Model CAS4110HU Hydraulic Driven Underdeck Compressor
Contents
1. FIGURE E 2 HYDRAULIC SYSTEM TROUBLESHOOTING CHART CAS4110HU 23000143 01 REV E 20110209 SECTION 6 1 GENERAL This section contains the exploded parts drawings with accompanying parts lists for associated assemblies These drawings are intended to be used in conjunction with the instructions found elsewhere in this manual For information pertaining to the compressor refer to its specific manual See Section 7 for reference data which may be useful in the repair and operation of your compressor 20 23 4 20 25 part oF ORIGINAL COMPRESSOR ITEM PART NO DESCRIPTION QTY 1 52702376 BASE 1 2 52070869 BRACKET HYD MOTOR MTG 1 3 52706302 TIGHTENER BOLT 8 2 4 60104598 TIGHTENER BAR 1 5 70073084 COMPRESSOR R70 1 6 70029548 MOTOR VALVE BLOCK 1 7 60118716 KEY OFFSET 25X 31X 39X1 50 1 8 70056664 PULLEY WAS 71056020 1 9 70056665 BUSHING SPL TAPER WAS 70056453 1 10 70580206 BELT POWER V 9093 3096 1 11 89086120 OIL 30WT NON DETERGENT 1 5GAL 12 70029117 IDENT PLACARD NOT SHOWN 1 13 72060095 CAP SCR 1 2 13X2 HHGR5 4 14 72062080 NUT 1 2 13 LOCK 12 15 72063005 WASHER 1 2 WRT 6 16 72060094 CAP SCR 1 2 13X1 3 4 HHGR5 4 17 72060986 CAP SCR 1 2 13X2 3 4 HHGR5 2 18 72066503 MUFFLER CLAMP 1 3 4 1 19 72532840 PIPENIPPLE1 1 4NPT X5 1 20 72053327 ELBOW 1 1 4NPT 90 2 21 72053213 1 1 4NPT 1 22 72053283 STREET ELBOW 3 8NPT 90 1 02. ALWAYS DRAIN THE RECEIVER BEFORE MOVING THE VEHICLE CAS4110HU 99900783 19950110 3 2 NOTES CAS4110HU 99900783 19950110 Section 4 PREVENTIVE MAINTENANCE 4 1 INTRODUCTION Proper maintenance on a regular schedule is essential to keep your unit operating efficiently Proper maintenance procedures and required service intervals are outlined in this section Personnel responsible for unit upkeep should become familiar with frequency and type of maintenance required and perform these tasks at recommended intervals 4 2 LUBRICATION The only lubrication required is on the carrier vehicle and the compressor itself Refer to the appropriate Owner s Manual for information on the truck and compressor for the type and frequency of lubrication required 4 3 HYDRAULIC SYSTEM 4 3 1 HYDRAULIC FLUID SELECTION Minimum viscosity specifications for hydraulic oil to be used in the hydraulic system are given in Figure D 1 Any major oil company can supply products which meet these requirements Oils selected for use with this class of equipment in addition to meeting viscosity requirements should have the following additives 1 Antifoam Inhibitors 2 Antioxidant Inhibitors 3 Rust Resistant Additives 4 Antiwear Additives 4 3 2 HYDRAULIC FLUID SPECIFICATIONS Figure D 1 states oil specifications for a full ran
3. SWIVEL SHUT CONTROL VALVE ENGAGE THE PTO AND STAHT THE COMPRESSOR IF THIS DOES NOT THE PROBLEM REPLACE THE MOTOR IF THE PROBLEM IS CORRECTED REPLACE THE VALVE 1 COMPRESSOR LOCKED UP DISCONNECT DRIVE SYSTEM AND TRY TO TURN THE COMPRESSOR BY HAND IF IT GANNOT BE TURNED REPAIR THE COMPRESSOR 2 HYDRAULIG MOTOR FAILURE REPLAGE THE MOTOR IF THE COMPRESSOR IS OPERATIONAL 1 HYDRAULIC MOTOR BEGINNING TO FAIL REPLACE HYDRAULIC MOTOR BEFORE THE REST OF THE SYSTEM IS DAMAGED 1 RESTRICTION IN OIL HOSES AND FITTINGS CHECK AND CORRECT ANY RESTRICTIONS 2 HYDRAULIC PUMP BEGINNING TO FAIL REPLACE PUMP BEFORE IT DAMAGES THE REST OF THE SYSTEM EXCESSIVE NOISE IN HYDRAULIC PUMP AND PUMP GETS VERY HOT HYDRAULIC SYSTEM DAMAGES PUMPS OIL TANK OVERFLOWS OIL IS COLD COMPRESSOR IS STARTED COLD AND FAILS TO CONTINUE TO OPERATE 1 RESTRICTIONS IN OIL HOSES AND FITTINGS CHECK AND CORRECT ANY RESTRICTIONS 2 OIL TANK VENT PLUGGED CHECK AND CLEAN OIL TANK VENT 3 HYDRAULIC OIL BREAKDOWN DRAIN AND REPLACE 1 TANK TOO FULL TO ALLOW FOR EXPANSION DRAIN EXCESS OIL FROM THE TANK 2 OIL TANK VENT PLUGGED CHECK AND CLEAN NOTE IF YOUR TRUCK HAS TWO TANKS THE RETURN HOSE FROM THE TOP TANK TO THE LOWER TANK MAY BE RESTRICTED 1 COMPRESSOR STARTED TOO QUICKLY INSUFFICIENT WARM UP AND PUMP HAS FAILED REPLACE THE PUMP START COMPRESSOR AND ALLOW IT TO WARM UP REFER TO SECTION 3
4. 5 GRADE 8 SIZE DIA TPI 5 16 24 3 8 24 7116 20 1 2 20 9 16 18 5 8 18 3 4 16 7 8 11 1 12 1 1 8 12 1 1 4 12 1 3 8 12 1 1 2 12 INCHES FT LB FT LB FT LB FT LB 19 14 27 20 SIZE DIA TPI 5 16 18 3 8 16 7 16 14 1 2 13 9 16 12 5 8 11 3 4 10 7 8 9 1 8 1 1 8 7 1 1 4 7 1 3 8 6 1 1 2 6 INCHES FT LB FT LB FT LB FT LB 17 13 25 18 When using the torque data in the charts above the following rules should be observed 1 Bolt manufacturer s particular specifications should be consulted when provided 2 Flat washers of equal strength must be used 3 Alltorque measurements are given in foot pounds To convert to inch pounds multiply by 12 4 Torque values specified are for bolts with residual oils or no special lubricants applied If special lubricants of high stress ability such as Never Seez compound graphite and oil molybdenum disulphite collodial copper or white lead are applied multiply the torque values in the charts by the factor 90 The use of Loctite does not affect the torque values listed above 5 Torque values for socket head capscrews are the same as for Grade 8 capscrews FIGURE G 1 TORQUE DATA CHART CAS4110HU 99900783 19950110 7 2 SINGLE TIRES FOR TRUCKS IN HIGHWAY SERVICE TIRE LOAD E TRE HOAD LIMITS AT VARIOUS INELATION PRE S RE 75 00 OOOOOOQ DIIS 000000 e N OOoooooooIinmooccoc T1 C TI TI ITI TH ITI ITI 2 I
5. 7 Ensure all mounting bolts are tight PTO SHIFTER CABLE N JA HYDRAULIC PUMP GASKET FIGURE B 1 PTO INSTALLATION 2 2 WARNING THE INSTALLER OF THE DRIVELINE MUST INSPECT THE FINAL POSITION OF THE DRIVELINE TO DETERMINE WHETHER ITS LOCATION PROVIDES SUFFICIENT PROTECTION TO AN OPERATOR OR OTHER PERSONNEL FROM HAZARDS ASSOCIATED WITH A ROTATING DRIVELINE IF PROTECTION IS INSUFFICIENT THE INSTALLATION OF A GUARD IS REQUIRED IF YOU ARE UNSURE OF METHODS TO GUARD A ROTATING DRIVELINE CALL IOWA MOLD TOOLING CO INC FOR INSTRUCTIONS FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH ADANGER CONTACT WITH A ROTATING DRIVELINE WILL CAUSE DEATH OR SERIOUS INJURY Keep clear of rotating drive shaft Never work on or near an installed power take off or driveline with the engine running 70392891 PTO SHIFTER Y CABLE GASKET ADJUSTABLE BRACKET N MOUNTING BRACKET FIGURE B 2 DRIVELINE amp PUMP INSTALLATION CAS4110HU 99900783 19950120 2 3 2 3 UNDERDECK COMPRESSOR 8 Connect the air hoses per the compressor INSTALLATION assembly drawing Due to variations the instructions should be used as a guide only 9 Install the engine speed control as shown and connect hoses from compressor to speed control 1 Position the compressor below the compressor compartment with the belt side to the rear of the 10 Fill the oil reservoir and open the sucti
6. Do not overfill the compressor with oil Use correct quantity of manufacturer s lubricant Repair leaks and clean spills immediately All electrical components and cable wiring must be installed and grounded in accordance with NFPA national electrical codes and applicable state and local codes Compressors generate high temperatures Do not touch or otherwise come in contact with hot surfaces Doing so can cause severe personal injury Before removing guards or servicing the compressor disconnect all power supplies Display warning signs and lock out electrical circuits All guards must be in position and secure before and during operation Gm CAS4110HU 99900783 19980224 iii TABLE OF CONTENTS PARA TITLE PAGE Section 1 GENERAL INFORMATION 1 1 INTRODUCTION scite pix ene np eanet 1 1 1 2 COMPRESSOR SPECIFICATIONS essen nennen nnn nennen 1 1 1 3 ORDERING INFORMATION 1 1 Section 2 INSTALLATION 2 1 GENERAL uran 2 1 2 2 PTO AND PUMP 1 2 1 222 1 PIO INSTALLATION N cte terii peu o chao aan 2 1 2 2 2 DRIVELINE AND PUMP INSTALLATION 2 2 2 3 UNDERDECK COMPRESSOR INSTALLATION 2 3 2 4 OIEGOOLERX OPTIONAL eae i tiet ee nei Eater tee e art rr ree erre reine 2 4 Section 3 OPERATION 3 1 INT
7. REF 70029548 MOTOR PART 1 REF 73054740 RELIEF VALVE 1 G REF 77041495 COIL 1 73054962 CARTRIDGE amp SOLENOID 1 C COMPRESSOR R70 70073084 REF 73054339 SAFETY VALVE 1 REF 70073722 LP INTAKE VALVE 1 W REF 70141696 HP INTAKE VALVE 1 REF 70073721 LP EXHAUST VALVE 1 REF 70073429 HP EXHAUST VALVE 1 REF 70048009 AIR FILTER 1 P REF 76391359 SEAL 1 CAS4110HU 99900783 20090409 1 1 SECTION 1 GENERAL INFORMATION 1 1 INTRODUCTION 1 2 COMPRESSOR SPECIFICATIONS This manual provides information on the installation operation and repair of the IMT DA4110HU Hydraulic Under Deck Compressor CAS44110HU 104 2945 47 62 gal 178 235 I 100 mesh 10 microns 175 psi off 150 psi on 12 psi off 10 psi on Delivery at 175 psi Fluid capacity Filter Hydraulic Suction Filter Hydraulic Return Pressure Switch Three means are used throughout this manual to gain the attention of operating and service personnel They are NOTES CAUTIONS and WARNINGS and are defined as follows NOTE Comp Pulley RPM A NOTE IS USED TO EITHER CONVEY ADDITIONAL INFORMATION OR TO PROVIDE FURTHER EMPHASIS FORA PREVIOUS POINT Normal Op Pressure Maximum Pressure GPM CAUTION Motor Pulley Dia Compressor Pulley Dia 900 rpm 800 1000 1850 psi 130 bar 2400 psi 165 bar 28 gpm 106 10 75 27 cm 22 19 56 cm A CAUTION IS USED WHEN THERE IS THE ST
8. CAS4110HU 99900783 20110209 Model CAS4110HU Hydraulic Driven Underdeck Compressor IOWA MOLD TOOLING INC BOX 189 500 HWY 18 WEST GARNER 50438 TEL 641 923 3711 TECHNICAL SUPPORT FAX 641 923 2424 MANUAL PART NUMBER 99900783 lowa Mold Tooling Co Inc is an Oshkosh Corporation company CAS4110HU 99900783 19980224 PRECAUTIONS Read before operating your compressor DANGER EXPLODING TANK WILL CAUSE DEATH SERIOUS INJURY OR PROPERTY DAMAGE Drain air tank after each use to prevent moisture build up and corrosion which leads to tank failure Assure that tank and compressor relief valves work properly and are at correct pressure settings DO NOT modify or repair air tank e LM drive vehicle with pressure in air tank 988E6ELZ Do not use air from this compressor for breathing or food processing Air from Failure to follow operating and maintenance procedures as outlined in this manual could result in equipment damage personal injury this compressor will cause or death Follow all maintenance severe injury or death if used procedures and intervals for breathing or food processing Hot oil under pressure can cause severe injury or death Shut down let cool and relieve pressure in compressor before servicing Maintenance must be performed only by trained and qualified personnel using correct tools specified torques and approved replacement parts
9. PREVENTIVE MAINTENANCE CHECKLIST CAS4110HU 99900783 19950110 4 4 CAS4110HU 99900783 19950110 5 1 INTRODUCTION This section deals with the disassembly and repair of the components as well as troubleshooting information 5 2 HYDRAULIC SYSTEM COMPONENTS Disassembly and repair of components in the hydraulic system requires special consideration for proper functioning and service life of the unit These steps are to be followed whenever a hydraulic component is removed from the system 1 ALWAYS relieve internal hydraulic pressure before proceeding with a repair carefully loosen a fitting and allow the pressure to bleed off 2 NEVER allow foreign matter dirt water metal particles etc to enter the system through the open connections Cap or plug any openings If dirt does get in a filter change is required after 50 hours of operation 3 ALWAYS check for high pressure leaks after completing a repair A high pressure leak is hazardous and must be repaired de 1 3 4 GAP MOTOR BOLTS MOUNTING BRACKET 5 1 SECTION 5 REPAIR 5 3 DRIVE BELT To adjust the drive belt tension and alignment 1 Loosen the four bolts securing the motor mounting bracket to the base plate 2 Turn the drawbolt in a clockwise direction to tighten the belt until there is 1 4 1 2 play at the center of the belt between the pulleys 3 Adjust the alignment drawbolt until the motor pulley is square with the compres
10. RODUCTION Tem 3 1 3 2 OPERATION nn 3 1 3 3 SYSTEM SHUTDOWN issssssssseeenen II Innen nnn nnne nene nnne nnn anre nn eain iaeei 3 1 Section 4 PREVENTIVE MAINTENANCE 4 1 INTRODUCTION 4 1 4 2 n 4 1 4 3 HYBRAUEIESYSTEM 32 0 seen denne 4 1 4 3 1 HYDRAULIC FLUID SELECTION nenn 4 1 4 3 2 HYDRAULIC FLUID SPECIFICATIONS 4 1 4 3 3 HYDRAULIC FLUID DETERIORATION 4 1 4 3 4 HYDRAULIC SYSTEM PURGING sese nennen nennen nnne nnns 4 2 4 3 5 FILTER ELEMENT REPLACEMENT 4 2 4 4 PREVENTIVE MAINTENANCE CHECKLIST 4 3 Section 5 REPAIR 5 1 INTRODUG HON c 5 1 5 2 HYDRAULIC SYSTEM COMPONENTS 5 1 5 3 P S 5 1 Section 6 PARTS 6 1 GENERAL uta een 6 1 Section 7 REFERENCE FIG B 1 B 2 B 3 4 D 1 D 2 E 2 F 1 G 2 LIST OF ILLUSTRATIONS TITLE PAGE PTO INSTALLAT N ede rtu eter 2 2 DRIVELINE AND PUMP 2 2 KILL SWITCH WIRING DIAGRAM nennen enne ener 2 3 OIL COOLER GENERAL H
11. RONG POSSIBILITY OF DAMAGE TO THE EQUIPMENT OR PREMATURE EQUIPMENT FAILURE WARNING AWARNING IS USED WHEN THERE IS THE POTENTIAL FOR PERSONAL INJURY OR DEATH Operate this equipment with respect and service it regularly These two things can add up to a safer working environment and longer equipment life 1 3 ORDERING INFORMATION When placing orders or requesting assistance refer to the information below TO BE COMPLETED BY DEALER CHASSIS INFORMATION TRANSMISSION MAKE MODEL PTO NUMBER PTO COMPRESSOR AND HYDRAULIC PUMP INFORMATION SERIAL NUMBER COMPRESSOR MODEL MODEL PUMP MAKE RESERVOIR CAPACITY ENGINE RPM CAS4110HU 99900783 19950110 1 2 NOTES CAS4110HU 99900783 19950110 2 1 GENERAL This section deals with the installation of the PTO and pump and the IMT hydraulic compressor The instructions are intended as a guide to assist you with your particular installation We can not cover every make model and year of truck manufactured world wide so these instructions will provide only general information Use this section as a guide only 2 2 PTO AND PUMP INSTALLATION The pump may either be installed directly on the PTO or as an optional method it may be driven by a driveline 2 2 1 PTO INSTALLATION Power take off manufacturers provide s
12. RROR page no DESCRIPTION OF ERROR 4 REQUEST FOR ADDITION TO MANUAL DESCRIPTION OF ADDITION REASON FOR ADDITION MAIL TO IOWA MOLD TOOLING Co Inc Box 189 Garner 50438 0189 ATTN Technical Publications CAS4110HU 99900783 This parts manual is provided to the user to assist in servicing the equipment It is the propertyof Iowa Mold Tooling Co Inc and as such may not be reproduced either whole or in part whether by chemical electrostatic mechanical or photographic means without the expressedwritten permission of an officer of Iowa Mold Tooling Co Inc One manual is provided with each piece of new equipment and additional manuals may be obtained at a nominal price IOWA MOLD TOOLING CO INC BOX 189 GARNER IA 50438 0189 TEL 641 923 3711 TECHNICAL SUPPORT FAX 641 923 2424
13. T CZ 0 20 0 20 388 MID oo 88 m 7 0 7 0 7 5 7 50 8 25 8 25 9 00 9 00 0 00 0 0 1 00 1 00 1 00 1 00 TI TIHITITIL ITE ITI C2 DEFINITE TIRE INFLATION PRESSURES ARE ESTABLISHED FOR EACH TIRE SIZE DEPENDING UPON THE LOAD IMPOSED ON THE TIRE FOR GREATER SABILITY RIDING COMFORT AND PROLONGED TIRE LIFE TIRES SHOULD BE INFLATED FOR THE LOADS CARRIED THE LOAD AND INFLATION TABLE SHOWN ABOVE INDICATES THE PROPER INFLATION PRESSURES TIRE AND RIM ASSOCIATION STANDARD TIRE LOADS AT VARIOUS INFLATION PRESSURES LOAD RANGE LETTERS AND CORRESPONDING PLY RATING D 8 PLY E 10 PLY F 12 PLY AND G 14 PLY FIGURE G 2 TIRE LOAD AND INFLATION PRESSURES CAS4110HU 99900783 The information within this manual has been compiled and checked but errors do occur To provide our customers with a method of communicating those errors we have provided the Manual Change Request form below In addition to error reporting you are encouraged to suggest changes or additions to the manual which would be of benefit to you We cannot guarantee that these additions will be made but we do promise to consider them When completing the form please write or print clearly Submit a copy of the completed form to the address listed below MANUAL CHANGE REQUEST DATE PRODUCT MANUAL MANUAL PART NO SUBMITTED BY ADDRESS CITY STATE ZIP TELEPHONE _ ERROR FOUND LOCATION OF E
14. YDRAULICS DIAGRAM 2 4 HYDRAULIC FLUID SPECIFICATIONS essent 4 1 PREVENTIVE MAINTENANCE CHECKLIST seen 4 3 DRIVE BELT ADJUSTMENT cocinas uae tait e 5 1 HYDRAULIC SYSTEM TROUBLESHOOTING CHART 5 2 CAS4110HU HYDRAULIC UNDERDECK COMPRESSOR 23000143 6 1 TORQUE DATA CRIART tite entes ia 7 1 TIRE LOAD AND INFLATION PRESSURES sees 7 2 CAS4110HU 99900783 19980224 iv RECOMMENDED SPARE PARTS LIST 1 Year Supply CAS4110HU HYDRAULIC DRIVEN TOPDECK COMPRESSOR For Manual 99900783 This spare parts list does not necessarily indicate that the items can be expected to fail in the course of a year It is intended to provide the user with a stock of parts sufficient to keep the unit operating with minimal down time waiting for parts There may be parts failures not covered by this list Parts not listed are considered as not being Critical or Normal Wear items during the first year of operations and you need to contact the distributor or manufacturer for availability SHELF ASSEMBLY LIFE ORDER DESIGNATION ITEM PARTNO DESCRIPTION QTY CODE MO QTY 23000143 01 19970403 HYDRAULIC UNDERDECK COMPRESSOR 6 70029548 MOTOR VALVE BLOCK 1 10 70058538 BELT POWER V 1 b 11 89086120 OIL 30WT NON DETERGENT 1 P 26 77041008 PRESSURE SWITCH 1 33 73054031 UNLOADER VALVE 1 C
15. art the compressor 1 Ensure the PTO is disengaged control valve is open pull the compressor switch out and the receiver drain cock is open 2 Start the truck engine and allow it to idle until it reaches the proper operating temperature refer to the Owner s Manual 3 Depress the clutch engage the PTO and carefully release the clutch pedal Allow the system to warm up for the time period specified in below COMPRESSOR WARM UP TIME AMBIENT AIR IDLING TIME TEMPERATURE F WARM UP 40 OR ABOVE NONE 20 TO 40 2 5 MINUTES 0 TO 20 5 10 MINUTES 20 TO 0 10 15 MINUTES 40 TO 20 15 20 MINUTES BELOW 40 20 MINUTES MIN 4 When starting the compressor the RPM s will automatically increase due to low volume of air in the system SECTION 3 OPERATION CAUTION 1000 RPM MAX Operating this unit in excess of 1000 RPM measured at the compressor flywheel will void your warranty Engine RPM may be different 3 3 SYSTEM SHUTDOWN System shutdown is accomplished as follows 1 Allow the compressor to build to maximum pressure and the truck engine will automatically idle down 2 Place the compressor control valve in the open off position 3 Depress the clutch pedal and disengage the PTO 4 Open the receiver drain cock and discharge the air in the receiver WARNING FEDERAL LAW PROHIBITS DRIVING THE CARRIER VEHICLE ON PUBLIC ROADS WITH THE RECEIVER FILLED WITH COMPRESSED AIR
16. d check the oil for breakdown To check oil quality 1 Place the oil in a clean glass 2 Smellthe oil to detect a burnt or rancid odor 3 Visually examine the oil for a dark or cloudy appearance 4 Allow the sample to stand for several minutes Inspect the sample for water which will settle to the bottom of the glass if present Water can result from a system leak or condensation due to temperature extremes When any of these conditions is observed the system should be purged and filled with new oil In addition the oil should be changed in the reservoir and complete system 1 After every 800 hours of operation or every six months whichever occurs first 2 After pump or other major hydraulic component failure drain the hoses 4 3 4 HYDRAULIC SYSTEM PURGING Purging the hydraulic system requires a new oil supply sufficient to completely fill the reservoir hoses filters valves etc and an extra allowance for loss during this procedure To reduce oil loss operate the engine at a low speed idle When purging new oil is supplied to the pump suction line via the reservoir and the old oil is discharged through the reservoir return line Two operators will be required one to operate the compressor and the other to regulate pump flow engine speed Purging is accomplished as follows 1 Drain the hydraulic reservoir and disconnect the suction hose to the pump Drain the hose and reassemble Change the suctio
17. ge of operating temperatures encountered in the temperate Zones Arctic conditions present special requirements which are not in the scope of the table and must be analyzed individually Consult your oil supplier for the proper hydraulic fluids for working under these severe conditions Electric reservoir heaters are available to improve conditions at extremely low temperatures 4 3 3 HYDRAULIC FLUID DETERIORATION Contamination ofthe hydraulic fluid by solvents water dust or other abrasives will cause deterioration ofthe fluid Sustained presence of the impurities will result in premature breakdown of antifoam lubrication anti rust and viscosity properties Introduction of water to the system and operation at high temperatures above 180 F will result in an increase in the oil oxidation rate Oxidation produces varnish forming materials and sludge in the oil Operating the system on a sustained basis with contaminated or broken down oil will increase wear and can significantly shorten the efficient service life of the unit AMBIENT TEMPERATURE RANGE F MINIMUM POUR POINT F MAXIMUM VISCOSITY 550 0 F MINIMUM VISCOSITY 550 100 F MINIMUM VISCOSITY 550 210 F MINIMUM VISCOSITY INDEX Below 32 32 90 Above 90 25 10 10 000 4000 140 190 100 130 150 200 200 315 41 43 47 90 90 90 FIGURE D 1 HYDRAULIC FLUID SPECIFICATIONS CAS4110HU 99900783 19950110 4 2 Periodically draw off a sample of the oil an
18. i c ITEM 23 24 26 2T 29 30 32 33 34 35 3T 38 40 41 42 6 1 6 PARTS PART OF RIGINAL COMPRESSOR TO SPEED CONTROL PART NO 72053283 72053049 72053013 72532013 77041008 72532552 72532974 72053651 72066340 72533032 70048069 73054031 72053767 72532949 72053589 99900783 72532145 72053013 72532834 72053751 72053211 IDLE PRESSURE RIGINAL DESCRIPTION STREET ELBOW 3 8NPT 90 PIPE NIPPLE 3 8NPT X CLOSE NIPPLE PIPE BLK 25 X CLOSE STREET TEE 1 4NPT BRASS PRESSURE SWITCH HOSE FITTING 1 4 1 4 STREET ELB 1 4NPT 90 SHORT ADAPTER 1 1 4NPT SWVL POPRIVET ELBOW MJIC 45 FJIC 12 12 AIR FILTER UNLOADER VALVE 155 175 PART OF COMPRESSOR ELBOW MSTR 90 MJIC 12 12 ADAPTER MSTR FSTR 20 12 STREET ELBOW 1 8NPT 90 MANUAL PLUG 1 5 88TR HH STL NIPPLE PIPE BLK 25 X CLOSE NIPPLE BEAD 90 DEG 1 MPT 1 25 ADAPTER MSTR FPT 16 1 NIPPLE PIPE BLK 1 25 X CLOSE o 22N gt 2NN202 gt 73 REF EE EEA FIGURE F 1 CAS4110HU HYDRAULIC UNDERDECK COMPRESSOR 23000143 1 CAS4110HU 23000143 02 20110209 6 2 R70 COMPRESSOR REF 10 FIGURE CAS4110HU HYDRAULIC UNDERDECK COMPRESSOR 23000143 2 CAS4110HU 99900783 19950110 7 1 SECTION 7 REFERENCE TORQUE DATA CHART DOMESTIC FINE THREAD BOLTS COARSE THREAD BOLTS SAE J429 GRADE 5 SAE J429 GRADE 8 SAE J429 SAE J429 GRADE
19. ing proper rubber seal seating and tighten as much as possible using both hands 3 Open the gate valve and check for leaks CAUTION PUMP FAILURE CAN RESULT IF THE SHUTOFF VALVE ISLEFT CLOSED CAS4110HU 99900783 19950110 4 3 4 4 PREVENTIVE MAINTENANCE CHECKLIST The checklist Figure D 2 is designed to assist you in keeping your unit in efficient operating condition Items in this section apply to the unit only The carrier vehicle should also be inspected regularly refer to the carrier vehicle s service manual ITEM DESCRIPTION INTERVAL any level ER paupe EVERY DAILY WEEKLY 200 Hms soom 1000 6 1500 9 2000 12 COMPRESSOR AIR INTAKE INSPECT AND CLEAN FRAME OIL LEVEL CHECK FRAME OIL CHANGE VALVES INSPECT AND CLEAN INTER COOLER CLEAN EXTERIOR LOW OIL LEVEL SWITCH CHECK OPERATE SAFETY VALVES CLEAN SAFETY VALVES V BELT DRIVE BELT TENSION CHECK RECEIVER DRAIN CONDENSATION MANUAL OPERATE SAFETY VALVES HYDRAULIC DRIVE CHECK OIL RESERVOIR LEVEL SYSTEM CHECK AND CHANGE FILTER CHECK SAFETY DOOR SWITCH CHECK PTO CABLE CHECK SPEED CONTROL amp RESET CHANGE HYDRAULIC OIL CHECK FOR LEAKS AND REPAIR GENERAL CHECK AND TIGHTEN ALL BOLTS CHECK LUBRIGATION INTERVALS ARE LISTED IN HOURS MONTHS WHICHEVER COMES FIRST UNLESS OTHERWISE SPECIFIED REFER TO THE APPROPRIATE COMPRESSOR MANUAL FOR INFORMATION REGARDING TYPE OF OIL AND FREQUENCY OF CHANGE FIGURE D 2
20. n filter cartridge Paragraph 4 3 5 NOTE THE METHOD OF WASTE DISPOSAL IS LEFT TO THE DISCRETION OF SERVICE PERSONNEL 2 Disconnect the reservoir return line at the reservoir and direct the discharge into a sump or waste container Plug the return line port on the reservoir and fill the reservoir with clean oil refer to Paragraph 4 3 1 NOTE BE THOROUGHLY FAMILIAR WITH THE FOLLOWING STEPS AND PREPARED TO PERFORM THEM IN AN UNINTERRUPTED SEQUENCE IF THIS IS NOT DONE EXCESSIVE OIL WASTE WILL OCCUR CAUTION DO NOT ALLOW THE RESERVOIR LEVEL TO DROP BELOW 1 3 CAPACITY DURING THIS OPERATION 3 Start the engine and engage the PTO Slowly release the clutch Activate the control valve so that the fluid passes through the motor Allow fluid to discharge for about 15 seconds Kill the engine 4 Reconnect the return line to the reservoir port and change the return line filter All components of the system are now purged 5 Checkthe reservoir oil level and add oil as necessary 4 3 5 FILTER ELEMENT REPLACEMENT To avoid residue accumulation in the reservoir and to protect the hydraulic components valves pumps motors etc the filters must be serviced on a regular basis They must be changed after the initial 50 hours of new unit operation and every 200 hours thereafter To change filter elements 1 Shutthe gate valve and remove the filter element 2 Install the new filter ensur
21. on gate compartment valve Disconnect the pressure hose at the hydraulic pump Engage the PTO and turn the vehicle engine 2 Liftthe compressor base into position so the with the starter until oil flows through the pressure base is flush with the bottom of the compartment side of the pump Reconnect the pressure hose Pull Be certain there is clearance within the compartment out the compressor switch and open the gate valve to and no interference is present Support the the air receiver Disengage the PTO and start the compressor in this position truck Depress clutch and engage PTO Release the clutch slowly It may be necessary to warm the truck 3 Using the base as a template drill eight holes engine so that it will pull at idle RPM Push in the 17 32 diameter through the compartment compressor switch This will close the control valve and start the compressor Allow for warm up time 4 Bolt the compressor base to the walls of the Close the gate valve on the air receiver This will compartment using 1 2 grade 5 cap screws flat activate the speed control Adjust the engine speed washers and lock nuts control for proper operating RPM Check for system leaks and proper operation 5 Connect the hydraulic hose from the pump to the relief valve connected to the hydraulic drive motor 11 Install compressor kill switch See Figure B 1 on the compressor See compressor assembly drawing 6 Connect the return line to the reservoir See compresso
22. pecific installation instructions for their products Those instructions should be followed when installing a PTO Some trucks may require modification of the transmission cross member to provide clearance and the exhaust pipe may need modification Check with the PTO manufacturer s representative for specific instructions regarding your particular make model and year of vehicle The following instructions are a guide in this application 1 Ifthe vehicle is new drain the transmission oil into a clean container for reuse If the vehicle is used drain and dispose of the transmission oil 2 Temporarily install the PTO with the proper gaskets and only two studs Snug the PTO down and check the backlash for maximum allowance of 1 32 to 1 16 If the backlash is excessive remove gaskets and check backlash again until it is corrected 3 Remove the PTO and apply Permatex to the gaskets If the holes for the studs are tapped through the transmission housing apply Permatex to the studs and tighten them down Make certain that the studs do not interfere with the transmission gears CAUTION AVOID CONTACT OF PERMATEX WITH AUTOMATIC TRANSMISSION FLUID SECTION 2 INSTALLATION 4 Install the PTO and gaskets Torque the nuts to 30 35 ft Ibs 4 14 4 84 kg m for a 6 bolt PTO and 45 50 ft Ibs 6 22 6 91 kg m for 8 bolt PTO s Recheck the backlash 5 Install the shifter cable to suit conditions Always allow for a
23. r assembly drawing 7 Torque all mounting bolts per Torque Data Chart if the compressor is positioned properly COIL GAS OR IGNITION SWITCH FUEL SOL DIESEL NORMALLY CLOSED DOOR SWITCH BATTERY FIGURE B 3 KILL SWITCH WIRING DIAGRAM CAS4110HU 99900783 19950120 2 4 2 4 OIL COOLER OPTIONAL Oil coolers vary in their installation dependent on available space and other considerations Install the oil cooler either in front of the carrier vehicle s radiator or as an alternative in a protective structure which is cooled by an electric fan Refer to Figure B 4 for general location within the hydraulic system PULLEY COMPRESSOR RESERVOIR GATE VALVE FILTER FIGURE B 4 OIL COOLER GENERAL HYDRAULICS DIAGRAM CAS4110HU 99900783 19950719 3 1 INTRODUCTION This section deals with the proper methods of system operation and shutdown These procedures should be followed to prevent damage and ensure efficient operation 3 2 OPERATION The compressor has an operating time limit of approximately 3 hours depending upon ambient air temperature outside air temperature weather conditions and whether an oil cooler has been installed CAUTION THE HYDRAULIC OIL TEMPERATURE MUST NOT BE ALLOWED EXCEED 190 F 88 C IF THE OIL TEMPERATURE REACHES THIS LIMIT THE SYSTEM MUST BE SHUT DOWN AND ALLOWED TO COOL Oil coolers will extend the 3 hour limit To st
24. slight overshift on lever or knob to ensure the PTO is fully disengaged CAUTION ITIS IMPORTANT THAT ROOM BE ALLOWED FOR FULL ENGAGEMENT OF THE PTO MODIFY THE EXHAUST OR OTHER OBSTRUCTIONS AS NEEDED CAUTION AVOID SHARP BENDS IN THE SHIFTER CABLE ALL BENDS SHOULD HAVE AT LEAST A 6 RADIUS TIGHTER BENDS WILL CAUSE DIFFICULT OPERATION OF THE SHIFTER KNOB 6 Replace the transmission oil If the PTO is located below the transmission oil level an additional quantity of oil will be required 7 Start the engine engage the PTO and allow it to run for 5 10 minutes Check for leaks unusual noise and proper operation 8 Retorque the mounting bolts CAS4110HU 99900783 19990119 2 2 2 DRIVELINE AND PUMP INSTALLATION The pump may be driven as shown in Figure B 2 as an optional method to the one shown in Figure B 1 The following steps are a guide in this application 1 Install the PTO refer to Paragraph 2 2 1 2 Loosely bolt the pump mounting bracket A to the adjustable bracket B 3 Bolt the adjustable bracket to the frame at a point that will not exceed 48 122 cm from the PTO and will not cause a joint angle greater than 8 4 Check pump rotation and install pump pump end yoke and PTO end yoke 5 Size cut and weld the driveline to the necessary length Ensure driveline balance Allow 1 2 54 cm extra for PTO end yoke 6 Install driveline lock set screws and lubricate U joints
25. sor Use a straightedge across the compressor pulley Figure E 3 and check the gap between the motor pulley and the straight edge The gap 1 3 4 on the compressor side of the motor pulley should be the same as on the far side of the pulley PULLEY COMPRESSOR FIGURE E 1 DRIVE BELT ADJUSTMENT CAS4110HU 9900783 19950110 PROBABLE CAUSE AIR COMPRESSOR SLOWS DOWN AS AIR PRESSURE INCHEASES AND THE ENGINE RPM REMAINS THE SAME OR INCREASES SLIGHTLY MOTOR DOES NOT TURN WHEN HYDRAULIC VALVE IS CLOSED OIL DOES NOT REACH 2300 2500 PSI MOTOR DOES NOT TURN WHEN HYDRAULIC SYSTEM IS ACTIVATED AND RELIEF VALVE REACHES 2300 2500 PSI EXCESSIVE NOISE IN HYDRAULIC MOTOR AND MOTOR GETS VERY HOT 5 2 1 RELIEF VALVE BYPASSING OIL ADJUST RELIEF VALVE TURN CLOCKWISE TO INCREASE BYPASS PRESSURE IF THIS DOES NOT CORRECT THE PROBLEM RETURN THE RELIEF VALVE TO THE ORIGINAL POSITION AND PROCEED WITH STEP 2 2 HYDRAULIC PUMP FAILURE DISCONNECT THE PRESSURE HOSES AT THE MOTOR INLET SWIVEL FIGURE F 1 CAP THE HOSE AND PLUG THE SWIVEL IF THE SYSTEM DOES NOT HAVE A PRESSURE GAUGE INSTALL ONE AT THE END OF THE HOSE FOR TESTING PURPOSES ENGAGE THE PTO AND RELEASE THE CLUTCH SLOWLY HYDRAULIC OIL PRESSURE SHOULD REACH 2300 2500 PSI BEFORE THE RELIEF VALVE OPENS 3 HYDRAULIC MOTOR OR VALVE FAILURE DISCONNECT PRESSURE HOSE FROM PUMP FIGURE F 1 AT GAUGE SWIVEL CONNECT PRESSURE HOSE FROM PUMP TO MOTOR INLET
Download Pdf Manuals
Related Search