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Hofmann monty 8700 Service Manual

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monty 8800
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Summary of Contents for Hofmann monty 8700

  • Page 1 8700 monty 8800 Service Manual...
  • Page 2 B L A N K P A G E...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS CHAPTER 1 INTRODUCTION ............................. 5 GENERAL ............................... 5 CHAPTER 2 TOOLS AND SAFETY ..........................6 TOOLS AND SPECIAL TOOLS ........................6 IMPORTANT SAFETY INSTRUCTIONS ......................8 ELECTRICAL SAFETY PRECAUTIONS ....................... 8 CHAPTER 3 AC/DC POWER DISTRIBUTION ......................9 LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE................
  • Page 4 8.18 AIR PRESSURE REDUCER: CHECK AND REPLACEMENT ..............109 8.19 KIT BEAD BREAKER DISK: CHECK AND REPLACEMENT..............110 CHAPTER 9 MECHANICAL SECTION ........................113 MECHANICAL SECTION ..........................113 TOOL CARRIAGE: CHECK AND ADJUSTMENT ..................113 TORQUE CONTROL DEVICE: CHECK AND REPLACEMENT ..............114 TOOTHED CURSORS: CHECK AND REPLACEMENT ................

  • Page 5: Chapter 1 Introduction

    CHAPTER 1 INTRODUCTION GENERAL This Service Manual describes maintenance, check and repair operations of the Hofmann Monty 8700 and is for use of qualified and trained personnel only. IMPORTANT! The identification data of each machine are printed on a adhesive label attached to the cabinet of the machines.

  • Page 6: Chapter 2 Tools And Safety

    CHAPTER 2 TOOLS AND SAFETY TOOLS AND SPECIAL TOOLS To repair and/or check this tire changer, the following standard tools are required: Keys : 6mm to 30mm Tube type keys : 7mm to 17mm Allen keys : 2.5 mm to 12 mm Socket keys : 17mm to 24mm Allen socket keys...
  • Page 7 Calibration tool # EAA0382G24A: Use this tool to calibrate the machine. Calibration Tool # EAK0341G12A: Use this tool to calibrate the vertical and horizontal axis of the machine. USB Stick Programmed with Single Tool Tire Changer Firmware # 3-89426AP1: Use this software to: ▪...

  • Page 8: Important Safety Instructions

    Air pressure reducer # EAA0348G92A. Use this reducer to adjust the tools and bead breaker carriages and to check the air pressure reducer of the centerpost torque control device. IMPORTANT SAFETY INSTRUCTIONS The units are CE, CSA or UL approved, but whenever using this equipment basic safety precautions should always be followed, including the following: Read all instructions.

  • Page 9: Chapter 3 Ac/Dc Power Distribution

    CHAPTER 3 AC/DC POWER DISTRIBUTION 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 INVERTER T1 The Electronic Inverter is bolted inside of Electric box in the backside of the machine. On this Inverter runs the firmware 1.8.x because it works with CTS potentiometer. Electronic Inverter principles An inverter is a motor control that adjusts the speed of an AC induction motor. It does this by varying the frequency of the AC power to the motor.

  • Page 12: Digital Input

    The electronic Inverter manages the following functions: Supplies 230VAC / 3 Phases to the centerpost motor M3. Manages the wheel clamping / unclamping of the centerpost Manages the torque and the speed of the centerpost motor. Protection fuse LED POWER SUPPLY INPUT AC2/3 Neutral AC1/2...
  • Page 13 TRANSFORMER T1 It transforms the 200VAC in 230VAC to supply the Inverter. TRANSFORMER T3 It transforms the 230VAC in 40VAC to supply the rectifier bridge. TRANSFORMER T3 It transforms the 208VAC in 40VAC to supply the rectifier bridge for North America.

  • Page 14: Dc Theory Of Operations

    CENTERPOST MOTOR M3 FOR CSA It is 0.75Kw, 3 phase single speed motor and it is supplied by the inverter T1. DC THEORY OF OPERATIONS PROCESSOR BOARD A1 The axis control board A1 is placed inside of the electric box and is supplied at 48VDc from the rectifier bridge. The board contains firmware to manages all functions of the electric and electronic devices.
  • Page 15 POWER SUPPLIES LEDs Relè to enable the 48VDC motors. DIGITAL INPUT JIN1 HOME POWER SUPPLY INPUT JIN2 QUICK MODE +48VDC GROUND JIN3 LOCK JIN4 UNLOCK JIN5 AUTO Capacitor for preloading enabling of relè enabling JIN6 BACKWARD 48VDC motors. JIN7 FORWARD JIN8 Dig_in8 JIN9...

  • Page 16: Diagnostic Leds

    DIAGNOSTIC LEDs The axis control board is equipped with LEDs which allow to check the status of the DC power supply, operation of the DC motors and any possible overload condition on the DC motors: LEDs LEDs DC POWER: To check the status of the DC power supplies, there are 5 as follows: LD1: Represents the presence of mains power of 48VDC from the rectifier bridge.
  • Page 17 TOOL CARRIAGE POTENTIOMETER B3 The tool carriage potentiometer is 10 turns 10K type. It is supplied at 5VDC by the CPU board A1 and controls the vertical position of the tool compared to the rim. TOOL POTENTIOMETER B4 The tool potentiometer is 5 turns 10K type. It is supplied at 5VDC by the CPU board A1 and controls the horizontal position of the tool compared to the rim.

  • Page 18: Solenoid Valve

    TOOL ARM MOTOR B The tool arm motor B is controlled by the axis control board. It is supplied at 48VDC and allows the forward / backward of the tool from the rim. RECTIFIER BRIDGE V1 Rectifier is of 86A type and transforms the 40VAC input into 48VDC output to supply the Motor driver section of the CPU board.

  • Page 19: Perseo: Software Updating And Diagnostic

    When the clamping or unclamping starts, the torque control assy, together with the link, raises due to pneumatic control of the system in order to hold the ring nut to lock or unlock the shaft. Once clamping or unclamping is completed, the ring nut starts the rotation pressing the cursor of the torque control assy.

  • Page 20: Connection Procedure

    CONNECTION PROCEDURE Disconnect the power supply from the machine. Remove the rear cover from the electric box. Connect the USB cable to your Windows PC; Connect the Pin connector to the procesor Board. Turn on the machine. Run PerseoManager.exe application. It must be lunch inside the provided folder, due to dependencies it requires.

  • Page 21: Software Update Procedure

    SOFTWARE UPDATE PROCEDURE Once the PC is connected to the Tyre Changer the following screen is displayed. To check if the Perseo is communicating with the machine, make sure to see PERSEO followed by (ONLINE) on the top left side of the screen (see red arrow). The software running in the machine is displayed in the middle column.
  • Page 22 Click on UPDATE button to start the software update and waiting for it completions DIAGNOSTIC: The PerseoManager software can be use as a tool to have a fast check of the system. The tool can check, for instance, if the potentiometers have been mounted in the right direction or check if the hardware elements works fine, shows statistic information.
  • Page 23 COUNTERS: Click on counters window to show statistic values related to: Number of calibrations procedures. Number of unclamp cycles. Number of invoked automatic (standard) procedures. Number of invoked automatic (custom) procedures. Usage time NOTE: THE COUNTERS CANNOT BE RESET...
  • Page 24 ADJUSTMENT: The adjustments window helps the service techs to check and adjust the potentiometers. The screen shows the nominal voltage range and the voltage range of every potentiometer at which they must be adjusted. Clicking the Update window, the application will show (real time) the voltage values related to all 4 potentiometers used by the tyre changer.
  • Page 25 CALIBRATION TUTORIAL The calibration tutorial allows to the service techs to access to: Tutorial: Calibration tutorial. Parameter setting: This function allows to modify the Offset value of the tool to make a fine alignment of the tool compared to the Bead Breaker discs after the calibration procedure. Clicking on “Parameter setting”...
  • Page 26 In case of incorrect value entering, out of maximum range or wrong steps, the following messages are displayed:...

  • Page 27: Chapter 4 Trouble Shooting Section

    CHAPTER 4 TROUBLE SHOOTING SECTION COMPLAINT 1: Turning the machine on, nothing works Check the power supply at the wall. Check the air pressure. Check the power supply plug e fuses on the wall Check the air lubricator filter. Check the power supply cable Check the main switch of the machine.
  • Page 28 COMPLAINT 6: The lower bead breaker is not synchronized and/or aligned with the upper one and hit the rims or works on the tire sidewall. Check if the worm screw of the lower bead breaker arm has excessive play on the lead nut. Check if the bead breaker disks are fine and not damaged.
  • Page 29 COMPLAINT 13: The MH arm does not have force. Check airline pressure inlet Check the air pressure outlet Check the air filter –lubricator assembly Check the MH cylinder Check the MH valve COMPLAINT 14: The automatic tool does not lift the tire bead. Check airline pressure inlet Check the air pressure outlet Check the air filter –lubricator assembly...
  • Page 30 FAULT 22: The tool carriage descends on its own. Check the cylinder. Check the valve. FAULT 23: The buzzer does not work. Replace the PCB. FAULT 24: The buzzer sounds continuously. Check that none of the potentiometers has a cable shorted to earth. Recalibrate the machine.

  • Page 31: Chapter 5 Calibration Section

    CHAPTER 5 CALIBRATION SECTION AXIS CALIBRATION PRECONDITION: ➢ Tool plastic protection and bead breaker rollers must be in good condition. ➢ Machine must be levelled at 0° +/-1° ➢ Bead breaker disks must be correctly adjusted at 50° /+1. ➢ Mounting dismounting tool must adjusted from 85°...
  • Page 32 WARNING! THE TOOL ROTATES CLOCKWISE TOGETHER WITH THE CENTER POST UNTILL THE CLAMPING PROCESS WILL BE AUTOMATICALLY COMPLETED. ➢ Press and hold “HOME” and “AUTO” buttons at the same time for at least 4” to enter in "Calibration Mode": The machine will emit a beep and the “LOCK / UNLOCK”...
  • Page 33 STEP 3 Move the lower bead breaker arm all way down with the relevant control. Press the horizontal axis joystick to move the bead breaker plastic protection as closest as possible to the cabinet. Then, raise the bead breaker arm and move the upper bead breaker arm (master) by hand. When the two discs are close together, use an electronic inclinometer to equalize the alignment: the inclinometer must show 90 °...
  • Page 34 After having installed the calibrating tool, check the perpendicularity of the instrument itself by using the inclinometer. The inclinometer must show an angle between 89.5 ° and 90 ° (*) PLEASE NOTE: CHECK THE PERPENDICULARITY EVERYWHERE THE INSTRUMENT IS DISASSEMBLED AND REASSEMBLED DURING CALIBRATION STEP 6 Rotate the center post and position the hook of the tool inside...
  • Page 35 STEP 7 Move the mounting / dismounting tool away. Remove the calibration tool and place it into the slot of the long range of the horizontal red calibrator with the joint facing inwards. Repeat the operation of step 6 (*). Press HOME button to confirm STEP 8 Move the mounting / dismounting tool upward to the end of stroke and rotate the center post to move the calibration...
  • Page 36 STEP 10 Position the long range of the horizontal calibration tool in front of the mounting / demounting tool side. Place gently the hook of the mounting / demounting tool on the top of the horizontal calibration tool. Press HOME button to confirm. STEP 11 Move upward the mounting / dismounting tool to the end of stroke.
  • Page 37 Lock the position of the arms using the appropriate command and turn the center post until the front sidewall of the calibrating tool will be in correspondence of the hook. Press HOME key: the hook will start to move automatically towards the calibration tool until it will be aligned to the bead breaker discs.

  • Page 38: Self Learning Procedure Of The Code Sended By The Transmitter

    SELF LEARNING PROCEDURE OF THE CODE SENDED BY THE TRANSMITTER Transmitter board Receiver board PRECONDITION: The self-learning operation of the encrypted code emitted by the transmitter will run with the receiver board powered on (machine turned on). • Remove the plastic cover from the joystick panel. •...
  • Page 39 After the replacement of the boards, it is required to proceede with the self-learning of cryptic code as follows: This procedure is done by pressing and releasing SW2 button on transmitter and SW1 on receiver module. LEDs LD2 on transmitter and LD6 on receiver will blink indicating that the modules automatically search for each other and the administrator send the encryption key.
  • Page 40 The battery must be mounted in one direction only, as per below pictures. Please take good note about this WARNING NOTICE: „BATTERY MAY EXPLODE IF MISTREATED. DO NOT RECHARGE, DISASSEMBLE OR DISPOSE OF IN FIRE“...

  • Page 41: Chapter 6 Electric Section

    CHAPTER 6 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 is VERY IMPORTANT BEFORE STARTING WITH ANY CONTROL AND/OR REPLACEMENT VERIFY IF ALL WIRES AND CONNECTORS ARE WELL FITTED.

  • Page 42: Main Rotary Switch Q1: Check And Replacement

    ▪ Take a multimeter and set it in Ohm ▪ 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: ▪...

  • Page 43: Centerpost Motor Cable: Check And Replacement

    ▪ Turn switch to “Off”. Check that there is no continuity ( =infinity) between any terminals 1,2,3 and 4. ▪ Turn switch to “On”. Check that there is continuity between terminals 1-2 and 3-4 (= 0 ~ 0,3) and discontinuity between terminals 1-3 and 1-4, as well as 2-3 and 2-4 ▪...

  • Page 44: Centerpost Motor And Belt: Check And Replacement

    ▪ Make sure that the wires are connect at triangle on the motor. ▪ Make sure that also the nuts that fix the internal motor wire to the terminal are well tightened at 1.5Nm / 1.1lbs-ft ▪ Remove the motor terminals cover and disconnect the wires on the terminals from Inverter ▪...
  • Page 45 ▪ Check if the belt tension is correct and if it is worn. ▪ Remove the belt from motor and check if gearbox pulley can be rotated easily by hand. ▪ Refer to paragraph 6.1, 6.2 and 6.3 TO CHECK THE CENTERPOST MOTOR WHEN IT IS NOISY: ▪...
  • Page 46 ▪ Remove the two bolts in the bottom to get the motor assembly free. ▪ Remove the pulley set screws. ▪ Remove the pulley by using an extractor tool. ▪ Remove the motor from its support. ▪ Take the new motor. ▪...

  • Page 47: Lower Bead Breaker Arm Motor A: Check And Replacement

    ▪ Unscrew the nut B (to the right), moving the sheet metal C away from the cabinet E, until the sheet metal C pushes on the nut A. ▪ Tighten the nuts with recommended tighten torque of 22,5±2,5Nm – 199inlbs±22inlbs ▪...
  • Page 48 ▪ Open the electric box. ▪ Turn the machine on. MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK ▪ Take the Voltmeter and select it in VDC. ▪ Position the Voltmeter probes on the connector terminals of the motor cable from J3 and J4 of the axis control board inside of electric box. ▪...
  • Page 49 ▪ Move the lower bead breaker arm all inward. ▪ Mount the actuator to the arm unless fixing it. ▪ Move the lower bead breaker arm all out ward. ▪ Take a ruler and align the worm screw to the hex arm by tightening or loosening the actuator fixing screw: use the hex arm edge as reference.

  • Page 50: Tool Arm Motor B: Check And Replacement

    ▪ Turn the machine on and check if it works fine. TOOL ARM MOTOR B: CHECK AND REPLACEMENT  : 1,5h  : 5mm allen key, multimeter.  : Defective motor may cause the following malfunction: 1. The tool arm does not move forward and/or backward. TO CHECK THE MOTOR: ▪...

  • Page 51: Transformer: Check And Replacement

    ▪ Remove the rear screws and the bracket of the protection. ▪ Remove the front screws and the plastic holding the motor to avoid its dropping. ▪ Take the new motor and fix it with front screws unless securing them. ▪...
  • Page 52 TO CHECK THE FUSE: ▪ Disconnect the machine from power supply. ▪ Open the electric box ▪ Pull out the fuse holder by hand from the transformer. ▪ Verify if there is continuity between the ends of the fuse. ▪ If necessary replace it with a new one of the same value.

  • Page 53: Rectifier Bridge: Check And Replacement

    ▪ Check if the machine works fine. RECTIFIER BRIDGE: CHECK AND REPLACEMENT  : 1h  : Voltmeter, small and medium cross screwdrivers, pliers.  : Defective rectifier bridge may cause the following malfunction: 1. Tuning the machine it does not work. 2.
  • Page 54 ▪ Position the black probe alternatively to the other rectifier bridge plug. ▪ Make sure that the Voltmeter will show a value similar to that one in the pictures TO REPLACE THE 86A RECTIFIER BRIDGE ▪ Install the new rectifier bridge to the electric panel. ▪...

  • Page 55: 200Vac-230Vac Transformer T1

    ▪ Turn the machine on. ▪ Check if the machine works fine again. 200VAC-230VAC TRANSFORMER T1  : 1h  : Voltmeter, small and medium cross screwdrivers, pliers.  : Defective transformer may cause the following malfunction: Smoke gets out from the electric box with consequent burning of the transformer. 2.
  • Page 56 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.

  • Page 57: Chapter 7 Electronic Section

    CHAPTER 7 ELECTRONIC SECTION WARNING! BEFORE APPROACHING THE ELECTRONIC PARTS OF THE MACHINE, DISCONNECT THE MACHINE FROM POWER SUPPLY. INVERTER: CHECK AND REPLACEMENT  : 1h  : Voltmeter, small and medium cross screwdrivers, 8mm tube type key, pliers.  : Defective inverter may cause the following malfunction: Centerpost motor does not turn at all.
  • Page 58 b. Pressing the rotational pedal the green led should be OFF. c. Pressing the clamping/unclamping button the green led should remain ON while the orange one should blink: If the led blinks but the ▪ Take the multimeter and select it in VAC up to 400. ▪...
  • Page 59 d. If the turntable rotates counter clockwise, check the 5VDC +/-0.1 potentiometer power supply: Disconnect the potentiometer from the Inverter connector and, if the power supply is below 4.9VDC, replace the Inverter Board. 2. THE CENTERPOST ROTATES ITSELF AFTER RELEASING THE ROTATION PEDAL. a.

  • Page 60: Controller Board A1: Check And Replacement

    d. Make sure that the machine is not plugged together with other electric devices. e. Check if the low torque is in slow speed or second speed. Low torque under load in second speed is not an issue. Check the belt tension. g.
  • Page 61 1. Turning the machine on, nothing works except the pneumatic functions ➢ Check the power supply and the fuses of the wall plug. ➢ Check the power supply cable and plug of the machine 6.1. ➢ Check the main switch of the machine 6.2. ➢...
  • Page 62 ➢ Check the operation of the motors, clicking on <- and ->, and potentiometers with the Perseo Manager. Make sure that the values are within the tolerances reported beside the each box 3.5. ➢ Check the LD2 led on the control board: It represents the presence of transformed 24VDC from the 48VDC by the board itself.
  • Page 63 ➢ Check the operation of the actuator, clicking on <- and ->, with the Perseo Manager 3.5. ➢ Check the wiring of the bead breaker motor 6.5. ➢ Check the bead breaker motor output (J3 and J4) on the axis control board, 3.4 and 6.5. ➢...
  • Page 64 ➢ Check if the bead breaker disks are fine and not damaged 9.7. ➢ Check if the bead breaker disks have excessive play 9.8. ➢ Check the play of the bead breaker carriages 9.11. ➢ Check both potentiometers B1 and B2 with the Perseo Manager 3.5 ➢...
  • Page 65 ➢ Check the tool carriage potentiometer with the Perseo Manager, 3.5, by moving up and down the carriage. ➢ Check the wiring and the potentiometer of the tool carriage potentiometer 7.6 ➢ Check the „AUTO MODE“ button. ➢ Chec the connection oft he „AUTO MODE“ button on JIN5 of digital input on the PCB board ➢...
  • Page 66 ➢ Check the output from J5 and J6 of the PCB, LD8 e LD9 3.4 ➢ Make sure that the hex bar of the tool is moving freely 6.6. ➢ Repace the PCB board.. ➢ Calibrate the machine 5.1. 9. The tool always positions itself in the same position regardless of the bead breaking discs one and, only after switching the machine off and on again, the tool starts positioning itself again, following bead breakers.
  • Page 67 11. The buzzer sounds continuously. ➢ Check if one of the potentiometers has a cable shorted to the ground. ➢ Check the alignment of the bead breaker arms with the perseo Manager 3.5. ➢ Check the potentiometer adjustment 7.4. ➢ Check the LF5 on the PCB 3.4 ➢...

  • Page 68: Bead Breaker Arms Potentiometers B1 And B2: Check And Replacement

    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 ▪...
  • Page 69 ▪ Take the multimeter and select it in Ohm. ▪ Position its terminals on the potentiometer wires blue and brown. ▪ Rotate the potentiometer: the multimeter must display a value from 0.2 to 10 Ohm. ▪ If it does not show that value replace the potentiometer. ▪...

  • Page 70: Procedure To Adjust Bead Breaker Disks Alignment

    ▪ Install the new potentiometer on its holder. ▪ Mount the threaded toothed wheel bushing. ▪ Mount the toothed wheel and lock it with the nut. IMPORTANT! MAKE SURE ABOUT THE POTENTIOMETER ROTATION DIRECTION BECAUSE A WRONG END STROKE DIRECTION WILL CAUSE THE BREAKAGE OF THE POTETIOMETER WHEN WILL ROTATE. TO ADJUST THE POTENTIOMETERS: ▪...

  • Page 71: Tool Potentiometer: Check And Replacement

    Turn the machine on. Move the bead breaker arms to maximum error point. Read the value displayed on the multimeter. Unlock the potentiometer counter nut. Turn the potentiometer with a flat screwdriver subtracting 0,020 Vdc from the value displayed. 10. Lock the counter nut again. 11.

  • Page 72: Tool Carriage Potentiometer: Check And Replacement

    ▪ Disconnect the potentiometer connector and remove the potentiometer from the arm. ▪ Check the potentiometer 7.3. ▪ 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 J14 of the CPU board.

  • Page 73: Turntable Cts Potentiometer: Check And Replacement

    ▪ Remove the potentiometer from the carriage and check it following  7.3. ▪ 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 J15 of the CPU board.
  • Page 74 ▪ Take the cable # EAW0286G14A to inspect the potentiometer: connect one end to potentiometer cable and the second end to the Inverter. ▪ Turn on the machine ▪ Take the multimeter and connect it to the cable # EAW0286G14A: set it in VDC and make sure that value displayed with pedal in rest position is 2,6VDC.
  • Page 75 ▪ Remove the rod from the potentiometer linkage. ▪ Release the set screw that secure the linkage to the potentiometer. ▪ Remove the linkage from the potentiometer. ▪ Loosen the 2 screws to remove the potentiometer assembly. ▪ Install the new potentiometer assembly. Connect the cable.
  • Page 76 ▪ Mount the linkage to the potentiometer. Make sure to bolt the rod to the middle hole on the pedal. ▪ Connect the machine to the power supply and check the if the potentiometer adjustment is 2.6VDC: if it is not correct, loosen the bolt and move up or down the potentiometer until to have reach the correct adjustment.

  • Page 77: Torque Control Proximity: Check And Replacement

    ▪ Loosen the 2 screws to remove the potentiometer assembly. ▪ Install the new potentiometer assembly. Connect the cable. ▪ Mount the control rod. ▪ Connect the machine to the power supply and check the if the potentiometer adjustment is 2.6VDC: if it is not correct, loosen the bolt and move the potentiometer until to have reach the correct adjustment.
  • Page 78 ▪ Remove the plastic protection from the torque control device to access to the switch and the cover from the electric box. ▪ Make sure that the proximity is mechanically fine and the Led on. ▪ Take a multimeter and set in VDC. ▪...

  • Page 79: Solenoid Valve: Check And Replacement

    ▪ If the gap is not correct, loose the fixing nuts and move the proximity until to have reached the correct gap. ▪ Connect the air switch to the extension. ▪ Connect air pressure and power supply. ▪ Check if the machine works fine. ▪...

  • Page 80: Bead Breaker Arms Blocking Solenoid Valve: Check And Replacement

    ▪ Position the multimeter terminals on those ones of the solenoid valve connector. ▪ Turn the clamp/unclamp switch: the motor should run and the multimeter should show 24 to 30VDC. ▪ If the multimeter will not show the power check the the PCB board and the wiring.
  • Page 81 ▪ Disconnect the pipes that go to the cylinders from the solenoid valve: if the cylinders returns to home position means that the solenoid valve is blocked and must be replaced. ▪ Disconnect the plug from the solenoid valve. ▪ Take a multimeter and set in VDC.

  • Page 82: Micro Camera - Lamp Led Assy: Check - Replacement - Setup

    MICRO CAMERA – LAMP LED ASSY: CHECK – REPLACEMENT - SETUP 7.11  : 1h.  : Medium philip and smal flat screwdriver.  : Defective camera can cause the following malfunction: 1. The monitor does not show anything. 2. Images not clear displayed on the monitor. TO CHECK THE MICROCAMERA: ▪...
  • Page 83 ▪ Connect the cables of the camera and of the LED lamp. ▪ Connect the machine to the power supply and to the air pressure and turn it on. MICRO CAMERA SETUP: The micro camera should arrive already configured to provide an analog output signal (as required to work properly with our monitor).
  • Page 84 ▪ Rotate the camera video and LED lamp support so that the camera is positioned towards the lower bead breaker arm (about 30° in relation to the lateral part of the cabinet). ▪ Tighten the screw to keep the unit in position. ▪...
  • Page 85 ATTENTION! Do not go as far as the end stop to avoid stressing the fixings of the video camera. ▪ Move the bead breaker arm fully out and check that the tip of the lower bead breaker disc remains visible in the screen.
  • Page 86 RADIO CONTROL DEVICE: CHECK – REPLACEMENT 7.12  : 1h.  : Medium philip and smal flat screwdriver, 6mm Allen key.  : Defective radio control device can cause the following malfunction: 1. Pressing the button underneath the machine does not start the clamping/unclamping procedure. ▪...
  • Page 87 ▪ Mount the plastic cover to the control panel making sure to do not pinch the antenna cable ▪ Connect the machine to the power supply and air pressure. ▪ Perform the self-learning procedure, par.5.2 ▪ Perform some tire mounting/dismounting operations to ensure that the device is working fine: if the plastic cover should move or pinch the antenna cable, you should see malfunctions of the radio control.

  • Page 88: Chapter 8 Pneumatic Section

    CHAPTER 8 PNEUMATIC SECTION 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 89: Air Filter - Lubricator Assy: Check And Replacement

    8.2 AIR FILTER – LUBRICATOR ASSY: CHECK AND REPLACEMENT  : 30’  : Allen key 3mm, medium standard screwdriver.  : Defective air filter lubricator assembly may cause the following malfunction: 1. Air leaking. 2. Oil leaking. 3. Incorrect air lubrication. 4.

  • Page 90: Bead Breaker Cylinders: Check And Replacement

    TO CHECK THE AIR LUBRICATION: ▪ Move up and down one of the bead breaker cylinder ‘tlil end of stoke and make sure, looking from the top transparent cap, that lubricator supplies one drop of oil every complete cycle of the cylinder. TO ADJUST THE AIR LUBRICATION: ▪...
  • Page 91 TO CHECK THE CYLINDER : ▪ 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 cylinder is leaking air. ▪...

  • Page 92: Bead Breaker Cylinders And Disks Valves: Check And Replacement

    ▪ Secure the cylinder to the cabinet with the bolt. ▪ Connect the air pipes. ▪ Plug the machine to the air pressure and to power supply. ▪ Connect the cylinder to the bead breaker carriage. ▪ Remove the cord. ▪...

  • Page 93: Bead Breaker Arms Blocking Cylinder: Check And Replacement

    BEAD BREAKER ARMS BLOCKING CYLINDER: 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.
  • Page 94 ▪ Remove the upper adjustment screws and the two screws with springs. ▪ 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. ▪...

  • Page 95: Wheel Lift Cylinder: Check And Replacement

    ▪ 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. ▪...
  • Page 96 ▪ Disconnect the air pipe where there is not any air pressure. ▪ If the air is getting out from the fitting, the lift cylinder is leaking air. ▪ If the air is getting out from the fitting, the control valve is leaking air. TO REPLACE THE CYLINDER: ▪...

  • Page 97: Wheel Lift Valve : Check And Replacement

    ▪ Remove the screw from lift 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. ▪...

  • Page 98: Mh Cylinder: Check And Replacement

    ▪ Remove the connecting rod and the unscrew the bolts to release the valve from the support. ▪ Unplug the air pipes from the valve. ▪ Plug the air pipes to the valve. ▪ Bolt the valve to the support. ▪...

  • Page 99: Mh Cylinder Control Valve: Check And Replacement

    TO REPLACE THE CYLINDER: ▪ Disconnect ait pressure from the machine ▪ Unplug the air hoses from the cylinder. ▪ Remove the bead depressor. ▪ Loosen the four screws and remove the cylinder. ▪ Take the cylinder lock it to the MH arm. ▪...

  • Page 100: Bead Inflating Valve: Check And Replacement

    8.10 BEAD INFLATING VALVE: CHECK AND REPLACEMENT  : 1h  : Allen key 4 and 5mm, 8,10 and 13mm key.  : Defective inflation spool valve may cause the following malfunction: Air leaking. No inflating action. Air leaking from the blaster jet. TO DISMOUNT THE FOOT PEDAL ASSY ON CSA VERSION: ▪...
  • Page 101 TO CHECK THE SPOOL VALVE: ▪ Open the foot pedal assembly following paragraph 7.7. ▪ 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. ▪...
  • Page 102 ▪ Turn the nuts to set the clearance at about 5mm between the nut and the bracket. ▪ Lock the counter nut. ▪ Release the pedal. ▪ Now turn the linkage and the nut to set the clearance at about 8/9mm between the two nuts.

  • Page 103: Bead Blaster Valve And Air Tank : Check And Replacement

    8.11 BEAD BLASTER VALVE AND AIR TANK : CHECK AND REPLACEMENT  : 1h  : End key 12mm, big pliers.  : Defective bead blaster valve may cause the following malfunction: No air from air jet. Air leaking from diaphragm. TO CHECK THE BEAD BLASTER VALVE: ▪...
  • Page 104  : Defective manometer may cause the following malfunction: 1. The manometer is not accurate. 2. The manometer does not return to zero. 3. The manometer is blocked. TO CHECK THE MANOMETER ▪ The accuracy of the manometer is: UP TO 4 BAR : ±...

  • Page 105: Tool Carriage Cylinder: Check And Replacement

    ▪ 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 sintered air filter absorber. ▪...

  • Page 106: Bead Breaker Cylinder Control Valve: Check And Replacement

    ▪ Disconnect the pipe with air pressure from the valve. ▪ Press the valve button and check if air pressure is coming out from the valve: if there is not air flow, replace the valve. ▪ If the air pressure is coming out from the pipe, the bead breaker cylinder valve is defective, 8.17. 8.16 BEAD BREAKER CYLINDER CONTROL VALVE: CHECK AND REPLACEMENT ...
  • Page 107  : 3h  : 8mm tube type, 10,14, 27, 32mm wrench, 5 and 12mm allen key, seeger pliers  : Defective bead breaker cylinder may cause the following malfunction: 1. Air leaking from the cylinder. 2. Air leaking from the control valve. 3.
  • Page 108 ▪ Remove the foot pedal assembly and the bead breaker pad. ▪ Remove the spring from the bead breaker arm. ▪ Remove the screws that secure the bead breaker cylinder to the support. ▪ Loosen all screws that secure the bead breaker support to the cabinet. BE CAREFUL! THE SUPPORT IS HEAVY AND IT COULD CRUNCH A HAND.

  • Page 109: Air Pressure Reducer: Check And Replacement

    ▪ Take out the cylinder from the cabinet and disconnect the air pipes. ▪ Take the new cylinder and install the washers on the piston rod and grease the brackets for the securing screws. ▪ Mount the bead breaker cylinder following in opposite way the dismounting procedure. ▪...

  • Page 110: Kit Bead Breaker Disk: Check And Replacement

    ▪ Turn the knob of air pressure reducer clockwise 'till end of stroke. ▪ Connect air pressure to the machine ▪ Press and hold the clamping pedal and check the pressure on the manometer of the reducer: it must 7 bar / 101.5 psi.
  • Page 111 ▪ Check if the cylinder shows external air leakage. ▪ Position the cylinder where it is leaking air. ▪ Check if the leakage is in between of cylinder and flanges or if is from the piston rod. ▪ In case of need, position a solution of soap/water on the interested part to have a better view about the leakage.
  • Page 112 ▪ Slide out the joint. ▪ Remove the 4 screws and slide out the cylinder from the holder. ▪ Install the new cylinder by fixing it to the bead breaker arm holder with the 4 screws. ▪ Tighten the joint with Loctite on the screw. ▪...

  • Page 113: Chapter 9 Mechanical Section

    CHAPTER 9 MECHANICAL SECTION 9.0 MECHANICAL SECTION The mechanical section is connected to the centerpost, the carriage 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.

  • Page 114: Torque Control Device: Check And Replacement

    9.2 TORQUE CONTROL DEVICE: CHECK AND REPLACEMENT  : 1h  : 13mm, 6 and 4mm allen keys.  : Defective torque control device assembly may cause the following malfunctions: 1. The center post does not clamp / unclamp the wheels. TO CHECK THE TORQUE CONTROL DEVICE ▪...
  • Page 115 ▪ Remove the plate that drive the switch. ▪ Remove the screws that secure the device to the center post. ▪ Pull off the holder. ▪ Slide off the device from the center post. ▪ Take the new torque control device and grease it. ▪...

  • Page 116: Toothed Cursors: Check And Replacement

    9.3 TOOTHED CURSORS: CHECK AND REPLACEMENT  : 2h  : 13mm, 6 and 4mm allen keys.  : Defective toothed cursors may cause the following malfunctions: 1. The center post does not clamp/unclamp the wheels. TO CHECK THE CURSORS ▪...

  • Page 117: Rubber Washer Absorber: Check And Replacement

    ▪ Install the new cursors on the center post and hold them in place with the dedicated tool. ▪ Mount the flange keeping in place the cursors. ▪ Mount and secure the driving arms. ▪ Connect the air pressure and power supply to the machine. ▪...
  • Page 118 ▪ Unscrew the ring nut. ▪ Remove the broken washer and install the new one. ▪ Lubricate the rubber washer with grease. ▪ Tighten the ring nut. Make sure to keep the stopper hooks to the top side. ▪ Mount the anti-rotational key with machined side oriented downward. ▪...

  • Page 119: Gear Box: Check And Replacement

    9.5 GEAR BOX: CHECK AND REPLACEMENT  : 2h  : Wrenches of 8,17,19mm, Seeger pliers, hammer.  : Incorrect gearbox may cause the following malfunctions: 1. Noisy rotation. 2. Low rotation torque. 3. Oil leaking. TO CHECK GEARBOX: ▪ Disconnect the machine from the power supply.

  • Page 120: Bead Breaker Disks: Check And Replacement

    ▪ Remove the remaining two screws and nuts to complete the gear box dismounting. BE CAREFUL! THE GEARBOX IS HEAVY AND IT COULD CRUNCH A HAND. ▪ Remove the pulley and the compensating ring from the defective gearbox and install them on the new one. ▪...

  • Page 121: Bead Breaker Disc Bearing: Check And Replacement

    ▪ Remove the defective disc. ▪ Install the new disc and secure it with the screws and Loctite. ▪ Perform the bead breaker discs alignment calibration following chapter 5. 9.7 BEAD BREAKER DISC BEARING: CHECK AND REPLACEMENT  : 30’ Each one ...

  • Page 122: Bead Breaker Discs Inclination Adjustment

    ▪ 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). ▪ Turn the machine on and check if it works fine 9.8 BEAD BREAKER DISCS INCLINATION ADJUSTMENT ...
  • Page 123 ▪ Leave the bead breaker disc in rest position. ▪ Remove the set screws from the upper bead breaker holder. ▪ Addition Loctite n°243 to one setscrew and tighten it to the hole dedicated to the disk adjustment in rest position (upper hole). ▪...
  • Page 124 ADJUSTMENT OF THE LOWER BEAD BREAKER DISK INCLINATION: ▪ Leave the bead breaker disc in rest position. ▪ Remove the counter and set screws from the lower bead breaker holder. ▪ Addition Loctite n°243 to one setscrew and tighten it to the lower hole of the bead breaker holder.
  • Page 125 ▪ To adjust the inclination of the disk in rest position, rotate the upper setscrew: rotating counter clockwise the inclination will decrease while it will increase rotating clockwise. Rotate the setscrew until to the disk at an inclination of >50°. ▪...

  • Page 126: Bead Breaker Discs Clearance: Check And Adjustment

    9.9 BEAD BREAKER 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.
  • Page 127 TO CHECK AND ADJUST THE UPPER BEAD BREAKER AMR BLOCKING CYLINDER: ▪ 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 ▪...

  • Page 128: Bead Breaker Carriage: Check And Adjustment

    9.10 BEAD BREAKER CARRIAGE: CHECK AND ADJUSTMENT  : 30’ each one  : Allen keys 4, 5 and 6mm, 8 and 17mm end keys, 13mm tube type key.  : Incorrect bead breaker carriage adjustment may cause the following malfunctions: 1.

  • Page 129: Manual Wheel Releasing

    TO REPLACE THE LEAD NUT: ▪ Remove the actuator worm screw from the lead nut following the par.6.5. ▪ Unscrew the lead nut from the holder. ▪ Mount the new nut and secure it with Loctite. ▪ Mount the actuator following par.5.5. ▪...
  • Page 130 ▪ Rotate the rod (A) counter clockwise to unscrew the knob completely. ▪ Remove the flange followed by the wheel. The shaft will remain on the centerpost. ▪ Remove the plastic protection around the centerpost ring nut. ▪ Unscrew the ring nut to make the shaft free and remove it. ▪...
  • Page 131 ▪ Tighten the nut (2) firmly with the wrench (B). ▪ Connect the machine to power supply and to air pressure. ▪ Turn on the machine and check if it works fine. MANUAL RELEASING OF THE STANDARD DEVICE Tools required: Tyre lever (A) 12mm diameter rod (B) ▪...
  • Page 132 ▪ Unscrew the knob and flange (E and D,Fig.5)and remove them. Apply some tape (Fig.6) to the knob to protect it from damage in the event of excessive force. ▪ Remove the flange (Fig.7) and then take the wheel off the unit. The shaft (7) remains on the centerpost. ▪...
  • Page 134 UPDATING GUIDE REVISION L January 2024 Chapter 8.12 : Updated text and pictures Pag. AUTHOR: Stefano Muzzioli...
  • Page 135 B L A N K P A G E...
  • Page 136 Notice : The information contained in this document is subject to change without notice. Hofmann makes no warranty with regard to present documentation. Hofmann shall not be liable for errors contained here- in or for incidental consequential damages in connection with furnishings, performance, or use of this material.

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