Model CAS35WG Maintenance & Parts

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Randolf Hawkins
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1 1 CAS5WG AIR COMPRESSOR / WELDER / GENERATOR IOWA MOLD TOOLING CO., INC. PO Box 189 Garner, IA 5048 Tel: FAX: Website: Manual # Revised Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation company.

2 2 1. GENERAL The following table provides list of routine maintenance items, including service intervals. The remainder of the section includes a part lists and assembly drawings of the compressor, welder, and AC generator. MAINTENANCE OPERATION SERVICE INTERVALS DAILY WEEKLY 250/ 500/6 INSPECT DRIVE COUPLING FOR WEAR AIR CLEANER - CHANGE AIR INTAKE - INSPECT CRANKCASE OIL LEVEL - CHECK, ADD IF NEEDED CRANKCASE OIL - CHANGE (SEE NOTE 1) CHECK CYLINDER HEAD STUD TORQUE (SEE NOTE 2) COOLING VANES (FINS) - CLEAN AIR RECEIVER - DRAIN CONDENSATION RECEIVER SAFETY VALVES - CHECK OPERATION CHECK ALL ELECTRICAL CONNECTIONS CHECK FITTINGS AND AIR LINES FOR LEAKS Service intervals are listed as hours/months, whichever occurs first. Use only IMT s synthetic compressor oil. The use of any other oil causes excessive carbon buildup, and will void the warranty on the compressor. NOTE 1. Under normal operating conditions, oil changes are required every months. When operating in a dirty environment, change the oil and air filter more frequently as your particular operating conditions dictate. Oil capacity is 1-1/ quarts. NOTE 2. Cylinder head stud torque MUST be checked after the initial 8-10 hours of operation. The compressor must be cold (room temperature) before retorquing of studs. Torque studs to 240 in-lb plus or minus 10 in-lb. FIGURE 1. ROUTINE MAINTENANCE CHECKLIST

3 2. PARTS DRAWINGS MAIN ASSEMBLY PARTS... 5 HYDRAULIC HOSE AND FITTING ASSEMBLY PARTS... 6 HYDRAULIC CONTROL BLOCK ASSEMBLY PARTS... 7 COMPRESSOR ASSEMBLY PARTS... 8 COMPRESSOR ASSEMBLY PARTS LIST AIR CONTROL ASSEMBLY CONTROL PANEL ASSEMBLY PARTS... 1 TRUCK INSTALLATION ASSEMBLY PARTS INTERNAL WIRING DIAGRAM CONTROL BOX WIRING DIAGRAM... 16

4 4 SHELL ASSEMBLY PARTS ITEM QUANTITY PART NO. DESCRIPTION BASE, CAS5WG SINGLE POINT LIFT FOLDING POINT LIFT PANEL, LEFT PANEL, REAR PANEL, RIGHT PANEL, FRONT BRACE COMPRESSOR/MOTOR CAS5WG LID PANEL, ACCESS THUMBSCREW, 1/4-20 X / HOSE CLIP

5 5 MAIN ASSEMBLY PARTS BASE (REF) 4 ITEM QUANTITY PART NO. DESCRIPTION 1 1 COMPRESSOR, ASSEMBLY WELDER/GENERATOR ASSEMBLY OIL COOLER, CAS5WG 1 FAN, OIL COOLER (PART OF OIL COOLER) AIR CONTROLLER, CAS5WG 5 1 HOSES (SEE HOSE ASSEMBLY DRAWING) MANIFOLD, CAS5WG CONTROL BOX ASSEMBLY DIODE/RELAY BRACKET ASSEMBLY BRACKET, COMPRESSOR HYDRAULIC MOTOR, COMPRESSOR

6 6 HYDRAULIC HOSE AND FITTING ASSEMBLY PARTS ITEM QUANTITY PART NO. DESCRIPTION HYDRAULIC HOSE ASSEMBLY, 1 X HYDRAULIC HOSE ASSEMBLY, /4 X HYDRAULIC HOSE ASSEMBLY, 5/8 X HYDRAULIC HOSE ASSEMBLY, /4 X HOSE, CASE DRAIN ASSEMBLY HYDRAULIC HOSE ASSEMBLY, 1 X HOSE, COMPRESSOR DRAIN

7 7 HYDRAULIC CONTROL BLOCK ASSEMBLY PARTS GENERATOR / WELDER SPEED ADJUSTMENT ITEM QUANTITY PART NO. DESCRIPTION HYDRAULIC CONTROL BLOCK ASSEMBLY (INCL. 1-11) FLOW CONTROL VALVE SOLENOID ASSEMBLY, AIR CONNECTOR, MALE CONNECTOR, FEMALE SOLENOID ASSEMBLY, GENERATOR RELIEF VALVE, 2400 PSI RELIEF VALVE, 2800 PSI CONTROL BLOCK CHECK VALVE 11 2REF COIL, SOLENOID 12V (PART OF SOLENOID ASSEMBLY, 7)

8 8 COMPRESSOR ASSEMBLY PARTS CONTINUED PARTS LIST ON PAGE

9 9 COMPRESSOR ASSEMBLY PARTS CONTINUED PARTS LIST ON PAGE

10 10 COMPRESSOR ASSEMBLY PARTS LIST ITEM QUANTITY PART NO. DESCRIPTION COMPRESSOR ASSEMBLY, COMPLETE ROD ASM CONNECTING HD PISTON, ASM HD750-HD VALVE ASSY, REED CAS45EL/EAR/HAR PUMP, OIL 7TRC RING, OIL MUSKEGON RING, COMPRSN MUSKEGON ASSY, CRANKSHAFT 7A COLLAR, OIL PUMP HD750/950/1250 7B CRANKSHAFT, HD1250 7C BEARING, CONE L D BEARING, CONE LM E PIN, ROLL.16 X HOUSING, FRONT BEARING HD750/ BEARING, CUP LM SEAL, GREASE -CHI HOUSING, REAR BEARING HD750/ BEARING, CUP CRANKCASE, MACH V-4 COMPR BOLT, HEX GR5 5/16-18 X WASHER, LOC GR5 5/ CLAMP, OIL SCREEN GASKET, REAR BEARING HOUSING.006 THK GASKET, REAR BEARING HOUSING.010 THK GASKET, FRONT BEARING HOUSING GASKET, REAR BEARING HOUSING.020 THK TUBE, OIL SCREEN SCREEN, OIL HD COVER, REAR BEARING HOUSING COMPR BUSHING, PLUNGER TRANSFER HD SPRING, OIL PUMP 19TRC WASHER, CU.X.50X TUBE, DIPSTICK HD PLUG, PIPE /8 RECESSED ZINC PLUG, PIPE 1/2 RECESSED ZINC PLUG, PIPE SQR HD 1/8 GAL BOLT, SOC HD GR5 5/16-18 X / NUT, HEX GR5 5/ NUT, HEX GR5 5/16-24 ZINC KEY, WOODRUFF.16 X STUD, 5/16-24 X 2 NC GR5 STL STUD, 5/16 X 1/ PIN, DRIVE LOCK.16 X DIPSTICK, ASM-HD GASKET, PUMP COVER QAS GASKET, CYL BLOCK BOTTOM CONTINUED DRAWING ON PAGE 8

11 11 COMPRESSOR ASSEMBLY PARTS LIST, continued DRAWING ON PAGE GASKET, REED VALVE/CYL HD GASKET, REED VALVE/HD HD CAP, BREATHER ANTI SPLASH BFFL WASHER, FLAT GR8 / BOLT, HEX GR8 /8-16 X 1 1/ PLUG, PIPE /4 RECESSED ZINC NUT, NYLOC GR8 / ELBOW, PIPE 45 STREET 1/ NIPPLE, PIPE 1/2 X 7 GAL SCH BUSHING, BELL RED /4 X 1/ PLACARD, AIR COMPR MODEL # (NOT SHOWN) CYLINDER BLOCK-HD SPACER-CYLINDER BLOCK HD GASKET-CYL BLOCK HD M HEAD, COMPRESSOR MACHINING

12 12 (ISSUES) AIR CONTROL ASSEMBLY ITEM QUANTITY PART NO. DESCRIPTION SWITCH, COMPRESSOR CYCLING 2 1 GROMMET VALVE, RELIEF ASME 1/4 X 200 PSI STREET TEE, BAR STOCK, NIPPLE,.25 LP BRASS 6 1 FITTING, ELBOW/M 1/4 X 1/8 7 1 TUBE, COPPER 8 1 HOSE, BRAIDED S/S AIRLINE 9 1 CONNECTOR, JIC M #12 X / CHECK VALVE 11 1 NIPPLE, /4 CLOSE BRASS 12 1 TEE, REDUCING /4 X 1/4 BRONZE 1 2 ELBOW, STREET 45 DEG / NIPPLE, PIPE /4 X BRASS 15 1 TEE, REDUCING BRANCH /4 X 1/2 BRONZE 16 1 NIPPLE, /4 X /4 HEX 17 1 ANCHOR COUPLING # AIR TEMP SWITCH WIRE 19 1 PLUG.875 BLACK PLASTIC

13 1 CONTROL PANEL ASSEMBLY PARTS ITEM QUANTITY PART NO. DESCRIPTION CONTROL BOX, ASSEMBLY (INCL. 2-20) CONTROL BOX HOUR METER METER, AC SWITCH, ON/OFF RECEPTACLE RECEPTACLE CIRCUIT BREAKER, 20 AMP CIRCUIT BREAKER, 0 AMP TERMINAL, WELDING 400A FEMALE SWITCH, HYDRA 120/ GROUND FAULT INTERRUPTOR, GRAY SWITCH, 10 AMP SWITCH, ROTARY 7 POLE 16A 400V SWITCH, WELDER, LOW-MED-HIGH PANEL, CONTROL CONNECTOR, 4-PIN MALE PLUG, BLUE CONNECTOR, 14-PIN FEMALE KNOB, CONTROL BOX

14 14 TRUCK INSTALLATION ASSEMBLY PARTS ITEM QUANTITY PART NO. DESCRIPTION 1 1 TRUCK BODY 2 1 CAS5WG COMPRESSOR / WELDER / GENERATOR BUMPER, RUBBER WASHER, FLAT /8 5 6 WASHER, SPLIT /8 6 6 NUT, 5/ BOLT, /8-16X2 HEX HEAD

15 15 INTERNAL WIRING DIAGRAM CABLE TO CONTROL BOX A B C D E F C.BREAKER DIODE BAR YELLOW RED GREEN ORANGE BLACK BLACK ORANGE ORANGE TERMINAL BLOCK WHITE BLACK GREEN YELLOW YELLOW GREEN BLACK YELLOW ORANGE YELLOW ORANGE BLACK AIR TEMP SWITCH AIR PRESSURE SWITCH COMPRESSOR SOLENOID ORANGE WELDER/GEN SOLENOID BLACK GREEN RED RED 4 FAN RELAY (5-PIN RELAY) FAN COMP. RELAY (4-PIN RELAY)

16 16 CONTROL BOX WIRING DIAGRAM HOUR METER VOLTMETER BLACK + - WHITE GEN ON/OFF AND HR. METER WIRE ASSEMBLY GREEN RED WHITE 120V0A / 240V20A AC POWER WIRE ASSY BLACK GREEN 0A 20A 20A 20A 240V BLUE/WHITE 1 RED/BLACK GREEN/BLACK 120V 4 BLUE/BLACK ORANGE/BLACK LOW/MED/HIGH-AC GFI 120 WHITE BLUE RED ORANGE BLACK GREEN BLACK/RED GREEN/WHITE RANGE SELECTOR BLACK/WHITE WELDER OUTPUT CABLE 1 2 STD/-10A RED/WHITE WELDER CONTROL WIRE ASSEMBLY

17 17. RECOMMENDED SPARE PARTS LIST ASSEMBLY DESIGNATION ITEM PART # DESCRIPTION QUANTITY MAIN ASSEMBLY OIL COOLER HYDRAULIC MOTOR 1 HYDRAULIC CONTROL BLOCK SOLENOID ASSEMBLY, GENERATOR SOLENOID ASSEMBLY, AIR 1 COMPRESSOR ASSEMBLY REED VALVE ASSEMBLY OIL PUMP OIL RING COMPRESSION RING CRANKSHAFT ASSEMBLY 1 7e ROLL PIN BUSHING, PLUNGER OIL PUMP SPRING WASHER, COPPER.X.50X GASKET, PUMP COVER GASKET, CYL BLOCK BOTTOM GASKET, REED VALVE/CYL GASKET, REED VALVE/HD CAP, BREATHER ANTI SPLASH CYLINDER BLOCK SPACER-CYLINDER BLOCK GASKET-CYL BLOCK 2 AIR CONTROL ASSEMBLY SWITCH, COMPRESSOR CYCLING AIR TEMP SWITCH WIRE 1 CONTROL PANEL ASSEMBLY SWITCH, ON/OFF CIRCUIT BREAKER, 20 AMP CIRCUIT BREAKER, 0 AMP SWITCH, HYDRA 120/ SWITCH, 10 AMP SWITCH, ROTARY 7-POLE SWITCH, WELDER 1 WELDING CABLES WELDING CABLE, 25' WELDING CABLE, 50'

18 18

MODEL DA435HA AIR COMPRESSOR Reference EFFECTIVE SERIAL #:THP

DA435HA: 99903795: 20060118 MODEL DA435HA AIR COMPRESSOR Reference 20013-002 EFFECTIVE SERIAL #:THP-19934-1005 IOWA MOLD TOOLING BOX 189, 500 HWY 18 WEST, GARNER, IA 50438 TEL: 641-923-3711 TECHNICAL SUPPORT