User Manual
Contents
1. JapuljAo 05 N sin lt r V ea ID i yano I Bua coyewnaud opides BONEN i ONEA Cs ip YOOU 3 Jauasoo peag 8 4 2 5 a kal I I 3901lUn 190 4 00 20145 BIONeA SS ld I I we 55918 iqie1 s BIEN J IVNOIZdO S ASP SPAA Jeq S 103 inss id I uonejju eS TA SA J u soo peag Paes Ip on 9509 uoljejJu jod2. sree ie ee ieee 4 3 0 SPECIFICATIONS AANTAY bec 5 4 0 DECALS PLACEMEN lana u Sau aa upaku sawa wankusqa Saha use 6 5 0 SAFETY INSTRUCTIONS uuu u ay ul u elec sedan AA 7 6 0 SAFETY DEVICE S NA AANI 7 7 0 TIRANSPORI u u AA AUN AA AA 8 8 0 UNPACKING a DEYN NAA 8 9 0 INSTALLATION u uu uuu AA AA AA 9 9 1_Tyre Changersiterequirements J AA 9 9 2 _PTyre Changerplacementandconnections a 9 10 0 EQUIPMENT COMPONENTS u NAGAGANAP 10 11 0 CONTROLS DESCRIPTION 3 uruy u tu a ua aan aaa ua 11 12 0 RIM AND TYRE IDENTIFICATION naa KATABAAN AA 12 13 0 VALVE POSITION kayan aD ENNA NTG 12 14 0 WHEELS AND TYRES CLASSIFICATION U U U U u u uu u 13 lt lt 13 14 2 UPIPyWheelSuu s RS Sua a 13 14S RUN FEAT Yre WHCEIS uu uuu titel um ka 13 J50 WDK RULES uuu u eum pusa 13 16 0 POSITIONING AND CENTERING ONTO CENTER PLATE 14 To WHEEL POGCKING Z kE AA TE a eens 15 Mal MSUMAUGIOCKING NA
3. JapuljAo 5 2 20145 ee 5 wue ssald 90 Ue 4907 buneladg 1 uoldie OJPUlIID ajuejado 05 100 liqie s 33 34 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 Date Signature Replacements Replacements Replacements Replacements 35
4. Saa 28 30 2 Extraordinary u a Qasa asan hawka ita dai 28 31 0 TROUBLESHOOTING CHART Za ANNA TANANG 29 32 0 WIRING DIAGRAMS AANI ANNA AA antes 31 330 PNEUMATIC DIAGRAMS IL u uuu NANANA NAN NAAN NAAN 32 340 SERVICE REPORT Sun ANAN AA AA AA 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 To prevent accidents or damages to the tyre changer use only recommended procedures and accessories 1 1 Tyre Changer data Please refer to Tyre Changer Model and Serial Number data on the Data 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 LOGO Made in Italy Type Nr 10Z 0200001 400 Amp 3 1 3 5 8 1 1 Ph 3 Hz 50 2013 Met VVelght 375 Air supply 8 10 bar 115 145 PI 2 0 GENERAL DESCRIPTION The Tyre Changer is intended for mounting and demounting most tyres with alloy or steel rim diameter from 12 to 30 and standard Run Flat
5. It is compulsory to follow the demounting mounting instructions carefully in order to avoid In order to perform a correct demounting and mounting process the following premises are strictly compulsory 1 Guidelines knowledge WDK literature provides all necessary guidelines for all tyre brands and models including all theoretical and practical instructions to avoid any possible damage to tyre rim and pressure sensor 2 Certified tyre changer This Tyre Changer is WDK certified and fulfils all WDK requirements 3 Qualified operator The specific technical courses provide the operators with the necessary WDK guidelines and service instructions Dedicated WDK official courses are available to get the WDK diploma when necessary 13 16 0 WHEEL LIFTING AND CENTERING ONTO CENTER PLATE Before lifting and positioning the wheel onto the centre plate please remove all weights from the rim by a proper tool carefully remove any object or tool which could interfere with lifting Put the wheel vertically onto the optional wheel positioning device rim back facing the Tyre Changer Press the control pedal ref 3 to lift the wheel positioning device Once the wheel is over the centre plate align the wheel central hole to the centre plate central hole Release the control pedal fef 3 to lower the wheel positioning device Rotate the wheel in order to make one fixing hole of the rim match with the driving pin of the centre pla
6. Original Instructions Ed 10 13 Cod 3019988 English MATIC 750 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 Crossage EVO 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 14 06 12 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 14 06 12 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 OF CONFORMITY CEMB S p a Via Riso
7. UHP tyres with maximum diameter of 1 200 mm 47 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 part of this Tyre Changer Use equipment only as described in this Manual Read and understand all instructions before operating this machine 3 0 SPECIFICATIONS Connections Electrical Feeding 400V 3Ph 50 60 Hz 230V 1Ph 50 60 Hz motoinverter Working air pressure 8 10 bar 116 145 psi Air feeding pressure regulator set at 10 bar 145 psi included Inflating air pressure regulator set at 3 5 bar 50 psi included Working capacity Rim diameter clamping 10 to 34 Maximum rim width 16 410 mm Maximum wheel diameter 47 1200 mm Motoinverter chuck details Motor power 0 75 Kw Maximum torque 1200 Nm Clockwise rotation speed 6 12 rpm Working noise level lt 70 dB Bead Breaking units Rollers BB cylinders power at 10 bar 11770 N 1200 kg Rollers BB maximum span 670 mm 26 Bead pressing cylinder power at 10bar 4218 N 430 kg Layout details Minimum overall dimensions mm 1180 x 1300 x 1770 H Net weight optional accessories excluded 425 kg Operating temperature range min 5 max 50 41 122 F Standard accessories ref page 24 WDK clamp with rubber protections Kit o
8. Before starting demounting a tyre it is of CRUCIAL IMPORTANCE to identify the measurements of the rim and of the tyre as well as to make sure that neither the rim nor the tyre are damaged Warning these very important procedures have to 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 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 B 65 ratio percentage between the height of the section and its width R type of tyre R radial D 15 keying diameter diameter of wheel and rim in inches E 91 index of the maximum load born by each wheel F maximum admitted speed of the tyre 210 Km h G TL type of tyre T Tubeless 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 Mind the position indications hour marks in order to put the valve and the pressure sensor
9. 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 comes 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 2 30 0 MAintenance 30 1 Standard Maintenance Routine maintenance according to the following instructions is of crucial importance t
10. XS B U0Z1J0H JapuljAo J u soo pe g 5 22 0 J u soo pe g eue oss Bu XEN Ip Ajddns ajuabjog 9 J u soo asouedns 5 5 5 5 eyes JapuljAo UONE SUBI pe g 5 5 5 J pul S5 SJOUSJUI 5 peag 1J u soo pe g 5 QUOIZE SEJ L
11. uu DS 15 J80 BEAD LOOSENINGu u uuu u ma sua Sauna AN ANA 16 18 1 CAC 16 16 2 lt a Aa eel 17 19 0 DEMOUNTING LOWER BEAD ON SPECIAL ennum nnne 18 20 0 RIMANDTYREMATCHING uu u a AANGAT NGABA AANO NAA 18 210 TYREDEMOUNTINGSu tup unu ANA Sat sata ut sana sat D Sisa busua sa 18 21 m uama nag eee 18 21 2 Lower bead Y SDS onde aaa 20 22 0 TYRE MOUNTING suy u van ANNA NAA ANAN 20 22 1 OWEN pead k uu uuu w asuaka ea pu 20 22 2 Upper pead MOUNT 21 22 5 UHP and RUN FLAT tyres Mounting AA AA Na NAG 22 230 INFLATION AA NAINA NA 23 24 0 STANDARD ACCESSORIES AA AA NAA AA 24 2501 OPTIONAL ACCESSORIES DAN NAN AA ANA 25 26 0 RE POSITIONING INA AINA AN aaa Saa ka AA AA 27 270 SIQRAGE Z ANAN NINDA ANA AN 27 28 0 SGRAPPING AA AA AA AA AA 27 29 0 NAAN 27 30 0 MAINTENANCE pa uk aaa usata 28 SO S andar a nalliteraiik
12. While spinning the wheel push the lower roller up over the edge of the rim then press and hold down the over stroke function button 5 going on lifting the roller until the bead detaches from the rim As soon as enough space is available grease both inner surface of the rim and tyre bead carefully with a proper tyre lubricating paste Note for a better control of the lower bead loosening please refer to the dedicated mirror fitted onto the Tyre Changer main frame T Press on the bead never on the sidewall of the tyre while loosening the bead 17 19 0 LOWER BEAD DEMOUNTING SPECIAL WHEELS The lower bead of reverse drop centre rims with significant width may be hard to break with the lower disk In this case it is possible to use the upper bead breaking disk to break the lower bead of the tyre tilt down the upper disk arm support to its lower position step 1 to get both upper and lower bead loosening disks at the same tilt angle step 2 follow instructions as per chapter 18 BEAD LOOSENING at page 16 Lower bead loosening arm 20 0 RIM AND TYRE MATCHING Driving could be affected by vibrations caused by deformations of the rim and or of the tyre To optimize the wheel balancing it is necessary to position the wheel onto the Tyre Changer again to bead break and lubricate the rim and the tyre spinning the tyre around the rim to a proper position Both upper and lower rollers make this proc
13. 2 or 3 o clock position and insert the plastic lever as per WDK rules for UHP and RUN FLAT tyres Spin the wheel clockwise until the tyre complete coming out Press the pedal ref 1 to move the mounting arm away push the rollers bead breaking unit away and pull out the tyre Check the status of the pressure sensor if any and replace it if necessary 21 3 Tyre demounting by hand lever LNL Lever no lever system The Tyre Changer is provided with a patented system which allows the use of a standard steel lever to demount special wheels as Wheels with very narrow rims Wheels with very tender tyre sidewalls Motorcycle wheels The above wheels can not easily or not at all demounted with the standard LeverLess system In order to demount a tyre manually by a standard lever pull the retractable claw up away from working area by lifting the handle ref 23 up fig 1 lean the manual lever onto the fixed claw fig 2 23 Handle Retractable claw W Fixed claw Once the manual demounting is finished the standard position of the retractable claw can be restored by lowering the handle ref 23 20 22 0 TYRE MOUNTING Check the rim and the tyre carefully as per instructions at page 12 of this manual If the rim has been moved lock it again onto the centre plate as per instructions at page 16 of this manual Lube 3 cm thickness along the whole internal surface of the rim and inte
14. 5 0 SAFETY INSTRUCTIONS The Tyre Changer has to be used by qualified and authorised personnel only A qualified operator is someone who has fully understood the instructions described in the operation instructions manual supplied by the manufacturer who has been specifically trained and who is aware of safety standards at the workplace It is essential to use proper service methods and change tyres in an appropriate and acceptable manner that does not endanger your safety the safety of others in the work of area or the equipment or vehicle in a safe manner It is assumed that prior to using the Tyre Changer the operator has a thorough understanding of the wheels and tyres being changed In addition it is assumed he has a thorough knowledge of the operation and safety features of the Tyre Changer accessories being utilized and has the proper hand and power tool necessary to service the vehicle in a safe manner Those in charge of using the machine shall not be under the influence of drugs alcohol or other substances which could compromise their physical and mental work capabilities For greater safety operators shall wear health amp safety footwear gloves protection goggles and shall NOT wear any form of 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
15. CHART PROBLEM Centre plate does not rotate 1 Missing electrical feeding SOLUTION 1 Turn power on 2 Power cord missing or not plugged 2 Check cord or plug in correctly 3 Replace fuses or enable 3 Fuses blown or differential disa differential bled 4 Tighten or replace drive belt 4 Drive belt loosened or damaged 5 Tighten pulley by proper 5 Motor pulley loosened screw 6 Micro switches cam shaft 6 Reconnect or replace shaft disconnected from pedal 7 Replace motor 7 Motor damaged or defective Chuck turns at one speed only or in one direction only after pedal is released 1 Foot pedal connection out of adjustment or not installed correctly 2 Micro switches fixing screws loosened or missing 3 Micro switch damaged or defec tive 4 Pedal return spring broken or loosened 1 Adjust foot pedal 2 Check screws tightening or replace screws 3 Replace micro switch 4 Replace return spring Chuck rotating motor turns at one speed 1 Micro switch damaged or defec only or in one direction only tive 2 Micro switch cable unplugged 3 Motor damaged 4 Motor cables unplugged 1 Replace micro switch 2 Check and connect micro switch cable 3 Replace motor 4 Check and connect motor cables Chuck rotating motor turns atone speed 1 Micro switch damaged or defec 1 Replace micro switch 2 Check and connect micro switch cable 3 Replace motor 4 Check and connect motor cables only o
16. Inflating pedal 0 BEFLATION Deflation button Connect the inflation hose to the valve of the tyre 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 4 continuously 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 pressure while doing so Press the deflation button to deflate the tyre if during inflation the pressure exceeds the value recommended by the tyre manufacturer 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 In order to use the optional Tubeless Inflating Device Activating button 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 feed the wheel valve As soon as the tyre beading is completed store the Inflating Device into its housing 23 24 0 STANDARD ACCESSORIES Plastic bead pressing clamp with extra plug for alloy rims with slippery edge s To be used together with rubber protections T for mounting UHP and RUN FLAT tyre Ta a
17. in correct and safe positions It is strictly 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 12 14 0 TYRE 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 Q to 160 km h U to 200 km h W to 270 km h R to 170 km h H to 210 km h ZR gt 240 km h S to 180 km h V to 240 km h ZR Y gt 300 km h T 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 structure the shoulder of the tyre can bear the weigh
18. make the lifting easier set the tyre pressing unit at 6 o clock position and press the tyre side fig 6 Get a further help by contemporarily lifting the lower tyre side by the lower bead loosening roller fig 7 Fig 6 Press down on pedal ref 2 to rotate the wheel clockwise until the entire bead is lifted from the rim NOTE rim and tyre must spin together as one In order to help the bead coming out and reduce the stress to the tyre insert the plastic lever as shown by picture aside and spin the wheel clockwise while lifting the tyre by the lower bead loosening roller NOTE The above mentioned action is compulsory for UHP and RUN FLAT tyres according to WDK rules tion before inserting the tool in the dropp centre operating the control lever 20 To avoid damaging the valve and or the pressure sensor move the same to the 1 o clock posi 19 21 2 Lower bead Before pulling out the lower bead spin the wheel to let the valve reach 1 or 2 o clock position in order to avoid possible damages to the valve and the sensor if any Lower the lever ref 20 to insert the demounting tool under the lower bead Raise the lever ref 20 to lift the demounting tool and the bead Raise the lower bead loosening roller to lift the tyre until the lower bead is 1 cm over the upper rim edge In order to help the above mentioned operation lift the tyre manually at
19. understand the danger warnings understand the characteristics of the machine keep unauthorised people away from the work area make sure the machine is started in full observance of all the applicable safety standards and rules make sure all operators are familiar with the machine and 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 JN The Tyre Changer may exclusively be used by expert specifically trained and authorised personnel only The use of the machine is forbidden to disabled operators if their disabilities may affect the safety of the working operations Tampering or modifications to the equipment that are not authorised in advance by the manufacturer relieve the lat ter from all forms of liability as regards to damages deriving from or referable to such actions Removal or tampering with the safety devices provides grounds to immediately cancel the warranty and involves violation of European Safety Regulations and codes 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 IN CASE OF FIRE USE ONLY DRY CHEMICHAL OR CO2 EXTINGUISHERS TO PUT T
20. 2 Replace control knob valve broken 3 Replace cylinder seal 3 Cylinder seal broken 4 Adjust or replace plates 4 Locking plates worn Bead pressing device doesn t react to 1 Pneumatic supply missing 1 Check line pressure controls or it moves irregularly 2 Control valve broken 2 Replace control valve 3 Mufflers obstructed 3 Clean or replace mufflers 4 Cylinder seal broken 4 Replace cylinder seal Mounting tool touches the rim during 1 Locking plates unadjusted or 1 Adjust or replace locking working steps defective plates 2 Wheel locking nut loosened 2 Tight locking nut correctly Inflating device doesn t work 1 Pneumatic supply missing 1 Check line pressure 2 Pedal control valve broken 2 Replace control valve 3 Pressure limit valve broken 3 Replace pressure limit valve 30 32 0 WIRING DIAGRAMS Motoinverter wiring diagrams Two speed clockwise 1 speed anticlockwise Power supply line LINEA ALIMENTAZIONE 230V 1Ph 50 60Hz Motoinverter a SCATOLA Gee Ue hgh Me Se a my 1 DELL UTENTE max 16A Installation 1 ld 30mA by the user I I I I I I I I L MARRONE NERO SPINA NEMA AZIONAMENTO L6 20P Electronic Plug board Plugand Connettori sockets GIALLO BIANCO PEDALIERA 12V Pedal switch Yellow White INTERRUTTORE F
21. HE FIRE OUT WATER FOAM POWDER mika DRY materials FLAMMABLE liquids oo gt ELECTRICAL equipment NO no ok 6 0 SAFETY DEVICES This Tyre Changer is provided with the following safety devices in order to grant the operator s safety Pressure limit valve installed into the Tyre Changer to avoid inflations over 3 5 bar 50 psi pressure Pressure regulator with manometer to limit the maximum system pressure to 10 bar 145 psi on Tyre Changers equipped with TubeLess inflating device Limit Valve installed onto the air tank to avoid exceeding 11 bar 160 psi pressure value it is in contravention of European Safety Rules Removing or tampering with safety devices immediately invalidates the guarantee and 7 0 TRANSPORT The Tyre Changer must be transported in its original packaging The packaged machine has to be moved by mean of a fork lift of suitable capacity 500 kg min 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 b
22. If necessary press the tyre side by the upper bead loosening roller to help the correct positioning and locking of the clamp fig 1 Keep the upper bead loosening roller at drop centre level spin slightly to insert the pressing tool between the roller and the clamp and pressing onto the tyre side until the upper bead reaches drop centre level fig 2 Make sure that the upper bead of the tyre rests on the left lip of the mount head and under the demounting claw on the right side of the head Start spinning the wheel paying attention to the bead not going between the rim edge and the bead loosening roller While spinning when clamp is roughly at 6 o clock position make sure that the whole bead within this section is right inside the drop centre If this necessary condition for a correct mounting is not accomplished use the bead pressing unit pushing its tool onto the tyre side to insert the bead into the drop centre fig 3 Act gently onto tyre sidewall during the above mentioned process Go on spinning the wheel until the upper bead is completely mounted Remove the clamp and the rubber protection by the help of the pressing unit Pull the pressing tool away and lift the roller away from the working position by acting on button 10 Press button 7 to move the bead sloosener from working position Press the pedal ref 1 to push the mounting arm up and move the roller bead breaking unit away from working positi
23. UNZIONE 1 VELOCITA AVANTI 2 VELOCITA AVANTI VELOCITA INDIETRO OPT i ee a an 3 S1 Slow speed clockwise 52 Fast speed clockwise S3 Speed counter clockwise 31 33 0 PNEUMATIC DIAGRAMS B U0Z1J0H 82 5 lt lt 5 5 99045 2500 Jano 1 u soo pe g 5 012 JapuljAo 9 E U0ZZIJO 25102 5 10 00 25100 25102 5 OJPUIIID O 5 J u soo pe g 119 1 u soo 5 J u soo peag J1o euo e s 22 0
24. 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 27 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 parts list this to be carried out by skilled personnel 28 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 JN WARNING follow RAEE and ROHS Conformity Declaration rules for a correct disposal 29 0 OIL TREATMENT JN OIL IS POLLUTANT DO NOT THROW AWAY OUTDOORS OR POUR ON THE GROUND
25. ating unit with pres cod 9236665 sure gauge and pneu matic locking Roller bead loose ning control unit Roller bead Locking nut loosening unit Center plate Wheel positioning device optional cod 9237720 Pedal control units 11 0 CONTROLS DESCRIPTION 1 Tilting pole pedal control 14 Deflation button inflating by pedal 4 2 Clockwise and anticlockwise centre plate ref 15 rota 15 Center plate tion pedal control 16 Upper bead loosener roller 3 Wheel positioning device control pedal optional 17 Press arm control switch 4 Inflation pedal contro 18 Lower bead loosener roller 5 Bead loosening rollers override engaging button 19 Operating arm contro button 6 Bead loosener locking and override ref 5 activation 20 QX leverless system control switch switch 7 loosener releasing button 8 Bead loosener forward movement button 9 Bead loosener back movement button 10 Upper bead loosening roller lifting button 11 Upper bead loosening roller lowering button 12 Lower bead loosening roller lowering button 13 Lower bead loosening roller lifting button 21 Upper bead loosener tilting control 22 Center plate pneumatic locking switch 23 Handle for disengagement of the Lever Less mounting tool Any test must be operated with no tyre onto the machine Ja Mind any component which could interfere with machine testing operations 11 12 0 AND TYRE IDENTIFICATION
26. ccording to WDK rules Rubber protection for steel rims marked with Rubber protection for alloy rims marked with Rubber protection for alloy convex rims marked with Plastic lever 7 Z SQ To be used during tyre demounting according to WDK rules Plastic protections for tool head Centering cone plastic protection X2 Centre plate rubber protection 2 Driving pin plastic protection Reduction ring for centre plate To be used to fit particular alloy rims Rim edge plastic protection 24 25 0 ACCESSORI OPTIONAL FPM 456 Clamping adaptor for reverse rims rims without centre hole BMWrims Suitable to lock any rim with any holes number onto the centre plate Rims without centre holes BMW rims PENS Art 455 08 Centering cones adaptor kit for light truck rims locking centre hole 0120 to 0190 mm Centering cones adaptor kit for light truck rims locking centre hole 0190 to 0220 mm Art 458 08 TT Art 611 11 Centering conical adaptor for steel rims locking Ey centre hole 075 to 2120 mm Art 659 11 Two sides centering conical adaptor for steel rims locking centre hole 075 to 0145 mm 25 9237720 Wheel positioning device Art 735 12 Tubeless tyres inflating device 26 26 0 RE POSITIONING To re position the Tyre Changer in a new workplace secure the moving parts i e the bead pressing
27. e 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 455 Kg Lifting point After tyre Changer positioning take of the lifting belt The machine must be moved by means of suitable capacity fork lift 500 kg min as per fig 1 or crane with liftin gbelt 500 kg min as per fig 2 Lifting point After having positioned the machine in its final location release the safety pin against accidental tilting of the arm fig 3 Put the pin together with the other standard ac cessories delivered with the machine for any future need 9 0 INSTALLATION 9 1 Tyre Changer site requirements When choosing the place of installation be sure that it complies with current safety at work regulations The Tyre Changer must be connected to the main electric power supply and the compressed air system It is therefore advisable to install the machine near these power sources The installation area must leave at least the room shown in picture fig 4 so as to allow all parts of the machine to operate correctly and without any restriction 9 2 Tyre Changer placement and connections Fig 4 Place Tyre Changer onto a levelled out smooth and not slippery floor with a suitable load capacity No bolt dow
28. ess easier by gently holding the tyre steady while the centre plate spins the rim until the correct matching position 21 0 TYRE DEMOUNTING Once the bead loosening process is completed and the wheel is already positioned onto the center plate check and ensure its locking and centering 21 1 Upper bead demounting Mounting tool in working position Turn the wheel until the valve is in the 1 o clock position roughly 10 cm 4 distance from the mounting tool in order to avoid possible damages to the valve or the pressure sensor 18 Press the pedal ref 1 to position the mounting arm close to the wheel while driving The mounting arm by handling fig 5 lock it in position 1 by ref 19 fig 5B to lock the operating arm and the hori zontal arm at the same time Automatically the mounting tool is moved up and away from the rim border to have a clearance of approx 2 mm when locked Lower the lever ref 20 to insert the mounting tool between the bead and the rim edge The mounting tool should pe netrate enough to hook the tyre bead to let the operator complete the tyre demounting spin slowly the wheel until the mounting tool is positioned correctly A gentle pressure on the tyre sidewall by the upper roller could help the mounting tool positioning Fig 5 Pos 1 Pos 2 Pos 3 As soon as the bead is perfectly hooked lift the mounting tool by raising lever ref 20 to pull out the bead To
29. f plastic inserts for mounting tool Plastic lever Plastic protections for centering cone Rubber protections for chuck Plastic protections for chuck dowel Step down ring Plastic protections for rim Main optional accessories ref page 25 Inflating device for tubeless wheels Overall dimensions mm FPM 456 flange for rims with reversed groove blind wheels and special wheels Centering cones for LCVs rims Packing details 2120 Gross weight 455 kg without optional accessories 1860 ooden pallet 4 0 DECALS PLACEMENT Cod 3035727 Cod 3033099 Cod 3033101 ATTENZIONE alle sei nportate mel PERICOLO sron plata covindls come pro LOCK WARNING hah The Iratrucbor Garen a 3005416 Cod 3019742 om qu Cod 3019739 3033102 VORSICHT Cod 3033098 Cod 3033097 3033095 Cod 3033096 Cod 3008944 DANGER pts i Cod 3005410 Cod 3001104 Cod 3000048 Cod 3019736 lt lt DOWN Cod 3038028 Cod 3038051 ATTENZIONE 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 Refer to the above mentioned codes for warning labels ordering
30. kwise Move the bead breaking arm onto the tyre by pressing buttons 8 9 an 10 11 Pay attention to the valve sensor position during bead loosening steps Wrong movements of the upper roller could damage the sensor Avoid contacts between the lubricating paste and the valve sensor if any 16 Spin the centre plate until the valve reaches position at 3 o clock position Lower the bead loosening roller until it touches the tyre using controls 9 for lowering and 8 for lifting Start spinning clockwise pressing pedal 22 Note the centre plate can spin at 2 different speeds according to operator s preferences While spinning the wheel push the bead loosening upper roller down under the edge of the rim then press and hold down the over stroke function button 5 going on lowering the roller until the bead detaches from the rim As soon as enough space is available grease both inner surface of the rim and tyre bead carefully with a proper tyre lubricating paste Once the bead gets loosened raise and move away the upper roller by acting on button 10 18 2 Lower bead Keep the bead loosening unit set up as for upper bead release the lower roller is always aligned with the upper one at 5 mm distance from rim lower border already Lift the lower roller until it touches the lower bead using controls 13 for lifting and 12 for lowering Start spinning the wheel anticlockwise by pressing pedal 2
31. l lifter tool doesn t move or it moves Pneumatic supply missing 1 Check line pressure slowly Control valve broken 2 Replace valve Mufflers broken or unadjusted 3 Clean adjust or replace Cylinder seal broken mufflers 4 Replace seals Mounting arm doesn t move or it moves slowly or too fast Pneumatic supply missing 1 Mufflers obstructed Mufflers unadjusted Cylinder seal broken Check line pressure Clean or replace mufflers Adjust mufflers Replace cylinder seals Mounting arm doesn t keep the memori zed position Pneumatic supply missing Knob control valve broken Pilot valve broken Cylinder seal broken Locking plates worn Check line pressure Replace knob control valve Replace pilot valve Replace cylinder seals Adjust or replace plates Mounting arm stays locked ina memori 1 Pedal activating valve broken 1 Replace activating valve zed position Bead loosening unit doesn t react to con 1 Pneumatic supply missing 1 Check line pressure trol pedal while cylinder shaft slides 2 Bead loosening cylinder valve 2 Replace cylinder valve broken 3 Clean or replace mufflers 3 Mufflers obstructed 4 Replace cylinder valve 4 Bead loosening cylinder seal broken Shovel blade bead loosening unit doesn t 1 Arm locking cylinders defective or 1 Replace locking cylinders keep the memorized position pneumatic supply missing check line pressure 2 Bead loosening control knob valve
32. level under the rim edge Make sure that the upper bead of the tyre rests on the left lip of the head and under the demountig claw on the right side of the head Press the pedal ref 2 to rotate the wheel clockwise contemporarily press the tyre manually from 5 o clock position to force the bead at drop centre position Keep it pressed while rotating up to 8 o clock position to complete the upper bead mounting Make sure that rim and tyre always spin together To make the upper bead mounting easier use the tyre pressing unit by setting it at 5 o clock position and pressing lever ref 17 to keep the bead at drop centre level while rotating up to 8 o clock position until the tyre complete mounting 21 22 3 UHP and RUN FLAT tyres mounting Some precise and careful operations are necessary to mount UHP and RUN FLAT tyres It is compulsory to follow WDK rules to avoid permanent damages to these tyres Lower bead mounting can be performed as per standard instruction at page 20 of this manual Once the lower bead is mounted keep the mounting arm and tool at working 4 sition and start WDK upper bead mounting procedure putting the tyre slightly tilted KA down to 3 o clock position NG Use the bead pressing clamp together with the proper rubber protection e steel rim ee alloy convex alloy rim locking the clamp onto rim edge with the valve at 3 o clock position
33. locked onto the cente plate before starting any operation on the wheel 15 18 0 BEAD LOOSENING JN Make sure the tyre is completely deflated before starting any operation on the wheel Remove all weights from the rim by a proper tool paying attention not to damage the rim Before starting any operation please check the eventual presence of a pressure sensor In positive case it is prefe rable to check its efficiency by a dedicated diagnostic tool The bead loosening rollers are mounted on special ttilting supports to ease bead loosening on wheels with high profile or soft tyres This procedure is Over Run OVER RUN PROCEDURE SHOULD NOT BE USED UHP AND RUN FLAT TIRES Push down the hook lever to release the upper roller Lift up the hook lever to release the lower roller 18 1 Upper bead loosening Check the correct centering and locking of the wheel onto the centre plate Check that the upper disk arm is in the right position step 1 to move the upper disk in its right position unlock it from rest position by pressing the right lever to the left A then lift the disk arm support by hand and lock it by pressing the right lever to the right B Turn the switch 6 clockwise to free the bead breaking unit and position it by handling the console in order to let the upper roller keep to 5 mm distance from the rim border then lock the bead breaking until by turning again te switch 6 cloc
34. n installation is required In case of bolt down installation please refer to all 4 holes on the base of the machine drilling through 100 mm into the floor and using suitable bolts for fixing 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 automatic circuit breaker differential set at 16 mA Should the Tyre Changer be lacking in electric plug the user must set one at least 16 A and conform to the voltage of the machine in compliance with the regulations in force 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 min 8 bar working pressure outlet Connect the machine to the pneumatic network by means of the air fitting on oiler filter regulator installed onto the rear section of the machine 10 0 EQUIPMENT COMPONENTS Leverless mouinting de mounting system TubeLess inflating unit optional Infl
35. o ensure the correct operation and lasting life of the Tyre Changer Before starting any maintenance job disconnect the electrical power supply by unplugging the machine AN from the main electrical feeding and disconnect it from the pneumatic supply by shutting off the valve To release the compressed air from the circuit press the inflation pedal ref 3 down for a few seconds On daily basis keep the machine clean eliminating any mould and dirt to ensure the perfect movement N of the slides and the tools and to grant the correct functioning of all centering and locking systems Do not clean with compressed air which can blast dirt between moving parts WT On daily basis check for worn or damaged plastic and rubber inserts and protections that should be IN replaced to prevent damages to rims and tyres ing N Every 2 3 days check the oil dropping into the cup 1 drop every 4 5 activa tions of the bead pressing tool or of the bead loosening systems necessary turn the screw on the top of the cup by a screwdriver For a long lasting correct functioning of the 10bar pressure limit device ensure that the drain level doesn t exceed the MAX DRAIN indication 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 u
36. on Keep the wheel locked onto the centre plate during the inflating operations Read the inflating instructions at page 23 carefully Once the tyre inflation is completed unlock the wheel and bring it down onto the floor taking advantage of the optional wheel positioning unit 22 23 0 INFLATION followed strictly This Tyre Changer is not projected to protect operators and objects from accidental tyres ex plosions Tyres must be inflated with the utmost caution The instructions below have to be read and 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 the tyre should burst or the rim should break under pressure operators could be seriously injured or even killed Make sure the rim and the tyre the same size O _ Also check the state of wear of the tyre and the to make sure there are no defects before WA starting to inflate Inflate the tyre with short blasts of air and check the pressure frequently while inflating This Tyre Changer 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 x
37. p by adding oil for pneumatic systems in class ISO On monthly basis unplug the machine ESSO Febis K32 MOBIL Vacouline from pneumatic feeding and remove Oil 1405 KLUBER Airpress 32 the filter cup to clean it from possible solid impurities On periodical basis clean the sliding guides of the bead loosening carriage by naphtha and lube them by oil or proper grease Perform the same cleaning and lubricating actions on every junction and mechanical sliding On periodical basis check the tensioning of centre plate 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 30 2 Extraordinary maintenance Non routine 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 31 0 TROUBLESHOOTING
38. r in one direction only tive 2 Micro switch cable unplugged 3 Motor damaged 4 Motor cables unplugged Chuck turns but wheel stays still 1 Wheel locking nut not holding 2 Driving pin not holding 1 Secure locking nut correctly 2 Position driving pin correctly Check line pressure Replace control valve Replace pilot valve Replace cylinder seal Clean or replace muffler Check or replace air hose Bead loosening unit do not move vertical ly or move slowly Pneumatic supply missing Control valve broken Pilot valve broken or defective Cylinder seal broken Mufflers obstructed Control valve air hose squeezed Check line pressure Replace control valve Replace cylinder seals Bead loosening rollers reach working position but do not perform overrun mo vement Pneumatic supply missing Control valve broken or defective Cylinder seals broken Roller bead loosening unit do not move Overrun pilot valve broken Pilot valve broken or defective Locking unlocking valve broken Replace overrun pilot valve Replace pilot valve Replace valve horizontally LeverLess mounting tool doesn t move vertically 1 Pneumatic supply missing 1 Check line pressure 2 Pneumatic supply hoses broken or 2 Replace pneumatic supply squeezed hoses 3 Control valve broken 3 Replace control valve 4 Mufflers obstructed 4 Clean or replace mufflers 5 Cylinder seal broken 5 Replace cylinder seals 29 PROBLEM SOLUTION Whee
39. rgimento 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 2002 96 CE e 2003 108 CE RAEE Raccolta differenziata 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 14 06 12 p CEMB S p a Ing Carlo Buzzi 5 1 0 INTRODUCTION u 2 uuu 4 dh hk Tyre Changer uu D kau aaa 4 5 ote Sen nae E 4 AA AA 4 2 0 GENERAL DESCRIPTION
40. rnal and external surface of tyre beads Avoid contacts between the lubricating paste and the valve sensor if any 22 1 Lower bead mounting Put the tyre onto the centre plate 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 mount demount head onto rim edge Incline the tyre to the bottom at 3 o clock position driving the lower bead to the mounting head in order to put the lower bead over the mounting lip on the left side of the head and under the demounting claw on the right side of the head Rotate the wheel by pressing the pedal ref 2 contemporarily press the tyre at 5 o clock position until the bead reaches the drop centre level Keep the tyre pressed until 8 o clock position while rotating to complete the lower bead mounting 22 2 Upper bead mounting Keep the mounting arm and the mount demount head at working position then put the tyre bead on the rim slightly tilted down to 3 o clock position Bead correctly positioned OK Bead correctly positioned over the mounting lip under the demounting claw OK LM Bead incorrectly positioned AK 7 causing bead damages Bead incorrectly positioned between the head lip NO and the rim edge Press the button ref 11 to lower the upper bead loosening roller until the upper bead reaches 3 cm
41. t of the vehicle even when the 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 Sistem 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 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 The bead breaking procedure should be operated by shovel blade bead breaker with standard wheels in order to save time while the rollers bead breaking unit has to be used for all LowProfile UHP and RUN FLAT tyres tyre damages and the consequent risks for the vehicle and the passengers safety 15 0 WDK RULES is German certified body charged with the evaluation of tyre changers functioning and their capability to perform good and safe operations on RUN FLAT and UHP tyres correctly to avoid permanent and potentially dangerous dama ges to tyres
42. te Wheel positionig device optional Driving pin 3 Centre plate Wheel positionig device control pedal 14 17 0 WHEEL LOCKING Insert the ring nut hub correctly the cone plastic cover preserving the alloy rims from damages Turn the ring nut hub clockwise by hand until you find the exact coupling position then press the hub and turn it clockwise by 90 to its full stroke Release the ring nut and make sure it raises by 0 40 10 mm approximately otherwise turn it slightly clockwise or counter clockwise lifting up the hub Make sure the plastic cone is in contact with the rim perfectly centred with the drop centre hole the split of the nose matching up with the driving pin Tighten the ring nut so that it moves up to the cones and continue tightening so that the wheel is pushed firmly on the flange of the spindle 17 1 Pneumatic locking system optional If the tyre changer is provided with the optional pneumatic locking system 1 2 3 Insert the ring nut hub correctly the cone plastic cover preserving the alloy rims from damages Turn the ring nut clockwise by hand until the exact coupling position press the ring nut until its end stroke and rotate the ring nut hub 90 by hand Release the ring nut and make sure thet it raises by 0 40 10 mm approximately Rotate the pneumatic locking switch onto the manometer panel to the locking position Make sure that rim is perfectly
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