IOWA MOLD TOOLING Diamond Air DA440PBU PTO User manual
DA440PBU: 99900403: 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.
●
●
●
DA440PBU: 99900403: 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. GENERAL 4-1
4-2. LUBRICATION 4-1
4-3. PREVENTIVE MAINTENANCE CHECKLIST 4-1
Section 5. PARTS
5-1. GENERAL 5-1
Section 6. REFERENCE
LIST OF ILLUSTRATIONS
FIGURE TITLE (PART NUMBER) PAGE
D-1. TABLE - PREVENTIVE MAINTENANCE CHECKLIST 4-1
DA440PBU COMPRESSOR (23000086-1) 5-1
DA440PBU COMPRESSOR (23000086-2) 5-2
INSTALLATION KIT (93709888) 5-3
DA440PBU COMPRESSOR USING 8" DRIVE PULLEY (23000083-1) 5-4
DA440PBU COMPRESSOR USING 8" DRIVE PULLEY (23000083-2) 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
DA440PBU: 99900403: iv19980224
RECOMMENDED SPARE PARTS LIST
1 Year Supply
DA440PBU PTO, BELT DRIVEN UNDERDECK COMPRESSOR
For Manual: 99900403
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.
23000086.01.19970620 PTO, BELT DRIVEN UNDERDECK COMPRESSOR
1 70058428 BELT-POWER V B66 2 C
2 70058620 BELT-V B38 2 C
17 60107965 PTO DRIVE SHAFT 1 W
19 70055062 PILLOW BLOCK 2 C
25 60111268 SHAFT 1 W
26 70055062 PILLOW BLOCK 2 C
29 73054031 UNLOADER VALVE 1 C
30 77041008 PRESSURE SWITCH 1 C
50 89086120 OIL-30WT NON-DETERGENT 1 P
55 70048069 MOISTURE REGULATOR 1 P
23000083.01.19970205 PTO, BELT DRIVEN UNDERDECK COMPRESSOR USING 8" DRIVE PULLEY
1 70058428 BELT-POWER V B66 2 C
2 70580106 BELT-V B40 2 C
17 60111269 PTO DRIVE SHAFT 1 W
19 70055062 PILLOW BLOCK 2 C
25 60111268 SHAFT 1 W
26 70055062 PILLOW BLOCK 2 C
29 73054031 UNLOADER VALVE 1 C
35 77041008 PRESSURE SWITCH 1 C
50 89086120 OIL-30WT NON-DETERGENT 1 P
55 70048069 MOISTURE REGULATOR 1 P
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
DA440PBU: 99900403: 1-119940729
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
DA440PBU PTO, belt driven underdeck
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
INFORMATIONORTOPROVIDE FURTHEREMPHASIS
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 USEDWHENTHEREIS THEPOTENTIAL
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:
DA440PBU: 99900403: 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 WILLCAUSE DIFFICULTOPERATION
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.
DA440PBU: 99900403: 2-219990119
2-3. UNDER-DECK COMPRESSOR
INSTALLATION
Due to the large variety of carrier vehicles, the
instructions in this paragraph should be used as a
guide only.
1. Position the compressor below the bed of the
truck in the desired location. The location selected
should provide adequate ventilation while at the
same time affording protection against road hazards
and dirt.
2. Lift the compressor base into position. Check
for belt clearance and approximate drive shaft
length.
3. Using the base as a template, drill two holes 17/
32" diameter, and two holes on the other side of the
frame 21/32" diameter.
4. Bolt the compressor base to the frame of the
truck using the 1/2" and 5/8" 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.
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.
DA440PBU: 99900403: 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. ALWAYSDRAINTHE
RECEIVER BEFORE MOVING THE VEHICLE.
DA440PBU: 4-199900403: 19940729
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).
DA440PBU: 5-123000086.01.19970620 SECTION 5. PARTS
MODEL DA440PBU PTO, BELT DRIVEN UNDERDECK COMPRESSOR (23000086-1)
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. 70058428 BELT - POWER V B66 2
2. 70058620 BELT - V B38 2
3. 52704923 BELT TIGHTENING SCR 3/4-10X8 2
4. 52704957 BASE-CMPRSR MTG 1
5. 52707614 BASE-BRG MTG 1
6. 52707741 FRAME 1
7. 60118290 SLEEVE KEEPER 8
8. 60107966 SLEEVE 8
9. 72060094 CAP SCR 1/2-13X1-3/4 HHGR5 8
10. 72532013 STREET TEE 1/4NPT BRASS 1
11. 72062004 NUT 1/2-13 HEX 1
12. 72062007 NUT 3/4-10 HEX 6
13. 72063053 WASHER 1/2 LOCK 13
14. 70073051 COMPRESSOR-DA440 1
15. 60010082 KEY 1/4X1/4X3-3/8 1
16. 60108226 KEY 1/4X1/4X2 1
17. 60107965 PTO DRIVE SHAFT 1-1/4X25 1
18. 60111335 PTO BELT GUARD 1
19. 70055062 PILLOW BLOCK 1-1/4 2
20. 70056116 BUSHING-SPLITTAPER 2
21. 70056272 PULLEY 2
22. 72060099 CAP SCR 1/2-13X4 HHGR5 2
23. 72062080 NUT 1/2-13 LOCK 4
24. 72063004 WASHER 7/16 WRT 6
25. 60111268 SHAFT 1-1/4X20 1
26. 70055062 PILLOW BLOCK 1-1/4 2
27. 70143234 BUSHING 1
ITEM PART NO. DESCRIPTION QTY
28. 70056388 SHEAVE-2 GROOVE 1
29. 73054031 UNLOADER VALVE 1REF
30. 77041008 PRESSURE SWITCH 1
31. 72060099 CAP SCR 1/2-13X4 HHGR5 4
32. 72062080 NUT 1/2-13 LOCK 4
33. 72063005 WASHER 1/2 WRT 4
34. 52707929 DIPSTICK 1
35. 72060100 CAP SCR 1/2-13X4-1/2 HHGR5 2
36. 72053022 PIPE NIPPLE 1/4NPT X 4-1/2 1
37. 72053146 PIPE NIPPLE 3/4NPT X 6 2
38. 72053148 PIPE NIPPLE 3/4NPT X 12 1
39. 72053173 STREET ELBOW 3/4NPT 45° 2
40. 72053245 PIPE PLUG 1/4NPT SQHD 1REF
41. 72053561 GREASE ZERK 1/8NPT 90° 1
42. 72053305 COUPLING 3/4NPT 2
43. 72053345 ELBOW 3/4NPT 45° 1
45. 72060092 CAP SCR 1/2-13X1-1/4 HHGR5 4
47. 72532102 ADAPTER 1/8FPT #4FSTR 1
48. 72532551 HOSE FITTING 1/8X1/4 1
49. 72532552 HOSE FITTING 1/4X1/4 2
50. 89086120 OIL - 30WT NON-DETERGENT 1GAL
51. 89392146 HOSE 1/4 200PSI 20"
53. 72053533 STREET ELBOW 1/4NPT 45° 2
54. 72053244 PIPE PLUG 1/8NPT SQHD 1
55. 70048069 MOISTURE REGULATOR 1
56. 72053371 REDUCER BUSHING 1/4-1/8NPT 1
57. 72053589 STREET ELBOW 1/8NPT 90° 1
DA440PBU: 5-3
INSTALLATION KIT (93709888)
99909888.01.19970205
ITEM PART NO. DESCRIPTION QTY
1. 72060150 CAP SCR 5/8-11X1-3/4 HHGR5 2
2. 72063007 WASHER 5/8 WRT 2
3. 72062091 NUT 5/8-11 LOCK 2
4. DRIVESHAFT 1REF
5. 72066291 WOODRUFF KEY 5/16X1-1/8 1
6. 72063005 WASHER 1/2 WRT 2
7. 72062080 NUT 1/2-13 LOCK 2
8. 72060093 CAP SCR 1/2-13X1-1/2 HHGR5 2
DA440PBU: 5-4
MODEL DA440PBU PTO, BELT DRIVEN UNDERDECK COMPRESSOR USING 8” DRIVE
PULLEY (23000083-1)
23000083.01.19970205
ITEM PART NO. DESCRIPTION QTY
1. 70058428 BELT - POWER V B66 2
2. 70580106 BELT - V B40 2
3. 52704923 BELT TIGHTENING SCR 3/4-10X8 2
4. 52704957 BASE-CMPRSR MTG 1
5. 52707614 BASE-BRG MTG 1
6. 52707741 FRAME 1
7. 60118290 SLEEVE KEEPER 8
8. 60107966 SLEEVE 8
9. 72060094 CAP SCR 1/2-13X1-3/4 HHGR5 8
10. 72532013 STREET TEE 1/4NPT BRASS 1
11. 72062004 NUT 1/2-13 HEX 1
12. 72062007 NUT 3/4-10 HEX 6
13. 72063053 WASHER 1/2 LOCK 13
14. 70073051 COMPRESSOR-DA440 1
15. 60010082 KEY 1/4X1/4X3-3/8 1
16. 60108226 KEY 1/4X1/4X2 1
17. 60111269 PTO DRIVE SHAFT 1-1/4X25 1
18. 60111335 PTO BELT GUARD 1
19. 70055062 PILLOW BLOCK 1-1/4 2
20. 70056116 BUSHING-SPLITTAPER 1
21. 70056272 PULLEY 1
22. 72060099 CAP SCR 1/2-13X4 HHGR5 2
23. 72062080 NUT 1/2-13 LOCK 4
24. 72063005 WASHER 1/2 WRT 6
25. 60111268 SHAFT 1-1/4X20 1
26. 70055062 PILLOW BLOCK 1-1/4 2
27. 70143234 BUSHING 1
28. 70056388 SHEAVE-2 GROOVE 1
29. 73054031 UNLOADER VALVE 1REF
ITEM PART NO. DESCRIPTION QTY
30. 72060101 CAP SCR 1/2-13X5 HHGR5 2
31. 72060099 CAP SCR 1/2-13X4 HHGR5 4
32. 72062080 NUT 1/2-13 LOCK 4
33. 72063005 WASHER 1/2 WRT 4
34. 52707929 DIPSTICK 1
35. 77041008 PRESSURE SWITCH 1
36. 72053022 PIPE NIPPLE 1/4NPT X 4-1/2 1
37. 72053146 PIPE NIPPLE 3/4NPT X 6 2
38. 72053148 PIPE NIPPLE 3/4NPT X 12 1
39. 72053173 STREET ELBOW 3/4NPT 45° 2
40. 72053245 PIPE PLUG 1/4NPT SQHD 1REF
41. 72053561 GREASE ZERK 1/8NPT 90° 1
42. 72053305 COUPLING 3/4NPT 2
43. 72053345 ELBOW 3/4NPT 45° 1
45. 72060092 CAP SCR 1/2-13X1-1/4 HHGR5 4
47. 72532102 ADAPTER 1/8FPT #4FSTR 1
48. 72532551 HOSE FITTING 1/8X1/4 1
49. 72532552 HOSE FITTING 1/4X1/4 2
50. 89086120 OIL - 30WT NON-DETERGENT 1GAL
51. 89392146 HOSE 1/4 200PSI 20"
53. 72053533 STREET ELBOW 1/4NPT 45° 2
54. 72053244 PIPE PLUG 1/8NPT SQHD 1
55. 70048069 MOISTURE REGULATOR 1
56. 72053371 REDUCER BUSHING 1/4-1/8NPT 1
57. 72053589 STREET ELBOW 1/8NPT 90° 1
58. 70056111 BUSHING-SPLIT TAPER 1
59. 70056316 PULLEY 1
60. 60104115 SLEEVE 2
DA440PBU: 5-6
DA440PBU COMPRESSOR-CLOCKWISE TRANSMISSION (23000952-1)
23000952.01.19970907
ITEM PART NO. DESCRIPTION QTY
1. 52704923 SCREW-BASE TIGHTENER 2
2. 52704957 BASE 1
3. 52707614 BEARING BASE 1
4. 52707741 FRAME 1
5. 60107966 SLEEVE 8
6. 60118290 SLEEVE 8
7. 72060094 CAP SCR 1/2-13X1-3/4 8
8. 70143234 BUSHING 1
9. 72062007 NUT 3/4-10 HEX 6
10. 72063053 WASHER 1/2 LOCK 12
11. 52707929 DIPSTICK 1
12. 70048069 AIR FILTER 1
13. 70073051 COMPRESSOR 1
14. 72053022 PIPE NIPPLE 1/4X4-1/2 XH 1
15. 73053561 UNLOADER VALVE (PART OF 13) 1REF
17. 72053245 PLUG 1/4NPT SQHD (PART OF 13) 1REF
18. 72053244 PIPE PLUG 1/8 SQHD 1
19. 72063004 WASHER 7/16 WRT 2
21. 72053533 STREET ELBOW 1/4NPT 45° STL 2
22. 72053589 STREET ELBOW 1/8NPT 90° BRS 1
23. 72060092 CAP SCR 1/2-13X1-1/4 4
24. 72532013 STREET TEE 1/4NPT BRS 1
ITEM PART NO. DESCRIPTION QTY
25. 70058620 BELT VB38 2
26. 70058428 BELT POWER-V866 2
27. 72532552 HOSE FTG-TYPE O 1/4 1/4 1
28. 77041008 PRESSURE SWITCH 1
29. 89086120 OIL-30WT NON-DETERGENT 1GAL
30. 72053561 GREASE ZERK 1/8NPT 90° 1
31. 72532095 UNION 1/8 INV FL/DBL END BRS 1
32. 60010082 KEY 1/4X1/4X3-3/8 1
33. 60107965 PTO SHAFT 1
34. 60108226 KEY 1/4X1/4X2 1
35. 70055062 BEARING-PILLOW BLOCK 4
36. 70056116 BUSHING 2
37. 70056272 PULLEY-BROWNING 2TB60 2
38. 72060099 CAP SCR 1/2-13X4 6
39. 72060921 CAP SCR 1/2-13X3-3/4 4
40. 72062080 NUT 1/2-13 LOCK 8
41. 72063005 WASHER 1/2 WRT 8
42. 60111268 SHAFT 1
43. 70056388 SHEAVE 1
44. 72060095 CAP SCR 1/2-13X2 4
45. 60120776 SPACER 2
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