Kunchy KC-508 Semi-Automatic Tyre Changer

Operating Instruction

Preface

Thank you for purchasing our semi-automatic tyre changer. It is of the best quality. In order to ensure proper operation and extended lifetime, please read the instructions for each operation section carefully.

The data of semi-automatic tyre changer:

Provide the "complete product code" and the "model of semi-automatic tyre changer" so that we can provide you with technical services and required parts more effectively. At the same time, it is easy to operate the machine using the technical parameters. If the data in the specification is inconsistent with the label, please refer to the label.

This manual is an indispensable part for machine operation. Before using the machine, you should read each part of the manual carefully. The operation safety and maintenance parts are necessary.

⚠️ Save this manual for future using!

1. Description of equipment

Pic.1 shows the Kunchy KC-508 Tire changer with the following labeled parts:

G: clamp jaw
I: working head
L: inflation inlet
M: operation arm
N: horizontal swing arm
P: column
Q: air connection head
R: bead breaker
S: rubber pad
T: crowbar
U: pedal control bead breaker
V: pedal control clamp
Y: turntable
Z: pedal control turntable
K: locking handle

2. Danger warning sign

Pic.2 displays various danger and warning signs associated with the operation of the tyre changer:

? DANGER: Indicates a severe hazard, potentially leading to serious injury or death. The symbol shows a person near a plant, implying general danger.
⚠️ General Warning: A triangle with an exclamation mark indicates a general warning or caution.
⚠️ Pinch Point/Crushing Hazard: A triangle with a hand near a rotating part warns of potential crushing injuries.
? Do Not Touch: A circle with a diagonal line over a hand indicates that touching is prohibited.
? Hearing Protection Required: A symbol indicating the need for hearing protection.
⚡ Electrical Hazard: A lightning bolt symbol warns of electrical danger.
♻️ Disposal/Environmental: Symbols related to recycling or proper disposal.

3. General description

3.1 Operation instruction

The semi-automatic tyre changer is designed to facilitate mounting and demounting tires with rim sizes from 9" to 25" and a maximum diameter of 1,070 mm.

Operation against instruction is prohibited.

The manufacturer shall not be liable for damage resulting from non-compliance with the instructions.

3.2 Safety operation rule

The semi-automatic tyre changer must be operated by trained personnel.
The manufacturer shall not be liable for any damage caused by modification of the machine without the manufacturer's approval.
Manufacturers will immediately discontinue their safety commitments if the user breaches safety rules and causes damage to the machine's safety devices.
If there is any damage to the safety warning sign during the whole process, the customer can contact the manufacturer according to the icon on page 3 to replace the damaging icon as soon as possible.

3.3 Transport

The semi-automatic tyre changer must be transported with the original packaging. Place as indicated on the packing box.
Move the packed machine by a forklift truck with corresponding lifting capacity. Refer to figure 3 for the forklift insertion direction.

Pic.3 shows a diagram illustrating the packaging dimensions (760 mm x 975 mm x 910 mm) and a weight of 200 Kg, indicating forklift insertion points.

4. Open package operation

Open protective boxes and plastic bags.
Refer to figure 1 (described in Section 1) to check whether the machine surface is intact and if any parts are missing or damaged.
If any problem is found, please do not use the machine and contact the supplier immediately.

5. Installation instruction

5.1 Space required

The installation position of the machine must meet the standard of safe working.
The semi-automatic tyre changer should be placed near the main power supply and compressed air system.
The minimum space of the installation position shall not be lower than the space shown in figure 4 and figure 4/A to ensure normal operation without any restriction.
If the machine is installed outdoors, a protective shelter must be built.

⚠️ The semi-automatic tyre changer is prohibited to use in explosive gas.

Pic.4 shows a diagram with dimensions 910+1110 mm (width) and 1430-1720 mm (height), indicating the machine's footprint. Pic.4/A shows required clearance around the machine: 500 mm on all sides.

5.2 Installation of components

Unscrew the fixed screws on the packing wooden pallet and place the semi-automatic tyre changer on the ground.
As shown in figure 5/a, unscrew 6 screws from the box body and install the vertical column at the designated position. Tighten the screws.

Note: For this semi-automatic tyre changer, the following three operations are not required:

Remove pin shaft, nut, washer, and adjusting spacer from the horizontal swing arm.
Apply lube to the support on the horizontal swing arm. Insert adjustment spacer to prevent friction of the horizontal swing arm.
Place the horizontal swing arm on the vertical column, insert the pin shaft, and tighten it with the nut and washer.

Note: Before connecting all power, check that the installation status of the machine is consistent with the installation requirements.

Connect the machine to the compressed air system (as shown in figure 5/c).
Step on the pedal to control the bead breaker; the piston rod of the cylinder can be extended (as shown in figure 5/d).
Install the tire pressure device as shown in figure 5/e. Insert the tire pressure device into the bearing, align the screw hole, but do not tighten with the nut or wrench yet.
The piston rod of the cylinder passes through the rotation hole in the pressure device.
Screw on the nut, but do not tighten it.
Place the spring at the specified point.
Tighten the screws on the tire pressure device as shown in figure 5/f.
Tighten the nut on the piston rod of the cylinder as shown in figure 5/g.

Pic.5 shows a series of diagrams (Pic.5/a through Pic.5/g) illustrating the component installation steps.

5.3 Commissioning

Before the machine is turned on, make sure the user's voltage and air pressure are consistent with the machine's requirements.
When the operating voltage of the machine needs to be changed, the terminal board can be adjusted properly (refer to part 14 circuit diagram).

⚡ The electrical system must be operated by a professional.

The compressed air system is connected to the machine by a pipe joint (Q) on the oil-water separator beside the box.
When connecting the circuit of the machine, the circuit must be equipped with a safety fuse, grounding wire, and must be installed with a 30mA automatic circuit breaker.

Note: The power plug of the tyre changer shall be prepared by the customer. The rated current of the power plug shall not be lower than 16A, and it must meet the voltage requirements of the machine.

5.4 Debugging machine

When the pedal (Z) is stepped on, the turntable (Y) should turn clockwise.
When the pedal is raised, the turntable should turn counterclockwise.

Note: If the turntable rotates in the opposite direction to the specified rotation, switch the two wires of the three-phase plug.

When the pedal (U) is stepped on, the pressure tyre device (R) will start. When the pedal is released, the tire pressure device returns to its original position.
When the pedal (V) is stepped on, four clamp jaws (G) will open. Step on the pedal again, and the clamp jaws are closed.

Pic.6 shows a diagram of the machine's controls (Y, G, Q, R, S, U, V, T, Z) and their relation to the pedals.

6. Adjust the jaw position of turntable

The clamps of the tyre changer have been adjusted to the central position before leaving the factory. The clamp rim from the outside size is from 9" to 21", and the inside size is from 13" to 25".

If you want to demount a larger or smaller rim, you can adjust the position of the four clamps, as shown in figure 6/b.

Adjustment range:

Clamp rim outside size: from the smallest 9"-19" to the largest 11"-21".
Clamp rim inside size: from the smallest 13"-23" to the largest 14"-25".

The operation is as follows:

Use a universal wrench to unscrew the screw (1).
Move the clamp jaw (2) and slider (3) to the position corresponding to one of the screw holes for the desired lock size.
Tighten the screw. Universal wrench torque must be 72 N.m.

Note: The corresponding positions of the four clamps should be ensured when the above adjustment is carried out.

Pic.6/b illustrates the jaw adjustment mechanism, showing screw (1), clamp jaw (2), slider (3), and the different rim size ranges for external and internal clamping.

7. Operation

Please read the instruction manual carefully and note before operating the machine.

The operation of the semi-automatic tyre changer is divided into the following three parts: breaking the bead / demount tire / mount tire.

Discharge all air from the tire and remove the balance lead from the tire.

Matters need attention:

More and more motorcycle rims are made from special materials such as aluminum magnesium alloys and carbon fiber. In order to lock into this kind of rim, a special repair tool for motorcycle tires must be used.
To avoid damage, the maximum pressure limit of the working plate is 5 bar.

7.1 Breaking the bead

You have to be very careful when operating the bead breaker. When the pedal is operated, the breaker arm will swing rapidly and forcefully, and any object within the movable range of the breaker arm is at risk of being crushed.
Check the tire to see if it has emptied the gas. If not, empty the gas.
Please close the clamp jaws of the turntable.

⚠️ Do not place your hand on the side wall of the tire during operation of the turntable. The clamp may press on your hand when it is open.

Lean against the tire on the rubber pad (S) on the right side of the automatic tyre changer.
Press the bead breaker closer to the edge of the rim by 1 cm (figure 8). It should be noted that the bead breaker should be placed on the tire instead of the rim.
Step on the pedal (U) and the pressure device is started. Release the pedal when the bead breaker completes the operation or the rim is off.
Gently rotate the tire and repeat the process for the rest of the tire until the flange is completely off the rim. Repeat on the other side of the tire.

Pic.7 shows a diagram of the machine's controls. Pic.8 shows a diagram illustrating the bead breaker operation on a tire.

7.2 Demount tire

Before any operation, check to see if the tire is out of air. And ensure that the balance lead has been removed from the rim.

⚠️ Apply special lubrication to the rim. Failure to apply lubricant may result in wheel rim damage.

⚠️ Do not put your hand under the tire when you lock the rim. To properly lock the tires, place the tire in the center of the turntable.

Clamp the rim outside between 10 and 20 inches:

Step the pedal (V) to the central position and locate the clamp (Y) according to the reference scale of the turntable.
Place the tire on the clamp so that the rim is near the lowest part of the clamp and step on the pedal (V) to the bottom.

Clamp the rim inside between 13 and 24 inches:

Make the clamp (G) closed completely.
Place the tire on the clamps and step the pedal V to clamp the rim.
Make sure that the rim is firmly fixed to the clamps.

⚠️ Don't put your hands on the wheel: if you put your hands between the rim and mounting head, it may cause injury when the column returns to its original position.

Lower the operating arm (M) until the dismounting head is supported on the rim edge and locked with the locking handle (K). In the process, the operating arm is locked in a fixed position in the vertical direction, and the working head is moved to 2mm above the rim.

Note: Once the operating arm is locked in the vertical direction, the working head must be manually removed from the rim (approximately 2mm) with the manual wheel on the left side of the horizontal swing arm.

With the crowbar T inserted between the bead and the front section of mounting head I, move the tire bead over the mounting head I with crowbar T (see pic.10).

Note: In order to avoid damaging the inner tube, if there is one, it should be 10cm to the right of the mounting head I during the above operation.

While the crowbar is in this position, rotate the turntable Y clockwise by pressing down on pedal Z until the tire is completely separated from the wheel rim.

⚠️ Keep your hands and body as far away as possible from the moving parts when operating the machine, to avoid getting hurt.

⚠️ Necklaces, bracelets, loose-fitting clothing, or external items can cause personal injury to the operator if they are close to the rotating parts.

Remove the inner tube if there is one. Repeat the same operation for the other bead.

Pic.9 shows a diagram of the machine's controls. Pic.10 shows a diagram illustrating the use of the crowbar to demount the tire bead.

7.3 Tire mounting

Note: To avoid explosion in inflating, it is important to check the tire and rim. Before mounting the tire, pay attention to the following points:

Don't mount the tire if the outside of the tire is damaged.
Check whether the rim is dented or deformed. In particular, there may be small cracks in the rims of alloy wheels, which cannot be seen with naked eyes, that will damage the durability of the wheel, so there will also be risks in the inflating process.
Make sure that the wheel rim and tire are of the same size. If you cannot make sure of it, do not mount the tire.

Lubricate the tire beads with special grease in order to avoid damaging them and to facilitate the mounting operations.

⚠️ Don't put your hands between tire and clamps in operating clamps, avoiding hands injury.

Note: When working with rims of the same size, it is not necessary to always lock and unlock the mounting bar; just move it away and return it to its original position about the horizontal operating arm.

⚠️ Don't put your hands on the wheel: if you put your hands between the rim and mounting head, it may cause injury when the operating arm returns to its original position.

Move the tire so that the bead passes below the front section of the mounting head and is brought up against the edge of the rear section of the mounting head itself.
Keep the tire bead pursed down into the wheel rim channel with your hands. Step pedal M to rotate the turntable clockwise. Continue until you have covered the entire circumference of the wheel rim.

⚠️ Keep your hands and body as far away from the operating arm when rotating the turntable, avoiding body injury.

Insert the inner tube, if there is one. Repeat the above operation for the other side of the bead.

Note: The turntable is always rotating clockwise during mounting and demounting processes, unless the machine is malfunctioning or operating mistakenly, in which case it may rotate anticlockwise.

Pic.11 shows a diagram of the machine's controls. Pic.12 shows a diagram illustrating tire mounting.

8. Inflating

You have to inflate the tire carefully, following below instructions strictly. Please note there is no protection device on the design of the tire changer for the safety of the operator on the machine or surrounding machine if the tire explodes suddenly.

? Danger of burst:

A burst of tire can cause serious injury or even death of the operator.
Check carefully that the wheel rim and the tire are of the same size.
Check the state of wear of the tire and ensure there are no defects before beginning the inflation stage.
Inflate the tire with brief jets of air, checking the pressure frequently.
All our tire changers are limited to a maximum inflating pressure of 3.5 bar; in any case, never exceed the pressure recommended by the manufacturer.
Keep your hands and body as far as possible from the tire during the inflation stage.

8.1 Inflating tire with nozzle

The standard semi-automatic tire changer is equipped with a pressure nozzle to inflate a tire.

Follow below instructions to inflate a tire:

Connect the nozzle fitting to the tire valve.
Check the wheel rim and the tire are of the same size.
Check the wheel flange and rim are with enough lubrication.

Pic.13 shows a diagram of the tire inflation nozzle.

Press the nozzle trigger. In this stage, control the inflating pressure until the tire fits to the rim completely.
Continue to inflate the tire and check the inflating pressure frequently, never to exceed the pressure indicated by the manufacturer.

? Danger of burst:

Never exceed the pressure indicated by the manufacturer: 3.5 bar.
Remove the tire from the turntable. If you need more inflating pressure, place the tire in a special protection cage to continue the inflation operation.
Never exceed the maximum inflation pressure.
Keep your hands and body as far away from the tire.
Only professionals are allowed to use the machine. Other people are not allowed to use or approach the machine during the inflation stage.

9. Relocate

Forklifts are needed to move the semi-automatic tire changer.
Disconnect the electric power supply and compressed air system.
Insert the crowbar on one side bottom of the tire changer, get the machine off the ground, and then insert the fork, lifting it up.
Place the tire changer in a new position.

Note: Location of the new place must comply with national safety regulations.

10. Storage

If the tire changer needs to be stored for some time, please follow below instructions:

Disconnect all energy supplies and lubricate the slide of the clamps on the turntable to prevent oxidation.

11. Scrap

Make sure all energy supplies are disconnected when deciding to scrap the equipment.
All nonferrous metals and nonmetals shall be disposed of as scrap in accordance with relevant laws and regulations.
Process the oil inside the machine at the place specified by applicable law.
Discard the remaining steel.

12. Maintenance

12.1 Warning

Untrained people are not allowed to carry out maintenance work.
Regular maintenance as described in the instructions is crucial for correct operation and long lifetime of the tire changer.
If maintenance is not carried out regularly, the operation and reliability of the machine may be compromised, thus placing the operator and anyone else in the vicinity at risk.

⚠️ Before carrying out any maintenance work, disconnect the electric and pneumatic supplies. Moreover, if it is necessary to break the bead load less 3-4 times in order to let the air pressure go out of the circuit.

Damaged parts must be replaced exclusively by expert personnel using the manufacturer's spare parts.
It is forbidden by national safety regulation to disassemble and replace safety devices (safety valves and regulating valves).

In particular, the manufacturer shall not be liable for any damage caused by users using parts of other manufacturers or damage by disassembly and damage of safety devices.

11.2 Maintenance

Clean the turntable once a week with diesel fuel to prevent the formation of dirt, and grease the clamp sliding guides.
Perform the following maintenance work once a month:
- Control the oil level of the oil-water separator. If the level is low, screw off the oil cup F before adding. Use only oils specified by ISO HG with viscosity ISO VG32. Such as: ESSO Febis K32, MOBIL Vacouline 1405, KLUBER32 (Pic.15).
- Step pedal bead breaker 3-4 times, checking if some oil is filled in oil cup F. If not, adjust screw D (Pic.15).

Note: After the first 20 days of work, retighten the clamp tightening screws and screws on turntable slides (Pic.16).

Note: In the event of a loss of power, check that the drive belt is tight or not as follows:

Disconnect power supply before operation.
Remove the left side body panel of the tire changer by unscrewing the four fixing screws.
Tighten the drive belt by means of the special adjusting screw X on the motor support (Pic.17).

Note: If the working head is not locked or cannot be stopped 2mm above the rim, the locking plate of the operating arm shall be adjusted as shown (Pic.18).

Note: For cleaning or replacing the silencer of opening/closing clamps (G), proceed as follows (see Pic.19):

Remove the left side panel of the machine body by unscrewing the four fixing screws.
Unscrew the silencer located on the pedal system V, on the clamp G opening/closing pedal.
Clean by a jet of compressed air, or if damaged, replace by the same spare parts.

Note: For cleaning or replacing the silencer of bead breaker R, see pic. 20, and proceed as shown in previous points 1 & 3.

Pic.15 shows the oil-water separator components (D, F). Pic.16 shows turntable slides and screws. Pic.17 shows the drive belt adjustment screw (X). Pic.18 illustrates the locking plate adjustment. Pic.19 shows components for opening/closing clamps. Pic.20 shows the bead breaker silencer.

13. Trouble shooting

Trouble	Cause	Troubleshooting
Turntable rotates only in one direction	Universal switch is damaged	Universal switch
Turntable doesn't rotate	1. Belt is damaged 2. Universal switch is damaged 3. Motor trouble	1. Replace the belt 2. Replace the universal switch 3. Replace motor
Turntable doesn't work	Belt loose	Adjust belt tension
Clamp open/close slowly	1. Silencer trouble	Clean or replace
Turntable doesn't lock the rim correctly	1. Clamp is damaged 2. Cylinder of turntable is damaged	1. Replace clamp 2. Replace the sealing ring of cylinder
The working head touches the rim when operation	1. Locking place position is incorrect or damaged 2. Turntable locking screw loose	1. Adjust or replace locking plate 2. Tighten screw
Pedal should not be located in working position	Return spring damage	Replace the return spring
Bead breaker operation difficult	1. Silencer trouble 2. Cylinder sealing ring of bead breaker is damaged	1. Clean or replace the silencer 2. Replace the sealing ring

14. Technical data

Parameter	Value
Power Supply Voltage	110 V, 60 Hz, 1 Ph
Motor	1.5 HP (1.1 kW)
Working Pressure	116 PSI - 145 PSI (8 bar - 10 bar)
Bead Breaker Force	Pneumatic 5500 lbs
Drive System Type	Electric / Pneumatic
Table Clamping	Dual Pneumatic Cylinders
Bead Breaking System	Adjustable Pneumatic Blade
External Rim Clamping	12" - 22" (305 mm - 559 mm)
Internal Rim Clamping	13" - 24" (330 mm - 609 mm)
Max. Wheel Width	13" (330 mm)
Max. Wheel Diameter	41" (1040 mm)
Turntable Rotating Torque	885 ft/lbs
Power Cord Length	78 47/64" (2000 mm)
Speed	7 RPM
Turntable Tire Width Capacity (Mounting)	5" - 12" (127 mm - 305 mm)
Bead Breaker Tire Width Capacity (Demounting)	1 1/2" - 13" (38 mm - 330 mm)
Noise Level	<70 dB
Product Dimensions	L 43.3" x W 55.12" x H 76.18" (1100 mm x 1400 mm x 1935 mm)
Product Weight	416.67 lbs (189 kg)

15. Circuit diagram and pneumatic system diagram

Diagrams are provided for the following systems:

230V - 1PH: User-owned plugs and sockets, sensor of the commutator, reset switch, motor connection, and motor details.
230V/400V - 3PH: User-owned plugs and sockets, reset switch, motor connection, and motor details.

These diagrams illustrate the electrical and pneumatic connections for the tyre changer.