IMT TH5K115 User manual

Manual # 99905539
TH5K115 Manual
Revised 20141008
IOWA MOLD TOOLING CO., INC.
PO Box 189
Garner, IA 50438
Tel: [phone] FAX: [phone]
Website: http://www.imt.com
Copyright © 2014 Iowa Mold Tooling Co., Inc.
All rights reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise without the
prior written permission of Iowa Mold Tooling Co., Inc.
Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation Company.
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i
Contents
Revisions .................................................................................................................................................... iii
Tirehand Introduction 5
TH5K115 Specifications 7
General Specifications..................................................................................................................................8
Dimensional Drawing...................................................................................................................................9
Capacity Chart............................................................................................................................................10
Installation 11
Tirehand Installation Introduction ..............................................................................................................12
Typical Tirehand Hydraulic Installation.....................................................................................................13
Loader Installation......................................................................................................................................14
Lift Truck Installation.................................................................................................................................15
Bulkhead Installation..................................................................................................................................16
Valvebank Installation................................................................................................................................17
Operation 19
Operator Training .......................................................................................................................................19
Tirehand Intended Use and Identification...................................................................................................20
TH5K115 Component Identification..........................................................................................................20
Tirehand Equipment Inspection..................................................................................................................21
Work Station Positioning............................................................................................................................21
Tirehand Controls.......................................................................................................................................22
Tirehand Fallback Arms .............................................................................................................................23
Tirehand Task Performance........................................................................................................................24
Tirehand Operating Restrictions.................................................................................................................26
Tirehand Electrical Safety ..........................................................................................................................27
Tirehand Warnings .....................................................................................................................................28
Maintenance 31
Tirehand Maintenance Introduction............................................................................................................31
Tirehand Lubrication Points .......................................................................................................................32
Purging Tirehand Trapped Air....................................................................................................................32
Hydraulic System........................................................................................................................................32
Tirehand Preventative Maintenance ...........................................................................................................33
Tirehand Inspection Chart ..........................................................................................................................35
Tirehand Repair 37
Tirehand Troubleshooting...........................................................................................................................38
Tirehand Cylinders .....................................................................................................................................39
Replacement Parts ......................................................................................................................................40
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ii Contents
Tirehand Hydraulic Motors ........................................................................................................................41
Tirehand Relief Valve Adjustment .............................................................................................................41
Tirehand Bearings.......................................................................................................................................42
Turntable Bearing Thread Tightening Sequence ........................................................................................44
Turntable Bearing Inspection......................................................................................................................45
Thread Torque Chart (English)...................................................................................................................46
Thread Torque Chart (Metric) ....................................................................................................................47
Tirehand Parts 49
Tirehand Parts Ordering Information..........................................................................................................50
SUB BASEASSEMBLY (40724893) ........................................................................................................51
Clamp Assembly (40724894) (Effective from 10/28/13)...........................................................................52
Clamp Assembly (40724894) (Effective thru 10/28/13) ............................................................................53
Sub Base Assembly (40724912).................................................................................................................54
Cylinder (51724847)...................................................................................................................................55
Cylinder (3B160870)..................................................................................................................................56
Cylinder (3B022850)..................................................................................................................................57
CAMERAKIT (40724928) ........................................................................................................................58
Hydraulic Kit w/Valve Bank (91724909)...................................................................................................59
Valvebank (73734735) ...............................................................................................................................60
Valvebank Schematic (73734735)..............................................................................................................61
Hydraulic Kit w/o Valve Bank (91724929)................................................................................................62
Harness – Tirehand Radio Remote (77441524)..........................................................................................63
Harness – Tirehand Chassis Interface(77441525)......................................................................................65
Harness – Tirehand Radio Remote (77441525)..........................................................................................66
Decal Kit (95724921) .................................................................................................................................67
Radio Remote 69
Camera Option 71
Camera Kit – Dual (40724922) ..................................................................................................................72
MONITOR-DUAL VISION
(77734784) .................................................................................................73
Camera-For Dual Vision Monitor
(77734785) .........................................................................................97
Cable-Coax 65’ for Dual Vision Monitor (77734786) .............................................................................101
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iii
Revisions
DATE LOCATION DESCRIPTION
20130529
Pages 49-57
Added parts information
20130701
91725567
PER ENGINEERING MARK-UP; 91725567 was 91724909
20130711
Chapter 8
PER ENGINEERING MARK-UP; Added Camera Option Information.
20131003
73734735
77441524
77441525
Added per engineering mark-up.
20131010
Chapter 8/9
Added Radio Remote chapter 8. Chapter 9 was 8.
20131106
91724929
Hose kit part number corrected.
20131205
91724909
91724929
40724894
Was 91725567 (ECN 12108)
Updated schematic and BOM (ECN 12108)
Added BOM and schematic (ECN 12098)
20141008
Chapter 7
Added cylinders.
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5
This manual includes operation, safety, and maintenance instructions and replacement parts for
your IMT Tirehand.
In addition to reading the manual, it is your responsibility to become familiar with government
regulations, hazards, and the specific operation of your equipment. Use caution and common
sense while operating and maintaining the equipment and follow all safety procedures and
regulations. Treat this equipment with respect and service it regularly.
MODIFICATIONS
Modifications to your equipment must be performed with IMT approved accessories, parts and
optional equipment. If in doubt, contact IMT prior to making any modifications. DO NOT alter or
modify any safety device! All safety devices must be inspected, tested and maintained in proper
working condition.
Decals regarding safety and operation are considered safety equipment, and must be kept clean
and legible.
The equipment owner and/or designated employee is responsible for informing all operators,
maintenance personnel, and others involved in equipment operation about the safe operation and
maintenance of the equipment. If questions arise concerning safe operation, contact IMT or your
IMT distributor for clarification.
WARRANTY
Warranty of this unit will be void on any part of the unit subjected to misuse due to overloading,
abuse, lack of maintenance and unauthorized modifications. No warranty - verbal, written or
implied - other than the official, published IMT new machinery and equipment warranty will be
valid with this unit.
NOTICE TO THE OWNER / USER
If your equipment is involved in a property damage accident, contact your IMT distributor
immediately and provide them with the details of the accident and the serial number of the
equipment. If an accident involves personal injury, immediately notify your distributor and IMT
Technical Support at:
IOWA MOLD TOOLING CO., INC.
500 HWY 18 WEST
GARNER, IA 50438
641 - 923 - 3711
Tirehand Introduction
CHAPTER 1
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6 TH5K115 Manual #99905539
RESPONSIBILITY
It is the user’s responsibility to maintain and operate this unit in a manner that will result in the
safest working conditions possible. In addition, it is the user’s responsibility to be aware of
existing Federal, State, and Local codes and regulations governing the safe use and maintenance
of this equipment.
MANUAL STRUCTURE
Throughout this manual, four means are used to draw the attention of personnel. They are NOTEs,
CAUTIONs and WARNINGs and DANGERs and are defined as follows:
NOTE
ANOTE is used to either convey
additional information or to provide
further emphasis for a previous point.
CAUTION
ACAUTION is used when there is the
very strong possibility of damage to the
equipment or premature equipment
failure.
WARNING
A WARNING is used when there is the
potential for personal injury or death.
DANGER
Danger indicates an imminently hazardous
situation which, if not avoided, will result
in death or serious injury. Danger is used
in the most extreme situations.
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7
In This Chapter
General Specifications............................................................8
Dimensional Drawing..............................................................9
Capacity Chart......................................................................10
CHAPTER 2
TH
5K115
Specifications
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8 TH5K115 Manual #99905539
General Specifications
GENERAL SPECIFICATIONS
TIREHAND MAXIMUM CAPACITY 5500 lb (2495 kg)
BODY ROTATION
350° Cylinder Rotation
PAD ROTATION SYSTEM
120° Rotating Pads
TIREHAND WEIGHT (FORKLIFT MOUNTED)
2500 lb (1134 kg)
CLAMPING SPAN
28" to 115" (71.1 - 292.1 cm)
CENTER OF GRAVITY-Forklift-mounted tirehand with
5500 lb (2495 kg) tire & rim assembly at 106" (269.2
cm) clamp opening
66" (167.6 cm)
METHOD OF CLAMPING
Parallelogram
CLAMPING LOAD HOLDING VALVES
Counterbalance valve
HYDRAULIC CONTROL VALVE
Located on base assembly
HYDRAULIC CONTROLS
5-function remote control (radio or cab-mounted)
OPTIMUM PUMP CAPACITY (supplied from carrier
vehicle)
12 U.S. GPM (45.4 liters/min) @ 2500 - 3000 PSI
(57 liters/min @ 172.4 bar)
COUNTERWEIGHT NEEDED
As required for stabilization
STANDARD FEATURES
Hydraulic fallback protection
Rim flange hardware on pads
Forklift or loader mounting
OPTIONAL FEATURES
Electric controls
Lateral shifting capabilities
VEHICLE COMPATIBILITY
The Tirehand will permanently adapt to either a forklift truck or a front-end loader. When mounting to a forklift truck,
it is recommended that the truck be equipped with a sideshifter. If adapted to a front-end loader, quick couplers are
available which enable the disconnection of the Tirehand so that the original bucket can be quickly coupled to the
machine for normal operations.
IMT reserves the right to change specifications and design without notice. Where applicable, specifications are in
accordance with SAE standards and ISO/DIS 3691-1, the international standard for Industrial Trucks - Safety
Requirements and Verification.
IOWA MOLD TOOLING CO., INC.
BOX 189, GARNER, IA 50438-0189
TEL: [phone] FAX: [phone]
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Chapter 2 TH5K115 Specifications 9
Dimensional Drawing
Dimensions in inches (mm).
115"
56" (1422)
79" (2006) 28"
(2920)
(711)
66" CG (1676) with 2500 lb (1134 kg)
106" (2692) between pads
83" (2110) from mounting surface
tirehand and 5500 lb (2495 kg) tire & rim.
to centerline of tire
11"
(280)
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10 TH5K115 Manual #99905539
Capacity Chart
CAPACITY CHART
MAXIMUM CAPACITY
5,500 LB
(2495 KG)
CLAMPING SPAN
70399030
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11
In This Chapter
Tirehand Installation Introduction.......................................... 12
Typical Tirehand Hydraulic Installation ................................. 13
Loader Installation................................................................14
Lift Truck Installation............................................................. 15
Bulkhead Installation ............................................................16
Valvebank Installation...........................................................17
CHAPTER 3
Installation
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12 TH5K115 Manual #99905539
Tirehand Installation Introduction
VEHICLE COMPATABILITY
The tirehand will permanently adapt to either a forklift truck or a front-end loader which has
sufficient capacity and stability, per the tirehand specifications. When mounting to a forklift
truck, it
is recommended that the truck be equipped with a sideshift. If adapted to a front-end loader, quick
couplers are available which enable the disconnection of the tirehand so that the original bucket
can be quickly coupled to the machine for normal operations.
Typical tirehand hydraulic installations include:
Bulkhead plate hydraulic installation - all of the tirehand hydraulics hoses connect together
in
a
bulkhead plate, which then connects hydraulically to the loader or forklift. With a bulkhead
plate installation, the valvebank is part of the forklift or loader rather than the tirehand. In
many cases, bulkhead installations are used on forklifts.
Valvebank hydraulic installation - when the valvebank is part of the tirehand, rather than the
loader or forklift. The forklift or loader must be equipped with a pressure line and a return line
which connects the forklift or loader hydraulic system to the valvebank in the tirehand. In
many cases, valvebank hydraulic installations are used on loaders.
Typical tirehand controls include:
Hydraulic cab controls, where additional functions in forklift or loader control valves are
hydraulically connected to the tirehand.
Electric cab controls, which includes a control box with toggles used to control the tirehand.
Radio remote controls.
For all installations, the tirehand requires 12 GPM (45.4 lpm) of hydraulic fluid at 2500 – 3000 PSI
(172.4 - 206.8 bar). A flow divider may be required if the forklift or loader pump provides excess
flow. Contact IMT for specific installation instructions on any type of installation.
Prior to connecting any electrical connections between the tirehand and the loader or forklift,
check the tirehand voltage. IMT tirehands may be 12V or 24V.
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Chapter 3 Installation 13
Typical Tirehand Hydraulic Installation
For all installations, the tirehand requires 12 GPM (45.4 lpm) of hydraulic fluid at 2500 – 3000
PSI (172.4 - 206.8 bar). Some of the components shown on the typical hydraulic installation
drawing, including the flow dividers, reservoir, filter, pump, and drain, are not provided by
IMT
but
are part of the loader or forklift. Contact IMT for specific installation instructions on any type
of installation.
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14 TH5K115 Manual #99905539
NOTE
Stop blocks should be welded to the loader
arms to limit articulation, if necessary
Locationsand sizes of stops to be
determined at time of installation.
Loader Installation
NOTE: Tirehand installations vary based on the carrier vehicle. Contact IMT for specific
installation assistance.
1 Mount the Tirehand to loader arms using the original loader pins.
2 Splice the flow control divider into the existing pressure line. Continue the original line to its
original destination (bucket, etc.), and route the controlled line (with 12 gpm (45.4 lpm) at
2500 - 3000 psi (172.4 - 206.8 bar)) to the tirehand
valvebank.
3 Route the hoses as shown in figure below.
4 Locate the control handle inside the cab where convenient to operate.
5 Connect the 3-wire power cable to 12-volt power. The green wire connects to 12V positive,
the black wire to the coil on the flow divider, and the white wire to ground.
6 Route the control cable to the tirehand and connect.
7 Check all hoses and cables for clearances. Make sure that steering or moving the arms will
not pinch or overstress the hoses or cables.
8 Fill the reservoir. Start the loader’s engine and operate all controls to purge air from the
system. With the loader running, check for leaks and repair if necessary.
9 Recheck all hoses and cables for clearance.
10 Check the reservoir oil level and fill if necessary.
11 Test operate the tirehand.
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Chapter 3 Installation 15
Lift Truck Installation
1 Mount the Tirehand to lift truck using the original carriage pin.
2 Splice the flow control divider into the existing pressure line. Continue the original line to its
original destination (forklift function, etc.), and route the controlled line (with 12 gpm (45.4 lpm)
at 2500-3000 psi (172.4 - 206.8 bar)) to the tirehand valvebank.
3 Route the hoses as shown in figure below.
4 Locate the control handle inside the cab where convenient to operate.
5 Connect the 3-wire power cable to 12-volt power. The green wire connects to 12V positive,
the black wire to the coil on the flow divider, and the white wire to ground.
6 Route the control cable to the Tirehand and connect.
7 Check all hoses and cables for clearances. Make sure that steering or other movements of
the lift truck will not pinch or overstress the hoses or cables.
8 Fill the reservoir. Start the lift truck’s engine and operate all controls to purge air from the
system.
9 With the lift truck running, check for leaks and repair if necessary.
10 Re-check all hoses and cables for clearance.
11 Check the reservoir oil level and fill if necessary.
12 Test operate the Tirehand.
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16 TH5K115 Manual #99905539
Bulkhead Installation
If the forklift on which the tirehand is installed includes control valves, all of the hydraulic lines
from
the forklift control valves must culminate at the front of the carriage. The forklift will connect
to the tirehand using a bulkhead plate. The forklift manufacturer must furnish oil for all hydraulic
functions. Install the tirehand with a bulkhead plate as follows:
1 Install the tirehand on the forklift, using the bulkhead plate for hydraulic connections. Use the
required hydraulic fluid flow at the correct pressure, per the tirehand specifications. See the
bulkhead plate drawing (60118044) in the parts manual for connection information.
2 Check lubrication points for adequate lubrication.
3 Operate the forklift to check for vertical obstructions.
TESTING
1 Raise the tirehand to provide adequate clearance for operating all tirehand functions.
Operate all tirehand functions and check for leaks.
2 Test the unit at rated capacity. Note any points of instability. Add counterweights if needed.
3 If the carrier vehicle is articulating, make certain that steering of the vehicle is not hindered by
the routing of the hydraulic hoses. Check for wear points and re-route if needed.
WARNING
Avoid serious injury! Keep clear of all pinch
points while operating this unit.
NOTE
If the tirehand operation is erratic, purge air
from the hydraulic system.
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Chapter 3 Installation 17
Valvebank Installation
When the Tirehand has a valvebank, connect the valvebank to the forklift or loader hydraulic
system using the hydraulic pressure and return line from the forklift or loader
1 Install the Tirehand on the loader or forklift, connecting the suction and return lines from the
forklift or loader to the tirehand valvebank. See the hydraulic layout drawing in the parts
manual for hydraulic information for a valvebank installation.
2 Check lubrication points for adequate lubrication.
3 Operate the forklift or loader to check for vertical obstructions. Add stop blocks, if needed, to
prevent the Tirehand from contacting the carrier vehicle.
TESTING
1 Raise the Tirehand to provide adequate clearance for operating all Tirehand functions.
Operate all Tirehand functions and check for leaks.
2 Test the unit at rated capacity. Note any points of instability. Add counterweights if needed.
If
the carrier vehicle is articulating, make certain that steering of the vehicle is not hindered by the
routing of the hydraulic hoses. Check for wear points and re-route if needed.
WARNING
Avoid serious injury! Keep clear of all pinch
points while operating this unit.
NOTE
If the tirehand operation is erratic, purge air
from the hydraulic system.
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