OPERATOR'S MANUAL AUTOMATIC TYRE CHANGER

RAE.2102 RAE.2102.T

RAE.2104 RAE.2104.T

3B

DJOH

GB

MADE IN ITALY Ver.2.0 del 04/08

RAE.2102 - RAE.2104 Automotive Equipment

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Italiano

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English

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Deutsch

eservados los derechos de traducción, grabación electrónica, reproducción y adaptación total o parcial con cualquier medio (incluidos microfilmes y copias fotostáticas). Las informaciones contenidas en el presente manual pueden sufrir variaciones sin aviso previo.

Español

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RAE.2102 - RAE.2104 Automotive Equipment

TABLE OF CONTENTS

Page TABLE OF CONTENTS

5

GENERAL INFORMATION TECHNICAL BRIEF MANUFACTURER'S LABEL TRANSPORT

6 6 6 6

MAIN PARTS OF THE MACHINE

7

UNPACKING AND ASSEMBLY

8

SAFETY REGULATIONS

9

WARNING SIGNALS

10

INSTALLATION PLACE OF INSTALLATION SAFETY DEVICES PNEUMATIC HOOK-UP ELECTRIC HOOK-UP

11 11 11 11 11

OPERATION CHECK

12

BEAD BREAKING WHEEL CLAMPING

13 13

TYRE DEMOUNTING TYRE MOUNTING

14 14

INFLATION

15

MAINTENANCE ROUTINE MAINTENANCE

16 16

STORAGE DEMOLITION TROUBLE SHOOTING

17 17 17

ACCESSORIES ON REQUEST

18

ENVIRONMENTAL INFORMATION

19

5

RAE.2102 - RAE.2104 MAIN PARTS OF THE MACHINE

20 8 25 23 11

10 16

21

7

6 2 19 12

22

18

t.i. version (with tubeless tyres inflating device)

4 24

14 5

1 2 3 4 5 6 7 8

13 3

1

Reverse control pedal Turntable Bead breaker pedal Bead breaker arm Clamp control pedal Clamp Vertical arm Horizontal arm

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10 11 12 13 14 16 17 18

standard version

Mounting bar Inflating gun with pressure gauge Pressure regulator with filter Wheel support Bead breaker Mounting head Tyre lever Air lubricator

19 20 21 22 23 24

Inflator pedal for t.i. version Inflating unit Air tank Body Control handle Tower tilt pedal

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RAE.2102 - RAE.2104 UNPACKING AND ASSEMBLY Remove the upper part of the packing and make sure that the machine has not been visibly damaged. Proceed with the following operations: - Remove the tower (horizontal + vertical arms) from its position on the pallet. - Remove the mounting bar from the wooden lath that is keeping it locked. During this operation it is advisable to keep the mounting bar in lowered position with a hand. - Assemble the bead breaker with the proper pin and fasten it with the locknut until there is a slight resistance in the rotation of the bead breaker. - Remove the side cover. - Place the tilting arm in its seat on the machine's body. In the meantime, insert the pneumatic hose A into its proper hole on the machine's body. - Insert pin B on the tilting arm and fasten it with the proper screws, using the washers provided. - Tilt arm C in vertical position and introduce pin D. Pin D must pass through the hole M of the tower tilt cylinder's stem. - Fasten pin D with snapring L. - Connect hose A to the valve placed on the pedal unit base inside the machine's body and controlled by the tower tilt pedal. - Fit the side cover.

C D

L

A M

ON T.I. VERSION, FURTHER TO THE ABOVE DESCRIBED OPERATIONS: - Remove the side cover. - Fix the tank to the machine. - Connect the air hose F to the tank's union. - Fix the inflating unit to its support on the vertical harm by means of two screws. - Connect the air spiral hose of the inflating unit to the union fixed on the outside of the machine's back. - Fit the side cover.

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RAE.2102 - RAE.2104

SAFETY REGULATIONS

- The machine must be used only by qualified and suitably trained personnel.

- Keep this instructions manual with care in a handy place; please consult it regularly.

- Before carrying out maintenance or making any adjustments, disconnect the electric and pneumatic supply from the machine and make sure that all moving parts are immobilised.

- Do not remove or deface the warning labels. In case such labels should have been removed or damaged, replace them immediately.

- Before using the machine, carefully read the warning signals. Such signals indicate the parts of the machine that might injure the operator during work.

- Pay the utmost attention to the moving parts of the machine. Necklaces, rings, watches, bracelets, ties, long hair and loose fitting clothes may be dangerous during work.

- Install the machine in compliance with the established regulations for accident prevention on the place of work.

- Never use the machine in an explosive atmosphere.

- Keep unauthorized persons at a proper distance from the area of work.

- Any unauthorized modifications made to the machine are dangerous for the operator and release the manufacturer from any liability in case of damage or injury ascribable to such operations.

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RAE.2102 - RAE.2104 WARNING SIGNALS PAY THE UTMOST ATTENTION TO THE WARNING LABELS ATTACHED TO THE MACHINE. USING THE MACHINE WITHOUT READING THE WARNING SIGNALS MAY BE SERIOUSLY DANGEROUS FOR THE OPERATOR.

A

A 000103700

B B - CAUTION: TOWER TILTING 000103500

C D F

E

H C

G

I

000103000

D

J

DANGER OF HAND CRUSHING BETWEEN CLAMP AND RIM.

DANGER OF HAND CRUSHING BETWEEN MOUNTING HEAD AND WHEEL. 000103100

E G - CAUTION: ELECTRIC CURRENT. CAUTION: AIR BLAST.

000103600

H - DANGER OF CRUSHING PARTS OF THE BODY BETWEEN THE BEAD BREAKER AND THE MACHINE. MAX. AIR SUPPLY LINE PRESSURE 16 BAR

000103400

000102800

F - INFLATING GUN CONNECTION. DO NOT DIRECTLY CONNECT THE COMPRESSOR. (only on standard version)

I - DANGER OF CRUSHING PARTS OF THE BODY BETWEEN THE BEAD BREAKER AND THE WHEEL. 000103200

000102700

J - DANGER OF CRUSHING PARTS OF THE BODY BETWEEN THE BEAD BREAKER ARM AND THE MACHINE.

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000103300

RAE.2102 - RAE.2104 INSTALLATION To take the machine away from the pallet, sling it as shown in the figure. Use this lifting point whenever you need to move the machine. It is not advisable to use the machine outdoors; should it be necessary, suitably protect the machine from inclement weather. Remember to disconnect the machine from the electric and air networks before moving the machine (see SAFETY REGULATIONS). The machine must be lifted with belts and devices adequate to the weight of the machine.

PLACE OF INSTALLATION - Comply with the minimum clearances shown in the figure. - Always install the machine on a firm and levelled floor. Fix the machine by means of the 4 holes predrilled in the base, using suitable metal plugs. - Make sure that the place of installation is at least 2 m. in height.

SAFETY DEVICES The machine is equipped with: - a pressure regulator set at 10 bar, placed on the outside, provided with a quick coupling for the connection to the line supply air. - safety valve set at 4,2 bar, placed inside the tyre changer, which prevent the air coming out from the inflating gun from exceeding the pressure of 4,2 bar. IT IS ABSOLUTELY FORBIDDEN TO TAMPER WITH THE MACHINE'S SAFETY DEVICES

PNEUMATIC HOOK-UP 1 - Connect the tyre changer to the compressed air line by means of the quick coupling supplied with the machine. The air supply line pressure must range from 8 bar to max. 16 bar. 2 - Connect the inflating gun to its proper coupling on the machine and fasten it.

ELECTRIC HOOK-UP ALL OPERATIONS RELATING TO THE ELECTRIC HOOK-UP MUST BE CARRIED OUT BY QUALIFIED PERSONNEL. - Make sure that the mains voltage corresponds to the machine's required voltage, as shown on the relevant data plate. - Suitably size the electric supply line in relation to the machine's power requirements. - Connect the tyre changer to a good grounding circuit. - Equip the machine with a 16A socket or plug, which must be in conformity with the safety standards in force. It is also recommended to provide the automatic circuit breaker (differential) set at 30mA.

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RAE.2102 - RAE.2104 OPERATION CHECK

WARNING: IN CASE OF THREE-PHASE HOOK-UP, IF THE TURNTABLE DOES NOT ROTATE CLOCKWISE WHEN PRESSING THE RELEVANT PEDAL, IT IS NECESSARY TO REVERSE THE POSITION OF THE TWO PHASE-WIRES IN THE PLUG. THIS OPERATION MUST BE CARRIED OUT BY QUALIFIED PERSONNEL.

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t.i. version

RAE.2102 - RAE.2104 BEAD BREAKING PAY ATTENTION TO THE WARNING SIGNALS

- Fully close the turntable clamps. - Remove the weights from the rim. - Fully deflate the tyre and remove the inflating valve. - Place the wheel in the bead breaking position, bringing it close to the rubber supports. - Take the bead breaker near the bead. Keep the necessary safety distance between the rim and the bead breaker, so that the latter works on the tyre and not on the rim. - Press the bead breaker pedal. - Free the bead from the rim repeating the above operation at various points around the tyre. - Turn the wheel, bringing the other side of it by the supports, and follow the same procedure to carry out the bead breaking of the second rim.

WHEEL CLAMPING PAY ATTENTION TO THE WARNING SIGNALS

- Check if there are any weights left on the rim; if so, remove them. - Carefully lubricate the lower and upper bead along their entire circumference. - Tilt the tower backwards in non-work position by pressing the relevant pedal - Place the wheel on the turntable. - Depending on the diameter of the rim, close the four clamps if the rim is to be clamped in the inside or open them if the rim is to be clamped in the outside . - Press pedal fully down, making sure that the rim is safely clamped.

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RAE.2102 - RAE.2104 TYRE DEMOUNTING PAY ATTENTION TO THE WARNING SIGNALS

- Tilt the tower forward by pressing the tower tilt pedal - Set the mounting bar in its working position and let the mounting head touch the edge of the rim. - Press the yellow button from the outside of the handle to lock both the mounting bar and the horizontal arm. The mounting head will automatically move 2/3 mm. away from the edge of the rim, thus protecting it from damage. - Position the tyre lever between the mounting head and the tyre bead and lift the bead above the forward portion of the mounting head itself. - Make the turntable rotate clockwise by pressing the relevant pedal lightly and repeatedly, then keep the pedal continuously pressed. - Rotate the wheel through one turn and at the same time press down with a hand on the side of the tyre opposite to the mounting head, in order to position the bead in the central groove of the rim. - If the wheel has an inner tube, tilt the tower backwards by means of the relevant pedal, without unlocking the horizontal arm and the mounting bar, and remove the tube. - Repeat the above described procedures to take out the second bead. Then tilt the tower backwards in non-work position and take the tyre off the rim.

TYRE MOUNTING PAY ATTENTION TO THE WARNING SIGNALS BEFORE STARTING THE MOUNTING PROCEDURES CHECK THAT:

- the diameter of the rim is exactly the same as the diameter of the tyre; - the tyre is in good condition and without any damages; - the rim is not bent or warped. MOREOVER:

- Carefully lubricate both the rim (near and on the bead breaking area) and the two beads of the tyre. - Clamp the rim as described in the WHEEL CLAMPING section. - Place the tyre over the rim and set the mounting bar in its working position, as described in the TYRE DEMOUNTING section. - Position the tyre as shown. - To facilitate mounting operations, keep the tyre slanted and press it with the right hand towards the rim groove. - Rotate the turntable clockwise by pressing the relevant pedal. - Insert the inner tube if the tyre has one. - Repeat the above procedure to mount the top bead. - Tilt the tower backwards in non-work position by pressing the relevant pedal. - Free the wheel from the clamps and remove it from the tyre changer.

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RAE.2102 - RAE.2104 INFLATION WARNING: TYRE INFLATION IS DANGEROUS. IF THIS OPERATION IS NOT CARRIED OUT WITH THE UTMOST CAUTION, THE TYRE MAY EXPLODE CAUSING SERIOUS INJURY OR DEATH OF THE OPERATOR. Therefore never exceed the maximum pressure stated by the tyre manufacturer both during bead breaking and tyre inflation. The machine is equipped with a pressure limiting device set at 4,2 bar (50 psi), which however does not exclude the risk of tyre explosion. Before inflating the tyre, check again and MAKE SURE that: · rim and beads are sufficiently lubricated; · the diameter of the rim perfectly corresponds to the diameter of the tyre; · both the rim and the tyre have no signs of damage. KEEP HANDS AND BODY WELL CLEAR OF THE POTENTIALLY DANGEROUS AREA DURING INFLATION. TYRES WITH INNER TUBES - Properly connect the chuck of the inflating gun to the tyre valve. - Inflate the tyre with short blasts of air. Between the blasts, always check the pressure on the inflator's gauge. Proceed this way until the beads are completely sealed. - Continue to inflate the tyre until you reach the required pressure, however NEVER EXCEED THE PRESSURE SPECIFIED BY THE TYRE MANUFACTURER.

TUBELESS TYRES (t.i. version) - Carefully remove dust, dirt and any other foreign matter from the areas near the air outlet holes. . - Secure the wheel on the turntable with inside clamping. - Properly connect the inflating chuck to the tyre valve. - Hold the tyre with your hands and lift it in order to close any eventual gap between the rim and the upper bead. - Press the tubeless inflating pedal fully down for a short period until an air blast comes out of the air outlet holes, wedging itself between the tyre and the lower edge of the rim. The tyre will expand and the bead will seat. - To fully inflate the tyre, gently press the tubeless inflating pedal (in intermediate position) until you reach the required pressure. Do not forget to constantly check the pressure on the inflating unit gauge placed on the vertical arm and to NEVER EXCEED THE PRESSURE SPECIFIED BY THE TYRE MANUFACTURER.

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RAE.2102 - RAE.2104 MAINTENANCE BEFORE CARRYING OUT MAINTENANCE: - DISCONNECT THE ELECTRIC SUPPLY FROM THE MACHINE; - DISCONNECT THE PNEUMATIC SUPPLY FROM THE MACHINE; - MAKE SURE THAT ALL MOVING PARTS OF THE MACHINE ARE STEADILY IMMOBILISED

ROUTINE MAINTENANCE DAILY CHECK: - Check that the slides are running well; remove any eventual residues of dirt.

WEEKLY CHECKS: - Make sure that the condensate level into the filter cup does not exceed the red mark on the level indicator. - The air lubricator+filter unit is equipped with a semi-automatic condensate drainage system; if necessary, however, carry out drainage manually by turning clockwise the ring placed on the bottom of the cup. - Press twice or thrice one of the pedals (for example the bead breaking pedal) to make sure that every two or three pedal movements a drop of oil falls into the lubricator transparent cup. If this does not happen, adjust the regulating screw placed on the top of the lubricator with a screwdriver.

MONTHLY CHECKS: - Disconnect the machine from the pneumatic supply and demount the lubricator cup to remove any eventual solid residues of dirt. - Check the oil level in the lubricator and, if necessary, top up with SAE20 non-detergent oil until you reach the required level. - Clean and lubricate with naphta the horizontal arm and mounting bar. - Check the stretch of the motor/reduction gear driving belts; using the machine, such belts may become loosen and worn out.

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RAE.2102 - RAE.2104 Automotive Equipment

STORAGE If the machine is to be kept idle for a long time, it is recommended to: - disconnect the machine from the electric supply; - disconnect the machine from the pneumatic network; - lubricate all moving parts, along with their guides, with naphta; - wrap the machine in a protective plastic sheet.

DEMOLITION In case the machine has to be scrapped, it is recommended to: - remove all electric and pneumatic connections; - disassemble the machine; divide its parts into unifom groups (electric parts, plastic, iron) and dispose of them in compliance with the regulations in force.

TROUBLE SHOOTING TROUBLES

POSSIBLE CAUSES

REMEDIES

When you press the pedal operating the turntable clamps or the bead breaker pedal, or when you turn the control handle, nothing happens.

There is no compressed air circulation in the machine because hoses are crimped or crushed

Put back the compressed air system in operation; if hoses are damaged, let them be replaced by qualified personnel.

Even though you press the pedal to rotate the turntable, the latter does not turn.

- Power plug faulty or not properly inserted. - No power from the mains electric supply. - Faulty reverse switch. - Short-circuited motor.

- Check the plug. - Reset the electric hook-up. - Let reverse switch be replaced by qualified personnel. - Let motor be replaced by qualified personnel.

IN CASE OF TROUBLES OR FAILURES DIFFERENT FROM THE ABOVE ONES, APPLY TO AUTHORIZED SERVICE CENTRES OR QUALIFIED PERSONNEL ONLY.

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RAE.2102 - RAE.2104 Automotive Equipment

ENVIRONMENTAL INFORMATION This product may contain substances that can be hazardous to the environment or to human health if it is not disposed of properly. We therefore provide you with the following information to prevent releases of these substances and to improve the use of natural resources. Electrical and electronic equipments should never be disposed of in the usual municipal waste but must be separately collected for their proper treatment. The crossed-out bin symbol, placed on the product and in this page, remind you of the need to dispose of properly the product at the end of its life. In this way it is possible to prevent that a not specific treatment of the substances contained in these products, or their improper use, or improper use of their parts may be hazardous to the environment or to human health. Furthermore this helps to recover, recycle and reuse many of the materials used in these products. For this purpose the electrical and electronic equipment producers and distributors set up proper collection and treatment systems for these products. At the end of life your product contact your distributor to have information on the collection arrangements. When buying this new product your distributor will also inform you of the possibility to return free of charge another end of life equipment as long as it is of equivalent type and has fulfilled the same functions as the supplied equipment. A disposal of the product different from what described above will be liable to the penalties prescribed by the national provisions in the country where the product is disposed of. We also recommend you to adopt more measures for environment protection: recycling of the internal and external packaging of the product and disposing properly used batteries (if contained in the product). With your help it is possible to reduce the amount of natural resources used to produce electrical and electronic equipments, to minimize the use of landfills for the disposal of the products and to improve the quality of life by preventing that potentially hazardous substances are released in the environment.

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