Oshkosh IMT CAS40PL Installation, Operation, Maintenance And Parts Manual

40 cfm/100 psig hydraulic, (optional) cold-weather, closed or open circulation reciprocating compressor

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CAS40PL, CAS40PL-CW

40 CFM/100 PSIG HYDRAULIC, (OPTIONAL)

COLD-WEATHER, CLOSED OR OPEN CIRCULATION

RECIPROCATING COMPRESSOR

INSTALLATION, OPERATION, MAINTENANCE AND PARTS MANUAL

NOTE

This publication contains the

latest information available at

the time of preparation. Every

effort has been made to ensure

accuracy.

Iowa Mold Tooling Co., Inc.

reserves the right to make

design change modifications

or improvements without prior

notification.

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 filter

components WILL VOID THE

COMPRESSOR WARRANTY!

KEEP THE MANUAL

WITH THE VEHICLE

An Oshkosh Corporation Company

Iowa Mold Tooling Co., Inc.

500 Highway 18 West

Garner, Iowa 50438

Phone: 641.923.3711

Fax: 641.923.2424

www.imt.com

1.800.247.5958

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 modifica-

tions to the system components

WILL VOID THE WARRANTY!

Always inform IMT before

beginning any changes to the

CAS40PL systems.

P/N 99906549_r02

Effective Date:

06/13/2023

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Summary of Contents for Oshkosh IMT CAS40PL

Page 1 ® An Oshkosh Corporation Company CAS40PL, CAS40PL-CW 40 CFM/100 PSIG HYDRAULIC, (OPTIONAL) COLD-WEATHER, CLOSED OR OPEN CIRCULATION RECIPROCATING COMPRESSOR INSTALLATION, OPERATION, MAINTENANCE AND PARTS MANUAL NOTE This publication contains the latest information available at the time of preparation. Every effort has been made to ensure Read this manual before installing, accuracy.
Page 2 BLANK PAGE...
Page 3: Table Of Contents
CAS40PL, CAS40PL-CW TABLE OF CONTENTS RECIPROCATING AIR COMPRESSOR TABLE OF CONTENTS TABLE OF CONTENTS ..............TOC - I Section 1: SAFETY ...............1 - 1 GENERAL INFORMATION ..................1 - 1 INTERNATIONAL SAFETY SYMBOL .................1 - 1 DANGERS, WARNINGS, CAUTIONS, AND NOTES ..........1 - 1 1.3.1 DANGERS ......................1 - 1 1.3.2...
Page 4 CAS40PL, CAS40PL-CW TABLE OF CONTENTS 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...
Page 5 CAS40PL, CAS40PL-CW TABLE OF CONTENTS RECIPROCATING AIR COMPRESSOR SECTION 4: OPERATION (CONTINUED) 4.3.2 ROUTINE SHUTDOWN PROCEDURE (FIRST AND ROUTINE) ......4 - 2 EXTREME CONDITION OPERATION ................4 - 2 SECTION 5: MAINTENANCE ..............5 - 1 GENERAL INFORMATION .....................5 - 1 MACHINE MAINTENANCE SCHEDULE ...............5 - 1 REPLACEMENT PARTS ....................5 - 2 TABLE 5A: ROUTINE MAINTENANCE SCHEDULE ..............5 - 3 TABLE 5B: ROUTINE REPLACEMENT PARTS KITS ............5 - 3...
Page 6 CAS40PL, CAS40PL-CW TABLE OF CONTENTS RECIPROCATING AIR COMPRESSOR SECTION 6: TROUBLESHOOTING ........... 6 - 1 GENERAL INFORMATION ..................6 - 1 TROUBLESHOOTING GUIDE ..................6 - 2 SECTION 7: ILLUSTRATED PARTS LIST ......... 7 - 1 PARTS ORDERING INFORMATION ................7 - 1 TABLE 7A: RECOMMENDED SPARE PARTS LIST ..............
Page 7: Safety
CAS40PL, CAS40PL-CW SECTION 1: SAFETY RECIPROCATING AIR COMPRESSOR SECTION 1: SAFETY GENERAL INFORMATION When you see the international warning symbol, pay extremely careful attention, and follow the given instructions or indications to avoid any The products provided by IMT Mfg., Inc. are ®...
Page 8 CAS40PL, CAS40PL-CW SECTION 1: SAFETY RECIPROCATING AIR COMPRESSOR • DO NOT perform any modifications to this shafts, and other moving parts. equipment without prior factory approval. • DO NOT wear jewelry, unbuttoned cuffs, ties, • DO NOT operate the compressor or any of its or loose-fitting clothing when you are working systems if there is a known unsafe condition.
Page 9: Cautions
CAS40PL, CAS40PL-CW SECTION 1: SAFETY RECIPROCATING AIR COMPRESSOR techniques to avoid injury. manual may be contained in a box titled with an IMPORTANT banner, as shown below, and may • ALWAYS read and follow safety related also contain the WARNING symbol, should the precautions found on containers of hazardous information be linked to a safety issue: substances.
Page 10 CAS40PL, CAS40PL-CW SECTION 1: SAFETY RECIPROCATING AIR COMPRESSOR BLANK PAGE 1 - 4 99906549_r02 (06/13/2023) IOWA MOLD TOOLING CO., INC. (641) 923-3711...
Page 11: Section 2: Specifications
CAS40PL, CAS40PL-CW SECTION 2: SPECIFICATIONS RECIPROCATING AIR COMPRESSOR SECTION 2: SPECIFICATIONS GENERAL INTRODUCTION in this manual. Refer to Figure 2-1 (page 2 - 3) or general The tables and figures in this section list the machine component locations. For additional specifications (including operational, output and information, including measurement dimensional) of the overall machine.
Page 12 CAS40PL, CAS40PL-CW SECTION 2: SPECIFICATIONS RECIPROCATING AIR COMPRESSOR TABLE 2A: SPECIFICATIONS GENERAL SYSTEM INFORMATION SPECIFICATION PACKAGE (continued) Dimensions: Length — 32.50” Width — 21.00” Height — 23.94” Weight: 245 lbs.(dry; add 10-12 lbs for full wet machine weight) CONTROLS Hydraulic pressure relief: 3000 PSIG 12 or 24V Hydraulic solenoid valve (for automatic load...
Page 13 CAS40PL, CAS40PL-CW SECTION 2: SPECIFICATIONS RECIPROCATING AIR COMPRESSOR OPEN CLOSED CENTER CENTER MANIFOLD MANIFOLD CLOSED - CENTER CONFIGURATION OPEN - CENTER CONFIGURATION DESCRIPTION DESCRIPTION RELAYS LOAD SENSE #4 MJIC 37° (1/4-12 UNF) PRESSURE SWITCH HYDRAULIC SUPPLY #12 MJIC 37° (1-1/16-12 UNF) COMPRESSOR AIR FILTER HOUSING HYDRAULIC RETURN #16 MJIC 37°...
Page 14 CAS40PL, CAS40PL-CW SECTION 2: SPECIFICATIONS RECIPROCATING AIR COMPRESSOR BLANK PAGE 2 - 4 99906549_r02 (06/13/2023) IOWA MOLD TOOLING CO., INC. (641) 923-3711...
Page 15: Section 3: Installation
CAS40PL, CAS40PL-CW SECTION 3: INSTALLATION RECIPROCATING AIR COMPRESSOR SECTION 3: INSTALLATION MACHINE PACKAGE WARNING RECEIPT/INSPECTION Install, operate, and maintain this equipment in full compliance with all applicable OSHA, Upon receipt of the machine package, inspect other Federal, state, local codes, standards, and the exterior of the shipping crate for signs of regulations.
Page 16: Determining The Cas40Pl Unit Mounting Location
CAS40PL, CAS40PL-CW SECTION 3: INSTALLATION RECIPROCATING AIR COMPRESSOR DETERMINING THE CAS40PL IMPORTANT UNIT MOUNTING LOCATION ® highly recommends consulting a hydraulic supply expert for specifying the correct When determining the location to mount the hydraulic supply components for vehicle CAS40PL unit, the following criteria must be side integration (including oil reservoir size, taken into consideration: hydraulic pressure relief, hose size, etc.) for...
Page 17 CAS40PL, CAS40PL-CW SECTION 3: INSTALLATION RECIPROCATING AIR COMPRESSOR Figure 3-1: Installation and Dimensions Diagram - Open Center 12V DC 99906549_r02 (06/13/2023) 3 - 3 IOWA MOLD TOOLING CO., INC. (641) 923-3711...
Page 18 CAS40PL, CAS40PL-CW SECTION 3: INSTALLATION RECIPROCATING AIR COMPRESSOR Figure 3-2: Installation and Dimensions Diagram - Open Center 12V DC with Cold Weather Option 3 - 4 99906549_r02 (06/13/2023) IOWA MOLD TOOLING CO., INC. (641) 923-3711...
Page 19: Hydraulic Oil Reservoir
CAS40PL, CAS40PL-CW SECTION 3: INSTALLATION RECIPROCATING AIR COMPRESSOR DESCRIPTION ROOF ACCESS PANEL CLEARANCE: 24” MACHINE LATERAL CLEARANCES: 10” MACHINE FRONT/REAR CLEARANCES: 10” COOLING AIR FLOW DIRECTION NOTE: The dimensions listed above are the minimum required clearance distances needed for properly cooling the machine. Additinal clearance room may be desired for easier acess for control and/or maintenance functions.
Page 20: Mandatory Reservoir Features
CAS40PL, CAS40PL-CW SECTION 3: INSTALLATION RECIPROCATING AIR COMPRESSOR 3.4.2.3 3.4.2.3 MANDATORY RESERVOIR MANDATORY RESERVOIR (but not too many) baffles to promote an ‘S’ shape flow within the reservoir, as viewed FEATURES FEATURES from above. The area of the end gaps should •...
Page 21: Reservoir Features To Avoid
CAS40PL, CAS40PL-CW SECTION 3: INSTALLATION RECIPROCATING AIR COMPRESSOR • Temperature Gauge: Located in approximation • Pressure port = Standard, #12, 3/4” hose (located at manifold block) to, or built in to, the sight glass assembly allows for temperature reading at a glance. •...
Page 22: Service Connections
CAS40PL, CAS40PL-CW SECTION 3: INSTALLATION RECIPROCATING AIR COMPRESSOR 3.5.4 SERVICE CONNECTIONS • The duty cycle and ambient operating temperatures. Refer to Figure 3-1 or Figure 3-2. Service • Other hydraulic equipment which may share connections are conveniently grouped at the the same hydraulic supply system (IMT lower rear section of the unit in the base frame.
Page 23 CAS40PL, CAS40PL-CW SECTION 3: INSTALLATION RECIPROCATING AIR COMPRESSOR TANK SPECIFICATIONS • 19 Gallon minimum capacity (recommended). • ASME-rated and compliant to applicable standards (200 psig minimum). • Supplied with an adequately-rated relief valve. • Supplied with a moisture drain. CONNECTION HOSING AND SERVICE VALVE SPECIFICATIONS •...
Page 24 CAS40PL, CAS40PL-CW SECTION 3: INSTALLATION RECIPROCATING AIR COMPRESSOR BLANK PAGE 3 - 10 99906549_r02 (06/13/2023) IOWA MOLD TOOLING CO., INC. (641) 923-3711...
Page 25: Section 4: Operation
RECIPROCATING AIR COMPRESSOR SECTION 4: OPERATION GENERAL INFORMATION NOTE The IMT CAS40PL compressor has a Flow control needs to be set by the installer for closed center units. comprehensive array of controls and indicators. Understanding the correct operation of the The compressor has been factory-tested.
Page 26: Routine Shutdown Procedure (First And Routine)
CAS40PL, CAS40PL-CW SECTION 4: OPERATION RECIPROCATING AIR COMPRESSOR provide less flow, or no flow, to prevent "Dead IMPORTANT Heading" Hydraulic Pressure. Do not stop the engine suddenly! Stop the When a demand is applied to the unit the engine after approximately five (5) minutes of receiver tank pressure drops until it reaches the unloaded idling.
Page 27: Section 5: Maintenance
SECTION 5: MAINTENANCE GENERAL INFORMATION WARNING The IMT CAS40PL requires routine maintenance DO NOT touch electrical wires, wire harnesses, to ensure its proper functioning and that its terminals, or other components when power is operational life is not prematurely shortened.
Page 28: Replacement Parts
CAS40PL, CAS40PL-CW SECTION 5: MAINTENANCE RECIPROCATING AIR COMPRESSOR NOTE Iowa Mold Tooling Co., Inc. Follow the prescribed periodic maintenance 500 Highway 18 West (PM) schedule as recommended. Perform the required PM schedule at recommended Garner, Iowa 50438 intervals. Failure to follow this prescribed periodic maintenance at the recommended Phone: 641.923.3711 intervals will impair the equipment safety,...
Page 29 CAS40PL, CAS40PL-CW SECTION 5: MAINTENANCE RECIPROCATING AIR COMPRESSOR 99906549_r02 (06/13/2023) 5 - 3 IOWA MOLD TOOLING CO., INC. (641) 923-3711...
Page 30 CAS40PL, CAS40PL-CW SECTION 5: MAINTENANCE RECIPROCATING AIR COMPRESSOR 5 - 4 9990654_r02 (06/13/2023) IOWA MOLD TOOLING CO., INC. (641) 923-3711...
Page 31: Parts Replacement And Adjustment Procedures
CAS40PL, CAS40PL-CW SECTION 5: MAINTENANCE RECIPROCATING AIR COMPRESSOR 5.4.1 REMOVING PANELS FOR MA- PARTS REPLACEMENT AND CHINE MAINTENANCE ACCESS ADJUSTMENT PROCEDURES Although most of the routine maintenance WARNING procedures can be accessed from either outside of the compressor package or via the top roof Follow all applicable safety recommendations as outlined in Section 1: Safety of this manual.
Page 32: Replacing Long-Side Panels
CAS40PL, CAS40PL-CW SECTION 5: MAINTENANCE RECIPROCATING AIR COMPRESSOR 1. With a #2 bit Phillips head screwdriver section gives details on checking and changing remove the eleven (11) 1/4-20 x 3/4” truss the compressor oil. screws [A] and the eleven (11) 1/4” nylon The compressor oil level sight glass is flat washers [B] from the panel side to be accessible from the outside of the canopy.
Page 33: Air Filter Maintenance
CAS40PL, CAS40PL-CW SECTION 5: MAINTENANCE RECIPROCATING AIR COMPRESSOR DESCRIPTION OIL DRAIN HOSE & PLUG OIL LEVEL SIGHT GLASS OIL FILL PORT & PLUG ACCEPTABLE OIL RANGE Acceptable oil range is from 1/4 (low) to 3/4 (high) range of the sight glass height.
Page 34: Replacing The Air Filter Element
CAS40PL, CAS40PL-CW SECTION 5: MAINTENANCE RECIPROCATING AIR COMPRESSOR DESCRIPTION DESCRIPTION AIR FILTER HOUSING CLAMP (x 2) AIR FILTER ELEMENT DUST EVACUATOR VALVE AIR FILTER HOUSING COVER Figure 5-3: Compressor Air Filter Maintenance routine scheduled interval (refer to Table 5A: 1. With the machine off, locate the air filter Routine Maintenance Schedule), or if it assembly, which is mounted on the inside of the front panel.
Page 35: Coupling Alignment
CAS40PL, CAS40PL-CW SECTION 5: MAINTENANCE RECIPROCATING AIR COMPRESSOR the roof panel and checking that the cooler is clean and free from debris will ensure that the CAS40PL package operates safely within the temperature limits described in Section 2, Specifications of this manual. Should the core become clogged, you can use low pressure compressed air to blow through the fins from the inside of the canopy to clean it...
Page 36: Replacing The Drive Coupling Element
CAS40PL, CAS40PL-CW SECTION 5: MAINTENANCE RECIPROCATING AIR COMPRESSOR DESCRIPTION SPIDER COUPLING MOTOR COUPLING HUB SET SCREW FOR MOTOR COUPLING HUB MOTOR DESCRIPTION COMPRESSOR UNIT BELL HOUSING COMPRESSOR COUPLING HUB Figure 5-5: Drive Coupling Element Replacement However, it may become worn or the element 1.
Page 37: Hub Alignment Check
CAS40PL, CAS40PL-CW SECTION 5: MAINTENANCE RECIPROCATING AIR COMPRESSOR Section 5.4.7.3). To ensure alignment, refer to Figure 5-6 and the following procedure: 5.4.7.2 COUPLING ASSEMBLY 1. Place a straight edge square on the outer diameter of both halves in locations 90° The following method is used for a full apart.
Page 38: Checking Hoses And Wiring
CAS40PL, CAS40PL-CW SECTION 5: MAINTENANCE RECIPROCATING AIR COMPRESSOR end may work itself loose over time. Check all IMPORTANT the hose fittings to see that there is no visible leakage. Hubs that are modified or machined by the customer are not covered under the SERVICING THE SYSTEM standard warranty terms.
Page 39: Pressure (Safety) Relief Valves
CAS40PL, CAS40PL-CW SECTION 5: MAINTENANCE RECIPROCATING AIR COMPRESSOR remove the drive assembly-side access side NOTE panel. If valves vent excessively more than once, Consult Figure 5-7. for the locations of the replace valve. fuses. IMT recommends using a fuse removal ®...
Page 40 CAS40PL, CAS40PL-CW SECTION 5: MAINTENANCE RECIPROCATING AIR COMPRESSOR BLANK PAGE 5 - 14 9990654_r02 (06/13/2023) IOWA MOLD TOOLING CO., INC. (641) 923-3711...
Page 41: Section 6: Troubleshooting
CAS40PL, CAS40PL-CW SECTION 6: TROUBLESHOOTING RECIPROCATING AIR COMPRESSOR SECTION 6: TROUBLESHOOTING GENERAL INFORMATION WARNING This troubleshooting guide has been compiled Before performing maintenance: from operational and test data. It lists Shut down machine, relieve all system pres- malfunctions, fault conditions, possible causes, sure and lock out all power, as per the Safety and suggested corrective actions for the most Section of this manual.
Page 42 CAS40PL, CAS40PL-CW SECTION 6: TROUBLESHOOTING RECIPROCATING AIR COMPRESSOR TROUBLESHOOTING GUIDE MALFUNCTION/FAULT POSSIBLE CAUSE CORRECTIVE ACTION Compressor will not start PTO/hydraulics not engaged Ensure hydraulics engaged. Compressor switch OFF Turn switch ON. Check and replace fuse if necessary (Section 5.5). 10A fuse blown Compressor pressure switch stuck Replace;...
Page 43: Troubleshooting Guide
CAS40PL, CAS40PL-CW SECTION 6: TROUBLESHOOTING RECIPROCATING AIR COMPRESSOR TROUBLESHOOTING GUIDE MALFUNCTION/FAULT POSSIBLE CAUSE CORRECTIVE ACTION Low air pressure Air filters soiled/plugged Replace air filter element (Section 5.4.4). Pressure switch setting too low May need to be replaced or reset; consult Service Depart- ment for reset instructions.
Page 44 CAS40PL, CAS40PL-CW SECTION 6: TROUBLESHOOTING RECIPROCATING AIR COMPRESSOR TROUBLESHOOTING GUIDE MALFUNCTION/FAULT POSSIBLE CAUSE CORRECTIVE ACTION Oil in discharge air (continued) Worn or scored cylinder Replace cylinder and rings. Knocking sound from compressor Crankcase oil level low Check; refill to correct level (Section 5.4.3). Worn main bearing Replace bearings and/or shaft.
Page 45: Section 7: Illustrated Parts List
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR SECTION 7: ILLUSTRATED PARTS LIST 7.1 PARTS ORDERING INFORMATION Part orders should be placed through the distributor from whom the unit was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the address or phone numbers below.
Page 46 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR TABLE 7A: RECOMMENDED SPARE PARTS LIST IMT PART KEY NO. DESCRIPTION NUMBER Kit, Compressor Service - Initial 50 Hours (Contains: 1 gallon reciprocating oil, IMT no. 71417223) 71417219 Kit, Compressor Service - 500 Hours (Contains: 1 gallon IMT reciprocating oil, IMT no. 71417223; 71417220 1 Air Filter Element, IMT no.
Page 47 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR IMPORTANT IMPORTANT The above table listing contains items that require maintenance on If additional spare parts are being stored for future use, a routine basis, and also those parts that may require maintenance ensure that they are stored in proper containers that over the course of the compressor package’s performance schedule.
Page 48: Compressor And Parts
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.2 COMPRESSOR AND PARTS LOW PRESSURE VRELIEF VALVE REUSE SOCKET HEAD BOLT 65 PSIG (2X) USE HIGH-TEMP THREAD SEALANT ON THESE PARTS RATED FOR +450°F OR GREATER HIGH PRESSURE RELIEF VALVE 217 PSIG (REPLACEMENT 200 PSIG)
Page 49 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.2 COMPRESSOR AND PARTS ITEM DESCRIPTION IMT PART NUMBER PLUG, MALE 37 JIC 08 TEE, 1/4” NPT MALE BRANCH ORIFICE, FILTER .032 DIA., 1/4 FPT X 1/4 MPT WASHER, LOCK 1/2 GRADE 8 COMPRESSOR, PARTS DD AL 70735274 HOSE, COMPRESSOR OIL DRAIN DD...
Page 50: Compressor Parts
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.3 COMPRESSOR PARTS PRESSURE RELIEF 65 PSIG PRESSURE RELIEF 217 PSIG ROTATION 277609_r3 7 - 6 99906549_r02 (06/13/2023) IOWA MOLD TOOLING CO., INC. (641) 923-3711...
Page 51 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.3 COMPRESSOR PARTS ITEM DESCRIPTION IMT PART NUMBER VALVE, RELIEF 200 PSI 1/4 NPT MALE (REPLACEMENT) 73540467 COMPRESSOR, TWO-STAGE PISTON 40CFM-175PSI 70047016 GASKET, AIR INLET 70535085 HOUSING, BELL HYD MOTOR TO COMPRESSOR 70580243 HUB, COUPLING COMPRESSOR DD 70580244...
Page 52: Display And Gauge Assembly
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.4 DISPLAY AND GAUGE ASSEMBLY ITEM DESCRIPTION IMT PART NUMBER APPROXIMATELY GAUGE, AIR PRESSURE w/ SWITCH 70048247 45° PANEL, GAUGE MECHANICAL TEE, PIPE GALV 1/4 x 1/4 x 1/8 CONNECTOR, 37FL/MPT #04 x 1/4 METER, PANEL HOUR AC/DC 77042124 DRAIN, CABLE-PULL 1/4”NPT...
Page 53 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.5A MOTOR AND DRIVE PARTS - OPEN CENTER 7.5B MOTOR AND DRIVE PARTS - CLOSED CENTER HUB AND SET SCREW HUB AND SET SCREW SUPPLIED WITH COMPRESSOR SUPPLIED WITH COMPRESSOR ASSEMBLY ASSEMBLY ASSEMBLY DRAWING STANDARD NOTES:...
Page 54 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.6 HYDRAULIC COOLER & PARTS - 12V WITH THRML / GAUGES (SHOWN) NOTES: 1. USE LOCTITE 567 THREAD SEALANT WITH PTFE OR EQUIVALENT SEALANT ON ALL MALE PIPE THREADS. 2. LUBRICATE ALL ELASTOMERIC SEALS/GASKETS/ O-RINGS BEFORE TIGHTENING.
Page 55: Hydraulic Cooler & Parts - With Thrml / Gauges
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.6 HYDRAULIC COOLER & PARTS - 12V WITH THRML / GAUGES ITEM DESCRIPTION IMT PART NUMBER CONNECTOR, #12 MSAE x #12 MJIC COOLER, OIL ASSY CAS40PL 71417119 KIT, ACOUSTICAL INSULATION CAS40PL 90490426 SCREW, SER WASH 5/16-18 x 0.75 CONNECTOR, (Varies for Thermal, or No Thermal Models)
Page 56: Frame Assembly
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.7 FRAME ASSEMBLY ASSEMBLY DRAWING STANDARD NOTES: 1. USE LOCTITE 567 THREAD SEALANT WITH TFE OR EQUIVALENT SEALANT ON ALL MALE PIPE THREADS. 2. ALL BOLTS TO BE TORQUED TO THEIR RESPECTIVE SAE TORQUE SPECIFICATIONS, FOR THEIR GRADES AND SIZES, UNLESS OTHERWISE SPECIFIED.
Page 57 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.7 FRAME ASSEMBLY ITEM DESCRIPTION IMT PART NUMBER SCREW, TRUSS #4-40 X 1/2 NUT, HEX LOCKING #4-40 UNC CAP, FEMALE JIC SHIPPING #12 1 1/16-12 BRACKET, AIR DISCHARGE / 6-PIN 71417365 ISOLATOR, HYD MINI 50 SH 66 LBS MAX 70661790...
Page 58: Frame And Canopy - 1 Of 3 (Assembly Part A)
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.8 FRAME AND CANOPY - 1 OF 3 (ASSEMBLY PART A) 6030180-001ID_r2_A 7 - 14 99906549_r02 (06/13/2023) IOWA MOLD TOOLING CO., INC. (641) 923-3711...
Page 59 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.8 FRAME AND CANOPY - 1 OF 3 (ASSEMBLY PART A) ITEM DESCRIPTION IMT PART NUMBER WASHER, NYLON FLAT 1/4 72063300 SCREW, TRUSS 1/4-20 X 3/4 SS 72063301 GAS SPRING, 6 STROKE, 10# 70661784 ID, CANOPY ASSY B (See page 7-14) ID, CANOPY ASSY C (See page 7-14)
Page 60: Frame And Canopy - 2 Of 3 (Assembly Parts B - C)
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.8 FRAME AND CANOPY - 2 OF 3 (ASSEMBLY PARTS B - C) INSTALL FOR MODELS USING MECHANICAL GAUGES ONLY DEFAULT INSTRUMENT PANEL LOCATION ITEM DESCRIPTION IMT PART NUMBER WASHER, NYLON FLAT 1/4 72063300 ITEM DESCRIPTION...
Page 61: Frame And Canopy - 3 Of 3 (Assembly Parts D - F)
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.8 FRAME AND CANOPY - 3 OF 3 (ASSEMBLY PARTS D - F) USE MEDIUM STRENGTH (BLUE) THREAD LOCKER 3-PLACES USE MEDIUM STRENGTH (BLUE) THREAD LOCKER ITEM DESCRIPTION IMT PART NUMBER INSLTN, HEAT SHIELD 90490426 ITEM...
Page 62 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.9 HYDRAULIC MANIFOLD ASSEMBLY - 12VDC OPEN CENTER (STANDARD & COLD WEATHER) PIN 1 RED TO YW ON HARNESS PIN 2 BLK TO BLK ON HARNESS NUTS INCLUDED WITH ALL BULKHEADS RETURN TO MOTOR...
Page 63 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.9 HYDRAULIC MANIFOLD ASSEMBLY - 12VDC OPEN CENTER (STANDARD & COLD WEATHER) ITEM DESCRIPTION IMT PART NUMBER CONNECTOR, O-RING 3/4 x 3/4 JIC CONNECTOR, #12 MSAE x #8 MJIC TERMINAL, DEUTSCH #0460-215-16141 PLUG, SAE O-RING #12 72535067 CONNECTOR, 2 PIN MALE DEUTSCH...
Page 64: Decal Identification/Locations - 1 Of 2
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.10 DECAL IDENTIFICATION/LOCATIONS - 1 OF 2 IMT PART ITEM DESCRIPTION NUMBER DECAL, READ MANUAL 70490443 DECAL, HOT PARTS 70490444 DECAL, ROTATING PARTS 70490445 DECAL, CONNECT AIR HOSE 70490446 DECAL, IMT SERVICE/REPAIR 70392962 DECAL, CAUTION AUTO START 70399431...
Page 65: Decal Identification/Locations - 2 Of 2
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.10 DECAL IDENTIFICATION/LOCATIONS - 2 OF 2 IMT PART NUMBER ITEM DESCRIPTION DECAL, LOGO, IMT CAS40PL 70490302 DECAL, AIR DISCHARGE 70490454 DECAL, 12VDC 70490455 DECAL, HYDRAULIC RETURN 70490456 DECAL, HYDRAULIC CASE DRAIN...
Page 66 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.11 HOSE AND TUBE ROUTING - OPEN CENTER 12V, NO THERMAL, WITH GAUGES HOSE AND TUBE ROUTING INSTRUCTIONS IMT PART ITEM DESCRIPTION QTY START END NUMBER HOSE, HYDRAULIC MOTOR IN DD HOSE, HYDRAULIC MANF TO MOTOR OUT DD HOSE, HYDRAULIC MOTOR TO COOLER HOSE, HYDRAULIC COOLER OUT...
Page 67 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.12 HOSE AND TUBE ROUTING - OPEN CENTER 12V, THERMAL & GAUGES IMT PART ITEM DESCRIPTION QTY START NUMBER C1 M1 HOSE, HYDRAULIC MOTOR IN DD HOSE, HYDRAULIC MANF TO MOTOR OUT DD HOSE, HYDRAULIC COOLER OUT HOSE, HYDRAULIC MOTOR CASE DRAIN DD HOSE, HYDR MOTOR TO THERM VLV 3/4 IN...
Page 68: Hydraulic Thermal Valve Assembly
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.13 HYDRAULIC THERMAL VALVE ASSEMBLY ASSEMBLY DRAWING STANDARD NOTES: 1. LUBRICATE ALL ELASTOMERIC SEALS/GASKETS/ O-RINGS BEFORE TIGHTENING. IMT PART ITEM DESCRIPTION NUMBER ELBOW, 90 DEG #12 MJIC x #16 MSAE VALVE, THERMAL BYPASS 1”...
Page 69: Wiring Diagram
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.14 WIRING DIAGRAM RELAY 12/24 VDC BATTERY SUPPLY N.O. MACHINE ACTIVATION 87A N.C. CIRCUIT 30 AMP JCASE STYLE FUSE (IMT NO. 71417227) SYSTEM GROUND AUXILIARY CIRCU IT 6 PIN CONNECTOR SYSTEM GROUND 10 AMP SAFETY...
Page 70 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.15 HYDRAULIC OIL FLOW SCHEMATIC DIAGRAM - OPEN CENTER, WITH THERMAL VALVE = AIR = DIRECTION = AIR / HYDRAULIC OIL = HYDRAULIC OIL COMPRESSOR SYSTEM HYDRAULICS THERMAL VALVE W / PRESSURE RELIEF TRUCK SYSTEM DETAIL A HYDRAULIC...
Page 71 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.16 HYDRAULIC OIL FLOW SCHEMATIC DIAGRAM - OPEN CENTER DETAIL A MACHINE HYDRAULICS TRUCK SYSTEM MACHINE PANEL HYDRAULIC OIL COOLER RETURN PRESSURE SOLENOID VALVE RELIEF VALVE CASE DRAIN = AIR = DIRECTION = AIR / HYDRAULIC OIL ROTATION...
Page 72: Hose Installation Guide
CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR 7.17 HOSE INSTALLATION GUIDE HOSE LAYOUT HOSE LAYOUT WRONG RIGHT WRONG RIGHT CONSIDERATION CONSIDERATION 1. Hose is weakened when 4. Use elbows or other installed in twisted position. adapters as necessary Pressure in twisted hose tends to eliminate excess hose to loosen fitting connections.
Page 73 CAS40PL, CAS40PL-CW SECTION 7: ILLUSTRATED PARTS LIST RECIPROCATING AIR COMPRESSOR TABLE 7B: MAINTENANCE TRACKING LOG DATE DESCRIPTION OF MAINTENANCE PART(S) REPLACED 7 - 29 IOWA MOLD TOOLING CO., INC. 99906549_r02 (06/13/2023) (641) 923-3711...

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