Form 4352T, 02-05 Supersedes Form 4352T, 08-03 OPERATION INSTRUCTIONS TC3500 Tire Changer © Copyright 1998 - 2003 Hunter Engineering Company
OWNER INFORMATION Model Number ____________________________________________________________________ Serial Number ____________________________________________________________________ Date Installed _____________________________________________________________________ Service and Parts Representative _____________________________________________________ Phone Number ____________________________________________________________________ Sales Representative ______________________________________________________
Demounting Trained Declined 90°/110° Position of Arm to Rim Standard Wheels with Bead Lever and Plastic Sleeve Protector Low Profile Wheels with Bead Lever, No Plastic Sleeve Protector Assistance of Bottom Roller Installation and Removal of Bead Depressor Tail Full Seating of Mount/Demount Head to Prevent Head Failure Bead Lubrication during Removal of Low Profile Tires Reverse Drop Center Wheels “HM” Bead Lever Technique Trained Declined 9
Contents 1. Getting Started...........................................................................................1 1.1 Introduction .............................................................................................................1 1.2 For Your Safety.......................................................................................................1 Hazard Definitions............................................................................................
3.7 Run-Flat Tire Service ............................................................................................34 Basic Run-Flat / EMT Information..................................................................34 Run-Flat “Zero Pressure” Tires and Rims .....................................................34 Tire Monitoring System (TMS) .......................................................................35 Sensors ...................................................................................
TC3500 Operation Instructions Contents • iii
1. Getting Started 1.1 Introduction This manual provides operation instructions and information required to maintain the TC3500 tire changer. An advanced operation section has been provided in “Advanced Procedures.” “References” This manual assumes that you are already familiar with the basics of tire changing. The first section provides the basic information to operate the TC3500. The following sections contain detailed information about equipment, procedures, and maintenance.
IMPORTANT SAFETY INSTRUCTIONS NOTE: Operators of this equipment should review the Hunter Training video before use. A certification test is also available. Read and follow all caution and warning labels affixed to equipment and tools. Read and understand all instructions before operating this machine. Misuse of this equipment can cause personal injury and shorten the life of the TC3500. To prevent accidents or damage to the TC3500, use only Hunter recommended procedures and accessories.
Do not operate TC3500 with worn rubber or plastic parts. Wheels equipped with low tire pressure sensors or special tire and rim design may require certain procedures. Consult manufacturer’s service manuals. Service and maintain machine regularly as outlined in “Maintenance and Calibration,” page 75. For further information contact: Hunter Engineering Company 11250 Hunter Drive Bridgeton, Missouri 63044 1-800-448-6848 Internet address: www.hunter.com 1.
1.6 Air Inflation Pedal The pedal on the left side of the base is a two-stage design. Refer to illustration on page 6. The pedal controls the air going to the inflation hose and the dual air inflation ring. CAUTION: Keep hands clear of wheel during sealing and seating of bead. When operating air inflator, stand to the left side of the base. Do not stand in front of the TC3500 while operating the air inflator. Step down partially on the pedal to inflate tires through inflator hose.
TC3500 Operation Instructions 1.
1.9 Equipment Components TC3500 6 • 1.
TC3500-SS TC3500 Operation Instructions 1.
8 • 1.
2. Basic Procedures 2.1 Bead Loosening (TC3500-SS Models only) For bead loosening with rollers, refer to “2.3 Bead Loosening Standard Rim and Tire,” page 13. Remove valve stem core and deflate tire completely. WARNING: All air pressure inside the tire must be removed before proceeding. Never attempt to loosen the bead until all air is removed from the tire. Failure to remove all air from tire may result in injury to operator, or damage to equipment, tire, or wheel.
Remove all weights from the rim to protect the rim and extend life of mount/demount head (if not done previously). Identify and recognize special wheel combinations such as Reverse Drop Center, AH2, and “Run-Flat” Extended Mobility Tires (EMT). Identify the inner locations on the rim where the rubber pads of the clamping arms will come in contact in a parallel manner.
Verify that the wheel has been properly clamped and centered. NOTE: On conical shaped rims, always clamp the rim at a position parallel to the feet to prevent slippage. If the rim clamping area is oily or wet, clean the backside of the rim or install the steel clamping jaws, RP6-2035, on the rubber pads to increase rim gripping ability or use the wheel securing device. Refer to “Installation of Wheel Securing Device,” page 11 or to “Installation of Steel Jaws,” page 12.
If lock pin will not engage, loosen clamping arms and reposition pin. CAUTION: The wheel securing device is not to be used as a safety related hold-down tool. Installation of Steel Jaws The steel clamping jaws, RP6-2035, may be used if the rim clamping area is oily or wet. Install the jaws onto the rubber pads to increase rim gripping ability. Place a steel jaw onto a rubber pad of a centering arm. Push the steel jaw completely onto the rubber pad.
Clamping Reverse Drop Center Wheels HINT: Identify reverse drop center wheels while you are loosening the bead of the tire. This will help you properly identify the proper procedure to use before demounting the tire. Wheels with a reversed offset drop center must be mounted on the tire changer upside down to remove the tire from the rim without damage.
CAUTION: Never rotate the wheel clockwise while bead loosening. Never lock the bead roller assembly with the lock knob while bead loosening. Push the upper and lower bead of the tire off the rim bead seat. CAUTION: Never place hands near the rollers while applying force and rotating tire. Hands could be pulled between the roller and tire causing injury. Lubricate the lower bead and rim by inserting brush of lubricant into wheel just behind the roller. Lubricate the upper bead and rim as above.
Position the straight end of the bead lever between right hand edge of mount/demount head and bead of tire. Slide plastic protector sleeve on the bead lever tool toward the tire. The mount/demount head should be positioned between the humps of the plastic protective sleeve. Push down on the tire sidewall at the 6 o’clock position. On very stiff tires, use the Bead Depressor “Tail” to slip the sidewall into the drop center of the rim.
2.5 Mounting Standard Tire to Rim Always be aware of this “checklist” when mounting tires to ensure proper service. There are four basic steps when mounting a tire to a rim: • Position the bead on top of the left lip of mount/demount head. • Position the bead under the right lip of the mount/demount head. • Lock the rim to the tire. • Slip the bead into the drop center.
NOTE: If the tire bead does not have sufficient lubrication and the tire fails to slip into drop center during mounting, the mount/demount head may fail before damage to tire bead takes place. For additional information on special wheels, refer to “Advanced Mounting Procedures.” Precautionary Notes When basic procedures are not followed, sharp angled wheel flanges increase potential damage to tires during mounting. Be sure the tire bead is placed on top of the mounting head.
Step down completely on the air inflation pedal to release a high-pressure air blast through nozzles on the air inflation ring to assist in seating the beads of the tire. Step down partially on the air inflation pedal to inflate tire and seat the beads. WARNING: Do not exceed 40 PSI when seating the beads of a tire. After beads have been seated, disconnect inflation hose and reinstall valve stem core previously removed. Then connect inflation hose and inflate tire to the required pressure.
3. Advanced Procedures The capabilities of the TC3500 allow the user to utilize numerous advanced procedures on a variety of rims and tires. For the operator to take advantage of these features, this section explains in detail what additional steps can be taken. 3.1 Advanced Bead Loosening Procedures Bead Loosening Soft Sidewall, Tall Profile Tires Swing the bead roller assembly in toward the column to the working position (against the stop). Set rim diameter.
Bead Loosening Tough, Low Profile Tires Swing the bead roller assembly in toward the column to the working position (against the stop). Set rim diameter. WARNING: Never place hands near the rollers while applying force and rotating wheel. Bring the upper bead roller down until it contacts the tire at the edge of the rim. Lock upper roller into the side of the tire by pushing the upper roller down while rotating wheel counterclockwise so it is approximately 1/4 inch below rim edge.
Lower the upper bead roller until it contacts the tire. Lock the upper roller into the side of the tire. Roller should be approximately 1/4 inch below rim flange. Rotate wheel counterclockwise. Gradually push the upper bead of the tire off the rim bead seat by rotating the tire repeatedly and pushing the upper roller down the sidewall. Apply roller force gradually. Let multiple rotations of the tire slowly push the tire off the safety hump.
Gradually push the bead of the tire off the rim bead seat by rotating the tire repeatedly and pushing the roller down the sidewall. Apply roller force gradually. Let multiple rotations of the tire slowly push the tire off the safety hump. After the bead of the tire has been broken loose from the safety hump of the rim bead seat, thoroughly lubricate tire and rim. Retract upper roller. Remove wheel and clamp face up to demount tire (providing rim is not of reversed drop center design). 3.
Lock the bead roller fixation knob. Rotate the wheel clockwise until the valve stem is at the 1 o'clock position. Lubricate and push the bead depressor post through the center hole of the rim until it has been inserted into the spring centering system. HINT: If the post will not insert into the center hole, the wheel support is depressed too far down. Release the clamping jaws and reposition the arms to allow for less compression of the support and try again.
Rotate wheel clockwise and position each of the attached blocks of the bead depressor onto the rim as shown. Each block should be positioned as far away from the next block as the cord will allow. For rims that have an extra deep drop center, position each of the following attached blocks under the rim lip as shown below. Rotate the wheel clockwise until the Bead Depressor “Tail” is installed between the 3 o'clock and 9 o'clock positions.
Push bottom roller up again to fully bring tire bead over head. Rotate the wheel counterclockwise approximately 1/2 inch to unfurl tire bead onto the bead lever. Slide the bead lever tool out from between the mount/demount head and the bead of the tire. The bead of the tire must remain over the right-hand end of the head. Rotate wheel clockwise until the entire bead is lifted from the rim. Retract the lower roller to the resting position. Remove the Bead Depressor “Tail” from the rim.
The force multiplier is used to help the operator to keep the polymer head down and fully seated when levering the upper bead during demounting of low-profile, stiff sidewall tires. The force multiplier may also be used to push the sidewall down in order to enable the mounting head to be hooked on to the edge of the wheel. Position the polymer head against the wheel edge in preparation for demounting.
Cylindrical Rims/Bead Loosening and Demounting Lower Bead WARNING: When demounting the lower bead on rims with a small drop center where section A is long and cylindrical, rolling up the bead with the lower bead roller can cause damage if not operated properly. Lock the upper roller against top bead. Place and lock the lower roller against the lower bead. Rotate wheel and loosen bottom bead from rim. Lubricate tire and rim thoroughly. Retract lower roller.
Mechanical Bead Pusher, RP6-2413 The Mechanical Bead Pusher is used for pushing the upper bead below the right hand area of the mount head, keeping the tire in the proper location during mounting of stiff, low profile tires. To use: Mount the bottom bead of the tire onto the wheel. Position the upper bead of the tire on the upper left side of the mounting head.
Position the fixed block of the bead depressor between the rim and the bead of the tire that was previously positioned below the rim lip. Swing the bead roller assembly in toward the unit to the working position (against the stop). Lock the bead roller assembly into the working position by pushing down on the fixation knob. Set the rim diameter approximately 2 inches larger than the actual rim diameter by moving the command unit away from or toward the unit.
Rotate the wheel clockwise until the upper bead of the tire is completely installed. To prevent rim from spinning inside the tire, grasp tire at location shown below and pull tire along with rim during rotation. Remove Bead Depressor “Tail” from rim. Removal of Bead Depressor “Tail” CAUTION: Never forcefully pull bead depressor “tail” out of tire after installation to avoid damage to tool and/or rim. With the upper roller depressing the sidewall of the tire, rotate the wheel counterclockwise.
Remove the block and shaft from the rim by pushing out to relax from rim. Retract the upper roller. Unlock the bead roller assembly by pulling up on the fixation knob and swing the bead roller assembly away to the resting position. Mounting Low Profile Tires on Rounded Edged Rims On certain types of alloy rims with round flanges, there is a potential to rub the surface of weak coated rims.
Push on the bead while rotating wheel clockwise instead of going over the top of the mounting head. Lock the rim to the tire by hand, or by using the bead lever or bead depressor “tail.” Slip the bead into the drop center. Rotate wheel clockwise to mount tire. 3.4 Mounting Stiff, Low Profile Tires on Rounded Edged Rims Using Roller and No Mounting Head CAUTION: This special case procedure does not perform properly on all tires.
Continue mounting by rotating the wheel counterclockwise until upper bead is mounted. Retract upper roller and swing bead roller assembly away to prepare for inflation. HINT: Use of bead depressor (without inserting tail) may assist in locking tire to rim during mounting. 3.5 Mounting 20-Inch and Larger Automotive Wheels and Tires Twenty-inch and larger wheels have recently been introduced into the market. The handling of these tires on the TC3500 will not pose any difficulties.
Continue rotating the tire and rim at different speeds until the rim spins inside the tire and the mark on the tire is positioned where needed in reference to the rim. Once matching has occurred, retract arms and inflate. 3.7 Run-Flat Tire Service Basic Run-Flat / EMT Information A Run-Flat / EMT tire is capable of supporting the vehicle’s weight, even when the air pressure is zero psi. The sidewall of the tire is approximately six times thicker than a standard tire.
The air pressure sensor will be located in two possible locations: Valve stem, integral type: located at the valve stem as an integral part of the valve. Drop Center, Band and Sensor type: located 180 degrees away from the valve stem and in the drop center of the rim. Extended Mobility Tires (EMT) should have a standard Low Tire Pressure Warning System. If the “LOW/FLAT TIRE” warning light is “ON,” check the inflation of the tire.
Chemical-based tire sealer and inflators (commonly referred to as “Fix-a-Flat”) will damage the sensors and void the customer’s warranty. Sensors The band type sensor fits over most wheels. Compatibility must be checked during installation. The valve type sensor is currently used on original equipment wheels. The valve type sensor can be installed only on wheels machined for an O-ring seat and sensor profile. Valve type sensors will soon be available for aftermarket changeover.
Measure and trim excess band clamp length. Remove burrs from end of bands. Wheel Diameter Cut-off Length 13” 16” 14” 13” 15” 10” 16” 7” 17” 3” 18” N/A Pass band clamp through counterweight with notch facing toward valve stem. Thread band clamp through sensor with label and counterweight valve cutout on same side. Position sensor 180 degrees from valve stem. Clamp screw must not be within two inches of sensor. TC3500 Operation Instructions 3.
Position counterweight under valve stem with notch for stem base. Tighten clamp to specified torque (30 in.-lbs.). Verify position of sensor, counterweight, and clamp screw. Note sensor number and wheel position. 38 • 3.
Demounting Run-Flat with Valve Type Sensor Mount wheel/tire assembly on TC3500. Inspect the wheel for safe serviceability and identify the type of sensor. Valve type sensors are identified as aluminum with a retainer nut. Remove the valve core. Remove the sensor retainer nut (11mm). Drop sensor into the tire. Liberally lubricate tire and wheel during bead loosening. Use multiple short strokes of bead roller. TC3500 Operation Instructions 3.
Properly clamp and secure the wheel on the tire changer. Position upper bead into drop center opposite demount head by using bead depressor tail. Lubricate “HM” bead lever. 40 • 3.
Insert bead lever (with protector sleeve) and pry top bead onto demount head. As required, rotate briefly counterclockwise to unfurl the toe of the bead on the demount head. Carefully rotate clockwise to remove upper bead. Remove bead depressor tail. TC3500 Operation Instructions 3.
Remove the sensor from inside the tire. Position lower bead opposite demount head into the drop center. Insert bead lever and pull back to pry the lower bead onto the demount head. Carefully rotate tire/wheel assembly to demount lower bead and remove tire from wheel. 42 • 3.
Mounting Run-Flat with Valve Type Sensor Inspect the wheel for safe serviceability and identify the type of sensor. Note wheel position on vehicle. Verify the tire is the proper size for the wheel. Properly position and secure the wheel on the changer. TC3500 Operation Instructions 3.
Clean the sensor and sensor mount surface on wheel. Inspect and lubricate O-ring. Insert the sensor and properly torque to manufacturer’s specification. Lube wheel flange area, bead seats, and drop center balcony. 44 • 3.
Fully lubricate the inner and outer portion of both beads of the tire. Verify the direction of rotation for directional tires. Position lower bead on mount/demount head. Rotate tire clockwise and lock to wheel for traction, making sure that sensor is just ahead of traction point. TC3500 Operation Instructions 3.
Mount bottom bead. Position upper bead on mount head. Install bead depressor tail. Verify sensor is just ahead of traction point. 46 • 3.
Rotate tire with wheel clockwise, maintaining traction. Tire and wheel must rotate clockwise without slippage. Carefully mount upper bead. Sensor should end up under mount head. Remove bead depressor tail. Verify air outlet of sensor is not blocked by bead of tire prior to inflation. Repositioning of tire bead may be necessary. Do not inflate tire on tire changer. TC3500 Operation Instructions 3.
Inflating Run-Flats WARNING: Always use an approved inflation safety cage and remote air gauge when inflating and seating beads on Run Flat tires. Use adequate lube during mounting to assist in bead seating. Relube as required. Remove tire/wheel and place in safety inflation cage. Attach clip-on hose from remote inflation gauge. Stand in safe zone away from wheel flanges and slowly inflate. 48 • 3.
Never exceed 80 psi to seat beads. If not seated, all pressure MUST be exhausted remotely before approaching tire in cage. Remove, inspect, and relubricate if beads do not seat. After beads seat, deflate tire using the remote device. Install valve core and re-inflate to specification inflation pressure using remote device. Remove tire/wheel assembly from cage. Demounting Run-Flat with Band Type Sensor Inspect the wheel for safe serviceability and identify the type of TMS sensor.
Remove valve core and fully deflate the tire. Loosen outer bead with multiple short strokes without damaging sensor. Apply lube to bead and wheel. Visually verify sensor location. 50 • 3.
Mark wheel and tire sidewall with tire crayon to index location. Loosen inner bead with short strokes without damaging sensor. Apply lube to bead and wheel. Clamp wheel on changer. Position sensor immediately to left of bead lever position. TC3500 Operation Instructions 3.
Slip tire into drop center opposite head using bead depressor tail. Pry upper bead over demount head. Depress bead with upper bead roller and insert “HM” bead lever tool. Unfurl bead by briefly rotating tire/wheel assembly counterclockwise. 52 • 3.
Rotate tire/wheel assembly clockwise, while grasping and pulling tire to maintain traction against wheel. Carefully remove upper bead. Remove bead lever and bead depressor tail. Re-loosen lower bead, if necessary. TC3500 Operation Instructions 3.
Reposition sensor immediately to left of bead lever position. Position lower bead into drop center opposite demount head. Insert bead lever with protective sleeve. Pull tire up and pry bead over demount head. Rotate to remove tire. Grasp bead lever and remove from underside of tire. 54 • 3.
Mounting Run-Flat with Band Type Sensor Inspect the wheel for safe serviceability and identify the type of TMS sensor. Verify the tire is the proper size for the wheel. Properly position and secure wheel on changer. TC3500 Operation Instructions 3.
Verify proper position of sensor and counterweight. Inspect and/or replace valve stem. Lube tire beads and wheel. Verify the direction of rotation for directional tires. 56 • 3.
Position lower bead on mount head. Rotate tire and “lock” to rim for traction. Verify sensor is just ahead of traction point. Mount bottom bead by rotating wheel and tire clockwise together. Position upper bead on mount head with sensor in anticipated “lock” position. TC3500 Operation Instructions 3.
Install bead depressor tail. Verify sensor is just ahead of traction point. Carefully mount upper bead by rotating tire with wheel clockwise, maintaining traction. Tire and wheel must rotate WITHOUT SLIPPAGE. Sensor must end up under mount head. WARNING: 58 • 3. Advanced Procedures Always use an approved inflation safety cage and remote air gauge when inflating and seating beads on Run-Flat / EMT tires.
3.8 Servicing BMW Z3 Motorsport Rear Reversed Drop Center 17x9AH2 Overview of Components Tire has a low profile, soft sidewall, with stiff, wide tight bead. Rim has a reverse drop center with AH2 bead lock system locking the tire to the rim. If using a side shovel type tire changer, the bead should be loosened at the valve stem location first. NOTE: A side shovel type tire changer is not the recommended equipment for servicing this wheel/tire combination.
An extremely deep drop center and low profile tire combination causes high mountability distance. Optional Bead Depressor “Tail” with Traction Device, RP6-3702, special tool required. Bead Loosening Clean demount head. Replace with a new unit if dirt is embedded in demount head. 60 • 3.
Clean rim. Note and record any damage to rim prior to servicing. Clamp wheel internally. Verify rim is squarely clamped by checking rotational runout. If not square, briefly release and reclamp. Deflate tire. Lubricate outer bead and sidewall before loosening outer bead. TC3500 Operation Instructions 3.
Loosen outer bead using multiple rotations. When bead is loosened, lubricate tire and rim at bead seat areas. Remove wheel from tire changer. Insert removable rubber coated jaws into clamping arms. Invert tire/wheel assembly and clamp externally. Loosen bead with multiple rotations. Lube inner bead and rim bead seat. 62 • 3.
Demounting Lock bead roller assembly. Install bead depressor tail with traction device. Lube “HM” bead lever. TC3500 Operation Instructions 3.
Insert “HM” bead lever. Pull “HM” bead lever back flush with rim while pushing with bottom roller to assist. Rotate clockwise to remove upper bead. IMPORTANT: 64 • 3. Advanced Procedures Stop rotation before traction device hits mounting head.
Demount outer bead. Mounting With wheel clamped externally and inverted, thoroughly lubricate rim flange, drop center, bead seats, and safety humps. Thoroughly lubricate tire bead face and inner toe area. TC3500 Operation Instructions 3.
Mount inner bead. Position and lock column. Place outer bead onto mount head. Position upper roller against bead and tire behind mount head. Install bead depressor tail and traction post. Lock tire to rim. Begin inserting blocks while continuing to mount outer bead. 66 • 3.
Continue mounting tire. Stop rotation immediately after tire is mounted. Ensure that bead depressor tail does not contact mount head. Remove bead depressor tail by backing up tire/wheel assembly after mounting. Release external clamping. Invert and clamp internally. TC3500 Operation Instructions 3.
Inflate tire, keeping clear of assembly. 3.9 Optional Steel Mount/Demount Head Assembly (RP6-2654) Use standard procedures for mounting and demounting. The optional steel mount/demount head assembly is to be used for mounting or demounting tires from steel rims only. DO NOT use the steel mount/demount head assembly on alloy rims, it could damage the finish. 68 • 3.
4. Maintenance and Calibration 4.1 Maintenance Schedule Proper care and maintenance are necessary to ensure that the TC3500 operates properly. Proper care will also ensure that rims and tires are not damaged during the mount/demount process. Maintenance Schedule Daily Perform the Following Maintenance Drain condensation from pressure regulator reservoir by pressing in on the fitting located on the bottom of the regulator.
4.2 Maintenance Replacement Parts QTY NAME NUMBER 1 Safety Goggles 179-15-2 1 Brush RP6-1506 1 Mounting Paste RP6-5749995 1 Steel Jaw Cover (Set Of 4) RP6-2035 1 Mount/Demount Head RP6-0343 1 Straight Bead Lever RP6-0322 1 “HM” Bead Lever RP6-2440 1 Bead Lever Protector Sleeve RP6-0326 1 Rubber Bonded External Clamping Jaw RP6-3656 4.3 Calibrating and Adjusting the Position of the Column Check the column position as follows: Clamp a 14 or 15 inch rim without tire.
4.4 Checking and Adjusting the Bead Rollers Check to ensure bead rollers operate in line with each other as follows: Position the bead roller assembly into its working position. Clamp a 14 or 15 inch rim without tire, from the outside of the rim with rubber jaws. Set the rim diameter indicator to the diameter of the rim mounted on the TC3500. Rotate the wheel so that the lower roller arm will not contact the tulip arm.
72 • 4.
5. Glossary 5.1 Rim Diagram TC3500 Operation Instructions 5.
5.2 Illustration of AH2 Rim (Asymmetrical Humps) “Bead Locking System” 74 • 5.
5.3 Illustrations of Various Rim Designs TC3500 Operation Instructions 5.
