DOSAGE TABLE & INSTALLATION GUIDE

Transcription

1 R ROTIS Pump Ride-On Tire Injection System DOSAGE TABLE & INSTALLATION GUIDE Version 14.1 July 2008 Manufactured and assembled in the USA. Patent pending.

2 Ride-On Tire Protection System (TPS) ROTIS Pump Dosage Table INTRODUCTION: This latest version of Inovex Industries Ride-On Tire Protection System (TPS) Dosage Tables has been produced to aid in the installation of Ride-On TPS by our dealers and customers. We believe that you will find that these are the most comprehensive and complete tire sealant dosage tables yet produced. The use of these tables is simple, with the tires being classified according to the tire industry standards (The Tire & Rim Association). The tires have been listed according to increasing rim diameter: Page/Section Section 1. Dosage Table Intro (I - XI) Section 2. Tire Size Designation by Rim Diameter (12 29) Section 4. Material Safety Data Sheet (MSDS) (30 34) WHAT S NEW: Complete Tire Listing Inovex Industries strives to provide the most complete and comprehensive Dosage Tables on the market. Our engineers are constantly updating our tables, adding new tire sizes and adjusting the dosages to ensure optimum performance. Please contact us at (703) , or toll free at (USA only) should you find a commercially available tire that is not listed in our tables. Our engineers will be happy to assist you in determining the optimum dosage requirements for your applications. FORMULATIONS: Commercial High-Speed (CHS) Formula For all high-speed vehicles: cars, light trucks, mobile homes, tractors, trailers, roll-offs, street sweepers, buses, delivery trucks, etc. The CHS formula offers protection against flats from objects up to ¼ (6.4 mm) in diameter, helps tires run cooler, and acts as a balancing compound. The CHS formula is ideal for any fleet that would like to improve its pressure maintenance program, ensure that their tires wear more evenly, minimize downtime, and maximize the life of their tires. Heavy Duty Off-Road (HD OTR) Formula Available for off-the-road commercial and industrial vehicles (operating speed less than 30 MPH / 50 Km/H). This industrial strength formula can seal punctures up to 1/2" in diameter in the tread area. Ride-On TPS Off-Road provides extra protection for severe service, and is ideal for all off-road equipment, farm tractors, forklifts, backhoes, construction equipment, mining and logging equipment, bobcats, etc. Tire Conditioner & Sealant Designed to condition casings and help reduce rim corrosion and scale buildup for off-road and agricultural tires. This specially formulated Tire Conditioner and Sealant reduces porosity air loss, helping tires run cooler and extending overall tire life. It also helps seal bead leaks and tread punctures from objects up to ¼ (6.4 mm) in diameter. Ride-On Tire Conditioner and Sealant lowers labor costs by helping with mounting and demounting of off-road and agricultural tires. Tire Conditioner & Ballast - Designed to condition casings and help reduce rim corrosion and scale buildup for off-road and agricultural tires. Ride-On Tire Conditioner &Ballast lowers labor costs by helping with mounting and demounting of off-road and agricultural tires. Dosage Table Introduction I

3 Auto and SUV Formula Exclusively manufactured for passenger and light trucks. The Ride-On Auto formula is the only known product in the world capable of being balanced on dynamic spin balancers. The Auto formula offers excellent protection for cars and light trucks against punctures from objects up to 1/4 (6.4 mm) in diameter. ATV Formula The ATV Formula is ideal for all ATV, UTV, industrial, and other offroad applications. This formula is a cross between our CHS and our HDOTR formulas. Motorcycle Formula A high-speed formulation for motorcycles, dirt bikes and scooters. Ride-On TPS for Bikes (Bike-On ) Designed especially for bicycles. REGULAR DUTY & SEVERE DUTY: Our Dosage Tables include columns for Regular Duty and Severe Duty dosages. The Regular Duty dosages are prescribed for vehicles operating in normal conditions, i.e., vehicles used in non-extreme or mostly on-road environments. The Severe Duty dosages are recommended if a vehicle is expected to encounter a large number of puncturing objects, i.e., construction vehicles, vehicles operating in landfills, street sweepers, etc. For vehicles in dual use highway and off-road conditions (i.e. trash hauler delivering to landfills), the Severe Duty dosage is recommended. The Regular Duty dosages are recommended for vehicles designed to operate at high speeds where tire balance is an issue. When tire balance is not a concern, the Severe Duty dosages are recommended. TUBE TIRES: The Ride-On Tire Protection System is designed to work in tube and tubeless applications. For tube passenger car and light truck tires (designated LT), it is recommended that you use the Severe dosage. For example, for a P235/75 15 tire, use 15 ounces of the Commercial High-Speed formulation. The Passenger & Light Truck formula is not recommended for tube tires. Identifying Tires Containing Ride-On Always identify the tires that contain Ride-On to prevent double treatment. You can mark the tires by using a permanent tire marker, by spray-painting valve stems, or by using Ride-On s special vehicle stickers or o-rings (available through your Ride-On dealer). Troubleshooting Air pressure, vehicle weight and centrifugal force are all needed for Ride-On to work effectively. When a puncture does not seal properly, check for the following: 1) Lack of sufficient amount of Ride-On TPS; 2) Puncturing object is outside of the coverage area; 3) Rips, tears, or belt/cord damage, Tread separation, Valve leaks, sidewall puncture; 4) Oily or lubricated puncturing object; 5) Object too small (i.e. a needle or finishing nail) Enlarge hole with a reamer or larger object. 6) Puncturing object larger than what the sealant is designed to seal; 7) Contamination of Ride-On inside of the tire due to excessively wet air source and/or contaminants inside tire; 8) Puncturing object has been in tire for a long time. If an object has been in a tire for a long time, the rubber takes the shape of the object. This occurs because rubber loses elasticity, and when the object is removed, an open hole remains instead of a closed injury. This is one reason why it is so important to check tires regularly for puncturing objects. To help seal such a Dosage Table Introduction II

4 puncture, re-air tire and drive until tire warms up. This will aid in the tire regaining elasticity. The re-airing/driving process may need to be repeated up to three times. 9) Was the vehicle driven (minimum 3 miles for on-the-road vehicles) once the object was removed? If the vehicle is not driven immediately, the tire may lose air pressure and the puncture may not seal properly. 10) Was Ride-On used as an after-the-fact repair? Ride-On TPS is designed to be used as a preventative, and is not recommended for use in applications where the tire has been punctured. If Ride-On is added to a tire after an object has already punctured the tire: a. Object Still in Tire: DO NOT REMOVE OBJECT! If the object is still lodged in the tire, pump the severe dosage requirement of Ride-On into the tire. Drive the vehicle for a minimum of 5-7 miles to ensure complete distribution of product. Remove object and drive the vehicle at least 2-3 more miles. Make sure to re-air the tire as necessary to avoid driving on a flat tire. The re-airing/driving process may need to be repeated up to 3 times before the puncture is sealed. b. If the object is no longer in the tire: Pump the severe dosage requirement of Ride-On into the tire. Drive the vehicle for a minimum of 5-7 miles to ensure complete distribution of product. Re-air tire and drive until tire warms up. This will aid in the tire regaining its elasticity. The reairing/driving process may need to be repeated up to 3 times before the puncture is sealed. Vibration and Other Ride Disturbances It is important to recognize that not all vehicle vibrations are related to tire balance. The following are some of the reasons that a tire may be vibrating in an up-and-down direction: 1) out-of-round tires or wheels; 2) flat spots on tires; 3) worn shock absorbers, struts, ball joints, kingpins; 4) shifted tire belts; 5) mismounted tire/wheel assembly; 6) excessive tire/wheel assembly run-out. If the tire is vibrating from side-to-side (wobbling), look for the following potential causes: 1) bent wheels; 2) bent axles; 3) improper wheel installation; 4) loose or damaged wheel bearings; 5) loose front end components. If the Severe Duty dosages or the Off-Road Formula is used, you may experience some vibration in high-speed vehicles. Precautions, Handling, Spill & Waste Disposal Use absorbent material to soak up small spills. Dispose of waste material in accordance with local, state and federal regulations. Maintain good shopkeeping practices. When working with pressurized air sources, ALWAYS WEAR SAFETY GLASSES. KEEP THIS PRODUCT OUT OF THE REACH OF CHILDREN. Ride-On TPS contains ethylene glycol. If ingested, consult a physician immediately. For further guidance, refer to Material Safety Data Sheet (MSDS) at the back of this manual. ROTIS PUMP Limited Warranty Information 1 Year Limited Warranty Inovex Industries, Inc. warrants that pumps and other products of its manufacture are free from all factory defects in material and workmanship for a period of 1 year from the date of purchase (unless otherwise noted). The date of purchase shall be determined by a dated sales receipt/invoice. For warranty work on the pump, a dated sales receipt noting the model and serial number of the pump is required. The dated sales receipt must accompany the returned pump. Inovex Industries obligation under this Warranty shall be limited to the repair or replacement of any Dosage Table Introduction III

5 parts found to be defective, provided the part or assembly is returned freight prepaid to Inovex Industries, Inc. or its authorized service center, and provided that none of the following warrantyvoiding characteristics are evident: The Inovex Industries, Inc. shall not be liable under this Warranty if the pump has not been properly installed; if it has been disassembled, modified, abused or tampered with; if the hose assembly has been damaged or improperly spliced; if the pump discharge has been reduced in size; if the pump has been used to pump liquids other than Ride-On TPS sealants; or if the label bearing the serial number has been removed. Inovex Industries, Inc. shall not be liable for any loss, damage or expenses resulting from installation or use of its products, or for consequential damages, including costs of removal, reinstallation or transportation. There is no other express warranty. All implied warranties, including those of merchantability and fitness for a particular purpose, are limited to one year from the date of purchase. This Warranty contains the exclusive remedy of the purchaser, and, where permitted, liability for consequential or incidental damages under any and all warranties are excluded. Installation of Ride-On TPS Using ROTIS Pump The ROTIS pump is shipped in two boxes. One box contains the hose, tools, dosage table, and a 55-gallon drum bung adapter. The second box contains the ROTIS pump housing. Please make sure you have all the parts before commencing the setup of the pump. Always wear eye protection when working with pressurized tires! WARNING: the ROTIS pump has an internal preset regulator that reduces the air pressure to the appropriate pressure for the safe operation of the pump. Tampering with the regulator may cause damage to the pump and will void the warranty. The system inlet pressure (pre-regulator) may be up to 180 psi max. INITIAL PUMP SETUP 1. Remove bung cap with NPT fine-thread (does not have valve fitting). Screw the bung adapter into the bung opening. Insert the pump shaft into the center of the bung adapter and push it all the way down into the 55-gallon drum. Tighten the setscrew on the adapter to keep the pump in place. WARNING: Please make sure to transfer the bung adapter from an emptied drum to the next drum. The pump will not sit in the 55-gallon drum correctly without the adapter. If the adapter is lost or misplaced, please call Inovex for pricing on a replacement adapter ( ). 2. Locate the end of the black ¾ - inch hose with a Cam-Lock nipple. Pull the 2 Cam-Lock ears on the pump discharge port all the way forward and remove the 2 locking pins from the ears. Insert the nipple end of the hose into the Cam-Lock attachment on the pump and push the 2 ears all the way back (it may take some effort) against the pump to lock the hose in place. Insert the locking pins (if supplied) through the holes on the Cam-Lock fitting to lock the hose in place. Dosage Table Introduction IV

6 3. Look under the pump s housing and locate the 2 color coded bulkhead hose connections. There are 2 color markers (yellow and black) next to the hose connections. Insert the yellow hose into the bulkhead fitting that has been marked with the yellow dot, and the black hose into the one that is marked with a black dot. Push the hose all the way in and test that it has locked into place by tugging on the hose to make sure that it does not slip out. The small air hoses can be detached from the pump by first pushing in the orange collar on the fitting all the way in, and then gently pulling the hoses out. WARNING: You can damage the fittings and the hoses If you pull the dual air line hoses out of the orange fittings without first pushing the orange collars in. 4. This ROTIS pump is supplied with an air hose to aid and speed up the reinflation of the tires after the installation of the Ride-On sealants. Please install an appropriate air chuck/tool of your choice on the free end of the hose (the opposite end from where the hose connects to the pump). This tool must have a valve in it to prevent air loss. 5. Once you have installed the tool onto the hose, insert the nipple at the pump end into the coupling on the pump. 6. Insert the supplied strait tool into the hydraulic coupling in the discharge end of the hose. Open the ball valve and insert the tip of the hose into the second bung opening of the drum. Dosage Table Introduction V

7 7. Select an appropriate nipple or coupling that matches your shop air system (not provided). Screw the nipple/coupling into the brass opening in the front of the pump. Please use Teflon tape to insure that the attachment is airtight. Connect shop air system to this coupling and check for any air leaks. Press the counter reset button (large button on the same level as the digits of the counter) if you hear any air leaks form inside the pump housing. This should stop any further leaks inside the housing. Make sure that the 5/32 yellow/black dual hoses installed in step 3 do not leak. If there is any air loss, the hoses are not inserted adequately into the fittings. Push the hoses in to make sure they lock. PRIMING THE ROTIS PUMP PRIOR TO INSTALLATION 8. Press and hold down the reset button on the counter and using the smaller digit buttons (one button under each digit on the counter) set the counter to While holding on to the other end of the hose (with its tip in the other bung opening) press the remote reset button (you must press and hold the button for a minimum of 1 second for it to reset). This will start and prime the pump. Allow the pump to count down and automatically shut-off when the counter reaches zero. If the discharge hose has not filled with product (sealant pumping from the discharge), press the Remote Counter Reset Button one more time and allow one more cycle. Remote Counter Reset Button 10. Once the pump has been primed and the hose is full of sealant, close the ball valve at the end of the hose. The ROTIS pump is now properly installed and ready for operation. The speed at which the ROTIS pump will inject Ride-On TPS into the tire depends on the pressure of the tire. The higher the pressure, the slower the installation will be. It is normal for the pump to take approximately seconds to inject 40-ounces of sealant into a tire that is at 100 psi. 11. Using the supplied dosage table, locate the tire size that you want to install sealant into. Please note that there are 3 different counter settings for Regular and Severe applications depending on the starting pressure of the tire (0 psi, 50 psi, and 100 psi). 0 psi for tires that have not been aired up. 50 psi for tires that are mounted and pressurized up to 50 psi. 100 psi for tires that are mounted and are pressurized above 50 psi. Dosage Table Introduction VI

8 Example: requires 40 oz. for Regular and 50 oz. for Severe. The counter should be set at: Regular Severe tire at 0 psi = 13 counter clicks 16 counter clicks tire up to 50 psi = 14 counter clicks 17 counter clicks tire from psi = 16 counter clicks 20 counter clicks Example: 445/ requires 56 oz. for Regular and 70 oz. for Severe. The counter should be set at: Regular Severe tire at 0 psi = 18 counter clicks 22 counter clicks tire up to 50 psi = 19 counter clicks 24 counter clicks tire from psi = 22 counter clicks 28 counter clicks 12. After finding the correct dosage according to your tire size, pressure and application (Regular or Severe), press and hold down the Remote Counter Reset Button on the counter and using the smaller Digit Buttons (one button under each digit on the counter) set the counter to the appropriate number. Counter Reset Button Digit Buttons 13. Rotate the tire into which Ride-On is to be installed so that the tire stem is between the 3 and 9 o clock position (bottom half of the tire). Use a valve core remover tool to unscrew and remove the valve core from the tire valve stem. Quickly attach the tool to the valve stem to prevent any air loss. Open the ball valve and press the Remote Counter Reset Button (refer to step 9, above). This will start the pump. Once the correct dosage has been injected, the pump will automatically shut off. 15. Close the Ball Valve, and disconnect the tool from the valve stem. Re-insert the valve core taking care not to over-tighten the valve core. Inflate the tire to the vehicle manufacturer s recommended tire inflation pressure using the supplied air line (refer to step 4). Press the Remote Counter Reset Button to reset the counter. Repeat step 13 for installation in new tire. CAUTION: Be sure to close the ball valve after each installation, otherwise, since the hose is under pressure, several ounces of Ride-On may squirt out of the hose. MAINTENANCE: Under normal use, the ROTIS pump system requires minimal maintenance. Drain the filter on a weekly basis (or more frequently if necessary), especially if the pump is being used everyday. To drain the filter, press the needle valve on the filter regulator to allow any accumulated moisture to drain out. Filter Regulator Needle Valve Always identify the tires that contain Ride-On to prevent double treatment. You can mark the tires using a permanent tire marker, or use Ride-On s o-rings. Alternatively, you can mark the vehicle using Ride-On trailer or tractor stickers. Dosage Table Introduction VII

9 Please note: It is NOT necessary to immediately drive the vehicle. Once the vehicle is driven, Ride-On TPS is evenly dispersed over the entire tread area of the inner surface of the tire. Do not be concerned with any initial vibrations. Until Ride-On TPS has completely coated the inside of your tires, you may experience a slight vibration. To avoid wheel balance problems, it is critical that the correct amount of Ride-On TPS is installed for your tire size. Ride-On TPS is a stable compound that can be stored in its original closed container for up to 3 years. Please store Ride-On indoors or out of direct sunlight. Once a drum has been opened, it is very important to keep the Ride-On in an airtight environment. This can be accomplished by connecting the quick connect on the pump hose to the drum return spout. If the product is to be stored for prolonged periods (more than four weeks), it is recommended that the pump be rinsed with water and the NPT bung cap retightened on the drum. ROTIS PUMP CLEANOUT PROCEDURES If you are not planning to use the ROTIS pump for a period longer than two weeks, we recommend that you clean the ROTIS pump and the ROTIS hose assembly. The procedure for cleaning the ROTIS pump is as follows (2-man procedure): a. Fill a clean plastic 55-gallon drum or a 5-gallon plastic pail with approximately 5 gallons of clean water. b. Carefully remove the ROTIS pump from the sealant barrel. Make sure that you unscrew the stainless steel pump-barrel adapter from the barrel and keep it in a safe place for future use. Also, reseal the sealant barrel by screwing the bung cap back onto the barrel. c. Place the ROTIS pump into the water-filled barrel or pail. Place the discharge end of the hose into another 5-gallon pail or sink. Set the counter on the pump to 50 clicks, connect the air supply to the pump, actuate the remote reset switch at the discharge end of the hose, and open the ball valve. (Warning make sure that someone is holding the pump tightly before pushing the remote reset switch. It is also a good idea to have someone hold the discharge end of the hose, because the wash water will be under a great deal of pressure and can wet a large area before it can be halted.) d. Wait until the pump has finished cycling and has stopped. If you run out of water the pump will start to cycle too fast for the counter to count down. In that case, in order to turn off the pump, the air supply must be manually disconnected or shut down. e. Once the pump has shut down, disconnect the air supply from the pump. f. Disconnect all four hoses (small yellow and black, the yellow air hose, and the black ¾-inch sealant hose) from the pump. Please note that there will be some water in the 3/4-inch black hose. g. Pull the pump out of the 55-gallon barrel or pail. h. Tilt the pump at a 45 degree angle, and while holding tightly, vigorously shake the water out of the pump body. Keep shaking the pump while holding it at a 45 degree angle until no more water comes out. If you have a problem shaking the pump, have someone press the ball check valve at the foot of the pump while another person holds the pump upright. i. It is also important that the water in the hose is also blown out. The hose can contain more than a gallon of water, and if the water is not removed, it can get into a tire or get re-circulated back into the drum, diluting the sealant. j. The water is blown out of the ¾-inch black sealant hose by using air from the pump end of the hose. Make sure that the ball valve at the discharge end of the hose is open and pointed in a safe direction. Continue blowing air through the hose until you see no more water exiting. k. If this is a rental return pump, please allow a minimum of 48 hours for the pumps and hose to dry out before packing them into their respective boxes. If the rental pump is returned without being cleaned, a $50.00 clean-out charge will be assessed. Dosage Table Introduction VIII