Oshkosh Corporation IMT CAS80R User manual

60-85 CFM HYDRAULIC-DRIVEN
ROTARY SCREW AIR COMPRESSOR
INSTALLATION, OPERATION, MAINTENANCE & PARTS MANUAL
®
An Oshkosh Corporation Company
PART NUMBER:
99905932
Revision 0
Effective Date:
FEBRUARY 2016
Sub-revision June 2019
NOTE
Use only IMT Premium
Synthetic 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!
Iowa Mold Tooling Co., Inc.
500 Highway 18 West
Garner, Iowa 50438
Phone: [phone]
Fax: [phone]
www.imt.com
KEEP THE MANUAL
WITH THE VEHICLE
Read this manual before
installing, operating or
servicing this equipment.
Failure to comply with the
operation and maintenance
instructions in this manual
WILL VOID THE EQUIPMENT
WARRANTY.
NOTE
Making unauthorized
modifications to the system
components WILL VOID THE
WARRANTY!
Always inform Iowa Mold
Tooling Co., Inc., before
beginning any changes to the
hydraulic-driven system.
NOTE
This publication contains the
latest information available at
the time of preparation. Every
effort has been made to ensure
accuracy. IMT reserves the
right to make design change
modifications or improve-
ments without prior notifica-
tion.
©2016 Iowa Mold Tooling Co., Inc.
All rights reserved.

NOTICE TO CUSTOMER
This manual is the final version and some of the information and specifications are subject to change
without notice.

CAS80R TABLE OF CONTENTS
Manual # 99905932 (February 2016) PAGE - I
TABLE OF CONTENTS
®
IOWA MOLD TOOLING CO., INC.
[phone] • www.imt.com
TABLE OF CONTENTS .....................................................I
SECTION 1: SAFETY.........................................................1
1.1 GENERAL INFORMATION ............................................................................................................1
1.2 SUMMARY OF DANGERS, WARNINGS, CAUTIONS AND NOTES ............................................1
1.2.1 DANGERS........................................................................................................................................................... 1
1.2.2 WARNINGS......................................................................................................................................................... 1
1.2.3 CAUTIONS.......................................................................................................................................................... 2
1.2..4 NOTES................................................................................................................................................................ 2
1.2.5 SAFETY DECALS............................................................................................................................................... 3
1.3 DISPOSING OF MACHINE FLUIDS ..............................................................................................3
SECTION 2: SPECIFICATIONS.........................................5
TABLE 2A: SPECIFICATIONS .............................................................................................................5
TABLE 2B: PRIME LUBRICANT CHARACTERISTICS.......................................................................6
TABLE 2C: BOLT AND TORQUE SPECIFICATIONS ..........................................................................6
SECTION 3: INSTALLATION.............................................7
3.1 MACHINE PACKAGE RECEIPT/INSPECTION .............................................................................7
3.2 GENERAL INSTRUCTIONS ..........................................................................................................7
3.3 DETERMINING THE IMT UNIT MOUNTING LOCATION..............................................................7
3.4 HYDRAULIC SYSTEM REQUIREMENTS.....................................................................................8
3.5 VENTILATION REQUIREMENTS..................................................................................................8
3.6 HYDRAULIC REQUIREMENTS.....................................................................................................9
3.6.1 HYDRAULIC OIL REQUIREMENTS................................................................................................................... 10
3.7 HYDRAULIC LINE SIZING.............................................................................................................10
TABLE 3A - OIL SELECTION GUIDE ............................................................................................10
3.7.1 SUCTION LINE SIZING ...................................................................................................................................... 11
TABLE 3B - SIZING FOR SUCTION HOSE........................................................................................................ 11
3.7.2 RETURN LINE SIZING........................................................................................................................................ 11
TABLE 3C - RETURN LINE SIZING.................................................................................................................... 11
3.7.3 PRESSURE LINE SIZING................................................................................................................................... 11
TABLE 3D - PRESSURE LINE SIZING............................................................................................................... 11
3.8 HYDRAULIC SYSTEM FILTRATION .............................................................................................11
Continued on next page...

TABLE OF CONTENTS CAS80R
PAGE - II Manual # 99905932 (February 2016)
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SECTION 3: INSTALLATION (CONTINUED)
3.9 HYDRAULIC OIL RESERVOIR .....................................................................................................11
3.9.1 DETERMINING RESERVOIR SIZE.....................................................................................................................11
3.9.2 DETERMINING RESERVOIR SHAPE ................................................................................................................11
3.9.3 MANDATORY RESERVOIR FEATURES ............................................................................................................11
3.9.4 RECOMMENDED OPTIONS...............................................................................................................................13
3.9.5 FEATURES TO AVOID........................................................................................................................................13
3.10 INSTALLATION .............................................................................................................................. 13
3.10.1 MACHINE LOCATION.........................................................................................................................................13
3.10.2 CLEARANCE.......................................................................................................................................................14
3.10.3 MOUNTING.........................................................................................................................................................14
3.10.4 SERVICE CONNECTIONS..................................................................................................................................14
3.10.5 ELECTRICAL CONNECTIONS...........................................................................................................................14
3.10.6 HYDRAULIC SUPPLY CIRCUIT..........................................................................................................................14
3.10.7 ROUTING............................................................................................................................................................14
SECTION 4: OPERATION..................................................17
4.1 GENERAL INFORMATION............................................................................................................ 17
4.2 PURPOSE OF CONTROLS........................................................................................................... 17
4.3 INITIAL START-UP PROCEDURE................................................................................................. 19
4.4 ROUTINE START-UP PROCEDURE............................................................................................. 19
4.5 COLD WEATHER START-UP PROCEDURE ................................................................................ 20
4.6 ROUTINE SHUTDOWN PROCEDURE......................................................................................... 20
4.7 OPERATING CONDITIONS........................................................................................................... 20
SECTION 5: MAINTENANCE............................................23
5.1 GENERAL INFORMATION ............................................................................................................ 23
5.2 MACHINE MAINTENANCE SCHEDULE....................................................................................... 24
5.3 REPLACEMENT PARTS ............................................................................................................... 24
5.4 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES ................................................... 24
TABLE 5A ROUTINE MAINTENANCE SCHEDULE ............................................................................... 25
5.4.1 SERVICING THE FUSES AND CIRCUIT BREAKER..........................................................................................26
5.4.2 SAFETY SHUTDOWN SYSTEMS.......................................................................................................................26
5.4.2.1 TESTING THE GAUGES’ SHUTDOWN FEATURE.................................................... 26
5.4.2.2 PRESSURE RELIEF VALVE....................................................................................... 27
5.4.3 LONG TERM STORAGE.....................................................................................................................................27
SECTION 6: TROUBLESHOOTING..................................29
6.1 GENERAL INFORMATION ............................................................................................................ 29
6.2 TROUBLESHOOTING GUIDE.......................................................................................................30

CAS80R TABLE OF CONTENTS
Manual # 99905932 (February 2016) PAGE - III
®
SECTION 7: ILLUSTRATED PARTS LIST........................33
7.1 PARTS ORDERING PROCEDURE ...............................................................................................33
TABLE 7A:RECOMMENDED SPARE PARTS LIST........................................................................................................... 34
TABLE 7B: MAINTENANCE TRACKING LOG................................................................................................................... 35
7.2A COMPRESSOR ASSEMBLY AND REPLACEMENT PARTS ........................................................36
7.2B COMPRESSOR AND MOUNTING PARTS ...................................................................................38
7.3A HYDRAULIC MOTOR AND DRIVE - OPEN CENTER ..................................................................39
7.3B CLOSED CENTER AND HYDRAULIC THERMAL VALVE............................................................ 39
7.4 COOLING SYSTEM 12V DC / 24V DC..........................................................................................40
7.5 CONTROL SYSTEM ......................................................................................................................41
7.6 FRAME AND CANOPY - OVERALL ASSEMBLY ..........................................................................42
7.6A FRAME AND CANOPY - FRONT SIDE PANEL.............................................................................43
7.6B FRAME AND CANOPY - ACCESS DOOR ....................................................................................43
7.6C FRAME AND CANOPY - ROOF PANEL........................................................................................43
7.6D FRAME AND CANOPY - BACK SIDE PANEL...............................................................................44
7.6E FRAME AND CANOPY - COMPRESSOR SIDE PANEL ............................................................... 44
7.6F FRAME AND CANOPY - HYDRAULIC DRIVE FRAME ................................................................45
7.7A CONTROL MANIFOLD - 12V DC / 24V DC OPEN CENTER........................................................46
7.7B HYDRAULIC THERMAL VALVE - 12V DC / 24V DC .....................................................................47
7.8 THERMAL CONTROL....................................................................................................................48
7.9 DECAL LOCATIONS (PART 1 OF 2) .............................................................................................49
7.9 DECAL LOCATIONS (PART 2 OF 2) .............................................................................................50
7.10 WIRING DIAGRAM ........................................................................................................................ 51
7.11 SCHEMATIC - HYDRAULIC OIL FLOW OPEN CENTER .............................................................52
7.12 SCHEMATIC - HYDRAULIC OIL FLOW OPEN CENTER, COLD WEATHER...............................53
7.13 SCHEMATIC - COMPRESSOR OIL / AIR FLOW (PART 1 OF 2).................................................54
7.13 SCHEMATIC - COMPRESSOR OIL / AIR FLOW (PART 2 OF 2)................................................. 55
7.14 HOSE AND TUBING - OPEN CENTER SYSTEM .........................................................................56
7.15 HOSE AND TUBING - OPEN CENTER, COLD WEATHER SYSTEM ..........................................58

TABLE OF CONTENTS CAS80R
PAGE - IV Manual # 99905932 (February 2016)
BLANK PAGE
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CAS80R SECTION 1: SAFETY
Manual # 99905932 (February 2016) PAGE - 1
®
IOWA MOLD TOOLING CO., INC.
[phone] • www.imt.com
1.1 GENERAL INFORMATION
The products provided by IMT are designed
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 actions.
1.2 SUMMARY OF
DANGERS, WARNINGS,
CAUTIONS AND NOTES
These boxed inserts are placed throughout
this manual in the sections where they apply.
This subsection is a general summary of
their contents.
1.2.1 DANGERS
• 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.
1.2.2 WARNINGS
•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 an 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 by
opening a service valve which will vent all
pressure to the atmosphere: remove all
electrical power.
•DO NOT use the compressor for
purposes other 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 equipment
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, or
DANGER
Identifies actions or conditions which will
cause death, severe injury, or equipment
damage or destructive malfunctions.
WARNING
Identifies actions or conditions which may
cause death, severe injury, or equipment
damage or destructive malfunctions.
SECTION 1:
SAFETY

SECTION1: SAFETY CAS80R
PAGE - 2 Manual # 99905932 (February 2016)
®
IOWA MOLD TOOLING CO., INC.
[phone] • www.imt.com
corrosive fumes, or other damaging
substance can be ingested by the
compressor intakes.
• Keep arms, hands, hair and 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
protection 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 restricted or closed-off.
•DO NOT install shut-off valves between
the compressor and the compressor
receiver tank (sump).
• 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 compressor.
• Keep metal tools, and other conductive
objects away from live electrical
components.
• Before performing maintenance or repair
operations on the compressor, ensure
that all power 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 power has been removed.
• Use this compressor only to compress
atmospheric 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, other 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
precautions found on containers of
hazardous substances.
1.2.3 CAUTIONS
• 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 intakes.
• Keep the equipment clean when
performing maintenance or service
actions. Cover openings 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 minimum levels.
• Ensure all plugs, hoses, connectors,
covers, and other parts removed for
maintenance actions 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.
1.2.4 NOTES
CAUTION
Identifies actions or conditions which will or
can cause injuries, equipment damage or
malfunctions.
NOTE
Additional information (or existing
information) which should be brought to the
attention of operators/maintainers affecting
operation, maintenance, or warranty
requirements.

CAS80R SECTION 1: SAFETY
Manual # 99905932 (February 2016) PAGE - 3
®
IOWA MOLD TOOLING CO., INC.
[phone] • www.imt.com
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 necessary to understand machine
function and operation. 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:
1.2.5 SAFETY DECALS
Safety decals are placed onto, or located
near, system components that can present a
hazard to operators or service personnel. All
pertinent decals listed in Section 7.9, Decal
Locations are located near a component
which is subject to respect in terms of safety
precautions. Always heed the information
noted on the safety decals.
1.3 DISPOSING OF MACHINE
FLUIDS
Always dispose of machine fluids under the
guidance of all applicable local, regional and/
or federal law.
IMT encourages recycling when allowed. For
additional information, consult the container
label of the fluid in question.
IMPORTANT
Additional, CRUTIAL information (or existing
information) which should be brought to the
attention of operators/maintainers affecting
operation, maintenance, or warranty
requirements.
WARNING
DO NOT REMOVE OR COVER ANY
SAFETY DECAL. Replace any safety
decal that becomes damaged or illegible.

SECTION 1: SAFETY CAS80R
PAGE - 4 Manual # 99905932 (February 2016)
BLANK PAGE
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CAS80R SECTION 2: SPECIFICATIONS
Manual # 99905932 (February 2016) PAGE - 5
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®
TABLE 2A: SPECIFICATIONS
GENERAL SYSTEM INFORMATION SPECIFICATION
RATINGS
Maximum compressor oil temperature 240°F
Maximum Hydraulic oil temperature 150°F
COMPRESSOR
Type: Encapsulated, Oil-injected, Rotary Screw
Compressor oil tank capacity: 5 U.S. Quarts (4.7L)
Compressor overheating protection: Shut Down at 240°F
Air inlet system: Dry-type, Single Stage Filter
Drive coupling: Internal Spline
Hydraulic motor: Gear Type
PACKAGE
Main frame: Formed Steel with Boltdown Provision
Electrical supply: 12V Standard; 24V Optional
Electrical connections: 4-pin Deutsch
Supply connections (customer hook-up):
Hydraulic: Oil In 3/4 in. 37° JIC
Hydraulic: Oil Out 1 in. 37° JIC
Electrical: 12V DC Positive and Ground (Standard)
24V DC Positive and Ground (Optional)
Electrical: High Temp Shutdown
Enclosure: Sheet Metal with Service Access
Cooler: Hydraulic Oil Cooler/Radiator Core - Electric Fan
Dimensions: 39.5” L x 21” W x 25” H
Weight: 375 lbs.
COMPRESSOR ICFM
CFM vs HYDRAULIC FLOW
HYDRAULIC FLOW
(GPM)
21
20
19
18
17
16
15
14
13
12
11
10
50 60 65 75 80 85 90
70
55
45
GPMvsCFMAT100PSIGSERVICEAIR
2440 PSIG MAX HYD PRESSURE @ COMPRESSOR @ 100 PSIG SERVICE AIR @ 85 CFM
2950 PSIG MAX HYD PRESSURE @ COMPRESSOR @ 150 PSIG SERVICE AIR @ 80 CFM
Ratings above are approximate and are based on 120°F Hydraulic Fluid Temperature.
SECTION 2:
SPECIFICATIONS

SECTION 2: SPECIFICATIONS CAS80R
PAGE - 6 Manual # 99905932 (February 2016) IOWA MOLD TOOLING CO., INC.
[phone] • www.imt.com
®
TABLE 2B: PRIME LUBRICANT CHARACTERISTICS
Viscosity 178 SUS at 100° F (38°C)
Flashpoint 457° F (236°C)
Pour Point -49° F (-45°C)
Contains Rust and Oxidation Inhibitors and Detergents
TABLE 2C: BOLT AND TORQUE SPECIFICATIONS
25 7 8
SOCKET HEAD
CAP SCREW
I.D. Marks No markings 3 lines 5 lines 6 lines Allen head
Material Low carbon
S.S.
Medium -carbon,
tempered
Medium - carbon,
quenched &
tempered
Medium carbon,
quenched &
tempered
High-carbon,
quenched &
tempered
Tensile strength
(minimum) 74,000 psi 120,000 psi 133,000 psi 150,000 psi 160,000 psi
SAE 2
SAE 5
SAE 7
SAE 8
US BOLT TORQUE SPECIFICATIONS (Torque in foot-pounds)
5588
Socket head
cap screw
Socket head
cap screw
Bolt
Diameter
Thread
per inch Dry Oiled Dry Oiled Dry Oiled
1/4 20 8 6129 14 11
5/16 18 17 13 25 18 29 23
3/8 16 30 23 45 35 49 39
1/2 13 75 55 110 80 113 90

CAS80R SECTION 3: INSTALLATION
Manual # 99905932 (February 2016) PAGE - 7
IOWA MOLD TOOLING CO., INC.
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®
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. Open the lid and
inspect the component parts and supports to
ensure that there has been no internal
movement of assemblies or components
which may have caused damage. To install
the IMT compressor system, refer to the
following sections:
3.2 GENERAL INSTRUCTIONS
This section provides general guidance for
locating and preparing the IMT 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.
3.3 DETERMINING THE IMT
CAS80R UNIT MOUNTING
LOCATION
When determining the location to mount the
CAS80R unit, the following criteria must be
taken into consideration:
• Refer to Section 3.10. The location must
allow for the machine dimensions
(Figure 3-4), and additional space
requirements for minimum cooling,
access and maintenance. Refer to
Figure 3-4 to determine the minimum
space requirement.
• The mounting surface must be level and
able to accommodate the four [4]
mounting bolts of the base frame.
• The mounting surface must be able to
support the unit’s weight (375 lbs.).
• The external gauges must be easily
visible to the operator.
WARNING
Install, operate, and maintain this
equipment in full compliance with all
applicable OSHA, other Federal, state,
local codes, standards, and regulations.
WARNING
Before performing maintenance or repair
operations on the compressor, ensure that
all power has been removed and locked
out to prevent accidental application.
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.
SECTION 3:
INSTALLATION

SECTION 3: INSTALLATION CAS80R
PAGE - 8 Manual # 99905932 (February 2016) IOWA MOLD TOOLING CO., INC.
[phone] • www.imt.com
®
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 compressor in any location
where it can intake exhaust fumes, dust or
debris.
3.4 HYDRAULIC SYSTEM
REQUIREMENTS
The following criteria should be taken into
consideration for the hydraulic system
requirements:
• The hydraulic flow and pressure
requirements of the air compressor.
• A continuous hydraulic load requirement
is needed when the compressor is
running.
• The duty cycle and ambient
temperatures.
• Other hydraulic equipment which may
share the same hydraulic supply
system.
3.5 VENTILATION
REQUIREMENTS
The variables involved with installing the
hydraulic pump system make it impossible to
recommend detailed specifics, as each
customer is potentially different in regard to
vehicle type, customer needs, etc. The
following information is therefore given not
as absolute instruction, but as good practice
guideline
Machine placement will play an important
factor in providing adequate and consistent
cooling air for the system operation. In this
regard, there are two types of mounting
locations to consider: open-mounting and
enclosed-mounting (Figure 3-1).
Open-mounting refers to machine
placement location on the service body,
whereby the machine is directly exposed to
the environmental ambient. Enclosed-
mounting refers to machine placement
location within an enclosure located on the
service body.
Open-mounting provides for the best cooling
situation, allowing for maximum unrestricted
air flow to interact with the heat displacement
components. The mounted unit must have a
minimum additional six inch (6”)
unobstructed clearance on all sides of the
machine.
Although enclosed mounted-units provide a
degree of shelter and security, this type of
machine location is not recommended, due
to its limiting effect on the air flow needed to
cool an operating system. Should this
mounting type be preferred, then provision
should be made to maximize the machine’s
exposure to the air (i.e., a pull-out mounting
IMPORTANT
IMT highly recommends consulting a
hydraulic supply expert for specifying the
correct hydraulic pump size and type, oil
reservoir size, hydraulic pressure relief,
and other hydraulic supply components for
your application.
NOTE
Hydraulic performance will derate at
temperatures above 150 degrees F.
NOTE
IMT recommends a dedicated pump and
hydraulic circuit.
IMPORTANT
Operation of the hydraulic system will
generate an amount of heat that will damage
system components. For this reason the
equipment package must have a proper
ventilation system installed.

CAS80R SECTION 3: INSTALLATION
Manual # 99905932 (February 2016) PAGE - 9
IOWA MOLD TOOLING CO., INC.
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Figure 3-1: Unit Mounting Types
AB
KEY DESCRIPTION
AOPEN-MOUNTING TYPE LOCATION
BENCLOSED-MOUNTING TYPE LOCATION
platform; removable enclosure walls, etc.).
For enclosed-mountings, it is also
recommended to install a safety switch on
the access door that allows for compressor
operation only when the door is open.
The unit must have a minimum additional six
inch (6”) unobstructed clearance on all sides
of the machine for operation.
Ideal ventilation regardless of the type of
mounting installation of the unit, needs to
provide adequate, unrestricted air flow
through the unit. Additionally, the cooler must
be exposed to, or provided with (ducted),
cool ambient air, and an exhaust fan within
the enclosed space to displace the heated
air.
3.6 HYDRAULIC
REQUIREMENTS
The hydraulic pump must be rated for 2,900
psi consistent operation, and 3,300 psi for
pressure spikes.
The compressor capacity will depend on
hydraulic oil flow.
If the compressor is being installed on a truck
that already has a
functioning hydraulic
system, check the specifications for that
system
to ensure that it meets minimum
requirements.
IMPORTANT
DO NOT mount Hydraulic Reservoir in same
enclosed space as the machine.
Installing enclosed-mounting type without
proper cooling air ducted to coolers is NOT
RECOMMENDED.
IMPORTANT
The relief valve is set to 3,300 psi. The pump
must be rated for this relief valve setting.
NOTE
The values depicted in TABLE 2A are
referential only: Due to the variable
relationship between CFM output and
hydraulic flow, adjustments should be
tested to achieve the desired CFM output in
regard to flow, load and system efficiency.
NOTE
The information in this manual is in regard
to a fixed displacement
pump. For systems
utilizing a variable displacement pump,
consult a qualified hydraulic system
specialist.

SECTION 3: INSTALLATION CAS80R
PAGE - 10 Manual # 99905932 (February 2016) IOWA MOLD TOOLING CO., INC.
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®
3.6.1 HYDRAULIC OIL REQUIREMENTS
Depending upon situational, or seasonal,
climate types, the viscosity of the oil can be
affected by temperature conditions. For
these particular cases, cold and/or extreme
condition augmentations to the hydraulic
system may be warranted. TABLE 3B
shows a suggested approach to oil viscosity
types, proportional to listed environmental
conditions.
3.7 HYDRAULIC LINE SIZING
Industrial hydraulic system design guidelines
generally call for the
following maximum fluid
velocities, which are then used to select line
sizes for any particular GPM:
In regard to a particular hydraulic system
GPM, line sizing selection for maximized
fluid velocity is matched via industrial
hydraulic system guidelines, that include:
• Suction @ 4 ft/sec
• Return @ 10 ft/sec
• Pressure @ 20 ft/sec
In cases where mobile hydraulics are to be
added to a pre-built chassis, the above
guidelines are not comprehensive due to the
following factors:
• Extreme start-up temperature variations
• Long suction line
• Piggy-backing of motor case drain flow
onto main return line
Pump failure, caused by cavitation of the
circulating fluid; and motor seal breakdown
due to excess return line pressure, can occur
if proper allowances are not taken for the
above factors when determining line sizing.
NOTE
This table should be used as guideline
when choosing the hydraulic oil best
suited for working condition. Consultation
with a professional hydraulic system
installer is strongly recommended to
determine the optimal hydraulic oil type
best matched for the operating conditions.
NOTE
Note that line size refers to the inside
diameter of the hose.
For cold weather operation below 0°F, the
next larger size hoses should be used.
TABLE 3A - OIL SELECTION GUIDE
EXTREME COLD CLIMATE COLD CLIMATE TEMPERATE CLIMATE
-40 to 32°F 0 to 80°F 32 to 120°F
No tank preheat Tank and suction
line preheat
Open-Mounted Enclosed-
Mounted
Open-Mounted Enclosed-
Mounted
IAW 32 AW 22 II AW 32 AW 32 AW 46
I A seasonal hydraulic oil change is recommended to get best component life. Recommended oils include:
Summer - When overnight temperatures do not go below 32°F (0°C), use AW 32.
Winter - When overnight temperatures is consistently below 32°F (0°C), use Texaco 5606H, PetroCanada Hydrex
MV Arctic 15, Shell fluid 41, Mobil Aero HFA, Anderol Royco 78C.
II When possible, change to AW 32 during summer months.

CAS80R SECTION 3: INSTALLATION
Manual # 99905932 (February 2016) PAGE - 11
IOWA MOLD TOOLING CO., INC.
[phone] • www.imt.com
®
3.7.1 SUCTION LINE SIZING
Based on the 4 ft/sec fluid velocity condition,
choose a suction hose size from TABLE 3B.
Upsize the hose, if necessary.
Hose size recommendations for the IMT
CAS80R are:
• Return line size: 1” (one inch)
• Pressure line size: 3/4” (0.75 inch)
3.7.2 RETURN LINE SIZING
Based on the 10 ft/sec fluid velocity
condition, choose a suction hose size from
Table 3C.
3.7.3 PRESSURE LINE SIZING
Based on the 20 ft/sec fluid velocity
condition, choose a suction hose size from
TABLE 3D.
3.8 HYDRAULIC SYSTEM
FILTRATION
IMT recommends using a 10 micron oil filter
on the hydraulic oil return line. Flow rating of
the filter must be equal to, or greater than,
the maximum GPM at which the system will
be operated.
3.9 HYDRAULIC OIL
RESERVOIR
3.9.1 DETERMINING RESERVOIR SIZE
In a conventional hydraulic system, minimum
tank size, in gallons, should be equal to the
maximum GPM flow rate, times two (x 2).
For the CAS80R, a minimum 35 gallon
reservoir is recommended.
3.9.2 DETERMINING RESERVOIR SHAPE
The reservoir structure should be tall and
narrow rather than shallow and broad
(Figure 3-3). A tall, narrow tank is
recommended because:
1. The oil level is well above suction line
opening, 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 off level) vehicle
angle.
3. To keep return flow well below the
surface so it does not break the surface
and cause aeration (cavitation) of the oil.
3.9.3 MANDATORY RESERVOIR FEATURES
Refer to Figure 3-3. The reservoir should
incorporate the following design features:
• In terms of location of the reservoir tank
within the hydraulic system, note that the
TABLE 3B - SIZING FOR SUCTION HOSE
Maximum Operating GPM Suction Hose Size
8-13 1”
14-15 1-1/4”
16-22 1-1/2”
IMPORTANT
Failure to match the correct system return
line sizing for the hydraulic system can
cause rupture of the hydraulic motor’s shaft
seal during cold start-ups.
TABLE 3C - RETURN LINE SIZING
Maximum GPM Return Line Size
8-14 3/4”
15-22 1”
TABLE 3D - PRESSURE LINE SIZING
Maximum GPM Pressure Line Size
8-12 1/2”
13-18 5/8”
19-22 3/4”
IMPORTANT
Use only a filter that is specifically intended
for hydraulic systems.

SECTION 3: INSTALLATION CAS80R
PAGE - 12 Manual # 99905932 (February 2016) IOWA MOLD TOOLING CO., INC.
[phone] • www.imt.com
®
hydraulic pump’s inlet line (suction line
out from the reservoir 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 baffle or baffles should be included to
prevent sloshing, or centrifugal motion of
the oil; the goal is to break up direct flow
of the oil from the return point to the
suction point. This allows for the cooling
action contact with the tanks’ inner
surfaces, and promote separation of any
air or contaminants that interact with the
flowing oil.
An ideal baffle design would position
several (but not too many) baffles to
promote an ‘S’ shape flow within the
reservoir, as viewed from above. The
area of the end gaps should be at least
twice the area of the suction line
diameter.
• A drain port with plug, situated at the
lowest point of the reservoir, is needed to
assure complete draining. It should be
installed using an
adaptor or housing
which does not protrude above the inner
surface of the floor of the tank. It should
be visible and
accessible for removal,
with sufficient space available for
catching the waste oil.
• If the return line entrance to the tank is
located near the top, it should be
extended downward within the tank to
minimize foaming and aeration of the
circulating oil. This extends oil integrity,
which in turn helps to maintain system
performance and reliability.
• An inline filter on the return line is
needed to protect the system against
contaminants being introduced into the
oil. The filter should be mounted
externally from the reservoir in a location
that allows for easy of service access.
• A breather and fill cap is needed at the
oil fill port, which needs to be located
above the system oil level. The breather
cap acts to both filter air that is drawn
into the reservoir as the oil level
diminishes, and bleeds air out as the
Figure 3-2: Unit Mounting Types
D
E
C
A
B
G
H
J
K
L
F
KEY DESCRIPTION
ASUCTION LINE
BSUCTION LINE STRAINER
CBAFFLE
DDRAIN
EFILL CAP / BREATHER I
FHYDRAULIC RESERVOIR
GFLUID FILER
HRETURN LINE
JDIFFUSER (SPLASH) PLATE
KCLEANOUT ACCESS COVER
LFLUID LEVEL SIGHT GLASS
I Breather cap is dessicant-filled to pro-
mote absorption of moisture.
Arrow indicates direction of
hydraulic oil flow.

CAS80R SECTION 3: INSTALLATION
Manual # 99905932 (February 2016) PAGE - 13
IOWA MOLD TOOLING CO., INC.
[phone] • www.imt.com
®
level is regained. This maintains
constant atmospheric pressure in the air
volume within the reservoir.
• A sight-glass provides a direct visual
indication of the oil level without having
to open, or otherwise access, the
reservoir.
3.9.4 RECOMMENDED OPTIONS
Although not essential for an adequately
functioning reservoir, the following
components will contribute to maximize the
hydraulic system’s efficiency and maintain a
quality operational level.
• Magnetic drain plug: Attracts and
concentrates ferrous contaminants at
the drain plug source for easier
accessibility and removal when cleaning
tank interior.
• A temperature gauge: Located in
approximation to, or built in to, the sight
glass assembly allows for temperature
reading at a glance.
• Filler port strainer: Prevents large
contaminant particles from blending with
system oil when adding new oil.
• Return line diffuser (splash) plate
reduces velocity of oil flow before return
oil stream merges with the main
reservoir oil volume.
• A reservoir heater: For those systems
that are exposed to cold climate
ambients, having the ability to preheat
the hydraulic oil prior to start up will
make for easier startups, and reduce the
strain of warming up the system under
adverse cold conditions.
3.9.5 FEATURES TO AVOID
A strainer used to screen the suction line is
not recommended for systems designed for
mobile equipment use. Having equipment
that likely experiences long suction lines,
cold startups and non-tracked or infrequent
maintenance practices may cause this
strainer to potentially promote system strain
(cavitation) than prolong fluid integrity
through filtration.
A pressurized reservoir is not recommended
for vehicles, as its complexity invites too
much potential for loss of system reliability if
it is not properly maintained.
3.10 INSTALLATION
3.10.1 MACHINE LOCATION
It is vital to locate the machine so that there
is no restriction of cooling air through the
enclosure (Refer to Figure 3-4). Cooling air
enters the enclosure at the right end when
facing the instrument panel end of the
machine, passes through the cooler and
KEY DESCRIPTION
A PREFERRED SHAPE: TALL AND NARROW
B SHAPE TO AVOID: BROAD AND SHALLOW
Figure 3-3: Reservoir Design Shape
A
B

SECTION 3: INSTALLATION CAS80R
PAGE - 14 Manual # 99905932 (February 2016) IOWA MOLD TOOLING CO., INC.
[phone] • www.imt.com
®
exits through vents in the upper sides and
the rear.
3.10.2 CLEARANCE
Refer to Figure 3-4. Ensure that adequate
surrounding clearance exists to allow for the
canopy shroud to be re-positioned or
removed for service access.
3.10.3 MOUNTING
Mounting surface or support should be
adequate for the weight of the machine (375
lbs.), and should be level for normal
operation. Mounting holes are located in the
frame footing for four (4) 1/2” hold down
bolts.
3.10.4 SERVICE CONNECTIONS
Refer to Figure 3-4. Service connections are
conveniently grouped at the lower rear
section of the unit in the base frame.
3.10.5 ELECTRICAL CONNECTIONS
This system is offered with either 12V DC or
24V DC negative ground. Refer to Section
7.10, Wiring Diagram.
3.10.6 HYDRAULIC SUPPLY CIRCUIT
It is recommended that the compressor unit
possesses a separate pump/flow/return
hydraulic circuit to other hydraulic
equipment. This is to prevent the possibility
of pressure/flow drops that may occur if
other hydraulically-powered equipment is
activated during compressor operation,
which may in turn, cause the compressor to
stall out. Alternatively, use of a diverter valve
will permit hydraulics to power different
equipment selectively.
3.10.7 ROUTING
Refer to Section 7.11, Schematic
Hydraulic Oil Flow. Ensure that all supply
hoses and electrical wiring are correctly
specified, adequately supported, and do not
touch or rest on any sharp edges. Wiring
should be protected with split loom to
prevent corrosion, and consequently, loss
due to down time.
Wire #1
(10 gauge)
Battery (+) VDC supply
Wire #3
(12 gauge)
Ignition (+) VDC supply
Wire #2
(10 gauge)
Fan Circuit
Wire #4
(10 gauge)
Ground