TECHNICAL MANUAL GTB16N 1/20
1. INTRODUCTION 1.1 Purpose 1.2 Before Service 1.3 Safety 1.3.1 Hazard Definitions 1.3.2 For Your Safety 1.4 Specifications & dimensions 1.5 Description 2. HYDRAULIC SYSTEM 2.1 Bead Loosening Arms 2.1.1 Right side (lower) Bead Loosening Arm Cylinder 2.1.2 Left side (upper) Bead Loosening Arm Cylinder 2.1.3 Cylinder for Wheel Diameter Adjustment) 2.2 Clamping Device 2.2.1 Dismounting Clamping cylinder 2.2.2 Dismounting raising/lowering cylinder clamping device 2.3 Hydraulic Pressure Unit 2.4 Hydraulic Circuit 3. ELECTRIC SYSTEM 3.1 Power Supply 3.2 Wiring Diagrams 3.3 Motor For Hydraulic Pressure Unit 3.4 Motor For Rotation Clamping Device 3.5 Command Unit 4. MECHANICAL SYSTEM 4.1 Gear Box 4.2 Carriage Clamping Device (up/down) 4.2.1 Regulation of the gliding strips 4.3 Tool Arm (in/out) 4.4 Motor Belt Tension 5. TROUBLE SHOOTING 6. MAINTENANCE 2/20
1. INTRODUCTION 1.1 PURPOSE Assist service personnel in troubleshooting and repairing the GTB16N (and its different brand names) 1.2 BEFORE SERVICE The following has to be verified. - that the equipment is being used and maintained properly - that the users of the TC have been properly trained and instructed 1.3 SAFETY Improper use and maintenance can cause unsafe and dangerous surroundings for the user as well as possible damage to tyre changer, rim and tyre. 1.3.1 Hazard Definitions Caution: Hazards/unsafe practices, which could result in minor personal injury or product or property damage Warning: Hazards or unsafe practices, which could result In severe personal injury or death Danger: Hazards or unsafe practices, which will result In severe personal injury or death 1.3.2. For Your Safety Misuse of the equipment can cause personal injury & shorten the life of the TC To prevent accidents or damage to the machine, use only Butler recommended procedures and accessories Read & follow all caution/warning labels on the machine and its accessories Never stand on the machine & keep hands and clothing clear of moving parts Wear approved eye protection when operating or servicing the TC Don t wear jewellery, loose clothing, neckties when operating/servicing the TC Wear non-slip footwear when servicing or operating the TC Wear proper back support when lifting or removing wheel from TC Shut off electrical supply from the TC before servicing or maintenance is done Do not operate the machine with worn parts. These may not perform properly and shorten the life time of the TC Inspect all components of the TC and replace as needed before using or servicing the machine 1.4 SPECIFICATIONS & DIMENSIONS The GTB16N is a hydraulically and electrically driven tire changer for service of light truck / truck wheels with dimensions within the spec range as described hereunder. The base on which the machines is to be fixed has to have a capacity of at least 500 Kg/m². 3/20
GTB16N Motor rotation. clamping device (Kw) 2 Rotation speed chuck (rpm) 10 Max. wheel diameter (mm/inch) 1320 (52) Max. wheel width (mm/ ) 540 (21,2) Max, wheel weight (kg) 1200 Clamping range (inch) 11 27 Minimum central opening (mm) 90 Motor for hydraulic unit (Kw) 1,5 Rotational torque (Nm) 2600 Min. clamping device height from floor (mm) 340 Internal bead loosening power (Nm) 18000 External bead loosening power (Nm) 18000 Operating pressure (bar) 130 Weight (kg) 1090 Stand-by function of the hydraulic unit 4/20
1.5 DESCRIPTION 1 Master switch 12 Handle mounting tool arm 2 Grease bucket holder 13 Electrical panel 3 Lower bead loosening roller 14 Motor for rotation clamping device 4 Hydraulic Power Unit 15 Clamping cylinder 5 Clamping Chuck 16 Command unit 6 Frame 17 Bead loosening disc (optional) 7 Dismounting/Mounting tool 18 Upper bead roller 8 Bead lever 19 upper bead loosening arm 9 Lower bead loosening Arm 20 Upp. bead loos. arm diameter cyl. 10 Clamp for alloy wheels 21 Upp. bead loos. arm opening cyl. 11 Lower bead loosening arm opening cylinder 22 Diameter adjustment wheel 23 Wheel positioning plate 24 Hook for machine lifting 2.1 BEAD LOOSENING ARMS 2. HYDRAULIC SYSTEM 2.1.1 Right side (lower) bead Loosener arm cylinder The arm is mounted at both sides and guided by two double bushings. Double bushings mean that a n aluminium bushing is pressed into a spacer. (Pict.1) The raised edge on the big bushing goes at the internal of the arm fixation support (Pict.2 &3) 5/20
When removing the cylinder, secure the arm so it doesn t smash down. Pict.1 Pict.2 Pict.3 A repair kit for this cylinder is available under the part#: GU6060 KIT Gasket 2.1.2 Left side (upper) bead loosener Arm Cylinder For the bushings see 2.1.1 When removing the cylinder, secure the arm so it doesn t smash down A repair kit for this cylinder is available under the part#: GU6060 KIT Gasket 2.1.3 Opening/closing cylinder for bead loosener arms (wheel diameter adjustment) The regulation screw has to be mounted so that the cylinder shaft and the internal part of the fork of the regulation cylinder are even (Pict.4). This cylinder is equipped with a non return valve (Pict.5) Pict.4 Pict.5 This cylinder is equipped with a blocking (non return valve). A repair kit for this cylinder is available under the part#: GU6070 KIT Gasket 2.2 CLAMPING DEVICE The clamping device consists of: - a clamping cylinder - gear box - clamping arms The clamping device has a non return valve at the back of the cylinder. (Pict.6, pt.5). This valve is activated only when opening the clamping device. This to secure that clamping does not release the wheel unwanted. Note the anti rotation plate for the valve (Pict.6, 4) 6/20
The valve (with protection cap) (Pict.7) is set at 130 Bar for the clamping cylinder. Pict. 6 Pict.7 2.2.1 Dismounting of the piston with shaft Loosen the four grains with counter nuts (Pict. 8, pt.1) Remove the big central nut of the shaft (Pict.8, pt.2) Remove hydraulic connectors (Pict.6, pt.3) and anti rotation device (Pict.6, pt.4) Remove the fixation plate (Pict.6, pt.2) Remove the non return valve (Pict.6, pt.5) Remove the 8 fixation screws (Pict6, pt.1) (Pict.9, pt.1) and remove the distributor (Pict.9, pt.2) Pict.8 Pict.9 At this point the piston with shaft can be dismounted (Pict.10) The gasket with incorporated OR is made of five pieces (Pict.11) Pict.10 Pict.11 7/20
2.2.2 Mounting of the piston with shaft A spacer rod (L=198,5mm, with 2 bushings in order to not damage the shaft.) (Pict.14) is put over the shaft (Pict.13). Insert piston /shaft into the cylinder until the OR (Pict.12, pt.1) touches the edge of the cylinder (Pict.12, pt.2) ) Pict.12 Pict.13 Pict.14 Pict.15 Once the small part of the shaft has passed the blue gasket (Pict.15), a series of distantials has to be used that are larger than the diameter (Pict.16)of the blue OR. When pulling the piston with shaft using its own tightening nut (Pict.17) and the distantials, make sure that the first one is centring the OR and not hanging on the shaft (Gasket would get cut when the bigger part of the shaft is pulled through. (Pict. 14) Pict.16 Pict.17 8/20
Position the rear flange with its hole and OR (Pict.18a, pt.2) in correspondence with the hole on the traction flange (Pict.18B). Make sure that the grain (Pict.18A, pt.1) is at the 12.00 o clock position when bleeding the cylinder. This to get immediately rid of the air trapped in the cylinder and hoses. Pict.18A Pict.18B Put the 8 bolts back in and hand tighten (Pict.19) Put the non return valve (Pict. 20, pt.5) back on and fix with the washer and two small screws (Pict. 20, pt.2) Fix the non return valve to the anti rotation device (Pict. 20, pt.4) Attach the hydraulic connectors (Pict. 20, pt.3) to the non return valve Bleed the air out of the cylinder keeping the grain in the 12.00 o clock position (Pict. 18, pt.a1) Pict.19 Pict.20 A repair kit for the gaskets of the clamping cylinder is available under the part# GU6010 KIT Gasket cylinder 2.3 HYDRAULIC PRESSURE UNIT Is composed of an electric motor, a hydraulic pump with oil tank and solenoid valves. The unit goes automatically in standby (pump motor stops after 4 sec) when the unit is not used. This timing can be regulated at the timer below: the upper one at (1) and the lower one at four (4). The machines multiplicates the upper with the lower value which becomes the automatic shut off time. Use a hydraulic oil 32 for room temperatures from 0 30 C. For higher temperatures use a hydraulic oil 46. 9/20
Attention: The machine is delivered without hydraulic oil! The line up of the high pressure hoses: 1. Carriage Clamping Device Cylinder down 2. Carriage Clamping Device Cylinder up 3. Closing diameter bead roller arms 4. Opening diameter bead roller arms 5. Opening Clamping device 6. Closing Clamping device 7. Backward movement left bead loosening arm 8. Forward movement left bead loosening arm 9. Forward movement right bead loosening arm 10. Backward movement right bead loosening arm Point 8 & 10 (forward movement of the bead loosening arms) are having a preset pressure to ensure they do not go over a certain amount of bead loosening power. 10/20
They are set to 1.700 Kg of trust. This setting is very difficult to achieve once the machine is in the field. The hydraulic unit operates at a maximum pressure of 130 BAR. Use hydraulic oil: Esso UNIVIS 46 (also other brand names are allowed) 2.4 HYDRAULIC SCHEME Cylinder 3: Opening /closing clamping device 750490110 Electromagnetic valve ED06Z Cylinder 2: Back/forwards right arm 750490000 Electromagnetic valve ED06Z Cylinder 1: Back/forwards left arm 750490010 Electromagnetic valve ED06Z Cylinder 4: Opening/closing arms 750490240 Electromagnetic valve ED08Z Cylinder 5: Raising/lowering clamping device 750490200 Electromagnetic valve ED08Z 3. ELECTRICAL SYSTEM 3.1 POWER SUPPLY 400V 50Hz 3Ph The power supply is converted into a 24VDC used to control the solenoid valves The electrical supply is automatically interrupted when the electrical panel is opened. The electrical systems have to be equipped with a differential protection set at 30mA The plug that has to be used to connect the machine has to be conform to the NIEC309, 230/400 Volt 16A, 3P + Ground, IP44 At delivery the machine is preset to operate at 400V... When connecting the plug, check that the hydraulic motor turns in the direction indicated by the arrow that is printed on the 11/20
electric motor itself. (see picture below) 3.2 WIRING DIAGRAMS The main board sits under three (3) fuses each of 16 Amps. 12/20
Main supply and supply command unit Motor for clamping device rotation and motor for hydraulic unit 13/20
Description of electrical motor commands Description of solenoid valve commands 14/20
Description of solenoid valve commands 3.3 MOTOR FOR HYDRAULIC PRESSURE UNIT 1,5 Kw Triphase 400 V, 50Hz Is protected by magneto thermal switch (of 10A in the main electrical Cabin) to avoid overheating of the motor in case of intensive use. The motor is shut off (goes in stand-by) when the machine is not used for about 5 sec. 3.4 MOTOR FOR ROTATION CLAMPING DEVICE 2 Kw Triphase 400 V, 50Hz Rotation speed at the clamping device: 8 rpm. Pulley diameter: 60mm The supply line to this motor is protected with fuses (16A). For the 220V version, 20A. The maximum rotational torque is 2600Nm. 3.5 COMMAND UNIT All of the controls are of the type man operated : immediate stop of operation as the control is released. 15/20
1 Clamping device moving up 2 Clamping device moving down 3 Opening clamping device 4- Closing clamping device 5 Rotation clamping device 6 Left bead loosening arm 7 Right bead loosening arm 4. MECHANICAL SYSTEM 4.1 Gear Box Type of oil: GX 85W140 The gear box is custom made using a welded steel box. 4.1.1 Elimination of the worm wheel play With time, some wear on the crown and the worm wheel is normal. This gear box has the possibility to eliminate this play. Remove the protection of the driving belts Loosen the tension of the belts and free the gear box pulley from the belts. Loosen the counter nut of the regulation screw (Pict.21, pt.1) Act on the regulation screw (Pict.21, pt.2) to take away the play. Control by hand turning on the pulley of the gear box to note if the play has gone. Note that the pulley should not be hard to turn. Lock the regulation screw with the counter nut and put back on the driving belts. Tension the driving belts and put the protection back on. Pict. 21 16/20
4.2 Carriage Clamping Device 4.2.1 Regulation of the gliding strips The carriage is moving on the base with the help of plastic gliding strips. Four (two on each slide) of these can be regulated to eliminate possible play after a certain number of working hours. Each strip has two fixing (Pict. 22, pt.1 and Pict.25) and two regulation (pressing) screws. (Pict. 22, pt.2) (Pict.24) Pict. 22 Pict. 23 The M10 grub screws are in place to secure the position and the lateral movement together with the carriage. (Pict. 25) Regulation: - torque (Pict. 23) at 12 Nm and lock with the counter nut Pict. 24 Pict. 25 The M10 mm grub screws regulate the play / pressure on the slides. (Pict. 24) Regulation: - bring the grub screw in contact with the gliding strips and tighten with 12Nm. Lock with the counter nut. - test the up and down movement of the carriage from the top to the bottom to see if the slides are not too tight and hamper the vertical movement. If so, loosen the screws a quarter turn and test again, until the carriage moves freely, without play and without speed loss in both directions. 17/20
4.3 Tool Arm (in/out) The tool arm is mounted in a sliding guide. The mechanical stop is mounted at the lower side of the arm and can be reached from the lower side of the frame as indicated below on Pict. 26. The arm is gas spring assisted with a force of 40 kg. (Pict.41) Pict.26 Pict.27 4.4 Motor belt tension The tension of the motor belt can be adjusted by rotating the hexagonal rod. First loosen the counter nut and adjust tension. Once having reached the right tension, lock again with the counter nut. 18/20
5. TROUBLE SHOOTING Problem Possible Cause Solution Motor of hydraulic pump does not work Motor for rotation of the clamping device does not work A power loss in the rotation of the clamping device motor No pressure in the hydraulic circuit Hydraulic pressure does not drop when opening clamping The machine does not switch on Loss of oil from a hose or a connector A command remains stuck The clamping cylinder looses pressure Electrical motor stops during use The machine does not react to the commands No pressure in the hydraulic system The machine is jerking (1) Call technical assistance Hydraulic motor or command Call technical assistance unit defect Rotation motor or command Call technical assistance unit defect Drive belt from motor to Tighten the drive belt gearbox is loose Hydraulic pump defect Replace pump (1) The valve of maximum pressure is stuck No electrical power The motor overloads are not active The transformers fuse jumped a. The connector is not tightened b. A hose is cracked a. A switch/handle broke b. A solenoid valve is stuck a. The distributor leaks oil b. The gaskets are damaged The motors overload protection kicked in a. Solenoid valve not feeded b. Solenoid valve is stuck c. Transformer fuse jumped d. Command unit broken a. The motor of the hydraulic unit turns in the opposite direction b. The hydraulic pump broke c. Not enough oil in tank a. Not enough oil in the tank b. Command button broke Release the clamping device (remove the wheel) unscrew the regulation knob completely and open and close the arms until the valve gets free (1) a. Connect the right power supply b. Activate the motor overloads c. Change the fuse a. Tighten the connector (1) b. Change the hose (1) a. Call technical assistance b. Call technical assistance a. Call technical assistance b. Call technical assistance Reactivate the overload of the motor (electrical panel) a. Call technical assistance b. Call technical assistance c. Change the fuse d. Call technical assistance a. Connect the motor in the right way b. Call technical assistance c. Fill the tank with hydraulic oil a. Add hydraulic oil b. Call technical assistance 19/20
6. MAINTENANCE Before carrying out any routine maintenance or adjustment procedure, disconnect the machine from the electrical supply. Make sure that no hydraulic hoses or cylinders are under pressure when repairing or servicing. Use a vacuum cleaner to remove dirt and dust. Never use compressed air. Lubricate the carriage sliding guides every 50 working hours Check the carriages on play. If necessary adjust as indicated in chapter 4 Grease once a month all moving parts of the machine (fig.28) Check once a month the oil level of the hydraulic unit. Change once a year all the hydraulic oil Check the oil level of the gearbox (put it first in horizontal position) Check every week the functioning of the safety devices. Check the tension of the clamping chuck motor belt. Pict.28 20/20