IMT CAS40PL Operation Manual And Parts List
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IMT CAS40PL Operation Manual And Parts List

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CAS40PL, CAS40PL-CW,
CAS40PLE, CAS40PLE-CW
40 CFM/100 PSIG HYDRAULIC ALL WEATHER
CLOSED OR OPEN CIRCULATION RECIPROCATING COMPRESSOR
OPERATION MANUAL AND PARTS LIST
NOTE
This publication contains the
latest information available at
the time of preparation. Every
eff ort has been made to ensure
accuracy.
Iowa Mold Tooling Co., Inc.
reserves the right to make
design change modifi cations
or improvements without prior
notifi cation.
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 fi lter
components WILL VOID THE
COMPRESSOR WARRANTY!
KEEP THE MANUAL
WITH THE VEHICLE
Iowa Mold Tooling Co., Inc.
500 Highway 18 West
Garner, Iowa 50438
Phone: 641.923.3711
Fax: 641.923.2424
www.imt.com
©2020 Iowa Mold Tooling Co., Inc.
All rights reserved
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
Making unauthorized modifi ca-
tions to the system components
WILL VOID THE WARRANTY!
Always inform IMT before
beginning any changes to the
CAS40PL systems.
P/N 99906549 rev 00
Eff ective Date:
FEBRUARY - 2020

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Summary of Contents for IMT CAS40PL

  • Page 1 WILL VOID THE WARRANTY! damaged components before 500 Highway 18 West Always inform IMT before operation. Substituting non-IMT beginning any changes to the oil or non-genuine IMT fi lter Garner, Iowa 50438 CAS40PL systems. components WILL VOID THE COMPRESSOR WARRANTY! Phone: 641.923.3711 Fax: 641.923.2424...
  • Page 2 BLANK PAGE...

  • Page 3: Table Of Contents

    SECTION 3: INSTALLATION ............3 - 1 MACHINE PACKAGE RECEIPT/INSPECTION ............3 - 1 GENERAL INSTRUCTIONS ..................3 - 1 DETERMINING THE CAS40PL UNIT MOUNTING LOCATION ........3 - 2 HYDRAULIC SYSTEM OVERVIEW ................3 - 2 3.4.1 HYDRAULIC SYSTEM FILTRATION ..............3 - 2 Figure 3-1: Installation and Dimensions Diagram - Open Center 12VDC ......
  • Page 4 TABLE OF CONTENTS 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 ................
  • Page 5 CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW TABLE OF CONTENTS 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 Identifi cation and Navigation ........... 4 - 3 EXTREME CONDITION OPERATION ...............
  • Page 6 TABLE OF CONTENTS CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 5: MAINTENANCE (CONTINUED) 5.4.8 CHECKING HOSES AND WIRING ..............5 - 11 SERVICING THE SYSTEM FUSE ................5 - 12 PRESSURE (SAFETY) RELIEF VALVES ..............5 - 12 LONG TERM STORAGE .................... 5 - 13 SECTION 6: TROUBLESHOOTING ..........
  • Page 7 CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW TABLE OF CONTENTS 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 ..................
  • Page 8 TABLE OF CONTENTS CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW BLANK PAGE TOC - VI 99906549 rev 00 (JANUARY-2020) IOWA MOLD TOOLING CO., INC. (641) 923-3711...

  • Page 9: Safety

    WARNING SYMBOL • 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 The international warning symbol (shown above) IMT compressor to supply breathing air.

  • Page 10: Cautions

    SECTION 1: SAFETY CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW • Keep metal tools, and other conductive objects NOTE away from live electrical components. Slowly remove fi ll cap to vent compressor • Before performing maintenance or repair oper- sump pressure. ations on the compressor, ensure that all pow- er has been removed and been locked out to prevent accidental application.

  • Page 11: Notes

    CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 1: SAFETY DISPOSING OF MACHINE tions are replaced before applying power to the compressor. FLUIDS • Avoid touching hot surfaces and components. Always dispose of machine fl uids under the guid- • Ensure that electrical wiring, terminals; hoses ance of all applicable local, regional and/or fed- and fi...
  • Page 12 CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 2: SPECIFICATIONS OPEN CENTER MANIFOLD CLOSED CENTER MANIFOLD CC DD CLOSED - CENTER CONFIGURATION OPEN - CENTER CONFIGURATION DESCRIPTION DESCRIPTION RELAY LOAD SENSE #4 MJIC 37° (1/4-12 UNF) PRESSURE SWITCH (24V MACHINES) HYDRAULIC SUPPLY #12 MJIC 37° (1-1/16-12 UNF) PRESSURE TRANSDUCER (12V MACHINES) HYDRAULIC RETURN #16 MJIC 37°...

  • Page 13: Section 2: Specifications

    CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 2: SPECIFICATIONS SECTION 2: SPECIFICATIONS GENERAL INTRODUCTION manual. Refer to Figure 2-1 for general machine compo- The tables and fi gures in this section list the nent locations. For additional information, includ- specifi cations (including operational, output and ing measurement specifi...
  • Page 14 SECTION 2: SPECIFICATIONS CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW TABLE 2A: SPECIFICATIONS GENERAL SYSTEM INFORMATION SPECIFICATION PACKAGE (continued) Dimensions: Length — 33.70” Width — 21.00” Height — 24.30” Weight: 245 lbs.(dry; add 10-12 lbs for full wet machine weight) CONTROLS 3000 PSIG...

  • Page 15: Section 3: Installation

    GENERAL INSTRUCTIONS confi ned spaces where ventilation is restricted or closed off . This section provides general guidance for lo- cating and preparing the CAS40PL compressor NOTE package for operation. Each installation is unique Install electrical components (circuit breakers, and can be aff ected by location, ventilation, and pressure switches, toggle switches, etc.) in...

  • Page 16: Determining The Cas40Pl Unit Mounting Location

    HYDRAULIC SYSTEM OVERVIEW NOTE The temperature of the hydraulic oil should not IMPORTANT exceed 160°F due to the rating of the IMT- sup- plied hydraulic motor. ® highly recommends consulting a hydraulic supply expert for specifying the correct hydrau- 3.4.1 HYDRAULIC SYSTEM...
  • Page 17 CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 3: INSTALLATION 051665ID_r0 Figure 3-1: Installation and Dimensions Diagram - Open Center 12VDC 99906549 rev 00 (JANUARY-2020) 3 - 3 IOWA MOLD TOOLING CO., INC. (641) 923-3711...
  • Page 18 SECTION 3: INSTALLATION CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW Figure 3-2: Installation and Dimensions Diagram - Open Center 12V, No Thermal Valve 051787_r2 3 - 4 99906549 rev 00 (JANUARY-2020) IOWA MOLD TOOLING CO., INC. (641) 923-3711...
  • Page 19 CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 3: INSTALLATION Figure 3-3: Installation and Dimensions Diagram - Open Center 12V, With Thermal Valve & Gauges 051788_r2 99906549 rev 00 (JANUARY-2020) 3 - 5 IOWA MOLD TOOLING CO., INC. (641) 923-3711...

  • Page 20: Hydraulic Oil Reservoir

    SECTION 3: INSTALLATION CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW DESCRIPTION ROOF ACCESS PANEL CLEARANCE: 24” MACHINE LATERAL CLEARANCES: 10” MACHINE FRONT/REAR CLEARANCES: 10” COOLING AIR FLOW DIRECTION NOTE: The dimensions listed above are the minimum required clearance distances needed for properly cooling the machine. Additinal clearance room may be desired for easier acess for control and/or maintenance functions.

  • Page 21: Recommended Reservoir Options

    CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 3: INSTALLATION • If the return line entrance to the tank is located near the top, it should be extended downward within the tank to minimize foaming and aer- ation of the circulating oil. This extends oil in- tegrity, which in turn helps to maintain system performance and reliability.

  • Page 22: Reservoir Features To Avoid

    NOTE Refer to Figure 3-1 or Figure 3-2. ® Isolator replacements are available from IMT Flow controller is optional to reduce fl ow if neces- order bolt down isolator no. 71417230 (unit uses four [x 4] isolators).

  • Page 23: Hydraulic Supply Circuit

    It is recommended that the • Other hydraulic equipment which may share compressor unit possesses a separate pump/ the same hydraulic supply system (IMT rec- fl ow/return hydraulic circuit to other hydrau- ommends a dedicated pump and hydraulic lic equipment.

  • Page 24: Air Reservoir Tank Installation

    • Pressure-rated for 200 psig (minimum). JIC male connector. MOUNTING SPECIFICATIONS IMPORTANT • If air tank is to be permanently mounted, IMT recommends a mounting with no less than Ensure that the air discharge hose is properly rated for high temperature.

  • Page 25: Section 4: Operation

    GENERAL INFORMATION The compressor has been factory-tested and its air and hydraulic valves have been adjusted to The IMT CAS40PL compressor has a compre- their specifi ed operating settings. The crankcase hensive array of controls and indicators. Under- has been factory-fi lled, but the oil needs to be...

  • Page 26: Routine Shutdown Procedure (First And Routine)

    SECTION 4: OPERATION CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW DESCRIPTION DESCRIPTION HOUR METER PNEUMATIC GAUGE PANEL DIGITAL DISPLAY CONTROLLER PRESSURE GAUGE Refer to Figure 4-2 for digital controller identifi cation and navigation. Note that machine control panel option will be either A or D from the table above, depending upon order specifi cation.
  • Page 27 CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 4: OPERATION Figure 4-2: Controller Screen Identifi cation and Navigation 99906549 rev 00 (JANUARY-2020) 4 - 3 IOWA MOLD TOOLING CO., INC. (641) 923-3711...

  • Page 28: Extreme Condition Operation

    SECTION 4: OPERATION CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW down for approximately fi ve (5) minutes. 3. Shut off hydraulic power supply. 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 problem. Machine re-...

  • Page 29: Section 5: Maintenance

    SECTION 5: MAINTENANCE GENERAL INFORMATION WARNING The IMT CAS40PL requires routine maintenance DO NOT touch electrical wires, wire harnesses, to ensure its proper functioning and that its opera- terminals, or other components when power is tional life is not prematurely shortened. This sec- applied to the compressor unit.

  • Page 30: Replacement Parts

    ® pressor system was purchased. If, for any rea- son, parts are not available in this manner, they can be purchased through IMT directly. 5 - 2 99906549 rev 00 (JANUARY-2020) IOWA MOLD TOOLING CO., INC.
  • Page 31 CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 5: MAINTENANCE 99906549 rev 00 (JANUARY-2020) 5 - 3 IOWA MOLD TOOLING CO., INC. (641) 923-3711...
  • Page 32 SECTION 5: MAINTENANCE CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 5 - 4 99906549 rev 00 (JANUARY-2020) IOWA MOLD TOOLING CO., INC. (641) 923-3711...

  • Page 33: Parts Replacement And Adjustment Procedures

    CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 5: MAINTENANCE 5.4.1 REMOVING PANELS FOR MA- PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES CHINE MAINTENANCE ACCESS Although most of the routine maintenance proce- WARNING dures can be accessed from either outside of the compressor package or via the top roof access Follow all applicable safety recommendations as outlined in Section 1: Safety of this manual.

  • Page 34: Replacing Long-Side Panels

    Refer to Figure 5-2 and the following procedure: The compressor is fully charged at the facto- 1. Place a container (of at least three [3] quarts ry with IMT Reciprocating Compressor Oil. This capacity) below the level of the compressor section gives details on checking and changing unit, within reach of the drain hose end [A].

  • Page 35: Air Filter Maintenance

    WARNING 6. At the oil fi ll port [C], remove the port plug then fi ll crankcase with a full charge of IMT ® NOTE THAT THE SYSTEM CAN BE STARTED reciprocating oil to the proper level indicated...

  • Page 36: Replacing The Air Filter Element

    The air fi lter element is replaced either at the roof panel and checking that the cooler is clean routine scheduled interval (refer to Table 5A: and free from debris will ensure that the CAS40PL Routine Maintenance Scehdule), or if it has package operates safely within the temperature failed the inspection process laid forth in Section limits described in Section 2, Specifi...

  • Page 37: Coupling Alignment

    CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 5: MAINTENANCE You may need to remove the fan from the shroud in order to reach parts of the core. DO NOT use high pressure air or a pressure washer. If the cooler has become internally clogged, it may need to be fl...

  • Page 38: Replacing The Drive Coupling Element

    SECTION 5: MAINTENANCE CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW DESCRIPTION SPIDER COUPLING MOTOR COUPLING HUB SET SCREW FOR MOTOR COUPLING HUB MOTOR DESCRIPTION COMPRESSOR UNIT BELL HOUSING COMPRESSOR COUPLING HUB Figure 5-5: Drive Coupling Element Replacement pulling directly outward; this will separate the NOTE coupling assembly.

  • Page 39: Hub Alignment Check

    Perform the checks and tasks listed below to els (drive assembly access panel and instrumen- keep the CAS40PL coupling in proper working tation panel) must be removed. Consult Section order. 99906549 rev 00 (JANUARY-2020) 5 - 11 IOWA MOLD TOOLING CO., INC.

  • Page 40: Servicing The System Fuse

    SECTION 5: MAINTENANCE CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 5.4.1, Removing Panels for Machine Mainte- WARNING nance Access to remove the drive assembly ac- cess side panel. Before performing maintenance: Shut down machine, relieve all system pres- Hoses and wires are routed away from potential sure and lock out all power, as per the Safety pinch points, heat sources, and other hazards.

  • Page 41: Long Term Storage

    SECTION 5: MAINTENANCE LONG TERM STORAGE Parts can wear out over time, regardless of the degree of usage. If storing the CAS40PL unit for long periods of time, prepare the unit by doing the following: • De-pressurize the air tank and open the drain valve on the tank.
  • Page 42 SECTION 5: MAINTENANCE CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW BLANK PAGE 5 - 14 99906549 rev 00 (JANUARY-2020) IOWA MOLD TOOLING CO., INC. (641) 923-3711...

  • Page 43: Section 6: Troubleshooting

    Should the problem persist after making the rec- ommended check, consult your nearest IMT ® rep- resentative or the IMT, Inc. Service Department. WARNING Install, operate, and maintain this equipment in full compliance with all applicable OSHA, other Federal, state, local codes, standards, and regulations.

  • Page 44: Troubleshooting Guide

    SECTION 6: TROUBLESHOOTING CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW TROUBLESHOOTING GUIDE MALFUNCTION/FAULT POSSIBLE CAUSE CORRECTIVE ACTION Compressor will not start PTO/hydraulics not engaged Ensure hydraulics engaged. Compressor switch OFF Turn switch ON. 10A fuse blown Check and replace fuse if necessary (Section 5.5).
  • Page 45 CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 6: TROUBLESHOOTING TROUBLESHOOTING GUIDE MALFUNCTION/FAULT POSSIBLE CAUSE CORRECTIVE ACTION Low air pressure Air fi lters soiled/plugged Replace air fi lter element (Section 5.4.4). Pressure switch setting too low May need to be replaced or reset; consult Service Depart- ment for reset instructions.
  • Page 46 SECTION 6: TROUBLESHOOTING CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW TROUBLESHOOTING GUIDE MALFUNCTION/FAULT POSSIBLE CAUSE CORRECTIVE ACTION Oil in discharge air (continued) Restricted crankcase breather Clean or replace breather. Worn piston rings Replace rings. Piston rings incorrectly installed Reinstall. Worn or scored cylinder Replace cylinder and rings.

  • Page 47: Section 7: Illustrated Parts List

    CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 7: ILLUSTRATED PARTS LIST SECTION 7: ILLUSTRATED PARTS LIST 7.1 PARTS ORDERING INFORMATION Part orders should be placed through the distributor from whom the unit was purchased. If for any reason parts cannot be obtained in this man- ner, contact the factory directly at the address or phone numbers below.
  • Page 48 Use only IMT ® Reciprocating Oil and Genuine IMT Parts. Inspect and replqce damaged components before operation. Substituting non-IMT oil or non-Genuine IMT fi lter compo- nents WILL VOID THE COMPRESSOR WARRANTY! If a hose needs to be replaced, refer to Sections 7.13 through 7.16 for hose identifi cation and part order numbers.
  • Page 49 CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 7: ILLUSTRATED PARTS LIST IMPORTANT IMPORTANT The above table listing contains items that require maintenance on a If additional spare parts are being stored for future use, routine basis, and also those parts that may require maintenance over ensure that they are stored in proper containers that the course of the compressor package’s performance schedule.

  • Page 50: Compressor And Parts

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.2 COMPRESSOR AND PARTS NOTES: REPLACES EXISTING BOLT 1. USE LOCTITE 567 THREAD SEALANT WITH PTFE OR EQUIVALENT SEALANT ON ALL MALE PIPE THREADS. 2. LUBRICATE ALL ELASTOMERIC SEALS/GASKETS/O-RINGS BEFORE TIGHTENING.
  • Page 51 CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 7: ILLUSTRATED PARTS LIST 7.2 COMPRESSOR AND PARTS ITEM DESCRIPTION PART NUMBER PLUG, MALE 37 JIC 08 ORIFICE, .63 HEX x 1/8F x 1/4M x 0.031 TEE, 1/4” NPT MALE BRANCH ORIFICE, FILTER .032 DIA., 1/4 FPT X 1/4 MPT...

  • Page 52: Compressor Parts

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.3 COMPRESSOR PARTS PRESSURE RELIEF 65 PSIG PRESSURE RELIEF 200 TO 217 PSIG (15 BAR) 277609_r2 7 - 6 99906549 rev 00 (JANUARY-2020) IOWA MOLD TOOLING CO., INC. (641) 923-3711...
  • Page 53 BLOCK, CLAMPING PIPE CAPSCREW, S.H. M10x1.5 x 35MM Pressure relief valve may vary at either 200 PSIG, or 217 PSIG, depending upon machine build. To verify proper pressure relief valve rating, consult the IMT Service Department with machine serial number available.

  • Page 54: Display And Controller

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.4 DISPLAY AND CONTROLLER 7.5 DISPLAY AND GAUGE ASSEMBLY (MECHANICAL CONTROL) ITEM DESCRIPTION PART NUMBER GAUGE, AIR PRESSURE w/ SWITCH PANEL, GAUGE MECHANICAL TEE, PIPE GALV 1/4 x 1/4 x 1/8...

  • Page 55: Motor And Drive Parts

    CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 7: ILLUSTRATED PARTS LIST 7.6 MOTOR AND DRIVE PARTS ITEM DESCRIPTION PART NUMBER ELBOW, 90 DEG #8 MJIC x #12 MSAE ELBOW, 90 DEG #4 MJIC x #6 MSAE TEE, JIC/JIC/SAE #12 MOTOR, HYDRAULIC 32CC 3/4...

  • Page 56: Hydraulic Cooler & Parts - 12V With Thrml / Gauges

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.7 HYDRAULIC COOLER & PARTS - 12V WITH THRML / GAUGES 6020235 12V W/THRML SHOWN NOTES: 1. USE LOCTITE 567 THREAD SEALANT WITH PTFE OR EQUIVALENT SEALANT ON ALL MALE PIPE THREADS.
  • Page 57 CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 7: ILLUSTRATED PARTS LIST 7.7 HYDRAULIC COOLER & PARTS - 12V WITH THRML / GAUGES ITEM DESCRIPTION PART NUMBER CONNECTOR, #12 MSAE x #12 MJIC TRANSDUCER, PRESS 1/8NPT 200PSI -40 to 125 C BRACKET, COOLER MOUNTING RIGHT...

  • Page 58: Hydraulic Cooler & Parts - 24V With Thrml / Gauges

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.8 HYDRAULIC COOLER & PARTS - 24V WITH THRML / GAUGES 6020240 24V W/THRML/GAUGES SHOWN TABULATED ASSEMBLIES PART NUMBER DESCRIPTION ITEM A DESCRIPTION ITEM B DESCRIPTION ITEM C DESCRIPTION HYD CLR & PRTS, 12V W/THRML/GAUGES RELAY, NO/NC WHTRPRF 12V w/BKT.
  • Page 59 CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 7: ILLUSTRATED PARTS LIST 7.8 HYDRAULIC COOLER & PARTS - 24V WITH THRML / GAUGES ITEM DESCRIPTION PART NUMBER CONNECTOR, #12 MSAE x #12 MJIC ADAPTER, #4 MBSPP X 1/4 MNPT SWITCH, PRESSURE NO/NC ADJUSTABLE MAX 362PSI EATON...

  • Page 60: Frame And Canopy - 1 Of 3 (Assembly Part A)

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.9 FRAME AND CANOPY - 1 OF 3 (ASSEMBLY PART A) NOTE: THIS END TO LID FASTEN WITH BLUE LOCTITE ZIP TIE HARNESS HERE 6030180ID_r3_1of2 7 - 14 99906549 rev 00 (JANUARY-2020) IOWA MOLD TOOLING CO., INC.
  • Page 61 CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 7: ILLUSTRATED PARTS LIST 7.9 FRAME AND CANOPY - 1 OF 3 (ASSEMBLY PART A) ITEM DESCRIPTION PART NUMBER SPACER, .313ID X 0.75OD X 0.375L WASHER, NYLON FLAT 1/4 SCREW, TRUSS 1/4-20 X 3/4 SS GAS SPRING, 6 STROKE, 20# CAPSCREW, HEX GR5 1/4-20 x 0.75...

  • Page 62: Frame And Canopy - 2 Of 3 (Assembly Parts B - C)

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.9 FRAME AND CANOPY - 2 OF 3 (ASSEMBLY PARTS B - C) INSTALL FOR MODELS USING MECHANICAL GAUGES ONLY (2x) (2x) (4x) (2x) (4x) (2x) (2x) DEFAULT INSTRUMENT PANEL LOCATION...

  • Page 63: Frame And Canopy - 3 Of 3 (Assembly Parts D - F)

    CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 7: ILLUSTRATED PARTS LIST 7.9 FRAME AND CANOPY - 3 OF 3 (ASSEMBLY PARTS D - F) USE MEDIUM STRENGTH (BLUE) THREAD LOCKER USE MEDIUM STRENGTH (BLUE) THREAD LOCKER DETAIL 3-PLACES ITEM DESCRIPTION PART NUMBER...

  • Page 64: Hydraulic Manifold Assembly - 12Vdc Open Center (Standard & Cold Weather)

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.10 HYDRAULIC MANIFOLD ASSEMBLY - 12VDC OPEN CENTER (STANDARD & COLD WEATHER) 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 SPECIFIED.
  • Page 65 WASHER, INTERNAL TOOTH 1 INCH BULKHEAD, MJIC x MJIC #6 Solenoid: For solenoid replacement, consult the IMT Service Department. Pressure Relief: For pressure relief replacement, consult the IMT Service Department. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER. 99906549 rev 00 (JANUARY-2020) 7 - 19 IOWA MOLD TOOLING CO., INC.

  • Page 66: Hydraulic Manifold Assembly - Closed Center 24V (Standard & Cold Weather)

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.11 HYDRAULIC MANIFOLD ASSEMBLY - CLOSED CENTER 24V (STANDARD & COLD WEATHER) 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 OTHERWISE SPECIFIED.
  • Page 67 862104-025 BULKHEAD, MJIC x MJIC #6 862106-038 Flow Regulator: For fl ow regulator replacement, consult the IMT Service Department. Solenoid: For solenoid replacement, consult the IMT Service Department. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER. 99906549 rev 00 (JANUARY-2020) 7 - 21 IOWA MOLD TOOLING CO., INC.

  • Page 68: Decal Identification/Locations - 1 Of 2

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.12 DECAL IDENTIFICATION/LOCATIONS - 1 OF 2 ITEM DESCRIPTION PART NUMBER DECAL, READ MANUAL DECAL, HOT PARTS DECAL, ROTATING PARTS DECAL, CONNECT AIR HOSE DECAL, IMT SERVICE/REPAIR 70392962 DECAL, CAUTION AUTO START...

  • Page 69: Decal Identification/Locations - 2 Of 2

    DECAL, HYDRAULIC CASE DRAIN DECAL, HYDRAULIC SUPPLY DECAL, COMPRESSOR FLUID DRAIN Decal shown is for model CAS40PL. decal no. 280136-A. Other models/part numbers include: CAS40PL-CW (no. 280137-A); CAS40PLE (no. 280134-A); CAS40PLE-CW (no. 280135-A). PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

  • Page 70: Hose And Tube Routing - Open Center 12V, No Thermal

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.13 HOSE AND TUBE ROUTING - OPEN CENTER 12V, NO THERMAL HOSE AND TUBE ROUTING INSTRUCTIONS ITEM PART NUMBER DESCRIPTION START HOSE, HYDRAULIC MOTOR IN DD HOSE, HYDRAULIC MANF TO MOTOR OUT DD...

  • Page 71: Hose And Tube Routing - Open Center 12V, With Thermal

    CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 7: ILLUSTRATED PARTS LIST 7.14 HOSE AND TUBE ROUTING - OPEN CENTER 12V, WITH THERMAL HOSE AND TUBE ROUTING INSTRUCTIONS ITEM PART NUMBER DESCRIPTION START HOSE, HYDRAULIC MOTOR IN DD HOSE, HYDRAULIC MANF TO MOTOR OUT DD...

  • Page 72: Hose And Tube Routing - Open Center 12V, No Thermal, With Gauges

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.15 HOSE AND TUBE ROUTING - OPEN CENTER 12V, NO THERMAL, WITH GAUGES HOSE AND TUBE ROUTING INSTRUCTIONS ITEM PART NUMBER DESCRIPTION START HOSE, HYDRAULIC MOTOR IN DD HOSE, HYDRAULIC MANF TO MOTOR OUT DD...

  • Page 73: Hose And Tube Routing - Open Center 12V, Thermal & Gauges

    CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 7: ILLUSTRATED PARTS LIST 7.16 HOSE AND TUBE ROUTING - OPEN CENTER 12V, THERMAL & GAUGES ITEM PART NUMBER DESCRIPTION START HOSE, HYDRAULIC MOTOR IN DD HOSE, HYDRAULIC MANF TO MOTOR OUT DD HOSE, HYDRAULIC COOLER OUT...

  • Page 74: Hydraulic Thermal Valve Assembly

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.17 HYDRAULIC THERMAL VALVE ASSEMBLY ASSEMBLY DRAWING STANDARD NOTES: 1. LUBRICATE ALL ELASTOMERIC SEALS/GASKETS/ O-RINGS BEFORE TIGHTENING. ITEM DESCRIPTION PART NUMBER ELBOW, 90 DEG #12 MJIC x #16 MSAE VALVE, THERMAL BYPASS 1” SAE 50PSI 100 DEG PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER.

  • Page 75: Electrical Schematic

    CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 7: ILLUSTRATED PARTS LIST 7.18 ELECTRICAL SCHEMATIC P/N1 VBBS FUSE FUSE VBB1 30 AMP JCASE STYLE FUSE (VANAIR 279301) FOR +12V AND +24V MACHINES VBB2 10 AMP N.O. N.C. CAN1L RELAY FAN MOTOR CAN1H LIVE FEED MUST BE CONNECTED TO "A"...

  • Page 76: Wiring Diagram

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.19 WIRING DIAGRAM RELAY 12/24 VDC BATTERY SUPPLY N.O. MACHINE ACTIVATION 87A N.C. CIRCUIT 30 AMP JCASE STYLE FUSE SYSTEM GROUND AUXILIARY CIRCU IT 6 PIN CONNECTOR SYSTEM GROUND 10 AMP...

  • Page 77: Hydraulic Oil Flow Schematic Diagram - Open Center, With Thermal Valve

    CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 7: ILLUSTRATED PARTS LIST 7.20 HYDRAULIC OIL FLOW SCHEMATIC DIAGRAM - OPEN CENTER, WITH THERMAL VALVE THERMAL VALVE W / PRESSURE RELIEF TRUCK SYSTEM COMPRESSOR SYSTEM HYDRAULICS RETURN PRESSURE SOLENOID MACHINE END PANEL CASE RELIEF VALVE...

  • Page 78: Hydraulic Oil Flow Schematic Diagram - Open Center

    SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW 7.21 HYDRAULIC OIL FLOW SCHEMATIC DIAGRAM - OPEN CENTER MACHINE HYDRAULICS MACHINE END PANEL TRUCK SYSTEM HYDRAULIC OIL COOLER RETURN PRESSURE SOLENOID VALVE RELIEF VALVE CASE DRAIN = FLOW DIRECTION = HYDRAULIC OIL...

  • Page 79: Hose Installation Guide

    CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW SECTION 7: ILLUSTRATED PARTS LIST 7.22 HOSE INSTALLATION GUIDE HOSE LAYOUT WRONG RIGHT HOSE LAYOUT WRONG RIGHT CONSIDERATION CONSIDERATION 1. Hose is weakened when 4. Use elbows or other installed in twisted position. adapters necessary Pressure in twisted hose tends to eliminate excess hose to loosen fi...
  • Page 80 SECTION 7: ILLUSTRATED PARTS LIST CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW TABLE 7B: MAINTENANCE TRACKING LOG DATE DESCRIPTION OF MAINTENANCE PART(S) REPLACED 7 - 34 99906549 rev 00 (JANUARY-2020) IOWA MOLD TOOLING CO., INC. (641) 923-3711...

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