Ravaglioli G1000A99NP Bedienungsanleitung

• For any further information please contact your local dealer.

For spare parts drawings refer to the section “ LIST OF COMPONENTS” enclosed to this manual.

INSTRUCTION MANUAL

TRANSLATION FROM THE

ORIGINAL INSTRUCTIONS

G1000A99NP

G800A121NP

7105-M007-0

7105-M007-0 - Rev. n. 0 (07/2017)

7105-M007-0

INSTRUCTIONS FOR

ASSEMBLY AND USE Page 2 of 19 GB

G1000A99NP - G800A121NP

SUMMARY

SYMBOLS USED IN THE MANUAL

AND ON THE MACHINE _________________ 4

1.0 GENERAL INTRODUCTION _________ 5

1.1 Introduction ___________________________5

2.0 INTENDED USE ____________________ 5

2.1 Training of personnel__________________5

3.0 SAFETY DEVICES __________________ 6

3.1 Residual risks _________________________6

4.0 GENERAL SAFETY RULES _________ 6

5.0 PACKING AND MOBILIZATION

FOR TRANSPORT __________________ 7

6.0 UNPACKING ________________________ 7

7.0 MOBILIZATION_____________________ 8

8.0 WORKING ENVIRONMENT

CONDITIONS _______________________ 8

8.1 Installation space _____________________8

8.2 Lighting _______________________________8

9.0 ASSEMBLY AND PREPARATION

FOR USE ___________________________ 9

9.1 Fixtures contained in the packing _____9

9.2 Assembly procedures on the

tyre-changer __________________________9

10.0 CONTROLS________________________ 13

11.0 USE OF THE LIFTING DEVICE ____ 14

12.0 ROUTINE MAINTENANCE _________ 14

13.0 TROUBLESHOOTING TABLE ______ 15

14.0 TECHNICAL DATA_________________ 15

15.0 STORING__________________________ 15

16.0 SCRAPPING _______________________ 15

17.0 FUNCTIONAL DIAGRAMS _________ 15

Table A - Pneumatic diagram

(G1000A99NP)__________________ 16

Table B - Pneumatic diagram

(G800A121NP)__________________ 18

18.0 LIST OF COMPONENTS

7105-M007-0 INSTRUCTIONS FOR

ASSEMBLY AND USE

Page 3 of 19

G1000A99NP - G800A121NP

INFORMATION PLATE LOCATION TABLE

Code numbers of plates

B1541000 Danger plate

B2668000 Wheel lifting device danger plate

999915200 Serial number plate

999916450 Lifting device pedal label

999916880 Max. capacity load 80 Kg plate

IF ONE OR MORE PLATES DISAPPEAR FROM THE MACHINE OR BECOMES DIFFICULT

TO READ. REPLACE IT AND QUOTE ITS/THEIR CODE NUMBER/S WHEN REORDERING.

7105-M007-0

INSTRUCTIONS FOR

ASSEMBLY AND USE Page 4 of 19 GB

G1000A99NP - G800A121NP

SYMBOLS USED IN THE MANUAL AND ON THE MACHINE

Symbols Description

Read instruction manual.

Wear work gloves.

Wear work shoes.

Mandatory. Operations or jobs to

be performed compulsorily.

Danger! Be particularly careful.

Symbols Description

B1541000

General danger.

Wear safety goggles.

Technical assistance necessary.

Do not perform any intervention.

Warning. Be particularly careful

(possible material damages).

Note. Indication and/or useful

information.

Move with fork lift truck or pallet

truck.

Lift from above.

7105-M007-0 INSTRUCTIONS FOR

ASSEMBLY AND USE

Page 5 of 19

G1000A99NP - G800A121NP

SOME OF THE PICTURES PRE-

SENT IN THIS MANUAL HAVE

BEEN OBTAINED FROM PICTURES

OF PROTOTYPES, THEREFORE

THE STANDARD PRODUCTION

PARTS AND COMPONENTS OF THE

ACCESSORY CAN BE DIFFERENT

IN SOME COMPONENTS.

1.0 GENERAL INTRODUCTION

This manual is an integral part of the product and

must be retained for the whole operating life of the

accessory.

Carefully study the warnings and instructions con-

tained in this manual. It contains important instruc-

tions regarding FUNCTIONING, SAFE USE and

MAINTENANCE.

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 INDI-

CATIONS MIGHT LEAD TO EVEN

SERIOUS DANGERS.

1.1 Introduction

Thank you for preferring this lifting device. We feel

sure you will not regret your decision.

This accessory has been designed for use in profes-

sional workshops and in particular it stands out for

its reliability and easy, safe and rapid operation: with

just a small degree of maintenance and care, this lifting

device will give you many years of trouble-free service

and lots of satisfaction.

2.0 INTENDED USE

The lifting devices G1000A99NP and G800A121NP

are accessories to be assembled as an option on

tyre-changers, and it is intended for use as an aid

during the positioning and removal and of the wheel

(max. 80 kg) from the mandrel.

USING THESE ACCESSORIES

OUTSIDE OF THE INTENDED USE

FOR WHICH THEY HAVE BEEN

DESIGNED (INDICATED IN THIS

MANUAL) IS INAPPROPRIATE AND

DANGEROUS.

THE MANUFACTURER CANNOT

BE HELD RESPONSIBLE FOR ANY

DAMAGE CAUSED BY IMPROPER,

ERRONEOUS, OR UNACCEPTABLE

USE.

AN INTENSIVE USE OF THE EQUIP-

MENT IN INDUSTRIAL ENVIRON-

MENT IS NOT RECOMMENDED.

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 accessory 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.

7105-M007-0

INSTRUCTIONS FOR

ASSEMBLY AND USE Page 6 of 19 GB

G1000A99NP - G800A121NP

4.0 GENERAL SAFETY RULES

• Any tampering with or modification to the device 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.

• Use of the machine is only permitted in places free

from explosion or fire hazard and in dry places

under cover.

• Original spare parts and accessories should be used.

THE MANUFACTURER DENIES

ANY RESPONSIBILITY IN CASE

OF DAMAGES CAUSED BY UNAU-

THORIZED MODIFICATIONS OR

BY THE USE OF NON ORIGINAL

COMPONENTS OR EQUIPMENT.

• Installation must be conducted only by qualified

personnel exactly according to the instructions that

are given below.

• Ensure that there are no dangerous situations dur-

ing the machine operating manoeuvres. Immediately

stop the lifting device if it miss-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 device by shutting off the pneumatic supply.

• Ensure that the work area around the device is free

of potentially dangerous objects and that there is no

oil since this could damage the tyre. Oil on the floor

is also a potential danger for the operator.

OPERATORS MUST WEAR SUIT-

ABLE WORK CLOTHES, PROTEC-

TIVE GLASSES AND GLOVES,

AGAINST THE DANGER FROM

THE SPRAYING OF DANGEROUS

DUST, AND POSSIBLY LOWER

BACK SUPPORTS FOR THE LIFT-

ING 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 CAR-

RIED OUT.

• The machine handles and operating grips must be

kept clean and free from oil.

3.0 SAFETY DEVICES

PERIODICALLY, AT LEAST MONTH-

LY, CHECK THE INTEGRITY AND

THE FUNCTIONALITY OF THE

SAFETY AND PROTECTION DE-

VICES ON THE DEVICE.

• Fixed guards and shelters.

On the machine are present some permanent protec-

tions that are supposed to avoid potential risks of

getting crushed, cut or pressed.

• Man-operated control (Fig._1 ref._1) makes the

pedal support stop in position after the release of

the drive pedal. This is to make sure that the device

cannot move without the operator’s assent.

• A slot (Fig._1 ref._2) located on the lifting plate al-

lows a partial free travel in return line next to the

floor, avoiding the risk of possible crushing of the foot

in between the pedal support and the floor.

Fig._1

3.1 Residual risks

The device was subjected to a complete analysis of

risks according to reference standard EN ISO 12100.

Risks are as reduced as possible in relation with tech-

nology and product functionality.

This manual stresses possible residual risks, also

highlighted in pictograms on the present manual and

adhesive warning signals placed on the device: their

location is represented in “PLATE LOCATION ON MA-

CHINETABLE” on page 3.

7105-M007-0 INSTRUCTIONS FOR

ASSEMBLY AND USE

Page 7 of 19

G1000A99NP - G800A121NP

• 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.

Unauthorized personnel must remain outside the

working area, as shown in Fig._2.

Avoid any hazardous situations. 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.

• When operating and servicing this device, carefully

follow all in force safety and accident-prevention

precautions.

The device must not be operated by professionally

unskilled persons.

IN CASE OF A CHANCE SUPPLY

FAILURE (COMPRESSED AIR),

MOVE THE PEDALS TO THE NEU-

TRAL POSITION.

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 DEVICE (SEE PARA-

GRAPH “TECHNICAL SPECIFICATIONS”).

The wheel lifting device is packed in a cardboard box

having the dimensions of 900x300x500.

Movement must be by pallet-lift or fork-lift trolley.

6.0 UNPACKING

DURING UNPACKING, ALWAYS

WEAR GLOVES TO PREVENT ANY

INJURY CAUSED BY CONTACT

WITH PACKAGING MATERIAL

(NAILS, ETC.).

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 unnail the cardboard box from

the pallet it is fixed to. After removing the packing,

and in the case of the device packed fully assembled,

check that the device is complete and that there is no

visible damage.

If the device is packed dismantled into its principal

parts, after removing the packing, lay the individual

parts on the floor and check them for any missing

components, damage, or irregularity.

If in doubt do not use the device and refer to profes-

sionally 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 collec-

tion points if they are pollutants or non biodegradable.

THE BOX CONTAINING THE FIX-

TURES IS CONTAINED IN THE

WRAPPING. DO NOT THROW IT

AWAY WITH THE PACKING.

7105-M007-0

INSTRUCTIONS FOR

ASSEMBLY AND USE Page 8 of 19 GB

G1000A99NP - G800A121NP

7.0 MOBILIZATION

THE LIFTING EQUIPMENT MUST WITHSTAND

A MINIMUM RATED LOAD EQUAL TO THE

WEIGHT OF THE DEVICE (SEE PARAGRAPH

TECHNICAL SPECIFICATIONS). DO NOT AL-

LOW THE LIFTED DEVICE TO SWING.

If the device 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.

• Disconnect all machine power supply sources.

• Lift and transport with suitable device with adequate

dimensions.

8.0 WORKING ENVIRONMENT CONDI-

TIONS

The device 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 device in ambient conditions other than

those specified above is only allowed after prior agree-

ment with and approval of the manufacturer.

8.1 Installation space

Fig. 2

USE THE DEVICE INDOORS OR IN A ROOFED

AREA. PLACE OF INSTALLATION MUST BE

DRY, ADEQUATELY LIT AND IN COMPLIANCE

WITH APPLICABLE SAFETY REGULATIONS.

The installation of the lifting device for wheel need

a useful space, on the side of the machine, of mm

600x1000 (as indicated in Fig._2) through the broken

line.

The operator must be able to see the entire equipment

and the surrounding area from the control position. He

must prevent unauthorized personnel or objects that

could be dangerous from entering the area.

8.2 Lighting

The machine does not require its own lighting for

normal working operations. However, it must be used

in an adequately lit environment.

In case of poor lighting, use lamps having total power

800/1200 Watt as envisaged by UNI 10380.

7105-M007-0 INSTRUCTIONS FOR

ASSEMBLY AND USE

Page 9 of 19

G1000A99NP - G800A121NP

9.0 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 in-

structions for the assembly of the components making

use of the attached series of illustrations.

9.1 Fixtures contained in the packing

The packing case contains also the fixtures box. Check

that all the parts listed are there.

Only for G1000A99NP model

Code Description N.

228501 M8 flange nut 2

710592000 Lifting device pedalboard unit 1

B1367300 TBEI M8x16 screw 2

710591930 Lifting device assembly unit 1

272038 TE M8x25 screw 4

228506 M8 flange nut 4

317022 Black Elastolan pipe 8x6

L=1600

317022 Black Elastolan pipe 8x6

L=1200

317022 Black Elastolan pipe 8x6

L=1000

Only for G800A121NP model

Code Description N.

730094930 Lifting device pedal unit 1

730024310 Pin 1

299052 Retainer ring D.9 2

730094750 Lateral lifting device assembly

unit

203193 TE M10x30 screw 4

228012 M10 self-locking nut 4

317022 Black Elastolan pipe 8x6

L=1200

317022 Black Elastolan pipe 8x6

L=1000

317007 Black rilsan pipe 8x6 L=100 1

9.2 Assembly procedures on the tyre-

changer

Only for G1000A99NP model

1 - Place the lifting device that is assembled next to the

tyre-changer on which it will be installed.

2 - Prepare and arrange near the screws and the ac-

cessories, which are necessary for fixing the lifting

device to the tyre-changer.

3 - After making sure the tyre-changer is insulated

from its power supply sources, proceed with the

fastening of the lifting device.

4 - Remove the lateral guard (Fig._3 ref._1) unscrewing

the screws (Fig._3 ref._2).

Fig. 3

5 - Unscrew screws (Fig._4 ref._1), nuts (Fig._4 ref._3)

and remove the closing plate (Fig._4 ref._2).

Fig. 4

7105-M007-0

INSTRUCTIONS FOR

ASSEMBLY AND USE Page 10 of 19 GB

G1000A99NP - G800A121NP

6 - Place the pedal support (Fig._5 ref._1)(#

710592000) from the inside next to hole left free.

Then fix with screws (Fig._5 ref._2)(# B1367300)

and nuts (Fig._5 ref._3)(# 228501), on issue.

Fig. 5

7 - Fix the lifting device (Fig._6 ref._1) (# 710591930)

to the tyre changer using screws (Fig._6 ref._2)

(# 272038) and nuts (Fig._6 ref._3) (# 228506),

on issue.

Fig. 6

8 - Fix the three pneumatic pipes (Fig._7 ref._1-2-3)

to the pedalboard, to the lifting cylinder and to the

machine as indicated in the figure.

- Pipe coming from the filter unit - pressure reducer

(# 317022) (L=1600 mm) (Fig._7 ref._1).

- Pipe coming from lifting device's cylinder (#

317022) (Fig._7 ref._2) (L= 1200 mm) (high

union).

- Pipe coming from the lifting device's cylinder (#

317022) (Fig._7 ref._3) (L= 1000 mm) (low

union).

BEFORE CONNECTING THE PIPES

(FIG. 7 REF. 2-3) MAKE SURE

THEY PASS THROUGH THE RUB-

BER FAIRLEAD (FIG. 7 REF. 4).

Fig. 7

Fig. 8

FASTEN THE PIPES AS SHOWN

IN FIG. 8, IN ORDER TO AVOID

THAT THEY INTERFERE WITH

THE BELT.

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