Diamond Air DA425EA Manuel utilisateur

DA425EA: 99900679: i19990121

Model DA425EA

Underhood Air Compressor

(Replaces Model HD750)

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 99900679

DA425EA: 99900679: ii

PRECAUTIONS

Read before operating your compressor!

19980521

71393886

DANGER

EXPLODINGTANK 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.

NEVER drive vehicle with pressure in air

tank.

●

DA425EA: 99900679: iii19980223 TABLE OF CONTENTS

PARA TITLE PAGE

SPARE PARTS LIST

Section 1. SPECIFICATIONS

1-1. GENERAL ................................................................................................ 1-1

1-2. SPECIFICATIONS.................................................................................... 1-1

Section 2. INSTALLATION

2-1. GENERAL ................................................................................................ 2-1

2-2. AIR COMPRESSOR................................................................................. 2-1

2-3. UNDERDASH SWITCH............................................................................ 2-1

2-4. UNDERHOOD SWITCH........................................................................... 2-1

Section 3. OPERATION

3-1. GENERAL ................................................................................................ 3-1

3-2. OPERATION ............................................................................................ 3-1

Section 4. MAINTENANCE & PARTS

4-1. GENERAL ................................................................................................ 4-1

PRESSURE SWITCH INSTALLATION INSTRUCTIONS ......................... 4-5

Section 5. REPAIR

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. CLUTCH REPLACEMENT ....................................................................... 5-3

5-6. TROUBLESHOOTING ............................................................................. 5-4

LIST OF ILLUSTRATIONS

FIGURE TITLE (PART NUMBER) PAGE

A-1. OUTSIDE DIMENSIONS.......................................................................... 1-1

C-1. AUTOMATIC SPEED CONTROL OPTION............................................... 3-1

D-1. ROUTINE MAINTENANCE CHECKLIST ................................................. 4-1

D-2. AIR COMPRESSOR - PARTS (51711330) ............................................... 4-2

D-2A. AIR COMPRESSOR - PARTS (51711330) ............................................... 4-3

D-2B. AIR COMPRESSOR - PARTS (51711330) ............................................... 4-4

D-3. PRESSURE SWITCH KIT & INSTALLATION INSTR (51710224) ............ 4-5

D-4. OPTION-SOLBERG AIR FILTER KIT (51709435).................................... 4-6

D-5. OPTION-AIR FILTER KIT (95709998) ...................................................... 4-6

REPAIR KITS ........................................................................................... 4-6

E-1. PISTON RING ORIENTATION ................................................................. 5-1

E-2. CYLINDER HEAD TORQUE SEQUENCE ............................................... 5-1

E-3. BEARING HOUSING TORQUE SEQUENCE .......................................... 5-3

E-4. ROD ALIGNMENT.................................................................................... 5-3

E-5. TROUBLESHOOTING CHART ................................................................ 5-4

DA425EA: 99900679: iv19980223

RECOMMENDED SPARE PARTS LIST

1 Year Supply

DA425EA AIR COMPRESSOR

For Manual: 99900679

This spare parts list does not necessarily indicate that the items can be expected to fail in the course of a year. It is intended to

provide the user with a stock of parts sufficient to keep the unit operating with minimal down-time waiting for parts. There

may be parts failures not covered by this list. Parts not listed are considered as not being Critical or Normal Wear items

during the first year of operations and you need to contact the distributor or manufacturer for availability.

51711330.01.19970619 UNDERHOOD AIR COMPRESSOR

2 60025010 CYLINDER BLOCK 2 W

3 60025008 CYLINDER HEAD 2 W

5 70073031 VALVE PLATE 2 C

18 76039141 AIR INTAKE FILTER-FOAM 2 P

33 76393802 FILTER SCREEN 4 P

44 51704023 INSERTASM 1 C

66 51029296 CONNECTING ROD 4 W

84 51704321 CRANKSHAFTASM 1 W

87 51014947 RING SET 1 W

92 70056437 PULLEY- 1 GROOVE 1 C

70056304 PULLEY- 2 GROOVE 1 C

70056441 PULLEY- 6 GROOVE 1 C

70056442 PULLEY- 7 GROOVE 1 C

93 77044419 CLUTCH FIELD 1 C

REF 51039013 GASKET SET 1 C

REF 77041369 PRESSURE SWITCH 1 C

REF 51086090 OIL-2 QTS 2 P

SHELF

LIFE

(MO) ORDER

QTYCODEQTYDESCRIPTIONPART NO.ITEM NO.

ASSEMBLY

DESIGNATION

DA425EA: 99900679: 1-119951003

SECTION 1. SPECIFICATIONS

FIGURE A-1. OUTSIDE DIMENSIONS

1-1. GENERAL

The IMT DA425EA air compressor is an underhood,

engine mounted, single stage, air cooled, 4-cylinder,

pressure lubricated unit, with a delivery rate of 25

CFM at 1400 RPM.The compressor is belt driven

from the engine crankshaft, through a magnetic

clutch. It is engaged and disengaged by use of an air

pressure sensing, electric switch. The pressure

switch is preset on factory installed units at

approximately 120 PSI to engage, and 150 PSI to

disengage.

CAUTION

OPERATING THE COMPRESSOR AT PRESSURES

ABOVE 150 PSI WILL SHORTEN THE SERVICE LIFE

AND VOID THE WARRANTY.

1-2. SPECIFICATIONS

Bore 2-5/8"

Stroke 2"

Cylinder Configuration V4

Displacement 35 CFM*

Delivery 25 CFM*

Lubrication Oil Pump

Oil Capacity 1-1/3 qts

Cooling Air

Height 13-3/8"

Width 15-3/4"

Length 13-7/8"

Material Aluminum Alloy

Weight 75 lbs.

* @ 1400 RPM - 100 PSI

DA425EA: 99900679: 2-119951003SECTION 2. INSTALLATION

2-1. GENERAL

This section pertains to the installation of the IMT

DA425EA compressor and related components.

Because installations will vary somewhat, dependent

on the chassis, it will describe the installation in

general terms only.

2-2. AIR COMPRESSOR

Each installation will differ dependent on the chassis

make, model, year of manufacture, and optional

equipment. Refer to the mounting kit for specific

information relating to your application.

2-3. UNDERDASH SWITCH

The installation kit will include the correct bracket

for the installation of the compressor, power switch

and the engine speed control. The bracket may

house switches for other functions, depending on the

total system.

1. Drill mounting holes in the underside of the dash.

It may be possible to utilize existing holes.

2. Install the switch, or switches, needed for your

installation.

3. Route the needed wiring harness to the rear of the

bracket and connect to the proper switches.

4. Securely fasten the assembled switch bracket to

the dash with bolts, nuts, and washers provided.

NOTE

IFTHE DASHBOARDISPLASTIC, THE GROUNDWIRE

MUST BE CONNECTED TO CHASSIS GROUND. THE

PLASTIC DASHBOARD IS NOT CONDUCTIVE AND

WILL NOT PROVIDE A GROUND.

5. Connect the positive side of the compressor

switch to the power switch. Connect the other side

of the switch to the underhood safety switch and the

indicator lamp.

6. Install the throttle cable mounting bracket to the

underside of the dash, near the switch bracket.

Install the cable and connect to the carburetor

linkage. Make certain that there is enough free play

to allow the engine to return to normal idle.

2-4. UNDERHOOD SWITCH

The purpose of the underhood switch is to prevent

the compressor from running unless the vehicle’s

hood is raised. This will ensure sufficient air flow to

the compressor during operation.

1. Select a location for the mercury switch that will

provide protection for the glass envelope and keep

the switch contacts open when the hood is closed.

The mercury should not be in contact with the

contacts to accomplish this.

2. Drill a 1/16 inch hole in the desired location and

install the switch bracket. Install the switch in the

bracket. Connect one lead to the underdash switch,

the other to the compressor pressure switch. When

wired properly, the switch in the cab must be “ON”

and the hood must be raised in order for the

compressor to operate.

CAUTION

WARRANTY ON THE COMPRESSOR WILLBE VOID IF

THE UNDERHOOD SAFETY SWITCH IS NOT USED.

FAILURE TO USE THIS SWITCH WILL ALLOW THE

COMPRESSOR TO OPERATE WITH THE HOOD

CLOSED AND WILL CAUSE OVERHEATING.

DA425EA: 99900679: 3-119951003 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.

B. Check the air intake filter pads on each head to

make certain that they are clean and unobstructed.

Dirty filters are a possible cause of reduced air

output.

2. With the compressor engaged:

On units having the automatic speed control option,

check the engine RPM for proper setting (1400

RPM max.) under compressor load.

3-2. OPERATION

To use the compressor, raise the hood to provide

adequate ventilation, start the vehicle engine, and

engage the compressor by operating the compressor

switch in the cab. On systems without automatic

engine speed control, adjust the engine RPM with

the manual throttle cable to maintain the proper

RPM setting while the compressor is pumping.

The system will now function automatically. It will

engage the compressor clutch when the air pressure

is below 120 psi, and disengage when the air

pressure reaches 150 psi.

NOTE

ON UNITS WITH MANUAL ENGINE SPEED CONTROL,

THE ENGINE RPM WILL INCREASE WHEN THE

COMPRESSOR CLUTCH DISENGAGES.

CAUTION

THIS UNIT IS EQUIPPED WITH AN UNDERHOOD

SAFETYSWITCH WHICH REQUIRESTHATTHE HOOD

BE RAISED WHILE THE COMPRESSOR IS IN

OPERATION. THIS IS INSTALLED TO ENSURE THAT

THE UNIT HAS ADEQUATE VENTILATION, AND THAT

THE UNIT IS NOT INADVERTANTLY LEFT ON WHEN

NOT IN USE AND THE VEHICLE IS IN MOTION.

BYPASSING THIS SAFETY DEVICE, OR OPERATING

THIS UNIT IN EXCESS OF 1400 RPM, WILL VOID THE

WARRANTY, AND WILL SHORTEN THE NORMAL

SERVICE LIFE OF THE COMPRESSOR.

DA425EA: 99900679: 3-219930125

DA425EA: 99900679: 4-119951003

Section 4. MAINTENANCE & PARTS

FIGURE D-1. ROUTINE MAINTENANCE CHECKLIST

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.

DA425EA: 99900679: 4-219970619

ITEM PARTNO. DESCRIPTION QTY

1. 60025012 CRANKCASE (PART OF 83) 1REF

2. 60025010 CYLINDER BLOCK 2

3. 60025008 CYLINDER HEAD 2

4. 60025009 PULSATION TANK 1

5. 70073031 VALVEPLATE 2

6. 70073030 DIPSTICK 1

7. 70014613 DIPSTICK TUBE 1

8. 60120238 OIL SCREEN TUBE (PART OF 83) 1REF

9. 60120289 OIL SCREEN (PART OF 83) 1REF

10. 72066008 OIL SCREEN CLAMP (PART OF 83) 1REF

11. 60101507 OIL FILL PIPE 1

12. 51705310 BREATHER CAP ASM (INCL:89,90) 1

13. 76393085 O-RING (PART OF 44&77) 1REF

14. 72053403 PLUG 3/8NPT SH (PART OF 83) 1REF

15. 72053413 PLUG 3/8NPT SQHD (PAR OF 83) 1REF

16. 70039300 IDENT PLATE 1

17. 70014626 AIR FILTER CLIP 8

18. 76039141 AIR INTAKE FILTER-FOAM 2

19. 73054026 DRAIN COCK 1

20. 72053406 PLUG 1NPT SH 1

21. 72060032 CAP SCR 5/16-18X2-3/4 12

22. 72060062 CAP SCR 7/16-14X1 4

23. 72060025 CAP SCR 5/16-18X1 HHGR5 12

24. 72063001 WASHER 1/4 WRT 12

25. 70024122 WASHER 5/16 FLAT COPPER 12

26. 72063052 WASHER 7/16 LOCK 4

28. 7Q072212 O-RING 2

29. 76039113 HEAD GASKET 2

30. 76039114 GASKET-CYL BLOCK/VLV PLT 2

31. 76039111 GASKET-CRNKCASE/CYL BLOCK 2

32. 60025229 MANIFOLD BLOCK (PART OF 79) 1REF

33. 76393802 FILTER SCREEN 4

36. 72053404 PLUG 1/2NPT SH(PART OF 79) 1REF

37. 72053405 PLUG 3/4NPT SH (PART OF 79) 1REF

38. 72053558 NIPPLE 3/4NPT X 2 1

39. 72053376 RED. BUSHING 3/4FPT 1MPT 1

40. 72053295 STREET ELBOW 3/4NPT 90° 1

41. 60106933 PLUG 3/4MPT (PART OF 79) 1REF

42. 72066426 BALL 9/16 (PART OF 44) 1REF

43. 76393107 O-RING (PART OF 79) 1REF

44. 51704023 INSERT ASM 1REF

45. 72661487 DRIVE PIN 1

47. 76039119 SEAL (PART OF 81) 1REF

48. 60025007 FRT BRG HSG (PART OF 81) 1REF

49. 70055011 FRT CUP BEARING (PART OF 81) 1REF

50. 70055012 FRT CONE BEARING (PART OF 84) 1REF

51. 60101271 CRANKSHAFT 1

52. 72066267 WOODRUFF KEY #6 1

53. 70055009 REAR CONE BRG (PART OF 84) 1REF

54. 60101269 OIL PUMP COLLAR 1REF

ITEM PARTNO. DESCRIPTION QTY

55. 72066307 DRIVE PIN (PART OF 84) 1REF

56. 70055010 REAR BRG CUP (PART OF 82) 1REF

57. 60025005 REAR BRG HSG (PART OF 82) 1REF

58. 70014583 COIL SPRING 1

59. 60101505 SLEEVE 1

60. 70051006 OIL PUMP 1

61. 60025006 PUMP COVER 1

63. 72053411 PLUG 1/8NPT SQHD 2

64. 72060731 SCR 5/16-18X3/4 SH (PART OF 83) 5REF

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

66. 51029296 CONNECTING ROD 4

67. 70029062 PISTON (PART OF 88) 4REF

68. 70014627 PISTON PIN (PART OF 88) 4REF

69. 72066018 RETAINING RING (PART OF 88) 8REF

70. 70014600 OIL RING (PART OF 87) 4REF

71. 70014599 COMPRESSION RING(PART OF 87) 8REF

73. 76039093 PUMP COVER GASKET 1

74. 76039112 FRT BRG HSG GASKET

(PART OF 83) 2REF

75. 72063050 WASHER 5/16 LOCK 1

76. 72053404 PLUG 1/2NPT SH 1

77. 70029593 INSERT (PART OF 44) 1REF

78. 7Q073017 O-RING (PART OF 44) 1REF

79. 51704827 MANIFOLD CHECK VALVE ASM

(INCL:32,36,37,41-44,77,78) 1

81. 51705709 FRT BRG HSG ASM

(INCL:47-49,PART OF 83) 1REF

82. 51705710 REAR BRG HSG ASM

(INCL:56,57,PART OF 83) 1REF

83. 51705811 CRANKCASE/CRANKSHAFT ASM 1

84. 51704321 CRANKSHAFT ASM

(INCL:50,51,53-55,PART OF 83) 1REF

85. 72063050 WASHER 5/16 LOCK (PART OF 83) 5REF

86. 72060025 CAP SCR 5/16-18X1(PART OF 83) 5REF

87. 51014947 RING SET (INCL:70,71) 1

88. 51029285 PISTON ASM (INCL:67-69) 4

89. 60107276 CAP 1/2HEX MOD (PART OF 12) 1REF

90. 70048080 BREATHER 1/4NPT (PART OF 12) 1REF

91. 70039124 OIL FILL DECAL 1

92. 70056437 PULLEY 1-GROOVE 5/8" 1REF

70056304 PULLEY 2-GROOVE 1/2" 1REF

70056441 PULLEY 6-GROOVE SERPENTINE 1REF

70056442 PULLEY 7-GROOVE SERPENTINE 1REF

93. 77044419 CLUTCH FIELD 1

94. 72066537 J-CLIP .19 VINYL 2

95. 70732444 CLUTCH HARDWARE KIT 1

100. 70029468 SHIM (PART OF 44) 1REF

101. 76039092 REAR BRG GASKET .006 AR

76039094 REAR BRGGASKET .010 AR

76039143 REAR BRG GASKET ,015 AR

76039144 REAR BRG GASKET .020 AR

FIGURE D-2. DA425EA UNDERHOOD AIR COMPRESSOR (51711330-1)

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