40 CFM/100 PSIG STANDARD RECIPROCATING …

1 An Oshkosh Corporation Company40 CFM/100 PSIG STANDARDRECIPROCATING COMPRESSORINSTALLATION, OPERATION, MAINTENANCE AND PARTS MANUALP/N 99905382 Revision 02 Effective Date: 6/2018 2014 Iowa Mold Tooling, Co., Inc. All rights 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 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 only IMT Premium RECIPROCATING Oil and Genuine IMT Parts.

2 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., Highway 18 West Garner, Iowa 50438 Phone: Fax: THE MANUALWITH THE VEHICLENOTICE TO CUSTOMERThis manual is the final version and some of the information and specifications are subject to changewithout 40 CFM / 100 PSIGTABLE OF CONTENTSM anual #99905382 Rev 02 (JUNE 2018)PAGE - ITABLE OF CONTENTS An Oshkosh Corporation CompanyTABLE OF 1: INFORMATION .. , CAUTIONS AND NOTES.

3 OF DANGER, WARNINGS, CAUTIONS AND NOTES .. SAFETY 3 SECTION 2: DESCRIPTION .. DESCRIPTIONS .. compressor COOLING ELECTRICAL AIR CONTROL HYDRAULIC CONTROL PRESSURE RELIEF 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 .. PACKAGE RECEIPT/INSPECTION .. INSTRUCTIONS .. THE CAS40P UNIT MOUNTING LOCATION .. 13 Continued on next OF CONTENTSCAS40P 40 CFM / 100 PSIGPAGE - II An Oshkosh Corporation CompanySECTION 4: installation (CONTINUED)FIGURE 4-2: CAS40P DIMENSIONS.

4 THE ELECTRICAL SUPPLY .. SYSTEM REQUIREMENTS .. THE HYDRAULIC SUPPLY AND RETURN .. THE AIR AIR RESERVOIR TANK 4-4 ELECTRICAL SYSTEM ..19 FIGURE 4-5 FLOW SCHEMATIC 5: OPERATION .. INFORMATION .. CONDITIONS .. TIME START-UP .. (FIRST-TIME AND ROUTINE).. START-UP .. CONDITION OPERATION .. 23 SECTION 6: MAINTENANCE .. GENERAL INFORMATION .. MACHINE MAINTENANCE 25 TABLE 6A: ROUTINE MAINTENANCE SCHEDULE .. PARTS .. REPLACEMENT AND ADJUSTMENT PROCEDURES .. REMOVING PANELS FOR MACHINE MAINTENANCE OPENING AND CLOSING THE ROOF PANEL.

5 29 TABLE 6B: ACCESS PANEL REMOVAL .. REMOVING AND REPLACING A SIDE CHECKING PRESSURE GAUGE .. compressor SYSTEM LUBRICATION .. CHECKING THE OIL CHANGING THE compressor AIR FILTER INSPECTING THE AIR FILTER(S).. REPLACING THE AIR FILTER(S) .. CHECKING THE COOLER CORE .. compressor VALVE on next #99905382 Rev 02 (JUNE 2018)CAS40P 40 CFM / 100 PSIGTABLE OF CONTENTSPAGE - III An Oshkosh Corporation CompanySECTION 6: MAINTENANCE (CONTINUED) installation .. LUBRICATION .. CENTRIFUGAL UNLOADER PISTON RING RE-ADJUSTING OR REPLACING THE compressor DRIVE BELTS.

6 DRIVE SHEAVE (PULLEY) TESTING PULLEY ALIGNMENT .. ADJUSTING THE MOTOR PULLEY FOR ALIGNMENT .. GASKET REPLACEMENT PRESSURE SWITCH DISASSEMBLING THE compressor .. FITTING AND REASSEMBLING .. 54 TABLE 6C: compressor TORQUE VALUES .. CHECKING HOSES AND SERVICING THE SYSTEM FUSE AND CIRCUIT REPLACING THE INTERCOOLER FINNED PRESSURE (SAFETY) RELIEF TERM STORAGE .. 57 SECTION 7: TROUBLESHOOTING .. INFORMATION .. GUIDE .. 59 SECTION 8: ILLUSTRATED PARTS LIST .. ORDERING PROCEDURE .. 65 TABLE 8A: RECOMMENDED SPARE PARTS 66 TABLE 8B: MAINTENANCE TRACKING LOG.

7 UNIT ASSEMBLY .. ASSEMBLY .. AND DRIVE PARTS .. AND AND PARTS (PART 1 OF 4) .. AND PARTS (PART 2 OF 4) .. AND PARTS (PART 3 OF 4) .. AND PARTS (PART 4 OF 4) .. 84 Continued on next #99905382 Rev 02 (JUNE 2018)TABLE OF CONTENTSCAS40P 40 CFM / 100 PSIGPAGE - IV An Oshkosh Corporation CompanySECTION 8: ILLUSTRATED PARTS LIST (CONTINUED) COOLING SYSTEM (12V) .. COOLING SYSTEM (24V) .. MANIFOLD FOR CONTROL MANIFOLD FOR DECAL LOCATIONS (PART 1 OF 2 / DECAL SHEET #95724529).. DECAL LOCATIONS (PART 2 OF 2 / DECAL SHEET #95724529).

8 compressor OVERHAUL KIT #73744209 - PIECE PARTS .. compressor GASKET REPLACEMENT KIT #73744208 - PIECE PARTS .. HYDRAULIC HOSE SYSTEM .. 108 APPENDIX PANEL ASSEMBLY .. 111 manual #99905382 Rev 02 (JUNE 2018)CAS40P 40 CFM / 100 PSIGSECTION 1: SAFETYPAGE - 1 An Oshkosh Corporation GENERAL INFORMATIONThe products provided by IMT are designed andmanufactured for safe operation and maintenance. But itis ultimately the responsibility of the users andmaintainers for safe use of this equipment. Part of thisresponsibility is to read and be familiar with the contentsof this manual before operation or performingmaintenance DANGERS, WARNINGS, CAUTIONS, AND NOTESSee information boxes at right SUMMARY OF DANGERS, WARNINGS, CAUTIONS, AND NOTEST hese boxed inserts are placed throughout this manualin the sections where they apply.

9 This subsection is ageneral summary of their DANGERS Keep tools or other conductive objects away from liveelectrical Component GroupManual SectionGENERAL , WARNINGS, CAUTIONS AND OF DANGERS, WARNINGS, CAUTIONS AND 1:SAFETYWARNINGI dentifies actions or conditions which can cause death, severe injury, or equipment damage or destructive actions or conditions which will or can cause injuries, equipment damage or information (or existing information) which should be brought to the attention of operators/maintainers affecting safety, operation, maintenance, or warranty actions or conditions which will cause death, severe injury, or equipment damage or destructive this manual before operating or servicing the CAS40P Air compressor System.

10 Failure to do so could result in damaged equipment, bodily injury, or #99905382 Rev 02 (JUNE 2018)SECTION 1: SAFETYCAS40P 40 CFM / 100 PSIGPAGE - 2 An Oshkosh Corporation Company Never touch electrical wires or components while themachine is operating. They can be sources of WARNINGS DO NOT EVER USE THIS compressor AS ABREATHING AIR SOURCE. IMT DISCLAIMS ANYAND ALL LIABILITIES FOR DAMAGE OR LOSSDUE TO FATALITIES, PERSONAL INJURIESRESULTING FROM THE USE OF AN IMTCOMPRESSOR TO SUPPLY BREATHING AIR. DO NOT perform any modifications to this equipmentwithout prior factory approval.