Diamond DA435HA User Manual
DA435HA: 99901219 20100927
Model DA435HA
Air 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
Iowa Mold Tooling Co., Inc. is an Oshkosh Truck Corporation company.
TEL: 641-923-3711
MANUAL PART NUMBER 99901219
DA435HA: 99901219: ii
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REVISIONS LIST
DATE LOCATION DESCRIPTION OF CHANGE
20000731 4-10 I2 70395091 WAS 73095091 ID DECAL
20010925 4-2 EN-1365 - CHANGED BLOCK TO 301996, SOLENOID TO 301997, VALVE TO 301998
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
20061127 4-4,5 ADDED ITEM 67 - 70392665 - RUBBER COUPLING TO 20056-2 PARTS LIST, 20056-3 DRAWING
20070405 Throughout ECN 10421 - MANUAL TITLE CHANGED TO CAS435HA
20100927 4-3 ECN 11273 -
4-3 UPDATED ITEMS M6, M11, M24, M25
4-4 M46 WAS 90° F ELBOW, IS NOW ELBOW 3/4JIC X 3/4NPT
4- 5 UPDATED DRAWING
4-7 EN-1369 - CHANGED BOLTS TO SS STAR DRIVE 1/4-20x3/4, ADDED 1/4 SS WASHER
4-9 ADDED DRAWING NO. TO BOM
4-10 ADDED AIR, HYDRAULIC TANK, HYDRAULIC PRESSURE DECALS
4-11 NEW HYDRAULIC INSTALLATION KIT DRAWING, BOM
CHART, ADD 99903712
6-1 through 6-8 REMOVED RELAY BOARD SECTION - OUTDATED
20056-1 - ITEM M30, 301438, REPL WITH 70048241
DA435HA: 99901219: iii
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19980930
PRECAUTIONS
Read before operating your compressor!
EXPLODING T ANK WILL CAUSE
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
71393886
pressure settings.
DO NOT modify or repair air tank.
●
●
EVER drive vehicle with pressure in air
tank.
DANGER
DA435HA: 99901219: iv
19980930
TABLE OF CONTENTS
PARA TITLE PAGE
SECTION 1. INTRODUCTION AND SPECIFICATIONS
1-1. INTRODUCTION ................................................................................................................ 1-1
1-2 ORDERING REPAIR PARTS ............................................................................................. 1-1
1-3. GENERAL INFORMATION................................................................................................. 1-1
1-4. SPECIFICATIONS.............................................................................................................. 1-1
SECTION 2. INST ALLATION
2-1. GENERAL .......................................................................................................................... 2-1
2-2. PTO AND PUMP INSTALLATION....................................................................................... 2-1
2-2-1. PTO INSTALLATION .......................................................................................................... 2-1
2-2-2. DRIVELINE AND PUMP INST ALLA TION ........................................................................... 2-2
2-3. COMPRESSOR INSTALLATION........................................................................................ 2-2
2-4. DRIVELINE INSTALLATION TECHNIQUES ...................................................................... 2-3
2-4-1. U-JOINT OPERATING ANGLES ........................................................................................ 2-3
2-4-2. SINGLE PLANE AND COMPOUND U-JOINT OPERATING ANGLES............................... 2-3
2-4-3. ELIMINA TING COMPOUND ANGLE INDUCED VIBRATION............................................. 2-4
2-4-4. ANGLE SIZE ...................................................................................................................... 2-5
SECTION 3. OPERA TION
3-1. GENERAL .......................................................................................................................... 3-1
3-2. OPERATION ...................................................................................................................... 3-1
SECTION 4. MAINTENANCE & PARTS
4-1. GENERAL .......................................................................................................................... 4-1
ROUTINE MAINTENANCE 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
INSTALLA TION KIT......................................................................51712642..................... 4-9
DECAL PLACEMENT......................................................................................................... 4-10
HYDRAULIC INST ALLATION KIT ................................................91707052..................... 4-11
DRIVELINE MOUNTING OPTION ...............................................31701761..................... 4-12
REPAIR KITS ..................................................................................................................... 4-12
SECTION 5. REP AIR
5-1. GENERAL .......................................................................................................................... 5-1
5-2. PISTON RING REPLACEMENT ........................................................................................ 5-1
5-3. OIL PUMP REPLACEMENT............................................................................................... 5-2
5-4. CRANKSHAFT AND BEARING REPLACEMENT .............................................................. 5-2
5-5. TROUBLESHOOTING ....................................................................................................... 5-4
SECTION 6. RELAY BOARD OPERATION
6-1. INTRODUCTION ................................................................................................................ 6-1
6-2. OPERATION ...................................................................................................................... 6-1
6-2-1. IGNITION “ON”................................................................................................................... 6-1
6-2-2. REMOTE STARTING THE VEHICLE................................................................................. 6-1
6-2-3. REMOTE ENGINE STOP................................................................................................... 6-1
6-2-4. REMOTE ENGINE SPEED (FROM CRANE)..................................................................... 6-3
6-2-5. COMPRESSOR ENGINE SPEED CONTROL (COMPRESSOR ONLY) ........................... 6-3
6-2-6. ENGINE SPEED CONTROL (CRANE&COMPRESSOR USED SIMULTANEOUSLY) ...... 6-3
6-3. INSTALLATION .................................................................................................................. 6-7
DA435HA: 99901219: 1-119980930
SECTION 1. INTRODUCTION AND SPECIFICATIONS
1-1. INTRODUCTION
This manual provides information 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 WHEN THERE IS THE STRONG
POSSIBILITY OF DAMAGE TO THE EQUIPMENT OR
PREMA TURE EQUIPMENT FAILURE.
WARNING
A W ARNING IS USED WHEN THERE IS THE POTENTIAL
FOR PERSONAL INJURY OR DEATH.
Operate this equipment with respect and service it
regularly for a safer working environment and
longer equipment life.
1-2. ORDERING INFORMATION
When placing orders or requesting assistance, refer
to the information below:
1-3. GENERAL INFORMATION
The IMT DA435HA air compressor is a single
stage, air cooled, 4-cylinder, pressure lubricated,
hydraulically driven unit, with a delivery rate of
35 CFM at 100 PSI.
CAUTION
OPERATING THE COMPRESSOR AT PRESSURES
ABOVE 150 PSI WILL SHORTEN THE SERVICE LIFE
AND VOID THE WARRANTY.
1-4. SPECIFICATIONS
Power Source Hydraulic Motor
Bore 2-5/8"
Stroke 2-1/2"
Cylinder Configuration V4
Dimensions 26-1/2"L x 19-1/8"H* x 19-3/4"W
Displacement 44 CFM**
Delivery 35 CFM**
Cooling Air
Fan Diameter 14-1/8"
Operating Speed 1400 RPM maximum
Lubrication Oil Pump
Oil Capacity 1-1/3 qts
Weight 200 lbs.
Reservoir requirement 12 Gallon minimum
Normal GPM @1400rpm 9.3 GPM
Normal Operating PSI 1850 PSI
Maximum PSI 2400 PSI
* Add 2-5/8” to height for air filter cap.
** @ 1400 RPM - 100 PSI
TRANSMISSION MAKE:
PTO NUMBER:
COMPRESSOR MODEL:
PUMP MAKE:
RESERVOIR CAPACITY:
TO BE COMPLETED BY DEALER
CHASSIS INFORMA TION
MODEL:
PTO %:
COMPRESSOR AND HYDRAULIC PUMP INFORMATION
SERIAL NUMBER:
MODEL:
ENGINE RPM:
DA435HA: 99901219: 1-219980930
NOTES
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SECTION 2. INSTALLATION
2-1. GENERAL
This section pertains to the installation of the IMT
DA435HA compressor, PTO and pump. The
instructions are intended as a guide to assist you
with your particular installation. These instructions
will provide only general information.
2-2. PTO AND PUMP INSTALLATION
The pump may either be installed directly on the
PTO (see Figure B-1) or, as an optional method, it
may be driven by a driveline (see Figure B-2).
2-2-1. PTO INSTALLATION
Power take-off manufacturers provide specific
installation instructions for their products. Those
instructions should be followed when installing a
PTO. Check with the PTO manufacturers
representative for specific instructions regarding
your particular make, model and year of vehicle.
The following instructions are a guide in this
application.
1. If the vehicle is new, drain the transmission oil
into a clean container for reuse. If the vehicle is
used, drain and dispose of the transmission oil
properly.
2. Temporarily install the PTO with the proper
gaskets and only two studs. Snug the PTO down
and check the backlash for maximum allowance of
.006" to .012". If the backlash is excessive, 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 Permatex Co., Inc., Kansas City, Kansas
4. Install the PTO and gaskets. Torque the nuts to
30 - 35 ft-lbs (4.14 - 4.84 kg-m) for a 6-bolt PTO
and 45 - 50 ft-lbs (6.22 - 6.91 kg-m) for 8-bolt
PTOs. Recheck the backlash.
5. Install the shifter cable to suit conditions.
Always allow for a slight overshift on lever or knob
to ensure the PTO is fully disengaged.
CAUTION
IT IS IMPORTANT THAT ADEQUATE SPACE BE
ALLOWED FOR FULL ENGAGEMENT OF THE PTO.
MODIFY THE EXHAUST OR OTHER OBSTRUCTIONS
AS NEEDED.
FIGURE B-1. PTO INSTALLATION
CAUTION
AVOID SHARP BENDS IN THE SHIFTER CABLE. ALL
BENDS SHOULD HAVE AT LEAST A 6" RADIUS.
TIGHTER BENDS WILL CAUSE DIFFICUL T OPERA TION
OF THE SHIFTER KNOB.
6. Replace the transmission oil. If the PTO is
located below the transmission oil level, an
additional quantity of oil will be required.
7. Start the engine, engage the PTO and check for
proper PTO rotation. Allow it to run for 5 - 10
minutes. Check for leaks, unusual noise and proper
operation.
8. Retorque the mounting bolts.
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2-2-2. DRIVELINE AND PUMP
INSTALLATION
The pump may be driven as shown in Figure B-2 as
an optional method to the one shown in Figure B-1.
The following steps are a guide in this application.
NOTE
BEFORE INSTALLING DRIVELINE, REFER TO
PARAGRAPH 2-4 FOR PROPER DRIVELINE
INST ALLATION 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, pump
end yoke and PTO end yoke.
WARNING
THE INSTALLER OF THE DRIVELINE MUST INSPECT
THE FINAL POSITION OF THE DRIVELINE TO
DETERMINE WHETHER ITS LOCATION PROVIDES
SUFFICIENT PROTECTION TO AN OPERATOR, OR
OTHER PERSONNEL, FROM HAZARDS ASSOCIATED
WITH A ROTATING DRIVELINE. IF PROTECTION IS
INSUFFICIENT, THE INSTALLATION OF A GUARD IS
REQUIRED. IF YOU ARE UNSURE OF METHODS TO
GUARD A ROTATING DRIVELINE, CALL IOWA MOLD
TOOLING CO., INC. FOR INSTRUCTIONS. FAILURE
TO DO SO MAY RESULT IN SERIOUS INJURY OR
DEATH.
5. Size, cut and weld the driveline to the necessary
length. Ensure driveline balance and run out meet
specification. Allow 1" (2.54cm) extra for PTO end
yoke.
6. Install driveline in phase with proper operating
angle calculations, lock set screws and grease Ujoints and mating spline.
7. Ensure all mounting bolts are tight.
2-3. COMPRESSOR INSTALLATION
See Installation Kit Drawing in the Parts Section for
specific installation and parts information.
FIGURE B-2. DRIVELINE & PUMP INSTALLATION
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2-4. DRIVELINE INSTALLATION
TECHNIQUES
2-4-1. U-JOINT OPERATING ANGLES
Every U-joint that operates at an angle creates
vibration.
U-joint operating angles are probably the most
common cause for driveline vibration in vehicles
that have been reworked or that have had auxiliary
equipment installed.
When reworking a chassis or installing a new
driveshaft in a vehicle, make sure that you follow
the basic rules that apply to u-joint operating angles,
as follows:
1. U-joint operating angles at each end of a shaft should
always be at least 1°.
2. U-joint operating angles on each end of a driveshaft
should always be equal within 1° of each other.
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 transmission and
pump components are in line when viewed from
either the top or side, but not both.
Determine the u-joint operating angle in an
application where the components are in line when
viewed from the top, but not in line when viewed
from the side, is as simple as measuring the slope of
the components in the side view, and adding or
subtracting those slopes to determine the angle. See
figure.
3. U-joint operating angles should not be larger than 3°. If
more than 3°, make sure they do not exceed the
maximum recommended angles for the RPM at which
they will be operating.
A u-joint operating angle is the angle that occurs at each
end of a driveshaft when the output shaft of the
transmission and the input shaft of the pump are not in
line. See figure.
The connecting driveshaft operates with an angle at
each u-joint. It is that angle that creates a vibration.
REDUCING AND CANCELING VIBRATION
A key point to remember about u-joint operating
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.
These angles should be SMALL and equal within 1°.
Determine the u-joint operating angles on a shaft
that is straight when viewed from the side and offset
when viewed from the top requires the use of a
special chart (See accompanying chart). In this type
of application, the centerlines of the connected
components must be parallel when viewed from the
top, as shown. These angles should also be SMALL
and equal within 1°. See figure.
Look at the angle chart and note that the smaller the
offset, the smaller the resultant angle.
To reduce the possibility of vibration, keep any
offset between connected points to a minimum.
DA435HA: 99901219: 2-419980930
There are two things which can be done to make
certain single plane angles are SMALL and
EQUAL:
Make sure that the transmission and pump are mounted
so that their centerlines are parallel when viewed from
both the side and the top.
Make sure the offset between them is mall in both views.
COMPOUND ANGLES
Compound u-joint operating angles occur when the
transmission and pump are not in line when viewed
from both, the top and side. Their centerlines,
however, are parallel in both views. See figure.
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 COMPOUND
ANGLE INDUCED VIBRATIONS
Compound u-joint operating angles are one of the
most common causes for driveline vibration. To
avoid thease problems, remember these important
considerations:
When setting up an application that requires compound ujoint operating angles, always keep the centerlines of the
transmission and pump parallel in both views.
Always keep the offset between their horizontal and
vertical centerlines small.
TRUE U-JOINT OPERATING ANGLE
The true u-joint operating angle, which must be
calculated for each end of the shaft with compound
angles, is a combination of the u-joint operating
angle in the top view, as determined from the chart,
and the measured u-joint operating angle in the side
view.
To determine the true u-joint operating angle for one
end of a shaft, (compound 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.
NOTE
CENTERLINES OF TRANSMISSION AND AXLE MUST
BE PARALLEL IN BOTH TOP AND SIDE VIEWS TO USE
THIS METHOD OF DETERMINING TRUE U-JOINT
OPERATING ANGLE. CONTACT IMT TECHNICAL
SUPPORT IF YOU HAVE AN APPLICATION WHICH
CANNOT BE INSTALLED WITH THEIR CENTERLINES
PARALLEL.
DA435HA: 99901219: 2-519980930
2-4-4. ANGLE SIZE
The magnitude of a vibration created by a u-joint
operating angle is proportional to the size of the ujoint operating angle. IMT recommends true u-joint
operating angles 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 safe driveshaft RPM
as recommended by the driveshaft manufacturer.
DRIVESHAFT
RPM
5000 3.2°
4500 3.7°
4000 4.2°
3500 5.0°
3000 5.8°
2500 7.0°
2000 8.7°
1500 11.5°
OPERATING ANGLE
MAXIMUM
ANGLE CHART
FOR DRIVESHAFTS HAVING AN ANGLE IN THE TOP VIEW
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