IMT CAS40PL User manual

Iowa Mold Tooling Co., Inc.
500 Highway 18 West
Garner, Iowa 50438
Phone: [phone]
Fax: [phone]
www.imt.com
©2020 Iowa Mold Tooling Co., Inc.
All rights reserved
KEEP THE MANUAL
WITH THE VEHICLE
P/N 99906549 rev 00
Effective Date:
FEBRUARY - 2020
CAS40PL, CAS40PL-CW,
CAS40PLE, CAS40PLE-CW
40 CFM/100 PSIG HYDRAULIC ALL WEATHER
CLOSED OR OPEN CIRCULATION RECIPROCATING COMPRESSOR
OPERATION MANUAL AND PARTS LIST
Read this manual before install-
ing, operating or servicing this
equipment. Failure to comply with
the operation and maintenance in-
structions in this manual will VOID
THE EQUIPMENT WARRANTY.
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!
NOTE
Making unauthorized modifica-
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 rev 00 (JANUARY-2020) TOC - I
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
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 - 2
1.3.4 NOTES ............................................................................................................. 1 - 3
1.4 SAFETY DECALS ................................................................................................... 1 - 3
1.5 DISPOSING OF MACHINE FLUIDS ....................................................................... 1 - 3
SECTION 2: SPECIFICATIONS ....................................................... 2 - 2
Figure 2-1: Machine Main Component Locations........................................................... 2 - 1
2.1 GENERAL INTRODUCTION ........................................................................................ 2 - 2
TABLE 2A: SPECIFICATIONS .............................................................................................. 2 - 2
TABLE 2B: CAPSCREW TIGHTENING TORQUE VALUES................................................. 2 - 3
TABLE 2C: COMPRESSOR TORQUE VALUES................................................................... 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 rev 00 (JANUARY-2020)
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
SECTION 3: INSTALLATION (CONTINUED)
Figure 3-2: Installation and Dimensions Diagram - Open Center 12V,
No Thermal Valve .................................................................................................... 3 - 4
Figure 3-3: Installation and Dimensions Diagram - Open Center 12V,
With Thermal Valve & Gauges................................................................................ 3 - 5
3.4.2 HYDRAULIC OIL RESERVOIR ........................................................................... 3 - 6
3.4.2.1 DETERMINING RESERVOIR SIZE........................................................... 3 - 6
3.4.2.2 DETERMINING RESERVOIR SHAPE....................................................... 3 - 6
3.4.2.3 MANDATORY RESERVOIR FEATURES................................................... 3 - 6
3.4.2.4 RECOMMENDED RESERVOIR OPTIONS............................................... 3 - 7
3.4.2.5 RESERVOIR FEATURES TO AVOID......................................................... 3 - 8
3.4.2.6 RECOMMENDED HYDRAULIC SYSTEM SPECIFICATIONS .................. 3 - 8
3.4.3 STANDARDS GUIDELINES ................................................................................ 3 - 8
3.5 INSTALLATION............................................................................................................. 3 - 8
3.5.1 MACHINE LOCATION ......................................................................................... 3 - 8
3.5.2 CLEARANCES..................................................................................................... 3 - 8
3.5.3 MACHINE STABILIZATION AND GROUNDING ................................................. 3 - 8
3.5.4 SERVICE CONNECTIONS.................................................................................. 3 - 8
3.5.5 ELECTRICAL CONNECTIONS ........................................................................... 3 - 8
3.5.6 HYDRAULIC SUPPLY CIRCUIT.......................................................................... 3 - 9
3.5.7 ROUTING ............................................................................................................ 3 - 9
3.5.8 HYDRAULIC SYSTEM REQUIREMENTS .......................................................... 3 - 9
3.6 CONNECTING THE HYDRAULIC SUPPLY AND RETURN.................................. 3 - 9
3.7 CONNECTING THE AIR SUPPLY ......................................................................... 3 - 9
3.7.1 AIR RESERVOIR TANK INSTALLATION .......................................................... 3 - 10
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
Continued on next page...

99906549 rev 00 (JANUARY-2020) TOC - III
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
SECTION 4: OPERATION (CONTINUED)
Figure 4-1: Instrumentation............................................................................................. 4 - 2
4.3.1 ROUTINE START-UP FROM MACHINE ............................................................. 4 - 2
4.3.2 ROUTINE SHUTDOWN PROCEDURE (FIRST AND ROUTINE) ....................... 4 - 2
Figure 4-2: Controller Screen Identification and Navigation ........................................... 4 - 3
4.4 EXTREME CONDITION OPERATION ....................................................................... 4 - 4
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 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
Continued on next page...

TOC - IV 99906549 rev 00 (JANUARY-2020)
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
SECTION 5: MAINTENANCE (CONTINUED)
5.4.8 CHECKING HOSES AND WIRING ................................................................... 5 - 11
5.5 SERVICING THE SYSTEM FUSE ............................................................................. 5 - 12
5.6 PRESSURE (SAFETY) RELIEF VALVES .................................................................. 5 - 12
5.7 LONG TERM STORAGE............................................................................................ 5 - 13
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 CONTROLLER................................................................................... 7 - 8
7.5 DISPLAY AND GAUGE ASSEMBLY (MECHANICAL CONTROL) ............................. 7 - 8
7.6 MOTOR AND DRIVE PARTS ..................................................................................... 7 - 9
7.7 HYDRAULIC COOLER & PARTS - 12V WITH THRML / GAUGES ......................... 7 - 10
7.8 HYDRAULIC COOLER & PARTS - 24V WITH THRML / GAUGES ......................... 7 - 12
7.9 FRAME AND CANOPY - 1 OF 3 (ASSEMBLY PART A) .......................................... 7 - 14
7.9 FRAME AND CANOPY - 2 OF 3 (ASSEMBLY PARTS B - C) .................................. 7 - 16
7.9 FRAME AND CANOPY - 3 OF 3 (ASSEMBLY PARTS D - F) .................................. 7 - 17
7.10 HYDRAULIC MANIFOLD ASSEMBLY - 12VDC OPEN CENTER
(STANDARD & COLD WEATHER)........................................................................... 7 - 18
7.11 HYDRAULIC MANIFOLD ASSEMBLY - CLOSED CENTER (24V)
(STANDARD & COLD WEATHER)........................................................................... 7 - 20
7.12 DECAL IDENTIFICATION/LOCATIONS - 1 OF 2..................................................... 7 - 22
7.12 DECAL IDENTIFICATION/LOCATIONS - 2 OF 2..................................................... 7 - 23
7.13 HOSE AND TUBE ROUTING - OPEN CENTER 12V, NO THERMAL ..................... 7 - 24
7.14 HOSE AND TUBE ROUTING - OPEN CENTER 12V, WITH THERMAL ................. 7 - 25
7.15 HOSE AND TUBE ROUTING - OPEN CENTER 12V, NO THERMAL,
WITH GAUGES ........................................................................................................ 7 - 26
7.16 HOSE AND TUBE ROUTING - OPEN CENTER 12V, THERMAL & GAUGES........ 7 - 27
Continued on next page...

99906549 rev 00 (JANUARY-2020) TOC - V
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
SECTION 7: ILLUSTRATED PARTS LIST (CONTINUED)
7.17 HYDRAULIC THERMAL VALVE ASSEMBLY........................................................... 7 - 28
7.18 ELECTRICAL SCHEMATIC...................................................................................... 7 - 29
7.19 WIRING DIAGRAM .................................................................................................. 7 - 30
7.20 HYDRAULIC OIL FLOW SCHEMATIC DIAGRAM - OPEN CENTER,
WITH THERMAL VALVE .......................................................................................... 7 - 31
7.21 HYDRAULIC OIL FLOW SCHEMATIC DIAGRAM - OPEN CENTER...................... 7 - 32
7.22 HOSE INSTALLATION GUIDE ................................................................................. 7 - 33
TABLE 7B: MAINTENANCE TRACKING LOG.................................................................... 7 - 34

TOC - VI 99906549 rev 00 (JANUARY-2020)
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
BLANK PAGE

SECTION 1:
SAFETY
99906549 rev 00 (JANUARY-2020) 1 - 1
SECTION 1: SAFETY
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
1.1 GENERAL INFORMATION
The products provided by IMT®Mfg., Inc. are de-
signed 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 ac-
tions.
1.2 INTERNATIONAL
WARNING SYMBOL
The international warning symbol (shown above)
is used on all decals, labels and signs that con-
cern 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
specific issues that are pertinent to the safe and
correct operation of the machine.
The symbols shown and defined in Section 1:
Safety are used throughout this manual and on
the machine to call attention to, and identify, pos-
sible hazards.
1.3.1 DANGERS
DANGER
Identifies 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
Identifies actions or conditions which may
cause death, severe injury, or equipment dam-
age 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.
• DO NOT perform any modifications to this
equipment without prior factory approval.
• DO NOT operate the compressor or any of its
systems if there is a known unsafe condition.
Disable the equipment by disconnecting it
from its power source. Install a lock-out tag to
identify the equipment as inoperable to other
personnel.
• DO NOT 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 influence 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, af-
ter 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 fill
cap. Remove all electrical power.

1 - 2 99906549 rev 00 (JANUARY-2020)
SECTION 1: SAFETY
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
NOTE
Slowly remove fill cap to vent compressor
sump pressure.
• DO NOT use the compressor for purposes oth-
er than for which it is intended. High pressure
air can cause serious and even fatal injuries.
• DO NOT operate the compressor outside of its
specified pressure and speed ratings. (See
Section 2: Specifications or refer to the equip-
ment data plate.).
• DO NOT use flammable solvents or cleaners
for cleaning the compressor or its parts.
• DO NOT operate the compressor in areas
where flammable, 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 cuffs, ties,
or loose-fitting clothing when you are working
near moving/rotating parts.
• ALWAYS confine 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 pro-
tection 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 confined spaces where ventilation is re-
stricted or closed-off.
• Ensure that hoses connected to service valves
are fitted with correctly sized and rated flow
limiting devices which comply with applicable
codes. Pressurized broken or disconnected
hoses can whip, causing injuries or damage.
• DO NOT use tools, hoses, or equipment that
have maximum ratings below that of this com-
pressor.
• Keep metal tools, and other conductive objects
away from live electrical components.
• Before performing maintenance or repair oper-
ations on the compressor, ensure that all pow-
er 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 pow-
er has been removed.
• Use this compressor only to compress atmo-
spheric 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, oth-
er Federal, state, local codes, standards, and
regulations.
• When lifting objects, be aware of proper lifting
techniques to avoid injury.
• ALWAYS read and follow safety related pre-
cautions found on containers of hazardous
substances.
1.3.3 CAUTIONS
CAUTION
Identifies 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 in-
takes.
• Keep the equipment clean when performing
maintenance or service actions. Cover open-
ings to prevent contamination.
• DO NOT operate the compressor if cooling air
is not available (fan/cooler not operating) or if
lubricant levels are below their specified min-
imum levels.
• Ensure all plugs, hoses, connectors, covers,
and other parts removed for maintenance ac-

99906549 rev 00 (JANUARY-2020) 1 - 3
SECTION 1: SAFETY
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
tions are replaced before applying power to
the compressor.
• Avoid touching hot surfaces and components.
• Ensure that electrical wiring, terminals; hoses
and fittings are kept in serviceable condition
through routine inspections and maintenance.
Replace any damaged or worn components.
1.3.4 NOTES
NOTE
Additional information (or existing information)
which should be brought to the attention of op-
erators/maintainers affecting operation, mainte-
nance, 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 nec-
essary to understand machine function and op-
eration. 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 affecting op-
eration, 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 de-
cals listed in Section 7.12, Decal Identification/
Locations, are located near a component which
is subject to respect in terms of safety precau-
tions. 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 fluids under the guid-
ance of all applicable local, regional and/or fed-
eral law.
IMT®encourages recycling when allowed. For
additional information, consult the container label
of the fluid in question.

OPEN
CENTER
MANIFOLD
W2
AA
T
Z
G
L
E
F
H
D
A
J
C
K
BB1
EE
C
FF GG
E
W
1
CLOSED - CENTER CONFIGURATION
M1
Y
X
CLOSED
CENTER
MANIFOLD
CC DD
OPEN - CENTER CONFIGURATION
M2
BB2
R
NPQ
T
V
U
SR
N
QU
V
T
P
B1
B2
KEY DESCRIPTION KEY DESCRIPTION
ARELAY ISLOAD SENSE #4 MJIC 37° (1/4-12 UNF)
B1PRESSURE SWITCH (24V MACHINES) THYDRAULIC SUPPLY #12 MJIC 37° (1-1/16-12 UNF)
B2PRESSURE TRANSDUCER (12V MACHINES) UHYDRAULIC RETURN #16 MJIC 37° (1-5/16-12 UNF)
CCOMPRESSOR AIR FILTER HOUSING VCASE DRAIN #6 MJIC (9/16-18 UNF)
DCOMPRESSOR UNIT W1CLOSED CENTER MANIFOLD ASSEMBLY
ELOW PRESSURE RELIEF VALVE W2OPEN CENTER MANIFOLD ASSEMBLY
FHIGH PRESSURE RELIEF VALVE XSOLENOID VALVE
GCOMPRESSOR OIL FILL PORT YFLOW REGULATOR
HCOMPRESSOR OIL DRAIN HOSE ZRELIEF VALVE
JCOOLER FAN & FAN MOTOR AA SOLENOID
KCONTROLLER BB1INSTRUMENT PANEL - DIGITAL DISPLAY
LHYDRAULIC MOTOR BB2INSTRUMENT PANEL - GAUGE DISPLAY
M1CLOSED CENTER: functional piping & access locations CC PRESSURE GAUGE (gauge panel only)
M2OPEN CENTER: functional piping & access locations DD HOUR METER (gauge panel only)
NSERVICE AIR DISCHARGE / CONNECTION MOUNT EE HYDRAULIC OIL COOLER
PDEUTSCH 6-PIN ELECTRICAL CONNECTION FF MANIFOLD CHECK VALVE
QCOMPRESSOR OIL DRAIN (refer to Item H) GG SPIDER COUPLING ELEMENT
RCOMPRESSOR OIL SIGHT GLASS
I Relay size depends upon machine build order. Refer to Figure 5-7, Electrical Schematic (Section 7.18), and Wiring Diagram (Section 7.19), to
determine correct relay size.
Figure 2-1: Machine Main Component Locations
2 - 1 99906549 rev 00 (JANUARY-2020)
SECTION 2: SPECIFICATIONS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW

SECTION 2:
SPECIFICATIONS
SECTION 2: SPECIFICATIONS
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
2.1 GENERAL INTRODUCTION
The tables and figures in this section list the
specifications (including operational, output and
dimensional) of the overall machine. Contact the
IMT®Service Department if additional specifi-
cations are needed that cannot be found in this
manual.
Refer to Figure 2-1 for general machine compo-
nent locations. For additional information, includ-
ing measurement specifications, refer to Figure
3-1 (machine and identification and dimensions)
in Section 3, Installation.
TABLE 2A: SPECIFICATIONS
GENERAL SYSTEM INFORMATION SPECIFICATION
CFM Rating @ 100 psi: 30 I40 II
Air Pressure (psi): 100 125 150 175 100 125 150 175
Hydraulic flow (gpm): 8.25 8.25 8.25 9.0 10 10 10 10
Hydraulic pressure (psig): 2300 2450 2575 2600 2300 2470 2550 2600
NOTE: Compressor adjustment should be set in accordance with rated RPMs.
I30 CFM = 690 COMPRESSOR RPM
II 40 CFM = 1100 COMPRESSOR RPM
COMPRESSOR
GENERAL SYSTEM INFORMATION SPECIFICATION
Type: Two-stage, two cylinder, reciprocating
Compressor oil reservoir capacity: 3 quarts
Air inlet system: Dry-type, single stage
Drive coupling: Direct drive, coupled
Hydraulic motor: Gear type
PACKAGE
Main frame: Formed powder-coated steel with a bolt-down provision
Electrical supply: 12V Standard; 24V Optional
Electrical connections: Weatherpack
Enclosure: Aluminum, powder-coated
Cooler: Hydraulic oil cooler/radiator core — electric fan
Package connections:
(Refer to Figures 3-1 and 3-2 in Section 3)
Discharge air — 3/4” JIC male
Hydraulic supply — 3/4” 37° JIC male
Hydraulic return — 1” 37° JIC male
Load sense line (closed center only) — 1/4” 37° JIC male
+12VDC or +24VDC (PTO activated)
Motor case drain 3/8" 37° JIC male
Continued on next page
99906549 rev 00 (JANUARY-2020) 2 - 2
IOWA MOLD TOOLING CO., INC.
[phone]

SECTION 2: SPECIFICATIONS CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
2 - 3 99906549 rev 00 (JANUARY-2020) IOWA MOLD TOOLING CO., INC.
[phone]
TABLE 2A: SPECIFICATIONS
GENERAL SYSTEM INFORMATION SPECIFICATION
PACKAGE (continued)
Dimensions: Length — 33.70”
Width — 21.00”
Height — 24.30”
Weight: 245 lbs.(dry; add 10-12 lbs for full wet machine weight)
CONTROLS
Hydraulic pressure relief: 3000 PSIG
Hydraulic solenoid valve (for automatic load
control):
12 or 24V
Air pressure switch (for automatic load control): Pre-set at factory
TABLE 2B: CAPSCREW TIGHTENING TORQUE VALUES
SIZE GRADE LUBRICATED
1/4 - 20 UNC 5 6 ft-bs
5/16 - 18 UNC 5 13 ft-lbs
3/8 - 16 UNC 5 23 ft-lbs
1/2 - 13 UNC 5 55 ft-lbs
3/4 - 10 UNC 5 200 ft-lbs
TABLE 2C: COMPRESSOR TORQUE VALUES
BOLTS SIZE GRADE TORQUE (ft.-lb.) POSITION
1/4-20 5 8 Side Plate Bolts
1/4-28 8 11.76 HP Valve Nut
3/8-16 5 26 Cylinder to Base Bolts
3/8-24 8 33.8 Connecting Rod Bolts
5/16-18 5 17 Head to Cylinder
5 10 LP & HP Valve Hold Down Covers
5 17 End Cover/Discharge Manifold Bolts
5/16-24 8 21.3 LP Valve Nut

SECTION 3:
INSTALLATION
99906549 rev 00 (JANUARY-2020) 3 - 1
SECTION 3: INSTALLATION
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
3.1 MACHINE PACKAGE
RECEIPT/INSPECTION
Upon receipt of the machine package, inspect the
exterior of the shipping crate for signs of shipping/
transit damage. Any damage should be reported
immediately to the shipping company.
NOTE
Before fully unpacking the unit, inspect the
component parts, supports and loose-packed
parts to ensure that there have been no inter-
nal movements of assemblies or components,
which may have been damaged during ship-
ment.
Should any damage be discovered during pack-
age inspection, contact the shipping company
immediately.
Iowa Mold Tooling Co., Inc.
500 Highway 18 West
Garner, Iowa 50438
Phone: [phone]
Fax: [phone]
www.imt.com
3.2 GENERAL INSTRUCTIONS
This section provides general guidance for lo-
cating and preparing the CAS40PL compressor
package for operation. Each installation is unique
and can be affected by location, ventilation, and
other factors such as electrical and hydraulic
power supply availability and location.
DISCLAIMER
DO NOT install in any enclosed space without
first contacting IMT.
WARNING
Install, operate, and maintain this equipment in
full compliance with all applicable OSHA, other
Federal, state, local codes, standards, and regu-
lations.
WARNING
Before performing maintenance or repair oper-
ations on the compressor, ensure that all power
has been removed and locked out to prevent
accidental start-up.
DO NOT assume that because the compressor
is in a STOPPED condition that power has been
removed.
WARNING
DO NOT perform any modifications to this
equipment without prior factory approval.
WARNING
DO NOT use plastic pipe, or incorrectly rated
piping or hose. Incorrectly rated connection
material can fail and cause injury or equipment
damage.
WARNING
DO NOT operate the compressor in enclosed or
confined spaces where ventilation is restricted
or closed off.
NOTE
Install electrical components (circuit breakers,
pressure switches, toggle switches, etc.) in
locations where exposure to water or moisture
will be most minimized.
NOTE
In order to prevent accidental damage to vehi-
cle components (fuel tanks, lines, brake lines,
wiring harnesses), note their location before
drilling any holes.

3 - 2 99906549 rev 00 (JANUARY-2020)
SECTION 3: INSTALLATION
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
3.3 DETERMINING THE CAS40PL
UNIT MOUNTING LOCATION
When determining the location to mount the
CAS40PL unit, the following criteria must be tak-
en into consideration:
• The mounting surface must be level and able to
accommodate the four (4) mounting bolts and
isolators of the base frame. Refer to Figure
3-1 or Figure 3-2 for layout of mounting hole
slots’ locations.
IMPORTANT
Mounting surface must be able to bear the
weight of the machine (255-260 lbs, wet).
• Mount the machine with a minimum of four (4)
mounting locations.
• The location must allow for the machine dimen-
sions, and additional space requirements for
minimum cooling, maintenance and access.
Refer to Figure 3-3 to determine the additional
minimum space requirement measurements.
• The external gauges/display must be easily
visible to the operator.
It is recommended, for most installations, to
mount the compressor on the driver’s side of the
vehicle. The unit should be situated in such a
manner that the fan (rear) and hydraulic cooler
(front) are not obstructed. Do not place the com-
pressor in any location where it can ingest ex-
haust fumes, dust or debris.
NOTE
When considering external system layout hoses
refer to Section 7.22, Hose Guide for proper
routing and mounting practices.
3.4 HYDRAULIC SYSTEM
OVERVIEW
IMPORTANT
IMT®highly recommends consulting a hydraulic
supply expert for specifying the correct hydrau-
lic supply components for vehicle-side integra-
tion (including oil reservoir size, hydraulic pres-
sure relief, hose size, etc.) for your application.
IMPORTANT
Contaminated hydraulic fluid allowed to enter
the pump will cause malfunction of the pump
controls. Hydraulic system hoses must be
flushed and cleaned prior to being connected to
the unit.
Refer to Figure 3-1 or Figure 3-2 for hydraulic
pump system connections.
Please take into consideration the following:
• The hydraulic flow and pressure requirements
of the system.
• A continuous hydraulic load is necessary when
compressor is running.
• The duty cycle and ambient operating tempera-
tures.
• Other hydraulic equipment which may share
that same hydraulic supply system (IMT rec-
ommends a dedicated pump and hydraulic
circuit).
WARNING
Follow all applicable safety recommendations
as outlined in Section 1: Safety of this manual.
WARNING
Improperly, or non-connected lines may cause
harm, and will damage the equipment.
The hydraulic hoses must be run to the machine.
Verify that hoses are hooked up properly to en-
sure proper flow. Also, verify that the hoses are
laid out properly so that no chafing or kinking
of the hoses is possible. Refer to Section 7.22,
Hose Installation Guide, for assistance with
proper hose layout and connecting functions.
NOTE
The temperature of the hydraulic oil should not
exceed 160°F due to the rating of the IMT- sup-
plied hydraulic motor.
3.4.1 HYDRAULIC SYSTEM
FILTRATION
IMT recommends using a 10 micron oil filter on

99906549 rev 00 (JANUARY-2020) 3 - 3
SECTION 3: INSTALLATION
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
ALTERNATE LID HINGE DIRECTION
DEFAULT LID HINGE DIRECTION
28.68
DISPLAY CONTROLLER
26.15
15.45
32.50
23.94
AIR DISCHARGE #12 MJIC 37° (1 1/16 - 12UNF)
ELECTRICAL CONNECTION (6 - PIN DEUTSCH)
HYDRAULIC RETURN #16 MJIC 37°(1 5/16 - 12 UNF)
HYDRAULIC SUPP LY #12 MJIC 37°(1 1/16 - 12UNF)
CASE DRAIN #6 MJIC 37°(9/16-18 UNF)
COMPRESSOR OIL DRAIN
COMPRESSOR OI L SIGHT GLASS
8.04
4.17
12.09
6.54
7.45
1/2 - 13 UNC NU T 8 - PLACES
3.51 23.48
21.25
1.00 30.50
1
8.44
NOTES: 1. DECAL AREA SHOWN IN DASHED [ ] LINES
Figure 3-1: Installation and Dimensions Diagram - Open Center 12VDC 051665ID_r0
DISCLAIMER
If machine package is to be mount-
ed within a confined space such as
beneath a canopy, the area must be
determined to allow for adequate air
flow to take place for cooling purpos-
es. Consult factory for assistance
in ensuring adequate air flow before
mounting the machine.
NOTE
The dimensions listed in this diagram
are the minimum required clearance
distances needed for properly cooling
the machine, and providing service
access. For additional clearances
needed, refer to Figure 3-4.

3 - 4 99906549 rev 00 (JANUARY-2020)
SECTION 3: INSTALLATION
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
CLOSED CENTER FLOW CONTROL ACCESS POINT
HYDRAULIC RETURN #16 MJIC 37° (1 5/16 - 12 UNF)
HYDRAULIC SUPPLY #12 MJIC 37°(3/4 JIC)
CASE DRAIN #6 MJIC (9/16 - 18 UNF)
COMPRESSOR OIL DRAIN
AIR DISCHARGE
3/4" JIC
ELECTRICAL CONNECTION
6-PIN DEUTSCH
ALTERNATE DISPLAY POSITION
COMPRESSOR AIR INLET
ALTERNATE
LID HINGE
DIRECTION
DEFAULT LID HINGE DIRECTION
NOTES: 1. DECAL AREA SHOWN IN SINGLE LENGTH DASHED LINES
PRESSURE GAUGE & HOUR METER OR CONTROLLER DISPLAY
1/2 - 13 UNC NUT 8 - PLACES
Figure 3-2: Installation and Dimensions Diagram - Open Center 12V, No Thermal Valve 051787_r2
DISCLAIMER
If machine package is to be mounted
within a confined space such as beneath
a canopy, the area must be determined to
allow for adequate air flow to take place
for cooling purposes. Consult factory for
assistance in ensuring adequate air flow
before mounting the machine.
NOTE
The dimensions listed in this diagram are
the minimum required clearance dis-
tances needed for properly cooling the
machine, and providing service access.
For additional clearances needed, refer to
Figure 3-4.

99906549 rev 00 (JANUARY-2020) 3 - 5
SECTION 3: INSTALLATION
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
COMPRESSOR AIR INLET
ALTERNATE DISPLAY POSITION
7.45
28.68
23.94
26.15
15.45
32.50
PRESSURE GAUGE & HOUR METER OR CONTROL DISPLAY
AIR FLOW
CLOSED CENTER FLOW CONTROL ACCESS POINT
6.54
12.09
ELECTRICAL CONNECTOR 6-PIN DEUTSCH
AIR DISCHARGE 3/4 JIC COMPRESSOR
OIL DRAIN
HYDRAULIC RETURN #16 MJIC 37° (1 5/16-12 UNF)
HYDRAULIC SUPPLY #12 MJIC 37° (3/4 JIC)
CASE DRAIN #6 MJIC 37° (9/16-18 UNF)
DEFAULT LID HINGE DIRECTION
ALTERNATE LID HINGE DIRECTION
21.00
3.51 23.48
18.44
1.40
1.00
1/2-13 UNC NUT 8-PLACES
30.50
NOTES: 1. DECAL AREA SHOWN IN SINGLE LENGTH DASHED LINES
Figure 3-3: Installation and Dimensions Diagram - Open Center 12V, With Thermal Valve & Gauges 051788_r2
DISCLAIMER
If machine package is to be mounted
within a confined space such as beneath
a canopy, the area must be determined to
allow for adequate air flow to take place
for cooling purposes. Consult factory for
assistance in ensuring adequate air flow
before mounting the machine.
NOTE
The dimensions listed in this diagram are
the minimum required clearance dis-
tances needed for properly cooling the
machine, and providing service access.
For additional clearances needed, refer to
Figure 3-4.

3 - 6 99906549 rev 00 (JANUARY-2020)
SECTION 3: INSTALLATION
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW, CAS40PLE, CAS40PLE-CW
the hydraulic oil return line. Flow rating of the fil-
ter must be equal to, or greater than, the maxi-
mum GPM at which the system will be operated.
IMPORTANT
Use only a filter that is specifically intended for
hydraulic systems.
3.4.2 HYDRAULIC OIL RESERVOIR
3.4.2.1 DETERMINING RESERVOIR
SIZE
In a conventional hydraulic system, minimum
tank size, in gallons, should be equal to the max-
imum GPM flow rate, times two (x 2).
3.4.2.2 DETERMINING
RESERVOIR SHAPE
The reservoir structure should be tall and narrow
rather than shallow and broad (Figure 3-4). A tall,
narrow tank is recommended because:
1. The oil level is well above suction line open-
ing, avoiding the possibility of drawing air into
the pump due to a vortex or “whirlpool” effect
within the tank during operation flow.
2. Allows for better oil level tolerance level of
the system if vehicle operates at an unusual
(slightly offlevel) vehicle angle.
3. To keep return flow well below the surface so
it does not break the surface and cause aer-
ation (cavitation) of the oil.
3.4.2.3 MANDATORY RESERVOIR
FEATURES
• The reservoir should incorporate the following
design features:
• In terms of location of the reservoir tank within
the hydraulic system, note that the hydraulic
pump’s inlet line (suction line out from the res-
ervoir to the pump) should be located near the
bottom of the tank, well below the oil level. The
suction line should protrude a minimum of two
(2”) inches into the reservoir to keep it away
from potential contaminant surface buildup.
A
B
B
C
C
D
Figure 3-6: Minimum Clearnace Distances Needed for Machine Cooling and Access
KEY DESCRIPTION
AROOF ACCESS PANEL CLEARANCE: 24”
BMACHINE LATERAL CLEARANCES: 10”
CMACHINE FRONT/REAR CLEARANCES: 10”
DCOOLING 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.
IMPORTANT
Additional allotted dimensions/surroundings
space of package must allow for continu-
ous circulation of air around and through
the machine for cooling purposes. DO NOT
install in an enclosed area.