Esco 40802 User manual

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1. PRELIMINARY INFORMATION
This use and maintenance manual, hereafter called “manual”, contains the information needed for use and maintenance of the machine
to which the manual refers.
1.1. WARNING
This manual must be considered an integral part of the machine to which it refers.
The Manual must be stored carefully by the user and must remain with the machine for the entire life of the latter.
1.2.CONFIDENTIALITY
It is forbidden to disclose, even partially, any and all of the contents in this manual to third parties not involved in the use and/or
maintenance of the captioned machine.
1.3.CONDITIONS FOR GUARANTEE VALIDITY
The manufacturer is not responsible for any action or damage caused by:
−improper use of the machine;
−incorrect use of the machine not according to instructions
−faulty supply of any energy or fluid necessary;
−lack of maintenance;
− alterations or unauthorised action, including any for improving safety; any and all actions on the machine must be
agreed with and authorised by the Manufacturer;
−use of non-original spare parts;
− failure to follow the instructions in this manual;
1.4.INFORMATION ON MAINTENANCE ASSISTANCE
For any problem concerning use or maintenance of the machine, you can get information and technical assistance by contacting the
Manufacturer’s head office. When contacting the Manufacturer, please quote all the data shown on the machine identification plate.
1.5.DEFINITIONS OF PERSONNEL QUALIFICATIONS
OPERATOR
This term indicates personnel who are able to operate the machine under normal conditions of use, excluding any and all maintenance
activities. The operator must be an expert tyre repairer and must know how to remove and refit tyres on tyre rims using correct
procedures.
MAINTENANCE MECHANIC
A qualified technician who can work on mechanical parts of the machine in order to carry out adjustments, maintenance work and
repairs as needed to guarantee good machine operation.
MANUFACTURER’S TECHNICIAN
A qualified technician made available by the Manufacturer.
1.6.DESCRIPTION OF PICTOGRAMS
Here is a list of the communication symbols appearing on the machines and in this manual.
This symbol represents a particularly important warning
which if unheeded can cause important damage or
serious danger for persons.
Warns of a very important note the contents of which
must be absolutely taken account of.
Shown when use of the machine
requires a
MAINTENANCE MECHANIC
The operator must wear suitable
working clothes
Shown when use of the machine
requires a
MANUFACTURER’S
TECHNICIAN
Crushing and injury hazard to
hands
It is compulsory to use boots with
non-slip soles and reinforced toe
caps
Work on the machine with more than
one person is prohibited
Hazardous substances It is compulsory to use hand-
protection gloves
Machine adjustment and lubrication
is forbidden with the machine in
operation
Crushing and injury hazards to
feet
It is compulsory to disconnect the
machine supplies (electric, air etc)
Do not remove protections and
safety devices

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2. MACHINE DESCRIPTION
TECHNICAL DATA
Components:
1 – tooth resting on the bead remover;
2 - guide claw resting on the rim;
3 – bead remover body with hose fitting;
5 – oil hose fitting;
Hydraulic working pressure: 700 bar
Maximum hydraulic pressure: 710 bar
Maximum oil supply flow rate 0,7 l/min
Oil content 0,5 l approx.
Uses hydraulic oil type:
MOBIL DTE 11, SHELL TELUS OIL T 15, or equivalent
Weight: kg 6,5
Oil hose fitting 1/7NTP
The actuator uses single effect cylinders.
Operation characteristics
The equipment is designed and built to separate the inside and outside beads
of OTR tyres.
Any other use can cause danger not foreseen by the manufacturer and serious
damage.
Noise
The equipment does not make any noise.
Vibration
The equipment does not cause any vibration.
3. CONDITIONS OF USE AND GENERAL SAFETY WARNINGS
It is indispensable that the user be aware of the indications in this Manual for all the foreseen operations.
3.1.CONDITIONS OF USE
Type of environment Industrial and/or handcraft environment: conforming to general safety standards,
protected against the weather. Professional use.
Environmental temperature From -5 to +40 °C
Environmental relative humidity 20 - 60 %
Altitude From -10 to + 1.000 m above sea level
Lighting level in the area of use Higher than 300 lux
Explosive atmosphere Use of the machine in explosive atmospheres is prohibited
Fire risk The equipment contains inflammable hydraulic oil and must not be used near
sources of heat and open flames.
Electromagnetic fields The machine is not equipped with any electronic devices.
Environment ventilation Ventilated environment conforming with general safety standards
Minimum dimensions of the
installation area At least 2 m radius around the operating position.
Professional capabilities of the user Aged 18 at least
Not disabled
See the various chapters
Supply sources The equipment must be connected to a oil-hydraulic unit with command and
control systems that guarantee safe use. The supply characteristics must not
exceed those shown in the technical data specifications.
Use of the machine under conditions differing from those stated above can be a cause of danger.

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3.2.SAFETY MEASURES
Main warnings on use of the machine
−Any repair or maintenance work on the machine must be done with the machine switched off and disconnected from all
supplies.
−Maintenance, repair and use of the machine must be entrusted to personnel trained for these jobs.
−The user must not, on his own initiative, carry out any operation or action on the machine that is not contemplated in this
manual.
−Use of the machine without the safety systems is absolutely forbidden.
−Do not modify the machine or its parts for any reason at all.
−Ask the manufacturer directly for any modifications to the machine.
In order to reach the above conditions it is necessary that:
−This Manual be available near the machine;
−Only adequately trained persons, with knowledge of the working process in which the equipment is used, be assigned to the
machine
Precautions that can reduce residual hazards
Residual hazards (which cannot be removed using technical solutions) have been identified using conventional symbols. These
symbols are present both on the machine and in the Instruction Manual.
As it is impossible for the Manufacturer to prevent all improper and incorrect use of the machine, any damage to persons and property
due to failure to observe instructions or to incapacity or lack of knowledge on the part of the operators, is to be considered as a
residual hazard, therefore the equipment must be used only by qualified operators.
Risks deriving from incorrect use
The instructions in this Manual, if followed and respected scrupulously by the operators, allow correct use of the machine and
optimisation of its functions.
Any operation differing from those described, carried out on the personal initiative of the operator, must be considered INCORRECT
USE.
Incorrect use of the machine as also the failure to respect accident prevention and safety standards, can determine dangerous
conditions for persons and compromise the integrity of the machine itself.
The extent of the risks deriving from incorrect use is to be considered a consequence of the type of incorrect use and is difficult to
estimate a priori.
Precautions that can prevent human error
To prevent error it is recommended to follow some suggestions, that can be considered forms of prevention meant to limit possible
human error deriving from lack of knowledge of the most suitable procedures for the above mentioned operations:
−Supply of correct information to operators as to safety problems;
−Manipulation of the machine under safe conditions, whether packaged or unpackaged, avoiding collisions and exposure to
corrosive substances;
−Correct use of the machine as to the work to be done;
−Detailed knowledge of the machine operation and of its limits;
−Correct use of the machine under safe conditions.
Forbidden uses
−Use of the machine for functions differing from those for which it was designed and built is absolutely forbidden;
−Use of the machine by personnel whose knowledge, competence and responsibility are not consistent with the required operator
qualification is forbidden;
−Entrusting machine control or maintenance to operators or maintenance personnel with insufficient specific training, even if
provided with adequate general knowledge, competence and responsibility, is absolutely forbidden;
−Replacing worn, damaged or broken parts with spare parts other than the original ones is forbidden;
−Operating the machine with incomplete documentation is forbidden;
− Use of the equipment before completion with a command and control system and components that make it useable under safe
conditions and until the complete assembly has not been declared conforming to the norms of Directive 98/37/CE.

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3.3.INDIVIDUAL PROTECTION DEVICES AND SAFETY DESCRIPTIONS
Operation Risk Individual protection device (IPD) Prescription
Machine handling - injuries to lower limbs;
- injuries to upper limbs.
- working clothes suitable for use in the
environment where the operations take place;
- machine handling gloves that guarantee a firm
and safe hold;
- boots with reinforced toe caps to avoid
crushing;
- hold the machine firmly by the
handles, using gloves that guarantee a
safe hold on the device.
Cleaning and
maintenance on and in
the machine
- injuries to lower limbs;
- injuries to upper limbs;
- ejection of compressed air;
- ejection of compressed oil.
- working clothes suitable for use in the
environment where the operations take place;
- gloves for handling objects with sharp edges
and cleaning and lubrication products;
- boots with reinforced toe caps;
- check also whether other IPDs are needed,
according to the type of operation to be carried
out (see the chapter on Maintenance).
- disconnect the compressed air supply;
- employ specialised personnel (see the
chapter on Maintenance);
Use of the machine - there are risks deriving from
the working environment;
- the equipment works at high
pressure, generating high forces
and danger of explosion;
- feet can be crushed by falling
objects;
- hands can be crushed by
incorrect operation.
- clothing and protection devices as to the
product and the working environment<,
- gloves for handling sharp objects and
lubrication and cleaning products;
- boots with reinforced toe caps to avoid
crushing;
- follow the warnings and instructions
in this manual and the safety
procedures; see instructions for use
- do not modify any machine parts;
- use of the equipment must be limited
to a single person; other persons must
remain at a safe distance of at least 2
m;
- use the equipment within its limits of
performance: maximum hydraulic
pressure 700 bar.

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4. INSTRUCTIONS FOR USE
Important notes
Personnel who are employed to use this machine must be:
- aged 18 at least;
- of healthy and robust constitution.
The machine is designed for use by expert professional tyre maintenance personnel.
4.1.USE OF THE MACHINE
Before use
Before using the machine always check all components. All components must be in perfect condition, there must be no oil leaks, dents
or marks on the cylinder or other parts and no deformation to the levers or the cylinder.
Connect the equipment to an oil-hydraulic system with adequate control systems and with a maximum pressure not higher than 700
bar. A single-effect supply is sufficient as the actuator uses single-effect cylinders.
The pump-control system assembly must be declared conforming, otherwise the equipment cannot be used.
For the connections, use hoses in new and undamaged condition, with a protective sleeve and suitable fittings.
Bead remover connection
Connect the bead remover to the single effect command circuit, with suitable
control systems, using the fittings provided.
The system must operate at a pressure no higher than 700 bar and with a flow
rate no higher than 0.7 l/min.
How to remove the bead
-
Check that the thrusters 3 are pushed back
- Find the insertion notch on the rim and insert the claw 1 into the notch.
- Act on the screw 2 so as to position and lock the bead remover as shown in
the figure.
- Actuate the pump: the two thruster 3 must push on the rim.
- When the rim has moved a few centimetres, insert a shim and then release
the bead remover.
- Reposition the bead remover at another insertion notch and repeat the
operations.
Precautions
The tyre must be completely deflated.
Work only on tyres that are locked in position and cannot rotate or turn, to
avoid uncontrolled movement.
Keep the bead remover always perpendicular as in the figure, to avoid bad
operation.
Hold the bead remover up with one hand and do not leave it simply hooked
on. Any sudden movement of the rim ring can cause the device to fall off the
rim and drop to the ground.
Wear strong gloves and boots with reinforced toe caps.
Keep other personnel at a safe distance of at least 2 m.
4.2.ANOMALIES AND TROUBLE SHOOTING
Anomalies to mechanical parts of the machine such as cracks, fissures, elongation are a sign of excess loads and any parts that show
such anomalies must be replaced and no longer used.
If there is any anomaly, call in the Manufacturer. Acting on the bead remover yourself can be dangerous as the equipment operates at
high pressure and the various components work under high loads. Incorrect assembly can cause serious accidents and injuries.

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5. MACHINE MAINTENANCE
For all maintenance operations we suggest you call in the Manufacturer.
During maintenance operations the machine must be disconnected.
Maintenance programme
Period Action How
8 hours Control of the machine general
conditions.
Inspect the general condition of the machine; all components must be in good conditions and
able to guarantee efficient operation.
Monthly
even if the
machine is
not
operating
Clean the machine and remove
dust.
Vacuum the dust and/or remove with a dry rag; do not use solvents.
If the machine is not in use, start it
for a few minutes and operate the
controls.
Switch the machine on and operate the controls.
3000
hours
Overhaul of all mechanical parts. Check for correct operation of all mechanical components; replace as necessary.
6. HANDLING AND STORAGE
6.1.HANDLING
The machine and its components must be put in a case and carried using the handles on the case. Do not stack the cases.
6.2.STORAGE
The machine must be stored in an area protected against the weather, at a temperature between +10 °C and +40 °C. Do not stack the
packing cases or the equipment.
WARNING!
IF THE EQUIPMENT SUFFERS FALLS, COLLISION OR OTHER ACCIDENTS, IT MUST BE CHECKED CAREFULLY
TO IDENTIFY ANY DAMAGE. IF THE EQUIPMENT IS DAMAGED, IT MUST BE PUT OUT OF SERVICE AND IT
CAN BE USED ONLY AFTER REPAIR. IT IS DANGEROUS TO USE DAMAGED EQUIPMENT.
7. DEMOLITION
If the equipment is demolished, you must follow the procedures dictated by current legislation. In particular, the bead remover must be
drained of oil and this oil must be disposed of separately.