Oshkosh IMT CAS40PL User manual

®
An Oshkosh Corporation Company
Iowa Mold Tooling Co., Inc.
500 Highway 18 West
Garner, Iowa 50438
Phone: [phone]
Fax: [phone]
www.imt.com
1.800.247.5958
©2023 Iowa Mold Tooling Co., Inc.
All rights reserved
KEEP THE MANUAL
WITH THE VEHICLE
P/N 99906549_r02
E󰀨ective Date:
06/13/2023
CAS40PL, CAS40PL-CW
40 CFM/100 PSIG HYDRAULIC, (OPTIONAL)
COLD-WEATHER, CLOSED OR OPEN CIRCULATION
RECIPROCATING COMPRESSOR
INSTALLATION, OPERATION, MAINTENANCE AND PARTS MANUAL
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
This publication contains the
latest information available at
the time of preparation. Every
e󰀨ort has been made to ensure
accuracy.
Iowa Mold Tooling Co., Inc.
reserves the right to make
design change modications
or improvements without prior
notication.
NOTE
Use only IMT Reciprocating
Compressor Oil and Genuine
IMT Parts. Inspect and replace
damaged components before
operation. Substituting non-IMT
oil or non-genuine IMT lter
components WILL VOID THE
COMPRESSOR WARRANTY!
NOTE
Making unauthorized modica-
tions to the system components
WILL VOID THE WARRANTY!
Always inform IMT before
beginning any changes to the
CAS40PL systems.

BLANK PAGE

TABLE OF
CONTENTS
99906549_r02 (06/13/2023) TOC - I
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
TABLE OF CONTENTS .................................................................. TOC - I
Section 1: SAFETY .......................................................................1 - 1
1.1 GENERAL INFORMATION .........................................................................................1 - 1
1.2 INTERNATIONAL SAFETY SYMBOL .........................................................................1 - 1
1.3 DANGERS, WARNINGS, CAUTIONS, AND NOTES .................................................1 - 1
1.3.1 DANGERS..........................................................................................................1 - 1
1.3.2 WARNINGS........................................................................................................1 - 1
1.3.3 CAUTIONS .........................................................................................................1 - 3
1.3.4 NOTES ...............................................................................................................1 - 3
1.4 SAFETY DECALS .......................................................................................................1 - 3
1.5 DISPOSING OF MACHINE FLUIDS...........................................................................1 - 3
SECTION 2: SPECIFICATIONS ..........................................................2 - 1
2.1 GENERAL INTRODUCTION ..........................................................................................2 - 1
TABLE 2A: SPECIFICATIONS ................................................................................................2 - 1
TABLE 2B: CAP SCREW TIGHTENING TORQUE VALUES..................................................2 - 2
TABLE 2C: COMPRESSOR TORQUE VALUES.....................................................................2 - 2
Figure 2-1: Machine Main Component Locations.............................................................2 - 3
SECTION 3: INSTALLATION ..............................................................3 - 1
3.1 MACHINE PACKAGE RECEIPT/INSPECTION .............................................................3 - 1
3.2 GENERAL INSTRUCTIONS...........................................................................................3 - 1
3.3 DETERMINING THE CAS40PL UNIT MOUNTING LOCATION.....................................3 - 2
3.4 HYDRAULIC SYSTEM OVERVIEW...............................................................................3 - 2
3.4.1 HYDRAULIC SYSTEM FILTRATION.....................................................................3 - 2
Figure 3-1: Installation and Dimensions Diagram - Open Center 12VDC ........................3 - 3
Continued on next page...

TOC - II 99906549_r02 (06/13/2023)
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
SECTION 3: INSTALLATION (CONTINUED)
Figure 3-2: Install & Dim Diagram - Open Center w Cold Weather Option ...............3 - 4
3.4.2 HYDRAULIC OIL RESERVOIR .............................................................................3 - 5
3.4.2.1 DETERMINING RESERVOIR SIZE.............................................................3 - 5
3.4.2.2 DETERMINING RESERVOIR SHAPE.........................................................3 - 5
3.4.2.3 MANDATORY RESERVOIR FEATURES.....................................................3 - 5
3.4.2.4 RECOMMENDED RESERVOIR OPTIONS.................................................3 - 6
3.4.2.5 RESERVOIR FEATURES TO AVOID...........................................................3 - 7
3.4.2.6 RECOMMENDED HYDRAULIC SYSTEM SPECIFICATIONS ....................3 - 7
3.4.3 STANDARDS GUIDELINES ..................................................................................3 - 7
3.5 INSTALLATION...............................................................................................................3 - 7
3.5.1 MACHINE LOCATION ...........................................................................................3 - 7
3.5.2 CLEARANCES.......................................................................................................3 - 7
3.5.3 MACHINE STABILIZATION AND GROUNDING ...................................................3 - 7
3.5.4 SERVICE CONNECTIONS....................................................................................3 - 7
3.5.5 ELECTRICAL CONNECTIONS .............................................................................3 - 7
3.5.6 HYDRAULIC SUPPLY CIRCUIT............................................................................3 - 7
3.5.7 ROUTING ..............................................................................................................3 - 8
3.5.8 HYDRAULIC SYSTEM REQUIREMENTS ............................................................3 - 8
3.6 CONNECTING THE HYDRAULIC SUPPLY AND RETURN....................................3 - 8
3.7 CONNECTING THE AIR SUPPLY ...........................................................................3 - 8
3.7.1 AIR RESERVOIR TANK INSTALLATION ..............................................................3 - 8
SECTION 4: OPERATION ...................................................................4 - 1
4.1 GENERAL INFORMATION.............................................................................................4 - 1
4.2 OPERATING CONDITIONS ...........................................................................................4 - 1
4.3 INITIAL (FIRST-TIME) START-UP..................................................................................4 - 1
4.3.1 ROUTINE START-UP FROM MACHINE ...............................................................4 - 2
Figure 4-1: Instrumentation...............................................................................................4 - 2
Continued on next page...

99906549_r02 (06/13/2023) TOC - III
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
SECTION 4: OPERATION (CONTINUED)
4.3.2 ROUTINE SHUTDOWN PROCEDURE (FIRST AND ROUTINE) .........................4 - 2
4.4 EXTREME CONDITION OPERATION ...........................................................................4 - 2
SECTION 5: MAINTENANCE ..............................................................5 - 1
5.1 GENERAL INFORMATION.............................................................................................5 - 1
5.2 MACHINE MAINTENANCE SCHEDULE .......................................................................5 - 1
5.3 REPLACEMENT PARTS ................................................................................................5 - 2
TABLE 5A: ROUTINE MAINTENANCE SCHEDULE ..............................................................5 - 3
TABLE 5B: ROUTINE REPLACEMENT PARTS KITS ............................................................5 - 3
5.4 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES ....................................5 - 5
5.4.1 REMOVING PANELS FOR MACHINE MAINTENANCE ACCESS ....................... 5 - 5
5.4.1.1 REMOVING LONG-SIDE PANELS FOR MAINTENANCE ACCESS........... 5 - 5
5.4.1.2 REPLACING LONG-SIDE PANELS.............................................................5 - 6
5.4.2 CHECKING PRESSURE READING......................................................................5 - 6
5.4.3 COMPRESSOR SYSTEM LUBRICATION ............................................................5 - 6
5.4.3.1 CHECKING THE OIL LEVEL .......................................................................5 - 6
5.4.3.2 CHANGING THE COMPRESSOR OIL........................................................5 - 6
5.4.4 AIR FILTER MAINTENANCE.................................................................................5 - 7
5.4.4.1 INSPECTING THE AIR FILTER ...................................................................5 - 7
5.4.4.2 REPLACING THE AIR FILTER ELEMENT...................................................5 - 8
5.4.5 COOLER CORE MAINTENANCE ..........................................................................5 -8
5.4.6 COUPLING ALIGNMENT ......................................................................................5 - 9
5.4.7 REPLACING THE DRIVE COUPLING ..................................................................5 - 9
5.4.7.1 REPLACING THE DRIVE COUPLING ELEMENT.....................................5 - 10
5.4.7.2 COUPLING ASSEMBLY.............................................................................5 - 10
5.4.7.3 HUB ALIGNMENT CHECK ........................................................................ 5 - 11
5.4.7.4 COUPLING MAINTENANCE ..................................................................... 5 - 11
5.4.8 CHECKING HOSES AND WIRING ..................................................................... 5 - 11
5.5 SERVICING THE SYSTEM FUSES AND RELAYS......................................................5 - 12
5.6 PRESSURE (SAFETY) RELIEF VALVES ....................................................................5 - 12
5.7 LONG TERM STORAGE..............................................................................................5 - 13
Continued on next page...

TOC - IV 99906549_r02 (06/13/2023)
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
SECTION 6: TROUBLESHOOTING ................................................... 6 - 1
6.1 GENERAL INFORMATION.......................................................................................... 6 - 1
6.2 TROUBLESHOOTING GUIDE .................................................................................... 6 - 2
SECTION 7: ILLUSTRATED PARTS LIST ......................................... 7 - 1
7.1 PARTS ORDERING INFORMATION........................................................................... 7 - 1
TABLE 7A: RECOMMENDED SPARE PARTS LIST.............................................................. 7 - 2
7.2 COMPRESSOR AND PARTS...................................................................................... 7 - 4
7.3 COMPRESSOR PARTS .............................................................................................. 7 - 6
7.4 DISPLAY AND GAUGE ASSEMBLY............................................................................ 7 - 8
7.5A MOTOR AND DRIVE PARTS PARTS - OPEN CENTER ............................................ 7 - 9
7.5B MOTOR AND DRIVE PARTS PARTS - CLOSED CENTER........................................ 7 - 9
7.6 HYDRAULIC COOLER & PARTS - WITH THRML / GAUGES.................................. 7 - 10
7.7 FRAME ASSEMBLY .................................................................................................. 7 - 12
7.8 FRAME AND CANOPY - 1 OF 3 (ASSEMBLY PART A) ........................................... 7 - 14
7.8 FRAME AND CANOPY - 2 OF 3 (ASSEMBLY PARTS B - C) ................................... 7 - 16
7.8 FRAME AND CANOPY - 3 OF 3 (ASSEMBLY PARTS D - F) ................................... 7 - 17
7.9 HYD MANIFOLD ASSEMBLY - OPEN CTR (STD & COLD WEATHER)................... 7 - 18
7.10 DECAL IDENTIFICATION/LOCATIONS - 1 OF 2...................................................... 7 - 20
7.10 DECAL IDENTIFICATION/LOCATIONS - 2 OF 2...................................................... 7 - 21
7.11 HOSE & TUBE ROUTING - OPEN CTR, NO THERMAL, W GAUGES.................... 7 - 22
7.12 HOSE & TUBE ROUTING - OPEN CTR, THERMAL & GAUGES ............................ 7 - 23
7.13 HYDRAULIC THERMAL VALVE ASSEMBLY............................................................ 7 - 24
7.14 WIRING DIAGRAM ................................................................................................... 7 - 25
7.15 HYD OIL FLOW DIAGRAM - OPEN CTR, WITH THERMAL VALVE ........................ 7 - 26
7.16 HYD OIL FLOW DIAGRAM - OPEN CTR ................................................................. 7 - 27
7.17 HOSE INSTALLATION GUIDE .................................................................................. 7 - 28
TABLE 7B: MAINTENANCE TRACKING LOG..................................................................... 7 - 29

SECTION 1:
SAFETY
99906549_r02 (06/13/2023) 1 - 1
SECTION 1: SAFETY
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
1.1 GENERAL INFORMATION
The products provided by IMT®Mfg., Inc. 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.
IMPORTANT
It is mandatory that all operators read this
manual before operating or servicing the
CAS40PL system. Failure to do so could result
in death, bodily injury or damage to equipment.
DANGER
DO NOT OPERATE IN AN ENCLOSED SPACE
WITHOUT ADEQUATE VENTILATION.
Running any combustion engine in an enclosed
space without adequate ventilation may result
in carbon monoxide (CO) poisoning and may
cause overheating, which may result in re and/
or explosion.
Carbon monoxide (CO) build-up may cause
death!
Overheating may result in re and/or explosion
resulting in injury/death and equipment
damage.
Consult IMT for recommendations when
mounting combustion engine driven IMT
equipment in an enclosed space.
1.2 INTERNATIONAL
WARNING SYMBOL
The international warning symbol (shown above)
is used on all decals, labels and signs that
concern information pertaining to bodily harm.
When you see the international warning symbol,
pay extremely careful attention, and follow the
given instructions or indications to avoid any
possible hazard.
1.3 DANGERS, WARNINGS,
CAUTIONS AND NOTES
These boxes are labeled clearly with the title
block listing either Danger, Warning, Caution, or
other non-safety issue. They draw attention to
specic issues that are pertinent to the safe and
correct operation of the machine.
The symbols shown and dened in Section 1:
Safety are used throughout this manual and
on the machine to call attention to, and identify,
possible hazards.
1.3.1 DANGERS
DANGER
Identies actions or conditions which will cause
death, severe injury, or equipment damage or
destructive malfunctions.
• Keep tools or other conductive objects away
from live electrical parts.
• Never touch electrical wires or components
while the machine is operating. They can be
sources of electrical shock.
1.3.2 WARNINGS
WARNING
Identies actions or conditions which may
cause death, severe injury, or equipment
damage or destructive malfunctions.
• 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 a IMT compressor to supply breathing
air.

1 - 2 99906549_r02 (06/13/2023)
SECTION 1: SAFETY
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
• DO NOT perform any modications 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 operate the compressor with any by-
pass or other safety systems disconnected or
rendered inoperative.
• DO NOT operate the equipment while you are
under the inuence of alcohol or drugs.
• DO NOT operate the equipment while you are
feeling ill.
• DO NOT attempt to service the equipment
while it is operating.
• Before performing maintenance, or replacing
parts, relieve the entire system pressure,
after the system has blown down, by opening
a service valve which will vent all pressure
to the atmosphere. After that, remove any
remaining residual pressure by slowly
opening the ll cap. Remove all electrical
power.
NOTE
Slowly remove ll cap to vent compressor sump
pressure.
• 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
specied pressure and speed ratings. (See
Section 2: Specications or refer to the
equipment data plate.).
• DO NOT use ammable solvents or cleaners
for cleaning the compressor or its parts.
• DO NOT operate the compressor in areas
where ammable, toxic, corrosive fumes, or
other damaging substance can be ingested
by the compressor intake.
• Keep arms, hands, hair and all other body
parts, and clothing away from fans, drive
shafts, and other moving parts.
• DO NOT wear jewelry, unbuttoned cu󰀨s, ties,
or loose-tting clothing when you are working
near moving/rotating parts.
• ALWAYS conne long hair when working near
moving/rotating parts.
• NEVER operate the equipment while wearing
a headset to listen to music or the radio.
• Wear personal protective equipment such as
gloves, work shoes, and eye and hearing
protection as required for the task at hand.
• DO NOT operate the compressor with any
guards removed or damaged, or other safety
devices inoperative.
• DO NOT operate the compressor in enclosed
or conned spaces where ventilation is
restricted or closed-o󰀨.
• Ensure that hoses connected to service valves
are tted with correctly sized and rated ow
limiting devices which comply with applicable
codes. Pressurized broken or disconnected
hoses can whip, causing injuries or damage.
• 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
hydraulic 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.
• When lifting objects, be aware of proper lifting

99906549_r02 (06/13/2023) 1 - 3
SECTION 1: SAFETY
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
techniques to avoid injury.
• ALWAYS read and follow safety related
precautions found on containers of hazardous
substances.
1.3.3 CAUTIONS
CAUTION
Identies actions or conditions which will or
can cause injuries, equipment damage or mal-
functions.
• 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 specied
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 ttings are kept in serviceable condition
through routine inspections and maintenance.
Replace any damaged or worn components.
1.3.4 NOTES
NOTE
Additional information (or existing information)
which should be brought to the attention of
operators/maintainers a󰀨ecting operation,
maintenance, or warranty requirements.
Note boxes are usually listed to convey and
give focus to a distinct piece of information,
which is not directly related to a safety issue, but
is necessary to understand machine function
and operation. Special note referrals in the
manual may be contained in a box titled with an
IMPORTANT banner, as shown below, and may
also contain the WARNING symbol, should the
information be linked to a safety issue:
IMPORTANT
Additional, CRUCIAL information (or existing
information) which should be brought to the attention
of operators / maintainers a󰀨ecting operation,
maintenance, or warranty requirements.
1.4 SAFETY DECALS
Safety decals are placed onto, or located
near, system components that can present a
hazard to operators or service personnel. All
pertinent decals listed in Section 7.11, Decal
Identication/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.
1.5 DISPOSING OF MACHINE
FLUIDS
Always dispose of machine uids under the
guidance of all applicable local, regional and/or
federal law.
IMT®encourages recycling when allowed. For
additional information, consult the container
label of the uid in question.

1 - 4 99906549_r02 (06/13/2023)
SECTION 1: SAFETY
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
BLANK PAGE