Ath-heinl 7256 User manual

OPERATING INSTRUCTIONS

ATH 7256

Manufacturer ATH-Heinl GmbH & CO.KG

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Contents

1.0 INTRODUCTION ................................................................................................................... - 3 -

1.1 General Information ........................................................................................................... - 3 -

1.2 Description ........................................................................................................................ - 4 -

1.3 Operation.......................................................................................................................... - 6 -

1.4 Technical Data ................................................................................................................ - 12 -

1.5 Scale Drawing ................................................................................................................. - 13 -

2.0 INSTALLATION ................................................................................................................... - 14 -

2.1 Transport & Storage Conditions ........................................................................................ - 14 -

2.2 Unpacking the machine .................................................................................................... - 15 -

2.3 Delivery Contents ............................................................................................................ - 15 -

2.4 Location .......................................................................................................................... - 17 -

2.5 Fixing ............................................................................................................................. - 18 -

2.6 Electrical Connection ........................................................................................................ - 18 -

2.7 Pneumatic Connection ...................................................................................................... - 18 -

2.8 Hydraulic Connection ....................................................................................................... - 19 -

2.9 Assembly ........................................................................................................................ - 19 -

2.10 Completion of Work ...................................................................................................... - 21 -

3.0 OPERATION ....................................................................................................................... - 22 -

3.1 Operating Instructions ..................................................................................................... - 22 -

3.2 Basic Information ............................................................................................................ - 23 -

4.0 MAINTENANCE ................................................................................................................... - 24 -

4.1 Consumables for installation, maintenance and servicing..................................................... - 24 -

4.2 Safety Regulations for Oil ................................................................................................. - 25 -

4.3 Notes ............................................................................................................................. - 25 -

4.4 Maintenance or Service Plan ............................................................................................. - 26 -

4.5 Troubleshooting / Error Display and Solutions .................................................................... - 27 -

4.6 Maintenance and Service Instructions ................................................................................ - 28 -

4.7 Disposal .......................................................................................................................... - 29 -

5.0 EG-/EU-KONFORMITÄTSERKLÄRUNG / EC-/EU-DECLARATION OF CONFORMITY...................... - 30 -

6.0 APPENDIX .......................................................................................................................... - 31 -

6.1 Pneumatic circuit diagram ................................................................................................ - 31 -

6.2 Electric circuit diagram ..................................................................................................... - 32 -

6.3 Hydraulic circuit diagram .................................................................................................. - 33 -

7.0 WARRANTY CARD ............................................................................................................... - 35 -

7.1 Scope of the Product Warranty ......................................................................................... - 36 -

8.0 INSPECTION LOG ............................................................................................................... - 37 -

8.1 Installation and Handover Log .......................................................................................... - 38 -

8.2 Inspection Plan ................................................................................................................ - 39 -

8.3 Visual inspection (authorised expert) ................................................................................. - 40 -

9.0 SPARE PART BOOK ............................................................................................................. - 44 -

10.0 NOTIZEN ........................................................................................................................... - 93 -

Manufacturer ATH-Heinl GmbH & CO.KG

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1.0 INTRODUCTION

1.1 General Information

THESE INSTRUCTIONS ARE AN INTEGRAL PART OF THE MACHINE.

THEY MUST BE READ AND UNDERSTOOD BY THE USER.

NO LIABILITY IS ASSUMED FOR ANY DAMAGES CAUSED BY FAILURE TO

FOLLOW THESE INSTRUCTIONS OR THE VALID SECURITY PROVISIONS.

WARNING: Follow the instructions to prevent injury or damage.

TIP: Provides more information on functionality and tips for using the device efficiently.

Appropriate protective clothing must be worn for all work on the described system.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.2 Description

1.2.1 Machine description

1. Operating unit

2. Switch for mounting head & carriage

3. Switch to open/close clamping jaws 4. Pedal turner left - right clamping head

5. Mounting lever bracket 6. Electrical control box

7. Electric motor 8. Oil tank

9. Hydraulic valves 10. Valve clamping cylinder

11. Pressure manometer

12. Gearbox

13. Gearbox motor

14. Clamping head

15. Clamping claws 16. Clamping jaws

17. Mounting lever and disc 18. Pressure limiting valve

19. Turning and notching device - mounting arm 20. Mounting arm

21.

22. Guide bed for mounting carriage

23. Mounting carriage entry point

mounting arm

24. Cylinder for lateral shift

mounting arm

25. Cylinder for lift clamping unit

11 12

18 19

22 23

Manufacturer ATH-Heinl GmbH & CO.KG

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1.2.2. Safety Equipment Description

The tyre changer has the following safety features

WARNING!!

Removal and manipulation of the machine's safety equipment

violates European safety regulations and absolves the manufacturer of any

liability.

Check valve for the clamping cylinder of the 4-jaw

clamping unit (swivel connection)

Double seal check valve on the lift cylinder of the

boom.

Pressure relief valve with factory setting of 160 bar

± 5%

This limits the hydraulic pressure and is

adjustable.

Overload protection for hydraulic motor (in the

electrical control box).

This cuts off the power supply when the engine

overheats

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3 Operation

1.3.1 Review of the different functions

Before using the tyre changer, check all functions with the operating part to ensure the machine is working

properly. This should be done before mounting.

WARNING!!

When operating the mounting machine, pay attention to all moving parts.

Make sure there is enough safety clearance. Make sure there are no other

people in the work area.

WARNING!!

Always keep enough safety clearance when loosening the mounting arm so

that it does not tilt outwards under tension.

WARNING!!

Ensure that there are no persons or objects in the working area of the

machine.

WARNING!!

When closing the jaw chuck, the process must be stopped immediately when

the minimum position is reached.

When tightening the rim, stop immediately when the maximum pressure is

reached. For aluminium rims, check the clamping pressure and set it lower if

required.

Failure to comply with this instruction may result in serious damage to the

mounting machine.

1.3.2 Precautions during tyre assembly

Before mounting the tyre, the following precautions must be observed:

 Only mount undamaged, clean, dry rims and tyres that are in good condition.

 Remove old balance weights.

 Check rim and tyre for damage, especially aluminium rims. Do not mount if damaged.

 Check that the rim and tyre size match.

 Before dismantling, let all air out of the tyre.

 Before mounting, coat the rim and tyre well with tyre lubricant to avoid damage.

 Always use a new valve.

 The tyre changer is not splash-proof, so do not clean wheels on the machine with water jets.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3.3. Operating the tyre mounting machine

This instruction manual only details the function of the machine, it does not replace professional training

and qualification of operating personnel.

WARNING!!

All tyre changers have movable or adjustable controls. It is essential to ensure

that the operator finds a working position where he can safely track and view

all work steps.

We have provided videos online that offer assistance in using the machine:

Link: https://www.youtube.com/watch?v=l4O7332Of98&list=UUkA-

6DJd2NsKjCwNovyxU1g&index=45

1.3.4. Clamping the wheel

WARNING!!

When tightening the rim, make sure that the clamping jaws are correctly

positioned on the rim to prevent the wheel from falling down.

There are different types of truck rims (Fig. 8 E/1-E6).

Use the four clamping jaws to select the appropriate clamp for the rim.

Manufacturer ATH-Heinl GmbH & CO.KG

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 Place the tyre on the inside of the table for the mounting arm.

 Continue moving the table until just before the clamping jaws.

 Lower the clamping head to the centre of the rim.

 Open the clamping jaws until they are smaller than the diameter of the mounting hole.

 Slide the tyre over the clamping jaws and open until the tyre is tight.

 Check that the rims sit correctly in all four jaws and that the tyre turns smoothly, otherwise it is not

possible to assemble.

WARNING!!

Note that the most secure tension is always at the inner hole.

WARNING!!

Never leave the work area while the wheel is still raised or tensioned.

1.3.5. Removing a tyre

Use the valve driver to let the air out of the tyre.

The tyre bead must first be completely pressed off from both sides

of the rim with the mounting plate. During this process, the

mounting paste is applied to the rim and the tyre bead.

The first bead with rim mounting hook is now mounted.

Feed the mounting hook between the bead and the rim.

The tyre is then levered over the rim by lowering the rim and

pulling the mounting hooks.

Turn counterclockwise to remove the bead.

Manufacturer ATH-Heinl GmbH & CO.KG

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Now remove the second bead with the bead breaker.

1.3.6. Removing a tyre with just a bead breaker

The tyre bead can be dismantled by pulling on most wheels.

Use the valve driver to let the air out of the tyre.

Pull apart both beads and apply plenty of tyre bead lubricant.

The tyre can then be jacked apart from the inside out with the

mounting plate.

Before the tyre is completely removed, remove the mounting plate

and move the rim down so that the tyre is pushed over the rim.

Manufacturer ATH-Heinl GmbH & CO.KG

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WARNING!!

If the tyre is pushed over the second shoulder, it may fall off. Take

appropriate precautions.

1.3.7. Mounting a tyre

Generously apply tyre bead lubricant to the rim and tyre.

The first bead is mounted by pushing in and turning the rim.

The second bead is mounted with the bead retaining clip. A

mounting plate can be used on several tyres.

Install the tyre clamp at the 6 o'clock position and mount it with the

mounting disc. This is a simple and straightforward mounting.

Manufacturer ATH-Heinl GmbH & CO.KG

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WARNING!!

During assembly, the mounting finger can get in the way, if so move it down.

In special cases, mounting can also be carried out with the

mounting finger.

WARNING!!

Damage to the tyre and machine can only be avoided with sufficient mounting

paste.

WARNING!!

As soon as the bead is removed, the tyre falls. Ensure that there are no

persons or objects in the danger area of the machine.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.4 Technical Data

Model ATH 7256

Clamping range (A)

–

1155

Clamping range expanded (A)

710 – 1550 mm

Rim diameter max. (B) 56 Zoll

Maximum wheel width (D) 1130 mm

Wheel diameter max. (C) 2550 mm

Wheel

weight max.

00 kg

Compression pressure / tension Ca. 7.000 / 8.000 kg

Mounting speed

Jaw chuck speed 4 / 8 U/min

Operating pressure max. 250 bar

Hydraulic motor

3,0

Gearbox motor 3,0 kW

Torque

11300 / 9300

Machine width (W) 2240 – 2540 mm

Machine depth (D) 2000 – 2400 mm

Machine height (H) 1020 – 1950 mm

Drive voltage (3x) 400/500 V/Hz

Noise level

–

dB(A)

Weight (net) 1145 kg

Manufacturer ATH-Heinl GmbH & CO.KG

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1.5 Scale Drawing

2240 – 2540 mm

1020 – 1950 mm

200

–

0 mm

Manufacturer ATH-Heinl GmbH & CO.KG

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2.0 INSTALLATION

The machine must be installed by an authorised person according to the instructions.

The operating instructions (including the log) are an important part

of the machine / product.

!!!PLEASE STORE CAREFULLY!!!

The product must be checked after completion of the installation, handover, if necessary briefing and then

regularly in accordance with the applicable regulations and legal provisions in the country of operation by a

suitable and approved company or facility.

2.1 Transport & Storage Conditions

When transporting and positioning the machine, always use suitable lifting and material handling

equipment and consider the machine’s centre of gravity.

The machine should only be transported with the original packaging.

Data:

Width

2.100 mm

Length

2.310 mm

Height 1.100 mm

Storage temperature -10 to +50 °C

Manufacturer ATH-Heinl GmbH & CO.KG

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2.2 Unpacking the machine

Remove the top cover of the packaging and make sure that no damage has occurred

during transport.

Remove the safety bolt to remove the machine from the pallet / rack.

Use a suitable lifting device (possibly with a stopping rope) to lower the machine from the

pallet / frame.

The packaging material used for the machine should be stored carefully.

Keep the packaging material out of the reach of children as it may be hazardous.

2.3 Delivery Contents

RMA0520 - mounting lever

RFZ0481 - bead clamp for steel rims

Grease gun

jaws extension

Manufacturer ATH-Heinl GmbH & CO.KG

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2.3.1. Optional Accessories

RAS1211 - aluminium clamping jaws

RLF0925 - aluminium clamping ring Ø280mm

RLF0924 - aluminium clamping ring Ø221mm

RLF0923 - aluminium clamping ring Ø200mm

RLF0922 - aluminium clamping ring Ø175mm

721423 - Tyre clamp for aluminium rims

RAR1110 - bead breaker

Manufacturer ATH-Heinl GmbH & CO.KG

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2.4 Location

The machine should be kept away from flammable and explosive materials, as well as from sunlight and

intense light. The machine should be placed in a well-ventilated location.

The machine must be set up on sufficiently firm ground, if necessary, according to the minimum

requirements of the information given in the foundation plan.

In addition to the ground conditions, the guidelines and instructions of the accident prevention regulations

as well as the workplace regulations must be observed when selecting an installation site.

When assembling on floor coverings, check their load-bearing capacity. A construction expert should be

consulted for inspection when mounting on floor coverings.

The machine should only be mounted and used within closed rooms. It has no corresponding safety

features (e.g. IP protection, galvanised design, etc.).

Temperature 4-40 °C

Sea level

< 1500 m

Humidity 50% at 40 °C – 90% at 20 °C

Drawing

Manufacturer ATH-Heinl GmbH & CO.KG

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2.5 Fixing

General and local regulations must be observed. Therefore, these steps should only be

carried out by a trained professional.

The machine must be set up and fixed on sufficiently firm ground, if necessary, according to the minimum

requirements of the information given in the foundation plan.

The machine must be fastened at the points provided with suitable or specified fastening material.

In addition to the ground conditions, the guidelines and instructions of the accident prevention regulations

as well as the workplace regulations must be observed when selecting an installation site.

When assembling on floor coverings, check their load-bearing capacity. A construction expert should be

consulted for inspection when mounting on floor coverings.

2.6 Electrical Connection

General and local regulations must be observed. Therefore, these steps may only be

carried out by a trained professional.

Pay attention to the necessary supply line (see technical data).

The connection should be made with a 230V Schuko plug or 5-phase 16 A CEE plug (partially included).

Voltage deviations should be 0.9 - 1.1 times the nominal voltage range and the frequency deviation should

be 0.99 - 1.01 times the frequency range.

Necessary protective measures must be taken to guarantee this.

At the end of the work, the direction that the motor rotates must be checked.

2.7 Pneumatic Connection

For all pneumatic systems, a compressed air maintenance unit (partially included) must

be installed between the supply line and the system.

The air pressure of the supply line must at least correspond to the technical data.

The compressed air maintenance unit must be set correctly and checked.

The compressed air maintenance unit must be serviced at regular intervals.

The maximum or minimum pressure ensures perfect functioning without any damage.

Manufacturer ATH-Heinl GmbH & CO.KG

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2.8 Hydraulic Connection

Before the system is put into operation or operated for the first time with oil, the

following must be observed with regard to the optimal, trouble-free and almost air-free

functioning

All hydraulic lines must be connected and tightened according to the hydraulic plan and, if applicable

according to the hose designation.

All hydraulic lines and cylinders must be vented according to the hydraulic plan and, if applicable, according

to the hose designation.

In order to ensure the faultless and safe functioning of the system and the hose assemblies used, the

hydraulic fluids used must comply with the specific instructions and recommendations of the manufacturer.

Used media that do not meet the specific requirements or which have unauthorised contamination damage

the entire hydraulic system and shorten the service life of the hydraulic systems used. Warning: (system

contamination can also occur when oil is refilled)

The minimum requirement and minimum oil quantity must be checked and ensured.

2.9 Assembly

These instructions are not to be viewed as assembly instructions; hints and tips are

provided only for trained expert installers. Suitable clothing and personal protection must

be worn for the following work.

Incorrect installation and settings lead to exclusion of liability and warranty.

Partly pre-assembled machines must be checked, introduced and approved by a competent person before

commissioning.

Machine assembly must be carried out by a qualified and competent person.

Manufacturer ATH-Heinl GmbH & CO.KG

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2.9.1. Foundation properties

When assembling on floor coverings, check their load-bearing capacity. A construction expert should be

consulted for inspection when mounting on floor coverings.

Foundation dimensions in mm Concrete grade Floor load

Length Width

Length of machine

+ 500 mm

Width of machine

+ 500 mm

B25 according to DIN

1045 425 kg / cm²

Floor

Ferroconcrete

Electro-soldered

grid

Gravel

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