Model 200 AIR/HYDRAULIC PUMP - IMT
Contents
1. 48 49 50 51 52 53 amp 54 into the pump body 8 Position the pump body in a vise with the filter port up Install the filter adapter copper washer and ball 9 10 11 12 amp 58 Reposition the pump body with the cylinder end up Install the cylinder u cup retainer nut and copper gasket 14 15 16 amp 17 Clamp the rear head 27 in a vise and insert the back up ring 59 Assemble the piston 22 23 24 25 26 28 29 30 31 32 amp 33 Apply Loctite to the threads of the socket head screws 29 and torque them to 50 55 in lbs Lubricate the piston rings and the inside of the air cylinder with oil Insert the piston into the air cylinder and squirt more oil around the circumfer ence of the piston Work the piston back and forth to distribute the oil Position the cylinder piston group on the rear head with the groove on the inside of the cylinder toward the top of the rear head Position the back up ring 59 on the pump body Position the spring guide hydraulic piston and spring 13 20 amp 21 over the air piston Align the pump body so the hydraulic piston slides through the retainer nut 17 Push the pump body down against the cylinder Install the four socket head screws and washers and torque them to 85 90 in lbs NOTE The easiest way to assemble the rear head cylinder and pump body is to start one screw and get it finger tight That will take up the spring tension and make i2. 51705747 C 2 AIR HYDRAULIC PUMP PARTS seeren 73051 460 C 2A AIR HYDRAULIC PUMP DRAWING oseere 73051 460 D 1 HYDRAULIC OIL SPECIFICATIONS o os eee een scene tere eeenaeeeneeeeeeeee PAGE 200 PUMP 99900120 19920508 SECTION 1 1 1 DESCRIPTION The IMT 200 Air Hydraulic Pump supplies hydraulic fluid pressure to selected tools such as the 210 HP Bead Breaker It consists of an in line air and hydraulic cylinder The ratio of hydraulic fluid pressure generated compared to supply air pressure is 100 1 In other words 100 PSI out for every 1 PSI in 100 PSI input air pressure equals 10 000 PSI output pressure Depressing the RELEASE pedal causes a decrease in pressure and pressing the PUMP end of the pedal provides fluid pressure WARNING The air hydraulic pump is capable of generating fluid pressure up to 10 000 PSI Make certain the tool in use is held securely and is in proper working condition Do not continue to operate the pump once the work is completed Failure to comply with these instructions could result in personal injury or damage to the equipment DESCRIPTION 1 2 OPERATION Operation of the unit is as follows Connect the hose of the Air Hydraulic Pump to the hydraulic coupling on the selected 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
3. Rust resistant additives Antiwear additives PAS 4 2 OIL SPECIFICATIONS Figure E 1 provides oil specifications for a full range of operating temperatures encountered in the tem perate 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 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 LUBRICATION Periodically a sample of the hydraulic oil in the system should be drawn off and its condition checked for breakdown To check oil quality Place oil sample in a clean glass Smell oil to detect a burnt or rancid odor Examine the oil for a cloudy or dark color 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 A When any of these conditions is observed the system should be purged and filled with new oil 4 4 LUBRICATION If the pump is operated on a
4. air line filter Stepping on the PUMP end of the pedal engages the pump producing the force necessary to run the tool Depressing the RELEASE end of the pump pedal will release the pressure 200 PUMP 99900120 19920508 2 1 GENERAL Most malfunctions are a direct result of foreign matter dirt dust water etc entering the pump Keep all unions clean and capped when the pump is not connected to a tool If the Air Hydraulic Pump is to be used only with one tool it is recommended that the pump be permanently attached to that tool This is accomplished by removing any quick disconnects from the tool 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 open couplings The pump is relatively easy to service Some tools will be required for disassembly These are 1 Vise Common screwdriver Needle nosed pliers Ice pick or sharp awl Allen wrenches Open end wrenches Retaining ring pliers Socket wrenches Ratchet Torque wrench SOPLADO 2 2 AIR HYDRAULIC PUMP Before disassembling the pump the outside must be thoroughly washed to prevent contaminating the interior Before washing remove the pedal 67 by removing one ofthe E retaining rings and sliding the pin 64 out of the hole Wash thoroughly with warm soapy water rinse with clean water and wipe or blow the pump d
5. continuous duty cycle for extended periods the manufacturer recommends an automatic air line oiler be installed in the air inlet as close to the pumping unit as possible Set the unit to feed approximately 1 drop of oil per minute into the system Use SAE No 10 oil Check the oil level in the reservoir after every 10 hours ofuse The oil should come to within 1 2 of the filler plug with all rams retracted Drain and replenish the reservoir with an approved high grade hydraulic oil after every 300 hours of use AMBIENT TEMPERATURE RANGE 0 90 F BELOW 32 F 39 907 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 150 200 200 315 43 47 90 90 FIGURE D 1 HYDRAULIC OIL SPECIFICATIONS 200 PUMP 99900120 19920508 The information within this manual has been compiled and checked but errors do occur To provide our customers with a method of communicating those errors we have provided the Manual Change Request form below In addition to error reporting you are encouraged to suggest changes or additions to the manual which would be of benefit to you We cannot guarantee that these additions will be made but we do promise to consider them When completing the form please write or print clearly Submit a copy of the completed form to the address listed below MANUAL CHANGE REQUEST DATE PRODUCT MANUAL MANUAL PAR
6. mechanism B Low relief valve setting C Inlet check ball not seating properly Correct or Replace PUMP WILL NOT BUILD MAXIMUM PRESSURE VISIBLE SIGN OF LEAKAGE THROUGH AIR EXHAUST MUFFLER Check piston sub assembly A Replace copper gasket and assemble in vertical position B Replace piston packing FIGURE B 1 TROUBLESHOOTING CHART 200 PUMP 99900120 20000706 3 1 SECTION 3 PARTS 3 1 GENERAL 3 2 ORDERING REPAIR PARTS This section contains the parts drawings and parts To order parts lists for the IMT 200HP Air Hydraulic Pump 1 Give the model number 2 Give the serial number located on the side of the pump 3 Give the part number description and quantity required Place your order with Iowa Mold Tooling Co Inc Box 189 Garner IA 50438 telephone 641 923 3711 Fax 641 923 2424 or your nearest distributor p ITEM PARTNO DESCRIPTION QTY 1 51073049 HOSE ASM 84 1 2 72532047 DISCONNECT NIPPLE 1 4MPT AIR 3 72532281 DISCONNECT COUPLER 1 4FPT 4 73051460 PUMP AIR HYD 5 QT SEE DWG 5 99900120 MANUAL 200 AIR HYD PUMP FIGURE C 1 PUMP ASSEMBLY W HOSE 51705747 200 PUMP 99900120 19920508 ITEM 1 NOT RON OOOND 01 00 O Add dd PARTNO 70141439 70072218 72060702 70024221 70141141 72066438 73054282 70141438 72066437 70024222 70142929 70048097 70141136 70024215 70142928 76391235 72062184 70141441 70142927 70141442 70072115 70029505 7166G027 76391344 7014
7. 0 off the rear head Push the air piston out of the cylinder Remove the three socket head screws and washers 28 amp 29 from the air piston assembly Remove all parts The piston poppet 31 can be pulled off the end of the exhaust valve stem 32 Remove the piston rings and back up rings 25 amp 33 with a small common screwdriver 200 PUMP 99900120 19920508 Place the pump body 8 in a vise with the cylinder end facing up Remove the retaining nut 17 The u cup will have to be pressed out from the other end of the pump body Remove the cylinder 15 with a 1 socket 2 2 Reposition the pump body in the vise so that the filter 12 is on top Remove the filter adapter copper washer and ball 9 10 11 amp 12 Insert a common screwdriver in the slot at the top of the poppet retainer 48 Rotate it back and forth to loosen it Grip the retainer and pull it out of the pump body NOTE Socket head screw and washer 3 amp 4 are used as a plug There is no need to remove them Relief valve 7 is factory preset at 10 000 PSI There should be no need for its removal If itis defective replace the entire relief valve assembly The new assembly is also preset Do not disassemble before installation or the setting will be incorrect Disassembly is complete 2 2 2 PUMP ASSEMBLY The pump is assembled as follows NOTE Use all components supplied with the seal kit Insert the release valve components
8. 200 PUMP 99900120 20070329 e AIR HYDRAULIC PUMP 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 99900120 lowa Mold Tooling Co Inc is an Oshkosh Truck Corporation company 200 PUMP 99900120 19920508 TABLE OF CONTENTS SECTION 1 DESCRIPTION 1 1 DESCRIPTION cotidiana tela 1 2 OPERATION uc aii SECTION 2 SERVICE 2 1 GENERAL custodiar a Cat eh ae eee 2 2 AIR HYDRAULIC PUMP 0 000 eee ecene cence eeeeeeeaaeeeaeeseeeeseaeesaneseeeeesaaes 2 2 1 PUMP DISASSEMBLY 0 0 eecceceeecceeee cent conc connnn narran nr rre 2 2 2 PUMP ASSEMBLY oia aietan taia aAa aaae cnet 2 3 CLEANING socio a ini i ii sea 2 4 STORAGE ma a e a dia aiea pa t a a dS 2 5 TROUBLESHOOTING viim eiin enida aiii iiai aiea SECTION 3 PARTS 3 1 GENERAL aid riada 3 2 ORDERING REPAIR PARTS inccciccocccncccnnonccnnnconnnnnnonncnnnconncnnnncan cnn SECTION 4 LUBRICATION 4 1 OIL SELECTION iio nn tiled aa lees eel etl ee 4 2 OIL SPECIFICATIONS 0 00 eee eeceeeee scenes enaeeeaeeeeeeeseeeenaeeseeeteeeeeatess 4 3 CONTAMINATION AND TESTING oooococccncccconnconnnonanonnonaconanannnn cana ncnnnann 4 4 LUBRICATION cositas LIST OF ILLUSTRATIONS FIGURE TITLE PART NUMBER B 1 TROUBLESHOOTING CHART 0 eeeeecceeeneeceneeeeeeeeeeeenaeeseeeeeeeesnaeeesas C 1 PUMP ASSEMBLY W HOSE c cococcocccccoccnconcconononnnnnnrnncnn conan nan
9. 2358 72063047 72060680 70141432 76039495 70142926 70072141 70141435 70072210 72060656 70141434 70141291 70072011 70141433 76391349 70141421 76391348 70141428 70072010 70141437 70072010 70141284 70141285 72066432 70142925 70141427 70072012 70141085 76392468 76392110 70034266 72063162 76391345 70141424 72060685 72532689 70142924 70141422 72066556 70142923 73029148 70141086 72601409 72060727 76391347 70142359 72601273 72601274 76391654 72532688 70142357 72063131 72060687 70392467 76392469 DESCRIPTION CHECK VALVE BODY 0 eee O RING envasar act CAP SCR 1 4 20X3 8 SH WASHER 1 4X3 8X 03 COPPER SPRING siii cir BALL 9 32 DIA oocnoioccccicccnns RELIEF VALVE 10 000 PSI PUMP BODY uu eee BALL 1 4 DIA WASHER COPPER 4 FILTER ADAPTER SHORT FILTER ASM PISTON sssusa WASHER COPPER CYLIND E Riris SPRING PISTON BODY PISTON RING GASKET REAR HEAD WASHER 10 LOCK CAP SCR 10 24X1 2 SH END PLATE PISTON PISTON POPPET NES VALVE STEM G GAP SCR 8 32X1 4 SH SEAL GUIDE cocaciiars AIR VALVE PROPPET as O RING POPPET RETAINER RELEASE VALVE POP BALL 3 32 DIA sis BALL RETAINER AIR_CYLINDER CAP SCR 10 2 FILLER PLUG COVER PLATE RETAINING RING RELEASE VALVE BODY FOO
10. T NO SUBMITTED BY ADDRESS CITY STATE ZIP TELEPHONE _ ERROR FOUND LOCATION OF ERROR page no DESCRIPTION OF ERROR REQUEST FOR ADDITION TO MANUAL DESCRIPTION OF ADDITION REASON FOR ADDITION MAIL TO IOWA MOLD TOOLING Co Inc Box 189 Garner IA 50438 0189 ATTN Technical Publications 200 PUMP 99900120 20000706 This parts manual is provided to the user to assist in servicing the equipment It is the propertyof lowa Mold Tooling Co Inc and as such may not be reproduced either whole or in part whether by chemical electrostatic mechanical or photographic means without the expressedwritten permission of an officer of lowa Mold Tooling Co Inc One manual is provided with each piece of new equipment and additional manuals may be obtained at a nominal price IOWA MOLD TOOLING CO INC BOX 189 GARNER IA 50438 0189 TEL 641 923 3711 TECHNICAL SUPPORT FAX 641 923 2424
11. T PEDAL ese INTAKE AIR VALVE BODY SCR 10X1 HWH SLFTPG CAP SCR 1 4 20X4 SH ERAN TUBE 3 SPRING U RELIEF VALVE FITTING SPRING CLIP uw WASHER a itccssicccsrtscscesteetarctincess CAP SCR 10 24X1 3 4 SH DECAL MODEL NO uu REPAIR KIT INCLUDES ITEMS W A e e e o Ces dd de dd INAP CA A AN ES ES AS Y ES NEP INDI e e de 3 2 QTY COMMENTS TORQUE TO 90 100 IN LBS TORQUE TO 40 50 FT LBS OILED TORQUE TO 90 100 FT LBS OILED TORQUE TO 80 100 IN LBS MILD HEAT MAY BE NEEDED TO REMOVE REINSTALL WITH LOCTITE 277 oF Oe OF LOCATE GROOVE TOWARD TOP NEAR COVER PLATE TORQUE TO 50 60 IN LBS TORQUE TO 25 30 IN LBS TORQUE TO 85 95 IN LBS OILED CROSS TORQUE IN 30 IN LB INCREMENTS TORQUE TO 12 18 IN LBS TORQUE TO 75 80 IN LBS TORQUE TO 50 60 IN LBS SEE FOLLOWING PAGE FOR DRAWING FIGURE C 2 AIR HYDRAULIC PUMP 73051460 200 PUMP 99900120 19920508 3 3 FIGURE C 2A AIR HYDRAULIC PUMP 73051460 200 PUMP 99900120 19920508 SECTION 4 4 1 OIL SELECTION Minimum viscosity specifications for hydraulic oil to be used in the 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 Antifoam inhibitors Antioxidant inhibitors
12. Wash the exterior of the pump with warm soapy water Rinse with clean water and dry using compresed air Pay particular attention to the release valve area of the pump This may become encrusted with dirt to the extent that the release mechanism will no longer function CAUTION Do not use solvent Solvents may be corrosive to the seals and damage them 2 4 STORAGE Anytime the pump is stored it is wise to wash any spilled chloride or other harmful chemicals from its exterior Use warm soapy water and be certain to rinse with clear water and dry thoroughly Doing so on a regular schedule will increase the life of the equipment 2 5 TROUBLESHOOTING Figure B 1 lists problems probable causes and solutions for the pump refer to the parts drawings SYMPTOM PROBABLE CAUSE PUMP DOES NOT RECIPROCATE Air piston stuck Check cylinder bore of pump for contamination or lack of lubrication Piston poppet not sealing Replace PUMP RECIPROCATES Check prime 1 Depress both air valve and hydraulic release valve at the same time BUT NO PRESSURE PUMP WILL NOT HOLD SYSTEM PRESSURE 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 PUMP WILL NOT BUILD TO MAXIMUM PRESSURE NO VISIBLE SIGNS OF LEAKAGE Check air supply 5 10 CFM 100 PSI Check for internal leakage A Release valve
13. ry CAUTION Do not use solvents Solvents may be corrosive to seals Proceed with disassembly in a clean warm environment one that is free of dust dirt etc and has a temperature of 70 F or warmer SECTION 2 SERVICE 2 2 1 PUMP DISASSEMBLY To disassemble proceed as follows refer to Figure C 2 for parts information Remove the twelve self tapping screws 69 and lift off the cover pump assembly Set the reservoir 57 and gasket 55 to one side Remove the six socket head screws 61 amp 84 and lift off the muffler 42 amp 72 the intake air valve body 68 the release valve body 66 and cover 63 The air valve may be disassembled by removing the socket head screw 36 drawing item 39 and 40 out of the top and items 36 and 38 out of the bottom The release valve may be further disassembled by drawing items 1 44 45 and 47 out of the bottom The pump assembly under the cover may also be disassembled Lift out the springs 5 34 amp 46 and ball 6 Clamp the rear head 27 in a vise Remove the four socket head screws 70 NOTE Itis easier to remove three socket head screws 70 completely and then using hand pressure to hold the pump body in place remove the fourth screw Spring tension 20 will cause the pump body to lift away from the cylinder 60 Carefully lift off the pump body 8 the hydraulic piston spring guide and spring 13 20 amp 21 Lift the cylinder 6
14. t easier to install the others Position the pump assembly in the vise with the top up Place new gaskets on the pump body and rear head Oil will help hold them in position Place the cover on top of the gaskets and insert the o rings 35 amp 2 With your fingers press item 1 44 45 and 47 into the ports in the release valve body Place the ball 6 and springs 5 amp 46 into the ports of the pump body Install item 58 must be pressed into place Align the release valve body on the cover and start the four socket head screws Do not tighten the screws Install items 36 37 38 and 40 in the air valve body Place the spring 34 in the port in the rear head Position the muffler 42 amp 72 between the valve bodies and secure the valve bodies in place torque the screws to 25 30 in lbs Position the pedal and slide the pin through the valve body and pedal Secure it with the other E retain ing ring Position the assembled pump in the reservoir Fill the reservoir with oil and prime the pump 200 PUMP 99900120 19920508 2 3 To prime the pump connect the air supply line to the air inlet Depress the PUMP end of the pedal and hold down the release valve with a common screw driver Allow the pump to cycle 15 20 times Remove the screwdriver and depress the PUMP end of the pedal If pressure builds the pump has primed if not repeat this step until it does build pressure 2 3 CLEANING
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