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45 CFM / 150 PSIG HYDRAULIC-DRIVEN,OPEN CENTER, 12V & 24V, (OPTIONAL) COLD-

WEATHER, ROTARY SCREW COMPRESSORINSTALLATION, OPERATION, MAINTENANCE AND PARTS MANUAL

©2018 Iowa Mold Tooling Co., Inc.All rights reserved.

P/N 99906316rev0

Effective Date:JANUARY 2018

Iowa Mold Tooling Co., Inc.500 Highway 18 WestGarner, Iowa 50438

Phone: 641.923.3711

Fax: 641.923.2424www.imt.com

1.800.247.5958

CAS45RS and CAS45RS-CW

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.

NOTEUse only Vanair Vanguard™ Premium Synthetic Oil and

Genuine Vanair Parts. Inspect and replace

damaged components before operation.

Substituting non-Vanair oil or non-genuine Vanair filter

components WILL VOID THE COMPRESSOR

WARRANTY!

NOTEMaking unauthorized

modifications to the system components WILL VOID THE

WARRANTY!

Always inform Vanair Manufacturing, Inc., before beginning any changes to

the CAS45S system.

KEEP THE MANUALWITH THE VEHICLE

NOTEThis 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.

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

IMT CAS45RS AND CAS45RS-CW TABLE OF CONTENTS

MANUAL #99906316 REV.0 PAGE - I

TABLE OF CONTENTS

IOWA MOLD TOOLING CO., INC.(800) 247-5958 • www.imt.com

TABLE OF CONTENTS ...................................................... ISECTION 1: SAFETY .....................................................1

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

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

1.2.1 DANGERS ........................................................................................................................................................ 1

1.2.2 WARNINGS ...................................................................................................................................................... 1

1.2.3 CAUTIONS ....................................................................................................................................................... 2

1.2.4 NOTES ................................................................................................................................................................... 3

1.3 SAFETY DECALS ....................................................................................................................3

1.4 DISPOSING OF MACHINE FLUIDS .......................................................................................3

SECTION 2: SPECIFICATIONS ..........................................5TABLE 2A: IMT CAS45RS & CAS45RS-CW SPECIFICATIONS ..............................................................5TABLE 2B: PRIME LUBRICANT CHARACTERISTICS.............................................................................6TABLE 2C: RECOMMENDED TORQUE SPECIFICATIONS ....................................................................6

SECTION 3: INSTALLATION..............................................73.1 MACHINE PACKAGE RECEIPT/INSPECTION............................................................................73.2 GENERAL INSTRUCTIONS .........................................................................................................7

3.3 DETERMINING THE COMPRESSOR UNIT MOUNTING LOCATION.........................................83.4 HYDRAULIC SYSTEM OVERVIEW .............................................................................................8

3.4.1 HYDRAULIC SYSTEM FILTRATION...................................................................................................................... 8

3.4.2 HYDRAULIC OIL RESERVIOR.............................................................................................................................. 9

3.4.2.1 DETERMINING RESERVOIR SIZE .............................................................................. 93.4.2.2 DETERMINING RESERVOIR SHAPE .......................................................................... 9

3.4.2.3 MANDATORY RESEROIR FEATURES ........................................................................ 9

Continued on next page...

TABLE OF CONTENTS IMT CAS45RS AND CAS45RS-CW

PAGE - II MANUAL #99906316 REV.0IOWA MOLD TOOLING CO., INC.

(800) 247-5958 • www.imt.com

SECTION 3: INSTALLATION (CONTINUED)3.4.2.4 RECOMMENDED RESERVOIR OPTIONS.................................................................103.4.2.5 RESERVOIR FEATURES TO AVOID ..........................................................................10

3.4.3 RECOMMENDED HYDRAULIC SYSTEM SPECIFICATIONS ............................................................................ 10

3.4.4 STANDARDS GUIDELINES................................................................................................................................. 10

3.5 INSTALLATION............................................................................................................................113.5.1 MACHINE LOCATION...........................................................................................................................................11

3.5.2 CLEARANCES ......................................................................................................................................................11

3.5.3 MOUNTING...........................................................................................................................................................11

3.5.4 SERVICE CONNECTIONS ...................................................................................................................................11

3.5.5 ELECTRICAL CONNECTIONS.............................................................................................................................11

3.5.6 HYDRAULIC SUPPLY CIRCUIT ...........................................................................................................................11

3.5.7 ROUTING..............................................................................................................................................................11Figure 3-4A: Dimension Diagram - CAS45RS Open Center Without Thermal Valve ................................................. 12

Figure 3-4B: Dimension Diagram - CAS45RS Open Center With Thermal Valve ...................................................... 13

SECTION 4: OPERATION ................................................ 154.1 GENERAL INFORMATION......................................................................................................... 154.2 PURPOSE OF CONTROLS ....................................................................................................... 15Figure 4-1: Main Machine Component Locations...................................................................................................... 16

4.3 NORMAL OPERATION .............................................................................................................. 174.3.1 INITIAL START-UP PROCEDURE: PRE-CHECKS............................................................................................. 17

4.3.2 ROUTINE START-UP PROCEDURE ................................................................................................................... 18

4.3.3 ROUTINE SHUT-DOWN PROCEDURE .............................................................................................................. 18Figure 4-5: Controller Screen Identification and Navigation ....................................................................................... 19

4.3.4 OPERATING CONDITIONS................................................................................................................................. 20

4.3.5 EXTREME CONDITION OPERATION ................................................................................................................. 20

SECTION 5: MAINTENANCE........................................... 215.1 GENERAL INFORMATION ........................................................................................................ 215.2 MACHINE MAINTENANCE SCHEDULE ................................................................................... 225.3 REPLACEMENT PARTS............................................................................................................ 22TABLE 5A: ROUTINE MAINTENANCE SCHEDULE .............................................................................. 23

5.4 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES................................................ 27


IMT CAS45RS AND CAS45RS-CW TABLE OF CONTENTS

MANUAL #99906316 REV.0 PAGE - IIIIOWA MOLD TOOLING CO., INC.(800) 247-5958 • www.imt.com

SECTION 5: MAINTENANCE (CONTINUED)5.4.1 ALIGNMENT......................................................................................................................................................... 27

5.4.2 SETTING THE MINIMUM PRESSURE VALVE.................................................................................................... 28

5.4.3 COMPRESSOR THERMAL VALVE...................................................................................................................... 28

5.4.4 SERVICING THE SYSTEM CIRCUIT BREAKER, FUSE AND RELAY................................................................ 28

5.4.5 SAFETY SHUTDOWN SYSTEMS ....................................................................................................................... 28

5.4.6 PRESSURE RELIEF VALVE ................................................................................................................................ 29

5.4.7 REPLACING THE DRIVE COUPLING................................................................................................................. 29

5.4.7.1 REPLACING THE DRIVE COUPLING ELEMENT...................................................... 30

5.4.7.2 COUPLING ASSEMBLY.............................................................................................. 315.4.7.3 HUB ALIGNMENT CHECK.......................................................................................... 315.4.7.4 COUPLING MAINTENANCE....................................................................................... 31

5.4.8 STORAGE AND INTERMITTENT USE................................................................................................................ 32

5.4.8.1 INTERMITTENT USE......................................................................................................... 325.4.8.2 LONG TERM STORAGE .................................................................................................... 32

SECTION 6: TROUBLESHOOTING .................................336.1 GENERAL INFORMATION.........................................................................................................33Figure W-1: Serial Plate / Serial Number Location..................................................................................................... 34

6.2 TROUBLESHOOTING GUIDE....................................................................................................34

SECTION 7: ILLUSTRATED PARTS LIST.......................377.1 PARTS ORDERING PROCEDURE............................................................................................37TABLE 7A: RECOMMENDED SPARE PARTS LIST .............................................................................387.2 COMPRESSOR REPLACEMENT PARTS ................................................................................407.3 COOLER ASSEMBLY (NO THERMAL VALVE)..........................................................................427.4 COOLER ASSEMBLY (WITH THERMAL VALVE) ......................................................................437.5 FRAME AND CANOPY ASSEMBLY...........................................................................................447.6 HOSE & TUBING ASSEMBLY - OPEN CENTER; NO THERMAL VALVE .................................467.7 HOSE & TUBING ASSEMBLY - OPEN CENTER; WITH THERMAL VALVE .............................487.8 DISPLAY AND CONTROLLER ASSEMBLY...............................................................................507.9 HYDRAULIC MANIFOLD ASSEMBLY - OPEN CENTER ..........................................................517.10 DECALS - PART 1 OF 2 .............................................................................................................527.10 DECALS - PART 2 OF 2 .............................................................................................................53

7.11A SCHEMATIC DIAGRAM - HYDRAULIC OIL FLOW, OPEN CENTER .......................................54


TABLE OF CONTENTS IMT CAS45RS AND CAS45RS-CW

PAGE - IV MANUAL #99906316 REV.0IOWA MOLD TOOLING CO., INC.

(800) 247-5958 • www.imt.com

SECTION 7: ILLUSTRATED PARTS LIST (CONT.)7.11B SCHEMATIC DIAGRAM - HYDRAULIC OIL FLOW, OPEN CENTER

WITH THERMAL VALVE ............................................................................................................ 557.12 ELECTRICAL SCHEMATIC........................................................................................................ 567.13 HOSE INSTALLATION GUIDE ................................................................................................... 57TABLE 7C: MAINTENANCE TRACKING LOG ....................................................................................... 59

IMT CAS45RS AND CAS45RS-CW SECTION 1: SAFETY

Manual #99906316 Rev.0 PAGE - 1IOWA MOLD TOOLING CO., INC.(800) 247-5958 • www.imt.com

1.1 GENERAL INFORMATIONThe products provided by Iowa Mold ToolingCo., Inc. are designed and manufactured forsafe operation and maintenance. But it isultimately the responsibility of the users andmaintainers for safe use of this equipment.Part of this responsibility is to read and befamiliar with the contents of this manualbefore operation or performing maintenanceactions.

1.2 DANGERS, WARNINGS, CAUTIONS AND NOTES

These boxes are labeled clearly with the titleblock listing either Danger, Warning,Caution, or other non-safety issue. Theydraw attention to specific issues that arepertinent to the safe and correct operation ofthe machine.

The symbols shown and defined in Section1: Safety are used throughout this manualand on the machine to call attention to, andidentify, possible hazards.

The international warning symbol (shownabove) is used on all decals, labels andsigns that concern information pertaining tobodily harm. When you see the internationalwarning symbol, pay extremely carefulattention, and follow the given instructionsor indications to avoid any possible hazard.

1.2.1 DANGERS

• 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.

1.2.2 WARNINGS

• 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 an IMT compressor to supply breathing air.

• DO NOT perform any modifications tothis equipment without prior factoryapproval.

• DO NOT operate the compressor or anyof its systems if there is a known unsafecondition. Disable the equipment bydisconnecting it from its power source.Install a lock-out tag to identify theequipment as inoperable to otherpersonnel.

• DO NOT operate the compressor withany by-pass or other safety systemsdisconnected 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, after 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

DANGERIdentifies actions or conditions which will cause death, severe injury, or equipment

damage or destructive malfunctions.

WARNINGIdentifies actions or conditions which may cause death, severe injury, or equipment

damage or destructive malfunctions.

SECTION 1:SAFETY

SECTION1: SAFETY IMT CAS45RS AND CAS45RS-CW

PAGE - 2 Manual #99906316 Rev.0 IOWA MOLD TOOLING CO., INC.(800) 247-5958 • www.imt.com

slowly opening the fill cap. Remove all electrical power.

• DO NOT use the compressor forpurposes other than for which it isintended. High pressure air can causeserious and even fatal injuries.

• DO NOT operate the compressoroutside of its specified pressure andspeed ratings. (See Section 2:Specifications or refer to the equipmentdata plate.).

• DO NOT use flammable solvents orcleaners for cleaning the compressor orits parts.

• DO NOT operate the compressor inareas where flammable, toxic, orcorrosive fumes, or other damagingsubstance can be ingested by thecompressor intakes.

• Keep arms, hands, hair and 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 protection as required for the task at hand.

• DO NOT operate the compressor withany guards removed or damaged, orother safety devices inoperative.

• DO NOT operate the compressor inenclosed or confined spaces whereventilation is restricted or closed-off.

• Ensure that hoses connected to servicevalves are fitted with correctly sized andrated flow limiting devices which complywith applicable codes. Pressurizedbroken or disconnected hoses can whip,causing injuries or damage.

• DO NOT use tools, hoses, or equipmentthat have maximum ratings below that ofthis compressor.

• Keep metal tools, and other conductiveobjects away from live electricalcomponents.

• Before performing maintenance or repairoperations on the compressor, ensurethat all power has been removed andbeen locked out to prevent accidentalapplication.

• DO NOT assume that because thecompressor is in a STOPPED conditionthat hydraulic power has been removed.

• Use this compressor only to compressatmospheric air. Use of this equipmentas a booster pump and/or to compressany other gaseous or aerosol substanceconstitutes improper use. It can alsocause damage or injuries. Such misusewill also void the warranty.

• Install, operate, and maintain thisequipment in full compliance with allapplicable OSHA, other 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 precautions found on containers of hazardous substances.

1.2.3 CAUTIONS

• Check all safety devices for properoperation on a routine basis.

• Ensure that no tools, rags, or otherobjects are left on compressor drivesystems or near intakes.

• Keep the equipment clean whenperforming maintenance or serviceactions. Cover openings to preventcontamination.

• DO NOT operate the compressor ifcooling air is not available (fan/cooler notoperating) or if lubricant levels are belowtheir specified minimum levels.

• Ensure all plugs, hoses, connectors,covers, and other parts removed formaintenance actions are replacedbefore applying power to thecompressor.

NOTESlowly remove fill cap to vent compressor

sump pressure.

CAUTIONIdentifies actions or conditions which will

or can cause injuries, equipment damage or malfunctions.

IMT CAS45RS AND CAS45RS-CW SECTION 1: SAFETY


• Avoid touching hot surfaces andcomponents.

• Ensure that electrical wiring, terminals;hoses and fittings are kept in serviceablecondition through routine inspectionsand maintenance. Replace anydamaged or worn components.

1.2.4 NOTES

Note boxes are usually listed to convey andgive focus to a distinct piece of information,which is not directly related to a safety issue,but is necessary to understand machinefunction and operation. Special notereferrals in the manual may be contained ina box titled with an IMPORTANT banner, asshown below, and may also contain theWARNING symbol, should the informationbe linked to a safety issue:

1.3 SAFETY DECALSSafety decals are placed onto, or locatednear, system components that can present ahazard to operators or service personnel. Allpertinent decals listed in Section 7.10,Decals are located near a component whichis subject to respect in terms of safetyprecautions. Always heed the informationnoted on the safety decals.

1.4 DISPOSING OF MACHINE FLUIDS

Always dispose of machine fluids under theguidance of all applicable local, regional and/or federal law.

IMT® encourages recycling when allowed.For additional information, consult thecontainer label of the fluid in question.

NOTEAdditional information (or existing

information) which should be brought to the attention of operators/maintainers affecting

operation, maintenance, or warranty requirements.

IMPORTANTAdditional, CRUTIAL information (or existing information) which should be brought to the attention of operators/maintainers affecting

operation, maintenance, or warranty requirements.

WARNINGDO NOT REMOVE OR COVER ANY

SAFETY DECAL. Replace any safety decal that becomes damaged or illegible.

SECTION 1: SAFETY IMT CAS45RS AND CAS45RS-CW

PAGE - 4 Manual #99906316 Rev.0

BLANK PAGE


IMT CAS45RS AND CAS45RS-CW SECTION 2: SPECIFICATIONS


SECTION 2: SPECIFICATIONS

TABLE 2A: IMT® CAS45RS & CAS45RS-CW SPECIFICATIONSGENERAL SYSTEM INFORMATION SPECIFICATION

RATINGSCapacity (CFM @ 150 psig): 45Air pressure rating (psig): 150Speed of compressor (RPM @ 100 psig): 4500Hydraulic motor RPM 4500Hydraulic flow (gpm @ 120°F hydraulic oil temperature): 11.0Hydraulic pressure (psig @ 100/150 compressor psig): 2150 @ 100 / 2550 @ 150 II

Maximum compressor oil temperature 240°FMaximum hydraulic oil temperature 160°F

COMPRESSORType: Encapsulated, Oil-injected, Rotary ScrewCompressor oil tank capacity: 4 U.S. Quarts (3.7L)Compressor overheating protection: Shut Down at 240°FAir inlet system: Dry-type, Single Stage FilterDrive coupling: Direct Drive, Flex Jaw CouplingHydraulic motor: Gear Type

PACKAGEMain frame: Formed Aluminum with Bolt-down ProvisionElectrical supply: 12V Standard; 24V OptionalElectrical connections: Deutsch 6-pin RoundSupply connections (customer hook-up): Hydraulic: Oil In = #12 3/4”, 37° JIC

Hydraulic: Oil Out = #16 1”, 37° JIC Case Drain: #6 3/8” JICAir Out: #12 3/4” JICElectrical: 12V DC (Standard)

24V DC (Optional)I Refer to Section 3.4, Hydraulic System Requirements, for additional speed requirement information.II Hydraulic relief valve setting is 3200 psi. Recommended hydraulic system pressure: 2600 psi continuous, 3000 psi

intermittent.

Table continued on next page

SECTION 2: SPECIFICATIONS IMT CAS45RS AND CAS45RS-CW


PACKAGE (continued)Enclosure: Sheet Metal with Service AccessCooler: Hydraulic Oil Cooler/Radiator Core - Electric FanDimensions: 33.6" L x 21.00" W x 22.81” HWeight: 196 lbs (dry)

NOTE: For cold weather machines: Cracking Pressure : 50 PSI

NOTE: Shift Temperature: 100°F

NOTE: For machine installation clearances, refer to Figure 3-2, Minimum Installation Clearances, in Section 3, Installation.

NOTE: Specifications are subject to change without notice.

TABLE 2B: PRIME LUBRICANT CHARACTERISTICSViscosity 178 SUS at 100°F (38°C)

Flash point 457°F (236°C)

Pour Point -49°F (-45°C)

Contains Rust and Oxidation Inhibitors and Detergents

TABLE 2C: RECOMMENDED TORQUE SPECIFICATIONS

TYPE DESCRIPTION: SAE 53 line ID marks

SAE 86 line ID marks

Bolt Diameter Thread / inch Dry Oiled Dry Oiled

1/4 20 8 6 12 9

5/16 18 17 13 25 18

3/8 16 30 23 45 35

1/2 20 90 65 120 90

TABLE 2A: IMT® CAS45RS & CAS45RS-CW SPECIFICATIONSGENERAL SYSTEM INFORMATION SPECIFICATION

IMT CAS45RS AND CAS45RS-CW SECTION 3: INSTALLATION


3.1 MACHINE PACKAGE RECEIPT/INSPECTIONUpon receipt of the machine package,inspect the exterior of the shipping crate forsigns of shipping/transit damage. Anydamage should be reported immediately tothe shipping company.

Access the roof panel to inspect thecomponent parts and supports. Removemanual from inside of canopy.

Should any damage be discovered duringpackage inspection, contact the shippingcompany immediately.

3.2 GENERAL INSTRUCTIONSThis section provides general guidance forlocating and preparing the IMT® CAS45RScompressor package for operation. Eachinstallation is unique and can be affected bylocation, ventilation, and other factors suchas electrical and hydraulic power supplyavailability and location.

NOTEBefore fully unpacking the unit, inspect the

component parts, supports and loose-packed parts to ensure that there have been

no internal movements of assemblies or components, which may have been

damaged during shipment.

WARNINGBefore performing maintenance or repair

operations on the compressor, ensure that all power has been removed and locked

out to prevent accidental application.

DO NOT assume that because the compressor is in a STOPPED condition

that power has been removed.

WARNINGInstall, operate, and maintain this

equipment in full compliance with all applicable OSHA, other Federal, state,

local codes, standards, and regulations.

WARNINGDo not install in any enclosed space

without first contacting IMT.

WARNINGGrounding must consist of a minimum two

(2) gauge wire between the instrument panel, the machine, and the truck chassis.

NOTEAlthough much of the information given in this installation section is detailed, these

guidelines should be considered as referential material only, due to the diverse

possibilities of the end user’s vehicle make, model and year, and the unit model

specifications.

NOTEInstall electrical components (circuit breakers, pressure switches, toggle

switches, etc.) in locations where exposure to water or moisture will be most

minimized.

NOTEContact IMT® at (641) 923.3711

Fax: (641) 923-2424www.imt.com

to report missing items, incorrect part numbers, or other discrepancies.

SECTION 3:INSTALLATION

SECTION 3: INSTALLATION IMT CAS45RS AND CAS45RS-CW


3.3 DETERMINING THE COMPRESSOR UNIT MOUNTING LOCATIONWhen determining the location to mount theCAS45RS unit, the following criteria must betaken into consideration:

• Refer to Section 3.5, Installation. The location must allow for the machine dimensions (Figures 3-3A through 3-3D), and additional space requirements for minimum cooling, access and maintenance.

• The mounting surface must be level and able to accommodate the four [4] mounting bolts of the base frame. Refer to Figures 3-3A through 3-3D for mounting hole location dimensions.

• The mounting surface must be able to support the units weight (196 lbs.).

• The external display must be easily visible to the operator.

It is recommended, for most installations, tomount the compressor on the driver’s side ofthe vehicle. The unit should be situated insuch a manner that the fan (rear) and intakeside (front) are not obstructed. Do not placethe compressor in any location where it canintake exhaust fumes, dust or debris.

3.4 HYDRAULIC SYSTEM OVERVIEW

Refer to Figures 3-3A through 3-3D forhydraulic pump system connections.

Please take into consideration the following:

• The hydraulic flow and pressure requirements of the system.

• A continuous hydraulic load is necessary when compressor is running.

• The duty cycle and ambient operating temperatures.

• Other hydraulic equipment which may share that same hydraulic supply system (IMT® recommends a dedicated pump and hydraulic circuit).

The hydraulic hoses must be run to themachine. Verify that hoses are hooked upproperly to ensure proper flow. Also, verifythat the hoses are laid out properly so thatno chafing or kinking of the hoses ispossible. Refer to Section 7.16, HoseInstallation Guide, for assistance withproper hose layout and connecting functions.

3.4.1 HYDRAULIC SYSTEM FILTRATIONIMT recommends using a 10 micron oil filteron the hydraulic oil return line. Flow rating ofthe filter must be equal to, or greater than,the maximum GPM at which the system willbe operated.

IMPORTANTIMT® highly recommends consulting a

hydraulic supply expert for specifying the correct hydraulic supply components for

vehicle-side integration (including oil reservoir size, hydraulic pressure relief,

hose size, etc.) for your application.

IMPORTANTContaminated hydraulic fluid allowed to

enter the pump will cause malfunction of the pump controls. Hydraulic system hoses

must be flushed and cleaned prior to being connected to the unit.

WARNINGFollow all applicable safety

recommendations as outlined in Section 1: Safety of this manual.

WARNINGImproperly, or non-connected lines will

damage the equipment.

NOTEThe temperature of the hydraulic oil should

not exceed 160°F due to the rating of the IMT-supplied hydraulic motor.



3.4.2 HYDRAULIC OIL RESERVOIR3.4.2.1 DETERMINING RESERVOIR SIZE

In a conventional hydraulic system, minimumtank size, in gallons, should be equal to themaximum GPM flow rate, times two (x 2).

3.4.2.2 DETERMINING RESERVOIR SHAPE

The reservoir structure should be tall andnarrow rather than shallow and broad(Figure 3-1). A tall, narrow tank isrecommended because:

1. The oil level is well above suction line opening, avoiding the possibility of drawing air into the pump due to a vortex or “whirlpool” effect within the tank during operation flow.

2. Allows for better oil level tolerance level of the system if vehicle operates at an unusual (slightly off level) vehicle angle.

3. To keep return flow well below the surface so it does not break the surface and cause aeration (cavitation) of the oil.

3.4.2.3 MANDATORY RESERVOIR FEATURES

• The reservoir should incorporate the following design features:

• In terms of location of the reservoir tank within the hydraulic system, note that the hydraulic pump’s inlet line (suction line out from the reservoir to the pump) should be located near the bottom of the tank, well below the oil level. The suction line should protrude a minimum of two (2”) inches into the reservoir to keep it away from potential contaminant surface buildup.

• A baffle or baffles should be included to prevent sloshing, or centrifugal motion of the oil; the goal is to break up direct flow of the oil from the return point to the suction point. This allows for the cooling action contact with the tanks’ inner surfaces, and promote separation of any air or contaminants that interact with the flowing oil.

• An ideal baffle design would position several (but not too many) baffles to promote an ‘S’ shape flow within the reservoir, as viewed from above. The area of the end gaps should be at least twice the area of the suction line diameter.

• A drain port with plug, situated at the lowest point of the reservoir, is needed to assure complete draining. It should be installed using an adapter or housing which does not protrude above the inner surface of the floor of the tank. It should be visible and accessible for removal, with sufficient space available for catching the waste oil.

• 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 aeration of the circulating oil. This extends oil integrity, which in turn helps to maintain system performance and reliability.

IMPORTANTUse only a filter that is specifically intended

for hydraulic systems.

KEY DESCRIPTION

A PREFERRED SHAPE: TALL AND NARROW

B SHAPE TO AVOID: BROAD AND SHALLOW

Figure 3-1: Reservoir Design Shape

A

B



• An in-line filter on the return line is needed to protect the system against contaminants being introduced into the oil. The filter should be mounted externally from the reservoir in a location that allows for easy of service access.

• A breather and fill cap is needed at the oil fill port, which needs to be located above the system oil level. The breather cap acts to both filter air that is drawn into the reservoir as the oil level diminishes, and bleeds air out as the level is regained. This maintains constant atmospheric pressure in the air volume within the reservoir.

• A sight-glass provides a direct visual indication of the oil level without having to open, or otherwise access, the reservoir.

3.4.2.4 RECOMMENDED RESERVOIR OPTIONS

Although not essential for an adequatelyfunctioning reservoir, the followingcomponents will contribute to maximize thehydraulic system’s efficiency and maintain aquality operational level.

• Magnetic drain plug: Attracts and concentrates ferrous contaminants at the drain plug source for easier accessibility and removal when cleaning tank interior.

• A temperature gauge: Located in approximation to, or built in to, the sight glass assembly allows for temperature reading at a glance.

• Filler port strainer: Prevents large contaminant particles from blending with system oil when adding new oil.

• Return line diffuser (splash) plate reduces velocity of oil flow before return oil stream merges with the main reservoir oil volume.

• A reservoir heater: For those systems that are exposed to cold climate ambients, having the ability to preheat the hydraulic oil prior to start up will make for easier startups, and reduce the strain of warming up the system under adverse cold conditions.

3.4.2.5 RESERVOIR FEATURES TO AVOID

A strainer used to screen the suction line isnot recommended for systems designed formobile equipment use. Having equipmentthat likely experiences long suction lines,cold startups and non-tracked or infrequentmaintenance practices may cause thisstrainer to potentially promote system strain(cavitation) than prolong fluid integritythrough filtration.

A pressurized reservoir is not recommendedfor vehicles, as its complexity invites toomuch potential for loss of system reliability ifit is not properly maintained.

3.4.3 RECOMMENDED HYDRAULIC SYSTEM SPECIFICATIONS

Refer to Figures 3-3A through 3-3D.

• Flow controller is optional to reduce flow if necessary. Consult IMT®.

HYDRAULIC LINESThe following is a minimum requirement andNO quick disconnects may be used. Linesare to be kept as straight and short aspossible.

• Pressure port = Standard, #12, 3/4” hose (located at manifold block)

• Load sense = #4 JIC = 1/4” hose (Used for closed center system only)

• Pressure relief/case drain = #6 JIC = 3/8” hose

• Hydraulic suction = Standard, #16, 1” hose

3.4.4 STANDARDS GUIDELINES• Hydraulic pressure relief factory set at

3200 psi.

WARNINGDo not operate machine without hydraulic

system completely assembled.



3.5 INSTALLATION3.5.1 MACHINE LOCATION

It is vital to locate the machine so that thereis no restriction of cooling air through theenclosure (Refer to Figure 3-2). Cooling airenters the enclosure at the rear (cooler)package end of the machine, passes throughthe cooler and exits through vents in theupper sides and the front.

3.5.2 CLEARANCESRefer to Figure 3-2. Ensure that adequatesurrounding clearance space exists aroundthe machine to allow for adequate coolingventilation through the canopy shroud,unobstructed service access, and a clear

view of the control panel. An approximaterecommendation of ten (10) inchesclearance, minimum, is needed for propercooling circulation, plus any additionalservice access room included whereneeded.

3.5.3 MOUNTINGMounting surface or support should beadequate for the weight of the machine (196lbs.), and should be level for normaloperation. Mounting holes are located in theframe footing for four (4) 1/2” hold downbolts.

3.5.4 SERVICE CONNECTIONSRefer to Figure 3-3A through 3-3D. Serviceconnections are conveniently grouped at thelower rear section of the unit in the baseframe.

3.5.5 ELECTRICAL CONNECTIONSRefer to Figure 3-3A through 3-3D. Thissystem is offered with either 12V DC or 24VDC circuits.

3.5.6 HYDRAULIC SUPPLY CIRCUITRefer to schematic drawings in Sections7.15A through 7.15D. It is recommendedthat the compressor unit possesses aseparate pump/flow/return hydraulic circuit toother hydraulic equipment. This is to preventthe possibility of pressure/flow drops thatmay occur if other hydraulically-poweredequipment is activated during compressoroperation, which may in turn, cause thecompressor to stall out. Alternatively, use ofa diverter valve will permit hydraulics topower different equipment selectively.

3.5.7 ROUTINGRefer to Figures 3-3A through 3-3D, and thewiring diagram. Ensure that all supply hosesand electrical wiring are correctly specified,adequately supported, and do not touch orrest on any sharp edges. Wiring should beprotected with split loom to preventcorrosion, and consequently, loss due todown time.

KEY DESCRIPTIONA BACK SIDE CLEARANCE = 10” MINIMUMB LEFT SIDE CLEARANCE = 10” MINIMUMC FRONT SIDE CLEARANCE = 10” MINIMUM I

D RIGHT SIDE CLEARANCE = 10” MINIMUME TOP SIDE (OVER HEAD) CLEARANCE = 42.63” MINI-

MUM, FOR (OPENED) HOOD ACCESSI The front (control panel) side may need additional clearance for

both access to the service panel there, and/or access to view the controller panel.

Figure 3-2: Minimum Installation Clearances

A

B

D

C

E



Figure 3-3A: Dimension Diagram - CAS45RS Open Center Without Thermal Valve

051614ID_r1

DISCLAIMERIf machine package is to be mounted

within a confined space such as beneath a canopy, the unit must have a minimum of ten (10) inch clearances on the front and back sides for ventilation.



Figure 3-3B: Dimension Diagram - CAS45RS Open Center With Thermal Valve

DISCLAIMERIf machine package is to be mounted

within a confined space such as beneath a canopy, the unit must have a minimum of ten (10) inch clearances on the front and back sides for ventilation.

051613ID_r1


PAGE - 14 Manual #99906316 Rev.0

BLANK PAGE


IMT CAS45RS AND CAS45RS-CW SECTION 4: OPERATION


4.1 GENERAL INFORMATIONA comprehensive array of controls andsafety systems are built into the CAS45RShydraulic compressor system. Refer toFigure 4-1 for a general overview to identifyand locate the system’s main components.Becoming familiar with the functionalinstrumentation, as given in Section 4.2,Purpose of Controls, will help the operator

recognize and interpret the readings ormalfunctions which will call for service orindicate the beginning of a problem.

IMPORTANTIf start-up and shut-down procedures are not

followed, damage to the system and its components may occur.

SECTION 4:OPERATION

4.2 PURPOSE OF CONTROLS

CONTROL OR INDICATOR PURPOSE

Discharge Air Pressure Screen

Continuously monitors service line discharge air pressure. Will activate shut-down if over-pressure occurs.

Discharge Air Temperature Screen

Continuously monitors service line discharge temperature. Will activate shut-down if over-temperature occurs.

Hour Meter Screen Indicates accumulated hours of operation for planning and logging service schedules.

Fault Reset Screen Fault message appears if over temperature or over pressure condition is encountered. Button must be pressed to clear.

Oil Fill/Level Plug Check/fill compressor oil level.

Minimum Pressure/Check Valve

Maintains minimum operating pressure and prevents back flow when unloaded/shutdown.

Pressure Transducer Controls operating pressure; prevents loaded start.

Inlet Solenoid Valve Opens/closes inlet valve in response to pressure transducer.

Air Inlet Valve Opens/closes in response to air demand and acts as check valve upon unload/shutdown to prevent oil blow back into filter.

Hydraulic Pressure Relief Valve

Relieves hydraulic pressure to return line in event of hydraulic over-pressure condition.

Hydraulic Solenoid Valve Responds to activation circuit to direct flow to compressor motor or to return line.

Air Pressure Relief Valve Opens sump pressure to atmosphere in case of air over-pressure condition.

SECTION 4: OPERATION IMT CAS45RS AND CAS45RS-CW


KEY DESCRIPTION KEY DESCRIPTION

A COOLER AND FAN ASSEMBLY N CONTROLLER MODULEB COMPRESSOR SEPARATOR ELEMENT P COMPRESSOR AIR FILTER HOUSINGC RELAY Q COMPRESSOR PRESSURE RELIEF V ALVED MINIMUM PRESSURE VALVE R DRIVE COUPLING ELEMENTE PRESSURE TRANSDUCER (x 2) S LIFTING BAILF THERMAL VALVE ASSEMBLY I T COMPRESSOR OIL FILTER ELEMENTG AIR INLET CONTROL SOLENOID U COMPRESSOR OIL FILL PORT / CAPH COMPRESSOR SIGHT GLASS V CONTROLLER DISPLAY PANELJ COMPRESSOR UNIT W COMPRESSOR OIL DRAINK HYDRAULIC MOTOR X HYDRAULIC OIL RETURN (TO TANK)L SOLENOID (12V or 24V) Y HYDRAULIC MOTOR CASE DRAINM DISCHARGE AIR OUTLET Z HYDRAULIC OIL SUPPLY (TO MOTOR)

I Thermal valve is included only with specified thermal valve option machines.

Figure 4-1: Main Machine Component Locations

A B

KL

S

P

N Q R

CD

E

J

GH

M

W VU

ET

XY

Z

COVER REMOVEDFOR CLARIT Y

F



4.3 NORMAL OPERATIONFollowing is an overview of the normaloperation of the IMT® CAS45RS hydrauliccompressor system from start-up to shut-down. This overview of a typical sequence ofevents may not cover all situations.

4.3.1 INITIAL START-UP PROCEDURE: PRE-CHECKS

Following are step-by-step instructions forthe initial start-up of the CAS45RS hydrauliccompressor system:

1. Ensure the compressor is positioned on a level surface so that the proper amounts of oil can be added, if required.

2. Unit should be bolted down.

3. Ensure all hose connections are tight and wiring connections correct and tight.

4. Check compressor oil level (refer to Figures 4-2 and 4-3).

Add or drain if necessary to accomplishthe recommended compressor oil level.

5. Ensure hydraulic oil to pump inlet, and prime if necessary.

6. Ensure service valve on compressor is closed.

7. Engage hydraulic system (PTO or hydraulic supply) and allow hydraulic oil to circulate back to tank. When solenoid is activated, oil should quickly circulate to the hydraulic motor on the compressor, and start producing air.

8. Check for leaks.9. Refer to Figure 4-5. Press the START

button on the Controller, and wait for the Main Screen (default is the Pressure Screen). Check pressure and temperature screens. Pressure may need adjustment to achieve desired operating pressure. Refer to Section 5, Table 5A: Routine Maintenance Schedule.

10. Partly open service valve to load compressor and allow to warm up. Monitor temperature; The ideal

IMPORTANTIf start-up and shut-down procedures are

not followed, damage to the system and its components may occur.

WARNING Do not rely on hoses to hold the module in

position.

KEY DESCRIPTIONA RED COMPRESSOR FILL CAPB FILL CAP BLEED VENT GROOVEC Open/crack cap slightly to allow bleed

vent to relieve pressure

Figure 4-2: Pressure Relief

A

B C

NOTEAn alternate compressor oil level check can be accomplished via the compressor sight glass. Refer to Table 5A, Key #1, in Section

5, Maintenance for details.

WARNINGDO NOT remove caps, plugs and/or other components when compressor is running or pressurized. Stop compressor and de-

pressurize system prior to maintenance of system. Relieve the entire system pressure

by opening the service valve, which will vent all pressure to the atmosphere.

Wear personal protective equipment such as gloves, work boots, and eye and

hearing protection as required for the task at hand.



operating temperature should be between 180°F (82°C) and 220°F (104°C); approximately 100 degrees over ambient temperature. NOTE: May be higher in high ambient conditions.

11. Cycle compressor on/off with service valve to ensure operation is working.

12. Close service valve.13. Disengage hydraulic system.14. Allow all air to vent to atmosphere.

Check compressor oil level and top off if necessary. Inspect for and correct any leaks; tighten any loose fittings.

4.3.2 ROUTINE START-UP PROCEDURE

1. Ensure the compressor is positioned on a level surface so that the proper amounts of oil can be added, if required.

2. Close the air service valve.3. Engage the hydraulic system (PTO or

hydraulic supply). This will activate the compressor.

4. Allow machine to warm up for several minutes before operating.

4.3.3 ROUTINE SHUT-DOWN PROCEDURE

KEY DESCRIPTION

A COMPRESSOR OIL FILL CAP (RED)

B OIL FILL PORT (cut-away view with cap removed)

C HIGH LEVEL MARK (top of thread/port)

D LOW LEVEL MARK (bottom thread of port) I

E ACCEPTABLE OIL LEVEL RANGEI When level is low, add oil as needed. NOTE: DO NOT mix dif-

ferent types of oil; mixing different types of oil will void the war-ranty. For complete oil change maintenance, refer to Table 5A in Section 5, Maintenance.

Figure 4-3: Compressor Oil Check

B

E

C

D

A

IMPORTANTIf start-up and shut-down procedures are not

followed, damage to the system and its components may occur.

IMPORTANTIf start-up and shut-down procedures are not followed, damage to the system and

its components may occur.

Figure 4-4: Operation Control Panel

A

B

C

D

E

F

G

H

KEY DESCRIPTON PURPOSE

A DISPLAY SCREEN Displays functional attributes of chosen controller task.

B START BUTTON Starts the machine.

C STOP BUTTON Cuts off power / stops the machine immediately.

D NAVIGATION PAD Where applicable, allows for sub-navigation on multiple line function screens.

E DATA BUTTON Shows the Data screen on the display.

F ESCAPE BUTTON Takes the operation back to the initial start screen (see Figure 4-5).

G “OK” CONTROL BUTTON

Takes the operation back to the initial start screen (see Figure 4-5).

H LED INDICATOR When lit (green) indicates panel is in operating state.



Figure 4-5: Controller Screen Identification and Navigation

1

MA

IN (D

EFA

ULT)

SC

REE

N

3

5

BA

24

KEY

SCRE

ENDE

SCRI

PTIO

NA

INIT

IAL S

CREE

NPR

E-SC

REEN

: This

autom

atic s

creen

appe

ars w

hen t

he co

ntroll

er is

first

initia

ted. It

re

mains

for a

few

seco

nds,

then c

hang

es to

the C

ontro

ller R

evisi

on S

creen

.

BCO

NTRO

LLER

REV

ISIO

N SC

REEN

PRE-

SCRE

EN: T

his sc

reen

show

s the

curre

nt ve

rsion

of th

e Disp

lay an

d Con

trolle

r so

ftwar

e. It r

emain

s for

a few

seco

nds,

then c

hang

es to

the M

ain S

creen

.

1MA

IN S

CREE

NTh

is is

the de

fault s

creen

(Pre

ssur

e Scre

en).

It sho

ws th

e cur

rent

pres

sure

statu

s of

the m

achin

e. Pr

essin

g ESC

from

any o

ther s

creen

will

bring

this

scre

en up

.

2SE

TTIN

G AD

JUST

MENT

DI

SPLA

Y SC

REEN

This

scre

en di

splay

s info

rmati

on; it

is no

t pos

sible

to ma

ke ad

justm

ents

from

this

scre

en.

3CU

T-IN

/CUT

-OUT

PRE

SSUR

E SC

REEN

This

scre

en sh

ows,

and a

llows

the o

pera

tor to

chan

ge, th

e pre

set c

ut-in

and c

ut-ou

t pr

essu

res f

or th

e ran

ge of

oper

ation

.

4SE

RVIC

E CO

NTAC

T SC

REEN

This

scre

en sh

ows t

he su

ppor

t pho

ne nu

mber

to co

ntact

the IM

T Se

rvice

De

partm

ent.

5TE

MPER

ATUR

E SC

REEN

This

scre

en sh

ows t

he cu

rrent

(runn

ing) t

empe

ratur

e of th

e mac

hine.



1. Close service valve.2. Allow compressor system to unload

and cool down for approximately five (5) minutes.

3. Shut off hydraulic power supply.

4.3.4 OPERATING CONDITIONS1. Operate only in well-ventilated areas.2. Ensure there are no obstructions of

cooling air intakes and outlets around the machine.

3. Do not leave anything resting on top of the machine. Hot cooling air will generate high heat and must not be restricted.

4. Operate machine with the top cover closed.

5. Refer to specifications for operating parameters.

4.3.5 EXTREME CONDITION OPERATIONWhen operating in extreme hot or coldconditions, extra attention should be given toany indications that could lead to a seriousproblem. Machine review and maintenancecheck schedules should be more frequentthan the normal suggestions given inSection 5, Table 5A: Routine MaintenanceSchedule.

IMPORTANTDo not stop the engine suddenly! Stop the

engine after approximately five (5) minutes of unloaded idling.

IMPORTANTBe sure to leave sufficient room around the machine for cooling air circulation during

operation. There must be a minimum of ten (10) inches for the cooler intake, and ten (10) inches for the sides and rear. Heated

air must be able to vent away from the intake.

IMT CAS45RS AND CAS45RS-CW SECTION 5: MAINTENANCE


5.1 GENERAL INFORMATIONA good maintenance program is the key tolong compressor life. This section contains aprogram that, when adhered to, should keepthe compressor in top operating condition.However, it should be understood that theseintervals are for normal operation in a goodclean environment. More frequentinspections, oil changes and generalmaintenance should be carried out in dustyenvironments, high ambient temperatures,heavy load applications or extended lightload conditions.

Follow the prescribed periodic maintenanceschedules given in Table 5A: RoutineMaintenance Schedule, in this section asrecommended. Failure to follow theprescribed periodic maintenance at therecommended intervals will impair thepackage safety, performance characteristics,shorten the package’s life, and willnegatively affect the warranty coverage ofthe package.

Before starting the compressor system,inspect the machine package for anysuspect condition that may cause a safetyhazard or hamper operation. Replacedamaged components with Genuine IMT®

Replacement Parts.

IMPORTANTIt is important to keep in mind that

operating the compressor package in a severe environment may require more

frequent service intervals than prescribed in the periodic maintenance schedule.

WARNINGFollow all applicable safety

recommendations as outlined in Section 1: Safety of this manual.

WARNINGDO NOT remove caps, plugs and/or other

components when compressor is running or pressurized. Stop compressor and de-pressurize

system prior to maintenance of system.

Wear personal protective equipment such as gloves, work shoes, and eye and hearing protection as

required for the task at hand.

WARNINGDO NOT work on any electrical components unless

the battery is disconnected.

WARNINGFollow the prescribed periodic maintenance (PM)

schedule as recommended. Perform the required PM schedule at recommended intervals.

Failure to follow this prescribed periodic maintenance at the recommended intervals will

impair the package safety, performance characteristics, shorten the package’s life, and will

negatively affect the warranty coverage of the package.

CAUTIONCompressors and drive motors generate heat and

create hot surfaces. Use caution when operating or servicing the compressor system. Some surfaces

and components may be hot.

IMPORTANTIt is important that the compressor oil be of the recommended type and that it is inspected and

replaced together with the oil filter and air filters, and (when necessary) the coalescer separator in

accordance with this manual.

SECTION 5:MAINTENANCE

SECTION 5: MAINTENANCE IMT CAS45RS AND CAS45RS-CW


5.2 MACHINE MAINTENANCE SCHEDULE

Refer to Table 5A: Routine MaintenanceSchedule. A routine maintenance schedulebased on time and/or hours logged, is givenin Table 5A. The intervals are determinedfrom machine usage under typical operationconditions. However, the operator must beaware that operating conditions will varydepending on such things as specificcustomer requirements, environmentaltemperatures and cleanliness of the ambientair. With this in mind, the specifications givenin Table 5A should be used as a guidelineinstead of a fixed agenda. A safe approachto routine maintenance would be to performthe given maintenance task more frequentlyunder harsher conditions.

IMT provides a routine maintenance parts listin Section 7, Table 7A. Should a non-routinepart need replacement or servicing, perusethe various parts list illustrations in Section 7to help determine the exact part and partnumber in question. Our parts and servicedepartments are ready to assist in identifyingand/or replacing non-routine parts.

For assistance in obtaining routinemaintenance or replacement parts, consultSection 7.1, Parts Ordering Procedure,and Table 7A: Recommended Spare PartsList.

5.3 REPLACEMENT PARTSReplacement parts should be purchasedthrough your local IMT representative orwhere the compressor system waspurchased. If, for any reason, parts are notavailable in this manner, they can bepurchased through IMT directly.

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

Garner, Iowa 50438

Phone: 641.923.3711Fax: 641.923.2424

www.imt.com800.247.5958

IMPORTANTDO NOT mix oils of different types. Use only original IMT® equipment filters. Mixing of different types of oils, or using non-IMT equipment filters will VOID

THE WARRANTY.

NOTEFor assistance when ordering new

replacement parts, consult Section 7.1, Parts Ordering Procedure, and Table 7A:

Recommended Spare Parts List.

NOTEIf additional spare parts are being stored for

future use, make certain that they are stored in proper containers that allow for

protection against contamination, and kept in a clean area of moderate temperature reading. For information on storing the

machine package for periods of non-use, consult Section 5.4.8.2, Long Term Storage.



TAB

LE 5

A:

RO

UTI

NE

MA

INTE

NA

NC

E SC

HED

ULE

WA

RN

ING

Befo

re p

erfo

rmin

g m

ainte

nanc

e:

Shut

down

mac

hine

, reli

eve a

ll sys

tem

pres

sure

and

lock

out

all p

ower

, as p

er th

e Saf

ety S

ectio

n of

this

man

ual. I

f mac

hine

is h

ot, a

llow

pack

age t

o co

ol

befo

re re

mov

ing

any p

anel.

NO

TE T

HAT

THE

SYST

EM C

AN B

E ST

ARTE

D RE

MOTE

LY:

Alwa

ys cl

early

tag

the s

tart-

up in

stru

men

tatio

n ag

ainst

accid

enta

l sys

tem

. sta

rt-up

s dur

ing

main

tena

nce.

MAIN

TENA

NCE

INTE

RVAL

SHo

urly,

Cale

ndar

Pe

riod

or

Cont

rolle

r Me

ssag

e-

which

ever

com

es

first

After 8 Hoursor Daily

After Initial50 Hours

After 500 Hoursor Annually

KEY

TASK

DES

CR

IPTI

ON

AC

TIO

N T

O T

AK

E / R

EFER

ENC

E

1Be

fore

star

ting,

chec

k com

pres

sor o

il lev

el.

BEFO

RE R

EMOV

ING

THE

CAP:

Pr

essu

re re

lief -

In or

der t

o rem

ove a

ny

resid

ual a

ir in t

he su

mp, fi

rst cr

ack t

he fil

l cap

[

] slig

htly u

ntil th

e ven

t gro

ove [

] sho

ws

abov

e the

thre

ad lin

e of th

e cap

for a

few

seco

nds.

This

will b

leed a

ny re

maini

ng ai

r pr

essu

re to

atmo

sphe

re.

••

•

NOTE

:En

sure

vehic

le is

situa

ted on

a lev

el su

rface

befor

e che

cking

oil le

vel. A

dd oi

l if

nece

ssar

y.RE

FERE

NCE:

• Opti

mal O

il Lev

el [

] I

• Oil F

ill Po

rt [

]• S

ight G

lass [

]I

Optim

al oil

leve

l: AT

PORT

- lie

s in t

he ar

ea be

twee

n the

botto

m of

the th

read

ed po

rtion o

f the o

il fill

port

and

the ed

ge of

the o

il fill

port

rim. A

T SIG

HT G

LASS

- lies

betw

een 1

/4 an

d 3/4

inter

vals

of the

visib

le (g

lass)

area

; bo

th giv

e the

same

leve

l of th

e sum

p.OR

DER:

• Rep

lacem

ent o

il no.

8908

6222

(gall

on co

ntaine

r).

2Ch

eck f

or an

y lea

ks or

loos

e bolt

s.•

••

Tighte

n if n

eces

sary.

3Af

ter s

tarti

ng, c

heck

pres

sure

read

ing fo

r co

rrect

oper

ating

pres

sure

.•

••

Allow

comp

ress

or to

war

m up

, and

verify

that

the le

vels

are a

ll with

in the

ir rec

omme

nded

rang

es. R

efer t

o Se

ctio

n 2,

Spec

ifica

tions

, for p

ress

ure o

pera

ting r

ange

.

4Ch

eck f

or le

aks.

••

•Vi

suall

y note

any l

eaks

or ev

idenc

e of le

aks a

roun

d the

comp

ress

or un

it and

hose

conn

ectio

ns. T

ighten

any

loose

conn

ectio

n poin

t whe

re ne

eded

. Rep

air or

repla

ce an

y dam

aged

part.

5Ins

pect

venti

lation

open

ings

••

•En

sure

open

ings a

re no

t bloc

ked o

r clog

ged w

ith de

bris.

Clea

r any

cong

estio

n fro

m the

mac

hine v

entila

tion a

reas

be

fore o

pera

ting t

he m

achin

e.

Con

tinue

d on

nex

t pag

e

TABL

E 5B

: ROU

TINE

REP

LACE

MENT

KIT

ORD

ER IN

FORM

ATIO

N I

KEY

NO.

DESC

RIPT

ION

PART

NO.

QTY

1Oi

l, Rota

ry Sc

rew

Comp

ress

or (g

allon

) II

8908

6222

12

Elem

ent, R

eplac

emen

t for C

ompr

esso

r Air F

ilter

7004

8253

13

Elem

ent, R

eplac

emen

t for C

ompr

esso

r Oil F

ilter

7004

8252

14

Elem

ent, R

eplac

emen

t for C

ompr

esso

r Sep

arato

r70

0482

511

I If

worki

ng in

dusty

or di

rty co

nditio

ns, r

educ

e the

reco

mmen

ded t

ime i

nterva

ls be

twee

n ser

vicing

by ha

lf for

engin

e and

com-

pres

sor o

il rep

lacem

ent, a

nd en

gine a

nd co

mpre

ssor

filter

servi

cing.

II

Use

only

IMT

Rotar

y Scre

w Oi

l and

Gen

uine I

MT P

arts.

Sub

stitut

ing no

n-IM

T oil

or no

n-IM

T ge

nuine

filter

comp

onen

ts wi

ll VO

ID T

HE C

OMPR

ESSO

R W

ARRA

NTY!

Insp

ect a

nd re

place

dama

ged c

ompo

nents

befor

e ope

ratio

n. Co

mpre

ssor

sys-

tem fil

l cap

acity

is ap

prox

imate

ly fou

r (4)

quar

ts of

oil.

PLEA

SE N

OTE:

WHE

N OR

DERI

NG P

ARTS

, INDI

CATE

MAC

HINE

SER

IAL

NUMB

ER.

CA

UTI

ON



6cle

an an

d ins

pect

the co

mpre

ssor

air in

take

filter

••

•

REFE

RENC

E:• A

ir Filte

r Elem

ent [

]Re

place

if me

mbra

ne is

wor

n, co

ntains

tear

s or

pinho

les, o

r if fil

ter is

dama

ged.

For d

etails

on or

derin

g and

chan

ging t

he

comp

ress

or ai

r filte

r, re

fer to

Key

#8 in

this

table.

7Ch

ange

comp

ress

or oi

l and

oil fi

lter e

lemen

t

Refer

to th

e CAU

TION

note

instru

ction

in K

ey

#1 be

fore r

emov

ing th

e fill

port

cap.

NOTE

:Th

e com

pres

sor o

il is t

he ke

y to a

long

usefu

l life

of the

air c

ompr

esso

r sys

tem. D

irt an

d othe

r for

eign m

atter

can b

e intr

oduc

ed in

to the

co

mpre

ssor

syste

m thr

ough

the a

ir inta

ke. A

cle

an ai

r filte

r will

ensu

re th

at the

comp

ress

or is

pr

otecte

d.

••

REFE

RENC

E:• O

il Filte

r Elem

ent [

]• O

il Filte

r Sea

l Ring

[]

• Oil L

evel

Sigh

t Glas

s []

• Oil D

rain

Hose

[]

• Oil F

ill Po

rt [

]• O

ptima

l Oil L

evel

[] I

I Op

timal

oil le

vel: A

T PO

RT -

lies i

n the

area

betw

een t

he bo

ttom

of the

thre

aded

portio

n of th

e oil f

ill po

rt an

d the

edge

of th

e oil f

ill po

rt rim

. AT

SIG

HT G

LASS

- lie

s betw

een 1

/4 an

d 3/4

inter

vals

of the

visib

le (g

lass)

area

; both

give

the s

ame l

evel

of the

sump

.OR

DER:

• For

initia

l 50 h

our in

terva

l, ord

er co

mpre

ssor

oil fi

lter r

eplac

emen

t elem

ent n

o. 70

0482

52, a

nd re

place

ment

oil

no. 8

9086

222 (

gallo

n con

taine

r).PR

OCED

URE

CONT

INUE

D ON

NEX

T PA

GE...

Con

tinue

d on

nex

t pag

e

TAB

LE 5

A:

RO

UTI

NE

MA

INTE

NA

NC

E SC

HED

ULE

WA

RN

ING

Befo

re p

erfo

rmin

g m

ainte

nanc

e:

Shut

down

mac

hine

, reli

eve a

ll sys

tem

pres

sure

and

lock

out

all p

ower

, as p

er th

e Saf

ety S

ectio

n of

this

man

ual. I

f mac

hine

is h

ot, a

llow

pack

age t

o co

ol

befo

re re

mov

ing

any p

anel.

NO

TE T

HAT

THE

SYST

EM C

AN B

E ST

ARTE

D RE

MOTE

LY:

Alwa

ys cl

early

tag

the s

tart-

up in

stru

men

tatio

n ag

ainst

accid

enta

l sys

tem

. sta

rt-up

s dur

ing

main

tena

nce.

MAIN

TENA

NCE

INTE

RVAL

SHo

urly,

Cale

ndar

Pe

riod

or

Cont

rolle

r Me

ssag

e-

which

ever

com

es

first




KEY

TASK

DES

CR

IPTI

ON

AC

TIO

N T

O T

AK

E / R

EFER

ENC

E

TABL

E 5B

: ROU

TINE

REP

LACE

MENT

KIT

ORD

ER IN

FORM

ATIO

N I

KEY

NO.

DESC

RIPT

ION

PART

NO.

QTY

1Oi

l, Rota

ry Sc

rew

Comp

ress

or (g

allon

) II

8908

6222

12

Elem

ent, R

eplac

emen

t for C

ompr

esso

r Air F

ilter

7004

8253

13

Elem

ent, R

eplac

emen

t for C

ompr

esso

r Oil F

ilter

7004

8252

14

Elem

ent, R

eplac

emen

t for C

ompr

esso

r Sep

arato

r70

0482

511

I If

worki

ng in

dusty

or di

rty co

nditio

ns, r

educ

e the

reco

mmen

ded t

ime i

nterva

ls be

twee

n ser

vicing

by ha

lf for

engin

e and

com-

pres

sor o

il rep

lacem

ent, a

nd en

gine a

nd co

mpre

ssor

filter

servi

cing.

II

Use

only

IMT

Rotar

y Scre

w Oi

l and

Gen

uine I

MT P

arts.

Sub

stitut

ing no

n-IM

T oil

or no

n-IM

T ge

nuine

filter

comp

onen

ts wi

ll VO

ID T

HE C

OMPR

ESSO

R W

ARRA

NTY!

Insp

ect a

nd re

place

dama

ged c

ompo

nents

befor

e ope

ratio

n. Co

mpre

ssor

sys-

tem fil

l cap

acity

is ap

prox

imate

ly fou

r (4)

quar

ts of

oil.

PLEA

SE N

OTE:

WHE

N OR

DERI

NG P

ARTS

, INDI

CATE

MAC

HINE

SER

IAL

NUMB

ER.

IMPO

RTA

NT



7CO

NTIN

UED

FROM

PRE

VIOU

S PA

GE:

Chan

ge co

mpre

ssor

oil a

nd oi

l filte

r elem

ent

NOTE

:Th

e com

pres

sor o

il is t

he ke

y to a

long

us

eful li

fe of

the ai

r com

pres

sor s

ystem

. Dirt

and o

ther f

oreig

n matt

er ca

n be i

ntrod

uced

int

o the

comp

ress

or sy

stem

throu

gh th

e air

intak

e. A

clean

air f

ilter w

ill en

sure

that

the

comp

ress

or is

prote

cted.

••

Cont

inue

d fro

m p

revio

us p

age..

.OR

DER

(con

tinue

d):

• For

topp

ing of

f com

pres

sor o

il res

ervo

ir, or

der r

eplac

emen

t oil n

o. 89

0862

22 (g

allon

conta

iner).

• F

or 50

0 hou

r inter

val, o

rder

comp

ress

or oi

l filte

r rep

lacem

ent e

lemen

t no.

7004

8252

, rep

lacem

ent o

il no.

8908

6222

(gall

on co

ntaine

r), ai

r filte

r rep

lacem

ent e

lemen

t no.

7004

8253

, and

sepa

rator

repla

ceme

nt ele

ment

no. 7

0048

251.

PROC

EDUR

E:Dr

ain co

mpre

ssor

. Rem

ove w

orn o

il filte

r. Co

at su

rface

of se

aling

ring o

n new

filter

elem

ent r

eplac

emen

t with

co

mpre

ssor

oil b

efore

mou

nting

into

place

; han

d tigh

ten, a

nd th

en w

ith a

filter

wre

nch,

turn f

ilter b

ody a

n ad

dition

al 1/2

to 3/

4 tur

n to s

ecur

e. Re

place

the c

ap on

the o

il dra

in tub

e and

re-se

cure

capp

ed en

d to c

lamp o

n the

cano

py.

Refill

comp

ress

or w

ith ne

w oil

; com

pres

sor o

il fill

is ap

prox

imate

ly fou

r (4)

quar

ts. D

iscar

d use

d oil u

nder

gu

idanc

e of a

ccep

table

refug

e/rec

ycle

laws.

Run c

ompr

esso

r for

appr

oxim

ately

five (

minu

tes) a

nd re

chec

k oil l

evel;

fill a

s nee

ded i

f nec

essa

ry.

8Re

place

intak

e air f

ilter

I•

REFE

RENC

E:• A

ir Filte

r Elem

ent [

]OR

DER:

• Air f

ilter r

eplac

emen

t elem

ent n

o. 70

0482

53.

Air f

ilter is

servi

ced a

t the 5

00 se

rvice

inter

vals,

an

nuall

y, or

if pr

ompte

d by t

he co

ntrol

pane

l ind

icatio

n. In

extre

me am

bient

oper

ation

cond

itions

At

the 5

00 ho

ur or

annu

al int

erva

ls, re

place

air f

ilter

rega

rdles

s of c

ondit

ion.

PROC

EDUR

E CO

NTIN

UED

ON N

EXT

PAGE

...

Con

tinue

d on

nex

t pag

e

TAB

LE 5

A:

RO

UTI

NE

MA

INTE

NA

NC

E SC

HED

ULE

WA

RN

ING

Befo

re p

erfo

rmin

g m

ainte

nanc

e:

Shut

down

mac

hine

, reli

eve a

ll sys

tem

pres

sure

and

lock

out

all p

ower

, as p

er th

e Saf

ety S

ectio

n of

this

man

ual. I

f mac

hine

is h

ot, a

llow

pack

age t

o co

ol

befo

re re

mov

ing

any p

anel.

NO

TE T

HAT

THE

SYST

EM C

AN B

E ST

ARTE

D RE

MOTE

LY:

Alwa

ys cl

early

tag

the s

tart-

up in

stru

men

tatio

n ag

ainst

accid

enta

l sys

tem

. sta

rt-up

s dur

ing

main

tena

nce.

MAIN

TENA

NCE

INTE

RVAL

SHo

urly,

Cale

ndar

Pe

riod

or

Cont

rolle

r Me

ssag

e-

which

ever

com

es

first




KEY

TASK

DES

CR

IPTI

ON

AC

TIO

N T

O T

AK

E / R

EFER

ENC

E

TABL

E 5B

: ROU

TINE

REP

LACE

MENT

KIT

ORD

ER IN

FORM

ATIO

N I

KEY

NO.

DESC

RIPT

ION

PART

NO.

QTY

1Oi

l, Rota

ry Sc

rew

Comp

ress

or (g

allon

) II

8908

6222

12

Elem

ent, R

eplac

emen

t for C

ompr

esso

r Air F

ilter

7004

8253

13

Elem

ent, R

eplac

emen

t for C

ompr

esso

r Oil F

ilter

7004

8252

14

Elem

ent, R

eplac

emen

t for C

ompr

esso

r Sep

arato

r70

0482

511

I If

worki

ng in

dusty

or di

rty co

nditio

ns, r

educ

e the

reco

mmen

ded t

ime i

nterva

ls be

twee

n ser

vicing

by ha

lf for

engin

e and

com-

pres

sor o

il rep

lacem

ent, a

nd en

gine a

nd co

mpre

ssor

filter

servi

cing.

II

Use

only

IMT

Rotar

y Scre

w Oi

l and

Gen

uine I

MT P

arts.

Sub

stitut

ing no

n-IM

T oil

or no

n-IM

T ge

nuine

filter

comp

onen

ts wi

ll VO

ID T

HE C

OMPR

ESSO

R W

ARRA

NTY!

Insp

ect a

nd re

place

dama

ged c

ompo

nents

befor

e ope

ratio

n. Co

mpre

ssor

sys-

tem fil

l cap

acity

is ap

prox

imate

ly fou

r (4)

quar

ts of

oil.

PLEA

SE N

OTE:

WHE

N OR

DERI

NG P

ARTS

, INDI

CATE

MAC

HINE

SER

IAL

NUMB

ER.



8CO

NTIN

UED

FROM

PRE

VIOU

S PA

GE:

Repla

ce in

take a

ir filte

rI

•Co

ntin

ued

from

pre

vious

pag

e...

Unsc

rew

wing

nut a

nd re

move

it, al

ong w

ith th

e was

her.

Pull t

he ho

using

cove

r upw

ard t

o dise

ngag

e fro

m the

ho

using

base

. Pull

filter

upwa

rd to

dise

ngag

e fro

m the

base

. Disc

ard w

orn f

ilter u

nder

prop

er re

fuge l

aw.

NOTE

: If cl

eanin

g, DO

NOT

tear

the f

ilter m

embr

ane.

For a

ir inle

t ser

vice o

r rep

lacem

ent, c

onsu

lt the

IMT

Servi

ce

Depa

rtmen

t.

9Re

place

sepa

rator

elem

ent

•

REFE

RENC

E:• S

epar

ator E

lemen

t []

• Elem

ent S

eal R

ing [

] I

ORDE

R:• S

epar

ator r

eplac

emen

t elem

ent n

o. 70

0482

51.

For c

ompr

esso

r oil d

rain

hose

loca

tion r

efer t

o Key

#8 of

this

Table

. I Co

at su

rface

of se

aling

ring o

n coa

lesce

r filte

r elem

ent w

ith co

mpre

ssor

oil

befor

e mou

nting

into

place

.Co

mpre

ssor

oil fi

ll is a

ppro

ximate

ly fou

r (4)

quar

ts.

10Ins

pect

exter

ior of

fron

t-mou

nted o

il coo

ler•

Clea

r awa

y any

debr

is fro

m the

coole

r cor

es bo

th wi

thin t

he en

closu

re an

d the

exter

ior; c

lean i

f nec

essa

ry.If c

ore b

ecom

es cl

ogge

d, us

e a lo

w pr

essu

re au

xiliar

y air s

ource

to bl

ow th

roug

h the

fins f

rom

inside

the c

anop

y (a

rrow

direc

tion)

to cl

ean i

t out.

The

fan m

ay ne

ed to

be re

move

d fro

m the

shro

ud in

orde

r to r

each

parts

of th

e co

re. D

o no

t use

high

pres

sure

air o

r a pr

essu

re w

ashe

r.

TAB

LE 5

A:

RO

UTI

NE

MA

INTE

NA

NC

E SC

HED

ULE

WA

RN

ING

Befo

re p

erfo

rmin

g m

ainte

nanc

e:

Shut

down

mac

hine

, reli

eve a

ll sys

tem

pres

sure

and

lock

out

all p

ower

, as p

er th

e Saf

ety S

ectio

n of

this

man

ual. I

f mac

hine

is h

ot, a

llow

pack

age t

o co

ol

befo

re re

mov

ing

any p

anel.

NO

TE T

HAT

THE

SYST

EM C

AN B

E ST

ARTE

D RE

MOTE

LY:

Alwa

ys cl

early

tag

the s

tart-

up in

stru

men

tatio

n ag

ainst

accid

enta

l sys

tem

. sta

rt-up

s dur

ing

main

tena

nce.

MAIN

TENA

NCE

INTE

RVAL

SHo

urly,

Cale

ndar

Pe

riod

or

Cont

rolle

r Me

ssag

e-

which

ever

com

es

first




KEY

TASK

DES

CR

IPTI

ON

AC

TIO

N T

O T

AK

E / R

EFER

ENC

E

TABL

E 5B

: ROU

TINE

REP

LACE

MENT

KIT

ORD

ER IN

FORM

ATIO

N I

KEY

NO.

DESC

RIPT

ION

PART

NO.

QTY

1Oi

l, Rota

ry Sc

rew

Comp

ress

or (g

allon

) II

8908

6222

12

Elem

ent, R

eplac

emen

t for C

ompr

esso

r Air F

ilter

7004

8253

13

Elem

ent, R

eplac

emen

t for C

ompr

esso

r Oil F

ilter

7004

8252

14

Elem

ent, R

eplac

emen

t for C

ompr

esso

r Sep

arato

r70

0482

511

I If

worki

ng in

dusty

or di

rty co

nditio

ns, r

educ

e the

reco

mmen

ded t

ime i

nterva

ls be

twee

n ser

vicing

by ha

lf for

engin

e and

com-

pres

sor o

il rep

lacem

ent, a

nd en

gine a

nd co

mpre

ssor

filter

servi

cing.

II

Use

only

IMT

Rotar

y Scre

w Oi

l and

Gen

uine I

MT P

arts.

Sub

stitut

ing no

n-IM

T oil

or no

n-IM

T ge

nuine

filter

comp

onen

ts wi

ll VO

ID T

HE C

OMPR

ESSO

R W

ARRA

NTY!

Insp

ect a

nd re

place

dama

ged c

ompo

nents

befor

e ope

ratio

n. Co

mpre

ssor

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