OPERATION INSTRUCTIONS Form 5290-T, 08-09a Supersedes Form 5290-T, 08-09 TCX500 Tire Changer Family ©Copyright 2005-2009 Hunter Engineering Company OWNER INFORMATION Model Number____________________________________________________________________ Serial Number____________________________________________________________________ Date Installed____________________________________________________________________ Service and Parts Representative_____________________________________________________ Phone Number___________________________________________________________________ Sales Representative______________________________________________________________ Phone Number ___________________________________________________________________ Concept and Procedure Explanation Safety Precautions Trained Declined Warning and Caution Labels □ □ Maintenance and Performance Checks Trained Declined Mounting Head Inspection □ □ Adjustment and Filling of Oilers □ □ Bead Breaking Trained Declined Standard Wheels □ □ Low Profile Wheels □ □ Clamping Trained Declined Steel Jaw Internal/External Clamping □ □ Demounting Trained Declined Standard Wheels with Bead Lever and Plastic Sleeve Protector □ □ Full Seating of Mount/Demount Head to Prevent Head Failure □ □ Bead Lubrication During Removal of Low Profile Tires □ □ Reverse Drop Center Wheels □ □ Mounting Trained Declined Standard Wheels □ □ Mounting of Stiff, Low Profile Tires □ □ Reverse Drop Center Wheels □ □ Proper Bead Lubrication for Mounting Protection □ □ Inflation Trained Declined Safety Precautions □ □ Lubrication and Removal of Valve Core □ □ Bead Sealing and Seating □ □ Individuals and Date Trained ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ ___________________________________ Contents CONTENTS ...........................................................................................................I 1. GETTING STARTED.......................................................................................1 1.1 Introduction............................................................................................................. 1 1.2 For Your Safety ...................................................................................................... 1 Hazard Definitions.................................................................................................. 1 IMPORTANT SAFETY INSTRUCTIONS............................................................... 2 1.3 Control Pedal Configurations ................................................................................. 4 1.4 Wheel Rotation Pedal............................................................................................. 4 1.5 Tire Bead Breaker Shovel Pedal............................................................................ 5 1.6 Wheel Clamping Pedal........................................................................................... 5 1.7 Air Inflation Pedal ................................................................................................... 5 1.8 Inflator and Pressure Limiter .................................................................................. 6 1.9 Mount / Demount Head .......................................................................................... 6 1.10 Equipment Components....................................................................................... 7 TCX505, TCX515, TCX535 Series (mid 2009 and later), Tire Changer Components........................................................................................................... 7 TCX500 Series (2005 to mid 2009), Tire Changer Components .......................... 8 2. BASIC PROCEDURES ...................................................................................9 2.1 Bead Breaking........................................................................................................ 9 2.2 Placing Wheel on Tire Changer ........................................................................... 10 Clamping the Wheel from Inside of Rim - Steel Rims ......................................... 10 Clamping the Wheel from Outside of Rim - Alloy Rims....................................... 10 2.3 Demounting Standard Tire from Rim ................................................................... 11 2.4 Mounting Standard Tire to Rim ............................................................................ 13 Mount a standard tire to rim:................................................................................ 13 Precautionary Notes ............................................................................................ 14 2.5 Tire Inflation.......................................................................................................... 14 2.6 Removal of Wheel from Tire Changer.................................................................. 15 2.7 Clamping Jaw Extensions AR46 (p/n RP11-8-11400276)................................... 15 3. ADVANCED PROCEDURES ........................................................................ 17 3.1 Advanced Bead Breaking Procedures ................................................................. 17 Bead Breaking “AH” Wheels (e.g. BMW M3, M5, Some Porsches, Range Rover, Lancia, etc.) ......................................................................................................... 17 Bead Breaking “AH” Wheels as follows: ....................................................... 17 3.2 Advanced Demounting Procedures ..................................................................... 18 Demounting Tire from Rim Using the Bead Lever Tool without the Plastic Sleeve Protector............................................................................................................... 18 Demounting Upper Bead............................................................................... 18 Demounting Lower Bead............................................................................... 19 “HM” Bead Lever and Sleeve Protector, RP6-2663 ............................................ 19 Benefits.......................................................................................................... 19 Use of “HM” Bead Lever................................................................................ 19 3.3 Advanced Mounting Procedures .......................................................................... 20 3.4 Mount/Demount Head Assembly ......................................................................... 20 Checking Mount/Demount Head Calibration ....................................................... 21 For Steel Heads ............................................................................................ 21 Set Position of Steel Mount/Demount Head on Hex Shaft............................ 21 For Plastic Heads .......................................................................................... 22 Set Position of Plastic Mount/Demount Head on Hex Shaft ......................... 22 TCX500 Tire Changer Family Operation Manual Contents • i Adjust the Offset of Lock Mechanism – Steel and Plastic Heads ................. 23 4. TCX515 OPERATIONAL SUPPLEMENT..................................................... 25 BP Arm Operation................................................................................................ 25 4.1 General Information.............................................................................................. 25 4.2 Part Identification.................................................................................................. 25 4.3 Operation.............................................................................................................. 26 Clamping the Wheel............................................................................................. 26 Demounting.......................................................................................................... 27 Removing Tire from Rim...................................................................................... 28 Mounting .............................................................................................................. 28 Using the Bead Press Head Hook to Lift the Tire................................................ 30 5. TCX535 OPERATIONAL SUPPLEMENT..................................................... 31 Bead Press System Operation ............................................................................ 31 5.1 General Information.............................................................................................. 31 5.2 Part Identification.................................................................................................. 31 5.3 Operation.............................................................................................................. 32 Clamping the Wheel............................................................................................. 32 Demounting.......................................................................................................... 32 Breaking the Inner Bead ...................................................................................... 33 Mounting .............................................................................................................