Ath-heinl M72 User manual

OPERATING INSTRUCTIONS

ATH M72

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 ................................................................................................................ - 15 -

1.5 Scale Drawing ................................................................................................................. - 16 -

2.0 INSTALLATION ................................................................................................................... - 17 -

2.1 Transport & Storage Conditions ........................................................................................ - 17 -

2.2 Unpacking the machine .................................................................................................... - 17 -

2.3 Delivery Contents ............................................................................................................ - 18 -

2.4 Location .......................................................................................................................... - 19 -

2.5 Fixing ............................................................................................................................. - 20 -

2.6 Electrical Connection ........................................................................................................ - 20 -

2.7 Pneumatic Connection ...................................................................................................... - 20 -

2.8 Hydraulic Connection ....................................................................................................... - 21 -

2.9 Assembly ........................................................................................................................ - 21 -

2.10 Completion of Work ...................................................................................................... - 22 -

3.0 OPERATION ....................................................................................................................... - 23 -

3.1 Operating Instructions ..................................................................................................... - 23 -

3.2 Basic Information ............................................................................................................ - 24 -

4.0 MAINTENANCE ................................................................................................................... - 25 -

4.1 Consumables for installation, maintenance and servicing..................................................... - 25 -

4.2 Safety Regulations for Oil ................................................................................................. - 26 -

4.3 Notes ............................................................................................................................. - 27 -

4.4 Maintenance or Service Plan ............................................................................................. - 27 -

4.5 Troubleshooting / Error Display and Solutions .................................................................... - 28 -

4.6 Maintenance and Service Instructions ................................................................................ - 29 -

4.7 Disposal .......................................................................................................................... - 32 -

5.0 EG-/EU-KONFORMITÄTSERKLÄRUNG / EC-/EU-DECLARATION OF CONFORMITY...................... - 33 -

6.0 APPENDIX .......................................................................................................................... - 34 -

6.1 Pneumatic circuit diagram ................................................................................................ - 34 -

6.2 Electric circuit diagram ..................................................................................................... - 35 -

6.3 Hydraulic circuit diagram .................................................................................................. - 36 -

7.0 WARRANTY CARD ............................................................................................................... - 37 -

7.1 Scope of the Product Warranty ......................................................................................... - 38 -

8.0 INSPECTION LOG ............................................................................................................... - 39 -

8.1 Installation and Handover Log .......................................................................................... - 40 -

8.2 Inspection Plan ................................................................................................................ - 41 -

8.3 Visual inspection (authorised expert) ................................................................................. - 42 -

9.0 SPARE PART BOOK ............................................................................................................. - 46 -

10.0 NOTES ............................................................................................................................... - 75 -

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 Handle with air valve To lock/unlock the horizontal & vertical movement of the assembly

head

2 Hexagonal bar For vertical adjustment of the assembly head

Square bar

For horizontal adjustment of the assembly head

Assembly head

To assemble/disassemble tyres

5 Assembly tower Can be swivelled backwards

6 Rotary plate To rotate the wheel

7 Clamping claws To clamp the wheel rim

Grease containers

To store the tyre grease

Bead breaker

To remove the tyre from the wheel rim

10 Housing

11 Foot pedal control

12 Tyre inflator To inflate the tyre

Compressed air

maintenance unit

Manufacturer ATH-Heinl GmbH & CO.KG

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Press the pedal down slightly so that the rotary plate

moves clockwise.

Once the pedal has been pressed down as far as it will go,

switch into the faster 2nd gear.

Pull the pedal upwards to move the rotary plate

anticlockwise.

Press the pedal to work with the bead breaker blade.

When you release it again, the bead breaker blade will

return to the starting position.

The clamping claws open in the first position.

The middle position (gently pressing the pedal) allows you

to close the clamping claws and set them to the wheel

being used.

The clamping claws are fully closed in the final position.

Press the pedal to swing the assembly tower backwards.

Press it again to swing the assembly tower forwards again.

When you press the button (1), both the hexagon (2) and

the square (3) are held in the position that has been set.

These can be unsecured again by pulling the button and

released to adjust the assembly head (4).

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3 Operation

1.3.1 Determining the wheel rim cut

On some wheel rims, the nut in the middle of the wheel rim is

very flat or there is no nut.

This type of wheel rim is not authorised for sale in some

countries.

On some wheel rims, the nut in the middle of the wheel rim is

very deep, meaning that, for assembly or disassembly, the tyre

has to be pushed in very deep. This increases the risk of

damaging the tyre.

Some wheels have a tyre pressure control system. This system

may not be damaged on assembly or disassembly.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3.2 Tyre bead breaker

Preparation

Check the following points before using the device:

- Check oil level, water level and air pressure on the maintenance unit

- Check whether the power supply is connected properly.

Unscrew the valve insert on the wheel valve and let out all the air.

Turn and/or tension the clamping plate into a position which does

not allow any components (cylinder, pneumatic fittings, etc.) to be

touched by the tyre.

Turn the wheel rim so that you can first apply the bead breaker to

the outer side of the wheel rim.

Place the depressurised wheel to the side, on the special rubber

pad on the machine housing.

You can place the bead breaker blade on the outside of the tyre

using the control lever. In order to complete the assembly without

any damage, the blade must be positioned around 1 cm from the

edge of the rim flange.

Press the gear change pedal for the bead breaker until the tyre has

come off the wheel rim and then release the pedal IMMEDIATELY.

Continue to turn the wheel and repeat the bead breaking process

until the tyre has come away from the wheel rim all the way

round.

In order to make it easier to then disassemble the tyre and/or to

proceed more gently on the tyre and the wheel rim, it is advisable

to cover the parts of the tyre and wheel rim that are being

released with a standard assembly paste each time you insert the

bead breaker blade.

Only used approved products!

Repeat the procedure for the second wheel side.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3.3 Clamping the wheels

Preparation

Check the following points before you mount the wheel:

- Dirt and old balancing weights must be removed from the wheel

Remove the locking device from the assembly head.

Move the assembly head into position as high and as far back as

possible and lock it again.

Now turn the assembly tower backwards.

Wheel rims with asymmetric drop-centres should be positioned so

that the narrow bead seat is facing up.

In order to prevent damage to alloy wheels when clamping, it is

recommended to only clamp these from the outside and to use

plastic protectors.

Gently press down the gear change pedal to set the required wheel

rim size (e.g. for a 20” wheel rim, set the clamping claws to 21”).

Release the pedal as soon as this has been set.

The pedal is now in the first rest position.

Position the wheel so the clamping claws only touch the tyre.

Press the wheel rim down until the rim flange touches the clamping

claws.

For hard tyres, the assembly arm can be used on the blank holder

with a cone adapter.

Manufacturer ATH-Heinl GmbH & CO.KG

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Press down on the gear change pedal to clamp the wheel rim and

then release your foot. The wheel has been clamped.

1.3.4 Setting up the assembly head

If you are

predominantly processing large wheels up to 24” or small 8” wheels, it is

advisable to adapt the assembly head settings to the wheel rim diameter.

The settings for the assembly head are set out in more detail in the MAINTENANCE

subsection.

Tip and/or swivel the assembly head into the working position

and release the locking device in order to bring the assembly

head up to the rim flange by hand and put it on. In order to do

so, the guide roller (3) and/or the plastic contact strip (for light

metal wheel rims) may touch the respective wheel rim contour.

When locking the assembly head, this automatically moves away

from the wheel rim in height and distance.

The settings for the automatic distance are set out in the

“Maintenance and service work” chapter.

In order to prevent light metal wheel rims from being damaged

during assembly, it is advisable to only assemble these using a

plastic protector and/or a plastic assembly head.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3.5 Disassembling a tyre

In principle, the guidelines of the German Rubber Industry Trade Association

(Wirtschaftsverband der deutschen Kautschukindustrie) should be observed when

disassembling tyres.

Turn and/or set the stretched wheel so that the

wheel valve is

approx. 10 cm in front of the assembly head

Press the tyre bead down against the opposite side of the

assembly head.

Then lever the tyre over the assembly head using the assembly

iron. During levering, the tyre moves into the drop-centre of the

wheel rim and facilitates simple and damage-free assembly.

In order to make it easier to lift the bead and to protect the

wheel, position the bead pusher opposite the assembly head.

Press the bead in 3, 6 and 12 o’clock position up to the first

wheel rim depression, ensuring that the tyre is not compressed

whilst doing so.

Press down the gear change pedal for the rotational motion of

the clamping plate so the rotational motion starts clockwise.

Whilst doing so, continue to hold the assembly iron on the bar of

the assembly head by pressing the iron against the assembly

head.

As soon as approx. 1/3 of the tyre bead has passed the rim

flange, there should be enough room to remove the assembly

iron.

Continue with the rotational motion until the whole tyre is above

the rim flange.

When working with tubular tyres, the tube should now be

removed from the tyre.

Manufacturer ATH-Heinl GmbH & CO.KG

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In order to lever the lower tyre bead, lift the tyre until it is at the

same height as the drop-centre of the wheel rim.

Then, position the assembly iron between the tyre and the

assembly head and lift the tyre directly under the assembly head.

Now lever the tyre bead over the wheel rim and commence the

rotational motion in the same way as for the upper bead.

After disassembly, press down on the gear change pedal to move

the assembly tower so it swivels back.

Then remove the tyre.

1.3.6 Assembling a tyre

In principle, the guidelines of the German Rubber Industry Trade Association

(Wirtschaftsverband der deutschen Kautschukindustrie) should be observed when

assembling tyres.

The tyre valve should be changed before assembly.

Clamp and/or set the wheel rim so that the wheel valve is

approximately 180 degrees over the assembly head.

Cover the tyre and the wheel rim in a sufficient amount of assembly

paste.

Manufacturer ATH-Heinl GmbH & CO.KG

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Check whether the assembly head is in the correct position for the

wheel rim. If necessary, set it up as described in the subsection

“Setting up the assembly head”.

Now place the tyre on the wheel rim at an angle so that the

assembly head does not touch any parts of the tyre when

swivelling.

Swivel the assembly tower by pressing the corresponding pedal.

Position the tyre so that the tyre bead is under the nose, but still on

the guideway of the assembly head.

When doing so, ensure that the tyre is opposite the assembly head

in the wheel rim depression.

Start the rotational movement of the clamping plate.

During the assembly process, ensure that the bead run is correct.

Failing to ensure this can cause serious damage to the tyre.

When working with tubular tyres, the tube must be positioned

correctly in the tyre. Ensure that it is positioned in the tyre such that

it will not be damaged during the remainder of the assembly

process.

Manufacturer ATH-Heinl GmbH & CO.KG

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When assembling the second bead, follow the exact same

procedure as for the first bead.

You must also ensure that the tyre is positioned correctly in relation

to the assembly head.

Start the rotational movement of the clamping plate.

During the assembly process, ensure that the bead run is correct.

Failing to ensure this can cause serious damage to the tyre.

In order to complete the process, release the wheel rim clamp to

remove the wheel.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3.7 Inflating tyres

The maximum tyre pressure may not exceed 3.5 bar.

All parts of the body should be kept away from the tyre.

During operation the noise level can reach 85 dB (A), so the operator should take

appropriate protective measures.

Ensure that the tyre has been fully lubricated.

Start the inflation process.

If the air volume of the tyre inflator is not sufficient to push the tyre

over the wheel rim, you can increase the air volume by removing the

inner valve. This must be replaced quickly afterwards.

Ensure that the tyre has been inflated to the correct pressure.

Consult the manufacturer’s specifications to establish this.

If the tyre pressure is too low, this can lead to increased wear and

decrease the service life of the tyre. The inside of the tyre can also

be damaged.

The tyre pressure must be checked once a week.

Only check the tyre pressure at normal tyre temperatures (i.e. the

vehicle has not been driven for more than an hour and not more

than 2-3 km)

Manufacturer ATH-Heinl GmbH & CO.KG

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1.4 Technical Data

Outer clamping range (B) 9-26 inches

Inner clamping range (B) 11-30 inches

Max. entry width (A)

13 inches

Max. entry diameter (B + tyre)

960 mm

Max. working range of bead breaker 4-13 inches

Max. force of bead breaker 2500 kg

Rotary plate torque 1100 Nm

Rotary plate speed 7 / 14 rpm

Power supply

380 / 50

–

16 V/Hz

(220 / 50 – 16 V/Hz - A)

Drive power 0.75 / 0.90 kW

(1.10 kW)

Motor speed

1400 / 2800 rpm

Working pressure 8-10 bar

(0.8-1.0 Mpa)

Noise emission < 70 dB

Net weight

261 kg

Gross weight 303 kg

Definition of wheel rim

A = wheel rim width (without “f” flange)

B = wheel rim diameter (without “f” flange)

f = flange

h = hump

t = drop-centre

z = centre ring

ET = offset

1 = rim centre

2 = contact surface

1 inch = 2.54 centimetres

Manufacturer ATH-Heinl GmbH & CO.KG

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1.5 Scale Drawing

Manufacturer ATH-Heinl GmbH & CO.KG

- 17 -

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

1.150 mm

Length

850 mm

Height 980 mm

Storage temperature -10 to +50 °C

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.

Manufacturer ATH-Heinl GmbH & CO.KG

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2.3 Delivery Contents

1 Steel assembly head

2 Plastic contact strip

3 Tyre assembly iron

4 Impact anchor

5 Seal kit and membrane for rapid air

vent

6 Plastic protector for side bead breakers

7 Manual tyre inflator

8 Compressed air maintenance unit

9 16A CEE plug

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.

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