Diamond DA435HA Manual 

Text of Diamond DA435HA User Guide:

• 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 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

• DA435HA: 4-18 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 00200

• Diamond DA435HA, DA435HA: 99901219: iii PRECAUTIONS Read before operating your compressor! 19980930 71393886 DANGER EXPLODING TANK 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 pressure settings. DO NOT modify or repair air tank. N EVER drive vehicle with pressure in air tank. ● ● ●

• Diamond DA435HA, DA435HA: 4-13 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. 20050630

• Diamond DA435HA, 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 TEL: 641-923-3711 MANUAL PART NUMBER 99901219 Iowa Mold Tooling Co., Inc. is an Oshkosh Truck Corporation company.

• Diamond DA435HA, DA435HA: 4-5 COMPRESSOR 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

• Diamond DA435HA, DA435HA: 4-9 DA435HA MOUNTING LOCATIONS (99903712) MOUNTING.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 12.0018.75 4.40 0.44 TYP. (4)

• Diamond DA435HA, DA435HA: 99901219: 5-3 NOTE THE CRANKSHAFT SHOULD HAVE NEW BEARINGS INSTALLED. IF NOT, PRESS THE NEW BEARINGS INTO POSITION ON THE CRANKSHAFT. 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. 11. Slide the crankshaft into the crankcase. Generously lubricate the bearing race and install the rear bearing housing and gaskets. 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 GA

• Diamond DA435HA, DA435HA: 4-7 CANOPY SYSTEM H1 301437 CANOPY 1 H2 977004-062 WASHER 1/4X.062X5/8 20 H3 983904-075 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

• Diamond DA435HA, 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 T

• Diamond DA435HA, 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 (p

• Diamond DA435HA, DA435HA: 4-12 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. 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

• Diamond DA435HA, DA435HA: 99901219: iv 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 ..........................................................................................................

• DA435HA: 99901219: 1-119980930 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

• Diamond DA435HA, DA435HA: 4-17 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 VALVE/CYL 2 76392642 GASKET-REED VALVE/HEAD 2 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 DRIVESH

• Diamond DA435HA, DA435HA: 4-199901219: 19980930 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. Section 4. MAINTENANCE & PARTS FIGURE D-1. ROUTINE MAINTENANCE CHECKLIST 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 war

• 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

• 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 le

• Diamond DA435HA, DA435HA: 99901219: 5-4 FIGURE E-5. TROUBLESHOOTING CHART 5-5. TROUBLESHOOTING 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 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 PRESS

• Diamond DA435HA, 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 FLAT GR8 4

• Diamond DA435HA, DA435HA: 4-16 HYDRAULIC INSTALLATION KIT (91707052) INSTALL: 20010925 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 GATE VALVE 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 GATE VALVE 1NPT 1 15. 7205318

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