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IMT CAS2545, Operation And Maintenance Manual

Get your hands on the IMT CAS2545 Operation And Maintenance Manual for free download. This comprehensive manual provides detailed instructions on how to operate and maintain your product effectively. Access the manual at 88.208.23.73:8080 and ensure the longevity of your IMT CAS2545.

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i 

 

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

 

Summary of Contents for CAS2545

Page 1: ...X 641 923 2424 Website http www imt com Copyright 2007 Iowa Mold Tooling Co Inc All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any for...

Page 2: ......

Page 3: ...ation 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...

Page 4: ...93 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 7744...

Page 5: ...sions 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...

Page 6: ......

Page 7: ...ator 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 de...

Page 8: ...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 use...

Page 9: ...ors 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 arrest...

Page 10: ...ompressor 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 compress...

Page 11: ...Section 1 Compressor Introduction 9 Warning Caution Decals WARNING Do not operate with cover removed...

Page 12: ...OTARY SCREW COMPRESSOR FLUID ONLY 1 CHECK FLUID LEVEL COLD WITH TRUCK OFF AND PARKED ON LEVEL GROUND 2 FLUID LEVEL MUST BE MAINTAINED BETWEEN MINIMUM AND MAXIMUM AS INDICATED IN FIGURE 3 CHECK OIL LEV...

Page 13: ...on indicator All instrumentation is on the front panel of the compressor The air delivery rate of the unit is 45 cfm at 100 psi CAUTION Operating the compressor at pressures above 150 psi will shorten...

Page 14: ...OW cfm 125 psi 25 30 35 40 45 Input Power hp 7 2 8 4 11 3 12 5 15 8 Compressor Speed rpm 4929 5717 7074 7882 8437 Hydraulic Motor Speed rpm 1893 2196 2717 3027 3240 Hydraulic Motor Flow gpm 6 7 9 10 1...

Page 15: ...Section 1 Compressor Introduction 13 CAS2545 Performance Charts...

Page 16: ...14 IMT CAS2545 Air Compressor Manual Part No 99904145...

Page 17: ...Section 1 Compressor Introduction 15...

Page 18: ...45 CAS2545 Component Identification TEMPERATURE GAUGE HYDRAULIC SOLENOID TEMPERATURE SWITCH LIGHTED PUSHBUTTON SWITCH HOURMETER MAIN POWER BODY INTERFACE RELAY MODULE 5 LB SWITCH 20 LB SWITCH FAN TEMP...

Page 19: ...rance is 28 inches Compressor performance is optimum with a level installation The maximum tilt allowed is 20 You do not need to use isolators with installation the gasket material is sufficient Use h...

Page 20: ...77441158 AIR OUT 3 4 NPT HYD OIL IN 12 JIC HYD OIL OUT 12 JIC 5 8 THREADS FOR LIFT EYE NOTE 1 WHEN INSTALLING IN CONJUNCTION WITH A HYDRAULIC AFTER COOLER THE MINIMUM SPACE BETWEEN THE COOLER AND THE...

Page 21: ...F SIDEPACK 99904166 1 PARTS LIST ITEM PART DESCRIPTION QUANTITY 3 60131197 SPACER COMPRESSOR 2 4 60131198 SPACER AFTER COOLER 2 6 76392821 WASHER BONDED PLTD 38 6 7 72060054 CAP SCR 38 16X 3 00 HH GR5...

Page 22: ...18363 MOUNT COOLER HYD 1 13 73052133 COOLER HYDRAULIC 1 14 60125752 SHROUD COOLER HYD AUX SIDEPACK 1 15 70733880 FAN 12 PUSHER 1 16 72060004 CAP SCR 25 20X 1 00 HH GR5 Z 4 17 72062104 NUT 25 20 HEX NY...

Page 23: ...the compressor comes with an IMT service truck package with a crane the unit will be wired and ready to use and will be controlled through the crane remote If the compressor comes with an IMT service...

Page 24: ...erial numbers of CAS3560051016 and higher RED 14 GA CONTRL POWER Switched 12VDC power comp on off switch RED 10 GA FAN FEED 12VDC to battery with 30A fuse fan power BLACK 14 GA GROUND To chassis groun...

Page 25: ...Installation 23 Cooler Installation 99903573 12 11 9 10 15 13 7 18 2 1 14 2 6 3 5 8 19 20 21 22 23 16 17 FOR MOUNTING RELAY 19 20 21 3 4 5...

Page 26: ...5 FRONT DECAL 70396470 DECAL 70396468 FRONT BLACK TO CHASSIS GROUND TO FAN SWITCH TO FAN RETERMINATE FAN CONNECTOR 77044573 SHROUD 1 70394069 SEAL 2 77045887 PIN 2 BLACK A RED B RED TO BATTERY 12VDC W...

Page 27: ...77041659 TEMP SWITCH FAN 1 13 60125752 COOLER SHROUD HYD AUX SIDEPACK 1 14 72061090 SCR SELF TAP 12 24X 62 PL HEX WH 1 15 70733880 FAN 1 16 72060004 CAP SCR 1 4 20X1 HHGR5Z 4 17 72062104 NUT 1 4 20 H...

Page 28: ...ate with cover removed 70396162 HIGH TEMP RESET 8500 RPM MAX FILL OIL BETWEEN MINIMUM AND MAXIMUM LEVELS USE IMT ROTARY SCREW COMPRESSOR FLUID ONLY 1 CHECK FLUID LEVEL COLD WITH TRUCK OFF AND PARKED O...

Page 29: ...AIL A SCALE 0 40 1 70029119 SERIAL PLACARD MOUNT WITH POP RIVETS 72066340 Placement Locations for Decals Not Shown on Compressor ITEM LOCATION 2 Place 1 on 52718087 lift station near relay module 7014...

Page 30: ...16 5 6 12 18 MIN 0 44 TYP 10 4 38 12 25 16 50 12 00 12 00 6 00 18 00 MIN 0 44 TYP 10 CAS3560 CAS2545 INSTALLATION ON SERIES 2 DOM WITH HEADACHE RACK AND STANDARD HEIGHT SIDEPACK ON COMPRESSOR SIDE CAS...

Page 31: ...e of oil separation from compressed air Also serves as reservoir area for compressor lubricant measured in rpm revolutions per minute PSI Refers to the operating pressure the system is set up at expre...

Page 32: ...the compressed air and seals the running clearances LUBRICATION SYSTEM Oil from the compressor oil sump at compressor discharge pressure is directed through the oil filter cooling system and to the si...

Page 33: ...gh compressor temperature 240 AUTOMATIC BLOW DOWN VALVE There is one blow down valve in the compressor system It is located inside the compressor The valve will automatically bleed the sump to atmosph...

Page 34: ...nt temperature Condensation is directed to the air tank where it is collected CONTROL SYSTEM OPERATION The following discussion explains the operation of the control system from a condition of no load...

Page 35: ...ccess plugs are in place and secured 2 With the compressor engaged a Adjust engine speed to ensure that compressor speed does not exceed 8500 rpm max under load Crack open air discharge valve until ai...

Page 36: ...will adversely affect the life of the compressor CAUTION Operating this unit in excess of 8500 rpm will void the warranty and will shorten the normal service life of the compressor Compressor Shut Do...

Page 37: ...re gauge reads between 100 and 125 psi This ensures that the oil temperature has had adequate time to come up to operating temperature and that most of the water in the system has been removed This wi...

Page 38: ......

Page 39: ...AINTENANCE CHART lists serviceable items on this compressor package The items are listed according to their frequency of maintenance followed by those items which need only As Required maintenance The...

Page 40: ...ves Check all electrical connections Air end oil change see Note 2 Inspect drive system for wear tension Air cleaner change Coalescer element change Service intervals are listed as hours months whiche...

Page 41: ...hook to lift the compressor Lift hooks or eyehooks with a rating of at least 600 pounds must be provided by the customer COMPRESSOR OIL SUMP FILL LEVEL AND DRAIN CHECKING COMPRESSOR OIL LEVEL The prop...

Page 42: ...with oil Excess oil will run out the oil fill tube AIR INTAKE FILTER The air intake filter is a heavy duty two stage dry type high efficiency filter designed to protect the compressor from dust and fo...

Page 43: ...hose fitting WARNING Do not substitute element Use only a genuine IMT replacement element This element is rated at 200 psi working pressure Use of any other element may be hazardous and could impair...

Page 44: ...by the vendor who supplies the cooler 1 Remove cooler 2 Circulate a suitable solvent to dissolve and remove varnish and sludge 3 Flush generously with IMT compressor lubricant 4 After cooler is reins...

Page 45: ...equently during the first 24 48 hours of operation Over tensioning shortens the belt and bearing life Keep belts free from foreign material which may cause slip Inspect V belts regularly Tension when...

Page 46: ...auses the belt to roll over in the sheaves or throws all of the load on one side of the belt stretching or breaking the cords on that side 1 4 GAP BETWEEN BACK FACE OF PULLEY AND MOTOR MOUNT FACE STRA...

Page 47: ...vy duty lubricant must rest with the individual supplier if they choose not to use the recommended IMT rotary screw lubricant The lubricant supplier s recommendation must therefore be based upon not o...

Page 48: ...elay controls hydraulic solenoid relay Power Main power to solenoid Normal Operation When the compressor is turned on the Power and Enable relays will light indicating normal operation When the oil te...

Page 49: ...no grinding present 2 Flush oil cooler a Remove both tubes from oil cooler b Verify that the plastic shroud and fan blades are intact Put power direct to red lead ground black lead at fan motor to ve...

Page 50: ...oil should cycle through the valve block but not through the hydraulic motor High Temp Reset light should be active until depressed If compressor does not stop running DO NOT PROCEED Contact IMT Techn...

Page 51: ...that cooler has no airflow obstructions Check air cooler core Clean as needed High ambient air temperature Contact IMT Technical Support Leaks Check for air leaking from tank or blow down fittings Saf...

Page 52: ...cooler Leaking compressor shaft seal Replace seal Water in air system Defective moisture separator drain trap Inspect and clean if required Replace separator trap if required Air cooler core dirty Ins...

Page 53: ...across 20 lb pressure switch N O If switch is not closing replace With the compressor off check for 12 volts across 5 lb pressure switch N C If switch does not close replace switch Speed control come...

Page 54: ......

Page 55: ...cription Qty 79733864 Belt tensioning gauge 1 92720758 Belt tensioning tool 1 89086192 Oil quart 1 89086201 Oil gallon 1 Lifting eye Ref 70048233 Oil filter 1 70048217 Air filter 1 70580187 V Belt 3 7...

Page 56: ...2053767 ELBOW M STR 90 M JIC 12 12 1 13 73540127 VALVE SOL SV12 21 0 N 12DW 1 14 60125143 VALVE BLOCK COMPRESSOR 1 15 73540139 VALVE RELIEF 2500 PSI RVPS10NS030 1 18 72063000 WASHER 19 W FLAT ANSI B27...

Page 57: ...5 72063172 WASHER 4 LOCK ZINC 4 66 72062206 NUT 4 40 HEX ZINC 4 67 72601806 SCR MACH 4 40 50 SKT HEAD 4 68 72532140 PLUG STR HEX HD STL 56 1 74 70146433 ENGINE FUNCTION MODULE E F M 1 80 51396385 HOSE...

Page 58: ...C 90 M BSPP 12 8 3 77 301256 MOTOR HYD 87 1 78 60130815 PULLEY DRIVER COMPRESSOR 1 81 72532365 ADPTR M STR M JIC 10 12 1 89 72661549 CLAMP DUCT 2 5 2 99 70397043 GASKET 2545 CPRSR INLET 1 100 70734163...

Page 59: ...55 70580187 BELT 3V 3 156 60130976 COMPRESSOR INLET CAP 1 166 72601762 WASHER LOCK 6MM PART OF 162 3 167 72601797 WASHER LOCK 8MM PART OF 162 4 168 72601873 CAP SCR M 8 1 25X 35 BTNHD PART OF 162 4 99...

Page 60: ...SAE 4 SS 2 53 70048215 FILTER AIR ASSY 1 54 76396153 INSERT RUBBER AIR FILTER 2 5 X 1 75 2 82 52720643 BRACKET WELDMENT LIFT CANOPY 1 87 72060025 CAP SCR 31 18X 1 00 HH GR5 Z PART OF 162 2 88 72062109...

Page 61: ...124 125 999904093 5 PARTS LIST ITEM PART DESCRIPTION OVERALL QUANTITY 2 73052132 COOLER AIR OIL CANOPY 1 8 60125146 SPACER COOLER 1 16 72060046 CAP SCR 38 16X 1 00 HH GR5 Z PART OF 161 6 18 72063000...

Page 62: ...38 16X 6 00 HH GR5 Z PART OF 162 1 117 73540113 VALVE THERMAL 1 118 72053676 ADPTR MPT M JIC 75 12 1 119 72531427 ELBOW MPT 90 M JIC 75 12 1 120 72534487 TEE MALE RUN 75 MPT 75 JIC 1 121 60125300 BRA...

Page 63: ...Parts 61 99904093 6 Drawing See parts list on page 63 5 9 44 19 29 41 7 144 159 169 RIVET MESH TO INSIDE OF ALUMINUM GRILL USING ITEM 158 151 150 138 137 136...

Page 64: ...160 12 41 72601652 SCR MACH 25 20X 75TRHTORXSS PART OF 160 12 44 70034429 PLUG PLSTC BUTTON PART OF 160 1 136 72053497 ADPTR MPT M JIC 50 8 1 137 51396580 HOSE FJ 50 X 24 00 100R16 1 138 72532679 PLU...

Page 65: ...D RED A BLACK B MAIN POWER BODY INTERFACE 6 PIN CONNECTOR HOURMETER 2 PUSH ON CONNECTIONS NOT POLARITY SENSITIVE LIGHTED PUSHBUTTON SWITCH 6 PIN CONNECTOR TEMPERATURE GAUGE LAMP CONTROL PWER G GROUND...

Page 66: ...25145 SHROUD FAN COMPRESSOR 1 22 89392146 HOSE GP 25X250 WP GRAY 801 4 2 23 72063051 WASHER 38 LOCK 3 24 72532366 ADPTR M STR M JIC 12 12 4 25 72060044 CAP SCR 38 16X 75 HH GR5 Z 4 26 72062103 NUT 38...

Page 67: ...72062109 NUT 31 18 HEX NYLOCK 2 89 72661549 CLAMP DUCT 2 5 2 91 71412608 TUBE ASM COALESCER 1 97 72534360 ELBOW MPT 90 TUBE 4 4 3 99 70397043 GASKET 2545 CPRSR INLET 1 100 70734163 CMPRSR CAS2545 1 10...

Page 68: ...ION CLIP 1 125 1 151 72661369 RIVET POP SS 156 X 25 GRIP 1 152 72066005 CLAMP HOSE 1 57 2 50 SAE 32 1 153 72601872 CAP SCR M6 1 X 12MM 3 154 52720744 WLDMT MOTOR BRKT CAS2545 1 155 70580187 BELT 3V 3...

Page 69: ...imum Pressure Valve Kit 70048233 Oil Filter Element 70075118 Oil Filter Fitting 70075121 Valve Core 70075122 Separator Head Gasket 70048234 Coalescer Element 71412614 Stand Tube 71412613 Filter Coupli...

Page 70: ...o 99904145 Compressor Spare Parts 70075117 Oil Filler Screw Cap Complete 94744159 Shaft Seal Kit Relief Valve 73540245 94744160 Inlet Valve Kit 70075120 Blowdown Nozzle 70075119 Terminal Block Compres...

Page 71: ...Parts 69 Electrical Schematic 77441156...

Page 72: ...70 IMT CAS2545 Air Compressor Manual Part No 99904145 Hydraulic Schematic 99904155...

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