Use and maintenance instruction manual
Contents
1. 4 2 4 to E 4 2 0 GENERAL DESCRIPTION ebore ber Ease o a 4 3 0 SPECIFICATIONS Genning ene eu 5 4 0 WARNING DECAL erir gus aa e aai 6 5 0 GENERALE SAFETY RULES 7 6 0 SAFETY b ce E E o a a a aa 7 7 0 TRANSPOR D P 8 8 0 UNPACKING nsn a a NT 8 MOUNUNG Ne ung t eik a a a 9 9 0 INSTALLA HON orisni a a aaa aaea 11 91 9pace Tequired POSITION e a a tcn vo 11 9 2 Tyre Changer placement and 11 10 0 EQUIPMENT COMPONENTS a E A a a 12 11 0 DESCRIPTION OF THE CONTROLS AND OPERATING 13 120 RIM AND a N Cosa uo Put 14 130 VALVE POSITION p earr E daa a rO N 14 14 0 WHEELS AND TYRES CLASSIFICATION needa 15 T Sandar Wheels orco a Doonan 15 14 2 Low profiled tyre 15 14 92. Apos vor xeui ingore voi l I i eS Se eee See Se Se ZHOS A 00 3NI1 Adds 30 230V 1Ph 50Hz NAXOS AJAD 91056 POQ 8 2 05 Z LdH Hdl LOW HN LY 660p po bww XG e ALINV 10d Fig NOLLOANNOO TIV ATddNS YOLOW 660 bwius D 1249206 TH 4 A 6 OL noez VOL I vol D v9r xaup pe 8 9 10 I La ee om om me a S ee oe J Josn Aq 5 uum rA ZHOS Hdl A ddns NOLLOAHNNOO ATAVO A Iddf1S WAMOd J 31 Motoinverter POWE R SUPPLY LINE 230V 1Ph 50 60Hz MOTOINVE RTER Q1 Monee ee Ree 1 INSTALLATION I BY THE USER 1 Id 30mA Tu Ti I I Bs ys SN TG I E j j al 8 d 1 emm PLUG NEMA i L6 20P 1 L L Plug and socket 1 Molex Minifit E od lt PEDA L SWITCH 12V s SLOW SPEED FAST SPEED CLOCKWIS
3. Fig 1 9 2 Tyre Changer placement and connections Place Tyre Changer onto a levelled out smooth and not slippery floor with a suitable load capacity The machine must not necessarily be anchored to the ground but if you prefer to do so drill 4 100 mm deep holes on the ground just at the 4 holes of the machine base by using a 10 mm drill bit for concrete and of suitable length Insert suitable metal anchor dowels in the holes drilled and secure firmly If the machine is installed outside it must be protected by a appropriate lean to shed The electric network of the installation area must be provided with adequate earth plate and connected to an appropriate automatic circuit breaker set at 16 A NOTE If the machine is supplied without the electrical plug the user shall fit one at least 16A that is suitable for the voltage of the machine and complies with current regulations Before connecting the machine please check that the characteristics of your networks correspond to those indicated by machine s data label Even small jobs done on the electrical system must be carried out by professionally qualified personnel The Manufacturer is not responsible for damages caused by electrical connection different from the original indications Unplug the unit from electrical and pneumatic outlets before moving and servicing The pneumatic network of the installation area must be provided with an air outlet for the constant supp
4. Use and maintenance instruction manual Original Instructions Ed 02 15 Cod 3038337 English SM 951 EC DECLARATION OF CONFORMITY CEMB S p a Via Risorgimento 9 23826 Mandello del Lario LC ITALY do hereby declare on our own responsibility that the product Passenger Car Tyre Changer Data Plate which this statement refers to meets the following directive 86 217 CEE 2006 42 CE as well as the following 2006 95 CE 2004 108 CE EN 12100 EN 60204 1 The signature of this declaration of conformity is the person authorised to provide for the technical literature file Mandello del Lario 18 12 13 p CEMB S p a The model of the present declaration complies with directive EN ISO IEC 17050 1 Ing Carlo Buzzi ROHS DECLARATION OF CONFORMITY CEMB S p a Via Risorgimento 9 23826 Mandello del Lario LC ITALY do hereby declare on our own responsibility that the product Passenger Car Tyre Changer which this statement refers to meets the following directive 2011 65 EU RoHS Scrapping must be made in accordance with the following directive 2002 96 CE e 2003 108 CE RAEE as well as with the national laws in force in the Country of Installation p CEMB S p a Ing Carlo Buzzi Mandello del Lario 24 06 14 Remarks for all the machines appliances distributed from 01 01 2006 on also all non original spare parts will have to meet the directive 2002 9 C E RoHS RAEE DECLARATION
5. In the case of wear or damage replace them with new inserts and new protections Every 2 3 days check the oil dropping into the cup 1 drop every 3 complete activations open closed of the bead breaker cylinder If necessary turn the adjustment screw by a screwdriver For a long lasting correct functioning of the 1Obar pressure limit device ensure that the drain level doesn t exceed the MAX DRAIN indication lf necessary drain the condensation by turning clockwise the drain tap keep the pneumatic feeding on to perform this adjustment On periodical basis check the oil level which has to keep between MIN and MAX refs If necessary unscrew the cup and top up by adding oil for pneumatic systems in class ISO HG i e ESSO Febis K32 MOBIL Vacou On monthly basis unplug the machine line Oil 1405 KLUBER Airpress 32 from pneumatic feeding and remove the filter cup to clean it from possible solid impurities On periodical basis clean the sliding guides of turntable by naphtha and lube them by oil or proper grease Perform the same cleaning and lubricating actions on every junction and mechanical sliding n On periodical basis check the tensioning of spindle rotation driving belt If necessary use a 13mm wrench to loosen the fixing bolts of the motor support plate then adjust the belt tension by acting on the tensioning screw and tight the fixing bolts 28 2 Extraordinary maintenance Non rout
6. FIC E NOUO 24 230 OPTIONAL AGCESSORIES ied ed ipaa urea ncs rE 25 P MEB i i sipRell cec ERE 26 250 STORAGE E a aE a a 26 200 SCRAPPIN aira E E E E EE 26 e MERO Nu iw pee 26 26 0 m 27 20 1 otahdardimalbiebariee s eiae duc aede qe ie asusta a S cM NU E Nu 27 28 2 Extraorainaty E Me 27 29 0 TROUBLESHOOTING CHAR 28 30 0 WIRING perta Dr Er EE Regie dura Du crue 30 31 0 PNEUMATIC DIAGRAM Eae E Spe ca p epu aiv vba ety oio Dose e eruca 33 320 SERVICE REPORTS iioi eun arua aee RO RU I E anes 34 1 0 INTRODUCTION Thank you for purchasing one of our Professional Tyre Changer designed for demounting and mounting operations on standard UHP and run flat tyres All you need to do to ensure the unit a correct function efficiency and a long service life is to follow the instructions given by this guide that shall be carefully read and fully understood in every single part 1 1 Tyre Changer data Please refer to Tyre Changer Model and Serial Number data on the D
7. NOTE It is possible that some parts or components of standard production are different from the illustrations contained in this manual 3 0 SPECIFICATIONS Connections Power supply 400V 3Ph 50 Hz standard version 400V 3Ph 60 Hz 220V 1Ph 50 Hz 220V 1Ph 60 Hz 220V 1Ph 50 60 Hz 2 speed Inverter The effective data can be checked on the data plate placed on the machine Operating pressure 8 10 bar 116 145 psi Air inlet pressure regulator set at 10 bar 145 psi included Inflating pressure limiter set at 3 5 bar 50 psi included Working capacity Rim clamping from outside from 10 to 26 Rim clamping from inside from 12 to 28 Maximum rim width 16 415 mm Maximum wheel diameter 43 1100 mm 400V 3Ph Turntable data Motor power 0 8 1 1 Kw Maximum torque 1200 Nm Clockwise rotation speed 7 14 rpm Working noise level lt 70 dB Bead breaker data Bead breaker cylinder force at 10 bar 30800 N 3140 kg Layout data Net weight of the machine without optional accessories 270 kg Operating temperature range min 5 C max 50 C 41 122 F Standard accessories ref page 21 Lubricating paste for mounting demounting operations Brush Bead lifting lever Jaw protectors for alloy rims Kit of protectors for mounting tool Protectors for bead breaker blade Overall dimensions mm Lubricator filter pressure regulator Main optional accessories r
8. OF CONFORMITY CEMB S p a Via Risorgimento 9 23826 Mandello del Lario LC ITALY do hereby declare on our own responsibility that the product Passenger Car Tyre Changer d which this statement refers to meets the following directive gt es 2002 96 CE e 2003 108 CE RAEE Raccoltadifferenziat This equipment is subject to the regulations foreseen by Directives 2002 96 CE and 2003 108 CE RAEE and therefore it cannot be scrapped as a generic scrap material but through specific collection circuits the symbol with barred tank marked on the product refers to this prescription Scrapping must be made in accordance with Directives 2002 96 CE and 2003 108 CE RAEE as well as with the local Regulations in force in the Country of installation the non respect of the Directive is subject to sanctions according to the national Laws of the Country of destination Abandonment or wrong scrapping of the equipment subject to Directive 2002 96 CE can cause serious damage to the environment The manufacturer is available according to the Directive to scrap the equipment for this service please contact the manufacturer or your dealer Mandello del Lario 24 06 14 CEMB S p a 2 Ing Carlo Buzzi 5 1 0 4 PYRE CM ANG Cl
9. RUN FLAT tyre Wheels 2535 2 pet od deol EE V et DC ubi qu ea 15 15 0 OPERATION tor NOR 16 16 0 BEAD BREAKING mnn 16 16 1 Bead breaker shovel adjusting operations 16 16 2 Bead ded o vont ooa epis iade Qe dc cunda oe 17 17 0 ADJUSTING THE TURNTABLE LOCKING 18 17 1 Additional adjustments of the turntable locking 5 19 18 0 WHEEL LOCKING ON THE ere Fa 19 190 YREJDEMOUNTINQG 2 sizes oes erties Contac aae ute sa vo Ve suot ea a Pedes ia 20 20 0 TYRE MOUNTING 5 5 uou a reU tel tuta ed 21 20 1 Lower pead Mounting ssnin T se Mdina 21 20 2 Upper bead tied asas rero oH 21 21 07 INFLATION 0252320095808 2059282 250222008 195020202025 02 020010 505 003290200009 000 86 0209829082 23 22 0 STANDARD AGCESSORIES deut eel Meus dia iu eren d ap OU dU DEN
10. fig 19 20 23 22 0 STANDARD ACCESSORIES Standard supply Lube paste bucket Brush Bead lifting lever Jaw Protectors for alloy rims Protectors for mounting demounting tool Protectors for mounting demounting tool Protectors for bead breaker blade AIR Filter Regulator Lubricator 24 23 0 OPTIONAL ACCESSORIES ROLL Roller plate QX Leverless mounting demounting device QCK Quick release kit for mounting tools RJP Kit of rubber coated jaw protectors MOTO AD Motorcycle wheels adaptors ATV AD Motorcycle wheels adaptors GUN Tubeless inflation external kit 25 24 0 RE POSITIONING To re position the Tyre Changer in a new workplace secure the moving parts i e the bead pressing arms etc disconnect all the power sources and install it again following all the instruction per chapter 9 0 of this manual Connections to power sources and connection amp inspections of the safety systems must be carried out by trained personnel 25 0 STORAGE If the tyre changer has to be stored away for extended periods of time Disconnect the power sources Empty the tanks containing operational fluids Protect parts that could be damaged if dust should settle on them Grease parts that could damage if they should dry up When re commissioning the tyre changer Follow the instructions given in chapter 9 0 of this manual Replace any damaged parts referring to the spare
11. internal pressure of the tyre is zero Those with INTERNAL SUPPORT which have a ring inside the rim that bears the sidewall of the tyre when there is no pressure inside it The internal support may be made of plastic Pax System or of metal Support Ring All the tyres which do not correspond to the above mentioned descriptions have to be considered as standard tyres This Tyre Changer is able to handle all types of wheels with standard tyres LowProfile UHP and RUN FLAT tyres with reinforced side RUN FLAT tyres with internal support PAX System or Support Ring type mounting demounting procedures need spe cial accessories to be used according to precise dedicated instructions The mounting and demounting procedure is similar with standard tyre LowProfile tyre UHP tyre or RUN FLAT tyre with reinforced side self supporting WARNING N It is compulsory to follow the demounting mounting instructions carefully in order to avoid tyre damages and the consequent risks for the vehicle and the passengers safety 15 15 0 N Before carrying out any operation deflate the tyre and take off all the wheel balancing weights The operation of the tyre changer is divided into three parts A BREAKING THE BEAD B REMOVING THE TYRE C MOUNTING THE TYRE Note for use The motorcycle rims are more and more frequently constructed by using special alloys or materials like carbon or magnesium To lock this kind
12. manufacturer s express prior authorization relieve the manufacturer from all forms of liability in the event of damages deriving from or referable to such actions Removal or tampering with the safety devices provides grounds to immediately cancel the warranty and involves a violation of European Safety Legislation The Tyre Changer is equipped with informative and warning decals which are designed and produced to last in time If they should deteriorate user may request replacement decals A IN CASE OF FIRE USE ONLY DRY CHEMICHAL OR CO EXTINGUISHERS TO PUT THE FIRE OUT WATER FOAM POWDER ae p DRY materials FLAMMABLE liquids ELECTRICAL equipment NO wo ox 6 0 SAFETY DEVICES The tire changer is equipped with safety devices that are designed to guarantee the safety of the machine operator Pneumatic safety valve installed inside the machine that prevents the pressure from exceeding 3 5 bar 50 psi during inflation Pressure regulator and gauge that limits the maximum pressure of the circuit to 10 bar 145 psi On Tyre Changers equipped with Tubeless inflating device Limit Valve installed onto the air tank that prevents the pressure from exceeding 11 bar 160 psi represents a breach of the European Safety Legislation Removing or tampering with safety devices immediately invalidates the guarantee 7 0 TRANSPORT The Tyre Changer must be transported in its orig
13. of rims it is necessary to use the motorcycle wheels adaptors kit and to limit the pressure exerted by turntable to 7 bar max in order to avoid any irreparable damage of deformation 16 0 BEAD BREAKING Before starting each operation make sure that there is no pressure sensor if this is the case it is advisable to check the status of its efficiency using an appropriate tool 16 1 Bead breaker shovel adjusting operations patented system Depending on the type of tyre to be demounted it is possible to lock the swing selector 1 or adjust the angle of pe netration of the shovel blade selector 2 as well as the stroke of the bead breaker arm selector 3 The selector 1 in ON position allows the shovel blade to swing while the selector 1 in OFF position lock the shovel blade to the bead breaker arm It is advisable to use the swinging shovel blade for breaking conventional tires with soft side For bead breaking a run flat tire turn the selector 2 to 21 while keeping the selector 1 to OFF For bead breaking a conventional tire turn the selector 2 to 27 with the selector 1 to ON For wheels having a pressure sensor it is advisable to limit the stroke by means of the regulator 3 During bead breaking operations pay particular attention to the position of pressure sensor if any usually inserted into the valve of the rim Wrong movements of the bead breaker blade could damage the sensor 16 16 2 Bead breaking Using
14. 21 Make sure the bead of the tyre rests on the shoe shaped part of the tool and under the finger tool in the opposite part fig 3 Press the pedal ref 3 to rotate the wheel clockwise contemporarily press the tyre manually from 5 o clock position to force the upper bead at drop centre position Keep it pressed while rotating up to 8 o clock position to complete the upper bead mounting fig 4 Fig 3 ATTENTION N Make sure that rim and tyre always spin together NOTE Demounting and mounting are always done with the clockwise turntable rotation Anticlockwise rotation is used only to correct operator s mistakes 22 21 0 INFLATION followed strictly This Tyre Changer is NOT projected to protect operators and objects from accidental tyres explosions Tyres must be inflated with the utmost caution The instructions below have to be read and ATTENTION If tyre bead fails to fit in place at 3 3 bar pressure it is necessary to repeat the bead loosening and lubricating procedures before trying again to inflate the tyre If tyre had to burst or rim had to break under pressure operators could be FN 3 seriously injured or even killed Make sure the rim and tyre are the same size Also check the conditions of the tyre and rim to make sure there are no defects before W starting to inflate Inflate the tyre with short blasts of air and check the pressure frequently while inflating This Tyre Chan
15. E _ l 1 53 SLOW COUNTERCLOCKWI SE 51 FASTC OUN TERCLOCKWISE 32 31 0 PNEUMATIC DIAGRAMS uognq E Bugeyaq 189 19 anssaJd TT W SEM ue 2509 IN IW RN _____ __________ a qeyuun AJEA peog Japui Ao JaxE2Jq Slot pg e IAT ER ajod us Burpoojun jddns uy 7 J E SA EA 2109 v VY aod SS ajod Bun Bunyi 33 32 0 SERVICE REPORTS All the operations made on the machine in the course of time must be reported herebelow so as to have an updated situation of the efficiency of the machine The user must carry out both cleaning and greasing operations according to the instructions given in this manual Any operation concerning the replacement of parts is strictly reserved to authorized and trained staff Replacements Replacements Replacements 34 Replacements Replacements Replacements Replacements 35
16. Pee ge fee Ne ee bs p Tf Fig 1 Avoid contacts between the lubricating paste and the valve sensor if any 20 1 Lower bead mounting see references at pag 17 fig 1 Put the tyre onto the rim tilting the tyre at 12 o clock position in order to make both upper and lower beads go under the upper rim edge Press pedal ref 1 to approach the mounting arm and position the mounting tool onto rim edge Incline the tyre to the bottom at 3 o clock position driving the lower bead to the mounting tool in order to put the lower bead over the shoe shaped part and under the finger tool Make sure the bead of the tyre rests on the shoe shaped part of the tool and under the finger tool in the opposite part Press the pedal ref 3 to rotate the wheel clockwise contemporarily press the tyre manually from 5 o clock position until the lower bead reaches the drop centre level Keep the tyre pressed while rotating up to 8 o clock position to complete the lower bead mounting 20 2 Upper bead mounting see references at pag 12 Keep the mounting arm and the mounting tool at working position and proceed to mounting the upper bead then put the tyre bead on the rim slightly tilted down to 3 o clock position Bead correctly positioned over the shoe Bead incorrectly positioned and damaged shaped part of the tool and under the finger between the shoe shaped part of the tool and tool the rim edge
17. a suitable tool remove all the counterweights from the rim being extra careful not to damage the rim itself Check that the tyre is deflated If not deflate it Close the clamps 13 of turntable 14 completely by pressing the pedal 2 Position the turntable in a way that one of flat sides is parallel to the rubber support surface 6 of the bead breaker Bead breaking must be done with the utmost care and attention When the bead breaker pedal is ope N rated the bead breaker arm moves quickly and powerfully Anything within its range of action can be in danger of being crushed Bead breaking with the jaws in open position can be extremly dangerous for operator s hands Make sure that the jaws are closed and NEVER keep your hands on the sides of the tyre Position the wheel against the rubber wheel support 6 on the right side of the tyre changer fig 2 Position the bead breaker blade 7 against the tyre bead at a minimum distance from the edge of the rim Use bead breaker shovel protector for alloy rims Pay attention to the blade which must operate correctly onto the tyre and not onto the rim fig 2 Press down the pedal 4 to activate the bead breaker and release it when the blade has reached the end of its travel or in any case when the bead is broken The PO SYSTEM patented device starts automatically after releasing the pedal 4 granting no bead breaker shovel stuck between the edge of the rim an
18. ata Plate see sample below to provide our Technical Service Dept with the necessary details for prompt assistance and spare parts tracking In case of discrepancies between Tyre Changer data on Data Plate and this Manual please refer to Tyre Changer dataplate only 1 2 Manufacturer data Please check the Declarations of Conformity at page 2 of this Manual and Tyre Changer Data Plate 1 3 Data plate XXM4YYZZZZZ Amp Fh Hz Year Met Vielight Air supply 8 10 bar 115 145 PS 2 0 GENERAL DESCRIPTION The tyre changer is designed to demount and mount tyres of cars and light commercial vehicles with rims of 10 to 28 and maximum diameter of 1100 43 mm The tyre changer is designed to demount and mount conventional tyres of passenger cars light industrial vehicles next generation self supporting RUN FLAT tyres and low profile tyres UHP on steel and or alloy rims even big size tyres The Tyre Changer is NOT intended for demounting completely or partially inflated tyres dirty tyres nor for rim bending or industrial wheels with split ring rims demounting All these operations are FORBIDDEN This manual is an integral part of the product Before using the tyre changer read carefully the warnings and instructions contained in this manual since they provide important information on operating safety and maintenance N Keep this Manual in good conditions for further references
19. between the bead and the front section of the mounting tool 12 move the tyre bead over the mounting tool Fig 3 Note In order to avoid damaging the inner tube if there is one it is advisable to carry out this operation with the valve at 2 o clock position Chains bracelets loose clothing or foreign objects in the vicinity of moving parts can represent a danger for the operator With the lever held in this position let the turntable 14 fig 1 page 17 rotate in a clockwise direction by pressing pedal 3 down until the upper tyre bead has completely come off of the wheel rim During the rotation while demounting the tyre it is necessary to push down on the tire sidewall at the opposite side of the mounting tool in order thus reducing the stress on the bead and let it come off of the wheel rim In order to remove the inner tube if there is one without unlocking the operating arm tilt back the tower by pushing pedal 1 down Repeat the operation for the lower bead until the tyre has completely come off of the wheel rim 20 20 0 TYRE MOUNTING Check the rim and the tyre carefully as per instructions at page 14 of this manual If the rim has been removed lock it again onto the turntable as described in the paragraph 19 0 Carefully lubricate the whole inner surface of the rim and the beads of the tyre both externally and internally right around the circumference for a width of at least 3 cm
20. ck pneumatic pressure 2 Replace clamps 3 Replace the seals 1 Replace spring 1 Check net pressure 2 Replace the supply pipes 3 Replace the valve 4 Clean up the silencers or replace them 5 Replace the seals 1 Check the net pressure 2 Replace the valve 3 Replace the valve PROBLEM The vertical arm does not move or it mo ves slowly or too fast The working tool touches the rim during mounting operations 1 The silencers are blocked 2 The silencers have not been adjusted 3 Foot control release spring is damaged 4 The compressed air supply is missing 5 Column sleeve too loosened or too tighten 1 The clamping plate has not been adjusted properly or is defective 2 The unlocking plate springs are damaged 29 SOLUTION 1 Clean up or replace the silencers 2 Adjust silencers 3 Replace foot control release spring 4 Check or restore pneumatic supply 5 Adjust column sleeve 1 Adjust or replace the locking plate 2 Replace the unlocking plate springs 30 0 WIRING DIAGRAM 400V 3Ph 50Hz 6 po EAS E 7H 05 AZ ae 40123138 03345 HSLHSANI ALIHV 10d M a 0 oS 6 e i _______ iii n i Lin L ZAA 9 t DOD yams paads Z ISIAH 3 Od 1 394905
21. d the bead of the tyre pushing it toward the outwards This avoids difficult manual operations and speeds up the work of the operator Spin the wheel lightly and repeat the procedure on the whole circumference of the rim and on both sides until the complete detachment of the bead from the rim is recommended to lubricate the tire during the bead braking thus preventing the bead from seating back to the rim and making the demounting operation easier If there is a sensor make sure it does not come into contact with the lubricant CAUTION While loosening the bead just press on the bead and never on the side of the tire 17 17 0 ADJUSTING THE TURNTABLE LOCKING MEASUREMENTS Before locking the wheel check the adjustment of the turntable and the dimensions of the wheel to lock The tyre 5 turntable is adjusted by the manufacturer at an intermediate measurement that goes from 10 to 20 ext in relation to the outside of the rim and from 12 to 22 int if the wheel is locked from the inside The adjustment can be done by turning the two knobs located under the plate between the two pneumatic cylinders fig 1 2 To increase the locking diameter turn the knob clockwise and observing the decal fig 4 match the pin of cylinders P with the number of inches to increase For example if we turn the knob until the reference pin matches 1 we have 1 increase and so on Each knob can be used sepa
22. der the influence of drugs alcohol or other substances which could compromise their physical and mental work capabilities For greater security against on the job injuries the operators shall wear safety footwear gloves protection goggles and shall NOT wear any form of loose clothing that could get caught up or restrict the operator s movements The operator must be able to read and ensure full comprehension of the use and maintenance manual to be able to use the machine correctly and safely read and understand the danger warnings understand the characteristics of the machine keep unauthorized people away from the working area make sure that the setting in motion of the machine has been carried out in compliance with all applicable rules and regulations make sure all operators are familiar with the machine and know how to use it safely and correctly avoid touching moving parts or pressurised parts without first disconnecting the machine from the electrical and air power supply keep the operation instruction manual with care in an easily accessible place so that it can be consulted whenever needed T The Tyre Changer must be used exclusively by experts who are specifically trained and by authorized personnel only The use of the machine is forbidden to disabled operators if their disabilities may affect the safety of the working operations Any tampering or modification to the equipment without the
23. e motor is damaged 4 The motor wires are not connected 1 The inverter is damaged 2 The foot control spring is damaged 1 The air supply is missing 2 The control valve is damaged 3 The silencers are blocked 4 The cylinder seal is damaged 5 The pilot valve is damaged or defective 1 No pneumatic supply 2 Silencer clogged 1 No pneumatic supply 2 Clamps worn 3 Turntable cylinder s defective 1 Return spring broken 1 The air supply is missing 2 Supply pipes broken or squashed 3 Control valve is damaged 4 The silencers are blocked 5 The cylinder seal is damaged 1 The air supply is missing 2 The control valve is damaged 3 The pressure limiter valve is da maged 28 SOLUTION 1 Check the wall socket 2 Check the machine plug is connect properly or if the plug wires are well connected 3 Replace the fuses 4 Tension or replace the belt 5 Tighten the pulley screw 6 Re connect the foot control 7 Replace the motor 1 Replace the inverter 2 Check the inverter wires are connected properly 3 Check the motor short circuit and replace it 4 Check the motor is wired correctly 1 Replace the inverter 2 Replace the foot control spring 1 Check the net pressure 2 Replace the valve 3 Clean up the silencers or replace them 4 Replace the seals 5 Replace the valve 1 Check pneumatic pressure 2 Clean or replace silencer 1 Che
24. ef page 22 Pneumatic bead pressing tool Leverless device Tubeless inflating system Quick release device for mounting tool Packing details 2040 Gross weight 295 Kg without optional accessories Carton Wooden pallet fig A 4 0 WARNING DECAL PLACEMENT Cod 3035727 Cod 3005416 Cod 3005411 ATTENZIONE Ameneesi alle istruzoei riportate eel d uso PERICOLO Questa ron e siste costedta come proie nose contre eni d pa te hae VORSICHT Cee Becenyungsanieitungen der Maschine autreerksam beogen GEFAHR Cod 3005742 A Cod 3005413 Cod AUN Cod 3000048 Cod 3037622 Cod 3037621 Cod 3016802 Cod 3005414 WARNING Replace any warning label immediately in case of damage or loss Do not operate the Tyre Changer in case of warning labels lack Do not hide any warning label by any mean Do not interpose objects that obstruct or reduce the visual capacity of the operator Refer to the above mentioned codes for warning labels ordering 5 0 GENERAL SAFETY RULES The Tyre Changer must be used by qualified and authorised personnel only A qualified operator is someone who has fully understood the instructions described in this operation and maintenance manual supplied by the manufacturer has been specifically trained and is aware of safety standards at his work place Those in charge of using the machine shall not be un
25. ger is automatically limited to an inflation pressure of 3 5 bar 50 psi The pressure regulator is NOT a safety device preventing explosions risks and damages NEVER EXCEED THE PRESSURE RECOMMENDED BY THE TYRE MANUFACTURER Keep hands and body as far away as possible from the tyre during inflation Pressure gauge Inflating pedal ei ue M 19 Connect the inflation hose to the valve of the tyre fig 19 Make sure the rim and the tyre have the same diameter Make sure the rim and tyre are sufficiently lubricated lubricate if necessary Press and release the inflation pedal ref 20continuously checking the pressure on the gauge frequently until the tyre bead fits completely on the rim Continue inflating to reach the pressure recommended by the tyre manufacturer Always inflate in short blasts and always checking the increasing pressure Press the deflation button to deflate the tyre if during inflation the pressure exceeds the value recommended by the tyre manufacturer Deflate button Fig 18 NOTE Sometimes even blowing air into the tubeless tyre it may not inflate This problem may be solved by using the optional accessory TUBELESS INFLATING DEVICE Activating button In order to use the optional Tubeless Inflating Device correctly fig 21 Press the safety valve against the rim border push the activating button onto the handle to blast air and press the inflating pedal ref 4 in order to start infla ting
26. ictly forbidden to mount tyres on rims with mismatching parameters diameter and width It is also forbidden to mount tyres with dimensions which are different from the ones stated in the car logbook 14 14 0 WHEELS TYRES CLASSIFICATION 14 1 Standard wheels A standard wheel is a car wheel with steel or alloy rim with center hole drop centre close to the external border of the rim and a standard tyre not RUN FLAT nor LowProfile 14 2 Low profiled tyres UHP wheels Low profile tyres UHP are those in which the height H and the width C have a ratio lower than 0 5 i e low profile series 45 stands for a ratio of H C 0 45 For tyres to be considered as low profile UHP they must also have a maximum speed code of equal to and or higher than V Maximum speed codes U up to 200 km h W up to 270 km h Be opto HOS H up to 210 km h ZR gt 240 km h AT V up to 240 km h ZR Y gt 300 km h T up to 190 km h 14 3 RUN FLAT tyres wheels RUN FLAT tyres are those which allow to continue to drive the vehicle for a preset number of miles and at a preset speed even if they have no internal pressure These parameters change from one manufacturer to another The market currently offers 2 different tyoes of RUN FLAT tyres Those with REINFORCED SIDEWALL SELF SUPPORTING where thanks to a different mix and a reinforced struc ture the shoulder of the tyre can bear the weight of the vehicle even when the
27. inal packaging and kept in the position indicated on the actual packaging The packaged machine has to be moved by mean of a fork lift of suitable capacity Please insert the forks as shown by the following picture fig 1 8 0 UNPACKING Remove the protective cardboard remove all fixing screw and free the Tyre Changer from its original pallet Check the perfect condition of the machine making sure that no part is damaged or missing referring to the picture at page 10 If in doubt please do not use the machine and get in touch with your Distributor for further steps Keep packing elements away from children All packing elements must be stored in the proper stocking areas Note All the most delicate surfaces of the Tyre Changer are coated by a special rust proof oil Some oil traces may leak after coating procedure please remove them accordingly Gross weigth 295 Kg fig 1 Use lifting equipment of suitable load bearing capacity that is able to take the weight of the tyre changer at least 500 Kg j to lift the machine use a transport strap with minimum load bearing capacity of at least 500 kg After tyre Changer positioning take of the lifting belt 8 1 Mounting the tilting tower After unpacking the machine mount the tilting vertical tower by following the instructions here below Lift the tilting vertical tower using a band of adequate ca pacity Insert the band as shown in the picture F1 Slightly
28. ine maintenance must be carried out by factory authorized personnel ONLY Defective parts should be exclusively replaced with genuine spare parts by factory authorized service personnel After 5 years from installation date the Tyre Changer must be serviced in all its main components to grant its correct functioning and the operators safety The Manufacturer is not responsible for claims due to non original spare parts or for damages caused by removal and tampering to the safety devices Removal or tampering with the safety devices max pressure valve pressure regulator represents a breach of European Regulations for Workplace Safety 29 0 TROUBLESHOOTING CHART PROBLEM The turntable does not turn The spindle rotation motor rotates at one speed only 3ph 400V motor version The spindle turns continuously 3ph 400V motor version Bead breaker does not move or it does but very slowly Clamp slow to open close Turntable does not lock the wheel rim correctly Pedals lock out of working position The tool does not move vertically The inflating device does not work CAUSE 1 The power supply is missing 2 Machine has not plugged correctly 3 The fuses have blown 4 The belt is loosened or broken 5 The motor pulley is unscrewed 6 The motor drive is not working properly 7 The motor is defective or damaged The inverter is damaged The inverter wires are not connected 1 2 3 Th
29. ing arm tilting make sure that nobody stays behind the tyre changer OUTER LOCKING WHEEL e Position the jaws 13 on the turntable 14 by pressing pedal 2 down to its intermediate position e Place the tyre on the jaws and keeping the rim pressed down press the pedal 2 as far as it will go to tighten the clamping jaws and lock the rim on the turntable INNER LOCKING WHEEL e Position the jaws 13 so that they are completely closed e Place the tyre on the jaws and press down the pedal 2 to open the jaws and thereby lock the rim 19 tyre exactly in the middle of turntable During rim locking NEVER keep your hands under the tyre For a correct locking operation set the Make sure that the rim is firmly fixed by the jaws Never keep your hands onto the wheel the operating arm recovery to working position could set the operator at risk of hand crushing between rim and mounting tool 19 0 TYRE DEMOUNTING Set the locking button 11 in position 2 Move th operating arm fig 1 until the mounting tool 12 rests on the rim upper edge Then lock everything by setting the locking button in position 1 fig 2 In this way the arm gets locked both in a vertical and in a horizontal direction while the mounting tool 12 is moved automatically of about 2 mm from the rim hands and other parts of the body as far as possible from mounting tool when the turntable is turning With the lever 5 inserted
30. loosen the screw of the tie rod by means of a 17mm spanner to easily position the vertical tower into its seat Connect the bushings to the pin then insert it into the hole in order to lock the vertical tower Connect the other bushings as in the picture After having inserted the pin completely tighten the Tighten the screw of the tie rod previously loosened to screw properly easily position the vertical tower into its seat Pull the tilting system cylinder rod manually so that the Fit the protection of the tilting vertical tower and tighten hole coincides with the holes in the vertical tower the screw being careful not to break it Insert the screw and tighten the nut but leave a little slack Insert the black pneumatic pipe into of pneumatic cylin Insert the red pneumatic pipe into the fitting placed on the der fitting rear of the machine to complete the assembly operation of the vertical tower 10 9 0 INSTALLATION 4 L 9 1 Space required to position 500 mm When choosing the place of installation be sure that it complies with the current safety at work regulations The Tyre Changer must be connected to the main electric power supply and the compressed air system is therefore advisable to install the machine near these power sources The installation area must leave at least the room shown in picture fig 1 to allow all parts of the machine to operate correctly and without any restriction
31. ly of 8 bars of minimum working pressure Connect the machine to the pneumatic network by means of the air fitting on the lubricator filter pressure regulator unit installed onto the right side of the machine fig 2 11 10 0 EQUIPMENT COMPONENTS Inflating device with pressure gauge Tilting tower Operating arm Pl Mounting demounting tool Lubricator filter pressure regulator Turntable with adjustable jaws patented Bead breaker arm with adjustable bead breaker shovel angle patented and P O System patented Wheel support Bead lifting lever Pedal control units Mounting demounting tool Finger tool Shoe shaped part fig 2 12 11 0 DESCRIPTION OF THE CONTROLS AND OPERATING TEST 1 Tilting tower pedal 2 Jaws control pedal 3 Turntable control pedal 4 Bead breaker control pedal 5 Operating arm control button up down 6 Deflate button T Turntable adjustment knob 8 Inflation pedal control 9 Bead breaker shovel adjustment selectors Any test must be operated with no tyre onto the machine Mind any component which could interfere with machine testing operations 13 12 0 AND TYRE IDENTIFICATION Before starting demounting a tyre it is of CRUCIAL IMPORTANCE to identify the measurements of the rim and of the tyre 5 well as to make sure that neither the rim nor the tyre are damaged WARNING these very important procedures have t
32. o be correctly performed to reduce risks of tyre bursting while re mounting and inflating the tyre on the rim Each rim bears an indication of their diameter width number of humps etc Example 8Jx15H2 A 8 Nominal width of the rim in inches 1 inch 25 4 mm B J Size of the flange C 15 Nominal diameter of the rim in inches D H2 Double hump anti bead removing edge Each tyre bears a considerable amount of details among which are the dimen sions type and maximum speed Example 205 65 R 15 91H TL 205 Width of the tyre the distance between tyre sides expressed in millimetres Ratio percentage between the height of the section and its width Type of tyre R radial Indicates the keying diameter in inches diameter of wheel which must be the same as the rim Index of the maximum load born by each wheel Maximum admitted speed of the tyre H 210 Km h Type of tyre TL Tubeless U OU T 1M H r 13 0 VALVE POSITION The picture on the right side symbolizes a rim as a clock face The valve positions described by the following working steps always refer to the represented clock face hours marks WARNING To avoid damaging the valve and the pressure sensor if the latter is installed you must always arrange the valve in the position indica ted following the instructions during bead breaking mounting and demounting operations fig 3 WARNING N It is str
33. omes into contact with skin rinse abundantly with neutral soap and water do not use solvents or irritant products Disposing of used oil Do not throw used oil away outdoors or pour it on the ground Drain into a suitable container and forward to specialised oil disposal centres or hand it over to authorised collection companies Oil spillages or leakages Eliminate the cause of the leakage and stop the oil spillage from spreading using absorbent material Clean the area where the oil has spilled using degreasing detergents to prevent slipping and dispose of the waste according to current state and Federal regulations Clean up the oil and send to special disposal centres according to current National regulations 26 28 0 28 1 Standard Maintenance Routine maintenance according to the following instructions is of crucial importance to ensure the correct operation and lasting life of the Tyre Changer Before starting any maintenance job disconnect the electrical power supply and disconnect the machine also from the pneumatic supply Release the compressed air from the circuit On daily basis keep the machine clean eliminating any mould and dirt to ensure the perfect movement of the turntable slides and the tools to grant the correct functioning of all locking devices On daily basis check for worn or damaged plastic mounting tool inserts and plastic and rubber protections in order to protect alloy rims
34. parts list this to be carried out by skilled personnel 26 0 SCRAPPING If you should decide that the tyre changer can no longer be used you are recommended to make it unusable by removing the power supply connections emptying the tanks and disposing of the fluids pursuant to current state and National regulation The tyre changer is considered as heterogeneous waste and must consequently be split up into parts made of similar material electrical parts plastic parts and ferrous parts which must be disposed of properly according to current National regulation T WARNING follow RAEE and ROHS Conformity Declaration rules for a correct disposal where applicable 27 0 OIL TREATMENT Clean up the oil and send to special disposal centres according to current national laws T OIL IS POLLUTANT DO NOT THROW AWAY OUTDOORS OR POUR ON THE GROUND General precautions Avoid direct and prolonged contact with skin Avoid the formation of oil mists in the air Avoid splashing Wear appropriate clothing gloves and goggles to protect against oil splashes Do not use greasy rags Do not eat or smoke if your hands are soiled with oil First Aid instructions If oil is swallowed do NOT induce vomiting but go immediately to the nearest medical centre with information on the type of oil swallowed If oil gets in eyes rinse abundantly with water until irritation ceases then go to the nearest medical centre If oil c
35. rately If the variation is done on both sides the references are summed together e g 2 1 z3 increase starting from a 20 base we can reach a maximum of 24 rim clamping from outside or 26 rim clamping from inside if i 1 er o hoe 18 17 1 Additional adjustments of the turntable locking measurements The values changed previously can be increased further still by moving the position of the 4 jaws as shown in the following figure fig 1 The increase of the clamping diameter ranges from 0 to a maximum of 2 that shall be added to the increase obtained after the adjustment described in the previous paragraph It is possible to reach a maximum of 26 rim clamping from outside or 28 rim clamping from inside To change the position Undo the screw 1 with an 8mm Allen wrench Move the locking jaw 2 and the slide 3 repositioning them into the hole of the slide just at the guide hole 4 depending on the locking requested dimensions Refer to the measurements given below Reposition the jaw and lock with the screw 1 ensuring that the tightening torque is 72 Nm ATTENTION it is important that the above steps are performed identically on all 4 tightening jaws to prevent any unbalance when locking 1 Q9 0 1 fig 1 2 18 0 WHEEL LOCKING ON THE TURNTABLE Before wheel locking release the working space by tilting back the vertical arm and pressing the pedal 1 T Dur
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