Oshkosh Corporation IMT CAS40P User manual

®
An Oshkosh Corporation Company
40 CFM/100 PSIG STANDARD
RECIPROCATING COMPRESSOR
INSTALLATION, OPERATION, MAINTENANCE AND PARTS MANUAL
P/N 99905382
Revision 02
Effective Date: 6/2018
©2014 Iowa Mold Tooling, Co., Inc.
All rights reserved.
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
Making unauthorized modifications to
the compressor or system components
WILL VOID THE WARRANTY!
Always inform Iowa Mold Tooling Co.,
Inc., before making any changes to the
CAS40P system.
NOTE
Use only IMT Premium Reciprocating
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!
Iowa Mold Tooling Co., Inc.
500 Highway 18 West
Garner, Iowa 50438
Phone: [phone]
Fax: [phone]
KEEP THE MANUAL
WITH THE VEHICLE

NOTICE TO CUSTOMER
This manual is the final version and some of the information and specifications are subject to change
without notice.

CAS40P 40 CFM / 100 PSIG TABLE OF CONTENTS
Manual #99905382 Rev 02 (JUNE 2018)
PAGE - I
TABLE OF CONTENTS
®
An Oshkosh Corporation Company
TABLE OF CONTENTS......................................................I
SECTION 1: SAFETY.........................................................1
1.1 GENERAL INFORMATION ............................................................................................................1
1.2 WARNINGS, CAUTIONS AND NOTES .........................................................................................1
1.3 SUMMARY OF DANGER, WARNINGS, CAUTIONS AND NOTES ..............................................1
1.3.1 DANGERS........................................................................................................................................................... 1
1.3.2 WARNINGS......................................................................................................................................................... 2
1.3.3 CAUTIONS.......................................................................................................................................................... 3
1.3.4 SAFETY DECALS............................................................................................................................................... 3
SECTION 2: DESCRIPTION ..............................................5
2.1 GENERAL DESCRIPTION.............................................................................................................5
2.2 COMPONENT DESCRIPTIONS .................................................................................................... 6
2.2.1 COMPRESSOR PUMP ....................................................................................................................................... 6
2.2.2 COOLING SYSTEM ............................................................................................................................................ 7
2.2.3 ELECTRICAL SYSTEM ...................................................................................................................................... 7
2.2.4 AIR CONTROL SYSTEM.................................................................................................................................... 7
2.2.5 HYDRAULIC CONTROL SYSTEM..................................................................................................................... 7
2.2.6 PRESSURE RELIEF VALVES............................................................................................................................ 8
2.2.7 MAIN FRAME AND ENCLOSURE ..................................................................................................................... 9
SECTION 3: SPECIFICATIONS .........................................11
TABLE 3A: SPECIFICATIONS .............................................................................................................11
TABLE 3B: CAPSCREW TIGHTENING TORQUE VALUES ...............................................................12
TABLE 3C: COMPRESSOR TORQUE VALUES .................................................................................12
SECTION 4: INSTALLATION .............................................13
4.1 MACHINE PACKAGE RECEIPT/INSPECTION .............................................................................13
4.2 GENERAL INSTRUCTIONS ..........................................................................................................13
4.3 DETERMINING THE CAS40P UNIT MOUNTING LOCATION ......................................................13
Continued on next page...

TABLE OF CONTENTS CAS40P 40 CFM / 100 PSIG
PAGE - II
®
An Oshkosh Corporation Company
SECTION 4: INSTALLATION (CONTINUED)
FIGURE 4-2: CAS40P DIMENSIONS .........................................................................................15
4.4 CONNECTING THE ELECTRICAL SUPPLY ................................................................................ 16
4.5 HYDRAULIC SYSTEM REQUIREMENTS .................................................................................... 16
4.6 CONNECTING THE HYDRAULIC SUPPLY AND RETURN ......................................................... 17
4.7 CONNECTING THE AIR SUPPLY................................................................................................. 17
4.7.1 AIR RESERVOIR TAN INSTALLATION............................................................................................................17
FIGURE 4-4 ELECTRICAL SYSTEM..........................................................................................19
FIGURE 4-5 FLOW SCHEMATIC DIAGRAM..............................................................................20
SECTION 5: OPERATION ................................................. 21
5.1 GENERAL INFORMATION ........................................................................................................... 21
5.2 OPERATING CONDITIONS .......................................................................................................... 21
5.3 FIRST TIME START-UP ................................................................................................................ 22
5.4 SHUTDOWN (FIRST-TIME AND ROUTINE)................................................................................. 23
5.5 ROUTINE START-UP .................................................................................................................... 23
5.6 EXTREME CONDITION OPERATION .......................................................................................... 23
SECTION 6: MAINTENANCE ............................................ 25
6.1 GENERAL INFORMATION ........................................................................................................... 25
6.2 MACHINE MAINTENANCE SCHEDULE....................................................................................... 25
TABLE 6A: ROUTINE MAINTENANCE SCHEDULE .............................................................................. 26
6.3 REPLACEMENT PARTS ............................................................................................................... 27
6.4 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES ................................................... 27
6.4.1 REMOVING PANELS FOR MACHINE MAINTENANCE ACCESS.....................................................................29
6.4.1.1 OPENING AND CLOSING THE ROOF PANEL ............................................................29
TABLE 6B: ACCESS PANEL REMOVAL ................................................................................................ 30
6.4.1.2 REMOVING AND REPLACING A SIDE PANEL............................................................31
6.4.2 CHEC ING PRESSURE GAUGE .......................................................................................................................33
6.4.3 COMPRESSOR SYSTEM LUBRICATION ..........................................................................................................33
6.4.3.1 CHECKING THE OIL LEVEL.........................................................................................34
6.4.3.2 CHANGING THE COMPRESSOR OIL..........................................................................34
6.4.4 AIR FILTER MAINTENANCE...............................................................................................................................34
6.4.4.1 INSPECTING THE AIR FILTER(S)................................................................................36
6.4.4.2 REPLACING THE AIR FILTER(S) .................................................................................36
6.4.5 CHEC ING THE COOLER CORE ......................................................................................................................37
6.4.6 COMPRESSOR VALVE MAINTENANCE............................................................................................................37
Continued on next page...
Manual #99905382 Rev 02 (JUNE 2018)

CAS40P 40 CFM / 100 PSIG TABLE OF CONTENTS
PAGE - III
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An Oshkosh Corporation Company
SECTION 6: MAINTENANCE (CONTINUED)
6.4.6.1 INSTALLATION ............................................................................................................. 40
6.4.6.2 LUBRICATION .............................................................................................................. 41
6.4.6.3 SERVICE....................................................................................................................... 41
6.4.7 CENTRIFUGAL UNLOADER INSTALLATION................................................................................................... 41
6.4.8 PISTON RING MAINTENANCE.......................................................................................................................... 43
6.4.9 RE-ADJUSTING OR REPLACING THE COMPRESSOR DRIVE BELTS ......................................................... 45
6.4.10 DRIVE SHEAVE (PULLEY) ALIGNMENT .......................................................................................................... 47
6.4.10.1 TESTING PULLEY ALIGNMENT .................................................................................. 50
6.4.10.2 ADJUSTING THE MOTOR PULLEY FOR ALIGNMENT .............................................. 50
6.4.11 GAS ET REPLACEMENT MAINTENANCE...................................................................................................... 51
6.4.12 PRESSURE SWITCH MAINTENANCE .............................................................................................................. 52
6.4.13 DISASSEMBLING THE COMPRESSOR ........................................................................................................... 52
6.4.13.1 FITTING AND REASSEMBLING .................................................................................. 54
TABLE 6C: COMPRESSOR TORQUE VALUES .....................................................................................54
6.4.14 CHEC ING HOSES AND WIRING..................................................................................................................... 56
6.4.15 SERVICING THE SYSTEM FUSE AND CIRCUIT BREA ER ........................................................................... 56
6.4.16 REPLACING THE INTERCOOLER FINNED TUBES......................................................................................... 57
6.4.17 PRESSURE (SAFETY) RELIEF VALVES........................................................................................................... 57
6.5 LONG TERM STORAGE ...............................................................................................................57
SECTION 7: TROUBLESHOOTING ..................................59
7.1 GENERAL INFORMATION ............................................................................................................59
7.2 TROUBLESHOOTING GUIDE.......................................................................................................59
SECTION 8: ILLUSTRATED PARTS LIST ........................65
8.1 PARTS ORDERING PROCEDURE ...............................................................................................65
TABLE 8A: RECOMMENDED SPARE PARTS LIST...............................................................................66
TABLE 8B: MAINTENANCE TRACKING LOG ........................................................................................67
8.2 COMPRESSOR UNIT ASSEMBLY................................................................................................68
8.3 COMPRESSOR ASSEMBLY .........................................................................................................74
8.4 MOTOR AND DRIVE PARTS.........................................................................................................76
8.5 FRAME AND PARTS......................................................................................................................78
8.6 CANOPY AND PARTS (PART 1 OF 4) ..........................................................................................80
8.6 CANOPY AND PARTS (PART 2 OF 4) ..........................................................................................82
8.6 CANOPY AND PARTS (PART 3 OF 4) ..........................................................................................84
8.6 CANOPY AND PARTS (PART 4 OF 4) ..........................................................................................84
Continued on next page...
Manual #99905382 Rev 02 (JUNE 2018)

TABLE OF CONTENTS CAS40P 40 CFM / 100 PSIG
PAGE - IV
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An Oshkosh Corporation Company
SECTION 8: ILLUSTRATED PARTS LIST (CONTINUED)
8.7 OIL COOLING SYSTEM (12V)...................................................................................................... 86
8.8 OIL COOLING SYSTEM (24V)...................................................................................................... 88
8.9 CONTROL MANIFOLD FOR 12V.................................................................................................. 90
8.10 CONTROL MANIFOLD FOR 24V.................................................................................................. 92
8.11 DECAL LOCATIONS (PART 1 OF 2 / DECAL SHEET #95724529).............................................. 94
8.11 DECAL LOCATIONS (PART 2 OF 2 / DECAL SHEET #95724529).............................................. 95
8.12 COMPRESSOR OVERHAUL KIT #73744209 - PIECE PARTS.................................................... 96
8.13 COMPRESSOR GASKET REPLACEMENT KIT #73744208 - PIECE PARTS ............................. 102
8.14 HYDRAULIC HOSE SYSTEM ....................................................................................................... 108
APPENDIX A....................................................................111
A.1 ROOF PANEL ASSEMBLY ........................................................................................................... 111
Manual #99905382 Rev 02 (JUNE 2018)

CAS40P 40 CFM / 100 PSIG SECTION 1: SAFETY
PAGE - 1
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An Oshkosh Corporation Company
1.1 GENERAL INFORMATION
The products provided by IMT 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.
System Component Group Manual Section
GENERAL DESCRIPTION 1.1
DANGERS, WARNINGS, CAUTIONS AND
NOTES
1.2
SUMMARY OF DANGERS, WARNINGS,
CAUTIONS AND NOTES
1.3
DANGERS 1.3.1
WARNINGS 1.3.2
CAUTIONS 1.3.3
SAFETY DECALS 1.3.4
SECTION 1:
SAFETY
WARNING
Identifies actions or conditions which
can 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.
DANGER
Identifies actions or conditions which
will cause death, severe injury, or
equipment damage or destructive
malfunctions.
IMPORTANT
Read this manual before operating or
servicing the CAS40P Air Compressor
System. Failure to do so could result in
damaged equipment, bodily injury, or
death.
Manual #99905382 Rev 02 (JUNE 2018)

SECTION 1: SAFETY CAS40P 40 CFM / 100 PSIG
PAGE - 2
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An Oshkosh Corporation Company
• 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
source. Install a lock-out tag to identify the equipment
as inoperable to other personnel.
•DO NOT attempt to service the equipment while it is
operating.
•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 it 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.
•DO NOT operate the compressor with any by-pass or
other safety systems disconnected or rendered
inoperative.
• Keep arms, hands, hair and other body parts, and
loose clothing away from fans, drive shafts, and other
moving parts.
•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.
Pressurized broken or disconnected hoses can whip
causing injuries or damage.
Manual #99905382 Rev 02 (JUNE 2018)

CAS40P 40 CFM / 100 PSIG SECTION 1: SAFETY
PAGE - 3
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An Oshkosh Corporation Company
•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 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.
• 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.
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.
• Wear appropriate protective (eye and hearing
protection) equipment and clothing when operating
or maintaining this equipment. DO NOT wear jewelry,
loose clothing; and long hair should be restrained
with headband or safety hat.
1.3.4 SAFETY DECALS
Safety decals are placed onto, or located near, system
components that can present a hazard to operators or
Manual #99905382 Rev 02 (JUNE 2018)

SECTION 1: SAFETY CAS40P 40 CFM / 100 PSIG
PAGE - 4
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An Oshkosh Corporation Company
service personnel. All pertinent decals listed in Section
8.11, Decal Locations are located near a component,
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.
Manual #99905382 Rev 02 (JUNE 2018)

CAS40P 40 CFM / 100 PSIG SECTION 2: DESCRIPTION
PAGE - 5
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®
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2.1 GENERAL DESCRIPTION
The CAS40P unit is designed for heavy-duty
performance, optimal power consumption, and for use in
areas where installation space is limited.
This type of compressor increases the pressure of the
supply air by reducing its volume. This equipment
operates by taking in successive volumes of air, in
repeated cycles, that is confined in an enclosed space, a
sealed chamber, which then compresses this air mass to
a higher pressure.
The reciprocating air compressor accomplishes this by
using pistons to compress the air inside a set of
cylinders, which confine the air mass. As the pistons
move into the cylinders, the area containing the air mass
decreases and the pressure increases.
The enclosure is constructed of powder-coated,
galvanneal sheet steel to protect the unit. It is designed
so that daily inspections can be accomplished without
removing any panels. However, the panels can be
removed easily for more extensive maintenance and
repairs.
The unit’s steel frame is also powder-coated and has bolt
holes for securing it to a vehicle body mounting platform
or base.
The component descriptions are presented in this section
as follows:
System Component Group Manual Section
GENERAL DESCRIPTION 2.1
COMPONENT DESCRIPTIONS 2.2
COMPRESSOR PUMP 2.2.1
COOLING SYSTEM 2.2.2
ELECTRICAL SYSTEM 2.2.3
AIR CONTROL SYSTEM 2.2.4
Continued on next page
SECTION 2:
DESCRIPTION
WARNING
DO NOT attempt to service the
equipment while it is operating.
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.
NOTE
The purpose of this section is to provide
descriptions of key machine components
and systems, and their functions. For
detailed information on servicing the
compressor, consult Section 6,
Maintenance.
Manual #99905382 Rev 02 (JUNE 2018)

SECTION 2: DESCRIPTION CAS40P 40 CFM / 100 PSIG
PAGE - 6
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2.2 COMPONENT DESCRIPTIONS
2.2.1 COMPRESSOR PUMP
Refer to Figure 2-1. The CAS40P contains a double acting
compressor, which is a two-stage, four cylinder splash-
HYDRAULIC CONTROL SYSTEM 2.2.5
PRESSURE RELIEF VALVES 2.2.6
MAIN FRAME AND ENCLOSURE 2.2.7
System Component Group Manual Section
KEY DESCRIPTION KEY DESCRIPTION
ACAS40P RECIPROCATING COMPRESSOR DINTERCOOLERS (x 2)
BOIL FILL PORT ECOMPRESSOR DRIVE SHEAVE (PULLEY)
CCOMPRESSOR AIR FILTER HOUSINGS (x 2) FSERVICE AIR OUT (TO SERVICE PORT)
Figure 2-1: Reciprocating Compressor Unit Views
AAB
B
VIEW B-B
VIEW A-A
17 .3 4
C
B
E
DD
F
A
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CAS40P 40 CFM / 100 PSIG SECTION 2: DESCRIPTION
PAGE - 7
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lubricated unit powered by a gear-type aluminum hydraulic
motor through V-belts and a pulley.
Air is drawn in through dual oversized, dry-type air filters that
are located on the compressor pump to provide easy access
and long service life.
2.2.2 COOLING SYSTEM
Refer to Figure 2-2. The compressor cooling system
consists of a hydraulic oil cooler and a 12VDC electric
fan. It maintains a constant cooling air flow through the
unit to ensure that it does not exceed its specified
operating temperature limits.
Oil flows through the radiator type hydraulic cooler as
long as the hydraulic system is supplying oil to the
compressor, providing continuous cooling of the
hydraulic circuit.
The fan is mounted at the unit’s rear and draws air
through the package, directly cooling the compressor,
and providing cooling air for the oil cooler. The fan
operates continuously anytime power is applied.
2.2.3 ELECTRICAL SYSTEM
Refer to Figure 2-3. The control system’s automatic
START/STOP feature is controlled by air tank pressure,
but a manual ON/OFF is also included. Air pressure can
be adjusted up to 150 psig. Instrumentation gauges for
system pressure and operation hour accumulation are
located on the outside panel.
2.2.4 AIR CONTROL SYSTEM
When the compressor is ON, the control system
automatically starts and stops in order to maintain the
receiver tank pressure between 95 psig (minimum) and
175 psig (maximum).
A pressure switch relieves pressure in the cylinders when
the unit is unloaded.
2.2.5 HYDRAULIC CONTROL SYSTEM
The hydraulic motor is used to power the compressor
unit. If the proper flow and pressure is supplied to the
motor there should be many hours of trouble-free use in
conjunction with the compressor.
IMPORTANT
The compressor should not be operated
continuously at pressure settings above
150 psig.
KEY DESCRIPTION
ACOOLER FAN & MOTOR ASSEM-
BLY
BOIL COOLER
CCOOLER PANEL
DDIRECTION OF COOLING AIR
FLOW
Figure 2-2: Cooler Assembly
A
B
C
D
Manual #99905382 Rev 02 (JUNE 2018)

SECTION 2: DESCRIPTION CAS40P 40 CFM / 100 PSIG
PAGE - 8
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KEY
DESCRIPTION
A
RELIEF VALVE (x 2) - Rated at 70 PSI
B
RELIEF VALVE - Rated at 200 PSI
Figure 2-4: Pressure Relief Valves
AA
B
The compressor unit has a built-in hydraulic manifold
which has a directional control valve (solenoid) and a
pressure relief valve (see Section 8.9 [12V] or 8.10
[24V]).
The pressure relief valve protects against an over-
pressure condition by diverting the oil to the return line if
such a condition occurs.
2.2.6 PRESSURE RELIEF VALVES
See Figure 2-4. There are three pressure relief valves
located on the compressor unit assembly: one each on
the cylinder heads (70 psig rating), and one on the
service assembly piping (200 psig rating). These spring-
backed, normally closed valves serve as safety devices
that protect against over-pressurization. As the pressure
begins to approach 70 psig for each of the head unloader
valves, its relief valve will crack open to slowly relieve
pressure. This siphoning action serves to vent excessive
pressure level build-up of air to atmosphere in real time
operation sequence. The valve located at the service
assembly piping regulates pressure in the same way,
bleeding off excessive air pressure over 200 psig.
KEY DESCRIPTION KEY DESCRIPTION
ARELIEF VALVE ADJUSTMENT
I
CHOUR METER
BPRESSURE GAUGE DOIL LEVEL SIGHT GLASS
I
The pressure relief valve is set at the factory. DO NOT adjust the pressure relief valve; consult the IMT Service
Department for pressure relief resets.
Figure 2-3: Instrumentation Locations
DA B C
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CAS40P 40 CFM / 100 PSIG SECTION 2: DESCRIPTION
PAGE - 9
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2.2.7 MAIN FRAME AND ENCLOSURE
Refer to Figure 2-5. The steel main frame is provided
with bolt down holes.
The enclosure panels, which are attached to the main
frame and frame supports, are made from steel and are
powder coated to provide a durable finish. The top panel
is hinged for easy access to oil fill and other routine
maintenance items.
The main enclosure housing provides overall protection
for the various unit assemblies. The cooler assembly
enclosure [B], is located on the opposite side from the
connection port panel of the package [D]. The service air
outlet [D
1
], compressor drain hose [D
2
], 6-pin Deutch
connection [D
3
] and hydraulic hose line connections [D
4
and D
5
] are found on the connection port panel.
Compressor oil level can be checked from the outside of
the enclosure (Figure 2-3, [D]), and filled via a fill port
located at the inside left rear corner facing from the
(opened) hinged-access roof panel (consult Section
KEY DESCRIPTION KEY DESCRIPTION
AMAIN ENCLOSURE D2COMPRESSOR DRAIN HOSE (on frame)
BCOOLER ASSEMBLY ENCLOSURE D36-PIN DEUTCH CONNECTION
CMAIN FRAME D4HYDRAULIC SUPPLY
DCONNECTION-SIDE PANEL D5HYDRAULIC RETURN
D1SERVICE AIR OUT EFRAME: MOUNTING HOLE SLOTS
Figure 2-5: Main Frame, Mounting and Enclosure
D1
B
EE
A
D
D2D3D5
C
D4
WARNING
DO NOT operate machine with the roof
panel open or removed.
Manual #99905382 Rev 02 (JUNE 2018)

SECTION 2: DESCRIPTION CAS40P 40 CFM / 100 PSIG
PAGE - 10
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6.4.3, Compressor System Lubrication 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.
Manual #99905382 Rev 02 (JUNE 2018)

CAS40P 40 CFM / 100 PSIG SECTION 3: SPECIFICATIONS
PAGE - 11
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TABLE 3A - SPECIFICATIONS
GENERAL SYSTEM INFORMATION SPECIFICATION
RATINGS
Capacity (CFM @ 100 [150 maximum] psig): 40 CFM
Air Pressure at tool
I
(psig): 100
Speed (RPM @ 100 psig): 890
Hydraulic flow (gpm @ 120°F hydraulic oil temperature): 10 (± 0.5)
Hydraulic pressure (psig @ 100/150 compressor psig): 2775
Maximum compressor oil temperature 250°F
Maximum Hydraulic oil temperature 180°F
COMPRESSOR
Type: Two-stage, four cylinder, reciprocating
Compressor oil reservoir capacity: 3 quarts
Air inlet system: Twin dry-type, single stage
Drive coupling: Belt drive
Hydraulic motor: Gear type
PACKAGE
Main frame: Formed powder-coated steel with a bolt-down
provision
Electrical supply: 12V Standard; 24V Optional
Electrical connections: Weatherpack
Enclosure: Galvanneal sheet steel, powder-coated
Cooler: Hydraulic oil cooler/radiator core — electric fan
Package connections: Discharge air — 3/4” NPT female
Hydraulic supply — 1/2” 37°JIC male
Hydraulic return — 3/4” 37°JIC male
+12VDC (PTO activated)
Dimensions: Length — 32.00”
Width — 22.00”
Height — 21.75”
Weight: 400 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.
SECTION 3:
SPECIFICATIONS
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SECTION 3: SPECIFICATIONS CAS40P 40 CFM / 100 PSIG
PAGE - 12
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TABLE 3B - CAPSCREW TIGHTENING TORQUE VALUES
SIZE GRADE LUBRICATED
1/4 - 20 UNC 5 6 ft•lbs
5/16 - 18 UNC 5 13 ft•lbs
3/8 - 16 UNC 5 23 ft•lbs
1/2 - 13 UNC 5 55 ft•lbs
3/4 - 10 UNC 5 200 ft•lbs
TABLE 3C - COMPRESSOR TORQUE VALUES
BOLTS SIZE GRADE TORQUE (ft.-lb.) POSITION
1/4-28 NF 8.8 8 LP. Valve Nut
3/8-24 NF 8.8 40 Cylinder to Base Bolt
5/16-18 NC 8.8 10 Head to Cylinder Bolt
10.9 Connecting Rod Bolt
8.8 LP & HP Hold Down Bolt
5/16-24 NF 8.8 12 Flywheel Bolt
7/16-14 NC 8.8 43 Cover Bolt
Manual #99905382 Rev 02 (JUNE 2018)

CAS40P 40 CFM / 100 PSIG SECTION 4: INSTALLATION
PAGE - 13
®
An Oshkosh Corporation Company
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 movements of assemblies or
components which may have caused damage. To install
the CAS40P compressor system, refer to the following
sections:
4.2 GENERAL INSTRUCTIONS
This section provides general guidance for locating and
preparing the CAS40P 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.
4.3 DETERMINING THE CAS40P UNIT
MOUNTING LOCATION
When determining the location to mount the CAS40P
unit, the following criteria must be taken into
consideration:
System Component Group Manual Section
GENERAL INSTRUCTIONS 4.2
DETERMINING THE CAS40P UNIT
MOUNTING LOCATION
4.3
CONNECTING THE ELECTRICAL SUPPLY 4.4
HYDRAULIC SYSTEM REQUIREMENTS 4.5
CONNECTING THE HYDRAULIC SUPPLY
AND RETURN
4.6
CONNECTING THE AIR SUPPLY 4.7
SECTION 4:
INSTALLATION
WARNING
Install, operate, and maintain this
equipment in full compliance with all
applicable OSHA, other Federal, state,
local codes, standards, and regulations.
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.
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.
Manual #99905382 Rev 02 (JUNE 2018)

SECTION 4: INSTALLATION CAS40P 40 CFM / 100 PSIG
PAGE - 14
®
An Oshkosh Corporation Company
• 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 (400 lbs.).
• The location must allow for the machine dimensions
(Figure 4-2), and additional space requirements for
minimum cooling, maintenance and access. Refer to
Figure 4-3 to determine the additional minimum
space requirement measurements.
• The external gauges must be easily visible to the
operator.
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 ingest
exhaust fumes, dust or debris.
KEY DESCRIPTION KEY DESCRIPTION
A0.75 inches D1.25 inches
B30.5 inches E18.56 inches
CMOUNTING SLOT Ø0.56 X 1.25 inches (x 4)
NOTE: For additional machine measurements, consult Figure 4-2.
Figure 4-1: Base Frame Mounting and Hole Locations
A
D
E
BC
C
CC
Manual #99905382 Rev 02 (JUNE 2018)