Ravaglioli G8641 Series User manual

GB TRANSLATION FROM THE
ORIGINAL INSTRUCTIONS
Technical services: RAVAGLIOLI S.p.A. - Via 1° Maggio, 3 - 40044 Pontecchio Marconi - Bologna Italy
Phone [phone] - Telex 510697 RAV I - Fax [phone] - e-mail: [email protected]
7300-M010-2_R
drhdhdfhdhdfhd
G8645D.XX - G8645ID.XX -
G8645V.XX - G8645IV.XX -
G8645ITD.30 - G8645ITV.30
7300-M010-2_R - Rev. n. 2 (11/2011)

INSTRUCTION, USE AND
MAINTENANCE MANUAL Page 2 of 33 GB
RAVAGLIOLI S.p.A. G8641 - G8645
7300-M010-1_R
SUMMARY
SYMBOLS USED IN THE MANUAL
AND ON THE MACHINE _________________ 6
1.0 GENERAL INTRODUCTION ________ 8
2.0 INTENDED USE ____________________ 8
2.1 Training of personnel __________________ 8
3.0 SAFETY DEVICES _________________ 8
3.1 Residual risks __________________________ 9
4.0 GENERAL SAFETY RULES _________ 9
5.0 PACKING AND MOBILIZATION
FOR TRANSPORT _________________ 10
6.0 UNPACKING ______________________ 10
7.0 MOBILIZATION ___________________ 11
8.0 WORKING ENVIRONMENT
CONDITIONS _____________________ 11
8.1 Work position ________________________ 11
8.2 Installation space ____________________ 11
8.3 Lighting _____________________________ 12
9.0 ANCHORING SYSTEM ____________ 12
10.0 ASSEMBLY AND PREPARATION
FOR USE __________________________ 12
10.1 Assembly procedure __________________ 12
10.2 Electrical connection ________________ 14
10.3 Controls _____________________________ 15
11.0 CONTROLS _______________________ 15
11.1 4 pedal control unit __________________ 15
11.2 Inflation pedal (on demand) __________ 16
11.3 Column handle _______________________ 16
12.0 USING THE MACHINE ____________ 17
12.1 Precaution measures during tyre
removal and fitting __________________ 17
12.2 Preliminary operations - Preparing
the wheel ____________________________ 17
12.3 Bead breaking _______________________ 17
12.3.1 Bead breaking tool with double
joint (on demand) _______________ 18
12.4 Clamping the wheel on
18” - 20” - 22” - 24” - 26” - 28” chuck _ 18
12.5 Clamping the wheel on 30” chuck _____ 18
12.6 Demounting the tyre _________________ 19
12.7 Mounting the tyre ____________________ 19
12.9 Tubeless tyre inflation device _________ 20
12.8 Tyre inflation with pressure gauge
(on demand) _________________________ 20
13.0 ROUTINE MAINTENANCE_________ 20
13.1 Lubricants ___________________________ 21
14.0 TROUBLESHOOTING _____________ 22
15.0 TECHNICAL DATA ________________ 23
15.1 G8641V technical data ________________ 23
15.2 G8641D technical data _______________ 23
15.3 G8645V technical data ________________ 23
15.4 G8645D technical data ________________ 23
15.5 Dimensions __________________________ 25
16.0 STORING _________________________ 27
17.0 SCRAPPING _______________________ 27
17.1 Instructions for the correct
management of waste from electric and
electronic equipment (in italian RAEE)
according to legislative decree 151/05 27
18.0 REGISTRATION PLATE DATA _____ 27
19.0 FUNCTIONAL DIAGRAMS_________ 27
Drawings A - Pneumatic circuit of automatic
machine _____________________ 28
Drawings B - Pneumatic circuit of automatic
machine (I) __________________ 30
Drawings C - Pneumatic circuit of automatic
machine (IT) _________________ 32
20.0 LIST OF COMPONENTS

INSTRUCTION, USE AND
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
KEY
1 – Column
2 – Machine body
3 – Inflation unit (on demand)
4 – Pedal control unit
5 – Bead breaker unit
6 – Complete turntable (10”-18”, 10”-24”)
7 – Complete turntable (10”-20”, 11”-22”)
8 – Lever handling cylinder
9 – Mounting/demounting lever
KEY
1 – Column
2 – Machine body
3 – Inflation unit
4 – Pedal control unit
5 – Bead breaker unit
6 – Complete turntable (10”-24”)
7 – Complete turntable (10”-20”, 11”-22”)
8 – Tank
9 – Lever handling cylinder
10 – Mounting/demounting lever
FIG. 1 - G8641D.XX - G8641V.XX
FIG. 2 - G8641ID.XX - G8641IV.XX

INSTRUCTION, USE AND
MAINTENANCE MANUAL Page 4 of 33 GB
RAVAGLIOLI S.p.A. G8641 - G8645
7300-M010-1_R
KEY
1 – Column
2 – Machine body
3 – Inflation unit (on demand)
4 – Pedal control unit
5 – Bead breaker unit
6 – Complete turntable (10”-18”, 10”-
26”)
7 – Complete turntable (8”- 30”)
8 – Complete turntable (10”-20”, 11”-
22”)
9 – Complete turntable (10”-28”)
10 – Lever handling cylinder
11 – Mounting/demounting lever
KEY
1 – Column
2 – Machine body
3 – Inflation unit
4 – Pedal control unit
5 – Bead breaker unit
6 – Complete turntable (10”-26”)
7 – Complete turntable (10”-28”)
8 – Tank
9 – Complete turntable (10”-20”, 11”-
22”)
10 – Lever handling cylinder
11 – Mounting/demounting lever
FIG. 3 - G8645D.XX - G8645V.XX
FIG. 4 - G8645ID.XX - G8645IV.XX

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MAINTENANCE MANUAL
Page 5 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
KEY
1 – Column
2 – Machine body
3 – Inflation unit
4 – Pedal control unit
5 – Bead breaker unit
6 – Complete turntable (8”-30”)
7 – Tank
8 – Gonfiatubeless gun
9 – Lever handling cylinder
10 – Mounting/demounting lever
FIG. 5 - G8645ITD.30 - G8645ITV.30

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MAINTENANCE MANUAL Page 6 of 33 GB
RAVAGLIOLI S.p.A. G8641 - G8645
7300-M010-1_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

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MAINTENANCE MANUAL
Page 7 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
INFORMATION PLATE LOCATION TABLE
Code numbers of plates
4-pedal symbols plate
Rotation direction indicating plate
Electricity danger plate
Protection device use plate
Bead breaker hazard plate
Head danger indicating plate
Unit move indicating plate
Headphones plate
Bursting tyre hazard plate
Inflation instructions indicating plate
Short instruction indicating plate
Pedal plate
Tilting pile plate
Serial number plate
B2661000
B4219000
99990758
999910050
999910060
999910070
999911770
999911870
999911890
999912050
999912830
999913060
999913280
999915200
IF ONE OR MORE PLATES ON THE MACHINE ARE LOST OR BECOME ILLEGIBLE, THEY
MUST BE REPLACED, STATING THE RELATIVE CODE NUMBER WHEN ORDERING THE
REPLACEMENT.

INSTRUCTION, USE AND
MAINTENANCE MANUAL Page 8 of 33 GB
RAVAGLIOLI S.p.A. G8641 - G8645
7300-M010-1_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.
3.0 SAFETY DEVICES
All the machines are equipped with:
• Fixed guards.
The machine is fitted with a number of fixed guards
intended to prevent potential crushing, cutting and
compression risks.
• Non-adjustable (balancing valve) pressure limiter.
This allows inflation of tyres in reasonable safety. In-
flation of tyres to over 4,2 ± 0,2 bar (60 PSI) is not
allowed.
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.
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-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.
AN INTENSIVE USE OF THE EQUIP-
MENT IN INDUSTRIAL ENVIRON-
MENT IS NOT RECOMMENDED.
2.0 INTENDED USE
“G8641 - G8645” model machines and relevant ver-
sions are car tyre changers intended for use solely for
mounting, demounting and inflating wheels having
max. diameter (41”) 45” and width max 16”.

INSTRUCTION, USE AND
MAINTENANCE MANUAL
Page 9 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
• 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. 8. Avoid any hazardous situ-
ations.
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.
IN CASE OF A CHANCE SUPPLY
FAILURE MOVE THE CONTROLS TO
THE NEUTRAL POSITION.
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 7.
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.
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.

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MAINTENANCE MANUAL Page 10 of 33 GB
RAVAGLIOLI S.p.A. G8641 - G8645
7300-M010-1_R
Fig. 6
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 1180x1150x1130.
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.

INSTRUCTION, USE AND
MAINTENANCE MANUAL
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
7.0 MOBILIZATION
If the machine 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.
• Sling with belts long at least 100 cm and with a ca-
pacity load greater than 1000 kg (see Fig. 7).
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.
Fig. 7 Fig. 8
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. 8 show work positions Aand B.
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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RAVAGLIOLI S.p.A. G8641 - G8645
7300-M010-1_R
2. Connect the flexible pipes (Fig. 11 pos. 1)
preassembled on the mandrel rotary distributor (Fig.
11 pos. 2), on the valve (Fig. 11 pos. 4) hosenipple
(Fig. 11 pos. 3). Fasten the pipes (Fig. 11 pos. 1)
with the prepared clamps (Fig. 11 pos. 5)
3. Connect the pipe (Fig. 11 pos. 14) from the greaser
reduction gear filter (Fig. 11 pos. 7)(air not lubri-
cated) to the compensation balancing valve (Fig. 11
pos. 15).
4. Connect the pipe (Fig. 11 pos. 11) from the pedal
board lower valve (Fig. 11 pos. 12) to the blow valve
(Fig. 11 pos. 4) union (Fig. 11 pos. 13).
5. Connect the pipe (Fig. 11 pos. 6) to the T coupling
(Fig. 11 pos. 8) and the coupling (Fig. 11 pos. 16)
placed on the tank (Fig. 11 pos. 9).
6. Connect the pipe (Fig. 11 pos. 18) from the blowing
unit (Fig. 11 pos. 17) to the pedal board (Fig. 11
pos. 12) upper union (Fig. 11 pos. 10).
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 Assembly procedure
Remove the packaging and free the machine from the
wrapping. Lift the machine and position it on the floor.
The location of the machine requires a usable space of
3450x2500, mm (as indicated in Fig. 8).
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.
8.3 Lighting
The machine does not require its own lighting for nor-
mal working operations.
However, it must be placed in an adequately lit environ-
ment.
For correct lighting, use lamps having total power 800/
1200 Watt as envisaged by UNI 10380.
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. 9.
The holes in the solid floor must be about 10 cm deep
with a diameter of 8 mm.
The bolts (Fig. 9 pos. 1) must be inserted in the holes
and fully tightened.
Fig. 9
a=762 mm
b=410 mm
c=525 mm
Fig. 10
Only for I version
1. Mount the tank (Fig. 10 pos. 1) on the base lower
part, as shown in picture 10, using the screws (Fig.
10 pos. 2) (tightening torque approx. 8 N·m), the
washers (Fig. 10 pos. 3) and the nuts (Fig. 10 pos.
4).

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RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
Fig. 12
2. Connect the pipe (Fig. 13 pos. 14) from the greaser
reduction gear filter (Fig. 13 pos. 7)(air not lubri-
cated) to the compensation balancing valve (Fig. 13
pos. 5).
3. Connect the pipe (Fig. 13 pos. 11) from the pedal
board lower valve (Fig. 13 pos. 12) to the blow valve
(Fig. 13 pos. 4) union (Fig. 13 pos. 13).
4. Connect the pipe (Fig. 13 pos. 6) to the coupling (Fig.
13 pos. 3) placed on the tank (Fig. 13 pos. 9).
5. Connect the pipe (Fig. 13 pos. 2) from the blowing
unit (Fig. 13 pos. 1) to the pedal board (Fig. 13 pos.
12) upper union (Fig. 13 pos. 10).
Fig. 11
Only for IT version
1. Mount the tank (Fig. 12 pos. 1) on the base lower
part, as shown in picture 12, using the screws (Fig.
12 pos. 2) (tightening torque approx. 8 N·m), the
washers (Fig. 12 pos. 3) and the nuts (Fig. 12 pos.
4).
Fig. 13

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MAINTENANCE MANUAL Page 14 of 33 GB
RAVAGLIOLI S.p.A. G8641 - G8645
7300-M010-1_R
10.2 Electrical connection
EVEN THE TINIEST PROCEDURE OF
AN ELECTRICAL NATURE MUST BE
CARRIED OUT BY PROFESSION-
ALLY QUALIFIED STAFF.
Fig. 14
Connect the net pneumatic supply to the coupling (Fig.
14 pos. 1) placed on the machine filter unit.
The pressure line leading from the compressed air sup-
ply system must have gauge 1/4x10 (Fig. 14-15 pos. 2).
The filter unit is already mounted on the machine.
Fig. 15 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
• 230/400 Volt – 16A
• 3P + Ground
• IP 44
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.
Only for I and IT version
Connect the net pneumatic supply to the coupling (Fig.
15 pos. 1) placed on the machine filter unit.

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RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
Fig. 16
FAILURE TO OBSERVE THE ABOVE
INSTRUCTIONS WILL IMMEDIATELY
INVALIDATE THE WARRANTY.
10.3 Controls
11.0 CONTROLS
The pedal control unit comprises 4 (four) pedals.
11.1 4 pedal control unit
“Pedal 1” on this pedal unit operates the automatic col-
umn and has two stable operating positions:
the first (pedal up) tilts the column away from the op-
erator; the second (pedal down) returns the column to
the working position.
“Pedal 2” opens and closes the turntable clamps. It has
three stable positions: open – close – approach clamps.
“Pedal 3” controls the bead breaker cylinder/shoe and
has 2 stable positions.
“Pedal 4” controls turntable rotation and has 3 stable
positions:
1. 0 position, turntable stopped;
2. Pressed down, the turntable is rotated clockwise;
3. Raised, the turntable is rotated anti-clockwise.
ONLY FOR VERSIONS WITH MOTOR
3PH, 230/400V – 50 HZ 2 SPEED
“Pedal 4” controls turntable rotation and has 3 stable
positions:
1. 0 position, turntable stopped;
2. Position 1 to the bottom – clockwise rotation of the
plate;
3. Position 2 to the bottom from position 1 – clockwise
rotation of the plate at double speed;
4. Position 1 to the top – anticlockwise rotation of the
plate.
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).
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).
On delivery, the machine is preset to operate at a voltage
230/400 V - 50 Hz three-phase (for version G8641V and
G8645V) or with a monophasic voltage of 200/265 V -
50/60 Hz (for versions G8641D and G8645D).

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RAVAGLIOLI S.p.A. G8641 - G8645
7300-M010-1_R
11.2 Inflation pedal (on demand)
The pressure on the inflation pedal and the keeping it
pressed, delivers air at controlled pressure (max 4,2 ±
0,2 bar).
11.3 Column handle
The column is fitted with a pneumatically operated han-
dle which allows clamping and release of the vertical
and horizontal arms.
Pushing the pushbutton located on this handle (Fig. 17)
the following operations can be carried out:
1° tripping: vertical arm descent (carried out manually);
2° tripping: locking of the vertical and horizontal arm in
working position;
3° tripping: unlocking of vertical and horizontal arm and
manual rise of vertical arm in rest position (all
upward).
Fig. 17
Version with tubeless inflation
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.
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.

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MAINTENANCE MANUAL
Page 17 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
12.0 USING THE MACHINE
12.1 Precaution measures during tyre re-
moval 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.
12.3 Bead breaking
After preparing the wheel as described in the previous
point, follow the instructions given below to carry out
the bead breaking procedure.
1. Position the wheel as indicated in Fig. 18 and move
the bead breaker tool toward the edge of the rim.
2. Operate the bead breaker shoe by pressing the rela-
tive pedal until the bead has detached. If the bead
does not detach the first time, repeat the operation,
on different points of the wheel, until it has come
completely away.
3. Reverse the position of the wheel and repeat the op-
eration on the other side.
4. Lubricate the tyre carefully along the entire circum-
ference of the bead on both sides. Failure to lubri-
cate might cause friction between the mounting tool
and the tyre, and would cause damage to the tyre
and/or the bead.
Fig. 18
NEVER INSERT ANY PART OF YOUR
BODY BETWEEN THE BEAD
BREAKER TOOL AND THE TYRE,
OR BETWEEN THE TYRE AND THE
WHEEL SUPPORT.
• Verify 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
“TD” and “AH”, in order to improve locking, bead break-
ing, assembly and disassembly performances..

INSTRUCTION, USE AND
MAINTENANCE MANUAL Page 18 of 33 GB
RAVAGLIOLI S.p.A. G8641 - G8645
7300-M010-1_R
Fig. 20
Fig. 21
In order to carry out the clamping of the wheel from the
outside: place the 4 self-centering jaws by using the ap-
propriate levers (Fig. 20 pos. 1) in correspondence to
the required clamping range.
Open the self-centering jaws and place them close to the
diameter of the rim to be clamped.
• Place the wheel on the turntable.
• Close the clamps, taking care that they engage the edge
of the rim.
12.5 Clamping the wheel on 30” chuck
The wheels must be clamped both from the inside and
from the outside compared to the edge of the rim.
In order to carry out the clamping of the wheel from the
inside: place the 4 self-centering jaws by using the
appropriate levers (Fig. 21 pos. 1) in correspondence
to the required clamping range.
• Close the turntable clamps, if open, by operating the
relative pedal.
• Place the wheel on the turntable.
• Press the pedal to open the clamps, until the wheel is
completely locked in place.
• Check that the rim is clamped and centred correctly
to ensure that the rim will not slip during the
operations which follow.
12.3.1 Bead breaking tool with double joint
(on demand)
The bead breaking tool is equipped with a double joint
(Fig. 19) that allows, during the bead breaking phase,
to optimize the relative position between the vane and
the bead of the tyre inserting the joint between the vane
and the edge of the rim.
If the machine is utilized with rims that have protected
edges or depressed tyres and/or tyres with heavy thick-
ness, it’s recommended to place the vane-joint so that
the hole (Fig. 19 pos. 2) can be utilized.
To change the position of the vane on the joint extract
the pin (Fig. 19 pos. 1) from the hole in which it is
inserted, turn the vane until the required hole corre-
sponds to the hole placed on the joint, then insert the
pin (Fig. 19 pos. 1) again into its new seat.
Fig. 19
12.4 Clamping the wheel on 18” - 20” - 22”
- 24” - 26” - 28” chuck
The wheels must be clamped both from the inside and
from the outside compared to the edge of the rim.
In order to carry out the clamping of the wheel from the
inside: place the 4 self-centering jaws by using the ap-
propriate levers (Fig. 20 pos. 1) in correspondence to
the required clamping range.
• Close the turntable clamps, if open, by operating the
relative pedal.
• Place the wheel on the turntable.
• Press the pedal to open the clamps, until the wheel is
completely locked in place.
• Check that the rim is clamped and centred correctly
to ensure that the rim will not slip during the opera-
tions which follow.

INSTRUCTION, USE AND
MAINTENANCE MANUAL
Page 19 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
In order to carry out the clamping of the wheel from the
outside: place the 4 self-centering jaws by using the ap-
propriate levers (Fig. 21 pos. 1) in correspondence to
the required clamping range.
Open the self-centering jaws and place them close to the
diameter of the rim to be clamped.
• Place the wheel on the turntable.
• Close the clamps, taking care that they engage the edge
of the rim.
12.6 Demounting the tyre
After clamping the wheel, the tyre is demounted follow-
ing the instructions given below, with reference to Fig.
22.
Fig. 23
1. Press the rotation pedal to turn the wheel clockwise
until the insert of the valve has reached the “1 o’clock”
position.
2. Unlock the arm using the push-button located on the
rod handle taking it to the 3rd tripping (see Fig. 17)
and releasing the arms.
3. Place the demounting/mounting arm on the external
edge of the rim (Fig. 23A pos. 1) pushing until the 1st
“tripping” the push-button (Fig. 17).
4. Lock it in position activating again the push-button
(Fig. 17) until the 2nd “tripping”.
5. Through the valve lever drive (Fig. 22 pos. 1), the
pneumatic cylinder activates the hook descent (mo-
bile part) (Fig. 23B pos. 2) which thread its way
between the edge of the rim and the tyre grabbing the
bead of the tyre itself. Then, reversing always through
the lever (Fig. 22 pos. 1) the cylinder direction, the
hook (Fig. 23C pos. 2) rises up again and thanks to
its movement the tyre steps over the edge of the rim
and places itself for the demounting operation on the
fixed part of the tool (Fig. 22D pos. 1).
6. Press the rotation pedal to turn the wheel clockwise
until the whole bead has been lifted from the rim.
7. Lift the tyre and repeat the operation on the other
bead.
If the motor slows down or stops during tyre demounting
and mounting, make the following checks:
• Check that the bead has been lubricated.
• Check that the bead has been pushed into the well.
• Check that the right side of the rim has been chosen
for demounting or mounting the tyre.
• Check that the rim well is not off-centre.
12.7 Mounting the tyre
To mount the tyre, proceed as follows:
1. Lubricate the tyre beads.
2. Place the tyre on the rim and place the mounting tool
on the outer edge of the rim.
3. Place the edge of the lower bead on the left-hand part
of the mounting tool and turn the turntable clock-
wise.
4. Repeat the operation on the upper bead, taking care
first to position the valve insert at “5-6 o’clock”.
Fig. 22

INSTRUCTION, USE AND
MAINTENANCE MANUAL Page 20 of 33 GB
RAVAGLIOLI S.p.A. G8641 - G8645
7300-M010-1_R
In the case the beads are not seated at 4,2±0,2 bar,
release all the air from the wheel, remove it from the
tyre changer and put it in a safety case to complete
the inflation procedure.
12.9 Tubeless tyre inflation device
Some types of tyres can be difficultly inflated if the beads
are not in contact with the rim.
The tubeless inflating device, assembled only on some
models, supplies air at high pressure to the selfcentering
chuck nozzles (Fig. 24 pos. 1) and therefore facilitates
the positioning of the beads against the rim starting the
normal inflation of the tyre.
In order to carry out the inflation of the tyre on these
models follow these indications:
• Connect the inflation terminal to the valve of the tyre
• Lift the lower bead while the pedal, placed on the left
side of the machine, is pushed at its second stage,
supplying that way the required air jet
• Go on inflating the tyre until the required pressure is
reached with the lateral pedal pushed on its first stage.
Fig. 24
A LIMITATION DEVICE IS PRESENT
IN THE AIR SUPPLY LINE FOR THE
TIRE INFLATION (4,2 ± 0,2 BAR/60
PSI).
IN ORDER TO ALLOW THE AIR JET
TO BREAK BOTH THE BEADS, DO
NOT KEEP THE BEAD LIFTED
FORCING IT.
12.8 Tyre inflation with pressure gauge (on
demand)
Connect the inflation device to the tyre valve and inflate
the tyre using the left pedal.
Well lubricated beads and rims make the beading in
and inflation much safer and easier.
13.0 ROUTINE MAINTENANCE
To guarantee the efficiency and correct functioning of the
machine, it is essential to carry out daily or weekly clean-
ing and weekly routine maintenance, as described be-
low.
Cleaning and routine maintenance must be conducted
by authorized personnel and according to the instruc-
tions given below.
• Disconnect the mains power supply before starting
any cleaning or routine maintenance operations.
• Periodically check the calibration of lubricator in pres-
sure/oiler gauge unit: one oil drop every four complete
strokes of self-centering chuck jaws.
• Remove deposits of tyre powder and other waste ma-
terials with a vacuum cleaner.
BEFORE CARRYING OUT ANY ROU-
TINE MAINTENANCE PROCEDURE,
DISCONNECT THE MACHINE FROM
ITS POWER SUPPLY SOURCES, TAK-
ING SPECIAL CARE OF THE ELEC-
TRICAL PLUG/SOCKET CONNEC-
TION.
DO NOT BLOW IT WITH COMPRESSED AIR.
• Do not use solvents to clean the pressure regulator.
• The conditioning unit is equipped with an automatic
vacuum-operated drain therefore it requires no manual
intervention by the operator (see Fig. 25).
BEFORE CARRYING OUT ANY MAIN-
TENANCE OPERATIONS, MAKE
SURE THERE ARE NO WHEELS
CLAMPED ON THE CHUCKING TA-
BLE AND THAT ALL SUPPLIES TO
THE MACHINE HAVE BEEN DIS-
CONNECTED.
Fig. 25
PRESSION
REGULATOR
AIR SUPPLY
AUTOMATIC
VACUUM-OPERATED
RELEASE
OILER