IMT CAS2545 Manual de instrucciones

Printed on 19 February, 2007

Manual Part No. 99904145

IMT CAS2545 Air Compressor

Operation, Maintenance and Spare Parts

Revised 20070220

IOWA MOLD TOOLING CO., INC.

PO Box 189

Garner, IA 50438

Tel: 641-923-3711 FAX: 641-923-2424

Website: http://www.imt.com

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any

form or by any means, electronic, mechanical, photocopying, recording or otherwise without the

prior written permission of Iowa Mold Tooling Co., Inc.

Iowa Mold Tooling Co., Inc. is an Oshkosh Truck Corporation Company.

Contents

Revisions .................................................................................................................................................... iii

Compressor Introduction 5

Compressor Safety........................................................................................................................................7

Safety Decals.....................................................................................................................................8

Warning & Caution Decals................................................................................................................9

Instruction Decals............................................................................................................................10

CAS2545 System Description & Specifications.........................................................................................11

CAS2545 Performance Data.......................................................................................................................12

CAS2545 Performance Charts....................................................................................................................13

CAS2545 Component Identification...........................................................................................................16

Installation 17

Compressor Installation Notes....................................................................................................................17

Compressor Installation (99904153)...........................................................................................................18

Compressor Installation, Telescopic Top (99904166) ................................................................................19

Electrical Installation ..................................................................................................................................21

Electrical Installation (Non-IMT Application) (77441157) (Effective 3-15-05) ........................................22

Cooler Installation (99903573)...................................................................................................................23

Decal Installation (99904154).....................................................................................................................26

Compressor Mounting Locations (99903712) ............................................................................................28

Operation 29

Compressor Terminology ...........................................................................................................................29

Description of Components ........................................................................................................................30

Compressor Operation Test ........................................................................................................................33

Compressor Start-Up & Shut-Down...........................................................................................................33

Sub-Zero Temperature Operating Instructions ...........................................................................................35

Maintenance & Repair 37

Maintenance Schedule ................................................................................................................................38

CAS2545 Maintenance Procedures ............................................................................................................39

Lubricant Recommendations ......................................................................................................................45

Relay Module..............................................................................................................................................46

Flash Recovery Procedure ..........................................................................................................................47

Compressor Troubleshooting......................................................................................................................49

Parts 53

Parts Ordering Information.........................................................................................................................53

CAS2545 Recommended Spare Parts List..................................................................................................53

Compressor Assembly (99904093).............................................................................................................54

99904093-2 Drawing.......................................................................................................................54

ii Contents

99904093-3 Drawing.......................................................................................................................56

99904093-4 Drawing.......................................................................................................................57

99904093-5 Drawing.......................................................................................................................59

99904093-6 Drawing.......................................................................................................................61

99904093-7 Drawing.......................................................................................................................63

99904093 Complete Parts List ........................................................................................................64

Oil Separator Block Spare Parts .................................................................................................................67

Compressor Spare Parts..............................................................................................................................68

Electrical Schematic (77441156)................................................................................................................69

Hydraulic Schematic (99904155) ...............................................................................................................70

Contents iii

Revisions

DATE LOCATION DESCRIPTION

20070115 99904166,

99903712

ECN 10334 - ADDED TELE TOP INSTALLATION INSTRUCTIONS

99904093 ADDED PART NUMBERS PER PAGE

20070220 99904093,

99904148,

99904154

ECN 10382 - UPDATE AFTER PILOT BUILD

This volume provides information on the installation, operation, and repair of IMT hydraulic air

compressors. In addition to reading the manual, it is your responsibility to become familiar with

government regulations, hazards, and the specific operation of your equipment. Use caution

and common sense while operating and maintaining the equipment and follow all safety

procedures and regulations. Treat this equipment with respect and service it regularly.

MODIFICATIONS

Modifications to your equipment must be performed with IMT approved accessories, parts and

optional equipment. If in doubt about the safety, compatibility, or appropriateness of any

modifications, contact IMT prior to making those modifications. DO NOT alter or modify any

safety device! All safety devices must be inspected, tested and maintained in proper working

condition.

Note that decals regarding safety and operation are considered safety equipment. They must be

maintained just as any other safety device. Decals must be kept clean and legible to the

operator, operational personnel, and bystanders as specified in the decal section of this manual.

DO NOT remove, disable, or disregard any safety device attached to your equipment.

The equipment owner and/or designated employee is responsible for informing all operators,

maintenance personnel, and others involved in equipment operation about the safe operation

and maintenance of the equipment. If questions arise concerning safe operation, contact IMT or

your IMT distributor for clarification.

WARRANTY

Warranty of this unit will be void on any part of the unit subjected to misuse due to overloading,

abuse, lack of maintenance and unauthorized modifications. No warranty - verbal, written or

implied - other than the official, published IMT new machinery and equipment warranty will be

valid with this unit.

NOTICE TO THE OWNER / USER

If your equipment is involved in a property damage accident, contact your IMT distributor

immediately and provide them with the details of the accident and the serial number of the

equipment. If an accident involves personal injury, immediately notify your distributor and IMT

Technical Support at:

IOWA MOLD TOOLING CO., INC.

500 HWY 18 WEST

GARNER, IA 50438

641 - 923 - 3711

SECTION 1

Compressor Introduction

6 IMT CAS2545 Air Compressor Manual Part No. 99904145

WARNING

READ YOUR MANUAL!! FAILURE TO READ, UNDERSTAND AND FOLLOW ANY SAFETY

PROCEDURES APPLICABLE TO YOUR EQUIPMENT MAY RESULT IN EQUIPMENT

DAMAGE, SERIOUS INJURY, OR DEATH.

Three means are used throughout this manual to gain the attention of personnel. They are

NOTEs, CAUTIONs and WARNINGs and are defined as follows:

NOTE

A NOTE is used to either convey additional information or to provide further emphasis for a

previous point.

CAUTION

A CAUTION is used when there is the very strong possibility of damage to the equipment or

premature equipment failure.

WARNING

A WARNING is used when there is the potential for personal injury or death.

Treat this equipment with respect and service it regularly for a safer working environment and

longer equipment life.

Section 1 Compressor Introduction 7

Compressor Safety

AIR COMPRESSOR SAFETY PRECAUTIONS

Safety is basically common sense. While there are standard safety rules, each situation has its

own peculiarities that cannot always be covered by rules. Through experience and common

sense, you are in the best position to ensure your safety. Lack of attention to safety can result in

accidents, personal injury, reduction of efficiency and worst of all, loss of life. Watch for safety

hazards. Correct them promptly. Use the following safety precautions as a general guide to safe

operation:

WARNING

All units are shipped with a detailed Operators and Parts Manual. This Manual contains vital

information for the safe use and effective operation of this unit. Carefully read the Operators

Manual before starting the unit. Failure to adhere to the instructions could result in SERIOUS

BODILY INJURY or PROPERTY DAMAGE.

Make sure all protective covers and guards are in place, and that the canopy / doors are

closed during operation.

Be very cautious in using this machine in flammable gas risk areas. Use in these areas may

require additional safety equipment such as gas detectors, exhaust spark arrestors and shut-

off valves, depending on local regulations of the level of risk involved.

Relieve pressure from the entire system before attempting to service the compressor or

removing any compressor parts.

Do not attempt to service any part while machine is operating.

Ensure adequate ventilation when releasing discharge air into a confined space.

WARNING

Check the compressor sump oil level only when the compressor is not operating and system

is completely relieved of pressure. Open service valve to ensure relief of system air pressure

when performing maintenance on compressor air/oil system.

FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTY AND

SERIOUS BODILY HARM.

Do not operate the compressor at pressure or speed in excess of its rating as indicated in

“Compressor Specifications”.

Periodically check all safety devices for proper operation.

Do not play with compressed air. Pressurized air can cause serious injury. Avoid bodily

contact with compressed air.

8 IMT CAS2545 Air Compressor Manual Part No. 99904145

Exercise cleanliness during maintenance and when making repairs. Keep dirt away from

parts by covering parts and exposed openings.

DANGER

Do NOT use IMT compressor systems to provide breathing air. Such usage, whether

supplied immediately from the compressor source, or supplied to breathing tanks for

subsequent use, can cause serious bodily injury. Air discharged from the compressor may

contain carbon monoxide or other contaminants.

IMT disclaims any and all liabilities for damage or loss due to personal injuries, including

death, and/or property damage including consequential damages from using any IMT

compressors for breathing air.

Do not disconnect or bypass safety circuit system.

Do not install safety devices other than authorized IMT replacement devices.

Close all openings and replace all covers and guards before operating compressor unit.

Do not leave tools, rags, or loose parts on the compressor or drive parts.

Do not use flammable solvents for cleaning parts.

Keep combustibles out of and away from the compressor and any associated enclosures.

Use hearing protection around the compressor. The compressor produces loud noises

which, over extended exposure, can cause hearing loss.

The owner, lessor, or operator of the compressor are hereby notified and forewarned that any

failure to observe these safety precautions may result in damage or injury.

IMT expressly disclaims responsibility or liability for any injury or damage caused by failure to

observe these specified precautions or by failure to exercise that ordinary caution and due care

required when operating or handling the compressor, even though not expressly specified

above.

Safety Decals

A compliment of warning decals are supplied with each unit. These decals must be affixed to the

unit after it has been painted, trimmed, and undercoated, etc. and prior to being put into service.

The decal placement should ensure decals are clearly visible to the user and service personnel.

All decals for the IMT CAS2545 Air Compressor can be ordered on a decal sheet, part number

95720760.

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