Castex CASC506 User manual
1
WARNING
⚫This manual is a necessary part of the product. Please read carefully.
⚫Keep the manual for later use when maintaining the machine.
⚫This machine can only be used for the designated purposes. Never use it for any other purpose.
⚫The manufacturer is not responsible for the damage incurred by improper use or use other than the intended
purpose.
Precautions
⚫The equipment can only be operated by qualified personnel with special training. Modification to any
components or parts, or use the machine for other purpose without either obtaining the agreement from the
producer, or observing the requirement of the instructions may lead to direct or indirect damage to the
equipment.
⚫The equipment should be installed on the stable ground.
⚫Keep the back panel 0.5M away from the wall for good ventilation. Enough room should be left on both
sides for convenient operation.
⚫Do not put the equipment a place with high temperature or moisture, or near the heating system, water tap,
air-humidifier or chimney.
⚫Do not put the equipment near the window with sunlight. Protect the unitwith a curtain or shield if necessary.
⚫Avoid lots of dust, ammonia, alcohol, thinner or spraying binder.
⚫People who are no operating the machines should be kept away when it is used.
⚫Use appropriate equipment and tools, protective and safety equipment, including eyeglasses, earplugs and
working boots.
⚫Pay special attention to the marks on the machine.
⚫Do not touch or approach the moving parts by hand during operating.
⚫Do not remove the safety device or keep it from working properly.
⚫Before moving the tire changer, contact maintenance personnel.
Contents
Safety Precautions………………………………………………………………..……………1
1. General Information……………………………………………………...…………………3
1.1 Usage………………………………………………………………………………………………………3
1.2 Features……………………………………………………………………………………………………3
1.3 Specifications………………………………………………………………………………………………3
1.4 Applicable Range…………………………………………..………………………………………………3
1.5 Working Conditions……………………………………………..…………………………………………3
1.6 Description of Safety Signs……………………………………………………………..…………………4
1.7 Position of Safety Signs……………………………………………………………………………………4
2. Main Structure……………………………………………………………….………………5
3. Installation and adjusting……………………………………………………………………6
3.1 Unpacking………………………………………………………….………………………………………6
3.2 Location…………………………………………………………………….………………………………6
2
3.3 Installation…………………………………………………………….……………………………………7
3.4 Power and Air Connections and Regulator…………………………………………………………………9
4. Operation………………………………………………………….…………………………10
4.1 Principles…………………………………………………………………………………….……………10
4.2 Demounting Tire…………………………………………………………………………….……………10
4.3 Mounting Tire………………………………………………………………………….…………………13
4.4 Inflating Tire……………………………………………………………………………………...………14
5. Trouble Shooting……………………………………………………………………………15
6. Maintenance…………………………………………………………………………………16
7. Storing and Scrapping………………………………………………………………………16
7.1 Storing……………………………………………………………………………………….……………16
7.2 Scrapping…………………………………………………………………………………………………16
8. Spare Parts List…………………………………………………………………………..…17
9. Exploded Drawings…………………………………………………………………………21
9.1 Column Assembly…………………………………………………………………………………………21
9.2 Turntable Assembly………………………………………………………………….……………………22
9.3 Gearbox & Motor Assembly………………………………………………………………………………23
9.4 Body Assembly……………………………………………………………………………………………24
9.5 Pedal Assembly ……………………………………………………………..……………………………25
9.6 Bead Breaker Cylinder & Breaker Arm Assembly……………………….………………………………26
Appendix 1: Electrical
Diagram………………………………….……………………………………..……………27
Appendix 2: Air Passage
Diagram…………………………………….………………………………….……………28
Appendix 3: Drawing of installation for small package…………...........................................29
10.Quick inflation system(optional)...........................................................................................30
11.Inflation box on the column(optional)..................................................................................35
12.Pneumatic shovel (optional)...................................................................................................37
1. General Information
1.1 Usage
The Machine is used for demounting, mounting and inflating tires of small vehicles. It features simple operation
and high reliability. In addition, it can also be a great help in car repair garage and tire dealers.
1.2 Features
⚫The equipment can be used for different purposes of demounting, mounting and inflating tires.
⚫The steel mount/demount is cast from excellent alloy material with special shape and durable performance.
The optional plastic mount/demount head with the equipment is made from special engineering plastic that
has enough intensity and not damage the tire and rim.
⚫The two clamping cylinder ensures accurate central alignment, so that the tires can be held tightly.
3
⚫The layout of the pedals gives convenience to the operating personnel.
⚫The distance of bead breaker is large enough for big tire.
⚫Tire lever and lubrication box are easy to reach.
1.3 Specifications
Dimensions
Maximum height：2000 mm
Length：950 mm
Width：900 mm
Noise
Working noise:≤70dB(A)
Air supply
Working pressure：8－10 bar
Bead breaker force：14000 N
1.4 Applicable Range
External Locking Rim diameter: 10″～21″
Internal Locking Rim diameter: 12″～24″
Max. wheel diameter：41″(1040mm)
Max. rim width：14″(355mm)
1.5 Working Conditions
Working temperature：-40℃－45℃
Transport/store temperature：-40℃－55℃
Humidity：30－95%
Electric specifications Voltage to
choose:
RPM of
turntable ：
6～7 n ／
min
1.6 Description of Safety Signs
⚫To prevent accidents from
occurring, make
sure to keep
hands and other body parts away
when fastening the
mount/demount head or when the
turntable is running.
⚫Caution should be taken when
separating the tire from rim. The
bead breaker shoe will move
rapidly and
forcefully when
the pedal is
depressed. Keep
body and
materials away
from the work area.
NO.
Voltage
Power
Phase
1
AC110V/60Hz
1.1kW
single
2
AC220V/50Hz
1.1kW
single
3
AC220V/60Hz
1.1 or
0.75kw
Single/t
hree
4
AC380V/50Hz
0.75kW
three
5
AC200V/50/60HZ
1.1kw
three
⚫
Please change the safety signs if it gets blurred or lost.
⚫
When one or more safety signs get lost, don’t operate the machine.
⚫
The safety signs must be kept within the sight of the operator.
4
1.7 Position of Safety Signs
⚫Be careful in the area of tilting column.
⚫The pressure of the compressed air should not exceed
10bar. When inflating the tire，The inflating gun
pressure value should be 3.5 bar.
5
2. Main Structure
`
Fig.1
The main operating parts are shown in fig.1
No.
Item
No.
Item
No.
Item
No.
Item
A
Tilting pedal
G
Bead breaker
shovel
M
Return spring
S
Clamping
cylinder
assembly
B
Jaw flex pedal
H
Bead breaker
arm
N
Locking handle
T
Hanger
C
Bead breaker
pedal
I
Hanger
O
Mount/demount
head
U
Frame
D
Turn table
control pedal
J
Column socket
P
Turntable
V
Side cover
E
Tire lever
K
Column
Q
Jaw
W
Pedal sign plate
F
Rubber buffer
L
Arm
R
slide
6
Fig.2
Accessories provided
are shown in Fig.2：
001- Inflating gun
002- Inflator tube
003- Tire lever
004- Jaw protector
7
3. Installation and adjusting
Fig.3
Fig.4
3.1 Unpacking
⚫Unpack according to the instructions on the package.
Remove the packing materials and inspect the machine
for possible damage or loss of accessories during
transportation. In case of doubt do not use the machine
and refer to professionally qualified personnel and/or to
the seller.
⚫Keep the packing materials out of the reach of children.
Handle in an appropriate way if the packing material is
likely to cause pollution.
⚫Remove the cabinet, column, swing arm and accessory
box fitted on the bottom plate and keep them in safety
place.
NOTE:
A special anti-rust oil applied on the delicate parts may
attract dust. Clean it when necessary.
3.2 Location
The place to install the machine should be in accordance with
safety regulations：
⚫The machine should be installed in a place close to the
main power source and compressed air system.
⚫Install the machine on smooth concrete ground or other
ground with hard flooring. 4 sets of anchor bolts can be
used to fasten the machine onto the ground to avoid
vibration and noise.
⚫Leave enough space for the operation and maintenance
of the machine. The space should be no less than 1M in
front and on the two sides of the machine, 0.5M behind
it so that operation on different parts shall not be
hindered.
⚫f the machine has to be installed outdoors, a protective
shelter should be built.
⚫Never operate the machine in a place with flammable
gas.
NOTE：
For safety and proper operation, keep the machine at least
0.5M away from any wall (Fig.4)
8
Fig.5
Fig.6
Fig.7
Fig.8-
a
3.3 Installation
⚫ Move the column C and arm D, put them on a soft
cushion.(Fig.5)
NOTE：
When you lift the column, the arm D will fall freely, be
careful!
NOTE：
ZH650 has two different size of packing, if it is
97x75x95mm, plz refer to Appendix 3 page30,
the Drawing of installation for small package.
You have to install part No. 2, 3, 4, 5, and turn
around 90 degree of part No.1 as the drawing.
3.3.1 Install return spring
⚫Use 6mm inner hexagon spanner to take off the screw
H which is inside of the plastic cover B. Take
Quadrate column E out, move the spring A, then
install hex column back.Put the spring A on the top of
hex column and install the plastic cover B back and
tighten screw. (Fig.6)
3.3.2 Install the column
⚫Use 6mm inner hexagon spanner to take off the screw
B and washer C, then take off the side cover A and
cover as fig.7.
⚫Lift column E as fig.7 , make pin hole of column and
body in line, insert pin axis H, tighten screw F and
washer G (screw M12x25)（If column can not be
fixed in, loose screw M, after installation finished,
tighten screw M again.）.
⚫Tilt column, make hoseφ4 M through hole O in the
body N (Fig. 8).
NOTE：
Before hoseφ4 O come through pin hole of column, make
sureφ4 hose O begins at the back of pin L to avoid hose
damaged.
⚫Pull column forward slowly, when the hole in column
and piston rod I in line, insert pin axis J, use washer
and screw J to fix.(M12x55,fasten M12 screw K) .
⚫Make column straight, finish column installation.
9
,,,
Fig.8-b
Fig. 9
Fig.10
⚫Connect hose in the column ：As fig.8-b ，
connectφ4 hose O to regulator Z
NOTE：
When the machines come out
factory, the regulator Z has already been
adjusted pressure (4 bar), please do not adjust it by
yourself.
3.3.3 Install Hanger
⚫As fig.9 Insert the two heads into twoφ5 holes
in the right side of column, make sure I heads,
hook is upward.
⚫Install side cover A and cover D, fasten with
screws as fig. 7 .
3.3.4 Lifting and installation
Take off 2 pieces of screws by spanner (Fig.10). Use
hoist to lift the machine, move pallet, locate the
machine.
10
Fig.12
Fig.13
Fig.14
4.
Operation
NOTE：
3.4 Power and Air Connections and Regulator
⚫Before installation, check if the power source and the
compressed air are in accordance with the specifications on
the nameplate. Any electrical connection should be done by
the specially trained technician.
⚫The power socket should be at a place within the sight of the
operator. The height should be between 24”～67”.
⚫Grounding protection of power is needed for machine shell.
⚫Air connection：Connect the inflation gun A to the coupling
located to the up of the air filter S (Fig.12).
⚫Connect the compressed air supply to the coupling located
between the lubricator and the air filter S(as fig.12 ，
direction of arrow）.
NOTE：
The tire changer is not equipped with overload protection.
Please connect power according to the electric diagramincluded
in the User’s manual. Otherwise, the manufacturer will not be
responsible for any accidents.
⚫Operation test: after power connected, press pedal D
(Fig.13), turntable will turn clockwise. This test is very
important.
⚫F.R.L. :Filter, Regulator, Lubricator Assembly(optional):
➢See Fig. 14：1- Lubricator；2- Filter；3- Regulator.
➢Adjust pressure: There is a button for the regulator 3.
When pulled up, the pressure can be increased or
decreased by turn it clockwise or counter-clockwise
(check the 4-Gauge). After adjusting the operation
pressure, press the button down to lock it.
➢The Filter 2 works to filter the water and impurity in the
compressed air. When water and impurities run beyond
the red line, turn open the ejection valve 5 to release
them.
➢The lubricator 1 is used to add a certain amount of
lubricant into gas for the moving parts in the cylinder
and regulator. Depress pedal C, 3～5 times, a drop of
lubricant will drop into the cup in the regulator. If it
doesn’t happen, the adjusting screw can be adjusted.
1
2
3
4
5
6
11
➢Do not operate the machine before having completing training and qualified for operating the tire changer.
Use appropriate equipment, tools and personal protective equipment, such as eye-glasses, ear-plugs and
working boots, when operating the tire changer.
➢Make sure that the power, air sources and the oil level in the oil cup are in accordance with the requirements.
4.1 Principles
⚫To avoid damage when mounting and demounting tire,
especially the alloy ones, use the special tire lever.
⚫For easier demounting and better protection of the tire
and rim, lubricate the area between the rim and tire bead,
where the bead breaker shoe goes in, with
industrial lubricant or thick soap solution.
⚫Pay special attention to rotary direction marked on some
flanges or tires.
⚫Fit the tire on the rim of matched size.
⚫Check for damages (distortions, surface damages,
excessive run out, erosion or overall wear) before
demounting.
⚫Never ignore the mounting and demounting
requirements of the special wheel.
⚫When inflating the tire, make sure the pressure
increases in an even way. Check the rim as often as
possible.
Fig.15
Fig.16
4.2 Demounting Tire
Preparing
⚫Deflate the tire thoroughly.
⚫Remove all the foreign substance and weights
from the rim（as fig.15）.
Demounting
NOTE：
Lubricate the bead with a brush with lubricant
before the shoe touches the bead. Otherwise the tire
bead will be worn (Fig.16).
12
Fig.17
Fig.18
Fig.19
Fig.20
⚫Place the tire between the bead breaker shoe
and rubber pad and keep the shoe between the
bead and rim, about 1cm to the bead
(Fig.17-a). Depress pedal C (Fig.17-b) to
separate the tire from rim.
⚫Repeat the above steps on other part of the tire
to get the tire separated thoroughly from the
rim.
NOTE：
When using the bead breaking arm, do not put
arms and hands between the tire and the bead
breaker
⚫Press switch handle button N (Fig. 18), fix arm.
⚫Press pedal A, tilt the column.
⚫Place the wheel on the turntable. Depress pedal
B, For the asymmetric deep groove rim, keep
the narrow rim upward（Fig. 19）.
⚫NOTE：Different types of clamping can be
chosen in accordance with different rims.
➢In case of inward clamping, shrink the jaws
together, place the wheel on the turntable and
depress pedal B to clamp (Fig.20-a).
➢In case of outward clamping, enlarge the jaws
outward (2-3cm away from periphery of the
rim) and place the wheel on the turntable. Press
down the rise/fall control lever to keep the rim
close to the jaws, and depress pedal B to clamp
it(as fig.20-b）.
13
Fig.21
Fig.22
Fig.23
14
⚫Press pedal A (Fig.18), let column back to
working position, pull back switch handle N
(Fig. 21-a), let the arm L and hex column M
move freely. Push N and press M, make
mounting head O against rim (Fig. 21-b), press
switch handle N lock arm and hex column.
Make sure mounting head keep a distance of
1~2mm from upper edge of rim and 2mm from
outer edge of rim to avoid mounting head
scratch rim.
⚫Insert lever into wheel near mounting head
(Fig. 22).
⚫Press lever as Fig. 22-2 and press wheel as fig.
22-1, until upper edge of wheel as Fig. 23, press
lever slowly, until upper edge of wheel hang on
the mounting head.
NOTE：
If inner tube, to avoid damage of inner tube, keep
the position of air inlet valve and mounting head
and lever as Fig. 24.
⚫Press pedal D (Fig. 22), turntable turn
clockwise, until edge of wheel fall off.
NOTE：
➢For very tough and low profile wheel,
wheel edgeis easy toslip off, to avoid this,
before turn clockwise of the turntable,
may turn anti-clockwise a little to make
the turntable back 1-2mm.
➢If the demounting process is prevented,
stop the turntable from turning around,
lift pedal D (fig. 22), let the turntable turn
anti-clockwise.
15
Fig.26
Fig.27
⚫If there is tube in the tire, remove it.
⚫Lift wheel, make the bottom edge of wheel as
Fig. 25.
⚫Press pedal D until bottom edge of wheel fall
off.
⚫Depress pedal A, tilt column, take off wheel,
and finish demounting.
NOTE：
Keep hands and the rest of human body away
from the moving parts of the machine. Never wear
necklace, bracelet or loose clothes when operating
the machine as it may cause danger!
4.3 Mounting Tire
NOTE：
Check the size of tire and rim to see if they match each
other.
⚫Clamp the rim tightly in the same way as demounting
tire.
⚫Use lubricant such as thick soap solution on the tire
and the rim.
⚫Put the beadon the rim with the left side upward, press
pedal A, make column back to working position
(Fig.26) .
⚫Check the coordination of mount/demount head and
rim. Readjust if necessary.
⚫Adjust relative position between the tire and the
mount/demount head to make the tire bead cross the
mount/demount head. At the end of the
mount/demount head, the tire bead should be placed
on the mount/demount head (Fig.27-A). At the
beginning of the mount/demount head, the tire bead
should be placed under the ball protuberance of the
mount/demount head (Fig.27-B).
⚫Press down the central part of the tire. Depress the
pedal D (Fig.22) to turn the turntable clockwise,
making the lower tire bead fall into the rim groove
completely (as fig.28-A).
Fig.24
Fig.25
16
Fig.28
⚫
If a tube needs to be installed in the tire, check first for
the possible damages. Round it onto the rim. Make sure
to keep the tube in the right position throughout the
mounting process.
⚫
To install the upper tire bead, place the tire well and
readjust position of the tire bead (same as mount of the
lower tire bead in Fig.28-B. Press down the tire opposite
to the mount/demount head to the rim groove
(Fig.29).
⚫
Depress the pedal D (Fig.22) to turn the turntable while
keeping pressing on the tire. When only 10~15cm isleft,
slow down to avoid damage of the tire bead. Stop the
motor if there is any indication for damage. Lift the
pedal D and turn the turntable counter-clockwise. Try
again when the tire is back to the original shape.
⚫
NOTE：
➢It is not necessary to move the handle of the
screw every time if the size of rim matches the
tire. Just move the swing arm.
➢In the process of operation, turntable always
goes clockwise, anti-clockwise is only for
correcting wrong operation
17
Fig.29
Fig.30 Fig.31
Danger！Danger of explosion！
The safety procedures should be closely followed.
Review and abide by the following instructions.
Otherwise serious injury or death can be resulted.
The manufacturer shall not be held responsible
for any possible accident when the safety
procedures are not followed
➢Carefully check the dimensions of rim and tire
to see if they match each other. Check and
make sure that the tire is notworn or damaged
before inflation.
➢When a high pressure is required, remove the
tire from the tire changer and resume the
inflation in a special protective hood.
➢e careful when inflating the tire. Keep hands
and the rest of human body away from tire.
➢The operator must adopt all the measures
necessary in order to guarantee safe
conditions.
4.4 Inflating Tire
Danger！！
Inflating can be highly dangerous. Take precautions and
pay close attention to the procedures. Check if the
compressed air is well connected before inflating
Inflating procedures are shown in Fig.30. The machine is
equipped with a gauge to read the pressure in the tire.
⚫ Connect the outlet of the gun to the air inflation valve
⚫Slowly press the switch on the inflating gun for several
times during inflation to make sure that the reading on
pressure gauge meets the manufacturer’s specifications.
The pressure should not exceed 3.5 bar.
⚫If the pressure exceeds the limit, press the button on the
gun inflator so that the pressure goes down to what is
required.
18
5. Trouble Shooting
Malfunction
Cause
Solution
The chuck does not rotate in any
direction.
1. Power plug not inserted.
2. Incorrect connection in the plug.
3. Electrical supply not suitable.
Check correct plugging and its
connection.(see cause 2 and 3)
Pressing the invertor pedal down
causes the chuck to turn in an
anti-clockwise direction.
Polarity inverted.
Invert the connections in the power
plug
The chuck turns with insufficient
power.
1. Supply voltage wrong.
2. Driving belt loosen.
1. Check the correspondence
between the supply voltage
and that on the maker’s plate.
2. Tighten the belt.
The bead breaker does not have
sufficient power to break the tire
bead.
1. The pneumatic supply is not
connected to the machine.
2. Insufficient pressure in the
pneumatic system.
3. Pressure reducer is closed or badly
adjusted (for versions with this
device).
1. Connect the pneumatic supply.
2. Correct the supply pressure.
3. Open or correctly adjust the
pressure reducer.
Other malfunctions should be checked and fixed by Professionally Qualified Personnel.
6. Maintenance
Note:
Only the specialized technician can do the maintenance. Before any maintenance is performed, disconnect the
power and keep the plug within the sight of the maintenance personnel. and shut off compressed air, push the air
valve switch to “Off” position and depress pedal 16 for 3 or 4 times to bleed the residual compressed air in the
machine.
To keep the tire change in good condition and to prolong the work life, it is necessary to do regular maintenance
according to the instructions on the user’s manual. Otherwise, the normal operation and reliability of the machine
will be affected, or personal injury would be caused.
⚫Keep the machine and working area clean and prevent dust or foreign matter from entering the moving parts.
⚫Keep the quadrate column and the moving parts clean and lubricate (clean with diesel as in Fig.32-1 & 2 & 3 ).
⚫Keep the swing arm clean and lubricate it periodically so that it can move expectably.
⚫Weekly lubricate the faying surface between moving parts and rubbing surface with lithium lubricant.
⚫Check the oil level in the sprayer regularly. If the oil level does not reach the second line, fill L-HM46 (Fig. 33).
⚫Clear away the condensed material in the water separator around the sprayer regularly.
⚫Regularly check and adjust the tension of the belt.
⚫Check all connecting parts and bolts regularly and tighten them if necessary.
⚫Check and adjust locker handle periodically, to make sure after locking, mount head and rim keep 2-3m distance.
19
Fig.32 Fig.33
7. Storing and Scrapping
7.1 Storing
When the equipment needs to be stored for a long time:
⚫Disconnect the power and compressed air.
⚫Lubricate all the parts: slide block and groove.
⚫Empty all the oil/liquid cups.
⚫Cover the equipment with plastic shield.
7.2 Scrapping
When the equipment can no longer be used, disconnect the power and compressed air and dispose in accordance with
the local regulations.
8. Spare parts list
This list is only for the reference of the maintenance personnel. The manufacturer will not be held responsible for any
use other than the designed purpose.
In case any damage occurs, please contact your dealer or factory with the corresponding codes in the list..
SPARE PARTS LIST
NO.
CODE
Description
Qty.
NO.
CODE
Description
Qty.
2065618 Parts of Column & Arm (Fig. 34)
101
2065619
Column
1
138
6000387
Screw M10x30
1
102
3005009
Union IPL 4-01
1
139
3005190
Knob
1
103
6000120
Screw M6*30
4
140
2037701
Spring
1
104
2065640
Screw M10*25
2
141
2064803
Hex column
1
105
6000123
Nut M10
2
142
3005188
Washer
1
106
2065638
Locking plate
1
143
2052501
Washer φ34*10*5
1
107
6000126
Nut M12
2
144
6000184
Screw M10*25
1
108
2065640
Screw M12*60
2
145
3005275
Rubber block
1
109
2065639
Spring
2
146
2065643
Rubber block plate
1
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