Ravaglioli PLUS91S User manual

1
7700-M002-3 - Rev. n. 3 (09/2011)
For spare parts drawings refer to the section “ LIST OF COMPONENTS” enclosed to this manual.
• For any further information please contact your local dealer.
GB TRANSLATION FROM THE
ORIGINAL INSTRUCTIONS
PLUS91S
PLUS91N
PLUS91SE
PLUS91SA
G800A69
7700-M002-3
INSTRUCTION MANUAL

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ASSEMBLING AND USE
INSTRUCTIONS Page 2 of 22
PLUS91S - PLUS91N
PLUS91SE - PLUS91SA - G800A69
SUMMARY
1.0 GENERAL INFORMATION __________ 5
2.0 INTENDED USE ____________________ 5
2.1 Staff training __________________________ 5
3.0 GENERAL SAFETY RULES _________ 5
4.0 TRANSPORT OF THE PACKAGED
DEVICE ____________________________ 6
4.1 Packing and mobilization for transport
of device only __________________________ 6
4.2 Transport of the device delivered
packaged together with the machine ___ 6
5.0 UNPACKING _______________________ 6
6.0 INSTALLATION AREA ______________ 6
7.0 ASSEMBLY AND START-UP ________ 7
7.1 Accessories inside the packaging _______ 7
7.2 Installation procedure _________________ 7
7.2.1 Plus91S device installation _________ 7
7.2.2 Plus91N device installation _________ 8
7.2.3 Plus91SE device installation _______ 8
7.2.4 Plus91SA device installation _______ 9
7.2.5 G800A69 lifting device
installation ________________________ 9
7.3 Pneumatic connection _______________ 10
8.0 USE OF THE DEVICE _____________ 11
8.1 Work environment condition _________ 11
8.2 Precaution measures during the
assembly and the disassembly of
tyres ________________________________ 11
8.3 Control unit _________________________ 11
8.4 Using the lift _________________________ 11
8.5 Rim clamping with tyre depressed on
self-centering chucks ________________ 13
8.6 Demounting tyres ____________________ 13
8.6.1 Demounting second bead through
bead lifting roll __________________ 15
8.7 Mounting tyres ______________________ 15
9.0 ROUTINE MAINTENANCE_________ 17
10.0 TROUBLESHOOTING TABLE _____ 17
11.0 TECHNICAL DATA ________________ 17
11.1 Weight _______________________________ 17
11.2 Dimensions __________________________ 18
12.0 STORING _________________________ 20
13.0 SCRAPPING _______________________ 20
14.0 FUNCTIONAL DIAGRAMS_________ 20
Drawings A - Pneumatic diagram __________ 21
15.0 LIST OF COMPONENTS

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PLUS91S - PLUS91N
PLUS91SE - PLUS91SA - G800A69
KEY
1 – Rotary bead depressing unit
2 – Control unit
3 – Pneumatic cylinder
4 – Pressing roll - bead lifting
5 – Entrainer G1000A98 (if required)
FIG. 1 - PLUS91S DEVICE
FIG. 2 - PLUS91N DEVICE
KEY
1 – Rotary bead depressing unit
2 – Control unit
3 – Pneumatic cylinder
4 – Pressing roll - bead lifting
5 – Entrainer G1000A98 (if required)

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PLUS91S - PLUS91N
PLUS91SE - PLUS91SA - G800A69
FIG. 3 - PLUS91SE DEVICE - G800A69
KEY
1 – Rotary bead depressing unit
2 – Control unit
3 – Pneumatic cylinder
4 – Pressing roll - bead lifting
5 – Entrainer G1000A98 (if required)
6 – Lifting device (G800A69 if required)
FIG. 4 - PLUS91SA DEVICE - G800A69
KEY
1 – Rotary bead depressing unit
2 – Control unit
3 – Pneumatic cylinder
4 – Pressing roll - bead lifting
5 – Entrainer G1000A98 (if required)
6 – Lifting device (G800A69 if required)

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INSTRUCTIONS
Page 5 of 22
PLUS91S - PLUS91N
PLUS91SE - PLUS91SA - G800A69
The technical documentation supplied is an integral part
of the fitting; therefore, if the equipment is sold all the
documentation must be consigned with it.
2.0 INTENDED USE
The PLUS91S and PLUS91N devices are fittings appli-
cable on all plated demounting machines with flag tool
holder arm (“swing” series) and these devices are des-
tined to be used as a supporting equipment during
tyres assembly and disassembly phases.
The PLUS91SE device is a fitting applicable on all the
tyre demounting machines series PC246, G7246,
PC250 and G7250 and it is destined to be used as a
supporting equipment during tyres assembly and dis-
assembly phases.
The PLUS91SA device is a fitting applicable on all the
tyre demounting machines series G7246, G7250,
G8246, G8250 in the “A” version and it is destined to
be used as a supporting equipment during tyres as-
sembly and disassembly phases.
The G800A69 lifting device is an accessory to be ap-
plied to PLUS91SE and PLUS91SA and it is intended
as an aid while the removal and positioning phases of
the wheel (max. 80 kg) from the chuck.
The fitting can operate on all the wheels having their
maximum dimensions included within the limits of the
tyre demounting machine on which it is assembled.
2.1 Staff training
The installation of the fitting is allowed only by suit-
ably trained and authorized personnel.
In view of the importance of the operations needed to
install and utilize the fitting and to carry out procedures
efficiently and safely, the personnel using the machine
must be correctly trained, so that they acquire the infor-
mation required for operation in line with the guidelines
provided by the manufacturer.
A careful reading of this instruction manual and a short
period of training with skilled personnel can be an enough
preventive preparation.
This accessory must be only destined to the use for
which it has been expressly conceived.
Any other use is considered improper and therefore
unacceptable.
The manufacturer may not be considered responsi-
ble for any damage caused by improper, incorrect or
unreasonable use of the accessory.
3.0 GENERAL SAFETY RULES
• Any tampering with or modification of the fitting
not authorised in advance by the manufacturer re-
lieves the latter of liability for damage consequent
on or related to such operations.
• Use of the fitting 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.
• Installation must be carried out by qualified staff, in
full accordance with the instructions provided below.
• Check that no dangerous situations arise during op-
eration; if malfunctions are noted, don’t use the fit-
ting, and contact your authorised dealer’s after-sales
service.
• The operator must wear appropriate working cloth-
ing, protective goggles, gloves and mask to avoid dam-
age deriving from hazardous dust emissions. Dangling
objects such as bracelets must not be worn, long hair
must be suitably protected, and shoes must be suit-
able for the type of operation to be carried out.
• The fitting handles and operating grips must be kept
clean and free from oil.
• Never activate the inflation fitting if the wheel is not
properly locked on the self-centering chuck.
1.0 GENERAL INFORMATION
The present manual is an integral part of the prod-
uct.
Read the warnings and instructions in this manual care-
fully, since they provide important information concern-
ing ASSEMBLY, USE AND MAINTENANCE SAFETY
OF THE FITTING.
N.B.: since the illustrations in this manual have been
obtained from photographs of prototypes, some parts
and components of the fitting may not be as shown
herein.
KEEP THIS MANUAL IN A SAFE
PLACE FOR FUTURE CONSULTA-
TION WHENEVER REQUIRED.

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PLUS91S - PLUS91N
PLUS91SE - PLUS91SA - G800A69
4.0 TRANSPORT OF THE PACKAGED
DEVICE
The lifting device must have a capacity at least equal to
the weight of the packaged device (see paragraph “Tech-
nical data”).
The load handling operations must be carried out only
by skilled personnel.
4.1 Packing and mobilization for trans-
port of device only
The device is supplied packed in a cardboard box. Move-
ment must be by pallet-lift or fork-lift trolley.
4.2 Transport of the device delivered
packaged together with the machine
1) Lower completely the pressing arm (Fig. 5 pos.1).
The device can be moved only if also the machine where
it is fixed is moved. Check that all the mobile ele-
ments of the device are locked. Follow all the instruc-
tions about the tyre changing machine described in
its use manual.
2) Follow the lifting procedure described in the manual
about the tyre changing machine where the accessory
is installed on.
Fig. 5
5.0 UNPACKING
This fitting is supplied completely assembled.
Carry out the unpacking and installation operations
described below with care.
Failure to comply with these recommendations may
cause damage to the fitting and put the operator at
risk.
The packaging components (plastic bags, expanded poly-
styrene, etc.) must not be left within reach of children
since they are potentially dangerous.
Dispose of all contaminating or non-biodegradable ma-
terials appropriately.
During the unpacking always wear gloves to avoid
scratches caused by the contact with the packing mate-
rial (rivets and so on...).
6.0 INSTALLATION AREA
Fig. 6
The installation of the device need a useful space, on the
machine side, of 600x1000 mm (as indicated in Fig. 6)
through the representation in dash line.
The operator must be able to see the entire equipment
and the surrounding area from the control position. In
this area, he must be able to see any unauthorised peo-
ple or items which might constitute a hazard.
PLUS91SE - PLUS91SA DEVICE - G800A69

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PLUS91S - PLUS91N
PLUS91SE - PLUS91SA - G800A69
7.0 ASSEMBLY AND START-UP
After removing the packaging from the fitting, check it
for damage or any anomalies and then follow the instruc-
tion provided below to put the lift into operation.
7.1 Accessories inside the packaging
Inside the packing case there are also accessories neces-
sary for the assembly of the Device on the tyre demounting
machine.
Check that all the pieces listed below are present:
N.
4
4
4
4
8
Code
203058
228307
203038
236006
236007
TE M10x25 screw
M10 triblock nut
TE M8x25 screw
8,4 flat washer
Fe 10,5x21x2 washer
Description
7.2 Installation procedure
7.2.1 Plus91S device installation
Before carrying out any operation it’s obbligatory to
cut the voltage to the tyre demounting machine.
Fasten the Plus91S Device (Fig. 7 pos. 1) to the ma-
chine, as shown in figure, utilizing the screws (# 203058)
(Fig. 7 pos. 2), (# 203038) (Fig. 7 pos. 3), the washers
(# 236007) (Fig. 7 pos. 4), (# 236006) (Fig. 7 pos. 5)
and the nuts (# 228307) (Fig. 7 pos. 6).
PLUS91N DEVICE
N.
4
4
8
Code
228307
203058
236007
M10 triblock nut
TE M10x25 screw
Fe 10,5x21x2 washer
Description
PLUS91S DEVICE
N.
1
1
1
Code
325181
317006
325054
V8 union
6x4 black pipe
6-8 reduction
Description
Fig. 7
N.
4
4
4
4
8
Code
203058
228307
203038
236006
236007
TE M10x25 screw
M10 triblock nut
TE M8x25 screw
8,4 flat washer
Fe 10,5x21x2 washer
Description
PLUS91SE - PLUS91SA DEVICE
G800A69 LIFTING DEVICE
N.
2
2
4
Code
203058
228307
236007
TE M10x25 screw
M10 triblock nut
Fe 10,5x21x2 washer
Description

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ASSEMBLING AND USE
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PLUS91S - PLUS91N
PLUS91SE - PLUS91SA - G800A69
7.2.2 Plus91N device installation
Before carrying out any operation it’s obbligatory to
cut the voltage to the tyre demounting machine.
Fasten the Plus91N Device (Fig. 8 pos. 1) to the ma-
chine, as shown in figure, utilizing the screws (# 203058)
(Fig. 8 pos. 2), the nuts (# 228307) (Fig. 8 pos. 3) and
the washers (# 236007) (Fig. 8 pos. 4).
The pin (Fig. 8 pos. 5) will substitute the one already
placed on the column unit (Fig. 8 pos. 6).
Fig. 8
7.2.3 Plus91SE device installation
Before carrying out any operation it’s obbligatory to
cut the voltage to the tyre demounting machine.
Fasten the Plus91SE Device (Fig. 9 pos. 1) to the ma-
chine, as shown in figure, utilizing the screws (# 203058)
(Fig. 9 pos. 2), (# 203038) (Fig. 9 pos. 3), the washers
(# 236007) (Fig. 9 pos. 4), (# 236006) (Fig. 9 pos. 5)
and the nuts (# 228307) (Fig. 9 pos. 6).
Fig. 9

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PLUS91S - PLUS91N
PLUS91SE - PLUS91SA - G800A69
7.2.4 Plus91SA device installation
Before carrying out any operation it’s obbligatory to
cut the voltage to the tyre demounting machine.
Fasten the Plus91SA Device (Fig. 10 pos. 1) to the ma-
chine, as shown in figure, utilizing the screws (# 203058)
(Fig. 10 pos. 2), (# 203038) (Fig. 10 pos. 3), the wash-
ers (# 236007) (Fig. 10 pos. 4), (# 236006) (Fig. 10
pos. 5) and the nuts (# 228307) (Fig. 10 pos. 6).
7.2.5 G800A69 lifting device installation
Before carrying out any operation it’s obbligatory to
cut the voltage to the tyre demounting machine.
Unscrew the cylinder fastening screw (Fig. 11 pos. 2)
and the screws (Fig. 11 pos. 3) fixing the lower bracket
(Fig. 11 pos. 4) to the machine. Downwards remove the
bracket (Fig. 11 pos. 4) from the shaft (Fig. 11 pos. 5).
Fix the lifting unit (Fig. 11 pos. 1) to the device, accord-
ing to the figure indications. In the end, fix again the
lower bracket: carry out the previously described opera-
tions in reverse order.
Fix on the lateral side of the demounting machine frame
the rotation stopper (Fig. 11 pos. 6), as shown in fig-
ure, using the screws (Fig. 11 pos. 7), the washers (Fig.
11 pos. 8) and the nuts (Fig. 11 pos. 9) supplied. Use
the casing-fixing screw (Fig. 11 pos. 10) to fix the lower
side of the rotation stopper (Fig. 11 pos. 6).
Fig. 10
Fig. 11

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PLUS91S - PLUS91N
PLUS91SE - PLUS91SA - G800A69
Apply the voltage again to the machine.
WHEN THE ASSEMBLY PROCEDURES ARE COM-
PLETE, MAKE A CHECK ON ALL MACHINE FUNC-
TIONS.
IN CASE OF DOUBTS DON’T UTILIZE THE MA-
CHINE AND CALL SKILLED TRAINED PERSON-
NEL OR THE JOBBER.
Fig. 15
d - Interpose between the two pipe sections (Fig. 15 pos.
1A - 1B) the “V”union (Fig. 15 pos. 2) (#325181).
Insert the reduction (Fig. 15 pos. 3) (#325054) and
connect the pipe (Fig. 15 pos. 4) coming from the
Plus device control valve to the “V” union (Fig. 15
pos. 2).
c - Cut off the pipe (Fig. 14 pos. 1) as shown in Fig. 14.
Fig. 14
7.3 Pneumatic connection
a - Fix with a clamp (Fig. 12 pos. 4) the union (Fig. 12
pos. 1) on the lateral duct (Fig. 12 pos. 3), exploiting
the black pipe (Fig. 12 pos. 2) that comes out from
it.
Fig. 12
b - In case of connection with tubeless inflation ma-
chine, it is advisable to introduce the black pipe (Fig.
13 pos. 1) through the hole placed on the tank sup-
port (Fig. 13 pos. 1).
Fig. 13
1
3
4
2
1
2