Diamond DA435HA, Manual

Page 1: ...Compressor PART NO 20013 Single Cooler 10GPM Replaces Model DA435HAR 10 IOWA MOLD TOOLING CO INC BOX 189 500 HWY 18 WEST GARNER IA 50438 TEL 641 923 3711 MANUALPART NUMBER 99901219 Iowa Mold Tooling Co Inc is an Oshkosh Truck Corporation company ...

Page 2: ...CTANK HYDRAULIC PRESSURE DECALS 4 11 NEW HYDRAULIC INSTALLATION KIT DRAWING BOM 20020328 Section 4 UPDATED IMPROVED DRAWING QUALITY 20030715 4 10 ADDED DECAL KIT NUMBER TO DECAL PLACEMENT DRAWING 20040408 4 5 ADDED M TO ITEM 66 RUBBER CAP 20050630 4 9 through 4 14 ECN 9835 UPDATE CONNECTIONS ON 99901281 ADD HARNESS 304710 ADD CONNECTOR CHART ADD 99903712 6 1 through 6 8 REMOVED RELAYBOARD SECTION ...

Page 3: ...USE DEATH SERIOUS INJURY OR PROPERTY DAMAGE Drain air tank after each use to prevent moisture build up and corrosion which leads to tank failure Assure that tank and compressor relief valves work properly and are at correct pressure settings DO NOT modify or repair air tank NEVER drive vehicle with pressure in air tank ...

Page 4: ...NCE CHECKLIST 4 1 OIL COOLING SYSTEM 200057 4 2 COMPRESSOR MOUNTING SYSTEM 200056 1 4 3 COMPRESSOR ASSEMBLY 200056 2 4 4 COMPRESSOR ASSEMBLY 200056 3 4 5 COMPRESSOR ASSEMBLY 200056 4 4 6 CANOPY SYSTEM 4 7 COMPRESSOR WIRING DIAGRAM 4 8 INSTALLATION KIT 51712642 4 9 DECAL PLACEMENT 4 10 HYDRAULIC INSTALLATION KIT 91707052 4 11 DRIVELINE MOUNTING OPTION 31701761 4 12 REPAIR KITS 4 12 SECTION 5 REPAIR...

Page 5: ...mation on the installation operation and repair of the IMT Model DA435HA Hydraulic Air Compressor Three means are used throughout this manual to gain the attention of operating and service 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...

Page 6: ...DA435HA 99901219 1 2 19980930 NOTES ...

Page 7: ...sive remove gaskets and check backlash again until it is corrected 3 Remove the PTO and apply Permatex to the gaskets If the holes for the studs are tapped through the transmission housing apply Permatex to the studs and tighten them down Make certain that the studs do not interfere with the transmission gears CAUTION AVOID CONTACT OF PERMATEX WITH TRANSMISSION FLUID Registered Trademark of Permat...

Page 8: ...ING DRIVELINE REFER TO PARAGRAPH 2 4 FOR PROPER DRIVELINE INSTALLATION TECHNIQUES 1 Install the PTO refer to Paragraph 2 2 1 2 Loosely bolt the pump mounting bracket A to the adjustable bracket B in Figure B 2 3 Bolt the adjustable bracket to the frame at a point that will not exceed 48 122cm from the PTO and will not cause a joint angle greater than 3 4 Check the pump rotation and install pump pu...

Page 9: ... angles To reduce the amount of vibration the angles on each end of a driveshaft should always be SMALL To cancel an angle vibration the u joint operating angles need to be EQUAL within 1 at each end of a shaft See figure 2 4 2 SINGLE PLANE AND COMPOUND U JOINT OPERATING ANGLES There are two types of u joint operating angles single plane and compound SINGLE PLANE Single plane angles occur when the...

Page 10: ...angle C in the formula shown in figure below insert the u joint operating angle measurement obtained in the side view and the u joint operating angle obtained from the chart into the formula Do the same for the other end of the shaft Compare the resultant calculated u joint operating angle for each end They should be EQUAL within 1 If they are not the driveshaft will vibrate 2 4 3 ELIMINATING COMP...

Page 11: ...les of 3 or less Obtain the true u joint operating angle as explained above and if it is greater than 3 compare it to the following chart The angles shown on the chart are the MAXIMUM u joint operating angles recommended by IMT and are directly related to the speed of the driveshaft Any u joint operating angle greater than 3 will lower u joint life and may cause vibration Remember to check maximum...

Page 12: ...DA435HA 99901219 2 6 19980930 ...

Page 13: ...or engaged Adjust engine speed to ensure that compressor speed does not exceed 1400 RPM max under load Crack open air discharge valve until air pressure drops to 140 PSI and maintains this pressure without cycling Doing so simulates a maximum load condition If engine speed increase is required readjust air discharge valve to 140 PSI after speed has been increased Repeat until appropriate compresso...

Page 14: ...DA435HA 99901219 3 2 19980930 NOTES ...

Page 15: ...s your particular operating conditions dictate Oil capacity is 1 1 3 quarts NOTE 2 Cylinder head stud torque MUST be checked after the initial 8 10 hours of operation The compressor must be cold room temperature before retorquing of studs Torque studs to 240 in lbs plus or minus 10 in lbs MAINTENANCE OPERATION SERVICE INTERVALS DAILY WEEKLY 250 3 500 6 AIR INTAKE INSPECT CRANKCASE OIL LEVEL CHECK ...

Page 16: ...OLT 1 4 20 HEX W PL WASHER 4 C10 301577 FAN PUSHER 1 C11 300444 TAPE 1 16X3 4 CLOSED CELLO 2FT C12 301434 SHROUD OIL COOLER FAN ASM 13 1 C13 961505 140 NUT 5 16 18 TINNERMAN 8 C14 300211 RELAY POWER 2 C15 300909 025 CIRCUIT BREAKER 25A 1 C16 931600 050 SCREW 6 32X1 2 MACHINE 4 C17 973700 063 NUT 6 32 HEX NYLOC 1 C18 301433 BRACKET OIL COOLER SIDE 35 17 1 C19 960212 050 ELBOW 1 2NPT 3 4JIC 2 C20 30...

Page 17: ... PART NO DESCRIPTION QTY M22 301665 MOTOR HYDRAULIC 1 M23 970408 088 ELBOW SAE 10 1 2JIC 1 M24 301928 125 CLAMP CONDUIT 1 1 4 1 M25 934504 075 SCREW TAP 1 4X3 4 1 M26 301430 TUBE AIR INLET 1 M27 301418 SLEEVE 1 M28 301419 TUBE W EXT 1 M29 301417 SLEEVE 1 75 ID X 1 25 ID 1 M30 70048241 AIR FILTER W 90 ELBOW 1 M31 300857 CAP AIRFILTER 1 M32 300855 BAND AIR FILTER MTG 1 M33 924305 166 NUT 5 16 18 NYL...

Page 18: ...60106933 CHECK VALVE INSERT CAP 2 42 7Q072212 O RING 4 43 76393107 O RING 2 ITEM PART NO DESCRIPTION QTY 44 70014583 OIL PUMP SPRING 1 45 70024122 WASHER 33X 5X 03 COPPER 12 46 70029293 CYL BLOCK SPACER 2 47 51714023 INSERT ASM INCL 6 10 2 48 70039124 TAG SYNTHETIC OIL 1REF 49 70039300 DECAL PATENT 1 50 70051006 OIL PUMP 1 51 70143153 DIPSICK 1 53 70733069 REED VALVE ASM 2 56 72053403 PLUG 3 8 SH ...

Page 19: ...RESSOR ASM 200056 3 00200056 03 20010925 CONTINUED ON FOLLOWING PAGE 84 87 79 45 83 46 87 79 49 45 82 7 6 8 10 9 43 40 40 63 69 56 M54 M55 M56 M57 M10 M58 62 60 64 66 37 42 85 53 84 87 79 45 36 83 46 82 47 36 66 67 67 ...

Page 20: ...DA435HA 4 6 COMPRESSOR ASM 200056 4 00200056 04 19990209 ...

Page 21: ...3904 075 BOLT STAR DRIVE 1 4 20 x 3 4 20 H4 961504 090 NUT 1 4 20 TINNERMAN 14 H5 301436 PANEL END RECIP 1 H6 301435 PANEL END COOLER 1 H7 301381 HARNESS 35 RECIP 1 H8 301581 HARNESS TOWER 3 WAY 1 H9 301607 HARNESS SHROUD 3 WAY 1 H10 98404 071 WASHER FLAT WIDE 1 4 SS 20 CANOPY 01 20010925 ...

Page 22: ...RATURE SHUTDOWN SWITCH FURNAS SWITCH COOLING FAN ASM COMPRESSOR WIRING DIAGRAM M10033 WIRING 01 19990209 FAN CIRCUIT BREAKER FAN RELAY SOCKET SHUTDOWN SWITCH SHUTDOWN RELAY SOCKET FURNAS PRESSURE SWITCH HYDRAULIC SOLENOID VALVE CUSTOMER CONNECTIONS BATTERY 12VDC IGNITION 12VDC PTO GROUND SIGNAL SYSTEM GROUND SPEED CONTROL COMPRESSOR ON ...

Page 23: ...UNTING 01 20050630 DA435HA INSTALLATION ON SERIES 1 AND SERIES 2 DOMINATOR 12 75 12 00 4 40 13 38 0 44 TYP 4 DA435HA INSTALLATION ON SERIES 2 DOMINATOR WITH HEADACHE RACK AND STANDARD HEIGHT SIDEPACK ON COMPRESSOR SIDE 13 38 12 00 18 75 4 40 0 44 TYP 4 ...

Page 24: ...642 01 20010925 INSTALLATION KIT 51712642 THROUGH 3 15 05 INSTALLATION DWG 99901281 SHOWN ITEM PART NO DESCRIPTION QTY 1 76391527 BUMPER RUBBER 4 2 938206107 WASHER 3 8 FLAT GR8 938206107 4 3 929106200 BOLT 3 8 16X2 HHGR5 4 4 99901281 DRAWING 1 ...

Page 25: ...42 01 REV B 20050630 INSTALLATION KIT 51712642 EFFECTIVE 3 15 05 INSTALLATION DWG 99901281 SHOWN ITEM PART NO DESCRIPTION QTY 1 76391527 BUMPER RUBBER 4 2 929106200 BOLT 3 8 16X2 HHGR5 4 3 938206107 WASHER 3 8 FLAT GR8 4 ...

Page 26: ... the correct harness and or jumper must be ordered Use the following chart to determine the correct harness and or jumper If your DA435HA connector looks like Connector A and your body connector looks like this No jumper is needed 20050629 and your body connector looks like this Use jumper 77441160 If you are not using an IMT body and your connector looks like Connector A use jumpers 301581 and 30...

Page 27: ...35HA connector looks like Connector B and your body connector looks like this Use jumper 77441158 and your body connector looks like this No jumper is needed If you are not using an IMT body and your connector looks like Connector B use jumper 77441157 20050630 ...

Page 28: ...E CONNECTOR TO LOOM 2 POSITION SPAL BODY SFL FEM TERMINAL AMP FAN MOTOR 10 RINGS CIRCUIT BREAKER MP 2 WAY MALE TERMINAL CABLE SEAL SHUTDOWN SWITCH 1 0 B L A C K 9 B B L A C K 5 1 4 R E D 2 C 1 4 B L A C K 2 8 B L A C K Y E L L O W 4 8 14 RED YELLOW B BC 30 87 30 87 3 YELLOW 20 BLACK 90 DK BLUE 6 14 RED 87a 88 85 87a 86 85 10 BLACK 7 DK GREEN SHUTDOWN SWITCH RELAY SOCKET LOAD VIEW FAN POWER RELAY S...

Page 29: ... WARNING CONNECT AIR 1 I6 300041 DECAL WARNING FAN GUARD 1 I7 301442 DECAL DRIVE COUPLING 1 I8 301634 DECAL COMBO 1 I9 301480 SERIALPLATE 1 I10 302265 DECAL AIR 1 I11 302266 DECAL HYD TANK 1 I12 302267 DECAL HYD PRESSURE 1 NOT SHOWN SEE PLACEMENT CHART DECALS 01 20030715 DECAL PLACEMENT ITEM LOCATION I4 HOSE REEL COMPARTMENT I5 HOSE REEL COMPARTMENT I6 INSIDE CANOPY I7 INSIDE CANOPY I3 I2 I1 I1 I2...

Page 30: ...GATE VALVE 1NPT 1 15 72053185 PIPE NIPPLE 1NPTXCL 1 16 51706446 HOSEASM 3 4x35FF 1 17 51709743 FILTERASM 100 MESH 1REF 18 72532712 BEAD NIPPLE 16MSTR 1 45 1 20 51706981 HOSEASM 1 2X35 1 21 89392349 HOSE 3 4 300 17 22 72066000 HOSE CLAMP SAE 12 1 23 51704576 HOSEASM 3 4X72FF 1 24 72053458 BARB NIPPLE 3 4MPT 3 4HOSE1 25 72053556 STREET ELBOW 3 4NPT 90 1 26 73054685 ROTARY FLOW DIVIDER 1REF 27 725323...

Page 31: ...ET 1 10 72063053 WASHER 1 2 LOCK 8 11 72062004 NUT 1 2 13 HEX 8 12 HYDRAULIC PUMP REF 13 72060094 CAP SCR 1 2 13X1 3 4 HHGR5 4 PISTON RING SET 51014947 70014599 COMPRESSION RING 8 70014600 OIL RING 4 CRANKSHAFT KIT 51705743 51705742 CRANKSHAFTASM INCL KEY CRANK 1 70055010 BEARING REAR CUP 1 70055011 BEARING FRT CUP 1 70055012 BEARING FRT CONE 1 70055009 BEARING REAR CONE 1 72066307 DRIVE PIN 1 601...

Page 32: ...A 44 70014583 OIL PUMP SPRING 1 W N A 45 70024122 WASHER 33X 5X 03 COPPER 12 W N A 46 70029293 CYL BLOCK SPACER 2 W N A 47 51714023 INSERT ASM 2 W N A 50 70051006 OIL PUMP 1 C N A 53 70733069 REED VALVE ASM 2 W N A 66 70392654 CAP 1 3 4 RUBBER 2 C N A 71 72661487 DRIVE PIN 1 C N A 81 76039093 PUMP COVER GASKET 1 C N A 82 76039111 CYL BLOCK GASKET BOTTOM 2 C N A 83 76392119 CYLINDER BLOCK GASKET 2 ...

Page 33: ...ET FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN THE NEED TO RESEAL THE UNIT LATER 5 Hone the cylinder to break the glaze and to remove the buildup at the top of the cylinders 6 Measure the inside diameter of the cylinder for roundness and excessive wear The bore should be 2 625 0 0025 tolerance If the bore is oversized the cylinder must be replaced 7 With a ring expander remove the compression a...

Page 34: ...olts 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 RE...

Page 35: ...aring housing and gaskets FIGURE E 3 BEARING HOUSING TORQUE SEQUENCE NOTE GASKET KITSARE SUPPLIED WITH TWO 2 EACH OF 006 010 015 AND 020 GASKETS USE THESE REAR BEARING GASKETS INANY COMBINATIONAND QUANTITY TO LIMIT ALL PLAY FRONT TO REAR BUT STILL ALLOW THE CRANKSHAFT TO TURN FREELY 12 Install the oil pump See paragraph 5 3 13 Install the connecting rods Thoroughly oil the crankshaft and rods befo...

Page 36: ... COMPRESSOR INTERNAL CIRCUIT BREAKER TRIPPED PTO SWITCH NOT ENGAGED DEFECTIVE PRESSURE SWITCH OR UNDERHOOD SWITCH COMPRESSOR RELIEF VALVE ENGAGED AIR LEAK IN PLUMBING WORN PISTON RINGS OR VALVE PLATES DEFECTIVE CHECK VALVE VALVES DIRTY FILTER AIR LEAK IN PLUMBING WORN VALVE PLATES OR PISTON RINGS LOW OIL PRESSURE NO OIL PRESSURE COMPRESSOR WILL NOT ENGAGE COMPRESSOR ENGAGES BUT WILL NOT PRESSURIZE...

Page 37: ...DA435HA 99901219 6 9 19980930 ...

Page 38: ...either whole or in part whether by chemical electrostatic mechanical or photographic means without the expressedwritten permission of an officer of Iowa Mold Tooling Co Inc One manual is provided with each piece of new equipment and additional manuals may be obtained at a nominal price IOWA MOLD TOOLING CO INC BOX 189 GARNER IA 50438 0189 TEL 641 923 3711 TECHNICAL SUPPORT FAX 641 923 2424 ...