210HP_Bead_Breaker
Contents
1. 79075107 u 3 2 D 1 HYDRAULIC OIL SPECIFICATIONS nn 4 1 000210HP 99900657 19920508 1 1 DESCRIPTION The ratio of hydraulic fluid pressure generated compared to supply air pressure is 100 1 In other words 100 PSI input air pressure equals 10 000 PSI output pressure The IMT 210HP Bead Breaker tool consists of two cylinders a clamping cylinder and a breaker cylinder at a 90 angle with respect to each other Both the clamping and bead break ing actions are performed automatically no mid sequence operation by the user is required The sequence of operation is as follows refer to Figure A 1 STEP 1 A air hydraulic pump supplies the hydraulic fluid pressure to the clamping cylinder Fluid pres sure is restricted to the clamping cylinder by spring pressure on the sequence ball and by the mated surfaces of the fluid return ball and its seat As the clamping rod moves out of the cylinder the jaw clamps firmly on the rim STEP 2 The internal hydraulic pressure of the clamping cylinder is sufficient to overcome the spring pressure against the sequence ball approxi mately 2500 PSI The ball is forced away from the seat and pressure increases inside the breaker cylinder STEP 3 The breaker rod has moved out of the cylinder and the tongue is pressing against the bead As pressure increases the tongue will break the bead of the tire from the rim STEP 42. Depressing the RELEASE pedal of the pump causes a decrease in pressure in the clamping cylinder With less pressure on the clamping cylinder side of the fluid return ball than on the breaker side the fluid return ball is lifted off the seat and the breaker rod retracts Retraction is due to an internal spring and pressure of the bead against the tongue The breaker rod retracts first followed by the clamping rod SECTION 1 OPERATION WARNING The optional air hydraulic pump is capable of generating fluid pressure up to 10 000 PSI Keep both hands on the handles and away from the clamping jaw or breaker tongue Make certain that the tool is properly aligned on the rim before allowing the bead breaking action Do not continue to operate the air hydraulic pump once the breaker rod is completely extended Failure to comply with these instructions could result in personal injury or damage to the equipment 1 2 OPERATION Operation of the unit is as follows Make certain the tire is completely deflated Connect the hose of the a air hydraulic pump to the hydraulic coupling on the Bead Breaker tool Connect the air supply line to the air hydraulic pump Air supply should be 5 10 CFM at 100 PSI to obtain proper operating characteristics In addition the air line should be equipped with an air line filter Position the Bead Breaker so that the cup point set screw in the jaw makes solid contact with the rim and the teeth are posit
3. a burnt or rancid odor 3 Examine the oil for a cloudy or dark color 4 Allow the sample to stand for several minutes and inspect it for water which will settle to the bottom Water can result from a leak in the system or condensation due to temperature extremes When any of these conditions is observed the system should be purged and filled with new oil AMBIENT TEMPERATURE RANGE 0 90 F BELOW 32 F 2 9eF O ABOVE 90 F MIN POUR POINT F 30 MAX VISCOSITY SSU 0 F 4000 140 195 MIN VISCOSITY SSU 100 F MIN VISCOSITY SSU 210 F 48 MIN VISCOSITY INDEX 25 4000 100 130 150 200 200 315 41 43 43 47 90 90 90 FIGURE D 1 HYDRAULIC OIL SPECIFICATIONS 000210HP 99900657 19920508 4 2 NOTES
4. 000210HP 99900657 20070329 Model 210HP Beadbreaker PARTS AND SERVICE MANUAL IOWA MOLD TOOLING CO INC BOX 189 GARNER IA 50438 0189 TEL 641 923 3711 TECHNICAL SUPPORT FAX 641 923 2424 MANUAL PART NUMBER 99900657 lowa Mold Tooling Co Inc is an Oshkosh Truck Corporation company 000210HP 99900657 19920508 PARAGRAPH TABLE OF CONTENTS TITLE PAGE SECTION 1 OPERATION 1 1 DESCRIPTION cuenta 1 1 1 2 OPERATION Seren 1 1 SECTION 2 SERVICE 2 1 GENERAL a RS ER 2 1 2 2 BEAD BREAKER ehren 2 1 2 2 1 CLAMPING CYLINDER DISASSEMBLY 2 1 2 2 2 CLAMPING CYLINDER ASSEMBLY 2 1 2 2 3 BREAKER CYLINDER DISASSEMBLY 2 2 2 2 4 BREAKER CYLINDER ASSEMBLY 2 2 2 2 5 PURGING OF AIR see 2 3 2 3 BEEANING rn ie ea 2 3 2 4 STORAGE unse ee ee at 2 3 2 5 TROUBEESHOOTING uan 2 4 SECTION 3 PARTS 3 1 NEO 3 1 3 2 ORDERING REPAIR PARTS o ae 3 1 SECTION 4 OIL SPECIFICATIONS 4 1 OILSELETTION 24er 4 1 4 2 OIL SPECIFICATIONS sr ar ana 4 1 4 3 CONTAMINATION AND TESTING 4 1 LIST OF ILLUSTRATIONS FIGURE TITLE PART NUMBER PAGE A 1 SEQUENCE OF OPERATION uci 1 2 A 2 BEAD BREAKER REFERENCE DRAWING eeenem 1 3 B 1 U CUP INSTALLATION uc aaa fell 2 2 B 2 TROUBLESHOOTING CHART 5 ertet n na kan b 2 4 C 1 BEAD BREAKER PARTS esses TODD Leere 3 1 C 1A BEAD BREAKER DRAWING
5. BLY REQUIREMENTS ITEM NUMBERS REFERENCED TO PARTS LIST ITEM ASSEMBLY REQUIREMENT 1 TORQUE 30 40 FT LBS 3 TORQUE 125 140 FT LBS 4 LUBRICATE BEFORE ASSEMBLY 9 TORQUE 40 50 IN LBS APPLY LOCTITEG TO THREADS 13 TORQUE 90 110 IN LBS 15 TORQUE 90 110 IN LBS 22 TORQUE 42 48 FT LBS APPLY LOCTITEG TO THREADS 29 TORQUE 25 40 FT LBS 38 TORQUE 175 225 FT LBS 47 TORQUE 80 90 FT LBS SEE FOLLOWING PAGE FOR DRAWING ITEM PART NO DESCRIPTION QTY 26 72060983 SET SCR 3 8 16X3 8 SHCONEPT 1 27 7Y036853 CLAW 1 28 72066319 ROLL PIN 3 8X2 1 4 1 29 7YO21599 VALVE SPRING CAP 1 30 70024222 WASHER COPPER PART OF 50 1REF 31 7YO16724 SPRING 1 32 72066437 BALL 1 4 DIA SS 2REF 33 72062024 NUT 1 2 13 HEX JAM 1 34 7Y202636 HANDLE 1 35 7Y202625 SPRING 1 36 7Q072224 O RING PART OF 50 1REF 37 7Q10P224 BACK UP WASHER PART OF 50 1REF 38 72533288 BREAKER CYLINDER HEAD 39 70393570 BREAKER ROD 40 7Y204237 RETAINING RING 41 7Y204236 BEARING 42 7Y201433 RETAINING RING 43 72533286 REDUCING NIPPLE 44 76393572 ROD WIPER PART OF 50 1REF 45 72533616 STREET ELBOW 45 1 46 70143089 TOOTH 2 47 72060794 CAP SCR 1 2 13X1 1 4 SH 4 49 72533287 COUPLER QUICK DISC F 1 50 94393571 SEAL KIT INCL 5 6 14 16 30 36 37 44 1 FIGURE C 1 BEAD BREAKER 210HP 79075107 000210HP 99900657 19920508 3 2 MO gt Pe KA Ay FIGURE C 1A BEAD BREAKER 210HP 79075107 000210HP 99900657 19920508 SECTION 4 O
6. IL 4 1 OIL SELECTION Minimum viscosity specifications for hydraulic oil to be used in the IMT 210 HP system are given in Figure D 1 Any major oil company can supply products which meet these requirements Oils selected by the user for this class of equipment in addition to meeting viscosity requirements should have the following additives 1 Antifoam inhibitors 2 Antioxidant inhibitors 3 Rust resistant additives 4 Antiwear additives 4 2 OIL SPECIFICATIONS Figure E 1 provides oil specifications for a full range of operating temperatures encountered in the temperate zones Arctic conditions present special requirements which are not within the scope of the table and must be given special consideration and individual analysis Consult your local oil supplier for the proper fluid for working under these severe conditions SPECIFICATIONS 4 3 CONTAMINATION AND TESTING Contamination of the hydraulic oil by solvents water dust or other abrasives will result in a premature breakdown of the oil s antifoam lubrication anti rust and viscosity properties Prolonged exposure to water or high temperatures above 180 F will cause an increase in the oxidation rate producing varnish forming materials and sludge in the oil Periodically a sample of the hydraulic oil in the system should be drawn off and its condition checked for breakdown To check oil quality 1 Place oil sample in a clean glass 2 Smell oil to detect
7. e back up washer and o ring 36 8 37 onto the head CAUTION When working the back up washer and o ring into position do so slowly Avoid stretching them excessively Lubricate the head 38 and cylinder threads with STP or equivalent Screw the head into the cylinder and torque to 175 225 ft Ibs Install the socket head screw and washer 14 8 15 and torque to 90 110 in Ibs Thread the T handle 34 into the head 38 until it bottoms out Tighten the lock nut 33 Purge the tool of air refer to paragraph 3 2 5 Assembly of the breaker cylinder is complete 2 3 2 2 5 PURGING OF AIR Note that these instructions are designed for use with the IMT 200 Air Hydraulic Pump If using a different pump use this information as a guide only Purging is accomplished as follows Connect the air hydraulic pump to the tool Connect the pump to the air supply Position the pump so that it is higher than the tool and depress the PUMP end of the pedal After the clamping and breaker rods are fully extended depress the RELEASE end of the pedal Repeat this cycle PUMP RELEASE about five times Extend both rods and keep them extended Check for leaks Make certain that the rods do not creep back into the cylinders 2 3 CLEANING Wash the exterior of the Bead Breaker with warm soapy water Rinse with clean water and blow the tool dry with an air nozzle Also pay particular attention to the cleanlines
8. e in vertical position B Replace piston packing FIGURE B 2 TROUBLESHOOTING CHART 000210HP 99900657 20040504 3 1 GENERAL This section contains the parts drawing and parts list for the IMT 210HP Bead Breaker ITEM PART NO DESCRIPTION QTY 72060066 CAP SCR 7 16 14X2 HH GR5 1 7Y036949 STRAP PIVOT HANDLE 1 70144173 CLAMP CYLINDER 1 7Y201360 SPRING RETAINER 4 7Q072220 O RING PART OF 50 1REF 7Y201430 SPRING 1 7Y017160 WASHER 1 72060562 SET SCR 1 4 20X1 SH 1 72066435 BALL 3 16 DIA SS 1 76393561 DECAL SER NO 1 70144175 BODY 1 72060708 CAP SCR 1 4 20X1 1 4 SH 2 70024221 WASHER COPPER PART OF 50 3 72060907 CAP SCR 1 4 20X3 1 2 SH 1 ME AE GE LXX 1X 13 2X 2 OOND I PWD OOCOONODO UI PWOMN 72066560 RETAINING RING E 5 8 4 20 70144172 STRAP 2 21 7Y205288 PIN 1 22 72060753 CAP SCR 3 8 16X1 SH 2 23 7Y204238 SPACER 2 24 70144174 JAW 1 25 72060985 SET SCR 3 8 16X1 2 SHCUPPT 1 7Q10P220 BACK UP WASHER PART OF 50 1REF 7R13P015 ROD WIPER PART OF 50 1REF 7R535015 U CUP PART OF 50 2REF 70393569 CLAMP ROD 1 3 1 SECTION 3 PARTS 3 2 ORDERING REPAIR PARTS To order parts 1 Give the model number 2 Give the serial number located on the Bead Breaker 3 Give the part number description and quantity required Place your order with lowa Mold Tooling Co Inc Box 189 Garner IA 50438 telephone 641 923 3711 Fax 641 923 2424 or your nearest distributor ASSEM
9. e spanner wrench Work the o ring 5 and back up washer 6 over the threaded portion of the body casting and remove them Grip the lip of the wiper 16 with the needle nosed pliers and pull the wiper from the groove in the cylinder Puncture the u cup 17 with an ice pick or sharp awl Pry it out of the groove and push it on through the cylinder If it is necessary to remove the spring 7 grip it and turn it counterclockwise This completes disassembly 2 2 2 CLAMPING CYLINDER ASSEMBLY To assemble the clamping cylinder proceed as follows NOTE Use all of the seals supplied in the seal kit It may avoid costly repairs in the future Thread the bottom spring anchor 4 on the slotted headless screw 9 and rotate the spring clockwise until it is tight Install the back up washer and o ring 5 amp 6 over the threaded portion of the body casting CAUTION Work the o ring 5 and back up washer 6 slowly into position Avoid stretching them excessively 000210HP 99900657 19920508 Position the cyinder 3 with the wiper pocket up Grasp the u cup 17 with the needle nosed pliers Figure B 1 and insert it into the cylinder Allow it to snap into place helping with the fingers if necessary Install the wiper 16 Lubricate the threads on the cylinder 3 and the body with STP or equivalent Screw the cylinder onto the body casting by hand Get it as tight as possible Torque the cylinder to 125 140
10. etaining Ring eo Spring x x V SECUN ES ZA Socket Head Screw Spacer E Retaining Ring Spring Anchor Socket Head Screw amp Washer Bolt Handle Block Clamping Rod Wiper U Cup Spring Anchor Spring Cylinder p Slotted Headless Screw Washer Spring Anchor Ball Fluid Return Ball O Ring Back up Washer Sequence Ball Spring Washer amp Cap U Cup lt Wiper gt Body Casting Tongue Breaker Rod gt Spring Pin Jaw ER 7 Cup Point Set Screw Cone Point Set Screw FIGURE A 2 BEAD BREAKER REFERENCE DRAWING 000210HP 99900657 19920508 1 4 000210HP 99900657 19920508 SECTION 2 2 1 GENERAL Most malfunctions are a direct result of foreign matter dirt dust water etc entering the tool through the open hydraulic coupler union Keep the union clean and capped when the pump is not connected to the tool If your pump is to be used only with the Bead Breaker it is recom mended that the pump be permanently attached to the tool This is accomplished by removing the quick disconnect coupler union the 45 elbow and the nipple inserting a swivel and attaching the hose from the pump directly to the swivel Use a pipe thread compound when assembling This will eliminate the possibility of contamination through the open coupling The Bead Breaker is relatively easy to service Some tools will be required for disassembly These are Spanner wrench Common scr
11. etaining rings or bearing from the rod Special tools are required for this operation Return the entire toolto the nearest service center if required Probe in the tongue end of the rod with a 5 32 Allen wrench and remove the socket head screw and washer 13 amp 14 Position the tool with the teeth up Grip the lip of the wiper 46 with the needle nosed pliers and pull it out ofthe groove Puncture the u cup 17 with and ice pick or sharp awl Pry the u cup from the groove and push it on through the cylinder Work the o ring 36 and back up washer 37 offthe head Breaker cylinder disassembly is now complete 2 2 4 BREAKER CYLINDER ASSEMBLY Cylinder assembly is accomplished as follows NOTE Use all of the seals supplied in the seal kit It may avoid costly repairs in the future Hold the spring 35 inside the rod Insert the socket head screw and washer 13 amp 14 into the hole in the tongue end of the rod and torque to 90 110 in Ibs 000210HP 99900657 19920508 Position the cylinder with the teeth up Grip the u cup 17 with the needle nosed pliers Figure B 1 and insert it into the cylinder Allow it to snap into place helping with the fingers if necessary Install the wiper 44 Insert the rod assembly 39 from the head end of the cylinder and slide it through the u cup and wiper 17 8 44 Slip the tongue 27 onto the rod 39 and fasten itin place with the spring pin 28 Work th
12. ewdriver Needle nosed pliers Ice pick or sharp awl Allen wrenches Open end wrenches Retaining ring pliers Socket wrenches Ratchet 10 Torque wrench 2 2 BEAD BREAKER These instructions deal with the complete disassembly of the Bead Breaker For informa tion concerning the service of your pump see the literature which accompanied it If you are using the IMT 200 Air Hydraulic Pump see manual part number 99900120 2 2 1 CLAMPING CYLINDER DISASSEMBLY Before disassembling the Bead Breaker the outside must be thoroughly cleaned to prevent contaminating the interior Use warm soapy water rinse with clear water and wipe or blow the tool dry 0 00 mAo0mN CAUTION Proceed with disassembly in a warm clean environment one that is free of dust dirt grease solvents etc and has a temperature of at least 70 F To disassemble the clamping cylinder proceed as follows refer to parts drawings SERVICE Remove the four E retaining rings 19 that secure the clamping straps Remove the straps Unscrew the bolt 1 at the top of the cylinder and remove the handle block 2 Probe in the hole at the top of the clamping rod with a 5 32 Allen wrench long leg in the hole Unscrew and remove the socket head screw and washer 13 amp 14 Reinstall the bolt 1 and handle block 2 removed in a previous step Pull the rod 18 out of the cylinder using the handle block Unscrew the cylinder 3 with th
13. ft lbs Slide the rod 18 carefully through the wiper 16 and u cup 17 and over the spring 7 until it bottoms out Insert the washer and socket head screw 13 amp 14 into the hole in the top of the rod With a 5 32 Allen wrench turn the socket head set screw clockwise into the spring anchor Torque to 90 110 in Ibs Position the handle block 2 over the hole at the top of the rod 18 and secure it with the bolt Do not tighten the bolt 1 Slide the clamping straps 20 over the jaw pin 21 and handle block pin and secure them with the four E retaining rings 19 Tighten the sequence ball spring washer and cap 29 30 31 8 32 Torque to 25 40 ft Ibs Purge the system of air refer to paragraph 3 2 5 This completes cylinder assembly Cl ae EN FIGURE B 1 U CUP INSTALLATION 2 2 2 2 3 BREAKER CYLINDER DISASSEMBLY Refer to parts drawings for location of parts The cylinder is disassembled as follows Loosen the jam nut 33 on the T handle 34 and remove the handle Probe inside the hole in the head with a 5 32 Allen wrench and remove the socket head screw and washer 14 amp 15 Remove the head 38 with a spanner wrench Grip the tongue 27 and pull it forward Drive out the spring pin 28 securing the tongue to the rod 39 and slide the tongue off the rod Push the rod back into the cylinder and pull it out the other end CAUTION Do not attempt to remove the r
14. ioned in the crevice between the bead of the tire and the rim NOTE When atire has a trash guard you may have to drive two straight tire irons between the rim and the tire bead to get a starting point for the teeth Step on the PUMP end of the pump pedal The clamping rod will begin to extend and the jaw will grip the rim CAUTION Make certain that the teeth are slipping in between the rim and the bead If not depress the RELEASE end of the pump pedal and realign the tool If the tool is not positioned correctly extending the breaker rod may damage the tool Continue pumping until the tongue of the Bead Breaker pushes the bead free of the rim Depress the RELEASE end of the pump pedal 000210HP 99900657 19920508 1 2 Clamping Rod mm PATH OF FLUID Fluid Return Ball Sequence Ball Fluid Return Ball Sequence Ball Clamping Rod Fluid Return Ball Sequence Ball Fluid Return Ball Teeth Tongue Step 3 Step 4 Breaker Rod FIGURE A 1 SEQUENCE OF OPERATION 000210HP 99900657 19920508 1 3 AS KE A E Retaining Ring 1 X fi 3 m Clamping Strap f f Et E x ae L gt LA Handle Socket Head Screw amp Washer LE mars ES VAZ wot AAA ud WU MEER GS aki KC Nd HS BT N gt Head A 7 IE Back up e SN Washer O Ring CAS ON M ae Spring Anchor y Retaining Ring Bearing R
15. m pump 1 2 Check air supplu 5 10 CFM 100 PSI Check clearance of inlet check ball Ball must be flush with or below end of filter adapter Hydraulic pump does not release 1 Beari Dirt under pedal in release valve area Clean pedal ng is misaligned on breaker rod Correct or replace Broken or weak springs Replace Hydraulic pressure in breaker cylinder increases before clamping rod is fully extended 1 2 Sequence ball not seated or broken or weak spring Correct or Replace Loose screw and ball not seated Correct or Replace Hydraulic pressure in breaker cylinder is not being released 1 2 Fluid return ball did not reseat Correct or Replace Dirt plugging return port Clean Weak or broken spring in breaker cylinder Replace Air piston stuck 1 Chec 1 Check cylinder bore of pump for contamination or lack of lubrication Piston poppet not sealing Replace k prime Depress both air valve and hydraulic release valve at the same time Outlet check ball not sealing properly Correct or Replace Release valve mechanism not sealing properly Check pin ball release poppet and poppet retainer Corect or Replace Check air supply 5 10 CFM 100 PSI Check for internal leakage A Release valve mechanism B Low relief valve setting C Inlet check ball not seating properly Correct or Replace Check piston sub assembly A Replace copper gasket and assembl
16. s of the pump CAUTION Do not use solvent Solvents may be corrosive to the seals and damage them 2 4 STORAGE Anytime the tool is put away a number of checks must be made Completely retract both rods An exposed rod may be subject to rusting pitting and damage from striking other tools If chloride is spilled on the tool rinse with clean water and blow dry Nicks and dents in the rod surfaces should be carefully dressed with fine grit emory paper If left untended they provide a starting point for rust NOTE The chrome plated rod surfaces provide the seal for the tool Any steps taken to ensure the continuing quality of the rod surfaces will increase the service life of the tool 000210HP 99900657 19920508 2 4 2 5 TROUBLESHOOTING Figure B 2 lists problems probable causes and solutions of the Bead Breaker and for conve nience the IMT 200 Air Hydraulic Pump See the parts drawings for reference SYMPTOM PROBABLE CAUSE RODS EXTEND TOO SLOWLY RODS FAIL TO RETRACT BOTH RODS EXTEND AT THE SAME TIME BREAKER ROD RETRACTS AFTER CLAMPING ROD PUMP DOES NOT RECIPROCATE PUMP RECIPROCATES RAM WILL NOT EXTEND PUMP EXTENDS RAM BUT WILL NOT HOLD SYSTEM PRESSURE PUMP EXTENDS RAM BUT WILL NOT BUILD TO MAXIMUM PRESSURE NO VISIBLE SIGNS OF LEAKAGE PUMP EXTENDS RAM BUT WILL NOT BUILD MAXIMUM PRESSURE VISIBLE SIGN OF LEAKAGE THROUGH AIR EXHAUST MUFFLER Insufficient hydraulic pressure fro
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