Hunter TCX575, Operation Instructions Manual

Page 1: ...Operation Instructions TCX575 Tire Changer Form 6097 T 01 12 Supersedes Form 6097 T 10 09c Copyright 2009 2012 Hunter Engineering Company ...

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Page 3: ...on will lose its validity Description of the machine machinery part Series TCX Tire Changers Machine type TCX400 Series TCX500 Series TCX600 Series TCX3000 Series Serial Number Various Applicable EC Directives 2006 42 EC 2006 95 EC 2009 105 EC 86 217 EEC 2004 108 EC Applicable Harmonized Standards EN ISO 12000 1 EN 60204 EN ISO 12000 2 Notified Body according to annex VII Not applicable name addre...

Page 4: ..._____ Phone Number ___________________________________________________________________ Concept and Procedure Explanation Safety Precautions Trained Declined Warning and Caution Labels Bead Press Rollers Maintenance and Performance Checks Trained Declined Mounting Head Inspection Adjustment and Filling of Oilers Bead Breaking Trained Declined Standard Wheels Low Profile Wheels Clamping Trained Decl...

Page 5: ...d Seating Individuals and Date Trained ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ _...

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Page 7: ...rom Outside of Rim Alloy Rims 13 2 3 Demounting Standard Tire from Rim 13 Top Bead Demounting 13 Difficult Tires 15 Precautionary Notes 17 Bottom Bead Demounting with Tool Head 17 Bottom Bead Demounting with Disc 18 Difficult Tires 20 Alternate Procedure 20 Using the Bead Lever 20 2 4 Mounting Standard Tire to Rim 22 Mount a standard tire to rim as follows 22 2 5 Match Mounting 25 2 6 Tire Inflati...

Page 8: ...5 1 Rim Diagram 37 5 2 Illustrations of Various Rim Designs 38 ...

Page 9: ...ng presented The owner of the TCX575 is solely responsible for enforcing safety procedures and arranging technical training The TCX575 is to be operated only by a qualified trained technician Maintaining records of personnel trained is solely the responsibility of the owner or management The TCX575 is intended for mounting demounting and inflating most tires with an approximate dimension of 40 inc...

Page 10: ...ccidents or damage to the tire changer use only Hunter recommended procedures and accessories Wear OSHA approved eye protection while operating the tire changer Wear non slip safety footwear when operating the tire changer Do not wear jewelry or loose clothing when operating the tire changer Wear proper back support when lifting or removing wheels from the tire changer WARNING Keep hands and cloth...

Page 11: ...turer s service manuals Service and maintain machine regularly as outlined in this Manual For further information contact Hunter Engineering Company 11250 Hunter Drive Bridgeton Missouri 63044 800 448 6848 314 731 3020 Internet address www hunter com 1 3 Control Pedals Control pedals on the TCX575 tire changer are configured as shown below PowerOut Version COLUMN ROTATION CLAMP NOTE SHOVEL CONTROL...

Page 12: ...se Release the pedal to stop rotation 1 5 Tire Bead Breaker Shovel Pedal Non PowerOut versions WARNING Keep arms and legs from between the bead breaker arm and the side of the housing Step down on the bead breaker shovel pedal to close bead breaker arm and loosen bead Release the pedal to allow the bead breaker arm to open 1 6 Tire Bead Breaker Shovel PowerOut Versions WARNING Keep arms and legs f...

Page 13: ...on the pedal and the clamps will move completely inward Change the position of pedal by briefly stepping down and then releasing 1 8 Column Rotation Pedal The column rotation pedal operates the automatic column WARNING Before activating automatic column make sure the path of the column is clear of people and other obstructions The column tilt pedal has two positions With the pedal up the column ro...

Page 14: ...instructions 1 11 Mount Demount Head The mount demount head is suspended from the column above the turntable The head has a mounting and demounting lip that is designed to install or remove the bead of tire as the wheel is rotated clockwise In addition the head also incorporates an automatic lever to ease the demounting process MOUNTING LIP The mounting lip is on the left side of the head DEMOUNTI...

Page 15: ...AL CONTROL BUTTON BPS LOCK RELEASE BUTTON BPS DISC AIR TANK CLAMP AND AIR JET 4 PLACES MOUNTING PASTE BEAD LOOSENING ARM AND SHOVEL TIRE BEAD LOOSENING PEDAL WHEEL ROTATION PEDAL WHEEL CLAMPING PEDAL COLUMN ROTATION PEDAL BPS UNIT BPS DISC BEAD LIFTER OILER REGULATOR TURNTABLE AIR INFLATION PEDAL BEAD PRESS CLAMP CONES EXTENSION SHOVEL BLADE POSITION ADJUSTMENT PIN TABLE HEIGHT ADJUSTMENT KNOB not...

Page 16: ...s System BPS Components The functional parts of the BPS are 1 Articulated Arm 6 Demounting match mounting disc 2 Rim Presser cone 7 Sliding locking lever 3 Control Lever 8 Demounting arm lock 4 Bead presser roller 9 Arm end of travel pin 5 Match mounting lock 7 5 3 1 9 2 4 8 6 ...

Page 17: ...AL OPERATION 5 RP11 4 402030 DECAL INFLATION PEDAL OPERATION 6 RP11 3020842 DECAL TABLE ROTATION 7 RP11 4 406883 DECAL MODEL SERIAL NUMBER 8 RP11 4 402027 DECAL MAXIMUM INLET PRESSURE 9 RP11 4 402018 DECAL HUNTER BEAD PRESS SYSTEM 10 RP11 3013640 DECAL BPS POSITIONING 11 RP11 4 402021 DECAL MANUAL TIRE BLEED VALVE 12 RP11 4 402038 DECAL VERTICAL COLUMN LOCK BUTTON OPERATION 13 RP11 4 402028 DECAL ...

Page 18: ...10 1 Getting Started Operation Instructions for TCX575 Tire Changer ...

Page 19: ... damage to equipment tire or wheel Remove valve stem core to deflate tire completely Remove all weights from the rim to protect the rim and extend life of the mount demount head The shovel blade has two position adjustment The second position is for wheels 10 wide and larger but also may be used to break the beads of extreme low profile tires PowerOut Versions Press the Out button to allow the bea...

Page 20: ...and break the opposite bead using the same procedure Non PowerOut Versions Swing the bead breaker arm out and position the wheel against the side of the tire changer between the bead breaker arm and the housing Swing the bead breaker arm toward the tire and position the shovel blade on the sidewall of the tire Locate the blade close but not contacting the edge of the rim Step down on the bead brea...

Page 21: ...nded position From this stopped position use additional partial steps on the clamping pedal to incrementally retract the clamps Set the clamps to the mark on the turntable that corresponds to the size of rim to be clamped 12 14 16 Place the wheel onto the turntable Continue to incrementally retract the clamps until all four clamps contact the rim Step down once only on the clamping pedal to fully ...

Page 22: ...omatic lever into the rim tire assembly CAUTION Always ensure that the automatic lever is inserted in a gap between the rim and the tire If the automatic lever is inserted without a gap tire damage can occur GOOD BAD MOUNT HEAD CORRECTLY PLACED MOUNT HEAD INCORRECTLY PLACED NOTE If the automatic lever does not completely seat under the upper bead continue to rotate until it does Press the wheel ro...

Page 23: ...he tool head VALVE STEM Pull up on the automatic lever to pull the bead over the edge of the rim Difficult Tires On difficult tires where the automatic bead lever does not have sufficient power to pull the tire over use the Bead Press System BPS on the opposite side of the tire and press down TOOL HEAD BPS DISC ...

Page 24: ... proper insertion of the automatic bead lever because not enough of a gap can be created between the tire and the rim edge NOT ENOUGH GAP BETWEEN TIRE AND RIM EDGE If this is the case reposition the upper BPS disc as shown below Lower the upper BPS disc and push down to create a gap between the tire and the rim edge A then insert the automatic bead lever B A PUSH DOWN AT THIS POINT B INSERT AUTOMA...

Page 25: ...ad it may become trapped and increases mounting stress to the tire bead Insufficient lubrication and failure to place tire into drop center during mounting may also cause the mount demount head to fail prematurely Bottom Bead Demounting with Tool Head Position the tire on the rim assembly as shown below Insert the automatic lever into the rim tire assembly Lift the tire up and over the automatic l...

Page 26: ...ockwise and demount the bottom bead Bottom Bead Demounting with Disc Demounting the bottom bead on certain wheel assemblies large and heavy assemblies and some run flat assemblies for example may be best performed by using the lower disc Return the tool head to the resting position Lower and align the lower disc to touch the bottom of the rim edge ...

Page 27: ...sc lock lever DISC LOCK LEVER While supporting the opposite side of the tire raise the lower disc until it is just above the rim edge This will create a gap between the rim edge and the tire With the tire in position press the wheel rotation pedal to rotate the wheel clockwise and demount the bottom bead ...

Page 28: ... Temporarily unlock the lower disc lock lever and pull the lower disc in between the rim edge and the tire Then lock the lower disc in place DISC REPOSITIONED AND LOCKED IN PLACE With the tire in position press the wheel rotation pedal to rotate the wheel clockwise and demount the bottom bead Alternate Procedure Using the Bead Lever NOTE Clean the mount demount head to remove dirt and debris befor...

Page 29: ...sh down on the tire sidewall 180 degrees from the mount demount head to slip the bead into the drop center of rim Using the bead lever tool lift the tire bead over the demounting lip of the head The bead lever tool must be pulled down parallel to the rim Lift the wheel rotation pedal to rotate the wheel counter clockwise slightly such that the upper bead rides up onto the demount lip Push the whee...

Page 30: ...heel Remove tire from rim 2 4 Mounting Standard Tire to Rim Always use this checklist as a guide when mounting tires to ensure proper service There are four basic steps when mounting a tire to a rim Position the bead on top of the mounting lip of the mount demount head Position the bead under the demounting lip of the mount demount head Lock the tire to the rim in the mounting position Slip the be...

Page 31: ...ing the column rotation pedal Lower the mount demount head into position on the edge of the rim and lock it into place Rotate the assembly clockwise until the lower bead drops into the drop center of the rim NOTE When mounting the top bead it is important to get the correct positioning of the tire on the mount demount head MOUNT HEAD CORRECTLY PLACED MOUNT HEAD INCORRECTLY PLACED ...

Page 32: ... tire under the finger of the mount demount head BACK OF TIRE OVER MOUNT DEMOUNT HEAD FRONT OF TIRE UNDER MOUNT DEMOUNT HEAD FINGER Move the articulated arm of the BPS to the 3 o clock position and lower the upper bead press disc down onto the edge of the tire With the tire in position press the wheel rotation pedal to rotate the wheel clockwise and mount the top bead ...

Page 33: ...ge of the rim and lower the upper bead press disc down Lower the upper bead press disc to approximately half the depth of the rim Position the lower disc at the rim edge on the bottom of the assembly and lock it in place Raise the lower disc such that the pitch between the upper and discs is approximately equal UPPER DISC LOWER DISC ...

Page 34: ... the rim WARNING Do not stand over tire during inflation Step down completely on the air inflation pedal pedal on the left side of the base to release a high pressure air blast through jets on the clamps to assist in seating the beads of the tire NOTE To increase the effectiveness of the inflation jets always liberally lubricate beads and raise the lower bead while activating inflation jets Step d...

Page 35: ...n Instructions for TCX575 Tire Changer 2 Basic Procedures 27 Disconnect inflation hose from valve stem 2 7 Removal of Wheel from Tire Changer Lift the clamping pedal to release the rim from the clamping device ...

Page 36: ...r AH in the rim size designation casting e g 8X17 AH AH wheels are designed so that the lowest point of the safety hump is located at the valve stem or 180 degrees out These two points are where it is easiest to loosen the bead from the bead seat AREA BETWEEN THE BEAD SEAT AND THE SAFETY HUMP CHANGES TO PREVENT TIRE SLIPPAGE ON RIM Bead Loosen AH Wheels as follows Swing the bead breaker arm out an...

Page 37: ...l to disengage the bead breaker arm and then swing the arm to the open position If the bead has not been completely loosened rotate the wheel 180 degrees and repeat the bead breaking procedure Turn the wheel and loosen the opposite bead using the same procedure NOTE Do not attempt to use the BPS Device for bead breaking It is only to be used to loosen beads that have already been loosened with the...

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Page 39: ... rubber and nylon components that should be replaced to prevent damage from occurring Replace worn parts as needed tool supports rubber pads lever protector sleeve and mount demount head Clean all areas that contact rims or tires to prevent possible scratching to rim Weekly Clean tire changer with shop towels or a vacuum cleaner Do not clean with or use compressed air which can blast dirt between ...

Page 40: ...n requires the use of an approximately 18 inch bare rim 1 Clamp rim without a tire on the tire changer turntable 2 Before making any adjustments loosen the four adjustment screws and tighten the head retaining bolt until some grip is obtained HEAD RETAINING BOLT ADJUSTMENT SCREWS ADJUSTMENT SCREWS 3 Position the tool head manually against the edge of the rim so that both sides of the tool head are...

Page 41: ...uld be touching the rim at the points shown below TOOL HEAD SHOULD TOUCH RIM AT THIS POINT TOOL HEAD SHOULD TOUCH RIM AT THIS POINT 4 Tighten the side adjustment screws but not completely Radial Adjustment of the Tool Head 1 Release the tool head then reposition it on the rim and lock it in place with the head position lock 2 Adjust the two front adjustment screws and set the tool head so the left...

Page 42: ...k the distance between the tool head and the rim The distance should be 06 inch 06 inch GAP 2 If the gap is not correct release the head position lock and adjust the nut beneath the post locking system cover to adjust the gap The cover must be removed Back off the nut to increase the gap and tighten to reduce the gap POST LOCKING SYSTEM COVER ADJUSTMENT NUT 3 Reposition the tool head on the rim an...

Page 43: ... must be removed Back off the nuts to increase the gap and tighten to reduce the gap HORIZONTAL POST LOCKING SYSTEM COVER REMOVED ADJUSTMENT NUTS CAUTION To ensure that the horizontal locking plate functions correctly the two nuts must be adjusted symmetrically 4 Reposition the tool head on the rim and lock it in place with the head position lock Re check gap 5 When the adjustments are complete ch...

Page 44: ...179 15 2 Brush RP6 1506 Mounting Paste RP6 3784 Mount Demount Head RP11 3314813 Hand Held Bead Lever straight RP11 3009516 Bead Lever Protector Sleeve Std 4 RP11 8 11400098 Jaw Protection Kit 2 sets 8 covers RP11 8 11400085 Mount demount Protector Kit consisting of 10 demounting protectors 5 mounting protectors 15 protector screws RP11 8 11400293 ...

Page 45: ...m Diagram OUTBOARD FLANGE POSITIVE OFFSET CENTERLINE OUTBOARD SAFETY HUMP DROP CENTER INBOARD SAFETY HUMP REAR SPACING RIM WIDTH OUTBOARD BEAD SEAT INBOARD BEAD SEAT INBOARD FLANGE RIM CENTERLINE NEGATIVE OFFSET RIM DIAMETER BOLT CIRCLE DIAMETER CENTER BORE MOUNTING PAD DIAMETER ...

Page 46: ...igns REVERSE DROP CENTER LONG DROP CENTER CONICAL CYLINDRICAL OUTBOARD OUTBOARD INBOARD INBOARD NO DROP CENTER OUTBOARD INBOARD RIM MUST BE INVERTED POSITION INBOARD RIM ON TOP WHEN MOUNTING DEMOUNTING MULTIPLE STROKES REQUIRED FOR REMOVAL OF LOWER BEAD RIM DISASSEMBLY REQUIRED DO NOT USE ON TCX550 ...

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Page 48: ...rs of shop field and teaching experience 9 9 Fully equipped service bays 9 9 Classrooms equipped with modern teaching aids 9 9 The most up to date wheel alignment balancing service and brake equipment on the market today Classes Available Align 1 Basic Alignment Theory and Practice 3 day 24 hours Align 2 Advanced theory Aftermarket Adjustment 2 day 16 hours Align 3 Advanced Diagnostics and OEM Pro...