Total Source 161TA6945 User manual

OPERATING MANUAL
SOLID TYRE PRESS
161TA6945 161TA6944
Original operating
manual
08/2021 – V01

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© 08-2021. TVH
®
and TotalSource
®
are registered trademarks. TVH Parts Holding NV, Brabantstraat 15, B-8790 Waregem. All rights reserved.
No part of this publication may be reproduced or communicated in any form or by any means, electronic or mechanical, including copying,
recording or use in an information storage or retrieval system, without prior and explicit permission of TVH Parts Holding NV. Printing errors
reserved. Photographs and illustrations are included for reference purposes only.
Responsible editor: TVH Parts Holding NV, Brabantstraat 15, BE-8790 Waregem
TVH is a supplier of after-market spare parts and accessories that are suitable for the maintenance and repair of OEM equipment.

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www.tvh.com/solidtyrepress-rv01
BG Bulgarian Можете да намерите това ръководство на Вашия език чрез линка, посочен по–
долу.
CS Czech Tento návod najdete ve svém jazyce prostřednictvím odkazu níže.
DA Danish Du kan finde denne vejledning på dit sprog via nedenstående link.
DE German Sie finden diese Bedienungsanleitung in Ihrer Sprache unter folgendem Link.
EL Greek Μπορείτε να βρείτε αυτό το εγχειρίδιο στη γλώσσα σας έσω του παρακάτω
συνδέσου.
EN English You can find this manual in your language via below link.
ES Spanish Encontrarás este manual en su propio idioma a través del siguiente enlace.
ET Estonian Oma emakeelse juhendi leiate allolevalt lingilt.
FI Finnish Löydät tämän manuaalin omalla kielelläsi alla olevan linkin takaa.
FR French Vous trouverez ce manuel dans votre langue via le lien ci-dessous.
GA Irish Tá an lámhleabhar seo ar fáil i do theanga tríd an nasc thíos.
HR Croatian Ovaj prirucnik mozete pronaci na svom jeziku putem donjeg linka.
HU Hungarian Ez a kézikönyv az Ön nyelvén az alábbi link alatt található.
IS Icelandic Hægt er að finna þessa handbók á þínu tungumáli á tenglinum hér að neðan.
IT Italian Cliccando sul link sottostante troverai il manuale nella tua lingua.
LT Lithuanian Šį vadovlėlį savo kalba rasite spustelėję žemiau esančią nuorodą.
LV Latvian Rokasgrāmatu latviešu valodā Jūs varat atrast izmantojot zemāk esošo saiti.
MT Maltese Tista’ ssib dan il-manwal bil-lingwa tiegħek permezz tal-link ta’ hawn taħt.
NL Dutch Je vindt deze handleiding in jouw taal via onderstaande link.
NO Norwegian Du finner denne håndboken på ditt språk via linken nedenfor.
PL Polish Niniejsza instrukcja obsługi dostępna jest w Twoim języku za pośrednictwem
poniższego linku.
PT Portuguese Pode encontrar este manual no seu idioma através do link abaixo.
RO Romanian Putei găsi acest manual în limba dvs. prin link-ul de mai jos.
SK Slovak Manuál vo vašom jazyku môžete nájst v priloženom vysvietenom riadku.
SL Slovenian Ta priročnik najdete v svojem jeziku preko spodnje povezave.
SV Swedish Du kan hitta denna manual på ditt språk via länken nedan.
TR Turkish Bu kılavuzu aşağıdaki bağlantıdan kendi dilinizde bulabilirsiniz.

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Thank you for using our product. For your safety and to ensure a correct operation, we would
like to bring to your attention some aspects of this manual:
• This booklet supplies useful instructions for the correct operation and maintenance of the
product. It is therefore necessary to pay the utmost attention to all of the paragraphs that
illustrate the most simple and secure way to operate and use this product.
• This booklet must be considered an integral part of the machine and must be included
with the deed of sale.
• Neither this publication, nor part of it, can be reproduced without written authorisation on
the part of the manufacturer.
• All of the information reported herein is based on data available at the moment of printing;
the manufacturer reserves the right to carry out modifications to its own products at any
moment, without notice and without incurring in any sanction. It is therefore suggested to
always check for possible updates.
The person responsible for the use of the product must make sure that all of the safety rules
in force in the country of its use are applied, to guarantee that the equipment is used in
conformity with the use for which it is destined and to avoid any dangerous situation for the
user.
The following warning signs are used in this manual to warn you for dangers and risks:
Informative, be careful.
Warning, can lead to injury and damage if instructions aren’t followed.
Danger, can lead to serious or fatal injury and serious damage if instructions
aren’t followed.
The following conventions are used in this manual:
1
6
3
2
5
4
1 Left
2Top
3 Back
4 Right
5 Bottom
6Front

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TABLE OF CONTENTS
1. INTRODUCTION..................................................................................... 6
2. DESCRIPTION....................................................................................... 8
2.1. Technical data .......................................................................................8
2.2. Main components of the product................................................................10
2.3. Placement of the decals..........................................................................10
2.4. Type plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3. SAFETY INSTRUCTIONS.........................................................................12
3.1. Explanation of the safety decals ................................................................12
3.2. Electrical diagram and hydraulic diagram ....................................................13
3.3. General safety instructions ......................................................................14
4. TRANSPORT AND STORAGE ....................................................................15
4.1. Transport ............................................................................................15
4.2. Storage ..............................................................................................17
5. ASSEMBLY AND INSTALLATION ...............................................................18
5.1. Packing list..........................................................................................18
5.2. Safety instructions for the assembly and installation of the product.....................18
5.3. Required materials for assembly ...............................................................19
5.4. Place designation of the product................................................................19
5.5. Securing the product to the ground ............................................................20
6. COMMISSIONING..................................................................................21
6.1. Connecting to the mains..........................................................................21
6.2. Testing the solid tyre press.......................................................................21
6.3. The emergency stop switch ......................................................................22
7. OPERATION.........................................................................................23
7.1. Safety instructions for operating the product ................................................23
7.2. Operating instructions ............................................................................23
8. MAINTENANCE ....................................................................................36
8.1. Safety instructions for the repair of the product .............................................36
8.2. Maintenance schedule............................................................................37
8.3. Maintenance instructions ........................................................................37
9. TROUBLESHOOTING .............................................................................40
10. FINAL DECOMMISSIONING AND DISPOSAL ................................................42
11. ANNEXES ...........................................................................................44
11.1. CEcertificate .......................................................................................44
11.2. Spare parts list tyre press........................................................................48
11.3. Spare parts list accessories .....................................................................62

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1. INTRODUCTION
This manual contains all the necessary information on the installation and operation of
the solid tyre press. Some of the maintenance operations should only be carried out by
professional technicians.
If you require this information and the maintenance steps, please contact your dealer.
Also included in this manual are a number of safety instructions to create a safe working
environment.
The solid tyre press is an indispensable piece of equipment for tyre mounting and
maintenance of solid tyres. The solid tyre press is a stationary model. It has the merit of
being easy to operate and of delivering reliable performance.
This solid tyre press uses a hydraulic and an electrical system.
The solid tyre press is only suitable for the assembly and disassembly of solid rubber tyres
on metal
rims. The type plate shows the maximum tyre dimensions that can be handled.
Please read the manual thoroughly and observe the safety procedures before putting the
unit into operation. The operator and all persons who come into contact with the equipment
should read it carefully and regularly and have access to it at all times.
Keep this manual near the equipment and in a safe place for future reference!
Contact your dealer for any further questions or concerns you may have.
We hope you will enjoy working with your solid tyre press.
If you wish to use this solid tyre press in extreme conditions such as extreme heat,
extreme cold, extreme drought, etc., please contact your dealer to discuss whether
this product is suitable for the activities you wish to undertake with the solid tyre
press.
Consult the manual of the truck and/or trailer to know where to place the trailer safety jack.

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This solid tyre press may be unsafe if adequate maintenance is neglected. Therefore,
adequate maintenance facilities, trained personnel and procedures should be
provided.
Maintenance and inspection shall be performed in conformity with the following
practices:
1. A scheduled planned maintenance, lubrication and inspection system should be
followed (see maintenance instructions chapter8).
2. Only qualified and authorised personnel shall be permitted to maintain, repair,
adjust and inspect the solid tyre press.
3. Modifications and additions which affect capacity and safe operation shall not
be performed by the customer or user without the manufacturer’s prior written
approval. Capacity, operation and maintenance plates or decals shall be changed
accordingly.
4. If modifications are made without the written approval of the manufacturer,
thewarranty will no longer apply.
Any person in charge of putting the machine into operation, the operation itself or
the maintenance of the machine is urged to carefully read and observe the following
instructions.
Make sure that the operators of this product are familiar with the safety instructions
and follow all the procedures. Neglecting these instructions can lead to injury or
death.
We guarantee a long period of trouble-free operation if the unit is operated and
maintained correctly.

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2. DESCRIPTION
2.1. Technical data
Always check the type plate for the correct information.
161TA6945
Type TP120
Capacity (kg) 120000
Max tyre dimension (mm) 1000x20
Total length (mm) 2080
Total width (mm) 850
Total height (mm) 2151
Operating pressure (bar) 230
Cylinder stroke (mm) 400
Oil tank capacity (L) 30
Electric motor power (kW) 7.5
Sound level dB(A) 70
Weight (kg) 1600
Humidity (%) 80
Input voltage AC380V 50Hz 3-phase
Protection degree (IPXXX) IP23
System pressure 23MPa
161TA6944
Type TP120
Capacity (kg) 120000
Max tyre dimension 1000x20
Total length (mm) 2080
Total width (mm) 850
Total height (mm) 2151
Operating pressure (bar) 230
Cylinder stroke (mm) 400
Oil tank capacity (L) 30
Electric motor power (kW) 7.5
Sound level dB(A) 70
Weight (kg) 1600
Humidity (%) 80
Input voltage AC220V 50Hz 3-phase
Protection degree (IPXXX) IP23
System pressure 23MPa

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1200 299
750
160
850
2151
2080 850
2550
50 104943
400
840

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2.2. Main components of the product
2.3. Placement of the decals
The safety and warning labels should be placed as described in the pictures below.
Seechapter3 for the explanation of the safety warnings. If the decals are damaged or
missing, replace them.
1
4
2
3
5
6
7
4
13
5
6
7
1
12
2
3
8
9
8
11
10
N° Component
1 Cylinder
2Hydraulic hoses
3Control panel
4ON/OFF button
5Pressure gauge
6Hydraulic pump unit
7Electrical equipment box
N° Component
8Safety decals
9Electric motor
10 Mounting holes
11 Fork pockets
12 Pressure plate
13 Type plate
1
12
3
4
13
14
11
2
5
6
7
8
9
10

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2.4. Type plate
TYPE
TYP
MODEL
MODÈLE
MODELL
SERIAL NBR.
SERIENUMMER - N° SÉRIE
SERIENNUMMER
YEAR OF CONSTRUCTION
BOUWJAAR - ANNÉE DE CONSTRUCTION
BAUJAHR
DIMENSION TYRES MIN/MAX
BANDENMAAT - DIMENSION PNEUS
REIFENMASS
Do not wash with water jet.
Niet met waterstraal reinigen. Ne pas laver avec jet d’eau. Nicht mit Wasserstrahl reinigen.
WEIGHT
GEWICHT - POIDS
EIGENGEWICHT kg
ELECTRO MOTOR
KWHz
Phase
/ mm
/ inch
NOM. CAP.
NOM. VERMOGEN
NOM. LEISTUNG kg
INPUT
EL. VERMOGEN - CAP. EL.
EL. LEISTUNG V
MAX. WORKPRESSURE
MAX. WERKDRUK - PRESSION MAX. DE SERVICE
MAX . ARBEITSDRUCK
bar
Brabantstraat 15 • BE- 8790 Waregem
T [phone] • F [phone]T [phone] • F [phone]
[email protected]
• www.totalsource.com
TVH 10314685
1
2
3
4
5
6
7
8
9
10
11
12
13
N° Explanation
1 Address
2CE marking
3 Brand
4 Description
5 Model
6Serial number
7Year of construction
8Weight (kg)
9Electric motor specifications (Hz/kW)
10 Minimum and maximum dimension of tyres
(inch)
11 Nominal power (kg)
12 Input voltage (V)
13 Maximum working pressure (bar)

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3. SAFETY INSTRUCTIONS
3.1. Explanation of the safety decals
If the decals are damaged or missing, please replace them.
N° Decal Explanation Reference
1
TYPE
typ
MODEL
modèle
modell
SERIAL NBR.
serienummer - n° série
seriennummer
YEAR OF CONSTRUCTION
bouwjaar - année de construction
baujahr
DIMENSION TYRES (MIN/MAX)
bandenmaat - dimension pneus
reifenmass
Do not wash with water jet.
Niet met waterstraal reinigen. Ne pas laver avec jet d’eau. Nicht mit Wasserstrahl reinigen.
WEIGHT
gewicht - poids
eigengewicht kg
ELECTRO MOTOR
KWHz
Phase
/ mm
/ inch
NOM. CAP.
nom. vermogen
nom. leistung kg
INPUT
el. vermogen - cap. el.
el. leistung V
MAX. WORKPRESSURE
max. werkdruk - pression max. de service
max . arbeitsdruck
bar
Brabantstraat 15 • BE- 8790 Waregem
T [phone] • F [phone]
[email protected]
• www.totalsource.com
TVH 10314685
Type plate 166TA6950
2Risk of entrapment of hands and fingers in the
moving parts
163TA4319
3Risk of entrapment of body parts 166TA6674
4Danger of high-pressure oil in hydraulic lines 166TA6676
5No unauthorised access 163TA4585
6No picture available No other persons apart from the user of the
device may come near the device
Contact
your dealer
7Eye protection mandatory 166TA6678

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N° Decal Explanation Reference
8Hearing protection mandatory 162TA5381
9Safety gloves mandatory 162TA1674
10 Safety shoes mandatory 123TA5144
11 Risk of electric shock 166TA6677
12 Brand 166TA2311
13 Read the manual before each use 166TA6675
14 Risk of entrapment in moving parts 126TA9774
3.2. Electrical diagram and hydraulic diagram
Electrical and hydraulic diagrams are available on request. If you wish to obtain them,
please contact your dealer.
• Only qualified and authorised personnel shall be permitted to maintain, repair,
adjust and inspect the solid tyre press.
• Modifications and additions which affect capacity and safe operation shall not
be performed by the customer or user without the manufacturer’s prior written
approval. Capacity, operation and maintenance plates or decals shall be changed
accordingly.
• If modifications are made without the written approval of the manufacturer,
thewarranty will no longer apply.

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3.3. General safety instructions
• Do not operate the product unless you are of age.
• The person responsible for the use of the product must make sure that all of the
safety rules in force in the country of its use are applied, to guarantee that the
equipment is used in conformity with the use for which it is destined and to avoid
any dangerous situation for the user.
• The solid tyre press must be installed and maintained in accordance with all the
applicable national and local codes. A power disconnect switch must be located
near the equipment. Check the technical data for voltage and phase requirements.
• Use the solid tyre press for the purpose for which it is designed. Do not carry out
any other work on it.
• Do not operate the solid tyre press if any components are damaged or missing.
• Immediately stop the solid tyre press in case of hose or line breaks, defective
cylinders or other components.
• The operator should wear safety glasses, hearing protection, safety shoes and
safety gloves when using or maintaining the solid tyre press.
• To prevent burns, fire and explosion, regularly check all pipes, hoses and
tubes. Never bend or crush the pipes! Have damaged pipes or hoses repaired
immediately.
• For safety reasons, the solid tyre press has a 4-way plug as a safety feature and
only fits into an earthed socket. If you cannot insert the plug into the socket,
youmay have an older, ungrounded socket. Contact an electrician to have the
outlet replaced. Do not use an adapter to ground the outlet.
• Read this manual carefully. Make sure that the manual is available at all times and
store it in a dry, dark place near the unit.
• Do not overload the solid tyre press in any way.
• Do not carry out repairs or maintenance work while the solid tyre press is running.
First cut off the power supply.
• Do not insert any objects into rotating parts such as cooling fans and/or electric
motors.
• The solid tyre press is a source of power. Through intensive use, incorrect
connection or overloading, parts can become hot. Avoid touching hot components
at all times.
• Do not wear loose clothing so that the clothing cannot get caught in the solid tyre
press.
• Protect the power cord from being walked on or becoming pinched. If the power
cord is damaged or frayed, replace it immediately.
• If an extension cord or receptacle is used, ensure that the total amperage required
for all equipment on the extension is less than the rating of the extension.
• Only people who work with the solid tyre press may be in the vicinity of the device.
Other people must keep a minimum distance of 3 metres.
• Pneumatic tyres cannot be fitted using the solid tyre press.

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4. TRANSPORT AND STORAGE
The operator should wear safety glasses, hearing protection, safety shoes and safety
gloves when using or maintaining the solid tyre press.
• If lifting equipment is used when installing the solid tyre press, the operators
must also be familiar with the operating procedures of the lifting equipment used.
Readthe manual before using the lifting equipment.
• The solid tyre press may only be lifted with the fork pockets intended for this
purpose.
• Make sure that nobody can be on top of, next to or under the solid tyre press during
the transport and/or lifting of the solid tyre press in connection with possible tilting
or falling.
• When moving the solid tyre press by lorry or van, make sure that the solid tyre
Press is secured with some tension straps, for example. Make sure that they are
not stretched over the control panel.
• Observe the weight of the solid tyre press.
• Do not install the solid tyre press in a place subjected to direct sunlight, excessive
dust, mechanical vibrations or shocks.
4.1. Transport
We recommend that once the solid tyre press has been delivered, it should not be
moved by a truck or van. Immediately move the solid tyre press to its designated
place with a forklift truck.
If you do want to use a truck or van, place the solid tyre press against the wall of the loading
space and secure the solid tyre press with straps that can hold its weight.
Jolting caused by the wheels catching on uneven surfaces can cause physical strain
and personal injury.
When using a forklift, make sure that the forklift truck can lift the solid tyre press.
See the type plate for the correct weight.

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1. Lifting
1. Make sure the solid tyre press is on a flat and stable surface.
2. Stand in front of the solid tyre press with the forklift.
3. Place the forks at the same height as the fork pockets.
4. Insert the forks in the fork pockets.
5. Drive the forklift truck as far forward as possible so that the solid tyre press hits the ends
of the forks.
6. Once the solid tyre press is on the forks, raise it about 200mm off the ground.
7. Tilt the mast of the forklift slightly backwards so that it is at an angle of 95degrees.
8. Drive at a slow pace, do not make abrupt movements and do not brake suddenly.
Correct pick-up Incorrect pick-up
200 mm

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2. Lowering
1. When lowering the solid tyre press, first return the mast of the forklift to its upright
position. Do this gently and slowly so that the solid tyre press cannot tip over.
2. Lower the forks until the solid tyre press is on the ground again
4.2. Storage
• Make sure that the solid tyre press is located on a flat surface.
• Make sure that there is no direct sunlight on the solid tyre press.
• Do not cover the solid tyre press so that it can cool down sufficiently.
• Do not place the solid tyre press in a humid area or a place where splashes of any kind of
liquid can hit it.
• The solid tyre press should be stored in a space between –20°C and 60°C.
– This solid tyre press uses hydraulic oil, extreme temperatures may lead to a change in
the oil’s viscosity.
• Keep the solid tyre press away from areas where sparks are generated.
• Provide good ventilation.
• Place protection around the solid tyre press so that no one can drive into or collide with it.
• Place a fire extinguisher close by.
• Install smoke detectors nearby.
• Do not place any objects on top of the solid tyre press. Keep a clean working space.

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5. ASSEMBLY AND INSTALLATION
5.1. Packing list
161TA6944
Description Amount Reference
Solid tyre press 1 161TA6944
Reduction table 1 166TA5332
Operating manual 1 166TA9027
161TA6945
Description Amount Reference
Solid tyre press 1 161TA6945
Reduction table 1 166TA5332
Operating manual 1 166TA9027
The necessary tools to assemble and disassemble tyres are not supplied with the solid tyre
press. All necessary tools can be found in chapter11C.
5.2. Safety instructions for the assembly and installation of the product
The operator should wear safety glasses, hearing protection, safety shoes and safety
gloves when using or maintaining the solid tyre press.
To prevent burns, fire and explosion, regularly check all pipes, hoses and tubes.
Never bend or crush the pipes! Have damaged pipes or hoses repaired immediately.
• If an extension cord or receptacle is used, ensure that the total amperage required
for all equipment on the extension is less than the rating of the extension.
• Protect the power cord from being walked on or becoming pinched. If the power
cord is damaged or frayed, replace it immediately.
• Do not install the solid tyre press near heat sources such as radiators or air ducts.
• Do not install the solid tyre press in a place subjected to direct sunlight, excessive
dust, mechanical vibrations or shocks.
• Ensure a safe, level, stable and load-bearing surface on which to place the solid
tyre press.
• Place the solid tyre press in such a place that inspection and maintenance can be
carried out in a reasonable manner afterwards.
• Provide additional lighting if visibility is restricted in the work area.
• If an extension cord or receptacle is used, ensure that the total amperage required
for all equipment on the extension is less than the rating of the extension.
• Place the solid tyre press in an open and well-ventilated area.
• To prevent fire or shock hazard, do not expose the solid tyre press to rain or
moisture.
• Make sure that the solid tyre press is installed as instructed in this manual and in
accordance with any applicable national or local norm.
• Only people who work with the solid tyre press may be in the vicinity of the device.
Other people must keep a minimum distance of 3metres.

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5.3. Required materials for assembly
See diagram below for dimensions
• 8wedge bolts
• 8expansion plugs
• Drilling machine
• Drill bit
• Power impact tool
Wedge bolt Expansion plug Hole
Spec Length Outer diameter Length Diameter Depth
mm mm mm mm mm
M16 150 22 90 23 100
5.4. Place designation of the product
A newly delivered solid tyre press or a solid tyre press on which a new accessory has been
fitted must not be installed or put into operation until all transport securing devices and
packaging have been removed and the machine has been thoroughly inspected. If one or
more components are found to be damaged, it is necessary to immediately notify your dealer
and agree on the action to be taken.
The danger zone is the area in which people can be in danger because of the movements of
the tyre press. Only the operator of the tyre press may enter the danger zone.
The machine must be placed on a level floor that can support the weight of the solid tyre
press. The solid tyre press should be firmly anchored to the floor with 8bolts. Use the
information in chapter5.3 as a guideline.
The continuous sound pressure level of the tyre press is maximum 70dB(A). During
the operation of the solid tyre press, it is recommended to place a rubber mat on the
base plate to dampen the noise of the rim extraction.
Danger zone
4000
850
4000

20/68
5.5. Securing the product to the ground
1. Place the machine on the ground. When doing so, leave the forks temporarily in place.
2. Using a pencil, mark the spots on the ground where you are going to drill by marking the
drill holes.
3. Move the forklift back so that the machine is out of the way.
4. Place your drill, with the attached drill bit, in a straight vertical position.
5. Drill the holes in the ground to a maximum depth of 100mm.
6. Place the expansion plugs in each hole and push them into the hole. If you cannot push
the expansion plugs in manually, give them a short but gentle tap with the hammer so
that they completely enter the drilled hole.
7. Reposition the solid tyre press. Make sure that the machine is back in the same place so
that the drill holes and the holes in the machine line up.
8. Now take the impact tool and the wedge bolts.
9. Place a wedge bolt into the impact tool.
10. Make sure the wedge bolt is at a straight vertical angle.
11. Secure the machine to the ground.