Ath-heinl A31 User manual

USER´S MANUAL

CONTENT

INTRODUCTION ....................................................................................................................................................................3

Description of assist arm ....................................................................................................................................................4

Technical data ....................................................................................................................................................................4

Transport and storage ........................................................................................................................................................5

Unpacking of machine ........................................................................................................................................................5

Standort ..............................................................................................................................................................................5

Fixing ..................................................................................................................................................................................5

OPERATION.........................................................................................................................................................................11

Safty instructions ..............................................................................................................................................................11

Use ...................................................................................................................................................................................13

MAINTENANCE ...................................................................................................................................................................16

Troubleshooting ................................................................................................................................................................16

Maintenance instruction....................................................................................................................................................16

KONFIRMITÄTSERKLÄRUNG............................................................................................................................................17

SPARE PARTS ....................................................................................................................................................................18

Spare part list A31 ............................................................................................................................................................20

Exploded drawing A34......................................................................................................................................................22

Spare part list A34 ............................................................................................................................................................23

ATTACHEMENT...................................................................................................................................................................26

Pneumatic sceme .............................................................................................................................................................26

GARANTYKARD..................................................................................................................................................................27

NOTES..................................................................................................................................................................................29

INTRODUCTION

THIS MANUAL IS AN INHERENT PART OF THE MACHINE.

IT MUST BE READ AND UNDERSTOOD FROM THE OPERATOR.

THERE IS NO RESPONSIBILITY FOR DAMAGES, WHICH ARE RESULTING FROM NON-

OBSERVANCE OF THIS MANUAL OR THE GUILTY SAFETY REGULATIONS.

ATTENTION: Follow the instructions to avoid injuries or damages.

TIP: Gives further informations to the functions and tips for using the machine efficiently.

Protective clothes must be worn for all works on the described machine.

Name plate:

Note all informations regarding the tire changer into the following gaps.

It is forbidden to remove the name plate from the tire changer.

Description of assist arm

A31

A34

1. Double acting pneumatic Cylinder

2. Beadholder

3. Control unit

Operation

3.1 Handle to control the up and down movement of the

bead holder, tire support disc and bead roller (only by A34).

4. Tire support disc

5. Bead roller

Technical data

Type

A31

A34

Working pressur

8-10 bar

Noise level

<80 dB(A)

Weight

80 kg

100 kg

3.1

INSTALLATION

The machine should be installed only by authorized personal according to the manual.

Transport and storage

Always use suitable means for transporting and

positioning the machine and keep attention to the gravity

center of the machine.

The machine should only be transported with the original

packing.

Type

A31

A34

Lenght

1.550 mm

1.220 mm

Width

820 mm

1050 mm

Height

310 mm

340 mm

Weight

110 kg

Storage

temperature

0°C ～+50 °C

Unpacking of machine

Remove the upper cover of the carton and make sure that there were no damages during the transport.

Remove the safety bolts to get the machine from the pallet.

For taking the machine from the pallet use a suitable means (eventually with sling).

The packing material of the machine should be stored carefully.

Keep the packing material away from children as it could be dangerous for them.

Standort

The machine should be kept away from flammable and explosive materials as well as from solar radiation and intensive

light. The machine should also be installed in a well-ventilated place.

The tire changer must be placed on a concrete floor or similar solid flooring.

When selecting the place of installation, besides the soil condition also the guidelines and instructions of the accident

prevention regulations and workplace regulations must be observed.

It is not allowed to install the machine outside, but only inside, as the machine has no corresponding safety provisions (IP-

protection, zinc coated and so on)

Temperature

0-50 °C

Air humidity

10-90% (ohne Kondensation)

Sea level

≤2000m

Fixing

Here, the general and local regulations must be observed. Therefore this step must be performed only

by an expert.

Pay attention to the correct current supply. (see technical data).

1. Preparation:

a. Disconnect the tire changer from any electrical or pneumatical connection

b. Check the correct fixing of tire changer

c. Remove all parts from the installation area (f.e. grease bucket)

d. Put the support bar under the connection point

2. Add the main post:

a. Fix the main plate on the maschine.

b. Fix the post oft he assist arm on the main plate.

3. Add arms

a. Mount the bend arm on the arm where control unit is add

b. Add the bead roller and tire support disk on the swivel part

c. Add both bead roller arms and secure them

4. Pneumatic connection

a. Remove the side wall

b. Cut the pneumatic line and add the T-connector. Now you can put the airline of the assist arm through the

hole in the machine and connect to the T-piece.

c. Now you can install the side wall again

5. Final step´s

a. Check the correct position of the sliding pieces

If needed, the distance can adjust as following:

Loose the fixing nut on the studs (A & B). The clearance can be adjusting by screw in or out the studs. To

finish the adjustment, the nuts should be fixed again.

By long term of using the clearance have to adjust again, to secure the precise movement of arms.

b. Before starting the operation all bolts, nuts and connections have tob e checked.

OPERATION

Safty instructions

THE TIRE CHANGER IS ONLY ALLOWED TO BE OPERATED BY SKILLED AND TRAINED TECHNICIANS OVER 18

YEARS.

BEFORE MOUNTING OR DEMOUNTING CHECK ALL COMPONENTS. THOSE MUST NOT HAVE ANY DAMAGES.

THE MACHINE IS ONLY TO BE USED ACCORDING TO ITS INTENDED AND SPECIFIED USE.

FOR A CORRECT MOUNTING OF THE RIMS IT IS PROBABLY NECESSARY TO USE A CORRESPONDING

ACCESSORY (e.g. PLASTIC PROTECCTION FOR CLAMPING JAWS, MOUNTING HEAD AND MOUNTING LEVER

OR MOTORCYCLE ACCESSORY).

DO ALWAYS TAKE THE INTENDED MATERIAL, e.g. THE CORRECT TIRE DIMENSION, SUITABLE VALVES OR THE

CORRECT MOUNTING GREASE.

BEFORE MOUNTING OR DEMOUNTING CHECK ALL COMPONENTS. THOSE MUST NOT HAVE ANY DAMAGES.

PAY ATTENTION TO POSSIBLE SPECIAL MOUNTING OR DEMOUNTING INSTRUCTIONS OF THE TIRE

MANUFACTURER.

DURING OPERATION PAY ATTENTION TO DANGEROUS SITUATIONS. IF THERE ARE ANY DANGERS SWITCH

OFF THE MACHINE IMMEDIATELY, DISCONNECT THE CURRENT SUPPLY AND THE AIR SUPPLY.

FOLLOWING CONTACT YOUR DISTRIBUTOR.

DURING MOUNTING OR DEMOUNTING OR INFLATING OF TIRES OBSERVE STRICTLY THE GUIDELINES OF WDK

(TRADE ASSOCIATION OF THE GERMAN RUBBER INDUSTRY).

MOUNTING OR DEMOUNTING OF TIRES WHICH ARE OLDER THAN 30 YEARS CAN CAUSE ACCIDENTS OR

DAMAGES.

Pay attention to possible shearing points on the tire changer.

Be careful while filling tires - damaged or dirty tires can cause serious injuries.

Moving parts of the machine can catch loose clothing, long hairs or jewelry.

ALL WARNING SYMBOLS MUST BE ALWAYS READABLE; THEY MUST BE REPLACED IMMEDIATELY IN CASE OF

ANY DAMAGE ON IT.

Assist arm

Risks for human and environment

Bursting tires, balancing weights or rim parts which blow away can cause serious

injuries.

By abrasion of brake linings harmful dust will be released.

Precautions and rules of conduct

Do only use impact screw drivers which are not blowing onto the rim.

To avoid dust, only clean rims and tires wet; if possible use washer for tires.

Remove dust on the brake drums with exhausting bell in connection with a suitable

industrial vacuum cleaner. Use equipment of Category U for nonasbestos dust and

equipment of Category K1 for asbestos-containing dust.

Do only use faultless rims. By flat mould rims, which are sticked together by spot

welding, the seam resistance has to be checked.

Faulty tires have to be made unusable.

While inflating the tire position a safety device for collecting parts which blow away.

Keep persons away from the danger zone.

On tire changers with vertical positioned tires the working with heavy weight tires

(e.g. earth mover tire molds) must be made by 2 persons.

At tires with a diameter > 1,4 m or a weight > 200 kg safety devices against falling

over must be used.

The inflating of tires must be observed and the maximum mounting pressures are

not allowed to exceed.

Behaviour in case of error

Detected errors have to be reported to the responsible person.

First Aid

Emergency call:

Keep in mind in case of an accident not only to save the injured person and to

render first aid but also to secure the scene of accident.

Report every accident immediately to the responsible person.

Place of first aid kit and first aid book:___________________

Record all information in the first aid book.

Maintenance, Disposal

Reparations are only allowed to be made by the after sales service of the

manufacturer.

Use

The product is a helping device for mount and demount very stiff tires.

All regulations of manufacturers of rim and tire have to be consider.

1. Demount

a. Breake the bead oft he tire.

b. Adjust the clamping claws to the size of the rime (f.e. by 20“ rim, adjust to 21“)

c. Take the additional cone adaptor and place them tot he midhole oft he rim. Now you can push the rim down

to clamp the rim more easily

d. Place the bead roller and the bead holder by the edge of the rim. For placing the crowbar, you have to push

down the bead of the rim. After placing the crowbar, the arms can be remove from the wheel.

e. Now the bead holder has to be placed opposite of the duck head, so the leverage of the crowbar is more

easily. Furthermore, it avoids damage on the wheel.

If the leverage is still too heavily, the tire can be pressed down on 3, 6 & 12 o´clock position.

f. As soon as you have levered the wheel, you can remove the bead holder and start to rotating in clockwise

direction.

g. Lift up the tire and demount the second bead.

If the tire is stuck in the rim bead, you can lose it by using the tire support disk.

Regarding the turning of the wheel the disc will moving.

By some wheels it´s also possible to use only the bead roller o demount the second bead.

Here you can mount as following:

oPlace the bead roll under the bead of the tire. Pay attention to have a small gap between the rim and the

bead roller. After this you can push up the bead above the edge of the rim.

2. Mount

a. Put grease on rim and wheel.

b. Mount the downside bead as usual.

The bead holder can assist you in this issue.

c. By mounting the upside bead you have to push the wheel with both bead roller and the bead holder under the

duck head, here you have to push the wheel on the height of the first gap inside the rim. Start with the

rotation of the wheel.

MAINTENANCE

TO GUARANTEE A SAFE OPERTION OF THE MACHINE THE OPERATOR IS OBLIGED TO MAINTAIN THE

MACHINE REGULARLY.

ONLY AUTHORIZED SERVICE PARTNERS ARE ALLOWED TO MAKE REPARATION WORKS. THE CUSTOMER IS

ONLY ALLOWED TO MAKE THIS AFTER CONSULTING THE MANUFACTURER.

For maintenance and reparation works the machine must be disconnected from ALL power supply

(main switch off, mains plug disconnected). There has to be made precautions for a reconnection by

accident.

For bleeding the complete compressed air out of the machine press the pedal for the bead breaker

several times.

Works on the electrical part of the machine respectively on the supply lines are only allowed to be

done by technicians respectively electrically skilled persons.

Troubleshooting

Error

Reason

Solution

No up or down movement

No compressed air

Check pneumatic supply

Leaking air hose

Seal or replace the air hose

Maintenance instruction

Time:

Part:

To-Do:

Weekly

Arm of bead holder

Clean and grease

Monthly

Joints

Grease

Sliding pieces

Grease

Notice: The shown scendule is for a normal use. We recommend to make the maintenance everytime before operating.

KONFIRMITÄTSERKLÄRUNG

Seriennummer / Serial number:

Konformitätserklärung

Declaration of conformity

Déclaration de conformité

Declaración de conformidad

Für / for / pour / para

Typ / Type / Type / Tipo

Hilfsmontagearm

Assist arm

Bras additionnel de montage

Brazo prensa-levanta talón neumático

ATH A31

ATH A34

Wurden folgende einschlägige Bestimmungen beachtet

The following EG-directives are considered

Les Directives suivantes de l’Union européenne ont été

respectées

Los siguientes directivas pertinentes de la Unión Europa

fuen cumplido

98/37/CEE - 91/368/CEE - 93/68/CEE - 89/336/CEE -

86/217/CEE

27/404/CEE - 73/23/CEE - EN 91/263/CEE - EN

92/31/CEE

EN 93/97/CEE - EN 98/13/CEE D.P.R. nr. 459 DEL

24/07/96

Folgende harmonisierten Normen und Vorschriften wurden

eingehalten

The following harmonized standards are applied

Les normes harmonisées suivantes ont été appliquées

Los siguientes normas y reglamentos armonizados fuen

cumplido

EN 292 - EN 60204-1 - EN 50081-1 - EN 50082-1

Hersteller

Manufacturer

Fabricant

Fabricante

ATH-Heinl GmbH &Co. KG

Kauerhofer Straße 2

D-92237 Sulzbach-Rosenberg

Germany

Hiermit wird unter eigener Verantwortung bestätigt, dass die oben bezeichneten Maschinen den genannten EG-

Richtlinien entsprechen.

Herewith we declare on our own responsibility that the above named machines are according to the named EC-

directives.

ATH-Heinl GmbH &Co. KG

Kauerhofer Straße 2

D-92237 Sulzbach-Rosenberg

Germany

Im Juni 2009

ATH-Heinl GmbH & Co. KG/ Hans Heinl (Geschäftsführer)

SPARE PARTS

Exploded drawing A31

Spare part list A31

Art. #

Name

Figure number / SPEC

0520129120

control box

KZH-04

1-1

020601074

Assist arm valve cover

ZL-20W-01-02-05

1-2

030201340

Cross recessed round head screw

GB/T 818-2000 M4X30

1-3

020205007

Assist Arm Control Valve

D4H2307-06B

1-4

020203066

Banjo bolt

Ø6-G1/8"

1-5

020203067

tower silencer

G1/4″

1-6

030501002

washer

GB/T 95-2002 C Ø4

1-7

030502002

washer

GB/T 93-1987 C Ø4

1-8

030301103

1hex nut A and B

GB/T 6170-2000 M4

0530303003

Assist Arm, Plastic Disk;

A31-02

020101020

Assist Arm End Plug

ZL-20W-01-01-01

030604018

Snap Ring A type

GB 894.1-86 Ø25

020601077

Plastic Disk;

ZL-20W-01-02-02

030201088

SHCS

GB/T 70.1-2000 M10X50

0530302105

connect shaft

M5-03

0530302209

Snap Ring

ZL-20-01-23

030502006

washer

GB/T 93-1987 C Ø10

030201082

SHCS

GB/T 70.1-2000 M10X20

0520301020

Assist Tower Cylinder

ZL-20-01-10-00

030501004

washer

GB/T 95-2002 C Ø6

030201042

SHCS

GB/T 70.1-2000 M6X12

0530303083

Assist Tower Cylinder Cover

SZL-22-01-10

0530102237

Turbo Blast Hook

A31-02-18

030301106

1hex nut A and B

GB/T 6170-2000 M8

0530303084

Presser arm welding

SZL-22-01-07

022101018

Metal Braided Hose Cover

030303101

round nut

GB/T 812-1988 M30x1.5

0530302245

washer Ø40 x Ø31 x 3

ZL-22-01-10

030818002

bearing

JH1-B3025

030303101

round nut

GB/T 812-1988 M30x1.5

0530302245

washer Ø40 x Ø31 x 3

ZL-22-01-10

0530303115

Arm axes

DZ2-05

020101021

Assist Tower Bent Arm Plug

ZL-20W-01-01-02

0530303086

Assist Tower Bent Arm

SZL-22-01-08

020601062

pressure head

ZL-20W-01-02-03

030201046

SHCS

GB/T 70.1-2000 M6X30

020601059

pressure block

ZL-20W-01-02-04

030301105

1hex nut A and B

GB/T 6170-2000 M6

0530303082

Slide Unit

SZL-22-01-06

020601087

Assist Tower Plastic Slide;

ZL-20W-01-02-01

0530302179

Slide Guide

ZL-20-01-03

0530303001

Assist Tower Welding

A31-01

020601088

Assist Tower Top Plug

ZL-20W-01-02-06

030502006

washer

GB/T 93-1987 C Ø10

030201093

SHCS

GB/T 70.1-2000 M10X75

030202026

Inner hexangular set screw

GB/T 77-2000 M8 x16

030201048

SHCS

GB/T 70.1-2000 M6 X40

030501004

washer

GB/T 95-2002 C Ø6

030301106

1hex nut A and B

GB/T 6170-2000 M8

0530302180

Assist Tower Air Hose Cover

ZL-20-01-04

0530303074

Tower Bracket Welding

SZL-22-01-04

030201065

SHCS

GB/T 70.1-2000 M8 X30

030501005

washer

GB/T 95-2002 C Ø8

030604002

Snap Ring A type

GB 894.1-86 Ø8

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