Use and Maintenance Manual M A T I C. Original manual

Transcription

1 Use and Maintenance Manual M A T I C Original manual

2 DICHIARAZIONE CE DI CONFORMITA CE DECLARATION OF CONFORMITY DECLARATION DE CONFORMITE CE CE - ÜBEREINSTIMMUNG Hofmann Megaplan GmbH Hauptstraße 59 A-5302 Henndorf Austria dichiara sotto la propria esclusiva responsabilità che il prodotto: declare on our own responsibility that the product: Déclare sous son propre responsabilité que le produit: erklärt unter ihrer eigenen Verantwortung, daß das Erzeugnis: Smontagomme auto Tyre Changer Démonte-pneus pour voitures Reifenmontiergerät für PKW Targhetta al quale questa dichiarazione si riferisce E CONFORME ALLE SEGUENTI DIRETTIVE: to which declaration refers is in conformity with the FOLLOWING DIRECTIVES: au quel cette déclaration se rapporte EST CONFORME AU DIRECTIVES SUIVANTES: darauf diese Erklärung Bezug nimmt, mit den folgenden Bestimmungen übereinstimmt: 98/37/CE - 91/368/CEE - 93/68/CEE /95/CE - 86/217/CEE 2004/108/CE - 87/404/CEE ed alle Norme: as well as to the following norms: ainsi qu aux normes suivantes: und folgender Vorschrift gemäß: EN EN Correggio, 15/10/2008 Il modello della presente dichiarazione è conforme a quanto previsto nella Norma EN The model of present declaration is in conformity with directive EN Le modèle de cette déclaration est conforme à la Norme EN Das Modell dieser Erklärung übereinstimmt mit der Bestimmung EN 45014

3 DICHIARAZIONE DI CONFORMITA RoHS RoHS DECLARATION OF CONFORMITY DECLARATION DE CONFORMITE RoHS RoHS - ÜBEREINSTIMMUNG Hofmann Megaplan GmbH Hauptstraße 59 A-5302 Henndorf Austria dichiara sotto la propria esclusiva responsabilità che il prodotto: declare on our own responsibility that the product: Déclare sous son propre responsabilité que le produit: erklärt unter ihrer eigenen Verantwortung, daß das Erzeugnis: Smontagomme Tyre Changer Démonte-pneus Reifenmontiergerät al quale questa dichiarazione si riferisce E CONFORME ALLA DIRETTIVA: to which declaration refers is in conformity with the FOLLOWING DIRECTIVE: au quel cette déclaration se rapporte EST CONFORME À LA DIRECTIVES SUIVANTES: darauf diese Erklärung Bezug nimmt, mit der folgenden Bestimmungen übereinstimmt: 2002/95/CE (RoHS) Lo smaltimento della stessa e dei suoi componenti dovrà avvenire secondo quanto previsto dalla Direttiva: Scrapping must be made in accordance with the following Directive: La mise à la ferraille de la machine et de ses composants doit être effectuée à la conformité aux Directive suivante: Verschrottung muß gemäß der folgenden Vorschrift durchgeführt werden: 2002/96/CE e/and/et/und 2003/108/CE (RAEE) e le disposizioni di Legge del Paese di destinazione della macchina/apparecchiatura. as well as with the national laws in force in the Country of Installation. ainsi qu aux lois nationales en vigueur dans le Pays de destination de la machine. sowie gemäß den in dem Installationsland geltenden Gesetzen. Correggio, 01/07/06 Nota: - Per le macchine/apparecchiature immesse sul mercato dopo il anche i ricambi non originali dovranno essere conformi alla direttiva 2002/95/CE (RoHS) Remarks: for all machines/appliances put in the market after 01/01/2006 any spare parts, including the non-original ones, must be in conformity with Directive 2002/95/CE (RoHS) Note: pour les machines mises sur le marché après le 01/01/2006 toutes les pièces détachées, inclus les pièces non d origine, devrons se conformer à la Directive 2002/95/CE (RoHS). Anm.: für alle Maschinen, die nach 1. Jan in den Markt eingeführt wurden, sollen alle Ersatzteile (inkl. die Nicht-Originalersatzteile) der Vorschrift 2002/95/CE (RoHS) entsprechen.

4 DICHIARAZIONE DI CONFORMITA RAEE RAEE DECLARATION OF CONFORMITY DECLARATION DE CONFORMITE RAEE RAEE - ÜBEREINSTIMMUNG Smontagomme Tyre Changer Démonte-pneus Reifenmontiergerät Hofmann Megaplan GmbH Hauptstraße 59 A-5302 Henndorf Austria dichiara sotto la propria esclusiva responsabilità che il prodotto: declare on our own responsibility that the product: Déclare sous son propre responsabilité que le produit: erklärt unter ihrer eigenen Verantwortung, daß das Erzeugnis: al quale questa dichiarazione si riferisce E CONFORME ALLA DIRETTIVA: to which declaration refers is in conformity with the FOLLOWING DIRECTIVE: au quel cette déclaration se rapporte EST CONFORME À LA DIRECTIVES SUIVANTES: darauf diese Erklärung Bezug nimmt, mit der folgenden Bestimmungen übereinstimmt: 2002/96/CE e 2003/108/CE (RAEE) Raccolta differenziata Specific garbage collection Collecte sélective getrennte Müllsammlung La presente macchina/apparecchiatura rientra nelle prescrizioni della Direttiva 2002/96/CE e 2003/108/CE (RAEE) e non può essere smaltita come rifiuto urbano generico ma attraverso raccolta separata; Il simbolo del bidone barrato riportato sul prodotto indica questa prescrizione. Lo smaltimento della stessa e dei suoi componenti dovrà avvenire secondo quanto previsto dalle Direttive 2002/96/CE e 2003/108/CE (RAEE) e le disposizioni di Legge del Paese di destinazione della macchina/apparecchiatura; il mancato rispetto della direttiva è sanzionabile secondo le disposizioni di Legge del Paese di dstinazione. L abbandono o smaltimento non corretto delle macchine/apparecchiature sottoposte alla Direttiva 2002/96/CE può provocare gravi danni all ambiente ed alle persone. Il costruttore è disponibile, ai sensi della Direttiva, allo smaltimento della macchina/apparecchiatura; per questo servizio contattare il costruttore o i rivenditori autorizzati secondo il Paese di destinazione della macchina/apparecchiatura. 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. Ce produit rentre dans les prescriptions des Directives 2002/96/CE et 2003/108/CE (RAEE) et il ne peut donc pas être mis à la ferraille comme du matériel générique mais à travers un circuit de collecte sélective; le symbole du «bidon barré» reproduit sur la machine se réfère à cette prescription. Le traitement de la machine et de ses composants devra se réaliser en conformité aux Directives 2002/96/CE et 2003/108/CE (RAEE) ainsi qu aux dispositions de Loi en vigueur dans le Pays de destination de la machine, le non-respect de la Directive est passible de sanctions par rapport aux Lois nationales du Pays de destination. L abandon ou un traitement erroné des produits sujets à la Directive 2002/96/CE peut provoquer de graves dégâts à l environnement. Le constructeur est disposé, aux termes de la Directive, à s occuper du traitement de la machine; pour ce service contacter le constructeur ou les revendeurs autorisés. Die vorliegende Maschine/Gerät fällt in den Vorschriften der 2002/96/CE Richtlinie, und kann nicht als allgemeiner Stadtmüll sondern durch getrennte Müllsammlung beseitigt werden; das Symbol mit der durchgestrichenen Mülltonne weist auf diese Vorschrift hin. Die Entsorgung des Gerätes und seiner Bestandteilen muss nach den 2002/96/CE und 2003/108/CE (RAEE) Richtlinien und nach den Vorschriften des Bestimmungslandes der Maschine/Gerätes erfolgen, die Nicht-Beachtung der Vorschrift ist sanktionierbar laut dem Gesetz des Bestimmungslandes Die unkorrekte Entsorgung oder Verlassen der zu der 2002/96/CE vorgelegenen Richtlinie Maschine/ Gerätes kann die Umwelt und die Personen schwer beschädigen. Gemäß der Richtlinie, steht der Hersteller für die Entsorgung der Maschine/Gerätes zur Verfügung; dazu setzen Sie sich mit dem Hersteller oder mit den berechtigten Händlern nach dem Bestimmungsortes der Maschine/Gerätes in Verbindung. Correggio, 01/07/06

5 INDE INTRODUCTION...7 DETAILS OF THE TYRE CHANGER _Part Identification _Description of the machine s controls _Danger warnings _General information _General safety instructions _Safety devices _Transport _Unpacking _Installation _Spaces required to position the machine _Positioning _Commissioning _Operational test _Identifying and checking the rim and tyre _Positioning the valve _Tyre classification _Clamps for conventional rims _Bead breaking _Demounting standard tyres _Mounting standard tyres _Demounting Run-Flat UHP tyres _Mounting Run-Flat UHP tyres _Articulated arm (optional) _Demounting _Mounting _Inflation _Machine supply...35 Optional accessories

6 19.0_Repositioning _Storage _Scrapping _Maintenance _General warnings _Routine maintenance _Oil treatment _General precautions _First Aid instructions _Disposing of old oil _Oil spillages or leakages _Technical specifications _Trouble shooting...42 Wiring diagrams...44 Pneumatic diagrams...46 Motor connection diagrams...49 Maintenance register

7 INTRODUCTION We thank you for purchasing one of our tyre changers, which are particularly suitable for mounting/demounting standard tyres and run flat tyres. The machine is manufactured exploiting the best of quality principles. To ensure correct operation and long life of the machine, all you need to do is follow these simple instructions, which shall be read and fully understood in every single part. DETAILS OF THE TYRE CHANGER When contacting our Service Department or when requesting spare parts, please provide a complete description of the Model of the tyre changer and its Serial Number. For the sake of simplicity and commodity, the details of your tyre changer are written in the space below. If the details given in this manual do not match those written on the nameplate of your tyre changer, those written on the nameplate are the ones to be considered valid. DETAILS OF THE MANUFACTURER: - Consult the Declaration of conformity and the data nameplate (fitted on the machine) NAMEPLATE DATA MANUFACTURER DATA This manual is an integral part of the machine. Before you use the tyre changer, read the warnings and instructions given in this manual carefully and thoroughly, because they provide important information on safe use and maintenance. Keep this manual with care for future consultation NOTE: some of the illustrations shown in this manual have been taken from pictures of prototypes. Consequently, some parts or components of the machines of standard production may differ from what is illustrated. 7

8 1.0_PART IDENTIFICATION Top bead breaking disc Inflation Articulatedarm (optional) Control panel Double tool Bottom bead breaking disc Lift Pedal controls 8

9 2.0_DESCRIPTION OF THE MACHINE S CONTROLS The pedal controls of the LIFT (N) are used to lift and lower the wheel. The pedal controls (L) are used to turn the spindle flange clockwise/anti-clockwise. The pedal controls (M) are used to move the flange carriage to the right and left. 1 The pedal control (N) is used to lift the tyre, once in position, from the bottom upright position to the top flat position on the flange and vice versa; press the right part of the pedal to lift the carriage and press the left part of the pedal to lower it. N L M 2 The pedal control (L) is used to turn the spindle flange clockwise/anti-clockwise, either at slow or fast speed. 3 The pedal control (M) is used to move the spindle flange carriage based on the size of the wheel. Press the right part of the pedal to move the spindle flange towards the tools and press the left part of the pedal to move it away. LASER POINTERS: they are used to facilitate the tyre mounting and demounting procedures. LASER 1: it is used to position the tools based on the diameter of the rim. (using pedal M) LASER 2: it is used to position the double tool based on the width of the rim (using the joystick) joystick M 9

10 Before you operate the bead breakers, set-up the machine by registering LASER POINTER 1 on the edge of the rim 1 MOVEMENT SELECTION PIN Y The top bead breaking disc is activated using lever (1) on the control panel. Move vertically upwards to raise the disc arm and move downwards to lower the disc arm, to be able to position it with precision compared to the tyre thanks to the laser pointer (1) on the rim edge. The bead breaking disc can work in two different ways, using the movement selection pin. Position the pin based on the process to be performed: ) Rim arch (for self-supporting Run-Flat and UHP with low profile) Y) Bead finding 2 Y The bottom bead breaking disc is activated using lever (2) on the control panel. Move vertically upwards to raise the disc arm and move downwards to lower the disc arm, to be able to position it with precision compared to the tyre thanks to the laser pointer 1 on the rim edge. The bead breaking disc can work in two different ways using the movement selection pin. Position the pin based on the process to be performed: Z) Rim arch (for self-supporting Run-Flat and UHP with low profile) ) Bead finding MOVEMENT SELECTION PIN Before you operate the lever (3), position the double tool correctly by registering LASER POINTER 2 on the edge of the rim 3 Move lever (3) horizontally to the left to move the double tool towards the work area and to the right to move it away from the work area. 10

11 Tool turned for the demounting phase: Move the joystick to the left from position (I) to (C) passing through (F) to move the double tool towards the wheel in the work area based on what function is required. C F I C F I Move the joystick towards positions (H) and (G) starting from position (I) to move the double tool vertically downwards (H) and upwards (G) to position it during the various tyre demounting and mounting phases. Move the joystick towards positions (E) and (D) starting from position (F) to move the double tool vertically downwards (E) and upwards (D) to position it during the various tyre demounting and mounting phases. Move the joystick towards positions (B) and (A) starting from position (C) to move the double tool vertically downwards (B) and upwards (A) to position it during the various tyre demounting and mounting phases. Selectable slow + fast movements Slow movements G A C B D F E I H 11

12 Tool turned for the mounting phase: In this position, the double tool is turned for the tyre mounting phase. When mounting the tyre, always register laser pointer (2) on the edge of the rim and position the joystick in the centre F. The bead presser is used to facilitate the demounting and mounting phases; it is optional on standard tyres but obligatory on Run-Flat and UHP tyres (low profile). Gauge Inflation lever The inflation control panel plus laser activator consists of 4 elements: the gauge, the inflation lever, the tyre deflation button and the switch for activating the laser pointers. Laser activation switch Deflation button 12

13 3.0_DANGER WARNINGS Cod Cod Laser + inflation contro Control panel Cod Cod Cod Cod Cod Cod Cod Cod Cod Cod Cod Cod Cod Pedal controls Cod Cod Cod Cod

14 4.0_GENERAL INFORMATION The tyre changer is designed to demount and mount tyres of cars and light vehicles with rims of 10 to 34 and maximum diameter of 1200 mm. The tyre changer is designed to demount and mount conventional tyres of cars, light industrial vehicles, tyres of new generation type self-supporting RUN-FLAT and low profile tyres (UHP) with steel and/or alloy rim, even of considerable dimensions. The tyre changer is NOT suitable for demounting inflated or dirty tyres, to straighten rims or to remove wheel bead wires, consequently all these procedures are FORBIDDEN. 5.0_GENERAL SAFETY INSTRUCTIONS The tyre changer is to be used exclusively by qualified and authorised personnel. A qualified operator is someone who has fully understood the instructions described in the use and maintenance manual supplied by the manufacturer, who has been specifically trained and who is aware of safety standards at the workplace. 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 abilities. For greater safety, operators shall wear health & 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 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 regulations. - make sure all operators are familiar with the machine and how to use it safely and correctly do not touch live parts or pressurised parts without first disconnecting the machine from the electrical mains and pneumatic power supply. - read and ensure full comprehension of the use and maintenance manual to be able to use the machine correctly and safely. - keep the use and maintenance manual with care in an easily accessible place so that it can be consulted whenever need be. The tyre changer may be used only and exclusively by duly trained and authorised experts. - People with disabilities are not allowed to use the tyre changer as far as they cannot operate this safely due to their disabilities. - Tampering or modifications to the equipment that are not authorised in advance by the manufacturer relieve the latter from all forms of liability with regard to damages deriving from or referable to such actions. - Removal or tampering with the safety devices provides grounds to immediately annul the warranty and involves violation of European Safety Standards. - The tyre changer is equipped with informative and warning adhesive plates that are designed and produced to last in time. If they should deteriorate the user may request replacement plates. IN THE CASE OF FIRE, USE POWDER ETINGUISHERS OR ALTERNATIVE CO 2 ETINGUISHERS TO PUT OUT FLAMES. 14

15 WATER Extinguisher FOAM Extinguisher POWDER Extiguisher CO 2 Extinguisher DRY Materials OK OK OK OK 6.0_SAFETY DEVICES FLAMMABLE Liquids ELECTRICAL Equipment NO OK OK OK NO NO OK OK The tyre changer is equipped with safety devices that are designed to guarantee the safety of the machine operator: - Pneumatic safety valve, arranged inside the machine that prevents the pressure from exceeding 4 bar during inflation. - Maximum pressure valve, fitted on the pneumatic circuit that limits the maximum pressure of the circuit to 10 bar - Maximum tank pressure valve, fitted on the tank to prevent the maximum pneumatic pressure from exceeding 11 bar (optional beak inflator 446/08) - Removal or tampering with the safety devices provides grounds to immediately annul the warranty and represents a breach of European Safety Standards. 7.0_TRANSPORT - The tyre changer is to be transported in its original packaging and kept in the position indicated on the actual packaging. - The packed machine is to be moved using a forklift truck of suitable load-bearing capacity, inserting the forks in the points indicated in the picture on page _UNPACKING Remove the wooden packaging structure and take the nylon covering off; remove the securing screws and take the machine off the original pallet using the dedicated hook to lift it with lifting equipment of suitable load-bearing capacity (see picture on page 15). Packaging elements must not be left at children s reach because they could be dangerous. Put the packaging material in dedicated waste collection areas if they are pollutant or non-biodegradable. NB. Seeing as the more delicate parts are covered with special rust inhibiting oil, feasible traces of dirt are not due to negligence but are just leftovers of this oil. Clean if necessary. Net weight: 545 Kg. Gross weight: 608 Kg. 15

16 9.0 INSTALLATION 9.1 Spaces required to position the machine When choosing the place of installation, remember to observe current standards on safety at the workplace. - The tyre changer needs to be connected to the electrical mains and to the compressed air supply. The machine should therefore be installed near such energy sources. - Furthermore, the chosen place of installation must avail of the spaces indicated in pictures 4-4/A at least, so that all of its parts are able to work without any restrictions. If the tyre changer is the type with an electric motor, it is forbidden to use it in an explosive environment unless it is a version specifically designed for such purpose. Lifting point 700 mm 700 mm 700 mm Fig. 4a 700 mm Fig _Positioning Position the tyre changer on flat, smooth and non-slippery ground of suitable load-bearing capacity. Position the tyre changer in the chosen workplace using the dedicated hook to lift it, as illustrated in picture 4a Use lifting equipment of suitable load-bearing capacity that is able to take the weight of the tyre changer (at least 560 Kg.). The machine must not necessarily be anchored to the ground, but if you prefer to do so, drill 100 mm holes in the ground by the 4 holes of the machine bed using a 10-mm bit for concrete of suitable length. Insert suitable metal anchor dowels in the holes drilled and secure firmly. If the tyre changer is installed outdoors, it must be sheltered by an appropriate structure to protect it against atmospheric events. The place where the tyre changer is installed must be equipped with an electrical safety system with efficient earthing and also supplied with appropriate differential 16A circuit breaker. The place of installation must avail of a pneumatic connection with minimum working pressure of 8 bar. 16

17 9.3_Commissioning Before you connect the machine electrically, check the nameplate fitted on it to make sure the electrical power supply to which it will be connected matches the electrical arrangement of the manufacturer. Work on the electrical system, even if trivial, must be carried out by professionally qualified personnel. The manufacturer is not liable for machine damages caused by the incorrect electrical connection of the same, different to the instructions herein. When moving the machine around to position it initially or if it is moved in the future to a different location, it must be disconnected from the electrical and pneumatic power sources. - Connect the machine to the electrical mains, which must have line fuses and an efficient earthing system pursuant to current standards. It must also be connected to an automatic differential circuit breaker calibrated at 16 A. NOTE: If the machine is supplied without an electrical plug, the user shall fit one (at least 16A) that is suitable for the voltage of the machine and that complies with current standards. - Connect the machine to the compressed air system using the fitting on the lubricator at the back of the machine. Pneumatic fitting Inflation fitting 17

18 10.0_OPERATIONAL TEST Inflation lever R joystick Q Laser activation switch P O M N L - Press the right part of the pedal (N) and the LIFT (P) should rise. Press the left part of the pedal and the LIFT should lower. - Press the right part of the pedal (L) and the spindle flange (R) should turn clockwise. Press the left part of the pedal (L) and the spindle flange (O) should turn anti-clockwise. - Press the right part of the pedal (M) and the flange carriage (O) should move to the right. Press the left part of the pedal and the carriage should move in the opposite direction. NB: If the flange should turn in the opposite direction to that indicated, you need to invert two wires on the plug, if it is three-phase. - Move the joystick in the various positions and the double tool (Q) will move to the various work positions (Ref. page 10) - Operate the lever (3) horizontally to the left and the double tool will move out at fast speed to the work zone (Q). Operate the lever to the right and the tool will move back in at fast speed to the stand-by zone. - Operate the levers (1 and 2) to move the top and bottom bead breaking discs; move up to raise the discs and down to lower them (ref. page 9) - Turn the laser activation switch ON to activate the 2 laser pointers (Laser1 and Laser2) and turn it OFF to de-activate them. All the procedures are to be performed without using a tyre, making sure that no other parts of the machine interfere with the movements when performing them. 18

19 11.0_IDENTIFYING AND CHECKING THE RIM AND TYRE Before you start to demount the tyre, it is of CRUCIAL IMPORTANCE to identify the measurements of the rim and the tyre. Also make sure neither is damaged. ATTENTION: These procedures are very important and are to be performed to reduce risks of the tyre bursting when re-mounting the tyre on the rim and inflating it. All rims bear an indication of their diameter, width, number of humps etc. If we take the picture below as an example, you can see that: Indication example 8Jx14H2 A= 8 Nominal width of the rim in inches (1 inch=25.4mm) B = J Size of the flange C = 15 Nominal diameter of the rim D = H2 It indicates if there is a double hump (anti bead removing edge) A B C D 8Jx15H2 The tyre bears a considerable amount of details, among which are the dimensions, type and maximum speed. Ad es. 205/65 R 15 91H TL A = 205 indicates the width of the tyre, in other words the distance between the sides expressed in millimetres. A B C D E F G B = 65 is the ratio expressed in percentage between the height of the section and its width. C = R means that the next number concerns the diameter. D = 15 indicates the keying diameter in inches (diameter of wheel), which must be the same as the rim. E = 91 is the index of the maximum load born for each wheel. F = H is the maximum admitted speed of the tyre (H= 210Km/h). G = TL means that the tyre is Tubeless. ATTENTION: It is strictly forbidden to mount tyres on rims that have different parameters (diameter and width). It is also forbidden to mount tyres with different dimensions compared to those stated in the logbook. 19

20 12.0_POSITIONING THE VALVE Fig. 6 shows a rim in the form of a clock, so that, following the various processing phases described hereafter, (chapter entitled Mounting and Demounting), you can position the valve and its sensor correctly so as not to damage them. ATTENTION: To avoid damaging the valve and the pressure sensor, if the latter is installed, you must always arrange the valve in the position indicated, following the instructions when mounting and demounting the tyre. fig _TYRE CLASSIFICATION LOW PROFILE tyres (UHP) are those in which the height (H) and the width (C) have a ratio lower than 0.5 (aspect ratio; i.e. the low profile series 45 has 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. RUN-FLAT tyres are those which, even when they have no internal pressure, allow you to continue to drive the vehicle for a preset number of miles and at a preset speed. These parameters change from one manufacturer to another. The market currently offers 2 different types of RUN-FLAT tyres: - Those with REINFORCED SIDE (SELF-SUPPORTING) where, thanks to a different mix and a reinforced structure, the shoulder of the tyre is able to bear the weight of the vehicle even when the pressure in the tyre is zero. - Those with INTERNAL SUPPORT have a ring inside the rim that bears the side 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). The tyre changer is able to handle all types of LOW PROFILE (UHP) and all types of RUN-FLAT tyres with REINFOR- CED SIDE; for other types, refer to the specific instructions of the dedicated accessories, if available. The mounting and demounting procedure is the same, be it a RUN-FLAT tyre with REINFORCED SIDE (SELF-SUP- PORTING) or a LOW PROFILE tyre (UHP). ATTENTION: It is of crucial importance to follow the instructions very carefully in order to avoid irrepairable damages to the tyre, which could compromise the vehicle s safety. All tyres that are not within the categories stated above are to be considered as standard tyres. 20

21 14.0_CLAMPS FOR CONVENTIONAL RIMS A conventional rim is a wheel of a vehicle with rim of steel or light aluminium alloy, with a drop centre hole and channel near the outer edge of the rim. For other types of rims, please consult the chapters on the accessories available on request. - Using a special tool, remove any counterweights on the rim, being particularly careful not to damage the rim. - Make sure none of the tools are in the work zone of the LIFT so that it is free to position the wheel correctly. - Position the wheel on the spindle using the LIFT, as follows: - Arrange the wheel on the left roller of the machine, vertically with the external edge of the tyre facing the left. - Using the lifting pedal, raise the platform and the wheel up to the flat position and align the drop centre hole of the wheel with the spindle flange. - Lower the LIFT and centre the driving pin. For rather wide wheels (wider than 24 ) or when using the optional flange for back-to-front wheels, you may need to widen the plastic rollers of the lift and/or change the tilt of the rollers before lifting. Driving pin Spindle flange LIFT LIFT pedal Extending rollers 21

22 There is a driving pin on the spindle flange that is to be fitted in one of the rim clamping holes. Position the ring nut hub and the appropriate nose on the spindle flange in relation to the diameter of the drop centre hole. Proceed as follows to couple the hub correctly: - Turn the hub clockwise by hand until you find the exact coupling position. Press the hub and turn clockwise by 90 as far as it will go. - Release the pin and make sure it raises by approximately 10mm, otherwise turn it slightly clockwise and/or anti-clockwise forcing the pin upwards so that it lifts. - Position the nose in contact with the rim, perfectly centred with the drop centre hole. The nose has a split that must match-up (if necessary) with the driving pin. - Tighten the ring nut so that it moves up to the nose and continue to tighten so that the wheel is pushed firmly on the flange of the spindle. ATTENTION: Before you start any work on the wheel, make sure it is clamped perfectly on the spindle. 14.1_BEAD BREAKING DEFLATE the tyre completely before starting any work. - Using an appropriate tool, remove any counterweights from the rim, being very careful not to damage it. ATTENTION: Do NOT start any work on the wheel before the tyre has been completely deflated. - Before starting any procedures, make sure there is no pressure sensor, otherwise check its state of efficiency using a special tester. 22

23 - Using the flange carriage movement pedal (M), put the wheel in the work position so that the laser pointer at the top matches-up with the edge of the rim (phase 1). Phase 1 - Choose the appropriate bead breaking method and change the pin on the bead breaking arm if necessary (both at the top and the bottom, see page 9). - Turn the spindle flange until the valve reaches the 2 o clock position. M - The bead breaking disc should be approximately 5mm from the outer edge of the rim. - Lower the bead breaking disc until it touches the tyre. - At this stage, turn clockwise. NB: The spindle flange can turn at 2 different speeds, which the operator may choose on a case-to-case basis for the most suitable working requirements. Phase 2 - When turning, push the bead breaking disc downwards (if you use the bottom bead breaker, push upwards) to penetrate the internal part of the rim, performing the type of bead breaking method chosen previously. If there is a pressure sensor, be careful not to knock or damage it accidentally. - Once the bead breaking disc has created enough space, start to lubricate carefully, both on the internal part of the rim and on the bead of the tyre; use a specific lubricant for tyres to do this. (phase 2) M If there is a pressure sensor, make sure it does not come into contact with the lubricant. - Once the tyre has come off the rim, put the bead breaking disc back in its initial position (out of the work zone). - Using the bottom bead breaking disc, repeat the procedures, putting the bottom disc in contact with the tyre and remove the rim (phase 3) Note: for this type of process, you can get a better view of the bottom exploiting the mirror fitted on the machine to position the bead breaking disc correctly. Phase 3 ATTENTION: While removing the rim, just press on the bead and never on the side of the tyre. 23

24 14.2_DEMOUNTING STANDARD TYRES - Proceed as follows to demount the tyre: - Turn the double tool so that the hook-shaped part of the tool is in the work position. - Turn the spindle until the valve is in the 12 o clock position. NOTE: If the wheel moves out of position when removing the rim, put it back in the work position exploiting the laser pointers 1 (the laser 1 must match-up with the edge of the rim picture 10). 3 G A C B D F E I H - Put the joystick in position (I) then raise (G) or lower (H) so that the hook tool is right above the top edge of the rim. - Move lever (3) to the left to position the double tool in the work zone. Fig. 10 To avoid damaging the valve and/or the sensor, move it to the 12 o clock position before moving the tool towards the channel. - Start to insert the tool in the tyre (picture 11 joystick position H) and possibly exploit the top bead breaking disc so as not to force the side of the tyre excessively. Fig. 11 Fig Once the tool reaches the channel (picture 12), move the tool towards the inner part by moving the joystick from (I) to (C). 24

25 - Remove the bead breaking disc, if it was used, by moving upwards and start to turn clockwise until the bead hooks on the tool (picture 11). Fig Move the tool towards the outer part of the rim, moving the joystick from (C) to (I) (picture 11). To avoid damaging the valve and/or pressure sensor (if installed), turn the spindle until the valve is in the 11 o clock position. Raise the tool until laser pointer (2) situated above it is positioned on the edge of the rim; at this stage, move the tool to the central position by moving the joystick from (I) to (F). - Make sure the whole circumference of the tyre has come off the rim but is still inside the rim s channel. If not, use the mobile bead presser, positioned at 180 compared to the tool, to obtain this condition (picture 13a). - If necessary, lift the tyre by about mm with the bottom bead breaking disc to facilitate demounting (picture 14). Fig. 13a ATTENTION: In these last phases, work very carefully without straining the tyre excessively. 3 G A C B D F E I H Fig. 14 Start turning clockwise and continue until the first bead has been completely demounted (picture 13). - Manually unhook the tyre from the hook (picture 15). - Move the tool to take it out of the work area by moving lever (3) from the left to the right. - Turn the spindle until the valve is in the 1 o clock position. - Raise the bottom bead breaking disc until it is approximately 10 mm beyond the upper edge of the rim (picture 14a). NOTE: To make this job easier, raise the tyre manually in the 6-7 o clock position. Fig. 14a - Turn the spindle clockwise until the tyre comes completely off the rim. NOTE: To make the job easier, raise the bottom part of the tyre to approximately the 2 o clock position and accompany it while it turns, and turn anti-clockwise if necessary. Fig Check the state of the pressure sensor, if there is one, and replace it if it is damaged. - Upon completion, move the bottom bead breaking disc out of the work zone. 25

26 14.3_MOUNTING STANDARD TYRES - Check the rim and the tyre, as described in the specific section of this manual. - If the rim has been removed, clamp the wheel on the spindle flange, as described in the WHEEL CLAMPING section. NOTE: To ensure safety, you are recommended to use a specific tool to replace the valve. - Turn the double tool so that the shoe-shaped part of the tool moves to the work position. ATTENTION: In these last phases, work very carefully without straining the tyre excessively. - 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 thickness of at least 30 mm. (picture 16) - Position the tyre horizontally on the rim, slightly tilted downwards to the 3 o clock position. (picture 17) Fig Lower the top bead breaking disc until it lowers the upper bead of the tyre by approximately 30 mm. - Manually press the tyre in the 5 o clock position and keep pressing it until it turns to the 9 o clock position, so that the tyre does not lift while it turns; continue to turn the tyre until the lower bead has fitted completely in place. ATTENTION: Make sure the tyre and the rim move together as one. - Raise the top bead breaking disc and turn the spindle to position the valve roughly in the 4 o clock position. - Position the tyre slightly tilted to the 11 o clock position to make it easier to position the mounting tool. - Move the joystick to position (F) then raise (D) or lower (E) so that laser pointer (2) matches-up with the edge of the rim. - Move the tool to the work position, moving lever (3) from right to left. Make sure the bead of the tyre rests perfectly on the shoe-shaped part of the tool. Fig Press on the side of the tyre in the 3 o clock position until the bead is forced to the height of the channel. - Start turning, accompanying the movement with your hand until the upper bead has fitted completely in place. Make sure the upper bead does not sit between the rim and the bead breaking disc. NOTE: If you have any difficulties in accompanying the bead by hand, you can always use the mobile bead presser in the 3 o clock position (picture 18) 26 Fig. 18

27 15.0_DEMOUNTING RUN-FLAT (Self-supporting) and UHP (Low profile) TYRES - Proceed as follows to demount the tyre: - Turn the double tool to move the hook-shaped part of the tool to the work position. - Turn the spindle until the valve is in the 12 o clock position. NOTE: If the wheel moves during the bead breaking phase, put it back in the work position exploiting laser pointer (1) (laser pointer (1) must matchup with the edge of the rim picture 19). 3 G A C B D F E I H - Move the joystick to position (I) then raise (G) or lower (H) to move the hook-shaped tool completely over the upper edge of the wheel. - Move lever (3) to the left to position the double tool in the work zone. To avoid damaging the valve and/or the sensor, move it to the 12 o clock position before moving the tool towards the channel Fig Start inserting the tool inside the tyre with the joystick in position (H) and exploit the top bead breaking disc to avoid forcing the side of the tyre excessively (fig.19). - Once the tool reaches the channel (picture 20), move the tool towards the inside by moving the joystick from position (I) to (C) Fig

28 - If you used the bead breaking disc, remove it by raising it and start turning clockwise until the bead hooks on the tool (picture 20a). - Move the tool towards the outer part of the rim, by moving the joystick from position (C) to (I). To avoid damaging the valve and/or the pressure sensor (if installed), turn the spindle until the valve is in the 11 o clock position. Raise the tool until laser pointer (2) situated over it is positioned on the edge of the rim; at this stage, move the tool to the central position by moving the joystick from (I) to (F). - Once you have created the space required, insert the plastic lever to make it easier to demount the tyre. - Make sure the whole circumference of the tyre has come off and is still sitting in the channel of the rim. If not, use the mobile bead presser, positioned at 180 compared to the tool, to obtain this condition. - If necessary, raise the tyre by approximately mm upwards using the bottom bead breaking disc to make it easier to demount (picture 21). Fig. 20a Fig. 21 ATTENTION: Be very careful in these last phases to avoid straining the side of the tyre excessively. 3 G Fig. 22 A C B D F E I H - Start turning clockwise and continue until the first bead has come off completely (picture 22). - Manually take the tyre off the hook (picture 24). - Move the tool back away from the work position by moving lever (3) from left to right. - Turn the spindle until the valve is in the 1 o clock position. - Raise the bottom bead breaking disc until it is approximately 10mm beyond the top edge of the rim. NOTE: To make this job easier, lift the tyre manually in the 6-7 o clock position and insert the plastic lever (picture 23). Fig

29 - Turn the spindle clockwise until the tyre comes completely off the rim (picture 23) NOTE: To make the job easier, raise the bottom part of the tyre roughly to the 2 o clock position and accompany it while it turns, and turn anti-clockwise if necessary. NB = the rim and the tyre must turn together as one. - If there is a pressure sensor, check its state and replace it if it is damaged. Fig Upon completion, move the bottom bead breaking disc away from the work zone. 15.1_MOUNTING RUN-FLAT (self-supporting) UHP (Low profile) TYRES - Check the rim and the tyre, as described in the specific section of this manual. - If the rim has been removed, clamp the wheel on the spindle flange, as described in the WHEEL CLAMPING section. NOTE: To ensure safety, you are recommended to use a specific tool to replace the valve. - Turn the double tool to move the shoe-shaped part of the tool to the work position. - 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 thickness of at least 30 mm. (picture 23). If there is a sensor, do not let it come into contact with the lubricant. Fig Position the tyre horizontally on the rim, slightly tilted downwards to approximately the 3 o clock position. - Lower the top bead breaking disc until it lowers the upper bead of the tyre by approximately 30 mm. Also lubricate with grease the whole upper side of the tyre. - Press the tyre manually in the 5 o clock position and keep pressing it until it turns to the 9 o clock position so that the tyre does not lift while it turns; continue to turn until the lower bead has fitted completely in place. Fig. 26 ATTENTION: Make sure the tyre and the rim move together as one. - Raise the top bead breaking disc and turn the spindle to move the valve to approximately the 4 o clock position. - Position the tyre slightly tilted to the 11 o clock position to make it easier to position the mounting tool. - Move the joystick to position (F) then raise (D) or lower (E) so that the laser pointer 2 matches-up with the edge of the rim. - Move the tool to the work position by moving lever (3) from the right to the left. Fig

30 - Insert and secure the clamp with the rubber protector suitable for the type of rim ( iron rim alloy rim alloy rim with protruding spokes). Fig If necessary, exploit the top disc positioned near the clamp (picture 27). - The clamp and its protector must be positioned before the valve (picture 27) - Position the bead breaking disc at the height of the channel, turn slightly and insert the bead presser between the disc and the clamp and press until it reaches the channel (picture 28). Make sure the bead of the tyre rests on the shoe-shaped part of the tool. - Start turning, when the clamp is roughly in the 5 o clock position, make sure the whole bead within this section is right inside the channel. Fig If this is not the case, which is an indispensable condition to be able to mount the tyre correctly, use the mobile bead presser to push the bead in the channel, pressing roughly in the 3 o clock position, and where necessary, to insert the bead of the tyre the channel of the rim. (picture 29) ATTENTION: In these last phases, work very carefully to avoid straining the side of the tyre excessively. - Start turning again until the tyre has fitted completely in place. Fig Remove the clamp and the protector, pushing the bead breaking disc to move the double tool out of the work zone and also using the mobile bead presser and the top bead breaking disc (picture 30). NOTE: When working with rims with diameter larger than 22 you need to position the bottom bead breaking disc near the edge of the bottom rim to make it easier to mount the second bead. This will prevent the pressure at the top from pushing the bead out of the rim from the bottom part. NB: This is not only necessary when working on large diameters, but may also be recommended even for rims with smaller diameter. 30

31 16.0_ARTICULATED ARM (OPTIONAL) This accessory is not designed to demount and mount RUN-FLAT (self-supporting) and UHP (low profile) tyres; consult the specific sections for these types of tyres. With this accessory, it is not indispensable to move the rim in the correct position by matching the laser pointer (1) up with the edge of the rim. It is on the other hand indispensable to move the double tool away from the work position, moving lever (3) to the right and as low as possible. The rim clamping and bead breaking procedures are performed in the same way (see chapter 15.1 and chapter 15.2 of this manual). Before you start any work, take the old balancing counterweights off the rim and make sure the tyre is deflated. Make sure the wheel is firmly secured to the spindle flange 16.1_DEMOUNTING Lower the operating arm using its handle so that the turret embraces the upper edge of the rim. Do not wear necklaces, bracelets, baggy clothing or hanging items when standing near moving components, as they could be dangerous if they get caught up. Keep hands and other parts of the body as far away as possible from the turret when the spindle is turning to avoid getting crushed. 31

32 With the lever (T), inserted between the bead and the front part of the turret (picture 31), turn it to move the bead of the tyre over the turret itself (picture 32). When making this movement, be careful not to accidentally knock your hand or the lever against the blocking pin or ring nut. NB: To avoid damaging the inner tube, if there is one, you are recommended to perform this procedure with the valve approximately 10 cm. to the right of the turret. T Keeping the lever in this position, turn the spindle flange clockwise, by pressing the pedal (L) until the tyre comes right off the rim. To remove the inner tube, if there is one, raise the arm and take it out. Repeat the procedures for the second bead. Raise the arm again and take the tyre off. Fig. 32 T Fig. 31 ATTENTION: It is important to check the following before starting to mount the tyre to avoid risks of the tyre bursting during inflation: Check visually and touch the tyre to make sure there are no defects and that the ply is not damaged. Make sure the rim is not dented or deformed. Especially for alloy rims, dints often cause minute internal fractures that cannot be seen by the naked eye but that could compromise the solidity of the rim and could consequently be dangerous in the inflation phase. Make sure the diameter and the width of the rim are identical. Do not fit tyres on rims unless you are able to establish their diameters exactly Fig. 34 Fig. 35 T L 32

33 16.2_MOUNTING Lubricate with special grease and meticulously over the whole internal surface of the rim and the beads of the tyre, both externally and internally, right around the circumference, for a thickness of at least 30 mm. (picture 36) Put the tyre on the rim and tilt it downwards to approximately the 11 o clock position to make it easier to position the turret. Lower the operating arm using its handle so that the turret embraces the upper edge of the rim. Get hold of the tyre so that the bead passes under the front part of the turret and rests on the edge of the rear part of the turret itself (picture 37). Press with your hands and accompany the bead of the tyre in the channel of the rim, pressing the pedal (L) to turn the self-centring chuck clockwise right around the circumference of the rim (picture 37). Fig. 36 Fig. 37 Keep your hands and other parts of the body as far away as possible from the turret when the self-centring chuck is turning to avoid getting crushed. Insert the inner tube, if there is one, and repeat the same procedures to mount the second bead of the tyre (picture 38). Fig. 38 NOTE: If you have difficulties in these procedures in manually accompanying the bead, you can always use the top bead breaking disc and the bead presser positioned in the 3 o clock position to perform the procedure correctly (picture 39). NOTE: Both mounting and demounting procedures are to be carried out by turning the spindle clockwise. The anti-clockwise turning direction is used just to make up for any operator mistakes. Fig

34 17.0_INFLATION Tyres are to be inflated with utmost caution. Strictly follow the instructions hereafter because the tyre changer is NOT designed and manufactured to safeguard the user (nor anybody standing near the machine) if the tyre should accidentally burst. 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 are the same size. Also check the state of wear of the tyre and the rim to make sure there are no defects before starting to inflate. Inflate the tyre with short blasts of air and check the pressure frequently while inflating. All our tyre changers are automatically limited to an inflation pressure of 4.2 bar (61 PSI) N E V E R E C E E D T H E P R E S S U R E R E C O M M E N D E D B Y T H E M A N U F A C T U R E R W H A T E V E R T H E C A S E Keep hands and body as far away as possible from the tyre during inflation. Connect the fitting of the gun to the tyre valve. Make sure the rim and the tyre have the same diameter again. Make sure the rim and tyre are sufficiently lubricated; lubricate if necessary. Press and release the gun trigger 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 manufacturer. Always inflate in short blasts and keep checking the pressure while doing so. 34

35 18.0_MACHINE SUPPLY Standard supply OPTIONAL ACCESSORIES Flange FRU/345 C SPECIAL (for clamping rims without drop centre hole) The flange FRU/345 C SPECIAL can be used on all wheels with any number of clamping holes. Fit the flange on the spindle making sure to position it carefully, securing it with the 2 knobs supplied. Unscrew the securing nuts. Position the pins based on the number of holes on the rim, inserting the driving pin in the slot and the securing screw in the threaded hole with the number desired. NB: The pin with the yellow screw must never be removed. Take the gauge supplied with the machine and measure the centre distance of 2 holes and block this measurement on the gauge. Turn the pins of the flange so that the centre distance matches the measurement made earlier on the rim. Tighten the securing screws of the pins. Insert the wheel, matching up the clamping holes with the threaded pins, position and tighten the wheel securing nuts. 35

36 Flange FPM/345 (for clamping rims with back-to-front channel, in other words, rims with the channels opposite the flanging of the rim) The flange FPM/345 can be used on all wheels with any number of clamping holes. Select the pins of the shape and length required and secure them on the connecting rods. Secure the flange on the spindle, making sure to position it carefully and secure it with the 2 knobs supplied. Position the pins based on the number of holes on the rim, inserting the driving pin in the slot and the securing screw in the threaded hole in the number desired. NB: The pin with the yellow screw must never be removed. Take the gauge supplied and measure the centre distance of 2 holes and block this measurement on the gauge. Turn the pins of the flange to match-up the centre distance with the measurement made earlier on the rim. Tighten the securing screws of the pins. Insert the wheel, matching-up the clamping holes with the threaded pins, positioned with the flange facing downwards, tighten with the pin and nose. 36

37 NB.: The flange FPM 345 can be used to clamp the wheels without using the nose. Position the wheel on the spindle, as described in the section entitled CLAMPING STANDARD WHEELS, position the flange on the wheel, matching-up the pins with the securing holes, avoiding those where the driving pin is already inserted, then tighten with the pin and nose. LT TRUCK NOSES for clamping rims with drop centre hole larger than Ø120 mm. Secure the flange on the spindle, making sure to position it carefully and secure it with the 2 knobs supplied. Insert the wheel, matching-up the driving pin with a hole, position and secure with the pin and nose. 37