The BOSS INSTRUCTIONS FOR USE AND MAINTENANCE ed. 10/04 Cod. 3013954
DICHIARAZIONE CE DI CONFORMITA' CE DECLARA ARATION OF CONFORMITY DECLARA ARATION DE CONFORMITE CE CE - ÜBEREINSTIMMUNG GIULIANO S.p.A. - Via Guerrieri, 6-42015 Correggio (RE) ITALY 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 AUX DIRECTIVES SUIVANTES: darauf diese Erklärung Bezug nimmt, mit den folgenden Bestimmungen übereinstimmt: 98/37/CEE - 91/368/CEE - 93/68/CEE - 89/336/CEE - 86/217/CEE - 87/404/CEE - 73/23/CEE - EN 91/263/CEE - EN 92/31/CEE - EN 93/97/CEE - EN 98/13/CEE D.P.R. nr. 459 DEL 24/07/96 ed alle Norme: as well as to the following norms: ainsi qu aux normes suivantes: und folgender Vorschrift gemäß: EN 292 - EN 60204-1 Correggio, 01/09/2004 GIULIANO S.p.A Il Presidente G. Maselli Il modello della presente dichiarazione è conforme a quanto previsto nella Norma EN 45014 The model of present declaration is in conformity with directive EN 45014 Le modèle de cette déclaration est conforme à la Norme EN 45014 Das Modell dieser Erklärung übereinstimmt mit der Bestimmung EN 45014 2
Contents 1. INTRODUCTION Page 4 2. DESCRIPTION OF THE MACHINE Page 5 2.1 General description Page 5 2.2 Mobile elements description Page 6 2.3 Stickers Page 7 3. OUTFIT Page 8 4. GENERAL INFORMATION Page 9 4.1 Intended use Page 9 4.2 General safety rules Page 9 5. TRANSPORT Page 9 6. UNPACKING Page 10 7. INSTALLATION Page 10 7.1 Space required Page 10 7.2 Positioning Page 11 7.3 Setting at work Page 11 7.4 Functioning tests Page 13 8. USE Page 16 8.1 Use of the scale bars Page 16 8.2 Rim clamping Page 17 8.3 Standard tyres bead breaking Page 20 8.4 Standard tyres removing operation Page 21 8.5 Standard tyres mounting operation Page 24 8.6 Tools replacement Page 27 8.7 PAX System tyres removing operation Page 28 8.8 PAX System tyres mounting operation Page 30 9. INFLATION Page 34 10. RESITING Page 35 11. STORAGE Page 35 12. SCRAPPING Page 35 13. MAINTENANCE Page 36 14. TECHNICAL FEATURES Page 37 15. DIAGRAMS Page 38 16. RESERVED FOR AUTHORIZED TECHNICIANS Page 50 3
1. INTRODUCTION Thank you for having chosen The BOSS, the smart station for mounting/removing operations of standard, run flat and PAX System tyres. The machine has been constructed to the best quality principles. For the best efficiency and a long working life simply follow the simple instructions contained in this guide, which must be read and understood thoroughly before use. TYRE-CHANGER IDENTIFICATION Aid the after-sales service by always specifying MODEL and SERIAL NUMBER of your tyre-changer, whose data are given below. In case of discrepancies between the data in this manual and those on the lift nameplate, the nameplate is to be considered as correct. MANUFACTURER: ADDRESS: GIULIANO S.p.A. Via Guerrieri, 6-42018 Correggio (RE) - ITALY Tel. 0522-731.111 / Fax 0522-633.109 - P.O. Box 58 NAMEPLATE DATA the BOSS The present guide is an integral part of the product. Before using your tyre-changer, read all the instructions carefully, since they provide important information concerning safety at work and maintenance. Keep this guide in a safe place and consult it whenever in doubt. Attention: some of the instructions contained in this guide are made by pictures of prototypes. Some parts of the standard production can therefore differ from what illustrated. 4
2. DESCRIPTION OF THE MACHINE 2.1_General description 37 30 32 31 34 1. Wheel Lift lifting control 2. Wheel Lift lowering control 3. Rim clamping on flange 4. Rim releasing from flange 5. Chuck lifting control 6. Chuck lowering control 7. Mobile tool (peak) pulling out 8. Mobile tool (peak) return 9. Mounting/removing tool leftward stroke 10. Mounting/removing tool rightward stroke 11. Mounting tool manual left positioning during removing phase 12. Mounting tool manual right positioning during removing phase 13. Left bead breaking tool leftward stroke 14. Left bead breaking tool rightward stroke 15. Right bead breaking tool leftward stroke 16. Right bead breaking tool rightward stroke 17. STOP button: immediate stop of automatic functions; (option) if pressed for more than one second it will stop pump motor (pump stand-by) 18. Hydraulic speed selection (low / intermediate / high) 19. ON LED signalling the machine is running 20. LED signalling an error in execution 33 35 Fig.1 30. LEFT bead breaking tool 31. RIGHT bead breaking tool 32. Tyre mounting/removing tool 33. Chuck rotation control pedal 34. Self-centering chuck for wheel locking 35. Wheel Lift 36. Tool-holding stand 37. Inflating gauge 36 F1. Automatic pulling out of tyre bead with stop of mounting tool in working position for removing phase F2. Mounting tool automatic moving to working position on inner bead. F3. Mounting tool repositioning for bead pulling out repetition. F4. Mounting tool automatic moving to working position on outer bead. 5
2.2_Mobile elements description A. Left bead breaking disk stroke controls (right/left) B. Right bead breaking disk stroke controls (right/left) C1. Tool stroke controls (right/left) C2. Manual pulling out of 1 bead D. Peak (pulling out / recovery) controls. E. Lift (lifting / lowering) controls F. Chuck (lifting / lowering) controls G. Wheel (clamping / releasing) controls 6
2.3_ Stickers Cod. 3005410 Cod. 3013839 Cod.3001104 Cod. 3013574 Cod.3025916 Fig.2 Cod. 3000961 7
3. OUTFIT Standard Outfit Optional accessories for PAX System Tires 58 Optional accessories for reverse mounted rims Optional accessories for oversize rims Fig.3 30. LEFT Bead-breaking tool for standard tyres 31. RIGHT Bead-breaking tool for standard tyres 40. Plastic band for PAX System tyres removing operation 43. Locking flange for reverse mounted special rims 44. Centering cone with locking ring nut and anti-slip pin (Ø14) for reverse mounted special rims 45. Centering cone (43-113 mm.) with locking ring nut 46. Bead pressing clamp for standard tyres 47. Shaped support plate for PAX System tyres mounting on special profiled rims 48. Spring support plate for PAX System tyres mounting 49. Bent lever for PAX System tyres mounting 50. Special lever for PAX System tyres removal 51. Roller tool for PAX System tyres 52. Disk+roller tool for PAX System tyres 53. Brush 54. Grease cup 55. Oversize centering cone (87-186 mm.) (ex. for wheels of small vans or with larger central hole) 56. Oversize anti-slip pin Ø16 for reverse mounted special rims 57. Flange for oversize centering cone (ex. for wheels of small vans or with larger central hole) 58. Anti-slip pin of right bead breaking arm (used with tool 52) 8
4. GENERAL INFORMATION 4.1_Intended use. The BOSS has been studied and manufactured expressly for mounting/removing operations of standard, run flat and Pax System tyres. Any other use is to be considered improper and thus irrational In particular, the constructor cannot be held responsible for any damage or injury caused by an improper use. 4.2_General SAFETY rules. The machine may only be used by technical staff, previously authorized and trained. Any tampering or modification, if not previously authorized by the constructor, relieves this one of eventual damages referred to the mentioned actions Any tampering or modification of the safety devices constitutes a breach of the European Safety Laws and the warranty will immediately become null and void. The tyre-changer is equipped with instruction and warning stickers designed and produced to last over time. In case they get damaged or destroyed the user must apply to the constructor for replacing them. 5. TRANSPORT The tyre-changer must be transported in its original package and kept in the position shown on the package itself. Move the machine by means of a fork-lift truck having adequate loading capacity. Fit the forks as shown in fig.4 1140 Kg. 585 2050 1830 Fig.4 9
6. UNPACKING Remove both protective carton and nylon. Check the lift for damage or missing parts. Use fig. 1 3 for reference. In case of doubt, do not use the machine and apply to your dealer. 7. INSTALLATION 7.1_Space required. When choosing the installation site it is necessary to observe the national laws in force for safety at work. The automatic tyre-changer requires to be connected to electric network and compressed air system. It is therefore reasonable to install the machine in proximity to these sources. Moreover, the installation site must present at least a free surface around the machine, as shown in fig. 5-5/a, to grant the tyre-changer a regular operation without limitation. Outdoor installed machines must be protected by a lean-to. It is forbidden to use the machine in explosive atmosphere, unless it is equipped with an anti-explosion electric motor. 500 mm. 500 mm. 500 mm. 500 mm. Fig.5 Fig.5/a 10
7.2_Positioning Position the tyre-changer in the chosen site using the proper support as lifting point (see fig. 6-7) Use a lifting truck having adequate capacity and a lifting cable which could sustain the tyre-changer weight (542 kg.) (fig. 8) ATTENTION: Remove the lifting hook once the machine has been positioned. Fig.6 7.3_Setting at work Before connecting the machine, make sure that network and machine electrical features correspond to each other. Any action on the electric system, even if small, must be performed by qualified professional staff only. Before proceeding, read the information given in the section reserved to Authorized Technicians. Fig.7 The manufacturer is not responsible for any damage caused by an electrical connection different from what specified in this manual. Connect the machine to the electric network, which must be equipped with line fuses and with a good earthing, as required by the current laws. Moreover, it must be connected to a feeding automatic switch (differential) set at 30 ma. Note: In case the machine is delivered without electric plug, the user must install one (at least 16A) in accordance with both the machine voltage and the current laws. Connect the machine to the compressed air system by means of the union jutting out from the back side (see fig. 9) Fig. 8 Fig. 9 11
7.3.1_Instructions for connection Any action on the electric system, even if small, must be performed by qualified professional staff only. Before proceeding, read the information given in the section reserved to Authorized Technicians. 7.3.1.1_Connection of 380-440V / 3ph + N Before proceeding, read the information given in the section reserved to Authorized Technicians. Among the poles of feeding cable, the neutral pole is recognizable by BLUE colour and by the following sticker, code nr. 3026714: Cod. 3026714 The neutral pole of feeding cable must be connected to the neuter of workshop main network. The manufacturer is not responsible for any damage caused by an electrical connection different from what specified in this manual. Connect the resting poles (BLACK, BLACK, BROWN) to the feeding system phases. To switch the machine on, turn the main switch to position 1 7.3.1.2_Connection of 200-240V / 3ph Before proceeding, read the information given in the section reserved to Authorized Technicians. Connect the resting poles (BLACK, BLACK, BROWN) to the feeding system phases. The manufacturer is not responsible for any damage caused by an electrical connection different from what specified in this manual. To switch the machine on, turn the main switch to position 1 12
7.4_Functioning tests Fig.10 ATTENTION! To stop any running automatic operation press stop button [17] F1: by pressing this button at a certain point of the removing phase of standard tyres (further information will be given on this subject) the bead will be automatically pulled out and the head stopped in working position. F2: automatic moving of the head to working position on inner bead. The bead-breaking tools are brought to rest position, the chuck gets down and the mounting / removing head moves fully leftwards. F3: by pressing this button the mounting tool gets ready for repeating the bead pulling out operation. F4: automatic moving of the head to working position on outer bead. The bead-breaking tools are brought to rest position, the chuck gets down and the mounting / removing head moves fully rightwards. 1. Wheel Lift Lifting Control. Keeping this button pressed, the Wheel Lift moves up so permitting to align the rim central hole with the flange. In this way, the operator doesn t need to lift the tyre by hand. 2. Wheel Lift Lowering Control. Keeping this button pressed, the Wheel Lift moves down to rest position. In this way, the operator can slide the tyre without having to lift it by hand. 3. Rim locking on flange. Press this button and keep it pressed to let the electro-hydraulic clamping device lead the centering cone and the ring nut against the rim. 4. Rim releasing from flange. Press this button and keep it pressed to let the electro-hydraulic clamping device release the centering cone and the ring nut. 5. Chuck lifting control. Keep this button pressed to lift the chuck trolley up to correct working position according to rim dimensions. Use the scale bars on tyre-changer to reach the desired position, then release button. 13
6. Chuck lowering control. Keep this button pressed to lower the chuck trolley to correct working position according to rim dimensions. Once the desired position is reached, release button. 7. Mobile tool pulling out control. By pressing this button the mobile tool of mounting/ removing head is pulled out to hook tyre edge during removing phase. 8. Mobile tool recovery control. By pressing this button the mobile tool of mounting/ removing head is retracted. If previously inserted between rim and bead, it will pull the bead out. 9. Leftward stroke of mounting/removing tool. Keep this button pressed to move the mounting/removing tool leftwards to rest position (end of stroke). In this way it possible to adjust tool working position and rim edge accordingly. Once the desired position is reached, release button. 10. Rightward stroke of mounting/removing tool. Keep this button pressed to move the mounting/removing tool rightwards to rest position (end of stroke). In this way it possible to adjust tool working position and rim edge accordingly. Once the desired position is reached, release button. 11. Mounting head reset button. By pressing this button, the operations controlled by F3 are performed, but in manual mode, step by step. At each pressure of the button the tool slightly moves of one step until it reaches, at the end of the cycle, the same position as by F3. 12. Head positioning by hand. By pressing this button, the operations controlled by F1 are performed, but in manual mode, step by step. At each pressure of the button the tool slightly moves of one step until it reaches, at the end of the cycle, the same position as by F1. 13. Leftward stroke of left bead-breaking tool. Keep this button pressed to let the left bead breaking tool move leftward till max. opening position (end of stroke). In this way it is possible to adjust bead breaker working position and rim groove according to each other. Once the desired position is reached, release button. 14. Rightward stroke of left bead-breaking tool. Keep this button pressed to let the left bead breaking tool move rightward till max. closing position (end of stroke). In this way it is possible to adjust bead breaker working position and rim groove according to each other. Once the desired position is reached, release button. 15. Leftward stroke of right bead-breaking tool. Keep this button pressed to let the right bead breaking tool move leftward till max. closing position (end of stroke). In this way it is possible to adjust bead breaker working position and rim groove according to each other. Once the desired position is reached, release button. 16. Rightward stroke of right bead-breaking tool. Keep this button pressed to let the right bead breaking tool move rightward till max. opening position (end of stroke). In this way it is possible to adjust bead breaker working position and rim groove according to each other. Once the desired position is reached, release button. 14
17. Stop. Press this button to stop any operation running at that moment. 18. SPEED: hydraulic speed selection. At each pressure of SPEED button the speed of the hydraulic movements changes (kept control mode). The LED-light of SPEED button shows the current selected speed as follows: High speed : LED-light condition! ON Low speed : LED-light condition! OFF Intermediate speed: LED-light condition! FLASHING At each starting, the machine automatically sets at High Speed condition (LEDlight ON). As long as the automatic functions F1, F2, F3, F4 are executed, the speed is automatically set by the system as follows: F1 Low speed F2 High speed F3 Low speed F4 High speed At the end of the automatic functions execution, the speed is reset at the latest setting made by the operator (and the LED-light gets back to the relevant condition) 19. ON: Pilot-light showing the machine is switched on. When this light is on, the machine is powered and the main switch in its back side is turned to position 1. OPTIONAL FUNCTION If the LED-light is flashing, the hydraulic system is in rest condition (pump OFF). The machine automatically enters this condition after one minute of inactivity of the controls associated to the hydraulic functions. It is possible to let the machine enter this condition by hand, by keeping STOP button pressed for at least 1 sec. At first pressure of any control related to these functions, the pump automatically starts running. 20.! : LED-light signalling an error on the executed function. If an anomaly is recognized by the checking system, the current movement gets stopped and the! LED-light turns ON. 33. Chuck rotation control pedal. Press this pedal down to let the chuck turn clockwise with a speed proportioned to the pressure. Pull the pedal up to let the chuck turn anti-clockwise with constant speed. 15
8._USE 8.1_ Use of the scale bars The tyre-changer is equipped with two scale bars, one in mm. and the other in inches, to be used to easily find the correct position of the wheel according to the mounting/removing tool. On the chuck flange carriage there are two indicators as a reference when using the scale bars. With standard tyres, the inch. scale bar shall be used, according to the measure expressed in inch. on the rims, and the mounting/removing tool [32] shall be used as a reference. With PAX System tyres, the mm. scale bar shall be used, according to the measure expressed in mm. on the rims, and the mounting/removing tools [51] and [52] shall be used as a reference, since mounting tool [32] is not used in this procedure. Read the measure on tyre and use buttons [5] and [6] to set the indicator at the right level on the relevant scale. Fig.12 Scale bar in mm. for PAX System tyres Fig.11 Scale bar in inches for standard tyres 16
8.2_ Rim clamping on chuck flange 8.2.1_Standard rims clamping Deflate the tyre Let the wheel onto the Wheel Lift ramp Fig.13 By means of the proper button [1], let Wheel Lift move up until the rim central hole coincides with the flange hub. Pay attention to let the anti-slip pin coincide with one of the fixing holes of the rim. Fig.14 Fit the centering cone onto the flange hub. Push the cone until it is set against the rim central hole (or in the rim closest seat among those present on the hub). Fig.15 Lock the rim automatically by keeping button [3] pressed. If necessary, press [4] to release. 17
8.2.2_Special rims There are some special rims on the market, whose tyre cannot be removed from the external side, as usual, but it requires to be removed from the inner side. These rims must be therefore clamped on the flange in a way different from what described at par. 8.1. Proceed as follows. Release the standard flange fastening hand-wheel shown by the arrow (fig.16) Take the standard flange out of the chuck shaft. (fig. 16/a) Set the special flange [44] on the chuck shaft and screw the fastening hand-wheel back on (fig. 17) Fig.16 Set the rim on the chuck shaft. Set the special locking cone [43] paying attention to also introduce the anti-slip pin in one of the rim holes in a way that it is driven into the proper flange groove (fig. 18-19) Push the cone until it is set against the rim central hole (or in the rim closest seat among those present on the hub) (Fig. 18) Lock the rim automatically by keeping button [3] pressed. If necessary, press [4] to release. Fig.16/a 44 Fig.17 43 Fig.18/a Fig.18 18
8.2.3_Oversize rims clamping (Optional) In case of operations on oversize rims or on van tyres having a too large central hole in comparison with standard cone measures (Ø 43-113 mm.) it is necessary to use flange [57] and locking cone [55], made expressly for this purpose. Set the flange [57] on the existing flange, as shown in fig.19/a, and fix it by means of the three screws shown by the arrow in fig. 19/b. Release the two screws shown in fig. 19/c to remove the antislip pin from flange. Replace the standard anti-slip pin by the long one delivered with the special flange. Tighten the 2 screws (fig. 19/d) By means of the proper button [1], let Wheel Lift move up until the rim central hole coincides with the flange hub. 57 Fig.19/a Pay attention to let the anti-slip pin coincide with one of the fixing holes of the rim. Fit the oversize centering cone [55] on the flange hub. Push the cone until it is set against the rim central hole (or in the rim closest seat among those present on the hub). (Fig. 19/e) Lock the rim automatically by keeping button [3] pressed. If necessary, press [4] to release. Fig.19/b Fig.19/c 55 Fig.19/e 19 Fig.19/d
8.3_ Bead breaking of standard tyres Before performing any operation, make always sure that the tyre is deflated Grease the tyre edges by means of a proper solution Position the left bead breaking tool at tyre inner side and bring it close to the rim edge by means of button [14] (fig. 20) DO NOT keep your hands on the wheel: the recovery back to working position could cause a hand-crushing between rim and tool. Fig.20 Press pedal [33] to let the tyre turn and, at the same time, move the left bead breaking tool towards the rim inner side (button [14]) to detach the bead (fig. 20). Keep your hands far from mounting tool when the chuck is rotating to avoid any risk of crushing. Bring the left bead breaking tool to rest position by means of button [13] Repeat the same operations for the outer bead using the right bead breaking tool (buttons [15] and [16]) (fig. 21) Fig.21 20
8.4_ Standard tyres removing operation Press pedal [33] to let the tyre turn and keep it pressed until the bead has been completely detached. By means of button [9] move the mounting/removing head leftwards until the pointer coincides with rim inner edge (fig. 22). RIF Fig.22 Press button [7] to extract the mobile tool (peak) and hook the tyre bead. In case the mobile tool doesn t hook the tyre bead, move the head lightly leftwards [9] and press again [7] to hook the bead. Then, bring the head back in position with the pointer coinciding with rim outer edge. In case of rims with arched spokes, bring the mounting head out of spokes space. RIF Fig.23 Press F1 : the head will automatically set in correct position to pull the bead out (fig. 24) Note: this operation can be also performed by hand by means of button [12], either with repeated short pressures or keeping it pressed. To facilitate the extraction of the bead it is possible to push the left bead breaking disk against the other bead, as shown in fig. 24 Use buttons [13] [14] to set it in position. 21 Fig.24
Go on rotating until the outer bead is completely detached, as shown in fig. 25-26 Fig.25 Press F2: the machine automatically resets and the head is brought to the left side of the rim. Reposition the chuck back to the previous height by means of buttons [5] [6], using the proper scale bar for reference. Fig.26 22
Move the mounting head in a way that the end of the fixed tool is set immediately out of rim edge. Let the tyre inner bead set on the fixed tool, as shown in fig.27 By means of buttons [13]-[14] push the left bead breaking disk until the bead is completely detached from rim. Fig.27 During this phase it is possible to hold the tyre by means of Wheel Lift to avoid the user any possible useless strain (fig. 28) Fig.28 23
8.5_ Standard tyres mounting operation ATTENTION: The following check is very important to prevent any risk of tyre bursting during inflating phase. Before starting mounting operation, check that: - Both by the touch and at sight, the tyre shall not present any defect and the ply shall be free from any damage. In case of defect/damage DO NOT mount the tyre. - The rim shall not present any dent or buckling. In particular for what concerns alloy rims, the dents often cause inner micro-fractures, which are not eye-catching and which can compromise the rim solidity with consequent danger during inflating phase. - The diameter of rim and tyre shall be exactly the same. Do not mount tyres onto rims if their relevant diameters have not been detected with accuracy. Move the mounting head in a way that the end of the fixed tool is set immediately out of rim edge. Let the tyre inner bead set on the fixed tool, as shown in fig.29 Fig.29 Let the tyre turn in anticlockwise direction, pulling pedal [33] up, until the inner bead is completely set on rim. 24
Move the mounting head to rest position by means of button [9] Let the chuck trolley go down by pressing button [6] Move the mounting head to rim right side, still in rest position. NOTE: by pressing F4, the two last operations executed in manual mode will be performed automatically by the tyre-changer. Turn the mounting head by 180 as shown in fig. 32a-b-c Fig.31 Fig.32a Fig.32b Fig.32c Lift the chuck trolley up to working position by means of button [15] Move the mounting head to working position by means of button [9]. Set the fixed tool at rim groove level (fig. 33) Use button [15] to bring the right bead breaking disk at rim groove level (fig. 33) 25 Fig.33
Fit the clamp to facilitate the mounting phase of outer bead. The clamp must be fitted as shown in fig. 34 to avoid any possible dangerous shock with mounting/removing tools. Fig.34 Let the chuck turn by means of pedal [33]; proceed until the tyre bead is completely set on rim (fig. 35-36) NOTE: be careful during rotation and pay attention to avoid any possible shock between clamp and mounting tools. Fig.35 Remove the clamp and move the tools to rest position by means of buttons [10] and [16] Let the chuck trolley down till end of stroke. Let the Wheel Lift up until it gets close to tyre [1] Press button [4] as long as centering cone and lock ring nut get released. Take the cone out. Set the tyre on Wheel Lift rollers and move it outwards, out of flange hub. Let the Wheel Lift [2] move down to floor and remove the wheel. 26 Fig.36
8.6_ Tools replacement for operating on PAX System tyres Replace left bead breaking disk (ref.30) by roller tool (ref. 51) as shown in fig. 37 a-b-c 51 30 Fig.37a Fig.37b Fig.37c Replace right bead breaking disk (ref. 31) by disk+roller tool (ref. 52) as shown in fig. 38 a-b-c 31 52 Fig.38a Fig.38b Fig.38c Move tool (52) to working position by pressing [15] Set the tool anti-rotation pin (ref.58 fig. 38e/f) in the proper arm hole (fig. 38d) 58 Fig.38d Fig.38e Fig.38f 27
8.7_ PAX System tyres removing operation Lock the wheel on the chuck flange and set it at the right height by means of the scale bar, as explained in par. 8.1 and 8.2 NOTE: PAX System tyres do not require the use of mounting/removing head; therefore it is advisable to move it to rest position, rightwards till end of stroke, by means of buttons [10] and [12]. Make sure that the tyre is deflated, otherwise deflate it. Let the tyre turn by pressing pedal [33] At the same time move the roller tool outwards by pressing [14] so as to create a gap between tyre and rim. Lubricate the obtained gap all along the rim circumference. Proceed with rotation and, at the same time, push the tyre bead into the proper rim groove (fig. 39) Bring the roller tool to rest position by means of [13] NOTE: PAX System tyres specifications confine themselves to the use of lubricants for touring tyres. Fig.39 Let the tyre turn by pressing pedal [33] At the same time move the disk+roller tool inwards by pressing [15] so as to create a gap between tyre and rim. 40 Lubricate the obtained gap all along the rim circumference. Introduce the plastic band end (ref. 40) under the tyre bead, in the gap created previously (fig. 40) Make sure that the plastic band tongue is set outside the tyre. Let the wheel turn slowly and, at same time, help the plastic band to get in position paying attention it is correctly positioned. Bring the disk+roller tool to rest position by pressing [16] NOTE: PAX System tyres specifications confine themselves to the use of lubricants for touring tyres. Fig.40 28
Introduce the shaped lever end (ref. 50) between plastic band tongue and tyre bead (fig. 41). Push the lever downwards to let the tyre bead get out from its seat (fig. 42). Remove the lever and recover the plastic band. 50 Let the Wheel Lift go up by pressing [1] in a way to slightly hold the tyre to: - set the tyre bead on roller - facilitate the extraction of tyre/inner ring from rim Let the wheel turn by pressing pedal [33] Fig.41 At the same time, move the roller tool outwards by pressing [14]. In this way, tyre and inner ring are pushed out of their seat (fig. 43-44) Always check that the bead is positioned between tool and inner ring so as not to damage the tyre body. Proceed by hand until tyre and inner ring are completely out of rim (fig. 45). Bring the roller tool to rest position by pressing [13] During pulling out operation pay attention not to strain the pressure sensor. NOTE: PULLING THE INNER RING OUT OF TYRE To pull the inner ring out of tyre, always refer to the instructions for PAX System mounting given by manufacturers. Fig.42 Fig.43 Fig.44 Fig.45 29
8.8_ PAX System tyres mounting operation ATTENTION: The following check is very important to prevent any risk of tyre bursting during inflating phase. Before starting mounting operation, check that: - Both by the touch and at sight, the tyre shall not present any defect and the ply shall be free from any damage. In case of defect/damage DO NOT mount the tyre. - The rim shall not present any dent or buckling. In particular for what concerns alloy rims, the dents often cause inner micro-fractures, which are not eye-catching and which can compromise the rim solidity with consequent danger during inflating phase. - The diameter of rim and tyre shall be exactly the same. Do not mount tyres onto rims if their relevant diameters have not been detected with accuracy. Important: for any intervention on pressure sensor always refer to the instructions given by manufacturers. For introducing the inner ring back into the tyre, always refer to the instructions for Pax System mounting given by manufacturers. Let the rim turn and grease it outside (fig. 46) Fig.46 Generously grease tyre beads and inner ring too (fig. 47) To facilitate this operation, set the tyre on Wheel Lift, lift it up at the right working height and let it roll on carriage. Align tyre and inner ring by means of Wheel Lift Manipulate tyre and inner ring to set them on the rim. 30 Fig.47
CLIP INNER RING POSITIONING Bring the disk+roller tool to working position by pressing button [15]. Go on until the tyre bead is set on the proper support (fig. 48) ATTENTION: during this mounting phase make sure that tyre bead is well positioned on the relevant tool support as not to damage the bead. Fig.48 Move the disk tool inwards [15] to enable the support ring to correctly set itself in the proper seat (fig. 49). ATTENTION: Let the roller touch the rim and perform at least one full turn of tyre in this position to make sure to properly set the clip inner ring in its seat. Move the tool to rest position by pressing [16] Fig.49 PLANE INNER RING POSITIONING Move the tool progressively inwards [15] to enable the support ring to correctly position itself in its seat. ATTENTION: to make sure to properly set the plane inner ring in its seat, check that its small teeth are well set into the seat. Move the tool to rest position by pressing [16] Fig.50 31
By means of the bent lever (ref. 49) let the inner bead get over the rim edge (fig. 51). 49 Fig.51 Fig.52 Turn the disk+roller tool by 180 as shown in fig. 53 a-b Fig.53a Fig.53b 32
Bring the disk+roller tool to working position by means of button [15] until the roller is placed against the rim. DO NOT keep your hands on the wheel: the recovery back to working position could cause a hand-crushing between rim and tool. Clamp the support plate (ref. 48) on rim to facilitate the mounting operations; pay attention to set it at tool right side (fig. 54) Let the tyre turn by pressing pedal [33] until the tyre bead gets positioned in the proper rim seat (fig. 55-56) Remove the spring support plate (ref. 48) 48 Fig.54 Fig.55 Fig.56 Bring the roller tool to working position by means of button [14] and move it until the roller is set against the rim. DO NOT keep your hands on the wheel: the recovery back to working position could cause a hand-crushing between rim and tool. Clamp the support plate on rim to facilitate the mounting operations; pay attention to set it at tool left side (fig. 57). Let the tyre turn by pressing pedal [33] until the tyre bead gets positioned in the proper rim seat (fig. 58-59). Remove the spring support plate (ref. 48) 48 48 Fig.57 Fig.58 Fig.59 33
It can happen that, owing to the particular shape of some wheels, the spring support plate can t be used on rim outer side. In such cases it is necessary to use the shaped support plate (ref. 47), as shown in fig. 60 See the instructions for spring support plate for use. 47 Fig.60 9._ TYRE INFLATION The greatest attention is called for inflating tyres. Keep strictly to the following instructions since the tyre changer is NOT designed and built to protect the user (or anyone else in the vicinity of the machine) in case of accidental tyre burst. Tyre burst or rim break can cause serious injury or even death to the operator. - Check carefully the dimension of rim and tyre, which must correspond to each other. - Also check the state of wear of tyre and rim in order to find out any possible defect before starting the inflation. - Inflate the tyre with brief jets of air, checking the pressure frequently. - All our tyre-changers are automatically limited to a max. inflating pressure of 3.5 bar (51 psi). NEVER EXCEED THE PRESSURE RECOMMENDED BY TYRE MANUFACTURER. - Keep yourself as far as possible from tyre during inflating phase. - Connect the airline gauge fitting to the tyre valve. - Check the diameter of rim and tyre again. - Make sure that rim and tyre are well greased, otherwise grease them. - Press and release the gauge trigger frequently, checking the pressure onto the manometer, until the tyre is perfectly fit onto the rim. - Go on inflating until the pressure recommended by manufacturer is reached. Always inflate by brief jets of air and often check the pressure. 34
10. RESITING To reinstall the tyre-changer in a new place it is necessary to dispose of a fork truck: - Disconnect the tyre-changer from compressed air and electric system - Lever one side of the base to lift it from ground; set the forks of the truck under the base and slide the tyre-changer onto them. - Set the machine in its new place, which must comply with the standards described in par.7.1 Note: the site chosen for installation must comply with European Standards for safety at work 11. STORAGE If the machine is to be out of use for a long period, proceed as follows: - Disconnect all power sources - Protect the machine from dust - Grease all points at risk of oxydation 12. SCRAPPING If the appliance is not to be used anymore, owners are advised to make it unusable by disconnecting all power sources. - Remove all iron-free parts (plastic, rubber, etc.) and dispose off through the collection centres provided and according to the national laws in force. - Collect the oil and dispose off through the collection centres provided and according to the national laws in force. - Collect the rest as scrap iron and dispose off according to the national laws in force. 35
13. MAINTENANCE 13.1_General information The EXTRAORDINARY maintenance is always forbidden to unauthorized staff. Maintenance, as per instructions given, is fundamental for a correct operation and a long working life of the tyre-changer. Shouldn t maintenance be carried out regularly, the working life as well as the reliability level could be compromised with risks both for users and for by-standers. Before carrying out any operation on the appliance, DISCONNECT both electric power supply, by unplugging it, and compressed air system, by turning off the tap. Moreover, to release the air from circuit, it is necessary to keep the inflating gauge trigger pressed for some seconds. Any defective part shall be replaced only by expert staff and by means of original spare parts. Removal or tampering with safety devices (as pressure relief valve, pressure regulator) involves a breach of the European Legislation for Safety at Work. In particular, THE MANUFACTURER cannot be held responsible for claims deriving from the use of nonoriginal spare parts or for damages caused by removal or tampering with safety devices. When 23.000 working cycles are reached, and in any case not longer than 10 years from installation and setting at work, the tyre-changer must be fully checked by authorized trained staff. 13.2_Regular maintenance For a perfect operation and a longer working life of your tyre-changer, follow the instructions below: 1) Periodically lubricate the chuck trolley guides, after having cleaned them carefully by means of a degreasing solution. 2) Periodically grease the lifting cylinder of chuck trolley by means of the proper greaser. Use a common lube. 3) Periodically check the oil level inside the hydraulic unit by means of the proper dipstick. If necessary, top up by means of oil AGIP ARNICA 68 or similar (ESSO INVAROL EP68, SHELL TELLUS T68, MOBIL DTE 25, CASTROL HYSPIN AWH68, CHEVRON EP HYDRAULIC OIL HV 68) 4) Periodically check the oil level inside the lubricator. If necessary, top up by unscrewing the cup. Only use oil for compressed air systems of class ISO HG with viscosity ISO VG 32, like ESSO Febis K32, MOBIL Vacouline Oil 1405, KLUBER Airpress 32 Note: in case of need of replacing the oil inside the hydraulic unit, the tank is equipped with proper drain plug for easy operation. Collect the hydraulic fluid and dispose off through the proper collection centres according to the national laws in force. 36
14. TECHNICAL DATAS TECHNICAL DATAS Rim clamping range Max. wheel diameter Tyre width Wheel Lift max. loading capacity Bead breaking force of LEFT tool Bead breaking force of RIGHT tool Working pressure Hydraulic working pressure Feeding voltage Hydraulic unit motor power Chuck rotation motor power Chuck rotation max. torque Chuck clockwise rotation speed Intake air pressure limiter Inflating device Dimensions Net weight Noise level in working conditions 12" 30" 305 762 mm 47" 1200 mm 16" 410 mm 60 kg 850 kg 1250 kg 8 10 bar 0 130 bar 400V / 3PH + N (230V / 3PH) 1,1 kw 0.75 kw 1200 Nm 3 14 rpm 10 bar 3,5 bar 1750 x 1360 x 1800 mm 542 kg < 70 db 37
ELECTRIC DIAGRAMS HYDRAULIC DIAGRAMS PNEUMATIC DIAGRAMS 38
15. DIAGRAMS 15.1_Board and protections X1 X2 PROTECTION VALUE PLAN 39
15.2_Power diagram, 400V/3ph+N 40
15.3_Power diagram 230V 3Ph 41
15.4_Upper board control diagram 42
15.5_Inner board control diagram 43
15.6_Lower board control diagram 44
15.7_Solenoid valves control diagram 45
15.8_Solenoid valves positioning 46
15.9_Hydraulic diagram 47
15.10_Pneumatic diagram 48
15.11_Motor connection diagram PUMP motor connection 200V / 3ph 220V / 3ph 230V / 3ph 240V / 3ph CHUCK motor connection PUMP motor connection 380V / 3ph 400V / 3ph 415V / 3ph 440V / 3ph 49
SECTION RESERVED TO AUTHORIZED TECHNICIANS 50
16. SECTION RESERVED TO AUTHORIZED TECHNICIANS 16.1_Check of inner connection for 380-440V / 3ph+N Switch the machine OFF, open the electric system box and check the connecting position of L5 wire on terminal board X2 (ref. 15 Electrical diagram 400V/3ph+N); it must correspond to the information given by plate code 3026712. Position defined by Power Supply / Alimentazione 380-440V / 3ph+N The position of plate and cables inside the panel is given below. L1 N L5 ATTENTION: a connection of the BLUE neutral pole of feeding cable differing from what specified in 7.3.1.1 can engage the coordinate protections F4+F5 to protect the chuck motor check electronics. The manufacturer is not responsible for any damage caused by wrong electrical connections. ATTENTION: reset of coordinate protections F4+F5 must be made according to what specified at 16.3 Reset of coordinate protections F4+F5. 51
16.2 - Check of inner connection for 200-240V/3ph Switch the machine OFF, open the electric system box and check the connecting position of L5 wire on terminal board X2 (ref. 15 Electrical diagram 230V/3ph); it must correspond to the information given by plate code 3026712 Position defined by Power Supply / Alimentazione 200-240V / 3ph The position of plate and cables inside the panel is given below. L1 N L5 The manufacturer is not responsible for any damage caused by wrong electrical connections. ATTENTION: a connection differing from what specified in 7.3.1.2 can engage the coordinate protections F4+F5 to protect the chuck motor check electronics. ATTENTION: reset of coordinate protections F4+F5 must be made according to what specified at 16.3 Reset of coordinate protections F4+F5. 52
16.3 Reset of Coordinate Protections F4+F5 In case of wrong connection, when switching the system ON the coordinate protection F4+F5 can get engaged to protect the electronics of chuck motor control board. In this case, the rotation becomes unavailable until the coordinate protections are reset. The manufacturer is not responsible for any damage caused by wrong electrical connections. In case of engagement of coordinate protection F4+F5 SWITCH THE MACHINE OFF by setting the main switch to position 0. Before powering the system again, IT IS NECESSARY to perform the following operations: 1- for 400V/3ph+N voltage, check that the BLUE neutral pole of feeding cable is properly connected to the neutral pole of main network 2-1- replace BOTH protections F4+F5 by means of original spare parts supplied by the manufacturer, in detail F4 Fuse 16gG 10x38 F5 SIOV S14K 275 The position of protections F4 + F5 is shown on plate code 3026173 hereby. F4 F5 ALWAYS REPLACE BOTH COORDINATE PROTECTIONS F4+F5. Partial replacements of coordinate protections F4+F5 can damage the machine. THE MANUFACTURER REFUSES ALL RESPONSIBILITY FOR DAMAGES CAUSED BY OPERATIONS DEROGATING THE INDICATIONS ABOVE. 53
16.4_Trouble Shooting PROBLEM OPERATION 1- Switch the machine OFF When switching ON the system for the first time, the magneto thermal switch on the plug is released. 2- Check that machine voltage corresponds to main power supply. Check connection between feeding cable and plug. ATTENTION: for 380-415V/3ph+N voltage: check that the BLUE neutral pole is properly connected to the main system neutral pole. To check the integrity of inner protections after a wrong connection - check fuses F1, F2, F3 - check fuse F5. ATTENTION: if F5 has burnt out, replace both F4+F5 only by spare parts supplied by manufacturer. 1- Switch the machine OFF When pressing rotation control pedal the chuck doesn't run 2- Check that machine voltage corresponds to main power supply. Check connection between feeding cable and plug. For 380-415V/3ph+N voltage: check that the BLUE neutral pole is properly connected to the main system neutral pole. 3- Check fuse F5 ATTENTION: if F5 has burnt out, replace both F4+F5 only by spare parts supplied by manufacturer. The LED-lights on control panel do not turn ON, both hydraulic and pneumatic controls are not executed. The LED-lights on control panel turn ON but both hydraulic and pneumatic controls are not executed. The LED-lights on control panel turn ON, pneumatic controls are executed, pump motor is running but the hydraulic controls are not executed. The LED-lights on control panel turn ON, pneumatic controls are executed, but pump motor doesn't run. 1- Switch the machine OFF 2- Check power fuses F2, F3 3- Check fuses F6, F7 on transformer 1- Switch the machine OFF 2- Check fuse F9 1- Switch the machine OFF 2- Reverse the rotation direction of pump motor (M1) by crossing 2 phases on pump motor terminal board Make sure that the pump motor (M1) is not in rest condition: press chuck locking button to check.if the pump motor doesn't run, proceed as follows: 1- Switch the machine OFF 2- Check the condition of thermal relay RT1: if engaged, wait for automatic resetting if not engaged, check fuse F8 54
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GIULIANO S.p.A. Via Guerrieri, 6-42015 CORREGGIO - ITALY Tel. +39. 522. 73.11.11 - Fax. +39. 522. 63.31.09 E-mail: giuliano@giuliano.it http://www.giuliano.it