DA435HA: 99901219:
5-2
19980930
11. Slide the cylinder down until it mates with the
crankcase. Start all cylinder mounting bolts, until
they are snug. Torque the bolts to 180 in-lbs in the
sequence shown. Do not torque to the full 180 in-lbs
all at once, but in 25-50 in-lb increments.
12. Position the gaskets and valve plate on top of the
cylinder. Position the head on the cylinder and turn
studs finger tight. Torque the studs/nuts to 240 in-lbs
in 25-50 pound increments per Figure E-2.
NOTE
INSTALL THE VALVE PLATE WITH THE MARKED
SURFACE FACING UP.
13. Install the pulsation tank, and torque to 180 in-
lbs.
14. Install the compressor, connect the wiring and
the air lines. Test the unit.
NOTE
IF PRESSURE FAILS TO BUILD AND THE
COMPRESSOR IS EXCESSIVELY NOISY, CHECK THE
VALVE PLATE. IT MAY HAVE BEEN INSTALLED UPSIDE
DOWN.
5-3. OIL PUMP REPLACEMENT
1. Remove the bolts and lift off the pump
cover.
2. With a single edged razor blade, or sharp putty
knife, remove the old gasket material. Take care not
to damage the machined surfaces.
3. Lift the pump out of the cavity.
4. Position a new gasket on the rear bearing
housing.
5. Insert the pump into the cavity. Position the
pump slightly to one side, using a common
screwdriver. Wedge the pump into position so that it
partially compresses the spring. Note that the driver
pin and slot in pump must be in line.
6. Place the pump cover into position and start two
bolts (bolts must be diagonally opposed). Strike the
pump cover with a rubber faced mallet to jar the
pump loose. When the tension spring can be felt
against the pump cover, the pump is loose.
7. Insert the two remaining bolts and torque to 180
in-lbs. The bolts should be torqued in a diagonal
pattern.
8. Install the air compressor in the vehicle.
Connect the air lines and wiring.
5-4. CRANKSHAFT AND BEARING
REPLACEMENT
If it is necessary to replace the crankshaft, related
components must also be replaced. Replace both
bearings, both races, the key, pump collar and pump
drive pin.
NOTE
DEPENDING ON THE CONDITION OF THE
CRANKSHAFT, BEARING MAY BE REPLACED
WITHOUT REPLACING THE CRANKSHAFT. REPLACE
THE BEARING RACES WHENEVER THE BEARINGS
ARE REPLACED.
1. Remove the pulsation tank, both heads,
cylinders, and pistons.
2. Remove the bolts on the connecting rods, and
lift them out. Reassemble the connecting rods to be
certain that the matched parts remain together on the
same crankshaft journals.
3. Remove the pump cover, oil pump, sleeve,
spring, and rear bearing housing.
4. Remove the hydraulic motor hub (#301266), and
the front bearing housing.
5. Pull the crankshaft from the crankcase.
6. Remove all gasket material with a single edged
razor blade, or sharp putty knife.
CAUTION
DO NOT GOUGE THE MACHINED SURFACES WHEN
REMOVING THE GASKETS. THIS MAY CAUSE LEAKS.
7. Press the bearing races out of the bearing
housing.
8. Press the tapered roller bearings off of the
crankshaft if only the bearings are being replaced. If
the crankshaft is to be replaced, discard the entire
assembly.
9. Press the new bearings into position.
