Unitrol PO-22H User manual

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

Operation Manual
WHEEL RIM STRAIGHTENING MACHINE
Model PO-22H
Serial number
Production date
MAN FACT RER:
“ NI-TROL” Co.Ltd.
l. Estrady 56
01-932 Warsaw, Poland
tel./fax [phone] & 834 90 13 (14)
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TABLE OF CONTENTS
1.0 INTROD CTION
2.0 OPERATORS’ TRAINING
3.0 TRANSPORTATION AND PACKAGING
4.0 INSTALLATION REQ IREMENTS
4.1 PLACE OF INSTALLATION
4.2 ELECTRICAL CONNECTION
5.0 IND STRIAL SAFETY
5.1 R LES 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 EQ IPMENT
10.0 TECHNICAL DESCRIPTION
10.1 GENERAL INFORMATION
10.2 TECHNICAL DATA
10.3 ELECTRICAL SYSTEM
10.4 HYDRA LIC SYSTEM
11.0 WHEEL RIM STRAIGHTENING MACHINE OPERATION
11.1 GENERAL PROTECTION INSTR CTIONS
11.2 MO NTING AND DEMO NTING SYSTEM OPERATION
11.3 SENSOR
11.4 CORRECTION
12.0 WHEEL RIM SPREADING DEVICE
13.0 ACCESSORIES
14.0 HEALTH AND SAFETY REG LATIONS
15.0 ELECTRICAL SYSTEM SCHEME
16.0 HYDRA LIC SYSTEM SCHEME
17.0 PICT RE CATALOG E OF SPARE PARTS
18.0 DECLARATION OF CONFORMITY
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1. INTROD CTION
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 obser ing 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 isible
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 co ered with the stretch foil or a cardboard
box.
4. INSTALLATION REQ IREMENTS
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 le el lower than demanded
- work place in a clean place
- work place should be located far from other machines
- explosi e, poisonous or corrosi e 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’ mo ements, far from a wall or other
machines.
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4.2 ELECTRICAL CONNECTION
Connecting the machine to the power supply must be done by authorised personnel.
The electric connection must correspond to the oltage 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;
- an effecti e grounding circuit which has been pre iously checked.
Prohibited is a connection the grounding wire to the gas or water supply pipes,
telephone line or any other installation.
5. IND STRIAL SAFETY
The manufacturer shall not be liable for any damages arising from modifications to
the machine which were not pre iously authorised. Remo ing or modifying the safety
de ices is not compliant with the European regulations.
5.1. R LES FOR THE OPERATOR
- The operator must a oid hazardous situations during work.
- In case the machine is working improperly, turn it off and call the customer ser ice.
- Remo e 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 protecti e glo es.
- 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
- Ser icing, maintenance work and spare parts exchange must be carried out by
authorised personnel.
- Before any ser ice 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 ha e 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 co ered to protect it from externals (dust, oil
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mist etc.). The parts which might get damaged in case they dry out ha e 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 ha e to be disassembled, while the rest has to be scrapped
as the steel scrap.
The electric wires can be scrapped as the copper scrap.
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 sol ents to pre ent apour
retention.
Rules for oil use
•A oid a long-lasting contact of oil with your skin.
•Pre ent forming of apours or mist which e aporate to the atmosphere.
•Obser e the following hygiene requirements:
- a oid spilling with oil (wear special clothing, put protecti e co ers on the
equipment).
- wash your hands often with soap and water; do not use any irritating clining.
materials or sol ent which remo e the protecti e 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
e eryday.
- do not smoke or eat with your hands oiled.
•Also the following pre enti e measures must be taken into account:
- wear protecti e oil-resistant glo es.
Oil: the first aid principles
•Oil swallowing: Generally, no special treatment is required. Do not e oke omiting
to pre ent breathing the oil apours in or oil getting into the respiratory tract.
•Getting of oil into the respiratory tract: if, in case of reflexi e omiting, the oil gets
into the respiratory tract, the injured person needs to be taken to hospital
immediately.
•Breathing in the oil apours: In case of breathng in the oil apours 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.
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9. RECOMMENDATIONS ON FIRE-FIGHTING EQ IPMENT
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
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 abo e gi en recommendation are of a general character. These are general
principles for fire-extinguishers’ use. Detailed application of each kind of
fire-extinguisher is pro ided by its manufacturer on customer’s order.
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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 quick release hydraulic adapter to 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 arious deformations;
- a set of centring rings to repair rims with different diameters of central holes;
- a de ice to locate rim deformations;
- mounting mechanical pressures with regulated set bolts;
- a le er for preliminary rim straightening.
10.2 TECHNICAL DATA
rim diameters range 10”-22”
maximum pressure in the hydraulic system 16 MPa (160 bar)
power supply 3 x 400 V / 50 Hz
hydraulic pump motor 0.55 kW
dri e motor 0.37 kW
noise le el < 70 dBa
weight 450 kg
straightening ser o-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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9
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. Centring ring 9. Straightening hydraulic piston 10. Lathe adapter

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 protecti e
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 HYDRA LIC SYSTEM
Straightening and mounting operations on the machine are carried out by means of
the hydraulic ser o-motors. The use of the hydraulic pump pro ides the pressure of
200 bar – the working pressure at the o erflow al e is set at 160 bar. The
monoblock two-chamber hydraulic di ider enables to change the direction of the
ser o-motor pistons mo ement. The straightening piston’s control chamber is
switched by means of the hand le er, 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 litres. The oil le el 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 ser o-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 fi e-bolt mechanical pressure with regulated
setting of bolts from dimension 98 mm to dimension 140 mm.
- a uni ersal mechanical pressure (three-, four-, and fi e-bolt with regulated setting of
bolts from dimension140 mm to dimension 210 mm (dimensions 98-210 mm for the
three-bolt system).
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11.1 GENERAL PROTECTION INSTR CTIONS
Before operation of the wheel rim straightening machine, read attenti ely the
following instructions:
- Some rims require the use non-standard of centring rings or working tools. In order
to pro ide 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 in ol ing washing. The use in humid
conditions is not recommended.
- The machine must not be used by unauthorised 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 le el 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 ser ice.
- In case of sudden accidents and/or during the machine’s inspection, press the
“emergency stop” (ENERGIA STOP) button.
- Do not modify the safety de ices.
- Fix all parts of the machine carefully in order to a oid any hazards, and wear
protecti e goggles.
- Proceed slowly during operation with the straightening piston; Rapid use of piston
with big force may caused a durable demage of the rim. You must wear the
protecti e goggles during this operation.
- Always check a proper clamping the rim in the adapter.
- Always monitor the normal le el of the pressure. If it exceeds, turn the machine off.
- Always control the direction of the motor’s mo ement. Rotation in the wrong
direction may damage the motor and the machine.
- Do not o erload the machine’s hand control le er.
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Fig. 2. CONTROL PANELS
1. Emergency stop button
2. Hydraulic pump switch
3. Dri e motor switch
4. Hydraulic adapter connecting (clamping) button
5. Hydraulic adapter disconnecting (loosening) button
6. Electrical system signal LED diode

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Fig. 3. Hydraulic pump
oil le el
hydraulic pump

11.2 MO NTING AND DEMO NTING 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 centring ring (Fig.4 no.3) with the outer
diameter adapted to the diameter of central hole of rim.
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Fig. 4. Mounting a wheel rim on the machine’s spindle
straightened wheel rim

- Slide the rim until it leans on the flanche 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.
- Remo e 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 e ery 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 equipe 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 adequted 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 mo ements of piston must be slow
and soft. O erly powerful mo ements of piston can cause new and other faults or
permanent demage 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 meassures.
12.0 WHEEL RIM SPREADING DEVICE
Additionally, the machine is supplied with the hook de ice to correct shape of rims
which are strongly deformed. The installation instructions for the hook de ice are
presented in the figure 5.
Pressing the le er number 4, the straightening piston number 2 turns it around and
mo es the hook number 5 along.
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16

13.0 Accessories – standard equipment
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1. Machine’s frame
2. Straightening piston
3. Support
4. Le er
5. Spreading hook
6. Bolt
Fig. 5. Hook device

No. Name Amount
1 Preliminary straightening le er 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 Uni ersal mechanical pressure D=205 mm 1
30 Wheel rim spreading de ice 1
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14.0 HEALTH AND SAFETY REG LATIONS during operation of the
straightening machine
General remarks
1. You can operate the straightening machine on your own only if:
- you ha e completed the right professional training;
- you ha e 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 o er 18 years old;
- you ha e the permission of your direct super isor (foreman) to operate the
straightening machine.
2. You must not start work, if you ha e any doubts about its safety.
3. You must ask your direct super isor for comprehensi e instructions to sol e 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).
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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 super isor 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 gi en tasks;
- report all the faults or hazards immediately to the super isor in order to remo e
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 super isor;
- report all the work accidents immediately to the direct super isor;
- in case of a work accident, lea e your work place in the same condition in which the
accident happened, until the emergency team arri es;
- in case of any doubts concerning safe task fulfilment, listen to the instructions of
your super isor and obser e 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.
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
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