IMT CAS440HT User manual

Printed on 23 January, 2012
Manual Part # 99900838
CAS440HT Air Compressor
Revised 20120124
IOWA MOLD TOOLING CO., INC.
PO Box 189
Garner, IA 50438
Tel: [phone] FAX: [phone]
Website: http://www.imt.com
Copyright © 2012 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.

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
Operation....................................................................................................................................................19
Shutdown....................................................................................................................................................20
Maintenance & Repair 21
Maintenance Schedule................................................................................................................................22
Compressor Hydraulic Oil..........................................................................................................................23
Hydraulic Fluid Deterioration.....................................................................................................................24
Compressor Hydraulic Oil Change.............................................................................................................25
Compressor Filter Element Replacement ...................................................................................................26
Drive Belt ...................................................................................................................................................26
Compressor Hydraulic System Precautions................................................................................................27
Troubleshooting Guide...............................................................................................................................28
Parts 29
CAS440HT Compressor Parts (23000080).................................................................................................30
Thread Torque Charts.................................................................................................................................33

ii Contents
Revisions
DATE LOCATION DESCRIPTION
20070817 MAINTENAN
CE
SCHEDULE,
2300080
CHANGED MAINTENANCE SCHEDULE COMPRESSOR OIL
CHANGE DURATION; ECN 10523 – CHANGED #28 72066516
TO 72661642
20071127 MAINT.
SCHEDULE ECN 10612 - CHANGED NOTE IN MAINTENANCE SCHEDULE TO 6 MONTHS
20090409 23000080 ADDED CALLOUT FOR ITEM #9 - MOTOR; ADDED
SPECIFICATIONS SECTION
20110610 23000080 ECN 11448 - NEW PRESSURE RELIEF VALVE.
20120124 23000080 ECN 11616 - CHANGED MOTOR MOUNTING BRACKET

3
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
SECTION 1
Compressor Introduction

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
procedures as outlined in this manual could result
in equipment damage, personal injury or death.
Follow all maintenance procedures and intervals.
Do not use air from this compressor for
breathing or food processing. Air from this
compressor will cause severe injury or death if
used for breathing or food processing.
Maintenance must be performed only by trained
and qualified personnel, using correct tools,
specified torques and approved replacement
parts.
Hot oil under pressure can cause severe injury
or death. Shut down, let cool and relieve
pressure in compressor before servicing.
All electrical components and cable wiring must
be installed and grounded in accordance with
NFPA, national electrical codes and applicable
state and local codes.
Do not overfill the compressor with oil. Use
correct quantity of manufacturer's lubricant.
Repair leaks and clean spills immediately.
Before removing guards or servicing the
compressor, disconnect all power supplies.
Display warning signs and lock out electrical
circuits.
Compressors generate high temperatures. Do
not touch or otherwise come in contact with hot
surfaces. Doing so can cause severe personal
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:
Do not attempt to remove any compressor parts without first relieving the entire system of
pressure.
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.
Do not operate the compressor at pressure or speed in excess of its rating as indicated in
Compressor Specifications.
Periodically check all safety devices for proper operation.
Do not play with compressed air. Pressurized air can cause serious injury to personnel.
Exercise cleanliness during maintenance and when making repairs. Keep dirt away from
parts by covering parts and exposed openings.
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.
Do not disconnect or bypass safety circuit system.
Do not install safety devices other than authorized IMT replacement devices.
Close all openings and replace all covers and guards before operating compressor unit.
Do not leave tools, rags, or loose parts on the compressor or drive parts.
Do not use flammable solvents for cleaning parts.
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
73540449 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
CAS440HT
DELIVERY AT 175 PSI 46 cfm (1300 lpm)
FLUID CAPACITY 32 gal (121 l)
FILTER - HYDRAULIC SUCTION 100 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
DIAMETER 18.88" (48 cm)
SECTION 2
CAS440HT Compressor Specifications

11
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.
SECTION 3
Installation

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
70392891
Rotating Shaft Hazard
Rotating parts will injure or kill.
Do not work around shafts
Keep body, hands, hair,
clothes away.
with engine on.
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.
21.12"
20" 20"
2.06"
3"3"
SUCTION
(DRILL 3-1/4" DIA. HOLE)
DRAIN
(DRILL 2" DIA. HOLE)
DRILL 1/2" DIA.
HOLE (6 PLCS)
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.
-+
BATTERY
IGNITION
SWITCH
NORMALLY
CLOSED
DOOR
SWITCH
COIL (GAS)
OR
FUEL SOL. (DIESEL)

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.
RELIEF
VALVE
COMPRESSOR
PULLE
Y
MOTOR
OIL
COOLER
RESERVOIR RETURN
FILTER CONTROL
VALVE
GATE
VALVE SUCTION
FILTER
PUMP