Ed.11/18 Cod. 3044302

PTC700

Use and maintenance instruction manual

EnglishOriginal Instructions

ATLAS PTC700

2

3

CONTENTS

1.0 INTRODUCTION.................................................................................................................................................4 1.1_Tyre-Changer data...................................................................................................................................4 1.2_Manufacturer data.............................................................................................................................4 1.3_Data plate....................................................................................................................................42.0 GENERAL DESCRIPTION.....................................................................................................................................43.0 SPECIFICATIONS.....................................................................................................................................54.0 WARNING LABEL PLACEMENT............................................................................................................................65.0 GENERAL SAFETY RULES.................................................................................................................................76.0 SAFETY DEVICES....................................................................................................................................77.0 TRANSPORT......................................................................................................................................................88.0 UNPACKING......................................................................................................................................................89.0 INSTALLATION................................................................................................................................................9 9.1_Space required for positioning...........................................................................................................9 9.2_Tyre-Changer placement and connections..............................................................................................9 9.3_Installation and assembly.................................................................................................................10 9.4_Connection to the electrical network..............................................................................................11 9.5_Connection to the compressed air network....................................................................................11 9.6_Laser pointers calibration...............................................................................................................1110.0 EQUIPMENT COMPONENTS.................................................................................................................1211.0 CONTROLS DESCRIPTION AND FUNCTION CONTROL..................................................................................1312.0 RIM AND TYRE IDENTIFICATION.......................................................................................................1413.0 VALVE POSITION......................................................................................................................................1414.0 WHEELS AND TYRES CLASSIFICATION...................................................................................................15 14.1_Standard wheels............................................................................................................................15 14.2_Low-profiled tyre (UHP)wheels...........................................................................................15 14.3_RUN-FLAT tyrewheels.......................................................................................................1515.0 WDK RULES...................................................................................................................................................1516.0 WHEEL POSITIONING AND CENTERING ONTO CLAMPING CHUCK........................................................1617.0 WHEEL CLAMPING OPERATION WITH SMART LOCK.................................................................................16 17.1_Tightening adjustment............................................................................................................17 17.2_Maintenance................................................................................................................................1818.0 SWITCHING ON/OFF........................................................................................................................................18 18.1_Machine start up...........................................................................................................................18 18.2_Switchingoffthemachine(anemergencystop)...........................................................................1819.0 RIM SETTING - STEP 1 - ...................................................................................................................1820.0 TYRE PRESSURE MONITORING SYSTEM (TPMS) ......................................................................................1921.0 BEAD BREAKING - STEP 2- ............................................................................................................................20 21.1_Upperbeadbreaking..........................................................................................................................20 21.2_Lower bead breaking.....................................................................................................................2122.0 MATCH-MOUNTING.........................................................................................................................................2123.0 TYRE DEMOUNTING - STEP 3 - .............................................................................................................................22 23.1_Upper bead demounting.........................................................................................................22 23.2_Lower bead demounting........................................................................................................23 23.3_UHPandRUN-FLAT tyresdemounting.....................................................................................2324.0 TYRE MOUNTING - STEP 4 - .................................................................................................................................24 24.1_Lower bead mounting.................................................................................................................24 24.2_Upper beadmounting.................................................................................................................25 24.3_UHPandRUN-FLATtyresmounting..............................................................................................2625.0 INFLATION...................................................................................................................................................27 25.1_Tubeless tyre inflation (optional)..............................................................................................2826.0 STANDARD ACCESSORIES..............................................................................................................................2927.0 OPTIONAL ACCESSORIES.........................................................................................................................3128.0 REPOSITIONING......................................................................................................................................3329.0 STORAGE......................................................................................................................................3330.0 SCRAPPING AND DISPOSAL.............................................................................................................................3331.0 OIL TREATMENT.................................................................................................................................3332.0 MAINTENANCE.................................................................................................................................................34 32.1_Standard maintenance................................................................................................................34 32.2_Laser pointers calibration.............................................................................................................35

32.2.1_Rimdiameterlaserpointercalibration(verticallaserpointer)......................................35 32.2.2_Rimwidthlaserpointercalibration(horizontallaserpointer)......................................38 32.3_Extraordinary maintenance.........................................................................................................4033.0 TROUBLESHOOTING CHART...................................................................................................................4134.0 WIRING DIAGRAM........................................................................................................................4435.0 CLAMPING CHUCK MOTOR WIRING DIAGRAM......................................................................................4636.0 CLAMPING CHUCK CARRIAGE AND TOOLS CARRIAGE MOVEMENT DIAGRAM....................................4737.0 PNEUMATIC DIAGRAMS...................................................................................................4848.0 SERVICE REPORTS......................................................................................................................51

CHAPTER Page

4

1.0 INTRODUCTION

Thanks for choosing this tyre changer.Thissuperautomatictouchlessleverlesstyrechangerisdesignedfortopprofessionaltyrespecialists,servicingrunflatandUHPtyreswithnotool/rimcontact.Inordertoensurecorrect,efficientandsafeoperation,andtoprolongtheworklifeofthemachine,pleasereadthismanual carefully and follow the instructions.

1.1 Tyre-Changer data:

Please refer to “Tyre-Changer Model” and “Serial Number” data on the Data-Plate to provide our Technical Service Dept. with the necessary details for prompt assistance and spare-parts tracking.Thesedataarefoundonadhesivelabelsappliedonthemachine.Forclarityandconvenience,wehaveinsertedFAC-SIMILEintheboxbelow.

1.2 Manufacturer data:

Pleasecheckthe“DeclarationsofConformity”atpage2ofthisManualandTyre-ChangerData-Plate.

1.3 Data plate:

This manual is an integral part of the product.Before using the tyre changer, read carefully the warnings and instructions contained in this manual since theyprovideimportantinformationonoperatingsafetyandmaintenance.

Keep this Manual in good conditions for further references.

NOTE: Some parts or components of standard production may differ from the illustrations contained in this manual.

2.0 GENERAL DESCRIPTION

Thetyrechangerisdesignedtodemountandmounttyresofcarsandlightcommercialvehicleswithrimsfrom12”to28”andmaximumdiameterof1200(47”)mm.

Thetyrechangerisdesignedtodemountandmountconventionaltyresofpassengercars,lightcommercialvehicles,nextgeneration“self-supporting”RUN-FLATtyresandlowprofiletyres(UHP)onsteeland/oralloyrims,evenbig-sizetyres.

TheTyre-ChangerisNOTintendedfordemountingcompletely-orpartially-inflatedtyres,dirtytyres,norforrim bendingorfordemountingindustrialwheelswithsplitringrims.AlltheseoperationsareFORBIDDEN.

5

Connections:-Powersupply:230V-1Ph-50/60HzFormoredetailedinformation,see chapter 9.4,“Connection to the electric network”onpage11.-Operatingpressure:8÷10bar(116÷145psi)-Supplypressure:8÷14bar(116÷203psi)-Air-feedingpressureregulatorsetat10bar(145psi)standardincluded-Inflatingair-pressureregulatorsetat3,5bar(50psi)standardincluded

Working capacity:-Rimclampingrange:12”to28”-Maximumrimwidth:16”(406mm)-Max.tyrediameter:47”(1200mm)

Motoinverter clamping chuck details:-Motorspower:0,75kW-2speed-Maximumtorque:1200Nm-Clockwiserotationspeed:7÷16rpm-Workingnoiselevel:<70dB

Bead-Breaking units:-Bead breaker cylindersforceat10Bar:12037N(1227Kg)-Maximumbeadbreakingrange:670mm(26’’)-Bead-pressingtoolcylinderpowerat10Bar:3055N(312kg)

Other Details:-Minimumoveralldimensionsmm:1800x1650x1650H-Netweight(optionalaccessoriesexcluded):561kg-Operatingtemperaturerange:min+5°Cmax+50°C(+41°÷+122°F)-Storagetemperaturerange:-5°÷+60°C(23°÷140°F)

Standard accessories (ref. page 29):-Lube paste bucket and brush-Plastictyrelever-Kitofnylonprotectorsformountingtool-PlasticprotectionsforSmartLockcenteringcone-Rubber protections for clamping chuck faceplate-Plasticprotectionsforclampingchuckdrivingpin

Main optional accessories (ref. page 31):-WLWheelLifter(Maxwheelweight80kg)-Wheelclampingadaptorforreversemountedandplasticcladwheels-ConesforclampinglighttruckandLCVswheels-Tubelessinflationexternalkit(Gun)-NylonconesforspecialLamborghini,Porsche,BMWwheels-WDKKit

1860

1140

Dimensions (mm)

1430

1650

1800 1650

3.0 SPECIFICATIONS

-PlasticconeØ70mmforclampingspecialalloyrims-Reducing ring for clamping chuck faceplate-AdjustmentknobforSmartLock-Cleaning brush for clamping chuck and Smart Lock-SpareOringsforSmartLock-Bead pressing clamp-Set of rubber protectors-Airlubricator,airfilter/watertrap-Calibration jig and magnet

Grossweight611Kg.(withoutoptionalaccessories)

Woodenpallet

Carton Box

Packing details (mm)

6

Cod. 3000048

Cod. 3040491R

Cod.3025916

Cod.3042077

Cod. 3041778

Cod.3040492

Cod.3040494

(optional)

Cod. 3005410

Cod. 3044247Cod. 3040487

Cod. 3040489 Cod. 3040486

Cod. 3044238 Cod. 3040490Cod. 3041345

Cod. 3041521C

Cod. 3042080

Cod. 3042078

Cod. 3042079

Cod. 3042081

DIMEN

SION

I / DIMEN

SION

S - Larghezza / W

idth: 30 mm

(± 1mm

)- Lunghezza / Lenght: 340 m

m (± 1 m

m)

MATERIALE: pvc antigraffio trasparente m

attato spessore 0.2 mm

con colla 3M;

Resistente agli agenti atmosferici;

Deformazione am

missibile dipendente dagli agenti atm

osferici ±2%;

COLO

RI:- giallo RAL 1021 / P 116C- nero

MATERIAL: pvc scratch resistant thickness 0.2 m

m w

ith 3M glue;

Weather resistant;

Maxim

um perm

issible deformation due to atm

ospheric condition ±2%;

COLO

RS:- yellow

RAL 1021 / P 116C- black

340 ± 1 mm

30 ± 1 mm

Rev.Data /Date

Descrizione / DescriptionDisegnato /

DrawnControllato /

CheckedApprovato / Approved

Modif. / Mod.

102/12/2015

Disegno rilasciato per produzione / Drawing released for production

S. CaramazzaI. Benedettini

A. MacchiaP97

Kg.0

vedinota/seenote

-

© Sicam

srl. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution as well as in the event of applications for industrial property rights.

ITA/IN

G

F E D C B A

43

21 1

23

45

67

8

D C B A

Disegnato / Drawn

1

HRCProf. / Depth

Rivestimento / Surface

1180

CORREGGIO (RE)

BWN1 / 1

A3

SW

26/10/2015A.M

acchiaData / Date

PVC

Approvato / ApprovedData / Date

Controllato / CheckedData / Date

Size/Gst.Missed details/Fehlende Angaben

Trattamento / Treatment

Mat. / Mat.Da / From

Repl. for

Doc.type

Foglio / Sheet

Ind.DP/TD

Repl. by

Format

MNR

Scala / ScaleConf. Mat. / Mat. meets

Crit. P.

Ling. / Lang.Peso / Weight

Syst.

P.B

artoli15/10/2015

© Sicam

srl. Si riserva a termini di legge la proprietà del presente disegno con divieto di utilizzo, riproduzione, m

odifica, distribuzione senza autorizzazione.

30/10/2015

1695105291

ETIC

HETTA

SICUREZZA

AREALA

VOROLIFT/S

TICKER

10:1

S.C

aramazza

ITA/IN

G

PVC

Kg.0

vedinota/seenote

-

© Sicam

srl. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution as well as in the event of applications for industrial property rights.

ITA/IN

G

F E D C B A

43

21 1

23

45

67

8

D C B A

Disegnato / Drawn

1

HRCProf. / Depth

Rivestimento / Surface

1180

CORREGGIO (RE)

BWN1 / 1

A3

SW

26/10/2015A.M

acchiaS.C

aramazza

Data / DateApprovato / Approved

Data / DateControllato / Checked

Data / DateSize/Gst.

Missed details/Fehlende AngabenTrattamento / Treatment

Mat. / Mat.Da / From

Repl. for

Doc.type

Foglio / Sheet

Ind.DP/TD

Repl. by

Format

MNR

Scala / ScaleConf. Mat. / Mat. meets

Crit. P.

Ling. / Lang.Peso / Weight

Syst.

P.B

artoli22/09/2015

© Sicam

srl. Si riserva a termini di legge la proprietà del presente disegno con divieto di utilizzo, riproduzione, m

odifica, distribuzione senza autorizzazione.

30/10/2015

1695105292

ETIC

HETTE

LEVASOLLE

VATO

RE/S

TICKER

1:2

ITA/IN

G

DIMEN

SION

I / DIMEN

SION

S - Larghezza / W

idth: 14 mm

(± 0,5 mm

)- Lunghezza / Lenght: 475 m

m (± 1 m

m)

MATERIALE: pvc bianco spessore 200 m

icron con colla acrilica permanente;

Resistente agli agenti atmosferici;

Deformazione am

missibile dipendente dagli agenti atm

osferici ±2%;

COLO

RI:- giallo RAL 1021 / P.116C- nero

MATERIAL: pvc w

hite thickness 200 micron w

ith permanent acrylic glue;

Weather resistant;

Maxim

um perm

issible deformation due to atm

ospheric condition ±2%;

COLO

RS:- yellow

RAP 1021 / P.116C- black

475 ± 1 mm

14 mm ± 0,5

Rev.Data /Date

Descrizione / DescriptionDisegnato /

DrawnControllato /

CheckedApprovato / Approved

Modif. / Mod.

102/12/2015

Disegno rilasciato per produzione / Drawing released for production

S. CaramazzaI. Benedettini

A. MacchiaP97

Cod. 3042601

Cod. 3042605(optional)

Cod. 3041958

Cod. 3019232B

Cod. 3042405

1 2 3 4

E E

F F

Il presente disegno è proprietà della Giuliano Group SpA e non può essere riprodotto o ceduto a terzi previa autorizzazione scritta

GREZZO

PESI SEMILAVORATI Kg.

MATERIALE

TRATT. TERMICO

DUREZZA

COD. MAT. GREZZ0

TRATT. SUP.

ISQ 87SEGUIRE LA SEGUENTE ISTRUZIONE:PER LE TOLLERANZE NON INDICATE SUL DISEGNO

p

SALDATURA AD ARCO CONFILO ANIMATO IN

ATMOSFERA DI GAS ATTIVO (80%Ar , 20% CO2)136

135 DI GAS ATTIVO (80%Ar , 20% CO2)

SALDATURA AD ARCO CONFILO IN ATMOSFERA

DESCRIZIONE

da S235

DOMEX 490÷740

a S355

T1

TIPO DI ACCIAIO

C20 ÷ C60

Sm x45°

R=

SMUSSINON QUOTATI

RACCORDINON QUOTATI

TOGLIERE TRUCIOLIE SPIGOLI VIVI

DATA:

UNITA' DI MISURA mm

MACCHINA

DIMENSIONI ISO

DISEGNO MOD.

SCALA: 1:1

N° PEZZI PER MACCHINA

DISEGNATORE

COD.LAV.DENOMINAZIONE

DIMENSIONI DA CONTROLLARE

FINITO

CODICE DI CONDIVISIONE

PROCEDIMENTI DI SALDATURA p (UN IEN 22553)

Dra

w2

1 2 3 4

A A

B B

C C

D D

DECALCO PULIZIA SMART LOCK

E MANDRINO 30 41521

SMTG

14/09/2016

Colognesi

Avery 806 YellowE806

CC

03/10/2017: C) Aggiunta fase di regolazione (Vezzani)10/10/2016: B) Modificata numerazione fasi di pulizia (Vignoli)18/05/2016: A) Modificata grafica adesivo ok Pellicciari

16

981

Cod.3025916

Cod.3025916

Cod. 3035727

Cod. 3042405

4.0 WARNING LABEL PLACEMENT

WARNING:Replace any warning label immediately in case of damage or loss.Do not operate the Tyre Changer in case of missing warning labels.Do not hide any warning label by any means. Do not interpose objects that can obstruct or reduce the visualcapacityoftheoperator.Refertotheabovementionedcodesforwarninglabelsordering.

7

The Tyre-Changer may only be used by specially trained and authorized expert personnel.

- The use of the machine is forbidden to disabled operators if their disabilities may affect the safety of the workingoperations.-Anytamperingormodificationtotheequipmentwithoutthemanufacturer’sexpresspriorauthorizationwillrelievethemanufacturerfromallresponsibilityfordamagederivingfromorreferabletosuchactions.-RemovingortamperingwithsafetydevicesimmediatelyinvalidatetheguaranteeandrepresentsaviolationofEuropeanSafetyLegislation.-TheTyre-Changerisequippedwithinformativeandwarninglabels,whicharedesignedandproducedtolastintime. If they should deteriorate, user shall request replacement decals.

5.0 GENERAL SAFETY RULESTheTyre-Changeristobeoperatedonlybyqualifiedandauthorisedpersonnel.

Aqualifiedoperatorissomeonewhohasfullyunderstoodtheinstructionsdescribedinthisoperationandmaintenancemanual,hasbeenspecificallytrainedandisawareofsafetystandardsathisworkplace.

Theoperatorsusingthemachineshallnotbeundertheinfluenceofdrugs,alcoholorotherintoxicatingSubstances,asthis may interfere with their ability to work safely.

Forgreatersecurityagainston-the-jobinjuries,theoperatorsshallwearsafetyfootwear,gloves,protectiongogglesandshallNOTwearanyformoflooseclothingthatcouldgetcaughtuporrestricttheoperator’smovements.

The operator must be able to:

- read and understand all instructions in the user and maintenance manual so as to be able to use the machine correctly and safely.- read and understand the danger warnings.- understand the characteristics of the machine.-keepunauthorizedpeopleawayfromtheworkingarea.- make sure that the setting in motion of the machine has been carried out in compliance with all applicable rules andregulations.- make sure all operators are familiar with the machine and know how to use it safely and correctly.-avoidtouchingmovingpartsorpressurisedpartswithoutfirstdisconnectingthemachinefromtheelectricalandairpower supply.-keeptheoperationinstructionmanualwithcareinaneasilyaccessibleplace,sothatitcanbeconsultedwheneverneeded.

INCASEOFFIRE,USEONLYDRYCHEMICHALORCO2EXTINGUISHERSTOPUTTHEFIREOUT

6.0 SAFETY DEVICESThetyrechangerisequippedwithsafetydevicesthataredesignedtoguaranteethesafetyofthemachineoperator:-Mainpowerswitchwithemergencystopfunction:cutsoffpowersuppliedtothemachine.-Pressurelimitingvalve,installedinsidethemachinepreventsthepressurefromexceeding3,5bar(50psi)duringinflation.-Pressureregulatorwithairsupplypressuregaugelimitedtomaximumworkingpressure(10bar(145psi)).OnTyre-Changersequippedwith“Tubelesstyrebeadseatingsystem”:-Maximumpressurevalve,installedontotheairtankpreventsthepressurefromexceeding11bar(160psi).

Removing or tampering with safety devices immediately invalidates the guarantee andrepresents a breach of the European Safety Legislation.

WATERextinguisher

FOAMextinguisher

POWDERextinguisher

CO2extinguisher

DRY materialsFLAMMABLE liquidsELECTRICAL equipment

OK OK OK OKOK OK OK

OK OKNONO NO

8

Grossweigth611Kg.

fig.2

fig.1

7.0 TRANSPORT- The Tyre-Changer must be transported in its original packaging and kept in the position indicated on the actual packaging.

-Thepackagedmachinehastobemovedbymeansofaforkliftofsuitablecapacity.Please,inserttheforksasshowninthefollowingpicture(Fig.1).

8.0 UNPACKINGRemovetheprotectivecardboard,removeallfixingscrewandfreetheTyre-Changerfromitsoriginalpallet.Check the perfect condition of the machine, making sure that no part is damaged or missing, by referring to the picture atpage 12.If in doubt, please do not use the machine and get in touch with your Distributor for further steps.

Keeppackingelementsawayfromchildren.Allpackingelementsmustbestoredintheproperstockingareas.

Note: AllthemostdelicatesurfacesoftheTyre-Changerarecoatedwithaspecialrust-proofoil.Someoiltracesmayleakaftercoatingprocedure:please,removethemaccordingly.

Useliftingequipmentofsuitableload-bearingcapacitythatisabletotaketheweightofthetyrechanger(atleast700Kg.);toliftthemachine,useatransportstrapwithminimumload-bearingcapacityofatleast700kg.(Fig.2)Aftertyre-changerpositioning,takeofftheliftingbelt.

Lifting point

9

Fig.1

500

500

500

1900

500

100

500

1900

500

500

500

1900

9.2 Tyre-Changer placement and connectionsPlaceTyre-Changerontoaflat,smoothandnotslipperyfloorwithasuitableloadcapacity.The machine need not necessarily be anchored to the ground, but if you prefer to do so, drill holes 100 mm deep onthe ground in correspondence of holes at the machine rear base by using a 10 mm drill bit of suitable length. Insert suitablemetalanchordowelsintheholesdrilledandsecurefirmly.If the machine is installed outside it must be protected by a appropriate lean-to shed.The installation site should be equipped with an electrical system with an adequate grounding circuit equipped with anappropriategroundfaultcircuit–breakersetfor16Aplacedinavisibleandaccessibleplacebytheoperatorandequipped with power indicator light.

NOTE:Ifthemachineissuppliedwithouttheelectricalplug,theusershallfitone-atleast16A-thatissuitableforthevoltageofthemachineandcomplieswithcurrentregulations.

Before connecting the machine, please check that the characteristics of your networkscorrespond to those indicated by machine’s data plate.

Unplug the machine from electrical power source and compressed air supply before moving and servicing it.

9.0 INSTALLATION

9.1 Space required for positioning

Whenchoosingtheplaceofinstallationbesurethatitcomplieswithcurrent safety-at-work regulations.The Tyre-Changer must be connected to the main electric power supplyandthecompressedairsystem.Itisthereforeadvisabletoinstallthe machine near these power sources.Theinstallationareamustleaveatleasttheroomshowninpicture“Fig.1”,soastoallowallpartsofthemachinetooperatecorrectlyand without any restriction.Lighting should be adequate to perform safe operations and complywith the current regulations for safety at work.

The Manufacturer is not responsible for damages caused by electrical connection differentfrom the original indications on the data plate.

Even small jobs done on the electrical system must be carried out by professionally qualifiedpersonnel.

During the first connection to the compressed air, attention must be paid to the movementof certain parts of the machine, which may be sudden and unexpected, creating potentialhazards in the action area.

10

9.3 Installation and assembly

1

2

3 4

Loosen 4 fixing bolts on controlconsole column.

Turn the control console column around so as toplace it in themostconvenientpositionfortheoperatorleavingenoughspacesothatthecolumndoesn’ttouchtheupperbeadbreakerdisk arm when it is in resting position.

Tighten the 4 fixing bolts on control consolecolumn.

Removethemirrorwhiteprotectivefilm. PlacetyrepastelubebucketbracketonSmartLock support, as shown in the photo.

11

Fig.2

Mount the hook for the brush on the inner side ofthe control console column.

Thepneumaticnetworkoftheinstallationareamustbeprovidedwithmin.8barworkingpressure outlet.

- Connect the machine to the compressed air network by means of the air connection unitlocated at the rear side of the machine (Fig.2).

9.5 Connection to the compressed air network

9.4 Connection to the electrical networkThe installation site should be equipped with an electrical system with adequate grounding circuit.Connectthemachinetoanelectricalpowersocket230V/1Ph/50-60Hzprotectedbysafetycircuitbreakerwiththefollowingfeatures:

-InterventionratedcurrentIn=20A,C curveaccordingtoIEC/EN60898standard-DifferentialcurrentId=30mA

NOTE: Ifthemachineissuppliedwithouttheelectricalplug,theusershallfitonethatissuitableforthevoltageofthemachine and complies with current regulations.

9.6 Laser pointers calibrationBefore starting demounting/mounting a tyre, please check positioning of laser pointers using a special calibration jig supplied with the standard accessories of the machine.Followtheinstructionsinchapter32.2onpag.35.

Positionthelifterplatform(optional)soastoalignitsholewiththepin.Tightenthescrewsfirmly,asshown in the photos.

5

6

7

8

12

10.0 EQUIPMENT COMPONENTS

Upperbeadbreakerarmopeningcontrollever

Pneumatic unitAdjustmentknobfor

Smart Lock Pressureregulator

Inflationhosewoundonapulley with return spring

Inflatingpressuregauge

Airsupplypressure gauge

Airfilter/watertrap

AirlubricatorDeflationbutton

BP 1 Plus (Patented)Bead pressing arm, complete

with self-storage function

Smart lock(Patented)

Ultra-quickwheelclampingsystem

PedalUnit

Control console

Kit GunTubelessinflation

external kit(optional)

Wheellifter(optional)

XTool(Patented)Touchlessleverlesstyre

demountdevice.

13

11.0 CONTROLS DESCRIPTION AND FUNCTION CONTROL

Any testing must be carried out without any tyre on the machine.Watch out for any component which could interfere with machine testing operations.

1-Clockwise and counterclockwise clamping chuck (ref.14)rotationcontrolpedal2-Wheelliftercontrolpedal(up/down), optional3-Inflationpedal4-STEP 1:Rim diameter and width setting joystick 5-STEP1: Laserverticalmovementenablingbutton 6-STEP 2:Lowerbeadbreakerdiskcontrollever(up/down)7-STEP 2:Upperbeadbreakerdiskcontrollever(up/down)8-STEP 2:Bead breaker disks radial“over-run”button

9-STEP 3:Demountingtoolcontrollever10 - Air supply11-STEP 4:Mounting tool selector switch12-Deflationbutton13-Beadpressingarmcontrolbuttons(up/down)14-Clamping chuck15-Bead breaker disks16-Mounting/demounting tools17-STEP 1 : Laserhorizontalmovementenabling button 18-MainPowerSwitch19-Upperbeadbreakerarmopeningcontrollever

2

13 12

14

16

31

45

6

789

11 17

18 1015

19

14

12.0 RIM AND TYRE IDENTIFICATIONBeforestartingdemountingatyre,itisofCRUCIALIMPORTANCEtoidentifythemeasurementsoftherimandofthetyre, as well as to make sure that neither the rim nor the tyre are damaged.

WARNING: theseveryimportantprocedureshavetobeperformedcorrectlytoreduceanyrisksoftyreburstingwhilere-mountingandinflatingthetyreontherim.

Each rim bears an indication of their diameter, width, number of humps etc.Example: 8Jx15H2

A=8 Nominalwidthoftherimininches(1inch=25.4mm)B=J SizeoftheflangeC=15 NominaldiameteroftherimininchesD=H2Doublehump(beadretentionsystem)

Each tyre bears a considerable amount of details, among which are thedimensions, type and maximum speed.

Example: 205/65 R 15 91H TL

A=205Widthofthetyre(thedistancebetweentyresides,expressedinmillimetres).B=65 Ratiopercentagebetweenthewidthofthesectionanditswidth.C=R Typeoftyre(R=radial).D=15Indicatesthekeyingdiameterininches(diameterofwheel),which must be the same as the rim.E=91 Indexofthemaximumloadbornbyeachwheel.F=H Maximumadmittedspeedofthetyre(H=210Km/h)G=TLTypeoftyre(TL=Tubeless)

WARNING:Itisstrictlyforbiddentomounttyresonrimswithmismatchingparameters(diameterandwidth).Itisalsoforbiddentomounttyreswithdimensionswhicharedifferentfromtheonesstated in the car logbook.

8J x 15H2

A DB C

AFECB DG

13.0 VALVE POSITION

Thepictureontherightsiderepresentsarimasaclockface(viewfromthetop).ThevalveorthetoolpositiondescribedbythefollowingworkingstepsALWAYSrefer to the represented clock-face hours-marks.

WARNING :To avoid damaging the valve or the pressure sensor, whereinstalled,youmustalwayssetthevalveintothepositionindicated,following the instructions during bead breaking, mounting anddemounting operations.

15

fig.1

14.0 WHEELS AND TYRES CLASSIFICATION

14.1 Standard wheels

A“standardwheel”isacarwheelwithsteeloralloyrim,withcenterhole,drop centre close to the external border of the rimandastandardtyre(neitherRUN-FLATnorLowProfile).

14.2 Low-profiled tyres (UHP) wheels

Lowprofiletyres(UHP)arethoseinwhichtheheight(H)andthewidth(C)havearatiolowerthan0.5(i.e.lowprofileseries45standsforaaspectratioofH/C=0.45).Fortyrestobeconsideredaslowprofile(UHP),theymustalsohaveamaximumspeedcodeequalto/orhigherthanV.

Maximum speed codesQ=to160km/hR=to170km/hS=to180km/hT=to190km/h

14.3 RUN-FLAT tyres wheels

RUN-FLATtyresarethosewhichallowtocontinuetodrivethevehicleforapresetnumberofmilesandatapresetspeed,eveniftheyhavenointernalpressure.Theseparameterschangefromonemanufacturertoanother.Themarketcurrentlyoffers2differenttypesofRUN-FLATtyres:-Thosewithreinforcedsidewall(self-supporting)where,thankstoadifferentmixandareinforcedstructure,theshoulderofthetyrecanbeartheweightofthevehicleevenwhentheinternalpressureofthetyreiszero.-Thosewithinternalsupportwhichhavearinginsidetherimthatbearsthesidewallofthetyrewhenthereisnopressureinsideit.Theinternalsupportmaybemadeofplastic(Pax-Sistem)orofmetal(Support-Ring).

Allthetyreswhichdonotcorrespondtotheabovementioneddescriptionshavetobeconsideredas“standardtyres”.

ThisTyre-Changerisabletohandlealltypesofwheelswith“standard”tyres,LowProfile(UHP)andRUN-FLATtyreswith reinforced side.RUN-FLAT tyres with internal support (PAX System or Support-Ring type) mounting/demounting procedures needspecial accessories to be used according to precise dedicated instructions.

It is compulsory to follow the demounting/mounting instructions carefully, in order to avoid tyre damages and the consequent risks for the vehicle and the passengers safety.

U=to200km/hH=to210km/hV=to240km/h

W=to270km/hZR=>240km/hZR(Y)=>300km/h

15.0 WDK RULESWDKisaGermancertifiedbodychargedwiththeevaluationoftyre-changersfunctioningandtheircapabilitytoperformgoodandsafeoperationsonRUN-FLATandUHPtyrescorrectly,toavoidpermanentand potentially dangerous damages to tyres.In order to perform a correct demounting and mounting process, the following premises are strictly compulsory:

1.Guidelinesknowledge-WDKliteratureprovidesallnecessaryguidelinesforalltyrebrandsandmodels,includingalltheoreticalandpracticalinstructionstoavoidanypossibledamagetotyre,rimandpressure sensor.2.Certifiedtyre-changer-ThisTyre-ChangercanbedeliveredwithWDKaccessoriestofulfilallWDKrequirements.3.TomeettherequirementsoftheWDKprocedure,thepneumaticbeadpressingarmmustbeusedwiththespecificbeadpressingtool(showninthepicturebeside).4.Qualifiedoperator–ThespecifictechnicalcoursesprovidetheoperatorswiththenecessaryWDKguidelinesandserviceinstructions.DedicatedWDKofficialcoursesareavailabletogettheWDKdiploma, when necessary.

WDKBeadpressing tool(optional)

16

16.0 WHEEL POSITIONING AND CENTERING ONTO CLAMPING CHUCK (OPTIONAL)Beforeliftingandpositioningthewheelontotheclampingchuck,removeallthecounterweightsfromtherimusinganappropriatetool,beingcarefulnottodamagetherimitself.Removeanyobjectortoolwhichcouldinterferewiththewheel lifter (availableasoptional).-Putthewheelverticallyontothewheellifter(optional),sothatinsideofrimfacestyrechanger(Fig.1).-Pressthecontrolpedalref.3toliftthewheelandpositionitontoclampingchuck.Oncethewheelisovertheclampingchuck, align the central hole of the rim with the rotation axle of the clamping chuck. Rotate the wheel in order to match oneofthelugholeswiththedrivingpinoftheclampingchuck(Fig.2).-Lower the lift by releasing pedal ref. 3. -Reversemountedwheelsshouldalwaysbepositionedandclampedon theclamping chuckupsidedown.Whenclamping,useFRRQuickwheelclampingadaptorforreversemountedandplasticcladwheels(availableasoptional,seepage31).FollowtheinstructionsgiveninFRRQuickmanual.

Fig.2

Clamping chuckDrivingpin3-Wheelliftercontrol pedal

Fig.1Wheellifter(optional)

17.0 WHEEL CLAMPING OPERATION WITH SMART LOCK (PATENTED)

-Patentedultra-quickwheelclampingsystemmakesiteasierforoperatorstoperformatoughandsteadywheelclampingbysimplyturningalever.

- The clamping is performed by an expanding nut. Both strength and grip can be easily calibrated by acting on itsadjustment button and by means of an appropriate adjustment knob.

-SMARTLOCKweighsjust:4,5Kg.

17

Wheel clamping operation with Smart LockLockinglever

SMART LOCK introduction /extraction handle.

Centering cone

Expanding nut

Elastic rubber rings(OR3093)

Conical terminal

Check the correct wheel positioning onto the clamping chuck.InsertSMARTLOCKmakingthecenteringconefittherimholecorrectly,leavingnospaceamongSMARTLOCKnut,therimandthetyre-changerclampingchuck.

Keeping the handle pressed down (to avoid eventual residual plays), tilt thelockingleververtically.

Duringwheelclampingoperationthequick-releasesystemmovesautomaticallyto hooking position (click).Check the perfect wheel locking onto the clamping chuck before performing any bead breaking, demounting or mounting operation.

Plasticprotectiontoavoidanydamageto

alloy rim

Wheel unlockingOncetheoperationsontothewheelarecompleted,liftuptheQuick-Releasesleeve.

TiltdownthelockinglevertounlockSMARTLOCK,inorder topullout the lockingnutandremove thewheel from the clamping chuck.

1

2

3

1 2 3

4

5

5

CL

ICK

4

Quick-Releasesleeve

17.1 Tightening adjustment

TheclampingforceofSMARTLOCKcouldbeloosenedafteralongtimeusebyaprogressivewearingofsomecomponents,thisrevealedbyaprogressiveslackofthelockinglever.

Torestore/increase/decreasetheSMARTLOCKtightening:presstheyellowadjustmentbuttonand,bymeansoftheadjustmentknob(standardsupplied),startturningmanuallytheconicalterminalthusactingontheexpandingnut.Then,release the button and keep on turning the conical terminal until the button pops up again.

Tighteningstrengthadjustmentbutton(yellow).

- +Adjustment

knob

+ Rotate clockwise to increase the clamping force

- Rotate counterclockwise to decrease the clamping force

18

Fig.2Fig.1

1

2

B

2

1

A 4

ON

OFF

1 2 3 4

E E

F F

Il presente disegno è proprietà della Giuliano Group SpA e non può essere riprodotto o ceduto a terzi previa autorizzazione scritta

GREZZO

PESI SEMILAVORATI Kg.

MATERIALE

TRATT. TERMICO

DUREZZA

COD. MAT. GREZZ0

TRATT. SUP.

ISQ 87SEGUIRE LA SEGUENTE ISTRUZIONE:PER LE TOLLERANZE NON INDICATE SUL DISEGNO

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SALDATURA AD ARCO CONFILO ANIMATO IN

ATMOSFERA DI GAS ATTIVO (80%Ar , 20% CO2)136

135 DI GAS ATTIVO (80%Ar , 20% CO2)

SALDATURA AD ARCO CONFILO IN ATMOSFERA

DESCRIZIONE

da S235

DOMEX 490÷740

a S355

T1

TIPO DI ACCIAIO

C20 ÷ C60

Sm x45°

R=

SMUSSINON QUOTATI

RACCORDINON QUOTATI

TOGLIERE TRUCIOLIE SPIGOLI VIVI

DATA:

UNITA' DI MISURA mm

MACCHINA

DIMENSIONI ISO

DISEGNO MOD.

SCALA: 1:1

N° PEZZI PER MACCHINA

DISEGNATORE

COD.LAV.DENOMINAZIONE

DIMENSIONI DA CONTROLLARE

FINITO

CODICE DI CONDIVISIONE

PROCEDIMENTI DI SALDATURA p (UN IEN 22553)

Dra

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1 2 3 4

A A

B B

C C

D D

DECALCO PULIZIA SMART LOCK

E MANDRINO 30 41521

SMTG

14/09/2016

Colognesi

Avery 806 YellowE806

CC

03/10/2017: C) Aggiunta fase di regolazione (Vezzani)10/10/2016: B) Modificata numerazione fasi di pulizia (Vignoli)18/05/2016: A) Modificata grafica adesivo ok Pellicciari

16

981

17.2 Maintenance -TheregularcleaningandlubricationoftheSMARTLOCKcomponents grant a long-lasting correct functioning of the tool.1- Clean the expanding nut with the metallic brush or use the standard supplied cleaning brush for Smart Lock.2-Blowcompressedairtoremovedirt.3- Clean the clamping chuck inner surface using the standard supplied cleaning brush.4-Blowcompressedairtoremovedirt.-PeriodicallylubricateallmovingmechanicalpartswithCRCorsimilar.- The replacement of 2 rubber rings (OR3093)isrecommendedevery12÷18monthsuseofSMARTLOCK.

18.0 SWITCHING ON/OFF18.1 Machine start up

- Turn the yellow/red main power switch clockwise(ref.18,page13).

18.2 Switching off the machine (an emergency stop)

- Turn the yellow/red main power switch counterclockwise(ref.18,page13).

STEP 1: rim diameter setting

-KeepingbuttonA pressed down, while simultaneously acting on the joystick (4)withhorizontalmovement(ref.1,Fig.1)andbringtheLASERpointerontotheedgeoftherimtoplaceitaccordingtoitsdiameter.

19.0 RIM SETTING - STEP 1

STEP 1: rim width setting

-PressandholddownbuttonB, while simultaneously acting on the joystick (4)withverticalmovements(ref.2,Fig.1)andbringtheLASERpointerontotheedgeoftherimtopositionitaccordingtothecorrectheightoftheupperrimedge.

WARNING:Before carrying out any operation on the wheel make sure that pointers are correctly positioned as showninpicture2toavoidanydamagetotherimortyre.

19

TPMSvalve

Traction point

20.0 Tyre Pressure Monitoring System(TPMS)TPMS,TyrePressureMonitoringSystemisanelectronicsystemdesignedtomonitortheairpressureinsidethetyresthrough special sensors mounted inside the wheels, which provide real-time tyre-pressure information and insidetemperaturedatatothevehicle’selectroniccontrolunit.Tyrepressuresystemalertsthedriverwhenthetyrepressurefalls 20% below the recommended pressure, thus increasing your safety on the road.ThischapterdescribesthecorrectpositioningofTPMSvalveduringthedifferentworkingstages,inordertoavoidanydamage.

Bead breaking:PlaceTPMSvalveat “2:00o’clock”position.Startpushingon thetyre bead using the upper bead breaker disk.

Upper bead demounting:Spintheclampingchuck(clockwise)bypressingthepedal1 until the valvereaches“1 o’clock”position(at about 10 cm from the demounting tool)so as toavoidpossible damagestotheTPMSvalve.

Warning: rim and tyre must spin together as one during bead demountingoperations,toavoiddisplacementofTPMSsensor.

Lower bead demounting, with demounting tool:Place TPMS valve below the demounting tool at “12:00 o’clock”position.

Lower bead demounting, with bead breaker disk:PlaceTPMSvalvetowardsthebeadbreakerdisk.

Lower bead mounting:PlaceTPMSvalveat“5:00o’clock”position,inanycaseatabout10cm from traction point.

Upper bead mounting:PlaceTPMSvalveat“5:00o’clock”position,inanycaseatabout10cm from traction point.

Demounting tool positioning:Place TPMS valve at “2:00 o’clock” position. Bring the demounting tool into working position. Whilespinning the wheel, insert the demounting tool into the dropcentrelevel.Stoptyrerotationwhenthevalvereaches11o’clockposition.

20

fig.1

fig.3

19

7

8

fig.2

Check for correct centering and locking of the wheel onto the clamping chuck.

21.1 Upper bead breaking

-Before starting any operation, check the correct centering and locking of the wheel onto the clamping chuck.-Beforestartinganyoperation,pleasecheckeventualpresenceofaTPMSpressuresensor.Ifso,checkitsefficiencyusing an appropriate tool.-Itispossibletounlockthedisksupportandenableaspringloadedmovement,changingtheangleofthedisk,increasingitspenetrationinsidetherim.Particularlyeffectivewithsofttyres.

Make sure the tyre is completely DEFLATED before starting any operation on the wheel.

21.0 BEAD BREAKING - STEP 2-

-Spintheclampingchuckuntilthevalvereaches“2 o’clock”position.

-Bringtheupperbeadbreakerdiskdownuntilittouchesthetyreusingcontrollever7forliftingandlowering(up/down).

- Start spinning clockwise by pressing pedal 1 (page13).

Note:theclampingchuckcanspinat2differentspeeds,accordingtooperator’spreferences.

-Whilespinningthewheel,pushtheupperbeadbreakerdiskdownbelowtheedgeoftherim,thenpressandholddownthe“over-run”functionbutton8 (Fig.2) whilegraduallyloweringthebeadbreakerdiskuntilthebeadisremovedfromthe rim, then release the button 8 (Fig.2). -Assoonasenoughspaceisavailable,apropertyrelubricatingpasteshouldbecarefullyappliedtoboththeinnersurfaceoftherimandthetyrebead(Fig.1).Useonlyspecifictyrelubricants.

During bead breaking operations, check thecorrectpositioningofTPMSpressure sensor (ifany), usual-lyinsertedintothevalveoftherim.Wrongmovementsofthebeadbreakerdiskscoulddamagethesensor.AvoidanycontactbetweenthelubricatingpasteandTPMSpressure sensor, if any.

-Oncethebeadgetsloosened,raiseandmoveawaytheupperbeadbreakerdiskbyactingonlever7 (Fig.2).

-Once the bead breaker disk is out of therim,itispossibletomovethebeadbreakerdisk arm away from the working position by actingonlever 19(fig.3).

19

21

fig.2

fig.3

fig.1

8

6

Lift the lower bead breaker disk until it touches the lower tyre bead using controllever 6 (Fig.1) for lifting and lowering.Start spinning clockwise, by pressing pedal 1.

-Whilespinningthewheel,pushthelowerbeadbreakerdiskupabovetheedgeoftherim,thenpressandholddownthe“over-run”functionbutton 8 (Fig.1)whilegraduallyliftingthebeadbreakerdiskuntilthebeadisremovedfromtherim, then release button 8 (Fig.1).

-Assoonasenoughspaceisavailable,apropertyrelubricatingpasteshouldbecarefullyappliedtoboththeinnersurfaceoftherimandthetyrebead(Fig.2).Useonlyspecifictyrelubricants.

NOTE:forabettercontrolofthelowerbeadbreakingyoucanusethededicatedmirrorfittedontothetyrechangermain frame.

21.2 Lower bead breaking

WARNING:Whilebreakingthebead,justpressonthebeadandneveronthesideofthetyre.

22.0 MATCH-MOUNTING

Drivingcouldbeaffectedbyvibrationscausedbydeformationsoftherimand/orofthetyre.Tooptimizethewheel-balancing,itisnecessarytopositionthe wheel onto the tyre changer again to bead-break and lubricate the rimand the tyre, spinning the tyre around the rim to a proper position.Both upper and lower disks make this process easier (Fig.3), by gently holding the tyre steady while the clamping chuck spins the rim until the correct matching position is reached.

22

Fig.2

Fig.3

Fig.4

9

23.0 TYRE DEMOUNTING - STEP 3-Oncethebeadbreakingprocessiscompleted,andthewheelisalreadypositionedontotheclampingchuck,checkand ensure its locking and centering.

23.1 Upper bead demounting

- Spin the clamping chuck by pressing the pedal 1 (page13)untilthevalvereaches“1 o’clock”position(at about 10 cmtotherightfromthedemountingtool)soastoavoidpossible damagestothevalveandthesensor-ifany(Fig.2).

-Movethecontrollever9 (Fig.1) to the left to position the demounting tool in the working area.- Start inserting the tool between the tyre bead and the rim edge by gradually pressing controllever 9 down to bring the tool to the end ofthestroke(Fig.3).Ifnecessary,usetheupperbeadbreakerdiskin order to reduce stress on the tyre sidewall, until the bead is perfectly hooked.- If using bead breaker disk, bring it back upwards, and start rotating clockwise until the tool hooks the bead.- If the tool fails to hook the tyre bead, rotate clockwise until the desired resultisachieved.

NOTE: STOP TYRE ROTATION WHEN THE VALVE REACHES 11 O’CLOCK POSITION -Move the control lever 9 upwards (gradually) andpull out the tyrebead,bringingthetoolattheendofthestroke(Fig.4).- Make sure the bead is loose all the way around the tyre and the bead isatdropcentrelevel.Ifnot,useBP1 PLUS pneumatic bead pressing armpositionedat180°fromthetoolforeasiertyredemounting.- Start spinning the wheel clockwise and continue until the upper bead has completely come off the wheel rim.

-Manuallyreleasethetyrebeadfromthedemountingtool.Movethedemountingtoolawaytotherestingposition,bymovingcontrollever 9 all the way to the right.- By gently pushing up the lower bead breaker disk against the tyre lower sidewall for a maximum of about 20-30 mm (1”)itwillbeeasiertodemounttheupperbead.

Before inserting the tool at drop-centre position by operating the control lever 9, spin the clamping chuck until the valve reaches “3 o’clock” position so as to avoid possible damages to the valve and the sensor - if any.

Fig.1

23

fig.2fig.1

fig.3 fig.4

8

6

9

23.2 Lower bead demounting

-Beforepullingoutthelowerbead,spintheclampingchuckuntilthevalvereaches“3o’clock”positionso as toavoidpossibledamagestothevalveandthesensor-ifany.

-Bringthelowerbeadbreakerdiskupbyoperatingthecontrollever 6 (Fig.1) to lift the tyre until the lower bead is about10mmovertheupperrimedge(Fig.2).Pressandholddownbutton8 (Fig.1)toactivatethe“over-run”functionand bring the disk close to the rim.

- Spin the wheel clockwise until the tyre comes off completely.

- Check the status of the pressure sensor - if any - and replace it if necessary. -Oncetheoperationsarecompleted,movethelowerbeadbreakerdiskawayfromtheworkingposition.

NOTE: rim and tyre must spin together as one.-Inordertohelpthelowerbeadcomingoutandtoreducethestresstothetyre:inserttheplasticleverandspinthewheel clockwise.

23.3 UHP and RUN-FLAT tyres demounting

-SomepreciseandcarefuloperationsarenecessarytodemountUHPandRUNFLATtyres.ItiscompulsorytofollowWDKrulestoavoidpermanentdamagestothesetyres.-UpperbeaddemountingofUHPorRunflattyrescanbeperformedbyinsertingthedemountingtool(Chapter23.1)insidethetyreandreachingthedropcentrelevel.Atthisstage,placeBP1 PLUS pneumatic bead pressing arm on the oppositesideofthedemountingtoolandpressthesidewalltofacilitatethefittingofthebeadinsidethedrop-centre.-Graduallypressthecontrollever9 (Fig.4)all the way up, and pull out the tyre bead, bringing the tool upwards at the end of the stroke.-By gently pushing up the lower bead breaker disk against the tyre lower sidewall for a maximum of about 20-30 mm (1”)itwillbeeasiertodemounttheupperbead.-Inserttheredplastictyrelever(Fig.3)- Start spinning the wheel clockwise and continue until the upper bead has completely come off the wheel rim.- Manually releasethetyrebeadfromthedemountingtool.Movethedemountingtoolawayfromtheworkingposition,bymovingthecontrollever9 (Fig.4) all the way to the right.-Thedemountingprocedureofthesecondbeadissimilarto“standard”tyre(Chapter23.1).

24

7

8

fig.1

fig.2 fig.3

24.0 TYRE MOUNTING - STEP 4-Checktherimandthetyrecarefully,asperinstructionsintherelevantparagraphofthismanual.

-Iftherimhasbeenremoved,clampitagainontotheclampingchuckasperinstructionsinparagraph“Wheelclam-pingoperationwithSmartLock”ofthismanual.Makesurethetwolasersarecorrectlypositionedontherimedge.

- Carefully lubricate the whole inner surface of the rim and the beads of the tyre, both externally and internally right aroundthecircumference,forawidthofatleast3cm(Fig.1).

Avoid any contact between lubricating paste and pressure sensor, if any.

24.1 Lower bead mounting-Placethetyreontotherim,tiltingthetyreto“3o’clock”positioninordertomakethebeadgoundertheupperrimedge,takingcareofpositioningthevalveat“5o’clock”position(Fig.3).-Bringtheupperbeadbreakerdiskdownuntilittouchesthetyreusingcontrollever7 (Fig.2)for lifting and lowering (up/down).- Rotate the wheel clockwise by pressing pedal 1 (page13),whilemanuallypressingthetyrein“5o’clock”positionuntilthelowerbeadreachesthedropcentrelevel.Keepthetyrepressedwhilerotatingtocompletethelowerbeadmounting.

WARNING:Rim and tyre must spin together as one.

25

fig.2

fig.3

fig.1

fig.4

fig.5 fig.6

11 Position 1

Central position (0)

24.2 Upper bead mounting

- Presspedalref. 1 (page13)torotatethewheelclockwiseuntilthevalvereaches“5o’clock”position.-Moveselectorswitch11 (Fig.1)totheleft(position 1)tobringtheuppermountingtoolinworkingposition(Fig.2).-Usingtheappropriatecontrolleverbringtheupperbeadbreakerdiskdownbelowtheedgeoftherim(Fig.3).Thisoperationwillallowinclinationoftyreto“3o’clock”position.-Pressthepedalref.1 (page13)torotatethewheelclockwise,contemporarilypressthetyremanuallyfrom“5o’clock”positiontoforcetheupperbeadatdrop-centreposition.Keepitpressedwhilerotatingtocompletetheupperbeadmounting(Fig.4).

-UseBP1 PLUSpneumaticbeadpressingarmtohandleparticularlydifficultstandardtyres(Fig.5).

-Pressdown thedescentbutton (Fig. 5) andpushwithbeadpressing tool against the tyre sidewall at “5o’clock”position.Press thepedal1 (page13) to rotate thewheelclockwiseuntil tyre iscompletelymounted.At theendofmounting procedure, the bead pressing tool lifts and stores itself automatically in rest position.

- Bring selector switch 11 backtocentralposition(0)inordertoplacethetoolinrestposition.-Bringtheupperbeadbreakerdiskinrestpositionusingtheappropriatecontrollever.

Descent button

26

Fig.1

Fig.4 Fig.5

11

24.3 UHP and RUN-FLAT tyres mounting

-LowerbeadmountingofUHPorRunflattyrescanbeperformedbyusingtheupperbeadbreakerdiskonly(page24).Rotatetherimclockwiseuntilthevalvereaches“5o’clock”position.Putthetyreontherimtilteddownto“3o’clock”position. Lower the upper bead breaker disk on the shoulder of the tyre, rotate the wheel clockwise and simultaneously push down the bead breaker disk to complete the mounting.-Oncethelowerbeadismounted,rotatetherimuntilthevalvereaches“5o’clock”position.Pressthetyrebytheupperbeadbreakerdiskuntilthebeadreachesdrop-centrelevel.Movetheselectorswitch11 (Fig.3)totheleft(position 1)and insert the mounting tool into the tyre.- Usethebeadpressingclamp(standardsupplied)togetherwiththeproperrubberprotection(•steelrim,••aluminiumrims,•••aluminiumrimswitharchedspokes)(Fig.1).Lockitontotherimedgewiththevalveat“5o’clock”position.Pressthetyrebeadwiththeupperbeadbreakerdisktofacilitatepositioningandlockingoftheclamp.-SpinslightlyandfitBP1 PLUSbeadpressingtoolbetweenthediskandtheclamp.Pressthetyreuntiltheupperbeadreachesdrop-centrelevel(Fig.4).-InaccordancewiththeWDKprocedure,thepneumaticbeadpressingarmmustbeusedwiththeWDKbeadpressingtool(Fig.2,optionalaccessory).- Start spinning the wheel making sure that the whole tyre bead is right inside the drop-centre.- If this necessary condition for a correct mounting is not accomplished, use the pneumatic bead pressing arm and pushthetyresidewalltofittheupperbeadintothedrop-centre(Fig.5).

-Goonspinningthewheeluntiltheupperbeadiscompletelymounted.-Removetheclampandtherubberprotectionwiththehelpofbeadpressingarmorbead breaker disk. Removethebeadpressingarmandmovethetoolinrestpositionbyrotatingtheselectorswitch 11 to the center posi-tion(0).Liftthebeadbreakerdiskupandbringittorestpositionusingthecontrollever 7.-Keepthewheellockedontotheclampingchuckduringtheinflatingoperations.Readtheinflatinginstructionscarefully.-Oncethetyreinflationiscompleted,unlockthewheelandbringitdownontothefloor,takingadvantageofthewheelpositioningdevice.

Rubber protectors WDKBeadpressingtool(optional)

WARNING:In these last phases, work very carefully to avoid straining the side of the tyre excessively.

Fig.2

Fig.3Position 1

Central position (0)

27

3

25.0 INFLATION

If tyre had to burst or rim had to break under pressure, operators could beseriously injured or even killed.

During inflation use personal protective equipment to protect hearing and sight.

Make sure the rim and tyre are the same size.

Also check the conditions of the tyre and rim to make sure there are no defects beforestarting to inflate.

Inflate the tyre with brief jets of air checking the pressure on the gauge frequently.

This Tyre-Changer is automatically limited to an inflation pressure of 3,5 bar (50 psi).NEVER EXCEED THE PRESSURE RECOMMENDED BY THE TYRE MANUFACTURER.

Keep hands and body as far away as possible from the tyre during inflation.

Tyres must be inflated with the utmost caution. The instructions below have to be read andfollowed strictly.This Tyre-Changer is NOT designed to protect operators and objects from accidental tyresexplosions.

ATTENTION: If tyre bead fails to fit in place at 3.5 bar pressure, it is necessary to repeat the beadloosening and lubricating procedures before trying again to inflate the tyre.

Inflationhosewoundonapulley with return spring

Inflatingpressuregauge

Airsupplypressure gauge

Deflationbutton

Inflationpedal

•Connecttheinflationhosetothevalveofthetyre.•Makesuretherimandthetyrehavethesamediameter.•Makesuretherimandtyrearesufficientlylubricated;lubricateifnecessary.•Pressandreleasetheinflationpedal(3)frequently,checkingthepressureonthepressuregaugeuntilthetyrebeadfitscompletelyontotherim.•Continueinflatingtoreachthepressurerecommendedbythetyremanufacturer.Alwaysinflateinshortblasts

and constantly check the pressure in the process.

•Pressthedeflationbuttontodeflatethetyreincasethepressureexceedsthevaluerecommendedbythetyremanufacturer.

NOTE: Sometimes, regular inflation may not be enough to seat the bead of tubeless tyres. This problem may be solved by using the optional accessory TUBELESS TYRE BEAD SEATING SYSTEM (GUN, ref. page 32).

28

Tubelessinflationexternalkithelpsseatingthebeadproperlyduringinflationoperations,whenservicinglowprofiledtyres.InordertoproperlyusetheoptionalTubelesstyrebeadseatingsystem:

•Pressthesafetyvalveagainsttherimedge,pushtheactivatingbuttonontothe handle to blast air, while simultaneously pressingtheinflationpedal(3)inordertofeedthewheelvalve.

Activatingbutton

Safetyvalve

25.1 Tubeless tyre inflation (optional)

Duringtheinflationstages(andespeciallyduringthebeadseatingoperation),itisrecommendedtowearanappropriatepersonalprotectiveequipmenttoprotecttheauditoryapparatusfrompossibleblastinjuriesandfromnoiselevelsthatsometimesexceedthepermittedthreshold.

Usealsoappropriateeyeprotectionsequipmenttoshadeyoureyesfromanypossibledebristhatmightflyduetothehighpressureinvolvedintyrebeadseating.

Thejetofairthatcomesoutwhentheinflatingdeviceisonhasaveryhighpressure:holdthehandlefirmlywithyourhandtoavoidanysortofbacklash.

29

X 2

X 2

26.0 STANDARD ACCESSORIES (STANDARD SUPPLIED)

-Lube paste bucket-Brush

-Plastictyrelever.TobeusedduringtyredemountinginaccordancewithWDKprocedure.

-Kitofnylonprotectorsformountingtool

-PlasticprotectionsforSmartLockcenteringcone

- Rubber protections for clamping chuck faceplate

-PlasticconeØ70mmforclampingspecialalloyrims

- Reducing ring for clamping chuck faceplate.Tobeusedtofitparticularalloyrims.

30

X 2

-AdjustmentknobforSmartLock

- Cleaning brush for Smart Lock and clamping chuck inner surface

-SpareOringsforSmartLock

-Plasticprotectionsforclampingchuckdrivingpin

-Plasticbeadpressingclampwithextra insert for rim edge with specialinclination. To be used together with rubberprotectionsformountingUHPandRUNFLATtyreaccordingtoWDKprocedure.

- Rubber protector for steel rims.(markedwith•)

- Rubber protector for aluminium rims(markedwith••)

- Rubber protector for aluminium rims witharched spokes.(markedwith•••)

-Airlubricator,airfilter/watertrap

- Calibrationjigandmagnet(seedetailsinchapter32.2)

31

27.0 OPTIONAL ACCESSORIES

Art. FRR QUICKWheelclampingadaptorforreversemountedandplasticcladwheels on center post tyre changer. Standard supplied with measuringcaliperandtwokitsofpins(6pins70mmlength;6pins100mmlength).Youcanhandlerimswith3,4,5or6lugholes(andtheirmultiples)in different shapes and design.

3 lug holes 4 lug holes

5 lug holes 6 lug holes

Reverse mounted wheelsSpecial rims

LTK3Centering cones adaptor kit for light-truck rimslocking(centrehole:Ø120toØ190mm).

LTK4Centering cones adaptor kit for light-truck rims locking(centrehole:Ø140toØ220mm).

LTK6Centering conical adaptor for steel rims locking (centrehole:Ø75toØ120mm).

LTK5Two-sides centering conical adaptor for steel rimslocking(centrehole:Ø75toØ145mm).

32

GUNTubelessinflationexternalkit

Art. UHP WDKKitforJBOSS

WL6Wheellifterforwheelpositioningandcenteringontoclampingchuck.LiftingcapacityKg.80

SPK 1 (LAMBORGHINI)NYLONCONEFORSPECIALLAMBORGHINIWHEELS,allowsclampingwheelswith center hole diameter from 55 to 85 mm.

SPK 2 (PORSCHE)NYLONCONEFORSPECIALPORSCHEWHEELS,allowsclampingwheelswith center hole diameter from 60 to 85 mm.

SPK 3(BMW)NYLONCONEFORSPECIALBMWWHEELS,allowsclampingwheelswith center hole diameter from 55 to 70 mm.

33

General precautions-Avoiddirectandprolongedcontactwithskin.-Avoidtheformationofoilmistsintheair.-Avoidsplashing.-Wearappropriateclothing,glovesandgogglestoprotectagainstoilsplashes.- Do not use greasy rags.- Do not eat or smoke if your hands are soiled with oil.

First Aid instructions-Ifoilisswallowed,doNOTinducevomitingbutgoimmediatelytothenearestmedicalcentrewithinformationonthetype of oil swallowed.- If oil gets in eyes, rinse abundantly with water until irritation ceases, then go to the nearest medical centre.-Ifoilcomesintocontactwithskin,rinseabundantlywithneutralsoapandwater.donotusesolventsorirritantproducts.

Disposing of used oilDo not throw used oil away outdoors or pour it on the ground.Drainintoasuitablecontainerandforwardtospecialisedoildisposalcentres,orhanditovertoauthorisedcollectioncompanies.

Oil spillages or leakagesEliminate the cause of the leakage and stop the oil spillage from spreading using absorbent material. Clean the area where theoilhasspilledusingdegreasingdetergentstopreventslippinganddisposeofthewasteaccordingtocurrentstateandnationalregulations.CleanuptheoilandsendtospecialdisposalcentresaccordingtocurrentNationalregulations.

31.0 OIL TREATMENT

OIL IS POLLUTANT! DO NOT THROW AWAY OUTDOORS OR POUR ON THE GROUND.Clean up the oil and send to special disposal centres according to current national laws.

28.0 RE-POSITIONINGTore-positiontheTyre-Changerinanewworkplace:securethemovingparts(i.e.thebeadpressingarms,etc.)disconnectallthepowersourcesandinstallitagainfollowingalltheinstructionperchapter9.0(INSTALLATION)ofthis manual.Connections to power sources and connection & inspections of the safety systems must be carried out bytrained personnel.

29.0 STORAGEIfthetyrechangerhastobestoredawayforextendedperiodsoftime:- Disconnect the power sources.-Emptythetankscontainingoperationalfluids.-Protectpartsthatcouldbedamagedifdustshouldsettleonthem.-Greasepartsthatcoulddamageiftheyshoulddryup.

Whenre-commissioningthetyrechanger:-Followtheinstructionsgiveninchapter9.0ofthismanual.- Replace any damaged parts, referring to the spare parts list - this to be carried out by skilled personnel.

30.0 SCRAPPING AND DISPOSALIfyoudecidethatthetyrechangercannolongerbeused,youarerecommendedtomakeitunusablebyremovingthepowersupplyconnections,emptyingthetanksanddisposingofthefluidsaccordingtocurrentstateandNationalregulation. The tyre changer is considered as heterogeneous waste and must consequently be split-up into parts madeofsimilarmaterial(electricalparts,plasticpartsandferrousparts),whichmustbedisposedofproperly,accordingtocurrentNationalregulation.

WARNING: follow RAEE and ROHS Conformity Declaration rules for a correct disposal(where applicable).

34

-Ondailybasis,keepthemachinecleaneliminatinganymouldanddirttoensuretheperfectmovementof slides, carriages and tools and to grant the correct functioning of clamping chuck and locking systems.

-Ondailybasis,checkforwornordamagednylon protectors for mounting tool, as well as plastic and rubber protectorstoavoidanydamagetotherimortyre.In case of wear or damage, replace them with new protectors.

32.1 Standard Maintenance

Routine maintenance according to the following instructions is of crucial importance to ensure the correct operation andlasting life of the Tyre-Changer.

Always disconnect the electrical power and air supply from the machine before servicing and removing any parts.Release all compressed air from the circuit by pressing the inflation pedal (ref. 3, page 13) for a few seconds.

32.0 MAINTENANCE

-Every7days,checktheoildroppinginto the cup (1 drop every 4/5activations of the bead pressingarmorofthebeadbreakersystem). Otherwise turn the screw on the top ofthecupbyascrewdriver.

- For a long lasting correctfunct ioning of the 10 bar pressure limitdevice,checkonregular basis and discharge the condensation when needed.

- I f necessary, d ra in the c o n d e n s a t i o n b y t u r n i n g clockwisethedraintap(keepthepneumatic feeding on to perform thisadjustment).

-Onmonthly basis, unplug themachine from pneumatic feeding andremovethefiltercuptocleanit from possible solid impurities.

- Periodically check the oil levelwhichshouldalwayskeepabovethecontainertrasparentpart.Otherwiseunscrew the cup and top-up by adding oil for pneumatic systems in classISOHG(i.e.ESSOFebisK32;MOBILVacoulineOil1405;KLUBERAirpress32).

-Onperiodicalbasis,cleantheslidingguidesofthebeadbreakercarriagebynaphthaandlubethembyoilorpropergrease.Performthesamecleaningandlubricatingactionsoneveryjunctionandmechanical sliding.

-Onperiodicalbasis,checkthetensioningofclampingchuckrotationdrivingbelt.Ifnecessary,usea13mmwrenchtoloosenthefixingboltsofthemotorsupportplate,thenadjustthebelttensionbyactingonthetensioningscrewandtightthefixingbolts.

35

32.2 Laser pointers calibration 32.2.1 Rim diameter laser pointer calibration (vertical laser pointer)

4

5

6

78

9

11 17

- Switch on the machine by turning the main power switch, located on the side of the machine,totheONposition.

Press and hold down laser horizontal movement button (17), while simultaneously moving rim diameter and width setting joystick lever (4) to the left until the clamping chuck carriage stops.

-Movethedemountingtoolcontrollever9 to the left, to position the demounting tool in the working area.

-Pressandholddown laserverticalmovementsenablingbutton(5),whilesimultaneouslymovingrimdiameterandwidthsettingjoysticklever(4)upwardstoliftthedemountingtooltotheendofthestroketothehighestposition.

36

max 4 mm

max 2 mm

Place the calibrationmagnet on the outmost part of thedemounting tool (asshown in thephoto).Align the laserbeam with the reference dot on the magnet.

Bring the demounting tool down to the end of the stroke limit, acting on commands 4 and 5. Check if the laser beam keeps aligned with the reference dot on the magnet.Otherwiseadjustthescrewsofthelaserpointersupport(seenextpage).

Maximum tolerance of lateral displacement is 4 mm.

Maximum tolerance of radial displacement is 2 mm.

Otherwiseadjustthescrewsofthelaserpointersupport,seethefollowingparagraph:“Adjustment procedure”

37

D

AB

C

Adjustment procedure

After the adjustment procedureis finished, recheck the correctalignment of laser pointer with the reference dot on the magnet located on the demounting tool both at the highest and at the lowest position.

If necessary, slightly loosen screws A and B to adjust the laser.Act on screwsC and D to adjust the laser in radial direction from clamping chuck. Tighten the screws A and B.

38

32.2.2 Rim width laser pointer calibration (horizontal laser pointer)

Install the calibration jig on clamping chuck

1

Fig.1

Remove the magnet from the tool.Bring the demounting tool to the highest position, using commands 4 and 5.

Calibration jig

Pivoting stick on the

jig Rim width laser reference dot

Rim diameter laser reference

dot

Rim diameter

laser reference

dot on pivoting

stick

Stick

Alignthelaserbeamwiththereferencedot 1 by means of commands 17 and 4. Check the correct positioningofthecalibrationjig.Usetheclamping chuck rotation control pedal (ref.1page13) to findthecorrectposition.

39

Otherwise adjust laser supportby acting on the screws E and F. E

F

Bring the demounting tool down to about 1 mm from calibration jig), acting on commands 4 and 5.

Turn the calibration jig so that the wide right side is under the demounting tool.

Turn the calibration jig so that it returns to position 1 (Fig.1,page38).In this position, both the two lasers must be aligned with the reference dots.

NB: At the end of these operations, you will have the correct calibration of lasers for the demounting tool. All other tools and disks adjustment procedures must be performed without moving clamping chuck and tools carriages (Do not act on commands 4, 5, 17).

40

The Manufacturer is not responsible for claims due to non-original spare parts or for damages causedby removal and tampering to the safety devices.Removal or tampering with the safety devices (max. pressure valve – pressure regulator) represents abreach of European Regulations for Workplace Safety.

- After 5 years from installation date, the Tyre-Changer must be serviced in all its main components to grant itscorrect functioning and the operators safety.

- Extraordinary maintenance must be carried out by factory authorized personnel ONLY.

- Defective parts should be exclusively replaced with genuine spare parts by factory authorized service personnel.

32.3 Extraordinary maintenance

41

33.0 TROUBLESHOOTING CHART

PROBLEM CAUSE SOLUTIONThe clamping chuck does not rotate 1)Thepowersupplyismissing;

2)Machinehasnotpluggedcorrectly;3)Thefuseshaveblown;4)Thebeltisloosenedorbroken;5)Themotorpulleyisunscrewed;6)Themotordriveisnotworkingproperly;7)Themotorisdefectiveordamaged.

1)Checkthewallsocket;2)Checkthemachineplugisconnect properly or if the plugwires are well connected.3)Replacethefuses;4)Tensionorreplacethebelt;5)Tightenthepulleyscrew;6)Re-connectthefootcontrol;7)Replacethemotor.

Motor runs but clamping chuck does not rotateforwardorreverse.

1)Looseorbrokendrivebelt.2)Pulleysfailed.3)Looseorbrokenfixingbolts4)Transmissiondamagedordefective.

1)Tightenorreplace2)Replacepulleys.3)Tightenboltsorreplacethem4)Replacetransmission.

Afterthefoot-controlreleasing,theclamping chuck motor rotates at onespeed only or just in one direction

1)Thefoot-controlhasnotbeensetuporadjustedcorrectly;2)Themicro-switchesscrewsareunscrewedormissing;3)Themicro-switchisdamagedordefective;4)Thefoot-controlspringisdamagedorloosened;

1)Adjusttheclampingchuckrotationcontrolpedal;2)Tightenthescrewswherenecessary or replace the missingones;3)Replacethemicroswitch;4)Replacethespring.

The clamping chuck motor rotates at onespeed only or just in one direction

1)Themicroswitchisdamagedordefective;2)Themicroswitchedisnotconnectedproperly;3)Themotorisdamaged;4)Themotorwiresarenotconnected.

1)Replacethemicroswitch;2)Checktheinverterwireandconnectitifnecessary;3)Replacethemotor;4)Checkandconnectthemotorwire.

Clamping chuck rotates, but will notmount or demount tyres.

1)Mounting/demountingtooloroperating arm needs adjustment.Operatorusingincorrectprocedures:2)Failuretouserubberlubricant.3)Attemptingtomountbadlybent or rusted wheels.4)Mismatchsizeoftyreandwheel

1)Adjustasrequired2)Lubricate3)Cleanorrepair4)Checkthattherimandtyrehavethe same diameter

The clamping chuck rotates but the wheelstays still

1)SmartLocksystemisnotclamping2)Anti-rotationpinisnotholding.

1)Checkthesystemisclampingcorrectly;2)Positionthepinproperly.

Motoinverterdoesnotwork 1)MotorOverload 1)Disconnectthemachinefromthe power supply for 5 minutes

Thebeadbreakerdiskdoesnotmoveverticallyoritmovesslowly

1)Theairsupplyismissing;2)Thecontrolvalveisdamaged;3)Thesilencersareblocked;4)Thecylindersealisdamaged;5)Thevalveisdamagedordefective.

1)Checkthenetpressure;2)Replacethevalve;3)Cleanupthesilencersorreplacethem;4)Replacetheseals;5)Replacethevalve.

The bead breaker disk positions itself correctlybutdoesnotperformthe“overrun”

1)Theairsupplyismissing;2)Thecontrolvalveisdamagedordefective;3)Thecylinderssealsaredamaged;4)Movementisnotactivated;5)Theoverrunswitchisdamaged;

1)Checknetpressure;2)Replacethecontrolvalve;3)Replacetheseals;4)Rotatetheswitch;5)Replacetheswitch;

Always disconnect the electrical power and air supply from the machine before servicing and removing any parts.

42

PROBLEM CAUSE SOLUTIONBead breaker operates, but willnot break beads.

1)Inadequateairsupply.2)Operatorusingincorrectprocedure.3)Beadbreakerdiskbindingor damaged.4)Valve/valvesobstructedordamaged.

1)Verifyminimum10BAR(150PSI).Check air lines for leaks,blockage, or kinks.2)Refertooperatinginstructions.3)Checkforbinding,replaceas needed.4)Checkoperating&controlvalves.Repairorreplaceasneeded.

Thetooldoesnotmovevertically 1)Theairsupplyismissing;2)Thesupplyunionisnotconnected;3)Thefeedinghosesaredamagedorsqueezed;4)Controlvalveisdamaged;5)Thesilencersareblocked;6)Thecylindersealisdamaged.

1)Checknetpressure;2)Plugtheunioncarefullyorchecktheairhosespassage;3)Replacethefeedinghoses;4)Replacethevalve;5)Cleanupthesilencersorreplacethem;6)Replacetheseals.

Fingertooldoesnotmoveup/down 1)Nopneumaticsupply2)Thesupplyfittingisnotconnectedcorrectly3)Supplytubesbrokenorsquashed4)Controlvalvebroken5)Mufflerobstructed6)Fingertoolactivatingcylinderdamaged

1)Checkthelinepressure2)Insertthefittingcorrectlyinthe supply socket or check thepipe route3)Replacethesupplytubes4)Replacethevalve5)Cleanthemufflerorreplaceit6)Checkcylinder,repairorreplace

The tool hit the rim duringmounting operations

1)Thelockingplatehasnotbeenadjustedproperlyorisdefective2)Theunlockingplatespringsaredamaged3)SmartLockisloosened

1)Adjustorreplacethelockingplate2)Replacetheunlockingplatesprings3)TightenSmartLock

Theinflatingdevicedoesnotwork 1)Theairsupplyismissing;2)Thecontrolvalveisdamaged;3)Thepressurevalveisdamaged.

1)Checkthenetpressure;2)Replacethevalve;3)Replacethevalve.

Gaugenotaccurate. 1)Airlinekinkedorobstructed.2)Needlestuckorbroken.3)Inletsideorsnubberofgaugeblocked.4)Gaugeoutofcalibration.

1)Removeandcleandebris,straighten hose.2)Replacegauge.3)Replacegauge.4)Replacegauge.

Pedalsdonotactuateorreturnproperly.

1)Misaligned,damagedorwornpedal linkage.2)Obstructioninairvalves.3)Objectsunderfootpedals.4)Returnspringbrokenormisaligned.5)Inadequatelubrication

1)Repairorreplace.2)Remove,cleanvalves,&reinstall.3)Removeforeignobjectsfrom under machine.4)Repair,replaceorrealign.5)Lubricate

Always disconnect the electrical power and air supply from the machine before servicing and removing any parts.

43

PROBLEM CAUSE SOLUTIONBead pressing arm will not raise/lower

1.Leakingairlinesorfittingsorvalve.2.Defectivevalve.3.Defectivecylinder.4. Slide bar binding.5. Inadequate lubrication.

1. Check for kinks, leaks ordebrisinairlinesorvalves.2. Replace3. Repair or replace.4.Adjusttensionnutfixingtheslidebar 5. Lubricate

Bead pressing arm bleeding down 1.Leakingairlinesorfittingsorvalve.2.Defectivecylinder.3.Checkvalveleakingordefective.

1. Check for kinks, leaks ordebrisinairlineorvalve.2. Repair or replace.3. Repair or replace.

The clamping chuck carriage does notmovehorizontally

1)Thelockingplatehasnotbeenadjustedproperlyorisdefective2)Theunlockingplatespringsaredamaged3)Theairsupplyismissing4)Thecontrolvalveisdamaged5)Thesilencersareblocked6)Thecylindersealisdamaged.7)Insufficientlubricationofmovingparts

1)Adjustorreplacethelockingplate2)Replacetheunlockingplatesprings3)Checkthenetpressure4)Replacethevalve5)Cleanupthesilencersorreplace them6)Replacetheseals.7)Lubricatemovingparts

Thetoolscarriagedoesnotmovevertically

1)Thelockingplatehasnotbeenadjustedproperlyorisdefective2)Theunlockingplatespringsaredamaged3)Theairsupplyismissing4)Thecontrolvalveisdamaged5)Thesilencersareblocked6)Thecylindersealisdamaged.7)Insufficientlubricationofmovingparts

1)Adjustorreplacethelockingplate2)Replacetheunlockingplatesprings3)Checkthenetpressure4)Replacethevalve5)Cleanupthesilencersorreplace them6)Replacetheseals.7)Lubricatemovingparts

The demounting tool does not per-formpresetmovementsintodropcentrelevel

1)Theairsupplyismissing;2)Thecontrolvalveisdamagedordefective;3)Thecylinderssealsaredamaged;4)Movementisnotactivated;5)Theoverrunbuttonisdamaged;6)Thepilotvalvedamagedordefective.

1)Checknetpressure;2)Replacethecontrolvalve;3)Replacetheseals;4)Presstheoverrunbutton;5)Replacethebutton;6)Replacethevalve.

Thetoolsdonotmoveintoworkingarea

1)Theairsupplyismissing;2)Thesupplyunionisnotconnected;3)Thefeedinghosesaredamagedorsqueezed;4)Controlvalveisdamaged;5)Thesilencersareblocked;6)Thecylindersealisdamaged.

1)Checknetpressure;2)Plugtheunioncarefullyorchecktheairhosespassage;3)Replacethefeedinghoses;4)Replacethevalve;5)Cleanupthesilencersorreplacethem;6)Replacetheseals.

Mounting/demounting tools hit the rim during operations

1)Laserpointersareinwrongposition2)SmartLockisloosened

1)Calibratelaserpointersusingthecalibration jig 2)TightenSmartLock

The wheel lifter does notmoveormoveslowly(optional)

1)Theairsupplyismissing;2)Thecontrolvalveisdamaged;3)Thesilencersareblocked;4)Thecylindersealsaredamaged.

1)Checknetpressure;2)Replacethevalve;3)Cleanupthesilencersorreplacethem;4)Replacetheseals.

The wheel lifter does not stop (optional)

1)Thecontrolvalveisdamaged;2)Thefootcontrolspringisdamaged

1)Replacethevalve;2)Replacethespring.

Always disconnect the electrical power and air supply from the machine before servicing and removing any parts.

44

34.0 WIRING DIAGRAM 230V 1Ph

SC

ATO

LA E

LETT

RIC

A

SPI

NA

1Ph

PR

OTE

ZIO

NE

A

CA

RIC

O

DEL

L'U

TEN

TE

LIN

EA A

LIM

ENTA

ZIO

NE

230V

1Ph

50/

60H

z

Imax

=20A

Cur

va C

IEC

/EN

608

98Id

=30m

A 16A

AM

N

L

L

N

L

N

L

L

N

N

-F1

F

2

mm

q3X

1,5-W

2

mm

q3X

2,5-W

1

-Q1

03.5

-SEZ

ION

ATO

RE

03.5

03.5

02.402.4

POWERSUPPLYLINE

Protection

by th

e us

erImax=20A

CCurve

IEC/E

N60898

Id=30m

A

Plug

MainPow

erSwitch

Ele

ctric

al b

ox

45

0 V

200

V23

0 V

0 V

6V

SC

HE

DA

3V

12

34

0V 6V3V

0V

LASE

RU

TEN

SIL

E

Bia

nco

Ros

so

Ara

ncio

ne

SC

ATO

LA E

LETT

RIC

A

43

21

LED

Mar

rone

Bia

nco

+-0V

0V

12V

10,5

V

SC

HE

DA

10,5

V

0V

12V

Led

+

Led

-

Puls

anti

Lase

r U

tens

ile

L-

Pul

sant

e La

ser

Car

rello

Man

drin

o(V

erde

)

Gia

llo

Ver

de

Lase

r C

arca

ssa

LASE

RC

ARC

ASS

A

0V

Marrone

0V

Ros

so

+- +-

Blu

Cav

o S

egna

li

Cav

o S

egna

li

Cav

o S

egna

li

Pul

sant

e La

ser c

arre

lloU

tens

ile (G

iallo

)

0 V

24V

Blu

L

Ner

o

Marrone

Bia

nco

Ver

de

Bianco

NR

osso

Blu

Mar

rone

Bia

nco

01.9

01.9

1A T

-F4

1A T

-F3

-T1

1 A T-F5

1 A T-F6

06.6

06.8

-S12

-S11

ELE

CTR

ICALBOX

White

Green

Orange

Brown

White

Red

Bla

ck

Green

Yellow BOARD

Bro

wn

White

Sig

nals

cab

le

BOARD

Red

White

Fram

eLa

ser To

ol

Lase

rR

ed

Blue

Blue

Sig

nals

cab

le

Sig

nals

cab

le

Fram

eLa

ser

Tool

La

ser

Bro

wn

Brown

White

Blu

eB

utto

ns

Chu

ck m

otor

ena

blin

g button(Green)

Tool

m

otor

en

ablin

g button(Yellow)

46

35.0 CLAMPING CHUCK MOTOR WIRING DIAGRAM

1 2 3 4

MOTORE

U V W

COLLEGAMENTO CAVO GESTIONE MOVIMENTI

1° VELOCITA' ORARIA

BIA

NC

O

GR

IGIO

GIA

LLO

MA

RR

ON

E

MOTOINVERTER

S1 S3 S4

PEDALIERA

MA

RR

ON

E

NER

O

BLU

FUNZIONE

S1

S2

S4

S2

S3 + S4

Cavo cod.3040603

SCHEMA COLLEGAMENTO MOTORE MANDRINO

2° VELOCITA' ORARIA

1° VELOCITA' ANTI-ORARIA

2° VELOCITA' ANTI-ORARIA

SWITCHCOMANDO

Cavo Segnali

N

L

01.6

01.6

01.6

Bro

wn

Bla

ck

Blu

eMOVEMENTCONTROLCABLECONNECTION

Yellow

Bro

wn

Grey

White

Pedalbox

CabelSignals cable

FUNCTIONclockwise speedclockwise speed

counterclockwise speedcounterclockwise speed

47

36.0 CLAMPING CHUCK CARRIAGE AND TOOLS CARRIAGE MOVEMENT DIAGRAM

JOYS

TIC

K 4

POS

IZIO

NI

PULS

ANTE

VER

DE

ABIL

ITA

ZIO

NE

CA

RR

ELLO

M

AND

RIN

O

PULS

ANTE

GIA

LLO

ABIL

ITAZ

ION

E C

ARR

ELLO

UTE

NS

ILE

Mar

rone

Marrone

Verde

Ver

de

0 V

EV. S

TRAN

GO

LA

UTE

NSI

LE

EV. S

ALIT

A U

TEN

SILE

(1)

EV. D

ISC

ESA

UTE

NSI

LE (2

)EV

. STR

ANG

OLA

M

AND

RIN

O

EV. A

RR

ETR

AMEN

TO

MAN

DR

INO

(4)

EV. A

VAN

ZAM

ENTO

M

AND

RIN

O (3

)

24V

-VEU

-VSU

-VTC

-VEC

-Y1

-S12

-Y2

06.7

-Y3 -S

12

02.8

06.10 06.5

-SJ2X2-1

02.8

X2-2 -SJ4

-SJ1

-SJ3

-Y4

06.7

-S11

-Y5

-S12

-Y6

CHUCKCARRIAGEMOTO

R

ENABLINGBUTT

ON(G

REEN)

4Position

Bro

wn

Brown

Green

Green

TOOL

CARRIAGE

MOTO

R

ENABLINGBUTT

ON(Y

ELLOW)

CarriageBa

ckMovem

ent

solen

oidva

lve(4)

CarriageForthMovem

ent

solenoidvalve(3)

ToolAscentsolenoidvalve(1)

Tool

Des

cent

solenoidvalve(2)

clam

ping

ch

uck

carr

iage

lockingvalve

tool

s ca

rria

-ge

lock

ing

valve

48

37.0 PNEUMATIC DIAGRAMS

Filtr

o R

egol

ator

e

Sorg

ente

Rub

inet

to

Ingr

esso

aria

Lubr

ifica

tore

Dis

tribu

toreCilin

dro

Pres

s Ar

m

Valv

ola

Pres

s Ar

m

Fine

cors

a sc

aric

oPr

ess

Arm

Cilin

dro

Ove

rcor

sa S

tallo

nato

ri

Valv

ola

Ove

rcor

sa S

tallo

nato

ri

Cilin

dro

dopp

io s

tadi

o m

ovim

ento

ung

hia

A B C

F

8-10

bar

- VP

- PA

- CP

- CO

- CU

8-14

bar

-VO

Abilit

azio

ne

mov

imen

to u

nghi

a

Valv

ola

mov

imen

to

ungh

ia

-VA-VM

- VN

RVa

lvol

a di

Non

Rito

rno

Valv

ola

sing

olo

cilin

dro

- VS

Cilin

dro

brac

cio

uten

sile

sm

onta

ggio

Valv

ola

smon

tagg

io

- CTS

- VTS

D

XTo

ol

movem

ent

valve

Cyl

inde

r for

bea

d breakerdisksover-

runmovem

ent

Valveforb

ead

brea

ker d

isksover-

runmovem

ent

BP1Pluscylinder

BP1Plusvalve

BP1Plusend

of s

troke

rele

ase

valve

Dis

tribu

tor

Airsupply

Airinletvalve

Lubr

icat

or

Filterregulator

Dem

ountingvalve

Dem

ount

ing

cylin

der

Dou

ble

stag

e cy

linde

r for

XToolmovem

ent

cylindervalve

XTo

ol

movem

ent

enablingvalve

49

Con

sens

o Le

va

A B

Sele

ttore

2 po

sizi

oni

SXD

X

Cilin

dro

mon

tagg

ioTa

llone

Sup

erio

reC

ilindr

o m

onta

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- CT2

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D

OPT

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Y2Y3

Y4

Y5Y6

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ione

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TC

Inflation

valve

Deflationbutton

Max.inflation

pres

sure

controldevice

Inflationhose

Low

er b

ead

brea

ker c

ylin

der

Low

er b

ead

bre-

akervalve

Upperbeadbreakercylinder

Upperbeadbre-

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ovem

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nmove-

mentlockingvalve

51

38.0 SERVICE REPORTS

All the operations made on the machine in the course of time must be reported herebelow so as to have anupdated situation of the efficiency of the machine.The user must carry out both cleaning and greasing operations according to the instructions given in thismanual.Any operation concerning the replacement of parts is strictly reserved to authorized and trained staff.

Date Signature

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52

Date Signature

Intervention

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Date Signature

Intervention

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Date Signature

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Date Signature

Intervention

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53

Date Signature

Intervention

Replacements

Notes

Date Signature

Intervention

Replacements

Notes

Date Signature

Intervention

Replacements

Notes

Date Signature

Intervention

Replacements

Notes