Ath M126 User manual

OPERATING INSTRUCTIONS

ATH M126

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

2.0 INSTALLATION ................................................................................................................... - 16 -

2.1 Transport & Storage Conditions ........................................................................................ - 16 -

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

2.3 Delivery Contents ............................................................................................................ - 17 -

2.4 Location .......................................................................................................................... - 18 -

2.5 Fixing ............................................................................................................................. - 19 -

2.6 Electrical Connection ........................................................................................................ - 19 -

2.7 Pneumatic Connection ...................................................................................................... - 19 -

2.8 Hydraulic Connection ....................................................................................................... - 20 -

2.9 Assembly ........................................................................................................................ - 20 -

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 .......................................................................................................................... - 30 -

5.0 EG-/EU-KONFORMITÄTSERKLÄRUNG / EC-/EU-DECLARATION OF CONFORMITY...................... - 31 -

6.0 APPENDIX .......................................................................................................................... - 32 -

6.1 Pneumatic circuit diagram ................................................................................................ - 32 -

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

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

7.0 WARRANTY CARD ............................................................................................................... - 34 -

7.1 Scope of the Product Warranty ......................................................................................... - 35 -

8.0 INSPECTION LOG ............................................................................................................... - 36 -

8.1 Installation and Handover Log .......................................................................................... - 37 -

8.2 Inspection Plan ................................................................................................................ - 38 -

8.3 Visual inspection (authorised expert) ................................................................................. - 39 -

9.0 SPARE PART BOOK ............................................................................................................. - 43 -

10.0 NOTES ............................................................................................................................... - 57 -

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 Lifting column Carries the lifting carriage

2 Lifting carriage Holder for assembly tools

Assembly rollers

For mounting or removing tyres

Mounting bracket

For fixing the machine to the floor

5 Hydraulic cylinder For swivelling the clamping arms

6 Clamping jaws Clamping mechanism

7 Mounting finger For mounting or removing tyres

Swivel arm

For the mounting finger, depending on whether this is

used or not.

9 Chuck Mechanism for swivelling and turning the wheel

Control box Hydraulic unit with operating lever

10 Control lever for mounting finger For changing the angle of the mounting finger

Control lever for lifting carriage

For lifting and lowering the lifting carriage

Control lever for swivelling the chuck

For swivelling the chuck into receiving or working

position

13 Control lever for rotating the chuck For rotating the chuck

Control lever for clamping

For clamping the wheel

Manometer

Displays the current operating pressure

16 Control box Contains all electrical components

17 Emergency stop For switching off the machine in an emergency

Manufacturer ATH-Heinl GmbH & CO.KG

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Operating the tyre changer

1 Control unit for opening and closing the clamping jaws.

2 Control unit for rotating the clamping jaws in a clockwise or counter clockwise direction

3 Control unit for swivelling the clamping jaws

4 Control unit for lifting and lowering the lifting carriage

Control unit for the hydraulic mounting finger

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, control and check all functions with the operating part to ensure the

machine is working properly. This should be done before each mounting process.

WARNING!

When operating the tyre changer, pay attention to all moving parts. Make

sure there is enough safety clearance so that the moving parts do not contact

you. 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 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

tyre changer.

1.3.2 Precautions during tyre mounting

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 changer

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 always finds a working position where he can safely track

and view all work steps.

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.

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

 Move 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 secure.

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

possible to assemble.

Manufacturer ATH-Heinl GmbH & CO.KG

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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.

Clamping the wheel

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

(Wirtschaftsverband der deutschen Kautschukindustrie) should be observed when

removing tyres.

Handling heavy loads:

- Loads up to 35 kg may be handled by one person, no special handling aids are required

(see also EN 1005);

- Loads between 35 and 70 kg should be handled by two persons (also check the spatial

requirements and instructions) or using the transport / lifting aids provided;

- Loads over 70 kg require a handling or lifting system.

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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Move the assembly tower all the way up.

Place the wheel in front of the machine’s clamping jaws and clamp

by operating the clamping lever.

In the case of aluminium rims, please use the enclosed

clamping ring

The wheel can then be brought into a 90° position by operating the

lever for swivelling.

Tyre bead breaker

Preparation

Check the following points before using the device:

- Check whether the power supply is connected properly.

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

Manufacturer ATH-Heinl GmbH & CO.KG

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First, the tyre bead must be completely pressed off from both sides

of the rim with the bead breaker roller. During this process, the

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

Start with the upper bead.

Place the bead breaker roller on the outside of the tyre. In order to

complete the assembly without any damage, the roller must be

positioned around 1 cm from the edge of the rim flange.

Operate the lever for lowering the assembly tower until the tyre is

released from the rim.

Begin the rotation process to release the entire tyre from the rim.

Operate the lever for lifting the assembly tower to release the

pressure from the tyre and allow for swivelling.

Swivel the wheel forward and lower the assembly tower until the

bead breaker roller is under the wheel. The wheel can then be

swivelled back towards the tower in order to press off the lower

bead.

Press off the lower tyre bead.

Place the bead breaker roller on the outside of the tyre. In order to

complete the assembly without any damage, the roller must be

positioned around 1 cm from the edge of the rim flange.

Operate the lever for lifting the assembly tower until the tyre is

released from the rim.

Begin the rotation process to release the entire tyre from the rim.

Then continue with the removal procedure.

Manufacturer ATH-Heinl GmbH & CO.KG

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Removing the tyre with the bead breaker roller

If the tyre is not being used again or reconditioned, it is

possible to completely push it off the rim from below. This

procedure may result in damage to the inner steel structure.

When the bead breaker roller is in the lower position (last step of

bead breaking), it is possible to continue the removal process by

pressing the lifting lever.

The tyre must be constantly rotated during this process.

Removing the tyre with the mounting finger

Swivel the finger into position ready for mounting.

Bring the mounting finger into a 90° position so that it can be

driven between the tyre and rim to grip the tyre with the hook.

Manufacturer ATH-Heinl GmbH & CO.KG

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> >

Lower the assembly tower until the tyre catches.

Where necessary, the angle of the mounting finger can be altered

to prevent the tyre from slipping off the finger.

The tower can then be moved upwards.

The lower roller pushes the tyre upwards and supports the removal

process.

At the same time, the lower bead can be removed with the roller.

Mounting the tyre

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

mounting paste.

Manufacturer ATH-Heinl GmbH & CO.KG

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Position the tyre such that it is in the upper recess of the rim.

Ensure that the tyre does not slip off the rim when lifting

Swivel the wheel and tyre upwards as one and press the tyre under

the rim flange using the roller.

If necessary, the hold-down clamp can be attached at this point.

In the case of sharp-edged rims (e.g. agricultural rims),

we recommend using the finger to mount the upper bead in order

to avoid damage to the tyre bead

Manufacturer ATH-Heinl GmbH & CO.KG

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Inflating the tyre

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.

A tyre explosion under pressure can be very dangerous. A tyre explosion can cause

serious injury to the operator and may even be fatal.

Inflate the tyre only after placing the wheel in an approved inflation chamber.

Do not stand in the vicinity of the wheel or cage during inflation.

Do not exceed the maximum inflation pressure recommended by the manufacturer.

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

Clamping range (A) 5-15 inches / 127-381 mm

Rim diameter (B) 19-26 inches

Max. entry width (D) 18 inches / 460 mm

Max. wheel diameter (C) 55 inches / 1400 mm

Max. wheel weight 380 kg

Bead breaking force of

roller

lifting/lowering

Approx. 4000 / 2000 kg

Contact force of finger 2000 kg

Mounting speed 6.8 rpm

Operating pressure 14 MPa / 140 bar

Max. operating pressure 14 MPa / 150 bar

Torque (max.) 1860 Nm (2700 Nm)

Power supply 3 Ph 400 V / 50/60 Hz – 16

Full load current 30 A

Short-circuit current

capacity 6 kA

Hydraulic pump 3.0 kW

Hydraulic motor 2.4/3.0 kW

Size of hydraulic tank 15 litres

Noise emission < 70 dB(A)

Net weight 485 kg

Gross weight 560 kg

1.5 Scale Drawing

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

1150 mm

Length

1630 mm

Height 1270 mm

Storage temperature -25 to +55 °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

1) Tyre lever

2) Hold

down clamp (plastic)

3) Mounting paste 4) Funnel for pouring in hydraulic oil

5) Brush for mounting paste 6) Aluminium clamping ring Ø 280 mm

7) Plastic contact strip for mounting finger 8) OPTIONAL: Instructional video

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.

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