Ravaglioli G1150.30MAGICIT User manual

INSTRUCTION MANUAL
For spare parts drawings refer to the section “ LIST OF COMPONENTS” enclosed to this manual.
• For any further information please contact your local dealer or call:
GB TRANSLATION FROM THE
ORIGINAL INSTRUCTIONS
Technical services: RAVAGLIOLI S.p.A. - Via 1° Maggio, 3 - 40037 Pontecchio Marconi - Bologna Italy
Phone [phone] - Telex 510697 RAV I - Fax [phone] - e-mail: [email protected]
G1150.30MAGIC
G1150.30MAGICIT
7107-M001-0_R - Rev. n. 0 (04/2010)
7107-M001-0_R

GB
Page 2 of 32
INSTRUCTION, USE AND
MAINTENANCE MANUAL G1150.30MAGIC - G1150.30MAGICIT
RAVAGLIOLI S.p.A.
7107-M001-0_R
SUMMARY
SYMBOLS USED IN THE MANUAL AND
ON THE MACHINE ______________________ 4
1.0 GENERAL INTRODUCTION ________ 6
2.0 INTENDED USE ____________________ 6
2.1 Training of personnel __________________ 6
3.0 SAFETY DEVICES _________________ 6
3.1 Residual risks __________________________ 6
4.0 GENERAL SAFETY RULES _________ 7
5.0 PACKING AND MOBILIZATION
FOR TRANSPORT __________________ 8
6.0 UNPACKING _______________________ 8
7.0 MOBILIZATION ____________________ 9
8.0 WORKING ENVIRONMENT CONDI-
TIONS _____________________________ 9
8.1 Work position __________________________ 9
8.2 Installation space ______________________ 9
9.0 ANCHORING SYSTEM ____________ 10
10.0 ASSEMBLY AND PREPARATION
FOR USE __________________________ 10
10.1 Accessories contained in the packing _ 10
10.2 Assembly procedure __________________ 10
10.3 Electrical connection ________________ 12
10.4 Working area modification ___________ 12
10.5 Controls _____________________________ 13
11.0 CONTROLS _______________________ 14
11.1 Control device________________________ 14
11.2 Pedalboard (see Fig. 14) ______________ 14
12.0 USING THE MACHINE ____________ 15
12.1 Precaution measures during tyre
removal and fitting __________________ 15
12.2 Preliminary operations - Preparing
the wheel ____________________________ 15
12.3 Wheel locking ________________________ 16
12.3.1 Reverse wheel pan protection ____ 17
12.4 Bead breaking through vertical rollers 17
12.5 Demounting the tyre _________________ 20
12.6 Tyre mounting _______________________ 23
12.7 Special use of the bead-breaker (with
G1000A118 equipment) ______________ 24
13.0 ROUTINE MAINTENANCE_________ 25
13.1 Lubricants ___________________________ 25
14.0 TROUBLESHOOTING _____________ 26
15.0 TECHNICAL DATA ________________ 27
15.1 Weight _______________________________ 27
15.2 Dimensions __________________________ 27
16.0 STORING _________________________ 28
17.0 SCRAPPING _______________________ 28
17.1 Instructions for the correct
management of waste from electric
and electronic equipment (in italian
RAEE) according to legislative decree
151/05 _______________________________ 28
18.0 REGISTRATION PLATE DATA _____ 28
19.0 FUNCTIONAL DIAGRAMS_________ 28
Drawings A - Electric wiring diagram _____ 29
Drawings B - Pneumatic diagram _________ 31
Drawings C - FI pneumatic diagram _______ 32
20.0 LIST OF COMPONENTS

GB Page 3 of 32 INSTRUCTION, USE AND
MAINTENANCE MANUAL
G1150.30MAGIC - G1150.30MAGICIT RAVAGLIOLI S.p.A.
7107-M001-0_R
KEY
1 – Chuck
2 – Tool
3 – Bead breaking
4 – Handle with tool adjustment release
5 – Control panel
6 – Frontal pedalboard
7 – Pin for bead breaking roll lock/release
8 – Column
9 – Filter unit - Pressure reducer
10 – Locking device
11 – Entrainer (on demand)
12 – Lever for bead breaker lateral opening release
13 – Arms movement cylinder
14 – Inflation pedalboard
15 – Roll for matching (on demand)
16 – Handle with release of bead breaker adjustment
KEY
1 – Chuck
2 – Tool
3 – Bead breaking
4 – Handle with tool adjustment release
5 – Control panel
6 – Frontal pedalboard
7 – Pin for bead breaking roll lock/release
8 – Column
9 – Filter unit - Pressure reducer
10 – Locking device
11 – Entrainer (on demand)
12 – Lever for bead breaker lateral opening release
13 – Arms movement cylinder
14 – Inflation pedalboard
15 – Roll for matching (on demand)
16 – Tubeless inflation unit
17 – Handle with release of bead breaker adjustment
FIG. 1 - G1150.30MAGIC
FIG. 2 - G1150.30MAGICIT

GB
Page 4 of 32
INSTRUCTION, USE AND
MAINTENANCE MANUAL G1150.30MAGIC - G1150.30MAGICIT
RAVAGLIOLI S.p.A.
7107-M001-0_R
2167000
2167000
99990758
4244000
2168000
710211210
2166000
1541000
2170000
3691000
SYMBOLS USED IN THE MANUAL AND ON THE MACHINE
Read instruction manual.
FORBIDDEN!
Wear work gloves.
Wear work shoes.
Wear safety earcaps.
Shock hazard.
Danger! Be particulary careful.
Move with fork lift truck or
transpallet.
Lift from above.
Burst danger.
Mandril rotation direction.
Wear safety goggles.
Danger! Moving mechanical parts.
Caution: hanging loads.
Mandatory. Operations or jobs to
be performed compulsorily
Bead breaker hand danger.
General danger.
Max inflation pressure rating.
Inflation pedal.
Technical assistance necessary.
Do not perform any intervention.
Symbols Description Symbols Description

GB Page 5 of 32 INSTRUCTION, USE AND
MAINTENANCE MANUAL
G1150.30MAGIC - G1150.30MAGICIT RAVAGLIOLI S.p.A.
7107-M001-0_R
1541000
2166000
2167000
2168000
2170000
3691000
4244000
99990758
710211210
•
*
♦♦
♦♦
♦
Danger indicating plate
Bead breaker hand danger indicating plate
Obligation to wear protective clothing plate
Tyre explosion plate
Maximum inflation pressure indication
Inflation pedal plate
Rotary parts danger plate
Electricity danger plate
Rotation direction plate
Serial number plate
Machine nameplate
Manufacturer name plate
PLATE LOCATION ON MACHINE INFORMATION TABLE
Code numbers of plates
IF ONE OR MORE PLATES DISAPPEARS FROM THE MACHINE OR BECOMES DIFFICULT
TO READ, IT MUST BE REPLACED. QUOTE THE CODE NUMBER WHEN REORDERING.

GB
Page 6 of 32
INSTRUCTION, USE AND
MAINTENANCE MANUAL G1150.30MAGIC - G1150.30MAGICIT
RAVAGLIOLI S.p.A.
7107-M001-0_R
1.0 GENERAL INTRODUCTION
This manual is an integral part of the product and
must be retained for the whole operating life of the
machine.
Carefully study the warnings and instructions contained
in this manual. It contains important instructions re-
garding FUNCTIONING, SAFE USE and MAINTE-
NANCE.
KEEP THE MANUAL IN A KNOWN,
EASILY ACCESSIBLE PLACE FOR
ALL OPERATORS TO CONSULT IT
WHENEVER IN DOUBT.
3.0 SAFETY DEVICES
All the machines are equipped with:
• man-operated controls (immediate stop of operation
when the control is released) for all operating devices;
• chucking table rotation;
• tool translation;
• bead breaking roller translation.
• Non-adjustable pressure limiter.
This allows inflation of tyres in reasonable safety. In-
flation of tyres to over 4 ± 0,2 bar (58 PSI) is not
allowed.
• Controls logic disposition
Its function is to prevent the operator from dangerous
mistakes.
• Motor protection devices
The new “Invemotor” motor is equipped with electronic
protection devices. They stop the motor if working de-
fected conditions appear to avoid that the motor itself
can be damaged and that the operator safety can be
compromised (overvoltage, overload, overtemperature).
For other details, see the chap. 14 “Fault-Finding”.
3.1 Residual risks
The machine was subjected to a complete analysis of
risks according to reference standard EN 1050.
Risks are as reduced as possible in relation with tech-
nology and product functionality.
This manual stresses possible residual risks, also
higlighted in pictograms and adhesive warning signals
placed on the machine: their location is represented in
“PLATE LOCATION ON MACHINE INFORMATION TA-
BLE” on page 5.
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-COM-
PLIANCE WITH SUCH INDICATIONS
MIGHT LEAD TO EVEN SERIOUS
DANGERS.
THIS ACCESSORY MUST ONLY BE
USED FOR THE PURPOSE FOR
WHICH IT IS SPECIFICALLY DE-
SIGNED.
ANY OTHER USE IS CONSIDERED
IMPROPER AND THEREFORE UNAC-
CEPTABLE.
THE MANUFACTURER CANNOT BE
HELD RESPONSIBLE FOR ANY DAM-
AGE CAUSED BY IMPROPER, ERRO-
NEOUS, OR UNACCEPTABLE USE.
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 machine 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 op-
erate the machine as intended by the manufacturer.
A CAREFUL READING OF THIS IN-
STRUCTION MANUAL FOR USE AND
MAINTENANCE AND A SHORT PE-
RIOD OF TRAINING WITH SKILLED
PERSONNEL CAN BE AN ENOUGH
PREVENTIVE PREPARATION.
AN INTENSIVE USE OF THE EQUIP-
MENT IN INDUSTRIAL ENVIRON-
MENT IS NOT RECOMMENDED.
2.0 INTENDED USE
The model G1150.30MAGIC machine and relative ver-
sions is a disassembling machine for car tires pro-
jected to be used exclusively for the mounting,
demounting, and inflation of wheels with dimensions
of max. diameter of 45" and max. width of 15".

GB Page 7 of 32 INSTRUCTION, USE AND
MAINTENANCE MANUAL
G1150.30MAGIC - G1150.30MAGICIT RAVAGLIOLI S.p.A.
7107-M001-0_R
4.0 GENERAL SAFETY RULES
• Any tampering with or modification to the machine
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.
• The machine may be used only in areas free from the
danger of explosion or fire.
• The use of only original accessories and spare parts is
advised. Our machine is designed to function only with
original accessories.
• Installation must be conducted only by qualified per-
sonnel exactly according to the instructions that are
given below.
• Ensure that there are no dangerous situations during
the machine operating manoeuvres. Immediately stop
the machine if it mis-functions and contact the assist-
ance service of an authorized dealer.
• In emergency situations and before carrying out any
maintenance or repairs, disconnect all supplies to the
machine by using the main switch.
• Ensure that the work area around the machine is free
of potentially dangerous objects and that there is no
oil since this could damage the tyres. Oil on the floor
is also a potential danger for the operator.
IN CASE OF A CHANCE SUPPLY
FAILURE MOVE THE CONTROLS TO
THE NEUTRAL POSITION.
• The machine handles and operating grips must be
kept clean and free from oil.
• The workshop must be kept clean, dry and not ex-
posed to atmospheric agents. Make sure that the work-
ing premises are properly lit.
The machine can be operated by a single operator. Un-
authorised personnel must remain outside the work-
ing area, as shown in Fig. 5. Avoid any hazardous situ-
ations.
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 SUP-
PORTS FOR THE LIFTING OF
HEAVY PARTS. DANGLING OB-
JECTS 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.
Do not use air-operated or electrical equipment when
the shop is damp or the floor slippery and do not ex-
pose such tools to atmospheric agents
• During inflation do not lean on the tyre or remain above
it. When beading in the tyre, keep hands away from
tyre and the rim flange.
• During inflation always stay to the side of the machine
and never in front of it.
• When operating and servicing this machine, carefully
follow all applicable safety and accident-prevention
precautions. The machine must not be operated by
professionally unskilled persons.

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Page 8 of 32
INSTRUCTION, USE AND
MAINTENANCE MANUAL G1150.30MAGIC - G1150.30MAGICIT
RAVAGLIOLI S.p.A.
7107-M001-0_R
Fig. 3
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 MA-
CHINE.
The machine is packed in a carton box which size is
mm 750x1900x1300.
Movement must be by pallet-lift or fork-lift trolley. The
fork lifting points are indicated on the packing.
6.0 UNPACKING
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 un-nail the cardboard box from the
pallet it is fixed to.
After removing the packing, and in the case of the ma-
chine packed fully assembled, check that the machine is
complete and that there is no visible damage.
If in doubt do not use the machine 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 col-
lection points if they are pollutants or non biodegrad-
able.
WHEN UNPACKING THE MACHINE,
ALWAYS WEAR GLOVES TO PRE-
VENT SCRATCHES AND CUTS
CAUSED BY CONTACT WITH PACK-
ING MATERIAL (NAILS, ETC...).
THE BOX CONTAINING THE ACCES-
SORIES IS CONTAINED IN THE
WRAPPING. DO NOT THROW IT
AWAY WITH THE PACKING.

GB Page 9 of 32 INSTRUCTION, USE AND
MAINTENANCE MANUAL
G1150.30MAGIC - G1150.30MAGICIT RAVAGLIOLI S.p.A.
7107-M001-0_R
• Protect the exposed corners with suitable material
(Pluribol/cardboard).
• Do not use metallic cables for lifting.
• Sling with belts long at least 450 cm and with a ca-
pacity load greater than 2500 kg.
Then carry out the lifting using the bracket (Fig. 4
pos. 1).
Fig. 4
Fig. 5
7.0 MOBILIZATION
THE LIFTING EQUIPMENT MUST WITHSTAND
A MINIMUM RATED LOAD EQUAL TO THE
WEIGHT OF THE MACHINE (SEE PARAGRAPH
TECHNICAL SPECIFICATIONS). DO NOT ALLOW
THE LIFTED MACHINE TO SWING
If the machine has to be moved from its normal work
post, the movement must be conducted following the
instructions listed below.
8.0 WORKING ENVIRONMENT CONDI-
TIONS
The machine 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 machine in ambient conditions other than
those specified above is only allowed after prior agree-
ment with and approval of the manufacturer.
8.1 Work position
Fig. 5 show work positions Aand Bwhich will be re-
ferred to during the description of the machine operat-
ing phases.
Position Ais the main positions for wheel fitting and
removal with the chucking table, while position Bis ideal
to follow tyre inflation operations.
Working in these positions allows better precision and
speed during operating phases as well as greater safety
for the operator.
8.2 Installation space
INSTALL THE MACHINE INDOORS OR IN A
ROOFED AREA. PLACE OF INSTALLATION
MUST BE DRY, ADEQUATELY LIT AND IN COM-
PLIANCE WITH APPLICABLE SAFETY REGULA-
TIONS.

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Page 10 of 32
INSTRUCTION, USE AND
MAINTENANCE MANUAL G1150.30MAGIC - G1150.30MAGICIT
RAVAGLIOLI S.p.A.
7107-M001-0_R
10.0 ASSEMBLY AND PREPARATION
FOR USE
After having freed the various components from the pack-
ing check that they are complete, and that there are no
anomalies, then comply with the following instructions
for the assembly of the components making use of the
attached series of illustrations.
10.1 Accessories contained in the packing
The packing case contains also the accessory box.
Check that all the parts listed are there.
N.
1
1
1
1
1
1
1
1
1
B1157000
710013421
G1000A67
790011620
790011640
710090223
710012940
710090480
B0223000
TWO-FACED CONE
REVERSE WHEELS PROTECTION
28’’ BEAD DEPRESSING W/ENTRAINER
BEAD SLIDING FOIL
INSTRUCTIONS FOR BEAD SLIDING FOIL
RAPID COUPLING
PIN EXTENSION
GUARD WITH OR
GREASE HOLDING RING
Fig. 7
10.2 Assembly procedure
1. Mount the ring (# B0223000) (Fig. 7 pos. 1) in the
accessory box, using the 2 provided screws already
present on machine body (Fig. 7 pos. 2).
The holes in the solid floor must be about 10 cm deep
with a diameter of 8 mm.
The bolts (Fig. 6 pos. 1) must be inserted in the holes
and fully tightened.
Fig. 6
a=621 mm
b=440 mm
The location of the machine requires a usable space of
3250x2750, mm (as indicated in Fig. 5).
The positioning of the machine must be according to the
distances shown. From the control position the opera-
tor is able to observe all the machine and surrounding
area. He must prevent unauthorized personnel or ob-
jects that could be dangerous from entering the area.
The machine must be fixed on a flat floor surface, pref-
erably of cement or tiled.
Avoid un-solid or irregular surfaces.
The base floor must be able to support the loads trans-
mitted during operation.
This surface must have a strength of at least 500 kg/m2.
The thickness of the solid floor must be sufficient to
guarantee that the anchoring bolts hold.
9.0 ANCHORING SYSTEM
The packed machine is fixed to a pallet by support feet.
Such feet also fix the machine to the ground through
anchor small blocks as shown in Fig. 6.
Code Description

GB Page 11 of 32 INSTRUCTION, USE AND
MAINTENANCE MANUAL
G1150.30MAGIC - G1150.30MAGICIT RAVAGLIOLI S.p.A.
7107-M001-0_R
4. Connect the black pipe (Fig. 10 pos. 1)and the blue
pipe (Fig. 10 pos. 2) on the provided quick couplings
as shown in figure 10.
2. Connect the mains pneumatic power supply by us-
ing the union placed on filter unit of the machine.
The pressurized pipe (see Fig. 8) coming from the
mains must have a section of 10x19.
Fig. 8
Fig. 9
Fig. 10
Only for IT version
3. Assemble “Gonfiatubeless” unit to the machine keep-
ing to the following instructions:
- fix the tank (Fig. 9 pos. 1)to the support flange
(Fig. 9 pos. 3)using the screws (Fig. 9 pos. 4) and
nuts (Fig. 9 pos. 2) equipped on issue;
- fix the flange (Fig. 9 pos. 3)to the machine (Fig. 9
pos. 7)using screws (Fig. 9 pos. 5) and the nuts
(Fig. 9 pos. 6).

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Page 12 of 32
INSTRUCTION, USE AND
MAINTENANCE MANUAL G1150.30MAGIC - G1150.30MAGICIT
RAVAGLIOLI S.p.A.
7107-M001-0_R
10.4 Working area modification
After the delivery, the machine is prearranged to operate
on wheel of 41” maximum diameter and a rim diameter
(10” - 26”). It’s also possible to move to move the base
as for the tools column to enlarge the working area from
43” (with rim diameter of 12” - 28”) to 45” (with rim
diameter of 14” - 30”) (see Figure 11).
Fig. 11
10.3 Electrical connection
As envisaged by the regulations in force, the machine is
not equipped with a master circuit breaker, but simply
has a plug-socket connection to the electrical mains.
The machine is supplied with 3mt. of free cable. A plug
corresponding to the following requirements must be
connected to the cable:
• Conformity to Norm IEC 309
• 230 Volt – 16A
• 2P + Ground
• IP 44
On delivery, the machine is preset to operate at a voltage
of 200 ÷ 265 V - 50/60 Hz monophase.
EVEN THE TINIEST PROCEDURE OF
AN ELECTRICAL NATURE MUST BE
CARRIED OUT BY PROFESSION-
ALLY QUALIFIED STAFF.
BEFORE CONNECTING THE MA-
CHINE:
• MAKE SURE THAT THE POWER
MAINS RATING CORRESPONDS
TO THE MACHINE RATING AS
SHOWN ON THE MACHINE
PLATE;
• CHECK THAT ALL POWER MAINS
COMPONENTS ARE IN GOOD CON-
DITION;
• CHECK THAT THE ELECTRICAL
SYSTEM IS PROPERLY
GROUNDED (EARTH WIRE MUST
BE THE SAME CROSS-SECTION
AREA AS THE LARGEST POWER
SUPPLY CABLES OR GREATER);
• MAKE SURE THAT THE ELECTRI-
CAL SYSTEM FEATURES A CUT-
OUT WITH DIFFERENTIAL PRO-
TECTION SET AT 30 MA.
FIT A TYPE-APPROVED PLUG TO
THE MACHINE CABLE (THE EARTH
WIRE IS YELLOW/GREEN AND
MUST NEVER BE CONNECTED TO
THE PHASE LEADS). MAKE SURE
THAT THE ELECTRICAL SYSTEM IS
COMPATIBLE WITH THE RATED
POWER ABSORPTION SPECIFIED IN
THIS MANUAL AND APT TO EN-
SURE THAT VOLTAGE DROP UN-
DER FULL LOAD WILL NOT EXCEED
4% OF RATED VOLTAGE (10% UPON
START-UP).
FAILURE TO OBSERVE THE ABOVE
INSTRUCTIONS WILL IMMEDIATELY
INVALIDATE THE WARRANTY.

GB Page 13 of 32 INSTRUCTION, USE AND
MAINTENANCE MANUAL
G1150.30MAGIC - G1150.30MAGICIT RAVAGLIOLI S.p.A.
7107-M001-0_R
Fig. 12
The base can be moved as for the column (Fig. 11 pos.
A) by unscrewing the fixing screws of the base (Fig. 11
pos. B) to the column and by sliding the base itself into
the proper slots until the required measure.
1. To remove the lateral guard (Fig. 12 pos. 1-2) of the
machine.
2. To unscrew the screws (Fig. 12 pos. 3) and the nuts
near the central slots (Fig. 12 pos. 4) playing atten-
tion to not remove the nuts from the proper screws.
3. To remove six remained screws (Fig. 12 pos. 5).
4. To move the base (Fig. 12 pos. 6) into the required
position (to 43” or 45”) and if necessary to use a lift-
ing device (Fig. 12 pos. 7).
5. To lock the base three screws (Fig. 12 pos. 3) with a
couple of 80 Nm.
6. To place six screws (Fig. 12 pos. 5) previously re-
moved and to lock them on the base side with a cou-
ple of 80 Nm.
7. To assembly again the lateral guard (Fig. 12 pos. 1-2)
of the machine.
NOTE: after the assembly, to check the right position of
the tools. Lock the rim on the chuck center. With
the bead breaker arm, check that the distance
between the roll and the rim edges (upper and
lower) is the same. Repeat all the procedures
starting from point one if the distance is not the
same.
MAKE SURE THAT THE TYRE
CHANGING MACHINE COLUMN IS
STABLE: USE A CABLE HELD BY A
HOIST AND HOOK THE CABLE TO
THE COLUMN ITSELF (FIG. 12 POS.
7).
10.5 Controls
BEFORE STARTING UP THE TYRE-
CHANGER, BE SURE TO BECOME
FAMILIAR WITH THE LOCATION
AND OPERATION OF ALL CON-
TROLS AND CHECK THEIR PROPER
OPERATION (SEE PAR. CONTROLS).

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Page 14 of 32
INSTRUCTION, USE AND
MAINTENANCE MANUAL G1150.30MAGIC - G1150.30MAGICIT
RAVAGLIOLI S.p.A.
7107-M001-0_R
Fig. 13
11.2 Pedalboard (see Fig. 14)
“Pedal A” has two maintained type operative positions.
When it is pushed downwards it controls the chuck
motor clockwise rotary movement. When the pedal is
lifted upwards it operates the opposite movement.
NOTE: the chuck unit speed can be continously adjusted
up to the maximum speed through a progressive
pressure on the pedal, only in clockwise direc-
tion.
“Pedal B” has a different function according to the the
version present on the machine.
Version with inflation with pressure gauge
The inflation pedal in this version has only one func-
tion. A continuous pressure supplies air at a controlled
pressure (max 4 ± 0,2 bar 58 PSI).
Version with tubeless inflation
11.0 CONTROLS
11.1 Control device
This unit has two buttons with different functions posi-
tioned on a single control unit (Fig. 13 pos. 3).
The two pneumatic buttons on the control operate the
vertical movement of the bead breaking roller arm (Fig.
13 pos. 1) and of the tool arm (Fig. 13 pos. 2).
The vertical control unit is also equipped with a
pushbutton for the control of bead breaking roll (Fig.
13 pos. 4) forward movement.
•Lever “A”for the tool setting on the wheel diameter,
through a thrust and return movement and together
with “B” unlocking push button.
•Lever “C”for bead breaker roller setting on the wheel
diameter, through a thrust and return movement and
together with “D” unlocking push button.
•Unlocking push button “B”, pushed before lever “A”
starting for the tool positioning. Releasing the push
button, the tool locks itself into the set position.
•Unlocking push button “D”pushed before lever “C”
starting for bead breaker roller positioning. Releasing
the push button, the roll locks itself into the set posi-
tion.
ATTENTION: “B” and “D” push buttons must be pushed
before starting the corresponding “A” and “D” levers; oth-
erwise, the levers do not allow any movement.
The inflation pedal has two functions. The supply of air
at a controlled pressure as in the previous version, and
a second function of a jet of air from the inflation nozzle
to assist the beading in of the tyre.
Version with lateral bead breaker
DO NOT CHANGE THE SET OPERAT-
ING PRESSURE VALUE BY MEANS
OF THE MAXIMUM PRESSURE
VALVES. THE MANUFACTURER
SHALL NOT BE RESPONSIBLE FOR
INJURY OR DAMAGE ARISING
FROM UNAUTHORISED CHANGES.
DO NOT CHANGE THE SET OPERAT-
ING PRESSURE VALUE BY MEANS
OF THE MAXIMUM PRESSURE
VALVES. THE MANUFACTURER
SHALL NOT BE RESPONSIBLE FOR
INJURY OR DAMAGE ARISING
FROM UNAUTHORISED CHANGES.

GB Page 15 of 32 INSTRUCTION, USE AND
MAINTENANCE MANUAL
G1150.30MAGIC - G1150.30MAGICIT RAVAGLIOLI S.p.A.
7107-M001-0_R
Fig. 14
KEY (Pedal Pos. B)
Pos. 1 - Tyre inflation with pressure gauge
Pos. 2 - Tyre inflation with pressure gauge + inflation
nozzle
12.0 USING THE MACHINE
12.1 Precaution measures during tyre
removal and fitting
Before fitting a tyre, observe the following safety rules:
• rim and tyre must be clean, dry and in good condition.
If necessary, remove the balancing weights and clean
the rim. Check:
- tyre bead and tread for damage.
- rim for dents and/or deformation (especially for alloy
rims, dents can cause internal micro-fractures, that
pass unobserved at visual inspection, and can com-
promise the solidity of the rim and constitute danger
even during inflation).
• adequately lubricate the contact surface of rim and
tyre bead. Use specific tyre lubricants only.
• replace the inner tube valve with a new valve. If the
tyre tube has a metal valve, replace the grommet.
• make sure that the tyre is the right size for the rim.
Never fit a tyre unless you are sure it is the right size
(the rated size of the rim and tyre is usually printed
directly on each of them).
• Do not use compressed air or water jets to clean the
wheels on the machine.
12.2 Preliminary operations - Preparing
the wheel
• Remove the wheel balancing weights from both sides
of the wheel.
REMOVE THE VALVE STEM AND
ALLOW THE TYRE TO COM-
PLETELY DEFLATE.
• Establish from which side the tyre should be
demounted, checking the position of the channel.
• Find the rim locking type.
• Try to establish the special types of wheels, such as
“EH2” and “EH2+”, in order to improve locking, bead
breaking, assembly and disassembly performances.

GB
Page 16 of 32
INSTRUCTION, USE AND
MAINTENANCE MANUAL G1150.30MAGIC - G1150.30MAGICIT
RAVAGLIOLI S.p.A.
7107-M001-0_R
Fig. 17
Fig. 18
Fig. 19
Fig. 15
Fig. 16
2. Dowel the wheel (Fig. 17 pos. 1) on the locking plat-
form and check that the dragging pin (Fig. 17 pos. 2)
enter in a hole placed on the rim hub.
NOTE: in case of use of rims without central hole, it’s
necessary to use the proper accessory (available
on demand).
To lock a rim proceed as follows:
1. Extract the central locking shaft and its cone (Fig. 16
pos. 1) through the proper handle (Fig. 16 pos. 2)
and, if necessary, turn it to make easy the extraction.
12.3 Wheel locking
All rims must be locked on the rubber plate (Fig. 15
pos. 1) through the central hole using the proper lock-
ing device (Fig. 15 pos. 2).
3. If the wheel hub is higher then the dragger (Fig. 18
pos. 2), use the extension (Fig. 18 pos. 1) supplied
on issue.
4. Insert the shaft and the relative cone (Fig. 19 pos. 1)
on the rim (Fig. 19 pos. 2).
5. Turn of 90° (Fig. 20 pos. 1) and lift the shaft (Fig. 20
pos. 2) to hook it inside the hole.

GB Page 17 of 32 INSTRUCTION, USE AND
MAINTENANCE MANUAL
G1150.30MAGIC - G1150.30MAGICIT RAVAGLIOLI S.p.A.
7107-M001-0_R
Fig. 20
Fig. 22
Fig. 21
Fig. 23
1
12.4 Bead breaking through vertical rollers
1. After the wheel has been locked onto the chuck, move
the bead breaking roller (Fig. 24 pos. 2) to vertical
working position: release the provided lever (Fig. 24
pos. 1) and rotate the roller at 180°.
Fig. 24
MOVE VERY CAREFULLY THE BEAD
BREAKING ARM TO VERTICAL PO-
SITION, IN ORDER TO AVOID POS-
SIBLE HANDS CRUSHINGS.
6. Lifting the shaft (Fig. 21 pos. 1) through the proper
handle (Fig. 21 pos. 2), turn the ring nut (Fig. 21
pos. 3) until the complete cone clamping (Fig. 21 pos.
4) on the wheel (Fig. 21 pos. 5).
7. For wheels with alloy rims, use a proper plastic guard
(Fig. 22 pos. 1).
NEVER LEAVE THE WHEEL FITTED
ON THE MACHINE FOR A PERIOD
LONGER THAN NECESSARY FOR
CARRYING WORK AND IN ANY CASE
NEVER LEAVE IT UNATTENDED.
12.3.1 Reverse wheel pan protection
In case of use of reverse wheels, to protect the rim, ap-
ply on the rubber platform a protection made to a trans-
parent plastic material available on demand (Fig. 23
pos. 1). We suggest you a constant replacement of it and
in any case if there are visible damages (see Fig. 23).

GB
Page 18 of 32
INSTRUCTION, USE AND
MAINTENANCE MANUAL G1150.30MAGIC - G1150.30MAGICIT
RAVAGLIOLI S.p.A.
7107-M001-0_R
Fig. 27
4. After the upper bead breaking, release the the roll
from the rim releasing the pushbutton (Fig. 13 Pos.
4) and operating the pushbutton (Fig. 13 Pos. 1).
5. Operate the lever (Fig. 28 Pos. 1) in order to let the
bead breaking roller arm (Fig. 28 Pos. 2) open and
go under the rim without changing its previously set
position.
Fig. 26
3. Keep on approaching, activating the wheel rotation
in clockwise sense (see Fig. 26) pushing the pedal
(Fig. 14 Pos. A) and at the same time push the but-
ton (Fig. 13 Pos. 4), keeping it pressed until the bead
breaking roller is inserted in the rim. Keep on with
the wheel rotation until the operation is completed
(see Fig. 27).
Fig. 25
ALWAYS VERIFY THAT THE ARM IS
HOOKED.
USE VERY CAREFULLY THE VERTI-
CAL BEAD BREAKING ROLLER IN
ORDER TO AVOID POSSIBLE
HANDS CRUSHINGS.
Approach the bead breaking roller (Fig. 25 Pos. 2)
to the rim edge (Fig. 25 Pos. 1), pressing the
pushbutton (Fig. 13 Pos. 1).
2. Define roll position on the rim diameter through the
lever (Fig. 25 Pos. 3) after the arms have been un-
locked with the push button (Fig. 25 Pos. 4) posi-
tioned on the lever itself.
THE BEADING DISC MUST EXERT
PRESSURE ON THE TYRE BEAD
BUT NEVER ON THE RIM.
USE VERY CAREFULLY THE VERTI-
CAL BEAD BREAKING ROLLER IN
ORDER TO AVOID POSSIBLE
HANDS CRUSHINGS.

GB Page 19 of 32 INSTRUCTION, USE AND
MAINTENANCE MANUAL
G1150.30MAGIC - G1150.30MAGICIT RAVAGLIOLI S.p.A.
7107-M001-0_R
Fig. 28
Fig. 29
6. Manually close the bead breaking roller arm in work-
ing position. Carry out the bead breaking roller 180°
rotation again, according to Fig. 24 indications. Then
approach the roll (Fig. 29 Pos. 1) pressing the
pushbutton (Fig. 13 Pos. 1).
USE VERY CAREFULLY THE VERTI-
CAL BEAD BREAKING ROLLER IN
ORDER TO AVOID POSSIBLE
HANDS CRUSHINGS.
Fig. 30
Fig. 31
7. Now rotate the wheel in clockwise sense (see Fig.
30) pressing the pedal (Fig. 14 Pos. A) and at the
same time activate the pushbutton (Fig. 13 Pos. 4),
keeping it pressed until the bead breaking roller is
inserted in the rim. Keep on with the wheel rotation
until the operation is completed (see Fig. 31).
THE BEADING DISC MUST EXERT
PRESSURE ON THE TYRE BEAD
BUT NEVER ON THE RIM.
WHILE THIS OPERATION IS BEING
CARRIED OUT PAY ATTENTION
NOT TO DEFORM THE TYRE SIDE.
GREASE THE BEAD BEFORE THE
ROLL RE-ENTERS.
USE ONLY TYRE LUBRICANTS. SUIT-
ABLE LUBRICANTS CONTAIN NO
WATER, HYDROCARBONS, OR SILI-
CON.

GB
Page 20 of 32
INSTRUCTION, USE AND
MAINTENANCE MANUAL G1150.30MAGIC - G1150.30MAGICIT
RAVAGLIOLI S.p.A.
7107-M001-0_R
Fig. 33
1
2
Fig. 34
8. Once bead breaking has been completed in the lower
part, move lower roll in the rest position releasing
the pushbutton (Fig. 13 Pos. 4) and activating the
push button (Fig. 13 Pos. 1).
12.5 Demounting the tyre
When both beads are broken, the tyre can be demounted.
1. Move the tool unit to assembly position.
2. Define the tool position on the rim diameter through
the lever (Fig. 32 Pos. 1) after the arm has been un-
locked with the push button (Fig. 32 Pos. 2) posi-
tioned on the lever itself.
Fig. 32
PAY ATTENTION WHEN REPOSI-
TIONING THE TOOL CARRIER ARM
TO AVOID CRUSHING HANDS. AL-
WAYS MAKE SURE THAT THE ARM
IS PROPERLY HOOKED TO THE CAR-
RIER
ALWAYS MAKE SURE THAT THE
ARM IS CORRECTLY HOOKED TO
THE CARRIER.
3. Press the pedal (Fig. 14 Pos. A) to rotate the wheel
in clockwise sense until the valve stem reaches “ hour
1” position (Fig. 33 Pos. 1).
4. Position the tool (Fig. 33 Pos. 2) just next the rim
edge using the provided push button (Fig. 13 Pos.
2) (see Fig. 34). While this phase is being carried
out, stay just next to a zone in the tyre where bead
breaking has been effectuated.
POSITION VERY CAREFULLY THE
TOOL HOLDER ARM IN ORDER TO
AVOID POSSIBLE HANDS
CRUSHINGS.
USE ONLY TYRE LUBRICANTS. SUIT-
ABLE LUBRICANTS CONTAIN NO
WATER, HYDROCARBONS, OR SILI-
CON.
WHILE THIS OPERATION IS BEING
CARRIED OUT PAY ATTENTION
NOT TO DEFORM THE TYRE SIDE.
GREASE THE BEAD BEFORE THE
ROLL RE-ENTERS.