Hoffmann MONTY 3550 TTGP, Service Manual

Page 1: ...e Changers Service Manual 07 13 Rev B 1 PASSENGER TIRE CHANGERS SERVICE MANUAL DO NOT COPY NOR DISTRIBUTE No part of this document may be photocopied reproduced or translated without prior written consent of Snap on ...

Page 2: ...Passenger Tire Changers Service Manual 07 13 Rev B 2 B L A N K P A G E ...

Page 3: ...and replacement Pag 39 6 5 Vertical rod blocking cylinder on 22 check and replacement Pag 41 6 6 Horizontal blocking cylinder on 26 check and replacement Pag 44 6 7 Horizontal blocking cylinder on 22 check and replacement Pag 44 6 8 Vertical rod lift cylinder check and replacement Pag 49 6 9 Valve with yellow button check and replacement Pag 50 6 10 Handle with valve check and replacement Pag 52 6...

Page 4: ...Passenger Tire Changers Service Manual 07 13 Rev B 4 7 5 Gear box check and replacement Pag 93 7 6 Turntable jaws Check replacement and adjustment Pag 93 CHAPTER 8 TROUBLE SHOOTING Pag 97 ...

Page 5: ...r In the sections dedicated to the check replacement and adjustment of the components there will be reported some symbols as follows Total amount of working time required to check replace and adjust the components this time is calculated considering the standard installation condition provided by the operator manual List of tools required to perform the work Information related to the possible fai...

Page 6: ...table run out and to check the proper contact of the jaws to the rim Electronic dynamometric key Use this key to lock the potentiometer set screw with proper torque Air pressure reducer 4002916 Use this reducer to adjust the tilting post end stroke screws and the turntable jaws Dynamometric key Use this key to lock the screws with the proper torque ...

Page 7: ...not in use Never use the cord to pull the plug from the outlet Grasp plug and pull to disconnect 5 To reduce the risk of fire do not operate equipment in the vicinity of open containers of flammable liquids gasoline 6 Keep hair loose fitting clothing fingers and all parts of the body away from moving parts 7 To reduce the risk of electric shock do not use on wet surfaces or expose to rain 8 Do not...

Page 8: ...6 The equipment is now locked out or tagged out 3 2 ELECTRICAL REQUIREMENTS NOTE ANY ELECTRICAL WIRING MUST BE PERFORMED BY LICENSED PERSONNEL ALL SERVICE MUST BE PERFORMED BY AN AUTHORIZED SERVICE TECHNICIAN Check on the plate of the machine that the electrical specifications of the power source are the same as that of the machine NOTE ANY ELECTRICAL OUTLET INSTALLATION MUST BE VERIFIED BY A LICE...

Page 9: ...gh a ON OFF Power Switch placed on Inverter cover and immediately is sent via to an anti disturb filter to the Electronic Inverter MAIN SWITCH Q1 MACHINES WITH ELECTRONIC INVERTER ONLY Main switch is used to supply all electric components of the machine INVERTER T1 It converts the 230V 1Ph in 230V 3Ph to be supplied to the turntable motor M1 and also changes the motor rotational speed from 50 to 1...

Page 10: ...ingle phase 3 phase single speed switch and 3 phase 2 speed switch TURNTABLE MOTOR M1 On inverter switch models it can be single or 3 phase single speed or 2 speed Three phase motors can be wired at star or delta They are supplied by the inverter switch On models with electronic Inverter the motor is supplied by the inverter T1 The motor is wired at 230Volts 3phase ...

Page 11: ...ECTORS ARE WELL FITTED 4 1 POWER SUPPLY CABLE ON ELECTRONIC INVERTER CHECK AND REPLACEMENT 1h Allen keys of 3 and 5mm small and medium screwdriver medium cross screwdriver faston pliers scissors pliers multimeter Defective power supply cable and plug may cause the following malfunction 1 Turning the switch on the turntable does not turn in any direction 2 Sometime the turntable does not turn 3 The...

Page 12: ...minals Disconnect the ground wire from terminal block Release cable strain relief from the inverter box Remove plug from cord and take the defective cable away Insert the new cable through the strain relief IMPORTANT USE ONLY APPROVED CABLES PLUGS GROUND WIRE MUST BE LONGER THAN THE OTHER ONES Fix new faston on inside cable ends and connect them to the switch terminals and to the plug Fix the main...

Page 13: ...e switch on the turntable does not turn in any direction 2 Sometime the turntable does not turn 3 The shut off switch of the shop shuts down 4 Turntable Motor burning 5 Turntable motor run with 1 or 2 phases TO CHECK THE CABLE Disconnect power supply Remove the plug form the wall Remove the side panel from the machine Remove the foot pedal assembly from the cabinet Extract the foot pedal assembly ...

Page 14: ...lug Take a multimeter and select it in MOhm Place the multimeter terminals on the ends of the same wire to check the continuity Cross the wire check to make sure that any wire is in short circuit IMPORTANT TO CHECK GROUND YELLOW GREEN WIRE DISCONNECT THE WIRE END FROM THE TERMINAL BLOCK TO REPLACE THE CABLE Release cable strain relief from the power cord Remove plug from cord and take the defectiv...

Page 15: ...or 2 phases TO CHECK THE INVERTER SWITCH Unplug the machine from the wall Disconnect the wires from the motor 4 2 By a multi meter make sure that there is continuity between the 3 phases on the switch and the wires of the 1st speed of the motor pressing the rotational pedal in the 1st stage If there is not continuity on all 3 phases replace the switch TO REPLACE THE INVERTER SWITCH Follow 4 2 4 4 ...

Page 16: ...BLE MOTOR M1 CABLE CHECK AND REPLACEMENT 1h Medium screwdrivers medium cross screwdrivers 7mm tube type wrench 3mm allen key pliers multimeter Defective chuck motor cable may cause the following malfunction 1 Low rotational torque 2 Noisy motor 3 Motor damaging burning 4 Turning the machine on the shut off switch of the shop shuts down 5 The turntable does not turn at all 6 Damaged Inverter TO CHE...

Page 17: ...SE ONLY APPROVED CABLE GROUND WIRE MUST BE LITTLE LONGER THAN THE OTHER ONES TO ALLOW THE GROUND IN CASE OF PHASE CABLE BREAKAGE NOTE Before connecting the wires ends tighten all terminals nuts on the motor Fix new fastons to the cable ends Connect the wires to the motor and inverter terminals Mount the motor terminal cover IMPORTANT WHEN REMOUNTING THE MOTOR TERMINALS COVER BE CAREFUL NOT TO CRUS...

Page 18: ...ER TENSION DANGER OF ELECTRIC SHOCK Press the rotational pedal to run the motor to verify if it is noisy TO CHECK THE MOTOR WHEN IT IS BURNT ON ELECTRONIC INVRTER Disconnect the power supply from the machine Refer to paragraph 5 4 to make sure about the wiring and the cable Remove all wires and connections from the motor terminal Select the multimeter in Ohm and check if there is continuity betwee...

Page 19: ...tall the pulley by using rubber hammer NOTE The mounting of the new pulley must be done very carefully in order to avoid motor bearings damaging NOTE Before connecting the wires ends tighten all terminals nuts Connect the wires FIRMLY to motor terminals following the voltage at which the machine is supplied Fix the motor on its support Install the motor assy on the machine and lock it firmly Mount...

Page 20: ...d speed 6 The shut off switch of the tire shop shuts off TO CHECK THE INVERTER Turn the machine off Remove the electric box from the cabinet 4 1 Disconnect the wires and the connectors from the inverter terminals marking the position Turn the machine on Take the multimeter and select it in VAC up to 400 Position the multimeter terminals on the output terminals of the inverter Press the rotational ...

Page 21: ...he terminals following the correct order Connect the machine to the power supply Turn the machine on and check if it works fine Turn the machine off Disconnect the machine from power supply Fix the electric box to the cabinet 4 1 Connect the machine to the power supply Check if the machine works fine ...

Page 22: ... medium cross screwdriver Note book PC Inverter firmware update kit WARNING The PC used to program the inverter and the inverter can t be connected both to the mains follow the admitted connection below Other admitted programmer devices PICkit 3 ICD 2 ICD 3 from Microchip WARNING ICD 2 and ICD 3 need specific programming cable ...

Page 23: ...n 2 different programming software don t use CD Pickit 2 v 2 61 Quik to install and easy to use MPLAB 8 91 More complete but more complex to install and to use a To install PICkit2 v2 61 open the folder PICkit 2 and start Setup program At the end of the installation a icon will be on the desktop b To install MPLAB 8 91 open the folder MPLAB and start Setup program ...

Page 24: ... shown below WARNING the blue connection must be inserted in the programmer connection marked with a small triangle b Connect the programming cable to the inverter programming port WARNING The inverter must be OFF Update firmware wit PICkit 2 a Start programming software with icon b With Device Family PIC18F the programmer auto detect the device to program In this case PIC18F2331 The board must be...

Page 25: ...Passenger Tire Changers Service Manual 07 13 Rev B 25 c With File Import menu load hex file as shown below The last revision of firmware hex file will be sent by e mail ...

Page 26: ...e procedure At the end a success message is shown green window e Switch off the power and remove the programming cable Update firmware wit MPLAB a Start programming software with icon b With File Import menu load hex file as shown below The last revision of firmware hex file will be sent by e mail ...

Page 27: ...assenger Tire Changers Service Manual 07 13 Rev B 27 c With Configure Configuration Bits check the box Configuration Bits set in code d With Configure Select Device chose 18F2331 device to be programmed ...

Page 28: ...th Programmer PICkit 2 chose the programmer g Switch on the power to the board The programming icons become active g Click on the programming icon first at left and wait for a finish message on the window g Switch off the power and remove the programming cable ...

Page 29: ...socket medium standard screwdriver Multimeter electronic dynamometric key Defective potentiometer may cause the following malfunction 1 Turning the machine on the turntable turns itself with rotational pedal in rest position TO CHECK THE POTENTIOMETER Turn the machine off Remove the side panel Unscrew the foot pedal assy from the cabinet Extract the foot pedal assy from the cabinet ...

Page 30: ...Disconnect the potentiometer connector from the Inverter Remove the protection from the potentiometer Take the multimeter and select Ohm With the rotational pedal in rest position place the multimeter terminals on CCW and CW terminals of the potentiometer the multimeter display should show 20KOhm ...

Page 31: ...the value should change constantly Place the multimeter terminals on CW and PX terminals of the potentiometer pressing the rotational pedal downward the value should change constantly TO REPLACE THE POTENTIOMETER Remove the rod from the potentiometer linkage Release the set screw that secure the linkage to the potentiometer Remove the linkage from the potentiometer ...

Page 32: ...ometer linkage tight the screw until it will not have axial play Connect the potentiometer to the Inverter Adjust the potentiometer 5 5 Connect the power supply MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK Check again if the potentiometer is properly adjusted Turn off the machine Mount the foot pedal assy on the cabinet Route the potentiometer cable Connect the machine to the power supply and ch...

Page 33: ... itself during the potentiometer adjustment 4 Turn on the machine WARNING MACHINE UNDER TENSION RISK OF ELECTRIC SHOCK 5 Unlock the securing screw of the potentiometer 6 Make sure that the rotational pedal is in rest position 7 Rotate the potentiometer with the screwdriver until the red led LD7 on the Inverter will remain ON 8 Secure the screw of the potentiometer with the dynamometric key at 0 8N...

Page 34: ...essing the valve pedal for half of its stroke 1st stage the dry air will go to the tire through to the air control valve that controls the tire inflating pressure during the inflating process Releasing the pedal the air contained in the tire will act the manometer showing the tire pressure Pressing the air releasing button the tire pressure will be reduced BEAD BLASTER The dry air pressure reach t...

Page 35: ...he glasses with the replacement of the glasses In all other cases the replacement of the whole assembly is required TO REPLACE THE AIR FILTER LUBRICATOR ASSY Disconnect the air pressure from the machine Unplug the hoses On machines with the assembly bolted to the side of the cabinet loosen the bracket screws and remove the assy On machines with the assembly bolted inside of the cabinet remove the ...

Page 36: ...or supplies one drop of oil every 2 complete cycle of the lift TO ADJUST THE AIR LUBRICATION Take a screwdriver and turn the regulator on top of the transparent cap Turning clockwise the oil drops will decrease Turning counter clockwise the oil drops will increase 6 3 TILTING POST CYLINDER CHECK AND REPLACEMENT 30 8mm tube type key 12 and 17 mm end keys 17mm socket pliers Defective cylinder may ca...

Page 37: ...s in between the fitting and the cylinder flange In case of need place some soap with water on the interested part to better see where the leaking is coming from TO CHECK THE CYLINDER WHEN TILTING POST ARM WILL NOT MOVE OR WILL MOVE SLOWLY OR AIR LEAKING THROUGH THE TILTING POST VALVE Position the cylinder where it leaks air Disconnect the air pipe where there is not any air pressure If the air is...

Page 38: ... slide off the pin from the cylinder Unlock the cylinder bolt with the end screw of 17 and the socket of 17mm and remove the screw to release the cylinder Take out the cylinder and disconnect the air pipes Connect the air pipes to the new cylinder Extract the piston rod of about 5cm 2 ...

Page 39: ...ck if the machine works fine Install the tilting post cover Mount the side panel 6 4 VERTICAL ROD LOCKING CYLINDER ON 26 CHECK AND REPLACEMENT 1h Allen key 4 5 and 6mm 17mm end key 13mm tube type key Defective vertical locking cylinders may cause the following malfunction 1 Air leaking from the cylinder 2 The vertical rod does not remain blocked TO CHECK THE CYLINDER Remove the cylinder cover Pres...

Page 40: ...r Unlock the adjustment screw over the cylinder head and turn it until it will out of the blocking plate range Remove the washer from the cylinder Unlock and remove the two front adjustment screws and the two screws with springs Lift the blocking plate and extract the cylinder with robust screwdriver Install the new cylinder Install the washer ...

Page 41: ...sher turn the screw of two more turns Connect the air pressure and the power supply For the mechanical adjustment refer to chapter 7 2 Check if the machine works fine 6 5 VERTICAL ROD LOCKING CYLINDER ON 22 CHECK AND REPLACEMENT 30 Allen key 3 4 5 and 6mm 17mm end key 13mm tube type key Defective vertical locking cylinders may cause the following malfunction 1 Air leaking from the cylinder 2 The v...

Page 42: ...etween pipes and fittings In case of air leaking in between pipes and fittings disconnect the air pressure remove the pipes from the fitting and cut a piece of pipe to renew its end Check if the cylinder is leaking from the fitting and the plastic body or in between the plastic body and the aluminum cylinder liner ...

Page 43: ...ir pipes Remove the screw underneath the arm to release the cylinder Once removed the screw lift the blocking plate with a screwdriver and remove the cylinder Remove the washer from the top of the cylinder and place it on the new cylinder Secure the cylinder to the arm with fixing screw Release the blocking plate Connect the pipes to the cylinder Connect the air pressure and make sure that the cyl...

Page 44: ...iner and seal or from the hole on the front flange NOTE IF THE CYLINDER WILL LEAK AIR FROM THE FITTING REPLACE THE FITTING ONLY TO REPLACE THE CYLINDER Disconnect the air pressure and the power supply Disconnect the air pipe from the cylinder Remove the rear bolt and take out the cylinder Mount the new cylinder NOTE DO NOT OVERTIGHT THE BLOT WHEN THE SCREW HEAD AND THE NUT WILL BE IN CONTACT WITH ...

Page 45: ...e Remove the rear cover to access to the cylinder According to the model the cylinder will be install in different configuration Check where the cylinder is leaking TO REPLACE THE CYLINDER Disconnect the air pressure from the machine Remove the plastic cap over the post tilt and then remove the horizontal arm end stroke ...

Page 46: ...then remove blocking plate and releasing spring On some models it is required to remove the rear screws with the springs and the washer in between cylinder and adjustment screw before sliding off the blocking plate By pressing with a finger from the back push off the cylinder In some models the cylinder comes off itself ...

Page 47: ... new cylinder Place the cylinder on its side of the tilt post by pressing it in the middle with a finger DO NOT FORCE THE PLACING WITH HAMMER OR OTHER HEAVY DEVICES Position the blocking plate on the tilt post With the left hand The plate must be placed in between the brackets over the top of the tilt post On some models the adjustment screw must be oriented towards the cylinder while the machines...

Page 48: ...is place with the right hand slide in gently the horizontal arm until to hang up the plate Place the releasing spring Enter the spring by hand inside of the post and hold it Take a screwdriver and pull up the right side of the spring Adjust the position of the spring inside of the post in order to avoid any contact with arm during the sliding ...

Page 49: ...nect the air pressure and check if the machine is working fine On models with two springs it is mandatory to adjust the horizontal spacing between tool and rim Mount the plastic cap of the end stroke screw Mount the cylinder protection 6 8 VERTICAL ROD LIFT CYLINDER CHECK AND REPLACEMENT 30 3 and 4mm allen keys 10mm 30mm end key rubber hammer Defective vertical rod cylinder may cause the following...

Page 50: ...he upper screw from the vertical Remove the cylinder from the vertical by using the rubber hammer Mount the new cylinder on the vertical rod Fix the tool cylinder to the bracket Secure the bottom side of the cylinder with the two set screws Mount the tool cylinder again Install the pipe Plug the machine to air pressure and power supply Check if the machine works fine again 6 9 VALVE WITH YELLOW BU...

Page 51: ...is air leaking from the valve fittings or the valve rod TO REPLACE THE VALVE Disconnect the air pressure and the power supply Remove the handles Disconnect the air pipes from the valve Remove the two bolts to dismount the valve from the arm Mount the new valve to the arm ...

Page 52: ...2 Air leaking from the valve rod or from the fittings TO CONTROL THE VALVE Disconnect the air pressure from the machine Remove the cover Check if the air leaking is coming from the button or in between the handle and the sliding arm or from the fittings If the air leaking is coming from thread of the fittings disconnect the air pressure from the machine Then remove the fitting s tighten them again...

Page 53: ...dle upward on the arm Place the spacer in between the handle and the arm and block it with the securing screw Install the pipes Connect the air pressure and check if the machine works fine Install the top cover 6 11 AUTOMATIC TOOL CYLINDER CHECK AND REPLACEMENT 30 8 allen key 19mm end key Defective automatic tool cylinder may cause the following malfunction 1 Air leaking from the cylinder 2 The cy...

Page 54: ...tion the cylinder where it leaks air Disconnect the air pipe where there is not any air pressure If the air is getting out from the fitting the tool cylinder is leaking air If the air is getting out from the fitting the control valve is leaking air TO REPLACE THE CYLINDER Disconnect the air pressure and the power supply Disconnect the air pipes from the cylinder Disconnect the automatic tool cylin...

Page 55: ...er would not lift the tire bead TO CHECK THE VALVE Remove the air pipe where there is not any pressure Check if the air is coming from the fitting Check if the air leaking is coming from the valve body TO REPLACE THE VALVE Disconnect the air pressure and the power supply Disconnect the air pipe from the valve Remove the round knob and the fixing nut Remove the 3 screws that secure the valve and th...

Page 56: ...he cylinder where it leaks air Check if the leaking is in between cylinder flange cylinder liner or if it is coming from the piston rod In case of need place some soap with water on the interested part to better see where the leaking is coming from TO CHECK THE FITTING AIR LEAKING Position the cylinder where it leaks air Check if the leaking is in between the fitting and the cylinder flange In cas...

Page 57: ...n rest position Remove the seeger ring and the nut Disconnect the air pressure Disconnect the air pipes Unscrew the two securing screws that hold the cylinder Remove the defective cylinder Take the new cylinder and install the washers on the piston rod and grease the brackets for the securing screws ...

Page 58: ...The jaws move when the clamping pedal is in middle position TO CHECK THE CYLINDER Make sure that cylinder liner is fine and not damaged Sometimes the cylinders leak air because of damaging from tools left on the machine cabinet TO CHECK THE EXTERNAL AIR LEAKING Position the cylinder where it leaks air Check if the leaking is in between cylinder flange cylinder liner or if it is coming from the pis...

Page 59: ...through the piston If the air pressure is getting out from the hose the leaking could be caused by the manifold revolving or the by the valve Connect the hose to cylinder again Disconnect the hose without air pressure from the turntable valve If the air pressure is getting out from the fitting the valve is leaking through the O rings Replace the valve TO REPLACE THE CYLINDER Open the turntable cyl...

Page 60: ... the machine works fine Belt the air pipes again to the cylinder 6 15 MANIFOLD REVOLVING CHECK AND REPLACEMENT 30 10 and 17mm end key and 24mm socket 10mm tube type key Defective valve may cause the following malfunction 1 The rims come off 2 Air leaking from the control valve 3 External Air leaking from the manifold 4 The jaws move when the clamping pedal is in middle position TO CHECK THE EXTERN...

Page 61: ...ssure is getting out from the pipe the leaking could be caused by the manifold revolving or the by the valve Connect the pipe to cylinder again Disconnect the pipe without air pressure from the manifold If the air pressure is getting out from the fitting the manifold is leaking through the O rings TO REPLACE THE MANIFOLD O RINGS Open the jaws of the turntable and disconnect the air pressure from t...

Page 62: ...pen close motion of the jaws Unlock the turntable from the gearbox hammering the plate with a rubber hammer Remove the turntable from the gearbox WARNING THE TURNTABLE ASSEMBLY IS VERY HEAVY LIFT IT WITH A FORK LIFT OR ASK HELP TO ANOTHER PERSON IMPORTANT ONCE REMOVED THE TURNTABLE MAKE SURE TO DO NOT LOOSE THE ROTATIONAL TANG Remove the manifold rotational bolt and the dust proof O ring ...

Page 63: ...he bracket are not sharp to avoid any possible damaging of the O ring during the assembly Lubricate the O rings and the bracket with white grease Mount the manifold Make sure to place the white mark or the lower fitting in opposite compared to the tang Install the dust proof O ring Install the rotational bolts Place the tang on the gearbox shaft ...

Page 64: ...ing trough the valve JAWS VALVE 1 The rims come off 2 Air leaking from the valve 3 The jaws move when the clamping pedal is in middle position BEAD BREAKER VALVE 1 Air leaking from the cylinder 2 Air leaking from the control valve 3 The bead breaker arm will not detach the tire bead 4 The bead breaker arm does not return in home position 5 Bead breaker cylinder very slow TO CHECK THE VALVES Remove...

Page 65: ...e machine to the air pressure and to the power supply Check if the machine works fine Mount the side panel 5 1 6 17 WHEEL LIFT CYLINDER CHECK AND REPLACEMENT 30 13mm end key 4mm allen key seeger pliers Defective wheel lift cylinder may cause the following malfunction 1 Air leaking from the cylinder 2 Lift will not lift the wheels 3 Wheel lift does not hold the wheels 4 Air leaking from the valve T...

Page 66: ...ce some soap with water on the interested part to better see where the leaking is coming from TO CHECK THE CYLINDER WHEN LIFT WILL NOT LIFT THE TIRE BEAD Position the cylinder where it leaks air Disconnect the air pipe where there is not any air pressure If the air is getting out from the fitting the lift cylinder is leaking air If the air is getting out from the fitting the control valve is leaki...

Page 67: ... the valve cover Disconnect the air pipe where there is not any pressure and check if there is air leaking from the fitting If there is not any air leaking from fitting and pipe but it is leaking from the air silencer the valve must be replaced TO REPLACE THE CONTROL VALVE Unplug the machine from air pressure and power supply Disconnect the air pipes from the valve Remove the nut and the pin split...

Page 68: ...rom the fitting Raise the cylinder and check if it leaks air from the lower flange or from the fitting Lower the cylinder and remove the hose from the lower fitting Keep pressing the control valve If the air comes out from the fitting the piston seal is defective If the air comes out from the hose the leaking is caused by the control valve Make the same operation with the rear side TO REPLACE THE ...

Page 69: ...H motion TO CHECK THE MH CONTROL VALVE Follow paragraph 7 14 TO REPLACE THE MH CONTROL VALVE Disconnect the air pressure form the machine Remove the joystick knob and the nut Remove the control valve cover Unscrew the screws that secure the valve to its cover Unplug the air hoses from the valve Loosen the screws to take out the defective valve Install the new valve and plug the air hoses Connect t...

Page 70: ...e Check if the mechanical components springs screws and linkage are fine Check if the valve is leaking air from the rear springs when the pedal is in rest position Check if the valve is leaking air from front locking nuts when the pedal is in rest position TO REPLACE THE SPOOL VALVE Disconnect the air pressure and power supply from the machine Remove the collar Unplug the pipes from the valve Remo...

Page 71: ...rn the nuts to set the clearance at about 5mm between the nut and the bracket Lock the counter nut Release the pedal Now turn the linkage and the nut to set the clearance at about 8 9mm between the two nuts Lock the nut to the linkage Plug the pipes Lock the valve to the pedal with the collar Plug in the air pressure Pressing half of spool valve pedal the air has to come out from the inflator pipe...

Page 72: ...ks fine again 6 23 AIR CONTROL CHECK AND REPLACEMENT 30 End key 8 7 and 14mm 4mm allen key Defective bead blaster valve may cause the following malfunction 1 The valve does not stop the tire inflation 2 The valve does not inflate the tire at all 3 The valve leaks air TO CHECK THE VALVE Take a deflated wheel and inflate it If the valve will show one of the above issue it must be replaced TO REPLACE...

Page 73: ... The manometer is not accurate 2 The manometer does not return to zero 3 The manometer is blocked TO CHECK THE MANOMETER Unplug the machine from air pressure and power supply Remove the steel panel from the back of the tool box If the machine does not have the tool box unscrew the screws that secure the manometer bracket to the post and unplug the air pipe from the manometer Remove the pipe Check ...

Page 74: ... manometer does not return to zero replace the manometer TO REPLACE THE MANOMETER Remove the nipples fitting to get the manometer off Pay attention to the washer Check if there is Loctite on the hole of the manometer fitting Fix the new manometer to tool box with nipples fitting Put just one drop of Loctite to seal To centre the manometer to the bracket place the plastic spacer with the protruding...

Page 75: ...ir pipe Plug the machine to the air pressure and check if the manometer works fine Fix the rear steel panel of the tool box 6 25 SPIRAL PIPES CHECK AND REPLACEMENT 1h for both 8mm tube type 4mm allen key small cross screwdriver scissors Defective spiral pipes may cause the following malfunction 1 Air leaking 2 The spiral pipes are damaged or broken 3 The vertical rod cylinder does not block proper...

Page 76: ... protection from the bracket Remove the pipes from the protection Cut the old long pipe at the end of the spiral Connect the new long pipe to the cut one Route the new long spiral pipe though the post pulling it out from the cabinet Route the new pipes through the protection Fit the pipes protection to the bracket with the pipes strain reliefs Plug the pipes to the cylinders and to fittings Plug t...

Page 77: ... Changers Service Manual 07 13 Rev B 77 Secure the pipes tightening the strain reliefs Slide in and out the arm to make sure that pipes are moving inside of their protection Mount the plastic covers of the cylinders ...

Page 78: ...19 24mm allen keys 4 5 and mm6 8mm tube type key medium flat screwdriver dynamometric key air pressure reducer Incorrect tilting post adjustment may cause the following malfunctions 1 Excessive play on the operating arm assembly 2 Tool scratches the rims Disconnect the machine from the air pressure Connect the air pressure reducer to the air filter inlet and adjust it at 6 bar Remove the tilting p...

Page 79: ...chines with former support move the tower from the handle of the horizontal arm and check the play in between tower and support If the tilting post will move tighten the two self locking nuts until to have removed completely the play If necessary use a bar to rotate the 24mm key when tighten the nuts Check the adjustment of the lateral set screw it must slightly touch the post Remove the front pla...

Page 80: ...d the screw and lock the counter nut Check again if both heads touch the support Mount the plastic protections Remove the air pressure reducer Connect the main air pressure Check if the machine works fine 7 2 AUTOMATIC TOOL CHECK REPLACEMENT AND ADJUSTMENTS 1h End key10 17 and 19mm allen keys 3 5 6 and 8mm rubber hammer 13mm tube type key rim of 17 Defective tool may cause the following malfunctio...

Page 81: ...ismounting Take the new tool and mount it to the vertical rod Tighten all screws so that the tool is not rigidly locked in place but can turn through a small sector relative to the support hub TO ADJUST THE TOOL ORIENTATION ON THE RIM Connect the machine to air pressure and power supply Block a 17 rim diameter rim in good condition to the centerpost Place the tool on the rim as normal operation an...

Page 82: ...L FINGER STROKE ON THE CONTROL CYLINDER Connect the ball joint to the cylinder rod Move the control cylinder all way up Connect the tool finger arm to the ball joint If the holes are not matching turn the ball joint until they will match Tighten the bolt firmly Lower the finger completely make sure that when the cylinder and tool finger will reach their end of stroke at the same time In case it ne...

Page 83: ...the clearance is lower release the arm unlock the screws and loosen them accordingly Then lock the screws again Check if the machine works fine TO ADJUST THE VERTICAL ROD BLOCKING PLATE Press the yellow button valve to lower completely the vertical tool rod Tighten as much as possible the vertical blocking cylinder adjustment screw in order to block the rod Pull the yellow button valve all towards...

Page 84: ...ock the horizontal arm Unlock the rear screws and tighten them all way in Then turn them backward of two turns each one Lock the counter nuts Place the tool on the rim as normal operation and then lock it Make sure that the clearance between plastic protection and rim is 2mm If the clearance is higher release the arm unlock the screws and tighten them accordingly Then lock the screws again If the ...

Page 85: ...he tool damaged the tires TO CHECK THE TOOL Check if the tool is broken or mechanically damaged If it has damage or broken proceed with the replacement TO REPLACE THE TOOL Block the vertical rod Loosen the two lateral set screws and the screw underneath the tool Unlock the tool with the rubber hammer from the rod Remove completely the screws to complete the tool dismounting Take the new tool and m...

Page 86: ...djuster screws until the tail of the tool is aligned to the rim edge Unlock and lock again the tool to make sure about the proper alignment TO ADJUST THE VERTICAL TOOL CLEARANCE Remove the top cover Block a 17 rim diameter rim in good condition to the centre post Unlock the front screws and tighten them all way down and then turn them backward of one turn each one Lock the counter nuts ...

Page 87: ...se the arm unlock the screws and loosen them accordingly Then lock the screws again Check if the machine works fine TO ADJUST THE VERTICAL ROD BLOCKING PLATE SPRINGS Block the vertical rod Check if the springs are completely compressed If they are completely compressed turn the screws back until to see some light in between of the every wire of the spring Check if the machine works fine TO ADJUST ...

Page 88: ...y Block the counter nut TO ADJUST THE VERTICAL ROD BLOCKING PLATE ON ARM WITH MANUAL TOOL LOWERING Press the yellow button to unlock the vertical rod So the vertical rod must be moved up and down by hand Unlock the rear set screw on the blocking plate Turn the set screw until to lock the vertical rod and then turn it backward until the rod will be free again Make sure that the rod is moving freely...

Page 89: ...n and rim is 2mm If the clearance is higher release the arm unlock the screws and tighten them accordingly Then lock the screws again If the clearance is lower release the arm unlock the screws and loosen them accordingly Then lock the screws again Check if the machine works fine TO ADJUST THE HORIZONTAL TOOL CLEARANCE ON 26 AND SUPER LX VERSIONS Remove the cylinder cover Block a 17 rim diameter r...

Page 90: ...achine works fine TO ADJUST THE HORIZONTAL ARM BLOCKING PLATE ON 26 AND SUPER LX VERSIONS Unlock the horizontal arm Unlock the 6mm counter nuts Tighten as much as possible the horizontal blocking cylinder adjustment set screws in order to block the arm Turn counter clockwise both set screws at turn every step until the horizontal arm will move smoothly again Block the counter nuts again Mount the ...

Page 91: ...her release the arm unlock the screws and tighten them accordingly Then lock the screws again If the clearance is lower release the arm unlock the screws and loosen them accordingly Then lock the screws again Check if the machine works fine TO ADJUST THE HORIZONTAL ARM BLOCKING PLATE ON 22 24 VERSIONS Press the yellow button to unlock the horizontal arm So it must be backward and forward Unlock th...

Page 92: ...ve play on the horizontal arm 2 Horizontal arm does not move smoothly TO CHECK THE ROLLERS Remove the horizontal arm protection Unlock the horizontal arm cylinder Unlock the counter nuts and then loosen the set screws to release the rollers Unlock completely the front and the rear rollers Rotate the rollers and check if they are worn out or damaged TO ADJUST THE ROLLERS Tighten all 4 setscrews unt...

Page 93: ...4 nuts to complete the gear box dismounting BE CAREFUL THE GEARBOX IS HEAVY AND IT COULD CRUSH A HAND Remove the pulley from the gearbox and mount it to new one Mount the new gear box with 4 rear screws and nuts Do not tighten firmly the screws and the nuts Mount the motor 4 5 Secure all the screws and nut of the gearbox Mount the belt and adjust it Mount the turntable Make sure that the tangs wil...

Page 94: ...ntric TO ADJUST THE TURNTABLE JAWS Unplug the air pressure from the machine and apply to the air pressure inlet of the machine an air pressure reducer with gauge Plug the air pressure again to the air pressure reducer Adjust the air pressure at 2bar 30psi with air the pressure reducer IMPORTANT DO NOT MAKE THE FOLLOWING STEPS WITHOUT THE AIR PRESSURE REDUCER OTHERWISE YOU WILL NOT BE ABLE TO ADJUS...

Page 95: ...maintaining individual eccentric spacers positioning Lock the run out control disk on the turntable and apply the gauge with magnetic base to the vertical hex bar Place the gauge to the disk and turn the turntable to check the run out It must be within 1mm If the maximum run out is within 1mm skip step 12 Readjust the individual clamps as needed turning the eccentric spacers moving the eccentric s...

Page 96: ... the rim equally during the clamping operation Readjust individual clamp if one or more clamp will not contact the rim properly Lock all 4 screws firmly Apply the gauge with magnetic base to the vertical hex bar and make sure that the maximum turntable run out is still within 1mm Remove the gauge with magnetic base from the vertical hex bar and the disk from the turntable Unplug the air pressure r...

Page 97: ...n it 2 Check if the tool is fine 3 Check the tool clearance from the rim 4 Check the orientation of the tool 5 Check the turntable run out 6 Call Snap On Hot Line Centre COMPLAINT 4 The turntable does not hold the rims 1 Check the air pressure 2 Check the teeth of the jaws 3 Check the jaws adjustment 4 Check if there is air leaking from the cylinder 5 Check if there air leaking from the manifold 6...

Page 98: ...3 Check the air filter lubricator assembly 4 Check the MH cylinder 5 Check the MH valve 6 Call Snap On Hot Line Centre COMPLAINT 14 The automatic tool does not lift the tire bead 1 Check airline pressure inlet 2 Check the air pressure outlet 3 Check the air filter lubricator assembly 4 Check the automatic tool cylinder 5 Check the automatic tool cylinder valve 6 Call Snap On Hot Line Centre ...

Page 99: ...___________________________________________________________ ____________________________________________________________________________________________ REVISION B July 2013 5 2 Inverter T1 Firmware update 8Updated Pag 22 6 24 Manometer check and replacement New Pag 73 6 25 spiral pipes check and replacement New Pag 75 ...

Page 100: ...ifications in this manual are based on the latest information available at the time of publication We reserve the right to change the specifications at any time without notice Snap on Equipment Srl unipersonale Via Provinciale per Carpi 33 42015 CORREGGIO RE ITALY Tel 39 0 522 733489 Fax 39 0 522 733610 E mail corrcs snapon com Internet http www snapon equipment eu Copyright 2013 Snap on Equipment...