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INSTRUCTION, USE AND
MAINTENANCE MANUAL
Page 2 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
SUMMARY
SYMBOLS USED IN THE MANUAL
AND ON THE MACHINE _________________ 6
1.0 GENERAL INTRODUCTION ________ 8
2.0 INTENDED USE____________________ 8
2.1 Training of personnel __________________8
3.0 SAFETY DEVICES _________________ 8
3.1 Residual risks __________________________9
4.0 GENERAL SAFETY RULES_________ 9
5.0 PACKING AND MOBILIZATION
FOR TRANSPORT _________________10
6.0 UNPACKING ______________________ 10
7.0 MOBILIZATION ___________________ 1 1
8.0 WORKING ENVIRONMENT
CONDITIONS _____________________ 11
8.1 Work position ________________________ 11
8.2 Installation space ____________________ 11
8.3 Lighting _____________________________ 12
9.0 ANCHORING SYSTEM ____________ 12
10.0 ASSEMBLY AND PREPARATION
FOR USE __________________________ 12
10.1 Assembly procedure __________________ 12
10.2 Electrical connection ________________ 14
10.3 Controls _____________________________ 15
11.0 CONTROLS _______________________ 15
11.1 4 pedal control unit __________________ 15
11.2 Inflation pedal (on demand) __________ 16
11.3 Column handle _______________________ 16
12.0 USING THE MACHINE ____________ 17
12.1 Precaution measures during tyre
removal and fitting __________________ 17
12.2 Preliminary operations - Preparing
the wheel ____________________________ 17
12.3 Bead breaking _______________________ 17
12.3.1 Bead breaking tool with double
joint (on demand) _______________ 18
12.4 Clamping the wheel on
18” - 20” - 22” - 24” - 26” - 28” chuck _ 18
12.5 Clamping the wheel on 30” chuck _____ 18
12.6 Demounting the tyre _________________ 19
12.7 Mounting the tyre ____________________ 19
12.9 Tubeless tyre inflation device_________ 20
12.8 Tyre inflation with pressure gauge
(on demand) _________________________ 20
13.0 ROUTINE MAINTENANCE_________ 20
13.1 Lubricants ___________________________ 21
14.0 TROUBLESHOOTING _____________ 22
15.0 TECHNICAL DATA ________________ 23
15.1 G8641V technical data ________________ 23
15.2 G8641D technical data _______________ 23
15.3 G8645V technical data ________________ 23
15.4 G8645D technical data ________________ 23
15.5 Dimensions __________________________ 25
16.0 STORING _________________________ 27
17.0 SCRAPPING _______________________ 27
17.1 Instructions for the correct
management of waste from electric and
electronic equipment (in italian RAEE)
according to legislative decree 151/05 27
18.0 REGISTRATION PLATE DATA _____ 27
19.0 FUNCTIONAL DIAGRAMS_________ 27
Drawings A - Pneumatic circuit of automatic
machine _____________________ 28
Drawings B - Pneumatic circuit of automatic
machine (I) __________________ 30
Drawings C - Pneumatic circuit of automatic
machine (IT) _________________ 32
20.0 LIST OF COMPONENTS
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
KEY
1 – Column
2 – Machine body
3 – Inflation unit (on demand)
4 – Pedal control unit
5 – Bead breaker unit
6 – Complete turntable (10”-18”, 10”-24”)
7 – Complete turntable (10”-20”, 11”-22”)
8 – Lever handling cylinder
9 – Mounting/demounting lever
KEY
1 – Column
2 – Machine body
3 – Inflation unit
4 – Pedal control unit
5 – Bead breaker unit
6 – Complete turntable (10”-24”)
7 – Complete turntable (10”-20”, 11”-22”)
8 – Tank
9 – Lever handling cylinder
10 – Mounting/demounting lever
FIG. 1 - G8641D.XX - G8641V.XX
FIG. 2 - G8641ID.XX - G8641IV.XX
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
KEY
1 – Column
2 – Machine body
3 – Inflation unit (on demand)
4 – Pedal control unit
5 – Bead breaker unit
6 – Complete turntable (10”-18”, 10”-
26”)
7 – Complete turntable (8”- 30”)
8 – Complete turntable (10”-20”, 11”-
22”)
9 – Complete turntable (10”-28”)
10 – Lever handling cylinder
11 – Mounting/demounting lever
KEY
1 – Column
2 – Machine body
3 – Inflation unit
4 – Pedal control unit
5 – Bead breaker unit
6 – Complete turntable (10”-26”)
7 – Complete turntable (10”-28”)
8 – Tank
9 – Complete turntable (10”-20”, 11”-
22”)
10 – Lever handling cylinder
11 – Mounting/demounting lever
FIG. 3 - G8645D.XX - G8645V.XX
FIG. 4 - G8645ID.XX - G8645IV.XX
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
KEY
1 – Column
2 – Machine body
3 – Inflation unit
4 – Pedal control unit
5 – Bead breaker unit
6 – Complete turntable (8”-30”)
7 – Tank
8 – Gonfiatubeless gun
9 – Lever handling cylinder
10 – Mounting/demounting lever
FIG. 5 - G8645ITD.30 - G8645ITV.30
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
2167000
2167000
99990758
4244000
2168000
710211210
2166000
1541000
2170000
3691000
SYMBOLS USED IN THE MANUAL AND ON THE MACHINE
Read instruction manual.
FORBIDDEN!
Wear work gloves.
Wear work shoes.
Wear safety earcaps.
Shock hazard.
Danger! Be particulary careful.
Move with fork lift truck or
transpallet.
Lift from above.
Burst danger.
Mandril rotation direction.
Wear safety goggles.
Danger! Moving mechanical parts.
Caution: hanging loads.
Mandatory. Operations or jobs to
be performed compulsorily
Bead breaker hand danger.
General danger.
Max inflation pressure rating.
Inflation pedal.
Technical assistance necessary.
Do not perform any intervention.
Symbols Description
Symbols Description
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INSTRUCTION, USE AND
MAINTENANCE MANUAL
Page 7 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
INFORMATION PLATE LOCATION TABLE
Code numbers of plates
4-pedal symbols plate
Rotation direction indicating plate
Electricity danger plate
Protection device use plate
Bead breaker hazard plate
Head danger indicating plate
Unit move indicating plate
Headphones plate
Bursting tyre hazard plate
Inflation instructions indicating plate
Short instruction indicating plate
Pedal plate
Tilting pile plate
Serial number plate
B2661000
B4219000
99990758
999910050
999910060
999910070
999911770
999911870
999911890
999912050
999912830
999913060
999913280
999915200
IF ONE OR MORE PLATES ON THE MACHINE ARE LOST OR BECOME ILLEGIBLE, THEY
MUST BE REPLACED, STATING THE RELATIVE CODE NUMBER WHEN ORDERING THE
REPLACEMENT.
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INSTRUCTION, USE AND
MAINTENANCE MANUAL
Page 8 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
1.0 GENERAL INTRODUCTION
This manual is an integral part of the product and
must be retained for the whole operating life of the
machine.
Carefully study the warnings and instructions contained
in this manual. It contains important instructions regarding FUNCTIONING, SAFE USE and MAINTE-
NANCE.
3.0 SAFETY DEVICES
All the machines are equipped with:
• Fixed guards.
The machine is fitted with a number of fixed guards
intended to prevent potential crushing, cutting and
compression risks.
• Non-adjustable (balancing valve) pressure limiter.
This allows inflation of tyres in reasonable safety. Inflation of tyres to over 4,2 ± 0,2 bar (60 PSI) is not
allowed.
2.1 Training of personnel
The machine may be operated only by suitably trained
and authorized personnel.
Given the complexity of the operations necessary to
manage the machine and carry out the operations safely
and efficiently, the personnel must be trained in such a
way that they learn all the information necessary to operate the machine as intended by the manufacturer.
A CAREFUL READING OF THIS INSTRUCTION MANUAL FOR USE AND
MAINTENANCE AND A SHORT PERIOD OF TRAINING WITH SKILLED
PERSONNEL CAN BE AN ENOUGH
PREVENTIVE PREPARATION.
KEEP THE MANUAL IN A KNOWN,
EASILY ACCESSIBLE PLACE FOR
ALL OPERATORS TO CONSULT IT
WHENEVER IN DOUBT.
THE MANUFACTURER DISCLAIMS
ALL RESPONSIBILITY FOR ANY
DAMAGE OCCURRED WHEN THE
INDICATIONS GIVEN IN THIS
MANUAL ARE NOT RESPECTED: AS
A MATTER OF FACT, THE NON-COMPLIANCE WITH SUCH INDICATIONS
MIGHT LEAD TO EVEN SERIOUS
DANGERS.
THIS ACCESSORY MUST ONLY BE
USED FOR THE PURPOSE FOR
WHICH IT IS SPECIFICALLY DESIGNED.
ANY OTHER USE IS CONSIDERED
IMPROPER AND THEREFORE UNACCEPTABLE.
THE MANUFACTURER CANNOT BE
HELD RESPONSIBLE FOR ANY DAMAGE CAUSED BY IMPROPER, ERRONEOUS, OR UNACCEPTABLE USE.
AN INTENSIVE USE OF THE EQUIPMENT IN INDUSTRIAL ENVIRONMENT IS NOT RECOMMENDED.
2.0 INTENDED USE
“G8641 - G8645” model machines and relevant ver-
sions are car tyre changers intended for use solely for
mounting, demounting and inflating wheels having
max. diameter (41”) 45” and width max 16”.
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
• The machine handles and operating grips must be
kept clean and free from oil.
• The workshop must be kept clean, dry and not exposed to atmospheric agents. Make sure that the working premises are properly lit.
The machine can be operated by a single operator. Unauthorised personnel must remain outside the working area, as shown in Fig. 8. Avoid any hazardous situ-
ations.
Do not use air-operated or electrical equipment when
the shop is damp or the floor slippery and do not expose such tools to atmospheric agents
• During inflation do not lean on the tyre or remain above
it. When beading in the tyre, keep hands away from
tyre and the rim flange.
• During inflation always stay to the side of the machine
and never in front of it.
• When operating and servicing this machine, carefully
follow all applicable safety and accident-prevention
precautions. The machine must not be operated by
professionally unskilled persons.
IN CASE OF A CHANCE SUPPLY
FAILURE MOVE THE CONTROLS TO
THE NEUTRAL POSITION.
3.1 Residual risks
The machine was subjected to a complete analysis of
risks according to reference standard EN 1050.
Risks are as reduced as possible in relation with technology and product functionality.
This manual stresses possible residual risks, also
higlighted in pictograms and adhesive warning signals
placed on the machine: their location is represented in
“PLATE LOCATION ON MACHINE INFORMATION TABLE” on page 7.
4.0 GENERAL SAFETY RULES
• Any tampering with or modification to the machine
not previously authorized by the manufacturer exempts
the latter from all responsibility for damage caused by
or derived from said actions.
• Removing of or tampering with the safety devices or
with the warning signals placed on the machine leads
to serious dangers and represents a transgression of
European safety rules.
• The machine may be used only in areas free from the
danger of explosion or fire.
• The use of only original accessories and spare parts is
advised. Our machine is designed to function only with
original accessories.
• Installation must be conducted only by qualified personnel exactly according to the instructions that are
given below.
• Ensure that there are no dangerous situations during
the machine operating manoeuvres. Immediately stop
the machine if it mis-functions and contact the assistance service of an authorized dealer.
• In emergency situations and before carrying out any
maintenance or repairs, disconnect all supplies to the
machine by using the main switch.
• Ensure that the work area around the machine is free
of potentially dangerous objects and that there is no
oil since this could damage the tyres. Oil on the floor
is also a potential danger for the operator.
OPERATORS MUST WEAR SUITABLE WORK CLOTHES, PROTECTIVE GLASSES AND GLOVES,
AGAINST THE DANGER FROM THE
SPRAYING OF DANGEROUS DUST,
AND POSSIBLY LOWER BACK SUPPORTS FOR THE LIFTING OF
HEAVY PARTS. DANGLING OBJECTS LIKE BRACELETS MUST
NOT BE WORN, AND LONG HAIR
MUST BE TIED UP. FOOTWEAR
SHOULD BE ADEQUATE FOR THE
TYPE OF OPERATIONS TO BE CARRIED OUT.
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
Fig. 6
5.0 PACKING AND MOBILIZATION FOR
TRANSPORT
HAVE THE MACHINE HANDLED BY SKILLED
PERSONNEL ONLY. THE LIFTING EQUIPMENT
MUST WITHSTAND A MINIMUM RATED LOAD
EQUAL TO THE WEIGHT OF THE PACKED MACHINE.
The machine is packed in a carton box which size is
mm 1180x1150x1130.
Movement must be by pallet-lift or fork-lift trolley. The
fork lifting points are indicated on the packing.
6.0 UNPACKING
The cardboard box is supported with plastic strapping.
Cut the strapping with suitable scissors.
Use a small knife to cut along the lateral axis of the box
and open it like a fan.
It is also possible to un-nail the cardboard box from the
pallet it is fixed to.
After removing the packing, and in the case of the machine packed fully assembled, check that the machine is
complete and that there is no visible damage.
If in doubt do not use the machine and refer to professionally qualified personnel (to the seller).
The packing (plastic bags, expanded polystyrene, nails,
screws, timber, etc.) should not be left within reach of
children since it is potentially dangerous.
These materials should be deposited in the relevant collection points if they are pollutants or non biodegradable.
WHEN UNPACKING THE MACHINE,
ALWAYS WEAR GLOVES TO PREVENT SCRATCHES AND CUTS
CAUSED BY CONTACT WITH PACKING MATERIAL (NAILS, ETC...).
THE BOX CONTAINING THE ACCESSORIES IS CONTAINED IN THE
WRAPPING. DO NOT THROW IT
AWAY WITH THE PACKING.
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
7.0 MOBILIZATION
If the machine has to be moved from its normal work
post, the movement must be conducted following the
instructions listed below.
• Protect the exposed corners with suitable material
(Pluribol/cardboard).
• Do not use metallic cables for lifting.
• Sling with belts long at least 100 cm and with a capacity load greater than 1000 kg (see Fig. 7).
THE LIFTING EQUIPMENT MUST WITHSTAND
A MINIMUM RATED LOAD EQUAL TO THE
WEIGHT OF THE MACHINE (SEE PARAGRAPH
TECHNICAL SPECIFICATIONS). DO NOT ALLOW
THE LIFTED MACHINE TO SWING.
Fig. 7
Fig. 8
8.0 WORKING ENVIRONMENT CONDITIONS
The machine must be operated under proper conditions
as follows:
• temperature: 0° +55° C
• relative humidity: 30 - 95% (dew-free)
• atmospheric pressure: 860 - 1060 hPa (mbar).
The use of the machine in ambient conditions other than
those specified above is only allowed after prior agreement with and approval of the manufacturer.
8.1 Work position
Fig. 8 show work positions A and B.
Position A is the main positions for wheel fitting and
removal with the chucking table, while position B is ideal
to follow tyre inflation operations.
Working in these positions allows better precision and
speed during operating phases as well as greater safety
for the operator.
8.2 Installation space
INSTALL THE MACHINE INDOORS OR IN A
ROOFED AREA. PLACE OF INSTALLATION
MUST BE DRY, ADEQUATELY LIT AND IN COMPLIANCE WITH APPLICABLE SAFETY REGULATIONS.
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RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
2. Connect the flexible pipes (Fig. 11 pos. 1)
preassembled on the mandrel rotary distributor (Fig.
11 pos. 2), on the valve (Fig. 11 pos. 4) hosenipple
(Fig. 11 pos. 3). Fasten the pipes (Fig. 11 pos. 1)
with the prepared clamps (Fig. 11 pos. 5)
3. Connect the pipe (Fig. 11 pos. 14) from the greaser
reduction gear filter (Fig. 11 pos. 7)(air not lubricated) to the compensation balancing valve (Fig. 11
pos. 15).
4. Connect the pipe (Fig. 11 pos. 11) from the pedal
board lower valve (Fig. 11 pos. 12) to the blow valve
(Fig. 11 pos. 4) union (Fig. 11 pos. 13).
5. Connect the pipe (Fig. 11 pos. 6) to the T coupling
(Fig. 11 pos. 8) and the coupling (Fig. 11 pos. 16)
placed on the tank (Fig. 11 pos. 9).
6. Connect the pipe (Fig. 11 pos. 18) from the blowing
unit (Fig. 11 pos. 17) to the pedal board (Fig. 11
pos. 12) upper union (Fig. 11 pos. 10).
10.0 ASSEMBLY AND PREPARATION
FOR USE
After having freed the various components from the packing check that they are complete, and that there are no
anomalies, then comply with the following instructions
for the assembly of the components making use of the
attached series of illustrations.
10.1 Assembly procedure
Remove the packaging and free the machine from the
wrapping. Lift the machine and position it on the floor.
The location of the machine requires a usable space of
3450x2500, mm (as indicated in Fig. 8).
The positioning of the machine must be according to the
distances shown. From the control position the operator is able to observe all the machine and surrounding
area. He must prevent unauthorized personnel or objects that could be dangerous from entering the area.
The machine must be fixed on a flat floor surface, preferably of cement or tiled.
Avoid un-solid or irregular surfaces.
The base floor must be able to support the loads transmitted during operation.
This surface must have a strength of at least 500 kg/m2.
The thickness of the solid floor must be sufficient to
guarantee that the anchoring bolts hold.
8.3 Lighting
The machine does not require its own lighting for normal working operations.
However, it must be placed in an adequately lit environment.
For correct lighting, use lamps having total power 800/
1200 Watt as envisaged by UNI 10380.
9.0 ANCHORING SYSTEM
The packed machine is fixed to a pallet by support feet.
Such feet also fix the machine to the ground through
anchor small blocks as shown in Fig. 9.
The holes in the solid floor must be about 10 cm deep
with a diameter of 8 mm.
The bolts (Fig. 9 pos. 1) must be inserted in the holes
and fully tightened.
Fig. 9
a=762 mm
b=410 mm
c=525 mm
Fig. 10
Only for I version
1. Mount the tank (Fig. 10 pos. 1) on the base lower
part, as shown in picture 10, using the screws (Fig.
10 pos. 2) (tightening torque approx. 8 N·m), the
washers (Fig. 10 pos. 3) and the nuts (Fig. 10 pos.
4).
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RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
Fig. 12
2. Connect the pipe (Fig. 13 pos. 14) from the greaser
reduction gear filter (Fig. 13 pos. 7)(air not lubricated) to the compensation balancing valve (Fig. 13
pos. 5).
3. Connect the pipe (Fig. 13 pos. 11) from the pedal
board lower valve (Fig. 13 pos. 12) to the blow valve
(Fig. 13 pos. 4) union (Fig. 13 pos. 13).
4. Connect the pipe (Fig. 13 pos. 6) to the coupling (Fig.
13 pos. 3) placed on the tank (Fig. 13 pos. 9).
5. Connect the pipe (Fig. 13 pos. 2) from the blowing
unit (Fig. 13 pos. 1) to the pedal board (Fig. 13 pos.
12) upper union (Fig. 13 pos. 10).
Fig. 11
Only for IT version
1. Mount the tank (Fig. 12 pos. 1) on the base lower
part, as shown in picture 12, using the screws (Fig.
12 pos. 2) (tightening torque approx. 8 N·m), the
washers (Fig. 12 pos. 3) and the nuts (Fig. 12 pos.
4).
Fig. 13
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
10.2 Electrical connection
EVEN THE TINIEST PROCEDURE OF
AN ELECTRICAL NATURE MUST BE
CARRIED OUT BY PROFESSIONALLY QUALIFIED STAFF.
Fig. 14
Connect the net pneumatic supply to the coupling (Fig.
14 pos. 1) placed on the machine filter unit.
The pressure line leading from the compressed air supply system must have gauge 1/4x10 (Fig. 14-15 pos. 2).
The filter unit is already mounted on the machine.
Fig. 15
As envisaged by the regulations in force, the machine is
not equipped with a master circuit breaker, but simply
has a plug-socket connection to the electrical mains.
The machine is supplied with 3 mt. of free cable. A plug
corresponding to the following requirements must be
connected to the cable:
• Conformity to Norm IEC 309
• 230/400 Volt – 16A
• 3P + Ground
• IP 44
BEFORE CONNECTING THE MACHINE:
• MAKE SURE THAT THE POWER
MAINS RATING CORRESPONDS
TO THE MACHINE RATING AS
SHOWN ON THE MACHINE
PLATE;
• CHECK THAT ALL POWER MAINS
COMPONENTS ARE IN GOOD CONDITION;
• CHECK THAT THE ELECTRICAL
SYSTEM IS PROPERLY
GROUNDED (EARTH WIRE MUST
BE THE SAME CROSS-SECTION
AREA AS THE LARGEST POWER
SUPPLY CABLES OR GREATER);
• MAKE SURE THAT THE ELECTRICAL SYSTEM FEATURES A CUTOUT WITH DIFFERENTIAL PROTECTION SET AT 30 MA.
Only for I and IT version
Connect the net pneumatic supply to the coupling (Fig.
15 pos. 1) placed on the machine filter unit.
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
Fig. 16
FAILURE TO OBSERVE THE ABOVE
INSTRUCTIONS WILL IMMEDIATELY
INVALIDATE THE WARRANTY.
10.3 Controls
11.0 CONTROLS
The pedal control unit comprises 4 (four) pedals.
11.1 4 pedal control unit
“Pedal 1” on this pedal unit operates the automatic col-
umn and has two stable operating positions:
the first (pedal up) tilts the column away from the operator; the second (pedal down) returns the column to
the working position.
“Pedal 2” opens and closes the turntable clamps. It has
three stable positions: open – close – approach clamps.
“Pedal 3” controls the bead breaker cylinder/shoe and
has 2 stable positions.
“Pedal 4” controls turntable rotation and has 3 stable
positions:
1. 0 position, turntable stopped;
2. Pressed down, the turntable is rotated clockwise;
3. Raised, the turntable is rotated anti-clockwise.
ONLY FOR VERSIONS WITH MOTOR
3PH, 230/400V – 50 HZ 2 SPEED
“Pedal 4” controls turntable rotation and has 3 stable
positions:
1. 0 position, turntable stopped;
2. Position 1 to the bottom – clockwise rotation of the
plate;
3. Position 2 to the bottom from position 1 – clockwise
rotation of the plate at double speed;
4. Position 1 to the top – anticlockwise rotation of the
plate.
FIT A TYPE-APPROVED PLUG TO
THE MACHINE CABLE (THE EARTH
WIRE IS YELLOW/GREEN AND
MUST NEVER BE CONNECTED TO
THE PHASE LEADS). MAKE SURE
THAT THE ELECTRICAL SYSTEM IS
COMPATIBLE WITH THE RATED
POWER ABSORPTION SPECIFIED IN
THIS MANUAL AND APT TO ENSURE THAT VOLTAGE DROP UNDER FULL LOAD WILL NOT EXCEED
4% OF RATED VOLTAGE (10% UPON
START-UP).
BEFORE STARTING UP THE TYRECHANGER, BE SURE TO BECOME
FAMILIAR WITH THE LOCATION
AND OPERATION OF ALL CONTROLS AND CHECK THEIR PROPER
OPERATION (SEE PAR. CONTROLS).
On delivery, the machine is preset to operate at a voltage
230/400 V - 50 Hz three-phase (for version G8641V and
G8645V) or with a monophasic voltage of 200/265 V 50/60 Hz (for versions G8641D and G8645D).
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
11.2 Inflation pedal (on demand)
The pressure on the inflation pedal and the keeping it
pressed, delivers air at controlled pressure (max 4,2 ±
0,2 bar).
11.3 Column handle
The column is fitted with a pneumatically operated handle which allows clamping and release of the vertical
and horizontal arms.
Pushing the pushbutton located on this handle (Fig. 17)
the following operations can be carried out:
1° tripping: vertical arm descent (carried out manually);
2° tripping: locking of the vertical and horizontal arm in
working position;
3° tripping: unlocking of vertical and horizontal arm and
manual rise of vertical arm in rest position (all
upward).
Fig. 17
Version with tubeless inflation
The inflation pedal has two functions. The supply of air
at a controlled pressure as in the previous version, and
a second function of a jet of air from the inflation nozzle
to assist the beading in of the tyre.
DO NOT CHANGE THE SET OPERATING PRESSURE VALUE BY MEANS
OF THE MAXIMUM PRESSURE
VALVES. THE MANUFACTURER
SHALL NOT BE RESPONSIBLE FOR
INJURY OR DAMAGE ARISING
FROM UNAUTHORISED CHANGES.
DO NOT CHANGE THE SET OPERATING PRESSURE VALUE BY MEANS
OF THE MAXIMUM PRESSURE
VALVES. THE MANUFACTURER
SHALL NOT BE RESPONSIBLE FOR
INJURY OR DAMAGE ARISING
FROM UNAUTHORISED CHANGES.
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
12.0 USING THE MACHINE
12.1 Precaution measures during tyre removal and fitting
Before fitting a tyre, observe the following safety rules:
• rim and tyre must be clean, dry and in good condition.
If necessary, remove the balancing weights and clean
the rim. Check:
- tyre bead and tread for damage.
- rim for dents and/or deformation (especially for alloy
rims, dents can cause internal micro-fractures, that
pass unobserved at visual inspection, and can compromise the solidity of the rim and constitute danger
even during inflation).
• adequately lubricate the contact surface of rim and
tyre bead. Use specific tyre lubricants only.
• replace the inner tube valve with a new valve. If the
tyre tube has a metal valve, replace the grommet.
• make sure that the tyre is the right size for the rim.
Never fit a tyre unless you are sure it is the right size
(the rated size of the rim and tyre is usually printed
directly on each of them).
• Do not use compressed air or water jets to clean the
wheels on the machine.
12.2 Preliminary operations - Preparing
the wheel
• Remove the wheel balancing weights from both sides
of the wheel.
REMOVE THE VALVE STEM AND
ALLOW THE TYRE TO COMPLETELY DEFLATE.
12.3 Bead breaking
After preparing the wheel as described in the previous
point, follow the instructions given below to carry out
the bead breaking procedure.
1. Position the wheel as indicated in Fig. 18 and move
the bead breaker tool toward the edge of the rim.
2. Operate the bead breaker shoe by pressing the relative pedal until the bead has detached. If the bead
does not detach the first time, repeat the operation,
on different points of the wheel, until it has come
completely away.
3. Reverse the position of the wheel and repeat the operation on the other side.
4. Lubricate the tyre carefully along the entire circumference of the bead on both sides. Failure to lubricate might cause friction between the mounting tool
and the tyre, and would cause damage to the tyre
and/or the bead.
Fig. 18
NEVER INSERT ANY PART OF YOUR
BODY BETWEEN THE BEAD
BREAKER TOOL AND THE TYRE,
OR BETWEEN THE TYRE AND THE
WHEEL SUPPORT.
• Verify from which side the tyre should be demounted,
checking the position of the channel.
• Find the rim locking type.
• Try to establish the special types of wheels, such as
“TD” and “AH”, in order to improve locking, bead breaking, assembly and disassembly performances..
Page 18
INSTRUCTION, USE AND
MAINTENANCE MANUAL
Page 18 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
Fig. 20
Fig. 21
In order to carry out the clamping of the wheel from the
outside: place the 4 self-centering jaws by using the appropriate levers (Fig. 20 pos. 1) in correspondence to
the required clamping range.
Open the self-centering jaws and place them close to the
diameter of the rim to be clamped.
• Place the wheel on the turntable.
• Close the clamps, taking care that they engage the edge
of the rim.
12.5 Clamping the wheel on 30” chuck
The wheels must be clamped both from the inside and
from the outside compared to the edge of the rim.
In order to carry out the clamping of the wheel from the
inside: place the 4 self-centering jaws by using the
appropriate levers (Fig. 21 pos. 1) in correspondence
to the required clamping range.
• Close the turntable clamps, if open, by operating the
relative pedal.
• Place the wheel on the turntable.
• Press the pedal to open the clamps, until the wheel is
completely locked in place.
• Check that the rim is clamped and centred correctly
to ensure that the rim will not slip during the
operations which follow.
12.3.1 Bead breaking tool with double joint
(on demand)
The bead breaking tool is equipped with a double joint
(Fig. 19) that allows, during the bead breaking phase,
to optimize the relative position between the vane and
the bead of the tyre inserting the joint between the vane
and the edge of the rim.
If the machine is utilized with rims that have protected
edges or depressed tyres and/or tyres with heavy thickness, it’s recommended to place the vane-joint so that
the hole (Fig. 19 pos. 2) can be utilized.
To change the position of the vane on the joint extract
the pin (Fig. 19 pos. 1) from the hole in which it is
inserted, turn the vane until the required hole corresponds to the hole placed on the joint, then insert the
pin (Fig. 19 pos. 1) again into its new seat.
Fig. 19
12.4 Clamping the wheel on 18” - 20” - 22”
- 24” - 26” - 28” chuck
The wheels must be clamped both from the inside and
from the outside compared to the edge of the rim.
In order to carry out the clamping of the wheel from the
inside: place the 4 self-centering jaws by using the appropriate levers (Fig. 20 pos. 1) in correspondence to
the required clamping range.
• Close the turntable clamps, if open, by operating the
relative pedal.
• Place the wheel on the turntable.
• Press the pedal to open the clamps, until the wheel is
completely locked in place.
• Check that the rim is clamped and centred correctly
to ensure that the rim will not slip during the operations which follow.
Page 19
INSTRUCTION, USE AND
MAINTENANCE MANUAL
Page 19 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
In order to carry out the clamping of the wheel from the
outside: place the 4 self-centering jaws by using the appropriate levers (Fig. 21 pos. 1) in correspondence to
the required clamping range.
Open the self-centering jaws and place them close to the
diameter of the rim to be clamped.
• Place the wheel on the turntable.
• Close the clamps, taking care that they engage the edge
of the rim.
12.6 Demounting the tyre
After clamping the wheel, the tyre is demounted following the instructions given below, with reference to Fig.
22.
Fig. 23
1. Press the rotation pedal to turn the wheel clockwise
until the insert of the valve has reached the “1 o’clock”
position.
2. Unlock the arm using the push-button located on the
rod handle taking it to the 3rd tripping (see Fig. 17)
and releasing the arms.
3. Place the demounting/mounting arm on the external
edge of the rim (Fig. 23A pos. 1) pushing until the 1
st
“tripping” the push-button (Fig. 17).
4. Lock it in position activating again the push-button
(Fig. 17) until the 2nd “tripping”.
5. Through the valve lever drive (Fig. 22 pos. 1), the
pneumatic cylinder activates the hook descent (mo-
bile part) (Fig. 23B pos. 2) which thread its way
between the edge of the rim and the tyre grabbing the
bead of the tyre itself. Then, reversing always through
the lever (Fig. 22 pos. 1) the cylinder direction, the
hook (Fig. 23C pos. 2) rises up again and thanks to
its movement the tyre steps over the edge of the rim
and places itself for the demounting operation on the
fixed part of the tool (Fig. 22D pos. 1).
6. Press the rotation pedal to turn the wheel clockwise
until the whole bead has been lifted from the rim.
7. Lift the tyre and repeat the operation on the other
bead.
If the motor slows down or stops during tyre demounting
and mounting, make the following checks:
• Check that the bead has been lubricated.
• Check that the bead has been pushed into the well.
• Check that the right side of the rim has been chosen
for demounting or mounting the tyre.
• Check that the rim well is not off-centre.
12.7 Mounting the tyre
To mount the tyre, proceed as follows:
1. Lubricate the tyre beads.
2. Place the tyre on the rim and place the mounting tool
on the outer edge of the rim.
3. Place the edge of the lower bead on the left-hand part
of the mounting tool and turn the turntable clockwise.
4. Repeat the operation on the upper bead, taking care
first to position the valve insert at “5-6 o’clock”.
Fig. 22
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INSTRUCTION, USE AND
MAINTENANCE MANUAL
Page 20 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
In the case the beads are not seated at 4,2±0,2 bar,
release all the air from the wheel, remove it from the
tyre changer and put it in a safety case to complete
the inflation procedure.
12.9 Tubeless tyre inflation device
Some types of tyres can be difficultly inflated if the beads
are not in contact with the rim.
The tubeless inflating device, assembled only on some
models, supplies air at high pressure to the selfcentering
chuck nozzles (Fig. 24 pos. 1) and therefore facilitates
the positioning of the beads against the rim starting the
normal inflation of the tyre.
In order to carry out the inflation of the tyre on these
models follow these indications:
• Connect the inflation terminal to the valve of the tyre
• Lift the lower bead while the pedal, placed on the left
side of the machine, is pushed at its second stage,
supplying that way the required air jet
• Go on inflating the tyre until the required pressure is
reached with the lateral pedal pushed on its first stage.
Fig. 24
A LIMITATION DEVICE IS PRESENT
IN THE AIR SUPPLY LINE FOR THE
TIRE INFLATION (4,2 ± 0,2 BAR/60
PSI).
IN ORDER TO ALLOW THE AIR JET
TO BREAK BOTH THE BEADS, DO
NOT KEEP THE BEAD LIFTED
FORCING IT.
12.8 Tyre inflation with pressure gauge (on
demand)
Connect the inflation device to the tyre valve and inflate
the tyre using the left pedal.
Well lubricated beads and rims make the beading in
and inflation much safer and easier.
13.0 ROUTINE MAINTENANCE
To guarantee the efficiency and correct functioning of the
machine, it is essential to carry out daily or weekly cleaning and weekly routine maintenance, as described below.
Cleaning and routine maintenance must be conducted
by authorized personnel and according to the instructions given below.
• Disconnect the mains power supply before starting
any cleaning or routine maintenance operations.
• Periodically check the calibration of lubricator in pressure/oiler gauge unit: one oil drop every four complete
strokes of self-centering chuck jaws.
• Remove deposits of tyre powder and other waste materials with a vacuum cleaner.
BEFORE CARRYING OUT ANY ROUTINE MAINTENANCE PROCEDURE,
DISCONNECT THE MACHINE FROM
ITS POWER SUPPLY SOURCES, TAKING SPECIAL CARE OF THE ELECTRICAL PLUG/SOCKET CONNECTION.
DO NOT BLOW IT WITH COMPRESSED AIR.
• Do not use solvents to clean the pressure regulator.
• The conditioning unit is equipped with an automatic
vacuum-operated drain therefore it requires no manual
intervention by the operator (see Fig. 25).
BEFORE CARRYING OUT ANY MAINTENANCE OPERATIONS, MAKE
SURE THERE ARE NO WHEELS
CLAMPED ON THE CHUCKING TABLE AND THAT ALL SUPPLIES TO
THE MACHINE HAVE BEEN DISCONNECTED.
Fig. 25
PRESSION
REGULATOR
AIR SUPPLY
AUTOMATIC
VACUUM-OPERATED
RELEASE
OILER
Page 21
INSTRUCTION, USE AND
MAINTENANCE MANUAL
Page 21 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
ANY DAMAGE TO THE MACHINE
DEVICES RESULTING FROM THE
USE OF LUBRICANTS OTHER THAN
THOSE RECOMMENDED IN THIS
MANUAL WILL RELEASE THE
MANUFACTURER FROM ANY LIABILITY.
Fig. 26
IN ORDER TO ALLOW A LONGER
LIFE OF THE FILTER AND OF ALL
MOVING PNEUMATIC DEVICES,
YOU HAVE TO MAKE SURE THAT
THE SUPPLIED AIR IS:
• EXEMPT FROM THE LUBRICATING
OIL OF THE COMPRESSOR;
• EXEMPT FROM HUMIDITY;
• EXEMPT FROM IMPURITY.
• Every week and/or when necessary, top up the oil tank
using the filler hole provided closed by a cap or screw
on the lubricator filter.
N.B: This operation should not be carried out by
unscrewing the cup of the lubricator filter.
• The use of synthetic oil might damage the pressure
regulator filter.
• Replace worn pieces (tool supports, rubber pads, lever guard, mounting tool) immediately.
• Periodically (preferably once a month) make a complete check on the controls, ensuring that they provide
the specified actions.
• Every week check operation of the safety device.
• Periodically (at least each 100 working hous) check
the lubricant level into the reduction unit (Fig. 26
pos. 1) removing the plug (Fig. 26 pos. 2) through the
spy hole prearranged on the frame.
THE MANUFACTURER DOES NOT
ACCEPT ANY DAMAGE RESULTING
FROM THE FRAILURE TO OBSERVE
THE ABOVE INSTRUCTION, AND
SUCH FAILURE COULD INVALIDATE
THE WARRANTY!!
13.1 Lubricants
Special lubricant for spindle movement control gearbox.
Use ESSO GEAR OIL GX140 (for G8641V and
G8645V version) and ESSO GEAR OIL GX90
(for G8641D and G8645D version).
Lubricate slides, screws/nut screws or racks and pinion with a soft brush using lubricant of ESSO GP type.
Page 22
INSTRUCTION, USE AND
MAINTENANCE MANUAL
Page 22 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
14.0 TROUBLESHOOTING
Possible troubles which might occur to the tyre-changer are listed below. The manufacturer disclaims all responsibility for damages to people, animals or objects due to improper operation by non-unauthorised personnel. In
case of trouble, call Technical Service Department for instructions on how to service and/or adjust the machine in
full safety to avoid any risk of damage to people, animals or objects.
In an emergency and before maintenance, set the main switch to "0" and lock it in this position.
CONTACT AUTHORISED TECHNICAL SERVICE
Do not try and service alone.
Problem
Possible cause
Remedy
Turntable does not hold/clamp the
wheel.
1. Compressed air supply pressure
below 6 Bar.
2. A turntable component has broken.
3. Worn clamps.
1. Check air supply pressure.
2. Call the after-sales service.
3. Call the after-sales service.
No movements take place when the
pedals are pressed.
1. Power supply failure.
2. Pedal unit not set correctly.
1. Check power supply.
2. Call the after-sales service.
Arms do not lock when column handle button is pressed.
1. Handle valve not set correctly.
2. Air leaking from clamping cylinders.
1. Call the after-sales service.
2. Call the after-sales service.
Inflation pedal unit not set correctly. Call the after-sales service.Nozzles do not deliver air when the
inflation pedal is pressed.
(Only for I version)
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INSTRUCTION, USE AND
MAINTENANCE MANUAL
Page 23 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
12” - 20,5”
12” - 22,5”
13” - 24,5”
12” - 26,5”
12” - 22,5”
13” - 24,5”
12” - 26,5”
12” - 20,5”
12” - 22,5”
13” - 24,5”
12” - 26,5”
12” - 22,5”
13” - 24,5”
12” - 26,5”
10” - 18”
10” - 20”
11” - 22”
10” - 24”
10” - 20”
11” - 22”
10” - 24”
10” - 18”
10” - 20”
11” - 22”
10” - 24”
10” - 20”
11” - 22”
10” - 24”
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
0,75 kW
0,75 kW
0,75 kW
0,75 kW
0,75 kW
0,75 kW
0,75 kW
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
15 rpm
15 rpm
15 rpm
15 rpm
15 rpm
15 rpm
15 rpm
232
234
246
252
254
266
272
232
234
246
252
254
266
272
Internal
clamping
External
clamping
Motor
power
Mandrel
rotation
max. speed
Net weightModel
G8641V.18
G8641V..20
G8641V..22
G8641V..24
G8641IV.20
G8641IV.22
G8641IV.24
G8641D.18
G8641D.20
G8641D.22
G8641D.24
G8641ID.20
G8641ID.22
G8641ID.24
15.0 TECHNICAL DATA
15.1 G8641V technical data
Recommended
electric supply: ............ three-phase 230/400V (50 Hz)
Maximum wheel diameter .................. 1050 mm / 41”
Wheel max. width ................................ 356 mm / 14”
Exercised pressure ...................................... 8-10 bar
Bead-breaker force (10bar) ............................ 30000N
Gear noise .............................................. < 80 dB (A)
15.2 G8641D technical data
Recommended
electric supply: ...... monophase 200/265V (50 - 60 Hz)
Maximum wheel diameter .................. 1050 mm / 41”
Wheel max. width ................................ 356 mm / 14”
Exercised pressure ...................................... 8-10 bar
Bead-breaker force (10bar) ............................ 30000N
Gear noise .............................................. < 80 dB (A)
15.3 G8645V technical data
Recommended
electric supply: ............ three-phase 230/400V (50 Hz)
Maximum wheel diameter .................. 1143 mm / 45”
Wheel max. width ................................ 407 mm / 16”
Exercised pressure ...................................... 8-10 bar
Bead-breaker force (10bar) ............................ 30000N
Gear noise .............................................. < 80 dB (A)
15.4 G8645D technical data
Recommended
electric supply: ...... monophase 200/265V (50 - 60 Hz)
Maximum wheel diameter .................. 1143 mm / 45”
Wheel max. width ................................ 407 mm / 16”
Exercised pressure ...................................... 8-10 bar
Bead-breaker force (10bar) ............................ 30000N
Gear noise .............................................. < 80 dB (A)
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INSTRUCTION, USE AND
MAINTENANCE MANUAL
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
12” - 20,5”
12” - 22,5”
13” - 24,5”
12” - 28,5”
12” - 30,5”
10” - 34”
12” - 22,5”
13” - 24,5”
12” - 28,5”
12” - 30,5”
10” - 34”
12” - 20,5”
12” - 22,5”
13” - 24,5”
12” - 28,5”
12” - 30,5”
10” - 34”
12” - 22,5”
13” - 24,5”
12” - 28,5”
12” - 30,5”
10” - 34”
10” - 18”
10” - 20”
11” - 22”
10” - 26”
10” - 28”
8” - 30”
10” - 20”
11” - 22”
10” - 26”
10” - 28”
8” - 30”
10” - 18”
10” - 20”
11” - 22”
10” - 26”
10” - 28”
8” - 30”
10” - 20”
11” - 22”
10” - 26”
10” - 28”
8” - 30”
0,75 kW
0,75 kW
0,75 kW
0,75 kW
0,75 kW
0,75 kW
0,75 kW
0,75 kW
0,75 kW
0,75 kW
0,75 kW
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
0,8/1,1 kW
15 rpm
15 rpm
15 rpm
15 rpm
15 rpm
15 rpm
15 rpm
15 rpm
15 rpm
15 rpm
15 rpm
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
6,5/13 rpm
286
288
286
293
288
293
298
296
303
298
303
263
273
288
288
288
293
283
298
298
298
303
Internal
clamping
External
clamping
Motor
power
Mandrel
rotation
max. speed
Net weightModel
G8645D.18
G8645D.20
G8645D.22
G8645D.26
G8645D.28
G8645D.30
G8645ID.20
G8645ID.22
G8645ID.26
G8645ID.28
G8645ITD.30
G8645V.18
G8645V.20
G8645V.22
G8645V.26
G8645V.28
G8645V.30
G8645IV.20
G8645IV.22
G8645IV.26
G8645IV.28
G8645ITV.30
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INSTRUCTION, USE AND
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GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
15.5 Dimensions
Fig. 27
Model
-
1408
1135
1560
1773,5
1395
1433
1160
1585
1798,5
1420
1458
1185
1610
1823,5
1450
1476
1215
1640
1885
G8641D.18
G8641V.18
G8641D.20
G8641V.20
G8641ID.20
G8641IV.20
G8641D.22
G8641V.22
G8641ID.22
G8641IV.22
G8641D.24
G8641V.24
G8641ID.24
G8641IV.24
G8641D - G8641V
A (mm)
(only for
I version)
B (mm)
C (mm)
D (mm)
E (mm)
Page 26
INSTRUCTION, USE AND
MAINTENANCE MANUAL
Page 26 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
Fig. 28
Model
-
1499
1135
1560
1879,5
1395
1523,5
1160
1585
1904,5
1420
1549
1185
1610
1928,5
1480
1610
1245
1670
1989,5
1540
1670
1305
1730
2050
1540
1670
1305
1730
2050
G8645D - G8645V
A (mm)
(only for
I version)
B (mm)
C (mm)
D (mm)
E (mm)
G8645D.18
G8645V.18
G8645D.20
G8645V.20
G8645ID.20
G8645IV.20
G8645D.22
G8645V.22
G8645ID.22
G8645IV.22
G8645D.26
G8645V.26
G8645ID.26
G8645IV.26
G8645D.28
G8645V.28
G8645ID.28
G8645IV.28
G8645D.30
G8645V.30
G8645ITD.30
G8645ITV.30
Page 27
INSTRUCTION, USE AND
MAINTENANCE MANUAL
Page 27 of 33
GB
RAVAGLIOLI S.p.A.
G8641 - G8645
7300-M010-1_R
Fig. 29
The validity of the Conformity Declaration enclosed
to this manual is also extended to products and/or
devices the machine model object of the Conformity
Declaration can be equipped with.
16.0 STORING
If storing for long periods (6 months or longer) disconnect the main power supply and take measures to protect the machine from dust build-up. Lubricate parts
that could be damaged from drying out. When putting
the machine back into operation replace the rubber pads
and the mounting tool. Moreover, carry out a verification of machine perfect functioning.
17.0 SCRAPPING
When the decision is taken not to make further use of
the machine, it is advisable to make it inoperative by
removing the connection pressure hoses.
The machine is to be considered as special waste and
should be dismantled into homogeneous parts.
Dispose of it in accordance with current legislation.
17.1 Instructions for the correct management of waste from electric and electronic equipment (in italian RAEE)
according to legislative decree 151/
05
• RAEE may not be disposed of as urban waste.
• These kinds of waste must be collected separately and
taken to dedicated collection and recycling centres,
according to OEM instructions and abiding by national
laws.
• The above symbol on the product means that anyone
wishing to dispose of the waste must follow the abovementioned instructions.
• Any incorrect management of the waste or its parts or
its abandonment outside dedicated areas could contaminate the environment, owing to the dangerous
substances contained in it, and cause damage to human health, flora and fauna.
• National laws provide for sanctions against those re-
sponsible for illegal disposal or abandonment of waste
from electric and electronic equipment.
Said plate must always be kept clean.
WARNING: Should the plate be accidentally damaged
(removed from the machine,damaged or even partially
illegible) inform immediately the manufacturer.
19.0 FUNCTIONAL DIAGRAMS
Here follows a list of the machine functional diagrams.
18.0 REGISTRATION PLATE DATA
CAUTION: DO NOT TAMPER WITH,
CARVE, CHANGE OR REMOVE THE
IDENTIFICATION PLATE;DO NOT
COVER IT WITH PANELS, ETC.,
SINCE IT MUST ALWAYS BE VISIBLE.
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