 2B80 70056043 PULLY-BROWNING 2BK110H 52705590 BELT GUARD 60104650 BRACE 73051614 HYD MOTOR-M20A897BEEF10 73540449 RELIEF VALVE (WAS 73054995) 73014671 FILL CAP 73141276...
- Page 34 CAS440HT Air Compressor Manual Part # 99900838 23000080 PARTS LIST ITEM PART # DESCRIPTION QUANTITY 72062104 NUT 1/4-20 LOCK 72063005 WASHER 1/2 WRT 77041008 PRESSURE SWITCH 72532013 STREET TEE 1/4NPT BRASS 72053411 PIPE PLUG 1/8NPT SQHD 72053371 REDUCER BUSHING 1/4-1/8NPT 72053533 STREET ELBOW 1/4NPT 45°...
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Page 35: Thread Torque Charts
Parts Thread Torque Charts FINE THREAD BOLTS (ENGLISH) COARSE THREAD BOLTS (ENGLISH) SIZE BOLT GRADE 5 GRADE 8 SIZE BOLT GRADE 5 GRADE 8 DIA. DIA. SAE J429 SAE J429 SAE J429 SAE J429 GRADE 5 GRADE 8 GRADE 5 GRADE 8 (DIA-TPI) (INCHES) PLAIN PLATED PLAIN... - Page 36 CAS440HT Air Compressor Manual Part # 99900838 FINE THREAD TORQUE CHART (METRIC) COARSE THREAD TORQUE CHART (METRIC) TIGHTENING TORQUE TIGHTENING TORQUE SIZE BOLT SIZE BOLT DIA (DIA- DIA. (DIA- (INCHES) TPI) (INCHES) TPI) SAE J429 SAE J429 SAE J429 SAE J429...
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