Unitrol PO-22 User manual

WHEEL RIM STRAIGHTENING MACHINE
Model PO-22
Instruction Manual
“UNI-TROL” Co.Ltd.
Ul. Estrady 56
01-932 Warsaw, Poland
tel./fax [phone] & 834 90 13 (14)

Uni-trol Co. Ltd. , ul.Estrady 56, 01-932 Warsaw, Poland
Ph./Fax + 4822 817 9422 e-mail: [email protected]
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Operation Manual
WHEEL RIM STRAIGHTENING MACHINE
Model PO-22
Serial number
Production date
MANUFACTURER:
“UNI-TROL” Co.Ltd.
Ul. Estrady 56
01-932 Warsaw, Poland
tel./fax [phone] & 834 90 13 (14)
TABLE OF CONTENTS
1.0 INTRODUCTION

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2.0 OPERATORS’ TRAINING
3.0 TRANSPORTATION AND PACKAGING
4.0 INSTALLATION REQUIREMENTS
4.1 PLACE OF INSTALLATION
4.2 ELECTRICAL CONNECTION
5.0 INDUSTRIAL SAFETY
5.1 RULES FOR THE OPERATOR
5.2 SERVICE, REPAIRS AND SPARE PARTS EXCHANGE
6. STORING
7. SCRAPPING
8. RECOMMENDATIONS AND WARNINGS CONCERNING OIL
9. RECOMMENDATIONS ON FIRE-FIGHTING EQUIPMENT
10.0 TECHNICAL DESCRIPTION
10.1 GENERAL INFORMATION
10.2 TECHNICAL DATA
10.3 ELECTRICAL SYSTEM
10.4 HYDRAULIC SYSTEM
11.0 WHEEL RIM STRAIGHTENING MACHINE OPERATION
11.1 GENERAL PROTECTION INSTRUCTIONS
11.2 MOUNTING AND DEMOUNTING SYSTEM OPERATION
11.3 SENSOR
11.4 CORRECTION
12.0 WHEEL RIM SPREADING DEVICE
13.0 ACCESSORIES
14.0 HEALTH AND SAFETY REGULATIONS
15.0 ELECTRICAL SYSTEM SCHEME
16.0 HYDRAULIC SYSTEM SCHEME
17.0 PICTURE CATALOGUE OF SPARE PARTS
18.0 DECLARATION OF CONFORMITY
1. INTRODUCTION
This operation manual is an integral part of the straightening machine for car wheel rims from 10”
to 22” with a turning lathe. The remarks and recommendations included in this manual must be
read carefully since they concern important instructions on the machine’s operation and
maintenance. The manual must be kept in a safe and easily accessible place.
The manufacturer or the distributor shall not be liable for any damages arising from not observing

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the instructions included in this manual.
The machine must be used according to its purpose. Any other application will be considered
wrong and improper. The manufacturer or the distributor shall not be liable for any damages
arising from improper, wrong or unreasonable use of the machine.
2. OPERATORS’ TRAINING
The machine must be operated only by authorised and specially trained personnel. The
operators’ training must be carried according to the manufacturer’s instructions. This shall assure
a high standard of the machine’s operation and safety.
3. TRANSPORTATION AND PACKAGING
Before transporting the machine packed, read the instructions on its packaging. Transportation
must be carried with a fork lift. Check if the fork lift operator has got the necessary licence. After
unpacking the machine, make sure there is a manual inside and check if the machine’s
subassemblies are complete with no visible damage. After unpacking the machine, the
packaging must be put in a place which is not accessible for children or animals.
The machine is packed on a pallet and covered with the stretch foil or a cardboard box.
4. INSTALLATION REQUIREMENTS
4.1 Place of installation
- a flat, solid, preferably concrete surface
- sufficient lighting (which is not flickering and eye-exhausting)
- roofed area protected from the outside weather conditions
- work place with the noise level lower than demanded
- work place in a clean place
- work place should be located far from other machines
- explosive, poisonous or corrosive materials must not be stored in the same place
- the operator has to see the whole machine and its surrounding during operation.
Unauthorised persons or unnecessary objects must be kept out of the machine’s
work place.
- mains connection must be done by authorised personnel
- the machine must be located in such a way that the operator can access it from the
front or from the back, not restricting his hands’ movements, far from a wall or other
machines.
4.2 ELECTRICAL CONNECTION
Connecting the machine to the power supply must be done by authorised personnel.
The electric connection must correspond to the voltage taken by the machine, stamped on its
rating support.
Connecting the machine to power supply requires the following parts:
- a separate electric switch which meets the safety regulations;
- a suitable circuit breaker;

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- an effective grounding circuit which has been previously checked.
Prohibited is a connection the grounding wire to the gas or water supply pipes, telephone line or
any other installation.
5. INDUSTRIAL SAFETY
The manufacturer shall not be liable for any damages arising from modifications to the machine
which were not previously authorised. Removing or modifying the safety devices is not compliant
with the European regulations.
5.1. RULES FOR THE OPERATOR
- The operator must avoid hazardous situations during work.
- In case the machine is working improperly, turn it off and call the customer service.
- Remove from the machine’s surrounding all the items which may be hazardous
during operation. Make sure there is no oil on the floor which may be hazardous
for the operator.
- For protection from dust and other externals, the operator must wear a special
clothing, goggles and protective gloves.
- During work you must take off your bracelets, rings, watches, and other loose
decorations. The operators with long hair must tie it back so that they could work
easily. The operator ought to equipe a suitable shoes.
5.2. TECHNICAL SERVICE, REPAIRS AND SPARE PARTS EXCHANGE
- Servicing, maintenance work and spare parts exchange must be carried out by
authorised personnel.
- Before any service work, disconnect the machine from the power supply.
- You must not use spare parts other than those supplied by the manufacturer.
- The machine’s spare parts and accessories have to meet safety regulations.
6. STORING
If the machine is to be stored for a long time, it must be disconnected from the power supply, with
the oil tank emptied, and covered to protect it from externals (dust, oil mist etc.). The parts which
might get damaged in case they dry out have to be lubricated.
7. SCRAPPING
When the machine is going to be scrapped, all the electric and electrical parts as well as those
made of plastic have to be disassembled, while the rest has to be scrapped as the steel scrap.
The electric wires can be scrapped as the copper scrap.

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8. RECOMMENDATONS AND WARNINGS CONCERNING OIL
Removing wasted oil
Wasted oil must not be poured to sewage, ditches, drainage canals or water ways. It must be
collected and brought to the oil waste utilization points.
Oil leakage or spills
Spilled oil must be wiped out by means of sand, ground or absorbent material. The leakage
surface needs to be degreased by means of solvents to prevent vapour retention.
Rules for oil use
Avoid a long-lasting contact of oil with your skin.
Prevent forming of vapours or mist which evaporate to the atmosphere.
Observe the following hygiene requirements:
- avoid spilling with oil (wear special clothing, put protective covers on the
equipment).
- wash your hands often with soap and water; do not use any irritating cleaning.
materials or solvent which remove the protective layer from your epidermis of
hands.
- do not dry your hands with dirty or oiled cloths.
- change the clothing which is soaked with oil, and put on a clean work clothing
every day.
- do not smoke or eat with your hands oiled.
Also the following preventive measures must be taken into account:
- wear protective oil-resistant gloves.
Oil: the first aid principles
Oil swallowing: Generally, no special treatment is required. Do not evoke vomiting to prevent
breathing the oil vapours in or oil getting into the respiratory tract.
Getting of oil into the respiratory tract: if, in case of reflexive vomiting, the oil gets into the
respiratory tract, the injured person needs to be taken to hospital immediately.
Breathing in the oil vapours: In case of breathing in the oil vapours or oil mist with high oil
concentration, the injured person needs to be taken in the open air.
Getting of oil in the eyes: Wash the eyes with water.
Oiled skin: Wash your skin with soap and water.
9. RECOMMENDATIONS ON FIRE-FIGHTING EQUIPMENT
While choosing the right fire-extinguisher, follow the recommendations below:
Dry inflammable matters
Water fire-extinguishers YES
Foam fire-extinguishers YES
Dry chemical fire-extinguishers YES*
CO2 fire-extinguishers YES*
YES* use only when there is no better fire-extinguisher nearby and when the fire is modest.
Inflammable liquids
Water fire-extinguishers NO

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Foam fire-extinguishers YES
Dry chemical fire-extinguishers YES
CO2 fire-extinguishers YES
Electric devices
Water fire-extinguishers NO
Foam fire-extinguishers NO
Dry chemical fire-extinguishers YES
CO2 fire-extinguishers YES
WARNING
The above given recommendation are of a general character. These are general principles for
fire-extinguishers’ use. Detailed application of each kind of
fire-extinguisher is provided by its manufacturer on customer’s order.
10.0 TECHNICAL DESCRIPTION
10.1 GENERAL INFORMATION
The machine is designed to repair of faults 10”-22” steel and aluminium rims. The rim repair is
carried out by means of the hydraulic piston supplied with the suitable shaped working tools.
The machine is supplied with a mechanical adapter with adequate holes destined for set the
position and mount a rim securely.
Repairs are easy, and the time of repair does not exceed few minutes. The working end caps
allow to fix a damaged rim in any place of its bend.
The straightening machine is supplied with:
- the working tools of different shapes to repair various deformations;
- a set of centering rings to repair rims with different diameters of central holes;
- a device to locate rim deformations;
- mounting mechanical pressures with regulated set bolts;
- a lever for preliminary rim straightening.
10.2 TECHNICAL DATA

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rim diameters range 10”-22”
maximum pressure in the hydraulic system 160 bar (16 MPa)
power supply 3 x 400 V / 50 Hz
hydraulic pump motor 0.55 kW
drive motor 0.55 kW
noise level < 70 dBA
weight 450 kg
straightening servo-motor’s force 45 kN
APPEARANCE
The machine’s dimensions with the description of its main parts are presented in the figure 1.

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Fig. 1. Wheel rim straightening machine model PO-22H 1. Control panel 2. Electrical box 3. Main switch 4. Cable connector 5. Tools box 6. Hydraulic pump box 7. Mounting adapter 8. Centering ring 9. Straightening hydraulic piston 10. Lathe adapter

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10.3 ELECTRICAL SYSTEM
The machine is adapted to alternating current of 3 x 400 V / 50 Hz.
It is supplied with four-wire power supply cable; the green-yellow wire is a protective conductor
while the other three wires are the phase conductors.
The main power switch is located on the control box –figure 1.
The machine is supplied with two control panels. The description of particular parts of each panel
is presented in the figure 2. The electrical system scheme is presented in the figure 6.
10.4 HYDRAULIC SYSTEM
Straightening and mounting operations on the machine are carried out by means of the hydraulic
servo-motors. The use of the hydraulic pump provides the pressure of 200 bar –the working

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pressure at the overflow valve is set at 160 bar. The monoblock two-chamber hydraulic divider
enables to change the direction of the servo-motor pistons movement. The straightening piston’s
control chamber is switched by means of the hand lever, while the adapter piston’s chamber – by
means of the electromagnets (switched on by the control panel).
The capacity of the oil tank on the hydraulic pump is about 8 liters. The oil level is checked on the
oil indicator –figure 3.
The hydraulic system’s scheme is presented in the figure 7.
11.0 WHEEL RIM STRAIGHTENING MACHINE OPERATION
The machine is supplied with the hydraulic system to mount wheel rims. Clamping is carried by
the hydraulic servo-motor set in the central position by means of a suitable adapter - figure 4.
There are three mechanical pressures supplied:
- a four-bolt mechanical pressure and a five-bolt mechanical pressure with regulated
setting of bolts from dimension 98 mm to dimension 140 mm.
- a universal mechanical pressure (three-, four-, and five-bolt with regulated setting of
bolts from dimension140 mm to dimension 210 mm (dimensions 98-210 mm for the
three-bolt system)
11.1 GENERAL PROTECTION INSTRUCTIONS
Before operation of the wheel rim straightening machine, read attentively the following
instructions:
- Some rims require the use non-standard of centering rings or working tools. In order
to provide correct operation and safety, non-standard spare parts must be re-
supplied by the manufacturer (or the distributor) on the customer’s order against
payment.
- The machine is used to correct wheel rims. If after the shape correction the rim
needs to be balanced, it must be done on the proper machine (balancing machine).
- The machine is not adapted to operations involving washing. The use in humid
conditions is not recommended.
- The machine must not be used by unauthorized personnel.
- The machine must be used only according to its purpose.
- Make sure the rims and the standard equipment tools, used during correction, meet
the instructions of the manufacturer.
- Before operation, check the indicator of the oil level of the hydraulic pump.
- Make sure the motor is turning in the right direction.
- If the machine is not working properly, turn it off and call for the technical service.
- In case of sudden accidents and/or during the machine’s inspection, press the
“emergency stop” (ENERGIA STOP) button.
- Do not modify the safety devices.
- Fix all parts of the machine carefully in order to avoid any hazards, and wear
protective goggles.
- Proceed slowly during operation with the straightening piston; Rapid use of piston
with big force may cause a durable damage of the rim. You must wear the
protective goggles during this operation.
- Always check a proper clamping the rim in the adapter.
- Always monitor the normal level of the pressure. If it exceeds, turn the machine off.
- Always control the direction of the motor’s movement. Rotation in the wrong
direction may damage the motor and the machine.
- Do not overload the machine’s hand control lever.

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Fig. 3. Hydraulic pump
oil level
hydraulic pump

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Fig. 4. Machine’s spindle with straightened rim
11.2 MOUNTING AND DEMOUNTING SYSTEM OPERATION (Figure 4)
Wheel rim mounting:
- Choose the proper mechanical pressure (Fig.4 no.1) for the rim which is going to be
straightened.
- On the spindle (Fig.4 no.2), slide the centering ring (Fig.4 no.3) with the outer
diameter adapted to the diameter of central hole of rim.
Fig. 4. Mounting a wheel rim on the
straightened wheel rim

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- Slide the rim until it leans on the flange of adapter (Fig.4 no.4).
- Slide the mechanical pressure (Fig.4 no.1) on the spindle (Fig.4 no.2) until the bolts
(Fig.4 no.6) are set in the holes of the screws which fix the wheel to the car’s hub.
- Put the washer (Fig.4 no.7) on the spindle (the flat side to mechanical pressure)
between the mechanical pressure and the nut of adapter (Fig.4 no.8).
- Turn the nut of adapter (Fig.4 no.8) manually.
- Press and hold the button (Fig.2 no.4) on the control panel until the rim is mounted
securely.
Wheel rim demounting:
- Press and hold the button (Fig.2 no.5) on the control panel (Fig.2) until can be
possible unscrew the nut (Fig.4 no.8) of adapter.
- Remove the washer (Fig.4 no.7).
- Take off the mechanical pressure (Fig.4 no.1) and then the repaired rim.
11.3 SENSOR
Faults of rim are indicated by the mechanical sensor. The sensor’s base is supplied as a
magnetic mount (with magnetic short-circuiting switch) which allow to use the sensor at every
angle. Positions of the faults can be marked by use a piece of chalk.
11.4 CORRECTION
After finding and marking a desired places of flaws of rim, can begin to correct them.
The operator must equipped the straightening piston in working tools, adequate to eliminated
fault of rim. Next the operator must find adequate point of support or point of fixing of
straightening piston. Choice mentioned points must be adequate to use a proper force of
straightening piston, directed on the contrary to force which was caused a fault of rim.
Recommended is that all movements of piston must be slow and soft. Overly powerful
movements of piston can cause new and other faults or permanent damage of rim.
Recommended is that corrected alloy rims can be heat up in points of correction by the propane-
butane burner to temperature 250 –350 degrees Celsius.
The operator must remember that all repairs of rims must be perform with his special attention
and use adequate working tools and with safety measures.

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12.0 WHEEL RIM SPREADING DEVICE
Additionally, the machine is supplied with the hook device to correct shape of rims which are
strongly deformed. The installation instructions for the hook device are presented in the figure 5.
Pressing the lever number 4, the straightening piston number 2 turns it around and moves the
hook number 5 along.
1. Machine’s frame
2. Straightening piston
3. Support
4. Lever
5. Spreading hook
6. Bolt
Fig. 5. Hook device

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13.0 Accessories –standard equipment
No.
Name
Amount
1
Preliminary straightening lever
1
2
S-shaped tool
1
3
Angle tool
1
4
Hammer tool
1
5
Locking washer
1
6
Magnetic mount
1
7
Scriber
1
8
Rod
I=63 mm
1
9
Rod
I=188 mm
1
10
Rod
I=88 mm
1
11
Rod
I=113 mm
1
12
Middle rod
I=96 mm
1
13
Middle rod
I=174 mm
1
14
Centring ring
D=64 mm
1
15
Centring ring
D=63.3 mm
1
16
Centring ring
D=60 mm
1
17
Centring ring
D=59.5 mm
1
18
Centring ring
D=72 mm
1
19
Centring ring
D=66.5 mm
1
20
Centring ring
D=66 mm
1
21
Centring ring
D=57 mm
1
22
Centring ring
D=56.5 mm
1
23
Centring ring
D=54 mm
1
24
Centring ring
D=65 mm
1
25
Centring ring
D=58 mm
1
26
Centring ring
D=59 mm
1
27
4-bolt mechanical pressure
D=140 mm
1
28
5-bolt mechanical pressure
D=140 mm
1
29
Universal mechanical pressure
D=205 mm
1
30
Wheel rim spreading device
1

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14.0 HEALTH AND SAFETY REGULATIONS during operation of the straightening machine
General remarks
1. You can operate the straightening machine on your own only if:
- you have completed the right professional training;
- you have completed the training in general and fire regulations, as well as the job position
training;
- you are in a good health condition, confirmed with the medical certificate;
- you are over 18 years old;
- you have the permission of your direct supervisor (foreman) to operate the straightening
machine.
2. You must not start work, if you have any doubts about its safety.
3. You must ask your direct supervisor for comprehensive instructions to solve any difficulties or
clear any doubts.
3. Operation of the straightening machine can be carried out only by a person who is well-rested,
sober, appropriately dressed up (the work clothing must be tight, without any loose trimmings).
Basic operations before the straightening machine operation
An operator of the straightening machine should:
- read the detailed manual instruction;
- listen to the commands and instructions of the professional supervisor concerning safe and
correct task fulfilment;
- consider how to work safely to fulfil one’s task;
- prepare necessary helpful workshop equipment, tools, personal protectors (if necessary);
- prepare the work place to fulfil the given tasks;
- report all the faults or hazards immediately to the supervisor in order to remove them quickly.
Other operations before the straightening machine operation
Substantial operations during a wheel rim straightening:
- mount the wheel rim;
- in case of power failure, turn off the straightening machine immediately;
- focus only on the substantial (safe) operations while using the straightening machine;
- do all your tasks accurately, according to the current manufacturing process;
- do only the tasks ordered by the direct supervisor;
- report all the work accidents immediately to the direct supervisor;
- in case of a work accident, leave your work place in the same condition in which the accident
happened, until the emergency team arrives;
- in case of any doubts concerning safe task fulfilment, listen to the instructions of your
supervisor and observe all his commands.
Basic operations after work:
- turn off the straightening machine and protect it from undesirable turning on;
- clean your work place carefully;
- clean and put away your personal protectors;
- check if your work place will not be hazardous after your departure.

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15.0 ELECTRICAL SYSTEM SCHEME
1. HYDRAULIC PUMP MOTOR
2. DRIVE MOTOR
3. HYDRAULIC PUMP MOTOR CONTACTOR
4. DRIVE MOTOR CONTACTOR
5. HYDRAULIC PUMP SWITCH
6. DRIVE MOTOR SWITCH
7. ELECTROMAGNETIC COIL DEMOUNTING HYDRAULIC ADAPTER
8. ELECTROMAGNETIC COIL MOUNTING HYDRAULIC ADAPTER
9. HYDRAULIC ADAPTER DEMOUNTING SWITCH
10. HYDRAULIC ADAPTER MOUNTING SWITCH
11. TIME RELAY
12. RELAY CONTROL TIME RELAY
13. FAN
14. RECTIFIER
15. EMERGENCY STOP BUTTON ( ENERGIA STOP)
16. WARNING LIGHT
17. TRANSFORMER 400 V / 24 V
18. MAIN SWITCH

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Fig. 6. Electrical system scheme
CAUTION:
The following control parts used twice in the straightening machine
are not shown in the scheme:
5 –hydraulic pump switch
9 –hydraulic adapter demounting switch
10 –hydraulic adapter mounting switch
15 –emergency stop (ENERGIA STOP)

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16.0 HYDRAULIC SYSTEM SCHEME
1. Filter
2. Motor –pump assembly
3. Monoblock two-chamber hydraulic divider
4. Rotating joint
5. Adapter servo-motor
6. Straightening piston
Fig. 7. Hydraulic system scheme of the straightening
machine with the monoblock two-chamber hydraulic
divider