Hofmann ATC 900 Service Manual Download

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CTC-CEN Service Manual 07-13 Rev.E

ATC 900 – CENTAUR –

MONTY 8600 – VULCAN PRO

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

Summary of Contents for ATC 900

Page 1: ...ice Manual 07 13 Rev E 1 ATC 900 CENTAUR MONTY 8600 VULCAN PRO 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: ...CTC CEN Service Manual 07 13 Rev E 2 B L A N K P A G E ...

Page 3: ...sks alignment Pag 35 6 6 Bead breaker arms potentiometers calibration Rev C Pag 36 CHAPTER 7 PNEUMATIC SECTION Pag 41 7 1 Pneumatic function Pag 41 7 2 Air filter lubricator assy EAA0350G85A check and replacement Pag 42 7 3 Opening arm cylinder EAA0350G44A check and replacement Pag 43 7 4 Valve control opening arm cylinder EAA0356G96A check and replacement Pag 44 7 5 Vertical blocking cylinder EAA...

Page 4: ...rizontal arm rollers check and adjustment Pag 80 8 4 Gear box EAA0347G76A check and replacement Pag 80 8 5 Bead breaker discs EAM0065G63A Check and replacement Pag 81 8 6 Bead breaker discs EAM0065G63A Check and replacement Pag 82 8 7 Bead breaker discs bearing 1 06963A Check and replacement Pag 83 8 8 Bead breaker discs inclination adjustment Pag 84 8 9 Bead breaker discs clearance Check and adju...

Page 5: ... 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 failure...

Page 6: ...er 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 Adequate ventilation should be provided when working on operating internal combustion engines 8 To reduc...

Page 7: ...CTC CEN Service Manual 07 13 Rev E 7 ELECTRIC DIAGRAM ...

Page 8: ...CTC CEN Service Manual 07 13 Rev E 8 PNEUMATIC DIAGRAMS ...

Page 9: ... or tagged out 4 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 LICENSED ELECTRICIAN BEFORE CONNECTIN...

Page 10: ... in 18VAC to supply the CPU board A1 through the connector X2 INVERTER T1 It supplies 230 3 to the turntable motor M3 and change the motor rotational speed from 50 to 100Hz CENTERPOST SWITCH S1 The switch forward the rotational and speed input to the inverter T1 for the motor M3 ...

Page 11: ...ms potentiometers the lower bead breaker arm actuator and the laser pointer BEAD BREAKER ARMS POTENZIOMETERS B1 AND B2 The bead breaker arm potentiometers are 3 turns type 5K first batch 10K the present one and they are supplied at 5 VDC by the CPU board They control the position of the bead breaker arms in order to allow a constant alignment of the bead breaker discs LOWER BEAD BREAKER ARM ACTUAT...

Page 12: ...e laser pointer is directly supplied by the CPU board through the connectors X4 and X5 It is used to make an easier positioning of the tool on the rim edge WARNING LASER RADIATION CLASS 2 LASER PRODUCT 1mW 650 nm CW DO NOT STARE INTO BEAM IEC 60825 1 2007 ...

Page 13: ...ELL FITTED 5 1 POWER SUPPLY CABLE AND PLUG 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 electric functions of machine do not work TO CHECK THE CABLE Disconnect power supply Remove the plug form the w...

Page 14: ...ground terminal block Install plug Tighten strain relief FIRMLY Plug the machine to the wall Check if the machine works fine Fix the inverter box again to the cabinet 5 2 MAIN ROTARY SWITCH Q1 2 15359A CHECK AND REPLACEMENT 0 5h Allen keys of 3 and 5mm small and medium screwdriver medium cross screwdriver faston pliers scissors pliers multimeter Defective main switch may cause the following malfun...

Page 15: ...rivers medium cross screwdrivers 7mm tube type wrench 4mm allen key pliers multimeter Defective chuck motor cable may cause the following malfunction 1 Low rotational torque 2 Noisy motor 3 Motor damaging burning TO CHECK THE CABLE Disconnect power supply from the wall Open the electric box Disconnect the wires white brown and black from the Inverter Remove the front motor protection to access to ...

Page 16: ...NT 1h End keys 13 17mm medium cross screwdriver 7mm tube type wrenches 3 and 4mm allen key multimeter loctite extractor Defective centerpost motor may cause the following malfunction 1 Motor is noisy 2 Motor is burnt 3 Low turntable torque TO CECK THE CENTERPOST MOTOR WHEN IT SHOWS LOW TORQUE OR IT IS NOISY Refer to paragraph 5 3 TO CHECK THE CENTERPOST MOTOR WHEN IT IS NOISY Disconnect power supp...

Page 17: ...nuts Plug the machine to the wall Turn the machine on MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK Check the rotation way of the motor If it is wrong reverse only two centerpost motor wires Turn the machine off and unplug it from the wall Mount the motor terminals cover IMPORTANT WHEN REMOUNTING THE MOTOR TERMINALS COVER BE CAREFUL NOT TO CRUSH WIRES Mount all protections and covers Turn the mac...

Page 18: ...not show any change of value the CPU board must be replaced TO REPLACE THE MOTOR Turn the machine off Remove the protection from the lower bead breaker arm Make sure that the bead breaker arm is unlocked Disconnect the motor from the arm Turn the worm screw handily to remove the actuator from the arm Remove the cable from electric box Remove the cable from the chain Move the lower bead breaker arm...

Page 19: ...ll and medium cross screwdrivers pliers Defective transformer may cause the following malfunction 1 Smoke gets out from the electric box with consequent burning of the transformer 2 Turning the machine on the lower bead breaker arm actuator M2 and the laser pointer do not work IMPORTANT BEFORE STARTING WITH THE INSPECTION OF THE TRANSORMER MAKE SURE THAT THE FUSE IS FINE TO CHECK THE FUSE Disconne...

Page 20: ...hten firmly all wires Turn the machine on MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK Check if the machine works fine again Turn the machine off Mount the electric box cover Check if the machine works fine 5 7 CENTERPOST SWITCH S1 2 15259A CHECK ADJUSTMENT AND REPLACEMENT 1h Small standard and cross screwdrivers 4 and 5 mm allen key 8mm key Defective turntable switch may cause the following mal...

Page 21: ...and 4 and press the pedal to verify if there continuity If not replace the switch In case the motor does not turn in second speed position the Voltmeter probes on terminals 1 4 and 1 8 and press the pedal to verify if there continuity If not replace the switch In case the motor does not turn in reversed speed position the Voltmeter probes on terminals 1 8 and push up the pedal to verify if there c...

Page 22: ...l all way down and make sure that switch has already switched to the second step before the pedal has reached the end of stroke Push the pedal all way up and make sure that switch that the switch engages before the back side of the pedal touches the pedals support TO REPLACE THE SWITCH Loosen the screw that hold the switch lever ...

Page 23: ...th the bracket from the foot pedal assembly Loosen the screws and remove the switch Install the new switch and secure the screws Install and secure the switch lever Turn the machine on MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK Check if the machine works fine Turn the machine off Mount the pedal assy cover ...

Page 24: ...rection only 5 Centerpost does not turn in second speed 6 The shut off switch of the tire shop shuts off TO CHECK THE INVERTER Turn the machine on Press the rotational pedal if the motor does not run or if the tire shop shut off switch shuts off the inverter must be replaced IMPORTANT BEFORE REPLACING THE EMC INVERTER MAKE SURE THAT THE TURNTABLE MOTOR AND WIRE ARE FINE TO REPLACE THE INVERTER Tur...

Page 25: ...wdriver 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 26: ...erent 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 27: ...elow 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 powered...

Page 28: ...CTC CEN Service Manual 07 13 Rev E 28 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 29: ...ure 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 30: ...CTC CEN Service Manual 07 13 Rev E 30 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 31: ...ammer 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 32: ... that there is power output from connector X3 blue TO REPLACE THE PROCESSOR BOARD A1 Turn off the machine Disconnect all connectors and wires IMPORTANT DO NOT REMOVE THE CONNECTORS PULLING FROM THE WIRES PULL FROM THE CONNECTOR ONLY Remove the 4 screws with the screwdriver IMPORTANT MARK CONNECTORS PROPERLY FOR AN EASY AND SAFE INSTALLATION Install the new board Install all connectors and wires Mo...

Page 33: ...R POTENTIOMETER Turn the machine off Remove the electric cover Position the upper bead breaker arm to the inward end of stroke Turn the machine on MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK Take the multimeter and select it in VDC Position its terminals on the potentiometer wires green and white Move the arm until end of stroke the multimeter must display a value from 4 6 to 0 121 on 5K potent...

Page 34: ...sion will be fine replace the CPU board TO REPLACE THE 3 TURNS POTENTIOMETER Remove the potentiometer protection Disconnect the potentiometer connector from the CPU board Slide the arm at the more convenient end stroke To slide the lower bead breaker arm press and hold SW1 or SW3 buttons on the CPU board Unplug the potentiometer from the CPU board Loosen the two screws with 5mm allen key Loosen th...

Page 35: ...potentiometer assy to the armr Mark the toothed wheel Slide the bead breaker arm all way in or out checking that the number of revolution made by wheel are 2 and making sure that the potentiometer will not be at the end of the stroke 6 5 PROCEDURE TO ADJUST BEAD BREAKER DISKS ALIGNMENT In case of complaints related to bead breaker disks misalignment out of the maximum tolerance allowed 1mm 0 04 we...

Page 36: ...gain 11 Calibrate the machine 12 Check if the arms are better aligned 13 Turn the machine off 14 Install the potentiometer cover again 6 6 BEAD BREAKER ARMS CALIBRATION SW 1 0 3 1 0 4 30 5mm Allen The bead breaker arm potentiometers calibration can be performed by pressing the following button placed on the CPU board inside of the electric box SW1 Inward lower bead breaker arm motion enable during...

Page 37: ...ARNING MAHINE UNDER TENSION RISK OF ELECTRIC SHOCK 3 Make sure that the bead breaker arm are unlocked 4 Press the button SW2 till the green LED 4 will start blinking The blinking LEDs show that the machine is in calibration status 5 Press and hold the button SW1 to move the lower bead breaker arm slave all inward ...

Page 38: ...ect alignment of the disks If necessary move the lower arm to equalize the disks alignment If the machine is without MH arm use the electronic inclinometer to make the alignment 7 Acquire the position pressing for a while the button SW2 Now the LED 4 will turn off while the 5 one will start blinking 8 Move the upper bead breaker arm master all way out ...

Page 39: ... breaker disk 10 Press and hold the button SW3 to move the lower bead breaker arm outward and place the disk as closest to the MH rod Complete the alignment by moving manually the upper bead breaker arm If the machine is without MH arm use the electronic inclinometer to make the alignment ...

Page 40: ... calibration points is done 12 Press and hold SW2 to confirm and store the calibration LEDs 4 and 5 will turn off and 2 further beeps will be emitted to indicate the calibration is completed Now the machine is ready to operate 13 Turn off the machine 14 Mount the cover to the electric box 15 It is allowed to escape the calibration at any time by pressing the button SW4 ...

Page 41: ...ss 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 the air tank equipped with a pressure relief valve set up at 12 bar The bead blaster valve is basically a diaphragm valve and it is directly bolted to the tank When inflator blaster pedal is...

Page 42: ...the machine Unplug the hoses Loosen the bracket screws and remove the assy Install the new air filter assy Plug in the air hoses Make the oil level Connect the air pressure Make the oil lubrication adjustment Check if the machine works fine again TO REPLACE THE GLASSES Disconnect the air pressure from the machine Turn counter clockwise the glass to remove it from the assy Take the new glass and ti...

Page 43: ...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 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 OPERATING ARM WILL NOT OPEN OR CLOSE Position the cylinder where it ...

Page 44: ...ne 7 4 VALVE CONTROL OPENING ARM CYLINDER EAA0356G96A CHECK AND REPLACEMENT 30 4mm allen key 8 and 12mm end key 10mm tube type key Defective valve may cause the following malfunction 1 Air leaking from the valve 2 The operating will not open or close and air leaking is reported from the valve TO CHECK THE VALVE Remove the foot pedal assembly cover Check if there is any leaking in between valve rod...

Page 45: ...to the air pressure and to the power supply Check if the machine works fine Mount the foot pedal assembly cover 7 5 VERTICAL LOCKING CYLINDER EAA0344G32A 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 CYLIND...

Page 46: ...inder 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 47: ...fer to chapter 8 2 Check if the machine works fine 7 6 HORIZONTAL BLOCKING CYLINDER EAA0344G33A CHECK AND REPLACEMENT 30 Allen key 4mm 17mm end key Defective horizontall locking cylinders may cause the following malfunction 1 Air leaking from the cylinder 2 The horizontal rod does not remain blocked TO CHECK THE CYLINDER Remove the cylinder cover Press the yellow button of the valve to block the h...

Page 48: ...cylinder 2 The cylinder would not lift the vertical rod TO CHECK THE CYLINDER Pull the yellow button of the valve to allow the lifting the vertical rod Check if the cylinder is leaking air TO REPLACE THE CYLINDER Disconnect the air pressure and the power supply Disconnect the air pipe from the cylinder Disconnect the automatic tool cylinder from the its bracket Release the two set screws that secu...

Page 49: ...d or from the fittings TO CHECK THE VALVE Remove the cylinder cover Check if there 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 ...

Page 50: ...e cylinder 2 The cylinder would not lift the tire bead 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 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 cylind...

Page 51: ...tool cylinder from the its bracket and from the tool Mount the new cylinder to upper bracket Connect the air pipes to the cylinder Plug the machine to the air pressure and power supply Connect the automatic tool cylinder to the tool Perform the adjustment of the connection automatic tool cylinder following par 8 2 Check if the machine works fine 7 10 AUTOMATIC TOOL CYLINDER VALVE EAA0328G73A CHECK...

Page 52: ...ir pressure and power supply Check if the machine works fine again 7 11 BEAD BREAKER CYLINDERS EAA0363G62A EAA0351G77A CHECK AND REPLACEMENT 30 each one 24 and 13mm end key Defective bead breaker cylinder may cause the following malfunction 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 goes down itse...

Page 53: ...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 OPERATING ARM 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 swing cylinder is leaking air If the air is ge...

Page 54: ...orks fine 7 12 BEAD BREAKER CYLINDERS AND DISCS VALVES EAA0350G58A EAA0377G25A EAA0350G57A CHECK AND REPLACEMENT 30 each one 4mm allen key 27mm end key medium Philip screwdriver Defective valve may cause the following malfunction 1 Air leaking from the control valve 2 The bead breaker arm will not detach the tire bead 3 The bead breaker arm goes down itself when machine remain not operated for som...

Page 55: ...w valve to the joystick Plug the machine to the air pressure and power supply Check if the machine works fine Mount the valves assembly cover 7 13 BEAD BREAKER ARMS BLOCKING CYLINDER EAA0344G48A CHECK AND REPLACEMENT 30 4 5 and 6mm Allen key 12 and 17mm end key 13mm tube type key Defective locking cylinders may cause the following malfunction 1 Air leaking from the cylinder 2 The bead breaker arm ...

Page 56: ... Check if the cylinder is leaking air in between cylinder liner and seal TO REPLACE THE CYLINDERS Disconnect air pressure and power supply from machine Disconnect the pipe from the cylinder Unlock the cylinder adjustment screw and remove the washer Remove the upper adjustment screws and the two screws with springs ...

Page 57: ...troke Then turn them back of one turn Block the counter nuts Install the two screws with springs Tighten them for about 10mm Install the washer and tighten the cylinder adjustment screw when the screw will touch the washer turn the screw of two more turns Connect the air pressure and the power supply For the mechanical adjustment refer to par 8 7 Check if the machine works fine ...

Page 58: ...ed for some time TO CHECK THE VALVE Remove the valves assembly cover Check the valve following Paragraph 7 10 If there will not be any air leaking from air pipe and fitting but there is air leaking through one of the silencers the valve must be replaced TO REPLACE THE VALVE Disconnect the air pressure and the power supply Lift with screwdriver the valve tang and pull the valve out Remove the nut f...

Page 59: ...inder 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 case of need place some soap with water on the interested part to better see where the l...

Page 60: ...t arm to disconnect the cylinder Disconnect the air pipes from the cylinder Remove the bolt from the to disconnect the cylinder from its cabinet Secure the cylinder to the cabinet with the bolt Connect the air pipes Fix the piston rod to the lift arm Mount the wheel holder the ring nut and the nut must be tightened until end of stroke and turned 1 8 of a turn backward Plug the machine to the air p...

Page 61: ...el lift lower itself after releasing the pedal TO CHECK THE CONTROL VALVE Remove the valve cover Check the valve according to paragraph 7 13 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 Remove the nut and the pin split Remove the connecting ...

Page 62: ...0 End key 13mm Defective cylinder may cause the following malfunction 1 Air leaking 2 Low bead pushing pressure TO CHECK THE MH CYLINDER Turn the machine on Lower the cylinder and check if it is leaking from the top flange Raise the cylinder and check if it leaks air from the lower flange Lower the cylinder and remove the hose from the lower fitting Keep pressing the control valve If the air comes...

Page 63: ...T 30 End key 5 and 22mm Allen key 3mm Defective control valve may cause the following malfunction 1 Air leaking 2 Low bead pushing pressure 3 Slow MH 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 it...

Page 64: ...ting action 3 Air leaking from the blaster jet TO CHECK THE SPOOL VALVE Open the foot pedal assembly Check if the mechanical components springs screws and linkage are fine Verify if the valve is leaking air from the rear springs when the pedal is in rest position Verify if the valve is leaking air from front locking nuts when the pedal is in rest position TO REPLACE THE SPOOL VALVE Disconnect the ...

Page 65: ...aster valve may cause the following malfunction 1 No air from air jet 2 Air leaking from diaphragm TO CHECK THE BEAD BLASTER VALVE Verify if it is leaking air from the diaphragm Verify it the bead seating jet is leaking air TO REPLACE THE BEAD BLASTER VALVE Disconnect the air pressure Remove the hoses Remove the valve from the tank niplex Mount the new valve to the niplex Install the hoses Plug th...

Page 66: ...ew valve Secure the pedal assembly to the cabinet Mount the air pipes Connect the air pressure and the power supply Check if the machine works fine Mount the pedal assembly protection 7 22 MANOMETER CHECK AND REPLACEMENT 30 End key 13 14 15 16 17mm Medium cross screwdriver loctite SB 852 TC SB 929 TC Defective manometer may cause the following malfunction 1 The manometer is not accurate 2 The mano...

Page 67: ...R Remove the nipples fitting to get the manometer off Pay attention to do 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 Tighten the sintered air filter absorber 0019181 also with one drop of Loctite to nipples fitting Tighten the air pipe also with one drop of Loctite to the sint...

Page 68: ...l pipes are damaged or broken 6 The vertical rod cylinder does not block properly 7 The horizontal rod cylinder does not block properly TO CHECK THE SPIRAL PIPES Unplug the machine from air pressure and power supply Remove the cylinders covers Check if the pipes are damaged or broken or simply not well fitted to the fittings TO REPLACE THE SPIRAL PIPES Disconnect the air spiral pipes from the cyli...

Page 69: ...tion Fit the pipes protection to the bracket with the pipes strain reliefs Plug the pipes to the cylinders and to fittings Plug the machine to the air pressure and to the power supply Extend the horizontal completely and adjust the length of the pipes 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 plas...

Page 70: ...ay cause the following malfunctions 1 Excessive play on the operating arm assembly 2 The opening arm touch against the end stroke screw during the closing 3 The operating arm moves downward whenever it is opened TO CHECK THE OPENING ARM BUSHINGS Close the swing arm Release the end stroke screws Please take good note to release that one in the bottom of one turn only that correspond to about 1mm Bl...

Page 71: ...oke stopper DANGER THE HORIZONTAL ARM IS NOW FREE AND IT COULD GET OUT FROM ITS BASEMENT BE CAREFUL VERY HEAVY AND UMBALNCED ASSEMBLY TWO PEOPLE ARE REQUIRED FOR THE NEXT OPERATION DUE TO WEIGHT OF THE ASSEMBLY IF TWO PEOPLE WILL NOT BE AVAILABLE IT IS MANDATORY TO DISMOUNT ALL COMPONENTS OF THE HORIZONTAL ARM TO MAKE IT LIGHTER Slide out the horizontal arm carefully Disconnect the opening cylinde...

Page 72: ... and take out the screw and the eccentric BE CAREFUL VERY HEAVY AND UMBALANCED ASSEMBLY TWO PEOPLE ARE REQUIRED FOR THE NEXT OPERATION DUE TO WEIGHT OF THE ASSEMBLY IF TWO PEOPLE WILL NOT BE AVAILABLE IT IS MANDATORY TO USE A LIFT Remove the operating arm basement Replace the worn bushings Mount the operating arm basement with the eccentric ...

Page 73: ...ll move freely again Connect the opening cylinder following par 7 2 Mount the horizontal arm carefully BE CAREFUL VERY HEAVY AND UMBALNCED ASSEMBLY TWO PEOPLE ARE REQUIRED FOR THE NEXT OPERATION DUE TO WEIGHT OF THE ASSEMBLY IF TWO PEOPLE WILL NOT BE AVAILABLE IT IS MANDATORY TO MOUNT ALL COMPONENTS OF THE HORIZONTAL ARM ONE BY ONE DANGER THE HORIZONTAL ARM IS NOT SECURED AND IT COULD GET OUT FROM...

Page 74: ...ssembly 2 The operating would not open 3 The operating arm remains unlocked in working position TO CHECK THE OPENING ARM LINKAGE Close the operating arm as normal condition Looking the two linkage arms from the top and bottom it should not be possible to see the short connecting rod UPPER OK UPPER NOT OK LOWER OK LOWER NOT OK TO ADJUST THE OPENING ARM LINKAGE Remove the anti rotational plates Turn...

Page 75: ... tool is broken or mechanically damaged TO REPLACE THE TOOL Disconnect the machine from air pressure and power supply Block the vertical rod with yellow button on the valve Disconnect the tool from the cylinder Loosen the screw underneath the tool and the two lateral set screws Unlock the tool with the rubber hammer Remove completely the screws to complete the tool dismounting Take the new tool an...

Page 76: ...e rim as normal operation and then lock it Tighten one of the two adjuster screws until the tail of the tool is aligned to the rim edge Tighten both screws keeping the tool in this position Move the tool away from the edge of the rim then tighten the screw under the tool fully home TO ADJUST THE TOOL FINGER STROKE ON THE CONTROL CYLINDER Connect the ball joint to the cylinder rod Move the control ...

Page 77: ... fine TO ADJUST THE VERTICAL TOOL CLEARANCE Block a 17 rim diameter rim in good condition to the centre post Unlock the front screws and tighten all way down and 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 t...

Page 78: ...e rod Pull the yellow button valve all towards the operator in order to lift the vertical tool rod Turn counter clockwise the vertical blocking cylinder adjustment screw until the vertical rod will move upward Then perform some rod lowering and raising operations to make sure that the rod is moving smoothly Block the counter nut TO ADJUST THE VERTICAL ROD BLOCKING PLATE SPRINGS Block the vertical ...

Page 79: ...ake 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 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 Unlock the horizontal ...

Page 80: ... arm Then turn back every one of of a turn to get the horizontal arm free again Now make a fine adjustment tightening or loosening of 1 8 of a turn every setscrew When the arm will move smoothly again and there will not be excessive play on the arm lock the counter nuts Mount the cover again 8 4 GEAR BOX CHECK AND REPLACEMENT 2h End keys 17mm allen keys 4mm Seeger pliers Incorrect gearbox may caus...

Page 81: ... place Mount the centerpost Secure it firmly with the screws and the nuts Mount the belt and adjust it Check if the machine works fine Mount the front protection 8 5 BEAD BREAKER DISCS EAM0065G63A CHECK AND REPLACEMENT 30 each one End keys 8 and 17mm allen keys 3 4 5 and 6mm 13mm tube type key electronic inclinometer Defective bead breaker discs may cause the following malfunctions 1 Low bead brea...

Page 82: ...screws with Loctite Then replace the old washers with the new ones Mount the disc assembly to the bead breaker arm holder Install the roll pin again Install the protection Check if the machine works fine again 8 6 BEAD BREAKER DISCS EAM0065G63A CHECK AND REPLACEMENT 30 Each one Allen key 4mm Bad bead breaker disc may cause the following malfunction 1 Disc touches the rim during bead breaking opera...

Page 83: ...ead breaker disc bearing may cause the following malfunctions 1 Disc touches the rim during bead breaking operation 2 The bead breaker disc goes on the tire sidewall during bead breaking 3 The disc is broken TO CHECK THE BEAD BREAKER DISC BEARING Turn the machine off Check if the bead breaker disc show a lot of play TO REPLACE THE BEAD BREAKER DISC BEARING Remove the red plastic cover Remove the b...

Page 84: ... if it works fine 8 8 BEAD BREAKER DISCS INCLINATION ADJUSTMENT 30 each one Allen keys 4 and 5 electronic inclinometer Incorrect bead breaker discs inclination may cause the following malfunctions 1 Low bead breaking efficiency TO CHECK THE DISC INCLINATION Remove the protection Leave the bead breaker disc in rest position Position the electronic inclinometer on the disc Make sure that the inclina...

Page 85: ...EAKER DISCS CLEARANCE CHECK AND ADJUSTMENT 30 each one Allen keys 4 5 and 6mm 8 and 17mm end keys 13mm tube type key Incorrect bead breaker discs clearance may cause the following malfunctions 1 Bead breaker arms misalignment 2 Bead breaker arms not synchronized 3 Bead breaker arms beeper beeps when arms are blocked TO CHECK THE DISC CLEARANCE Block a 17 rim in good condition to the center post Po...

Page 86: ...UST THE UPPER BEAD BREAKER AMR BLOCKING CYLINDER Please refer to par 8 2 for the adjustment Check if the arm moves smoothly pushing and pulling it by hand Perform the bead breaker arm calibration Check if the machine works fine Mount the protection TO CHECK AND ADJUST THE LOWER BEAD BREAKER AMR BLOCKING CYLINDER Please refer to par 5 5 to disconnect and connect the actuator Please refer to par 8 2...

Page 87: ...etscrews and replace the damaged units TO ADJUST THE BEAD BREAKER CARRIAGE Tighten all setscrews unless lock rigidly the carriage on the squared bar Move the carriage up and down and make sure that will move unless jerking In case the carriage will jerk stop the movement and adjust the screws Then continue the control When the carriage will move smoothly without any significant play block all coun...

Page 88: ...or following the par 5 5 Move forward and backward by hand the actuator worm screw to check if there is play If yes the nut is worn out and must be replaced TO REPLACE THE LEAD NUT Remove the actuator worm screw from the lead nut following the par 5 5 Unscrew the lead nut from the holder Mount the new nut and secure it with Loctite Mount the actuator following par 5 5 Perform the bead breaker arms...

Page 89: ...he transformer 5 6 4 Check the bead breaker potentiometers 6 3 5 Check the lower bead breaker arm actuator 5 5 6 Check the CPU board 5 5 7 Call Snap On Hot Line Center COMPLAINT 4 Turning the machine on the centerpost turns 1 st speed clockwise only or in 2nd speed only or counter clockwise only 1 Check the centerpost switch 5 7 2 Check the centerpost switch mechanical adjustment 5 7 3 Check the i...

Page 90: ...ker discs clearance 8 7 5 Check the bead breaker disc inclination 8 6 6 Check the bead breaker carriage 8 8 7 Call Snap On Hot Line Center COMPLAINT 11 The air control does not inflate the tire 1 Check the air control 7 21 COMPLAINT 12 All pneumatic cylinders are too slow 1 Check airline pressure inlet 7 2 2 Check the air pressure outlet 7 2 3 Check the air filter lubricator assembly 7 2 4 Call Sn...

Page 91: ...PLAINT 16 The bead breaker discs are not aligned 1 Check the bead breaker potentiometers 6 3 2 Check the lower bead breaker arm actuator 5 5 3 Check the CPU board 5 5 4 Check the bead breaker discs clearance 8 7 5 Call Snap On Hot Line Center ...

Page 92: ...ed and if they will show pressure within the homologated tolerances we will be forced to invoice them DEUTSCH Nachdem einige Wika Manometer 0023484 aufgrund ungenauer Reifendruckanzeige unter Gewährleistung ausgetauscht wurden möchten wir hier nochmals auf die geprüfte Genauigkeit des Manometers aufmerksam machen bis 4 bar 0 08 bar von 4 bis 10 bar 0 16 bar über 10 bar 0 25 bar Bitte beachten wenn...

Page 93: ... no vuelve a cero antes de sustituirlo recomendamos desconectar el filtro absorvente posterior 0019181 mostrado en la figura y asegurarse que el manómetro vuelve a cero Si el manómetro vuelve a cero sustituir el filtro absorvente posterior 0019181 El manómetro sustituido en garantía por falta de precisión se comprobarán al retorno y si se comprueba la tolerancia homologada nos veremos obligados a ...

Page 94: ...di sostituzione valvola vi preghiamo di prendere ben nota di ordinare il Kit valvola di comando MH EAA0377G99A anziché solo la valvola EAA0328G73A Il kit contiene le viti ed i dadi necessari all installazione dell attuale valvola della Stampotecnica sul braccio premitallone DEUTSCH Aus der Praxis erreichen uns Berichte über Luftverluste aus dem Steuerventil aus Aluminium oder über langsames selbst...

Page 95: ...da en aluminio o una auto bajada lenta del brazo presiona talones MH debido a que los tornillos de la tapa de la vávula se aflojan La queja se ha resuelto fijando los tornillo de la tapa de la válvula con Loctite En el caso de recivir identica queja de la calle se recomienda fijar los tornillos de la tapa de la válvula con Loctite antes de sustituirla En caso de sustituir la válvula pedimos de tom...

Page 96: ...da CPU attraverso delle prolunghe In caso di necessità ordinate gentilemente le seguenti parti 1 x EAA0377G07A POTENZIOMETRO CON CAVO CONDUTTORE 1 x EAA0377G08A POTENZIOMETRO CON CAVO CONDOTTO DEUTSCH Wir möchten Ihnen mitteilen dass ab der oben genannten Seriennummer alle oben angegebenen Maschinenmodelle mit Potentiometern für die Abdrückarme mit einem einzigen Kabel ausgestattet sind das direkt...

Page 97: ...zos destalonadores con un solo cable que se conecta directamente la placa CPU Anteriormente los potenciómetros estaban dotados de cables cortos conectados a la CPU a tavés de prolongaciones En el caso de necesitarlos pedir lo siguiente 1 x EAA0377G07A POTENCIÓMETRO CON CABLE MAESTRO 1 x EAA0377G08A POTENCIÓMETRO CON CABLE ESCLAVO NEW POTENTIOMETER OLD POTENTIOMETER NEUES POTENTIOMETER ALTES POTENT...

Page 98: ...ity of the discs themselves on very soft tires avoiding possible slippage of the discs over the tire sidewall during the operation The former bead breaker discs will be no longer available Since new and old discs are not interchangeable each other and cannot work together in case of replacement of the former disc with the new one you have to order the following assemblies 1 x EAA0371G67A ASSY LOWE...

Page 99: ...sembly from the arm 7 Mount the new bead breaker disc assembly on the arm and secure it with the snap ring 8 Fix the bead breaker disc to the cylinder and secure the pin with the screw 9 Connect the air pressure to the machine 10 Adjust the disc inclination following paragraph 8 6 of the dedicated Service Manual 11 Check if the machine works fine ...

Page 100: ...eitenwand Die alten Abdrückscheiben sind nicht mehr lieferbar Da alte und neue Scheiben nicht gegeneinander austauschbar sind und nicht zusammen benutzt werden können sind bei einem Austauschen der alten gegen neue Abdrückscheiben folgende Baugruppen zu bestellen 1 x EAA0371G67A untere Abdrückscheibe kpl 1 x EAA0371G66A obere Abdrückscheibe kpl Die Abdrückscheiben sind wie folgt auszutauschen 1 Di...

Page 101: ... 7 Die neue Abdrückscheibe am Arm montieren und mit dem Sicherungsring sichern 8 Die Abdrückscheibe am Zylinder befestigen und den Stift mit der Schraube sichern 9 Die Maschine wieder an die Druckluftversorgung anschließen 10 Den Neigungswinkel der Abdrückscheibe gemäß Kapitel 8 6 des Servicehandbuches einstellen 11 Prüfen dass die Maschine ordnungsgemäß funktioniert ...

Page 102: ...matici durante le operazioni I precedenti dischi stallonatori non saranno più disponibili Siccome vecchi e nuovi dischi non sono intercambiabili fra loro e non possono lavorare insieme in caso di sostituzione di un disco vecchio con uno nuovo dovrete ordinare i seguenti gruppi 1 x EAA0371G67A GRUPPO DISCO COMPLETO INFERIORE 1 x EAA0371G66A GRUPPO DISCO COMPLETO SUPERIORE Per sostituire i dischi se...

Page 103: ...cio 7 Montare il gruppo disco stallonatore sul braccio e assicurarlo con l anello elastico 8 Fissare il disco stallonatore al cilindro e bloccare il perno con la vite 9 Collegare l aria compressa alla macchina 10 Regolare l inclinazione del disco seguendo il paragrafo 8 6 del Manuale di Servizio dedicato 11 Controllare se la macchina funziona bene ...

Page 104: ...ante la operación de destalonamiento El anterior disco destalonador no continuará estando disponible A partir que tanto el viejo como el nuevo disco destalonador no pueden ser intercambiables entre ellos y no pueden trabajar juntos en caso de sustitución de un disco viejo por uno nuevo se debe pedir el siguiente grupo 1 x EAA0371G67A GRUPO DISCO COMPLETO INFERIOR 1 x EAA0371G66A GRUPO DISCO COMPLE...

Page 105: ...dor del brazo 7 Montar el grupo disco destalonador en el brazo y fijarlo con el segger 8 Fijar el disco destalonador al cilindro y apretar el tornillo 9 Conectar la máquina al aire comprimido 10 Regular la inclinación del disco siguiendo el capítulo 8 6 del Manual de Servicio 11 Comprobar el funcionamiento correcto de la máquina ...

Page 106: ... cours des opérations Les disques détalonneurs précédents ne seront plus disponibles Etant donné que les anciens et les nouveaux disques ne sont pas interchangeables et ne peuvent pas travailler ensemble en cas de remplacement d un disque ancien par un neuf vous devrez commander les groupes suivants 1 x EAA0371G67A GROUPE DISQUE COMPLET INFERIEUR 1 x EAA0371G66A GROUPE DISQUE COMPLET SUPERIEUR Pou...

Page 107: ...Monter le groupe disque détalonneur sur le bras et l assurer avec une bague élastique 8 Fixer le disque détalonneur au vérin et bloquer la broche avec la vis 9 Raccorder l air comprimé à la machine 10 Régler l inclinaison du disque en suivant les instructions rubr 8 6 du Manuel de Service dédié 11 Contrôler si la machine fonctionne correctement ...

Page 108: ...ce allowed 1mm 0 04 we would like to inform you that it is now available the following procedure to correct the output analog value of the potentiometer s improving the bead breaker disks alignment accuracy PROCEDURE 15 Fix to the multimeter terminals two small crocodiles style ones 16 Remove the cover from the bead breaker arm potentiometer 17 Select the multimeter in Vdc 18 Position the red croc...

Page 109: ... Abdrückscheiben noch über die maximal zulässige Toleranz von 1mm 0 04 möchten wir darauf hinweisen dass es jetzt folgende Möglichkeit gibt den analogen Ausgangswert des der Potentiometer zu korrigieren und damit die Genauigkeit der Ausrichtung der Abdrückscheiben zu verbessern VORGANG 1 Zwei kleine Krokodilklemmen am Multimeter anschließen 2 Abdeckung vom Abdrückarmpotentiometer abnehmen 3 Multim...

Page 110: ...llonatori fuori dalla tolleranza massima 1mm 0 04 gradiamo informarvi che è ora disponibile un una procedura per correggere il valore analogico in uscita del potenziometro i migliorando la precisione dell allineamento dei dischi stallonatori PROCEDURA 1 Fissare ai terminale del multimetro due piccoli terminali a coccodrillo 2 Remuovere la protezione del potenziometro stallonatore 3 Selezionare Vdc...

Page 111: ...esalineación de los discos destalonadores fuera de la tolerancia máxima 1mm 0 04 nos complace informarles que hay disponible un nuevo procedimiento para corregir el valor analógico de salida del potenciómetro para mejorar la precisión de la alineación de los discos destalonadores PROCEDIMIENTO 1 Instalar a los terminales del tester dos terminales pequeños del tipo cocodrilo 2 Quitar la protección ...

Page 112: ... le désalignement des disques de déjantage hors de la tolérance maximale 1mm 0 04 nous souhaitons vous informer qu il existe maintenant une procédure pour corriger la valeur analogique à la sortie du ou des potentiomètre s ce qui améliore la précision de l alignement des disques de déjantage PROCEDURE 1 Raccorder les deux pinces crocodiles au multimètre 2 Déposer le protecteur du potentiomètre du ...

Page 113: ...очного устройства сверх допуска 1 мм мы сообщаем что теперь есть возможность проведения следующей процедуры по исправлению аналогового значения потенциометра на выходе что повышает точность центрирования дисков разбортовочного устройства ПРОЦЕДУРА 1 Установить на клеммах универсального измерительного прибора два небольших зажима типа крокодил 2 Снять крышку с потенциометра на рычаге разбортовочног...

Page 114: ...того колеса вала верхнего потенциометра 9 Используя отвертку повернуть вал потенциометра уменьшив значение на 0 020 В относительно отображаемого на дисплее 10 Снова застопорить контргайку 11 Выполнить калибровку установки 12 Проверить изменилось ли центрирование рычагов 13 Выключить установку 14 Вернуть на место крышку потенциометра ...

Page 115: ...ilter absorber 0019181 The replaced manometers under warranty due to low accuracy will be inspected and if they will show pressure within the homologated tolerances we will be forced to invoice them DEUTSCH Nachdem einige Wika Manometer 0023484 aufgrund ungenauer Reifendruckanzeige unter Gewährleistung ausgetauscht wurden möchten wir hier nochmals auf die geprüfte Genauigkeit des Manometers aufmer...

Page 116: ...cias y la aguja retorna a cero después de quitar el tubo de inflado de la rueda no debe ser sustituido En el caso en que el manómetro no vuelve a cero antes de sustituirlo recomendamos desconectar el filtro absorvente posterior 0019181 mostrado en la figura y asegurarse que el manómetro vuelve a cero Si el manómetro vuelve a cero sustituir el filtro absorvente posterior 0019181 El manómetro sustit...

Page 117: ...CTC CEN Service Manual 07 13 Rev E 117 300KPa 25KPa 400KPa 25KPa ...

Page 118: ... Check and replacement Text Pag 41 7 15 Wheel lift cylinder EAA0344G93A Check and replacement Text Pag 50 8 1 Opening arm bushings 1 10065a Check and replacement Text Pag 58 8 3 Horizontal arm rollers EAA0347G76A Check and adjustment Text Pag 68 8 4 Gear box Check and replacement Text Pag 68 8 5 Bead breaker discs EAM0065G63A Check and replacement Text Pag 70 8 6 Bead breaker discs EAM0065G63A Che...

Page 119: ...CTC CEN Service Manual 07 13 Rev E 119 B L A N K P A G E ...

Page 120: ...ions 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 All R...

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