Corghi ProLine 124 User manual

Cod. 4-135703 - 05/2018
Italiano Manuale d’uso 2
English Operator’s manual 82
Français Manuel d’utilisation 162
Deutsch Betriebsanleitung 242
Español Manual de uso 322
Tel. ++39 0522 639.111 - Fax ++39 0522 639.150
www.corghi.com - [e-mail]
ProLine
124 (No CE) - 221 -
321 - 324

82 ProLine 124-221-321-324 Operator manual
TRANSLATION FROM THE ORIGINAL LANGUAGE
Copyrighted material. All rights reserved.
The included information may be changed without notice.
Thank you for selecting our tyre changer
CORGHI
Dear Customer,
Thank you for purchasing a Corghi equipment.
Your machine has been designed to provide years of safe and reliable service, as long
as it is used and maintained in accordance with the instructions provided in this manual.
Anyone using and/or carrying out maintenance on this equipment must read, understand
and follow all warnings and instructions provided in this manual, and be properly trained.
This Instruction Manual should be considered an integral part of your equipment and
should remain with the equipment. However, nothing in this manual, and none of the
devices installed on the equipment, can replace proper training, correct operation, careful
evaluation of procedures and safe working practices.
Always be sure that your equipment is in excellent working order. In case any malfunction
or possible dangerous situation are observed, immediately shut down the machine and
resolve the situation before you proceed.
For any question related to the correct equipment use or maintenance, contact your
local official Corghi dealer.
Sincerely,
Corghi
USER INFORMATION
User
Name _____________________________________________________________________
User
Address ___________________________________________________________________
Model
number____________________________________________________________________
Series
number____________________________________________________________________
Date of
purchase___________________________________________________________________
Date of
installation_________________________________________________________________
Spare parts
and service manager ________________________________________________________
Telephone
number____________________________________________________________________
Commercial
manager ___________________________________________________________________
Telephone
number____________________________________________________________________

ProLine 124-221-321-324 Operator manual 83
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TRAINING CHECK
Qualified Rejected
Safety measures
Warning and caution labels
High risk areas and other potential hazards
Operative safety procedures
Checking maintenance and performance
Head mounting inspection
Adjustment and lubrication
Clamping
Steel/alloy rims
Reversed channel rims
Internal/external locking with steel jaws
Bead breaking
Standard wheels
Low profile wheels
Demounting
Standard wheels with plastic guards for tool head and lever
Proper tool head positioning to avoid damage
Bead lubrication when removing the low profile tyres
Reverse rims
Mounting
Standard wheels
Mounting of stiff, low profile tyres
Wheels with reversed channel rim
Bead lubrication for proper mounting
Inflating procedure
Safety measures
Lubrication and removal of the valve insert
Tubeless tyre inflation

84 ProLine 124-221-321-324 Operator manual
Personnel and training dates
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

ProLine 124-221-321-324 Operator manual 85
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Table of contents
1. COMMISSIONING......................................................................................87
1.1 INTRODUCTION....................................................................................87
1.1.a. PURPOSE OF THE MANUAL ...........................................87
1.2 FOR YOUR SAFETY...............................................................................87
1.2.a. GENERAL WARNINGS AND INSTRUCTIONS.................88
1.2.b. LABELS PLACEMENT........................................................91
1.2.c ELECTRICAL AND PNEUMATIC CONNECTIONS.............. 97
1.2.d TECHNICAL DATA...............................................................99
1.2.e. AIR PRESSURE..................................................................100
1.3. ADDITIONAL RIM/TYRE INFORMATION.........................................101
1.4. INTENDED MACHINE USE...............................................................101
1.5. PERSONNEL TRAINING....................................................................101
1.6. PRELIMINARY CHECKS.....................................................................102
1.7. DURING USE......................................................................................102
1.8. OPTIONAL ACCESSORIES.................................................................102
2. TRANSPORT, STORAGE AND HANDLING...............................................103
3. UNWRAPPING..........................................................................................104
4. MOUNTING..............................................................................................105
5. LIFTING/HANDLING.................................................................................107
5.1 INSTALLATION AREA.........................................................................108
6. DESCRIPTION OF THE MACHINE...........................................................109
6.1. OPERATOR POSITION.......................................................................110
7. OVERALL DIMENSIONS (mm) ...............................................................110
8. MAIN WORKING ELEMENTS OF THE MACHINE...................................111
9. BASIC PROCEDURES - USE....................................................................115
9.1. PRELIMINARY CHECKS....................................................................116
9.2. DECIDING FROM WHICH SIDE OF THE WHEEL THE TYRE
MUST BE REMOVED................................................................................116
9.3. BEAD BREAKING...............................................................................117
9.4. CLAMPING THE WHEEL....................................................................119
9.5. WHEEL DEMOUNTING......................................................................123
9.5.a. TOOL HEAD POSITIONING (PROLINE 324-321)..........123
9.5.b. TOOL HEAD POSITIONING (PROLINE 124-221).........123
9.5.c. WHEEL DEMOUNTING...................................................124
9.6. WHEEL MOUNTING...........................................................................126
9.7 APPROVED UHP AND RUN FLAT TYRE DEMOUNTING AND
MOUNTING PROCEDURE........................................................................127
9.8. TYRE INFLATION................................................................................127
9.8.A. SAFETY INDICATIONS.....................................................127
9.8.B. TYRE INFLATION..............................................................129

86 ProLine 124-221-321-324 Operator manual
9.8.C. SPECIAL PROCEDURE.....................................................129
10. INSTALLATION AND USE OF HELPER ACCESSORY............................132
10.1. HTB 21- HTB 24................................................................................132
10.1.A.INSTALLATION................................................................132
10.1.B. CALIBRATION..................................................................133
10.1.C. TECHNICAL DATA..........................................................134
10.1.D. FUNCTIONAL PARTS.....................................................134
10.1.E. LABELS PLACEMENT.....................................................134
10.1.F. TYRE MOUNTING/DEMOUNTING................................135
10.2. HSU 24...............................................................................................137
10.2.A. INSTALLATION...............................................................137
10.2.B. TECHNICAL DATA..........................................................138
10.2.C. FUNCTIONAL PARTS......................................................139
10.2.D. LABELS PLACEMENT....................................................139
10.2.E. TYRE MOUNTING/DEMOUNTING...............................140
10.3. HSA 21...............................................................................................141
10.3.A. INSTALLATION...............................................................141
10.3.B. TECHNICAL DATA..........................................................141
10.3.C. FUNCTIONAL PARTS......................................................141
10.3.D. LABELS PLACEMENT....................................................142
10.3.E. TYRE MOUNTING/DEMOUNTING...............................143
11. TROUBLESHOOTING.............................................................................145
12. MAINTENANCE......................................................................................147
13. SCRAPPING............................................................................................150
14. ENVIRONMENTAL INFORMATION........................................................150
15. INFORMATION AND WARNINGS ABOUT OIL.......................................151
16. FIREFIGHTING EQUIPMENT TO BE USED..........................................152
17. GLOSSARY.............................................................................................153
18. GENERAL WIRING DIAGRAM ..............................................................157
19. PNEUMATIC SYSTEM DIAGRAM .........................................................160

ProLine 124-221-321-324 Operator manual 87
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1. COMMISSIONING
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, in order to provide the customers with any necessary safety
information, please ask the new owner to complete and return to the manufacturer the
ownership transfer form attached to the previous page of this manual. Alternately, the new
owner can send an email to [email protected].
This manual presumes that the technicians have a thorough understanding of rims and
tyre identification and maintenance. 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 explains the basic information regarding the equipment. The
following sections contain detailed information regarding the equipment, procedures and
maintenance. Italics are used to refer to specific parts of this manual that offer additional
information or clarifications. These references must be read in order to obtain information
additional to the instructions provided. The owner of the equipment is solely responsible
for enforcing safety procedures and arranging technical training. The equipment must
only be used by qualified, specifically trained technicians. The owner or management
is exclusively responsible for storing the documentation relative to qualified personnel.
The equipment is designed for mounting, demounting and inflating tyres for light vehi-
cles (cars, motorcycles, not trucks) with a maximum external diameter of 43 inches and a
maximum width of 14 inches.
Additional copies of this manual and the documentation enclosed with the machine can
be requested from the manufacturer, specifying the machine type and serial number.
WARNING: Design details are subject to change. Some illustrations may vary slightly in
appearance from the machine you have.
1.2 FOR YOUR SAFETY
DESCRIPTION OF THE HAZARD
These symbols identify situations that could be detrimental to your safety and/or cause
equipment damage.
DANGER: It indicates an imminent dangerous situation that, if not
avoided, could lead to serious injury or death.
DANGER

88 ProLine 124-221-321-324 Operator manual
WARNING: It indicates a potentially dangerous situation that, if not
avoided, could lead to serious injury or death.
WARNING
CAUTION: It indicates a potentially dangerous situation that, if not
avoided, could cause slight or mild injuries.
CAUTION
WARNING: Used without the safety hazard symbol indicates a potential situation
of hazard that, if not avoided, could cause material damage.
WARNING
1.2.a. GENERAL WARNINGS AND INSTRUCTIONS
Proceed with caution to prevent any injuries. Carefully read, understand and follow
the warnings and instructions given in this manual. This manual is an integral part of
the product. For future reference, store it together with the machine in a safe place.
WARNING
1. Accidents could occur if the maintenance procedures described in this manual are not
executed correctly, or if the other instructions it contains are not observed. This manual
makes continuous reference to the possibility that accidents can occur. Any accident
could lead to serious or fatal injuries to the operator or people nearby, or cause material
damage.
2. Overinflated tyres can explode, producing hazardous flying debris that may result in
an accident.
3. Tyres and rims that do not have the same diameter “do not correspond”. Never attempt
to mount or inflate tyres and rims that do not correspond. For example, never mount a
16.5” tyre on a 16” rim and vice versa. It is very dangerous. Tyres and rims that do not
correspond could explode and cause accidents.
4. Never exceed the inflation pressure for the tyre indicated by the manufacturer on the
side of the tyre itself. Carefully check that the air hose is well inserted in the valve

ProLine 124-221-321-324 Operator manual 89
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5. Never bring your head or other
body parts close to a tyre
during inflation or bead inser-
tion operations. This machine
is not a safety device against
the possible risk of explosion
of tyres, air chambers or rims.
6. Keep a safe distance from the
tyre changer during inflation,
in order to remain outside the
vertical cylinder area occupied by the wheel. Do not approach it.
A bursting tyre can cause projections of its parts in surrounding areas with a force
sufficient to cause serious injury or death.
Do not mount a tyre if its dimensions (indicated on the side) do not correspond
exactly to the rim dimensions (printed inside the rim) or if the rim or the tyre is
defective or damaged.
Never exceed the pressure recommended by the tyre manufacturer.
The tyre changer is not a safety device and does not prevent tyres and rims from
exploding. Keep all persons not working on the machine out of the working area.
DANGER
7. Risk of crushing. Presence of moving parts. Contact with moving parts can cause acci-
dents.
The machine can only be used by one operator at a time.
฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀demounting and mounting process.
฀฀฀฀฀฀฀฀฀฀-
eration.
฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀the lever
8. Danger of electric shock.
฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀cable.
฀฀฀฀฀฀฀฀฀฀฀฀฀฀or greater than those of the machine. Cables with rated features that
are lower than those of the machine could overheat and cause a fire.

90 ProLine 124-221-321-324 Operator manual
฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀tripping is avoided.
9. Risk of eye injuries. During the bead insertion and inflation phase,
debris, dust and fluids could be projected into the air. Remove
any debris present on the tyre tread and on the tyre surface. Wear
protectivegoggleswithOSHA,CE approvalorothercertifieddevices
during all work phases.
10. Always carefully inspect the machine before using it. Missing,
damaged or worn equipment (including the hazard adhesive labels) must be repaired
or replaced before start-up.
11. Never leave nuts, bolts, tools or other materials on the machine. They could be
entangled in moving parts and cause malfunctions or be ejected.
12. Do NOT mount or inflate tyres that are cut, damaged, decayed or worn. Do NOT mount
tyres on damaged, bent, rusted, worn, warped or deformed rims.
13. Should the tyre get damaged during the mounting phase, do not try to complete
the mounting operation. Remove it, take it away from the service area and mark it as
damaged.
14. Inflatetyresingradualsteps,whilecontinuouslymonitoringthepressureandobserving
the tyre itself, the rim and the bead. NEVER exceed the pressure limits indicated by
the manufacturer.
15. The internal parts in this equipment could create contacts or sparks if exposed to
flammable vapours (petrol, paint thinners, solvents, etc.). Do not install the machine
in a narrow area or position it below floor level.
16. Do not operate the machine while under the influence of alcohol, medicines and/or
drugs. If you are taking prescription or non-prescription medicines, contact a physician
to be aware of the side effects that they might have on the ability to operate the
machine safely.
17. Always use OSHA, CE approved and authorised personal protective
equipment (PPE) or equipment with equivalent certifications while
operating the machine. Consult your supervisor for additional
instructions.
18. Do not wear jewellery, watches, loose clothing, ties and tie up long
hair before using the machine.
19. Wear protective, non-slip footwear while using the tyre changer.
20. While positioning, lifting or removing wheels from the tyre changer,
wearan appropriatebacksupportandusea correctliftingtechnique.
21. Onlyappropriatelytrainedpersonnelcanuse,serviceand repairthe
machine. Repairs must only be performed by qualified personnel.
Manufacturer technicians are the most qualified individuals. The
employer must determine if an employee is qualified to carry out
any machine repair safely if the operator has attempted to make
the repair.

ProLine 124-221-321-324 Operator manual 91
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22. Before starting the machine, the operator must pay close attention to the warnings
of the adhesive labels affixed to the equipment.
23. Disconnecting the pneumatic supply, both due to non-use or to maintenance of the
machine or the pneumatic system of the workshop, can leave pneumatic actuators
under pressure. Discharge the machine pneumatic system using the controls on the
actuators.
24. Use a lifting device if the wheel weighs more than 10 kg, with a
lifting frequency of more than 20 wheels/hour.
1.2.b. LABELS PLACEMENT
No. Part Number Drawing Description
1 4-136038 LABEL, CORGHI LOGO
FRONT
2 461236 LABEL, CORGHI LOGO
LATERAL
3
4-135683 LABEL, PROLINE 124
4-135682 LABEL, PROLINE 221
4-135681 LABEL, PROLINE 321
4-135680 LABEL, PROLINE 324
4 446429 LABEL,OPERATINGPRESSURE
5 446442
LABEL, DANGER - PRESSUR-
ISED CONTAINER
6 4-113355 LABEL, FILTER

92 ProLine 124-221-321-324 Operator manual
No. Part Number Drawing Description
7 446598 LABEL, SWITCH OFF THE
POWER
9 418135 LABEL, ROTATION DIRECTION
10 446433 LABEL,DANGER-TURNTABLE
11 446435 LABEL, DANGER - TOOL HEAD
12 446434
LABEL, RISK OF INJURY, REAR
POLE,DONOTSTANDBEHIND
THE MACHINE
13A 461931 LABEL, DANGER OF INFLA-
TION
13B 462778
LABEL, DANGER OF INFLA-
TION (ONLY AMERICAN MAR-
KET)
13C 432740
LABEL, DANGER OF INFLA-
TION (ONLY AMERICAN MAR-
KET)
14 435150
LABEL, INFLATION PEDAL
(only 124 TI - 321 TI -
324 TI)
16 446388 PLATE, CORRECT POWER
SUPPLY
17 446431
LABEL, HAND CRUSHING
HAZARD (IF BEAD BREAKER
IS PRESENT)

ProLine 124-221-321-324 Operator manual 93
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No. Part Number Drawing Description
21 425211 LABEL, DANGER OF ELECTRIC
SHOCK
22 446436 LABEL, DOYFE UNION
23 -
ISO9001
Code
Serial N.
X-XXXXXXXX/XX - XX
XXXXXXXXX
QUAL. SYS. CERTIFIED
ANNO DI COSTRUZIONE /
MANUFACTURED
Mod.
V
A
kW
Hz
Ph
bar/psi
LABEL, MODEL SERIAL NUM-
BER
24
463509 LABEL, COLUMN TILTING
439213 LABEL, TURNTABLE OPEN-
ING/CLOSING
439212 LABEL, BEAD BREAKER AC-
TIVATION
439214 LABEL, ROTATION
TURNTABLE
25 35017099 LABEL, RISK OF IMPACT,
FRONT POLE
26 462081A RISK OF CRUSHING HANDS
27 450005
WARNING POSTER ENGLISH/
FRENCH (ONLY AMERICAN
MARKET)
28 4-136235 LABEL 2 POSITIONS
HANDLE

94 ProLine 124-221-321-324 Operator manual
1
2
3
4
5
6
7
9
10
11
12
13A
14 16
17
21
22
23
24
25
26
25 12
11
10
ProLine 324
ProLine 321
12 12
25 25
5
6
23
1
3
24
2
4
7
21
9
16
17
26
11
11
10
13A 10
28
28

ProLine 124-221-321-324 Operator manual 95
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13B
13C
ProLine 221
ProLine 124
2
24
2
7
21
41
3
3
13A 10 10
26
17
17
16
11
9
22
21
4
7
1
24
9
16
26
5
6
23
10
11
13B
10
14
27
5
6
23

96 ProLine 124-221-321-324 Operator manual
HAZARD LABELS KEY
part n. 446431. Risk of bead breaker crushing.
part n. 446442. Danger - pressurised container.
part n. 425211A. Danger of electric shock.
part n. 461931. Inflation hazard.
part n. 462778. Inflation hazard (for North America market).
part n. 432740. Inflation hazard (for North America market).

ProLine 124-221-321-324 Operator manual 97
UK
part n. 446433. Risk of crushing hands.
part n. 446434. Risk of pole tilting.
part n. 446435. Risk of crushing hands.
part no. 35017099 Risk of front pole tilting
part n. 425083. Earth ground terminal.
part n. 446237. Earth ground terminal.
part n. 462081A. Risk of crushing hands.
450005. WARNING POSTER OF SAFETY. It must be applied close
to the tyre changer in a position visible to the operator.
1.2.c. ELECTRICAL AND PNEUMATIC CONNECTIONS
A good earth connection is essential for correct operation of the machine.
WARNING
The electric connection used must be suitably sized:
฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀
฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀

98 ProLine 124-221-321-324 Operator manual
ensure that the voltage drop under full load does not
exceed 4% (10% during
start-up)oftheratedvoltagevaluespecifiedontheplate
- The user must:
฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀- A, Fig. 2 - equipped with a differential automatic
฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀฀sockets.
Make sure that the available pressure and performance of the compressed air system are
compatible with what is necessary for correct machine operation - see
the section “Technical data”. For the correct operation of the machine, the pneumatic
supply line must provide a pressure range from a minimum of 8 bar to a maximum of 16 bar.
For correct equipment operation, the air produced must be suitably treated (not
above 5/4/4 according to standard ISO 8573-1).
WARNING
Check that the lubrication cup (B, Fig. 2a contains
฀฀฀฀฀฀฀฀The pneumatic supply inlet point, in the workshop
line, must be equipped with a pneumatic supply
shut-off valve, placed upstream the filter/regulator
unit supplied with the machine (B Fig. 2a).
2
A
B
2a
ISO9001
Code
Serial N.
X-XXXXXXXX/XX - XX
XXXXXXXXX
QUAL. SYS. CERTIFIED
ANNO DI COSTRUZIONE /
MANUFACTURED
Mod.
V
A
kW
Hz
Ph
bar/psi
1

ProLine 124-221-321-324 Operator manual 99
UK
Before proceeding with the electrical and
pneumatic connection and whenever the
electrical and pneumatic power supply is
restored, make sure that the machine is in
the configuration
described below:
- pedal A COMPLETELY LOW
(turntable E closed).
ONLY FOR VERSIONS WITH TILTING POLE:
- pedal B COMPLETELY LOW
(pole C not tilted).
DANGER
1.2.d TECHNICAL DATA
- Turntable locking
ProLine 221 - ProLine 321
- internal ..........................................................................................................from 12” to 23”
- external .........................................................................................................from 10” to 21”
ProLine 124 (standard position) - ProLine 324
- internal ..........................................................................................................from 14” to 28”
- external .........................................................................................................from 12” to 26”
-Power supply voltage
- single-phase..................................................................................115-230±10%Volt 50/60Hz
- three-phase...................................................................................230-400±10%Volt 50/60Hz
- DV.................................................................................................. 230±10%Volt 1ph 50/60Hz
- Rim width - ProLine 221 - ProLine 124...........................................................from 4” to 13”
- Rim width - ProLine 321 .................................................................................. from 4” to 14”
- Rim width - ProLine 324 .................................................................................. from 4” to 16”
- Maximum wheel diameter - ProLine 221 .......................................................940 mm (37”)
- Maximum wheel diameter - ProLine 321 - ProLine 324..............................1120 mm (44”)
- Maximum wheel diameter - ProLine 124......................................................1250 mm (49”)
- Maximum opening of bead breaker ProLine 124 - 221 - 321: 75 mm (3”) / 330 mm (13”)
- Maximum opening of bead breaker ProLine 324: ................100 mm (4”) / 400 mm (16”)
-Bead breaking force .....................................................................15000 N (pressure 10 bar)
- Operating pressure ..................................................................................................8 - 10 bar
- Air consumption (TI version.................................180 Nl/min (average) 764 Nl/min (max)
- Air consumption (NON-TI version.......................155 Nl/min (average) 520 Nl/min (max)
- Weight - ProLine 321 ....................................................................295 kg (310 kg TI version)
- Weight - ProLine 221 .....................................................................................................223 kg
B
A
C

100 ProLine 124-221-321-324 Operator manual
- Weight - ProLine 324 .................................................................... 239 kg (255 kg TI version)
- Weight - ProLine 124 ..................................................................................................... 235 kg
- Noise level when operating ................................................................................... 70 dB (A)
Motor rating kW Number of
rpm Torque Nm
Weight of electric/
electronic part kg
400Volt/3ph 50Hz DV 0,75 6,5-13 1100 12
400Volt/3ph 50Hz 0,75 6,5 1100 7,5
200/230Volt/3ph 60Hz 0,75 6,5 1070 7,5
200/230Volt/3ph 50Hz 0,75 6,5 1070 7,5
200/230Volt/1ph 60Hz 1,1 6,5 980 13,6
200/230Volt/1ph 50Hz 1,1 6,5 980 13,6
110/115Volt/1ph 60Hz 1,1 61000 14,5
The noise levels indicated correspond to emission levels and do not necessarily represent
safe operating levels. Although emission levels and exposure levels are connected, this
relation cannot be used as a safe parameter to determine whether or not further precautions
are necessary. The noise level to which the operator is exposed to depends on a number of
factors, such as duration of exposure, characteristics of the workplace, other sources of noise
etc. Permissible noise exposure levels may also vary from country to country. In all cases,
this information will enable machine users to better assess the danger and risks involved.
1.2.e. AIR PRESSURE
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DANGER
The machine is equipped with an internal pressure limiting valve to minimize the risk of
over inflating the tyre.