Diamond DA435HA User Manual

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Page 1

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

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DA435HA: 99901219: ii

--------

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6-1 through 6-8 REMOVED RELAY BOARD SECTION - OUTDATED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

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DA435HA: 99901219: iii

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

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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

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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:

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DA435HA: 99901219: 1-219980930

NOTES

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DA435HA: 99901219: 2-1

19980930

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 manufacturers 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 PTOs. 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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DA435HA: 99901219: 2-2

19980930

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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DA435HA: 99901219: 2-319980930

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.

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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.

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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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DA435HA: 99901219: 2-619980930

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DA435HA: 99901219: 3-119980930

SECTION 3. OPERATION

3-1. GENERAL

Each compressor is bench tested under load at the factory to ensure proper break-in and operation. While it is not necessary to follow any break-in procedure, the following checks should be made before putting the unit into service, as well as, periodically during use.

1. Before start-up: A. Check the oil level in the compressor crankcase with the dipstick on the unit. If oil is needed, use only IMTs synthetic compressor oil. Always check compressor oil level with the truck and compressor on level ground.

B. Check the air intake filter to make certain that it is clean and unobstructed. A dirty filter is a possible cause of reduced air output.

C. Avoid operating the compressor package when the side-to-side or front-to-rear tilt is greater than 20°.

2. With the compressor 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.

3-2. OPERATION

To use the compressor, start the vehicle engine and engage the compressor by operating the compressor switch.

The system will now function automatically. It will engage the hydraulic solenoid when the air pressure is below 120 psi, and disengage when the air

pressure reaches 150 psi.

CAUTION

OPERATING THIS UNIT IN EXCESS OF 1400 RPM, WILL VOID THE WARRANTY , AND WILL SHORTEN THE NORMAL SERVICE LIFE OF THE COMPRESSOR.

If engine speed increase is required, readjust air discharge valve to 140 PSI after speed has been increased. Repeat until appropriate compressor RPM (NOT engine) is acheived.

Checking compressor RPM can be done using a phototach on the drive coupling through the air cleaner access hole. A hydraulic flow meter can be used, but is nat as accurate.

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DA435HA: 99901219: 3-219980930

NOTES

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DA435HA: 4-199901219: 19980930

Section 4. MAINTENANCE & PARTS

4-1. GENERAL

The following table provides list of routine maintenance items, including service intervals. The remainder of Section 4 includes a part lists and assembly drawings of the compressor.

SERVICE INTERVALS

MAINTENANCE OPERATION

INSPECT DRIVE COUPLING FOR WEAR AIR CLEANER - CHANGE AIR INTAKE - INSPECT CRANKCASE OIL LEVEL - CHECK, ADD IF NEEDED CRANKCASE OIL - CHANGE (SEE NOTE 1) CHECK CYLINDER HEAD STUD TORQUE (SEE NOTE 2) COOLING VANES (FINS) - CLEAN SAFETY VALVES - CHECK OPERATION

SAFETY VALVES - CLEAN AIR RECEIVER - DRAIN CONDENSATION RECEIVER SAFETY VALVES - CHECK OPERATION TIGHTEN AND CHECK ALL VAL VES CHECK ALL ELECTRICAL CONNECTIONS CHECK FITTINGS AND AIR LINES FOR LEAKS INSPECT CHECK VAL VES FOR PROPER OPERATION

DAILY WEEKLY 250/3 500/6

INSPECT CHECK VALVES FOR CARBON BUILDUP

Service intervals are listed as hours/months, whichever occurs first.

Use only IMT’s synthetic compressor oil. The use of any other oil causes excessive carbon buildup, and will void the

warranty on the compressor.

NOTE 1.

Under normal operating conditions, oil changes are required every 3 months. When operating in a dirty environment,

change the oil and air filter more frequently as 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.

FIGURE D-1. ROUTINE MAINTENANCE CHECKLIST

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DA435HA: 4-2

00200057.01: 20010925

OIL COOLING SYSTEM (200057)

ITEM PART NO. DESCRIPTION QTY

200057 OIL COOLING SYSTEM 1

C1 80021 KIT HYD BLK N.O. SLND 1

301996 BLOCK-HYDRAULIC VALVE 1 301997 SOLENOID-HYDRAULIC 12VDC N.O. 1

301998 VALVE-RELIEF PILOTED SPOOL 1 C2 970508-106 CONNECTOR 1/2JIC 3/4SAE 1 C3 975508-019 HOSE ASM 1/2X19 SXE 1 C4 976512-1212 TEE 3/4NPT 3/4JIC MALE RUN 1 C5 975412-021 HOSE ASM 3/4X21” 2 C6 975412-029 HOSE ASM 1/2X29 SXS 1 C7 961504-090 NUT 1/4-20 TINNERMAN 4 C8 929705-075 BOLT 5/16-18X3 WHIZLOCK GR5 12 C9 974604-088 BOLT 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 300836 OIL COOLER 12X13.5 1 C21 938205-071 WASHER 5/16 FLAT 6 C22 924305-166 NUT 5/16-18 NYLOC GR5 6 C23 301432 SUPPORT-OIL COOLER 35/175 RS 1 C24 929105-275 BOLT 5/16-18X2-3/4 HHGR5 2

C24 C21 C22

M10029

C23

C8 C21 C22

C19

C20

C19

C18

C13

C10 C11

C12

C14

C15

C16,C17

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DA435HA: 4-300200056.01: 20100927

COMPRESSOR MTG SYSTEM (200056-1)

ITEM PART NO. DESCRIPTION QTY

M1 70000-001 COMPRESSOR REF M2 929806-150 BOLT 3/8-16X1-1/2 HHGR8 6 M3 929704-050 BOLT 1/4-20X1/2 WHIZLOC 2 M4 301405 BASE 1 M5 961504-090 NUT 1/4-20 TINNERMAN 6 M6 978512-023 HOSE ASSY SS 3/4 1 M7 910212-075 CONNECTOR-TUBE 3/4X3/4NPT 1 M8 77041369 PRESSURE SWITCH W/UNLOADER 1 M9 961608-025 REDUCING NIPPLE 1/2X1/4NPT 1 M10 975200-025 INSERT-BRASS 2 M11 902203-022 REDUCER TEE 3/4X1/2X1/2 1 M12 922108-020 NIPPLE 1/2X2 SCH40 1 M13 301578 SWITCH-TEMP 1 M14 902415-020 TEE-PIPE 1/2 1 M15 922108-050 PIPE NIPPLE 1/2X5 SCH40 1 M16 929806-125 BOLT 3/8-16X1-1/4 HH 6 M17 301260 BRACKET 1 M18 938206-071 WASHER 3/8 FLAT 12 M19 925506-198 NUT 3/8-16 NYLOC GR8 12 M20 301248 BRACKET-HYD MTR MNT 1 M21 970412-106 ELBOW SAE#12 3/4JIC 1

M31

M34

M35

M30

M32

M29

M28

M33

CONTINUED ON FOLLOWING PAGE

ITEM 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-AIR FILTER 1 M32 300855 BAND-AIR FILTER MTG 1 M33 924305-166 NUT 5/16-18 NYLOC GR5 2 M34 938205-071 WASHER 5/16 FLAT 2 M35 301602 ISOLATOR 2 M36 301266 HUB-HYD MTR 1 M37 301267 SPIDER 1 M38 301265 HUB-CPRSR COUPLING 1 M39 301446 BRACKET-AIR FILTER 1 M40 929105-125 BOLT 5/16-18X1-1/4 HHGR5 2 M41 929405-125 BOLT5/16-24X1-1/4 HHGR5 1 M42 301628 WASHER-HUB RECIP 1 M43 300570-075 CLAMP 3/4 HOSE 1 M44 929105-100 BOLT 5/16-18X1 HHGR5 1 M45 925305-283 NUT 5/16-18 WHIZLOC 1

M39 M40

M36 M37 M38 M41 M42

M43 M45

M27

M26

M23

M18 M19

M22

M21

M20

M16

M18 M19

M17

M16

M44

M15

M14

M13

M12

M24 M25

M11

M4 M5

M8 M9 M10

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DA435HA: 4-400200056.02: 20061127

COMPRESSOR ASM (200056-2)

ITEM PART NO. DESCRIPTION QTY

200056 COMPRESSOR & MTG SYS REF 70000-001 COMPRESSOR REF

1. 51014947 RING SET-3 (INCL:2-3) 1

2. 70014599 COMPRESSION RING (part of 1) 8REF

3. 70014600 OIL RING (part of 1) 4REF

4. 51029283 CONNECTING ROD ASM 4

5. 51029285 PISTON ASM (INCL:88-90) 4

6. 7Q073017 O-RING (part of 47) 2REF

7. 70029468 SHIM (part of 47) 2REF

8. 76393085 O-RING (part of 47) 2REF

9. 72066426 BALL 19/32 STL (part of 47) 2REF

10. 70029593 INSERT (part of 47) 2REF

11. 51706913 CRANKCASE/CRANKSHAFT ASM

(INCL:12-33,91-94) 1

12. 51705661 CRANKSHAFT

(part of 11,INCL:13-17) 1REF

13. 60101269 OIL PUMP COLLAR (part of 12) 1REF

14. 60108748 CRANKSHAFT (part of 12) 1REF

15. 70055009 CONE BEARING (part of 12) 1REF

16. 70055012 CONE BEARING (part of 12) 1REF

17. 72066307 ROLL PIN .16X.44 (part of 12) 1REF

18. 51705709 FRT BRG HSG ASM

(part of 11,INCL:19-21) 1REF

19. 60025007 FRT BRG HSG (part of 18) 1REF

20. 70055011 CUP BEARING (part of 18) 1REF

21. 76039119 SEAL (part of 18) 1REF

22. 51705710 REAR BRG HSG ASM

(part of 11,INCL:23-24) 1REF

23. 60025005 REAR BRG HSG (part of 22) 1REF

24. 70055010 CUP BEARING (part of 22) 1REF

25. 60025012 CRANKCASE (part of 11) 1REF

26. 60120138 OIL SCREEN TUBE (part of 11) 1REF

27. 60120289 OIL SCREEN ([part of 11) 1REF

28. 72053403 PLUG 3/8 SH (part of 11) 1REF

29. 929105-100 CAP SCR 5/16-18X1 (part of 11) 5REF

30. 72060731 CAP SCR 5/16-18X3/4 SH(part of 11) 5REF

31. 938005-078 WASHER 5/16 LOCK (part of 11) 5REF

32. 72066008 OIL SCREEN CLAMP (part of 11) 1REF

33. 76039112 FRT BRG HSG GASKET(part of 11) 2REF

34. 60025006 REAR BRG HSG COVER 1

35. 60025193 PULSATION TANK 1

36. 60025194 CYLINDER BLOCK 2

37. 60025492 HEAD 2

38. 60101505 PLUNGER TRANSFER BUSHING 1

39. 60101507 BREATHER PIPE 1

40. 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 4

57. 72053404 PLUG 1/2 SH 1

58. 72053411 PLUG 1/8 SQHD 2

60. 72601708 STUD 5/16-18X3-1/2 12

62. 72062001 NUT 5/16-18 HEX 12

63. 72060063 CAP SCR 7/16-14X1-1/4 HHGR5 4

64. 72063001 WASHER 1/4 WRT 12

65. 72060731 CAP SCR 5/16-18X3/4 SH 4

66. 70392654M CAP 1-3/4 RUBBER 2REF

67. 70392654 COUPLING, RUBBER 2REF

69. 72063052 WASHER 7/16 LOCK 4

70. 72066267 WOODRUFF KEY .16X.62(part of 12) 1

71. 72661487 DRIVE PIN 1

79. 72601060 STUD 5/16X2 NC GR5 12

80. 73731843 DIPSTICK ASM 1

81. 76039093 PUMP COVER GASKET 1

82. 76039111 CYL BLOCK GASKET-BOTTOM 2

83. 76392119 CYLINDER BLOCK GASKET 2

84. 76392641 REED VALVE/CYL GASKET 2

85. 76392642 REED VALVE/HEAD GASKET 2

87. 72062036 NUT 5/16-24 HEX 12

88. 72066018 RET’G RING 5/8 STD INT(part of 5) 8REF

89. 70014627 PISTON PIN (part of 5) 4REF

90. 70029062 PISTON (part of 5) 4REF

91. 76039092 GASKET .006 (part of 11) 1REF

92. 76039094 GASKET .010 (part of 11) 1REF

94. 76039144 GASKET .020 (part of 11) 4REF

M10 975200-025 INSERT-BRASS 2 M46 981412-075 ELBOW-3/4JIC X 3/4 NPT LG 90° 1 M47 960412-075 NIPPLE 3/4MPT 3/4MPT HEX 1 M48 906130-015 PIPE CAP 3/8NPT 1 M49 922106-030 PIPE NIPPLE 3/8NPT X 3 1 M50 907215-020 PIPE COUPLING 1/2NPT SCH40 1 M51 923108-030 PIPE NIPPLE 1/2X3 GALV 1 M52 72531856 REDUCER COUPLING 3/4FPT 1 M53 70143495 BREATHER CAP 1 M54 907601-005 REDUCER BUSHING 3/8 1/8NPT 1 M55 922102-020 PIPE NIPPLE 1/8NPT X 2 SCH40 1 M56 907215-005 PIPE COUPLING 1/8 SCH40 GALV 1 M57 975104-012 ELBOW 1/8 X 1/4 90° COMPRSN 1 M58 89034176 TUBING 1/4 AIR BRAKE .75FT

CONTINUED ON FOLLOWING PAGE

Page 19

DA435HA: 4-5

00200056.03: 20010925

COMPRESSOR ASM (200056-3)

CONTINUED ON FOLLOWING PAGE

40 43

8 6 7

46 82

M57

M10

M58

M56

M55

M54

Page 20

DA435HA: 4-6

00200056.04: 19990209

COMPRESSOR ASM (200056-4)

Page 21

DA435HA: 4-7

CANOPY.01: 20010925

CANOPY SYSTEM

H1 301437 CANOPY 1 H2 977004-062 WASHER 1/4X.062X5/8 20 H3 983904-075 BOL T, ST A R 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, FLA T WIDE 1/4” SS 20

Page 22

DA435HA: 4-8

WIRING.01: 19990209

COMPRESSOR WIRING DIAGRAM

FAN

POWER RELAY

HIGH TEMPERATURE

SHUTDOWN

SWITCH RELAY

HYDRAULIC VALVE BLOCK ASM W/ N.O. SOLENOID AND RELIEF VALVES

COOLING FAN ASM

M10033

HIGH TEMPERAT URE SHUTDOWN SWITCH

SHUTDOWN RELAY SOCKET

FAN RELAY SOCKET

CIRCUIT BREAKER

FURNAS

SWITCH

FURNAS PRESSURE SWITCH

SHUTDOWN SWITCH

HYDRAULIC SOLENOID VALVE

FAN

BATTERY 12VDC IGNITION 12VDC PTO GROUND SIGNAL

CUSTOMER CONNECTIONS

SYSTEM GROUND SPEED CONTROL COMPRESSOR ON

Page 23

DA435HA: 4-9

MOUNTING.01: 20050630

DA435HA MOUNTING LOCATIONS (99903712)

DA435HA INSTALLATION ON SERIES 1 AND SERIES 2 DOMINATOR

4.40

13.38

12.75 12.00

DA435HA INSTALLATION ON SERIES 2 DOMINATOR WITH HEADACHE RACK AND STANDARD HEIGHT SIDEPACK ON COMPRESSOR SIDE

4.40

13.38

0.44 TYP. (4)

12.0018.75

Page 24

DA435HA: 4-10

51712642.01: 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 FLA T GR8 (938206107) 4

3. 929106200 BOLT 3/8-16X2 HHGR5 4

4. 99901281 DRAWING 1

1 TYP (4)

2 TYP (4)

3 TYP (4)

Page 25

DA435HA: 4-1151712642.01: 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 FLA T GR8 4

Page 26

DA435HA: 4-12

20050629

COMPRESSOR HARNESS CHART

Effective March 15, 2005, the connectors in the harnesses used on the DA435HA were upgraded. The old and new connectors are not interchangeable, so for replacement parts, 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.

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 301607.

Page 27

DA435HA: 4-13

20050630

COMPRESSOR HARNESS CHART, CONTINUED

If your DA435HA 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.

Page 28

DA435HA: 4-14

304710: 20050629

HARNESS (304710) EFFECTIVE 3/15/05

LOCKING

#8 SPAD

ORANGE 4A

FORKS

14 YELLOW

YELLOW

28 BLACK

14 YELLOW

SWITCH

3 YELLOW

2-WAY WP TOWER CONNECTOR

2 FEMALE TERMINALS

2 GRAY CABLE SEALS

BUTT

9B BLACK

10 BLACK

14 RED

14 GA WIRE

14 BLACK

14 RED

MP 2 WAY MALE

SHUTDOWN SWITCH

TERMINAL, CABLE SEAL,

#10 RINGS

WIRE TIE

CONNECTOR

FAN MOTOR

FEM TERMINAL AMP

PIN "F" IS

14 BLACK ORANGE YELLOW

DK GREEN

14 RED

TO LOOM

NOT USED

8-PIN CONNECTOR

YELLOW

BLACK

SHUTDOWN

SWITCH

87a

87 30

RELAY SOCKET

(LOAD VIEW)

10 BLACK

YELLOW

7 DK GREEN

14 RED

FAN POWER

CIRCUIT BREAKER

DK. BLUE

87a

RELAY SOCKET

(LOAD VIEW)

2 POSITION SPAL BODY SFL

ALL WIRE IS 16 GA GPT. EXCEPT 14 GA AS SHOWN.

Page 29

DA435HA: 4-15

DECALS.01: 20030715

DECAL PLACEMENT (80015)

ITEM PART NO. DESCRIPTION QTY

I1 71393715 DECAL-DIAMOND AIR 2 I2 70395091 DECAL-DA435HA COMPRESSOR 2 I3 300913 DECAL-OIL DRAIN 1 I4 *300040 DECAL-DANGER BREATHING AIR 1 I5 *300042 DECAL-WARNING CONNECT AIR 1 I6 *300041 DECAL-WARNING FAN GUARD 1 I7 *301442 DECAL-DRIVE COUPLING 1 I8 301634 DECAL COMBO 1 I9 301480 SERIAL PLATE 1 I10 302265 DECAL - AIR 1 I11 302266 DECAL - HYD. TANK 1 I12 302267 DECAL - HYD. PRESSURE 1

* NOT SHOWN-SEE PLACEMENT CHART

DECAL PLACEMENT

ITEM LOCATION

I4 HOSE REEL COMPARTMENT I5 HOSE REEL COMPARTMENT I6 INSIDE CANOPY I7 INSIDE CANOPY

I10

I11

I12

Page 30

DA435HA: 4-16

INSTALL: 20010925

HYDRAULIC INSTALLATION KIT (91707052)

1. 72531427 ELBOW 3/4NPT #12MJIC 1

2. 72053676 ADAPTER 3/4MPT #12MJIC 3

3. 51707317 HOSE ASM 3/4X100 1

4. 51703585 HOSE ASM 1/2X220 FF 1

5. 72053141 PIPE NIPPLE 3/4NPT X CL 1

6. 73054129 GA T E V A L V E 3/4NPT 1

7. 73052040 HYD FILTR 25MIC 1-1/4FPT 1REF

8. 72053180 REDUCER BUSHING 1-1/4 3/4 1

9. 72532658 ELBOW #8MJIC #8FJIC 2

(NOT SHOWN)

10. 72053377 REDUCER BUSHING 1-1/4 1 3

11. 72431549 BARB NIPPLE 1MPT 1HOSE 3

12. 89039481 HOSE 1” 100R4 14FT

13. 72066515 HOSE CLAMP 1” 2-BOLT 4

14. 73054001 GA TE VALVE 1NPT 1

15. 72053185 PIPE NIPPLE 1NPTXCL 1

16. 51706446 HOSE ASM 3/4x35FF 1

17. 51709743 FILTER ASM 100-MESH 1REF

18. 72532712 BEAD NIPPLE #16MSTR 1” 45° 1

20. 51706981 HOSE ASM 1/2X35 1

21. 89392349 HOSE 3/4 300# 17”

22. 72066000 HOSE CLAMP SAE#12 1

23. 51704576 HOSE ASM 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. 72532358 ADAPTER 3REF

28. 72532376 HOSE FITTING 4REF

29. 72532695 TEE MJIC 1REF

30. 51711092 KIT-RELA Y BRD 1REF

31. 93710121 INSTALLA TION KIT W/CRANE 1REF (INCLUDES 26-30)

32. 72533373 UNION BULKHD #8JIC 1

33. 72533371 UNION BULKHD #12JIC 1

34. 72531836 RED BUSHING 1-1/4 3/4NPT 1

35. 72533564 ADAPTER 1-1/4MPT #16MJIC 1

36. 72533028 ADAPTER #12MJIC #16FJIC 1

Page 31

DA435HA: 4-17

31701761.01: 19980930

DRIVELINE MOUNTING OPTION (31701761)

ITEM PART NO. DESCRIPTION QTY

1. POWER TAKE-OFF REF

2. 70058146 END YOKE 1

3. 72060578 SET SCR 3/8-16X3/8 HH 1

4. 70058195 DRIVESHAFT ASM 1

5. 70058094 END YOKE 1

6. 60101988 MOUNTING BRACKET 1

7. 72063005 WASHER 1/2 WRT 4

8. 72060093 CAP SCR 1/2-13X1/2 HHGR5 4

9. 52703382 PUMP MOUNTING BRACKET 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

WARNING

GASKET KIT (51393217)

7Q072212 O-RING - CYL HEAD 4 76039092 GASKET-REAR BRG HSG .006 2 76039093 GASKET-PUMP COVER 1 76039094 GASKET-REAR BRG HSG .010 2 76039111 GASKET-CYL BLOCK BOTTOM 2 76039112 GASKET-FRT BRG HSG 2 76039119 SEAL 1 76039143 GASKET-REAR BRG HSG .015 2 76039144 GASKET-REAR BRG HSG .020 2 76392119 GASKET-CYL BLOCK 2 76392641 GASKET-REED V ALVE/CYL 2 76392642 GASKET-REED V AL VE/HEAD 2

REPAIR KITS

PISTON RING SET (51014947)

70014599 COMPRESSION RING 8 70014600 OIL RING 4

CRANKSHAFT KIT (51705743)

51705742 CRANKSHAFT ASM(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 60101269 OIL PUMP COLLAR 1

Page 32

DA435HA: 4-18

99901219: 20000221

RECOMMENDED SPARE PARTS LIST

Model DA435HA Air Compressor

SHELF ASSEMBLY LIFE ORDER DESIGNATION ITEM NO. PART NO. DESCRIPTION QTY CODE (MO) QTY

0020057.01.19990209 OIL COOLING SYSTEM

C1 80009 CONTROLS-HYDRAULIC 1 C N/A C10 301577 FAN PUSHER 1 C N/A C11 300444 TAPE 1/16X3/4 CLOSED CELLO 2FT C N/A C14 300211 RELAY-POWER 2 C N/A C15 300909-025 CIRCUIT BREAKER 25A 1 C N/A C20 300836 OIL COOLER 12X13.5 1 C N/A

00200056.01.19990209 COMPRESSOR MTG SYSTEM

M6 301605 TUBE ¾ AIR DISCHARGE 1 P N/A M8 77041369 PRESSURE SWITCH W/UNLOADER 1 C N/A M13 301578 SWITCH-TEMP 1 C N/A M22 301665 MOTOR-HYDRAULIC 1 C N/A M31 300857 CAP-AIR FILTER 1 C N/A N/A 300854 REPLACEMENT AIR FILTER ELEMENT 1 C N/A

00200056.02.19990209 COMPRESSOR ASM

2 70014599 COMPRESSION RING 8 W N/A 3 70014600 OIL RING 4 W N/A 11 51706913 CRANKCASE/CRANKSHAFT ASM 1 W N/A 36 60025194 CYLINDER BLOCK 2 C N/A 38 60101505 PLUBGER TRANSFER BUSHING 1 C N/A 42 7Q072212 O-RING 4 C N/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 C N/A 84 76392641 REED VALVE/CYL GASKET 2 C N/A 85 76392642 REED VALVE/HEAD GASKET 2 C N/A M53 70143495 BREATHER CAP 1 C N/A

CANOPY.01.19980930 CANOPY SYSTEM

H7 301381 HARNESS-35 RECIP 1 C N/A H8 301581 HARNESS-TOWER 3-WAY 1 C N/A H9 301607 HARNESS-SHROUD 3-WAY 1 C N/A

51712642.01.19990209 INSTALLATION KIT

91707052.01.19980930 HYDRAULIC INSTALLATION KIT

For additional instructions, see DOMINSTALL: 99901223: 19990812

1 76391527 BUMPER-RUBBER 4 W N/A 2 938206107 WASHER 3/8 FLAT GR8 4 W N/A 3 929106200 BOLT 3/8-16X2 HHGR5 4 W N/A

17 51709743 FIL TER ASM 100-MESH 1 P N/A 7 73052091 HYD FILTER 25/MIC-1 ¼ FPT 1 P N/A

Page 33

DA435HA: 99901219: 5-1

19980930

SECTION 5. REPAIR

5-1. GENERAL

This section describes the disassembly and assembly procedures for the air compressor. In all cases, remove the compressor from the vehicle before proceeding with disassembly and repair within a clean environment. Refer to the parts drawing in section 4 of this manual for parts locations.

5-2. PISTON RING REPLACEMENT

1. Remove the pulsation tank.

2. Unscrew the head bolts and remove the heads.

NOTE

A RUBBER FACED MALLET WILL HELP WHEN REMOVING THE HEAD. T AP THE SIDES OF THE HEAD CAREFULLY UNTIL THE HEAD IS LOOSE. LIFT OFF THE HEADS.

3. Remove the cylinder bolts. Tap the sides of the cylinder several times to break it loose from the gasket. Rock the cylinder back and forth and lift until it is free. Lift it off the pistons.

8. With the ring expander, install the new ring kit. Make certain that the oil ring is on the bottom and the beveled inside edge of the compression ring is toward the top of the piston.

9. Position the cylinder base gasket on the crankcase. Use a few drops of oil to hold it in position. Install the cylinder block spacer and gasket on the crankcase.

10. Rotate the rings so that the gaps of the three rings are 120° apart. Lightly lubricate the inside of the cylinder. Rotate the crankshaft so that a piston is at the top of the stroke. Compress the rings with a ring compressor, and slide the cylinder over the piston. Repeat for the other piston.

CAUTION

DO NOT LUBRICATE THE RINGS. USE A LIGHT LUBRICANT, SUCH AS WD-40 ONLY, ON THE CYLINDER WALLS. OILING THE RINGS WILL PREVENT THEM FROM SEATING AND CAUSE EXCESSIVE OIL CONSUMPTION.

4. Use a single edged razor blade, or sharp putty knife, to remove the old gasket material.

CAUTION

DO NOT ALLOW THE GASKET MA TERIAL T O FALL INTO THE CRANKCASE. DO NOT NICK THE HEAD, CYLINDER, OR CRANKCASE MATING FACES WHILE REMOVING THE OLD GASKET. REMOVE ALL OF THE OLD GASKET MATERIAL TO PROVIDE A SMOOTH, CLEAN SURFACE FOR THE NEW GASKET. 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 and oil rings.

FIGURE E-1. PISTON RING

ORIENTATION

FIGURE E-2. CYLINDER HEAD TORQUE

SEQUENCE

Page 34

DA435HA: 99901219: 5-219980930

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.

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.

13. Install the pulsation tank, and torque to 180 inlbs.

14. Install the compressor, connect the wiring and the air lines. Test the unit.

NOTE

IF PRESSURE FAILS TO BUILD AND THE COMPRESSOR IS EXCESSIVEL Y NOISY, CHECK THE V ALVE PLA TE. IT MA Y HA VE BEEN INST ALLED 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.

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.

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.

CAUTION

DO NOT GOUGE THE MACHINED SURFACES WHEN REMOVING THE GASKETS. THIS MA Y 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.

Page 35

DA435HA: 99901219: 5-3

THE CRANKSHAFT SHOULD HAVE NEW BEARINGS INSTALLED. IF NOT, PRESS THE NEW BEARINGS INTO POSITION ON THE CRANKSHAFT.

19980930

NOTE

10. Generously oil the front bearing race and install the front bearing housing with gasket. Torque the bolts to 180 in-lbs. Torque the bolts as shown in the pattern below.

FIGURE E-3. BEARING HOUSING

TORQUE SEQUENCE

NOTE

GASKET KITS ARE SUPPLIED WITH TWO (2) EACH OF .006, .010, .015, AND .020 GASKETS. USE THESE REAR BEARING GASKETS IN ANY COMBINA TION AND 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 before installing them. When installing the rods, make certain that the tabs are aligned on the same side of the rod as shown below.

11. Slide the crankshaft into the crankcase. Generously lubricate the bearing race and install the rear bearing housing and gaskets.

FIGURE E-4. ROD ALIGNMENT

14. Install the pistons, rings, heads and pulsation tank.

Page 36

DA435HA: 99901219: 5-4

19980930

5-5. TROUBLESHOOTING

LOW OIL PRESSURE

NO OIL PRESSURE

COMPRESSOR WILL NOT ENGAGE

COMPRESSOR ENGAGES BUT WILL NOT PRESSURIZE TANK

COMPRESSOR DOES NOT RECOVER PRESSURE AS FAST AS IT SHOULD

LOW OIL LEVEL LOOSE PIPE PLUG ON OIL PUMP COVER WORN OR DEFECTIVE OIL PUMP CRACK OR SCRATCH ON OIL PUMP COVER DEFECTIVE OIL PUMP BLOCKED OIL PASSAGE DAMAGED OIL PUMP DRIVE PIN NO POWER SUPPLIED TO COMPRESSOR INTERNAL CIRCUIT BREAKER TRIPPED PTO SWITCH NOT ENGAGED DEFECTIVE PRESSURE SWITCH OR UNDERHOOD SWITCH COMPRESSOR RELIEF V ALVE 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

FIGURE E-5. TROUBLESHOOTING CHART

Page 37

DA435HA: 99901219: 6-919980930

Page 38

DA435HA: 99901219: 6-1020020328

This parts manual is provided to the user to assist in servicing the equipment. It is the propertyof Iowa Mold Tooling Co., Inc and, as such, may not be reproduced 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