IMT CAS3560 Leitfaden
Printed on 30 June, 2009
Manual Part No. 99903566
IMT CAS3560 Air Compressor
Operation, Maintenance, and Spare Parts
Revised 20090630
IOWA MOLD TOOLING CO., INC.
PO Box 189
Garner, IA 50438
Tel: 641-923-3711 FAX: 641-923-2424
Website: http://www.imt.com
Copyright © 2009 Iowa Mold Tooling Co., Inc.
All rights reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise without the
prior written permission of Iowa Mold Tooling Co., Inc.
Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation company.
i
Contents
Revisions .................................................................................................................................................... iii
Compressor Introduction 5
Compressor Safety........................................................................................................................................7
Safety Decals ................................................................................................................................................9
Warning & Caution Decals..............................................................................................................10
Instruction Decals............................................................................................................................11
CAS3560 System Description & Specifications.........................................................................................12
Performance Charts ....................................................................................................................................14
Performance Data (English)........................................................................................................................16
Performance Data (Metric) .........................................................................................................................17
CAS3560 Component Identification...........................................................................................................18
Installation 21
Electrical Installation ..................................................................................................................................21
Compressor Installation (99903532)...........................................................................................................22
99903532 Drawing ..........................................................................................................................23
Electrical Installation (Non-IMT Application) (77441157) (Effective 3-15-05) ........................................24
Electrical Installation (Non-IMT Application) (77441084) (Through 3-15-2005).....................................24
Cooler Installation (99903573)...................................................................................................................25
Compressor Space Requirements ...............................................................................................................27
Decal Installation (99903551).....................................................................................................................28
Decal Placement (99903551)...........................................................................................................29
Compressor Mounting Locations (99903712) ............................................................................................32
Operation 33
Compressor Terminology ...........................................................................................................................33
Description of Components ........................................................................................................................34
Compressor Operation Test ........................................................................................................................37
Compressor Start-Up & Shut-Down...........................................................................................................38
Sub-Zero Temperature Operating Instructions ...........................................................................................39
Maintenance & Repair 41
Maintenance Schedule ................................................................................................................................42
CAS3560 Maintenance Procedures ............................................................................................................43
Lubricant Recommendations ......................................................................................................................48
Relay Module..............................................................................................................................................49
Flash Recovery Procedure ..........................................................................................................................50
Compressor Troubleshooting......................................................................................................................52
ii Contents
Parts 55
Parts Ordering Information.........................................................................................................................55
Recommended Spare Parts List ..................................................................................................................55
Compressor Assembly Complete Parts List (99903574) ............................................................................56
99903574-1 Drawing.......................................................................................................................60
99903574-2 Drawing.......................................................................................................................62
99903574-3 Drawing.......................................................................................................................64
99903574-4 Drawing.......................................................................................................................66
99903574-5 Drawing.......................................................................................................................68
Discharge Valve (70733872) ......................................................................................................................70
Compressor Air End ...................................................................................................................................71
Air Inlet Valve (70733873).........................................................................................................................72
Electrical Schematic ...................................................................................................................................73
Hydraulic Schematic...................................................................................................................................74
Hydraulic Schematic (99903516) ...............................................................................................................75
Contents iii
Revisions
DATE LOCATION DESCRIPTION
20031103 99903573 ECN 9305 - UPDATED FITTINGS, WIRING ON COOLER
INSTALLATION
20031230 77441084 (see
"Electrical
Installation
(Non-IMT
Application)
(77441084)
(Through 3-15-
2005)" on page
24)
Added non-IMT installation.
20040319 99903516 ECN 9401 - Revision to 99903516 Hyd. Schematic.
20040621 99903551 Added 99903551 Decal Installation Drawing.
20041110 99903574-2 Added sightglass, seal, and removal tool part numbers to compressor
assembly drawing.
20050315 99903532,
99903574
ECN 9647, 9713 - New harness with intro. of Dom II Series II;
20050711 99903532 ECN 9835 - 99903532 installation updates, hose changes to
99903573,74; added 99903712 standard mounting locations.
20050907 99903712,
99903573,
99903532
ECN 9907 - Added note regarding 10" minimum space between
compressor and hydraulic aftercooler.
20060523 99903532,
99903574,
99903573
ECN 10131, 10103, 10087- Mounting bolt length changes, hardware
quantity changes, fitting changes.
20061108 Updated ownership statement & IMT logo.
20070103 99903574 Added component parts lists to individual drawing pages.
20070815 99903573 Added harness and relay numbers to cooler install drawing 99903573.
Added metric units to specifications.
20090630 99904154 ECN 11062 - ADDED 70397804 COMPRESSOR CLEARANCE DECAL
TO DECAL KIT. ADDED CLEARANCE REQUIREMENT IN
INSTALLATION SECTION, AND WARNING IN SAFETY SECTION.
5
This volume provides information on the installation, operation, and repair of IMT hydraulic air
compressors. In addition to reading the manual, it is your responsibility to become familiar with
government regulations, hazards, and the specific operation of your equipment. Use caution
and common sense while operating and maintaining the equipment and follow all safety
procedures and regulations. Treat this equipment with respect and service it regularly.
MODIFICATIONS
Modifications to your equipment must be performed with IMT approved accessories, parts and
optional equipment. If in doubt, contact IMT prior to making any modifications. DO NOT alter or
modify any safety device! All safety devices must be inspected, tested and maintained in proper
working condition.
Decals regarding safety and operation are considered safety equipment, and must be kept clean
and legible.
The equipment owner and/or designated employee is responsible for informing all operators,
maintenance personnel, and others involved in equipment operation about the safe operation
and maintenance of the equipment. If questions arise concerning safe operation, contact IMT or
your IMT distributor for clarification.
WARRANTY
Warranty of this unit will be void on any part of the unit subjected to misuse due to overloading,
abuse, lack of maintenance and unauthorized modifications. No warranty - verbal, written or
implied - other than the official, published IMT new machinery and equipment warranty will be
valid with this unit.
NOTICE TO THE OWNER / USER
If your equipment is involved in a property damage accident, contact your IMT distributor
immediately and provide them with the details of the accident and the serial number of the
equipment. If an accident involves personal injury, immediately notify your distributor and IMT
Technical Support at:
IOWA MOLD TOOLING CO., INC.
500 HWY 18 WEST
GARNER, IA 50438
641 - 923 - 3711
SECTION 1
Compressor Introduction
6 IMT CAS3560 Air Compressor Manual Part No. 99903566
WARNING
READ YOUR MANUAL!! FAILURE TO READ, UNDERSTAND AND FOLLOW ANY SAFETY
PROCEDURES APPLICABLE TO YOUR EQUIPMENT MAY RESULT IN EQUIPMENT
DAMAGE, SERIOUS INJURY, OR DEATH.
MANUAL STRUCTURE
Throughout this manual, three means are used to draw the attention of personnel. They are
NOTEs, CAUTIONs and WARNINGs and are defined as follows:
NOTE
A NOTE is used to either convey additional information or to provide further emphasis for a
previous point.
CAUTION
A CAUTION is used when there is the very strong possibility of damage to the equipment or
premature equipment failure.
WARNING
A WARNING is used when there is the potential for personal injury or death.
Section 1 Compressor Introduction 7
Compressor Safety
AIR COMPRESSOR SAFETY PRECAUTIONS
Safety is basically common sense. While there are standard safety rules, each situation has its
own peculiarities that cannot always be covered by rules. Through experience and common
sense, you are in the best position to ensure your safety. Lack of attention to safety can result in
accidents, personal injury, reduction of efficiency and worst of all, loss of life. Watch for safety
hazards. Correct them promptly. Use the following safety precautions as a general guide to safe
operation:
WARNING
All units are shipped with a detailed Operators and Parts Manual. This Manual contains vital
information for the safe use and effective operation of this unit. Carefully read the Operators
Manual before starting the unit. Failure to adhere to the instructions could result in SERIOUS
BODILY INJURY or PROPERTY DAMAGE.
Make sure all protective covers and guards are in place, and that the canopy / doors are
closed during operation.
Be very cautious in using this machine in flammable gas risk areas. Use in these areas may
require additional safety equipment such as gas detectors, exhaust spark arrestors and shut-
off valves, depending on local regulations of the level of risk involved.
Relieve pressure from the entire system before attempting to service the compressor or
removing any compressor parts.
Do not attempt to service any part while machine is operating.
Ensure adequate ventilation when releasing discharge air into a confined space.
For proper airflow, maintain a minimum of 8" of clearance on each end of the compressor. If
installing the compressor with a hydraulic aftercooler, keep 10" minimum between the
compressor and aftercooler, and maintain 8" on each end of the compressor-cooler
combination.
WARNING
Check the compressor sump oil level only when the compressor is not operating and system
is completely relieved of pressure. Open service valve to ensure relief of system air pressure
when performing maintenance on compressor air/oil system.
FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTY AND
SERIOUS BODILY HARM.
Do not operate the compressor at pressure or speed in excess of its rating as indicated in
“Compressor Specifications”.
8 IMT CAS3560 Air Compressor Manual Part No. 99903566
Periodically check all safety devices for proper operation.
Do not play with compressed air. Pressurized air can cause serious injury. Avoid bodily
contact with compressed air.
Exercise cleanliness during maintenance and when making repairs. Keep dirt away from
parts by covering parts and exposed openings.
DANGER
Do NOT use IMT compressor systems to provide breathing air. Such usage, whether
supplied immediately from the compressor source, or supplied to breathing tanks for
subsequent use, can cause serious bodily injury. Air discharged from the compressor may
contain carbon monoxide or other contaminants.
IMT disclaims any and all liabilities for damage or loss due to personal injuries, including
death, and/or property damage including consequential damages from using any IMT
compressors for breathing air.
Do not disconnect or bypass safety circuit system.
Do not install safety devices other than authorized IMT replacement devices.
Close all openings and replace all covers and guards before operating compressor unit.
Do not leave tools, rags, or loose parts on the compressor or drive parts.
Do not use flammable solvents for cleaning parts.
Keep combustibles out of and away from the compressor and any associated enclosures.
Use hearing protection around the compressor. The compressor produces loud noises
which, over extended exposure, can cause hearing loss.
The owner, lessor, or operator of the compressor are hereby notified and forewarned that any
failure to observe these safety precautions may result in damage or injury.
IMT expressly disclaims responsibility or liability for any injury or damage caused by failure to
observe these specified precautions or by failure to exercise that ordinary caution and due care
required when operating or handling the compressor, even though not expressly specified
above.
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