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GB

INSTRUCTION, USE AND

MAINTENANCE MANUAL

SUMMARY

SYMBOLS USED IN THE MANUAL ________ 4

1.0 GENERAL INTRODUCTION __________ 7

1.1 Introduction ____________________________ 7

2.0 INTENDED USE _____________________ 7

2.1 Training of personnel __________________ 7

3.0 SAFETY DEVICES ___________________ 8

3.1 Residual risks __________________________ 8

4.0 GENERAL SAFETY RULES __________ 8

5.0 PACKING AND MOBILIZATION FOR

TRANSPORT ________________________ 9

6.0 UNPACKING ________________________ 10

7.0 MOBILIZATION _____________________ 10

8.0 WORKING ENVIRONMENT CONDI-

TIONS ______________________________ 11

8.1 Working position ______________________11
8.2 Installation space _____________________11
8.3 Lighting _______________________________11

9.0 ANCHORING SYSTEM ______________ 12

10.0 ELECTRICAL CONNECTIONS _______ 12

11.0 ASSEMBLY AND PREPARATION FOR

USE ________________________________ 13

11.1 Fixtures contained in the packing _____13
11.2 Assembly procedures _________________14

12.0 CONTROLS _________________________ 15

12.1  Control for bead breaking roll release _15
12.2  Bead-breaking control unit ____________16
12.3  Vertical arm control ___________________16
12.4 Pedalboard ____________________________16

13.0 USING THE MACHINE ______________ 17

13.1 Precaution measures during tyre re-

moval and fitting ______________________17

13.2 Preliminary operations - Preparing

the wheel ______________________________17

13.3 Mandrel height adjustment ___________18

13.3.1 Reverse wheel pan protection ______18

13.4  Wheel clamping _______________________18
13.5  Bead breaking through vertical rolls __20
13.6  Demounting the tyre __________________22
13.7  Mounting the tyre _____________________24
13.8  For rims with spoke end raised com-

pared to the rim-edge _________________24

13.9 Special use of the bead-breaker _______25
13.10 Tyre inflation with machine without

tubeless inflation ______________________25

13.11 Tyre inflation with machine with

tubeless inflation ______________________25

14.0 ROUTINE MAINTENANCE __________ 26

14.1 Lubricants ____________________________27

15.0 TROUBLESHOOTING TABLE _______ 28

16.0 TECHNICAL DATA __________________ 29

16.1 Weight _________________________________29
16.2 Dimensions ____________________________30

17.0 STORING ___________________________ 31

18.0 SCRAPPING ________________________ 31

19.0 REGISTRATION PLATE DATA ______ 31

20.0 FUNCTIONAL DIAGRAMS __________ 31

Table A - Electric diagram __________________32
Table B - Pneumatic diagram

(KARACTER.TLX) _________________36

Table C - Pneumatic diagram

(KARACTER.TLXFI) _______________39

21.0 LIST OF COMPONENTS

KARACTER.TLX - KARACTER.TLXFI

7108-M007-0_B

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Содержание KARACTER.TLX

Страница 1: ...the section LIST OF COMPONENTS enclosed to this manual GB TRANSLATION FROM THE ORIGINAL INSTRUCTIONS Rev n 0 06 2018 7108 M007 0_B BUTLER ENGINEERING and MARKETING S p A a s u Via dell Ecologia 6 420...

Страница 2: ...16 13 0 USING THE MACHINE_______________ 17 13 1 Precaution measures during tyre re moval and fitting_______________________17 13 2 Preliminary operations Preparing the wheel__________________________...

Страница 3: ...er 5 Control unit 6 Inflation pedal 7 Column unit 8 Tool box 9 Inflation pressure gauge unit 10 Arm lock side control 11 Tool arm locking device 12 Tool arm release push button 13 Device for wheel cla...

Страница 4: ...ions or jobs to be performed compulsorily Danger Be particularly careful Symbols Description Move with fork lift truck or pallet truck Lift from above Wear safety goggles Technical assistance necessar...

Страница 5: ...Page 5 of 41 INSTRUCTION USE AND MAINTENANCE MANUAL GB PLATE LOCATION ON MACHINE INFORMATION TABLE KARACTER TLX KARACTER TLXFI 7108 M007 0_B...

Страница 6: ...n pedal plate B4244000 Rotating parts danger plate 710211210 Rotation direction plate 99990758 Electricity danger plate 999912460 Supply pressure indicating plate 999914160 Voltage 230V 50 60 Hz 1 Ph...

Страница 7: ...n with a minimum mainte nance and care this tyre changer will operate for many years without problems thus satisfying Your needs 2 0 INTENDED USE The machines described in this manual and their differ...

Страница 8: ...The machine was subjected to a complete analysis of risks according to reference standard EN ISO 12100 Risks are as reduced as possible in relation with tech nology and product functionality This man...

Страница 9: ...ine handles and operating grips must be kept clean and free from oil The workshop must be kept clean dry and not exposed to atmospheric agents Make sure that the working premises are properly lit The...

Страница 10: ...ls screws timber etc should not be left within reach of children since it is potentially dangerous These materials should be deposited in the relevant collec tion points if they are pollutants or non...

Страница 11: ...N MUST BE DRY ADEQUATELY LIT AND IN COMPLIANCE WITH APPLICABLE SAFETY REGULATIONS The location of the machine requires a usable space as indicated in Fig 4 The positioning of the machine must be accor...

Страница 12: ...ded from supply Tighten the screws with an approximate tightening torque of 70 Nm 10 0 ELECTRICAL CONNECTIONS EVEN THE TINIEST PROCEDURE OF AN ELECTRICAL NATURE MUST BE CARRIED OUT BY PRO FESSIONALLY...

Страница 13: ...in structions for the assembly of the components making use of the attached series of illustrations 11 1 Fixtures contained in the packing The packing case contains also the fixtures box Check that al...

Страница 14: ...203035 on the rivets already present on machine body Fig 7 2 Fit the tool box Fig 8 ref 1 to machine column using the 4 special screws provided Fig 8 ref 2 272172 Fig 8 Only for KARACTER TLXFI 3 Fit...

Страница 15: ...ED IN CHAP TER 20 ONCE THE ASSEMBLY OPERATIONS HAVE BEEN ENDED CHECK ALL MACHINE FUNC TIONS CARRY OUT A DAILY CHECK OF MAINTAINED TYPE CONTROLS CORRECT FUNCTIONING BEFORE STARTING MACHINE OPERATION 12...

Страница 16: ...and of two push buttons Fig 12 ref B with different functions fit onto a single control block The unit can be gripped for moving the bead breakers and positioning them for operation The bead breaking...

Страница 17: ...ean the wheels on the machine 13 2 Preliminary operations Preparing the wheel Remove the wheel balancing weights from both sides of the wheel REMOVE THE VALVE STEM AND ALLOW THE TYRE TO COMPLETE LY DE...

Страница 18: ...ws to remove the mandrel mobile part and to dowel the sup port plate at the required height In order to adjust the central support s height pull the knob outwards Fig 15 ref 1 and lift or lower the ce...

Страница 19: ...1 on the rim Fig 20 ref 2 Fig 20 2 1 4 Through the proper handle Fig 21 ref 1 push downwards Fig 21 ref 2 turn it through 90 Fig 21 ref 3 and lift the shaft Fig 21 ref 4 to hook it into the hole Fig 2...

Страница 20: ...aking through vertical rolls 1 After the wheel has been locked move the upper bead breaking roller Fig 25 ref 2 near rim edge press the push button Fig 25 ref 1 MOVE VERY CAREFULLY THE BEAD BREAKER AR...

Страница 21: ...lever Fig 12 ref A LH Fig 27 6 Only now turn the wheel clockwise see Fig 28 by pressing the pedal Fig 14 ref 1 and at the same time by operating the lever Fig 12 ref A LH keeping it pressed until ther...

Страница 22: ...sion during mounting demounting It spreads the force applied to the mounting tool over the largest area possible It significantly reduces the wear on the tool WITH ROUNDED OR FLAT EDGE RIMS THE ARM SH...

Страница 23: ...the bead Lubricate Fig 31 When the upper bead is being demounted it might happen that the lower bead re sets in the rim In this case use bead breaker s lower roll to bead break again and if the tyre...

Страница 24: ...to position the valve insert at 5 6 o clock When mounting hard low profile tyres it may be useful to use the upper bead breaker roll to push the bead into the groove see Fig 35 Fig 35 13 8 For rims w...

Страница 25: ...ated at 4 2 0 2 bar release all the air from the wheel remove it from the tyre changer and put it in a safety cage to complete the inflation procedure 13 11 Tyre inflation with machine with tube less...

Страница 26: ...URC ES TAKING SPECIAL CARE OF THE ELECTRICAL PLUG SOCKET CONNECTION BEFORE CARRYING OUT ANY MAINTENANCE OPERATIONS MAKE SURE THERE ARE NO WHEELS CLAMPED ON THE MAN DREL AND THAT ALL SUPPLIES TO THE MA...

Страница 27: ...HER THAN THOSE RECOMMENDED IN THIS MANUAL WILL RELEASE THE MANUFACTURER FROM ANY LIABILITY At regular intervals at least every 100 working hours check reduction gear lubricating oil level Execute this...

Страница 28: ...movements take place when the pedal is pressed 1 Supply missed 2 Inflation pedal unit not set cor rectly 1 Check power supply 2 Call for technical as sistance The mandrel doesn t rotate 1 Inverter ove...

Страница 29: ...Recommended electric supply single phase 200 265V 50 60 Hz Wheel maximum diameter 46 Wheel max width 15 Rim locking diameter 10 26 Bead breaking power per roll 10 bar 1200 kg Vertical bead breaker max...

Страница 30: ...Page 30 of 41 GB INSTRUCTION USE AND MAINTENANCE MANUAL 16 2 Dimensions Fig 40 For version with tubeless inflation only KARACTER TLX KARACTER TLXFI 7108 M007 0_B...

Страница 31: ...ent amendments we communicate what follows the meaning of the crossed dustbin symbol reported on the equipment indicates that the product must not be thrown among the undifferentiated rub bish that is...

Страница 32: ...TEILELISTE LISTE DES PIECES DETACHEES LISTA DE PIEZAS Pag 32 di 41 SCHEMA ELETTRICO 1 4 ELECTRICAL SCHEME 1 4 SCHALTPLAN 1 4 SCHEMA ELECTRIQUE 1 4 ESQUEMA ELECTRICO 1 4 Tavola N A Rev 0 710805510 KAR...

Страница 33: ...TEILELISTE LISTE DES PIECES DETACHEES LISTA DE PIEZAS Pag 33 di 41 SCHEMA ELETTRICO 2 4 ELECTRICAL SCHEME 2 4 SCHALTPLAN 2 4 SCHEMA ELECTRIQUE 2 4 ESQUEMA ELECTRICO 2 4 Tavola N A Rev 0 710805510 KAR...

Страница 34: ...TEILELISTE LISTE DES PIECES DETACHEES LISTA DE PIEZAS Pag 34 di 41 SCHEMA ELETTRICO 3 4 ELECTRICAL SCHEME 3 4 SCHALTPLAN 3 4 SCHEMA ELECTRIQUE 3 4 ESQUEMA ELECTRICO 3 4 Tavola N A Rev 0 710805510 KAR...

Страница 35: ...Frequenzumformer Mikro Pedalleiste Connecteur variateur micro p dale de direction Conector inversor micro pedalera P1 Potenziometro comando motore Motor control potentiometer Potenziometer f r Motors...

Страница 36: ...ISTE DES PIECES DETACHEES LISTA DE PIEZAS Pag 36 di 41 Tavola N B Rev 0 710805020 KARACTER TLX KARACTER TLXFI 7108 M007 0_B SCHEMA PNEUMATICO 1 3 PNEUMATIC CIRCUIT DIAGRAM 1 3 PNEUMATIKPLAN 1 3 SCHEMA...

Страница 37: ...san 4x2 7 nero L 1900 4x2 7 black rilsan pipe L 1900 Rilsan Schlauch 4x2 7 schwarz L 1900 Tuyau rilsan 4x2 7 noir L 1900 Tubo rilsan 4x2 7 negro L 1900 22 B5815000 Raccordo V D 4 V D 4 union Verbindun...

Страница 38: ...00 53 317036 Tubo elastolan 10x6 5 L 1600 10x6 5 elastolan pipe L 1600 Elastolan Schlauch 10x6 5 L 1600 Tuyau elastolan 10x6 5 L 1600 Tubo elastolan 10x6 5 L 1600 54 Valvola comando stallonatore later...

Страница 39: ...STE DES PIECES DETACHEES LISTA DE PIEZAS Pag 39 di 41 Tavola N C Rev 0 710805030 KARACTER TLX KARACTER TLXFI 7108 M007 0_B SCHEMA PNEUMATICO 1 3 PNEUMATIC CIRCUIT DIAGRAM 1 3 PNEUMATIKPLAN 1 3 SCHEMA...

Страница 40: ...an 4x2 7 nero L 1900 4x2 7 black rilsan pipe L 1900 Rilsan Schlauch 4x2 7 schwarz L 1900 Tuyau rilsan 4x2 7 noir L 1900 Tubo rilsan 4x2 7 negro L 1900 22 B5815000 Raccordo V D 4 V D 4 union Verbindung...

Страница 41: ...colle talons lat ral V lvula mando destalonador lateral 55 325118 Raccordo girevole Rotary union Gerader Anschluss Raccord pivotant Enlace girable 56 317007 Tubo rilsan 8x6 nero L 100 8x6 black rilsan...

Страница 42: ...PARTS TO BE REPLACED THE REPLACEMENT MUST BE CARRIED OUT PROFESSIONALLY QUALIFIED PER SONNEL DIE ZEICHNUNGEN DIENEN NUR ZUR IDENTIFIZIERUNG DER ERSATZTEILE DIE ERSETZUNG MUSS DURCH QUALIFIZIERTES PER...

Страница 43: ...0401 14 PEDALIERA PER INVERTER PEDALBOARD FOR INVERTER PEDALLEISTE F R INVERTER P DALES DE DIRECTION POUR INVERSEUR PEDALERA PARA INVERTER Tavola N 10A Rev 0_710890830 15 GRUPPO PEDALIERA NO FI PEDALB...

Страница 44: ...LIST OF COMPONENTS TEILELISTE LISTE DES PIECES DETACHEES LISTA DE PIEZAS Pag 3 di 22 ASSIEME GENERALE MAIN ASSEMBLY GENERALSATZ ASSEMBLAGE GENERAL JUNTO GENERAL Tavola N 1 Rev 0 7108 R007 0_B KARACTE...

Страница 45: ...66900 13 710891000 14 710890260 15 710890410 16 710891060 B1157000 17 G1000A52 18 G1000A86 19 710013421 20 710814150 21 790011620 22 790190050 23 B0326001 24 B1205900 25 B0223000 26 B1119300 27 B13490...

Страница 46: ...670 39 710811680 40 710811910 41 710812800 42 710813460 43 710813950 44 710814020 45 710814480 46 710890590 47 710811650 48 730022700 49 730023890 50 B8830000 51 903169 52 710890780 53 710890790 54 90...

Страница 47: ...LISTA DE PIEZAS Pag 6 di 22 ASSIEME GENERALE MAIN ASSEMBLY GENERALSATZ ASSEMBLAGE GENERAL JUNTO GENERAL Tavola N 1 Rev 0 790010121 69 B1505000 70 B1146000 71 770090000 72 790090810 73 790090120 74 KAR...

Страница 48: ...E LISTE DES PIECES DETACHEES LISTA DE PIEZAS Pag 7 di 22 GRUPPO SUPPORTO BRACCI ARMS SUPPORT UNIT ARMTR GERSATZ GROUPE SUPPORT BRAS GRUPO SOPORTE BRAZOS Tavola N 2 Rev 0 710890750 KARACTER TLX KARACTE...

Страница 49: ...PIEZAS Pag 8 di 22 GRUPPO CARRO STALLONATORE SUPERIORE UPPER BEAD BREAKER CARRIAGE UNIT OBERER ABDR CKER WAGENSATZ GROUPE CHARIOT D COLLE TALON SUP RIEUR GRUPO CARRO DESTALONADOR SUPERIOR Tavola N 3...

Страница 50: ...PIEZAS Pag 9 di 22 GRUPPO CARRO STALLONATORE INFERIORE LOWER BEAD BREAKER CARRIAGE UNIT UNTERER ABDR CKER WAGENSATZ GROUPE CHARIOT D COLLE TALON INF RIEUR GRUPO CARRO DESTALONADOR INFERIOR Tavola N 4...

Страница 51: ...E DES PIECES DETACHEES LISTA DE PIEZAS Pag 10 di 22 GRUPPO TUBO COMANDI CONTROLS TUBE UNIT SATZ VON STEUERUNGENROHR GROUPE TOUYAUX COMMANDES GRUPO TUBO MANDOS Tavola N 5 Rev 0 710890560 KARACTER TLX K...

Страница 52: ...STE LISTE DES PIECES DETACHEES LISTA DE PIEZAS Pag 11 di 22 GRUPPO APPOGGIO RUOTA WHEEL BEARING UNIT RADTR GERSATZ GROUPE APPUI ROUE GRUPO APOYA RUEDA Tavola N 6 Rev 0 710890860 KARACTER TLX KARACTER...

Страница 53: ...TE DES PIECES DETACHEES LISTA DE PIEZAS Pag 12 di 22 GRUPPO RIDUTTORE VSF VSF REDUCTION GEAR UNIT UNTERSETZERSATZ VSF GROUPE REDUCTEUR VSF GRUPO REDUCTOR VSF Tavola N 7 Rev 0 710890150 KARACTER TLX KA...

Страница 54: ...S PIECES DETACHEES LISTA DE PIEZAS Pag 13 di 22 GRUPPO LAMA CON MOTORE BLADE UNIT WITH MOTOR BLECHSATZ MIT MOTOR GROUPE LAME AVEC MOTEUR GRUPO CUCHILLA CON MOTOR Tavola N 8 Rev 0 710890770 KARACTER TL...

Страница 55: ...RA PER INVERTER PEDALBOARD FOR INVERTER PEDALLEISTE F R INVERTER P DALES DE DIRECTION POUR INVERSEUR PEDALERA PARA INVERTER Tavola N 9 Rev 0 710490401 17 3 11 8 1 18 13 6 19 10 9 5 15 15 12 12 20 2 16...

Страница 56: ...ES DETACHEES LISTA DE PIEZAS Pag 15 di 22 GRUPPO PEDALIERA NO FI PEDALBOARD UNIT NO FI PEDALENSATZ KEIN FI GROUPE P DALES DE DIRECTION PAS DE FI GRUPO PEDALERA NO FI Tavola N 10A Rev 0 710890830 KARAC...

Страница 57: ...S DETACHEES LISTA DE PIEZAS Pag 16 di 22 GRUPPO PEDALIERA GONFIAGGIO INFLATION PEDALBOARD UNIT AUFPUMPPEDALLEISTESATZ GROUPE P DALES DE GONFLAGE GRUPO PEDALERA INFLADO Tavola N 10B Rev 0 710890110 KAR...

Страница 58: ...CES DETACHEES LISTA DE PIEZAS Pag 17 di 22 GRUPPO VALVOLE PNEUMATICHE PNEUMATIC VALVES UNIT DRUCKLUFTVENTILESATZ GROUPE VANNES PNEUMATIQUES GRUPO V LVULAS NEUM TICAS Tavola N 11 Rev 0 710890320 KARACT...

Страница 59: ...ELISTE LISTE DES PIECES DETACHEES LISTA DE PIEZAS Pag 18 di 22 GRUPPO MANOMETRO PRESSURE GAUGE UNIT MANOMETERSATZ GROUPE MANOM TRE GRUPO MAN METRO Tavola N 12 Rev 0 B1166900 KARACTER TLX KARACTER TLXF...

Страница 60: ...FILTRO RIDUTTORE LUBRIFICATORE GREASER REDUCTION GEAR FILTER AIR TREATMENT UNIT AUFBEREITUNGLUFTSATZ FILTER DES SCHMIERUNTERSETZERS GROUPE TRAITEMENT AIR FILTRE R DUCTEUR GRAISSEUR GRUPO TRATAMIENTO A...

Страница 61: ...DE PIEZAS Pag 20 di 22 GRUPPO CILINDRO PNEUMATICO D 125 D 125 PNEUMATIC CYLINDER UNIT SATZ PNEUMATISCHEN ZYLINDERS D 125 GROUPE CYLINDRE PNEUMATIQUE D 125 GRUPO CILINDRO NEUM TICO D 125 Tavola N 14 Re...

Страница 62: ...S DETACHEES LISTA DE PIEZAS Pag 21 di 22 CILINDRO PNEUMATICO D 125 D 125 PNEUMATIC CYLINDER PNEUMATIKZYLINDER D 125 CYLINDRE PNEUMATIQUE D 125 CILINDRO NEUM TICO D 125 Tavola N 15 Rev 0 710890410 KARA...

Страница 63: ...DES PIECES DETACHEES LISTA DE PIEZAS Pag 22 di 22 GRUPPO ALBERO DI BLOCCAGGIO LOCKING SHAFT UNIT SPERWELLESATZ GROUPE ARBRE DE BLOCAGE GRUPO RBOL DE BLOQUEO Tavola N 16 Rev 0 710891060 KARACTER TLX K...

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