Hofmann ATC 900 Service Manual
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Hofmann ATC 900 Service Manual

Centaur; vulcan pro;
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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
1
CTC-CEN Service Manual 07-13 Rev.E

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  • Page 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 CTC-CEN Service Manual 07-13 Rev.E...
  • Page 2 B L A N K P A G E CTC-CEN Service Manual 07-13 Rev.E...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS CHAPTER 1 INTRODUCTION Pag. General Pag. CHAPTER 2 TOOLS AND SAFETY Pag. Tools and special tools required Pag. Important safety instructions Pag. Electrical safety precautions Pag. CHAPTER 3 ELECTRIC, PNEUMATIC AND HYDRAULIC DIAGRAMS Pag. Electric diagram Pag. Pneumatic diagram Pag.
  • Page 4 7.22 Manometer: Check and replacement Pag. 7.23 Spiral pipes: Check and replacement Pag. CHAPTER 8 MECHNICAL SECTION Pag. Mechanical section Pag. Opening arm bushings # 1-10065A check and replacement Pag. 8.1.1 Opening arm bushings # 1-10065A check and adjustment Pag. Automatic tool # EAA0356G25A: check, replacement and adjustment Pag.

  • Page 5: Chapter 1 Introduction

    1.1 GENERAL This Service Manual describes maintenance, check and repair operations of the Dual bead breaker and Automatic tool tire changer platform under Hofmann, John Bean and Boxer brands and is for use of qualified and trained personnel only. Keep this manual constantly updated, by adding Service Bulletins related to the tire changers.

  • Page 6: Important Safety Instructions

    Electronic inclinometer: Use the electronic level to adjust the bead breaker disc inclination Kit Inverter firmware update # EAK0306G03A. Use this kit to update directly on site the firmware of the Snap On Inverters instead to replace it 2.2 MPORTANT SAFETY INSTRUCTIONS The units are CE or UL approved, but whenever using this equipment basic safety precautions should always be followed, including the following: Read all instructions.

  • Page 7: Electric Diagram

    ELECTRIC DIAGRAM CTC-CEN Service Manual 07-13 Rev.E...

  • Page 8: Pneumatic Diagram

    PNEUMATIC DIAGRAMS CTC-CEN Service Manual 07-13 Rev.E...

  • Page 9: Chapter 4 Ac/Dc Power Distribution

    CHAPTER 4 AC/DC POWER DISTRIBUTION 4.1 LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE 1. Notify all affected employees that a lockout or tagout system is going to be utilized and why. The authorized employee should know the electrical power the machine uses and it’s hazards. 2.
  • Page 10 TRANSFORMER T3 It transforms the 230VAC 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: Dc Theory Of Operation

    CENTERPOST MOTOR M3 It is 1,5 Hp, 3 phase single speed motor and it is supplied by the inverter T1. 4.4 DC THEORY OF OPERATIONS PROCESSOR BOARD A1 The processor board A1 (CPU) is placed inside of the electronic box and it is directly supplied at 18 VAC by the transformer T3.
  • Page 12 LASER POINTER The 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: Chapter 5 Electric Section

    CHAPTER 5 ELECTRIC SECTION WARNING! BEFORE APPROACHING THE ELECTRIC PARTS OF THE MACHINE, DISCONNECT THE MACHINE FROM ELECTRIC SUPPLY Very often electric failures are only caused by loosened wires or connectors not well fitted. Therefore it is VERY IMPORTANT BEFORE STARTING WITH ANY CONTROL AND/OR REPLACEMENT VERIFY IF ALL WIRES AND CONNECTORS ARE WELL FITTED.

  • Page 14: Main Rotary Switch Q2 # 2-15359A: Check And Replacement

     Check wires continuity from power supply plug to main switch wires terminals. IMPORTANT! TO CHECK GROUND (YELLOW/GREEN) WIRE, DISCONNECT THE WIRE END FROM THE TERMINAL BLOCK. TO REPLACE THE CABLE:  Disconnect the power supply wires from the plug and switch teminals. ...

  • Page 15: Centerpost Motor M3 Cable: Check And Replacement

    TO REPLACE THE SWITCH:  Check that the tabs for contacts on the new switch are correctly oriented.  Connect wires ends FIRMLY to the new switch terminals as shown in the appropriate electric diagram (3.0).  Mount the switch to the electronic box 5.1. ...

  • Page 16: Centerpost Motor M3 # 2-49166A And Belt # 8-06831A: Check And Replacement

    TO REPLACE THE CABLE:  Release cable strain relief on the electric box and on the motor.  Take the wrong cable away.  Insert the new cable through the strain relief. IMPORTANT! USE ONLY APPROVED CABLE. GROUND WIRE MUST BE LITTLE LONGER THAN THE OTHER ONES TO ALLOW THE GROUND IN CASE OF PHASE CABLE BREAKAGE.

  • Page 17: Lower Bead Breaker Arm Actuator M1 Eaa0377G02A: Check And Replacement

     Select the multimeter in Ohm and check if there is continuity between all terminals of the motor. If there continuity the motor must be replaced. TO REPLACE THE CENTERPOST MOTOR:  Remove the two bolts in the bottom to get the motor assembly free. ...
  • Page 18  Take the Voltmeter and select it in VDC.  Position the Voltmeter probes on the connector terminals X3 coming from the CPU board inside of electric box.  Push the upper bead breaker arm by hand: whenever it will move the multimeter display should show 24VDC.

  • Page 19: Transformer T3 # 7-02702A: Check And Replacement

    MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK  Push and pull the upper bead breaker arm by hand inward and outward to make sure that actuator is running. At the same time use the 5mm allen key to adjust the alignment of the actuator to the bead breaker arm.

  • Page 20: Centerpost Switch S1 # 2-15259A: Check And Replacement

     Verify if the power supply among the terminals 0 – 230 is correct.  Make sure that the output among terminals 0 and 18 is correct. TO REPLACE THE TRANFORMER:  Turn the machine off.  Disconnect the machine from power supply. ...
  • Page 21  Make sure that the switch is mechanically in good condition.  Press or push the pedal to make sure that the switch is properly adjusted: if not make a new adjustment  Disconnect the wires from the switch terminals. IMPORTANT! MARK WIRES PROPERLY FOR AN EASY AND SAFE INSTALLATION ...
  • Page 22  Turn half of a turn the spacer #3 and check if it is in the correct position.  Press the pedal all way down and make sure that switch has already switched to the second step before the pedal has reached the end of stroke. ...
  • Page 23  Push the switch lever out.  Loosen the two screws and remove the switch with the bracket from the foot pedal assembly.  Loosen the screws and remove the switch.  Install the new switch and secure the screws. ...

  • Page 24: Chapter 6 Electronic Section

    CHAPTER 6 ELECTRONIC SECTION WARNING! BEFORE APPROACHING THE ELECTRONIC PARTS OF THE MACHINE, DISCONNECT THE MACHINE FROM POWER SUPPLY. 6.1 INVERTER T1 # EAA0358G49A: CHECK AND REPLACEMENT  : 1h  : Voltmeter, small and medium cross screwdrivers, 8mm tube type key, pliers. ...

  • Page 25: Inverter T1 # Eaa0358G49A: Firmware Update

    6.2 INVERTER T1# EAA0358G49A Rev.B: FIRMWARE UPDATE  : 2h  : Medium cross screwdriver, Note book PC. Inverter firmware update kit WARNING: The PC used to program the inverter and the inverter can’t be connected both to the mains, follow the admitted connection below.
  • Page 26 Software installation. Use the programming software included in the memory stick inside the kit. The stick contain 2 different programming software (don’t use CD): • Pickit 2 v.2.61 (Quik to install and easy to use) • MPLAB 8.91 (More complete, but more complex to install and to use).
  • Page 27 will be on the desktop. At the end of the installation a icon Programmer connection a) Connect the programmer to the USB port, and the programming cable as shown below. WARNING: the blue connection must be inserted in the programmer connection marked with a small triangle.
  • Page 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. CTC-CEN Service Manual 07-13 Rev.E...
  • Page 29 d) Push the Write button to start the update procedure: At the end a success message is shown (green window). e) Switch off the power and remove the programming cable. Update firmware wit MPLAB a) Start programming software with icon. b) With File ->...
  • Page 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). CTC-CEN Service Manual 07-13 Rev.E...
  • Page 31 e) With Programmer -> PICkit 2 chose the programmer. g) Switch on the power to the board. The programming icons become active. g) Click on the programming icon (first at left) and wait for a finish message on the window. g) Switch off the power and remove the programming cable.

  • Page 32: Cpu Board A1: Check And Replacement

    6.3 CPU BOARD A1 # EAP0275G50A: CHECK AND REPLACEMENT  : 1h  : Medium cross screwdriver, 5mm allen key, 7mm key, multimeter.  : Defective processor board may cause the following malfunction: 1. Turning the machine on, the lower bead breaker will not move, the laser pointer will not work. IMPORTANT! BEFORE STARTING WITH ANY REPLACEMET CHECK CAREFULLY IF ALL WIRES AND CONNECTORS ARE WELL FITTED AND IF THE FUSE IS FINE.
  • Page 33  Disconnect the actuator M2 following par.5.5  Proceed following the next steps.  At the end adjust the actuator following par. 5.5.  Perform the bead breaker arm calibration. TO CHECK THE 3 TURNS MASTER POTENTIOMETER:  Turn the machine off. ...
  • Page 34  If it does not show that value replace the potentiometer.  If the multimeter will display the correct value, check the extension cable from the connector X6 of the CPU board.  If also the cable extension will be fine, replace the CPU board. TO REPLACE THE 3 TURNS POTENTIOMETER: ...

  • Page 35: Procedure To Adjust Bead Breaker Disks Alignment

     Remove the threaded toothed wheel bushing.  Remove the potentiometer from its holder.  Install the new potentiometer on its holder.  Mount the threaded toothed wheel bushing.  Mount the toothed wheel and lock it with the nut. ...
  • Page 36 4. Position the red crocodile to the green wire and the black one on the white wire of the potentiometer. 5. Turn the machine on. 6. Move the bead breaker arms to maximum error point. 7. Read the value displayed on the multimeter. 8.
  • Page 37 Procedure: Remove the cover from the electric box. Turn on the machine: WARNING! 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.
  • Page 38 6. Move the upper bead breaker (master) all inward. Place the MH rod in front of the disks to make sure about the correct 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.
  • Page 39 9. Place the MH rod in contact with the upper bead 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 11. Acquire the position by pressing shortly the button SW2. Now the LEDs 4 and 5 will remain turned on to show that the acquiring of 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.

  • Page 41: Chapter 7 Pneumatic Section

    CHAPTER 7 PNEUMATIC SECTION 7.1 PNEUMATIC FUNCTION The pneumatic section is related to all those functions and devices controlled by air pressure. The working pressure required by machine to work properly must be from 8 to 12 bar and it is reported on the sticker label.

  • Page 42: Air Filter - Lubricator Assy # Eaa0350G85A: Check And Replacement

     REALISING: The air flow is forced to the side “B” of the cylinder 6.5 through the valve 6.2 to close the cylinder and release the tire bead. Air contained in side “A” will escape through the valves. 7.2 AIR FILTER – LUBRICATOR ASSY # EAA0350G85A: CHECK AND REPLACEMENT ...

  • Page 43: Opening Arm Cylinder # Eaa0350G44A: Check And Replacement

    7.3 OPENING ARM CYLINDER # EAA0350G44A: CHECK AND REPLACEMENT  : 30’  : Allen key 6mm, 17 and 24mm end keys  : Defective opening arm cylinder may cause the following malfunction: 1. External air leaking from the flange or from the piston rod 2.

  • Page 44: Valve Control Opening Arm Cylinder # Eaa0356G96A:check And Replacement

     Remove the upper and lower securing screws and remove the cylinder.  Mount the new cylinder tightening the screws firmly.  Mount the cylinder rod to the operating arm bushing: tighten the rod until it will touch the pin inside of the bushing, then turn backward of 1 turn.

  • Page 45: Vertical Blocking Cylinder # Eaa0344G32A: Check And Replacement

     If there will not be any leaking from the fitting and pipe, but the air is getting out from the silencer of the other fitting, the valve has an internal leaking and must be replaced. TO REPLACE THE VALVE: ...
  • Page 46 TO REPLACE THE CYLINDER:  Disconnect the air pressure and the power supply.  Disconnect the air pipes from the cylinder.  Unlock the adjustment screw over the cylinder head and turn it until it will out of the blocking plate range. ...

  • Page 47: Horizontal Blocking Cylinder # Eaa0344G33A: Check And Replacement

     Install the two front adjustment screws and turn them until end of stroke.  Then turn them back of two turns.  Block the counter nuts.  Install the two screws with springs. Tighten them for about 10mm  Tighten the cylinder adjustment screw: when the screw will touch the washer turn the screw of two more turns.

  • Page 48: Vertical Rod Lift Cylinder # Eaa0363G79A: Check And Replacement

    TO REPLACE THE CYLINDER:  Disconnect the air pressure and the power supply.  Disconnect the air pipe from the cylinder.  Remove the rear bolt and take out the cylinder.  Mount the new cylinder. NOTE: DO NOT OVERTIGHT THE BLOT. WHEN THE SCREW HEAD AND THE NUT WILL BE IN CONTACT WITH THE CYLINDER SUPPORT, STOP THE TIGHTENING.
  • Page 49  : Defective valve may cause the following malfunction: 1. Air leaking from the valve rod 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: ...

  • Page 50: Automatic Tool Cylinder # Eaa0363G81A: Check And Replacement

     Mount the new valve to the arm.  Connect the air pipes to the valve.  Mount the handles.  Connect the air pressure and the power supply.  Check the machine works fine.  Mount the cylinder cover. 7.9 AUTOMATIC TOOL CYLINDER # EAA0363G81A: CHECK AND REPLACEMENT ...

  • Page 51: Automatic Tool Cylinder Valve # Eaa0328G73A: Check And Replacement

    TO CHECK THE CYLINDER WHEN THE AUTOMATIC TOOL 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 tool cylinder is leaking air. ...

  • Page 52: Bead Breaker Cylinders # Eaa0363G62A / Eaa0351G77A: Check And Replacement

     Disconnect the air pipe from the valve.  Remove the round knob and the fixing nut.  Remove the 3 screws that secure the valve and the bracket together. Then disconnect the other 2 air pipes.  Mount the new valve. ...
  • Page 53  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.

  • Page 54: Bead Breaker Cylinders And Discs Valves # Eaa0350G58A / Eaa0377G25A

     Disconnect the cylinder from the carriage.  Disconnect the air pressure and the power supply.  Disconnect the air pipes from the cylinder.  Remove the bolt to disconnect the cylinder from the cabinet.  Secure the cylinder to the cabinet with the bolt. ...

  • Page 55: Bead Breaker Arms Blocking Cylinder # Eaa0344G48A: Check And Replacement

    TO REPLACE THE VALVE:  Disconnect the air pressure and the power supply.  Remove the knob and the nut.  Remove the valve from the bracket.  Disconnect the pipes from the valve.  Mount the new joystick.  Install the air pipes to the new valve.
  • Page 56  Turn the switch of the valve to block the vertical rod of the operating arm.  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. ...
  • Page 57  Move the blocking plate and push off the cylinder.  Mount the new cylinder.  Install the two front adjustment screws and turn them until end of stroke.  Then turn them back of one turn.  Block the counter nuts. ...

  • Page 58: Bead Breaker Arms Valve Blocking # Eaa0377G26A: Check And Replacement

    7.14 BEAD BREAKER ARMS VALVE BLOCKING # EAA0377G26A: CHECK AND REPLACEMENT  : 30’  : 4mm allen key, 27mm end key, medium Philip screwdriver.  : Defective valve may cause the following malfunction: Air leaking from the control valve. The bead breaker arm will not detach the tire bead.

  • Page 59: Wheel Lift Cylinder # Eaa0344G93A: Check And Replacement

     Plug the machine to the air pressure and power supply.  Check if the machine works fine.  Mount the valves assembly cover. 7.15 WHEEL LIFT CYLINDER # EAA0344G93A: CHECK AND REPLACEMENT  : 30’  : 17mm end key. ...
  • Page 60  Open completely the cylinder  Disconnect the air pressure and the power supply.  Remove the self locking nut of the stabilizer bar.  Remove the ring nut from the wheel holder.  Remove the wheel holder.  Remove the screw from lift arm to disconnect the cylinder. ...

  • Page 61: Wheel Lift Valve # Eaa0349G00A: Check And Replacement

    7.16 WHEEL LIFT VALVE # EAA0349G00A: CHECK AND REPLACEMENT  : 30’  : 8 and 10mm end key, 3mm allen key, pliers.  : Defective control valve may cause the following malfunction: 1. Air leaking from the valve. 2. Lift will not lift the wheels. 3.

  • Page 62: Mh Cylinder # Eaa0345G61A: Check And Replacement

     Plug the air pipes to the valve.  Bolt the valve to the support.  Mount the connecting rod and install the split pin and the self locking nut.  Plug the machine to the air pressure and to power supply. ...

  • Page 63: Mh Cylinder Control Valve #Eaa0328G73A: Check And Replacement

     Take the cylinder lock it to the MH arm.  Plug the hoses  Install the bead depressor.  Connect the air pressure and check if it works fine again. 7.18 MH CYLINDER CONTROL VALVE #EAA0328G73A: CHECK AND REPLACEMENT ...

  • Page 64: Bead Inflating Valve # Eaa0329G75A: Check And Replacement

     Loosen the screws to take out the defective valve.  Install the new valve and plug the air hoses.  Connect the air pressure again.  Adjust the lowering and raising cylinder speed by turning the two adjustable exaust valve. ...

  • Page 65: Bead Blaster Valve # 1-29581A And Air Tank: Check And Replacement

     Lock the counter nut.  Release the pedal.  Now turn the linkage and the nut to set the clearance at about 8mm between the two nuts.  Lock the nut to the linkage.  Lock the valve to the pedal with the collar. ...

  • Page 66: Manometer: Check And Replacement

    TO REPLACE THE VALVE:  Disconnect the machine from the air pressure and power supply.  Remove the foot pedal assembly protection.  Disconnect the air pipes from the valve.  Loosen the screws that secure the foot pedal assembly to cabinet. ...
  • Page 67  Remove the pipe. Check if Loctite is blocking the pipe.  sintered air filter absorber # 0019181 and check if the manometer returns to zero. Remove the  If the manometer return to zero replace the air filter absorber only. ...

  • Page 68: Spiral Pipes: Check And Replacement

    7.23 SPIRAL PIPES: CHECK AND REPLACEMENT  : 1h for both  : 4mm allen key, small cross screwdriver, scissors.  : Defective spiral pipes may cause the following malfunction: 4. Air leaking. 5. The spiral pipes are damaged or broken. 6.
  • Page 69  Release the pipe strain relief and remove them from pipes protection. Then remove the protection from the bracket.  Remove the pipes from the protection.  Route the new pipes through the protection.  Fit the pipes protection to the bracket with the pipes strain reliefs. ...

  • Page 70: Mechanical Section

    CHAPTER 8 MECHANICAL SECTION 8.0 MECHANICAL SECTION The mechanical section is connected to the centerpost, the tool and to the bead breakers adjustments. Usually this parts do not require the replacement and in any case their replacement is required after years of intensive working. 8.1 OPENING ARM BUSHINGS # 1-10065A: CHECK AND REPLACEMENT ...
  • Page 71  Disconnect the air pressure and the power supply.  Disconnect the air pipes and the laser connector from the horizontal arm.  Disconnect air pipes holder and the horizontal arm end stroke stopper. DANGER! THE HORIZONTAL ARM IS NOW FREE AND IT COULD GET OUT FROM ITS BASEMENT.
  • Page 72  Remove the lower and the upper linkages.  Remove the eccentric anti-rotational plate.  Remove the ring nut 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.
  • Page 73 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 USE A LIFT  Tighten the ring nut firmly until to lock the operating arm basement. ...

  • Page 74: Opening Arm Bushings # 1-10065A Check And Adjustment

    8.1.1 OPENING ARM BUSHINGS LINKAGE: CHECK AND ADJUSTMENT  : 1h  : End keys 32mm, allen key 5 and 8mm, 10, 17, 20 and 25mm ring nut socket keys.  : Incorrect adjustment may cause the following malfunctions: 1. Excessive play on the operating arm assembly. 2.

  • Page 75: Automatic Tool # Eaa0356G25A: Check, Replacement And Adjustment

     Mount the anti-rotational plates.  Check if the machine works fine. 8.2 AUTOMATIC TOOL # EAA0356G25A: CHECK – REPLACEMENT AND ADJUSTMENTS  : 1h  : End key10,17 and 19mm, allen keys 3,5,6 and 8mm, rubber hammer, 13mm tube type key, rim of 17”. ...
  • Page 76 TO ADJUST THE TOOL ORIENTATION ON THE RIM:  Connect the machine to air pressure and power supply.  Block a 17” rim diameter rim in good condition to the centerpost.  Place the tool on the rim, as normal operation, and then lock it. ...
  • Page 77  Connect the tool finger arm to the ball joint.  If the holes are not matching, turn the ball joint until they will match.  Tighten the bolt firmly.  Lower the finger completely: make sure that when the cylinder and tool finger will reach their end of stroke at the same time.
  • Page 78 TO ADJUST THE VERTICAL ROD BLOCKING PLATE:  Press the yellow button valve to lower completely the vertical tool rod.  Tighten as much as possible the vertical blocking cylinder adjustment screw in order to block the rod.  Pull the yellow button valve all towards the operator in order to lift the vertical tool rod.
  • Page 79  If they are completely compressed, turn the screws back until to see some light in between of the every wire of the spring.  Check if the machine works fine.  Install the protection. TO ADJUST THE HORIZONTAL TOOL CLEARANCE: ...

  • Page 80: Horizontal Arm Rollers: Check And Adjustment

    8.3 HORIZONTAL ARM ROLLERS # EAA0347G76A: CHECK AND ADJUSTMENT  : 30’  : End keys 13mm, allen keys 4mm.  : Incorrect rollers adjustment may cause the following malfunctions: 1. Excessive play on the horizontal arm. 2. Horizontal arm does not move smoothly. TO CHECK THE ROLLERS: ...

  • Page 81: Bead Breaker Discs # Eam0065G63A: Check And Replacement

     Remove the two tangs from the gearbox shaft  Unlock the last two screws the secure the gearbox to the cabinet.  Unscrew the two screws that secure the gearbox inside of the cabinet.  Remove the remaining two screws and nuts to complete the gear box dismounting. BE CAREFUL! THE GEARBOX IS HEAVY AND IT COULD CRUCH A HAND.
  • Page 82 TO REPLACE THE DISC:  Remove the plastic protection.  Remove the rollpin. Then remove the bushing.  Remove the washers and then loosen the four screws to complete the dismounting of the disc.  Mount the pin to the disc and secure the screws with Loctite. Then replace the old washers with the new ones. ...

  • Page 83: Bead Breaker Discs Bearing # 1-06963A: Check And Replacement

     Check if the bead breaker discs are damaged or worn out. TO REPLACE THE BEAD BREAKER DISC  Loose the four screws that secure the disc to its support.  Remove the defective disc.  Install the new disc and secure it with the screws and Loctite. ...

  • Page 84: Bead Breaker Discs Inclination Adjustment

     Install the new bearing with loctite to the support.  Tighten the 12mm screw firmly.  Tighten again the lateral set screw.  Mount again the bead breaker disc.  Turn the machine and perform the bead breaker discs alignment calibration (6.5). ...

  • Page 85: Bead Breaker Discs Clearance: Check And Adjustment

    TO ADJUST THE DISC INCLINATION:  Remove the counter setscrews from the bead breaker holder.  To adjust the inclination of the disc in rest position, turn the upper set screw.  To adjust the inclination of the disc in second stage turn the lower setscrew.
  • Page 86  If the clearance is higher, release the arm, unlock the screws and tighten them accordingly. Then lock the screws and check the clearance again.  If the clearance is lower, release the arm, unlock the screws and loosen them accordingly. Then lock the screws and check the clearance again.

  • Page 87: Bead Breaker Carriage: Check And Adjustment

     Please refer to par.8.2.  Check if the machine works fine  Mount the protection. 8.10 BEAD BREAKER CARRIAGE: CHECK AND ADJUSTMENT  : 30’ each one  : Allen keys 4, 5 and 6mm, 8 and 17mm end keys, 13mm tube type key. ...
  • Page 88 3. Lower Bead breaker arm moves forward and backward unless find the correct position. TO CHECK THE LEAD NUT:  Disconnect the air pressure and power supply.  Disconnect the actuator 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.

  • Page 89: Chapter 9 Trouble Shooting

    CHAPTER 9 TROUBLE SHOOTING SECTION COMPLAINT 1: Turning the machine on the centerpost does not turn, the lower bead breaker arm does not move at all and the laser pointer does not turn on. Check the power supply at the wall. Check the power supply plug and fuses on the wall: 5.1 Check the power supply cable: 5.1 Check the transformer fuses:5.6...
  • Page 90 Check the air pressure inlet: 7.2 Check the opening arm cylinder: 7.3 Check the opening arm cylinder valve: 7.4 Check the opening arm end stroke screws: 8.1 Check the opening arm bushing linkage: 8.1.1 Call Snap On Hot line Center. COMPLAINT 8: When the operating arm opens it moves downward and when it closes it catches against the end stroke screws..
  • Page 91 COMPLAINT 16: The bead breaker discs are not aligned Check the bead breaker potentiometers:6.3 Check the lower bead breaker arm actuator:5.5 Check the CPU board: 5.5 Check the bead breaker discs clearance:8.7 Call Snap On Hot Line Center CTC-CEN Service Manual 07-13 Rev.E...

  • Page 92: Chapter 10 Service Bulletins

    CHAPTER 10 SERVICE BULLETINS Service-Bulletin No. SB 852 TC 10-May-12 Models affected: All passenger tire changer with tire inflator Alle Pkw-Reifenmontiermaschinen mit Füllvorrichtung Starting from s/n: Subject: Homologated Wika manometer 0023484 accuracy Genauigkeit des geprüften Wika-Manometers 0023484 ENGLISH Following up some cases of Wika manometer # 0023484 replaced under warranty due to inaccurate tire pressure reading, we would like to inform you that that the homologated accuracy of the manometer is the following: •...
  • Page 93 Prego prendere ben nota che se il manometro mostra la pressione degli pneumatici entro queste tolleranze e se la sua lancetta ritorna a zero dopo aver staccato il tubo di gonfiaggio dalla ruota, non deve essere sostituito. Nel caso in cui il manometro non ritorni a zero, prima di sostituirlo raccomandiamo di scollegare il filtro sinterizzato smorzatore posteriore # 0019181, mostrato in figura, e assicuratevi che il manometro ritorni a zero.
  • Page 94 Service-Bulletin No. SB 867 TC 13-Jul-12 Models affected: Mounting Help arms Starting from s/n: Subject: Control of the MH arm control valve ENGLISH Feedback from the field reported cases of air leaking from the aluminum made control valve or slow self - lowering of the Mounting Hel arm due to the loosened end cap screws.
  • Page 95 Dans le cas d’un remplacement de la soupape, nous vous prions de mentionner dans l’ordre de commande le Kit soupape de commande MH # EAA0377G99A et non pas la soupape # EAA0328G73A. Le Kit contient les vis et les écrous nécessaires à l’installation de la soupape courante Stampotecnica sur le bras presse-talon.
  • Page 96 Service-Bulletin No. SB 879 TC 23-Jul-12 Models affected: ATC 900, Monty 8600, Centaur, Vulcan Pro Starting from s/n: 0612.EEWH42AE1.8 Subject: Wired multiturn potentiometer ENGLISH We would like to inform you that starting from the above serial number all the reported machine models are equipped by the bead breaker potentiometers with a unique cable to be directly connected to the CPU board.
  • Page 97 ESPAÑOL Nos complace informarles que a partir del número de serie mostrado más arriba, todos los modelos arriba indicados se equiparán con los potenciómetros de los brazos 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.
  • Page 98 Service-Bulletin No. SB 896 TC 18-Oct-12 Models affected: ATC 900, Centaur, monty 8600, Vulcan Pro Starting from s/n: EEWH742AE.13 Subject: New bead breaker discs – Neue Abdrückscheiben ENGLISH Starting from the serial number reported above, all the listed tire changers are equipped by the new bead breaker discs.
  • Page 99 Push off the pin. Remove the snap ring from the pin. Push off the pin to remove the bead breaker disc assembly from the arm. Mount the new bead breaker disc assembly on the arm and secure it with the snap ring. Fix the bead breaker disc to the cylinder and secure the pin with the screw.
  • Page 100 DEUTSCH Ab der oben angegebenen Seriennummer werden alle aufgeführten Reifenmontiermaschinen mit den neuen Abdrückscheiben ausgestattet. Die Form der neuen Abdrückscheiben verbessert die Stabilität der Scheiben bei sehr weichen Reifen und vermeidet ein mögliches Abrutschen der Scheiben auf der Reifenseitenwand. 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.
  • Page 101 Den Sicherungsring vom Stift abnehmen Den Stift ganz herausdrücken, um die komplette Abdrückscheibe vom Arm abnehmen zu können. Die neue Abdrückscheibe am Arm montieren und mit dem Sicherungsring sichern. Die Abdrückscheibe am Zylinder befestigen und den Stift mit der Schraube sichern. Die Maschine wieder an die Druckluftversorgung anschließen.
  • Page 102 ITALIANO A partire dal numero di serie sopra riportato, tutti I modelli di smonatgomme elencati sono equipaggiati con nuovi dischi stallonatori. La forma dei nuovi dischi stallonatore migliora la stabilità dei dischi stessi sugli pneumatici molto soffici, evitando possibili scivolamenti dei dischi sui fianchi degli pneumatici durante le operazioni. I precedenti dischi stallonatori non saranno più...
  • Page 103 Rimuovere l’anello dal perno. Spingere fuori il perno per rimuovere il gruppo disco stallonatore dal braccio. Montare il gruppo disco stallonatore sul braccio e assicurarlo con l’anello elastico. Fissare il disco stallonatore al cilindro e bloccare il perno con la vite. Collegare l’aria compressa alla macchina.
  • Page 104 ESPAÑOL A partir del número de serie arriba mostrado, todos los modelos de desmontadoras de ruedas indicados, estarán equipados con un nuevo disco destalonador. La forma del nuevo disco destalonador mejora la estabilidad del disco en neumáticos con talones muy blandos, evitando de esta forma posibles deslizamientos de este sobre el talón del neumático durante la operación de destalonamiento.
  • Page 105 Quitar el segger del perno. Retirar el perno para retirar el grupo del disco destalonador del brazo. Montar el grupo disco destalonador en el brazo y fijarlo con el segger. Fijar el disco destalonador al cilindro y apretar el tornillo. Conectar la máquina al aire comprimido.
  • Page 106 FRANÇAIS A partir du numéro de série reporté ci-dessus, tous les modèles de démonte-pneus cités sont équipés de nouveaux disques détalonneurs. Les nouveaux disques détalonneurs ont une forme qui améliore leur stabilité en particulier sur les pneus très souples, de manière à éviter qu’ils ne glissent sur les flancs des pneus au cours des opérations. Les disques détalonneurs précédents ne seront plus disponibles.
  • Page 107 Retirer la bague de la broche. Extraire la broche pour retirer le groupe disque détalonneur du bras. Monter le groupe disque détalonneur sur le bras et l’assurer avec une bague élastique. Fixer le disque détalonneur au vérin et bloquer la broche avec la vis. Raccorder l’air comprimé...
  • Page 108 Service-Bulletin No. SB 921 TC 24-Jan-13 Models affected: monty 8600 – John Bean Centaur – Boxer Vulcan Pro – ATC900 Starting from s/n: Subject: Procedure to adjust bead breaker disks alignment – Ausrichtung der Abdrückscheiben ENGLISH In case of complaints related to bead breaker disks misalignment out of the maximum tolerance 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.
  • Page 109 21. Read the value displayed on the multimeter. 22. Unlock the potentiometer counter nut. 23. Turn the potentiometer with a flat screwdriver subtracting 0,020 Vdc from the value displayed. 24. Lock the counter nut again. 25. Calibrate the machine. 26. Check if the arms are better aligned. 27.
  • Page 110 8. Die Kontermutter am Poti lösen 9. Poti mit einem flachen Schraubendreher auf den Anzeigewert minus 0,020 VDC einstellen 10. Kontermutter wieder kontern. 11. Maschine justieren 12. Prüfen, ob die Arme besser ausgerichtet sind 13. Maschine ausschalten. 14. Potentiometer-Abdeckung wieder anbringen. ITALIANO In caso di lamentele relative al disallineamento dei dischi stallonatori fuori dalla tolleranza massima, 1mm/0,04”, gradiamo informarvi che è...
  • Page 111 Allentare dado bloccaggio ruota dentata/albero del potenziometro superiore 8. Con un cacciavite ruotare l’albero potenziometro togliendo 0,020 Volt al valore di riferimento. 9. Bloccare il controdado ancora. 10. Calibrare la macchina. 11. Verificare se i bracci stallonatori sono allineati meglio. 12.
  • Page 112 Aflojar la tuerca dentada del potenciómetro superior. 8. Con un destornillador girar el tornillo del potenciómetro quitando 0.020 voltios al valor de referencia. 9. Fijarlo y controlarlo ahora.. 10. Calibrar la máquina. 11. Verificar si los brazos destalonadores están ahora mejor nivelados. 12.
  • Page 113 Desserrer l’écrou de blocage roue dentée/arbre du potentiomètre supérieur 8. Avec un tournevis, tourner l’arbre potentiomètre en soustrayant 0,020 Volt à la valeur de référence. 9. Bloquer le contre-écrou du serrage. 10. Calibrer la machine. 11. Vérifier si les détalonneurs sont mieux alignés. 12.
  • Page 114 7. Снять показание на дисплее универсального измерительного прибора. 8. Ослабить контргайку зубчатого 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.
  • Page 115 Service-Bulletin No. SB 929 TC 25-Feb-13 Models affected: Passenger tire changer with tire inflator and KPa manometer Starting from s/n: Subject: KPa Wika manometer 0031373 accuracy ENGLISH Following up some cases of Wika manometer # 0031373 replaced under warranty due to inaccurate tire pressure reading, we would like to inform you that the manometer is 2.5 class and its homologated tolerance is +/- 25KPa on all pressures measured.
  • Page 116 ITALIANO A seguito di alcuni casi di manometri Wika # 0031373 sostituiti in garanzia a seguito della lettura imprecisa della pressione degli pneumatici, gradiamo informarvi che questo manometro è in classe 2.5 ed la sua tolleranza omologata è di +/- 25 KPa su tutte le pressioni misurate. Prego prendere ben nota che se il manometro mostra la pressione degli pneumatici entro queste tolleranze e se la sua lancetta ritorna a zero dopo aver staccato il tubo di gonfiaggio dalla ruota, non deve essere sostituito.
  • Page 117 300KPa -> +/-25KPa 400KPa -> +/-25KPa CTC-CEN Service Manual 07-13 Rev.E...
  • Page 118 UPDATING GUIDE: REVISION A – July 2012 ________________________________________________________________________________________ REVISION B – July 2012 Updated parts of chapters : 7.12 Bead breaker cylinders and discs valves: # EAA0350G58A / EAA0377G25A: check and replacement (Text) Pag. 7.14 Bead breaker arms valve blocking # EAA0377G26A: check and replacement (Text) Pag.
  • Page 119 B L A N K P A G E CTC-CEN Service Manual 07-13 Rev.E...
  • Page 120 AUTHOR: Stefano Muzzioli Copyright statement This manual and the materials contained within are copyright protected. The manual, or any section, page, drawing, or diagram, may not be reproduced by any means without the written consent. The information and specifications 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.

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