ZIPPER MASCHINEN ZI-RMM95 Tire Mounting Machine User Manual

: June 6, 2024
: ZIPPER MASCHINEN

ZIPPER MASCHINEN ZI-RMM95 Tire Mounting Machine

SAFETY SIGNS

| CE-Conformal! – This product complies with the EC-directives.
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| Read the operation manual carefully before first use!
| CRUSH HAZARD! – KEEP FEET AND OTHER BODY PARTS AWAY FROM THE WHEEL PRESSING UNIT DURING OPERATION
| CRUSH HAZARD – KEEP HANDS OFF TURNING PLATE AND MOUNTING HEAD DURING OPERATION
| CRUSH HAZARD – KEEP HANDS AND OTHER BODY PARTS OFF CLAMPING CYLINDERS DURING OPERATION
| CRUSH HAZARD – KEEP HANDS AND OTHER BODY PARTS OFF CLAMPING SHOES AND TYRE!
| Wear personal protective equipment!

ILLUSTRATIONEN

TECHNIC

components

PREFACE

Dear Customer!

This manual contains information and important instructions for the installation and correct use of the ZIPPER “Tire mounting machine” ZI-RMM95. Following the usual commercial name of the machine (see cover) is substituted in this manual with the name “machine”.

| This manual is part of the product and shall not be stored separately from the product. Save it for later reference and if you let other people use the product, add this instruction manual to the product.
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Please read and obey the security instructions!
Due to constant advancements in product design, construction pictures and content may diverse slightly. However, if you discover any errors, inform us please.
Technical specifications are subject to changes!

Please check the product contents immediately after receipt for any eventual transport damage or missing parts.

Claims from transport damage or missing parts must be placed immediately after initial product receipt and unpacking before putting the product into operation.

Please understand that later claims cannot be accepted anymor e.

Copyright

© 2018 This document is protected by international copyright law. Any unauthorized duplication, translation or use of pictures, illustrations or text of this manual will be pursued by law. Court of jurisdiction is the regional court Linz or the competent court for 4707 Schlüsslberg, Austria!

Customer service contact

ZIPPER MASCHINEN GmbH
Gewerbepark 8, A-4707 Schlüsslberg AUSTRIA
Tel.: +43 7248 61116-700
Fax: +43 7248 61116720
Mail: info@zipper-maschinen.at

SAFETY

This section contains information and important notices for safe commissioning and handling of machine.

For your own safety, read these operating instructions carefully before putting the machine into operation. This will enable you to handle the machine safely and prevent misunderstandings as well as possible damage to property and persons. Also observe the symbols and pictograms used as well as the safety instructions and hazard warnings!

Intended use of the machine

The machine is intended exclusively for the following activities: Mounting and dismounting tyres on rims and inflating these tyres.

ZIPPER-MASCHINEN assumes no responsibility or warranty for any other use or use beyond this and for any resulting damage to property or injury.

Technical Restrictions

The machine is intended for use under the following ambient conditions:

Relative humidity: max. 70 %
Temperature (for operation): +5° C bis +50° C
Temperature (for storage and/or transport): -20° C bis +55° C

Prohibited Use / Forseeable Misuse

Operation of the machine without adequate physical and mental aptitude
Operating the machine without appropriate knowledge of the operating instructions (machine + motor).
Changes in the design of the machine
Operating the machine in wet and rainy conditions
Operating the machine in a potentially explosive environment
Remove the safety markings attached to the machine.
Modify, circumvent or disable the safety devices of the machine.
Use of the machine for the transport of persons

The prohibited/hazardous use or disregard of the information and instructions presented in this manual will result in the voiding of all warranty and damage claims against Zipper Maschinen GmbH.

User Requirements

The physical and mental suitability as well as knowledge and understanding of the operating instructions are prerequisites for operating the machine. Persons who, because of their physical, sensory or mental abilities or their inexperience or ignorance, are unable to operate the machinery safely must not use it without the supervision or instruction by a responsible person.
Please note that local laws and regulations may determine the minimum age of the operator and restrict the use of this machine!
Put on your personal protective equipment before working on the machine.
Work on electrical components or equipment may only be carried out by a qualified electrician or carried out under the guidance and supervision of a qualified Electrician.

General Safety Instructions

To avoid malfunctions, damage and health hazards when working with the machine, the following points must be observed in addition to the general rules for safe working:

Choose a level, vibration-free, non-slip surface for the installation location.
Ensure sufficient space around the machine!
Ensure sufficient lighting conditions at the workplace to avoid stroboscopic effects!
Only use perfect tools that are free of cracks and other defects (e.g. deformations).
Remove setting tools from the machine before switching on.
Keep the area around the machine free of obstacles (e.g. dust, chips, cut workpiece parts etc.).
Check the strength of the machine connections before each use.
Never leave the running machine unattended. If necessary, stop the machine before leaving.
The machine may only be operated, serviced or repaired by persons who are familiar with it and who have been informed of the dangers arising in the course of this work.
Ensure that unauthorised persons maintain an appropriate safety distance from the machine and keep children away from the machine in particular.
Wear suitable protective equipment (ear protection, gloves when handling tools) as well as close-fitting work protective clothing – never wear loose clothing, ties, jewellery etc. – danger of being drawn in!
Hide long hair under hair protection.
Always work with care and the necessary caution and never use excessive force.
Do not overload the machine!
Do not work on the machine if it is tired, not concentrated or under the influence of medication, alcohol or drugs!
Do not use the machine in areas where vapours from paints, solvents or flammable liquids represent a potential danger (danger of fire or explosion!).
Make sure that the ON/OFF switch is in the “OFF” position before connecting the machine to the power source.
Do not use the power tool if it cannot be switched on and off with the ON/OFF switch.
Ensure that the unit is earthed.
Only use suitable extension cords.
Always shut down the machine before carrying out any conversion, adjustment, measuring, cleaning, maintenance or repair work and always disconnect it from the power supply for maintenance or repair work. Before starting any work on the machine, wait until all tools or machine parts have come to a complete standstill and secure the machine against unintentional restarting

Electrical Safety

Proper plugs and matching sockets reduce the risk of electric shock. The plug of the power tool must be adapted to the socket. Never modify the plug in any way. Do not use adapter plugs with earthed power tools.
There is an increased risk of electric shock if your body is in ground contact. Avoid physical contact with earthed objects, such as pipes, radiators, etc.
Water that penetrates power tools increases the risk of electric shock. Do not expose the power tools to rain or moisture.
A damaged or tangled cable increases the risk of electric shock. Handle the cable with care. Never use the cable to carry, pull or disconnect the power tool. Keep the cable away from heat, oil, sharp edges or moving parts.
If you are using an outdoor power tool, use an extension cord suitable for outdoor use!
Use of the power tool in a humid environment is only permitted if the power source is protected by a residual current circuit breaker.
Do not use the power tool if it cannot be switched on and off with the ON-OFF switch.

Special Safety instructions for that machine

Keep away from the machine when operating any of the foot pedals! Take especially care to keep hands off the tyre plate area and keep the feet off the bed-breaking device
Never exceed the recommended max. tyre pressure of the tyre manufacturer.
Always check tyre, rim and tyre position on rim before and during inflating process.

Hazard warnings

Despite intended use, certain residual risks remain. Due to the design and construction of the machine, hazardous situations may occur which are identified as follows in these operating instructions:

| A safety instruction designed in this way indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

| Such a safety instruction indicates a potentially hazardous situation which, if not avoided, may result in serious injury or even death.

| A safety instruction designed in this way indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
| A safety note designed in this way indicates a potentially dangerous situation which, if not avoided, may result in property damage.

Irrespective of all safety regulations, their sound common sense and corresponding technical suitability/training are and remain the most important safety factor in the error-free operation of the machine. Safe working depends first and foremost on you!

TRANSPORT

| Damaged or insufficiently strong hoists can result in serious injury or even death. Always check hoists for adequate load-bearing capacity and perfect condition, secure loads carefully and never stand under suspended loads.

To ensure proper transport, also observe the instructions and information on the transport packaging regarding centre of gravity, attachment points, weight, means of transport to be used and the prescribed transport position, etc. The tire mounting machine must be moved in its original packaging to the place of operation. The packed machine can be moved with a fork truck or a manual fork lift.
The machine is heavy. At least two persons are required for transport and installation.

ASSEMBLY

Preparatory Activities

Check delivery content

Check the machine immediately after delivery for transport damage and missing parts.

Workplace requirements

Choose a suitable site for the operation. It must fulfill the regulations for workplace safety applicable in your country and must provide a suitable electronic supply connection and pressure air connection with 8-10bar. The ground must be level and solid and capable to bear the machines weight. Take care to position the machine so that it has at least 1m of free space around. Fix the machine through the 4 bores in the machine base to the ground!

Electrical Connection

| Dangerous electrical voltage! The machine may only be connected to the mains supply and the associated checks carried out by a qualified electrician or under the instruction and supervision of a qualified electrician!

The connection of the machine to the electric power supply and the following checks are to be carried out by respectively certified electricians only! The electronic connection of the machine is designated for operation with a grounded power socket!
The connector plug may not be altered or manipulated! A damaged cable has to be replaced immediately! The supply net must be secured with at least 16A. Check, whether the supply net voltage and frequency complies with the machine motors requirements!

Compressed air connection

Connect the machine to compressed air supply at the compressed air connection (16). ATTENTION: The ZI-RMM95 may be only operated with pressure levels between 8-10 Bar.

Test run

Check the function of the foot pedals and of the pressure air hose. If you notice any malfunctions check all connections again

OPERATION

| In order to avoid damages, use the provided mounting lever to initiate the demounting and mounting of tyres.
The connecting area between tyre and rimbed, where the bed-breaker separates the tyre from the rim, should always be lubricated with suitable lubricants to prevent the rim from damage. Check for eventual prescribed running directions for tyre mounting of the tyre wall. Tyres and rims must match together regarding their technical dimensions. Always check the tyre extensively for any abnormalities like deformation, surface damage, excessive or uneven wear etc. before mounting it
. Always check whether tyre/rim requires special mounting procedures. For this inform yourself in documentations etc. oft he respective manufacturer.
When inflating tyres, check tyre pressure and tyre form frequently.

Dismount tyre from the rim

Slowly release the air from the tyre.
Remove all balance weights and other foreign materials from the rim. Lubricate the tyre bead with suitable lubricant or soap suds, before you separate the tyre from the rim with the bead-breaker to prevent the tyre bead from damage.

Place the tyre to the tyre positioning plate (20), so that the bead-breaker (19) edge is max.
1cm far from the rim edge.
Keep hands/feet of danger area of bead-breaker!
Operate foot pedal (1), the bead-breaker will press the tyre off the rim.
Remove these steps several times until the tyre is separated from the rim entirely. Place the tyre onto the tyre disc (5). ATTENTION: for asymmetric lowbed-rims place the rims so that the flat side shows upwards.
Operate foot pedal (2) for clamping and centering the rim.
Attention: For sensible rims use the four provided plastic clamps.
If you wish to clamp your rim from inside to outside, first operate pedal (2) until jaws are centered in the middle, place the rim onto the tyre disc and operate the pedal (2) again.
Swing the swing arm (9) into working position over the rim edge, press the mounting bar downwards until the mounting head (7) clears the rim edge 1-2mm
Fix the head in this position with the height fixation lever (11) and fix the swing arm position as well.

See figure D:

Slip the outer tyre bead with the help of the provided mounting bar over the mounting head (7).
Operate the foot pedal (3) to move the tyre disc (5) until the outer tyre bead is slipped over the rim edge entirely. Always check the postion of the valve during rotation to avoid damage!

See figure E:

Remove the air tube first, if present.
Slip with the mounting lever the lower tyre bead over the mounting head.
Operate the foot lever (3) to pull the entire lower tyre bead over the rim edge.

Mount tyre onto a rim

Check whether tyre and rim match regarding technical dimensions, especially width and diameter!
If using a new rim, clamp it as described, if you mount a new tyre on a already clamped rim – let it be clamped.
Lubricate the tyre bead with suitable lubricant!

See Figure F:

Place the tyre onto the rim in a way, that the left side is higher than the right side and bring the mounting head into position as shown in the figure.
Position the tyre in a way that the tyre bead is over the left (see Fig. F 1) but is simultaneously under the right side (see Fig. F 2) of the mounting head.
Operate foot pedal (1), the inner tyre bead gets pulled under the rim edge.
If required, insert now the tyre-tube in a way that it will not constrain the mounting.

See Figure G:

Perform the mounting similarily.
But when having the last 10-15cm being pulled under the rim edge take special care that the tyre bead gets not damaged. Stop the tyre disc if required and reverse if necessary. Try to easy the pull down by pressing onto the tyre on the other side already being pulled under the rim.

Inflate tyres

| Always check whether tyre and rim match together in all technical aspects. Check extensively, whether there is any damage or anormality of the tyre or rim and check whether the tyre is really mounted onto the rim correctly.
NEVER exceed the max. tyre pressure recommended by the tyre manufacturer. When inflating air into the tyre, check the pressure frequently, check regularily the tyre shape.
During the air inflating process itself keep yourself away from the tyre as much as possible

In order to inflate a tyre connect the provided inflating device to the air hose (14).
Connect the inflating device to the tyre valve. Through pressing the lever of the inflating device air gets inflated into the tyre

CLEANING, MAINTENANCE, STORAGE, DISPOSAL

Cleaning

| Wrong cleaning agents can attack the varnish of the machine. Do not use solvents, nitro thinners, or other cleaning agents that could damage the machine’s paint. Observe the information and instructions of the cleaning agent manufacturer!

Prepare the surfaces and lubricate the bare machine parts with an acid-free lubricating oil.

Maintenance

| Danger from electric voltage and compressed air! Manipulation of the machine with the power supply or compressed air supply upright can lead to serious injuries or death. Always disconnect the machine from the power supply and compressed air supply before carrying out any maintenance work.

The machine is low-maintenance and only a few parts have to be serviced. Nevertheless, malfunctions or defects which could impair the safety of the user must be rectified immediately!
IMPORTANT: deaerate the machine at least every 3 months completely! Inspection and Maintenance Plan

Upkeep and Maintenance Plan

Clean tyre disc and lubricate clamping jaw joints.| Clean tyre disc and lubricate clamping jaw joints.
Lubricate Swing arm (9), mounting bar (8) and all other moving parts and joints| Lubricate Swing arm (9), mounting bar (8) and all other moving parts and joints
Check and tighten all screw fittings if necessary.| Check and tighten all screw fittings if necessry.
Check drive belt tension| Check drive belt tension
Deaerate entire hydraulic system completely| Deaerate entire hydraulic system completely

Check lubricant level

Check the lubricant level in the lubricant container (17). Add SAE 30 oil if necessary.

Check drive belt tension

Remove the cover on the left side of the tyre changing machine to gain access to the drive belts.
For this unscrew the four fixing screws of the cover and remove it.
If the belt is not tightened sufficiently or is dirty or polluted with lubricants, it might slip on the pulleys and cause stalling. In order to tighten the belt, please adjust it with a bolt being positioned on the motor plate.

Storage

| Improper storage can damage and destroy important components. Only store packed or unpacked parts under the intended ambient conditions!

In case of a longer interruption of operation or shutdown, clean the machine and then store it out of the reach of children in a dry place protected from frost and other weather influences !
Disconnect the machine from the power supply and the air compression supply.
Release the tension of the hydraulic system before disconnecting it (16) from the compressed air supply

Disposal

| Observe the national waste disposal regulations. Never dispose of the machine, machine components or equipment in residual waste. If necessary, contact your local authorities for information on the disposal options available.
If you buy a new machine or an equivalent device from your specialist dealer, he is obliged in certain countries to dispose of your old machine properly.
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TROUBLESHOOTING

| Danger from electric voltage and compressed air! Manipulation of the machine with the power supply or compressed air supply upright can lead to serious injuries or death. Always disconnect the machine from the power supply and compressed air supply before carrying out any troubleshooting work

Many possible sources of error can be excluded in advance if the machine is properly connected to the mains.
If you are unable to carry out necessary repairs properly and/or do not have the required training, always consult a specialist to correct/solve the problem!

Failure	Possible cause / solution
Tyre disc turns in one direction only	Problem: commutator broken

Solution: let commutator be replaced
Tyre disc does not rotate at all| Problem: defect belt
Solution: replace belt
Problem: belt not tensioned
Solution: tension the belt
Problem: commutator broken
Solution: let commutator be replaced Problem: motor defect
Lösung: let this possibity be checked by a certified electrician who should check the power supply, the cables and the motor to localize the error exactly.
Tyre disc stalls during rotation| Problem: belt slips
Solution: clean + tension belt
Clamping slowly jaws open/close too| Problem: pressure air silencer in the machine
Solution: Through belt access door you gain access to silencers as well, clean them!
Release pressure from hydraulic system beforehand!
Jaws do not clamp rim sufficiently| Problem: insufficient compression rate supply Solution: check compression air supply pressure Problem: jaws defect
Solution: replace jaws
Problem: pressure air silencer in the machine
Solution: Through belt access door you gain access to silencers as well, clean them!
Release pressure from hydraulic system beforehand!
Problem: clamping cylinder defect
Solution: replace cylinders