Oshkosh IMT CAS40PL User manual

®
An Oshkosh Corporation Company
Iowa Mold Tooling Co., Inc.
500 Highway 18 West
Garner, Iowa 50438
Phone: [phone]
Fax: [phone]
www.imt.com
1.800.247.5958
©2023 Iowa Mold Tooling Co., Inc.
All rights reserved
KEEP THE MANUAL
WITH THE VEHICLE
P/N 99906549_r02
E󰀨ective Date:
06/13/2023
CAS40PL, CAS40PL-CW
40 CFM/100 PSIG HYDRAULIC, (OPTIONAL)
COLD-WEATHER, CLOSED OR OPEN CIRCULATION
RECIPROCATING COMPRESSOR
INSTALLATION, OPERATION, MAINTENANCE AND PARTS MANUAL
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
This publication contains the
latest information available at
the time of preparation. Every
e󰀨ort has been made to ensure
accuracy.
Iowa Mold Tooling Co., Inc.
reserves the right to make
design change modications
or improvements without prior
notication.
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 lter
components WILL VOID THE
COMPRESSOR WARRANTY!
NOTE
Making unauthorized modica-
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_r02 (06/13/2023) TOC - I
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
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 - 3
1.3.4 NOTES ...............................................................................................................1 - 3
1.4 SAFETY DECALS .......................................................................................................1 - 3
1.5 DISPOSING OF MACHINE FLUIDS...........................................................................1 - 3
SECTION 2: SPECIFICATIONS ..........................................................2 - 1
2.1 GENERAL INTRODUCTION ..........................................................................................2 - 1
TABLE 2A: SPECIFICATIONS ................................................................................................2 - 1
TABLE 2B: CAP SCREW TIGHTENING TORQUE VALUES..................................................2 - 2
TABLE 2C: COMPRESSOR TORQUE VALUES.....................................................................2 - 2
Figure 2-1: Machine Main Component Locations.............................................................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_r02 (06/13/2023)
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
SECTION 3: INSTALLATION (CONTINUED)
Figure 3-2: Install & Dim Diagram - Open Center w Cold Weather Option ...............3 - 4
3.4.2 HYDRAULIC OIL RESERVOIR .............................................................................3 - 5
3.4.2.1 DETERMINING RESERVOIR SIZE.............................................................3 - 5
3.4.2.2 DETERMINING RESERVOIR SHAPE.........................................................3 - 5
3.4.2.3 MANDATORY RESERVOIR FEATURES.....................................................3 - 5
3.4.2.4 RECOMMENDED RESERVOIR OPTIONS.................................................3 - 6
3.4.2.5 RESERVOIR FEATURES TO AVOID...........................................................3 - 7
3.4.2.6 RECOMMENDED HYDRAULIC SYSTEM SPECIFICATIONS ....................3 - 7
3.4.3 STANDARDS GUIDELINES ..................................................................................3 - 7
3.5 INSTALLATION...............................................................................................................3 - 7
3.5.1 MACHINE LOCATION ...........................................................................................3 - 7
3.5.2 CLEARANCES.......................................................................................................3 - 7
3.5.3 MACHINE STABILIZATION AND GROUNDING ...................................................3 - 7
3.5.4 SERVICE CONNECTIONS....................................................................................3 - 7
3.5.5 ELECTRICAL CONNECTIONS .............................................................................3 - 7
3.5.6 HYDRAULIC SUPPLY CIRCUIT............................................................................3 - 7
3.5.7 ROUTING ..............................................................................................................3 - 8
3.5.8 HYDRAULIC SYSTEM REQUIREMENTS ............................................................3 - 8
3.6 CONNECTING THE HYDRAULIC SUPPLY AND RETURN....................................3 - 8
3.7 CONNECTING THE AIR SUPPLY ...........................................................................3 - 8
3.7.1 AIR RESERVOIR TANK INSTALLATION ..............................................................3 - 8
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
4.3.1 ROUTINE START-UP FROM MACHINE ...............................................................4 - 2
Figure 4-1: Instrumentation...............................................................................................4 - 2
Continued on next page...

99906549_r02 (06/13/2023) TOC - III
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
SECTION 4: OPERATION (CONTINUED)
4.3.2 ROUTINE SHUTDOWN PROCEDURE (FIRST AND ROUTINE) .........................4 - 2
4.4 EXTREME CONDITION OPERATION ...........................................................................4 - 2
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 PARTS 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
5.4.8 CHECKING HOSES AND WIRING ..................................................................... 5 - 11
5.5 SERVICING THE SYSTEM FUSES AND RELAYS......................................................5 - 12
5.6 PRESSURE (SAFETY) RELIEF VALVES ....................................................................5 - 12
5.7 LONG TERM STORAGE..............................................................................................5 - 13
Continued on next page...

TOC - IV 99906549_r02 (06/13/2023)
TABLE OF CONTENTS
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
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 GAUGE ASSEMBLY............................................................................ 7 - 8
7.5A MOTOR AND DRIVE PARTS PARTS - OPEN CENTER ............................................ 7 - 9
7.5B MOTOR AND DRIVE PARTS PARTS - CLOSED CENTER........................................ 7 - 9
7.6 HYDRAULIC COOLER & PARTS - WITH THRML / GAUGES.................................. 7 - 10
7.7 FRAME ASSEMBLY .................................................................................................. 7 - 12
7.8 FRAME AND CANOPY - 1 OF 3 (ASSEMBLY PART A) ........................................... 7 - 14
7.8 FRAME AND CANOPY - 2 OF 3 (ASSEMBLY PARTS B - C) ................................... 7 - 16
7.8 FRAME AND CANOPY - 3 OF 3 (ASSEMBLY PARTS D - F) ................................... 7 - 17
7.9 HYD MANIFOLD ASSEMBLY - OPEN CTR (STD & COLD WEATHER)................... 7 - 18
7.10 DECAL IDENTIFICATION/LOCATIONS - 1 OF 2...................................................... 7 - 20
7.10 DECAL IDENTIFICATION/LOCATIONS - 2 OF 2...................................................... 7 - 21
7.11 HOSE & TUBE ROUTING - OPEN CTR, NO THERMAL, W GAUGES.................... 7 - 22
7.12 HOSE & TUBE ROUTING - OPEN CTR, THERMAL & GAUGES ............................ 7 - 23
7.13 HYDRAULIC THERMAL VALVE ASSEMBLY............................................................ 7 - 24
7.14 WIRING DIAGRAM ................................................................................................... 7 - 25
7.15 HYD OIL FLOW DIAGRAM - OPEN CTR, WITH THERMAL VALVE ........................ 7 - 26
7.16 HYD OIL FLOW DIAGRAM - OPEN CTR ................................................................. 7 - 27
7.17 HOSE INSTALLATION GUIDE .................................................................................. 7 - 28
TABLE 7B: MAINTENANCE TRACKING LOG..................................................................... 7 - 29

SECTION 1:
SAFETY
99906549_r02 (06/13/2023) 1 - 1
SECTION 1: SAFETY
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
1.1 GENERAL INFORMATION
The products provided by IMT®Mfg., Inc. 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.
IMPORTANT
It is mandatory that all operators read this
manual before operating or servicing the
CAS40PL system. Failure to do so could result
in death, bodily injury or damage to equipment.
DANGER
DO NOT OPERATE IN AN ENCLOSED SPACE
WITHOUT ADEQUATE VENTILATION.
Running any combustion engine in an enclosed
space without adequate ventilation may result
in carbon monoxide (CO) poisoning and may
cause overheating, which may result in re and/
or explosion.
Carbon monoxide (CO) build-up may cause
death!
Overheating may result in re and/or explosion
resulting in injury/death and equipment
damage.
Consult IMT for recommendations when
mounting combustion engine driven IMT
equipment in an enclosed space.
1.2 INTERNATIONAL
WARNING SYMBOL
The international warning symbol (shown above)
is used on all decals, labels and signs that
concern 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
specic issues that are pertinent to the safe and
correct operation of the machine.
The symbols shown and dened in Section 1:
Safety are used throughout this manual and
on the machine to call attention to, and identify,
possible hazards.
1.3.1 DANGERS
DANGER
Identies 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
Identies actions or conditions which may
cause death, severe injury, or equipment
damage 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.

1 - 2 99906549_r02 (06/13/2023)
SECTION 1: SAFETY
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
• DO NOT perform any modications 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 inuence 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,
after 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 ll cap. Remove all electrical
power.
NOTE
Slowly remove ll cap to vent compressor sump
pressure.
• 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
specied pressure and speed ratings. (See
Section 2: Specications or refer to the
equipment data plate.).
• DO NOT use ammable solvents or cleaners
for cleaning the compressor or its parts.
• DO NOT operate the compressor in areas
where ammable, 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 cu󰀨s, ties,
or loose-tting clothing when you are working
near moving/rotating parts.
• ALWAYS conne 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 conned spaces where ventilation is
restricted or closed-o󰀨.
• Ensure that hoses connected to service valves
are tted with correctly sized and rated ow
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

99906549_r02 (06/13/2023) 1 - 3
SECTION 1: SAFETY
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
techniques to avoid injury.
• ALWAYS read and follow safety related
precautions found on containers of hazardous
substances.
1.3.3 CAUTIONS
CAUTION
Identies 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
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 specied
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 ttings 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
operators/maintainers a󰀨ecting operation,
maintenance, 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 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:
IMPORTANT
Additional, CRUCIAL information (or existing
information) which should be brought to the attention
of operators / maintainers a󰀨ecting operation,
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 decals listed in Section 7.11, Decal
Identication/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.
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 uids 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 uid in question.

1 - 4 99906549_r02 (06/13/2023)
SECTION 1: SAFETY
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
BLANK PAGE

SECTION 2:
SPECIFICATIONS
SECTION 2: SPECIFICATIONS
99906549_r02 (06/13/2023) 2 - 1
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
2.1 GENERAL INTRODUCTION
The tables and gures in this section list the
specications (including operational, output and
dimensional) of the overall machine. Contact
the IMT®Service Department if additional
specications are needed that cannot be found
in this manual.
Refer to Figure 2-1 (page 2 - 3) or general
machine component locations. For additional
information, including measurement
specications, refer to Figure 3-1 (machine and
identication 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 ow (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, dual 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 (with convertor)
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
Motor case drain 3/8" 37° JIC male
Continued on next page

SECTION 2: SPECIFICATIONS
2 - 2 99906549_r02 (06/13/2023) IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
TABLE 2A: SPECIFICATIONS
GENERAL SYSTEM INFORMATION SPECIFICATION
PACKAGE (continued)
Dimensions: Length — 32.50”
Width — 21.00”
Height — 23.94”
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: CAP SCREW 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 2: SPECIFICATIONS
99906549_r02 (06/13/2023) 2 - 3
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
CENTER
MANIFOLD
CLOSED
CENTER
MANIFOLD
VV
21
OPEN
S
GK
E
F
H
D
J
C
C
BB1
E
Y
Z
X
B
A
AA
BB
DD
BB
CC
W
OPEN - CENTER CONFIGURATION
L2Q
M
N
P
T
U
S
BB
BB
CLOSED - CENTER CONFIGURATION
1
LQ
M
N
P
U
T
RS
KEY DESCRIPTION KEY DESCRIPTION
ARELAYS IRLOAD SENSE #4 MJIC 37° (1/4-12 UNF)
BPRESSURE SWITCH SHYDRAULIC SUPPLY #12 MJIC 37° (1-1/16-12 UNF)
CCOMPRESSOR AIR FILTER HOUSING THYDRAULIC RETURN #16 MJIC 37° (1-5/16-12 UNF)
DCOMPRESSOR UNIT UCASE DRAIN #6 MJIC (9/16-18 UNF)
ELOW PRESSURE RELIEF VALVE V1OPEN CENTER MANIFOLD ASSEMBLY
FHIGH PRESSURE RELIEF VALVE V2CLOSED CENTER MANIFOLD ASSEMBLY
GCOMPRESSOR OIL FILL PORT WPRESSURE RELIEF VALVE
HCOMPRESSOR OIL DRAIN HOSE XSOLENOID VALVE
JCOOLER FAN & FAN MOTOR ASSEMBLY YFLOW REGULATOR
KHYDRAULIC MOTOR ZSOLENOID VALVE
L1CLOSED CENTER: functional piping & access locations AA INSTRUMENT PANEL (Pressure gauge & hour meter - pneumatic
control option only)
L2OPEN CENTER: functional piping & access locations
MSERVICE AIR DISCHARGE / CONNECTION MOUNT BB HYDRAULIC OIL COOLER
NDEUTSCH 6-PIN ELECTRICAL CONNECTION CC AIR DISCHARGE CHECK VALVE
PCOMPRESSOR OIL DRAIN (refer to Item H) DD SPIDER COUPLING ELEMENT
QCOMPRESSOR OIL SIGHT GLASS
I Relay sizes depend upon machine build order. Refer to Figure 5-7, Electrical Schematic (Section 7.15), and Wiring Diagram (Section 7.16), to deter-
mine correct relay sizes.
Figure 2-1: Machine Main Component Locations

SECTION 2: SPECIFICATIONS
2 - 4 99906549_r02 (06/13/2023) IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
BLANK PAGE

SECTION 3:
INSTALLATION
99906549_r02 (06/13/2023) 3 - 1
SECTION 3: INSTALLATION
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
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 locating and preparing the CAS40PL
compressor package for operation. Each
installation is unique and can be a󰀨ected by
location, ventilation, and other factors such as
electrical and hydraulic power supply availability
and location.
DISCLAIMER
DO NOT install this system in any enclosed
space without rst contacting IMT.
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 start-up.
DO NOT assume that because the compressor
is in a STOPPED condition that power has been
removed.
WARNING
DO NOT perform any modications 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
conned spaces where ventilation is restricted
or closed o󰀨.
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 vehicle
components (fuel tanks, lines, brake lines,
wiring harnesses), note their location before
drilling any holes.

3 - 2 99906549_r02 (06/13/2023)
SECTION 3: INSTALLATION
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
3.3 DETERMINING THE CAS40PL
UNIT MOUNTING LOCATION
When determining the location to mount the
CAS40PL unit, the following criteria must be
taken 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 (refer to Figure 3-1 or
3-2).
• The location must allow for the machine
dimensions, 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
compressor in any location where it can ingest
exhaust fumes, dust or debris.
NOTE
When considering external system layout hoses
refer to Section 7.19, 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
hydraulic supply components for vehicle
side integration (including oil reservoir size,
hydraulic pressure relief, hose size, etc.) for
your application.
IMPORTANT
Contaminated hydraulic uid allowed to enter
the pump will cause malfunction of the pump
controls. Hydraulic system hoses must be
ushed 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 ow and pressure requirements
of the system.
• A continuous hydraulic load is necessary when
compressor is running.
• The duty cycle and ambient operating
temperatures.
• Other hydraulic equipment which may share
that same hydraulic supply system (IMT
recommends 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
ensure proper ow. Also, verify that the hoses
are laid out properly so that no chang or kinking
of the hoses is possible. Refer to Section 7.19,
Hose Installation Guide, for assistance with
proper hose layout and connecting functions.

99906549_r02 (06/13/2023) 3 - 3
SECTION 3: INSTALLATION
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
COMPRESSOR AIR INLET
7.45
29.50
ALTERNATE DISPLAY POSITION
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 #16 MJIC 37° (9/16-18 UNF)
AIR FLOW
23.94
26.57
15.45
32.50
CLOSED CENTER FLOW CONTROL ACCESS POINT
PRESSURE GAUGE & HOUR METER
NOTES: 1. DECAL AREA SHOWN IN DASHED GRAY LINES
21.00
ALTERNATE LID HINGE DIRECTION
DEFAULT LID HINGE DIRECTION
1/2-13 UNC-2B (4X)
30.50
1.25
18.50
1.00
Figure 3-1: Installation and Dimensions Diagram - Open Center 12V DC
DISCLAIMER
If machine package is to be mounted within a conned space such as beneath a canopy, the area must be determined to allow for adequate air ow to take place for cooling purposes. Consult factory for assistance in ensuring adequate air ow 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.
051787-001_r0_TP

3 - 4 99906549_r02 (06/13/2023)
SECTION 3: INSTALLATION
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
COMPRESSOR AIR INLET
7.45
29.50
ALTERNATE DISPLAY POSITION
AIR FLOW
23.94
26.57
15.45
32.50
CLOSED CENTER FLOW CONTROL ACCESS POINT
PRESSURE GAUGE & HOUR METER
NOTES: 1. DECAL AREA SHOWN IN DASHED GRAY LINES
21.00
ALTERNATE LID HINGE DIRECTION
DEFAULT LID HINGE DIRECTION
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 #16 MJIC 37° (9/16-18 UNF)
1/2-13 UNC-2B (4X)
30.50
1.25
18.50
1.00
Figure 3-2: Installation and Dimensions Diagram - Open Center 12V DC with Cold Weather Option
051788-001_r0_TP
DISCLAIMER
If machine package is to be mounted within a conned space such as beneath a canopy, the area must be determined to allow for adequate air ow to take place for cooling purposes. Consult factory for assistance in ensuring adequate air ow 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.

99906549_r02 (06/13/2023) 3 - 5
SECTION 3: INSTALLATION
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
NOTE
The temperature of the hydraulic oil should
not exceed 160°F due to the rating of the IMT-
supplied hydraulic motor.
3.4.1 HYDRAULIC SYSTEM
FILTRATION
IMT recommends using a 10 micron oil lter
on the hydraulic oil return line. Flow rating of
the lter must be equal to, or greater than, the
maximum GPM at which the system will be
operated.
IMPORTANT
Use only a lter that is specically 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
maximum GPM ow 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
opening, avoiding the possibility of
drawing air into the pump due to a vortex
or “whirlpool” e󰀨ect within the tank during
operation ow.
2. Allows for better oil level tolerance level of
the system if vehicle operates at an unusual
(slightly o󰀨 level) vehicle angle.
3. To keep return ow well below the surface
so it does not break the surface and cause
aeration (cavitation) of the oil.
A
B
B
C
C
D
Figure 3-3: 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.
For machine dimensions, refer to Section 3, Figures 3-1 through
3-3.
IMPORTANT
Additional allotted dimensions/surroundings
space of package must allow for continuous
circulation of air around and through the
machine for cooling purposes. DO NOT
install in an enclosed area.

3 - 6 99906549_r02 (06/13/2023)
SECTION 3: INSTALLATION
IOWA MOLD TOOLING CO., INC.
[phone]
CAS40PL, CAS40PL-CW
RECIPROCATING AIR COMPRESSOR
3.4.2.3 3.4.2.3 MANDATORY RESERVOIR MANDATORY RESERVOIR
FEATURESFEATURES
•• The reservoir should incorporate the followingThe reservoir should incorporate the following
design features:design features:
•• In terms of location of the reservoir tank withinIn terms of location of the reservoir tank within
the hydraulic system, note that the hydraulicthe hydraulic system, note that the hydraulic
pump’s inlet line (suction line out from thepump’s inlet line (suction line out from the
reservoir to the pump) should be locatedreservoir to the pump) should be located
near the bottom of the tank, well below thenear the bottom of the tank, well below the
oil level. The suction line should protrude aoil level. The suction line should protrude a
minimum of two (2”) inches into the reservoirminimum of two (2”) inches into the reservoir
to keep it away from potential contaminantto keep it away from potential contaminant
surface buildup.surface buildup.
A
B
KEY DESCRIPTION
A PREFERRED SHAPE: TALL AND NARROW
BSHAPE TO AVOID: BROAD AND SHALLOW
• A ba󰀪e or ba󰀪es should be included to
prevent sloshing, or centrifugal motion of the
oil; the goal is to break up direct ow 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 owing oil.
• An ideal ba󰀪e design would position several
(but not too many) ba󰀪es to promote an ‘S’
shape ow 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 adapter or housing which does
not protrude above the inner surface of the
oor of the tank. It should be visible and
accessible for removal, with su󰀩cient 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 in-line lter on the return line is needed
to protect the system against contaminants
being introduced into the oil. The lter should
be mounted externally from the reservoir
in a location that allows for easy of service
access.
• A breather and ll cap is needed at the oil ll
port, which needs to be located above the
system oil level. The breather cap acts to
both lter air that is drawn into the reservoir
as the oil level diminishes, and bleeds air
out as the 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.
3.4.2.4 RECOMMENDED RESERVOIR
OPTIONS
Although not essential for an adequately
functioning reservoir, the following components
will contribute to maximize the hydraulic
system’s e󰀩ciency 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.
Figure 3-4: Reservoir Design Shape