Tc589x_manual_version5 Tc589x Manual
2012-10-16
: Tc589X Manual tc589x_manual tirechangers manuals s
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1 INDEX PAGE Technical Specifications ..................................................................................................................3 General Safety Warnings .................................................................................................................4 Specific Product Warnings And Precautions ...................................................................................6 Assembly Instructions......................................................................................................................7 Transport Unpacking Product Description Workplace Requirements Assembly Procedure Pneumatic Link Up Electric Link Up Warning Label ................................................................................................................................13 Operating Instructions....................................................................................................................14 To Perform Preliminary Operating Texts How to Break the Tire Bead Demounting the Tire from the Wheel Mounting the Tire onto the Wheel Rim Inflating the Tire FRL Instructions ............................................................................................................................20 Routine Maintenance .....................................................................................................................21 Troubleshooting Guide ..................................................................................................................22 Mounting Head’s Angle Adjusting.................................................................................................23 IP Version .......................................................................................................................................24 Exploded Drawings And Spare Parts List ......................................................................................29 Electric Schematic .........................................................................................................................40 Pneumatic Schematic .....................................................................................................................43 2 ITEM DESCRIPTION Electric Requirements .......................................................................................... 120volt 60 Hz 1ph Max. Wheel Diameter ................................................................................................ 46″ (1168mm) Max. Wheel Width ....................................................................................................... 15″ (380mm) Outside Clamping – Rim Sizes ............................................................................................ 12″~25″ Inside Clamping – Rim Sizes ............................................................................................... 13″~27″ Max. Bead Breaker Opening........................................................................................ 13″ (330mm) Max. Inflation Pressure ........................................................................................... 145 PSI (10 bar) Bead Breaker Force........................................................................................... 5500 LB. (2500kgs) Max. Rotating Torque (Turntable) ................................................................... 795 ft·lbs (1078N·m) Noise Level .............................................................................................................................<70dB Overall Dimensions (L×W×H) ................................. 60″×60″×84″ (1524mm×1524mm×2146mm) Net Weight .............................................................................................................. 675Lbs. (306kg) THE MANUFACTURER RESERVES THE RIGHT TO CHANGE PRODUCT SPECIFICATIONS WITHOUT NOTICE. PICTURES OF PRODUCTS IN PICTORIAL GUIDE MAY NOT BE PICTURES OF THE ACTUAL PRODUCT RECEIVED. GENERAL OUTLINED ASSEMBLY PROCEDURES ARE ACCURATE. 3 Keep this manual in a safe place. The manual contains valuable information regarding the safe operation and maintenance of your equipment. The manual contains parts information that will help to identify tire changer parts if replacement parts are needed. The manufacturer or distributor is not responsible for any personal injury, machine damage, or collateral damage that results from improper use of this machine. Please read and understand this manual BEFORE you begin operation of the tire changer. Improper use of the tire changer will void manufacturers and distributors warranty. READ AND UNDERSTAND THIS MANUAL BEFORE ATTEMPTING TO USE YOUR NEW TIRE CHANGER. 1) THIS TIRE CHANGER OPERATES ON COMPRESSED AIR AND ELECTRICITY. YOU MUST DISCONNECT THE TIRE MACHINE FROM BOTH POWER SOURCES BEFORE ATTEMPTING TO INSTALL, REPAIR, OR MAKE ADJUSTMENTS TO THE TIRE CHANGER. COMPRESSED AIR IS STORED IN THE INFLATION TANK AND AIR SUPPLY SYSTEM OF THE TIRE CHANGER. ALL COMPRESSED AIR MUST BE EVACUATED FROM THE MACHINE BEFORE ANY REPAIRS CAN BE ATTEMPTED. COMPRESSED AIR IS VERY DANGEROUS. AIR CAN BE EVACUATED FROM THE SYSTEM BY PRESSING AND RELEASING ALL AIR CONTROL FOOT PEDALS. THE SOUND OF ESCAPING AIR WILL CEASE AS THE COMPRESSED AIR IS PURGED FROM THE SYSTEM. USE COMMON SENSE. 2) ALL REPAIR WORK SHOULD BE PERFORMED BY A QUALIFIED, MECHANICALLY INCLINED PERSON. ANY COMPETENT PERSON THAT IS ABLE TO UNDERSTAND WRITTEN AND SPOKEN (ENGLISH) INSTRUCTIONS SHOULD BE ABLE TO INSTALL AND SERVICE THIS MACHINE. IF YOU ARE NOT MECHANICALLY INCLINED, PLEASE EMPLOY A PERSON WITH MECHANICAL SKILLS TO HELP INSTALL YOUR TIRE CHANGER OR MAKE ANY NECESSARY FUTURE REPAIRS. REMEMBER TO DISCONNECT THE TIRE CHANGER FROM ALL POWER SOURCES BEFORE MAKING ANY REPAIRS OR ADJUSTMENTS. 3) KEEP WORK AREA CLEAN AND DRY. ALLOW PLENTY OF ROOM TO INSTALL YOUR TIRE CHANGER. MAKE SURE THAT ALL MOVING PARTS OF THE TIRE CHANGER REMAIN UNOBSTRUCTED WHEN THE MACHINE IS IN OPERATION. 4) THE TIRE CHANGER IS TO BE USED BY PERSONS 16 YEARS OR OLDER, THAT ARE SKILLED IN THE OPERATION OF AUTOMOTIVE SERVICE EQUIPMENT. 5) KEEP SMALL CHILDREN AWAY FROM WORK AREA. SERIOUS PERSONAL INJURY MAY OCCUR IF THE MACHINE IS NOT OPERATED PROPERLY. 6) STORAGE OF EQUIPMENT SHOULD BE IN A DRY AREA TO INHIBIT RUST. IF THE MACHINE IS NOT TO BE USED FOR A LONG PERIOD OF TIME. PLEASE DISCONNECT FROM BOTH THE ELECTRICAL AND AIR SUPPLY. 7) DO NOT WEAR LOOSE FITTING CLOTHES OR JEWELRY WHEN OPERATING YOUR TIRE CHANGER. Moving machine parts (while in operation) could become tangled with loose clothing, jewelry, or long hair resulting in personal injury or death. 4 8) PAY ATTENTION AT ALL TIMES WHEN OPERATING THE TIRE CHANGER. DO NOT USE THE MACHINE IF YOU ARE TIRED, OR UNDER THE INFLUENCE OF DRUGS OR ALCOHOL. STAY ALERT AT ALL TIMES. USE COMMON SENSE. KEEP HANDS AWAY FROM MOVING PARTS. 9) CHECK THE TIRE CHANGER FOR DAMAGED OR WORN PARTS BEFORE OPERATING. Damaged or worn parts will affect the performance of the tire changer. These defective parts may cause personal injury or damage to the wheel/tire assembly. REPLACE ANY DAMAGED OR WORN PARTS IMMEDIATELY; TO ASSURE PROPER PERFORMANCE OF YOUR TIRE CHANGER. 10) REPLACEMENT PARTS AND ACCESSORIES. Use only authorized replacement parts for your tire changer. Counterfeit parts or accessories may result in damage to the machine, wheel/tire assembly, or personal injury. Authorized parts are only available from your distributor. 11) PERIODIC MAINTENANCE SHOULD BE PERFORMED AT REGULARLY SCHEDULED INTERVALS. Daily inspection of the machine and a weekly maintenance schedule will keep your machine working at optimal performance. Maintenance should be performed by qualified personnel. 12) DO NOT USE THE MACHINE FOR TASKS THAT COULD CAUSE DAMAGE. The tire changer bead breaker is NOT designed to crush rims 13) MAKE SURE THE MACHINE CAN BE EASILY DISCONNECTED FROM THE AIR AND ELECTRIC POWER SOURCES. The electrical disconnect socket and the air disconnect coupler should be in close proximity to the operator, in case the machine needs to be quickly disconnected from either power source. 5 1) BEFORE PERFORMING ANY SERVICES OR MAINTENANCE; ALWAYS DISCONNECT THE TIRE CHANGER FROM ITS AIR SUPPLY SOURCE. DEPRESS AND RELEASE AIR ACTUATED PEDALS SEVERAL TIMES TO EVACUATE ALL COMPRESSED AIR FROM THE MACHINE AND DISCONNECT THE POWER CORD FROM ITS ELECTRICAL SUPPLY SOURCE. (Don’t forget about the bead breaker) 2) TIRE CHANGER OPERATES ON CLEAN, DRY, COMPRESSED AIR REGULATED TO 125 PSI. DO NOT EXCEED 150 PSI INLET PRESSURE TO THE REGULATOR OR MACHINE DAMAGE COULD OCCUR. AIR REGULATOR ON THE SIDE OF MACHINE SHOULD BE SET NO HIGHER THEN 125 PSI. 3) THE AUTOMATIC OILER PROVIDES LUBRICATION TO THE MOVING PARTS OF THE TIRE CHANGER. IF THE AUTOMATIC OILER IS NOT USED, ADD TWO DROPS OF AIR TOOL OIL (DAILY) TO THE AIR SUPPLY LINE. THIS WILL HELP TO PROVIDE SUFFICIENT LUBRICATION TO THE MOVING PARTS AND SEALS. 4) ALWAYS INFLATE THE TIRE TO THE AIR PRESSURE RECOMMENDED BY THE TIRE MANUFACTURER. NEVER OVER INFLATE THE TIRE. 5) MAKE SURE THAT THE TIRE AND RIM SIZE ARE A PERFECT MATCH. SEVERE PERSONAL INJURY WILL RESULT IF THE TIRE SIZE AND RIM SIZE ARE DIFFERENT AND THE INFLATED TIRE “BLOWS OFF” THE RIM WHEN INFLATED. ALWAYS DISPOSE OF OLD TIRES ACCORDING TO LOCAL AND NATIONAL TIRE DISPOSAL REGULATIONS. 6) TO AVOID PERSONAL INJURY AND/OR TIRE MACHINE DAMAGE, ALWAYS MAKE SURE THE RIM IS FIRMLY SECURED ON THE TIRE CHANGER (with the clamping jaws) BEFORE REMOVING, INSTALLING, OR INFLATING A TIRE. 7) NEVER PLACE YOUR HANDS BETWEEN THE WHEEL RIM AND THE JAWS DURING THE LOCKING/CLAMPING STAGE. THE AIR OPERATED CLAMPING JAWS EXERT AN EXTREME AMOUNT OF PRESSURE AND SEVERE PERSONAL INJURY MAY OCCUR IF ANY EXTREMITIES ARE “CAUGHT” IN THE JAWS. 6 TRANSPORT The machine weighs approximately 700 lbs. You must use a forklift, pallet jack, or other machinery capable of safely moving this heavy package. See Fig.1. Fig. 1 UNPACKING The tire changer is shipped in a palletized wooden box with easy opening tabs. (Fig.2) Please use the easy opening tabs when uncrating the machine; rather than destroying the box and possibly damaging the tire changer Fig. 2 7 PRODUCT PHOTO AND PARTS DESCRIPTION Fig. 3 1 3 5 7 9 11 13 BEAD BREAKER PEDAL MOTOR FWD/REVERSE PEDAL CLAMPING JAWS HEXAGONAL SHAFT LOCK LEVER FOR HEX SHAFT FILTER/ REGULATOR/OILER RUBBER WHEEL SUPPORT 2 4 6 8 10 12 14 JAW CLAMPING PEDAL TURNTABLE MOUNT/DEMOUNT HEAD SWING ARM COLUMN BEAD BREAKER PADDLE TIRE TOOL WORK AREA REQUIREMENTS You will need a work radius of about 3 feet around the machine to operate your tire changer effectively. Place the tire changer on a level concrete floor. (It must be off of the shipping pallet) The tire changer may be bolted to the concrete floor, but it is not required. The tire changer must be removed from the skid to operate properly. 8 ASSEMBLY PROCEDURE CAUTION: This equipment requires two people to assemble. MOUNTING THE SWING ARM ASSEMBLY Fig. 4 STEP 1: With the swing arm assembly still attached to the shipping pallet, remove the tie wrap holding the lock plate tight. STEP 2: Slide the Hex Shaft (120, Fig.4) through the lock plate until the Mount/Demount head (123, Fig. 4) is against the swing arm (119, Fig. 4). STEP 3: Remove the lock cover (116, Fig. 4) from the parts box and slide it over the Hex Shaft (120, Fig. 4). Carefully place the cover into position by pushing it onto the tabs of the lock plate (107, Fig.4). STEP 4: Remove the spring, Knob Cap and screw (117,115, 114, Fig. 4) from the parts box. Place the spring over the Hex Shaft so that it fits all the way down onto the lock plate (118, Fig. 4). Place the Knob cap and screw (115, 114, Fig. 4) on to the end of the Hex Shaft (120, Fig. 4) and thread the screw into the hex shaft. STEP 5: Remove the nuts, flat washers, and lock washers from the studs on the chassis (128,129, Fig. 4) and set them aside. STEP 6: Remove the lag bolts and the strap that secures the Swing Arm Assembly to the shipping pallet. STEP 7: With able assistance, lift the Swing Arm Assembly (101 Fig.4) and stand it upright onto the machine. STEP 8: With assistance, lift the Swing Arm Assembly (101 Fig.3) onto the studs and secure with the nuts flat and lock washers from the studs (128,129, Fig. 4). Tighten the nuts using a 16mm wrench. 9 BEAD BREAKER ARM ASSEMBLY STEP 1: Remove pin, flat washer and snap-ring (322, 320, 319, Fig.5) from the hardware kit. Fig. 5 STEP 2: Place the rubber pad (329, Fig.5) on to the Bead Breaker Cylinder shaft (310, Fig.5) and slide it up to the body assembly (2, Fig.3) such that it covers the slot (see photo). STEP 3: Insert the Bead Breaker Arm assembly (321, 323, 315, Fig. 5) into the bracket on the right rear of the body assembly. Slide the pin (322, Fig.5) through the body assembly and through the Bead Breaker Arm assembly (321, 323, 315, Fig5). Install the flat washer and place the snap-ring on the bottom of the pin (322, Fig.5) using snap-ring pliers. STEP 4: Slide the Bead Breaker Arm assembly (321, 323, 315, Fig5) on to the Bead Breaker Cylinder shaft (310, Fig.5) as shown above. Place the flat washer (318, Fig5) and thread the locking nut (317, Fig5) on to the Bead Breaker Cylinder shaft (310, Fig.5). STEP 5: Thread the locking nut (317, Fig5) on to the Bead Breaker Cylinder shaft (310, Fig.5) using a 24 mm deep well socket until about a half inch of thread shows beyond the locknut. 10 STEP 6: Attach the spring (330, Fig.5) on to the side of the body assembly near the Bead Breaker Arm assembly pivot bolt. Insert the brake tool into the hole near the rear of the Bead Breaker Arm (322, Fig.5). Hook the spring with the tool, (330, Fig.5) and pull it toward you. Attach the spring (330, Fig.5) on to the center of the pin found within the Bead Breaker Arm (See photo below). PNEUMATIC IP60 A 7 9 8 3 2 5 Fig. 6 4 1 6 11 STEP 1: Pull the hose (4, Fig.6) through hole on the back side of the tire changer. (2, Fig.6). STEP 2: Slide the hose clamp (6, Fig.6) on to the rubber hose (4, Fig.6). Insert the rubber hose (4, Fig.6) from of the body to the connection (5, Fig.6) of the air tank. Make sure the other hose clamp inside the body assembly is also tight. STEP 3: Holding the air tank, (1, Fig.6) remove the two nuts and lock washers (3,Fig.6) from the studs on the body assembly (2, Fig.6) STEP 4: Place the air tank (10, Fig.3) on to the studs (9, Fig.3). Then place the lock washers and thread the nuts on to the two studs. Tighten the nuts (3, Fig.6) using a 16mm wrench. STEP 5: Remove the side cover (not shown). Leave it off until the machine is completely built. STEP 6: Fix the post (7, Fig.6) using screws (8, Fig.6) in the pre-drilled holes on the right rear of the machine. STEP 7: Mount the inflating unit (IP60, Fig.6) to the post using the 5mm Allen head screws(10, Fig.6) STEP 8: Press the 8mm tubing from the top of the inflator post (A Fig.6) into the push-lock fitting at the base of the pressure reading gauge. STEP 9: Press the 8mm tubing from the bottom of the inflator post into the push-lock bulkhead fitting on the back of the tire changer (See photo). STEP 10: Connect the tire changer to a compressed air network. (Suggested supply pressure is 150psi) The connector is located on the Filter/Regulator/Lubricator at the right rear corner of the tire changer. STEP 11: Adjust the regulator to 115psi. Check for air leaks. Correct all air leaks before installing the side cover. If OK, install the side cover and fasten with the 3 cap screws using a 5mm Allen wrench. ELECTRICAL Before making any electric connection, check that the supplied voltage corresponds with the motor voltage of machine (information is stamped on the information plate at the rear of the machine). For USA customers, the voltage is 110 volts and the amp requirement is 20. It is absolutely essential that the system is equipped with a good grounding circuit. Do not use an extension cord. 12 CJ001: Caution: Disconnect the air supply and power supply cord before performing any maintenance work on the machine. CJ002: Danger: Electric voltage present. Electrical shock hazard. CJ003: Caution: When clamping a tire, never have your hands under the tire. CJ004: Danger: Compressed air cylinder inside. CJ005: Danger: Keep hands free of wheel; your hands could be crushed between the rim and the mounting head. CJ006: Danger: During bead breaking NEVER touch the sidewalls of the tire with your hands. Bead breaking with the table top slides open can crush the operator’s hands. CJ007: Caution: Bead breaking must be done with the utmost care and attention. When the bead breaker pedal is operated, the bead beaker arm moves quickly and powerfully. Anything within its range of action is in danger of being crushed. CJ008: Important safety instructions label. 13 TO PRELIMINARY OPERATING TESTS STEP 1: Connect the tire changer to its air and electrical supply sources, and allow adequate time for the compressed air system to reach the recommended 150-PSI. STEP 2: Depress the Reverse Pedal (3, Fig2) down; the turntable should turn in a clockwise direction. Pull the pedal up and the turntable should turn anticlockwise. STEP 3: Press the bead breaker pedal (1, Fig2) to activate the paddle. When the pedal is released. The pedal should return to its original position. STEP 4: Press the jaw clamp pedal (2, Fig.2) once to open the four jaws. Press the pedal again to close the jaws. TO BREAK TIRE BEAD: Fig. 1 Fig. 2 CAUTION: Before you attempt to break the bead, the tire must be deflated fully. This can be done by removing the valve core and allowing all the air to escape. Remember that old tire/wheel assemblies and “junk yard” rims require special considerations. The bead breaker system is very powerful, but certain older rims may have been galled to the tires and it may be difficult for these “beads to be broken”. Rust penetrating fluid will help to “loosen” the wheel and tire assembly before the bead breaker is used. Frozen tires will also present a unique “bead breaking” experience and care must be used when dealing with frozen wheel assemblies. All wheel weights should be removed before breaking the bead or changing the tire. STEP 1: Close the turntable clamping jaws completely (Fig. 3). This will prevent tires from striking the turntable slides during the bead breaking process. Fig. 3 14 STEP 2: Open the bead breaker arm by hand. Place the wheel up against the Rubber Wheel Support. Position the Bead Breaker Paddle against the bead (where the tire and the rim meet…but the paddle needs to be held on the tire area…not the rim). (see Fig.4 ) Fig. 4 STEP 3: Depress the bead breaker pedal fully to activate the paddle (Fig 5). Release pressure on the bead breaker pedal when the blade has reached the end of its travel and / or when the tire bead becomes free of the rim (“Broken”). Fig. 5 STEP 4: Rotate the tire slightly, and repeat the procedure around the entire circumference of the wheel rim, until the bead is completely detached from the rim. (Fig.5) STEP 5: Repeat the above steps for the other side of the wheel / tire. 15 TO REMOVE THE TIRE FROM THE WHEEL: CAUTION: Before carrying out this procedure; make sure the bead is broken free on the wheel and all wheel weights are removed. STEP 1: Spread tire lubricant liberally on the complete circumference of the broken tire bead. NOTE: Failure to lubricate the tire bead may cause serious damage to the bead or tire changer. STEP 2: Place the wheel / tire evenly on the turntable. To lock the wheel on the turntable, proceed as follows according to the wheel size: OUTSIDE CLAMPING: 1. Position the four jaws by depressing the jaw clamping pedal (Fig. 7) halfway down. 2. Place the wheel on the four jaws and, while keeping the wheel rim pressed down, depress the jaw clamp pedal as far as it will go. 3. As the jaws move in they will lock the wheel. Check to make sure the wheel is firmly secured by the jaws. Fig. 7 INSIDE CLAMPING: 1. Operate the clamping pedal until the four jaws are completely closed (Fig 8). 2. Place the wheel over all four jaws. Depress the jaw clamping pedal to open the jaws, this will lock the wheel in place. 3. Check to make sure the wheel is firmly secured by the jaws. 16 Fig. 8 STEP 3: Lower the hex shaft until the mount/demount head (Fig. 9) rests next to the wheel and on top of the tire. Then, lock the hex shaft in position, using the lock lever (Fig. 10, 11) Fig. 911 STEP 4: Fig. 10 Insert the lever between the tire bead and the front section of the mounting head (Fig. 12). Fig. 13 Fig. 12 STEP 5: Move the tire bead over the mounting head by pulling the lever over the mount/demount head, and briefly pushing upward on the reverse pedal (Fig. 13). NOTE: To avoid damaging the inner tube (if there is one), it is recommended to perform step 7 with the inner tube valve stem positioned about 1” to the right of the mounting head. STEP 6: With the lever (Fig. 13) held in position, rotate the turntable in a clockwise direction by fully depressing the reverse pedal. Continue until the tire is completely separated from the wheel. STEP 7: Remove the inner tube (if there is one), and repeat the above steps 6 through 9 for the bottom side of the wheel / tire (See Fig. 14, 15). Fig. 14 Fig. 15 17 TO MOUNT THE TIRE ONTO THE WHEEL: CAUTION: Before carrying out this procedure, deflate the tire fully, and remove all the wheel weights. STEP 1: Spread tire lubricant liberally on the complete circumference of the tire bead to avoid damage to the tire bead to avoid damage to the tire and to facilitate the mounting procedure (Fig.16). Fig. 16 STEP 2: Lock the wheel, using the inner part of the clamping jaws. NOTE: When you are working with wheels of the same size, it is not always necessary to lock and unlock the hex shaft. Instead, move the swing arm sideways with the hex shaft locked. Fig. 17 Fig. 18 STEP 3: Move the tire so that the bead passes below the front section of the mounting head and is brought up against the edge of the rear section of the mounting head. (See Fig. 17) Keep the tire bead pressed down into the wheel rim channel with your hands (Fig. 18). Keep hands clear of the mounting head. Then, depress the reverse pedal to rotate the turntable clockwise. Continue this process throughout the entire circumference of the wheel and tire. STEP 4: Insert the inner tube (if there is one). STEP 5: Repeat the steps above the mount the other side of the tire. 18 TO INFLATE THE TIRE: CAUTION: An over inflated tire can fail, causing serious injury or even death to the operator. Always make sure the wheel and the tire are of the same size. Check the condition of the tire, and make sure it has no defects before beginning the inflation process. Keep your hands and body as far away from the tire as possible. Inflate the tire with brief jets of air, checking the air pressure frequently. Never inflate a tire above and or below the air pressure recommended by the tire manufacturer. STEP 1: To inflate the tire, attach the air hose nozzle to the tire valve stem with the locking lever in the “UP” position. Check the condition of the tire, and make sure the nozzle is pressed down completely over the threads of the valve stem (Fig. 19). Fig. 19 STEP 2: When the air gauge nozzle is firmly in place, press the locking lever down to lock onto the valve stem. Remember to inflate the tire with brief jets of air, checking the air pressure frequently. Once the proper air pressure has been reached on the gauge, disconnect the nozzle from the valve stem and screw a valve core into the stem (Use caution when inserting the valve core, air will blow out of the stem when the nozzle is removed). Re-attach the nozzle and adjust the air pressure as needed. NOTES: Failure to follow all warnings and instructions may lead to serious personal injury or death to the operator or a bystander. NEVER exceed 50psi (3.5 bar) when seating beads or inflating tires. If a higher tire inflation pressure is required, remove the wheel from the tire changer and continue the inflation procedure with the wheel inside a special protection cage (commercially available). NEVER exceed the maximum inflation pressure given by the tire manufacturer. ALWAYS keep hands and entire body back while inflating a tire. ONLY specially trained personnel should be allowed to perform these operations. 19 The FRL consists of the air filter (moisture separator), pressure regulator, and lubricator. The filter is designed to prevent excessive amounts of water (normally found in compressed air) from contaminating the moving parts of the tire changer. The pressure regulator helps to regulate pressure and prevent the valves, cylinders and other moving parts from being damaged by excessive air pressure. The lubricator provides oil to the pneumatic parts located inside the tire changer. SPECIFICATION Maximum supply pressure 150psi Minimum ambient operating temperature 5deg. C / 41deg. F Recommended lubricating oil 50W SAE Oil (non-detergent) Required regulator air pressure setting 110psi to 125psi OPERATION AND MAINTENANCE This is the pressure regulator. Open (pull up) the knob and turn to adjust the air pressure. Set air pressure at: 110 to125psi. Close (Push down) the knob to lock the regulator when the correct air pressure is achieved. pressure. Check the oil level in the lubricator at the beginning of each work day. Keep the reservoir filled with 50W SAE oil. Make sure the air supply is disconnected from the changer before removing the oil cap. 20 The air filter separates water from the air as the air flows into the machine. When the water level reaches 50% of the glass bowl, it is necessary to drain the water by pulling the locking ring and venting the water. The oil indicator should be checked to make sure that one drop of oil is injected into air system every 3-4 times the Bead Breaker Pedal is depressed. To regulate the rate of oil injection, adjust the flow with the oil regulator screw. IMPORTANT: Oil is needed in the air supply system to properly maintain the seals and working parts of the tire changer. CAUTION: Always disconnect the tire changer from its air and electrical supply before beginning any maintenance procedures. Press and release the bead breaker pedal and the inflation pedals several times to evacuate all compressed air that is still in the air tank or the air system of the tire changer. Before each use, inspect the general condition of the tire changer. Check for loose screws, misalignment of parts, binding of moving parts, broken parts, loose or damaged air supply hose / electric power cord, and any other condition that may affect its safe operation. If abnormal noise or vibrations are noticed, disconnect the tire changer from its air and electric supply sources immediately and correct the problem before further use. Never use damaged or unsafe equipment. Use pressurized air to keep the turntable clean. Make sure that there is no debris under the jaw guides to prevent their full range of motion. Clean the turntable (weekly) with a mild detergent. The jaw guides should be greased once a week. Filter/Regulator/Lubricator (FRL) routine maintenance is discussed in Chapter 7. After the first week of use, check all screws, bolts and fittings. Make sure all screws are tight. Turntable slide blots are subject to constant movement and need to be tightened regularly. BELT MAINTENANCE If the turntable begins to lose power, the drive belt may be loose. Remove the side cover of the tire changer to check the belt. If the belt is loose, tighten the belt with the adjusting screw located on the motor support. Leave a slight amount of deflection in the belt to prevent motor damage. LOCK LEVER MAINTENANCE In the event the lock lever does not properly lock the hex shaft in place, or the mounting head doesn’t move slightly off the mounted rim when the lever is engaged: remove the plastic cover and adjust the nuts slightly to increase the tension. 5 PORT FOOT VALVE MAINTENANCE To clean or replace the 5 port foot valves, remove the side cover, which is located on the left side of the tire changer body, by unscrewing the three socket head cap screws. To remove the 5 port foot valve: Mark and remove the air lines from the foot valve. Mark the location of the valve on the bracket. Remove the four mounting screws and disconnect the rod. Clean the 5 port foot valve, using a jet of compressed air. Or if necessary, replace the rod o-rings and exhaust mufflers. 21 PROBLEM 1: Turntable does not rotate. Causes: No power to the machine. Solutions: Check the electric supply and reset breaker if needed. Make sure the plug is in the socket. Do not use an extension cord. Adjust or replace the belt. Make sure the switch contacts are working properly. Test switch. Check for loose wires in the motor. Test motor. Clean under pedal. Repair or replace reverse pedal assembly. Motor belt broken or loose. Switch or switch connections are bad. Motor or motor connections are bad. Motor pedal broken or loose object underneath prevents full movement. PROBLEM 2: Turntable vibrates while mounting/removing tire. Causes: Belt loose or glide fasteners are loose. Solutions: Adjust belt tension and tighten all fasteners. PROBLEM 3: Jaws clamping cylinders slow to open/close. Causes: Silencer (air muffler) is clogged. Solutions: Clean or replace silencer (air muffler). PROBLEM 4: Clamping cylinders jaws do not lock the wheel rim correctly. Causes: Solutions: Replace jaws. Replace cylinder or rebuild cylinder with gaskets. Correct air leak, replace fitting if necessary. Jaws worn. Worn air cylinder Leaking air fittings PROBLEM 5: Mounting Head touches the wheel rim during tire mounting/demounting process. Causes: Locking slide for hex shaft is incorrectly adjusted or defective. Locking slide for hex shaft screw is loose. Solutions: Adjust or replace locking slide. Tighten screw. See section 10 for head adjustment. PROBLEM 6: Bead Breaker Pedal and Jaw Clamp Pedal do not return to original position. Causes: Pedal return spring is broken. Solutions: Replace pedal return spring. PROBLEM 7: Bead breaker not operating properly. Causes: The pedal stop bolt is not adjusted correctly. Solutions: Adjust the height of the pedal stop bolt. (The stop bolt is under the bead breaker pedal. See photo above. 5 port valve muffler (silencer) is clogged. 5 port valve O-rings are broken or worn. Bead breaker cylinder piston V-seal or rod O-ring is damaged. Insufficient air supply to the changer. Lack of lubrication. Clean or replace 5 port valve mufflers (silencers). Replace the 5 port valve O-rings. Replace bead breaker cylinder piston V-seal or the breaker cylinder assembly. Make sure the inlet air pressure is sufficient. Fill the lubricator; adjust the lubricator as explained in chapter 7. 22 The angle of the mount/demount head is preset to accommodate rim sizes from 12” to 18”. If the rim size is out of this pre-set range, an adjustment to the angle of the mount/demount head must be made. To adjust the mount/demount head angle: STEP 1: Lock the wheel on the turntable. (using the movable jaws) STEP 2: Loosen the retaining bolt under the mounting head but do not remove. STEP 3: Lower the hex shaft (7, Fig3) until the mounting head (6, Fig3) rests next to the wheel rim and on top of the wheel. Move the locking lever back to lock the hex shaft. The mounting head will rise up approximately 2mm. STEP 4: Loosen the adjusting screws on the side of the mounting head. STEP 5: Adjust the angle of the mounting head by hand. Maintain 2mm clearance from the edge of the wheel. STEP 6: Tighten the adjusting screws. STEP 7: Release the locking lever and allow the hex shaft to rise. Move the locking lever back to lock the hex shaft. Tighten the retaining bolt under the mounting head. 23 IP VERSION If the tire changer is equipped with the IP set, there is a tire inflator pedal on the left side of the machine. When the pedal is depressed half way, the inflator will operate. While the pedal is depressed, the air gauge on the inflator box will indicate the pressure of the air flowing through the hose into the tire. When the pedal is not depressed, this gauge will display the air pressure inside the tire (when the inflation hose is attached to the valve stem). The accuracy of the air gauge is not absolute. It is provided as a reference only. The air pressure of the tire should be rechecked with a digital hand held gauge to assure proper inflation pressure before the tire and wheel are installed on a vehicle. NEVER INFLATE A TIRE ABOVE THE TIRE MANUFACTURER’S SPECIFICATIONS. A tire changer’s bead blaster system delivers a large volume of highly pressured air into the cavity of a tubeless tire to help “seat the beads” of the tire to the wheel assembly. Many tubeless tires have extremely stiff sidewalls and the beads of these tires will not seat properly by just pumping air through the valve stem. (Even with the valve core removed) The “bead blaster” system of the modern tire changer takes the place of the “spray ether and a match technique” used by tire people with no regard for their own safety. See movie clip below. All tire changer bead blaster systems operate in the same basic way, but the Atlas and Coseng tire changers utilize a special internal hose and oversized tank system that delivers up to 50% more volume and pressure than most competitors’ bead blaster systems. Fig. IP1 Compressed air is stored in the external tank until that air is needed for the bead blaster. The delivery of the air is controlled by a foot pedal on the machine. When the pedal is partially depressed, the air flows into the tire through the hose attached to the valve stem. When the pedal is fully depressed, a large volume of compressed air is “blasted” into the cavity of the tire through holes located on the turntable slide mechanism. (Just behind the clamping jaws). This blast of air occurs while additional air is being introduced through the valve stem inflation hose. The combination of the valve stem air supply and the "bead blasted" air is usually enough to seat the beads of the most stubborn tires. 24 The “blast” of compressed air applies pressure to the top sidewall, temporarily seating the top bead of the tire to the rim. The large volume of compressed air is then directed toward the bottom sidewall and the lower bead of the rim. This process takes less than one second in most car and light truck cars. The continual flow of the air through the valve stem maintains the pressure against both beads; forcing them to seat permanently and allowing the tire to be inflated to the correct pressure. BEAD SEATING AND INFLATING WARNING: A WHEEL/ TIRE ASSEMBLY CAN EXPLODE (causing death, injury, or damage) WHEN THE FOLLOWING OCCUR: The diameter of the rim is different from the tire size. The rim or tire is defective. The recommended inflation pressure is exceeded during bead seating. The tire inflation pressure is higher than the maximum recommended by the tire manufacturer. The operator does not observe and follow safe procedures. 25 TUBE TIRES STEP 1: Remove the valve core from the inside of the valve stem. STEP 2: Clip the inflator hose air chuck to the tire valve. Make sure it is properly connected. STEP 3: Check that the tire size and the rim diameter correspond. STEP 4: Lubricate the tire and rim beads thoroughly. STEP 5: Press the tire inflator pedal down to the middle position to start inflation of tube. CAUTION: Do NOT use the BEAD BLASTER. STEP 6: Press and release (frequently) the inflating pedal (middle position only). Check the tire’s air pressure each time the pedal is released. Make sure the inner tube is not pinched between the rim and tire. Continue to inflate cautiously until the correct air pressure is achieved. Install the valve core into the valve stem. TUBELESS TIRES STEP 1: Remove the valve core from the inside of the valve stem. STEP 2: Clip the inflator hose air chuck to the tire valve. Make sure it is properly connected. STEP 3: Check the size of the wheel and the size of the tire. They MUST be the same. STEP 4: Lubricate the tire and rim beads thoroughly. STEP 5: Press the tire inflator pedal down to the middle position. STEP 6: If the tire beads do NOT seat properly; you may use the BEAD BLASTER INFLATOR SYSTEM by depressing the pedal fully. A strong jet of air will be released through the air holes located behind the turntable jaws to help seat the bead of the tire. You may need to attempt the bead seating process several times before the beads will seat. Allow the air tank (at the back of the tire changer) to fill completely with air before a new bead seating attempt is made. STEP 7: Continue to keep the pedal pressed to the middle position to allow regulated air to flow through the inflation hose and inflate the tire, releasing frequently to check the inflation pressure. CAUTION: Always keep hands and body away from the tire when inflating. Continue to inflate the tire to the manufacturer’s recommended air pressure. Never exceed the tire manufacturer’s recommended air pressure. Check the air pressure with a digital air gauge. NOTES: Failure to follow all warnings and instructions may lead to serious personal injury or death to the operator or any bystanders. NEVER exceed 50 psi (3.5 bar) air pressure when inflating a tire mounted on the tire changer. If more than 50 PSI air pressure is required, remove the wheel from the tire changer and continue the inflation procedure with the wheel/tire assembly inside a special protection cage. NEVER exceed the maximum inflation pressure given by the tire manufacturer. ALWAYS keep hands and body away from tire when inflating. ONLY allow fully trained personnel to use the tire changer. Do not allow unqualified persons to operate or be close to the tire changer (when in operation). 26 27 No. IP1 IP2 Code I2110301 PQ-L10 Qty 1 1 IP3 I2330341 1 IP4 IP5 IP6 IP7 IP8 IP9 IP10 IP11 IP12 IP13 I2110312 PT08-01 KP-L25 C233030104 I21103011702 I2110313 PC08-01 I211011701 C211011704 PC12-04 1 1 1 1 1 4 4 1 4 2 IP14 IP15 IP16 IP17 I2110314 I2110315 C211011220 I2110316 2 1 1 1 IP18 IP19 IP20 IP21 IP22 IP23 IP24 IP25 IP26 IP27 IP28 IP29 IP30 IP31 IP32 IP33 IP34 IP35 IP36 IP37 IP38 IP39 IP40 IP41 IP42 IP43 IP44 IP45 IP46 IP47 I2110317 PC08-01 PC-3T-0803 C2110327 GB/T41 GB/T5781 GB/T5781 GB/T41 GB/T41 GB/T42 PL12-04 I233030303 I233030304 I233030301 I233030305 I233030302 I233030103 I233030105 I233030106 GB/T5781 GB/T5782 C211016504 I2330340 GB/T5781 I233017001 MOV-03B PL08-01 1 1 2 1 4 4 2 2 2 2 2 2 1 1 1 1 1 1 2 2 2 1 1 6 1 1 1 PC10-02 GB/T5781 8 3 IP48 IP49 IP50 IP51 IP52 2 IP2110117 C211033002 2 1 1 1 Description Tank safety valve Hose (tank to quick exhaust valve) Hose (input to quick exhaust valve) T-union 1/8" Complete quick exhaust valve Tie-in Rotating valve casing Hose(Rotating union to slide) union 1/8" Rotating union mandrel O-ring Φ65x2.65 Connector 1/2" Hose(exhaust valve to Rotating union) Hose(5-way valve to IP air input) Hose(5-way valve to air input) complete 5-way valve Hose(5-way valve to quick exhaust valve) L-union 1/8" T-union Solenoid hose Nut M6 Screw M6 Screw M10 Nut M10 Spring washer Washer Angle connector 1/2" Tie-in T-Union quick exhaust valve support Union Union Union L-Union Nip Screw M8 Spring washer and washer T Union Air manometer Screw M5 Frame Exhaust valve L-Union1/8" No. IP53 IP54 Code IP55 Connector 1/4" Screw for fixing air manometer Hose(rotating union to rear flange of clamping cylinder) Hose(rotating union to front flange of clamping cylinder) Complete rotating union Air outlet hose for IP version Hose 28 Description Front cover Rear cover 1 Support Screw Screw Hanger Hose φ8 Complete IP box Pressure regulator IP56 IP57 IP58 IP59 IP60 IP61 I2330339 TC07081401 4 2 1 1 1 1 IP101 IP102 IP103 I2110101 GB/T 1239.6 GB/T 50 1 1 1 Inflation pedal support Spring Washer φ8 IP104 IP105 IP106 IP107 GB/T 5780 I2110102 I2110103 I2110104 1 1 1 1 Bolt M8×30 Pedal lever Inflation pedal Connecting rod IP108 IP109 IP110 IP111 IP112 IP113 IP114 IP115 IP116 IP117 IP118 IP119 GB/T 5780 GB/T 50 GB/T 1337 GB/T 70 GB/T 1337 GB/T 50 GB/T 70 GB/T 68 GB/T5781 GB/T 1239.6 GB/T 5780 GB/T41 1 1 1 1 1 1 1 1 4 1 1 1 Bolt M4×20 Washer φ4 Self-locking nut M4 Screw M6×20 Self-locking nut M6 Washer φ6 Screw M8×25 Screw M8×25 Screw M10X70 Spring Bolt M4×20 Nut M10 1 Complete inflation pedal CIP GB/T5781 GB/T5781 Qty 1 1 29 30 31 32 33 34 35 36 No. 2 3 4 5 6 7 8 9 10 11 12 13 Code BZ-233(A)/211 0101 C2110615 GB/T 70 GB/T 95 C2110102 GB/T 70 GB/T 95 C2110113 C211010105 C2110158 GB/T 70 GB/T 40 GB/T 41 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 C5030138 C2110135 GB/T41 GB/T 95 C2110137 C2110133 C2110127 C2110134 GB/T 95 GB/T 70 C2110128 GB/T 41 GB/T 78 GB/T 70 C2110132 C2110129 C2110131 C2110130 C2110126 C2110125 C2110124 489244220020 C2110124 GB/T 119 GB/T 78 GB/T 95 GB/T 80 GB/T 95 GB/T 41 GB/T 78 C2110123 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 4 4 4 1 Vertical column Column pin Self-locking nut M16 Washer φ16 Column adjusting screw Locking block handle bar Locking block support Cone washer Washer φ8 Screw M8×20 Locking block Nut M12 Screw M12×30 Screw M8×40 Knob Plastic cover Spring Locking plate Horizontal arm Hexagonal vertical arm Buffer bush Mounting head plastic protector Munting head Pin Screw M10×25 Washer φ10 Screw M12×15 Washer φ10 Nut M10 Screw M10×25 Complete mounting head 201 202 203 204 205 206 C2110122 C2110145 C2110144 C2110120 GB/T 5781 C2110163 1 4 4 1 1 1 Turntable Slide Jaw Turntable washer Screw M16×40 Cap 1 Qt. Description No. Code Qt. Description 1 Body 213 GB/T 894.1 4 Circlip φ12 1 6 6 1 6 6 1 4 1 4 1 1 Front cover Screw M6×55 Washer φ6 Left cover Screw M6×25 Washer φ6 Rubber wheel support Rubber foot Bead liftng lever Screw M6x15 Rubber plug φ21 Rubber plug φ45 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 GB/T 80 GB/T 95 C211012101 C2110148 C211011904 C211011902 C211011901 PC08-01 JB/T 6997 JB1092 C211011906 GB/T 95 GB/T 1337 C211011905 GB/T 41 GB/T 95 C211011903 PL08-01 C2110119 C2110143 4 4 2 4 8 2 2 2 2 4 2 2 2 2 16 16 2 2 2 1 4 Screw M12×85 Washer φ12 Slide guide Flat spacer for chuck Tightener Cylinder rod Front flange Union 8-1/8" V-seal O-ring φ70 Piston Washer φ12 Self-locking nut M12 Cylinder casing Washer φ8 Nut M8 Rear flange L-union 8-1/8" Complete clamping cylinder Complete self-centering chuck Metal guide 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 C2110353 C211010607 C211010603A GB/T 1337 GB/T 95 JB1092 GB/T 95 JB1092 C211010606 C211010601 JB/T 1091 C211010602 GB/T 41 GB/T93 C2110114 C2110111 GB/T 1337 GB/T 96 TC07082001 1 1 1 1 1 1 1 2 1 1 2 1 12 12 1 1 1 1 1 Union 8-1/4" Washer φ12 Bead breaker cylinder casing Self-locking nut M12 Washer φ12 O-ring φ16 Washer φ14 O-ring φ180 Bead breaker cylinder lid (front) Bead breaker cylinder rod V-seal Piston Nut M6 Spring washerφ6 Shovel Bead breaker arm pin (front) Self-locking nut M16 Washer φ16 Cotter C2110105 C2110142 C2110168 GB/T 1337 GB/T 95 GB/T 5287 GB/T93 GB/T 5783 C2110108 1 1 1 1 2 1 1 1 1 Bead breaker arm Bead breaker arm pin (rear) Rotating pin Self-locking nut M12 Washer φ12 Washer φ8 Spring washerφ8 Screw M8×15 Cushion 37 207 208 209 210 211 212 336 C2110147 C2110120 GB/T 894 C2110150 C2110121 GB/T 95 C2110106A 1 1 1 4 2 4 1 Control plate Washer Circlip φ65 Connecting rod Slide guide with pin Washer φ12 Complete bead breaker cylinder 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 1 1 1 1 2 2 1 1 2 1 1 1 1 2 1 2 4 2 2 2 1 1 1 1 1 1 2 2 2 2 2 2 434 435 436 437 438 439 440 C211011201 C211011201 C211011202 C211011213 GB/T 95 GB/T 70 C211011206 C211011207 GB/T 845 C211011215 C211011218 C211011216 C211011209 C211011211 C211011208 GB/T 1337 GB/T95 GB/T 973 GB/T 894.1 GB/T95 C211011203 GB/T 1337 GB/T95 C211011219 C211011210 GB/T 70 GB/T 41 GB/T95 GB/T 70 GB/T 70 GB/T95 GB/T 1337 C2110112200 1 GB/T 41 GB/T95 GB/T 70 PT08-01 PL08-01 C2110361 C2110361 441 C2110361 1 442 C2110361 1 443 444 445 446 447 448 C2110361 C2110361 QXS-L8 PC08-01 C211011220 C211011220 1 1 4 4 1 1 433 C2110104 C2110109 C211010608 GB/T6173 GB/T5781 JSM-L-Z6 C211015208 1 2 1 1 12 1 1 Spring Screw M12X20 Washer φ12 Nut M12X1.25 Screw M6X16 L-union 8-1/4" Spacer Bead breaker pedal Clamping pedal Reverse pedal Twist-spring Washer φ8 Screw M8×20 Connecting rod Switch lever Self tapping screw ST3×8 Cam cover Switch support Flat spring Cam Spring Pedals support Self-locking nut M4 Washer φ4 Screw M4X28 Circlip φ12 Washer φ12 Pedals shaft Self-locking nut M8 Washer φ8 Spacer Cam connecting rod Screw M8×50 Nut M8 Washer φ6 Screw M6×25 Screw M6×25 Washer φ6 Self-locking nut M8 330 331 332 333 334 335 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 GB/T 70 GB/T95 C211015203 GB/T 1096 GB/T 1096 JB1092 C211015205 GB/T 1337 10 10 1 1 1 2 1 10 Screw M6×20 Washer φ6 Upper cover Key 10×40 Key 14×40 O-ring φ34 Plastic cap Self-locking nut M8 C2110152 1 Complete gearbox 601 602 603 604 605 606 607 608 609 610 611 612 613 614 C2110201 GB/T 1096 C2110141 GB/T 71 GB/T 11544 C2110211 C2110212 C2110202 C2110213 C202011217 C2110154 C2110154 IEC947-3 C2110154 1 1 1 1 1 1 1 1 1 1 2 8 1 2 Motor MY8024 Key 6 ×20 Motor pulley Screw M6×10 Belt A26" Cable (switch to motor) Cable (switch to capacitor) Capacitor 35μF Cable Switch jacket Shock absorber washer Shock absorber washer Reverse switch Washer 2 5-Way valve casing 615 GB/T95 2 Washer φ8 8 8 8 2 1 1 1 Nut M6 Washer φ6 Screw M6×25 T-union 8-8-1/8" L-union 8-1/8" Hose (valve to valve) Hose (tank to valve) Hose (valve to bead breaker cylinder) Hose (valve to bead breaker cylinder) Hose (valve to clamping cylinder) Hose (valve to clamping cylinder) Silencer 1/8" Union 8-1/8" Complete 5-way valve Complete pedals 616 617 618 619 620 GB/T 93 GB/T 70 GB/T 70 GB/T 41 C2110110 2 2 4 4 1 Spring washer Screw M10×25 Screw M8×25 Nut M8 Motor support 801 802 803 804 JSM-3T-8 C2110351 JSM-L-Z6 C2110331 1 1 1 1 T-unon 8-1/4"-1/4" Quick change adapter L-union 8-1/4" Lubricator 38 501 502 503 504 505 506 507 508 509 510 C211015203 GB/T 297 GB/T 10708 C211015207 GB/T 41 GB/T 1096 C211015206 GB/T 292 C211015202 C211015201 1 2 1 1 1 1 1 2 1 1 Bottom cover Roller bearing 30204 V-seal Gear box pulley Nut M10 Key 6×20 Worm screw Bearing 7010 Worm gear shaft Worm gear 805 806 807 808 809 810 811 39 C2110332 C2110333 200-03-03 C2110161 GB/T 95 GB/T 819 GB/T 41 1 1 1 1 2 2 2 Filter and pressure reducer Pressure gauge Filter and pressure reducer+lubr. Gauge support Washer φ4 Screw M4×10 Nut M4 40 41 42 43 44
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