Carlisle TyrFil User manual

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TyrFil Flushless Pump
FLATPROOFING TECHNICAL MANUAL

This manual is intended to assist the tire fill technician in the operation of the TyrFil Flushless Pump. It covers the basic
operation of the machine, procedures for filling a pneumatic tire and general maintenance of the machine. Inside you will
find the basic steps incorporated in the control, air/water valve procedure for filling a tire, general troubleshooting and
general procedures for fixing the machine if problems occur. If any mistakes are found in this manual, please contact us
so that we can correct them.
Your cooperation is deeply appreciated.
THANK YOU AND WELCOME TO THE TEAM,
Carlisle TyrFil
Technical Services Department
Office: [phone]
Normal Hours of Operation: 8:30 AM – 4:30 PM EST

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TyrFil Flushless Pump | Flatproofing Technical Manual
INTRODUCTION .............................................................................4
DISCLAIMER ..................................................................................4
I. REQUIREMENTS ..................................................................5
Technical Training ....................................................................5
Floor Space .............................................................................5
Equipment and Tools ...............................................................5
Supplies ...................................................................................6
II. SAFETY ..................................................................................7
General Precautions ................................................................7
Material Precautions ................................................................8
Safety Supplies ........................................................................8
III. PREPARATION ......................................................................9
Tire & Wheel Preparation .........................................................9
Equipment Set-Up ...................................................................9
IV. TIRE FLATPROOFING PROCESS ..................................... 11
Start-Up Procedures ............................................................. 11
Processing ............................................................................. 12
Tire Pressurization ................................................................. 14
Clean-Up Procedures ............................................................ 14
V. PUMP MAINTENANCE .......................................................16
VI. MISCELLANEOUS .............................................................. 17
Tires with Tubes ..................................................................... 17
Changing Products ................................................................18
On-Site Flatproofing ..............................................................19
Tote Maintenance ..................................................................19
Waste Disposal ......................................................................20
Salvaging Rims ......................................................................20
VII. TROUBLESHOOTING .........................................................21
VIII. SERVICE ..............................................................................24
TABLE OF CONTENTS

4TyrFil Flushless Pump | Flatproofing Technical Manual
INTRODUCTION
Flatproofed tires must be processed correctly to provide the customer with the maximum benefits of no flat
tires: full tire life, consistent internal pressure, no rim slippage, improved safety, proper tire flex, cost savings
and retreadability.
The tire flatproofing process includes the following steps:
• Inspecting tires and wheels for defects
• Pre-stretching the tire overnight
• Pumping material through the valve stem into the tire replacing all of the air
• Pressurizing the tire to the recommended inflation pressure
• Curing at the proper time and temperature to ensure optimum filled tire performance
It is a precision process and should only be performed by a Carlisle TyrFil Certified Technician. Proper training
and this Manual provide the necessary information to flatproof tires. This Manual is intended for use with
the TyrFil™Flushless Pumping System. As always, we remain available to assist you with all aspects of your
flatproofing business. For any questions or problems, please call our Sales and Technical Center at (800)
821-4147.
Disclaimer
This Carlisle TyrFil Flatproofing Technical Manual contains information pertaining to flatproofing tires with our
manufactured products that have been installed through the Carlisle TyrFil approved processing systems.
This Manual contains information regarding the flatproofing process only, it does not contain other information
which may be relevant with respect to the flatproofing process (for example, the tire manufacturer’s
specifications and information, workplace safety information, etc.). It is important that all flatproofing
processors follow not only the safety procedures set forth in this Manual, but also standard safe operation
and work conditions, and other safety procedures that may pertain to the facility in which the flatproofing is
taking place, and the specific tire manufacturer’s safety information.
Although this Manual has been developed for the purpose of instruction, the flatproofing processor must
be properly trained in all phases of the job performance, which include, without limitation, installing TyrFil
products into the tire in a safe manner, the proper use and operation of the equipment and the proper
maintenance of such equipment.
Carlisle TyrFil shall not be responsible for any injury or damage to persons or property in connection with the
processing or use of our products. Further, Carlisle TyrFil shall not be responsible for any injury or damage
to persons or property due to a customer’s actions, the customer’s disregard for the safety procedures set
forth in this Manual or other safety procedures, the customer’s failure to comply with the tire manufacturer’s
product guidelines, or due to a customer’s failure to follow our instructions, verbal or written, pertaining to the
flatproofing process.
Carlisle TyrFil’s technical and sales staff make routine visits to its customer’s locations for the purpose
of reviewing processing rooms and procedures. However, a customer should not rely on such visits as
assurance that it has taken all safety and other precautions.
Carlisle TyrFil maintains a knowledgeable technical support staff who can assist our customers with any
questions or troubleshooting that may be needed in connection with our products. Further, Carlisle TyrFil
maintains an inventory of parts, and written technical and safety data on its products.
Any questions regarding information contained in this Manual, our products, or our recommended equipment
should be directed to the Carlisle TyrFil Sales and Technical Center at [phone].

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TyrFil Flushless Pump | Flatproofing Technical Manual
I. REQUIREMENTS
Technical Training
Training by the Carlisle TyrFil Technical Department is essential to any
successful flatproofing operation. All flatproofing technicians need to
go through our certification process which includes training videos,
demonstrations, hands-on practice and a short quiz. All certified
technicians will receive a wall plaque and uniform patches.
Floor Space
The volume of your business determines the amount of space required. Space must be provided for:
• Pumping area
• Tires and materials storage
• A temperature-controlled curing area
The minimum space required is 400 square feet (37 square meters), approximately the dimensions of a
residential double garage. This area should be well-lit, well-ventilated, and heated (if necessary) to maintain a
minimum of 72˚ F (22˚ C).
Equipment and Tools
TyrFil Flushless Pump – Carlisle TyrFil’s original flatproofing pump was pioneered by Graco, Inc. in the early
1970’s and has had many innovations since. The Graco®pump has an excellent performance reliability
record. The TyrFil Flushless Pump and replacement parts are readily available through Carlisle TyrFil. Visit
www.carlisletyrfil.com to download the TyrFil Flushless Pump Catalog.
Air Compressor – The pump is air driven and requires a minimum of 21 cubic feet per minute (cfm) (.6
cubic meters). Be certain to consider other air operated equipment being used when determining if your
compressor is sufficient for your flatproofing needs.
Material Handling Equipment – A forklift or pallet jack may be required to handle large tires and to move totes.
Miscellaneous Tools – Have available: a large pipe wrench, channel locks, vise grips, pliers, bung wrench,
assorted screwdrivers, wrenches, hammers, and a valve core remover.

6TyrFil Flushless Pump | Flatproofing Technical Manual
Supplies
Product – Flatproofing materials are supplied in
Intermediate Bulk Container (IBC) sets. Intermediate Bulk
Containers are commonly known as “totes”. A kit or set is
comprised of one ISO-side and one CAT-side. Each tote
set is 4,500 lb/550 gal (2045.45 kg/2081.75 l).
Solvent – Isopropyl alcohol (99% pure) is the
recommended solvent for cleaning machinery and tools.
It can generally be purchased locally. Solvents should be
stored in UL/FM (Underwriters’ Laboratory/Fire Marshall)
approved containers and handled in accordance with all
federal, state, and local regulations. If local or insurance
regulations prohibit or restrict the use of flammable
solvents, Carlisle TyrFil offers a product line of non-
flammable, biodegradable solvents suitable for use with
the flatproofing equipment.
Hypodermic Needles – Needles are used for venting tires
during the filling process. The standard size is 12 gauge
3-inch. Other sizes are available. For your convenience,
these are available from Carlisle TyrFil.
Nails or Screws – A nail or sheet metal screw is used
to plug the venting hole. A #10 ribbed roofing nail is
recommended and can be found at any hardware store.
Self-locking plastic bags – These are used for retaining
liquid batch samples while they cure.
Waste Container – Empty 5-gallon pails are useful for collecting waste material. Using a plastic liner makes
disposal easier. *
Cleaning Rags – keep plenty of rags on hand for clean-up. A clean pumping operation is essential for proper
tire processing. *
* Be sure to follow all federal, state and local regulations when disposing of any cured or uncured
material or other related items.
INTERMEDIATE BULK
CONTAINERS (TOTES)

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TyrFil Flushless Pump | Flatproofing Technical Manual
II. SAFETY
General Precautions
SAFETY SHOULD BE YOUR NUMBER ONE PRIORITY. IN ORDER TO PROMOTE SAFETY, CARLISLE TYRFIL
WANTS TO EMPHASIZE THE FOLLOWING:
Safety Datasheets (SDS) identify the properties
of ISO-side and CAT-side products and the
precautions that should be taken when handling
them. Safety Datasheets have been prepared in
accordance with the U.S Department of Labor and
the Occupational Safety and Health Administration
(OSHA) for each product. Please read them
carefully. In accordance with Federal law, these
must be available to all employees on-site. If you do
not have a copy, call immediately to have one faxed
and/or mailed.
Operators must wear eye protection when using equipment. Gloves rated to withstand the chemical hazards
are to be worn to prevent skin contact anytime a risk of exposure exists. Exposure to fumes must be limited
using methods of control including proper ventilation.
Use extreme care when disconnecting any material supply hoses. Be sure to release the pressure and loosen
the couplings slowly before disconnecting completely.
To reduce the risk of serious injury from moving pump parts or the splashing of flatproofing products in the
eyes, always disconnect the air supply from the pump and close the release-type ball valve on the air motor
when servicing the air motor or cylinder displacement unit.
Spilled material must be cleaned promptly for easier clean up and to avoid falls. Cured urethane is extremely
difficult to remove from concrete floors. Use a barrier such as cardboard or roofing felt in your flatproofing
area to protect the floor and replace as needed.
In case of a liquid spill, soak up the spilled material with an oil absorbent, such as sawdust or vermiculite.
Sweep it into a waste container and neutralize it with a decontamination solution (95% waste, 3% ammonia,
2% detergent). Spilled solvent (isopropyl alcohol) is a fire hazard and should be cleaned up promptly.
Smoking, grinding, or open flames should not be permitted in the work area. Be sure to handle spills, clean-
up, and disposal in accordance with all federal, state, and local regulations.
For a chemical emergency (spill, leak, fire, exposure or accident): call Chemtrec – day or
night – from the United States or Canada [phone]
Minor spills or leaks (less than five (5) gallons) can be cleaned up according to instructions in the SDS.
The fluid output pressure of the pump is 5 times the input pressure. This output pressure can exceed
the burst pressure for most tires. Therefore, extreme care must be taken to ensure the tire is not
pressurized beyond the manufacturer’s recommendations.

8TyrFil Flushless Pump | Flatproofing Technical Manual
Be sure to inspect all rims, lock rings, wheels, and associated restraining
bolts for structural defects prior to filling. While filling, use a safety cage, or
other OSHA approved restraining device to protect yourself. Flatproofing
equipment should never be left unattended while the pump is in operation.
Please refer to other reference materials, such as from the Tire Association of
North America (TANA) and OSHA, on proper tire preparation and handling.
Material Precautions
The ISO-side (isocyanate) is especially sensitive to water and will solidify from
exposure to moisture and humidity. A desiccant is required on the ISO-side.
Material temperature should be at least 72˚ F (22˚ C) while processing. Cold
materials become thick, which slows pumping and can result in inadequate
mixing and poor/slow cure.
Safety Supplies
Signs- “No Smoking” signs should be posted due to hazards presented by chemicals.
Tire Cage- Tires should be filled in a tire cage. Tires over-pressurized with air or liquid can fail with explosive
force. Cages are mandatory when working on wheels with split rim or lock ring assemblies. Position tires with
the lock ring facing away from the operator and work area.
Fire Extinguisher- Extinguishers should be within easy reach as
isopropyl alcohol is flammable and poses a fire hazard.
Eye Protection- Eye protection is essential and should be
worn at all times as liquids, pressurized air and solvent can
accidentally be splashed in the eyes. Personal protective
equipment requirements are described in the SDS.
Gloves- Natural rubber, latex or neoprene gloves should be
used to reduce skin contact and potential irritation caused
by sensitization to flatproofing materials. Personal protective
equipment requirements are described in the SDS.
Industrial First Aid Kit- Kits should be properly stocked and readily accessible for
emergencies.
Respirator- Isopropyl alcohol, the tire filling process, and clean up can produce
fumes. Good ventilation is required in work areas to prevent exposure to fumes.
If adequate ventilation is not available, a respiratory protection program must be
implemented. All cartridge/mask selections must be conducted by a qualified
individual in accordance with a written respiratory protection program. Refer to the
SDS.
Note: Compliance is unique at each pumping location and should be in
accordance with all local, state and federal regulations.
SAFETY CAGE

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TyrFil Flushless Pump | Flatproofing Technical Manual
III. PREPARATIONS
Tire & Wheel Preparation
Any pneumatic tire can be flatproofed regardless of pressure or rated load specifications. New tires provide
the best long-term value, although used tires are often flatproofed.
All new tires should be pre-stretched before filling. Inflate new tires to maximum rated inflation pressure and
maintain overnight. Tires grow during service and pre-stretching allows the tire to be filled to its capacity and
will minimize long term carcass growth. Used tires do not need to be pre-stretched and typically take 15-20%
more material than new tires.
Tires, especially used tires, should always be inspected prior to flatproofing. Flat tires should be repaired. To
be effectively flatproofed, tires must be able to hold air for at least three hours and be free of cuts or other
defects that reduce casing strength.
Wheels should be inspected for cracks, metal fatigue, and corrosion. Damaged or rusted wheels are a safety
hazard and should be avoided.
Tires and wheels have recommended load carrying capacities. The load carrying capacities should not be
exceeded. When calculating the total vehicle weight, take into consideration the extra weight of the flatproofing
material.
A tire or wheel with a defect should not be used in flatproofing, as it could result in a premature tire or wheel
failure. Allow time for drying if washing is required.
Tire contaminants, such as water, sealants, glycol, calcium chloride, soaps, waxes, or even dirt, must be
removed before flatproofing.
For tube type tires, always use new properly sized tubes. Wheels that require the use of flaps to protect the
tube during inflation and operation must be filled with the flap in place. If you remove the flap, the tube has a
greater chance of rupturing during the flatproofing and curing process.
Tire and wheel assemblies should be at a minimum of 72˚ F (22˚ C) before processing. Cold tires will slow the
curing process.
Equipment Set-up
1. Arrange Totes and
Drums – Totes should
be arranged with the
ISO-side on the left and
the CAT-side on the right.
The lower cylinders of
the pump are labeled
as to which hose goes
to which side. When
moving the pump, be
sure to keep tote hoses
on their proper side.
It is a good idea to
place roofing felt in the
pumping area, especially
under the tire being filled,
for easier clean-up.

10 TyrFil Flushless Pump | Flatproofing Technical Manual
2. Assemble Tools and Supplies – Make certain all necessary tools (valve core remover, extra valves,
screws, hammer, screwdriver, pliers, bags, etc.) are on hand. If possible, stage the tires to be filled in
the vicinity of the pump.
3. Prepare Totes
a. Remove shipping cap. Remove foil if it is present.
b. Liberally grease the threads on the tote connector
and screw it onto the tote’s ball valve and hand
tighten. (DO NOT TIGHTEN WITH A WRENCH)
c. Remove dust cap from kamlock on suction/
supply hose.
d. Apply grease to the tote connector and connect
the kamlock to the tote connector. Lock kamlock
in place by pulling back on the handles.
e. Connect the supply/suction hose to the king
combo on the intake side of the pump and tighten
hose clamp.
f. Repeat for both ISO- and CAT-sides.
4. Install Desiccant Cartridge – It is essential that a desiccant is used on the ISO-side tote as the
material is moisture sensitive. The CAT-side tote will need to be vented.
To Install the Desiccant Cartridge:
a. Remove the white 2" inch center bung on the ISO-
side tote.
b. Apply grease liberally to the threads on the
desiccant holder. This will make removal easier.
c. Remove the seal on ends of the desiccant
canister.
d. Loosen top hose clamp on desiccant sleeve and
insert desiccant container with inspection window
facing forward and the arrow pointing down.
e. Tighten hose clamp.
Note: It is essential to change the cartridge when the desiccant in the inspection window turns from
blue to pink, as moisture will contaminate the material.
5. Connect Hoses – Connect 1 ½" clear supply hoses from the pump to the tote connectors. Make
certain that the ISO-side hose is connected to the ISO-side tote and that the CAT-side hose to the
CAT-side tote. Fully open ball valves when pumping. Ball valves should be closed when not in use.
6. Air Supply – Connect air-line to the pump. Adjust the regulator to 80 psi (550 kPa). Note: Adjusting
the regulator to higher pressures provides only a modest increase in pump speed. Higher pressures
increase the risk of premature air motor failure. The easiest way to increase the speed on the pump is
to fill the tires through the largest valve stem possible. A tire with an air-water valve can be filled up to
2 times faster than a tire with a standard valve.

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TyrFil Flushless Pump | Flatproofing Technical Manual
IV. TIRE FLATPROOFING PROCESS
Flatproofed tires are pressurized not with air, but with flatproofing material. It is important that before
processing, you know the operating pressure of the tire. Refer to the manufacturer’s data for the tire you are
filling or the current Yearbook by the Tire and Rim Association, Inc., ETRTO Standards Manual or the JATMA
Yearbook to determine proper pressurization for each tire. Tires must be correctly pressurized for optimum
performance in ride, footprint, and durability. In no case should a tire be pressurized above the maximum
pressure indicated on the tire sidewall.
In addition to the pressure, you should know the estimated pounds of flatproofing material necessary to fill
the tire. Carlisle TyrFil has a Flatproofing Weight Chart in addition to a Computerized Flatproofing Estimator on
www.CarlisleTyrFil.com to help you to approximate weights and costs for flatproofing tires.
Note: These provide only an estimate of the amount of pounds required to fill each tire. Use the following
procedures when flatproofing tubeless tires (for tires with tubes, see the Miscellaneous Section).
Start-up Procedures
1. Remove manifold head, mixing tube and fluid gun from the solvent container and wipe off with a rag to
remove excess solvent. Visually check to ensure all the items are free of any residue. If any solvent is
accidentally pumped into a tire, it will contaminate the material and could result in a failure.
2. Apply a coat of grease to all quick connects and use Teflon®tape at all connections (i.e. at both ends
of the mixer tube and whip hose).
3. For the ½-inch mixer, insert all three mixing elements into the mixing tube. For the ¾-inch mixer, insert
four mixing elements. Do not use broken elements. Note: as elements are fragile, it is important to
always keep extra available.
4. Attach manifold head to the manifold handle using the quick connects. Be sure to attach the correct
side up (it will read ISO and CAT). On the opposite side, the manifold head will read “this side down”.
5. Connect mixing tube to the manifold head. Attach fluid gun to the whip hose. Complete assembly by
attaching the whip hose to the mixing tube and tighten all connections. See the TyrFil Flushless Pump
Parts Catalog for proper assembly of the manifold.
6. Adjust air supply to the pump to 80 psi. Make sure the
manifold hand valve is in the off position when turning pump
on.
7. Slowly open the hand valve and run 2 cycles on the stroke
counter into a waste container to rid the system of any residual
solvent. A cycle is one complete up and down stroke. When
pumping material, make certain manifold and dispensing
valves are fully open. Partially opening the valves can cause
improper ratio of ISO- and CAT-side material.
8. Make sure the cylinder pressure gauges are within 50 psi of
each other, when pump is operating.
9. Prepare a quality control sample sometime during the filling
process. It is important to prepare a sample with each batch
of tires that were flatproofed as a means of checking for a
proper cure. Pump a sample [approximately ½ - 1 cycle (6-12
oz/.15-.3 kg) into a self-locking plastic bag]. 8

12 TyrFil Flushless Pump | Flatproofing Technical Manual
Note: Write the date and lot number on the bag and lay it on
the flatproofed tire during the curing process. After the cure is
completed, the sample should be retained for future reference
should any problems arise while the flatproofed tire is in
service.
10. Reset stroke counter to zero.
Processing
Important: Never leave a pump operating unattended.
1. Position tire vertically in the tire cage with the valve stem
between the 4 o’clock and 8 o’clock position, with 6 o’clock
being ideal.
2. Select the proper core holder and filling adapter for the
valve stem. To avoid leaks, make sure all gaskets are in
place and threaded connections are assembled with Teflon®
tape. Remember, tires with longer or angled valve stems will
take longer to fill because of the increased back pressure.
Whenever possible, use the largest valve stem available.
3. Remove the valve core from the tire that has been inflated for
pre-stretching. It is important to keep the bead seated. Do
not let air bleed excessively. See page 13 for Bead Reseating
instructions.
4. Insert the valve core into the core holder and immediately
connect the filling adapter to the tire valve stem. Attach the
filling adapter to the fluid gun.
5. Fully open the valve on the manifold and begin filling the tire.
6. Check the internal tire pressure frequently by closing the hand
valve on the manifold and opening the pressure gauge valve.
7. Continue pumping until the tire has enough pressure to keep
the bead seated or tube inflated. To check the level of material
in the tire, tap the casing lightly with a hammer (unfilled portion
will sound louder).
8. When the venting pressure is reached, close the manifold hand
valve. Insert a hypodermic needle into a tread groove at the
12 o’clock position just deep enough to vent trapped air. Stop
inserting further when you start to hear air escape from the tire.
For steel belted tires and thick casings (greater than 12 ply) you
will need to drill a 1⁄8-inch hole through the tire to assist needle
insertion.
9. Use of Carlisle TyrFil’s specially designed SmartNeedle™
Inserter will make needle insertion much easier, safer, and will
avoid damaging the needle or your hand.
Note: After insertion of the needle, the tire pressure will drop. It is necessary to maintain at least 30%
until all of the air is completely vented and the tire is full of flatproofing material.
1
5
8
10

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TyrFil Flushless Pump | Flatproofing Technical Manual
10. Turn the manifold valve back on and continue pumping. Check
the tire pressure often during the venting stage. To keep the
pressure from dropping too quickly, place a finger or thumb
over the needle to stop the air from escaping. Note: while it is
essential to “vent” or remove all of the air from the tire, keeping
some air pressure during the flatproofing process assures the
tire will keep its bead seat and remain on the wheel. If the air is
released too quickly, the bead could collapse. If this happens,
the flatproofing process must be stopped and the bead
reseated before continuing. Bead Reseating Instructions are as
stated below. The bead can be reseated using the Flushless Manifold while still attached to the tire’s
valve system.
a. To reseat the bead, turn off the manifold hand valve and remove the SmartGauge™from the
manifold.
b. Temporarily remove the needle from the tire and plug the hole with a nail. Insert the nail only
deep enough to seal the hole, because you will be removing the nail after the bead has seated.
c. Attach the air hose to the male quick connect on the Flushless Manifold.
d. Open the ¼" ball valve on the SmartGauge™stem located on the manifold to inflate the tire.
After the bead has seated, add enough pressure to the tire to prevent another collapse.
e. Close the ¼" ball valve and remove the air hose from
the quick connect and replace the SmartGauge™. Turn
on the manifold hand valve and continue filling the tire.
f. Finish by removing the nail and reinserting the needle to
vent the tire.
11. Continue pumping until material flows from the hypodermic
needle and then turn off the hand valve. Remove the needle
slowly from the tire and plug the hole with a roofing nail or
a sheet metal screw. Note: needles are reusable if properly
cleaned with solvent.
12. Check tire pressure. Turn on the hand valve and pressurize the
tire to its recommended psi. Remember, all tires, especially
small tires, will pressurize fast. Always pressurize to the
manufacturer’s specifications.
Caution! There is a fundamental difference between
pressurizing a tire with air and pressurizing a tire with flatproofing materials. Gasses are
compressible, while liquids are uncompressible. Pressurizing a tire with air is a gradual
process with pressure building slowly from the initial introduction of air. With TyrFil
flatproofing materials, the tire is vented during the filling process so there is very little
pressure build-up until the tire is totally filled. Then the pressure builds rapidly, with the
pumping of a very small additional amount of material stretching the carcass.
13. Depress the plunger on the fluid gun and reinstall the valve core by turning clockwise making certain
the valve core is securely seated. Pull back on the plunger and check the pressure gauge. If the tire
has been sealed, the pressure gauge will read zero. Then disconnect the fluid gun and place over a
waste container.
14. Lay the filled tire on its side and place on a pallet. Handle tires with tubes carefully, as some tubes split
easily. Do not cure tires in an upright position. Upright curing can create an air pocket on top and a flat
spot on the bottom.
10
11
11

14 TyrFil Flushless Pump | Flatproofing Technical Manual
15. Lay the sample on the filled tire for use in checking the
progress of the cure. Use a tire marker to identify stroke or
weight count and psi on the tire. Document in the flatproofing
log. This log is used to record processing data and customer
warranty information.
Note: It is very important to keep accurate records as this
ensures adequate warranty documentation in the unlikely
event that the need arises. In the Flatproofing Log, you should
include: date of processing, customer name, pumper’s name,
type of tire, product used, lot #, final tire pressure and pounds
of material. All entries should be in ink and a copy should be
made of each entry sheet. Flatproofing log sheets are available
through Carlisle TyrFil for your convenience.
16. Put rim stickers on the wheel.
Note: Warmth speeds the cure. Tires flatproofed with materials
at 72˚ F (22˚ C) and placed in a warm room [minimum 72˚ F (22˚
C)] will cure 70% in 24 hours and 100% in 72 hours. Tires can
go into service 24-48 hours after processing.
Tire Pressurization
Over-pressurization - Do not over-pressurize tires. In addition to the potential danger of bursting the tire,
over-pressurization will cause “crowning” (extreme tread wear at the center of the tire) and possible splitting
of the carcass upon impacting curbs, potholes, etc. Once the material has cured, there is no way to correct
this problem. If a tire becomes over-pressurized during the filling process, close the manifold valve and open
the drain valve. Pressure inside the tire will force the flatproofing material out through the drain valve. Close
the drain valve and check pressure again.
Under-pressurization - Do not under-pressurize the tire. This can cause excessive flexing of the casing and
material, which may lead to overheating and eventual tire failure. Unlike a tire filled with air, a complete loss of
pressure can result from the leakage of only a small amount of material from the tire after it is filled. If leakage
is observed, the tire may need to be re-pressurized.
Re-pressurization - Voids or air pockets are created when uncured material escapes from a newly
flatproofed tire. Once the flatproofing material has cured, a tire with voids can be re-pressurized by injecting
additional material through the sidewall. Contact the Carlisle TyrFil Technical Department prior to sidewall
injection.
Clean-Up Procedures
Proper shutdown and cleaning of the pump and equipment is vital. When you have finished processing tires,
the equipment must immediately be cleaned of all reactive materials. If left in the machine, they will cure,
become insoluble and clog the equipment.
1. Open the hand valve over a waste container until the pistons
are in the down position. This allows the piston rods to be
submerged in the throat seal lubricant. Then close the manifold
hand valve.
2. Turn off the air supply to the air motor by closing the ball valve
at the regulator.
15
16
1

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TyrFil Flushless Pump | Flatproofing Technical Manual
3. Open the manifold valve to release the pressure inside the
cylinders and hoses. Close the manifold valve when the
pressure on the cylinders is zero.
4. Remove the manifold head from the handle over a waste
container and allow excess material to drain.
5. Rest the manifold on the ground or breakdown on a table for
easier disassembly and clean-up. Close the pressure gauge
valve and remove the pressure gauge.
6. Remove the whip hose and mixing tube from the manifold
head.
7. Wash the manifold head in solvent. Open ball valve on the
manifold and rinse the gauge port with solvent. Store manifold
head in the solvent when clean.
8. Eject the mixing elements from the mixing tube and wash the
elements in the solvent. Store mixing elements in a safe place
to avoid breakage. Clean mixing tube with a steel brush and
place mixing tube in the solvent container.
9. Wipe off any excess material from the manifold handle with a
clean rag and place on hanger.
10. Thoroughly clean and store tools in their proper place.
11. Clean all mixed material off floor and machine.
4
5
7
8
8

16 TyrFil Flushless Pump | Flatproofing Technical Manual
V. PUMP MAINTENANCE
Proper maintenance is critical to long equipment life, reliability and efficiency. This section covers the
maintenance to the TyrFil Flushless Pump. Flatproofing does not have to be a dirty business as long as the
pump is kept clean and in good working order.
Fluid Gun and Manifold – Clean after each use with 99% isopropyl alcohol.
High Pressure Hoses – Replace ISO-side hose once a year under normal operating conditions. Normal
refers to the equipment being used at least once per week. For long term storage, the high pressure hoses
should be removed and lower cylinders sealed with airtight plugs.
Pressure Gauge – Replace if cross contamination occurs.
Lower Cylinders – Seals should be replaced if line pressures fall below the normal operating range or if
excessive cup seal leakage occurs.
Suction Side Hoses – Replace ISO-side hose once a year. Replace CAT-side hose when damaged. If cross
contamination occurs, all hoses must be replaced. For long term storage, remove suction hoses and the
lower cylinders sealed with air tight plugs.
Wet Seal Cups – During initial setup, the wet seal cups should
be filled ¼ full with throat seal liquid (TSL) oil. This oil provides
critical lubrication to the piston rods and also serves as a moisture
barrier for the Teflon®packings. TSL oil is consumed during normal
operation and therefore it should be checked on a weekly basis
even when the pump has not been used. Do not run cup seals dry
as seal damage will result.
The cup seals require periodic adjustment. Use the spanner wrench
supplied with the pump to tighten if they are loose. Packing should
be hand tightened only.
With normal use the TSL oil will change color as flatproofing
material slowly penetrates the seals. ISO-side material will begin to
harden once it has accumulated in the cup. When ISO-side material
begins to solidify in the cup, scoop out the jelled material. Once the
cup has been cleaned, refill with clean TSL oil and double check the
seal to see if it is tight.
Replacement parts are available through Carlisle TyrFil. See our
TyrFil Flushless Pump Parts Catalog found at www.carlisletyrfil.com.

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TyrFil Flushless Pump | Flatproofing Technical Manual
VI. MISCELLANEOUS
Bias Tires with Tubes (under 12 ply)
Tires in this category can be flatproofed in the same manner as filling a tubeless tire with one exception, never
allow the pressure to drop to less than 30% of the final pressure.
Tires with Tubes (12 ply and above or radial)
These tires require some extra precautions but are not difficult to flatproof if the following procedures are
used. A pilot hole must be made in the tire to make the insertion of the needle easier. Care must be taken not
to damage the tube when drilling the tire. It is the needle that should puncture the tube, not the drill bit. Below
are three methods that you can use:
Method 1: If the tire and tube are mounted and pre-drilling is required (12 ply or greater/radial tire) a vacuum
must be applied to the tube with a tube deflator before the tire can be safely drilled. This will prevent the
tube from being torn by the drill bit. When the tube is deflated, drill a pilot hole at the 12 o’clock position in
the tread groove. After drilling the hole, the tube must be expanded before flatproofing. To do this, replace
the valve core and inflate the tube. This step will ensure that the tube will fill properly. The tire can now be
flatproofed. Follow flatproofing guidelines for a regular tube-type tire.
It is recommended that the Flatproofing Technician practice with an unmounted tube before performing this
procedure in the tire. The vacuum device will make a distinct sound when all of the air has been removed
from the tube. It is important that you can identify this sound. If not, you will not know when the tire can be
safely drilled.
Caution: If the tube is not expanded before flatproofing, pressure can build up rapidly inside the tire
resulting in an over-pressurized condition or possibly burst the tire casing, causing injury. Also, failure
to keep pressure in the tube during the venting process could cause the tube to sag allowing the
needle to puncture another hole or rupture the tube.
Method 2: Mark the 12 o’clock position on the tire with tire chalk and dismount it. With the tube removed, drill
a hole at the 12 o’clock mark. Remount the tire and tube and proceed with processing.
Method 3: Mark and drill the tire before mounting. This third option only works if you have prior knowledge
that the tire will be flatproofed.
IMPORTANT: ALWAYS USE THE PROPER SAFETY DEVICES WHEN FILLING TIRES WITH TWO PIECE
RIMS OR LOCK RINGS.
Step 1: Position the tire in the normal filling position.
Step 2: Remove the valve core and fill the tire as you normally would.
Step 3: When 30% of the final desired pressure has been reached, insert the needle in the vent hole and
puncture the tube.
Step 4: Continue filling the tire, maintaining 30% of the final desired pressure in the tube. Regulate by
covering and uncovering the needle with your finger. This pressure will keep the tube seated
in the tire.
Step 5: The tire is filled when material flows from the needle.
Step 6: Remove the needle and insert a nail into the vent hole to seal the tire. Remember, the nail must also
be long enough to penetrate the tire and tube.
Step 7: Pressurize the tire and then lay it flat to cure.

18 TyrFil Flushless Pump | Flatproofing Technical Manual
Common Problems When Flatproofing Tires with Tubes
Tubes Tearing – Tubes can tear when being vented to release air, or when being sealed. Use nails when
plugging tube-type tires as screws may tear the tube.
Trapped Air – One-piece rims may trap air between the tire and tube.
Difficulty Sealing – Vent holes through the tire and tube are sometimes difficult to align and difficult to reseal.
Helpful Steps for Tires with Tubes
Reinforce – Bond a 2" x 4" reinforcing patch to the tube where it will be punctured to vent air.
Mark Tread – To position the hypodermic needle, mark the tire tread to locate the patch on the tube. With
large tires, predrill the vent hole before assembling tire and tube.
Lubricate – Lubricate the hypodermic needle with grease before puncturing tire and tube. When tire is full,
seal it with a lubricated nail.
Changing Products
Different types of TyrFil™can be pumped interchangeably though the same equipment. If the material is
changed over prior to pump start-up, follow normal start-up procedures after changing totes. If during
processing, use the following procedure to change from one product to the other:
Step 1. Drain Hoses – The clear supply hoses connecting totes to the pump contain more than a gallon of
usable material. To avoid wasting this, run approximately 6-8 strokes into a scrap container to clear
the hoses.
Step 2. Change Totes – Disconnect supply hoses and temporarily hang them, open-end-up, on the pump.
Immediately clean up any material spilled when disconnecting or reconnecting supply hoses.
Step 3. Position Totes – Correctly position the new material and connect to supply hoses.
Step 4. Cycle Machine – Place fluid gun over waste container and cycle machine until old material flowing
from gun is clearly replaced by new material (approximately six to eight strokes).
Step 5. Continue Processing – Begin processing as before, using new material. Although different types
of TyrFil can be used without a problem in the same equipment, if you run out of one product
during processing never add a different product to the same tire. Poor tire performance will result.
Tote sets do not always empty identically. However, they should empty at approximately the same
rates. Avoid allowing air from an empty container to be pumped into the system. Change to full
totes before the old ones are completely empty.
Cross Contamination
Cross contamination occurs when the ISO- and CAT-side hoses are accidentally switched and connected to
the opposite side. This can happen when switching empty totes or changing from one product to another.
Unfortunately, when this happens, it is not usually realized until it is too late. In most cases, you will need to
replace the lower cylinder unit, material supply hoses, line gauges, pressure gauge and manifold hoses. If this
mistake is realized before the pump is operated, it can be simply corrected by reconnecting the supply hoses
to their proper sides.

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TyrFil Flushless Pump | Flatproofing Technical Manual
On-Site Flatproofing
Carlisle TyrFil does not recommend on-site flatproofing, however for reasons of convenience and efficiency, it
can be done if:
1. The site can meet the 72˚ F (22˚ C) temperature requirements for storing the material, pumping the material
and curing the processed tires.
2. An adequate compressed air supply is available.
3. All necessary safety precautions are followed.
4. The required auxiliary equipment (tire cage and necessary tools) are available.
Carlisle TyrFil does not recommend flatproofing tires mounted on a vehicle. Except for unusual
circumstances, it has proven to be far more convenient and efficient to transport the tires to a dedicated
pumping location for flatproofing. If it is necessary to flatproof tires mounted on a vehicle, contact your
Technical Representative to discuss the specific application.
Changing from Another Supplier
Carlisle TyrFil marks its isocyanate component as the ISO-side. Not all manufacturers follow this practice.
Some mark the isocyanate as the “B” side. If you are changing to our products from another supplier,
contact our Sales and Technical Center for assistance.
Tote Maintenance
Totes should always be stored indoors, both when full and empty. It is important to always replace all bungs
and dust caps when a tote is not in use. This is especially important after the tote is emptied and put aside for
retrieval by Carlisle TyrFil or one of its agents. Below are some helpful hints for maintaining totes:
Storage Full – Should be stored indoors and heated to 72˚ F (22˚ C) before use.
Storage Empty – All bungs and dust covers should be replaced and they should be stored indoors or in a
weather protected area.
Handling – Totes are very heavy and should only be moved by a certified forklift driver. Take care not to dent
the cage, damage the pallet, or puncture the bottle when moving the totes.
In Use – Do not spill material on or around the totes. This makes for a dirty work area and the material is
difficult to clean off of totes.
Pick-up – Between 4 and 54 totes can be picked up at one time, usually within 72 hours. Empty totes should
not be stored for more than 60 days. For any questions regarding the tote pick-up program, call your Carlisle
TyrFil regional sales manager.
Drainage – Drain totes completely before disconnecting and starting with a new tote. It is important to
properly drain totes for many reasons and it is a simple thing to do. When the material in the tote is low,
simply prop the rear of the tote up with a 4-foot length of a 4" x 4" piece of wood. This will ensure that the tote
drains all of its material into the pump. Only completely empty totes can be returned.

20 TyrFil Flushless Pump | Flatproofing Technical Manual
Waste Disposal
Protection of the environment should be a primary concern of everyone. Proper procedures must be in
compliance with local, state and federal waste disposal regulations. Should materials become contaminated,
and thus not usable, they will have to be handled as hazardous waste and disposed of according to local,
state and federal regulations.
Solvent Containers – See the SDS for disposal of empty isopropyl alcohol containers.
Liquid Waste – In most states (check your local, state and federal regulations), liquid waste containing flush
and alcohol must be kept in a closed drum, labeled “FLAMMABLE WASTE”, in an approved solvents storage
area until delivered to a licensed disposer.
Salvaging Rims
Flatproofed tires mounted on wheels with split rims can be removed with a hydraulic press. All other
flatproofed tires can be removed from rims by the following procedure:
1. Use Reciprocating Saw – Grind teeth off saw blade to create a knife edge.
2. Cut Casing – Cut through the sidewall, around both sides, near the rim. Then make one or more cuts
across the tread, from one sidewall cut to another.
3. Remove Tread – Peel off casing to expose the cured material inside.
4. Remove Core – Cut across cured material from side-to-side and pry away from the rim.
5. Remove Sidewall – Pry remaining bead off the rim.