Bosch TCE 4540, Original Instructions Manual

Page 1: ...e neumáticos it Istruzioni originali Smontagomme sv Bruksanvisning i original Däckmonteringsmaskin nl Oorspronkelijke gebruiksaanwijzing Bandenmonteermachine pt Manual original Máquina de montagem de pneus pl Instrukcją oryginalną Zmieniacz opon cs Původní návod k používání Stroj pro montáž a demontáž pneu matik tr Orijinal işletme talimatı Lastik sökme ve takma makinesi zh 原始的指南 轮胎装配机 ...

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Page 3: ...demounting 34 5 1 1 Wheel mounting 34 5 1 2 Preparations for demounting 35 5 1 3 Demounting 36 5 2 Tire mounting 38 5 2 1 Mounting preparations 38 5 2 2 Mounting of non critical rim tire combinations 39 5 2 3 Mounting of critical rim tire combinations 40 5 3 Inflation 42 5 3 1 Inflation of tires with tube 42 5 3 2 Inflation of tires without tube 42 5 4 Mounted wheel removal 43 5 5 Functioning anomali...

Page 4: ...dition to these warnings the following symbols are also used i Info In addition to these warnings the following symbols are also used Single step procedure instructions for a procedure that can be completed in just one step Intermediate result an intermediate result is dis played during a procedure Final result the final result is displayed at the end of the procedure 1 2 TCE 4540 Disposal Old ele...

Page 5: ...hese instructions Any other use different from that specified has to be considered improper and there fore not allowed i The manufacturer is not liable for any damage caused by improper use 3 2 Requirements TCE 4540 has to be installed on an even surface made of concrete or similar materials and has to be firmly anchored A pneumatic connection is requested 3 3 Delivery specification Denomination O...

Page 6: ...ange It is cen tred in one of the holes for the rim bolts 6 Roller base Placement of the wheel on the locking flange after lif ting Once locked the wheel is lowered 7 Wheel lifter Lifting of the wheel from the floor to a safe working height and lowe ring of the wheel at the end of mounting and demounting operations 3 6 Description of function Below are reported the main functions of the listed com...

Page 7: ...ad safely for examp le the upper bead of the tire in the semi drop centre e g in case of RFT or UHP tires 16 Hydraulic control unit Hydraulic control drive 16a Left lever lifting lowering of lower bead breaker arm 16b Central lever sliding forward backward of the tightening flange 16c Right lever lifting lowering of upper bead breaker arm 16d Left button clockwise rotation of mounting tool 16e Cen...

Page 8: ...e standard accesso ries and the packaging materials i Dispose correctly of packaging material hand it over to the designated collection points 4 2 Installation 1 Loosen the four screws that fix TCE 4540 to the pallet 652061 02_Mi Warning damage risk The lifting belts can crush the flexible supply pipes of the cylinder or damage the applied parts of the TCE 4540 Insert the lifting belts carefully 2...

Page 9: ...l support bracket 652061 05_Mi 5 Put an appropriate lubricator in the mounting paste holding device 4 3 Pneumatic connection 1 Connect the TCE 4540 to the compressed air supply unit 652004 06_Mi 2 Adjust to a pressure between 8 and 12 bar Pull the red knurled screw pressure reducing val ve first upwards and then twist it to adjust ope rating pressure Check pressure on the manometer 4 4 Electrical c...

Page 10: ...ng to use the TCE 4540 it is necessary to adjust some valves in the hydraulic control unit The capacity adjustment valves 1 with knobs regu late the lifting lowering and entering exiting speed of the mounting tool Initially they are pre calibrated as open meaning that they are at maximum speed and they can be adjusted by the operator The pressure relief valve 2 checks the pulling pressure of the m...

Page 11: ...be scratched or deformed Read the Wdk publications available in German and English www wdk de moun ting demounting instructions criteria catalogue Inner temperature of the tire must be at least 15 C only in case of RFT UHP Read the Wdk publications available in German and English www wdk de mounting demounting instructions tire overheating Adjust pressure to the type of tire Plastic protection on ...

Page 12: ...ocked using the flange block panel Before starting tyre disassembly operations there is a risk that the lock nut will block which is difficult to release at the end of operations 652061 09_Mi Fig 4 Blocking of the wheel on the tightening flange 5 1 2 Preparations for demounting Avoid valve damage 1 Lubricate with mounting paste the side of the tire till the edge of the rim 2 Tilt downwards the uppe...

Page 13: ...ng tightening flange rotation Do not insert the fingers between the tire and the rim 1 Operate the locking flange pedal to rotate the tighte ning flange Fig 5 press the bead of the tire with both bead breaking rollers towards the rim shoulder Fig 6 2 Lubricate with mouting paste both rim shoulders i Only when both tire beads are in the semi drop cen tre the operation is finished i If the rim moves...

Page 14: ...ntrol unit lower the tool Stepping on the tightening flange pedal rotate the tightening flange to grip the tyre bead and use the lower roller to extract the bead completely 6520 61 16 _Mi 7 Using the joystick of the hydraulic control unit lift the tool in order to hoist the heel up to the upper edge of the rim Hoist the thrust block over the hump using the lower roller to help extract the tyre and...

Page 15: ...been damaged during mounting operations The operator has to be specifically trained Do not exert excessive forces on the tire or the rim Adjust the slow rotation speed Use a sufficient quantity of mounting paste In case of anomalies e g suspicious noi ses stop mounting immediately For mounting of critical rim tire combina tions read the Wdk publications available in German and English www wdk de m...

Page 16: ...o not insert the fingers between the tire and the rim 1 Position the flat part of the tool on the edge of the rim by means of the central button AUTO of the hydraulic control unit Rotate the tightening flange stepping on its pedal being careful that the bead does not enter into the lowered well of the rim in order to eliminate yielding of the bead 65 20 61 1 9_ M i i Be sure that the lower tire be...

Page 17: ...Position the flat part of the tool on the edge of the rim by means of the central button AUTO of the hydraulic control unit Rotate the tightening flange stepping on its pedal until the bead enters the cen tre groove of the rim in order to eliminate yielding of the bead 2 Rotate the tightening flange stepping on its pedal until the bead is completely mounted i Be sure that the lower tire bead slide...

Page 18: ...part of the bead with mounting paste 8 Operate the locking flange pedal to rotate the tighte ning flange i During rotation the pneumatic bead pressing device pushes the tire bead inside the semi drop centre 652061 22_Mi i Mounting is complete when the bead pressing device arrives close to the mounting tool thus releasing it completely from the bead 652061 23_Mi Fig 8 Bead fitting concluded 9 Move a...

Page 19: ...reaching nominal pressure 5 3 2 Inflation of tires without tube 1 Screw the valve element 2 Connect the tire inflater to the tire valve 3 Lift the tire with both hands so that the air between the rim and the tire can not come out again 4 Operate the tire inflation pedal to inflate the tire until the bead is clearly seated in its groove 652061 24_Mi Fig 9 Inflation with tire inflater i Use the quick ...

Page 20: ...o high it is possible to lower it with the button beside to the manometer 5 4 Mounted wheel removal Place no object in the area of the wheel supporting bracket 1 To release the rim from the locking flange unscrew the tightening pin remove the tightening ring nut and the centring cone 2 Place the centring cone the tightening ring nut and pin in the object compartment 3 Lift the wheel by means of th...

Page 21: ...locking flange pedal is pressed down the locking plate turns clockwise 1 Phases inversion du ring plug connection 2 The pedal is pulled up with the foot 1 Invert the 2 phases in the network plug qualifiede lectrician is required 2 Press down the pedal The locking plate transmits insufficient torque low force 1 Wrong network tension 2 Loosen transmission belt 1 Check the correspon dence of the netw...

Page 22: ...m with nebulized oil or kerosene and lu be with motor oil or appropriate grease x Remove condensate x Check oil level in the oil nebulizer x Check transmission belt tensio ning in order to avoid its sliding x Check the oil level in the gearbox and keep it al ways between minimum and maximum level x Change oil in the oil nebulizer x Change oil in the gearbox x 6 2 2 Condensate removal 1 Turn left t...

Page 23: ...pment is not being used for other reasons always disconnect the network plug from its socket It is suggested to clean accurately the TCE 4540 also its tools and accessories and carry out a protection treatment e g spraying of a thin oil film 7 3 Disposal Disconnect the TCE 4540 from the mains tension and take off the power supply cable Oil are water pollution risk fluids and have to be disposed of...

Page 24: ...nd weights Function Specifications TCE 4540 H x W x D 1700 x 1880 x 1850 mm Net weight 500 kg Gross weight 542 kg 8 3 Reach Function min max Tire width 3 22 Maximum tire diameter 1250 mm Rim diameter 10 30 9 Glossary Rim structure and names 652001 26_Rf 1 1 3 4 3 2 D Fig 11 Rim 1 Rim edge 2 Rim shoulder 3 Hump lifted edge 4 Semi drop centre D Rim diameter RFT Run Flat Tyre tire with emergency func...