Ravaglioli G1000A99NP User manual

• For any further information please contact your local dealer.
For spare parts drawings refer to the section “ LIST OF COMPONENTS” enclosed to this manual.
GB
INSTRUCTION MANUAL
TRANSLATION FROM THE
ORIGINAL INSTRUCTIONS
G1000A99NP
G800A121NP
7105-M007-0
7105-M007-0 - Rev. n. 0 (07/2017)

7105-M007-0
INSTRUCTIONS FOR
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G1000A99NP - G800A121NP
SUMMARY
SYMBOLS USED IN THE MANUAL
AND ON THE MACHINE _________________ 4
1.0 GENERAL INTRODUCTION _________ 5
1.1 Introduction ___________________________5
2.0 INTENDED USE ____________________ 5
2.1 Training of personnel__________________5
3.0 SAFETY DEVICES __________________ 6
3.1 Residual risks _________________________6
4.0 GENERAL SAFETY RULES _________ 6
5.0 PACKING AND MOBILIZATION
FOR TRANSPORT __________________ 7
6.0 UNPACKING ________________________ 7
7.0 MOBILIZATION_____________________ 8
8.0 WORKING ENVIRONMENT
CONDITIONS _______________________ 8
8.1 Installation space _____________________8
8.2 Lighting _______________________________8
9.0 ASSEMBLY AND PREPARATION
FOR USE ___________________________ 9
9.1 Fixtures contained in the packing _____9
9.2 Assembly procedures on the
tyre-changer __________________________9
10.0 CONTROLS________________________ 13
11.0 USE OF THE LIFTING DEVICE ____ 14
12.0 ROUTINE MAINTENANCE _________ 14
13.0 TROUBLESHOOTING TABLE ______ 15
14.0 TECHNICAL DATA_________________ 15
15.0 STORING__________________________ 15
16.0 SCRAPPING _______________________ 15
17.0 FUNCTIONAL DIAGRAMS _________ 15
Table A - Pneumatic diagram
(G1000A99NP)__________________ 16
Table B - Pneumatic diagram
(G800A121NP)__________________ 18
18.0 LIST OF COMPONENTS

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G1000A99NP - G800A121NP
INFORMATION PLATE LOCATION TABLE
Code numbers of plates
B1541000 Danger plate
B2668000 Wheel lifting device danger plate
999915200 Serial number plate
999916450 Lifting device pedal label
999916880 Max. capacity load 80 Kg plate
IF ONE OR MORE PLATES DISAPPEAR FROM THE MACHINE OR BECOMES DIFFICULT
TO READ. REPLACE IT AND QUOTE ITS/THEIR CODE NUMBER/S WHEN REORDERING.

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SYMBOLS USED IN THE MANUAL AND ON THE MACHINE
Symbols Description
Read instruction manual.
Wear work gloves.
Wear work shoes.
Mandatory. Operations or jobs to
be performed compulsorily.
Danger! Be particularly careful.
Symbols Description
B1541000
General danger.
Wear safety goggles.
Technical assistance necessary.
Do not perform any intervention.
Warning. Be particularly careful
(possible material damages).
Note. Indication and/or useful
information.
Move with fork lift truck or pallet
truck.
Lift from above.

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SOME OF THE PICTURES PRE-
SENT IN THIS MANUAL HAVE
BEEN OBTAINED FROM PICTURES
OF PROTOTYPES, THEREFORE
THE STANDARD PRODUCTION
PARTS AND COMPONENTS OF THE
ACCESSORY CAN BE DIFFERENT
IN SOME COMPONENTS.
1.0 GENERAL INTRODUCTION
This manual is an integral part of the product and
must be retained for the whole operating life of the
accessory.
Carefully study the warnings and instructions con-
tained in this manual. It contains important instruc-
tions regarding FUNCTIONING, SAFE USE and
MAINTENANCE.
KEEP THE MANUAL IN A KNOWN,
EASILY ACCESSIBLE PLACE FOR
ALL OPERATORS TO CONSULT IT
WHENEVER IN DOUBT.
THE MANUFACTURER DISCLAIMS
ALL RESPONSIBILITY FOR ANY
DAMAGE OCCURRED WHEN THE
INDICATIONS GIVEN IN THIS
MANUAL ARE NOT RESPECTED:
AS A MATTER OF FACT, THE NON-
COMPLIANCE WITH SUCH INDI-
CATIONS MIGHT LEAD TO EVEN
SERIOUS DANGERS.
1.1 Introduction
Thank you for preferring this lifting device. We feel
sure you will not regret your decision.
This accessory has been designed for use in profes-
sional workshops and in particular it stands out for
its reliability and easy, safe and rapid operation: with
just a small degree of maintenance and care, this lifting
device will give you many years of trouble-free service
and lots of satisfaction.
2.0 INTENDED USE
The lifting devices G1000A99NP and G800A121NP
are accessories to be assembled as an option on
tyre-changers, and it is intended for use as an aid
during the positioning and removal and of the wheel
(max. 80 kg) from the mandrel.
USING THESE ACCESSORIES
OUTSIDE OF THE INTENDED USE
FOR WHICH THEY HAVE BEEN
DESIGNED (INDICATED IN THIS
MANUAL) IS INAPPROPRIATE AND
DANGEROUS.
THE MANUFACTURER CANNOT
BE HELD RESPONSIBLE FOR ANY
DAMAGE CAUSED BY IMPROPER,
ERRONEOUS, OR UNACCEPTABLE
USE.
AN INTENSIVE USE OF THE EQUIP-
MENT IN INDUSTRIAL ENVIRON-
MENT IS NOT RECOMMENDED.
2.1 Training of personnel
The machine may be operated only by suitably
trained and authorized personnel.
Given the complexity of the operations necessary to
manage the accessory and carry out the operations
safely and efficiently, the personnel must be trained
in such a way that they learn all the information
necessary to operate the machine as intended by the
manufacturer.
A CAREFUL READING OF THIS
INSTRUCTION MANUAL FOR
USE AND MAINTENANCE AND A
SHORT PERIOD OF TRAINING
WITH SKILLED PERSONNEL CAN
BE AN ENOUGH PREVENTIVE
PREPARATION.

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4.0 GENERAL SAFETY RULES
• Any tampering with or modification to the device not
previously authorized by the manufacturer exempts
the latter from all responsibility for damage caused
by or derived from said actions.
• Removing of or tampering with the safety devices or
with the warning signals placed on the machine leads
to serious dangers and represents a transgression of
European safety rules.
• Use of the machine is only permitted in places free
from explosion or fire hazard and in dry places
under cover.
• Original spare parts and accessories should be used.
THE MANUFACTURER DENIES
ANY RESPONSIBILITY IN CASE
OF DAMAGES CAUSED BY UNAU-
THORIZED MODIFICATIONS OR
BY THE USE OF NON ORIGINAL
COMPONENTS OR EQUIPMENT.
• Installation must be conducted only by qualified
personnel exactly according to the instructions that
are given below.
• Ensure that there are no dangerous situations dur-
ing the machine operating manoeuvres. Immediately
stop the lifting device if it miss-functions and contact
the assistance service of an authorized dealer.
• In emergency situations and before carrying out any
maintenance or repairs, disconnect all supplies to
the device by shutting off the pneumatic supply.
• Ensure that the work area around the device is free
of potentially dangerous objects and that there is no
oil since this could damage the tyre. Oil on the floor
is also a potential danger for the operator.
OPERATORS MUST WEAR SUIT-
ABLE WORK CLOTHES, PROTEC-
TIVE GLASSES AND GLOVES,
AGAINST THE DANGER FROM
THE SPRAYING OF DANGEROUS
DUST, AND POSSIBLY LOWER
BACK SUPPORTS FOR THE LIFT-
ING OF HEAVY PARTS. DANGLING
OBJECTS LIKE BRACELETS MUST
NOT BE WORN, AND LONG HAIR
MUST BE TIED UP. FOOTWEAR
SHOULD BE ADEQUATE FOR THE
TYPE OF OPERATIONS TO BE CAR-
RIED OUT.
• The machine handles and operating grips must be
kept clean and free from oil.
3.0 SAFETY DEVICES
PERIODICALLY, AT LEAST MONTH-
LY, CHECK THE INTEGRITY AND
THE FUNCTIONALITY OF THE
SAFETY AND PROTECTION DE-
VICES ON THE DEVICE.
• Fixed guards and shelters.
On the machine are present some permanent protec-
tions that are supposed to avoid potential risks of
getting crushed, cut or pressed.
• Man-operated control (Fig._1 ref._1) makes the
pedal support stop in position after the release of
the drive pedal. This is to make sure that the device
cannot move without the operator’s assent.
• A slot (Fig._1 ref._2) located on the lifting plate al-
lows a partial free travel in return line next to the
floor, avoiding the risk of possible crushing of the foot
in between the pedal support and the floor.
Fig._1
3.1 Residual risks
The device was subjected to a complete analysis of
risks according to reference standard EN ISO 12100.
Risks are as reduced as possible in relation with tech-
nology and product functionality.
This manual stresses possible residual risks, also
highlighted in pictograms on the present manual and
adhesive warning signals placed on the device: their
location is represented in “PLATE LOCATION ON MA-
CHINETABLE” on page 3.

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• The workshop must be kept clean, dry and not
exposed to atmospheric agents. Make sure that the
working premises are properly lit.
The machine can be operated by a single operator.
Unauthorized personnel must remain outside the
working area, as shown in Fig._2.
Avoid any hazardous situations. Do not use air-
operated or electrical equipment when the shop is
damp or the floor slippery and do not expose such
tools to atmospheric agents.
• When operating and servicing this device, carefully
follow all in force safety and accident-prevention
precautions.
The device must not be operated by professionally
unskilled persons.
IN CASE OF A CHANCE SUPPLY
FAILURE (COMPRESSED AIR),
MOVE THE PEDALS TO THE NEU-
TRAL POSITION.
5.0 PACKING AND MOBILIZATION FOR
TRANSPORT
HAVE THE MACHINE HANDLED BY SKILLED
PERSONNEL ONLY.
THE LIFTING EQUIPMENT MUST WITHSTAND
A MINIMUM RATED LOAD EQUAL TO THE
WEIGHT OF THE PACKED DEVICE (SEE PARA-
GRAPH “TECHNICAL SPECIFICATIONS”).
The wheel lifting device is packed in a cardboard box
having the dimensions of 900x300x500.
Movement must be by pallet-lift or fork-lift trolley.
6.0 UNPACKING
DURING UNPACKING, ALWAYS
WEAR GLOVES TO PREVENT ANY
INJURY CAUSED BY CONTACT
WITH PACKAGING MATERIAL
(NAILS, ETC.).
The cardboard box is supported with plastic strapping.
Cut the strapping with suitable scissors. Use a small
knife to cut along the lateral axis of the box and open
it like a fan.
It is also possible to unnail the cardboard box from
the pallet it is fixed to. After removing the packing,
and in the case of the device packed fully assembled,
check that the device is complete and that there is no
visible damage.
If the device is packed dismantled into its principal
parts, after removing the packing, lay the individual
parts on the floor and check them for any missing
components, damage, or irregularity.
If in doubt do not use the device and refer to profes-
sionally qualified personnel (to the seller).
The packing (plastic bags, expanded polystyrene, nails,
screws, timber, etc.) should not be left within reach
of children since it is potentially dangerous. These
materials should be deposited in the relevant collec-
tion points if they are pollutants or non biodegradable.
THE BOX CONTAINING THE FIX-
TURES IS CONTAINED IN THE
WRAPPING. DO NOT THROW IT
AWAY WITH THE PACKING.

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7.0 MOBILIZATION
THE LIFTING EQUIPMENT MUST WITHSTAND
A MINIMUM RATED LOAD EQUAL TO THE
WEIGHT OF THE DEVICE (SEE PARAGRAPH
TECHNICAL SPECIFICATIONS). DO NOT AL-
LOW THE LIFTED DEVICE TO SWING.
If the device has to be moved from its normal work
post, the movement must be conducted following the
instructions listed below.
• Protect the exposed corners with suitable material
(Pluribol/cardboard).
• Do not use metallic cables for lifting.
• Disconnect all machine power supply sources.
• Lift and transport with suitable device with adequate
dimensions.
8.0 WORKING ENVIRONMENT CONDI-
TIONS
The device must be operated under proper conditions
as follows:
• temperature: 0° + 55° C
• relative humidity 30 - 95% (dew-free)
• atmospheric pressure: 860 - 1060 hPa (mbar).
The use of the device in ambient conditions other than
those specified above is only allowed after prior agree-
ment with and approval of the manufacturer.
8.1 Installation space
Fig. 2
USE THE DEVICE INDOORS OR IN A ROOFED
AREA. PLACE OF INSTALLATION MUST BE
DRY, ADEQUATELY LIT AND IN COMPLIANCE
WITH APPLICABLE SAFETY REGULATIONS.
The installation of the lifting device for wheel need
a useful space, on the side of the machine, of mm
600x1000 (as indicated in Fig._2) through the broken
line.
The operator must be able to see the entire equipment
and the surrounding area from the control position. He
must prevent unauthorized personnel or objects that
could be dangerous from entering the area.
8.2 Lighting
The machine does not require its own lighting for
normal working operations. However, it must be used
in an adequately lit environment.
In case of poor lighting, use lamps having total power
800/1200 Watt as envisaged by UNI 10380.

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9.0 ASSEMBLY AND PREPARATION FOR
USE
After having freed the various components from the
packing check that they are complete, and that there
are no anomalies, then comply with the following in-
structions for the assembly of the components making
use of the attached series of illustrations.
9.1 Fixtures contained in the packing
The packing case contains also the fixtures box. Check
that all the parts listed are there.
Only for G1000A99NP model
Code Description N.
228501 M8 flange nut 2
710592000 Lifting device pedalboard unit 1
B1367300 TBEI M8x16 screw 2
710591930 Lifting device assembly unit 1
272038 TE M8x25 screw 4
228506 M8 flange nut 4
317022 Black Elastolan pipe 8x6
L=1600
1
317022 Black Elastolan pipe 8x6
L=1200
1
317022 Black Elastolan pipe 8x6
L=1000
1
Only for G800A121NP model
Code Description N.
730094930 Lifting device pedal unit 1
730024310 Pin 1
299052 Retainer ring D.9 2
730094750 Lateral lifting device assembly
unit
1
203193 TE M10x30 screw 4
228012 M10 self-locking nut 4
317022 Black Elastolan pipe 8x6
L=1200
1
317022 Black Elastolan pipe 8x6
L=1000
1
317007 Black rilsan pipe 8x6 L=100 1
9.2 Assembly procedures on the tyre-
changer
Only for G1000A99NP model
1 - Place the lifting device that is assembled next to the
tyre-changer on which it will be installed.
2 - Prepare and arrange near the screws and the ac-
cessories, which are necessary for fixing the lifting
device to the tyre-changer.
3 - After making sure the tyre-changer is insulated
from its power supply sources, proceed with the
fastening of the lifting device.
4 - Remove the lateral guard (Fig._3 ref._1) unscrewing
the screws (Fig._3 ref._2).
Fig. 3
5 - Unscrew screws (Fig._4 ref._1), nuts (Fig._4 ref._3)
and remove the closing plate (Fig._4 ref._2).
Fig. 4

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6 - Place the pedal support (Fig._5 ref._1)(#
710592000) from the inside next to hole left free.
Then fix with screws (Fig._5 ref._2)(# B1367300)
and nuts (Fig._5 ref._3)(# 228501), on issue.
Fig. 5
7 - Fix the lifting device (Fig._6 ref._1) (# 710591930)
to the tyre changer using screws (Fig._6 ref._2)
(# 272038) and nuts (Fig._6 ref._3) (# 228506),
on issue.
Fig. 6
8 - Fix the three pneumatic pipes (Fig._7 ref._1-2-3)
to the pedalboard, to the lifting cylinder and to the
machine as indicated in the figure.
- Pipe coming from the filter unit - pressure reducer
(# 317022) (L=1600 mm) (Fig._7 ref._1).
- Pipe coming from lifting device's cylinder (#
317022) (Fig._7 ref._2) (L= 1200 mm) (high
union).
- Pipe coming from the lifting device's cylinder (#
317022) (Fig._7 ref._3) (L= 1000 mm) (low
union).
BEFORE CONNECTING THE PIPES
(FIG. 7 REF. 2-3) MAKE SURE
THEY PASS THROUGH THE RUB-
BER FAIRLEAD (FIG. 7 REF. 4).
Fig. 7
Fig. 8
FASTEN THE PIPES AS SHOWN
IN FIG. 8, IN ORDER TO AVOID
THAT THEY INTERFERE WITH
THE BELT.