IMT Diamond Air DA440PBT User manual
DA440PBT: 99900780: ii
PRECAUTIONS
Read before operating your compressor!
19980224
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.
●
●
●
DA440PBT: 99900780: iii19990119 TABLE OF CONTENTS
PARA TITLE PAGE
SPARE PARTS LIST iv
Section 1. INTRODUCTION
1-1. GENERAL INFORMATION 1-11-
2. ORDERING INFORMATION 1-1
Section 2. INSTALLATION
2-1. GENERAL 2-1
2-2. PTO INSTALLATION 2-1
2-3. UNDER-DECK COMPRESSOR INSTALLATION 2-1
Section 3. OPERATION
3-1. OPERATION 3-1
3-2. SYSTEM SHUTDOWN 3-1
Section 4. PREVENTIVE MAINTENANCE
4-1. PREVENTIVE MAINTENANCE 4-1
4-2. LUBRICATION 4-1
4-3. PREVENTIVE MAINTENANCE CHECKLIST 4-1
Section 5. PARTS
5-1. COMPRESSOR PARTS 5-1
Section 6. REFERENCE
LIST OF ILLUSTRATIONS
FIGURE TITLE (PART NUMBER) PAGE
D-1. TABLE - PREVENTIVE MAINTENANCE CHECKLIST 4-1
DA440PBT COMPRESSOR-RH, 3/4 TON SGL WHEEL (23000146-1) 5-1
DA440PBT COMPRESSOR-RH, 3/4 TON SGL WHEEL (23000146-2) 5-2
INSTALLATION HARDWARE-RH, 3/4 TON, SGL WHEEL 5-3
DA440PBT COMPRESSOR-LH, 1 TON DUALWHEEL (23000147-1) 5-4
DA440PBT COMPRESSOR-LH, 1 TON DUALWHEEL (23000147-2) 5-5
DA440PBU COMPRESSOR-CW TRANSMISSION (23000952-1) 5-6
DA440PBU COMPRESSOR-CW TRANSMISSION (23000952-2) 5-7
F-1. TORQUE DATA CHART 6-1
F-2. TIRE LOAD AND INFLATION PRESSURES 6-2
DA440PBT: 99900780: iv19980224
RECOMMENDED SPARE PARTS LIST
1 Year Supply
DA440PBT PTO, BELT DRIVEN TOPDECK COMPRESSOR
For Manual: 99900780
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.
23000146.01.19970624 RH, 3/4 TON, SINGLE WHEEL COMPRESSOR
5 60111268 SHAFT-BELT 18" 1 W
6 60118327 SHAFT-BELT 15" 1 W
8 70580116 BELT-BP70 2 C
9 70580115 BELT-BP33 2 C
12 70055062 BEARING-PILLOW BLOCK 4 C
24 77041008 PRESSURE SWITCH 1 C
31 70048069 AIR FILTER 1 P
32 73054031 UNLOADER VALVE 1 C
23000147.01.19961014 LH, 1 TON, DUAL WHEEL COMPRESSOR
4 70055062 BEARING-PILLOW BLOCK 2 C
5 70580126 BELT B84 2 C
6 60120068 SHAFT 1 W
14 77041008 PRESSURE SWITCH 1 C
18 70048069 AIR FILTER 1 P
21 73054031 UNLOADER VALVE 1 C
COMPRESSOR (R30)-70073051
REF 70073727 LP INTAKE VALVE 1 W
REF 70073726 LP EXHAUST VALVE 1 W
REF 70732447 HP INTAKE VALVE 1 W
REF 73054340 HP EXHAUST VALVE 1 W
REF 70073766 RING SET 1 W
REF 70143298 RELEASE VALVE KIT 1 W
REF 70732429 INTERCOOLER TUBE LH 1 W
REF 70732430 INTERCOOLER TUBE RH 1 W
REF 70732448 AIR FILTERS 1 P
REF 76391490 SHAFT SEAL 1 W
REF 73054339 POP OFF 70PSI 1 W
REF 73054031 PILOT VALVE 1 C
SHELF
LIFE
(MO) ORDER
QTYCODEQTYDESCRIPTIONPART NO.ITEM NO.
ASSEMBLY
DESIGNATION
DA440PBT: 99900780: 1-119941223
SECTION 1. GENERAL INFORMATION
TO BE COMPLETED BY DEALER
CHASSIS INFORMATION
TRANSMISSION MAKE:
PTO NUMBER:
COMPRESSOR MODEL:
PUMP MAKE:
RESERVOIR CAPACITY:
MODEL:
PTO %:
SERIAL NUMBER:
MODEL:
ENGINE RPM:
COMPRESSOR AND HYDRAULIC PUMP INFORMATION
1-1. INTRODUCTION
This manual provides information on the
installation, operation and repair of the IMT
DA440PBt PTO, belt driven topdeck 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
INFORMATIONORTOPROVIDEFURTHER EMPHASIS
FOR A PREVIOUS POINT.
CAUTION
A CAUTION IS USED WHEN THERE IS THE STRONG
POSSIBILITY OF DAMAGE TO THE EQUIPMENT OR
PREMATURE EQUIPMENT FAILURE.
WARNING
AWARNINGIS USEDWHENTHEREISTHEPOTENTIAL
FOR PERSONAL INJURY OR DEATH.
Operate this equipment with respect and service it
regularly. These two things can add up to a safer
working environment and longer equipment life.
1-2. ORDERING INFORMATION
When placing orders or requesting assistance, refer
to the information below:
DA440PBT: 99900780: 2-119990119SECTION 2. INSTALLATION
2-1. GENERAL
This section deals with the installation of the PTO.
The instructions are intended as a guide to assist you
with your particular installation. We can not cover
every make, model and year of truck manufactured
world-wide, so these instructions will provide only
general information. Use this information as a guide
only.
2-2. PTO INSTALLATION
Power take-off manufacturers provide specific
installation instructions for their products. Those
instructions should be followed when installing a
PTO. Some trucks may require modification of the
transmission cross-member to provide clearance and
the exhaust pipe may need modification. 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.
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 1/32"
to 1/16". 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 AUTOMATIC
TRANSMISSION FLUID.
4. Install the PTO and gaskets. Torquethe 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.
CAUTION
AVOID SHARP BENDS IN THE SHIFTER CABLE. ALL
BENDS SHOULD HAVE AT LEAST A 6" RADIUS.
TIGHTERBENDS WILLCAUSEDIFFICULTOPERATION
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 allow it to
run for 5 - 10 minutes. Check for leaks, unusual
noise and proper operation.
8. Retorque the mounting bolts.
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.
DA440PBT: 99900780: 2-219990119
2-3. TOP-DECK COMPRESSOR
INSTALLATION
Due to the large variety of carrier vehicles, the
instructions in this paragraph should be used as a
guide only. Refer to Figure E-2 for reference.
1. Position the compressor across the frame of the
truck in the desired location. The location selected
should provide adequate ventilation while at the
same time affording access to the compressor.
2. Lift the compressor base into position. Check
for belt clearance and approximate drive shaft
length.
3. Using the base as a template, drill four 17/32"
diameter holes. The 3/4-ton/RH will be drilled
through the top of frame rails. The 1-ton/LH will be
drilled through the sides of the frame rails.
4. On the 3/4-ton/LH, insert spacers between base
and frame rails. No spacers are used with the 1-ton/
RH. Bolt the compressor base to the frame of the
truck using the 1/2" hardware.
5. Using the appropriate driveshaft with knuckles
in place, measure the exact length required, cut off
excess shaft and weld in place (1/4" weld all
around).
6. Install the driveshaft to the PTO and the
compressor, tighten the lock bolts and tie-wire in
place.
7. Tighten all bolts per Torque Data Chart.
8. Connect the 3/4" air hose from the compressor
to the air tank.
9. Install the engine speed control and connect the
hoses from compressor to speed control.
DA440PBT: 99900780: 3-119950719 SECTION 3. OPERATION
3-1. OPERATION
This section deals with the proper methods of
system operation and shutdown. These procedures
should be followed to prevent damage and ensure
efficient operation.
Start the compressor as follows:
1. Ensure the PTO is disengaged and the receiver
drain cock is open.
2. Start the truck engine and allow it to idle until it
reaches the proper operating temperature (refer to
the Owners Manual).
3. Depress the clutch, engage the PTO and
carefully release the clutch pedal.
4. Activate the engine speed control by closing the
receiver drain cock. The compressor is now
operating and supplying working air.
NOTE
WHEN STARTING THE COMPRESSOR, THE RPM’S
WILL AUTOMATICALLY INCREASE DUE TO LOW
VOLUME OFAIR IN THE SYSTEM
CAUTION
1000 RPM MAX.
Operating this unit in excess of 1000 RPM, measured at
the compressor flywheel, will void your warranty. Engine
RPM may be different.
3-2. SYSTEM SHUTDOWN
System shutdown is accomplished as follows:
1. Allow the compressor to build to maximum
pressure and the truck engine will automatically idle
down.
2. Place the compressor control valve in the open
(off) position.
3. Depress the clutch pedal and disengage the PTO.
4. Open the receiver drain cock and discharge the
air in the receiver.
WARNING
FEDERAL LAW PROHIBITS DRIVING THE CARRIER
VEHICLE ON PUBLIC ROADS WITH THE RECEIVER
FILLEDWITH COMPRESSEDAIR. ALWAYS DRAINTHE
RECEIVER BEFORE MOVING THE VEHICLE.
DA440PBT: 4-199900780: 19941223
Section 4. PREVENTIVE MAINTENANCE
FIGURE A. PREVENTIVE MAINTENANCE CHECKLIST
4-1. PREVENTIVE MAINTENANCE
Proper maintenance on a regular schedule is
essential to keep your unit operating efficiently.
Proper maintenance procedures and required service
intervals are outlined in this section. Personnel
responsible for unit upkeep should become familiar
with frequency and type of maintenance required
and perform these tasks at recommended intervals.
4-2. LUBRICATION
The only lubrication required is on the carrier vehicle
and the compressor itself. Refer to the appropriate
Owners Manual for information on the truck and
compressor for the type and frequency of lubrication
required.
CAUTION
USE ONLY A 30W NON-DETERGENT OIL IN THE
COMPRESSOR. DO NOT USE A SYNTHETIC OIL.
4-3. PREVENTIVE MAINTENANCE
CHECKLIST
The checklist (Figure A) is designed to assist you in
keeping your unit in efficient operating condition.
Items in this section apply to the unit only. The
carrier vehicle should also be inspected regularly
(refer to the carrier vehicles service manual).
DA440PBT: 5-123000146.01.19970624 SECTION 5. PARTS
DA440PBT COMPRESSOR-RH, 3/4 TON, SINGLE WHEEL (23000146-1)
5-1. COMPRESSOR PARTS
This section contains the exploded parts drawings
with accompanying parts lists for associated
assemblies. These drawings are intended to be used
in conjunction with the instructions found elsewhere
in this manual. For information pertaining to the
compressor, refer to its specific manual.
ITEM PART NO. DESCRIPTION QTY
1. 52712404 BASE WELDMENT 1
2. 52712567 BEARING BRACKET 1
3. 52706205 TIGHTENER BOLT 4" 2
4. 52704923 SCREW-BELTTIGHTENER 1
5. 60111268 SHAFT-BELT 18" 1
6. 60118327 SHAFT-BELT 15" 1
7. 70073051 COMPRESSOR-R30 1
8. 70580116 BELT-BP70 GATES 9003-2070 2
9. 70580115 BELT-BP33 GATES 9003-2033 2
10. 70056272 PULLEY 2
11. 70056388 SHEAVE 4" 2-GROOVE 1
12. 70055062 BEARING-PILLOW BLOCK 4
13. 70143234 BUSHING 1
14. 72060957 CARR BOLT 1/2-13X2 SQNK GR2 4
15. 72060094 CAP SCR 1/2-13X1-3/4 HHGR5 4
16. 72060095 CAP SCR 1/2-13X2 HHGR5 4
ITEM PART NO. DESCRIPTION QTY
17. 72062007 NUT 3/4-10 HEX 2
18. 72062080 NUT 1/2-13 LOCK 16
19. 72063005 WASHER 1/2 WRT 12
20. 72053013 PIPE NIPPLE 1/4NPT X CLOSE 1
21. 72532013 STREET TEE 1/4NPT BRS 1
22. 72053411 PIPE PLUG 1/8NPT SQHD 1
23. 72053533 STREET ELBOW 1/4NPT 45° 1
24. 77041008 PRESSURE SWITCH 1
27. 72532552 HOSE FITTING 1/4 1/4 1
28. 72532974 STREET ELBOW 1/4NPT 90° SHT 1
29. 72601430 CARR BOLT 3/8-16X2 SQNK GR2 4
31. 70048069 AIR FILTER 1
32. 73054031 UNLOADER VALVE 1REF
33. 72053245 PIPE PLUG 1/4NPT 1
34. 70056116 BUSHING-SPLIT TAPER 2
35. 72035361 GREASE ZERK 1/8NPT 90° 2
DA440PBT: 5-4
DA440PBT COMPRESSOR-LH, 1 TON, DUAL WHEEL (23000147-1)
23000147.01.19961014
ITEM PART NO. DESCRIPTION QTY
1. 52713749 FRAME WELDMENT-LH 1
2. 70073051 COMPRESSOR 1
3. 52706205 TIGHTENER BOLT 4" 2
4. 70055062 BEARING-PILLOW BLOCK 2
5. 70580126 BELT-B84 GATES 9093-2083 2
6. 60120068 SHAFT 1-1/4 X 10-1/4 1
7. 70056111 BUSHING 1
8. 70056523 PULLEY DUAL GROOVE 9" 1
9. 72060102 CAP SCR 1/2-13X5-1/2 HHGR5 2
10. 72062080 NUT 1/2-13 LOCK 4
11. 72063005 WASHER 1/2 WRT 4
12. 72532974 STREET ELBOW 1/4NPT 90° SHT 1
13. 72053013 PIPE NIPPLE 1/4NPT X CLOSE 1
ITEM PART NO. DESCRIPTION QTY
14. 77041008 PRESSURE SWITCH 1
15. 72532552 HOSE FITTING 1/4 1/4 1
18. 70048069 AIR FILTER 1
19. 72532013 STREET TEE 1/4NPT BRS 1
21. 73054031 UNLOADER VALVE 1REF
22. 72053411 PIPE PLUG 1/8NPT SQHD 1
23. 72053533 STREET ELBOW 1/4NPT 45° 1
24. 72053245 PIPE PLUG 1/4NPT 1
25. 72060093 CAP SCR 1/2-13X1-1/2 HHGR5 4
26. 72063005 WASHER 1/2 WRT 4
27. 72062080 NUT 1/2-13 LOCK 4
28. 72060108 CAP SCR 1/2-13X6 HHGR5 2
29. 60118856 SUPPORT 1
DA440PBT:99900780: 6-119941223
When using the torque data in the charts above, the following rules should be observed.
1. Bolt manufacturers particular specifications should be consulted when provided.
2. Flat washers of equal strength must be used.
3. All torque measurements are given in foot-pounds. To convert to inch-pounds, multiply by 12.
4. Torque values specified are for bolts with residual oils or no special lubricants applied. If special
lubricants of high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphite,
collodial copper or white lead are applied, multiply the torque values in the charts by the factor .90. The use of
Loctite does not affect the torque values listed above.
5. Torque values for socket-head capscrews are the same as for Grade 8 capscrews.
FIGURE F-1. TORQUE DATA CHART
SECTION 6. REFERENCE
Table of contents
Other IMT Air Compressor manuals
