vulcstar (vs900) - TipTop Automotive

585 3003
VULCSTAR (VS900)
Vulcanizing machine for truck
and agricultural tyres of up
to 900 mm in tread width
Seite
Table of contents
page
I. Introduction /general information�������������������������������� 2
II. Safety instructions ������������������������������������������������������ 4
III Technical data�������������������������������������������������������������� 6
IV. Description of the machine������������������������������������������ 8
V. Installation of the machine
(before putting it into operation for the first time)������ 10
VI. Standard shipment���������������������������������������������������� 13
VII. Handling of the machine for tread repair������������������ 15
VIII. Handling of the machine for tread repair
and building-up of tread pattern�������������������������������� 23
IX. Handling of the machine for sidewall repair�������������� 35
X. Curing time chart ������������������������������������������������������ 44
XI. Maintenance�������������������������������������������������������������� 46
XII. Trouble shooting�������������������������������������������������������� 49
Xlll. Accessories���������������������������������������������������������� 52/53
XlV. Exploded view ���������������������������������������������������������� 54
XV. Spare parts list���������������������������������������������������������� 56
I. Introduction/general Information
•This manual explains the correct handling of the machine. It
should be studied before the machine is put into operation
for the first time, and read regularly when the machine is
operated.
•Whenever the machine is sold again, pass on this manual to
the new owner.
•The REMA TIP TOP VULCSTAR vulcanizing machine is designed for the vulcanization of an injury filled with uncured
rubber on a light truck or agricultural tyre and the repair patch
applied to it. The machine is also adapted to the working
conditions, under which these operations are carried out.
•For information about the preparation of injuries, refer to the
separate REMA TIP TOP repair instructions.
•Besides the explanations and safety instructions in this
manual, the user/operator of the VULCSTAR machines has
to take into account the precautions relating to the use of all
technical devices.
•All the information given in this manual refers only to the use
of original REMA TIP TOP materials, accessories and spare
parts.
•We reserve the right to carry out modifications which we
consider to be technically advantageous.
•A proper repair requires not only the use of high quality repair materials and tools but also an appropriate working environment, for example:
- good illumination
- well-trained staff
- periodical cleaning of the working place and the tools
•© 2009 These instructions are copyright. Their reproduction
(including reproduction through various photographic methods and storage by any electronic medium) is subject to the
approval of REMA TIP TOP GmbH, 85586 Poing / Germany.
Any commercial use of these instructions or any part of them
is prohibited.
page
página
II.a
II.b
II.a General safety instructions
•Before putting the machine into operation, read the manual
carefully step by step. Always observe the safety instructions!
• Always keep the manual accessible to the operators.
•When the machine has to be put out of service and to be disposed of, observe the relevant regulations on waste separation,
recycling and the correct disposal of used parts.
•The local air and electrical power supply must be equal to that
stated on the machine data plate. If it is not equal to that stated
on the machine data plate, do not plug the machine in! Have it
connected by a qualified specialist!
•Never exceed or change the settings etc. listed in this manual.
•Allow only a qualified specialist to carry out any work on electric
parts.
•Make sure that the outside heating element is covered with
enough granules. Risk of excessive heat build-up on the tyre
surface.
•Avoid rolling over cables! Risk arising from damaged cables!
•Avoid any risk from electric cables etc.! Danger of stumbling!
•Make sure that the tyre to be vulcanized is secured correctly. Use the appropriate supports and / or the
REMA TIP TOP Tyre Support to prevent the tyre from tipping
over or falling down.
•Always check the Airpower-Bag and the heating system together
with all the connection cables and air lines for damage, before
putting the machine into operation! Risks due to electric tension
and breakage of structural parts!
•Immediately remove defective or damaged parts from the work
place, and replace them by original REMA TIP TOP spare parts.
Make sure that the machine cannot be put back into operation
until it is repaired completely.
•Keep your hands clear of the space between the tyre and the
pressure-exerting parts while inflating the Airpower-Bag. Risk
of injury due to entrapment.
•Do not leave the machine unattended when it is operating.
Observe the relevant measures for fire protection and the regulations regarding the use of electric heating systems.
•Do not touch the heating elements and granules without protective gloves, when the machine is working or cooling down.
Danger of burning!
•Protect the machine/heating elements/Airpower-bags and the
granules from moisture, sharp-edged objects, and dirt! Fire risk,
risk of short-circuits!
•Do not bend, fold or twist the heating mat or its cable; do not
open the connectors! Risk of electric shock.
•Do not open the control box. Allow only a qualified electrician
to carry out any work on it. Risk due to electric tension!
•Use the REMA TIP TOP VULCSTAR vulcanizing machine only
for curing injuries filled with uncured rubber on tyres or other
moulded rubber parts!
•Deposit all objects only on the shelves designed for this purpose. Fire risk!
•When using an extension lead, make sure that the cable diameter is sufficient. Always completely unwind cable drums. Fire
risk!
•Observe general safety instructions and the specific regulations
for prevention of accidents from the employer´s liability insurance association.
•Keep the machine in good working order by cleaning and servicing it regularly!
•Make sure that the safe floor-load is not exceeded where the
vulcanizing machine is located! (Machine weight plus weight of
tyre: load = approx. 1000 kg/m²).
II.b Safety instructions Airpower-Bag
• Protect the Airpower-Bag from oil, solvents and acids.
•Fill the Airpower-Bag only with compressed air free from oil.
•Do not put the Airpower-Bag on hot, sharp-edged or pointed
objects.
•Use the Airpower-Bag only together with REMA TIP TOP vulcanizing machines. Do not use it as a lifting device etc.
•The operating pressure must not exceed the maximum.
Explosion hazard!
•Do not change the pre-set pressure on the safety valve or damage it.
•Use only original REMA TIP TOP pressure blocks for the transmission of pressure.
•Always make sure that all locking pins and structural parts etc.
are seated and secured correctly before inflating the AirpowerBag.
II.a III. Technical data
Betriebsspannung
Power input
Operating temperature
Temperature control
Curing time control
Operating pressure
Dimensions
Weight
Noise level
Space requirement
when in use
basic model
(heating system for granules),
Inner heating mat
basic model
(heating system for granules)
Inner heating mat
heating system for granules
Inner heating mat
heating system for granules
Inner heating mat
mechanical timer
Airpower-Bag size IV
Airpower-Bag size VI
Vibrator
VULCSTAR (length x height x width)
Heating system for granules
Airpower-Bag size IV
Airpower-Bag size VI
standard shipment
while the vibrator operates
230 V
230 V
2,2 kW
max. 0,3 kW
190 °C +/- 10 °C / 375 °F +/- 50 °F
130 °C +/- 10 °C / 265 °F / +/- 50 °F
temperature measured with thermocouple
in the heating element, electronic control system
and setting of desired value
with automatic temperature limiting unit
0 - 6 hours with final cutoff of heating circuits
3 bar / 43 psi / safety valve 3.3 bar / 48 psi
2.5 bar / 36 psi / safety valve 2.8 bar / 41 psi
5 - 6 bar / 73 - 87 psi through pressure
regulating flow control valve
approx. 1200 x 1100 x 1600 mm
approx. 500 x 700 mm
(effective surface area of heating element)
approx. 300 x 470 mm
approx. 400 x 470 mm
approx. 700 kg (including 350 kg of granules)
minimum safe floor-load required where the machine is
located together with tyre of maximum size: 1000 kg/m²
max 80 db A
approx. 1600 x 1600 mm (length x width) /
area: approx. 2,6 m²
We reserve the right to carry out modifications which we consider to be technically advantageous.
Dimensions
Dimensiones
IV. Description of the machine
The following main targets have been set for the development of
the REMA TIP TOP VULCSTAR vulcanizing machine:
maximum flexibility, easy handling, easy maintenance and unlimited suitability for any present and future sizes and shapes of
tyres
The REMA TIP TOP Vulcstar 900 is a further development from
Vulcstar 700, and has been designed in response to the constantly changing tyre sizes / aspect ratios in the tyre industry. The
machine Vulcstar 900 now makes it easy to repair agricultural
tyres of up to 850 mm in tread width.
Repair area up to 850 mm in the tread , up to 520 mm in the
sidewall.
With accessories from VS 700 (not in standard shipment, available as options, see spare parts list), the application area of the
VS 900 vulcanizing machine can be extended to include injuries
to the tread, sidewall and shoulder of tyres starting from 295/80
R22.5.
These targets have been reached with the use of a pressure system which is flexible and can be adapted to suit any contour and
shape of a tyre.
The pressure system is convincingly simple and reliable, and does
not require a large stock of contour plates or time-consuming
refinishing work on the repair area.
Thus, lugs on agricultural tyres can be built up with uncured
rubber in their original size and shape and then be cured in the
vulcanizing machine without any change of shape or contour, so
that it is virtually unnecessary to spend a lot of time on filling the
voids between the lugs with pressure equalizing pads etc.. – Less
post-cure buffing and refinishing work!
In addition, REMA TIP TOP repair patches are easy to cure with
the Vulcstar machine, whether laminated with MTR Rubber (if this
is required) or applied with Special Cement BL, HR Solution or
MTR-Solution.
Lieferumfang /
standard shipment /
livraison standard /
volumen de suministro
estándar
Laufflächenreparatur /
tread repair /
réparation bande de roulement /
reparación en la banda de rodamiento
V. 10
V. Installation of the machine (before putting
it into operation for the first time
Several preparations have to be made upon delivery,
before putting the REMA TIP TOP VULCSTAR machine
into operation for the first time.
•Choose the place where the machine should be in­stalled,
provide the necessary access; make sure that there is
enough space for work, and that the safe floor-load is not
exceeded where the vulcanizing machine is located! (load:
approx. 1000 kg/m²).
•Check whether the shipment is complete and in good condition.
•Move the REMA TIP TOP VULCSTAR vulcanizing machine
to the appropriate place using the appropriate lifting device
(e.g. fork lift truck).
•Make sure that the machine is secured correctly and stands
on an even surface, far enough from other machines, walls
etc.
•Remove the packing and check whether the pressure bed
is dry and clean.
•Fill about 2 thirds of the pressure bed gradually with original
REMA TIP TOP granules (approx. 10 bags) and distribute
them evenly.
Safety instruction: Use only dry granules!
•Put the heating element on the surface of the granules, with
the connection cable towards the rear of the vulcanizing
machine, then put another two sacks of granules into the
pressure bed, distributing them evenly. The heating element must be covered with an approx. 5 - 6 cm thick layer
of granules.
Put the enclosed accessories on the appropriate tool
shelves, and mount the lower front panel.
•Then connect the VULCSTAR machine to the local mains
and compressed air supply. The indicator lamp for mains
power supply illuminates.
Safety instruction: The local air and electrical power supply must be equal to that stated on the machine data plate.
If it is not equal to that stated on the machine data plate, do
not plug the machine in! Have it connected by a qualified
specialist!
Then put the machine into operation by setting the timer to
15 minutes. Thus check whether the heating system and
the control box work correctly. The indicator lamp for the
operation of the heating system is on during the previously
set curing time.
-A
t the end of the previously set curing time, the heating
system switches off automatically. At this moment, a significant increase in temperature should be noted on the
surface of the granules.
Safety instruction: Use protective gloves! Danger of
burning!
- If the indicator lamp for the operation of the heating system does not illuminate, check whether the fuse and the
mains power supply are appropriate and work correctly.
If no defect is found, disconnect the machine from the
mains. Have the machine checked by a qualified electrician.
If the previously set time has not elapsed on the timer or
if the machine has not switched off automatically at the
end of the previously set time, disconnect the machine
from the mains, and have it checked by a REMA TIP TOP
technician.
•If no defects have been found during the a.m. trial service,
the machine is ready for normal operation.
V. 11
5
6
7
2
4
8
16
3
14
15
13
19
20
12
17
18
22
14
23
11
Abb./fig./esq. 6.1
28
27
30
29
34
35
31
32
36
26
Abb./fig./esq. 6.2
37
39
38
49
44
41
42
45
40
43
51
46
47
50
48
Abb./fig./esq. 6.3
12
VI. Standard shipment
1*Vulcstar control box including heating element for pressure granules
2 Pressure bed
3 Front panel (can be demounted
for transport)
4*pressure granules,
(14 sacks, each 25 kg)
5Upper pressure unit with vertical
adjustment
6 Cross arm (can be adjusted)
7Supporting point for vertical adjustment of pressure unit
8 Tool shelves
9Machine feet with rubber pads
(non shown)
10Vibrator, Pressure regulating
flow control valve 6 bar/87 psi
(non shown)
11 Spatula for pressure granules
12socket adapter set: socket adapter
casing, pressure spindle with guide
bushing and special locking pin
13* Airpower-Bag IV and Vl
14pressure blocks L 2 / L 3 and
S2/S3
15Pressure plate for agricultural tyres
AS 1
16Pressure plate for agricultural tyres
AS 2
17 Pressure block AS 2
18Counter pressure plates GD 1 and
GD 2
19counter-pressure bar with spindle /
extension of counter-pressure bar
20Tubular socket wrench for pressure
spindle
21Locking pin (20 mm diameter) for
frame
22Height adjusting lever for upper
pressure unit
23 shovel for granules
24 bucket for granules
25 diamond-shaped tool tray
Options
26* Vulcstar inner heating mat ll, lV
27* Airpower-Bag Il
28 pressure block, L1 / S1
29 (Pneumatic) wrench with adapter
30 tyre support
31pressure clamp for shoulder and
sidewall repairs
32 Pressure bar (40 mm diameter)
33shearing pins (10 pcs not visible), for
pressure bar
34Locking pin for sidewall pressure
clamp
35Locking pin (12 mm diameter) for
pressure bar
36Adapter for sidewall pressure clamp
/ T-piece
Control box for electrical /
pneumatic system
37 Timer 0 - 6 hours
38 Fuse holder, 10 A
39 Mains switch
40 Indicator lamp
for mains power supply
41 Indicator lamp for heating
element for pressure granules
(heating element ON)
42 Indicator lamp
for inner heating mat
(inner heating mat ON)
43 Indicator lamp
for overheating cutout ON
44 Connector for inner heating mat
45 Connection cable for heating
element for pressure granules
46 Mains cable
47 Fitting for compressed air
supply
48 Pneumatic hand lever valve
for vibrator
49 FI fault current breaker
50 EWO air fittings for tools
51 Mains supply connector
The parts marked with an asterisk *) are
wear parts, for which no guarantee claim
based on any legal provisions whatsoever
can be accepted.
VI.
Volumen de suministro
13
Abb./fig./esq. 7.1
Abb./fig./esq. 7.2
Abb./fig./esq. 7.4
14
VII.Handling of the machine
for tread repairs to truck,
and agricultural tyres
The handling of the machine is shown
on a truck tyre tread injury which has
been prepared according to the onestage system des­cribed in the current
REMA TIP TOP repair instructions.
7.1 Switch the machine off by setting the mains switch to - 0 -.
(fig. 7.1)
Safety instruction: Work on electric
parts, only when the machine is switched
off. Risk due to electric tension!
7.2 Remove the heating element from
the granule filling; then using a
spatula, adapt the surface of the
granulate roughly to the diameter of
the tyre. (fig. 7.2)
Safety instruction: Hold the heating
element only by its holding loop to
remove it from the granule filling. Risk
of damage to the heating element. Use
protective gloves! Danger of burning!
7.3 Put the heating element on the
granules, with its cable outlet
towards the rear of the vulcanizing
machine. Then cover it completely
with granules. (fig. 7.3)
Layer of granules
on heating element:
sidewall repairs:
2 - 3 cm
tread / shoulder:
depth of tread pattern
+ 3 - 4 cm
Safety instruction: use protective
gloves! Danger of burning!
7.4 We recommend drawing auxiliary
lines (cross) on the outside of the
tyre as far as the bead in order
to make it easier to centre the
tyre in the VULCSTAR vulcanizing
ma­chine.
Move the tyre to the vulcanizing
machine and position the repair
area covered with heat resistant foil,
as shown on the fig. 7.4.
Note: Make sure that the skive is filled
completely, without any air entrapment.
Avoid air entrapment by filling the skive
evenly and by evenly stitching on the
skive filling.
Safety instruction: Always observe the
relevant regulations for prevention of
accidents (e.g. the German UVV regulations), when changing the position of
the tyre.
15
Abb./fig./esq. 7.5
Abb./fig./esq. 7.6a
Abb./fig./esq. 7.6b
Abb./fig./esq. 7.7a
16
Abb./fig./esq. 7.7b
7.5 Then tip the tyre forwards into the
pressure bed so as to centre the
repair area over the heating element
in the granule filling. (fig. 7.5)
Now, the tyre stands upright in the
middle of the vulcanizing machine.
Build up granules evenly around the
tyre, making sure that the outside
heating element is always covered
with granules. This will ensure an
even distribution of heat over the
whole repair area.
Attention: Standard tyres in sizes such
as 295/80 R22.5 must be accurately
positioned in the centre of the pressure
bed. Otherwise, it may be difficult to
adjust the cross-arm and the counterpressure plate GD 1/2.
7.6 If inner heating mats are available
(option), select the one which fits
the repair patch applied. Powder
both sides of the selected inner
heating mat with talcum. The heating mat has to cover the whole
repair patch (together with any
cushion gum applied to it) plus
an at least 15 - 20 mm-wide area
around the (laminated) patch. Now,
powder the repair area with talcum,
and centre the inner heating mat
onto the repair area, with its cable
outlet towards the rear of the vulcanizing machine. (fig. 7.6a and 7.6b)
Safety instruction: always check the
inner heating mat for visible defects
or damage, before use! Immediately
remove defective parts and replace
them by original REMA TIP TOP spare
parts.
7.7 Select the Airpower-Bag which fits
the selected inner heating mat and
the repair patch applied. Powder
the selected Airpower-Bag with talcum.
The Airpower-Bag has to cover
the repair patch (together with any
cushion gum applied to it) plus an
approx. 15 mm – wide area around
them.
Now, centre the Airpower-Bag onto
the inner heating mat / the repair
patch powdered with talcum. The
compressed air connector of the
Airpower-Bag has to face in the
axial direction. (fig. 7.7a and 7.7b)
Note: If the Airpower-Bag and the inner
heating mat are regularly powdered with
talcum, they will last much longer, and
the repair will be more stable.
Safety instruction: Always check the
Airpower-Bag and the inner heating
mat for defects or damage before use.
Immediately remove defective parts and
replace them by original REMA TIP TOP
spare parts.
17
Abb./fig./esq. 7.8a
Abb./fig./esq. 7.8b
Abb./fig./esq. 7.8c
Abb./fig./esq. 7.9
Abb./fig./esq. 7.10a
18
Abb./fig./esq. 7.10b
7.8 If necessary, adjust the upper pres­
sure unit to the required height using
the height adjusting device. Then
insert the locking pin again. (fig. 7.8a)
Move the cross-arm forward, until
the recess for the pressure spindle
is centred over the repair area. Then,
fit the socket adapter casing on the
cross-arm. Secure the socket adapter
casing with the special locking pin.
Then centre the required pressure
block onto the airpower bag. Insert
the guide bushing for the pressure
spindle in the matching socket on the
pressure block. Insert the pressure
spindle in the guide bushing, and
tighten the spindle with your hands.
Finally, make sure again that all these
elements are centred exactly over the
(fig. 7.8b and 7.8c)
repair area. Safety instruction: Check all parts for any
defects or damage! Immediately remove
defective parts and replace them by original REMA TIP TOP spare parts.
Always insert the locking pins and check
whether they are seated correctly.
The pressure spindle must be tightened
only with your hands, in order to prevent
the pressure block on the centre of the
repair patch/airpower bag from building
up mechanical pressure. The optimum
distribution of equal pressure over the
repair patch must be ensured by an air
cushion which is built up while inflating the
airpower-bag.
7.9.Screw the valve core of the AirpowerBag in; then inflate the Airpower-Bag
up to 1.0 bar / 15 psi, using a tyre
inflator, thus locking the pressure sys(fig 7.9)
tem. Safety instruction: Inflate the Air­powerBag only with compressed air free from oil!
Re-check whether all the locking pins are
seated correctly.
7.10 Open the hand lever valve and let
the vibrator operate for approx.
45 - 60 seconds. Thus the granules
are compacted, filling the voids and
providing a contour that snugly fits the
tyre and ensures optimum distribution
of heat. If the granule layer under the
repair area becomes too thin during
this process, push granules towards
the tyre using the spatula.
(fig. 7.10a and 7.10b)
After this time, close the hand lever
valve again, and check again whether
all pressure exerting parts and locking
elements are seated precisely.
If the position of pressure exerting
parts has to be changed, release the
pressure in the Airpower-Bag, and
repeat the operations described from
no .7.8 onwards.
Safety instruction: The vibrator generates
high-frequency vibrations. Do not put any
fragile parts / objects on the machine. Use
the vibrator only together with the original
pressure regulating flow control valve.
Risk of excessive stress and increased
noise level.
19
Abb./fig./esq. 7.11
Abb./fig./esq. 7.12a
Abb./fig./esq. 7.12b
Abb./fig./esq. 7.13
Abb./fig./esq. 7.14
20
7.11 Increase the pressure in the
Airpower-Bag up to 3 bar / 43 psi
for truck tyres (up to 2.5 bar / 36 psi
for agricultural tyres), and remove
the tyre inflator. Check the valve of
the Airpower-Bag for air tightness,
then close the valve with the valve
cap. (fig. 7.11)
Do not use the vibrator any longer until the end of the curing
process!
Safety instruction: Fill the Airpower–
Bag only with compressed air free from
oil.
7.12 Select the appropriate curing time
according to the chart X. (see page
44). Switch the vulcanizing machine
on by setting the mains switch to
I. Wind up the timer with one complete revolution, then reset it to the
required curing time.
(fig. 7.12a and 7.12b)
Safety instruction: Do not leave the
machine unattended when it is operating. Observe the relevant measures
for fire protection and the regulations
regarding the use of electric heating
systems.
Never use the machine with humid
granules! Risks due to electric current
and formation of steam.
7.13 At the end of the previously set
curing time, the heating system is
automatically cut off by the timer.
Switch the vulcanizing machine off
by setting the mains switch to - 0 -.
Completely release the pressure in
the Airpower-Bag by removing the
valve core, then remove the pressure-exerting parts. (fig 7.13)
Safety instructions: Use protective
gloves! Danger of burning due to hot
granules / hot parts! Deposit all the
parts on the tool shelves designed for
this purpose! Risks due to falling parts!
7.14 Remove the tyre from the vulcanizing machine. Using a brush, remove
any granules from the tyre. Then
check whether the repair area has
been correctly vulcanized. Do not
speed up the cooling-down process of the repair area using water,
compressed air etc. (fig. 7.14)
7.15 If necessary, finish-buff the outside
of the repair area after the vulcanization and complete cooling of the
repair
21
Abb./fig./esq. 8.2
Abb./fig./esq. 8.3
Abb./fig./esq. 8.4
22
Abb./fig./esq. 8.5
VIII. Handling of the machine
for tread repairs to agricultural tyres and for building-up tread
patterns
This chapter shows how to use the
machine for building-up a tread lug,
and for curing a tread injury which
has been prepared according to the
one-stage system described in the
current REMA TIP TOP repair instructions.
Select the repair patch which fits the
tyre and injury size, according to the
repair chart; apply the patch according to the one-stage system described
in the current REMA TIP TOP repair
instructions.
8.1 Skive filling / building-up tread lugs
Fill the skive according to the onestage system described in the repair
instructions. To speed up skive filling, we recommend the use of our
REMA TIP TOP - Extruder – Normal
(ref.no. 517 7505) together with the
MTR Extruder Rope Rubber (ref.
no. 516 1016). Shape the lug with
uncured rubber in its original size
and contour. (fig. 8.1)
Note: During skive filling / tread lug
building, you should regularly stitch on
the extruded portions of rope rubber
with a thin roller-stitcher.
Use Thermopress MTR – Solution /Rub­
ber only together with REMA TIP TOP
vulcanizing machines or in retreading
systems at operating temperatures of at
least 100 °C (212 °F).
8.2 Trim any uneven spots and adapt
them to the original contour, using
an offset knife (ref.no. 595 2139).
(fig. 8.2)
8.3 In order to avoid the granules sticking to the skive filling, coat the
surface of the skive filling with
Thermopress MTR Solution (drying
time 1 - 2 minutes), and cover the
skive filling with heat resistant foil
(ref.no. 517 6977). (fig. 8.3)
8.4 Switch the machine off by setting
the mains switch to - 0 -.
(fig. 8.4)
Safety instruction: Work on electric
parts, only when the machine is switched
off. Risk due to electric tension!
8.5 Remove the heating element from
the granule filling; then using a
spatula, adapt the surface of the
granulate roughly to the diameter of
the tyre. (fig. 8.5)
Safety instruction: Hold the heating
element only by its holding loop to
remove it from the granule filling. Risk
of damage to the heating element. Use
protective gloves! Danger of burning!
23
radial
Abb./fig./esq. 8.7
Abb./fig./esq. 8.9
24
8.6 Put the heating element on the
granules, with its cable outlet
towards the rear of the vulcanizing
machine. Then cover it completely
with granules. (fig. 8.6)
Layer of granules
on heating element
sidewall repairs:
2 - 3 cm
tread / shoulder:
depth of tread pattern
+ 3 - 4 cm
8.7 To cure sidewall or shoulder repairs
with large repair patches applied,
put the heating element on the
granules, with its cable outlet
towards the rear of the vulcanizing
machine (heating element in radial
direction). Then cover it com­pletely
with granules as described in section 8.6. (fig. 8.7)
Safety instruction: use protective
gloves! Danger of burning!
8.8 We recommend drawing auxiliary
lines (cross) on the outside of the
tyre as far as the bead in order
to make it easier to centre the
tyre in the VULCSTAR vulcanizing
ma­chine. Then introduce the counter pressure bar.
Note: Once the tyre has been positioned
in the machine, it is no longer possible
to introduce the counter pressure bar!
8.9 Move the tyre to the vulcanizing
machine and position the repair
area covered with heat resistantfoil,
as shown on the fig. 8.9. Tyres with
a section width not exceeding 520
mm can be positioned by tipping
them over the wall of the pressure
bed. Tyres wider than 520 mm must
be positioned using lifting equipment (repair stand/ fork lift truck).
Note: Make sure that the skive is filled
completely, without any air entrapment.
Avoid air entrapment by filling the skive
evenly and by evenly stitching on the
skive filling. When positioning the tyre in
the machine, make sure that the pressure granules which cover the heating
element for pressure granules are not
dispersed or shifted away, leaving little
or no depth of granulate to take up the
tyre profile or shape.
Safety instruction: Always observe the
relevant regulations for prevention of
accidents (e.g. the German UVV regulations), when changing the position of
the tyre.
Abb./fig./esq. 8.10
Abb./fig./esq. 8.10a
Abb./fig./esq. 8.10b
Abb./fig./esq. 8.11a
26
Abb./fig./esq. 8.11b
8.10 Then lift the tyre/tip the tyre forwards into the pressure bed so as
to centre the repair area over the
heating element in the granule filling.
(fig. 8.10a)
Now, the tyre stands upright in the
middle of the vulcanizing machine.
Build up granules evenly around the
tyre, making sure that the outside
heating element is always covered
with granules. This will ensure an
even distribution of heat over the
whole repair area. (fig. 8.10b)
8.10.a When the tyre is safely positioned
in the pressure bed, open the hand
lever valve, and let the vibrator operate. Prior to this operation, do not
apply pressure to the repair area
using the airpower bag. (fig.8.15a page 30)
Let the tyre compress the granules
only with its own weight until it stops
sinking in. (Attention: The tread lugs
should be at least 2 - 3 cm away
from the heating element for pressure granules in order to avoid
burning damage to the tyre!) In
order to ensure that there are enough
pressure granules around the tread
lugs, use the spatula to compensate
for any loss of granules flowing away.
(fig. 8.15b page 30)
8.11 If inner heating mats are available
(option), select the one which fits
the repair patch applied. Powder
both sides of the selected inner
heating mat with talcum. The heating mat has to cover the whole
repair patch (together with any
cushion gum applied to it) plus
an at least 15 - 20 mm-wide area
around the (laminated) patch. Now,
powder the repair area with talcum,
and centre the inner heating mat
onto the repair area, with its cable
outlet towards the rear of the vulcanizing machine.
(fig. 8.11a and 8.11b)
Note: If the two-way repair system is
used, the pressure plate for agricultural
tyres should be used to stabilize the
repair area and to avoid deformation to
the tread lugs.
Safety instruction: always check the
inner heating mat for visible defects
or damage, before use! Immediately
remove defective parts and replace
them by original REMA TIP TOP spare
parts.
27
Abb./fig./esq. 8.12a
Abb./fig./esq. 8.12b
Abb./fig./esq. 8.13a
Abb./fig./esq. 8.13b
Abb./fig./esq. 8.13c
28
8.12 Select the Airpower-Bag which fits
the selected inner heating mat and
the repair patch applied. Powder
the selected Airpower-Bag with talcum.
The Airpower-Bag has to cover
the repair patch (together with any
cushion gum applied to it) plus an
approx. 15 mm – wide area around
them.
Now, centre the Airpower-Bag onto
the inner heating mat / the repair
patch powdered with talcum. The
compressed air connector of the
Airpower-Bag has to face in the
axial direction.
(fig. 8.12a and 8.12b)
Note: If the Airpower-Bag and the inner
heating mat are regularly powdered with
talcum, they will last much longer, and
the repair will be more stable.
Safety instruction: Always check the
Airpower-Bag and the inner heating
mat for defects or damage before use.
Immediately remove defective parts and
replace them by original REMA TIP TOP
spare parts.
8.13 If necessary, adjust the upper
pres­sure unit to the required height
using the height adjusting device.
Then insert the locking pin again.
(fig. 8.13a)
Move the cross-arm forward, until
the recess for the pressure spindle
is centred over the repair area.
Then, fit the socket adapter casing on the cross-arm. Secure the
socket adapter casing with the
special locking pin. Then centre
the required pressure block onto
the airpower bag. Insert the guide
bushing in the matching socket on
the pressure block. Then, secure
the guide bushing in the cross-arm
with the locking pin. Finally, make
sure again that all these elements
are centred exactly over the repair
area. (fig. 8.13b and 8.13c)
Safety instruction: Check all parts for
any defects or damage! Immediately
remove defective parts and replace
them by original REMA TIP TOP spare
parts.
Always insert the locking pins and
check whether they are seated correctly.
The pressure spindle must be tightened
only with your hands, in order to prevent the pressure block on the centre
of the repair patch/airpower bag from
building up mechanical pressure. The
optimum distribution of pressure over
the top side of the repair patch must be
ensured by an air cushion which is built
up while inflating the airpower-bag.
29
Abb./fig./esq. 8.14
Abb./fig./esq. 8.15a
Abb./fig./esq. 8.15b
Abb./fig./esq. 8.16
30
Abb./fig./esq. 8.17
8.14 Screw the valve core of the
Airpower-Bag in; then inflate the
Airpower-Bag up to 2.0 bar / 30 psi,
using a tyre inflator, thus securing
the pressure system. (fig 8.14)
Safety instruction: Inflate the AirpowerBag only with compressed air free from
oil! Re-check whether all the locking
pins are seated correctly.
Check again whether all pressure exerting parts and locking elements are
seated precisely. If the position of pressure exerting parts has to be changed,
release the pressure in the airpower bag,
and repeat the operations described
from no. 8.13.
8.15 Open the hand lever valve and
let the vibrator operate for approx.
45 - 60 seconds. Thus the granules
are compacted, filling the voids
and providing a contour that snugly
fits the tyre and ensures optimum
distribution of heat. If the granule
layer under the repair area becomes
too thin during this process, push
granules towards the tyre using the
spatula. (fig. 8.15a and 8.15b)
After this time, close the hand
lever valve again, and check again
whether all pressure exerting parts
and locking elements are seated
precisely.
If the position of pressure exerting
parts has to be changed, release
the pressure in the Airpower-Bag,
and repeat the operations described
from no .8.13 onwards.
Safety instruction: The vibrator generates high-frequency vibrations. Do not
put any fragile parts / objects on the
machine. Use the vibrator only together
with the original pressure regulating flow
control valve. Risk of excessive stress
and increased noise level.
8.16 Select the appropriate counterpressure plate (distance between
the tyre and the edge of the pressure bed). Position it near the
tyre (distance: approx. 1 cm), and
secure it using the pressure spindle.
Generate enough pressure using
the pneumatic wrench or the tubular socket wrench. (fig. 8.16)
Safety instruction: Use a counter-pressure plate to ensure that the required
parts snugly fit the surface of the skive,
if the tyre section width makes this possible.
8.17 Increase the pressure in the
Airpower-Bag up to 2.5 bar / 36 psi,
and remove the tyre inflator. Check
the valve of the Airpower-Bag for air
tightness, then close the valve with
the valve cap. (fig. 8.17)
Do not use the vibrator any longer until the end of the curing
process!
Safety instruction: Fill the Airpower–
Bag only with compressed air free from
oil.
Abb./fig./esq. 8.18b
Abb./fig./esq. 8.19
Abb./fig./esq. 8.20a
Abb./fig./esq. 8.20b
Abb./fig./esq. 8.21
32
8.18 Select the appropriate curing time
according to the chart X. (see
page 44).
Switch the vulcanizing machine on
by setting the mains switch to - I -.
Wind up the timer with one complete revolution, then reset it to the
required curing time.
(fig. 8.18a and 8.18b)
Safety instruction: Do not leave the
machine unattended when it is operating. Observe the relevant measures
for fire protection and the regulations
regarding the use of electric heating
systems.
Never use the machine with humid
granules! Risks due to electric current
and formation of steam.
8.19 At the end of the previously set
curing time, the heating system is
automatically cut off by the timer.
Switch the vulcanizing machine off
by setting the mains switch to - 0 -.
Completely release the pressure in
the Airpower-Bag by removing the
valve core, then remove the pressure-exerting parts. (fig 8.19)
Safety instructions: Use protective
gloves! Danger of burning due to hot
granules / hot parts! Deposit all the
parts on the tool shelves designed for
this purpose! Risks due to falling parts!
8.20 Remove the tyre from the vulcanizing machine. Using a brush, remove
any granules from the tyre. Then
check whether the repair area has
been correctly vulcanized. Do not
speed up the cooling-down process of the repair area using water,
compressed air etc.
(fig. 8.20a and 8.20b)
8.21 If necessary, finish-buff the outside
of the repair area after the vulcanization and complete cooling of the
repair. Use finish buffer (ref.no. 595
5552). (fig. 8.21)
Caution: use safety eye goggles!
33
Abb./fig./esq. 9.2
Abb./fig./esq. 9.1
axial
Abb./fig./esq. 9.3
radial
Abb./fig./esq. 9.4
Abb./fig./esq. 9.5
Abb./fig./esq. 9.6
34
IX. Handling of the machine
for sidewall repairs to truck,
and agricultural tyres
The handling is shown on a sidewall
injury which has been prepared according to the one-stage system described
in the current REMA TIP TOP repair
instructions.
Attention! In order to be able to repair
standard truck tyres (in sizes such as
305/70 R22.5), several parts from the
attached list of accessories must be
ordered, as these parts are not included in
the standard shipment of the machine.
9.1 Switch the machine off by setting the
mains switch to - 0 -.
(fig. 9.1)
Safety instruction: Work on electric parts,
only when the machine is switched off.
Risk due to electric current!
9.2 Remove the heating element from
the granule filling; then using a spatula, adapt the surface of the pressure
granulate roughly to the diameter of
the tyre. (fig. 9.2)
Safety instruction: Hold the heating element only by its holding loop to remove
it from the granule filling. Risk of damage
to the heating element. Use protective
gloves! Danger of burning!
9.3.Put the heating element on the granules, with its cable outlet towards
the rear of the vulcanizing machine
(heating element in axial direction.
(fig. 9.3) Then cover it completely with
granules:
Layer of granules
on heating element
sidewall repairs:
2 - 3 cm
tread / shoulder:
depth of tread pattern + 3 - 4 cm
9.4.To cure sidewall or shoulder re­pairs
with large repair patches applied, put
the heating element on the granules,
with its cable outlet towards the rear
of the vulcanizing machine (heating
element in radial direction, fig. 9.4).
Then cover it completely with granules as described in section 9.3.
Safety instruction: Use protective gloves!
Danger of burning!
9.5 We recommend drawing auxiliary lines
(cross) on the outside of the tyre as far
as the bead in order to make it easier
to centre the tyre in the VULCSTAR
vulcanizing ma­chine.
Move the tyre to the vulcanizing
machine and position the repair area
as shown on the fig. 9.5.
9.6 Then tip the tyre forwards into the
pressure bed so as to centre the
repair area over the heating element
in the granule filling. (fig. 9.6)
Safety instruction: When changing the
position of the tyre, always make sure
that it is secured correctly! Observe the
relevant regulations for prevention of accidents (e.g. the German UVV regulations),
35
Abb./fig./esq. 9.7a
Abb./fig./esq. 9.7b
Abb./fig./esq. 9.8a
Abb./fig./esq. 9.8b
Abb./fig./esq. 9.9a
36
Abb./fig./esq. 9.9b
9.7 The tyre is inclined in the vulcanizing
machine, the inclination depending
on the position of the repair patch
Build up granules evenly around the
tyre, making sure that the outside
heating element is always covered
with granules. This will ensure an
even distribution of heat over the
whole repair area.
(fig. 9.7a and 9.7b)
Safety instruction: Prevent the al­ready
inclined tyre from tipping over. If necessary, use the tyre support (ref. no. 585
3159) for this purpose.
9.8 If inner heating mats are available
(option), select the one which fits
the repair patch applied. Powder
both sides of the selected inner
heating mat with talcum. Powder
both sides of the selected inner
heating mat with talcum. The heating mat has to cover the whole
repair patch (together with any
cushion gum applied to it) plus
an at least 15 - 20 mm-wide area
around the (laminated) patch.
Now, powder the repair area with
talcum, and centre the inner heating mat onto the repair area, with its
cable outlet towards the rear of the
vulcanizing machine.
(fig. 9.8a and 9.8b)
Safety instruction: always check the
inner heating mat for visible defects
or damage, before use! Immediately
remove a damaged heating mat and
replace it by the original spare part.
9.9 Select the Airpower-Bag which fits
the selected inner heating mat and
the repair patch applied. Powder
the selected Airpower-Bag with talcum.
The Airpower-Bag has to cover
the repair patch (together with any
cushion gum applied to it) plus an
approx. 15 mm – wide area around
them.
Now, centre the Airpower-Bag onto
the inner heating mat / the repair
patch powdered with talcum. The
compressed air connector of the
Airpower-Bag has to face in the
radial direction. (fig. 9.9a and 9.9b)
Note: For sidewall repairs, the valves of
the Airpower Bag always have to protrude over the bead.
If the Airpower-Bag and the inner heating mat are regularly powdered with
talcum, they will last much longer, and
the repair will be more stable.
Safety instruction:
Always check the Airpower-Bag for
defects or damage before use.
Immediately remove a defective Air­
power-Bag and replace it by the original
spare part.
37
Abb./fig./esq. 9.10a
Abb./fig./esq. 9.10b
Abb./fig./esq. 9.10c
Abb./fig./esq. 9.11
Abb./fig./esq. 9.12
38
9.10 If necessary, adjust the upper
pressure unit to the required height
using the height adjusting device.
Then insert the locking pin again.
(fig. 9.10a)
Move the cross-arm forwards, until
the recess for the pressure clamp is
centred over the repair area. Then,
fit the pressure clamp on the crossarm. Secure the pressure clamp
with the special locking pin.
Note: Keep the distance between the
airpower bag and the pressure clamp as
short as possible in order to prevent the
excessive inflation of the airpower bag.
(fig 9.10b and 9.10c)
Safety instruction: Check all parts for
any defects or damage! Immediately
remove defective parts and replace
them by original REMA TIP TOP spare
parts. Always insert the locking pins
and check whether they are seated
correctly.
The optimum distribution of pressure
over the top side of the repair patch
must be ensured by an air cushion
which is built up while inflating the airpower-bag.
9.11 S
crew the valve core of the Air­
power-Bag in; then inflate the Air­
power-Bag up to 1.0 bar / 15 psi,
using a tyre inflator, thus locking
the pressure system. (fig. 9.11)
Safety instruction: Inflate the Air­powerBag only with compressed air free from
oil!
9.12 O
pen the hand lever valve and let
the vibrator operate for approx.
45 - 60 seconds. Thus the granules are compacted, filling the
voids and providing a contour that
snugly fits the tyre and ensures
optimum distribution of heat. If the
granule layer under the repair area
becomes too thin during this process, push granules towards the
tyre using the spatula. (fig. 9.12)
After this time, close the hand
lever valve again, and check again
whether all pressure exerting parts
and locking elements are seated
precisely.
If the position of pressure exerting
parts has to be changed, release
the pressure in the AirpowerBag, and repeat the operations
described from no. 9.8 onwards.
Safety instruction: The vibrator generates high-frequency vibrations. Do not
put any fragile parts / objects on the
machine.
Use the vibrator only together with the
original pressure regulating flow control
valve. Risk of excessive stress and
increased noise level.
39
Abb./fig./esq. 9.13a
Abb./fig./esq. 9.13b
Abb./fig./esq. 9.14
Abb./fig./esq. 9.15a
Abb./fig./esq. 9.15b
Abb./fig./esq. 9.16
40
9.13 Select a counter pressure plate
depending on the distance between
the bead and the machine frame.
Install the counter pressure bar with
the pressure spindle.
Position the counter pressure plate
near the bead, and secure it with
the pressure spindle. Gene­rate
enough pressure using the pneumatic wrench or the tubular socket
wrench. (fig. 9.13a and b)
Safety instruction: The counter pressure plate is essential to provide a
contour that snugly fits the tyre and
optimizes the flow of the skive filling
rubber.
9.14 Increase the pressure in the
Airpower-Bag up to
3 bar / 43 psi (size II and IV)
2.5 bar / 36 psi (size VI)
and remove the tyre inflator.
Check the valve of the AirpowerBag for air tightness, then close the
valve with the valve cap. (fig. 9.14)
Do not use the vibrator any longer until the end of the curing
process.
Safety instruction: Fill the Air­power–
Bag only with compressed air free from
oil.
9.15 Select the appropriate curing time
according to the chart X. (see page
44).
Switch the vulcanizing machine on
by setting the mains switch (28) to
- I -. Wind up the timer with one
complete revolution (26), then reset
it to the required curing time.
(fig. 9.15a and 9.15b)
Safety instruction: Do not leave the
machine unattended when it is operating. Observe the relevant measures
for fire protection and the regulations
regarding the use of electric heating
systems. Never use the machine with
humid granules! Risks due to electric
current and formation of steam.
9.16 At the end of the previously set
curing time, the heating system is
automatically cut off by the timer.
Switch the vulcanizing machine off
by setting the mains switch to - 0 -.
Completely release the pressure in
the Airpower-Bag by removing the
valve core, then remove the pressure-exerting parts. (fig. 9.16)
Safety instructions: Use protective
gloves! Danger of burning due to hot
pressure granules / hot parts! Deposit all
the parts on the tool shelves designed
for this purpose! Risks due to falling
parts!
41
Abb./fig./esq. 9.17
42
9.17 Remove the tyre from the vulcanizing machine. Using a brush, remove any pressure granules from the
tyre. Then check whether the repair
area has been correctly vulcanized.
Do not speed up the cooling-down
process of the repair area using
water, compressed air etc.
(fig. 9.17)
9.18 If necessary, finish-buff the outside
of the repair area after the vulcanization and complete cooling of the
repair.
Caution: Use safety eye goggles.
43
X. Curing time chart
(All the information given refers only to the use of original REMA TIP TOP materials and ambient temperatures of at least +15
°C / 59 °F)
Caution: In case of sidewall repairs to truck tyres with a height/width ratio of under 75% and a narrow radius (e.g. 305 / 70 R
22.5), inner heating mats may prevent the correct positioning of the pressure blocks. In this case, precisely fitting the pressure
block S 1or S 2 on the tyre contour and centring it onto the injury is more important than using an inner heating mat.
without
inner heating system
with
inner heating system
with
SPEED inner heating system
Truck and agricultural tyres in case
of tread and shoulder repairs
3,5 hours Truck and agricultural tyre
sidewall repairs
2,5 hours 2,0 hours 1,3 hours
In general all rubber-only
or penetrating injuries with or without repair patches,
or repairs to lugs in the tread and shoulder area of agricultural tyres
max. tyre thickness in mm x 5 mins.
(e.g. 25 mm
x 5 mins.
= 125 mins.)
3,0 hours1,5 hours
max. tyre thickness
in mm x 5 mins. - 30 mins.
(e.g. 25 mm
x 5 Min. - 30 mins. = 95 mins.)
max. tyre thickness
in mm x 3 mins.
(e.g. 25 mm
x 3 mins.
= 75 mins.)
These recommended curing times refer only to the use of a cold vulcanizing machine. Within a series of curing processes carried out at intervals no longer than 30 minutes, you can reduce the curing times given in the above chart by 20 minutes from
the second curing process onwards.
This rule will also be applicable, if the pressure granules are pre-heated separately for 60 minutes, that is without any tyre placed
in the vulcanizing machine.
At ambient temperatures ranging between 0 °C / 32 °F to +15°C / 59 °F, the curing times given in the above chart have to be
extended by 20 minutes.
Note: In order to cure laminated (cushion-backed) repair patches (except for those with SV Blue Bonding Rubber) or uncured
rubber patches, we recommend using an inner heating mat. If no inner heating mat is used, extend the curing times specified,
by 60 minutes respectively.
44
3,0 horas1,5 horas
2,5 horas 2,0 horas 1,3 horas
Grosor máximo del neumático en mm x 5 min
(p. ej.: 25 mm x
5 min = 125 min)
45
Material
1 x monatlich
Universalöl
Airpower - Bag
Formgranulat
REMA TIP TOP
Formgranulat
XI. Maintenance
As the REMA TIP TOP Vulcstar machines are very reliable, thanks to their construction and the high quality of their parts and
materials, they have long intervals between servicing. For safety and warranty reasons, damaged machine parts should immediately be replaced by original REMA TIP TOP spare parts. Any work on electric components as well as any work which exceeds
maintenance work has to be carried out only by a qualified specialist.
Maintenance schedule
Machine part
Type of maintenance work
Required material
Sliding surfaces of
the cross-arm
Clean and slightly lubricate them
Once every month
Universal oil
Check for tightness and damage
Airpower - Bag
Check the safety valve
Visually check for damage
Locking pins
Screw links
Check, tighten loose screws,
if necessary
Compressed air supply
Drain the water separator
in the air line
Pressure granules
Remove foreign bodies;
compensate for loss of granules,
if necessary
46
Every time the machine
is put into operation
A month after putting the
machine into operation for
the first time, then: once
every three months
Periodically
Immediately remove
damaged parts, and
replace them by
original
REMA TIP TOP
spare parts
Granulat
granulat
REMA TIP TOP
Materiales
1 vez por mes
Aceite universal
Airpower - Bag
Pernos de seguridad
Granulado
regularmente
Granulado
REMA TIP TOP
47
48
Nur original- REMA TIP TOP Reparaturmaterial und - MTR-Rubber verwenden
XII. Trouble shooting
Trouble
Possible reason
The mains switch does not
illuminate
The machine has not been
switched on
Switch the machine on by means of
the mains switch
No mains power supply
Restore the electric power supply
Defective fuse
Replace the fuse
The time set does not
elapse on the timer face
Defective timer
Replace the part by original REMA TIP TOP
spare part
The heating element in the
granules does not heat up
No mains power supply
See “possible solution - mains switch”
The inner heating mat
does not heat up
Timer not set
Set the timer to the required curing time
Defective timer
Replace the part by original REMA TIP TOP
spare part
Defective heating element
or control box
Remove the parts and replace them by the
respective original REMA TIP TOP spare parts.
Send the old parts to REMA TIP TOP for inspection
The mains switch does
not illuminate
See “possible solution – mains switch”
Timer not set
Set the timer to the required curing time
Defective timer
Replace the part by the original REMA TIP TOP
spare part
Defective inner heating mat
or control box
Replace the inner heating mat by the original
REMA TIP TOP spare part
Remove the control box together with the pressure
granule heating system and replace them by the
original REMA TIP TOP spare parts. Send the old
parts to REMA TIP TOP for inspection
Evidence of insufficient
curing pressure on the tyre
outside/sidewall
The layer of granules between the
heating element and the tyre is too thin
The vibrator has not worked long
enough to provide sufficient density
of the granules
The vibrator has worked too long, thus
causing too large a quantity of granules
to flow away from the repair area
Evidence of insufficient
curing pressure on the
tyre inside
Repair area not
vulcanized enough
Make sure that the layer of granules on the heating
element is thick enough. See item 7.3 page 15
Put the vibrator into operation and let it operate for
approx. 45 - 60 seconds according to this manual
item 7.10, page 19
Use only REMA TIP TOP granules
Air entrapment in the skive filling
Fill the skive carefully and stitch on thoroughly
No counter pressure plate
The counter pressure plate is essential to
provide a contour that snugly fits the tyre
Make sure of sufficient pressure
(Tubular socket wrench, pneumatic wrench)
Wrong counter-pressure plate selected
Select the largest possible counter-pressure
plate and position it near the bead
After the compacting of the granules,
the pressure in the Airpower-Bag has
not been increased
After compacting the granules, increase the
pressure in the Airpower-Bag up to 3 bar /
43 psi or 2.5 bar / 36 psi
The inner heating mat selected
is too small
The inner heating mat has to cover the repair patch
all around. Use the right size!
The Airpower-Bag selected is too small
The Airpower-Bag has to cover the repair patch all
around. Use the right size!
The Airpower-Bag does not exert
enough pressure
Check the operating pressure (3 bar / 43 psi or
2.5 bar /36 psi) in the Airpower-Bag
Insufficient counter-pressure put
on the tyre outside
Check whether the repair area is correctly
positioned in the pressure granules and whether
there are enough granules under the repair area
Curing time too short
Observe or determine the curing times
according to this manual
The required temperature has
not been reached within the
previously set curing time
The layer of pressure granules between the
heating element and the tyre is too thick, or the
heating element is too far away from the tyre
At ambient temperatures below +15 °C/ 59 °F,
extend the curing time accordingly
The repair material/skive filling
used vulcanizes too slowly
Use only original REMA TIP TOP repair material
and REMA TIP TOP MTR Rubber
Too high mechanical pressure on
Airpower-Bag
Tighten the pressure spindle only with your hands.
Inflate the Airpower-Bag up to 1 bar
49
Vulcanisation insuffisante
Granulat inapproprié
Pression insuffisante
Membrane gonflable Airpower-Bag
choisie trop petite
50
El temporizador
no finaliza
No se ha dado cuerda al temporizador
No se ha dado cuerda al temporizador
La almohadilla
eléctrica interior
no se calienta
51
Xlll. Zubehör / Accessories / Accessoires / Accesorios
Pos.
1
2
3
4
5
6
7
8
9
10
11
12
Pos.
Ref. No.
1
2
3
4
5
6
7
8
9
10
11
12
585 3159
585 3290
585 3173
585 1807 585 3142
585 3269
585 3056
585 3087
517 6946 585 3018 585 3025 585 3276
tyre support
Adapter for sidewall pressure clamp / T-piece
Pressure bar (40 mm diameter), complete
(Pneumatic) wrench with adapter
pressure clamp for shoulder and sidewall repairs
Locking pin for sidewall pressure clamp
Pressure block L 1 Pressure block S 1
Airpower Bag size II approx 300 x 320 mm
Vulcstar inner heating mat II 230 V approx 200 x 380 mm
Vulcstar inner heating mat IV 230 V approx 310 x 475 mm
Locking pin (12 mm diameter) for pressure bar
Pos.
Réf.
1
2
3
4
5
6
7
8
9
10
11
12
585 3159
585 3290
585 3173
585 1807 585 3142
585 3269
585 3056
585 3087
517 6946 585 3018 585 3025 585 3276
Pos.
№ Ref.
1
2
3
4
5
6
7
8
9
10
11
12
52
Xlll. Zubehör / Accessories / Accessoires / Accesorios
7
9
8
4
1
11
6
12
3
5
2
10
53
XIV. Explosionszeichnung / Exploded view / Vue éclatée / Despiece
21
22
13
17
25
12
26
36
1
14
24
41
32
37
10
31
9
34
19
28
27
23
15
44
16
1
44
35
20
40
6
54
7
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
55
XV. Spare Parts List
Vulcstar / Vulcstar accessories
Ref. No. 585 3003
Pos.
Ref. No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
585 3049 *
Vulcstar control box including heating element for pressure granules, approx 500 x 700 mm
585 3032 *
pressure granules, (14 sacks, each 25 kg)
585 3018 *
Vulcstar inner heating mat II, 230 V, approx 200 x 380 mm
585 3025 *
Vulcstar inner heating mat IV, 230 V, approx 310 x 475 mm
517 6946 *
Airpower Bag size II, approx 300 x 320 mm
517 6939 *
Airpower Bag size IV, approx 300 x 470 mm
517 6757 *
Airpower Bag size VI, approx 400 x 470 mm
585 3056
Pressure block L 1
585 3063
Pressure block L 2
585 3070
Pressure block L 3
585 3087
Pressure block S 1
585 3094
Pressure block S 2
585 3104
Pressure block S 3
585 3135
Pressure plate for agricultural tyres AS 1
585 3111
Counter-pressure plate GD 1
585 3128
Counter-pressure plate GD 2
585 3142
pressure clamp for shoulder and sidewall repairs
585 3173
Pressure bar (40 mm diameter), complete
585 7825
Tubular socket wrench for pressure spindle
540 0052
Set of 4 rubber pads, approx 100 x 100 x 30 mm
585 3180 * Mains cable
585 3197
Mains supply connector
585 3207 *
Vibrator with fastening screws
585 3214
Hand lever valve
585 3221
Mains switch
585 3238
Timer 0 - 6 hours
585 3245
Pressure regulating flow control valve 6 bar / 87 psi
585 3252 *
counter-pressure bar with spindle / extension of counter-pressure bar
585 3269
Locking pin for sidewall pressure clamp
585 3276
Locking pin (12 mm diameter) for pressure bar
585 3283
Locking pin (20 mm diameter) for frame
557 8434
Safety pin for locking pin (20 mm diameter)
585 3290
Adapter for sidewall pressure clamp / T-piece
585 3440
Height adjusting lever
585 3166
Spatula for pressure granules
585 3317
Fuse-holder 10 A (with cap)
585 1807 *
(Pneumatic) wrench with adapter
585 3430 *socket adapter set: socket adapter casing, pressure spindle with guide bushing
and special locking pin
585 3470
adapter
585 3136
Pressure plate for agricultural tyres AS 2
585 3095
Pressure block AS 2
585 3540
shovel for granules
585 3550
bucket for granules 22 liters (4x)
585 3416
diamond-shaped tool tray, 600 x 145 x 8 mm, 4x
585 3159
tyre support
Safety instruction.
Allow only a qualified specialist to carry out any work on electric parts!
The parts marked with an asterisk *) are wear parts, for which no liability based on any legal regulations whatsoever can
be accepted.
56
Réf. 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
57
№ Ref. 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
58
Anschlussplan - Wiring diagram - Schéma des connexions - Esquema de conexiones
Anschlussplan für den Anschluss von Vulcstar 2001 Geräten an ein 115 V Netz (USA)
Sicherheitshinweis: Arbeiten an stromführenden Bauteilen nur von einem Fachmann durchführen lassen!
Wiring diagram for connecting Vulcstar 2001 to 115 Volt USA-mains supply
Security remarks: The wiring has to be done only by a qualified electrician!
Schéma des connexions pour Vulcstar - version 2001 pour le branchement sur l´alimentation secteur
115 Volts (Etats Unis).
Consigne de sécurité : Il faut que le branchement ne soit fait que par un électricien qualifié.
Esquema de conexiones Vulcstar 2001 para la conexión a la red eléctrica 115 voltios (EE.UU.)
Instrucción de seguridad: ¡La conexión debe ser llevada a cabo únicamente por un electricista autorizado!
Wenn dieses Messergebnis erreicht wur­
de bitte nach nebenstehendem Schaltbild
anschließen.
When this measuring result has been
attained, connect according to the wiring
diagram opposite.
Lorsque ce résultat de mesure est indiqué, faites le branchement conformément
au schéma ci-contre.
Una vez conseguido este resultado de
me­dición, conecte el aparato según el
es­quema de conexiones al lado.
Starting from serial number/ab Seriennr./à partir du numéro de série/
a partir del número de serie : 01-039-002
59
Air Power Bag
Anwendungshinweise / Instructions for use /
Notice d´utilisation / Nota de utlilización
Typ / Type
Type / Tipo
Air Power Bag II 517 6946
Air Power Bag IV 517 6939
Air Power Bag VI 517 6757
300 mm x 320 mm
300 mm x 470 mm
400 mm x 470 mm
max. 3 bar / 43 psi
max. 3 bar / 43 psi
max. 2,5 bar / 36 psi
Air Power Bag
1. Use for tread repairs
- The Air Power Bag has to cover the repair patch sufficiently,
- with its air connector valve facing in the running
direction. (see fig.1)
Abb. / Fig. / Esquema 1
2. Use for sidewall and shoulder repairs:
- The Air Power Bag has to cover the repair patch sufficiently.
- Make sure that the air connector valve protrudes over the bead. (see fig.2)
richtig
Correct
Correct
CORRECTO
Air Power Bag II
Air Power Bag IV
Air Power Bag VI
2.
Ventil wird geknickt / The valve is twisted. /
Le raccord d´air est plié. / La válvula de
conexión se dobla.
Abb. / Fig. / Esquema 2
Die Ventile des Air Power Bag müssen über den Wulst hinausragen! Ein Abknicken der Ventile führt
zur Beschädigung des Air Power Bag.
The valves of the Air Power Bag have to protrude over the bead. Twisting the valves causes damage
to the Air Power Bag.
La valve et la soupape de la membrane gonflable Airpower-Bag doivent dépasser du talon. Toute
déformation de la valve et de la soupape occasionnera des dommages de la membrane gonflable.
La válvula de conexión así como la válvula de sobrepresión del colchón neumático Air Power Bag
tienen que solapar el talón. Todo tipo de deformación de dichas válvulas causará deterioros en el
colchón neumático.
60
Air Power Bag
•
•
•
•
•
•
•
•
•
•
•
Air Power Bag
Use the Air Power Bag only together with the VULCSTAR
and TRUCKMASTER vulcanizing machines. Do not
use it as a lifting device etc.
Always check the Air Power Bag for damage before
use.
Always position the Air Power Bag with the vulcanette/
logo facing upwards.
Use only original REMA TIP TOP pressure blocks for
the transmission of pressure.
Always make sure that all locking pins are seated
and secured correctly on the vulcanizing machine/the
pressure units before inflating the Airpower-Bag.
Fill the Airpower Bag only with compressed air free
from oil.
The maximum operating pressure must not be exceeded. (For information about the right operating pressure
for the repair, refer to the user´s manual of the vulcanizing machine.)
Do not change the pre-set pressure on the safety
valve or damage it.
Protect the Airpower-Bag from oil, grease, solvents
and acids.
Do not put the Airpower-Bag on hot, sharp-edged or
pointed objects.
Observe the general safety regulations and the regulations for prevention of accidents.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
61
Printed in Germany
Vll.09
581 1190
REMA TIP TOP GmbH
Gruber Straße 63
85586 Poing / Germany
62
Tel.: +49 8121 707-322
Fax: +49 8121 707-349
www.rema-tiptop.com