IMT CAS3560 Guide

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: [phone] FAX: [phone]
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.

Section 1 Compressor Introduction 9
Safety Decals
A compliment of warning decals are supplied with each unit. These decals must be affixed to the
vehicle after it has been painted, trimmed, and undercoated, etc. and prior to being put into
service. The decal placement should ensure decals are clearly visible to the user and service
personnel.
All decals for the IMT CAS3560 Air Compressor can be ordered on a decal sheet, part number
95718232.

10 IMT CAS3560 Air Compressor Manual Part No. 99903566
Warning & Caution Decals
WARNING
Do not operate with
cover removed.
CAUTION Minimum 8" (20 cm) clearance
on each end of compressor. 70397804

Section 1 Compressor Introduction 11
Instruction Decals
FILL OIL TO THIS
LEVEL IN
SIGHTGLASS.
USE IMT ROTARY SCREW
COMPRESSOR FLUID ONLY.
1. CHECK FLUID LEVEL COLD WITH
TRUCK OFF AND PARKED ON LEVEL
GROUND.
2. FLUID LEVEL MUST FILL 1/2 to 3/4
OF THE SIGHTGLASS.
3. DO NOT FILL ABOVE THE TOP OF
THE SIGHTGLASS.
FILL OIL TO THIS
LEVEL IN
SIGHTGLASS.
OIL FILL
HIGH TEMP / RESET
8000 RPM MAX AIR
LIFT HOOK
PRESSURE
COMP. OIL TEMP
TANK
In addition to these instruction decals, the CAS3560 air compressor is marked with a serial
number tag at the bottom of the back of the unit.

12 IMT CAS3560 Air Compressor Manual Part No. 99903566
CAS3560 System Description & Specifications
The IMT CAS3560 air compressor is a single-stage, air-cooled, rotary screw, pressure
lubricated, hydraulically driven unit designed for mobile or industrial applications. The
compressor provides high pressure air for use in air tools, tire service trucks, and other mobile or
stationary compressed air needs.
The compressor includes an oil-flooded, rotary screw-type design, a compressor inlet system, a
capacity control system, a lubricating oil system, and a discharge system in addition to basic
instrumentation. The instrumentation includes a temperature gauge, an hourmeter, a hi-temp
warning indicator, an oil level sightglass, and an air restriction indicator. All instrumentation is on
the front panel of the compressor. The air delivery rate of the unit is 65 CFM (1.8 cubic meters
per minute) at 150 PSI (10.3 bar).
CAUTION
Operating the compressor at pressures above 150 PSI (10.3 bar) will shorten the service life
and void the product warranty.
The unit has openings for cooling air intake on each end. Free airflow on all sides is desirable.
The front and rear of the compressor cannot be blocked.

Section 1 Compressor Introduction 13
CAS3560 Specifications
Units (English) Units (Metric)
Power Source Hydraulic Motor Hydraulic Motor
Dimensions 20" W x 33" L x 24.5" H 508 mm W x 838 mm L x 622 mm H
Delivery See charts. See charts.
Cooling Air Air
Fan Diameter 16" 406 mm
Operating Speed See charts (see "Performance Charts"
on page 14).
See charts (see "Performance Charts"
on page 14).
Lubrication Oil pump Oil pump
Oil Capacity 6 qts 5.7 L
Maximum
Compressor Oil
Temperature
250oF 121oC
Maximum
Hydraulic Oil
Temperature
180oF 82oC
Weight 365 lb wet 166 Kg wet
Normal Hydraulic
Flow
See charts (see "Performance Charts"
on page 14).
See charts (see "Performance Charts"
on page 14).
Normal Operating
Pressure
1850 psi 128 bar
Maximum Pressure 2400 psi 165 bar
Ambient Operating
Temperature
0oF to 120oF -18oC to 49oC
* Add 2-5/8" (67 mm) to height for air filter cap.
Specifications subject to change without prior notice.

14 IMT CAS3560 Air Compressor Manual Part No. 99903566
Performance Charts
Comp
r
esso
r
A
i
r
Output
v
s. Hyd
r
aulic Oil Input
0
10
20
30
40
50
60
70
80
90
100
7 8 9 10111213141516171819
Oil Flow (GPM)
Compressor Air Output vs Compressor Input Speed
0
10
20
30
40
50
60
70
80
90
100
3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000
Compressor Input Speed (RPM)
Air
Output
(CFM)
Air
Output
(CFM)

Section 1 Compressor Introduction 15
Comp
r
esso
r
A
i
r
Output
v
s. Comp
r
esso
r
Input HP
0
10
20
30
40
50
60
70
80
90
100
5.0 7.0 9.0 11.0 13.0 15.0 17.0 19.0 21.0 23.0 25.0
Compressor Input HP
Compressor Air Output vs. Hydraulic Oil Pressure
0
10
20
30
40
50
60
70
80
90
100
1500 1600 1700 1800 1900 2000 2100 2200 2300
Hydraulic Oil Pressure (psi)
Air
Output
(CFM)
Air
Output
(CFM)

16 IMT CAS3560 Air Compressor Manual Part No. 99903566
Performance Data (English)
CFM @ 100 PSI 40 45 60 75 90
Input Power (HP) 7.1 8.3 11.9 15.5 19.1
Compressor Speed (RPM) 3772 4222 5574 6925 8276
Hydraulic Motor Speed (RPM) 2599 2909 3840 4771 5702
Hydraulic Motor Flow (GPM) 8.27 9.22 12.08 14.94 17.8
Hydraulic Motor Pressure (PSI) 1531 1564 1660 1756 1852
Hydraulic Motor Torque (FT-LB) 14.4 15.0 16.3 17.1 17.6
CFM @ 125 PSI 35 45 55 65 75
Input Power (HP) 8.9 11.8 14.7 17.6 20.5
Compressor Speed (RPM) 3956 4990 6020 7051 8082
Hydraulic Motor Speed (RPM) 2726 3438 4148 4858 5568
Hydraulic Motor Flow (GPM) 8.67 10.88 13.1 15.31 17.5
Hydraulic Motor Pressure (PSI) 1766 1828 1889 1951 2013
Hydraulic Motor Torque (FT-LB) 17.1 18.0 18.6 19.0 19.3
CFM @ 150 PSI 25 35 45 55 65
Input Power (HP) 9.8 13.0 16.2 19.4 22.7
Compressor Speed (RPM) 4037 5101 6165 7229 8292
Hydraulic Motor Speed (RPM) 2781 3514 4248 4981 5713
Hydraulic Motor Flow (GPM) 8.79 11.08 13.67 15.66 18.0
Hydraulic Motor Pressure (PSI) 1924 1989 2054 2119 2184
Hydraulic Motor Torque (FT-LB) 18.4 19.4 20.0 20.5 20.8

Section 1 Compressor Introduction 17
Performance Data (Metric)
CFM @ 6.9 bar 1133 1274 1700 2124 2550
Input Power (Kw) 5.3 6.2 8.9 11.6 14.2
Compressor Speed (RPM) 3772 4222 5574 6925 8276
Hydraulic Motor Speed (RPM) 2599 2909 3840 4771 5702
Hydraulic Motor Flow (LPM) 31.3 34.9 45.7 56.6 67.4
Hydraulic Motor Pressure (bar) 105.6 107.8 114.4 121 127.7
Hydraulic Motor Torque (Nm) 19.5 20.3 22.1 23.2 23.9
CFM @ 8.6 bar 990 1274 1560 1840 2124
Input Power (Kw) 6.6 8.8 10.9 13.1 15.3
Compressor Speed (RPM) 3956 4990 6020 7051 8082
Hydraulic Motor Speed (RPM) 2726 3438 4148 4858 5568
Hydraulic Motor Flow (LPM) 32.8 41.2 49.6 57.9 66.2
Hydraulic Motor Pressure (bar) 121.8 126 130 134.5 138.8
Hydraulic Motor Torque (Nm) 23.2 24.4 25.2 25.8 26.2
CFM @ 10.3 bar 708 991 1274 1560 1840
Input Power (Kw) 7.3 9.7 12.1 14.5 16.9
Compressor Speed (RPM) 4037 5101 6165 7229 8292
Hydraulic Motor Speed (RPM) 2781 3514 4248 4981 5713
Hydraulic Motor Flow (LPM) 33.3 41.9 51.8 59.3 68.1
Hydraulic Motor Pressure (bar) 132.6 137.1 141.6 146 150.1
Hydraulic Motor Torque (Nm) 24.9 26.3 27.1 27.8 28.2

18 IMT CAS3560 Air Compressor Manual Part No. 99903566
CAS3560 Component Identification
A
20 LB Pressure Switch
5 LB Pressure Switch
Relay Module
Oil Fill Tube
Oil Filter
Pressure
Relief Valve
Hydraulic
Solenoid
Hi-Temp
Shutdown
Switch
Temp. Sender (not shown - visible
from side or top)
Fan
Fan Temp. Switch
Coalescer
(inside)
Min. Pressure
Valve (under cap)
Cooler
(Not shown -
visible from back)