OPERATOR'S MANUAL

AUTOMATIC TYRE CHANGER

RAE.2102
RAE.2102.T

RAE.2104
RAE.2104.T

3B

DJOH

GB

MADE IN ITALY
Ver.2.0 del 04/08

RAE.2102 - RAE.2104
Automotive Equipment

diritti di traduzione, di memorizzazione elettronica, di

riproduzione e di adattamento totale o parziale
con qualsiasi mezzo (compresi microlm e copie fotostatiche) sono riservati.
Le informazioni contenute in questo manuale sono soggette a variazioni senza preavviso.

Italiano

ll rights reserved. No part of this publication may be

translated, stored in an electronic retrieval system,
reproduced, or partially or totally adapted by any means
(including microlm and photostats) without prior permission.
The information contained herein may be subject to modications without prior notice.

English

es droits de traduction, de mmorisation lectronique,

de reproduction et dadaptation complte ou partielle
par tout type de moyen (y compris microlms et copies
photostatiques) sont rservs.
Les informations fournies dans ce manuel peuvent tre
modies tout moment et sans pravis.

Franais

lle Rechte der bersetzung, der Speicherung,

Reproduktion sowie der gesamten oder teilweisen Anpassung durch ein beliebiges Mittel (einschlielich Mikrolm und Fotokopien) sind vorbehalten.
Die in diesem Handbuch enthaltenen Informationen knnen ohne Vorbescheid gendert werden.

Deutsch

eservados los derechos de traduccin, grabacin

electrnica, reproduccin y adaptacin total o parcial
con cualquier medio (incluidos microlmes y copias fotostticas).
Las informaciones contenidas en el presente manual pueden sufrir variaciones sin aviso previo.

Espaol

Elaborazione graca e impaginazione

Ufcio Pubblicazioni Tecniche

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RAE.2102 - RAE.2104
Automotive Equipment

TABLE OF CONTENTS

Page
TABLE OF CONTENTS

GENERAL INFORMATION
TECHNICAL BRIEF
MANUFACTURER'S LABEL
TRANSPORT

6
6
6
6

MAIN PARTS OF THE MACHINE

UNPACKING AND ASSEMBLY

SAFETY REGULATIONS

WARNING SIGNALS

10

INSTALLATION
PLACE OF INSTALLATION
SAFETY DEVICES
PNEUMATIC HOOK-UP
ELECTRIC HOOK-UP

11
11
11
11
11

OPERATION CHECK

12

BEAD BREAKING
WHEEL CLAMPING

13
13

TYRE DEMOUNTING
TYRE MOUNTING

14
14

INFLATION

15

MAINTENANCE
ROUTINE MAINTENANCE

16
16

STORAGE
DEMOLITION
TROUBLE SHOOTING

17
17
17

ACCESSORIES ON REQUEST

18

ENVIRONMENTAL INFORMATION

19

RAE.2102 - RAE.2104
MAIN PARTS OF THE MACHINE

20
8
25
23
11

10
16

21

6
2
19
12

22

18

t.i. version
(with tubeless tyres inating device)

4
24

14
5

1
2
3
4
5
6
7
8

13
3

Reverse control pedal

Turntable
Bead breaker pedal
Bead breaker arm
Clamp control pedal
Clamp
Vertical arm
Horizontal arm

17

10
11
12
13
14
16
17
18

standard version

Mounting bar
Inating gun with pressure gauge
Pressure regulator with lter
Wheel support
Bead breaker
Mounting head
Tyre lever
Air lubricator

19
20
21
22
23
24

Inator pedal for t.i. version

Inating unit
Air tank
Body
Control handle
Tower tilt pedal

RAE.2102 - RAE.2104
UNPACKING AND ASSEMBLY
Remove the upper part of the packing and make sure that the machine has not
been visibly damaged.
Proceed with the following operations:
- Remove the tower (horizontal + vertical arms) from its position on the pallet.
- Remove the mounting bar from the wooden lath that is keeping it locked. During
this operation it is advisable to keep the mounting bar in lowered position with a
hand.
- Assemble the bead breaker with the proper pin and fasten it with the locknut until
there is a slight resistance in the rotation of the bead breaker.
- Remove the side cover.
- Place the tilting arm in its seat on the machine's body. In the meantime, insert
the pneumatic hose A into its proper hole on the machine's body.
- Insert pin B on the tilting arm and fasten it with the proper screws, using the
washers provided.
- Tilt arm C in vertical position and introduce pin D. Pin D must pass through the
hole M of the tower tilt cylinder's stem.
- Fasten pin D with snapring L.
- Connect hose A to the valve placed on the pedal unit base inside the
machine's body and controlled by the tower tilt pedal.
- Fit the side cover.

C
D

A
M

ON T.I. VERSION, FURTHER TO THE ABOVE DESCRIBED OPERATIONS:

- Remove the side cover.
- Fix the tank to the machine.
- Connect the air hose F to the tank's union.
- Fix the inating unit to its support on the
vertical harm by means of two screws.
- Connect the air spiral hose of the inating
unit to the union xed on the outside
of the machine's back.
- Fit the side cover.

RAE.2102 - RAE.2104

SAFETY REGULATIONS

- The machine must be used only by qualied and suitably

trained personnel.

- Keep this instructions manual with care in a handy place;

please consult it regularly.

- Before carrying out maintenance or making any adjustments,

disconnect the electric and pneumatic supply from the machine
and make sure that all moving parts are immobilised.

- Do not remove or deface the warning labels. In case such

labels should have been removed or damaged, replace them
immediately.

- Before using the machine, carefully read the warning signals.

Such signals indicate the parts of the machine that might injure
the operator during work.

- Pay the utmost attention to the moving parts of the machine.

Necklaces, rings, watches, bracelets, ties, long hair and loose
tting clothes may be dangerous during work.

- Install the machine in compliance with the established regulations for accident prevention on the place of work.

- Never use the machine in an explosive atmosphere.

- Keep unauthorized persons at a proper distance from the

area of work.

- Any unauthorized modications made to the machine are

dangerous for the operator and release the manufacturer from
any liability in case of damage or injury ascribable to such
operations.

RAE.2102 - RAE.2104
WARNING SIGNALS
PAY THE UTMOST ATTENTION TO THE WARNING LABELS ATTACHED TO THE MACHINE.
USING THE MACHINE WITHOUT READING THE WARNING SIGNALS MAY BE
SERIOUSLY DANGEROUS FOR THE OPERATOR.

A
000103700

B
B - CAUTION: TOWER TILTING
000103500

C
D
F

H
C

000103000

DANGER OF HAND CRUSHING

BETWEEN CLAMP AND RIM.

DANGER OF HAND CRUSHING

BETWEEN MOUNTING HEAD
AND WHEEL.
000103100

E
G - CAUTION: ELECTRIC CURRENT.
CAUTION: AIR BLAST.

000103600

H - DANGER OF CRUSHING PARTS OF THE

BODY BETWEEN THE BEAD BREAKER AND
THE MACHINE.
MAX. AIR SUPPLY LINE
PRESSURE 16 BAR

000103400

000102800

F - INFLATING GUN CONNECTION. DO NOT DIRECTLY CONNECT THE COMPRESSOR.

(only on standard version)

I - DANGER OF CRUSHING PARTS OF THE

BODY BETWEEN THE BEAD BREAKER AND THE
WHEEL.
000103200

000102700

J - DANGER OF CRUSHING PARTS OF THE

BODY BETWEEN THE BEAD BREAKER ARM AND
THE MACHINE.

10

000103300

RAE.2102 - RAE.2104
INSTALLATION
To take the machine away from the pallet, sling it as shown in the gure.
Use this lifting point whenever you need to move the machine.
It is not advisable to use the machine outdoors; should it be necessary,
suitably protect the machine from inclement weather.
Remember to disconnect the machine from the electric and air networks
before moving the machine (see SAFETY REGULATIONS).
The machine must be lifted with belts and devices adequate to the weight
of the machine.

PLACE OF INSTALLATION
- Comply with the minimum clearances shown in the gure.
- Always install the machine on a rm and levelled oor.
Fix the machine by means of the 4 holes predrilled in the base,
using suitable metal plugs.
- Make sure that the place of installation is at least 2 m. in height.

SAFETY DEVICES
The machine is equipped with:
- a pressure regulator set at 10 bar, placed on the outside, provided
with a quick coupling for the connection to the line supply air.
- safety valve set at 4,2 bar, placed inside the tyre changer, which prevent the air coming out from the inating gun from exceeding the pressure of 4,2 bar.
IT IS ABSOLUTELY FORBIDDEN TO TAMPER WITH THE MACHINE'S
SAFETY DEVICES

PNEUMATIC HOOK-UP
1 - Connect the tyre changer to the compressed air line by means of the
quick coupling supplied with the machine. The air supply line pressure
must range from 8 bar to max. 16 bar.
2 - Connect the inating gun to its proper coupling on the machine and
fasten it.

ELECTRIC HOOK-UP
ALL OPERATIONS RELATING TO THE
ELECTRIC HOOK-UP MUST BE CARRIED
OUT BY QUALIFIED PERSONNEL.
- Make sure that the mains voltage corresponds to the machine's required
voltage, as shown on the relevant data plate.
- Suitably size the electric supply line in relation to the machine's power
requirements.
- Connect the tyre changer to a good grounding circuit.
- Equip the machine with a 16A socket or plug,
which must be in conformity with the safety standards
in force. It is also recommended to provide the
automatic circuit breaker (differential) set at 30mA.

11

RAE.2102 - RAE.2104
OPERATION CHECK

WARNING:
IN CASE OF THREE-PHASE HOOK-UP, IF THE TURNTABLE DOES NOT ROTATE CLOCKWISE WHEN PRESSING THE RELEVANT PEDAL, IT IS NECESSARY TO
REVERSE THE POSITION OF THE TWO PHASE-WIRES
IN THE PLUG. THIS OPERATION MUST BE CARRIED
OUT BY QUALIFIED PERSONNEL.

12

t.i. version

RAE.2102 - RAE.2104
BEAD BREAKING
PAY ATTENTION TO THE WARNING SIGNALS

- Fully close the turntable clamps.

- Remove the weights from the rim.
- Fully deate the tyre and remove the inating valve.
- Place the wheel in the bead breaking position,
bringing it close to the rubber supports.
- Take the bead breaker near the bead. Keep the
necessary safety distance between the rim and the
bead breaker, so that the latter works on the tyre
and not on the rim.
- Press the bead breaker pedal.
- Free the bead from the rim repeating the above
operation at various points around the tyre.
- Turn the wheel, bringing the other side of it by the
supports, and follow the same procedure to carry
out the bead breaking of the second rim.

WHEEL CLAMPING
PAY ATTENTION TO THE WARNING SIGNALS

- Check if there are any weights left on the rim; if so, remove them.
- Carefully lubricate the lower and upper bead along their entire circumference.
- Tilt the tower backwards in non-work position by pressing the relevant
pedal
- Place the wheel on the turntable.
- Depending on the diameter of the rim, close the four clamps if the rim is
to be clamped in the inside or open them if the rim is to be clamped in
the outside .
- Press pedal fully down, making sure that the rim is safely clamped.

13

RAE.2102 - RAE.2104
TYRE DEMOUNTING
PAY ATTENTION TO THE WARNING SIGNALS

- Tilt the tower forward by pressing the tower tilt pedal

- Set the mounting bar in its working position and let the mounting head
touch the edge of the rim.
- Press the yellow button from the outside of the handle to lock both the
mounting bar and the horizontal arm. The mounting head will
automatically move 2/3 mm. away from the edge of the rim, thus
protecting it from damage.
- Position the tyre lever between the mounting head and the tyre bead
and lift the bead above the forward portion of the mounting head itself.
- Make the turntable rotate clockwise by pressing the relevant pedal
lightly and repeatedly, then keep the pedal continuously pressed.
- Rotate the wheel through one turn and at the same time press down
with a hand on the side of the tyre opposite to the mounting head, in
order to position the bead in the central groove of the rim.
- If the wheel has an inner tube, tilt the tower backwards by means of
the relevant pedal, without unlocking the horizontal arm and the
mounting bar, and remove the tube.
- Repeat the above described procedures to take out the second bead.
Then tilt the tower backwards in non-work position and take the tyre off
the rim.

TYRE MOUNTING
PAY ATTENTION TO THE WARNING SIGNALS
BEFORE STARTING THE MOUNTING PROCEDURES CHECK THAT:

- the diameter of the rim is exactly the same as the diameter of the tyre;
- the tyre is in good condition and without any damages;
- the rim is not bent or warped.
MOREOVER:

- Carefully lubricate both the rim (near and on the bead breaking area)
and the two beads of the tyre.
- Clamp the rim as described in the WHEEL CLAMPING section.
- Place the tyre over the rim and set the mounting bar in its working position, as described in the TYRE DEMOUNTING section.
- Position the tyre as shown.
- To facilitate mounting operations, keep the tyre slanted and press it
with the right hand towards the rim groove.
- Rotate the turntable clockwise by pressing the relevant pedal.
- Insert the inner tube if the tyre has one.
- Repeat the above procedure to mount the top bead.
- Tilt the tower backwards in non-work position by pressing the relevant
pedal.
- Free the wheel from the clamps and remove it from the tyre changer.

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RAE.2102 - RAE.2104
INFLATION
WARNING: TYRE INFLATION IS DANGEROUS. IF THIS OPERATION
IS NOT CARRIED OUT WITH THE UTMOST CAUTION, THE TYRE MAY
EXPLODE CAUSING SERIOUS INJURY OR DEATH OF THE OPERATOR.
Therefore never exceed the maximum pressure stated by the tyre manufacturer both during bead breaking and tyre ination.
The machine is equipped with a pressure limiting device set at 4,2 bar (50 psi),
which however does not exclude the risk of tyre explosion.
Before inating the tyre, check again and MAKE SURE that:
rim and beads are sufciently lubricated;
the diameter of the rim perfectly corresponds to the diameter of the tyre;
both the rim and the tyre have no signs of damage.
KEEP HANDS AND BODY WELL CLEAR OF THE POTENTIALLY DANGEROUS AREA DURING INFLATION.
TYRES WITH INNER TUBES
- Properly connect the chuck of the inating gun to the tyre valve.
- Inate the tyre with short blasts of air. Between the blasts, always check the
pressure on the inator's gauge. Proceed this way until the beads are completely
sealed.
- Continue to inate the tyre until you reach the required pressure, however
NEVER EXCEED THE PRESSURE SPECIFIED BY THE TYRE
MANUFACTURER.

TUBELESS TYRES (t.i. version)

- Carefully remove dust, dirt and any other foreign matter from the areas near the
air outlet holes. .
- Secure the wheel on the turntable with inside clamping.
- Properly connect the inating chuck to the tyre valve.
- Hold the tyre with your hands and lift it in order to close any eventual gap
between the rim and the upper bead.
- Press the tubeless inating pedal fully down for a short
period until an air blast comes out of the air outlet holes,
wedging itself between the tyre and the lower edge of the rim.
The tyre will expand and the bead will seat.
- To fully inate the tyre, gently press the tubeless inating
pedal (in intermediate position) until you reach the required
pressure. Do not forget to constantly check the pressure
on the inating unit gauge placed on the vertical arm and to
NEVER EXCEED THE PRESSURE SPECIFIED BY THE
TYRE MANUFACTURER.

15

RAE.2102 - RAE.2104
MAINTENANCE
BEFORE CARRYING OUT MAINTENANCE:
- DISCONNECT THE ELECTRIC SUPPLY FROM THE MACHINE;
- DISCONNECT THE PNEUMATIC SUPPLY FROM THE MACHINE;
- MAKE SURE THAT ALL MOVING PARTS OF THE MACHINE ARE
STEADILY IMMOBILISED

ROUTINE MAINTENANCE
DAILY CHECK:
- Check that the slides are running well; remove any eventual residues of dirt.

WEEKLY CHECKS:
- Make sure that the condensate level into the lter cup does not exceed the red mark on the level indicator.
- The air lubricator+lter unit is equipped with a semi-automatic condensate drainage system; if necessary,
however, carry out drainage manually by turning clockwise the ring placed on the bottom of the cup.
- Press twice or thrice one of the pedals (for example the bead breaking pedal) to make sure that every two or
three pedal movements a drop of oil falls into the lubricator transparent cup. If this does not happen, adjust the
regulating screw placed on the top of the lubricator with a screwdriver.

MONTHLY CHECKS:
- Disconnect the machine from the pneumatic supply and demount the lubricator cup to remove any eventual
solid residues of dirt.
- Check the oil level in the lubricator and, if necessary, top up with SAE20 non-detergent oil until you reach the
required level.
- Clean and lubricate with naphta the horizontal arm and mounting bar.
- Check the stretch of the motor/reduction gear driving belts; using the machine, such belts may become loosen
and worn out.

16

RAE.2102 - RAE.2104
Automotive Equipment

STORAGE
If the machine is to be kept idle for a long time, it is recommended to:
- disconnect the machine from the electric supply;
- disconnect the machine from the pneumatic network;
- lubricate all moving parts, along with their guides, with naphta;
- wrap the machine in a protective plastic sheet.

DEMOLITION
In case the machine has to be scrapped, it is recommended to:
- remove all electric and pneumatic connections;
- disassemble the machine; divide its parts into unifom groups (electric parts, plastic, iron)
and dispose of them in compliance with the regulations in force.

TROUBLE SHOOTING
TROUBLES

POSSIBLE CAUSES

REMEDIES

When you press the pedal

operating the turntable clamps or
the bead breaker pedal, or when
you turn the control handle, nothing
happens.

There is no compressed air

circulation in the machine because
hoses are crimped or crushed

Put back the compressed air system

in operation; if hoses are damaged,
let them be replaced by qualied
personnel.

Even though you press the pedal

to rotate the turntable, the latter
does not turn.

- Power plug faulty or not properly

inserted.
- No power from the mains electric
supply.
- Faulty reverse switch.
- Short-circuited motor.

- Check the plug.

- Reset the electric hook-up.
- Let reverse switch be replaced by
qualied personnel.
- Let motor be replaced by qualied
personnel.

IN CASE OF TROUBLES OR FAILURES DIFFERENT FROM THE ABOVE ONES, APPLY TO AUTHORIZED
SERVICE CENTRES OR QUALIFIED PERSONNEL ONLY.

17

RAE.2102 - RAE.2104
Automotive Equipment

ENVIRONMENTAL INFORMATION
This product may contain substances that can be hazardous to the environment or to human health
if it is not disposed of properly.
We therefore provide you with the following information to prevent releases of these substances and
to improve the use of natural resources.
Electrical and electronic equipments should never be disposed of in the usual municipal waste but must be separately collected for their proper treatment.
The crossed-out bin symbol, placed on the product and in this page, remind you of the
need to dispose of properly the product at the end of its life.
In this way it is possible to prevent that a not specic treatment of the substances contained in these products, or their improper use, or improper use of their parts may be
hazardous to the environment or to human health. Furthermore this helps to recover,
recycle and reuse many of the materials used in these products.
For this purpose the electrical and electronic equipment producers and distributors set up proper
collection and treatment systems for these products.
At the end of life your product contact your distributor to have information on the collection arrangements.
When buying this new product your distributor will also inform you of the possibility to return free of
charge another end of life equipment as long as it is of equivalent type and has fullled the same
functions as the supplied equipment.
A disposal of the product different from what described above will be liable to the penalties prescribed by the national provisions in the country where the product is disposed of.
We also recommend you to adopt more measures for environment protection: recycling of the internal and external packaging of the product and disposing properly used batteries (if contained in the
product).
With your help it is possible to reduce the amount of natural resources used to produce electrical
and electronic equipments, to minimize the use of landlls for the disposal of the products and to
improve the quality of life by preventing that potentially hazardous substances are released in the
environment.

19