40 CFM/100 PSIG STANDARD RECIPROCATING COMPRESSOR an oshkosh corporation company 40 cfm/100 psig standard

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  • ®

    An Oshkosh Corporation Company

    40 CFM/100 PSIG STANDARD RECIPROCATING COMPRESSOR

    INSTALLATION, OPERATION, MAINTENANCE AND PARTS MANUAL

    P/N 99905382

    Revision 02

    Effective Date: 6/2018 ©2014 Iowa Mold Tooling, Co., Inc.

    All rights reserved.

    NOTE

    Read this manual before installing,

    operating or servicing this

    equipment. Failure to comply with

    the operation and maintenance

    instructions in this manual WILL

    VOID THE EQUIPMENT WARRANTY.

    NOTE

    Making unauthorized modifications to

    the compressor or system components

    WILL VOID THE WARRANTY!

    Always inform Iowa Mold Tooling Co.,

    Inc., before making any changes to the

    CAS40P system.

    NOTE

    Use only IMT Premium Reciprocating

    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!

    Iowa Mold Tooling Co., Inc. 500 Highway 18 West

    Garner, Iowa 50438

    Phone: 641.923.3711

    Fax: 641.923.2424

    KEEP THE MANUAL

    WITH THE VEHICLE

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

  • CAS40P 40 CFM / 100 PSIG TABLE OF CONTENTS

    Manual #99905382 Rev 02 (JUNE 2018) PAGE - I

    TABLE OF CONTENTS

    ®

    An Oshkosh Corporation Company

    TABLE OF CONTENTS......................................................I

    SECTION 1: SAFETY.........................................................1 1.1 GENERAL INFORMATION ............................................................................................................1

    1.2 WARNINGS, CAUTIONS AND NOTES .........................................................................................1

    1.3 SUMMARY OF DANGER, WARNINGS, CAUTIONS AND NOTES ..............................................1

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

    1.3.2 WARNINGS......................................................................................................................................................... 2

    1.3.3 CAUTIONS.......................................................................................................................................................... 3

    1.3.4 SAFETY DECALS............................................................................................................................................... 3

    SECTION 2: DESCRIPTION ..............................................5 2.1 GENERAL DESCRIPTION.............................................................................................................5

    2.2 COMPONENT DESCRIPTIONS ....................................................................................................6

    2.2.1 COMPRESSOR PUMP ....................................................................................................................................... 6

    2.2.2 COOLING SYSTEM ............................................................................................................................................ 7

    2.2.3 ELECTRICAL SYSTEM ...................................................................................................................................... 7

    2.2.4 AIR CONTROL SYSTEM.................................................................................................................................... 7

    2.2.5 HYDRAULIC CONTROL SYSTEM..................................................................................................................... 7

    2.2.6 PRESSURE RELIEF VALVES............................................................................................................................ 8

    2.2.7 MAIN FRAME AND ENCLOSURE ..................................................................................................................... 9

    SECTION 3: SPECIFICATIONS .........................................11 TABLE 3A: SPECIFICATIONS .............................................................................................................11

    TABLE 3B: CAPSCREW TIGHTENING TORQUE VALUES ...............................................................12

    TABLE 3C: COMPRESSOR TORQUE VALUES .................................................................................12

    SECTION 4: INSTALLATION .............................................13 4.1 MACHINE PACKAGE RECEIPT/INSPECTION .............................................................................13

    4.2 GENERAL INSTRUCTIONS ..........................................................................................................13

    4.3 DETERMINING THE CAS40P UNIT MOUNTING LOCATION ......................................................13

    Continued on next page...

  • TABLE OF CONTENTS CAS40P 40 CFM / 100 PSIG

    PAGE - II ®

    An Oshkosh Corporation Company

    SECTION 4: INSTALLATION (CONTINUED) FIGURE 4-2: CAS40P DIMENSIONS .........................................................................................15

    4.4 CONNECTING THE ELECTRICAL SUPPLY ................................................................................ 16

    4.5 HYDRAULIC SYSTEM REQUIREMENTS .................................................................................... 16

    4.6 CONNECTING THE HYDRAULIC SUPPLY AND RETURN ......................................................... 17

    4.7 CONNECTING THE AIR SUPPLY................................................................................................. 17

    4.7.1 AIR RESERVOIR TANK INSTALLATION............................................................................................................17

    FIGURE 4-4 ELECTRICAL SYSTEM..........................................................................................19

    FIGURE 4-5 FLOW SCHEMATIC DIAGRAM..............................................................................20

    SECTION 5: OPERATION ................................................. 21 5.1 GENERAL INFORMATION ........................................................................................................... 21

    5.2 OPERATING CONDITIONS .......................................................................................................... 21

    5.3 FIRST TIME START-UP ................................................................................................................ 22

    5.4 SHUTDOWN (FIRST-TIME AND ROUTINE)................................................................................. 23

    5.5 ROUTINE START-UP .................................................................................................................... 23

    5.6 EXTREME CONDITION OPERATION .......................................................................................... 23

    SECTION 6: MAINTENANCE............................................ 25 6.1 GENERAL INFORMATION ........................................................................................................... 25

    6.2 MACHINE MAINTENANCE SCHEDULE....................................................................................... 25

    TABLE 6A: ROUTINE MAINTENANCE SCHEDULE .............................................................................. 26

    6.3 REPLACEMENT PARTS ............................................................................................................... 27

    6.4 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES ................................................... 27

    6.4.1 REMOVING PANELS FOR MACHINE MAINTENANCE ACCESS.....................................................................29

    6.4.1.1 OPENING AND CLOSING THE ROOF PANEL ............................................................29

    TABLE 6B: ACCESS PANEL REMOVAL ................................................................................................ 30

    6.4.1.2 REMOVING AND REPLACING A SIDE PANEL............................................................31

    6.4.2 CHECKING PRESSURE GAUGE .......................................................................................................................33

    6.4.3 COMPRESSOR SYSTEM LUBRICATION ..........................................................................................................33

    6.4.3.1 CHECKING THE OIL LEVEL.........................................................................................34

    6.4.3.2 CHANGING THE COMPRESSOR OIL..........................................................................34

    6.4.4 AIR FILTER MAINTENANCE...............................................................................................................................34

    6.4.4.1 INSPECTING THE AIR FILTER(S)................................................................................36

    6.4.4.2 REPLACING THE AIR FILTER(S) .................................................................................36

    6.4.5 CHECKING THE COOLER CORE ......................................................................................................................37

    6.4.6 COMPRESSOR VALVE MAINTENANCE...................................................................................

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