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Diamond Air DA425HA User Manual

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DA425HA: 99900682:
19980223
i
Model DA425HA
Air Compressor
(Dual Cooler - 10GPM)
(Replaces Model 1143)
IOWA MOLD TOOLING CO., INC.
BOX 189, 500 HWY 18 WEST, GARNER, IA 50438
TEL: 515-923-3711
TECHNICAL SUPPORT FAX: 515-923-2424
MANUAL PART NUMBER 99900682

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Summary of Contents for Diamond Air DA425HA

  • Page 1 DA425HA: 99900682: 19980223 Model DA425HA Air Compressor (Dual Cooler - 10GPM) (Replaces Model 1143) IOWA MOLD TOOLING CO., INC. BOX 189, 500 HWY 18 WEST, GARNER, IA 50438 TEL: 515-923-3711 TECHNICAL SUPPORT FAX: 515-923-2424 MANUAL PART NUMBER 99900682...
  • Page 2 DA425HA: 99900682: 19980223 PRECAUTIONS Read before operating your compressor! 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.

  • Page 3: Table Of Contents

    DA425HA: 99900682: 19980223 TABLE OF CONTENTS PARA TITLE PAGE GENERAL INFORMATION INTRODUCTION ORDERING INFORMATION Section 1. SPECIFICATIONS 1-1. GENERAL 1-2. SPECIFICATIONS Section 2. INSTALLATION 2-1. GENERAL 2-2. PTO AND PUMP INSTALLATION 2-2-1. PTO INSTALLATION 2-2-2. DRIVELINE AND PUMP INSTALLATION 2-3.
  • Page 4 DA425HA: 99900682: 19980223...

  • Page 5: General Information

    DA425HA: 99900682: 19950922 GENERAL INFORMATION CAUTION INTRODUCTION A CAUTION IS USED WHEN THERE IS THE STRONG POSSIBILITY OF DAMAGE TO THE EQUIPMENT OR PREMATURE EQUIPMENT FAILURE. WARNING A WARNING IS USED WHEN THERE IS THE POTENTIAL FOR PERSONAL INJURY OR DEATH.
  • Page 6 DA425HA: 99900682: 19970206 NOTES...

  • Page 7: Section 2. Installation

    This section pertains to the installation of the IMT check the backlash for maximum allowance of 1/32" DA425HA compressor, PTO and pump. The to 1/16". If the backlash is excessive, remove instructions are intended as a guide to assist you with gaskets and check backlash again until it is your particular installation.

  • Page 8: Compressor Installation

    DA425HA: 99900682: 19950922 2-2-2. DRIVELINE AND PUMP 2-3. COMPRESSOR INSTALLATION INSTALLATION 1. Prepare the mounting location of the compressor by locating and drilling four (4) holes, 7/16" The pump may be driven as shown in Figure B-2 as diameter, as shown in Figure B- 3.

  • Page 9: Section 3. Operation

    DA425HA: 99900682: 19950922 SECTION 3. OPERATION 3-1. GENERAL 3-2. OPERATION Each compressor is bench tested under load at the To use the compressor, start the vehicle engine and engage the compressor by operating the compressor factory to ensure proper break-in and operation.
  • Page 10 DA425HA: 99900682: 19930125 NOTES...

  • Page 11: Section 4. Maintenance & Parts

    DA425HA: 99900682: 19950922 Section 4. MAINTENANCE & PARTS 4-1. GENERAL The following table is a list of routine maintenance items, including service intervals. It also includes a parts list and assembly drawing of the compressor. FIGURE D-1. ROUTINE MAINTENANCE CHECKLIST...

  • Page 12: Mounting Hardware Kit 51712642

    DA425HA: 51712642.01: 19940927 77040048 BUTT CONNECTOR 16-14GA MOUNTING HARDWARE KIT (51712642) 77040000 TERMINAL SPD #10 16-14GA ITEM PART NO. DESCRIPTION 77041345 TOGGLE SWITCH 51709571 COMPRESSOR 10GPM(see dwg) 1REF 77041056 IN-LINE FUSE 20AMP 51709573 COMPRESSOR 8GPM (see dwg) 1REF 89044233 CABLE 14GA BRN 24"...

  • Page 13: Option-Relay Board Kit 51711092

    DA425HA: 51709571.01: 19980106 OPTION-RELAY BOARD KIT (51711092) ITEM PART NO. DESCRIPTION 77041378 RELAY BOARD 77041383 RELAY 77041100 FUSE 20AMP 72601576 SHT MTL SCR #10X1-1/2 99900661 INSTALLATION INSTRUCTIONS CONTINUED ON FOLLOWING PAGE DA425HA10 COMMPRESSOR ASM W/ENCLOSURE (51709571-1) ITEM PART NO. DESCRIPTION ITEM PART NO.
  • Page 14 DA425HA: 51709571.02: 19980106 DA425HA10 COMMPRESSOR ASM W/ENCLOSURE (51709571-2)
  • Page 15 DA425HA: 51707079.01: 19970619 DA425HA AIR COMPRESSOR CONTINUED ON FOLLOWING PAGE (51707079-1) ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 1. 60025012 CRANKCASE (PART OF 83) 1REF 54. 60101269 OIL PUMP COLLAR (PART OF 84) 1REF 2. 60025010 CYLINDER BLOCK 55. 72066307 ROLL PIN .16X.44 (PART OF 84)
  • Page 16 DA425HA: 51707079.02: 19980106 DA425HA AIR COMPRESSOR (51707079-2) CONTINUED ON FOLLOWING PAGE...
  • Page 17 DA425HA: 51707079.03: 19970619 DA425HA AIR COMPRESSOR (51707079-3) CONTINUED ON FOLLOWING PAGE...

  • Page 18: Optional Hydraulic Installation Kit 91707052

    93710121.01: 19970707 DA425HA: 91707052.01: 19970707 OPTIONAL HYDRAULIC INSTALLATION KIT (91707052) OPTIONAL INSTALLATION KIT W/CRANE (93710121) ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 1. 72531427 ELBOW 3/4NPT #12MJIC 18. 72532712 BEAD NIPPLE #16MSTR 1" 45° 2. 72053676 ADAPTER 3/4MPT #12MJIC 20.

  • Page 19: Option-Air Filter Kit 95709998

    DA425HA: 95709998.01: 19950922 OPTION-AIR FILTER KIT (95709998) ITEM PART NO. DESCRIPTION 1. 70029546 BREATHER MANIFOLD 2. 70048117 AIR FILTER CONE 3. 76392274 GASKET 4. 60106236 SLEEVE 5. 72063049 WASHER 1/4 LOCK 6. 72060270 CAP SCR 1/4-28X1/2 HHGR5 8. 72060035 CAP SCR 5/16-18X3-1/2 HHGR5 9.
  • Page 20 DA425HA: 31701761.01: 19950922 4-10 WARNING DRIVELINE MTG OPTION (31701761) THE INSTALLER OF THE DRIVELINE MUST INSPECT ITEM PART NO. DESCRIPTION POWER TAKE-OFF THE FINAL POSITION OF THE DRIVELINE TO 2. 70058146 END YOKE DETERMINE WHETHER ITS LOCATION PROVIDES 3. 72060578...
  • Page 21 DA425HA: 51705811.01: 19970619 4-11 13. 70055010 BEARING-CUP (PART OF 11) 1REF CRANKSHAFT & CRANKSHAFT ASM 14. 60025012 CRANKCASE (51705811) 15. 72053413 PIPE PLUG ITEM PART NO. DESCRIPTION 16. 60120238 TUBE-OIL SCREEN 1. 51704321 CRANKSHAFT 17. 60120289 SCREEN-OIL 2. 60101269 COLLAR-OIL PUMP (PART OF 1) 1REF 18.
  • Page 22 DA425HA: 51712285.01: 19980106 4-12 DA425HA10 COMPRESSOR ASM W/O CONTINUED ON FOLLOWING PAGE COOLER (51712285-1) ITEM PART NO. DESCRIPTION ITEM PART NO. DESCRIPTION 49. 72533116 ELBOW 3/4MPT 3/4BARB 1. 52709542 REAR COOLER MTG PLATE 50. 72533117 BARB NIPPLE 3. 72053535 STREET ELBOW 3/4NPT 45°...
  • Page 23 DA425HA: 51712285.02: 19980106 4-13 DA425HA10 COMPRESSOR ASM W/O COOLER (51712285-2)
  • Page 24 DA425HA: 4-14...

  • Page 25: Section 5. Repair

    DA435HA: 99900682: 19930125 SECTION 5. REPAIR 5-1. GENERAL 5-2. PISTON RING REPLACEMENT NOTE A RUBBER FACED MALLET WILL HELP WHEN REMOVING THE HEAD. TAP THE SIDES OF THE HEAD CAREFULLY UNTIL THE HEAD IS LOOSE. LIFT OFF THE HEADS. CAUTION DO NOT LUBRICATE THE RINGS.

  • Page 26: Oil Pump Replacement

    DA435HA: 99900682: 19950922 5-4. CRANKSHAFT AND BEARING REPLACEMENT NOTE INSTALL THE VALVE PLATE WITH THE MARKED SURFACE FACING UP. 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.

  • Page 27: Clutch Replacement

    DA435HA: 99900682: 19950922 NOTE 5-5. CLUTCH REPLACEMENT THE CRANKSHAFT SHOULD HAVE NEW BEARINGS INSTALLED. IF NOT, PRESS THE NEW BEARINGS CAUTION INTO POSITION ON THE CRANKSHAFT. CLUTCH FAILURE MAY BE DUE TO A LEAKING CHECK VALVE. MAKE CERTAIN THAT THE CHECK VALVES ARE FUNCTIONING PROPERLY BEFORE INSTALLING THE NEW CLUTCH.

  • Page 28: Troubleshooting

    DA435HA: 99900682: 19950922 To reinstall the clutch: 6. Connect the coil wire to the air pressure switch. 1. Position the magnetic coil assembly over the 7. Move the compressor switch in the cab to the on front bearing housing and secure the assembly with position to activate the clutch.

  • Page 29: Section 6. Relay Board Operation

    DA425HA: 99900682: 19930125 SECTION 6. RELAY BOARD OPERATION 6-1. INTRODUCTION 6-2. OPERATION 6-2-1. IGNITION “ON” 6-2-2. REMOTE STARTING THE VEHICLE FIGURE F-1. BOTTOM VIEW OF RELAY 6-2-3. REMOTE ENGINE STOP FIGURE F-2. INTERNAL WIRING...
  • Page 30 DA425HA: 99900682: 19930125 FIGURE F-3. RELAY BOARD - COMPONENTS & WIRING...

  • Page 31: Remote Engine Speed (From Crane)

    DA425HA: 99900682: 19950922 6-2-4. REMOTE ENGINE SPEED (FROM 6-2-6. ENGINE SPEED CONTROL WHEN CRANE) BOTH CRANE AND COMPRESSOR ARE USED SIMULTANEOUSLY 6-2-5. COMPRESSOR ENGINE SPEED CONTROL (COMPRESSOR ONLY)
  • Page 32 DA425HA: 99900682: 19930125 FIGURE F-4. IGNITION “ON” FIGURE F-5. REMOTE CONTROL HANDLE - TYPICAL...
  • Page 33 DA425HA: 99900682: 19930125 FIGURE F-6. REMOTE STARTING OF VEHICLE - IGNITION “ON”...
  • Page 34 DA425HA: 99900682: 19930125 FIGURE F-7. SPEED CONTROL - COMPRESSOR ONLY...

  • Page 35: Installation

    DA425HA: 99900682: 19930125 WIRING CHART 6-3. INSTALLATION TERM WIRING CONNECTION 12-VOLT POWER SWITCH FROM CRANE GROUND TO SPEED CONTROL SPEED CONTROL FROM COMPRESSOR ENGINE STOP FROM CRANE FROM FUEL SOLENOID / DISTRIBUTOR GRD TO FUEL SOLENOID / DISTRIBUTOR GRD 12-VOLT FROM IGNITION...
  • Page 36 DA425HA: 99900682: 19930125...
  • Page 37 DA425HA: 99900682:...
  • Page 38 DA425HA: 99900682: 6-10 LIMITED WARRANTY IOWA MOLD TOOLING CO., INC. BOX 189, GARNER, IA 50438-0189 TEL: 515-923-3711 TECHNICAL SUPPORT FAX: 515-923-2424...

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