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
®
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
®
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
®
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
®
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
®
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
®
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)