Corghi ProLine 124 Operator's Manual
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Corghi ProLine 124 Operator's Manual

Automatic tyre changer
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Tel. ++39 0522 639.111 - Fax ++39 0522 639.150
www.corghi.com - info@corghi.com
ProLine
124 (No CE) - 221 -
321 - 324
Cod. 4-135703 - 05/2018
Manuale d'uso
Operator's manual
Manuel d'utilisation
Betriebsanleitung
Manual de uso
2
82
162
242
322

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Summary of Contents for Corghi ProLine 124

  • Page 1 124 (No CE) - 221 - 321 - 324 Cod. 4-135703 - 05/2018 Italiano Manuale d’uso English Operator’s manual Français Manuel d’utilisation Deutsch Betriebsanleitung Español Manual de uso Tel. ++39 0522 639.111 - Fax ++39 0522 639.150 www.corghi.com - info@corghi.com...
  • Page 2 CORGHI Dear Customer, Thank you for purchasing a Corghi equipment. Your machine has been designed to provide years of safe and reliable service, as long as it is used and maintained in accordance with the instructions provided in this manual.
  • Page 3 Bead lubrication when removing the low profile tyres Reverse rims Mounting Standard wheels Mounting of stiff, low profile tyres Wheels with reversed channel rim Bead lubrication for proper mounting Inflating procedure Safety measures Lubrication and removal of the valve insert Tubeless tyre inflation ProLine 124-221-321-324 Operator manual...
  • Page 4 Personnel and training dates _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ ProLine 124-221-321-324 Operator manual...

  • Page 5: Table Of Contents

    MUST BE REMOVED................116 9.3. BEAD BREAKING................117 9.4. CLAMPING THE WHEEL..............119 9.5. WHEEL DEMOUNTING..............123 9.5.a. TOOL HEAD POSITIONING (PROLINE 324-321)..123 9.5.b. TOOL HEAD POSITIONING (PROLINE 124-221)..123 9.5.c. WHEEL DEMOUNTING...........124 9.6. WHEEL MOUNTING................126 9.7 APPROVED UHP AND RUN FLAT TYRE DEMOUNTING AND MOUNTING PROCEDURE................127 9.8.
  • Page 6 10.3.E. TYRE MOUNTING/DEMOUNTING.......143 11. TROUBLESHOOTING................145 12. MAINTENANCE..................147 13. SCRAPPING....................150 14. ENVIRONMENTAL INFORMATION............150 15. INFORMATION AND WARNINGS ABOUT OIL........151 16. FIREFIGHTING EQUIPMENT TO BE USED..........152 17. GLOSSARY.....................153 18. GENERAL WIRING DIAGRAM ..............157 19. PNEUMATIC SYSTEM DIAGRAM ............160 ProLine 124-221-321-324 Operator manual...

  • Page 7: Commissioning

    Alternately, the new owner can send an email to service@corghi.com. This manual presumes that the technicians have a thorough understanding of rims and tyre identification and maintenance.

  • Page 8: General Warnings And Instructions

    4. Never exceed the inflation pressure for the tyre indicated by the manufacturer on the side of the tyre itself. Carefully check that the air hose is well inserted in the valve ProLine 124-221-321-324 Operator manual...
  • Page 9 8. Danger of electric shock. cable. or greater than those of the machine. Cables with rated features that are lower than those of the machine could overheat and cause a fire. ProLine 124-221-321-324 Operator manual...
  • Page 10 Repairs must only be performed by qualified personnel. Manufacturer technicians are the most qualified individuals. The employer must determine if an employee is qualified to carry out any machine repair safely if the operator has attempted to make the repair. ProLine 124-221-321-324 Operator manual...

  • Page 11: Labels Placement

    FRONT LABEL, CORGHI LOGO 461236 LATERAL 4-135683 LABEL, PROLINE 124 4-135682 LABEL, PROLINE 221 4-135681 LABEL, PROLINE 321 4-135680 LABEL, PROLINE 324 446429 LABEL, OPERATING PRESSURE LABEL, DANGER - PRESSUR- 446442 ISED CONTAINER 4-113355 LABEL, FILTER ProLine 124-221-321-324 Operator manual...
  • Page 12 LABEL, DANGER OF INFLA- 432740 TION (ONLY AMERICAN MAR- KET) LABEL, INFLATION PEDAL 435150 (only 124 TI - 321 TI - 324 TI) PLATE, CORRECT POWER 446388 SUPPLY LABEL, HAND CRUSHING 446431 HAZARD (IF BEAD BREAKER IS PRESENT) ProLine 124-221-321-324 Operator manual...
  • Page 13 ING/CLOSING LABEL, BEAD BREAKER AC- 439212 TIVATION LABEL, ROTATION 439214 TURNTABLE LABEL, RISK OF IMPACT, 35017099 FRONT POLE 462081A RISK OF CRUSHING HANDS WARNING POSTER ENGLISH/ 450005 FRENCH (ONLY AMERICAN MARKET) LABEL 2 POSITIONS 4-136235 HANDLE ProLine 124-221-321-324 Operator manual...
  • Page 14 ProLine 324 ProLine 321 ProLine 124-221-321-324 Operator manual...
  • Page 15 ProLine 221 ProLine 124 ProLine 124-221-321-324 Operator manual...
  • Page 16 446442. Danger - pressurised container. part n. 425211A. Danger of electric shock. part n. 461931. Inflation hazard. part n. 462778. Inflation hazard (for North America market). part n. 432740. Inflation hazard (for North America market). ProLine 124-221-321-324 Operator manual...

  • Page 17: Electrical And Pneumatic Connections

    1.2.c. ELECTRICAL AND PNEUMATIC CONNECTIONS WARNING A good earth connection is essential for correct operation of the machine. The electric connection used must be suitably sized: ProLine 124-221-321-324 Operator manual...
  • Page 18 Check that the lubrication cup (B, Fig. 2a contains The pneumatic supply inlet point, in the workshop line, must be equipped with a pneumatic supply shut-off valve, placed upstream the filter/regulator unit supplied with the machine (B Fig. 2a). ProLine 124-221-321-324 Operator manual...

  • Page 19: Technical Data

    - Maximum wheel diameter - ProLine 124 ............1250 mm (49”) - Maximum opening of bead breaker ProLine 124 - 221 - 321: 75 mm (3”) / 330 mm (13”) - Maximum opening of bead breaker ProLine 324: ....100 mm (4”) / 400 mm (16”) -Bead breaking force ..............

  • Page 20: Air Pressure

    - Weight - ProLine 324 ..............239 kg (255 kg TI version) - Weight - ProLine 124 ..................... 235 kg - Noise level when operating ................... 70 dB (A) Number of Weight of electric/ Motor rating Torque Nm electronic part kg...

  • Page 21: Additional Rim/Tyre Information

    2. Employers are required to make sure that every employee demonstrates and maintains the ability to work on the wheels safely, including the performance of the following activities: ProLine 124-221-321-324 Operator manual...

  • Page 22: Preliminary Checks

    Use the controls to bleed the air they contain. 1.8. OPTIONAL ACCESSORIES Contact the sales network to find all the optional accessories suitable for this machine. ProLine 124-221-321-324 Operator manual...

  • Page 23: Transport, Storage And Handling

    (pallet) (Fig. 3). Before moving the machine, refer to the LIFTING/ HANDLING section. WARNING Keep the packing material intact for possible future transport of the machine. ProLine 124-221-321-324 Operator manual...

  • Page 24: Unwrapping

    ProLine 321 - 324 (fig.4A): 1 body 2 head 3 included 4 air tank (TI version only) 5 pole guard 6 arm guard ProLine 124 - 221 (fig.4B): 1 body 2 head (with internal tank for ProLine 124) 3 included ProLine 124-221-321-324 Operator manual...

  • Page 25: Mounting

    - Fit the hose connector of tank 2 into hose Q, fasten the tank 2 to the machine with nuts and washers R, and tighten the clamp O onto the hose Q (fig. 5G) (T.I. version only). ProLine 124-221-321-324 Operator manual...
  • Page 26 Adjust valves A on the cylinder, by turning them clockwise the speed decreases, while counter- clockwise it increases. - Refit the side cover N (Fig. 5A). ProLine 124 - 221 - Remove the side cover N (Fig. 6A). ProLine 124-221-321-324 Operator manual...

  • Page 27: Lifting/Handling

    7A and 7B. This lifting point must be used whenever you need to change the position of the machine. Do not attempt to move the machine until it has been disconnected from the power and pneumatic supply networks. ProLine 124-221-321-324 Operator manual...

  • Page 28: Installation Area

    - Relative humidity 30% ÷ 95% without con- densation. - Temperature 0°C ÷ 50°C. WARNING Whenever the machine is disconnected from the pneumatic line for long periods, before restoring the pneumatic supply, check the configuration of the pedals as shown below. ProLine 124-221-321-324 Operator manual...

  • Page 29: Description Of The Machine

    As well as the manufacturer’s details, it indicates: Mod. ISO9001 ISO 9001 - company Quality System QUAL. SYS. CERTIFIED ANNO DI COSTRUZIONE / Code MANUFACTURED CE - CE marking. X-XXXXXXXX/XX - XX Serial N. bar/psi XXXXXXXXX ProLine 124-221-321-324 Operator manual...

  • Page 30: Operator Position

    B (fig.9a), keeping hands away from machine moving parts. 7. OVERALL DIMENSIONS (mm) Maximum length A = 1200 Minimum width B1 = 1250 Maximum width B2 = 1700 Maximum height H = 2020 ProLine 124-221-321-324 Operator manual...

  • Page 31: Main Working Elements Of The Machine

    Clamping handle: at 2 positions - Z position button for tool head and horizontal axis unlocked - Y position button for tool head and horizontal axis locked Vertical and horizontal arm (to position the mounting/ demounting tool). ProLine 124-221-321-324 Operator manual...
  • Page 32 21 Inflation gun. 22 Shoe guard (option) 23 Vertical pole 24 Vertical arm (to position the mounting/demounting tool). 25 Vertical arm lever locking 26 Swivelling arm. 27 Swivelling arm adjustment handle. 28 Safety valve 29 Round pole ProLine 124-221-321-324 Operator manual...
  • Page 33 PROLINE 321-324 PROLINE ProLine 124-221-321-324 Operator manual...
  • Page 34 PROLINE WARNING RISK OF EXPLOSION With regard to the technical characteristics, warnings, maintenance and any other information about the air tank (optional), consult the relevant operator's and maintenance manual provided with the documentation of the accessory. ProLine 124-221-321-324 Operator manual...

  • Page 35: Basic Procedures - Use

    (Fig. 12c). 2. Disconnect the power supply plug (Fig 12a). 3. Isolate the compressed air line by disconnecting the closing valve (quick release connector) (Fig. 12b.) ProLine 124-221-321-324 Operator manual...

  • Page 36: Preliminary Checks

    C, except in the area of the valve hole A where the curvature is less pronounced B. On these wheels the bead must first be broken in correspondence of the valve hole, on both the top and bottom sides. ProLine 124-221-321-324 Operator manual...

  • Page 37: Bead Breaking

    (A, Fig.16), keeping your hands away from moving parts. - Press pedal A (Fig. 14B ProLine 321-324 - Fig. 14A ProLine 124-221) and bring it into completely lowered configuration. In this configuration, the jaws are completely closed. - Remove the internal valve to fully deflate the tyre (Fig.
  • Page 38 - Position the wheel as shown in fig.16 and move the bead breaker shoe near the rim edge. WARNING During the bead breaking operation, you are advised to keep the turntable closed (locking wedges towards the centre) ProLine 124-221-321-324 Operator manual...

  • Page 39: Clamping The Wheel

    “non-working” position (tool at the top and the horizontal arm completely retracted) (A Fig. 18B). - Press button (position Y, Fig. 18A) to lock the arms into the “non-working” position. - Press pedal (C, Fig. 18C) to take the column into the “non-working” position (B Fig. 18B). ProLine 124-221-321-324 Operator manual...
  • Page 40 ONLY FOR PROLINE 124 E 324: - If necessary, set the diameter range (11” 24” o 13” 27”), using the turntable jaw fixing screw: to fully open the turntable jaws (Fig. 18D). the locking nut A, Fig. 18E and jaw fixing screw B, Fig. 18F.
  • Page 41 Setting the diameter range (11” 24” or 13” 27”), using the adjustment device must be carried out with the turntable completely stopped without acting on the commands. - Turntable jaws opening and closing is carried out by sequentially pressing the control pedal PROLINE 124 - 324: 13”-26” 11”-24”...
  • Page 42 (Fig. 19c). E.g.: Rim 18”, pre-position the jaws making the notch match with value 18”. - If the rim is blocked from the inside (Fig. 19d), it ProLine 124-221-321-324 Operator manual...

  • Page 43: Wheel Demounting

    (Fig. 22A). Important: press the button Y to lock both the vertical and horizontal arms simultaneously while the mounting/ demounting tool head goes slightly upwards moving away from the rim edge (fig. 23A). ProLine 124-221-321-324 Operator manual...

  • Page 44: Wheel Demounting

    The operator can tilt the pole freely (e.g. when demounting wheels of the same size) without repositioning the tool head. 9.5.b TOOL HEAD POSITIONING (ProLine 124 - ProLine 221) - Take the horizontal arm into the operating position (Fig. 24) - Lower the vertical arm until the tool head touches the upper rim edge.
  • Page 45 Turntable rotation can be stopped at any moment by releasing the drive pedal. To rotate in the opposite direction, simply raise up the pedal. ProLine 124-221-321-324 Operator manual...

  • Page 46: Wheel Mounting

    Press the turntable control pedal (D) to rotate clockwise and mount the bead. Use the rim channel by pressing on the right wall of the tyre to reduce traction force on the bead as the wheel rotates (fig.28). ProLine 124-221-321-324 Operator manual...

  • Page 47: Approved Uhp And Run Flat Tyre Demounting And Mounting Procedure

    MOUNTING PROCEDURE For a detailed description of the UHP and RUN FLAT tyre demounting/mounting procedure, please refer to the instructions in the manual developed by WDK (German Tyre Industry Association). 9.8. TYRE INFLATION 9.8.A. SAFETY INDICATIONS DANGER ProLine 124-221-321-324 Operator manual...
  • Page 48 This machine is not a safety device against the possible risk of explosion of tyres, air chambers or rims. 5. Maintain a suitable distance from the tyre changer while inflating. Do not approach it. ProLine 124-221-321-324 Operator manual...

  • Page 49: Tyre Inflation

    (fig.31), then clamp the arm in this position. - Remove the valve core if it has not already been removed (Fig. 32). - Connect the Doyfe connector of the inflating hose to the valve stem (Fig. 33). ProLine 124-221-321-324 Operator manual...
  • Page 50 - Remove the valve core if it has not already been removed (Fig. 32). - Connect the Doyfe connector of the inflating hose to the valve stem (Fig. 33). WARNING To increase the effectiveness of the air jets, manually lubricate and lift the lower bead before activating the nozzles. ProLine 124-221-321-324 Operator manual...
  • Page 51 Operate the air jets only after making sure that the rim is correctly blocked. WARNING RISK OF EXPLOSION. Do not mount a tyre and a rim that do not have the same diameter (e.g., 16 and 1/2 inch tyre and a 16 inch rim). ProLine 124-221-321-324 Operator manual...
  • Page 52 Installation by NON-qualified personnel does not ensure the product correct performance. The accessory can only be installed on CORGHI tyre changer: HTB 21 exclusively on Proline 321 and 324 machine HTB 24 exclusively on Proline 321 and 324 machine...
  • Page 53 1. Lock a wheel on the turntable, take the bead presser arm into working position. 2. If the arm centring cone does not appear in the centre of the wheel, turn the fixing screws of the accessory. ProLine 124-221-321-324 Operator manual...
  • Page 54 6- Pneumatic pressure arm 7- Tool 8. Centring tool 9 - Bead breaker disc 10.1.e. Labels placement Ref. Code Description Label HTB 24 Label HTB 21 Unlocking control plate 4-405458 Label, dimensions 462081 Label, risk of crushing ProLine 124-221-321-324 Operator manual...
  • Page 55 Position the rim presser roller tangent to the external diameter of the rim (Fig. 48), press the down lever until creating the necessary space between the mounting/ demounting tool and the cover in order to insert the bead lift (fig. 49). ProLine 124-221-321-324 Operator manual...
  • Page 56 NOTE: stop rotation when the bead presser is next to the mounting/demounting tool. - Press the up lever and free the wheel from the roller and from the bead presser. ProLine 124-221-321-324 Operator manual...
  • Page 57 2 using the rotation shaft previously removed. Pay attention to the position of the arms when inserting the shaft into the cylinder hole and fasten as shown in fig. 58 - Fasten the control box on the main arm side ProLine 124-221-321-324 Operator manual...
  • Page 58 fixed base 2 (fig.62) and tighten nut 3 - Install the Y-connection (fig.63) 10.2.b. Technical data HSU24 - Pneumatic cylinder force (a 8 bar) 4000 N ..........1000 mm ..........1200 mm ....360 mm ....100 mm ........320 mm ProLine 124-221-321-324 Operator manual...
  • Page 59 K- Bead lift disc L. Locking pin F- Presser roller N- Presser arm O- Rotation release pin P- Control valve Q- Cylinder 10.2.d. Labels placement Ref. Code Description Unlocking control plate 4-405458 Label, dimensions 462081 Label, risk of crushing ProLine 124-221-321-324 Operator manual...
  • Page 60 (1-2 mm) and press the rollers downwards for 5-7 cm beyond the top edge of the rim. - Act on the turntable rotation pedal until complete bead insertion (fig.70). ProLine 124-221-321-324 Operator manual...
  • Page 61 - Connect air supply hose. 10.3.b. Technical data HSA21 - Pneumatic cylinder force (at 8 bar) ..3000 N ............330 mm .........800 mm ..........230 mm 10.3.c. Functional parts 1- Helper control 2- Pneumatic pressure arm 3- Tool ProLine 124-221-321-324 Operator manual...
  • Page 62 10.3.d. Labels placement Ref. Code Description Unlocking control plate 4-405458 Label, dimensions 462081 Label, risk of crushing ProLine 124-221-321-324 Operator manual...
  • Page 63 10.3.e. Tyre mounting/demounting Demounting ProLine 124-221-321-324 Operator manual...
  • Page 64 Mounting ProLine 124-221-321-324 Operator manual...
  • Page 65 Replace the reduction gear. Gear unit noisy. The turntable makes a 1/3 of a turn and then stops Reduction gear is seizing. Replace the reduction gear. Turntable stops under strain, but the motor is running Insufficient belt tension. ProLine 124-221-321-324 Operator manual...
  • Page 66 Replace cylinders or seals. Lack of supply to clamping cylinders. Check the operation of controls and pneumatic circuit. No air passage through valve Replace the valve. Vertical arm ascends under strain Faulty clamping plate. Replace the plate. ProLine 124-221-321-324 Operator manual...
  • Page 67 The manufacturer declines all liability for damage resulting from tampering with such valves. WARNING Before making any adjustments orcarrying out maintenance on the machine, disconnect the electrical and compressed air supply and make sure that all moving parts are locked in place. ProLine 124-221-321-324 Operator manual...
  • Page 68 If a manual operation is not sufficient, use the specific key provided (fig.42e). Clean with a dry cloth. Avoid contact with solvents. ProLine 124-221-321-324 Operator manual...
  • Page 69 NOTE: for oil warnings, refer to the specific chapter in the machine user manual. ProLine 124-221-321-324 Operator manual...
  • Page 70 This prevents the inappropriate disposal of the substances contained in this product, or the improper use of parts of this product, and the resulting hazards for the environment and human ProLine 124-221-321-324 Operator manual...
  • Page 71 Precautions for the use of oil - Avoid contact with skin. - Do not allow oil mists to form or spread in the atmosphere. - Adopt the following simple hygienic precautions: that irritate the skin or remove its natural protective oil ProLine 124-221-321-324 Operator manual...
  • Page 72 YES* Use only if more appropriate extinguishers are not at hand or when the fire is small. WARNING This table contains general instructions to be used as guidelines for users. Contact the manufacturer for details of the applications of each type of extinguisher. ProLine 124-221-321-324 Operator manual...
  • Page 73 flexure is transmitted to the tread. Radial: the casing consists of one or more plies with the cords in radial direction. A radial casing in itself is quite unstable. To make it stable and prevent incorrect tread movement in ProLine 124-221-321-324 Operator manual...
  • Page 74 (conventional tyres) with the last casing ply. 13 - Shoulder. This is the outer part of the tread, between the corner and start of the sidewall. ProLine 124-221-321-324 Operator manual...
  • Page 75 (or tyre in the case of tubeless tyres). It consists of three elements: the valve closing cap (a) (to protect the internal mechanism from dust and guarantee air tightness), an internal mechanism (b) and the base (c) (the outer lining). ProLine 124-221-321-324 Operator manual...
  • Page 76 It is generally used for mounting low profile tyres. Discharge regulator. Union allowing regulation of the air flow. Bead breaking. Operation used to detach the bead from the rim edge. ProLine 124-221-321-324 Operator manual...
  • Page 77 18. GENERAL WIRING DIAGRAM ProLine 124-221-321-324 Operator manual...
  • Page 78 ProLine 124-221-321-324 Operator manual...
  • Page 79 ProLine 124-221-321-324 Operator manual...
  • Page 80 19. PNEUMATIC SYSTEM DIAGRAM ProLine 124-221-321-324 Operator manual...

This manual is also suitable for:

Proline 221Proline 321Proline 324

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