Manual Part # 99900838

CAS440HT Air Compressor

Revised 20090409

IOWA MOLD TOOLING CO., INC.

PO Box 189
Garner, IA 50438
Tel: 641-923-3711 FAX: 641-923-2424
Website: http://www.imt.com

Copyright © 2009 Iowa Mold Tooling Co., Inc.

All rights reserved

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise without the
prior written permission of Iowa Mold Tooling Co., Inc.

Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation company.

Printed on 9 April, 2009

 i

Contents
Revisions ..................................................................................................................................................... ii

Compressor Introduction 3
Compressor Precautions ...............................................................................................................................5
Compressor Safety........................................................................................................................................6
Compressor Information Record...................................................................................................................7
CAS440HT Recommended Spare Parts .......................................................................................................8

CAS440HT Compressor Specifications 9

Installation 11
PTO & Pump Installation ...........................................................................................................................11
PTO Installation..........................................................................................................................................11
Driveline and Pump Installation .................................................................................................................13
Topdeck Compressor Installation ...............................................................................................................15
Oil Cooler (optional)...................................................................................................................................17

Operation 19
CAS440HU/HT Operation .........................................................................................................................19
CAS440HU/HT Shutdown .........................................................................................................................20

Maintenance & Repair 21

CAS440HU & CAS440HT Maintenance Schedule....................................................................................22
Compressor Hydraulic Oil ..........................................................................................................................23
Hydraulic Fluid Deterioration.....................................................................................................................23
Compressor Hydraulic Oil Change.............................................................................................................24
Compressor Filter Element Replacement ...................................................................................................25
Drive Belt ...................................................................................................................................................25
Compressor Hydraulic System Precautions................................................................................................26
Troubleshooting Guide ...............................................................................................................................27

Parts 29
CAS440HT Compressor Parts (23000080).................................................................................................29
Thread Torque Charts .................................................................................................................................32
ii Contents

Revisions
DATE LOCATION DESCRIPTION
20070817 MAINTENAN CHANGED MAINTENANCE SCHEDULE COMPRESSOR OIL
CE CHANGE DURATION; ECN 10523 – CHANGED #28 72066516
SCHEDULE, TO 72661642
2300080
20071127 MAINT. ECN 10612 - CHANGED NOTE IN MAINTENANCE SCHEDULE TO 6
SCHEDULE MONTHS
20090409 23000080 ADDED CALLOUT FOR ITEM #9 - MOTOR; ADDED
SPECIFICATIONS SECTION
 3

SECTION 1

Compressor Introduction
This volume provides information on the installation, operation, and repair of IMT hydraulic air
compressors. In addition to reading the manual, it is your responsibility to become familiar with
government regulations, hazards, and the specific operation of your equipment. Use caution
and common sense while operating and maintaining the equipment and follow all safety
procedures and regulations. Treat this equipment with respect and service it regularly.

MODIFICATIONS

Modifications to your equipment must be performed with IMT approved accessories, parts and
optional equipment. If in doubt, contact IMT prior to making any modifications. DO NOT alter or
modify any safety device! All safety devices must be inspected, tested and maintained in proper
working condition.

Decals regarding safety and operation are considered safety equipment, and must be kept clean
and legible.

The equipment owner and/or designated employee is responsible for informing all operators,
maintenance personnel, and others involved in equipment operation about the safe operation
and maintenance of the equipment. If questions arise concerning safe operation, contact IMT or
your IMT distributor for clarification.

WARRANTY

Warranty of this unit will be void on any part of the unit subjected to misuse due to overloading,
abuse, lack of maintenance and unauthorized modifications. No warranty - verbal, written or
implied - other than the official, published IMT new machinery and equipment warranty will be
valid with this unit.

NOTICE TO THE OWNER / USER

If your equipment is involved in a property damage accident, contact your IMT distributor
immediately and provide them with the details of the accident and the serial number of the
equipment. If an accident involves personal injury, immediately notify your distributor and IMT
Technical Support at:
IOWA MOLD TOOLING CO., INC.
500 HWY 18 WEST
GARNER, IA 50438
641 - 923 - 3711
4 CAS440HT Air Compressor Manual Part # 99900838

WARNING

READ YOUR MANUAL!! FAILURE TO READ, UNDERSTAND AND FOLLOW ANY SAFETY
PROCEDURES APPLICABLE TO YOUR EQUIPMENT MAY RESULT IN EQUIPMENT
DAMAGE, SERIOUS INJURY, OR DEATH.

MANUAL STRUCTURE
Throughout this manual, three means are used to draw the attention of personnel. They are
NOTEs, CAUTIONs and WARNINGs and are defined as follows:

NOTE

A NOTE is used to either convey additional information or to provide further emphasis for a
previous point.

CAUTION

A CAUTION is used when there is the very strong possibility of damage to the equipment or
premature equipment failure.

WARNING

A WARNING is used when there is the potential for personal injury or death.
 Section 1 Compressor Introduction 5

Compressor Precautions

Failure to follow operating and maintenance Do not use air from this compressor for
procedures as outlined in this manual could result breathing or food processing. Air from this
in equipment damage, personal injury or death. compressor will cause severe injury or death if
Follow all maintenance procedures and intervals. used for breathing or food processing.

Maintenance must be performed only by trained Hot oil under pressure can cause severe injury
and qualified personnel, using correct tools, or death. Shut down, let cool and relieve
specified torques and approved replacement pressure in compressor before servicing.
parts.

All electrical components and cable wiring must Do not overfill the compressor with oil. Use
be installed and grounded in accordance with correct quantity of manufacturer's lubricant.
NFPA, national electrical codes and applicable Repair leaks and clean spills immediately.
state and local codes.

Before removing guards or servicing the Compressors generate high temperatures. Do

compressor, disconnect all power supplies. not touch or otherwise come in contact with hot
Display warning signs and lock out electrical surfaces. Doing so can cause severe personal
circuits. injury.

All guards must be in position and secure before

and during operation.
6 CAS440HT Air Compressor Manual Part # 99900838

Compressor Safety
WARNING

AVOID PERSONAL INJURY OR PROPERTY DAMAGE! READ YOUR MANUAL! All units
are shipped with a detailed operators and parts manual which contains vital information for the
safe use and efficient operation of this unit.

AIR COMPRESSOR SAFETY PRECAUTIONS

Safety is basically common sense. While there are standard safety rules, each situation has its
own peculiarities that cannot always be covered by rules, and with your experience and common
sense, you are in a position to ensure your safety. Lack of attention to safety can result in death,
serious injury, accidents, and efficiency reductions. Watch for safety hazards and correct them
promptly. Use the following safety precautions as a general guide to safe operation:
ƒ Do not attempt to remove any compressor parts without first relieving the entire system of
pressure.
ƒ Do not attempt to service any part while the machine is operating.
WARNING

AVOID PERSONAL INJURY OR PROPERTY DAMAGE! Check the compressor sump oil
level only when the compressor is not operating and the system is completely relieved of
pressure. Open the service valve to ensure relief of system air pressure when performing
maintenance on compressor air/oil system.

ƒ Do not operate the compressor at pressure or speed in excess of its rating as indicated in
Compressor Specifications.
ƒ Periodically check all safety devices for proper operation.
ƒ Do not play with compressed air. Pressurized air can cause serious injury to personnel.
ƒ Exercise cleanliness during maintenance and when making repairs. Keep dirt away from
parts by covering parts and exposed openings.
ƒ Do not install a shut-off valve between the compressor and compressor oil sump.
DANGER

AVOID DEATH OR SERIOUS INJURY!

Do not use IMT compressor systems to provide breathing air. Such usage, whether supplied
immediately from the compressor source, or supplied to breathing tanks for subsequent use,
can cause serious bodily injury.
 Section 1 Compressor Introduction 7

IMT disclaims any and all liabilities for damage for loss due to personal injuries, including
death, and/or property damage including consequential damages arising out of any IMT
compressors used to supply breathing air.

ƒ Do not disconnect or bypass safety circuit system.

ƒ Do not install safety devices other than authorized IMT replacement devices.
ƒ Close all openings and replace all covers and guards before operating compressor unit.
ƒ Do not leave tools, rags, or loose parts on the compressor or drive parts.
ƒ Do not use flammable solvents for cleaning parts.
ƒ Keep combustibles out of and away from the compressor and any associated enclosures.
The owner, lessor, or operator of the compressor are hereby notified and forewarned that any
failure to observe these safety precautions may result in damage or injury.

IMT expressly disclaims responsibility or liability for any injury or damage caused by failure to
observe these specified precautions or by failure to exercise that ordinary caution and due care
required when operating or handling the compressor, even though not expressly specified
above.

Compressor Information Record

TO BE COMPLETED BY DEALER
CHASSIS INFORMATION
TRANSMISSION MAKE: MODEL:
PTO NUMBER: PTO %:
COMPRESSOR AND HYDRAULIC PUMP INFORMATION
COMPRESSOR MODEL: SERIAL NUMBER:
PUMP MAKE: MODEL:
RESERVOIR CAPACITY: ENGINE RPM:
8 CAS440HT Air Compressor Manual Part # 99900838

CAS440HT Recommended Spare Parts

Recommended Spare Parts for one-year for CAS440HT Top-deck Compressor:

NOTE: This spare parts list does not necessarily indicate that the items can be expected to fail in
the course of a year. It is intended to provide the user with a stock of parts sufficient to keep the
unit operating with the minimal down-time waiting for parts. There may be parts failures not
covered by this list. Parts not listed are considered as not being Critical or Normal Wear items
during the first year of operations and you need to contact the distributor or manufacturer for
availability.
PART NO. DESCRIPTION QTY CODE
COMPRESSOR ASSEMBLY COMPONENTS (23000080)
70058486 BELT 1 P
73051614 HYDRAULIC MOTOR 1 W
73054998 RELIEF VALVE 1 W
70048069 MOISTURE REGULATOR 1 P
73052092 RETURN FILTER 1 P
COMPRESSOR (70073051)
70073727 LP INTAKE VALVE 1 W
70073726 LP EXHAUST VALVE 1 W
70732447 HP INTAKE VALVE 1 W
73054340 HP EXHAUST VALVE 1 W
70073766 RING SET 1 W
70143298 RELEASE VALVE KIT 1 W
70732429 INTERCOOLER TUBE LH 1 W
70732430 INTERCOOLER TUBE RH 1 W
70732448 KIT - VALVE SET 1 P
76391490 SHAFT SEAL 1 W
73054339 POP-OFF, 70 psi 1 W
73054031 PILOT VALVE 1 C
 9

SECTION 2

CAS440HT Compressor Specifications

CAS440HT
DELIVERY AT 175 PSI 46 cfm (1300 lpm)
FLUID CAPACITY 32 gal (121 l)
FILTER - HYDRAULIC SUCTION100 mesh
FILTER - HYDRAULIC RETURN 10 microns
PRESSURE SWITCH 175 psi off / 150 psi on (12 psi off/ 10
psi on)
COMPRESSOR PULLEY RPM 980 rpm (900 - 1000)
NORMAL OPERATING PRESSURE 1850 psi (130 bar)
MAXIMUM PRESSURE 2400 psi (165 bar)
GPM 16 gpm (60 lpm)
MOTOR PULLEY DIAMETER 10.75" (27 cm)
COMPRESSOR PULLEY 18.88" (48 cm)
DIAMETER
 11

SECTION 3

Installation

PTO & Pump Installation

In some cases the customer or his agent may have to install a compressor, PTO, and pump.
These instructions will provide general information to assist with installation. The pump may be
installed either directly on the PTO or may be driven by a driveline.

PTO Installation
A power take-off (PTO) must be properly matched to the vehicle’s transmission as well as the
requirements of the crane. In order to properly select a PTO the following information is needed:
1 Make and model of transmission in the carrier vehicle.
2 Power requirements of the crane being driven.
3 Necessary PTO speed.
4 Direction in which the PTO must turn.
5 PTO torque required.
If possible, use a hydraulic pump directly mounted to the PTO. This will eliminate an auxiliary
driveshaft and it is easier to install as it eliminates driveline angle and phasing errors. It is also
quieter and should require less maintenance since driveline lubrication will not be necessary.

PTO manufacturers provide specific installation instructions with their products. Their
instructions should be followed when installing the PTO. The following steps are provided as an
introduction to the installation.

NOTE

IT MAY BE NECESSARY TO REMOVE AND MODIFY EXHAUST COMPONENTS TO

PROVIDE SPACE FOR PTO CLEARANCE.

1 Chock the wheels of the vehicle.

2 Secure any part attached to or on the vehicle which could move or pose a hazard.
12 CAS440HT Air Compressor Manual Part # 99900838

3 Run the engine and transmission in a well ventilated area. Listen for noises which indicate
any engine/transmission problems. The engine and transmission should be in good operating
condition before the installation of the PTO.
4 Become familiar with the PTO manufacturer’s installation instructions, warnings, and
precautions.
5 After the engine and transmission have cooled, drain the transmission fluid. Check the fluid
for signs of damage such as metal chips, etc.
6 With the vehicle engine “Off”, visually inspect the transmission for gear damage or foreign
particles lodged between gear teeth.
7 Remove the PTO from its shipping container. Inspect for foreign objects which may have
lodged in the PTO cavity.
8 Mount the PTO per manufacturer’s instructions.
9 Check backlash per manufacturer’s instructions.
10 Refill the transmission with manufacturer’s recommended lubricant to the proper level.
11 Install the shifter cable to suit conditions. Always allow a slight overshift on lever or knob to
make certain PTO is fully engaged.
CAUTION
AVOID SHARP BENDS IN THE SHIFTER CABLE. ALL BENDS SHOULD HAVE A
MINIMUM 6" RADIUS. TIGHTER BENDS CAUSE DIFFICULT OPERATION OF THE
SHIFTER CABLE.
12 Make sure the vehicle has all safety and operation decals.
13 Start the engine, engage the PTO and allow to run for 5 to 10 minutes. Check for leaks,
unusual noise and proper operation.
14 Check PTO mounting bolts for proper torque as specified by manufacturer.
 Installation 13

Driveline and Pump Installation

The pump may be driven using a driveline rather than directly mounting to the PTO. The
following steps are a guide in this application.

NOTE

Before installing driveline, refer to instructions for proper driveline installation techniques.

1 Install the PTO (see instructions).

2 Loosely bolt the pump mounting bracket to the adjustable bracket.
3 Bolt the adjustable bracket to the frame at a point that will not exceed 48" (122cm) from the
PTO and will not cause a joint angle greater than 8°.
4 Check the pump rotation. Install pump, pump end yoke and PTO end yoke.
5 Size, cut and weld the driveline to the necessary length. Ensure driveline balance and run
out meet specification. Allow 1" (2.54 cm) extra for PTO end yoke.
6 Install driveline in phase with proper operating angle calculations. Lock set screws. Grease
U-joints and mating spline.
7 Ensure all mounting bolts are tight.
14 CAS440HT Air Compressor Manual Part # 99900838

DANGER

CONTACT WITH A ROTATING DRIVELINE

WILL CAUSE
DEATH OR SERIOUS INJURY
KEEP AWAY
Keep clear of rotating drive shaft.
Never work on or near an installed
power take-off or driveline with the
engine running.
70392891

WARNING

AVOID DEATH OR SERIOUS INJURY! The driveline installer must inspect the final position
of the driveline to determine whether an operator or other personnel are protected from
rotating driveline hazards. If the protection is insufficient, a guard MUST be installed. Contact
IMT for information on installing a guard.
 Installation 15

Topdeck Compressor Installation

The topdeck compressor is mounted on an oil reservoir which is bolted to the deck of the carrier
vehicle. Due to variations, use these instructions only as a guide.
1 Locate compressor position on the deck. Layout mounting hole pattern per figure. Drill six
1/2" holes for mounting. Locate the positions of reservoir ports per figure.
20" 20" DRILL 1/2" DIA.
HOLE (6 PLCS)

21.12"

DRAIN SUCTION
(DRILL 2" DIA. HOLE) (DRILL 3-1/4" DIA. HOLE)

2.06"

3" 3"
2 Using 3/8" bolts, flat washers, lock washers and nuts, secure the compressor and tank to the
deck of the truck.
3 Locate a position on the deck for a hole for the hose which runs from the pump to the control
valve. Position the hole to provide the least interference with truck frame members, exhaust
and driveshaft, and as near the compressor oil reservoir as possible. Drill a 1-3/4" hole at this
location. Place a 1-3/4" diameter grommet into the hole to help prevent hose wear.
4 Route the hose through the hole and connect it to the pump and control valve using the
fittings provided.
5 Drill a 2-1/4" hole in the bed of the truck for the hose from the cooler to the inlet side of the
return filter. Install 2-3/4" diameter grommet into hole. Position the hole to provide the least
interference with truck frame members, exhaust and driveshaft; and as near the compressor
reservoir as possible. Install hose from cooler to return filter.
6 Drill two 5/8" diameter holes through the deck for the hoses from the air driven throttle
control. Install the speed control on the engine. Route the hoses through these holes and
connect them as shown in the Parts Section.
7 Install the barbed nipples, hose and hose clamps from the suction port of the reservoir to the
suction filter.
8 Drill a 1" hole for the receiver drain as near the drain as possible and route a 1/2" diameter
hose through the hole. Connect one end to the receiver drain. This will prevent drainage of
the receiver onto the deck of the truck.
16 CAS440HT Air Compressor Manual Part # 99900838

9 Connect the wiring to the compressor where applicable.

10 Fill the oil tank and open suction gate valve. Disconnect pressure hose at hydraulic pump.
Engage the PTO and turn the engine with starter until oil comes out the pressure side of the
pump. Connect pressure hose. Pull out the compressor switch and open the gate valve to
the tank. Disengage the PTO and start the truck engine. Depress the clutch and engage the
PTO. Release the clutch slowly. It may be necessary to allow the truck to idle until warmed
up enough to pull at idle RPM. Push the compressor switch in. This will close the control
valve and start the compressor. Allow the compressor to warm up (See Operation Section).
Close the gate valve on the air tank. This will activate the speed control to the proper RPM.
Check the system for leaks and proper operation.
11 Install compressor kill switch. See figure.
COIL (GAS)
OR
IGNITION FUEL SOL. (DIESEL)
SWITCH

NORMALLY
CLOSED
DOOR
- + SWITCH

BATTERY
 Installation 17

Oil Cooler (optional)

Oil coolers vary in their installation dependent on available space and other considerations.
Install the oil cooler in front of the carrier vehicle's radiator, or, as an alternative, in a protective
structure which is cooled by an electric fan. See figure for general location within the hydraulic
system.
PULLEY

MOTOR
COMPRESSOR

OIL
COOLER

RETURN CONTROL
RESERVOIR FILTER VALVE
RELIEF
VALVE
PUMP
GATE
VALVE SUCTION
FILTER
 19

SECTION 4

Operation

CAS440HU/HT Operation
The compressor has an operating time limit of approximately three hours depending upon
ambient air temperature (outside air temperature), weather conditions and whether an oil cooler
has been installed. Oil coolers will extend the three hour limit.

CAUTION

THE HYDRAULIC OIL TEMPERATURE MUST NOT BE ALLOWED TO EXCEED 190°F

(88°C). IF THE OIL TEMPERATURE REACHES THIS LIMIT, THE SYSTEM MUST BE
SHUT DOWN AND ALLOWED TO COOL. OIL COOLERS WILL EXTEND THE THREE-
HOUR LIMIT.

To start the compressor:

1 Ensure the PTO is disengaged, control valve is open (pull the compressor switch out) and
the receiver drain cock is open.
2 Start the truck engine and allow it to idle until it reaches the proper operating temperature
(refer to the vehicle owner’s manual).
3 Depress the clutch, engage the PTO and carefully release the clutch pedal. Allow the
system to warm up for the time period as shown in chart.
COMPRESSOR WARM-UP TIME
AMBIENT AIR TEMPERATURE IDLING TIME (WARM-UP)
(°°F)
+40° OR ABOVE NONE
+20° TO +40° 2 - 5 MINUTES
0° TO +20° 5 - 10 MINUTES
-20° TO 0° 10 - 15 MINUTES
-40° TO -20° 15 - 20 MINUTES
BELOW -40° 20 MINUTES MINIMUM
4 When starting the compressor, the RPMs will automatically increase due to low volume of air
in the system.
20 CAS440HT Air Compressor Manual Part # 99900838

CAUTION

1000 RPM MAXIMUM! Operating this unit in excess of 1000 RPM, measured at the
compressor flywheel, will void your warranty. Engine RPM may be different.

5 The flow required to the compressor is 16 GPM.

CAS440HU/HT Shutdown
Shut down the compressor system as follows:
1 Allow the compressor to build to maximum pressure and the truck engine will automatically
idle down.
2 Place the compressor control valve in the open (off) position.
3 Depress the clutch pedal and disengage the PTO.
4 Open the receiver drain cock and discharge the air in the receiver.
WARNING

Federal law prohibits driving the carrier vehicle on public roads with the receiver filled with
compressed air. Always drain the receiver before moving the vehicle.
 21

SECTION 5

Maintenance & Repair

This section contains instructions for performing the inspection, lubrication, and maintenance
procedures required to maintain the compressor in proper operating condition. The importance
of performing the maintenance described herein cannot be over emphasized.

The periodic maintenance procedures to be performed on the equipment covered by this manual
are listed below. It should be understood that the intervals between inspections specified are
maximum interval. More frequent inspections should be made if the unit is operating in a dusty
environment, in high ambient temperature, or in other unusual conditions. A planned program of
periodic inspection and maintenance will help avoided premature failure and costly repairs.
Daily visual inspections should become a routine.

The LUBRICATION AND MAINTENANCE CHART lists serviceable items on this compressor
package. The items are listed according to their frequency of maintenance, followed by those
items which need only “As Required” maintenance.

The maintenance time intervals are expressed in hours. The hourmeter shows the total number
of hours your compressor has run. Use the hourmeter readings for determining your
maintenance schedules. Perform the maintenance at multiple intervals of the hours shown. For
example, when the hourmeter shows “100” on the dial, all items listed under “EVERY 10
HOURS” should be serviced for the tenth time, and all items under “EVERY 50 HOURS” should
be serviced for the second time, and so on.

DANGER

Compressor must be shut down and completely relieved of pressure prior to checking fluid
levels. Open drain valve on air tank, and compressor service valve, to ensure relief of system
air pressure. Failure to comply with this warning may cause damage to property and serious
bodily harm.
22 CAS440HT Air Compressor Manual Part # 99900838

CAS440HU & CAS440HT Maintenance

Schedule
ITEM MAINTENANCE DESCRIPTION SERVICE INTERVAL (Hours/Months)
DAILY WEEKLY EVERY 500/3 1000/6 1500/9 2000/12
200
HOURS
COMPRESSOR Air intake - inspect and clean.
Compressor oil level - check, add if
needed.
Compressor oil - change.
Safety valves - operate.
Safety valves - clean.
Valves - inspect and clean.
Inter cooler - clean exterior.
Low oil level switch - check.

V-BELT DRIVE Belt tension - check.

RECEIVER Drain condensation - manual.

Safety valves - operate.

HYDRAULIC Oil reservoir level - check.

DRIVE SYSTEM Filter - check and change.
Leaks - check, repair.
Safety door switch - check.
PTO cable - check.
Speed control & reset - check.
Hydraulic oil - change.

GENERAL Lubrication - check.

Bolts - check, tighten if needed.
Electrical connections - check.
Service intervals are listed as hours/months, whichever occurs first.

Under normal operating conditions, oil changes are required every 6 months. When operating in a dirty environment, change the oil
and air filter more frequently as your particular operating conditions dictate.
Rev. 20071127
 Maintenance & Repair 23

Compressor Hydraulic Oil

The hydraulic oil is the power transmission medium, system lubricant, and coolant. Under
normal operating conditions, the hydraulic oil must meet the following viscosity and grade
specifications:

AMBIENT TEMPERATURE RANGE 0 - 90º BELOW 32 - 90º ABOVE 90º

32º
Minimum Pour Point, ºF -30º -25º +10º +10º
Maximum Viscosity, SSU @ 0º F 4000 4000 --- ---
Minimum Viscosity, SSU @ 100º 140-190 100-130 150-200 200-315
F
Minimum Viscosity, SSU @ 210º 40 41 43 47
F
Minimum Viscosity Index 139 90 90 90

Additives including anti-foam inhibitors, antioxidant inhibitors, rust resistance, and anti-wear
must be part of the oil.

Arctic conditions present special requirements which are not in the scope of the table and must
be analyzed individually. Consult your oil supplier for proper hydraulic fluids for working under
these severe conditions. Electric reservoir heaters are available to improve conditions at
extremely low temperatures.

Hydraulic Fluid Deterioration

Contamination of the hydraulic fluid by solvents, water, dust or other abrasives will cause
deterioration of the fluid. Sustained presence of the impurities will result in premature
breakdown of antifoam, lubrication, anti-rust and viscosity properties. Introduction of water to
the system and operation at high temperatures (above 180°F) will result in an increase in the oil
oxidation rate. Oxidation produces varnish forming materials and sludge in the oil.

Operating the system on a sustained basis with contaminated or broken down oil will increase
wear and can significantly shorten the efficient service life of the unit.

Periodically, draw off a sample of the oil and check the oil for breakdown. To check oil quality:
1 Place the oil in a clean glass.
2 Smell the oil to detect a burnt or rancid odor.
3 Visually examine the oil for a dark or cloudy appearance.
24 CAS440HT Air Compressor Manual Part # 99900838

4 Allow the sample to stand for several minutes. Inspect the sample for water which will settle
to the bottom of the glass if present. Water can result from a system leak or condensation
due to temperature extremes.
In case of any of these conditions, the system should be purged and filled with new oil. In
addition, the oil should be changed in the reservoir and complete system:
1 After every 800 hours of operation or every six months, whichever occurs first.
2 After pump or other major hydraulic component failure, drain the hoses.

Compressor Hydraulic Oil Change

Check the oil in the hydraulic reservoir quarterly, and replace the oil on an annual basis.

Purging the system requires a new oil supply sufficient to completely fill the reservoir, lines,
cylinders, etc., and an extra quantity for loss during this procedure. To minimize oil loss during
this process, operate the truck engine at low RPM.

Two operators are required during the purging operation: one to operate the compressor and the
other to regulate pump flow (engine speed).

CAUTION

DO NOT ALLOW THE RESERVOIR OIL LEVEL TO DROP BELOW 1/3 CAPACITY DURING
THIS OPERATION.

1 Drain the hydraulic oil reservoir. Disconnect the suction hose to the pump, drain and
reassemble. Change the suction filter cartridge.
NOTE
DISPOSE OF WASTE OIL IN A RESPONSIBLE MANNER, FOLLOWING ANY FEDERAL,
STATE, OR LOCAL REGULATIONS.
2 Remove the reservoir return line. Direct flow into a sump or waste container. Plug the drain
port on the reservoir and fill with new oil.
NOTE
READ AND FOLLOW THE FOLLOWING INSTRUCTIONS WITHOUT INTERRUPTION OR
STOP THE ENGINE AT THE END OF EACH STEP. IF THIS IS NOT DONE, EXCESS OIL
WASTE WILL BE DISCHARGED.
3 Start the truck engine and engage the PTO. Slowly release the clutch. Activate the control
valve so that the fluid passes through the motor. Allow fluid to discharge for about 15
seconds. Kill the engine.
4 Reconnect the return line to the reservoir port. Change the return line filter. All components
of the system are now purged.
 Maintenance & Repair 25

5 Check hydraulic oil level. Top off if necessary.

Compressor Filter Element Replacement

To avoid residue accumulation in the reservoir and to protect the hydraulic components (valves,
pumps,motors, etc.), the filters must be serviced on a regular basis.

They must be changed after the initial 50-hours of new unit operation and every 200-hours
thereafter.To change filter elements:
1 Shut the gate valve and remove the filter element.
2 Install the new filter ensuring proper rubber seal seating and tighten as much as possible
using both hands.
3 Open the gate valve and check for leaks.
CAUTION

Avoid pump failure! Open the shutoff valve.

Drive Belt
To adjust the drive belt tension and alignment:
1 Loosen the four bolts securing the motor mounting bracket to the base plate.
2 Turn the drawbolt in a clockwise direction to tighten the belt until there is 1/4" - 1/2" play at
the center of the belt between the pulleys.
3 Adjust the alignment drawbolt until the motor pulley is square with the compressor. Use a
straightedge across the compressor pulley and check the gap between the motor pulley and
the straight edge. The gap (1-3/4") on the compressor side of the motor pulley should be the
same as on the far side of the pulley.

STRAIGHT EDGE

PULLEY

1-3/4"
GAP COMPRESSOR
BOLTS

MOUNTING
BRACKET
26 CAS440HT Air Compressor Manual Part # 99900838

Compressor Hydraulic System Precautions

To avoid malfunction of the compressor hydraulic system, follow these steps whenever a
hydraulic component is removed from the system.
1 ALWAYS relieve internal hydraulic pressure before proceeding with a repair. Carefully
loosen a fitting and allow the pressure to bleed off.
2 NEVER allow foreign matter (dirt, water, metal particles, etc.) to enter the system through the
open connections. Cap or plug any openings. If dirt does get in, a filter change is required
after 50 hours of operation.
3 ALWAYS check for high pressure leaks after completing a repair. A high pressure leak is
hazardous and must be repaired.
 Maintenance & Repair 27

Troubleshooting Guide
CAS440HU & CAS440HT Troubleshooting Guide

Symptom Probable Cause

Air compressor slows 1 Relief valve bypassing oil. Adjust relief valve. Turn clockwise to increase
down as air pressure bypass pressure. If this does not correct the problem, return the relief valve
increases and the engine to the original position. Proceed with step #2.
RPM remains the same, 2 Hydraulic pump failure. Disconnect the pressure hoses at the motor inlet
or increases slightly. swivel. Cap the hose. Plug the swivel. If the system does not have a
pressure gauge, install one at the end of the hose for testing purposes.
Engage the PTO and release the clutch slowly. Hydraulic oil pressure
should reach 2300 - 2500 PSI before the relief valve opens.
3 Hydraulic motor or valve failure. Disconnect the pressure hose from the
pump at the gauge swivel. Connect the pressure hose from the pump to the
motor inlet swivel. Shut control valve. engage the PTO. Start the
compressor. If this does not correct the problem, replace the motor. If this
does correct the problem, replace the valve.

Motor does not turn when 1 Compressor is locked up. Disconnect the drive system and try to turn the
hydraulic valve is closed. compressor by hand. If it cannot be turned, repair the compressor.
Oil does not reach 2300 - 2 Hydraulic motor failure. Replace the motor if the compressor is operational.
2500 psi.

Motor does not turn when 1 Hydraulic motor is beginning to fail. Replace the hydraulic motor before it
the hydraulic system is damages the rest of the system.
activated. Relief valve
reached 2300 - 2500 psi.

Excessive noise in 1 Restrictions in oil hoses and fittings. Check and correct any restrictions.
hydraulic pump. Pump 2 Oil tank vent plugged. Check and clean oil tank vent.
gets very hot.
3 Hydraulic oil breakdown. Drain and replace.

Hydraulic system 1 Tank too full to allow for expansion. Drain excess oil.
damaged pumps. Oil tank 2 Oil tank vent plugged. Check and clean.
overflows.
NOTE: If your truck has two tanks, the return hose from the top tank to the lower
tank may be restricted.

Oil is cold. Compressor is 1 Compressor started too quickly. Insufficient warm-up causes pump failure.
started cold and fails to Replace pump, start compressor, and allow sufficient warm-up time.
continue to operate.
28 CAS440HT Air Compressor Manual Part # 99900838
 29

SECTION 6

Parts

CAS440HT Compressor Parts (23000080)

61

ORIGINAL
PART OF
COMPRESSOR

TO
TO SPEED 54 AIR
CONTROL TANK
(IDLE PRESSURE)
53
52 1
58 59
TO
AIR 56
TANK
57
66
PART OF
COMPRESSOR 25
8 26
TO 26 24 26
PUMP 17
1 43 42 5 25 24
26
44 6 13
19 43 71
19 10 4
21 19 7
16
45 9 50 24
49 26 28
48 40
19 25
47
42 69
15 40 36 41 26
3 21 33
20 20 37 28 17
22 51 22 39 29
21 36 33
21 19 51 51 38
11,12
2 26 14 73 28
50 26 32
20 50 50
26
22 FRONT OF
34,60, 32 TRUCK
72 28
30

34 31
35
30 CAS440HT Air Compressor Manual Part # 99900838

23000080 PARTS LIST

ITEM PART # DESCRIPTION QUANTITY
1. 70073051 COMPRESSOR 1
2. 52719724 RESERVOIR 1
3. 52720047 BASE WELDMENT 1
4 52070749 BRACKET 1
5. 70058486 BELT-POWER V 2B80 1
6. 70056043 PULLY-BROWNING 2BK110H 1
7. 52705590 BELT GUARD 1
8. 60104650 BRACE 1
9. 73051614 HYD MOTOR-M20A897BEEF10 1
10. 73054995 RELIEF VALVE-FV1196-AG1004 1
11. 73014671 FILL CAP 1
12. 73141276 FILL NECK SCREEN 1
13. 60106708 BUSHING 1
14. 52702304 BOLT-CMPRSR HOLD DOWN 1
15. 52706302 TIGHTENER BOLT 8" 2
16. 73052133 OIL COOLER 1
17. 60104673 SLEEVE .39X1X1.19 2
19. 72060094 CAP SCR 1/2-13X1-3/4 HHGR5 9
20. 72060091 CAP SCR 1/2-13X1 HHGR5 4
21. 72062080 NUT 1/2-13 LOCK 10
22. 72063053 WASHER 1/2 LOCK 4
24. 72060008 CAP SCR 1/4-20X2 HHGR5 2
25. 72060004 CAP SCR 1/4-20X1 HHGR5 3
26. 72063001 WASHER 1/4 WRT 13
28. 72661642 HOSE CLAMP 1-3/4 T-BOLT (WAS 72066516) 4
29. 72532833 BEAD NIPPLE 1MPT 1-1/4HOSE 2
30. 72531550 BARB NIPPLE 1-1/4MPT 1-1/4 1
31. 73052091 RETURN FILTER 10MIL 1-1/4FPT 1
32. 89393401 HOSE 1-1/4 100R4 40"
33. 89393401 HOSE 1-1/4 100R4 60"
34. 72053211 PIPE NIPPLE 1-1/4NPT X CLOSE 1
35. 72053327 ELBOW 1-1/4NPT 90° 1
36. 72053141 PIPE NIPPLE 3/4NPT X CLOSE 2
37. 72053604 TEE 3/4NPT 1
38. 73053285 STREET ELBOW 3/4NPT 90° 1
39. 72053436 REDUCER COUPLING 1.0-3/4NPT 1
40. 72053747 ADAPTER #12MSTR 3/4FPT 1
41. 72053676 ADAPTER 3/4MPT #12MJIC 1
42. 51705296 HOSE ASM 3/4X20 FF 1
43. 72532367 ADAPTER #16MSTR #12MJIC 2
44. 73054435 PRESSURE GAUGE 5000PSI 1
45. 72531131 STREET ELBOW 1/4NPT 90° 1
46. 72053747 ADAPTER #12MSTR 3/4FPT 1
47. 72053713 ELBOW 3/4MPT 1/4FPT 90° SWVL 1
48. 72053558 ADAPTER 3/4MPT 3/4MPT 1
 Parts 31

23000080 PARTS LIST

ITEM PART # DESCRIPTION QUANTITY
49. 72053750 ADAPTER #16MSTR 3/4FPT 1
50. 72062104 NUT 1/4-20 LOCK 7
51. 72063005 WASHER 1/2 WRT 6
52. 77041008 PRESSURE SWITCH 1
53. 72532013 STREET TEE 1/4NPT BRASS 1
54. 72053411 PIPE PLUG 1/8NPT SQHD 1
55. 72053371 REDUCER BUSHING 1/4-1/8NPT 1
56. 72053533 STREET ELBOW 1/4NPT 45° 1
57. 70048069 MOISTURE REGULATOR 1
58. 72532552 HOSE FITTING 1/4-1/4 TYPE O 1
59. 72053013 PIPE NIPPLE 1/4NPT X CLOSE 1
60. 72532960 PIPE NIPPLE 1-1/4X11 1
61. 72053245 PIPE PLUG 1/4NPT SQHD 1REF
65. 89086120 OIL-30W NON-DETERGENT 1GAL
66. 73054031 VALVE-UNLOADER 155-175PSI 1REF
67. 70029117 IDENTIFICATION PLACARD 1
69. 72532833 BEAD NIPPLE 1MPT 1-1/4HOSE 1
71. 72532834 NIPPLE-BEAD 90 DEG 1.00 MPT 1.25 1
72. 72053307 COUPLING -BLK 1.25 1
73. 52721052 TIGHTENER BOLT 1
REV. H 20070817
32 CAS440HT Air Compressor Manual Part # 99900838

Thread Torque Charts

FINE THREAD BOLTS (ENGLISH) COARSE THREAD BOLTS (ENGLISH)
SIZE BOLT GRADE 5 GRADE 8 SIZE BOLT GRADE 5 GRADE 8
DIA. DIA.

SAE J429 SAE J429 SAE J429 SAE J429

GRADE 5 GRADE 8 GRADE 5 GRADE 8
(DIA-TPI) (INCHES) PLAIN PLATED PLAIN PLATED (DIA- (INCHES) PLAIN PLATED PLAIN PLATED
TPI)
(FT-LB) (FT-LB) (FT-LB) (FT-LB) (FT-LB) (FT-LB) (FT-LB) (FT-LB)
5/16-24 0.3125 19 14 27 20 5/16-18 0.3125 17 13 25 18
3/8-24 0.375 35 26 49 35 3/8-16 0.375 31 23 44 33
7/16-20 0.4375 55 41 78 58 7/16-14 0.4375 49 37 70 52
1/2-20 0.5 90 64 120 90 1/2-13 0.5 75 57 105 80
9/16-18 0.5625 120 90 170 130 9/16-12 0.5625 110 82 155 115
5/8-18 0.625 170 130 240 180 5/8-11 0.625 150 115 220 160
3/4-16 0.75 300 225 420 315 3/4-10 0.75 265 200 375 280
7/8-11 0.875 445 325 670 500 7/8-9 0.875 395 295 605 455
1-12 1 645 485 995 745 1-8 1 590 445 910 680
1 1/8-12 1.125 890 670 1445 1085 1 1/8-7 1.125 795 595 1290 965
1 1/4-12 1.25 1240 930 2010 1510 1 1/4-7 1.25 1120 840 1815 1360
1 3/8-12 1.375 1675 1255 2710 2035 1 3/8-6 1.375 1470 1100 2380 1780
1 1/2-12 1.5 2195 1645 3560 2670 1 1/2-6 1.5 1950 1460 3160 2370

NOTES
1 Tightening torques provided are midrange.
2 Consult bolt manufacturer’s particular specifications, when provided.
3 Use flat washers of equal strength.
4 All torque measurements are given in foot-pounds.
5 Torque values specified are for bolts with residual oils or no special lubricants applied. If special lubricants of
high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphite, collodial copper or
white lead are applied, multiply the torque values in the charts by the factor .90. The use of Loctite does not affect
the torque values listed above.

WARNING

Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical
grade and size. Once a bolt has been torqued to 75% of its proof load and then removed, the
torque coefficient may no longer be the same as when the bolt was new thus giving
indeterminate clamp loads after torquing. Failure to replace gear-bearing bolts may result in bolt
failure due to metal fatigue causing death or serious injury.
 Parts 33

FINE THREAD TORQUE CHART (METRIC) COARSE THREAD TORQUE CHART (METRIC)

TIGHTENING TORQUE TIGHTENING TORQUE

SIZE BOLT SIZE BOLT DIA

(DIA- DIA. (DIA- (INCHES)
TPI) (INCHES) TPI)
SAE J429 SAE J429 SAE J429 SAE J429
GRADE 5 GRADE 8 GRADE 5 GRADE 8

PLAIN PLATED PLAIN PLATED PLAIN PLATED PLAIN PLATED

(KG-M) (KG-M) (KG- (KG-M) (KG-M) (KG-M) (KG-M) (KG-M)
M)
5/16-24 0.3125 3 2 4 3 5/16-18 0.3125 2 2 3 2
3/8-24 0.375 5 4 7 5 3/8-16 0.375 4 3 6 5
7/16-20 0.4375 8 6 11 8 7/16-14 0.4375 7 5 10 7
1/2-20 0.5 12 9 17 12 1/2-13 0.5 10 8 15 11
9/16-18 0.5625 17 12 24 18 9/16-12 0.5625 15 11 21 16
5/8-18 0.625 24 18 33 25 5/8-11 0.625 21 16 30 22
3/4-16 0.75 41 31 58 44 3/4-10 0.75 37 28 52 39
7/8-11 0.875 62 45 93 69 7/8-9 0.875 55 41 84 63
1-12 1 89 67 138 103 1-8 1 82 62 126 94
1 1/8-12 1.125 123 93 200 150 1 1/8-7 1.125 110 82 178 133
1 1/4-12 1.25 171 129 278 209 1 1/4-7 1.25 155 116 251 188
1 3/8-12 1.375 232 174 375 281 1 3/8-6 1.375 203 152 329 246
1 1/2-12 1.5 304 228 492 369 1 1/2-6 1.5 270 210 438 328

NOTES
1 Tightening torques provided are midrange.
2 Consult bolt manufacturer’s particular specifications, when provided.
3 Use flat washers of equal strength.
4 All torque measurements are given in kilogram-meters.
5 Torque values specified are for bolts with residual oils or no special lubricants applied. If special lubricants of
high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphite, collodial copper or
white lead are applied, multiply the torque values in the charts by the factor .90. The use of Loctite does not affect
the torque values listed above.

WARNING

Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical
grade and size. Once a bolt has been torqued to 75% of its proof load and then removed, the
torque coefficient may no longer be the same as when the bolt was new thus giving
indeterminate clamp loads after torquing. Failure to replace gear-bearing bolts may result in bolt
failure due to metal fatigue causing death or serious injury.