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
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

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.

A 9824 TI User Manual 11
23. This machine may only be used, maintained or repaired by properly trained employees of
your company. Repairs should only be performed by qualified personnel. Your CORGHI service
representative is the most qualified person. The employer is responsible for determining if an em-
ployee is qualified to safely make any repairs to the machine should repair be attempted by users.
24. The user should understand all warning decals affixed to this equipment before operating.
25. Lock the rim on the turntable during inflation.
1.2.b. DECAL PLACEMENT
No. Part Number Drawing Description
1460384 DECAL, CORGHI LOGO
(FRONT SIDE)
2
427424B DECAL, CORGHI LOGO
(LEFT SIDE)
3
4-100534 DECAL, A 9824 TI
4
446429 DECAL,MAX.INLETPRESSURE
16 BAR
5
446442 DECAL, WARNING UNDER
PRESSURE TANK
6
450022 DECAL, FILTER
7
446598 DECAL, DISCONNECT POWER
SUPPLY
8
432740 DECAL,EXPLOSION HAZARD
9
418135 DECAL, DIRECTION OF ROTA-
TION

12 A 9824 TI User Manual
No. Part Number Drawing Description
10
446433 DECAL, HAND CRUSHING
HAZARD
11
446435 DECAL, HAND CRUSHING
HAZARD
12
429974 DECAL, CORGHI LOGO
13
450007 DECAL, SAFETY INSTRUC-
TIONS
14
435150 DECAL, INFLATING PEDAL
15
446388 DECAL, CORRECT FEEDING
NETWORK
16
446431 DECAL, HAND/FOOT
CRUSHING HAZARD
17
450005 POSTER, SAFETY INSTRUC-
TIONS
18
425211 DECAL, ELECTRIC HAZARD
19
446436 DECAL, INFLATION VALVE
20
42015 - Correggio (RE) Italy
ISO9001
Code
Serial N.
X-XXXXXXXX/XX - XX
XXXXXXXXX
QUAL. SYS. CERTIFIED
ANNO DI COSTRUZIONE /
MANUFACTURED
Mod.
V
A
kW
Hz
Ph
bar7psi
Port.max
DECAL, MODEL SERIAL NUM-
BER

A 9824 TI User Manual 13
15
6
7
8
9
11
19
14
15
16
18
12
2
3
4
10
13
17
20
No. Part Number Drawing Description
21
429976 DECAL, PEDALS CONTROL
21

14 A 9824 TI User Manual
DANGER WARNING DECALS
part nr 446433. Crushing Hazard.
part nr 446435. Crushing hazard.
part nr 446431. Crushing hazard.
part nr 446442. EXPLOSION HAZARD. Do not puncture
Danger - pressurised container.
part nr 425211A. Risk of electrical shock.
part nr 432740. Explosion hazard.
part nr 450005. Safety instructions.
Must be applied near the tire changer in a prominent
position by the operator.

A 9824 TI User Manual 15
part nr 450007. Safety instructions.
part nr 425083. Earth ground terminal.
1.2.c. ELECTRICAL AND PNEUMATIC CONNECTIONS
The dimensions of the electric hook-up used must be suitably sized in relation to:
• the electric power absorbed by the machine, indicated on its data plate (Fig. 1);
• the distance between the machine and the power supply hook-up point, so that voltage
drops under full load do not exceed 4% (10% during start-up) compared with the rated voltage
specified on the data plate.
- The operator must:
• t a power plug on the power supply lead in compli-
ance with the relevant safety standards;
• connect the machine to its own electrical connection
- A, Fig. 2 - and fit a differential safety circuit-breaker
with 30 mA residual current;
• t fuses to protect the power supply line, rated as
indicated on the general wiring diagram in this manual;
• connect the machine to an industrial socket; the
machinemustnot be connectedtodomestic sockets.
2
A
42015 - Correggio (RE) Italy
ISO9001
Code
Serial N.
X-XXXXXXXX/XX - XX
XXXXXXXXX
QUAL. SYS. CERTIFIED
ANNO DI COSTRUZIONE /
MANUFACTURED
Mod.
V
A
kW
Hz
Ph
bar7psi
Port.max
1

16 A 9824 TI User Manual
An effective grounding connection is essential for correct operation of the machine.
NOTICE
Make sure the available pressure and the rendered capacity of the compressed air system
arecompatiblewiththoserequiredfor correct machine operation-seethe“TechnicalData”
section. For correct machine operation, the compressed air supply line must provide a
pressure range from no less than 8.5 bar to no more than 16 bar and guarantee an air flow
rate greater than the average consumption of the machine, which is equal to 187 Nl/min.
For correct equipment operation, the air produced must be suitably treated (not
above 5/4/4 according to ISO 8573-1)
NOTICE
Check that the Lubricator unit B fig. 2a contains air
lubricating oil; top up if necessary. Use SAE20 oil.
Thecustomermust provide anair cut-off valveupstre-
am of the air treatment and regulator device supplied
with the machine.
1.2.d TECHNICAL DATA
- Turntable clamping capacity
- internal clamping.................................................................................................... from 13”
- external clamping........................................................................................ from 10” to 24”
- Rim width ........................................................................................................ from 3.5” to 13”
- Maximum tyre diameter ..................................................................................................... 47”
- Maximum tyre width ........................................................................................................... 14”
- Power supply voltage: .................................................................................................seetable
- Bead breaker aperture:
- normal position.............................................................................................. from 2” to 12”
- racing position ............................................................................................... from 5” to 15”
- Bead breaking force ............................................................................. 15000 N (pressure 145 psi)
- Operating pressure .......................................................................................................145 psi
- Weight............................................................................................................................. 238 Kg
-Noise levels in operating conditions ..................................................................< 70 dB (A)
2a
B

A 9824 TI User Manual 17
Model Motor rating kW Rotation
speed rpm
Torque
Nm
Weight of electric/
electronic part kg
A9824 TI
400Volt/3ph 50Hz 0.75 8.5 1200 11.5
200/230Volt/3ph 60Hz 0.75 8.5 1200 11.5
200/230Volt/3ph 50Hz 0.75 8.5 1200 11.5
200/230Volt/1ph 50Hz 0.75 8.5 800 11.5
200/230Volt/1ph 60Hz 0.75 8.5 800 11.5
115Volt/1ph 50/60Hz 0.55 11 950 10
115Volt/1ph 60Hz 0.75 8.5 800 11.5
200/230Volt/1ph 50/60Hz DV 0.75 6-15 1200 10.2
AIR MOTOR / 6.5 800 /
The noise levels indicated correspond to emission levels and do not necessarily represent safe
operating levels. Although there is a relationship between emission levels and exposure levels, this
cannot be used reliably to establish whether or not further precautions are necessary. The factors
which determine the level of exposure to which the operator is subject to include the duration of the
exposure, the characteristics of the workplace, other sources of noise, etc. The permitted exposure
levels may also vary according to the country. However, this information will enable machine users
to make a more accurate assessment of hazards and risks.
1.2.e. AIR PRESSURES
The machine is equipped with an internal pressure limiting valve to minimize the risk of over
inflating the tyre.
•EXPLOSION HAZARD
•Never exceed the tyre pressure recommended by the tyre
manufacturer. Never mismatch tyre size and rim size.
•Avoid personal injury or death
DANGER
1. Never exceed these pressure limitations:
• Supply line pressure (from compressor) is 220 psi (15 bar).
• Operating pressure (gauge on regulator) is 145 psi (10 bar).
Bead setting pressure (gauge on hose) is the tyre manufacturer’s maximum pressure as stated on
the sidewall of the tyre
2. Activate air inflation jets only when sealing the bead.
3. Bleed air pressure system before disconnecting supply line or other pneumatic components.
Air is stored in a reservoir for operation of inflation jets.
4. Only activate the air inflation jets if the rim securing device is locked in place and the

18 A 9824 TI User Manual
tyre is properly clamped (when possible).
1.3. SPECIAL RIM/TYRE CONSIDERATIONS
Wheels equipped with low tyre pressure sensors or special tyre and rim designs may require
special procedures. Consult wheels and tyre manufacturers' service manuals.
NOTICE
1.4. INTENDED USE OF THE MACHINE
This machine must be used only to remove and replace an automotive tyre on an au-
tomotive rim, using the tools with which it is equipped. Any other use is improper and
can result in an accident.
The machine can not work on motorcycle wheels.
1.5. EMPLOYEE TRAINING
1. The employer is obligated to provide a programme to train all employees who service
rim wheels in the hazards involved in servicing those rim wheels and the safety procedures
to be followed. Service or servicing means the mounting and demounting of rim wheels,
and related activities such as inflating, deflating, installing, removing and handling.
• The employer shall insure that no employee services any rim wheel unless the employee
has been trained and instructed in correct procedures of servicing the type of wheel being
serviced, and in safe operating procedures.
• Information to be used in the training programme shall include, at a minimum, the ap-
plicable information contained in this manual.
2. The employer shall ensure that each employee demonstrates and maintains the ability
to service rim wheels safely, including performance of the following tasks:
• Demounting tyres (including deation).
• Inspecting and identifying rim wheel components.
• Mounting tyres.
• Using any restraining device, cage, barrier, or other installation.
• Handling rim wheels.
• Inating the tyre.
• Understanding the necessity to stand back from the tyre changer during tyre ination
and during inspection of the rim wheel following inflation, never leaning over.
• Installing and removing rim wheels.
3. The employer shall evaluate each employee’s ability to perform these tasks and to
service rim wheels safely, and shall provide additional training as necessary to assure
that each employee maintains his or her proficiency.
1.6. PRE-USE CHECKS
Before beginning work, carefully check that all components of the machine, especially rub-

A 9824 TI User Manual 19
ber or plastic parts, are in place, in good condition and working properly. If the inspection
reveals any damage or excessive wear, no matter how slight, immediately replace or repair
the component.
1.7. DURING USE
Intheevent you hearanystrange noise orfeelunusual vibration, ifacomponent or systemisnot
operating properly, or if there is anything unusual at all, stop using the machine immediately.
• Identify the cause and take any necessary remedial action.
• Contact your supervisor if necessary.
Never allow any bystander to be within 20 feet of the machine during operation.
To stop the machine in an emergency:
• disconnect the power supply plug;
• cut off the compressed air supply network by disconnecting the shut-off valve (snap coupling).
2. TRANSPORT, STORAGE AND HANDLING
Conditions for transporting the machine
The tyre changer must be transported in its original packing and stowed in the position shown
on the packing itself.
- Packing dimensions:
• width ................................................................................................................................. 840 mm
• depth .............................................................................................................................. 1140 mm
• height ................................................................................................................................ 970 mm
- Weight with packing: ...................................................................................................kg 288
Machine storage and shipping specifications
Temperature: -25° - +55°C.
Do not stack other goods on top of the packing or damage may result.
NOTICE
Handling
To move the packing, insert the tines of a fork-lift
truck into the slots on the base of the packing itself
(pallet) (Fig. 2b).
Before moving the machine, refer to the HOISTING/
HANDLING section.
2b

20 A 9824 TI User Manual
Keep the original packing in good conditions to be used if the equipment has to be
shipped in the future.
NOTICE
3. UNPACKING/ASSEMBLY
Take the utmost care when unpacking, assembling, hoisting and installing the ma-
chine as described below.
Failure to observe these instructions can damage the machine and compromise the
operator’s safety.
WARNING
- Remove the upper part of the packing and make sure that the machine has not suffered
damage in transit; identify the points at which the machine is anchored to the pallet.
- The machine comprises 3 main units (fig.4):
1 body
2 column with internal tank and mounting head arm
3 box with pressure gauge and standard equipment
4
1
2
3
1/8"