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)
®
IOWA MOLD TOOLING CO., INC.
[phone] • www.imt.com
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
®
IOWA MOLD TOOLING CO., INC.
[phone] • www.imt.com

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
®
IOWA MOLD TOOLING CO., INC.
[phone] • www.imt.com