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Operation Instructions for TCX56/57 Tire Charger

10

1.2 For Your Safety

Hazard Definitions

These symbols identify situations that could be detrimental to your safety and/or cause
equipment damage.

DANGER: Indicates an imminently hazardous situation which, if not avoided,

will result in death or serious injury.

DANGER

WARNING: Indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.

WARNING

CAUTION: Indicates a potentially hazardous situation which, if not avoided,

may result in minor or moderate injury.

CAUTION

NOTICE: Used without the safety alert symbol indicates potentially hazardous

situation, which, if not avoided, may result in property damage.

NOTICE

1.3 General Warnings and Instructions

Avoid Personal Injury. Carefully read, understand and follow the warnings and
instructions given in this manual. This manual is an essential part of the product.
Keep it with the machine in a safe place for future reference.

WARNING

1. If the use and maintenance procedures provided in this manual are not properly

performed, or the other instructions in this manual are not followed, an accident could
occur. Throughout this manual reference is made that “an accident” could occur. Any
accident could cause you or a bystander to sustain severe personal injury or death, or
result in property damage.

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Summary of Contents for TCX56

Page 1: ... Copyright 2009 2012 Hunter Engineering Company Code 4 132467 01 15 TCX56 57 Tire Changer Family Operating Instructions TCX 57 Leverless version TCX 56 Standard version ...

Page 2: ......

Page 3: ...er and should remain with the Tire Changer However nothing in this manual and none of the devices installed on the Tire Changer substitute for proper training careful operation good judgment and safe work practices Always be sure that your Tire Changer is in optimum working order If you suspect that anything is not working properly or that a dangerous situation may exist immediately shut down the ...

Page 4: ...__________________ Phone Number_____________________________________________________________________________ Sales Representative_______________________________________________________________________ Phone Number_____________________________________________________________________________ Training Checklist Safety Precautions Trained Declined Warning and Caution Labels Pinch Points and Other Pote...

Page 5: ... Individuals and Dates Trained ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ _________...

Page 6: ... Clamping Pedal 21 1 13 Column Rotation Pedal 21 1 14 Air Inflation Pedal 21 1 15 Moving Parts 22 1 16 Inflator and Pressure Limiter 22 1 17 Mount Demount Head 22 1 18 Equipment Components 24 1 19 Bead Press System BPS Components 25 2 Basic Procedures 26 2 1 Bead Breaking 26 2 2 Placing Wheel on Tire Changer 27 Clamping the Wheel from Inside of Rim Steel Rims 27 Clamping the Wheel from Outside of ...

Page 7: ...om Rim Using the Bead Lever Tool without the Plastic Sleeve Protector 51 Demounting Upper Bead 51 Demounting Lower Bead 51 3 3 Advanced Mounting Procedures 52 3 4 Standard Mount Demount Head Assembly 52 Checking Mount Demount Head Calibration 52 For Steel Heads 52 Set Position of Steel Mount Demount Head on Hex Shaft 52 For Plastic Heads 54 Set Position of Plastic Mount Demount Head on Hex Shaft 5...

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Page 9: ...57 tire changer family The following sections contain detailed information about equipment procedures and maintenance Italics are used to refer to specific parts of this manual that provide additional information or explanation For example Refer to Equipment Components page 24 These references should be read for additional information to the instructions being presented The owner of the tire chang...

Page 10: ... Used without the safety alert symbol indicates potentially hazardous situation which if not avoided may result in property damage NOTICE 1 3 General Warnings and Instructions Avoid Personal Injury Carefully read understand and follow the warnings and instructions given in this manual This manual is an essential part of the product Keep it with the machine in a safe place for future reference WARN...

Page 11: ...nough force to cause serious injury or death Never mount any tire unless the tire size molded into the sidewall matches the rim size stamped into the rim exactly or if the rim or tire are defective Never exceed tire pressure recommended by tire manufacturer This tire changer is not a safety device and will not restrain exploding tires and rims keep area clear of bystanders DANGER 7 Crushing Hazard...

Page 12: ...al arcing or sparking parts which should not be exposed to flammable vapors gasoline paint thinners solvents etc This machine should not be located in a recessed area or below floor level 16 Never operate the machine if you are under the effects of alcohol medications and or drugs If you are taking prescription or over the counter medication you must consult a medical professional regarding any si...

Page 13: ...Operation Instructions for TCX56 57 Tire Charger 13 ...

Page 14: ...rsion 3 2 5 9 1 14 16 10 8 9 13 7 9 6 4 18 11 15 17 14 11 16 12 19 IIAXXXXXX ANNO DI COSTRUZIONE MANUFACTURED 20XX 0 11XXXXXX XX MADE IN ITALY Port max 11250 HUNTER DRIVE BRIDGETON MISSOURI 63044 HUNTER ENGINEERING COMPANY XX XX XX XX ac X XX XX XX XX A V lb kW Hz Ph TCX500E SERIES Model Serial N XX bar psi Code ...

Page 15: ...ION 12 RP11 4 115412 DECAL DANGER WARNING INDICATION 13 RP11 3016568 DECAL BPS LOCK 14 RP11 4 115411 DECAL DANGER OPERATION 15 RP11 4 407099 DECAL TOOL MOVEMENT 16 RP11 4 115243 DECAL WARNING OPERATION 17 RP11 4 113552 DECAL TL TOOL LABEL 18 RP11 4 115246 DECAL ELECTRICAL HAZARD 19 RP11 4 113016 DECAL RECOMMENDED TPMS SENSOR START POSITION 20 Rif SN DECAL BPS SERIAL NUMBER NOT SHOWN Electrical ind...

Page 16: ... in the O off position before plugging the power cord into the electrical power outlet Specific Precautions Power Source The TCX56 57 is equipped with motoinverter 220VAC 1PH 50 60Hz and standard plug 220V L6 20P plug This machine must be connected to a 20 amp branch circuit Please refer all power source issues to a certified electrician WARNING A protective ground connection through the grounding...

Page 17: ...se symbols may appear on the equipment Alternating current Earth ground terminal Protective conductor terminal Risk of electrical shock 1 3 b Air Pressures The machine is equipped with an internal pressure limiting valve to minimize the risk of over inflating the tire EXPLOSION HAZARD Never exceed tire pressure recommended by tire manufacturer Never mismatch tire size and rim size Avoid personal i...

Page 18: ... services any rim wheel unless the employee has been trained and instructed in correct procedures of servicing the type of wheel being serviced and in the safe operating procedures Information to be used in the training program shall include at a minimum the applicable information contained in this manual 2 The employer shall ensure that each employee demonstrates and maintains the ability to serv...

Page 19: ...al vibration if a component or system is not operating properly or if there is anything unusual at all stop using the machine immediately Identify the cause and take any necessary remedial action Contact your supervisor if necessary Never allow any bystander to be within 20 feet of the machine during operation To stop the machine in an emergency disconnect the power supply plug cut off the compres...

Page 20: ...dal to stop rotation Depressing the pedal halfway rotates the wheel at slow speed Depressing the pedal all the way rotates the wheel at fast speed Lift up on the pedal to rotate the wheel counterclockwise Release the pedal to stop rotation 1 11 Tire Bead Breaker Shovel control Keep arms and legs from between the bead breaker arm and the side of the housing WARNING 4 402023 CRUSH HAZARD CRUSH HAZAR...

Page 21: ...he reference on the table top is more or less in line with the tyre diameter stamped on the sliding clamp Place the wheel on the table top and push down on the wheel while depressing the pedal all the way to clamp the wheel 1 13 Column Rotation Pedal The column rotation pedal operates the automatic column Before activating automatic column make sure the path of the column is clear of people and ot...

Page 22: ...ents the operator from using excessive air pressure Bead seating pressure should never exceed the tire manufacturer s maximum bead seating pressure as stated on the sidewall of the tire If tires being mounted require more than the tire manufacturer s maximum bead seating pressure the wheel should be removed from the tire changer placed in an inflation cage and inflated per manufacturer s instructi...

Page 23: ... Leverless version TCX57 AUTOMATIC LEVER RETRACTED AUTOMATIC LEVER EXTENDED MOUNTING LIP The mounting lip is on the left side of the head DEMOUNTING LIP The demounting lip is on the right side of the head AUTOMATIC LEVER In addition the head also incorporates an automatic lever to ease the demounting process The bead of tire is placed on top of mounting lip during mounting The bead of tire is plac...

Page 24: ...OSITION ADJUSTMENT PIN WHEEL ROTATION PEDAL COLUMN ROTATION PEDAL AIR INFLATION PEDAL TABLE CAPACITY ADJUSTMENT KNOB TURNTABLE OILER REGULATOR BEAD LIFTER BEAD LIFTER LOCK BPS UNIT BEAD PRESS CLAMP CONES EXTENSION MOUNT DEMOUNT HEAD TCX 57 Leverless Version WHEEL CLAMPING PEDAL BPT BPS DISC AIR TANK MOUNTING PASTE HEAD POSITION LOCK INFLATION HOSE PRESSURE GUAGE AIR RELEASE BUTTON TCX 56 Standard ...

Page 25: ...nts The functional parts of the BPS are 1 Articulated Arm 2 Rim Presser cone 3 Control Lever 4 Bead presser disc 5 Match mounting lock 6 Demounting match mounting disc 7 Sliding locking lever 8 Demounting arm lock 9 Rotating arm end of stroke pin 10 Mounting arm 7 10 7 4 2 4 9 5 6 8 1 3 ...

Page 26: ...ts 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 Press the Out button to allow the bead breaker arm to open and position the wheel against the side of the tire changer between the bead breaker arm and the ...

Page 27: ...eeds inverted on changer AH Run Flat Extended Mobility Tires and standard tires with pressure sensors If you are not fully familiar with these special wheel considerations DO NOT USE the tire changer See your supervisor Clamping the Wheel from Inside of Rim Steel Rims Identify the inner locations on the rim where the clamps will come in contact Position the clamps in the fully retracted position c...

Page 28: ...e used to help maintain rim protection when clamping externally Plastic covers also be used to prevent wheel slip Plastic jaw covers may be replaced periodically when worn by ordering kit RP11 8 11100358 which contains 2 sets of plastic covers This tire changer is equipped with an adjustable turntable there are two knobs that allow extended clamping capacity up to 26 up to 26 clamping externally u...

Page 29: ... clock position Position the mount demount head against the outer edge of the upper rim lip Slide the mount demount head in or out along the upper rail and lower the head into position Pull the head position lock handle to lock head into position A plastic protector sleeve may be installed on the bead lever tool to aid in rim protection Plastic protectors bead lever Position the bead lever between...

Page 30: ... bead lever tool from the tire when it easily slides out approximately after a quarter rotation of the wheel Continue to press the wheel rotation pedal to rotate the wheel clockwise until the entire bead is lifted from the rim Lift tire and repeat this procedure for lower bead Lift the mount demount arm assembly up and away from the wheel Remove tire from rim For additional information on demounti...

Page 31: ...t demount head in or out along the upper rail and lower the head into position Lock the lever Adjust the diameter knob for correct side spacing The mount demount head will automatically build in the proper vertical spacing NOTICE Always make sure the wheel is being rotated while inserting the automatic lever Locate an area with a gap between the tire and wheel Press the wheel rotation pedal to rot...

Page 32: ...LACED BAD If the automatic lever does not completely seat under the upper bead continue to rotate until it does NOTICE Press the wheel rotation pedal until the valve location is in the one o clock position Position the valve stem directly beneath the tool head VALVE STEM Pull up on the automatic lever to pull the bead over the edge of the rim ...

Page 33: ...have sufficient power to pull the tire over use the Bead Press System BP or BPS if equipped on the opposite side of the tire and press down TOOL HEAD BPS DISC Press the wheel rotation pedal to rotate the wheel clockwise and fully demount the upper bead If the bead does not establish traction use the provided spatula shown below ...

Page 34: ...omatic bead lever B A PUSH DOWN AT THIS POINT B INSERT AUTOMATIC BEAD LEVER Raise the BPS disc and then rotate Precautionary Notes NOTICE When basic procedures are NOT followed sharp angled wheel flanges increase potential damage to tires during mounting Be sure the mounting head is placed on the rim with sufficient gap between the bead and bead seat If the tire is incorrectly pushed onto the rim ...

Page 35: ... tire assembly Lift the tire up and over the automatic lever and raise the automatic lever to lift the lower bead Alternatively you may lift the tire up first lower the automatic lever lift the tire into place and then lower the automatic lever beneath the bottom bead With the tire in position press the wheel rotation pedal to rotate the wheel clockwise and demount the bottom bead ...

Page 36: ... 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 Lock the disc in place using the disc lock lever DISK LOCK LEVER ...

Page 37: ...ise and demount the bottom bead Difficult Tires Some of the more difficult tires may have the tendency to fold under the lower disc TIRE FOLDING UNDER DISC If this is the case reposition the lower disc While supporting the opposite side of the tire again raise the lower disc until it is just above the rim edge Create a gap between the rim edge and the tire Temporarily unlock the lower disc lock le...

Page 38: ...location is in the one o clock position Position the mount demount head against the outer edge of the upper rim lip Slide the mount demount head in or out along the upper rail and lower the head into position Push the button on handle to lock head into position A plastic protector sleeve may be installed on the bead lever tool to aid in rim protection Position the bead lever between the demounting...

Page 39: ...e wheel counter clockwise slightly such that the upper bead rides up onto the demount lip Push the wheel rotation pedal to rotate the wheel clockwise Remove the bead lever tool from the tire when it easily slides out approximately after a quarter rotation of the wheel Continue to press the wheel rotation pedal to rotate the wheel clockwise until the entire bead is lifted from the rim Lift tire and...

Page 40: ...s 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 bead into the drop center These four basic steps to mounting do not necessarily follow the same sequence however all ...

Page 41: ...the tire on the mount demount head NOTICE MOUNT HEAD CORRECTLY PLACED MOUNT HEAD INCORRECTLY PLACED Position the tire such that the back of the tire is over the mount demount head and the front of the tire under the finger of the mount demount head BACK OF TIRE OVER MOUNT DEMOUNT HEAD FRONT OF TIRE UNDER MOUNT DEMOUNT HEAD FINGER ...

Page 42: ...o rotate the wheel clockwise and demount the bottom bead 2 6 Mounting of difficult tires low profile or Run Flat tires Mount the first bead as usual Move the valve to about 5 o clock Bring the BPS arm to the working position with the bead breaker disc in its limit stop position Rotate the BPT arm anti clockwise and stop at h 2 Tilt down the mobile part of the arm and secure with its pin Rotate the...

Page 43: ... until it is next to the fixed arm Fit the edge guard at about 4 o clock or in the traction point if different Lower the PT arms carriage until the tyre bead is level with the well of the rim Start rotating the chuck at the same time guiding rotation of the mobile arm with your hand During this stage check that the section of bead between the fixed and mobile discs remains inside the well of the r...

Page 44: ... never press hard enough to cause deformation of the tread surface WARNING Keep turning until the second bead is completely mounted checking that the edge guard remains in place in the traction point The PT has a mechanical system which automatically gradually reduces the pressure applied by the bead pressing disc as it rotates to prevent damage to the tyre NOTICE Raise the PT arms Unlock the BPT ...

Page 45: ...procedure 2 8 Tire Inflation EXPLOSION HAZARD Never exceed tire pressure recommended by tire manufacturer Never mismatch tire size and rim size Avoid personal injury or death DANGER Verify that both upper and lower tire beads and rim bead seat have been properly lubricated with an approved mounting paste Do not lock the rim on the turntable during inflation Remove valve stem core if not already do...

Page 46: ...your body over a tire during inflation process or when attempting to seat beads This machine is not intended to be a restraining device for exploding tires tubes or rims 5 Always stand back from the tire changer when inflating never lean over An exploding tire and rim may be propelled upward and outward with enough force to cause serious injury or death Do not mount any tire unless the tire size m...

Page 47: ...tire during inflation WARNING 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 AIR JET FROM HERE To increase the effectiveness of the inflation jets always liberally lubricate beads and raise the lower bead while activating inflation jets NOTICE ...

Page 48: ... sealing bead Bleed air pressure from system before disconnecting supply line or other pneumatic components Air is stored in a reservoir for operation of inflation jets Only activate the air inflation jets if the rim securing device is locked in place and the tire is properly clamped WARNING Never mount a tire to a rim that is not the same diameter e g 16 1 2 inch tire mounting on a 16 inch rim WA...

Page 49: ...ADAPTORS IN REDUCER CONFIGURATION ON 4 WHEEL JAW ADAPTORS IN EXTENSION CONFIGURATION ON 30 WHEEL The jaw adaptors may be configured for either extension or reduction by removing the two nuts and screws from the adaptor as shown below rotating the adaptor plate 180 and re securing ROTATE ADAPTOR PLATE REMOVE NUTS AND SCREWS JAW ADAPTORS IN REDUCER CONFIGURATION JAW ADAPTORS IN EXTENSION CONFIGURATI...

Page 50: ...ing System wheels may be identified by looking on the back of a rim for 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 break the bead from the bead seat AREA BETWEEN THE BEADSEAT AND THE SAFETYHUMP CHANGES TOPREVENT TIRE SLIPPAGE ON RIM ...

Page 51: ...e up and over the mount demount head Demounting Upper Bead Position mount demount head onto the outer edge of the upper rim lip Position bead breaker tool without plastic sleeve protector between demounting lip of the head and the bead of the tire The demounting lip is on the right side of the head Using the bead lever tool pry the tire bead over the demounting lip of the head Position the bead le...

Page 52: ...here are plastic and steel mount demount head assemblies available for the TCX56 tire changer family Both use standard procedures for mounting and demounting To change the mount demount head assembly 1 Loosen the set screws steel heads only and the adjustment bolts 2 Remove the head retaining bolt 3 Remove the mount demount head assembly HEX SHAFT PIN SET SCREWS ADJUSTMENT BOLTS HEAD RETAINING BOL...

Page 53: ...t head Double check distance with feeler gauge See above figure 6 Keep the roller in contact with the edge of the rim alternately loosen and tighten the two adjustment bolts until the gap is 1 4 inch BACK EDGE OF HEAD OVER HANG Measure with depth gauge inch specification 7 Fully tighten the set screws checking when done that sides of the tool head are still the same distance from the edge of the r...

Page 54: ...require the use of a 17 18 inch bare rim Figure below is a summary of the desired end result Set Position of Plastic Mount Demount Head on Hex Shaft 1 Clamp a 17 18 rim without a tire on the tire changer turntable 2 Loosen the head retaining bolt slightly so that the head is still attached HEX SHAFT PIN ADJUSTMENT BOLTS HEAD RETAINING BOLT ...

Page 55: ...ain position the mount demount head on the outer edge of upper rip lip and lock in this position 2 Use gauges to measure distances between head and the top of the rim Measure at inserts on steel head TIRE MOUNTING LIP TOP GAP Measure with feeler gauge 5 64 inch specification TIRE DEMOUNTING LIP SIDE GAP Measure with feeler gauge 5 64 inch specification Change the offset by removing the plastic cov...

Page 56: ...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 SCREW ADJUSTMENT SCREW 3 Position the tool head manually against the edge of the rim so that both sides of the tool head are resting on it Keep the tool head in position without engaging the head position lock Ho...

Page 57: ...crews 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 side is touching the rim and the right side is flush with the edge of the rim TOOL HEAD SHOULD TOUCH RIM AT THIS POINT TOOL HEAD SHOULD BE FLUSH WITH EDGE OF RIM ...

Page 58: ...e 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 and lock it in place with the head position lock Re check gap Adjusting the Horizontal Gap 1 Release the tool head then reposition it on the rim and lock it in place ...

Page 59: ...TAL POST LOCKING SYSTEM COVER ADJUSTMENT NUT To ensure that the horizontal locking plate functions correctly the two nuts must be adjusted symmetrically NOTICE 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 check the gap between the hook of the tool head and the outboard safety hump of the rim The distance sho...

Page 60: ... equipment and make sure that all moving parts are suitably immobilized HAZARDOUS VOLTAGE Turn of and lock out system power before servicing Contact may cause electric shock or death DANGER Before carrying out cleaning or maintenance operations on the machine or when replacing machine parts turn off the machine and disconnect all power sources Follow any lock out tag out procedures in your jurisdi...

Page 61: ...d as a single integrated system To avoid compromises in terms of safety performance durability and function and to prevent voiding of the warranty do not substitute Hunter Engineering Company components with components manufactured by other companies Use only ORIGINAL replacement PARTS supplied by Hunter Engineering Company During maintenance procedures Never modify or alter the machine or any of ...

Page 62: ...eaning solvents to clean pressure regulator oiler Periodically Refill the pressure regulator oiler using only Hunter Lubri Oil 148 133 2 as needed Petroleum based oils should never be used in the oiler and may void all warranties Adjust the oiler to release one drop of oil every three rotations of the clamping table by adjusting the screw on top Check for loose bolts and tighten per specifications...

Page 63: ...Operation Instructions for TCX56 57 Tire Charger 63 5 Glossary 5 1 Rim Diagram ...

Page 64: ...Operation Instructions for TCX56 57 Tire Charger 64 5 2 Illustrations of Various Rim Designs ...

Page 65: ...Operation Instructions for TCX56 57 Tire Charger 65 ...

Page 66: ...___________________________________________ Model Number_____________________________________________________________________________ Serial Number_____________________________________________________________________________ Date Purchased____________________________________________________________________________ Date Installed______________________________________________________________________...

Page 67: ......

Page 68: ...teaching experience Fully equipped service bays Classrooms equipped with modern teaching aids The most up to date wheel alignment balancing service and brake equipment on the market to day 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 Procedures 2 day 16 hours Performan...

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