Hunter TCX575 User manual

Operation Instructions
TCX575 Tire Changer
Form 6097-T, 01-12
Supersedes Form 6097-T, 10-09c
©Copyright 2009-2012 Hunter Engineering Company

EC Declaration of Conformity
We herewith declare, HUNTER ENGINEERING COMPANY
11250 Hunter Drive
Bridgeton, Missouri 63044-2391 USA
that the following described machine in our delivered version complies with the appropriate basic safety and health
requirements based on its design and type, as brought into circulation by us. In case of alteration of the machine, not agreed
upon by us, this declaration will lose its validity.
Description of the machine/machinery part Series TCX Tire Changers
Machine type: TCX400 Series
TCX500 Series
TCX600 Series
TCX3000 Series
Serial Number: Various
Applicable EC Directives 2006/42/EC
2006/95/EC
2009/105/EC
86/217/EEC
2004/108/EC
Applicable Harmonized Standards EN ISO 12000-1
EN60204
EN ISO 12000-2
Notified Body according to annex VII Not applicable
(name, address)
Responsible for: Not applicable
Date/Authorized Signature: _________________________ January 06, 2011
Title of signatory: Stephen Hassenfritz
Engineering Administrator
Archives
____________
Mach.-No.

OWNER INFORMATION
Model Number____________________________________________________________________
Serial Number ____________________________________________________________________
Date Installed ____________________________________________________________________
Service and Parts Representative_____________________________________________________
Phone Number ___________________________________________________________________
Sales Representative ______________________________________________________________
Phone Number ___________________________________________________________________
Concept and Procedure Explanation
Safety Precautions Trained Declined
Warning and Caution Labels □□
Bead Press Rollers □□
Maintenance and Performance Checks Trained Declined
Mounting Head Inspection □□
Adjustment and Filling of Oilers □□
Bead Breaking Trained Declined
Standard Wheels □□
Low Profile Wheels □□
Clamping Trained Declined
Steel Jaw Internal/External Clamping □□
Demounting Trained Declined
Standard Wheels with Bead Lever and Plastic Sleeve Protector □□
Operation of Leverless Head to Prevent Head Damage to Tires □□
Bead Lubrication During Removal of Low Profile Tires □□
Reverse Drop Center Wheels □□
Single/Dual Arm Bead Press System Overview □□

Mounting Trained Declined
Standard Wheels □□
Mounting of Stiff, Low Profile Tires □□
Proper Bead Lubrication for Mounting Protection □□
Single/Dual Arm Bead Press System Operation □□
Inflation Trained Declined
Safety Precautions □□
Lubrication and Removal of Valve Core □□
Bead Sealing and Seating □□
Individuals and Date Trained
___________________________________ ___________________________________
___________________________________ ___________________________________
___________________________________ ___________________________________
___________________________________ ___________________________________
___________________________________ ___________________________________
___________________________________ ___________________________________

Contents
1. GETTING STARTED........................................................................................1
1.1 Introduction.................................................................................................................1
1.2 For Your Safety ...........................................................................................................1
Hazard Definitions.................................................................................................. 1
IMPORTANT SAFETY INSTRUCTIONS............................................................... 1
1.3 Control Pedals............................................................................................................. 3
1.4 Wheel Rotation Pedal .................................................................................................4
1.5 Tire Bead Breaker Shovel Pedal (Non-PowerOut versions)................................... 4
1.6 Tire Bead Breaker Shovel - PowerOut Versions......................................................4
1.7 Wheel Clamping Pedal ............................................................................................... 5
1.8 Column Rotation Pedal ..............................................................................................5
1.9 Air Inflation Pedal .......................................................................................................5
1.10 Inflator and Pressure Limiter...................................................................................6
1.11 Mount / Demount Head.............................................................................................6
1.12 Equipment Components ..........................................................................................7
TCX575 Tire Changer Components ...................................................................... 7
Bead Press System (BPS) Components ............................................................... 8
TCX575 Tire Changer Decal Locations ................................................................. 9
2. BASIC PROCEDURES ..................................................................................11
2.1 Bead Breaking...........................................................................................................11
PowerOut Versions .............................................................................................. 11
Non-PowerOut Versions ...................................................................................... 12
2.2 Placing Wheel on Tire Changer...............................................................................13
Clamping the Wheel from Inside of Rim - Steel Rims ......................................... 13
Clamping the Wheel from Outside of Rim - Alloy Rims ....................................... 13
2.3 Demounting Standard Tire from Rim...................................................................... 13
Top Bead Demounting ......................................................................................... 13
Difficult Tires ........................................................................................................ 15
Precautionary Notes ............................................................................................ 17
Bottom Bead Demounting with Tool Head........................................................... 17
Bottom Bead Demounting with Disc .................................................................... 18
Difficult Tires.................................................................................................. 20
Alternate Procedure ............................................................................................. 20
Using the Bead Lever .................................................................................... 20
2.4 Mounting Standard Tire to Rim ...............................................................................22
Mount a standard tire to rim as follows: ............................................................... 22
2.5 Match Mounting ........................................................................................................ 25
2.6 Tire Inflation...............................................................................................................26
2.7 Removal of Wheel from Tire Changer.....................................................................27
3. ADVANCED PROCEDURES .........................................................................28
3.1 Advanced Bead Breaking Procedures....................................................................28
Bead Breaking “AH” Wheels (e.g. BMW M3, M5, Some Porsches, Range Rover,
Lancia, etc.).......................................................................................................... 28
Bead Loosen “AH” Wheels as follows: .......................................................... 28
4. MAINTENANCE, CALIBRATION AND REPLACEMENT PARTS.................31
4.1 Maintenance Schedule.............................................................................................31
4.2 Mount/Demount Head Assembly.............................................................................32
Mount/Demount Head Calibration ....................................................................... 32
Horizontal Adjustment of the Tool Head........................................................ 33
Radial Adjustment of the Tool Head.............................................................. 33
Adjusting the Vertical Gap............................................................................. 34
Adjusting the Horizontal Gap......................................................................... 34
4.3 Replacement Parts....................................................................................................36
5. GLOSSARY....................................................................................................37

5.1 Rim Diagram..............................................................................................................37
5.2 Illustrations of Various Rim Designs......................................................................38

Operation Instructions for TCX575 Tire Changer 1. Getting Started 1
1. Getting Started
1.1 Introduction
This manual provides operation instructions and information required to maintain the
TCX575 tire changer. An advanced operation section has been provided in
“Advanced Procedures,” page 28.
“References”
This manual assumes that you are already familiar with the basics of tire identification
and service. The first section provides the basic information to operate the TCX575.
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. For example, Refer to “Equipment
Components,” page 6. These references should be read for additional information to
the instructions being presented.
The owner of the TCX575 is solely responsible for enforcing safety procedures and
arranging technical training. The TCX575 is to be operated only by a qualified trained
technician. Maintaining records of personnel trained is solely the responsibility of the
owner or management.
The TCX575 is intended for mounting, demounting, and inflating most tires with an
approximate dimension of 40 inches in diameter and 15 inches in width.
1.2 For Your Safety
Hazard Definitions
Watch for these symbols:
CAUTION: Hazards or unsafe practices, which could result in minor
personal injury, product, or property damage.
WARNING: Hazards or unsafe practices, which could result in
severe personal injury or death.
DANGER: Immediate hazards, which will result in severe personal
injury or death.
These symbols identify situations that could be detrimental to your safety and/or
cause equipment damage.
IMPORTANT SAFETY INSTRUCTIONS
Keep all instructions permanently with the unit.
Use equipment only as described in this manual.

2 1. Getting Started Operation Instructions for TCX575 Tire Changer
To reduce the risk of fire, do not operate the equipment in the vicinity of open
containers of flammable liquids (gasoline).
Do not operate the equipment with a damaged cord or if the equipment has been
damaged - until it has been examined by a qualified serviceman.
If an extension cord is necessary, a cord with a current rating equal to or more than
that of the equipment should be used. Cords rated for less current than the
equipment may overheat. Care should be taken to arrange the cord so that it will not
be tripped over or pulled.
Always unplug equipment from electrical outlet when not in use. Never use the cord
to pull the plug from the outlet. Grasp plug and pull to disconnect.
Read and follow all caution and warning labels affixed to equipment and tools. Keep
all decals, labels, and notices clean and visible.
Read and understand all instructions before operating this machine.
Misuse of this equipment can cause personal injury and shorten the life of the tire
changer.
To prevent accidents or damage to the tire changer, use only Hunter recommended
procedures and accessories.
Wear OSHA approved eye protection while operating the tire changer.
Wear non-slip safety footwear when operating the tire changer.
Do not wear jewelry or loose clothing when operating the tire changer.
Wear proper back support when lifting or removing wheels from the tire changer.
WARNING: Keep hands and clothing clear of moving parts.
Do not lean or reach over tire when inflating.
Never stand on the tire changer.
WARNING: Do not exceed these pressure limitations:
• Supply line pressure (from compressor) is 220 psi.
• Operating pressure (gauge on regulator) is 145 psi.
• Bead seating pressure (gauge on hose) is the tire
manufacturer’s maximum pressure as stated on the
sidewall of the tire.
Mixing tire and rim sizes may affect steering, handling, and the braking of the vehicle.
Keep hands and clothing clear of moving parts.
DANGER: Activate air inflation jets only when sealing bead.
Bleed air pressure from system before disconnecting supply line or other pneumatic
components. Air is stored in a reservoir for operation of inflation jets.
WARNING: Only activate the air inflation jets if the rim securing
device is locked in place and the tire is properly
clamped (when possible).

Operation Instructions for TCX575 Tire Changer 1. Getting Started 3
WARNING: Never mount a tire to a rim that is not the same diameter
(e.g., 16 1/2 inch tire mounting on a 16 inch rim).
CAUTION: Do not hose down or power wash electric tire changers.
Do not operate the tire changer with worn, rubber or plastic parts.
Wheels equipped with low tire pressure sensors or special tire and rim designs may
require certain procedures. Consult manufacturer’s service manuals.
Service and maintain machine regularly as outlined in this Manual. For further
information contact:
Hunter Engineering Company
11250 Hunter Drive
Bridgeton, Missouri 63044
800-448-6848
314-731-3020
Internet address: www.hunter.com
1.3 Control Pedals
Control pedals on the TCX575 tire changer are configured as shown below:
PowerOut Version
COLUMN
ROTATION CLAMP
NOTE:
SHOVEL
CONTROLLED
BY
POWEROUT
BUTTONS
TABLE
ROTATION
Non-PowerOut Version
COLUMN
ROTATION CLAMP SHOVEL
TABLE
ROTATION
NOTE: If the unit is equipped with a wheel lift, there is an
additional pedal at the far right upper portion of the face of
the unit.

4 1. Getting Started Operation Instructions for TCX575 Tire Changer
Throughout this manual, control pedals are referred to by the associated symbol.
TABLE ROTATION SHOVEL
(non PowerOut)
CLAMP
COLUMN
R
O
TATI
O
N
1.4 Wheel Rotation Pedal
Step down on the rotation pedal to rotate the wheel clockwise.
Release the pedal to stop rotation. Depressing the pedal halfway rotates
the wheel at slow speed. Depressing the pedal all the way rotates the
wheel at fast speed.
Lift up on the pedal to rotate the wheel counterclockwise. Release the
pedal to stop rotation.
1.5 Tire Bead Breaker Shovel Pedal (Non-PowerOut versions)
WARNING: Keep arms and legs from between the bead breaker arm
and the side of the housing.
Step down on the bead breaker shovel pedal to close bead
breaker arm and loosen bead.
Release the pedal to allow the bead breaker arm to open.
1.6 Tire Bead Breaker Shovel - PowerOut Versions
WARNING: Keep arms and legs from between the bead breaker arm
and the side of the housing.
The PowerOut system provides bead breaking controls on the handle for
convenience, particularly with larger diameter assemblies.
Press the "In" button to close bead breaker arm and loosen bead.
Press the "Out" button to allow the bead breaker arm to open.

Operation Instructions for TCX575 Tire Changer 1. Getting Started 5
1.7 Wheel Clamping Pedal
The wheel clamping pedal has three positions (modes of operation): up
(expand), neutral (stop), and down (retract).
With the clamps in the fully retracted position or clamped against the
outside of a rim, step down fully on the pedal to expand the wheel clamps
(clamps move outward). The clamps continue to expand until contacting
the rim or until fully expanded.
While the clamps are expanding, partially stepping down on the pedal will
stop the clamps. The pedal can also be placed in the stopped position
with the clamps in the fully expanded position. From this stopped position,
additional partial steps on the pedal will incrementally retract clamps.
With the clamps in the fully expanded position or clamped against the
inside of a rim, step down partially on the pedal to retract the wheel clamps
(clamps move inward). To completely retract the clamps, step down fully
on the pedal and the clamps will move completely inward.
Change the position of pedal by briefly stepping down and then releasing.
1.8 Column Rotation Pedal
The column rotation pedal operates the automatic column.
WARNING: Before activating automatic column, make sure the path
of the column is clear of people and other obstructions.
The column tilt pedal has two positions.
With the pedal up, the column rotates toward the operator.
With the pedal down, the column rotates away from the operator.
1.9 Air Inflation Pedal
On the left side of the base, the air inflation pedal operates the two-stage air inflation
system. Refer to illustration on page 6. The pedal controls the air going to the
inflation hose and the air inflation jets.
WARNING: Do not lean or reach over tire when inflating.
CAUTION: Keep hands clear of wheel during sealing and seating of
beads.
When operating air inflator, stand to the left side of the base. Do not stand in front of
the tire changer while operating the air inflator.
Step down partially on the pedal to inflate tires through inflation hose.
Step down completely on the pedal to activate the air inflator jets to seal
tire beads.

6 1. Getting Started Operation Instructions for TCX575 Tire Changer
1.10 Inflator and Pressure Limiter
As a safety device, the pressure limiter prevents the operator from using excessive
air pressure.
Bead seating pressure should never exceed the tire manufacturer’s maximum bead
seating pressure as stated on the sidewall of the tire.
If tires being mounted require more than the tire manufacturer’s maximum bead
seating pressure, the wheel should be removed from the tire changer, placed in an
inflation cage, and inflated per manufacturer’s instructions.
1.11 Mount / Demount Head
The mount/demount head is suspended from the column above the turntable.
The head has a mounting and demounting lip that is designed to install or remove the
bead of tire as the wheel is rotated clockwise.
In addition, the head also incorporates an automatic lever to ease the demounting
process.
MOUNTING
LIP
The mounting
lip is on the left
side of the
head.
DEMOUNTING
LIP
The
demounting lip
is on the right
side of the
head.
A
UTOMATIC LEVER
EXTENDED
AUTOMATIC
LEVER
AUTOMATIC LEVER
RETRACTED
The bead of tire is placed on top of mounting lip during mounting.
The bead of tire is placed on top of demounting lip during demounting.
The automatic lever is placed inside the tire to ease the demounting process.

Operation Instructions for TCX575 Tire Changer 1. Getting Started 7
1.12 Equipment Components
TCX575 Tire Changer Components
HEAD POSITION
LOCK
MOUNT/DEMOUNT
HEAD
INFLATION HOSE
PRESSURE
GUAGE
A
IR RELEASE
BUTTON
BPS VERTICAL
CONTROL
BUTTON
BPS LOCK
RELEASE
BUTTON
BPS DISC
AIR TANK
CLAMP AND AIR
JET (4 PLACES)
MOUNTING
PASTE
BEAD
LOOSENING
ARM AND
SHOVEL
TIRE BEAD
LOOSENING
PEDAL
WHEEL
ROTATION
PEDAL
WHEEL
CLAMPING
PEDAL
COLUMN
ROTATION
PEDAL
BPS UNIT
BPS DISC
BEAD LIFTER
OILER/REGULATOR
TURNTABLE
AIR INFLATION
PEDAL
BEAD PRESS
CLAMP CONES &
EXTENSION
SHOVEL BLADE
POSITION
ADJUSTMENT
PIN
TABLE HEIGHT
ADJUSTMENT
KNOB
(not shown)
BEAD LIFTER
LOCK

8 1. Getting Started Operation Instructions for TCX575 Tire Changer
Bead Press System (BPS) Components
The functional parts of the BPS are:
1. Articulated Arm 6. Demounting/match mounting disc
2. Rim Presser cone 7. Sliding locking lever
3. Control Lever 8. Demounting arm lock
4. Bead presser roller 9. Arm end of travel pin
5. Match mounting lock
7
5
3
1
9
2
4
8
6

Operation Instructions for TCX575 Tire Changer 1. Getting Started 9
TCX575 Tire Changer Decal Locations
No. Part Number Description
1 RP11-4-402023A DECAL-RIM, TABLE, BEAD BREAKER, BEAD AIR PRESSURE
2 RP11-3020482 DECAL-TURNTABLE HEIGHT ADJUSTMENT
3 128-1231-2 DECAL-HUNTER LOGO
4 RP11-4-404470 DECAL-PEDAL OPERATION
5 RP11-4-402030 DECAL-INFLATION PEDAL OPERATION
6 RP11-3020842 DECAL-TABLE ROTATION
7 RP11-4-406883 DECAL-MODEL SERIAL NUMBER
8 RP11-4-402027 DECAL-MAXIMUM INLET PRESSURE
9 RP11-4-402018 DECAL-HUNTER BEAD PRESS SYSTEM
10 RP11-3013640 DECAL-BPS POSITIONING
11 RP11-4-402021 DECAL-MANUAL TIRE BLEED VALVE
12 RP11-4-402038 DECAL-VERTICAL COLUMN LOCK BUTTON OPERATION
13 RP11-4-402028 DECAL-WARNING PRESSUREL IMITATIONS
14 RP11-3016548 DECAL-BPS LOCK
15 RP11-4-402022 DECAL-WARNING OPERATION

10 1. Getting Started Operation Instructions for TCX575 Tire Changer

Operation Instructions for TCX575 Tire Changer 2. Basic Procedures 11
2. Basic Procedures
2.1 Bead Breaking
WARNING: All air pressure inside the tire must be removed before
proceeding. Never attempt to loosen the bead until all
air is removed from the tire. Failure to remove all air
from tire may result in injury to operator, or damage to
equipment, tire, or wheel.
Remove valve stem core to deflate tire completely. Remove all weights from the rim
to protect the rim and extend life of the mount/demount head.
The shovel blade has two-position adjustment. The second position is for wheels 10”
wide and larger, but also may be used to break the beads of extreme low profile tires.
PowerOut Versions
Press the "Out" button to allow the bead breaker arm to open and position the wheel
against the side of the tire changer, between the bead-breaker arm and the housing.

12 2. Basic Procedures Operation Instructions for TCX575 Tire Changer
Press the "In" button to bring the bead breaker arm toward the tire and position the
shovel blade on the sidewall of the tire. Locate the blade close, but not contacting,
the edge of the rim.
Press the "In" button again to close bead breaker arm and loosen bead.
Release the "In" button to disengage the bead-breaker arm and press the "Out"
button to allow the bead breaker arm to open. If the bead has not completely
loosened, rotate the wheel and repeat the bead breaking procedure at a different
area on the tire.
Turn the wheel and break the opposite bead using the same procedure.
Non-PowerOut Versions
Swing the bead-breaker arm out and position the wheel against the side of the tire
changer, between the bead-breaker arm and the housing.
Swing the bead-breaker arm toward the tire and position the shovel blade on the
sidewall of the tire. Locate the blade close, but not contacting, the edge of the rim.
Step down on the bead-breaker shovel pedal .
The bead-breaker arm will be pulled toward the tire changer to loosen the bead.
Release the pedal to disengage the bead-breaker arm and then swing the arm to the
open position. If the bead has not completely loosened, rotate the wheel and repeat
the bead breaking procedure at a different area on the tire.
Turn the wheel and break the opposite bead using the same procedure.