60 cfm/150 psig standard rotary screw compressor

®
An Oshkosh Corporation Company
60 CFM/150 PSIG STANDARD ROTARY SCREW COMPRESSOR
INSTALLATION, OPERATION, MAINTENANCE AND PARTS MANUAL
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
NOTE
Making unauthorized modifications to
the compressor or system components
WILL VOID THE WARRANTY!
Use only IMT Premium Synthetic 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!
Always inform Iowa Mold Tooling Co.,
Inc., before making any changes to the
CAS60R hydraulic system.
Iowa Mold Tooling Co., Inc.
500 Highway 18 West
Garner, Iowa 50438
Phone: 641.923.3711
Fax: 641.923.6063
PART NUMBER:
99905395
Effective Date: 3/14
©2014 Iowa Mold Tooling Co., Inc.
All rights reserved.
NOTICE TO CUSTOMER
This manual is the final version and some of the information and specifications are subject to change
without notice.
CAS60R 60 CFM / 150 PSIG
TABLE OF CONTENTS
TABLE OF CONTENTS
SECTION 1: SAFETY.........................................................1
1.1
GENERAL INFORMATION ............................................................................................................1
1.2
DANGERS, WARNINGS, CAUTIONS AND NOTES .....................................................................1
1.3
SUMMARY OF WARNINGS, CAUTIONS AND NOTES................................................................1
1.3.1
DANGERS........................................................................................................................................................... 1
1.3.2
WARNINGS ......................................................................................................................................................... 1
1.3.3
CAUTIONS .......................................................................................................................................................... 3
1.3.4
SAFETY DECALS ............................................................................................................................................... 3
SECTION 2: DESCRIPTION ..............................................5
2.1
GENERAL INFORMATION ............................................................................................................5
2.2
COMPONENT DESCRIPTIONS ....................................................................................................5
2.2.1
COMPRESSOR ASSEMBLY............................................................................................................................... 6
2.2.2
OIL INJECTED, SINGLE STAGE ROTARY SCREW COMPRESSOR ............................................................... 6
2.2.3
OIL RESERVOIR AND PRIMARY OIL SEPARATION......................................................................................... 7
2.2.4
AIR INLET VALVE AND VALVE CONTROL SOLENOID..................................................................................... 7
2.2.5
COMPRESSOR AIR FILTER............................................................................................................................... 7
2.2.6
SPIN-ON OIL COALESCER/SEPARATOR FOR SECONDARY SEPARATION ................................................. 8
2.2.7
SPIN-ON OIL FILTER.......................................................................................................................................... 8
2.2.8
MINIMUM PRESSURE/DISCHARGE CHECK VALVE ASSEMBLY.................................................................... 8
2.2.9
PRESSURE SWITCH.......................................................................................................................................... 8
2.2.10
PRESSURE RELIEF VALVE .............................................................................................................................. 9
2.3
HYDRAULIC DRIVE SYSTEM.......................................................................................................9
2.4
COMPRESSOR COOLING SYSTEM ............................................................................................10
2.5
INSTRUMENTATION SYSTEM......................................................................................................11
2.5.1
HOUR METER .................................................................................................................................................... 12
2.5.2
AIR PRESSURE GAUGE.................................................................................................................................... 12
2.5.3
AIR TEMPERATURE GAUGE............................................................................................................................. 12
2.5.4
RESET BUTTON ................................................................................................................................................. 12
2.6
ELECTRICAL CONNECTIONS......................................................................................................13
2.7
MAIN FRAME AND ENCLOSURE.................................................................................................13
Continued on next page...
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - I
TABLE OF CONTENTS
CAS60R 60 CFM / 150 PSIG
SECTION 3: SPECIFICATIONS.........................................15
TABLE 3A:
CAS60R SPECIFICATIONS.............................................................................................. 15
TABLE 3B:
PRIME LUBRICANT CHARACTERISTICS ...................................................................... 16
TABLE 3C:
RECOMMENDED TORQUE SPECIFICATIONS .............................................................. 16
SECTION 4: INSTALLATION.............................................17
4.1
MACHINE PACKAGE RECEIPT/INSPECTION ............................................................................. 17
4.2
GENERAL INSTRUCTIONS .......................................................................................................... 17
4.3
DETERMINING THE CAS60R UNIT MOUNTING LOCATION...................................................... 17
4.4
HYDRAULIC SYSTEM REQUIREMENTS..................................................................................... 18
4.5
INSTALLATION .............................................................................................................................. 20
4.5.1
MACHINE LOCATION ......................................................................................................................................... 20
4.5.2
CLEARANCE....................................................................................................................................................... 20
4.5.3
MOUNTING ......................................................................................................................................................... 20
4.5.4
SERVICE CONNECTIONS.................................................................................................................................. 21
4.5.5
ELECTRICAL CONNECTIONS ........................................................................................................................... 21
4.5.6
HYDRAULIC SUPPLY CIRCUIT.......................................................................................................................... 21
4.5.7
ROUTING ............................................................................................................................................................ 21
SECTION 5: OPERATION..................................................25
5.1
GENERAL INFORMATION............................................................................................................ 25
5.2
PURPOSE OF CONTROLS........................................................................................................... 25
5.3
INITIAL START-UP PROCEDURE................................................................................................. 26
5.4
ROUTINE START-UP PROCEDURE............................................................................................. 28
5.5
ROUTINE SHUTDOWN PROCEDURE......................................................................................... 28
5.6
OPERATING CONDITIONS........................................................................................................... 28
SECTION 6: MAINTENANCE ............................................29
6.1
GENERAL INFORMATION ............................................................................................................ 29
6.2
MACHINE MAINTENANCE SCHEDULE....................................................................................... 30
6.3
ROUTINE MAINTENANCE SCHEDULE ....................................................................................... 31
6.4
REPLACEMENT PARTS ............................................................................................................... 32
6.5
PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES ................................................... 32
6.5.1
REMOVING PANELS FOR MACHINE MAINTENANCE ACCESS ..................................................................... 34
6.5.1.1
REMOVING AND REPLACING THE ROOF (TOP) PANEL ....................................... 34
6.5.1.2
REMOVING AND REPLACING THE MAIN CANOPY PANEL ................................... 36
6.5.1.3
REMOVING AND REPLACING THE COOLER AND
INSTRUMENTATION ACCESS PANEL ...................................................................... 36
Continued on next page...
PAGE - II
MANUAL #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
TABLE OF CONTENTS
SECTION 6: MAINTENANCE (CONTINUED)
6.5.2
COMPRESSOR OIL MAINTENANCE................................................................................................................. 37
6.5.2.1 ADDING OR CHANGING THE COMPRESSOR OIL ..................................................... 37
6.5.3
PERFORMING AN OIL FILTER CHANGE.......................................................................................................... 39
6.5.3.1 REMOVING THE OIL FILTER ........................................................................................ 39
6.5.3.2
6.5.4
REPLACING THE OIL FILTER................................................................................... 40
COALESCER (AIR/OIL SEPARATOR) REPLACEMENT.................................................................................... 40
6.5.4.1
REMOVING THE COALESCER ELEMENT................................................................ 41
6.5.4.2
REPLACING THE COALESCER ELEMENT .............................................................. 41
6.5.5
COMPRESSOR AIR FILTER MAINTENANCE ................................................................................................... 41
6.5.5.1
REMOVING THE AIR FILTER..................................................................................... 41
6.5.5.2
COMPRESSOR AIR FILTER INSPECTION ............................................................... 42
6.5.5.3
REPLACING THE AIR FILTER ................................................................................... 43
6.5.6
REPAIRING THE INLET CONTROL SYSTEM ................................................................................................... 43
6.5.6.1
6.5.7
REBUILDING THE AIR INLET VALVE ASSEMBLY .................................................... 43
PERFORMING MAINTENANCE ON THE DRIVE BELTS .................................................................................. 46
6.5.7.1
ADJUSTING THE DRIVE BELTS................................................................................ 46
6.5.7.2
DRIVE BELT TENSION DATA..................................................................................... 47
6.5.7.3
REPLACING THE DRIVE BELTS ............................................................................... 48
6.5.8
CLEANING THE COOLER CORE ...................................................................................................................... 49
6.5.9
PRESSURE SWITCH.......................................................................................................................................... 50
6.5.10
SERVICING THE MINIMUM PRESSURE/DISCHARGE CHECK VALVE........................................................... 51
6.5.10.1 REBUILDING THE MINIMUM PRESSURE/DISCHARGE CHECK VALVE ................ 52
6.5.10.2 SETTING THE MINIMUM PRESSURE VALVE........................................................... 53
6.5.11
COMPRESSOR THERMAL CONTROL VALVE .................................................................................................. 54
6.5.12
SERVICING THE FUSES AND CIRCUIT BREAKER ......................................................................................... 54
6.5.13
SAFETY SHUTDOWN SYSTEMS ...................................................................................................................... 55
6.5.13.1 TESTING THE GAUGES’ SHUTDOWN FEATURE.................................................... 56
6.5.13.2 PRESSURE RELIEF VALVE ....................................................................................... 56
6.5.14
LONG TERM STORAGE..................................................................................................................................... 56
SECTION 7: TROUBLESHOOTING ..................................57
7.1
GENERAL INFORMATION ............................................................................................................57
7.2
TROUBLESHOOTING GUIDE.......................................................................................................57
Continued on next page...
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - III
TABLE OF CONTENTS
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST........................ 61
8.1
PARTS ORDERING PROCEDURE............................................................................................... 61
TABLE 8A:RECOMMENDED SPARE PARTS LIST............................................................................................................62
TABLE 8B: MAINTENANCE TRACKING LOG....................................................................................................................63
8.2
COMPRESSOR ASSEMBLY AND REPLACEMENT PARTS........................................................ 64
8.3
HYDRAULIC MOTOR AND DRIVE ............................................................................................... 66
8.4
COOLING AND CONTROL SYSTEM (1 OF 3) (12V) ................................................................... 68
8.4
COOLING AND CONTROL SYSTEM (2 OF 3) (12V) ................................................................... 70
8.4
COOLING AND CONTROL SYSTEM (3 OF 3) (12V) ................................................................... 72
8.5
COOLING AND CONTROL SYSTEM (1 OF 3) (24V) ................................................................... 74
8.5
COOLING AND CONTROL SYSTEM (2 OF 3) (24V) ................................................................... 76
8.5
COOLING AND CONTROL SYSTEM (3 OF 3) (24V) ................................................................... 78
8.6
FRAME AND PARTS (12V) ........................................................................................................... 80
8.7
FRAME AND PARTS (24V) ........................................................................................................... 82
8.8
CANOPY AND PARTS (1 OF 2) .................................................................................................... 84
8.8
CANOPY AND PARTS (2 OF 2) .................................................................................................... 84
8.9
CANOPY PANELS......................................................................................................................... 86
8.10 THERMAL CONTROL ................................................................................................................... 88
8.11 DECAL LOCATIONS (PART 1 OF 2 / DECAL SHEET #95724529).............................................. 90
8.11 DECAL LOCATIONS (PART 2 OF 2 / DECAL SHEET #95724529).............................................. 91
PAGE - IV
MANUAL #99905395
®
An Oshkosh Corporation Company
SECTION 1: SAFETY
CAS60R 60 CFM / 150 PSIG
SECTION 1:
SAFETY
1.1 GENERAL INFORMATION
The products provided by Iowa Mold Tooling Co., Inc.,
are designed and manufactured for safe operation and
maintenance. But it is ultimately the responsibility of the
users and maintainers for safe use of this equipment.
Part of this responsibility is to read and be familiar with
the contents of this manual before operation or
performing maintenance actions.
1.2 DANGERS, WARNINGS,
CAUTIONS, AND NOTES
See information boxes at right column.
1.3 SUMMARY OF DANGERS,
WARNINGS, CAUTIONS AND
NOTES
These boxed inserts are placed throughout this manual
in the sections where they apply. This subsection is a
general summary of their contents.
1.3.1 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.
1.3.2 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 to this equipment
without prior factory approval.
•
DO NOT operate the compressor or any of its
systems if there is a known unsafe condition. Disable
the equipment by disconnecting it from its power
®
An Oshkosh Corporation Company
Manual #99905395
IMPORTANT
Read this manual before operating or
servicing the CAS60R AIR
COMPRESSOR SYSTEM. Failure to do so
could result in damaged equipment,
bodily injury, or death.
DANGER
Identifies actions or conditions which
will cause death, severe injury, or
equipment damage or destructive
malfunctions.
WARNING
Identifies actions or conditions which
may cause death, severe injury, or
equipment damage or destructive
malfunctions.
CAUTION
Identifies actions or conditions which
will or can cause injuries, equipment
damage or malfunctions.
NOTE
Additional information (or existing
information) which should be brought to
the attention of operators/maintainers
affecting safety, operation, maintenance,
or warranty requirements.
PAGE - 1
SECTION 1: SAFETY
CAS60R 60 CFM / 150 PSIG
source. Install a lock-out tag to identify the equipment
as inoperable to other personnel.
PAGE - 2
•
DO NOT operate the compressor with any by-pass or
other safety systems disconnected or rendered
inoperative.
•
DO NOT operate the equipment while you are under the
influence of alcohol or drugs.
•
DO NOT operate the equipment while you are feeling ill.
•
DO NOT attempt to service the equipment while it is
operating.
•
Before performing maintenance, or replacing parts,
relieve the entire system pressure by opening a service
valve which will vent all pressure to the atmosphere:
remove all electrical power.
•
DO NOT use the compressor for purposes other than
for which it is intended. High pressure air can cause
serious and even fatal injuries.
•
DO NOT operate the compressor outside of its
specified pressure and speed ratings. (See Section
3: Specifications or refer to the equipment data
plate.)
•
DO NOT use flammable solvents or cleaners for
cleaning the compressor or its parts.
•
DO NOT operate the compressor in areas where
flammable, toxic, or corrosive fumes, or other
damaging substance can be ingested by the
compressor 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 loosefitting 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 with any guards
removed or damaged, or other safety devices
inoperative.
•
DO NOT operate the compressor in enclosed or
confined spaces where ventilation is restricted or
closed-off.
•
DO NOT install shut-off valves between the
compressor and the compressor receiver tank
(sump).
•
Ensure that hoses connected to service valves are
fitted with correctly sized and rated flow limiting
devices which comply with applicable codes.
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 1: SAFETY
CAS60R 60 CFM / 150 PSIG
Pressurized broken or disconnected hoses can whip,
causing injuries or damage.
•
DO NOT use tools, hoses, or equipment that have
maximum ratings below that of this compressor.
•
Keep metal tools, and other conductive objects away
from live electrical components.
•
Before performing maintenance or repair operations
on the compressor, ensure that all power has been
removed and been locked out to prevent accidental
application.
•
DO NOT assume that because the compressor is in
a STOPPED condition that hydraulic power has been
removed.
•
Use this compressor only to compress atmospheric
air. Use of this equipment as a booster pump and/or
to compress any other gaseous or aerosol substance
constitutes improper use. It can also cause damage
or injuries. Such misuse will also void the warranty.
•
Install, operate, and maintain this equipment in full
compliance with all applicable OSHA, 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.
1.3.3 CAUTIONS
•
Check all safety devices for proper operation on a
routine basis.
•
Ensure that no tools, rags, or other objects are left on
compressor drive systems or near intakes.
•
Keep the equipment clean when performing
maintenance or service actions. Cover openings to
prevent contamination.
•
DO NOT operate the compressor if cooling air is not
available (fan/cooler not operating) or if lubricant
levels are below their specified minimum levels.
•
Ensure all plugs, hoses, connectors, covers, and
other parts removed for maintenance actions are
replaced before applying power to the compressor.
•
Avoid touching hot surfaces and components.
•
Ensure that electrical wiring, terminals; hoses and
fittings are kept in serviceable condition through
routine inspections and maintenance. Replace any
damaged or worn components.
1.3.4 SAFETY DECALS
Safety decals are placed onto, or located near, system
components that can present a hazard to operators or
service personnel. All pertinent decals listed in Section
8.11, Decal Locations are located near a component
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 3
SECTION 1: SAFETY
CAS60R 60 CFM / 150 PSIG
which is subject to respect in terms of safety precautions.
Always heed the information noted on the safety decals.
WARNING
DO NOT REMOVE OR COVER ANY
SAFETY DECAL. Replace any safety
decal that becomes damaged or illegible.
PAGE - 4
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 2: DESCRIPTION
CAS60R 60 CFM / 150 PSIG
SECTION 2:
DESCRIPTION
2.1 GENERAL INFORMATION
The IMT CAS60R hydraulic module air compressor
system offers superior performance and reliability while
requiring very minimal maintenance.
This compressor system is equipped with a rotary screw
compressor unit, which is renowned for its durability and
reliability.
System Component or Component Group
Manual Section
GENERAL INFORMATION
2.1
COMPONENT DESCRIPTIONS
2.2
HYDRAULIC DRIVE SYSTEM
2.3
COMPRESSOR COOLING SYSTEM
2.4
INSTRUMENTATION SYSTEM
2.5
ELECTRICAL SYSTEM
2.6
MAIN FRAME AND ENCLOSURE
2.7
2.2 COMPONENT DESCRIPTIONS
The package includes:
•
Heavy duty rotary screw air compressor with
integral air inlet valve assembly
•
Oil separation system
•
Minimum pressure/discharge check valve
•
Compressor oil cooling system
•
Hydraulic drive and valving
•
Instrumentation and control system
WARNING
DO NOT attempt to remove any
compressor part or work on the
compressor or its systems without first
relieving the entire system pressure.
Open a service valve to atmosphere to
assure all pressure is vented.
Consult Section 6, Maintenance for
specific maintenance procedures.
NOTE
Read this manual before operating or
servicing this equipment. Failure to
comply with the operation and
maintenance instructions in this manual
WILL VOID THE EQUIPMENT WARRANTY.
This manual should be read in
conjunction with other appropriate
supplied manuals, such as the vehicle
owner’s manual, etc.
The component descriptions are arranged in this section
as follows:
System Component or Component Group
COMPONENT DESCRIPTIONS
COMPRESSOR ASSEMBLY
Manual Section
2.2
2.2.1
Continued on next page
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 5
SECTION 2: DESCRIPTION
B
CAS60R 60 CFM / 150 PSIG
C
D
G
F
A
E
KEY
DESCRIPTION
A
COMPRESSOR ASSEMBLY UNIT
(also oil reservoir and primary
separation)
B
AIR FILTER HOUSING
C
AIR INLET SOLENOID CONTROL
VALVE (air inlet valve is nested
beneath the air filter housing)
D
SEPARATOR/COALESCER
E
SPIN-ON OIL FILTER
F
MINIMUM PRESSURE/CHECK
VALVE (canister located directly
beneath coalescer element on the
housing—see Figure 2-6)
G
PRESSURE RELIEF VALVE
(200 PSI)
Figure 2-1: Compressor Unit
System Component or Component Group
Manual Section
OIL INJECTED, SINGLE STAGE ROTARY
SCREW COMPRESSOR
2.2.2
AIR INLET VALVE AND VALVE CONTROL
SOLENOID
2.2.3
COMPRESSOR AIR FILTER
2.2.4
OIL RESERVOIR AND PRIMARY OIL SEPARATION
2.2.5
SPIN-ON OIL COALESCER/SEPARATOR
FOR SECONDARY SEPARATION
2.2.6
SPIN-ON OIL FILTER
2.2.7
MINIMUM PRESSURE/DISCHARGE
CHECK VALVE ASSEMBLY
2.2.8
PRESSURE SWITCH
2.2.9
PRESSURE RELIEF VALVE (200 PSI)
2.2.10
2.2.1 COMPRESSOR ASSEMBLY
This assembly incorporates various features into one unit
(refer to Figure 2-1):
•
Oil injected, single stage rotary screw compressor
[A]
•
Oil reservoir and primary oil separator (compressor
housing encasement acts as both reservoir and
primary oil separator [A])
•
Inlet valve (beneath air filter housing [B]) and
solenoid control valve [C]
•
Air filter unit (within housing [B])
•
Secondary spin-on oil coalescer/separator [D]
•
Spin-on oil filter [E]
•
Minimum pressure valve/check valve [F]
•
Pressure relief valve [G]
This makes for a very compact integrated compressor
assembly with reduced hose connections and
consequently, fewer potential leak points.
2.2.2 OIL INJECTED, SINGLE STAGE ROTARY
SCREW COMPRESSOR
Lubricant is injected into the compressor air end unit and
mixes directly with the air in the compression chamber.
Internal porting also injects oil into the bearings and seal
area. The lubricant has three primary functions:
•
PAGE - 6
As a coolant, it controls the rise of air temperature
normally associated with the heat of compression.
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 2: DESCRIPTION
CAS60R 60 CFM / 150 PSIG
•
Seals the leakage paths between the rotors and
the stator, and also between the rotors themselves.
•
Acts as a lubricating film between the rotors
allowing one rotor to directly drive the other, which
is an idler. It also lubricates the bearings and seal.
A
B
The screw compressor assembly is mounted inside the
main casting and consists of a male and female rotor,
supported with anti-friction bearings suitably sized for
long life.
2.2.3 OIL RESERVOIR AND PRIMARY OIL
SEPARATION
The main casting, which contains the screw compressor,
is also the oil reservoir and primary oil separation unit.
The initial (primary) oil separation is caused by both
changes in velocity and direction. The main casting also
contains the oil level/fill plug and oil drain connection. A
separate oil reservoir is not required.
2.2.4 AIR INLET VALVE AND VALVE CONTROL
SOLENOID
KEY
DESCRIPTION
A
AIR INLET VALVE
B
AIR INLET SOLENOID CONTROL
Figure 2-2: Air Inlet Control
Refer to Figure 2-2. The inlet valve and control solenoid
valve assembly are mounted directly on top of the
compressor module. On initial start-up, the solenoid is
energized and the inlet valve opens from pilot air being
passed through the solenoid actuated valve. When final
pressure is reached, a pressure switch de-activates the
solenoid and the inlet valve closes. At the same time, the
compressor pressure will relieve down to a low pressure
(typically about 40 psig). Only the compressed air within
the compressor module will reduce down to this lower
pressure, due to the operation of the discharge minimum
pressure/check valve. This reduction in internal air
pressure reduces the power requirement considerably
during this unloaded state. The pressure switch, located
in the downstream air line, senses air demand and upon
reducing pressure in discharge line (i.e. air being used)
will re-activate the inlet valve and the compressor again
starts to load and produce air.
A
B
The discharge air pressure switch will typically be set
with a 30 psi differential pressure.
2.2.5 COMPRESSOR AIR FILTER
Refer to Figure 2-3. The air filter is a dry type,
replaceable element and is mounted directly on top of the
inlet valve assembly. The element is easily replaced for
service change out. Refer to Section 5, Maintenance.
®
An Oshkosh Corporation Company
Manual #99905395
KEY
DESCRIPTION
A
AIR FILTER ELEMENT
B
AIR FILTER HOUSING
Figure 2-3: Compressor Air Filter
PAGE - 7
SECTION 2: DESCRIPTION
CAS60R 60 CFM / 150 PSIG
2.2.6 SPIN-ON OIL COALESCER/SEPARATOR FOR
SECONDARY SEPARATION
Refer to Figure 2-4. The spin-on element screws directly
onto the filter support housing at the rear of the
compressor module. The separator element (coalescer)
recovers the finer particles of residual oil after preseparation, which occurs in the compressor unit reservoir
to allow for maximum oil separation from the compressed
air before service output. Oil, which is collected in this
element, is scavenged back into the compressor unit.
2.2.7 SPIN-ON OIL FILTER
Figure 2-4: Separator/Coalescer
Refer to Figure 2-5. The spin-on oil filter is located on the
filter support housing at the rear of the compressor. The
filter incorporates a by-pass valve which will open to bypass the filter during cold start-up when the oil is very
viscous. It will also open if the filter element is plugged.
Filter element rating is 10 micron.
2.2.8 MINIMUM PRESSURE/DISCHARGE CHECK
VALVE ASSEMBLY
Refer to Figure 2-6. This combined valve, located in the
filter support housing, has two functions.
MINIMUM PRESSURE VALVE Maintains Minimum Pressure: This prevents downstream
air to pass until compressor system is up to minimum
pressure valve setting, which aids in maintaining good oil
supply to the compressor. It also is a requirement for
good oil separation.
Figure 2-5: Spin-on Oil Filter
Maintains a pressure of approximately 65 psig in the
compressor unit to ensure oil injection during load
conditions. Once this internal pressure is exceeded, it will
allow air to discharge downstream to the service outlet.
DISCHARGE CHECK VALVE Acts As a Back Pressure Check Valve: This allows for
compressor to be unloaded to lower pressure than
supply air line system, and permits compressor air
pressure to be totally relieved when stopped. It prevents
air in service lines or downstream receiver from venting
back through the compressor during unload (when the
compressor automatically will unload to approximately 40
psig internally), and also during shutdown.
2.2.9 PRESSURE SWITCH
Figure 2-6: Minimum Pressure/
Check Valve
PAGE - 8
Refer to Figure 2-7. The pressure switch pressure levels
are preset at the factory.
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 2: DESCRIPTION
CAS60R 60 CFM / 150 PSIG
A
KEY
DESCRIPTION
A
AIR PRESSURE GAUGE (Reference)
B
PRESSURE SWITCHI
IMPORTANT
I
B
DO NOT adjust pressure switch
levels—switch is pre-set at the factory and
affixed with a tamper-proof seal. Tampering
with the pressure switch may void the
warranty!
Should pressure need to be serviced or
replaced, consult the factory service
department.
A
Figure 2-7: Pressure Switch
The pressure switch provides a control for the inlet valve
solenoid, much like a pneumatic regulator valve. When
the pressure in the service line drops below the set limit,
it reactivates the inlet valve control solenoid, allowing the
inlet valve to draw in more air. The pressure switch has
both a high and low pressure setting.
2.2.10 PRESSURE RELIEF VALVE
Refer to Figure 2-8. The pressure relief valve is a safety
device that protects the unit against high pressure if the
compressor system controls malfunction. The pressure
relief valve is located at the upper right side of the
compressor unit, facing the drive shaft. The pressure
relief valve is designed to open if the internal pressure of
the compressor exceeds 200 psi (13.8 bar).
2.3 HYDRAULIC DRIVE SYSTEM
Refer to Figure 2-9. Scope of supply may vary
depending upon customer specifications.
The packaged compressor unit will normally contain the
hydraulic motor, hydraulic pressure relief valve, and on/
off solenoid valve.
Input hydraulic oil pressure feed is connected to the
bulkhead provided on the compressor package. Within
the package, the high pressure oil feeds to a manifold
containing the pressure relief valve and directional
solenoid valve. If a malfunction in the hydraulic motor/
compressor assembly causes the hydraulic pressure to
®
An Oshkosh Corporation Company
Manual #99905395
Figure 2-8: Pressure Relief Valve
NOTE
Hydraulic pump, oil reservoir, return line
oil filter and hoses to and from the
completed packaged compressor are
not furnished with the compressor. This
is the customer’s responsibility. Refer to
Section 4.4 for hydraulic system
requirements.
PAGE - 9
SECTION 2: DESCRIPTION
A
C
D
F
G
CAS60R 60 CFM / 150 PSIG
B
E
KEY
DESCRIPTION
A
HYDRAULIC MOTOR
B
HYDRAULIC OIL SUPPLY LINE (From manifold)
C
HYDRAULIC OIL RETURN LINE (To manifold)
D
DRIVE BELT
E
MOTOR DRIVE SHEAVE
F
VERTICAL POSITIONING BOLT
NOTE: Manifold and pressure relief valve are not shown.
Refer to either Section 8.6 (12V) or Section 8.7 (24V), key
#5 and #6 respectively, to visually identify the locations of
these parts.
Figure 2-9: Hydraulic Motor
rise, it will bypass to the return line to safeguard damage
or potential injury.
The directional solenoid valve is normally activated by
the on/off selector switch mounted in the instrument
cluster on the package. This valve is also connected
through the compressor safety circuits for overtemperature and over-pressure. If either condition
occurs, it will shut the unit down by diverting oil back to
the tank. It is possible to add a remote on/off switch in
parallel with the instrument cluster to permit on/off
operation from another location on the vehicle.
Hydraulic oil from the manifold is hosed directly to the
hydraulic motor and the outlet from the motor passes to
the return line connection on the package. Customer is
responsible for providing both hydraulic feed and return
lines.
The hydraulic motor powers the compressor via a belt
drive system.
2.4 COMPRESSOR COOLING
SYSTEM
Refer to Figure 2-10. The package contains a cooler
assembly powered by an electric fan. Oil from the
compressor sump passes through this cooler before
being filtered for re-injection into the compressor. When
the oil temperature reaches 160°F, the thermal valve
activates to gradually begin rerouting progressive
amounts of heated oil to the cooler to maintain the correct
operating temperature for the compressor oil. The valve
PAGE - 10
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 2: DESCRIPTION
CAS60R 60 CFM / 150 PSIG
B
E
A
F
C
D
KEY
DESCRIPTION
KEY
A
FAN & MOTOR ASSEMBLY (motor not shown)
D
COMPRESSOR OIL COOLER
B
INSTRUMENT PANELI
E
HYDRAULIC OIL COOLER
C
COOLER SHROUD
F
COOLING AIR FLOW DIRECTION
I
DESCRIPTION
Refer to Figure 2-11 for instrument panel details.
Figure 2-10: Cooler Assembly
is fully opened when oil temperature reaches 185°F, at
which time all oil flow is diverted to the cooler for
maximum cooling effect. Conversely, should the oil
become cooled during operation, the reverse case is
applicable; the valve begins closing, gradually rerouting
the oil to bypass the cooling path, becoming fully closed
when the temperature falls below 160°F.
The purpose of maintaining an elevated temperature
during operation is to keep intake air moisture in
suspension as it passes through the compressor.
Thermal valve activation is affected by ambient
conditions, load/unload cycles (or low oil level).
2.5 INSTRUMENTATION SYSTEM
Refer to Figure 2-11 for instrument panel component
locations.
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 11
SECTION 2: DESCRIPTION
A
KEY
B
CAS60R 60 CFM / 150 PSIG
C
DESCRIPTION
D
E
KEY
F
DESCRIPTION
A
INTAKE VENT - Keep passageway clean and
clear
D
AIR TEMPERATURE SWITCH
B
HOUR METER
E
CAPPED ACCESS HOLE (no standard function)
C
AIR PRESSURE GAUGE
F
RESET BUTTON
Figure 2-11: Instrumentation
2.5.1 HOUR METER
Figure 2-11 [B]: Monitors operation hours for service.
2.5.2 AIR PRESSURE GAUGE
Figure 2-11 [C]: Monitors service air pressure and
incorporates an over-pressure shutdown switch.
2.5.3 AIR TEMPERATURE GAUGE
Figure 2-11 [D]: Monitors discharge air temperature at
the compressor and incorporates an over-temperature
shutdown switch.
2.5.4 RESET BUTTON
Figure 2-11 [E]: Cancels and/or resets over-pressure/
over-temperature shut-down condition.
WARNING
NEVER FORCE the reset button back
into position, or hinder it in any way, in
order to allow for machine operation. A
tripped reset button indicates a problem
that should be addressed and resolved
before operation can continue.
PAGE - 12
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 2: DESCRIPTION
CAS60R 60 CFM / 150 PSIG
2.6 ELECTRICAL CONNECTIONS
Refer to Figure 2-12; for complete electrical connection
procedure, refer to Section 4.5.5. Electrical connections
to be made by the installer are provided at the bulkhead
connection location. There are normally only three
electrical connections to be made:
1. Ignition supply
2. Battery supply
3. Ground
C
A
D
B
E
F
2.7 MAIN FRAME AND ENCLOSURE
Refer to Figure 2-13. The steel mainframe is provided
with bolt down holes.
The enclosure, which is attached to the mainframe, is
made from steel and is powder coated to provide a
durable finish. There are two main components:
KEY
DESCRIPTION
A
6-PIN DEUTCH CONNECTOR
B
HYDRAULIC SUPPLY LINE (IN)
C
1. The main enclosure housing [B], which is bolted
to the frame [A], provides overall protection for
the various unit assemblies.
COMPRESSOR OIL FILL PORT
(reference)
D
SERVICE AIR OUTLET
E
ELECTRICAL CONNECTIONS
2. Cooler/instrumentation housing [C], which is
bolted to the frame [A].
F
HYDRAULIC RETURN LINE
(OUT)
The service air outlet (Figure 2-12, [D]) is located on the
main bulkhead connection strip, and the service valve
incorporates a venting feature which relieves
downstream air to the atmosphere when it is in the
closed position.
Figure 2-12: Package Connections
Compressor oil level can be checked and filled from the
outside of the enclosure (consult Section 6.5.3 for oil
check/change information).
Safety and Information decals are appropriately located
on the machine. Please read and understand all the
information contained thereon. For decal locations and
information, refer to Section 8.11.
WARNING
DO NOT REMOVE OR COVER ANY
SAFETY DECAL. Replace any safety
decal that becomes damaged or illegible.
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 13
SECTION 2: DESCRIPTION
CAS60R 60 CFM / 150 PSIG
A
B
C
KEY
DESCRIPTION
A
MAIN FRAME
B
MAIN ENCLOSURE HOUSING
C
COOLER/INSTRUMENTATION
HOUSING
Figure 2-13: Main Frame and
Enclosure
PAGE - 14
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 3: SPECIFICATIONS
CAS60R 60 CFM / 150 PSIG
SECTION 3:
SPECIFICATIONS
TABLE 3A: CAS60R SPECIFICATIONS
GENERAL SYSTEM INFORMATION
SPECIFICATION
RATINGS
Capacity (CFM @ 150 psig):
60
Air Pressure at toolI (psig):
150
Speed of compressor (RPM @ 100 psig):
7160
Hydraulic motor RPM
2130
Hydraulic flow (gpm @ 120°F hydraulic oil temperature):
16
Hydraulic pressure (psig @ 100/175 compressor psig):
2300
Maximum compressor oil temperature
250°F
Maximum Hydraulic oil temperature
180°F
COMPRESSOR
Type:
Encapsulated, Oil-injected, Rotary Screw
Compressor oil tank capacity:
5 U.S. Quarts (4.7L)
Compressor overheating protection:
Shut Down at 250°F
Air inlet system:
Dry-type, Single Stage Filter
Drive coupling:
V-belt Drive System
Hydraulic motor:
Gear Type
PACKAGE
Main frame:
Formed Steel with Boltdown Provision
Electrical supply:
12V Standard; 24V Optional
Electrical connections:
Weatherpack
Hydraulic: Oil In 3/4 in. 37° JIC
Supply connections (customer hook-up):
Hydraulic: Oil Out 1 in. 37° JIC
Electrical: 12V DC Positive and Ground (Standard)
24V DC Positive and Ground (Optional)
Electrical: High Temp Shutdown
Enclosure:
Sheet Metal with Service Access
Cooler:
Hydraulic Oil Cooler/Radiator Core - Electric Fan
Dimensions:
42"L x 20"W x 21"H
Weight:
375 lbs.
I
Air output expectations are at the end of the hose reel, not at the air end. The system includes an air tank and a hose
reel with 50ft of 3/8” or 1/2” air hose.
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 15
SECTION 3: SPECIFICATIONS
CAS60R 60 CFM / 150 PSIG
TABLE 3B: PRIME LUBRICANT CHARACTERISTICS
Viscosity
178 SUS at 100° F (38°C)
Flashpoint
457° F (236°C)
Pour Point
-49° F (-45°C)
Contains
Rust and Oxidation Inhibitors and Detergents
TABLE 3C: RECOMMENDED TORQUE SPECIFICATIONS
Capscrew
Tightening Torque
Size
Grade
Approximate
Metric Equivalent
Dry
Lubricated
1/4-20 UNC
5
6 mm
8 ft-lbs
6 ft-lbs
5/16-18 UNC
5
8 mm
17 ft-lbs
13 ft-lbs
3/8-16 UNC
5
10 mm
30 ft-lbs
23 ft-lbs
1/2-13 UNC
5
12 mm
75 ft-lbs
55 ft-lbs
3/4-10 UNC
5
20 mm
260 ft-lbs
200 ft-lbs
PAGE - 16
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 4: INSTALLATION
CAS60R 60 CFM / 150 PSIG
SECTION 4:
INSTALLATION
4.1 MACHINE PACKAGE RECEIPT/
INSPECTION
Upon receipt of the machine package, inspect the
exterior of the shipping crate for signs of shipping/transit
damage. Any damage should be reported immediately to
the shipping company. Open the lid and inspect the
component parts and supports to ensure that there has
been no internal movement of assemblies or components
which may have caused damage. To install the CAS60R
compressor system, refer to the following sections:
4.2 GENERAL INSTRUCTIONS
This section provides general guidance for locating and
preparing the CAS60R compressor package for
operation. Each installation is unique and can be affected
by location, ventilation, and other factors such as
electrical and hydraulic power supply availability and
location.
System Component or Component Group
Manual Section
GENERAL INSTRUCTIONS
4.2
DETERMINING THE CAS60R UNIT
MOUNTING LOATION
4.3
HYDRAULIC SYSTEM REQUIREMENTS
4.4
INSTALLATION
4.5
4.3 DETERMINING THE CAS60R UNIT
MOUNTING LOCATION
When determining the location to mount the CAS60R
unit, the following criteria must be taken into
consideration:
• Refer to Section 4.5. The location must allow for the
machine dimensions (Figure 4-2), and additional
space requirements for minimum cooling, access
and maintenance. Refer to Figure 4-3 to determine
the minimum space requirements.
®
An Oshkosh Corporation Company
Manual #99905395
WARNING
Install, operate, and maintain this
equipment in full compliance with all
applicable OSHA, other Federal, state,
local codes, standards, and regulations.
WARNING
Before 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.
WARNING
DO NOT perform any modifications to
this equipment without prior factory
approval.
WARNING
DO NOT use plastic pipe, or incorrectly
rated piping or hose. Incorrectly rated
connection material can fail and cause
injury or equipment damage.
WARNING
DO NOT operate the compressor in
enclosed or confined spaces where
ventilation is restricted or closed off.
PAGE - 17
SECTION 4: INSTALLATION
CAS60R 60 CFM / 150 PSIG
• The mounting surface must be level and able to
accommodate the four [4] mounting bolts of the base
frame. Refer to Figure 4-1.
• The mounting surface must be able to support the
unit’s weight (375 lbs.).
• The external gauges must be easily visible to the
operator.
IMPORTANT
IMT highly recommends consulting a
hydraulic supply expert for specifying
the correct hydraulic pump size and
type, oil reservoir size, hydraulic cooler,
hydraulic pressure relief, and other
hydraulic supply components for your
application.
It is recommended, for most installations, to mount the
compressor on the driver’s side of the vehicle. The unit
should be situated in such a manner that the fan (rear)
and hydraulic cooler (front) are not obstructed. Do not
place the compressor in any location where it can intake
exhaust fumes, dust or debris.
4.4 HYDRAULIC SYSTEM
REQUIREMENTS
The following criteria should be taken into consideration
for the hydraulic system requirements:
• The hydraulic flow and pressure requirements of the
air compressor.
NOTE
The temperature of the hydraulic oil
should not exceed 140 °F due to the
rating of the IMT-supplied hydraulic
motor.
• A continuous hydraulic load requirement is needed
when the compressor is running.
• The duty cycle and ambient temperatures.
• Other hydraulic equipment which may share the
same hydraulic supply system.
NOTE
IMT recommends a dedicated pump and
hydraulic circuit.
A
B
C
KEY
DESCRIPTION
A
2.00”
B
31.25”
C
0.63”
D
19.00”
NOTE: For additional machine measurements, consult Figure 4-2.
D
Figure 4-1: Base Frame and Mounting Hole Locations
PAGE - 18
Manual #99905395
®
An Oshkosh Corporation Company
®
An Oshkosh Corporation Company
1.88
1.05
3/4" MALE JIC
HYDRAULIC
OIL SUPPLY
6 PIN
DEUTSCH
CONNECTOR
1.37
7.19
4.19
15.88
19.00
Manual #99905395
HYDRAULIC OIL
SUPPLY
AIR OUTLET
1" MALE JIC
HYDRAULIC
OIL RETURN
1.05
COMPRESSOR
OIL DRAIN HOSE
COMPRESSOR
OIL FILL
1.16
0.00
17.38
16.34
0.00 2.00
AIR
FLOW
13.75
35.25
37.38
21.50
31.00
35.38
1" JIC X 1" SAE FITTING
HYDRAULIC OIL RETURN
DIRECTION CAN BE AS SHOWN
OR OPPOSED
0.56
(8 PLACES)
26.22
AIR
FLOW
GUAGE PANEL
CAS60R 60 CFM / 150 PSIG
SECTION 4: INSTALLATION
050737ID_r1 // 050740ID_r1
Figure 4-2: CAS60R Dimensions
PAGE - 19
SECTION 4: INSTALLATION
CAS60R 60 CFM / 150 PSIG
4.5 INSTALLATION
4.5.1 MACHINE LOCATION
It is vital to locate the machine so that there is no
restriction of cooling air through the enclosure (Refer to
Figure 4-3). Cooling air enters the enclosure at the
instrument panel end of the machine, passes through the
cooler and exits through vents in the upper sides and the
rear.
4.5.2 CLEARANCE
Refer to Figure 4-3. Ensure that adequate surrounding
clearance exists to allow for the canopy shroud to be repositioned or removed for service access.
4.5.3 MOUNTING
Mounting surface or support should be adequate for the
weight of the machine (375 lbs.), and should be level for
KEY
DESCRIPTION
KEY
DESCRIPTION
A
INSTRUMENTATION SIDE: 10 inches
D
LEFT SIDE (facing instrument panel): 10 inches
B
RIGHT SIDE (facing instrument panel): 10 inches
E
C
VERTICAL CLEARANCE: 10 inches
UNIT ACCESS AND SERVICE LINE SIDE: 10
inches
F
Additional allotted dimensional/surrounding space (measurements A through E) of package must allow for continuous circulation of air around and through the machine for cooling purposes. DO NOT install in an enclosed area.
NOTE: The dimensions listed are the minimum required clearance distances needed for properly cooling and/or accessing
the machine. Additional clearance room may be desired for easier access for control and/or maintenance functions.
Figure 4-3: Recommended Minimum Clearance Distances Needed for Machine Cooling and Access
PAGE - 20
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 4: INSTALLATION
CAS60R 60 CFM / 150 PSIG
normal operation. Mounting holes are located in the
frame footing for four (4) 1/2” hold down bolts.
4.5.4 SERVICE CONNECTIONS
Refer to Figure 4-4. Service connections are
conveniently grouped at the lower rear section of the unit
in the base frame.
SERVICE LINE
CONNECTION TYPE
Hydraulic Supply
(High Pressure)
1-1/6 - 12 x 37° flare (male) 3/4” JIC
Hydraulic Return
(Low Pressure)
1-5/16 - 12 X 37° flare
(male) - 1” JIC
Air Service
3/4” NPT (female)
Electrical Connections
4 pin with leads (3 qty.)
4.5.5 ELECTRICAL CONNECTIONS
This system is offered with either 12V DC or 24V DC
negative ground. Refer to Figures 4-4, and either 4-6 (for
12V machines), or 4-7 (for 24V machines).
Wire #1
Battery (+) VDC supply
Wire #9
Ignition (+) VDC supply
Wire #7 / 13 / 15
Ground - Battery / Chassis
C
A
D
B
E
F
KEY
DESCRIPTION
A
6-PIN DEUTCH CONNECTOR
B
HYDRAULIC SUPPLY LINE (IN)
C
COMPRESSOR OIL FILL PORT
(reference)
D
SERVICE AIR OUTLET
E
ELECTRICAL CONNECTIONS
F
HYDRAULIC RETURN LINE
(OUT)
Figure 4-4: Package Connections
4.5.6 HYDRAULIC SUPPLY CIRCUIT
Refer to Figures 4-5. It is recommended that the
compressor unit possesses a separate pump/flow/return
hydraulic circuit to other hydraulic equipment. This is to
prevent the possibility of pressure/flow drops that may
occur if other hydraulically-powered equipment is
activated during compressor operation, which may in
turn, cause the compressor to stall out. Alternatively, use
of a diverter valve will permit hydraulics to power different
equipment selectively.
4.5.7 ROUTING
Refer to Figures 4-5, 4-6 or 4-7. Ensure that all supply
hoses and electrical wiring are correctly specified,
adequately supported, and do not touch or rest on any
sharp edges. Wiring should be protected with split loom
to prevent corrosion, and consequently, loss due to down
time.
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 21
SECTION 4: INSTALLATION
CAS60R 60 CFM / 150 PSIG
263906_r1
Figure 4-5: Schematic Flow Hydraulic Oil Diagram
PAGE - 22
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 4: INSTALLATION
CAS60R 60 CFM / 150 PSIG
271324_r1
Figure 4-6: Electrical System (12V)
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 23
SECTION 4: INSTALLATION
CAS60R 60 CFM / 150 PSIG
271983_r0
Figure 4-7: Electrical System (24V)
PAGE - 24
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 5: OPERATION
CAS60R 60 CFM / 150 PSIG
SECTION 5:
OPERATION
5.1 GENERAL INFORMATION
WARNING
The CAS60R compressor has a comprehensive array of
controls and indicators. Understanding the correct
operation of the system will help you to understand and
recognize when it is operating optimally. The information
in the Operation Section will help the operator to
recognize and interpret the readings, which will call for
service or indicate the beginning of a malfunction.
System Component or Component Group
Before starting, performing maintenance,
or replacing parts, relieve the entire
system pressure by opening a service
valve which will vent all pressure to the
atmosphere: remove all electrical power.
NOTE
Manual Section
GENERAL INFORMATION
5.1
PURPOSE OF CONTROLS
5.2
INITIAL START-UP PROCEDURE
5.3
NORMAL START-UP PROCEDURE
5.4
NORMAL SHUTDOWN PROCEDURE
5.5
OPERATING CONDITIONS
5.6
Before starting the IMT CAS40P
compressor, read this section
thoroughly and familiarize yourself with
the controls and indicators - their
purpose, location and use.
5.2 PURPOSE OF CONTROLS
CONTROL OR INDICATOR
PURPOSE
Discharge Air Pressure
(Pressure Gauge)
Continuously monitors service line discharge air temperature. Will
activate shutdown if over-pressure occurs.
Discharge Air Temperature
(Temperature Gauge)
Continuously monitors service line discharge temperature. Will activate shutdown if over-temperature occurs.
Hour Meter Gauge
(Operation Hours)
Indicates accumulated hours of operation for planning and logging
service schedules.
Reset Button
To reset latch-in relay in event of over-pressure or over-temperature.
Oil Fill/Level Plug
To check/fill compressor oil level.
Minimum Pressure Check Valve
Maintains minimum operating pressure and prevents back flow when
unloaded/shutdown.
Pressure Switch
Controls operating pressure.
Inlet Solenoid Valve
Opens/closes inlet valve in response to pressure switch.
Continued on next page
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 25
SECTION 5: OPERATION
CAS60R 60 CFM / 150 PSIG
5.2 PURPOSE OF CONTROLS
CONTROL OR INDICATOR
PURPOSE
Air Inlet Valve
Opens/closes in response to air demand and acts as check valve
upon unload/shutdown to prevent oil blow back into air filter.
Fan Temperature Switch
Thermostatically switches cooling fan on/off to maintain optimum
operating temperature.
Hydraulic Pressure Relief Valve
Relieves hydraulic pressure to return line in event of hydraulic overpressure condition.
Hydraulic Solenoid Valve
Responds to on/off switch 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.
Fault Reset
Fault button pops out if over temperature or over pressure condition is
encountered. Button must be pressed to reset.
5.3 INITIAL START-UP PROCEDURE
WARNING
DO 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
air tank drain/vent 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.
Refer to Figure 5-1. Open fill cap
SLOWLY (contents under pressure) to
make sure all pressure has been
relieved.
The compressor has been factory-tested and its air and
hydraulic valves have been adjusted to their specified
operating settings. Although the compressor unit has
also been filled at the factory, some settling may have
occurred in transit. Refer to procedure below, and Figure
5-2 for all unit checks to perform before initial start-up:
1. Position the compressor on a level surface so
that proper amounts of liquid can be added if
necessary.
2. Unit should be securely bolted down.
WARNING
Do not rely on hoses to hold the module
in position.
3. Ensure all hose connections are tight, and wiring
connections are correct and tight.
4. Check compressor oil level and add if necessary.
• Refer to Section 6.5.2 for procedure on checking
and refilling oil to proper level.
5. Ensure hydraulic oil to pump inlet, and prime if
necessary.
6. Make sure service valve on compressor is
closed.
7. Engage hydraulic system (PTO or hydraulic
supply), and allow hydraulic oil to circulate back
PAGE - 26
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 5: OPERATION
CAS60R 60 CFM / 150 PSIG
to tank. Oil should quickly circulate to the
hydraulic motor on the compressor, and start
producing air.
A
8. Check for leaks.
9. Check pressure and temperature gauges.
Readings should be within the operating ranges
specified in Table 3A (found in Section 3,
Specifications).
B
C
IMPORTANT
KEY
Pressure settings are pre-set at the
factory—DO NOT manually attempt to
adjust the pressure switch. Consult the
factory if pressure readings deviate from
the specified pressure rating range.
RED COMPRESSOR FILL CAP
B
FILL CAP BLEED VENT GROOVE
C
Open/crack cap slightly to allow
bleed vent to relieve pressure
10. Partially open service valve to load compressor
and allow to warm up. Monitor the temperature
gauge for ideal operating temperature, which
should be between 165°F and 190°F.
Figure 5-1: Pressure Relief
NOTE
11. Cycle compressor on/off with service valve to
ensure proper operation.
Temperature may be above 190°F in high
ambient conditions.
12. Close the service valve.
B C
D
®
A
DESCRIPTION
A
E
G H
F
KEY
DESCRIPTION
KEY
J
K
DESCRIPTION
A
HOUR METER
F
ELECTRICAL CONNECTION PLUG
B
PRESSURE GAUGE
G
HYDRAULIC SUPPLY LINE (IN)
C
AIR TEMPERATURE GAUGE
H
SERVICE AIR PORT (AIR OUT)
D
FAULT RESET BUTTON
J
COMPRESSOR OIL PORT/OIL CHECK
E
HYDRAULIC RETURN LINE (OUT)
K
COMPRESSOR OIL DRAIN TUBE
Figure 5-2: Operation Check Locations
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 27
SECTION 5: OPERATION
CAS60R 60 CFM / 150 PSIG
13. Disengage hydraulic system; compressor
ceases to produce air.
WARNING
If the reset button on the instrument
panel has been tripped, NEVER FORCE
the button back into position, or hinder it
in any way, in order to allow for machine
operation. A tripped reset button
indicates a problem that should be
addressed and resolved before operation
can continue.
14. Allow air to vent to atmosphere. Check
compressor oil level and add if necessary. Check
and correct any leaks, tighten any loose fittings
and check drive belt tension.
5.4 ROUTINE START-UP
PROCEDURE
1. Check compressor oil level and add if necessary.
Refer to Section 6.5.2.
2. Close the air service valve.
3. Engage hydraulic system (PTO or hydraulic
supply). This will activate the compressor.
4. Allow machine to warm up for several minutes
before operating.
5.5 ROUTINE SHUTDOWN
PROCEDURE
1. Close service valve and allow compressor to
unload and cool down (approximately five [5]
minutes.).
2. Shut off hydraulic power supply.
5.6 OPERATING CONDITIONS
1 . Operate only in well ventilated areas.
2. Ensure there are no obstructions of cooling air
intakes and outlets around the unit.
3. Do not leave anything resting on top of the
machine. Hot cooling air will generate high heat
and must not be restricted.
4. Be sure to leave sufficient room around the unit
for cooling air circulation. A minimum of ten (10)
inches clearance is needed for the cooler intake
and sides, and ten (10) inches for the rear of the
unit. Heated air must be able to vent away from
the intake.
5. Operate machine with top cover closed.
6. Refer to specifications for operating parameters.
PAGE - 28
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
SECTION 6:
MAINTENANCE
6.1 GENERAL INFORMATION
WARNING
A good maintenance program is the key to long
compressor life. This section contains a program that,
when adhered to, should keep the compressor in top
operating condition. However, it should be understood
that these intervals are for normal operation in a good
clean environment. More frequent inspections, oil
changes and general maintenance should be carried out
in dusty environments, high ambient temperatures or
extended light load conditions.
Follow the prescribed periodic maintenance schedules
given in this section as recommended. Failure to follow
the
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.
NOTE
It 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.
Before starting the compressor system, inspect the
machine package for any suspect condition that may
cause a safety hazard or hamper operation. Replace
damaged components with Genuine IMT Replacement
Parts.
System Component or Component Group
6.1
MACHINE MAINTENANCE SHEDULE
6.2
ROUTINE MAINTENANCE SHEDULE
6.3
REPLACEMENT PARTS
6.4
PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
6.5
An Oshkosh Corporation Company
Wear personal protective equipment
such as gloves, work shoes, and eye and
hearing protection as required for the
task at hand.
WARNING
Follow all applicable safety
recommendations as outlined in Section
1: Safety of this manual.
WARNING
DO NOT work on any electrical
components unless the battery is
disconnected.
CAUTION
Always wear personal protective
equipment such as gloves, work shoes,
eye, and hearing protection as required
for the task at hand.
Manual Section
GENERAL INFORMATION
®
DO 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.
Manual #99905395
CAUTION
Compressors 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.
PAGE - 29
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
WARNING
It is important that the compressor oil be
of a recommended type and that it is
inspected and replaced together with the
oil and air filters, in accordance with this
manual.
CAUTION
Do not mix oils of different types.
CAUTION
Use only original IMT equipment filters.
Other filters may not have correct
pressure rating or may have different
thread.
NOTE
Using replacement parts other than
Genuine IMT Replacement Parts will void
the warranty.
6.2 MACHINE MAINTENANCE
SHEDULE
Refer to Section 6.3, Routine Maintenance Schedule.
A routine maintenance schedule based on time and/or
hours logged, is given in Section 6.3. The intervals are
determined from machine usage under typical operation
conditions. However, the operator must be aware that
operating conditions will vary depending on such things
as specific customer requirements, environmental
temperatures and cleanliness of the ambient air. With this
in mind, the specifications given in Section 6.3 should be
used as a guideline instead of a fixed agenda. A safe
approach to routine maintenance would be to perform the
given maintenance task more frequently under harsher
conditions.
IMT provides a routine maintenance parts list in Section
8, Table 8A. Should a non-routine part need replacement
or servicing, peruse the various parts list illustrations in
Section 8 to help determine the exact part and part
number in question. Our parts and service departments
are ready to assist in identifying and/or replacing nonroutine parts.
PAGE - 30
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
6.3 ROUTINE MAINTENANCE SCHEDULE
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
KEY
If working in dusty or dirty conditions,
reduce the recommended time intervals
between servicing by half for engine and
compressor oil change, and engine and
compressor filter servicing.
After 500
Hours or
Annually
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
NOTE:
Hourly or Calendar
Period - whichever
comes first
After Initial
50 Hours
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
MAINTENANCE
INTERVALS
After 8
Hours or
Daily
WARNING
TASK DESCRIPTION
ACTION TO TAKE
1
Before starting, check
compressor oil level.
•
•
•
Ensure vehicle is situated on a level surface before
checking oil level. Add oil if necessary.
2
Check for any leaks or loose
bolts.
•
•
•
Tighten if necessary.
3
Check drive belt for tension.
•
•
•
Re-tension if necessary.
•
•
•
4
After starting, check
pressure gauge for correct
operating pressure.
5
Check for leaks.
•
•
Visually note any leaks or evidence of leaks around
the compressor unit and hose connections. Tighten
any loose connection point where needed. Repair or
replace any damaged part.
6
Change oil filter element
•
•
Always replace the oil and oil filter element at the
same change interval.
7
Compressor oil change
•
•
Drain and refill air/oil compressor sump tank.
8
Inspect intake air filter.
•
•
Change if necessary.
9
Replace separator element
•
Replace.
10
Inspect exterior of frontmounted oil cooler.
•
Clean if necessary.
•
NOTE
For routine, as well as non-routine, maintenance
procedures, consult the sections listing table in Section
6.5 to locate specific maintenance components.
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 31
SECTION 6: MAINTENANCE
Iowa Mold Tooling Co., Inc.
500 Highway 18 West
Garner, Iowa 50438
Phone: 641.923.3711
CAS60R 60 CFM / 150 PSIG
6.4 REPLACEMENT PARTS
Replacement parts should be purchased through your
local IMT representative or where the compressor
system was purchased. If, for any reason, parts are not
available in this manner, they can be purchased through
IMT directly.
Fax: 641.923.6063
NOTE
If 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 6.5.14, Long
Term Storage.
6.5 PARTS REPLACEMENT AND
ADJUSTMENT PROCEDURES
DANGER
Adjustments should be made with
compressor switched OFF since
electrical terminals inside pressure
switch will be exposed, and opening the
canopy exposes the belt drive system.
WARNING
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
NOTE
It may be necessary to change the
compressor fluid and fluid filter more
frequently if the compressor fluid has
water contamination, or if the
compressor system is operated in a dirty
environment.
PAGE - 32
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
System Component or
Part Group Task
Manual
Section
Parts Replacement and Adjustment Procedures
Removing Panels for Machine Maintenance
Access
6.5
6.5.1
Removing and Replacing the Roof (Top) Access
Panel
6.5.1.1
Removing and Replacing the Main Canopy Panel
6.5.1.2
Removing and Replacing the Cooler and Instrumentation Access Panel
6.5.1.3
Compressor Oil Maintenance
6.5.2
Lubrication Guide
6.5.2.1
Adding or Changing the Compressor Oil
6.5.2.2
Oil Filter Replacement
6.5.3
Removing the Oil Filter
6.5.3.1
Replacing the Oil Filter
6.5.3.2
Coalescer (Air/Oil Separator) Replacement
6.5.4
Removing the Coalescer Element
6.5.4.1
Replacing the Coalescer Element
6.5.4.2
Compressor Air Filter Maintenance
CAUTION
Use only original equipment filters. Other
filters may not have correct pressure
rating or may have different thread.
WARNING
DO 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
air tank drain/vent 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.
Refer to Figure 6-1. Open fill cap
SLOWLY (contents under pressure) to
make sure all pressure has been
relieved.
6.5.5
Removing the Air Filter
6.5.5.1
Compressor Air Filter Inspection
6.5.5.2
Replacing the Air Filter
6.5.5.3
Repairing the Inlet Control System
6.5.6
Rebuilding the Air Inlet Valve Assembly
6.5.6.1
Performing Maintenance on the Drive Belts
A
B
C
6.5.7
Adjusting the Drive Belts
6.5.7.1
Drive Belt Tension Data
6.5.7.2
KEY
Replacing the Drive Belts
6.5.7.3
A
RED COMPRESSOR FILL CAP
Cleaning the Cooler Core
6.5.8
B
FILL CAP BLEED VENT GROOVE
Pressure Switch
6.5.9
C
Servicing the Minimum Pressure/Discharge Check
Valve
6.5.10
Open/crack cap slightly to allow
bleed vent to relieve pressure
Rebuilding the Minimum Pressure/Discharge
Check Valve
6.5.10.1
DESCRIPTION
Figure 6-1: Pressure Relief
Continued on next page
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 33
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
System Component or
Part Group Task
Setting the Minimum Pressure/Discharge Check
Valve
Manual
Section
6.5.10.2
Compressor Control Thermal Valve
6.5.11
Servicing the Fuses and Circuit Breaker
6.5.12
Safety Shutdown Systems
6.5.13
Testing the Gauges’ Shutdown Feature
6.5.13.1
Pressure Relief Valve
6.5.13.2
Long Term Storage
6.5.14
6.5.1 REMOVING PANELS FOR MACHINE
MAINTENANCE ACCESS
In order to perform many of the maintenance procedures
one or more of the machine panels will need to be
temporarily removed. Consult Table 6A, Figure 6-2 and
the proper panel removal sub-section listed below to
remove the desired panel.
System Component or
Part Group Task
REMOVING PANELS FOR MACHINE
MAINTENANCE ACCESS
WARNING
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
NOTE
The canopy panel is comprised of the
main side panels and the utility-access
side panel as a single panel unit. Care
should be taken to minimize bending of
the main canopy while it is being
removed to avoid any bending. Place the
canopy on a level surface while
maintenance is being performed.
PAGE - 34
Manual
Section
6.5.1
Removing and Replacing the Roof (Top) Panel
6.5.1.1
Removing and Replacing a Side Panel
6.5.1.2
Removing and Replacing the Cooler and Instrumentation Access Panel
6.5.1.3
6.5.1.1 REMOVING AND REPLACING THE ROOF
(TOP) PANEL
TOP PANEL REMOVAL:
Refer to Figure 6-2.
1. With a flat head screwdriver turn the stud
screw [D] a quarter turn to allow the stud
screw anchor [E] to detach from the panel
clip. Repeat for all four (4) stud screws to
free the panel.
2. Lift panel away from machine and set aside.
TOP PANEL REPLACEMENT:
1. Carefully replace the roof panel onto the top
portion of the machine aligning the four (4)
stud screws [D] so that they match up with
the four panel clips [F] located at the corners
and mid-section of the panel edges.
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
TABLE 6A - ACCESS PANEL REMOVAL
PANEL
REMOVE FOR MAINTENANCE OF:
ROOF (TOP) PANEL [A]
Compressor Air Filter, Air Inlet Valve Assembly Rebuild
COOLER AND INSTRUMENTATION
ACCESS PANEL [B]
Fuses and Circuit Breaker
CAS60R MAIN CANOPY PANELI [C]
Compressor Oil Filter, Compressor Oil Replacement, Coalescer
Replacement, Compressor Air Filter, Air Inlet Valve Rebuild, Drive Belts,
Cooler Core Cleaning, Minimum Pressure/Discharge Check Valve Rebuild
Compressor Shaft Seal Rebuild
I
The canopy panel is comprised of the main side panels and the utility-access side panel as a single panel unit.
WARNING
Before removing any access panel for maintenance:
Shut down machine, relieve all system pressure and lock out
all power, as per the Safety Section of this manual.
NOTE THAT THE SYSTEM CAN BE STARTED REMOTELY:
Always clearly tag the start-up instrumentation against
accidental system start-ups during maintenance.
A
B
G
C
H
J
D
E
L
M
F
K
N
KEY
DESCRIPTION
KEY
P
DESCRIPTION
A
TOP (ROOF) PANEL
H
NYLON WASHER, 1/4-20 (x4)
B
COOLER AND INSTRUMENATION ACCESS
PANEL
J
COOLER ASSEMBLY (reference)
C
CAS60R MAIN CANOPYI
K
TRUSS SCREW, 5/16-18 (x4)
D
STUD SCREW (x4)
L
NYLON WASHER, 5/16-18 (x4)
E
STUD SCREW - ANCHOR DETAIL
M
MAIN CANOPY MOUNTING FLANGE (detail:
x4; 2 per each side)
F
PANEL CLIP (x4)
N
6-PIN DEUTCH CONNECTOR
G
TRUSS SCREW, 1/4-20 (x4)
P
CONNECTOR MOUNTING SCREW (x4)
Figure 6-2: Package Panel Connections
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 35
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
2. Once all stud screws are set in their panel
clips, turn each stud screw a quarter turn to
fasten the roof plate to the machine.
6.5.1.2 REMOVING AND REPLACING THE MAIN
CANOPY PANEL
Most routine and non-routine maintenance issues can be
accessed by the removal of the main canopy. Refer to
Figure 6-2 and the following procedure.
MAIN CANOPY PANEL REMOVAL:
1. With a Phillips head screwdriver remove the
four (4) fastening sets consisting of the 5/1618 truss screws [K], and the 5/16-18 nylon
washers [L], from the four mounting flanges
[M] used to fasten the main canopy to the
base frame.
2. Remove the four connector screws [P]
securing the 6-pin Deutch connector [N] to
the frame.
3. Carefully disengage the connector from the
panel, from the inside.
4. Remove panel from the frame and set aside.
5. Retain all screws and washers for reassembly.
MAIN CANOPY PANEL REPLACEMENT:
1. Carefully re-set the main canopy panel into
position so that the slots on each of the four
(4) mounting flanges [M] aligns to the
mounting holes on the base frame.
2. Secure into place with four (4) pairs of 5/16-18
nylon washers [L] and 5/16-18 truss screws
[K], as shown in Figure 6-2.
3. Position the 6-pin Deutch connector [N] in
alignment from the inside with the connector
access and screw holes at the corner of the
main panel, as indicated in Figure 6-2.
4. Replace the four (4) connector mounting
screws [P] from the panel-side into the
connector’s mounting holes.
5. Tighten the connector mounting screws to
secure the connector.
6.5.1.3 REMOVING AND REPLACING THE COOLER
AND INSTRUMENTATION ACCESS PANEL
The cooler and instrumentation access panel is removed
in order to change a fuse or the circuit breaker. Refer to
Figure 6-2 and the following procedure.
PAGE - 36
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
COOLER AND INSTRUMENT ACCESS PANEL
REMOVAL:
1. With a Phillips head screwdriver remove the
four (4) fastening sets consisting of the 1/4-20
truss screws [G], and the 1/4-20 nylon
washers [H], from the cooler and
instrumentation access panel [B].
2. Retain screws and washers for re-assembly.
3. Remove panel from the frame and set aside.
COOLER AND INSTRUMENT ACCESS PANEL
REPLACEMENT:
1. Carefully re-set the cooler and
instrumentation access panel [B] into
position so that the four (4) mounting holes
align with the mounting holes on the top
edges of the cooler assembly [J].
2. Secure into place with four (4) pairs of 1/4-20
nylon washers [H] and 1/4-20 truss screws
[G], as shown in Figure 6-2.
6.5.2 COMPRESSOR OIL MAINTENANCE
Having the proper amount of oil in the compressor
system is essential to prolonging the equipment’s useful
life. Checking the compressor oil is the most important
service to perform on the CAS60R package. The
compressor is fully charged at the factory with IMT
Premium Synthetic Oil.
System Component or
Part Group Task
IMPORTANT
DO NOT mix different types of
compressor oil—mixing oil will void the
warranty! Use ONLY genuine IMT
Premium Synthetic Oil.
Manual
Section
Compressor Oil Maintenance
6.5.2
Adding or Changing the Compressor Oil
6.5.2.2
WARNING
The result of poorly maintained
lubrication and/or filters may produce
hazardous conditions resulting in
overheating, which could cause machine
shutdown. Damage to equipment and
serious bodily harm may result.
6.5.2.1 ADDING OR CHANGING THE
COMPRESSOR OIL
Consult Figure 6-1, Figure 6-3 and the following
procedure to check the compressor oil.
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 37
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
WARNING
NOTE
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
The vehicle should be situated on a level
surface to ensure that the oil level
reading is accurate. Otherwise a false oil
level indication will occur.
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
1. Locate the oil fill port [B] on the unit, access
and service line utility side of the unit
package [A].
2. Slowly, as per Figure 6-1, unscrew the red,
knurled fill cap [B] enough to gradually
relieve any internal sump pressure, and then
remove the cap.
3. Refer to Figure 6-3. Determine the oil level:
correct level is within minimum (to bottom
threads on oil fill port [E]) to maximum (until
oil runs out of port [D]) range (within [F]).
C
A
D
F
B
E
G
KEY
DESCRIPTION
KEY
DESCRIPTION
A
UNIT ACCESS AND SERVICE LINE SIDE OF UNIT
PACKAGE
D
MAXIMUM ACCEPTABLE OIL LEVEL (even with
bottom rim edge of oil fill port)
B
COMPRESSOR (RED KNURLED) OIL FILL PORT
CAP
E
MINIMUM OIL LEVEL (even with bottom threads of
the fill port)
C
PROFILE OF COMPRESSOR FILL PORT
F
ACCEPTABLE OIL RANGE
For oil supply order rotary screw compressor oil no. 89086222 (available in one [1] gallon containers).
Figure 6-3: Compressor Oil Fill Level Check
PAGE - 38
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
Note that overfill can only occur if unit is not
level.
4.
If adding oil...
Carefully add lubricant and monitor oil level,
allowing time for oil to level out. A complete refill is
approximately 5-1/4 quarts.
If changing oil...
A) Place a vessel capable of containing at least
six quarts of oil below the oil drain tube (Figure 6-3, [G]) to catch the oil as it discharges.
NOTE
C) Replace and tighten the oil drain tube cap
to the oil drain tube [G].
When performing a system oil change
the oil filter element and coalescer
elements should also be changed at the
same time. Refer to Sections 6.5.3, Oil
Filter Replacement, and 6.5.4, Coalescer
(Air/Oil Separator) Replacement
respectively.
D) Replace the oil filter per the procedural
steps given in Section 6.5.3. Once the oil
filter element has been replaced, add new
system oil.
NOTE
B) Unscrew the end cap of the oil drain tube
and allow the oil to completely drain from
the compressor unit.
5. Replace the red oil fill cap [B] tightly by hand.
6. Run unit and recheck oil level after shutdown,
allowing time for oil to settle.
Dispose of used oil and worn filter
element appropriately and in accordance
with any pertinent environmental
regulations.
7. Add appropriate amount of oil to achieve
acceptable range [F].
Oil drain is provided with short drain hose [G]. This can
be routed to a more convenient location if required,
dependent upon installation. Use only 80 pipe or suitably
rated hose.
6.5.3 PERFORMING AN OIL FILTER CHANGE
Refer to Figure 6-4. The compressor oil filter is a spinon, throw away type.
System Component or
Part Group Task
Manual
Section
Performing an Oil Filter Change
6.5.3
Removing the Oil Filter
6.5.3.1
Replacing the Oil Filter
6.5.3.2
Access the compressor unit by removing the roof panel
and the main CAS60R canopy panel, per Section 6.5.1.
6.5.3.1 REMOVING THE OIL FILTER
1. Drain oil from compressor unit per Section
6.5.2.1.
®
An Oshkosh Corporation Company
Manual #99905395
IMPORTANT
Always change the oil when changing
the oil filter element. Refer to Section
6.5.2.1.
WARNING
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
PAGE - 39
SECTION 6: MAINTENANCE
NOTE
Always replace the oil when replacing
the oil filter.
CAS60R 60 CFM / 150 PSIG
2. Remove worn filter element [C] using strap
wrench, if necessary, by turning counterclockwise. Discard as appropriate and in
accordance with any pertinent regulations.
3. Clean the filter head’s [A] connection surface
with a lint-free wipe or cloth.
6.5.3.2 REPLACING THE OIL FILTER
1. Apply a light film of oil to the seal surface on
the new filter element.
2. With the seal-side facing upward, pour
approximately one (1) cup of fill oil into the
element for priming.
A
3. Screw new element onto oil filter mounting
post [B] clockwise by hand until seal
contacts filter head; then turn an additional 3/
4 turn by hand.
B
C
4. Refer to Section 6.5.2, and replace the
system oil.
5. Run compressor and test for leaks.
KEY
DESCRIPTION
A
OIL FILTER HEAD
B
OIL FILTER MOUNTING POSTI
C
OIL FILTER ELEMENTII
I Shown extracted in this view—post does
not have to be removed from the filter head.
II For oil filter maintenance, order replace-
ment filter no. 70048249.
Figure 6-4: Compressor Oil Filter
6.5.4 COALESCER (AIR/OIL SEPARATOR)
REPLACEMENT
Refer to Figure 6-5. This is a spin-on, throw away type
unit. If oil carryover into the service line occurs and the oil
scavenge return line scavenge shows little or no oil
return, then change the element. Verify oil level.
System Component or
Part Group Task
Manual
Section
Coalescer (Air/Oil Separator) Replacement
6.5.4
Removing the Coalescer Element
6.5.4.1
Replacing the Coalescer Element
6.5.4.2
WARNING
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
PAGE - 40
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
Access the compressor unit by removing the roof panel
and the main CAS60R canopy panel per Section 6.5.1.
6.5.4.1 REMOVING THE COALESCER ELEMENT
1. Remove old element [A] (use strap wrench if
required) by turning counter-clockwise.
2. Discard worn element as appropriate and in
accordance with any pertinent regulations.
C
6.5.4.2 REPLACING THE COALESCER ELEMENT
1. Apply a light film of oil to the seal surface [C]
on the new element.
2. Screw element on clockwise until it seats
evenly and snugly on the mounting post [B];
rotate an additional 3/4 turn (by hand), taking
care not to damage the element.
A
6.5.5 COMPRESSOR AIR FILTER MAINTENANCE
Refer to Figure 6-6 and Figure 6-7. For correct filtration,
use only original IMT equipment filters.
System Component or
Part Group Task
Manual
Section
Compressor Air Filter
B
KEY
6.5.5
Removing the Air Filter
6.5.5.1
Compressor Air Filter Inspection
6.5.5.2
Replacing the Air Filter
6.5.5.3
WARNING
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
DESCRIPTION
A
COALESCER ELEMENT FILTERI
B
COALSCER ELEMENT MOUNTING
POST
C
ELEMENT SEALING GASKETII
I
For maintenance on coalescer, order
replacement element no. 70048248.
II
Coat element gasket surface with a layer
of machine fill oil to ensure a complete seal
of the element with the mounting surface.
Figure 6-5: Coalescer Maintenance
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
Access the air filter inlet housing by removing the roof
panel per Section 6.5.1.
6.5.5.1 REMOVING THE AIR FILTER
1. Per Figure 6-6, unscrew the wing nut [A] on
top of the air filter housing cover [B] and
remove filter cover.
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 41
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
2. Remove and discard the filter element [C] as
appropriate, and in accordance with any
pertinent regulations.
6.5.5.2 COMPRESSOR AIR FILTER INSPECTION
Consult Figure 6-6 and the following procedure to
inspect the compressor air filter.
1. Place a bright light source [F] inside of the
filter element and carefully inspect the filter
from the outside in a dark environment to
detect any pinholes or tears that may have
developed [H].
2. Inspect the gaskets on the top and bottom of
the air filter element [C] for any damage or
wear.
3. Replace the element if it shows any damage
or wear, even if the inspection occurs before
the recommended replacement interval.
Consult Section 6.5.5.3 if filter needs to be
replaced.
A
D
B
E
F
G
C
KEY
I
DESCRIPTION
KEY
DESCRIPTION
A
WING NUT
E
AIR FILTER HOUSING
B
AIR FILTER COVER
F
C
AIR FILTER ELEMENT
Typical light source placed within filter to shine outward,
exposing any pinholes or tears.
D
AIR INLET COVER MOUNTING STUD
G
Light shiing through pinholes indicates a worn filter element.
For maintenance on air filter, order replacement element no. 700482850.
Figure 6-6: Air Filter and Air Filter Check
PAGE - 42
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
6.5.5.3 REPLACING THE AIR FILTER
Refer to Figure 6-6 and the following procedure:
1. Clean cover [B] and remove any dirt inside
filter housing [E], taking extreme care that no
dust or dirt particles reach the air intake of the
compressor.
2. Fit the new element inside housing [E].
3. Replace cover [B] onto mounting stud [D],
and tighten wing nut [A] on top of air filter
assembly.
4. Perform test run and functional test.
6.5.6 REPAIRING THE INLET CONTROL SYSTEM
System Component or
Part Group Task
Manual
Section
B
6.5.6
C
Repairing the Inlet Control System
Rebuilding the Air Inlet Valve Assembly
A
6.5.6.1
Refer to Figure 6-7. The inlet control system consists of
two main sub-assemblies, in addition to the air filter:
1. Inlet Valve Assembly [D] The inlet valve opening/closing (load/unload) is
controlled by admitting/exhausting pilot air
pressure through the solenoid valve to the piston,
which is part of the inlet valve assembly. The air
inlet valve is not a routine maintenance item.
However, there is a rebuild kit available; refer to
Section 6.5.6.1.
D
E
F
2. Inlet Control Solenoid Valve [F] The solenoid valve attaches directly to the inlet
valve, and responds to signals from the pressure
switch to admit/vent pilot air pressure to the inlet
valve to control load/unload. The solenoid valve
is not a routine maintenance item. In the unlikely
event of failure, the complete valve should be
replaced. Consult the IMT Parts Department to
obtain a replacement valve.
Access the compressor unit by removing the roof panel
and, if needed, the main CAS60R canopy panel per
Section 6.5.1.
6.5.6.1 REBUILDING THE AIR INLET VALVE
ASSEMBLY
Should a condition occur that requires air inlet valve
maintenance (see Section 7.2, Troubleshooting
Guide), an air inlet assembly rebuild kit is available. To
®
An Oshkosh Corporation Company
Manual #99905395
KEY
DESCRIPTION
A
WING NUT
B
AIR FILTER COVER
C
AIR FILTER ELEMENT
D
AIR INLET VALVE ASSEMBLY
E
AIR FILTER HOUSING
F
AIR INLET SOLENOID
CONTROL VALVE
Figure 6-7: Air Inlet Control System
PAGE - 43
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
rebuild the air inlet valve, order air inlet rebuild kit no.
73744210. Refer to Figure 6-8, and the following
procedure:
WARNING
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
1. Locate the compressor’s air filter
compartment housing [E] at the top of the
compressor unit, and remove the wing nut [B]
from cover [C].
2. Remove air filter [D], and put it aside
temporarily so it will not get damaged or
soiled; the full air filter inlet valve [A1] is now
accessible.
3. Loosen the two (2) pan head screws [F] to
free the nested air inlet assembly.
4. Grasp the valve [A1] and pull upwards to
disengage it from its seating.
NOTE
Use all of the parts provided in the kit
regardless of the old part condition.
5. Disassemble the valve and replace used parts
with new parts found in the kit. Refer to
Figure 6-8 to assure correct integration of
replacement parts and part re-assembly
positions.
6. Replace the base flange o-ring [Y] with new
o-ring into air inlet base flange [Z] seating.
7. Once the valve’s parts have been replaced
with the kit parts and re-assembled, place
the rebuilt, complete inlet valve assembly
into position on the valve seating within the
air filter housing.
8. Replace the two (2) pan head screws [F] and
tighten securely.
9. Replace the air filter housing [C] into position
on the inlet base flange [Z].
10. Inspect the air filter: exchange it for a new
one if air filter is soiled (refer to Section
6.5.5.2, Compressor Air Filter Inspection
PAGE - 44
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
A1
B
F
C
D
E
H
G
J
L
K
N
M
Y
Z
P
A2
Q
R
S
T
U
V
Assembled Part
W
Kit Part: Air Inlet
Rebuild Kit
KEY
X
DESCRIPTION
KEY
DESCRIPTION
A1
AIR INLET VALVE ASSEMBLYI (shown assembled)
N
SPRING - LOWER
A2
AIR INLET VALVE (exploded view)
P
PISTON
B
AIR FILTER COVER WINGNUT
Q
V-RING
C
AIR FILTER COVER
R
NOZZLE
D
AIR FILTER
S
GOVERNOR HOUSING
E
AIR FILTER HOUSING
T
O-RING
F
PAN HEAD SCREW
U
LOCK WASHER
G
ELBOW
V
DISC SET
H
PAN HEAD SCREW
W
O-RING
J
SPRING GUIDE
X
CONTROL LINKAGE
K
SPRING - UPPER
Y
O-RING FOR BASE FLANGEII
L
HEX NUT
Z
AIR INLET BASE FLANGE
M
SPRING GUIDE - LOWER
I
II
For air inlet valve maintenance order rebuild kit no. 73744210.
NOTE: Flange seat o-ring is not included with the rebuild kit. When rebuilding the air inlet valve, order flange
seat replacement o-ring no. 76399332.
Figure 6-8: Air Inlet Valve Assembly
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 45
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
for air filter condition check, etc.). If filter is in
satisfactory shape, or if using a replacement
filter element, seat the air filter [D] into
position in the housing [E].
11. Replace the cover [C].
12. Replace the wing nut [B], and secure tightly.
6.5.7 PERFORMING MAINTENANCE ON THE DRIVE
BELTS
Correct tensioning and alignment is important for belt life,
bearing life and power transmission. Drive belt tensioning
and alignment is performed at the factory at time of
shipment. However, since maximum belt elongation will
occur within the first 50 hours of operation (of new belts),
the belts’ tension should be checked several times during
this period and corrected as required. The belts should,
thereafter, be checked periodically in order to obtain
maximum life and performance.
System Component or
Part Group Task
Manual
Section
Performing Maintenance on the Drive Belts
6.5.7
Adjusting the Drive Belts
6.5.7.1
Drive Belt Tension Data
6.5.7.2
Replacing the Drive Belts
6.5.7.3
Access the drive system by removing the roof panel and
the main CAS60R canopy panel per Section 6.5.1.
6.5.7.1 ADJUSTING THE DRIVE BELTS
Refer to Figure 6-9 and the following procedure:
WARNING
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
1. Slightly loosen the vertical tap bolt [B].
2. Back off adjusting bolt lock nut [E]; screw the
adjusting bolt clockwise to tighten belts or
PAGE - 46
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
D
B
A
K
L
C
E
J
G
B
C
N
F
H
J
M
KEY
DESCRIPTION
KEY
DESCRIPTION
A
HYDRAULIC MOTOR
H
NUT (horizontal tap bolt)
B
VERTICAL TAP BOLT
J
MOTOR DRIVE SHEAVE
C
WELD NUT
K
BRACKET PIVOT ANGLE
D
HYDRAULIC MOTOR BRACKET
L
DRIVE BELT (under tension)
E
ADJUSTMENT/LOCKING NUT
M
LOOSENED BELT
F
HORIZONTAL TAP BOLT (anchor and adjustment)
N
COMPRESSOR SHEAVEI
G
BASE PLATE OF HYDRAULIC MOTOR BRACKET
For belt replacement order belt no. 70580211.
I
Compressor sheave remains stationary when performing belt adjustment or removal.
Figure 6-9: Drive Belt Adjustment/Removal
counter-clockwise to loosen belts. This will
allow the hydraulic motor sheave [J] to be repositioned on an angle [K], in order to tighten
or slacken the belts.
A
B
3. After adjustments have been made, ensure
that belt is properly tensioned (refer to
Section 6.5.7.2). Then, with belt properly
positioned to the correct tension, tighten
vertical tap bolt [B], and locking nut [E] to
insure no further movement.
IMPORTANT
KEY
DO NOT over-tension the belts.
A
FOUR (4) POUNDS OF FORCE
APPLIED
B
ONE QUARTER INCH (0.25”) GIVE
(Deflection at center)
6.5.7.2 DRIVE BELT TENSION DATA
Refer to Figure 6-10 and the following procedure:
DESCRIPTION
Figure 6-10: Drive Belt Tension Deflection
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 47
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
•
Deflection at center of belt span: 0.25 inches with a force
of 4 (four) pounds.
•
Pulley alignment is set at factory and should not need to
be adjusted. If it is found necessary to adjust the pulley
alignment, loosen the four bolts that hold down the base
plate to the frame and adjust per the following
instructions:
1. Ensure sheaves are aligned by using a long
straight edge that will span the length of both
pulleys.
2. Position the straight edge on the sides of the
sheaves; if they are in line, there should be
no gaps between the straight edge and the
sheaves (for the full contact distance across
each sheave side).
3. Adjust as necessary to get correct alignment
and tension.
IMPORTANT
DO NOT over-tension the belts.
4. It may be necessary to repeat and check
several times before both tension and
alignment are satisfactory.
6.5.7.3 REPLACING THE DRIVE BELTS
Although the drive belts should be checked for fit and
wear on a routine basis, they are not considered routine
maintenance items. However, the drive belts are subject
to wear out over a period of time and use, and should be
replaced if worn, cracked or otherwise damaged. The
belt is loosened by pivoting the hydraulic motor
assembly’s bracket, which temporarily repositions the
hydraulic motor sheave enough to loosen the belt. Refer
to Figure 6-9 and the following procedure.
WARNING
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
PAGE - 48
1. Loosen the horizontal tap bolt [F] and
securing nut [H] enough to allow movement,
but DO NOT remove the tap bolt.
2. Loosen the adjustment/locking nut [E].
3. Loosen the vertical tap bolt [B] to allow for the
hydraulic motor bracket [D] to pivot the motor
assembly toward the compressor unit, which
causes the belts to slacken.
4. When the belts are slackened enough to be
slipped off of the sheaves, remove all of the
belts from the compressor sheave [N] and
motor sheave [J].
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
5. Discard worn belts appropriately.
6. With the bracket still in the “loosened”
position, thread new serpentine belts into
place over the compressor sheave [N] and
motor drive sheave [J].
7. Re-position the motor bracket angle [K] to
tighten the belts, checking at intervals for a
proper tension deflection.
NOTE
BELT TENSION DEFLECTION DATA:
Deflection at center of belt span is 0.25
inches with a force of four (4) pounds
(Refer to Figure 6-10).
8. When the belt has been adjusted to proper
tension, tighten the adjustment/locking nut
[E].
9. Hold horizontal tap bolt nut [H] in place with a
wrench while tightening the horizontal tap
bolt [F].
10. Recheck the belt tension, and adjust as
necessary until proper tightness is achieved.
IMPORTANT
DO NOT over-tension the belts.
6.5.8 CLEANING THE COOLER CORE
NOTE
Refer to Figure 6-11.
COOLER EXTERIOR:
Remove leaves, paper, and debris from outside face [A]
of cooler assembly.
Do not use high pressure air or pressure
washer to clean cooler core.
COOLER INTERIOR:
WARNING
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 49
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
F
A
B
E
D
C
KEY
DESCRIPTION
KEY
A
OUTSIDE FACE OF COOLER ASSEMBLY
D
COOLER SHROUD
B
HYDRAULIC OIL COOLER
E
FAN AND MOTOR ASSEMBLY
C
COMPRESSOR OIL COOLER
F
DIRECTION OF CLEANING AIR SOURCEI
I
DESCRIPTION
Independent compressed air source situated from inside the canopy blowing outwards.
Figure 6-11: Cooler Assembly Maintenance
Access the interior by removing the roof panel, and if
necessary, the main CAS60R canopy panel per Section
6.5.1.
Use compressed air and carefully blow through the core
from the inside of the canopy [F] (through fan assembly
or remove fan assembly).
IMPORTANT
Because of the risks involved with
manually re-adjusting the pressure
switch settings, the switch cover
contains a tamper-proof seal, and should
not be breached for any reason.
Tampering with the pressure switch may
void the warranty!
PAGE - 50
The oil cooler core is aluminum. If this does, at some
point, require internal cleaning, this is best done by a
suitably equipped radiator shop. Internal cleaning is not a
normal maintenance item if the oil is maintained in good
condition.
6.5.9 PRESSURE SWITCH
Refer to Figure 6-12. The pressure switch is mounted
directly on the sub-assembly piping located on the piping
behind the pressure gauge on the instrument panel.
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
A
KEY
DESCRIPTION
A
PRESSURE SWITCHI
B
AIR PRESSURE GAUGE (reference)
IMPORTANT
I
B
DO NOT adjust pressure switch
levels—switch is pre-set at the factory and
affixed with a tamper-proof seal. Tampering
with the pressure switch may void the
warranty!
Should pressure need to be serviced or
replaced, consult the factory service
department.
A
Figure 6-12: Pressure Switch
.
WARNING
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
WARNING
Altering the pre-set pressure switch
levels could result in bodily injury or
damage to the machine.
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
The pressure switch is accessed by removing the roof
panel, and if necessary, the cooler and instrumentation
access panel per Section 6.5.1.
The pressure switch defines pressure level parameters
for both low and high pressure operation. These levels
are pre-determined and adjusted at the factory for
optimal package performance.
Should the pressure switch sustain damage, or become
faulty, contact the factory service department for
recommended action.
6.5.10 SERVICING THE MINIMUM PRESSURE/
DISCHARGE CHECK VALVE
Refer to Figure 6-13. The minimum pressure valve is
normally factory set to 65 psig. This valve is not a routine
maintenance item.
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 51
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
6.5.10.1 REBUILDING THE MINIMUM PRESSURE/
DISCHARGE CHECK VALVE
Should a condition occur that requires the minimum
pressure/check valve to be serviced (see Section 7.2,
Troubleshooting Guide), a repair kit is available. To
repair the minimum pressure/check valve, order
minimum pressure/discharge check valve kit no.
73744211. Refer to Figure 6-13, and the following
procedure.
WARNING
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
Access the compressor unit by removing the roof panel
and the main CAS60R canopy panel per Section 6.5.1.
KEY
DESCRIPTION
A
MINIMUM PRESSURE/ DISCHARGE
CHECK VALVE
B
BUSHING
CI
VALVE HEAD COUPLING
DI
SPRING
EI
PISTOL COUPLING
FI
PRESSURE SPRING
G
I
Assembled Part
Kit Part: Air Inlet
Rebuild Kit
SPRING GUIDE
HI
O-RING
I
J
O-RING
K
VALVE BODY
L
GRUB SCREW
D
M
LOCK NUT
E
B
C
This replacement part is found in the minimum pressure / discharge check valve
rebuild kit no. 73744211.
F
I
A
G
H
J
K
L
M
Figure 6-13: Minimum Pressure/Discharge Check Valve
PAGE - 52
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
1. Locate the minimum pressure/discharge
check valve [A] situated beneath the
coalescer element on the compressor unit.
2. Loosen and remove the hex nut [M] securing
the grub screw [L] in position.
3. Loosen the grub screw [L] to relieve any
spring tension in the valve.
4. Loosen and carefully remove the valve body
[K], which holds the internal parts in place.
The internal parts will be free to drop out with
the removal of the valve body.
5. Wipe internal surface of valve body [K] with a
clean cloth.
6. Consult Figure 6-13, and re-assemble the kit
by replacing all old parts with corresponding
part provided in the kit. Use all parts provided
in the kit regardless of current part condition.
7. Once the kit parts (parts C through J) have
been situated in correct order into the valve
body, replace the valve body back into the
mounting position. Retighten body securely.
8. Replace the grub screw [L] into position on
valve body [K], and hand-tighten. Replace
the lock nut [M] over the grub screw, and
position it loosely over the grub screw.
6.5.10.2 SETTING THE MINIMUM PRESSURE
VALVE
Refer to Figure 6-13 and the following procedure:
1. Start the machine and allow it to assume idle
speed.
2. Start the compressor and allow it to
accumulate pressure build-up.
3. Using the panel pressure gauge as a guide,
adjust the grub screw [L] until minimum
pressure level is achieved.
IMPORTANT
Refer to the IMT Service Department for
the minimum pressure reset level
settings.
4. Tighten the lock nut [M] to secure the grub
screw at the proper minimum pressure level.
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 53
SECTION 6: MAINTENANCE
A
CAS60R 60 CFM / 150 PSIG
6.5.11 COMPRESSOR CONTROL THERMAL VALVE
B
Refer to Figure 6-14. The thermal valve controls the
compressor oil temperature and permits for rapid
compressor oil warm up. The valve commences to pass
a portion of the oil through the cooler at 160°F (71°C),
and is fully open at 185°F (85°C). The valve is preset,
and cannot be adjusted. In the unlikely event of failure,
this item is to be replaced as a complete item. Consult
the IMT Service Department for thermal valve
replacement assistance.
WARNING
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
C
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
KEY
DESCRIPTION
A
HYDRAULIC THERMAL CONTROL
VALVE
B
COMPRESSOR AIR FILTER (reference)
C
COMPRESSOR OIL FILTER (reference)
Figure 6-14: Compressor Thermal
Control Valve
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
6.5.12 SERVICING THE FUSES AND CIRCUIT
BREAKER
The fuse and circuit breaker can both be found on the
inside of the control panel, accessed with the shroud
removed. Consult Figure 6-15 for the location of the
fuses and circuit breaker. IMT recommends using a fuse
removal tool, though pliers will suffice when removing the
fuse.
WARNING
DANGER
Fuses will need to be replaced if blown
when tripped. When changing a fuse, or
dealing directly with any function of the
electrical system maintenance, always
be aware of the safety warnings given in
Section 1, Safety.
Before performing maintenance:
Shut down machine, relieve all system
pressure and lock out all power, as per
the Safety Section of this manual.
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Always clearly tag the start-up
instrumentation against accidental
system start-ups during maintenance.
Access the fuse and breaker locations by removing the
cooler and instrumentation access panel per Section
6.5.1.
PAGE - 54
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
C
A
B
KEY
A
DESCRIPTION
14 AMP FUSE
REPLACEMENT PART
I
I
DC)II
Order replacement 14 amp fuse no. 77041905.
B1
30 AMP CIRCUIT BREAKER (for 12V
B2
20 AMP CIRCUIT BREAKER (for 24V DC)III
III
C
10 AMP FUSE (Red)IV
IV
II
Order replacement 30 amp breaker no. 77441489.
Order replacement 20 amp breaker no. 77441490.
Order replacement 10 amp fuse no. 77041906.
Figure 6-15: Fuses and Circuit Breakers
6.5.13 SAFETY SHUTDOWN SYSTEMS
Protection for over-pressure and/or over-temperature is
provided. If either condition should occur, the diverter
valve should activate to divert hydraulic fluid back to the
tank and the compressor will stop, the fault reset on the
instrument panel will pop out and stay out until reset.
IMPORTANT
Reason for shutdown should be
investigated before pressing reset.
WARNING
NEVER FORCE the reset button back
into position, or hinder it in any way, in
order to allow for machine operation. A
tripped reset button indicates a problem
that should be addressed and resolved
before operation can continue.
®
An Oshkosh Corporation Company
Manual #99905395
IMPORTANT
Because of the risks involved with
manually re-adjusting the pressure
switch settings, the switch cover
contains a tamper-proof seal, and should
not be breached for any reason.
Tampering with the pressure switch may
void the warranty!
PAGE - 55
SECTION 6: MAINTENANCE
CAS60R 60 CFM / 150 PSIG
6.5.13.1 TESTING THE GAUGES’ SHUTDOWN
FEATURE
Periodically (every 6 months or every 500 hours), the
shutdown system should be tested as follows:
Refer to Figure 6-16.
D
A
B
KEY
C
1. While compressor is operating, close service
valve and allow compressor to unload
(approximately two [2] minutes).
2. Touch across button contact [B] on gauge
face to bezel [A] (surrounding the respective
gauge) with an insulated screwdriver.
WARNING
DESCRIPTION
A
GAUGE BEZEL
B
GAUGE TEST METAL CONTACT
C
INSULATED SCREWDRIVER
D
SAFETY TEST CONTACT CONNECTION
Figure 6-16: Safety Shutdown Test
NOTE
Both the temperature and the pressure
gauges should be tested using the
contact method explained above.
Before making the contact connection
[D] between the test contact [B] and the
bezel [A], ensure that you are not
touching the machine to allow for
grounding—only the screwdriver should
be making any connection with the
machine, and at the contact points
indicated.
3. The reset button should pop out and the
compressor should stop, indicating that the
gauge shutdown contact is working.
4. Switch compressor OFF and press reset
button to reactivate shutdown system.
6.5.13.2 PRESSURE RELIEF VALVE
Refer to Figure 6-17. Although the pressure relief valve
has a reset ring at the cap, DO NOT test the pressure
relief valve by pulling on the reset ring. The pressure
relief valve requires no safety testing.
6.5.14 LONG TERM STORAGE
Parts can wear out over time, regardless of the degree of
usage. If storing the CAS60R unit for long periods of
time, depressurize the air tank and open the drain valve
on the tank. Cover with a tarp or plastic to prevent the
accumulation of dust, but leave the bottom open for air
circulation. Whenever possible, store in a sheltered area
to minimize exposure to the elements.
Figure 6-17: Pressure Relief Valve
PAGE - 56
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 7: TROUBLESHOOTING
CAS60R 60 CFM / 150 PSIG
SECTION 7:
TROUBLESHOOTING
7.1 GENERAL INFORMATION
The information contained in this section has been
compiled from field report data and factory experience. It
contains symptoms and usual causes for the most
common types of problems that may occur. However, DO
NOT assume that these are the only problems that may
occur. All available data concerning the trouble should be
systematically analyzed before undertaking any repairs
or component replacement procedures.
A detailed visual inspection is worth performing for
almost all problems, and may avoid unnecessary
additional damage to the machine. The procedures which
can be performed in the least amount of time and with the
least amount of removal or disassembly of parts, should
be performed first. Always remember to:
1. Check for loose wiring.
2. Check for damaged piping.
3. Check for parts damaged by heat or an
electrical short circuit, usually noticeable by
discoloration or a burnt odor.
Should the problem persist after making the
recommended check, consult your nearest IMT
representative or the Iowa Mold Tooling Co., Inc. Service
Department.
WARNING
DO NOT operate the compressor or any
of its systems if there is a known unsafe
condition. Disable the equipment by
disconnecting it from its power source.
NOTE THAT THE SYSTEM CAN BE
STARTED REMOTELY:
Install a lock-out tag to identify the
equipment as inoperable to other
personnel to prevent accidental
application.
WARNING
Before starting, performing maintenance,
or replacing parts, relieve the entire
system pressure by opening a service
valve, which will vent all pressure to the
atmosphere.
IOWA MOLD TOOLING CO., INC.
500 Highway18 West
Garner, Iowa 50438
Phone: 641.923.3711
Fax: 641.923.6063
www.imt.com
7.2 TROUBLESHOOTING GUIDE
MALFUNCTION/FAULT
Compressor shuts down
air with demand present
POSSIBLE CAUSE
Compressor discharge
temperature switch is open
CORRECTIVE ACTION
Cooling air flow is insufficient; clean
cooler and check for proper ventilation.
Low fluid sump level; add fluid.
Fan not operating. Check ground and fan
switch.
Continued on next page
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 57
SECTION 7: TROUBLESHOOTING
CAS60R 60 CFM / 150 PSIG
7.2 TROUBLESHOOTING GUIDE
MALFUNCTION/FAULT
Compressor shuts down air
with demand present
(Continued)
Compressor will not build
up pressure
Compressor over pressures
POSSIBLE CAUSE
CORRECTIVE ACTION
Plugged oil filter
Replace oil filter.
Dirty cooler core
Clean cooler core.
Contaminated cooler core
Remove and clean cooler core.
Hydraulic pressure and flow
incorrect
Adjust and reset.
Air demand is too great
Check service lines for leaks or open
valves. Too much air demand.
Dirty air filter
Check the filter and clean or change
element if required.
Pressure switch out of
adjustment
DO NOT ATTEMPT TO ADJUST.
Contact the IMT Service Department for
assistance.
Defective pressure switch
Replace pressure switch.
Motor does not speed up
Check hydraulic flow and pressure and
adjust if necessary.
Belts slipping
Readjust or tighten belts.
Service valve wide open
Close service valve.
Solenoid valve stuck
Replace solenoid valve.
Leak in air pilot line
Check for leaks and correct.
Pressure regulator out of
adjustment
Contact factory service department.
Defective pressure switch
Replace pressure switch; Contact factory
service department.
Leak in air control line
Check line and correct.
Inlet valve jammed
Free or replace valve.
Restriction in control line
Dirt or ice present. Clean or free up.
Solenoid valve not energized or
faulty
Check for power. Replace if necessary.
Faulty gauge
Check using an auxiliary air source.
Replace if necessary.
Defective safety valve
Replace safety valve.
Plugged coalescer
Replace coalescer.
Continued on next page
PAGE - 58
Manual #99905395
®
An Oshkosh Corporation Company
SECTION 7: TROUBLESHOOTING
CAS60R 60 CFM / 150 PSIG
7.2 TROUBLESHOOTING GUIDE
MALFUNCTION/FAULT
Insufficient air delivery
Oil carryover
Compressor overheating
POSSIBLE CAUSE
CORRECTIVE ACTION
Plugged air filter
Replace air filter.
Plugged coalescer
Replace coalescer element.
Motor speed to low
Check hydraulic flow and pressure and
adjust if necessary.
Inlet valve stuck
Free or replace inlet valve. Order rebuild
kit if necessary.
Belts slipping
Readjust belt tension.
Oil level overfull
Drain to proper level.
Plugged oil scavenge line
Remove and clean tube thoroughly.
Discharge pressure too low
Check minimum pressure valve and
adjust. Replace if necessary.
Defective coalescer
Replace coalescer element.
Insufficient oil
Check oil level and fill to proper level.
Restricted cooling air flow
Reposition machine to assure proper air
flow.
Fan not operating
Check ground connection and ensure
proper connection.
Check fan switch.
Check air pressure switch.
Check circuit breaker.
Check for short in wires.
Check fan motor.
System retains pressure
after shutdown
Plugged oil filter
Replace oil filter.
Cooler core plugged
Clean cooler core.
Pressure set too high
Contact factory service department.
Contaminated cooler core
Remove and clean cooler core.
Unit running too fast
Check hydraulic flow and pressure and
adjust if necessary.
Thermal valve
Faulty valve; replace thermal valve.
Solenoid valve stuck
Should be no power to solenoid valve.
Replace solenoid valve.
Pressure switch faulty; replace.
Leak back from air line
Check minimum pressure valve for leaks.
Continued on next page
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 59
SECTION 7: TROUBLESHOOTING
CAS60R 60 CFM / 150 PSIG
7.2 TROUBLESHOOTING GUIDE
MALFUNCTION/FAULT
Compressor stalls
PAGE - 60
POSSIBLE CAUSE
CORRECTIVE ACTION
Belts slipping
Readjust or tighten belts.
Insufficient hydraulic system
pressure flow. This can occur if
another hydraulically activated
component is used off same
pump system. Activating the
secondary component may drop
hydraulic supply system
pressure/flow and leave
insufficient for compressor.
NOTE: Even a momentary drop
in supply hydraulic supply
pressure/flow may initiate
compressor blowdown to
commence.
Check setting on supply pressure system
relief valve.
Check to ensure adequate pressure/flow.
Check if other systems are activated off
same supply.
Pressure relief valve set too low
Contact factory service department.
Leak in seals on pressure relief
valve.
Remove and check seals or fit new valve
cartridge.
Air pressure set too high for
hydraulic system.
Adjust pressure switch to reduce air
pressure.
Leak in solenoid valve cartridge
(directional flow control valve) on
manifold.
Remove and check seals or fit new valve
cartridge.
Check over-pressure or overtemperature
Adjust if necessary.
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
SECTION 8:
ILLUSTRATED PARTS LIST
8.1 PARTS ORDERING PROCEDURE
Part orders should be placed through the distributor
from whom the unit was purchased. If for any reason
parts cannot be obtained in this manner, contact the
factory directly at the address or phone numbers
below.
When ordering parts always indicate the Serial Number
of the machine package. This can be obtained from the
Bill of Lading for the machine package, or from the
compressor unit serial number plate. See Figure 8-1 for
location of machine package serial plate. Consult Table
8A: Recommended Spare Parts List on the next page
for a listing of replacement parts.
IOWA MOLD TOOLING CO., INC.
500 Highway 18 West
Garner, Iowa 50438
Phone: 641.923.3711
Fax: 641.923.6063
www.imt.com
P SIG
Figure 8-1: Machine Package Serial Number Plate Location
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 61
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
TABLE 8A: RECOMMENDED SPARE PARTS LIST
KEY
NO.
PART NUMBER
DESCRIPTION
QTY
IDENTIFICATION
REFERENCE
SECTION
KEY NO.
ROUTINE/SCHEDULED MAINTENANCE ITEMS
1
70048249
Filter, Oil Element Replacement
1
8.2
10
2
70048248
Coalescer, Replacement Element
1
8.2
8
3
70048250
Filter, Air Element Replacement
4
89086222
Oil, Rotary Compressor (1 Gallon Container)
5
70580211
Belt, Drive Replacement
6
91724538
Kit, Hose and Tubing
1
8.2
5
5.25
qts.
-
-
1
6.9
Figure 6-9 &
Figure 6-10
1
-
Kit
Instructions
NON-ROUTINE MAINTENANCE ITEMS
7
73744210
Kit, Air Inlet Rebuild
1
6.8.1
Figure 6-8
8
76399332
O-ring, Flange Seat for Inlet Valve
1
6.8.1
Figure 6-8
9
73744211
Kit, Minimum Pressure / Discharge Check Valve
1
6.12
Figure 6-13
10
77041906
Fuse, 10A (Red)
1
6.13
Figure 6-15
11
77041905
Fuse, 14A
1
6.13
Figure 6-15
12
77441489
Breaker, Circuit 30A (for 12V DC)
1
6.13
Figure 6-15
13
77441490
Breaker, Circuit 20A (for 24V DC)
1
6.13
Figure 6-15
14
77040596
Boot, Rubber Reset Switch Replacement
1
8.4 // 8.5
9 // 7
1
15
73744222
Kit, Shaft Seal Replacement
When ordering parts, always indicate the machine serial number found on the serial plate (see Figure 8-1).
I
-
The compressor shaft seal may wear over a period of prolonged operation. Although there is a kit available for
seal replacement, special tooling is needed to perform a complete seal and ring replacement. Consult the IMT
service department for information on shaft seal replacement.
IMPORTANT
IMPORTANT
Use only approved oil and genuine IMT parts. Inspect
damaged components before operation. Substituting
non-approved oil will void the compressor warranty.
If additional spare parts are being stored for
future use, ensure 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
6.5.14, Long Term Storage.
IMPORTANT
The above table listing contains items that require
maintenance on a routine basis, and also those parts that
may require maintenance over the course of the
compressor package's performance schedule. Although
this recommended list is pro-offered as a comprehensive
guide to replacement parts, damage may occur to the
machine beyond the scope of this listing.
Should any part of the compressor package that is not
listed in Table 8A become damaged or inoperable, use
the various sub-sections in Section 8 to best locate and
identify the damaged part(s).
PAGE - 62
Manual #99905395
NOTE
An optional heating package is offered for
cold weather operation. Consult factory for
details.
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
TABLE 8B: MAINTENANCE TRACKING LOG
DATE
DESCRIPTION OF MAINTENANCE
®
An Oshkosh Corporation Company
Manual #99905395
PART(S) REPLACED
PAGE - 63
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.2 COMPRESSOR ASSEMBLY AND REPLACEMENT PARTS
6
7
12
8
5
13
4
9
3
2
10
1
11
PAGE - 64
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.2 COMPRESSOR ASSEMBLY AND REPLACEMENT PARTS
ITEM
DESCRIPTION
PART NUMBER
QTY
70734662
1
1
COMPRESSOR ASSEMBLY
2
FLEX HOSE
1
3
AIR FILTER BODY
1
4
AIR INLET VALVE
73744210
1
5
AIR FILTER
70048250
1
6
AIR FILTER COVER
1
7
WING NUT
1
8
COALESCER ELEMENT FILTER
9
SOLENOID AND INLET VALVE ASSEMBLED
10
70048248
1
Consult Factory
1
OIL FILTER
70048249
1
11
MINIMUM PRESSURE/CHECK VALVE
73744211
1
12
PRESSURE RELIEF VALVE (200PSI)
1
13
DRIVE SHAFT (MALE ROTOR)
1
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 65
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.3 HYDRAULIC MOTOR AND DRIVE
6100030ID_r1
PAGE - 66
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.3 HYDRAULIC MOTOR AND DRIVE
ITEM
DESCRIPTION
PART NUMBER
QTY
1
ELBOW, 90 DEG #12 MJIC x #10 MSAE
1
2
ELBOW, 90 DEG #16 MJIC x #16 MSAE
1
3
BUSHING, QD STYLE SK TYPE 1"
1
4
HYDRAULIC MOTOR
73540474
1
5
SHEAVE, 4 GROOVE 10.6 DIA
60030467
1
6
BRACKET, HYDRAULIC MOTOR MNTG ASSY
1
7
NUT, HEX 1/2-13
1
8
NUT, HEX LOCKING 1/2-13 GR8
6
9
CAPSCREW, HEX GR8 1/2-13X11/2
4
10
CAPSCREW, HEX GR8 1/2-13 x1 3/4
2
11
CAPSCREW, HEX GR8 1/2-13 x 5
1
12
WASHER, FLAT 1/2
8
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 67
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.4 COOLING AND CONTROL SYSTEM (1 OF 3) (12V)
6020038ID_r0_1of3
PAGE - 68
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.4 COOLING AND CONTROL SYSTEM (1 OF 3) (12V)
ITEM
DESCRIPTION
PART NUMBER
QTY
77441491
1
1
GAUGE, HOUR METER
2
ELBOW, 90 DEG 1/8P x 1/4JIC LONG
1
3
RELAY, NO/NC WEATHERPROOF w/RESISTOR
1
4
ELBOW, 90 DEG #12 MJIC x #12 MSAE
2
5
SWITCH, HIGH TEMP. SHUTDOWN
70734663
1
6
BREAKER, CIRCUIT w/ STUDS 30A
77441489
1
7
GAUGE, AIR PRESSURE w/ SWITCH
70048247
1
8
COOLER, OIL 60 CFM
51724560
1
9
BOOT, RUBBER RESET SWITCH
77040596
1
10
WASHER, NYLON FLAT 1/4
4
11
WASHER, NYLON 5/16-18
10
12
SCREW,TRUSS HD 5/16-18 x 3/4 SS
10
13
SCREW, TRUSS HD 1/4-20 x 3/4
4
14
BUMPER, RUBBER 9/16 DIA
2
15
GAUGE, TEMP. MURPHY
70734664
1
16
SWITCH, PRESSURE ADJUSTABLE
77041904
1
17
PLATE, COOLER SHROUD TOP HYD SRS65
1
18
CAP, FEMALE JIC 1 5/16-12 #16
1
19
SEAL, KNOCKOUT 1/2”
1
20
FAN AND MOTOR ASSY.
21
GROMMET, RUBBER 1 x 1 3/32 x 3/32
22
COOLER, OIL 2.00 CORE SINGLE PASS SPCL
23
SHROUD, COOLER
1
24
GUARD, OIL COOLERS
1
25
TEE, PIPE GALV 1/8
1
26
COUPLING, PIPE GALV 1/8 300#
1
27
NIPPLE, PIPE GALV 1/8 x 3
1
28
NUT, HEX FLANGE 5/16-18
13
29
NUT, HEX LOCKING 5/16-18
1
30
SCREW, SER WASH 5/16-18 x 0.75
2
31
SCREW, SER WASH 5/16-18 x 1
1
32
SCREW, HEX SELF THREAD 1/4 x 3/4
4
33
SCREW, SELF-DRILL #8 x 1/2
3
34
ELBOW, 37FL/90M #08 x 1/2
2
35
NIPPLE, HEX RED 1/4 x 1/8
1
36
PLUG, 1/2, PUSH IN, BLACK PLASTIC
1
®
An Oshkosh Corporation Company
51724557
Manual #99905395
1
1
51724558
1
PAGE - 69
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.4 COOLING AND CONTROL SYSTEM (2 OF 3) (12V) (CONT.)
6020038ID_r0_2of3
PAGE - 70
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.4 COOLING AND CONTROL SYSTEM (2 OF 3) (12V) (CONT.)
ITEM
DESCRIPTION
PART NUMBER
QTY
77441491
1
1
GAUGE, HOUR METER
2
ELBOW, 90 DEG 1/8P x 1/4JIC LONG
1
3
RELAY, NO/NC WEATHERPROOF w/RESISTOR
1
4
ELBOW, 90 DEG #12 MJIC x #12 MSAE
2
5
SWITCH, HIGH TEMP. SHUTDOWN
70734663
1
6
BREAKER, CIRCUIT w/ STUDS 30A
77441489
1
7
GAUGE, AIR PRESSURE w/ SWITCH
70048247
1
8
COOLER, OIL 60 CFM
51724560
1
9
BOOT, RUBBER RESET SWITCH
77040596
1
10
WASHER, NYLON FLAT 1/4
4
11
WASHER, NYLON 5/16-18
10
12
SCREW,TRUSS HD 5/16-18 x 3/4 SS
10
13
SCREW, TRUSS HD 1/4-20 x 3/4
4
14
BUMPER, RUBBER 9/16 DIA
2
15
GAUGE, TEMP. MURPHY
70734664
1
16
SWITCH, PRESSURE ADJUSTABLE
77041904
1
17
PLATE, COOLER SHROUD TOP HYD SRS65
1
18
CAP, FEMALE JIC 1 5/16-12 #16
1
19
SEAL, KNOCKOUT 1/2”
1
20
FAN AND MOTOR ASSY.
21
GROMMET, RUBBER 1 x 1 3/32 x 3/32
22
COOLER, OIL 2.00 CORE SINGLE PASS SPCL
23
SHROUD, COOLER
1
24
GUARD, OIL COOLERS
1
25
TEE, PIPE GALV 1/8
1
26
COUPLING, PIPE GALV 1/8 300#
1
27
NIPPLE, PIPE GALV 1/8 x 3
1
28
NUT, HEX FLANGE 5/16-18
13
29
NUT, HEX LOCKING 5/16-18
1
30
SCREW, SER WASH 5/16-18 x 0.75
2
31
SCREW, SER WASH 5/16-18 x 1
1
32
SCREW, HEX SELF THREAD 1/4 x 3/4
4
33
SCREW, SELF-DRILL #8 x 1/2
3
34
ELBOW, 37FL/90M #08 x 1/2
2
35
NIPPLE, HEX RED 1/4 x 1/8
1
36
PLUG, 1/2, PUSH IN, BLACK PLASTIC
1
®
An Oshkosh Corporation Company
51724557
Manual #99905395
1
1
51724558
1
PAGE - 71
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.4 COOLING AND CONTROL SYSTEM (3 OF 3) (12V) (CONT.)
6020038ID_r0_3of3
PAGE - 72
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.4 COOLING AND CONTROL SYSTEM (3 OF 3) (12V) (CONT.)
ITEM
DESCRIPTION
PART NUMBER
QTY
77441491
1
1
GAUGE, HOUR METER
2
ELBOW, 90 DEG 1/8P x 1/4JIC LONG
1
3
RELAY, NO/NC WEATHERPROOF w/RESISTOR
1
4
ELBOW, 90 DEG #12 MJIC x #12 MSAE
2
5
SWITCH, HIGH TEMP. SHUTDOWN
70734663
1
6
BREAKER, CIRCUIT w/ STUDS 30A
77441489
1
7
GAUGE, AIR PRESSURE w/ SWITCH
70048247
1
8
COOLER, OIL 60 CFM
51724560
1
9
BOOT, RUBBER RESET SWITCH
77040596
1
10
WASHER, NYLON FLAT 1/4
4
11
WASHER, NYLON 5/16-18
10
12
SCREW,TRUSS HD 5/16-18 x 3/4 SS
10
13
SCREW, TRUSS HD 1/4-20 x 3/4
4
14
BUMPER, RUBBER 9/16 DIA
2
15
GAUGE, TEMP. MURPHY
70734664
1
16
SWITCH, PRESSURE ADJUSTABLE
77041904
1
17
PLATE, COOLER SHROUD TOP HYD SRS65
1
18
CAP, FEMALE JIC 1 5/16-12 #16
1
19
SEAL, KNOCKOUT 1/2”
1
20
FAN AND MOTOR ASSY.
21
GROMMET, RUBBER 1 x 1 3/32 x 3/32
22
COOLER, OIL 2.00 CORE SINGLE PASS SPCL
23
SHROUD, COOLER
1
24
GUARD, OIL COOLERS
1
25
TEE, PIPE GALV 1/8
1
26
COUPLING, PIPE GALV 1/8 300#
1
27
NIPPLE, PIPE GALV 1/8 x 3
1
28
NUT, HEX FLANGE 5/16-18
13
29
NUT, HEX LOCKING 5/16-18
1
30
SCREW, SER WASH 5/16-18 x 0.75
2
31
SCREW, SER WASH 5/16-18 x 1
1
32
SCREW, HEX SELF THREAD 1/4 x 3/4
4
33
SCREW, SELF-DRILL #8 x 1/2
3
34
ELBOW, 37FL/90M #08 x 1/2
2
35
NIPPLE, HEX RED 1/4 x 1/8
1
36
PLUG, 1/2, PUSH IN, BLACK PLASTIC
1
®
An Oshkosh Corporation Company
51724557
Manual #99905395
1
1
51724558
1
PAGE - 73
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.5 COOLING AND CONTROL SYSTEM (1 OF 3) (24V)
6020048ID_r0_1of3
PAGE - 74
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.5 COOLING AND CONTROL SYSTEM (1 OF 3) (24V)
ITEM
DESCRIPTION
PART NUMBER
QTY
77441491
1
1
GAUGE, HOUR METER
2
ELBOW, 90 DEG 1/8P x 1/4JIC LONG
1
3
ELBOW, 90 DEG #12 MJIC x #12 MSAE
2
4
SWITCH, HIGH TEMP. SHUTDOWN
70734663
1
5
GAUGE, AIR PRESSURE w/ SWITCH
70048247
1
6
COOLER, OIL 60 CFM
51724560
1
7
BOOT, RUBBER RESET SWITCH
77040596
1
8
WASHER, NYLON FLAT 1/4
4
9
WASHER, NYLON 5/16-18
10
10
SCREW, TRUSS HD 5/16-18 x 3/4 SS
10
11
SCREW, TRUSS HD 1/4-20 x 3/4
4
12
BUMPER, RUBBER 9/16 DIA
2
13
GAUGE, TEMP. MURPHY
70734664
1
14
SWITCH, PRESSURE ADJUSTABLE
77041904
1
15
PLATE, COOLER SHROUD TOP HYD SRS65
1
16
CAP, FEMALE JIC 1 5/16-12 #16
1
17
SEAL, KNOCKOUT 1/2”
1
18
BREAKER, CIRCUIT w/ STUDS 20A 24V
77441490
1
19
FAN & MOTOR ASSY., 125/185 24V
51724559
1
20
RELAY, NC/NO WEATHERPROOF 24V
1
21
GROMMET, RUBBER 1 x 1 3/32 x 3/32
1
22
COOLER, OIL 2.00 CORE SINGLE PASS SPCL
23
SHROUD, COOLER
1
24
GUARD, OIL COOLERS
1
25
TEE, PIPE GALV 1/8
1
26
COUPLING, PIPE GALV 1/8 300#
1
27
NIPPLE, PIPE GALV 1/8 x 3
1
28
NUT, HEX FLANGE 5/16-18
13
29
NUT, HEX LOCKING 5/16-18
1
30
SCREW, SER WASH 5/16-18 x 0.75
2
31
SCREW, SER WASH 5/16-18 x 1
1
32
SCREW, HEX SELF THREAD 1/4 x 3/4
4
33
SCREW, SELF-DRILL #8 x 1/2
3
34
ELBOW, 37FL/90M #08 x 1/2
2
35
NIPPLE, HEX RED 1/4 x 1/8
1
36
PLUG, 1/2, PUSH IN, BLACK PLASTIC
1
®
An Oshkosh Corporation Company
Manual #99905395
51724558
1
PAGE - 75
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.5 COOLING AND CONTROL SYSTEM (2 OF 3) (24V) (CONT.)
6020048ID_r0_2of3
PAGE - 76
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.5 COOLING AND CONTROL SYSTEM (2 OF 3) (24V) (CONT.)
ITEM
DESCRIPTION
PART NUMBER
QTY
77441491
1
1
GAUGE, HOUR METER
2
ELBOW, 90 DEG 1/8P x 1/4JIC LONG
1
3
ELBOW, 90 DEG #12 MJIC x #12 MSAE
2
4
SWITCH, HIGH TEMP. SHUTDOWN
70734663
1
5
GAUGE, AIR PRESSURE w/ SWITCH
70048247
1
6
COOLER, OIL 60 CFM
51724560
1
7
BOOT, RUBBER RESET SWITCH
77040596
1
8
WASHER, NYLON FLAT 1/4
4
9
WASHER, NYLON 5/16-18
10
10
SCREW, TRUSS HD 5/16-18 x 3/4 SS
10
11
SCREW, TRUSS HD 1/4-20 x 3/4
4
12
BUMPER, RUBBER 9/16 DIA
2
13
GAUGE, TEMP. MURPHY
70734664
1
14
SWITCH, PRESSURE ADJUSTABLE
77041904
1
15
PLATE, COOLER SHROUD TOP HYD SRS65
1
16
CAP, FEMALE JIC 1 5/16-12 #16
1
17
SEAL, KNOCKOUT 1/2”
1
18
BREAKER, CIRCUIT w/ STUDS 20A 24V
77441490
1
19
FAN & MOTOR ASSY., 125/185 24V
51724559
1
20
RELAY, NC/NO WEATHERPROOF 24V
1
21
GROMMET, RUBBER 1 x 1 3/32 x 3/32
1
22
COOLER, OIL 2.00 CORE SINGLE PASS SPCL
23
SHROUD, COOLER
1
24
GUARD, OIL COOLERS
1
25
TEE, PIPE GALV 1/8
1
26
COUPLING, PIPE GALV 1/8 300#
1
27
NIPPLE, PIPE GALV 1/8 x 3
1
28
NUT, HEX FLANGE 5/16-18
13
29
NUT, HEX LOCKING 5/16-18
1
30
SCREW, SER WASH 5/16-18 x 0.75
2
31
SCREW, SER WASH 5/16-18 x 1
1
32
SCREW, HEX SELF THREAD 1/4 x 3/4
4
33
SCREW, SELF-DRILL #8 x 1/2
3
34
ELBOW, 37FL/90M #08 x 1/2
2
35
NIPPLE, HEX RED 1/4 x 1/8
1
36
PLUG, 1/2, PUSH IN, BLACK PLASTIC
1
®
An Oshkosh Corporation Company
Manual #99905395
51724558
1
PAGE - 77
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.5 COOLING AND CONTROL SYSTEM (3 OF 3) (24V) (CONT.)
6020048ID_r0_3of3
PAGE - 78
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.5 COOLING AND CONTROL SYSTEM (3 OF 3) (24V) (CONT.)
ITEM
DESCRIPTION
PART NUMBER
QTY
77441491
1
1
GAUGE, HOUR METER
2
ELBOW, 90 DEG 1/8P x 1/4JIC LONG
1
3
ELBOW, 90 DEG #12 MJIC x #12 MSAE
2
4
SWITCH, HIGH TEMP. SHUTDOWN
70734663
1
5
GAUGE, AIR PRESSURE w/ SWITCH
70048247
1
6
COOLER, OIL 60 CFM
51724560
1
7
BOOT, RUBBER RESET SWITCH
77040596
1
8
WASHER, NYLON FLAT 1/4
4
9
WASHER, NYLON 5/16-18
10
10
SCREW, TRUSS HD 5/16-18 x 3/4 SS
10
11
SCREW, TRUSS HD 1/4-20 x 3/4
4
12
BUMPER, RUBBER 9/16 DIA
2
13
GAUGE, TEMP. MURPHY
70734664
1
14
SWITCH, PRESSURE ADJUSTABLE
77041904
1
15
PLATE, COOLER SHROUD TOP HYD SRS65
1
16
CAP, FEMALE JIC 1 5/16-12 #16
1
17
SEAL, KNOCKOUT 1/2”
1
18
BREAKER, CIRCUIT w/ STUDS 20A 24V
77441490
1
19
FAN & MOTOR ASSY., 125/185 24V
51724559
1
20
RELAY, NC/NO WEATHERPROOF 24V
1
21
GROMMET, RUBBER 1 x 1 3/32 x 3/32
1
22
COOLER, OIL 2.00 CORE SINGLE PASS SPCL
23
SHROUD, COOLER
1
24
GUARD, OIL COOLERS
1
25
TEE, PIPE GALV 1/8
1
26
COUPLING, PIPE GALV 1/8 300#
1
27
NIPPLE, PIPE GALV 1/8 x 3
1
28
NUT, HEX FLANGE 5/16-18
13
29
NUT, HEX LOCKING 5/16-18
1
30
SCREW, SER WASH 5/16-18 x 0.75
2
31
SCREW, SER WASH 5/16-18 x 1
1
32
SCREW, HEX SELF THREAD 1/4 x 3/4
4
33
SCREW, SELF-DRILL #8 x 1/2
3
34
ELBOW, 37FL/90M #08 x 1/2
2
35
NIPPLE, HEX RED 1/4 x 1/8
1
36
PLUG, 1/2, PUSH IN, BLACK PLASTIC
1
®
An Oshkosh Corporation Company
Manual #99905395
51724558
1
PAGE - 79
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.6 FRAME AND PARTS (12V)
6030038ID_r1
PAGE - 80
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.6 FRAME AND PARTS (12V)
ITEM
DESCRIPTION
PART NUMBER
QTY
1
TERMINAL, FEMALE
2
2
CONNECTOR, FEMALE
1
3
TEE, JIC/JIC/SAE 3/4
1
4
ADAPTER, #12 MSAE O-RING x 3/4 FNPT
1
5
MANIFOLD, HYDRAULIC SOLENOID
71414997
1
6
VALVE, PRESSURE RELIEF
73540470
1
7
VALVE, SOLENOID WITH 12V. COIL
73540471
1
8
EYENUT, 5/8-11
1
9
SEAL, CABLE GREEN 16-14 GA
2
10
CAP, FEMALE JIC 1 1/16-12 #12
1
11
GROMMET, RUBBER 11/16 x 1 x 3/16
1
12
ROD, TIE DOWN BODY 5/8-11 x 12
1
13
NUT, HEX LOCKING 5/8-11 GR8
1
14
FRAME, HYDRAULIC VIKING
1
15
BUSHING, RED STEEL 3/4 x 1/2
1
16
NUT, HEX 5/8-11
1
17
NUT, HEX LOCKING 3/8-16
2
18
CAPSCREW, HEX GR8 3/8-16 x 5
2
19
WASHER, FLAT 3/8
2
20
WASHER, FLAT 5/8
1
21
CONNECTOR, 37FL/MPT #08 x 1/2
1
22
TEE, 37FL M BR 1 JIC X 3/4NPT
1
23
BULKHEAD, MJIC x MJIC #12
1
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 81
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.7 FRAME AND PARTS (24V)
6030054ID_r0
PAGE - 82
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.7 FRAME AND PARTS (24V)
ITEM
DESCRIPTION
PART NUMBER
QTY
1
TERMINAL, FEMALE
2
2
CONNECTOR, FEMALE
1
3
TEE, JIC/JIC/SAE 3/4
1
4
ADAPTER, #12 MSAE O-RING x 3/4 FNPT
1
5
MANIFOLD, HYDRAULIC SOLENOID
71414997
1
6
VALVE, PRESSURE RELIEF
73540470
1
7
VALVE, SOLENOID w/ 24V COIL
73540472
1
8
ROD, THREADED 5/8-11 GR B7
1
9
EYENUT, 5/8-11
1
10
SEAL, CABLE GREEN 16-14 GA
2
11
CAP, FEMALE JIC 1 1/16-12 #12
1
12
GROMMET, RUBBER 11/16 x 1 x 3/16
1
13
NUT, HEX LOCKING 5/8-11 GR8
1
14
FRAME, HYDRAULIC
1
15
BUSHING, RED STEEL 3/4 x 1/2
1
16
NUT, HEX 5/8-11
1
17
NUT, HEX LOCKING 3/8-16
2
18
CAPSCREW, HEX GR8 3/8-16 x 5
2
19
WASHER, FLAT 3/8
2
20
WASHER, FLAT 5/8
1
21
CONNECTOR, 37FL/MPT #08 x 1/2
1
22
TEE, 37FL M BR 1 JIC x 3/4NPT
1
23
BULKHEAD, MJIC x MJIC #12
1
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 83
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.8 CANOPY AND PARTS (1 OF 2)
6030041ID_r0_1of2
8.8 CANOPY AND PARTS (2 OF 2)
6030041ID_r0_2of2
PAGE - 84
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.8 CANOPY AND PARTS (1 OF 2)
ITEM
I
DESCRIPTION
1
BUMPER, RUBBER 3/16 MTG REV.0
2
CLIP
3
CANOPYI
PART NUMBER
QTY
7
71415013
4
1
Refer to Section 8.9 for canopy panel details.
8.8 CANOPY AND PARTS (2 OF 2)
ITEM
DESCRIPTION
PART NUMBER
QTY
1
PLATE,TOP SRS65
1
2
RETAINER
4
3
WASHER
4
4
SPRING
4
5
STUD, FLAT HEAD
4
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 85
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.9 CANOPY PANELS
271356_r2
PAGE - 86
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.9 CANOPY PANELS
ITEM
DESCRIPTION
PART NUMBER
QTY
1
TOP, CANOPY
1
2
PANEL, CANOPY R.H.
1
3
PANEL, CANOPY L.H.
1
5
ANGLE, SUPPORT
1
6
ANGLE, CANOPY MTG.
4
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 87
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.10 THERMAL CONTROL
6120110ID_r0
PAGE - 88
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.10 THERMAL CONTROL
ITEM
DESCRIPTION
PART NUMBER
QTY
1
ELBOW, 90 DEG. MJIC x MBSPP 1/2
1
2
ADAPTER, FEMALE PIPE x BSPP 1/2
1
3
VALVE, THERMAL 1/2 BSPP
4
ADAPTER, MJIC x MBSPP 1/2 x 1/2
1
5
TEE, 37FL/M BR #8 x 1/2
1
®
An Oshkosh Corporation Company
73540475
Manual #99905395
1
PAGE - 89
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
8.11 DECAL LOCATIONS (PART 1 OF 2 / DECAL SHEET #95724529)
KEY
PART NUMBER
QTY
1
70399256
2
5
70397804
2
10
70392982
2
Part numbers are provided for those decals that
have an individual part number. For all others, use
the decal sheet number (no. 95724529) for consultation and/or ordering replacements.
WARNING
DO NOT REMOVE OR COVER ANY
SAFETY DECAL. Replace any safety
decal that becomes damaged or illegible.
PAGE - 90
Manual #99905395
®
An Oshkosh Corporation Company
CAS60R 60 CFM / 150 PSIG
SECTION 8: ILLUSTRATED PARTS LIST
8.11 DECAL LOCATIONS (PART 2 OF 2 / DECAL SHEET #95724529)
7
®
6
5
1
2
3
4
8
NOTE
Part numbers are provided for those decals
that have an individual part number. For all
others, use the decal sheet number (no.
95724529) for consultation and/or ordering
replacements.
WARNING
DO NOT REMOVE OR COVER ANY
SAFETY DECAL. Replace any safety
decal that becomes damaged or
illegible.
1
5
2
6
4
3
7
8
®
An Oshkosh Corporation Company
Manual #99905395
PAGE - 91
SECTION 8: ILLUSTRATED PARTS LIST
CAS60R 60 CFM / 150 PSIG
BLANK PAGE
PAGE - 92
Manual #99905395
®
An Oshkosh Corporation Company
BLANK PAGE
®
An Oshkosh Corporation Company
IOWA MOLD TOOLING CO., INC.
500 Highway 18 West
Garner, Iowa 50438
Phone: 641.923.3711
Fax: 641.923.6063
www.imt.com
Printed in the U.S.A.
Specifications Subject to
Change Without Prior Notice
050737
050740
090033_r0
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