Corghi A 9824 TI User manual

A 9824 TI
Code 4-103090C - 11/2013
Italiano Manuale d’uso
English Operator’s manual
Français Manuel d’utilisation
Deutsch Betriebsanleitung
Español Manual de uso

2 A 9824 TI User Manual
Copyrighted materials. All rights reserved.
The information contained herein may be subject to modifications without prior notice.
Thank you for choosing our Tyre Changer
CORGHI
Dear Purchaser
Thank you for purchasing your Corghi Tyre Changer.
Your Tyre Changer has been designed to provide years of safe and dependable service,
as long as it is used and maintained in accordance with the instructions provided in this
manual.
All persons who will use and/or maintain this Tyre Changer must read, understand and
follow all warnings and instructions provided in this manual, and be properly trained.
This Owner’s Manual should be considered an internal part of your Tyre Changer and
should remain with the Tyre Changer. However, nothing in this manual, and none of the
devices installed on the Tyre Changer, substitute for proper training, careful operation,
good judgement and safe work practices.
Always be sure that your Tyre Changer is in optimum working order. If you suspect that
anything is not working properly, or that a dangerous situation may exist, immediately
shut down the Tyre Changer and remedy any condition before you proceed.
If you have any questions concerning the proper use or maintenance of your Tyre Changer,
please call your authorized Corghi representative.
Sincerely,
Corghi SpA
OWNER INFORMATION
Owner
Name_______________________________________________________________
Owner
Address_____________________________________________________________
Model
Number_____________________________________________________________
Serial
Number_____________________________________________________________
Date
Purchased___________________________________________________________
Date
Installed ____________________________________________________________
Service and Parts
Representative_______________________________________________________
Phone
Number_____________________________________________________________
Sales
Representative_______________________________________________________
Phone
Number_____________________________________________________________

A 9824 TI User Manual 3
TRAINING CHECKLIST
Trained Declined
Safety Precautions
Warning and Caution Labels
Pinch Points and Other Potential Hazards
Safe Operating Procedures
Maintenance and Performance Checks
Mounting Head Inspection
Adjustment and Lubrication
Clamping
Steel / Alloy Wheels
Reverse Drop Centre Wheels
Steel Jaw Internal/External Clamping
Bead Breaking
Standard Wheels
Low Profile Wheels
Demounting
Standard Wheels with Bead Lever and Plastic Sleeve Protector
Full Seating of Mount/Demount Head to Prevent Head Failure
Bead Lubrication During Removal of Low Profile Tyres
Reverse Drop Centre Wheels
Mounting
Standard Wheels
Mounting of Stiff, Low Profile Tyres
Reverse Drop Centre Wheels
Proper Bead Lubrication for Mounting Protection
Inflation
Safety Precautions
Lubrication and Removal of Valve Core
Bead Sealing and Seating

4 A 9824 TI User Manual
Individuals and Dates Trained
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A 9824 TI User Manual 5
TABLE OF CONTENTS
1. GETTING STARTED .........................................................................7
1.1 INTRODUCTION ..............................................................................................7
1.1.a. Purpose of the manual .......................................................................................7
1.2 FOR YOUR SAFETY .........................................................................................7
1.2.a. General warning and instructions .....................................................................8
1.2.b. Decal placement...............................................................................................11
1.2.c. Electrical and pneumatic connections............................................................15
1.2.d. Technical data ...................................................................................................17
1.2.e. Air pressures......................................................................................................18
1.3 SPECIAL RIM/TYRE CONSIDERATIONS......................................................18
1.4 INTENDED USE OF THE MACHINE............................................................18
1.5 EMPLOYEE TRAINING..................................................................................19
1.6 PRE-USE CHECKS.........................................................................................19
1.7 DURING USE..................................................................................................19
2. TRANSPORT, STORAGE AND HANDLING..................................20
3. UNPACKING/ASSEMBLY ...............................................................21
4. HOISTING/HANDLING..................................................................24
4.1 INSTALLATION CLEARANCES.....................................................................24
5. A 9824 TI DESCRIPTION................................................................25
6. OVERALL DIMENSIONS ...............................................................27
7. EQUIPMENT COMPONENTS........................................................27
8. OPTIONAL ACCESSORIES ............................................................29
9. BASIC PROCEDURES - USE ..........................................................30
9.1 PRELIMINARY CHECKS................................................................................30
9.2 DECIDING FROM WHICH SIDE OF THE WHEEL THE TYRE MUST BE .....
DEMOUNTED ................................................................................................31
9.3 BEAD BREAKING ..........................................................................................31

6 A 9824 TI User Manual
9.4 CLAMPING THE WHEEL ..............................................................................33
9.5 TYRES WITH SOFT WALLS...........................................................................35
9.5.a. Demounting .......................................................................................................35
9.5.b. Mounting............................................................................................................38
9.6 APPROVED UHP AND RUN FLAT TYRE DEMOUNTING AND MOUNTING
PROCEDURE ...................................................................................................40
9.7 LOW PROFILE TYRES ...................................................................................40
9.7.a. Demounting .......................................................................................................40
9.7.b. Mounting............................................................................................................42
9.8 TYRES INFLATION.........................................................................................43
9.8.a. Safety indications..............................................................................................43
9.8.b. Inflating tyres.....................................................................................................45
9.8.c. Inflating tubeless tyres (TI versions only)......................................................46
10. TROUBLESHOOTING ..................................................................48
11. MAINTENANCE............................................................................51
12. INFORMATION ABOUT SCRAPPING..........................................53
13. ENVIRONMENTAL INFORMATION............................................53
14. INFORMATION AND WARNINGS CONCERNING HYDRAULIC
FLUID ............................................................................................... 54
15. FIREFIGHTING MEANS USABLE ...............................................55
16. GLOSSARY ....................................................................................55
17. GENERAL ELECTRIC LAYOUT DIAGRAMS...............................59
18. PNEUMATIC SYSTEM DIAGRAM................................................62

A 9824 TI User Manual 7
1. GETTING STARTED
1.1 INTRODUCTION
1.1.a. PURPOSE OF THE MANUAL
The purpose of this manual is to provide the instructions necessary for optimum operation,
use and maintenance of your machine. If you sell this machine, please deliver this manual
to the new owner. In addition, so we can contact our customers with any necessary safety
information, please ask the new owner to complete and return to Corghi the change of
ownership form attached to the previous page of this manual. Alternatively, the new owner
can send an email to [email protected].
This manual presumes that the technician has a thorough understanding of rim and tyre
identification and service. He/she must also have a thorough knowledge of the operation
and safety features of all associated tools (such as the rack, lift, or floor jack) being utilized,
and have the proper hand and power tools necessary to work in a safe manner.
The first section provides the basic information to safely operate the A 9824 TI tyre changer
family. The following sections contain detailed information about equipment, procedures,
and maintenance. “Italics” are used to refer to specific parts of this manual that provide
additional information or explanation.
Thesereferencesshouldbereadforadditionalinformationtothe instructionsbeingpresented.
The owner of the tyre changer is solely responsible for enforcing safety procedures and
arranging technical training. The tyre changer is to be operated only by a qualified and
trained technician. Maintaining records of personnel trained is solely the responsibility of
the owner or management.
The A 9824 TI tyre changer family is intended for mounting, demounting, and inflating tyres
of lightweight vehicles (cars, not trucks or motorcycles) with maximum dimensions of 47
inches in diameter and 14 inches in width.
Copies of this manual and of the documents accompanying the machine may be obtained
from Corghi by specifying the type of machine and its serial number.
NOTICE: Design details are subject to change. Some illustrations may vary slightly in ap-
pearance from the machine you have.
1.2 FOR YOUR SAFETY
HAZARD DEFINITIONS
These symbols identify situations that could be detrimental to your safety and/or cause
equipment damage.
DANGER: Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
DANGER

8 A 9824 TI User Manual
WARNING: Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
WARNING
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury.
CAUTION
NOTICE: Used without the safety alert symbol, indicates a potentially hazardous
situation, which, if not avoided, may result in property damage.
NOTICE
1.2.a. GENERAL WARNING AND INSTRUCTIONS
Avoid Personal Injury. Carefully read, understand and follow the warnings and instructions given in this manual.
This manual is an essential part of the product. Keep it with the machine in a safe place for future reference.
WARNING
1. If the use and maintenance procedures provided in this manual are not properly
performed, or the other instructions in this manual are not followed, an accident could
occur. Throughout this manual reference is made that “an accident” could occur. Any
accident could cause you or a bystander to sustain severe personal injury or death, or
result in property damage.
2. Overinflated tyres can explode, producing hazardous flying debris that may result in
an accident.
3. Tyres and rims that are not the same diameter are “mismatched.” Never attempt to
mount or inflate any tyre and rim that are mismatched. For example, never mount a
16.5” tyre on a 16” rim and vice versa. This is very dangerous. A mismatched tyre and
rim could explode, resulting in an accident.

A 9824 TI User Manual 9
4. Never exceed the bead setting pressure provided by the
tyre manufacturer, as stated on the sidewall of the tyre.
Carefully monitor the gauge on the air hose.
5. If tires being mounted require more than the tire manu-
facturer’s maximum bead seating pressure and , the wheel
should be removed from the tire changer, placed in an
inflation cage, and inflated per manufacturer’s instructions
6. The use of inflation devices (e.g. guns) connected to
power sources outside of the machine is not permitted
7. Never place your head or any part of your body over a tyre during the inflation process
or when attempting to seat beads. This machine is not intended to be a restraining
device for exploding tyres, tubes or rims.
8. Always stand back from the tyre changer when inflating, never lean over.
An exploding tyre and rim may be propelled upward and outward with enough force to cause
serious injury or death.
Never mount any tyre unless the tyre size (molded into the sidewall) matches the rim size
(stamped into the rim) exactly or if the rim or tyre are defective.
Never exceed the tyre pressure recommended by the tyre manufacturer.
This tyre changer is not a safety device and will not restrain exploding tyres and rims. Keep
the area clear of bystanders.
DANGER
9. Crushing Hazard. Moving Parts Present. Contact with moving parts could result in an
accident.
• Only one operator may work with the machine at a time.
• Keep all bystanders clear of tyre changer.
• Keep hands and ngers clear of rim edge during the demounting
and mounting process.
• Keep hands and ngers clear of mount/demount head during
operation.
• Keep hands, feet and other body parts away from moving parts.
• Do not use tools other than those supplied with tyre changer.
• Use proper tyre lubricate to prevent tyre binding.
• Pay attention while moving tyre/rim or lever.
10. Electric Shock Hazard.
Avoid Personal Injury. Carefully read, understand and follow the warnings and instructions given in this manual.
This manual is an essential part of the product. Keep it with the machine in a safe place for future reference.
WARNING

10 A 9824 TI User Manual
• Never hose down or power wash electric tyre changers.
• Do not operate the machine with a damaged power cord
• If an extension cord is necessary, a cord with a current rating equal to or
greater than that of the machine must be used. Cords rated for less current
than the machine can overheat, resulting in a fire.
• Care should be taken to arrange the cord so that it will not be tripped
over or pulled.
11. Risk of Eye Injury. Flying debris, dirt and fluids may be discharged dur-
ing bead seating and the inflation process. Remove any debris from the
tyre tread and wheel surfaces. Wear OSHA, CE or other approved safety
glasses during mount and demount procedures.
12. Always inspect the machine carefully before using it. Missing, broken, or
worn equipment (including warning stickers) must be repaired or replaced
prior to operation.
13. Never leave nuts, bolts, tools or other equipment on the machine. They may become trapped
between moving parts and cause a malfunction.
14. NEVER install or inflate tyres that are cut, damaged, rotten or worn. NEVER install a tyre on a
cracked, bent, rusted, worn, deformed or damaged rim.
15. If a tyre becomes damaged during the mounting process, do not attempt to finish mounting.
Remove from the service area and properly mark the tyre as damaged.
16. To inflate tyres, use short bursts while carefully monitoring the pressure, tyre, rim and bead.
NEVER exceed the tyre manufacturer’s pressure limits.
17. This equipment has internal arcing or sparking parts which should not be exposed to flammable
vapours (gasoline, paint thinners, solvents, etc.). This machine should not
be located in a recessed area or below floor level.
18.Neveroperatethemachine if youareundertheeffectsof alcohol, medica-
tions and/or drugs. If you are taking prescription or over the counter medica-
tion, you must consult a medical professional regarding any side effects of
the medication that could hinder your ability to operate the machine safely.
19. Always use OSHA, CE or other approved and mandated Personal Protec-
tive Equipment (PPE) during use of the machine. See your supervisor for
more instructions.
20. Remove jewellery, watches, loose clothing, ties and restrain long hair
before using the machine.
21. Wear non-slip safety footwear when operating the tyre changer.
22. Wear proper back support and employ a proper lifting technique when
placing, moving, lifting or removing wheels from the tyre changer.