Mounting Tires (Removing and Installing Tires)
Mounting tires (removing and installing tires)
Information
Tools
Tire removal/mounting machine
Only use recommended tire removal/mounting machine and auxiliary equipment (special mounting lever, bead holding-down device).
WE 1084 Tire removal/mounting machine
Auxiliary equipment
Auxiliary equipment
1 - Special mounting lever with plastic protection.
2 - Holding-down device 9539 - for holding down the tire bead.
3 - Wulstboy - for holding down the tire bead (alternative to holding-down device 9539/item 2)
4 - Adhesive weight remover - commercially available
Requirements/information on removing/mounting tires
Information
* Tire temperature during removal/mounting must be approx. 20 degrees C (at least 15 degrees C). Allow enough time to heat the vehicle/tires in a suitable environment if necessary (at room temperature of more than 15 degrees C). Example: If the room temperature of the workshop is approx. 20 degrees C and the tire temperature is approx. - 15 degrees C, approx. 3 hours are required to heat the tires to the required temperature.
* Before removal/mounting, it is important to establish whether a Tire Pressure Monitoring system (TPM) is fitted! The tire valve serves as the distinguishing feature. Without TPM: rubber valve. With TPM: aluminum valve. If a TPM system is fitted, read the special information on the Tire Pressure Monitoring system (see module in this main chapter).
* Vehicles with TPM: Before changing a tire, read out the remaining life span of the wheel electronics unit (battery capacity) using the PIWIS Tester. The value you read out gives an indication as to whether or not it needs to be replaced (not a 100% value). If the values are considerably lower than expected for the next tire change, talk to the customer and determine whether he/she is happy to have the wheel electronics unit(s) replaced at this time.
* Use only TIP TOP Universal, Order No. 593 0601 (3.5 kg bucket) or Contifix as the removal/mounting paste (sliding compound). Use sufficient sliding compound.
* No large point load for wheel (rim) and tire during removal/mounting. If this is not observed, damage will occur that will render a tire unusable (ready for disposal) and/or require a new rim.
* Before removal/mounting, check the mounting head (of the mounting machine) for damage (scoring, soiling). Clean or replace the mounting head if necessary to prevent paint damage and pressure marks on the rim flange.
* All parts that touch the disc wheel and tire are made of plastic to prevent damage to paintwork during removal/mounting. Protect the rim flange with adhesive tape if necessary. The mounting lever can also be covered with adhesive tape in order to avoid damaging the area around the spokes (during removal).
* If you do not have a mounting lever with plastic protection, use a rim flange protector (assembly aid) and avoid letting it slip on to the rim flange.
* Check the disc wheel for damage (sealing face between tire/rim, true running, superficial damage and deformation).
* If you intend to continue using the tire, check it for damage (sealing face between tire/rim, ply damage, tire beads, sidewalls and tread depth).
* The rubber valve must generally be replaced when a tire change is necessary. In vehicles with TPM (aluminum valve), the valve only needs to be replaced in exceptional cases. This is elaborated further in: "Special information on TPM" (module in this main chapter).
* When mounting tires, pay particular attention to the direction of rotation and the inside/outside.
* When replacing only one tire on an axle, make sure that the tread depth of the new tire does not differ from that of the other tire by more than 30%!
Special notes for Tire Pressure Monitoring (TPM)
Information
* If the old wheels are still in the vicinity after assembly work (for example changing winter tires and/or wheels from another vehicle with TPM), these will still be detected by the system. If one or more of these wheels has a minimum pressure of more than 0.5 bar below the required pressure, this can trigger a warning in the instrument cluster. In this case, remove the other wheels or use the PIWIS Tester to tune the vehicle to be outside the radio range of these wheels.
* Before changing a tire, read out the remaining life span of the wheel electronics unit (battery capacity) using the PIWIS Tester.
Wheel electronics unit (shown as an example)
* For vehicles with a TPM, the valve and wheel electronics unit -A- are only replaced in exceptional cases. The following points can make replacement necessary.
Component overview for TPM valve/wheel electronics
-A- - Wheel electronics
-B- - Valve complete (No. 2 to No. 7)
-1- - Self-locking (Torx) fastening screw
-2- - Valve cap (plastic)
-3- - Valve insert
-4- - Union nut
-5- - Washer chamfered on both sides
-6- - Bead seat sealing ring
-7- - Valve
The valve -B- must be replaced if:
* The wheel electronics unit -A- is removed
* The self-locking fastening screw -1- is loose
* The union nut -4- is loose
* The valve -7- is leaking at the valve seat
* The valve -7- (valve body) is bent or broken.
The wheel electronics unit -A- must be replaced if:
* The housing is visibly deformed
* The filter surface (on the bottom) is so soiled that it cannot be cleaned by wiping
* Tire sealant (tire sealing liquid) has been used
Instructions for fitting the TPM valve are provided below.
1. Loosely fit the wheel electronics unit -A- at the valve -7- (do not tighten screw -1-). Insert this assembly into the valve bore (of the rim) with the bead seat sealing ring -6-.
Fit washer, chamfered on both sides, -5- and screw on the union nut -4- until it is seated correctly.
TPM valve
Wheel electronics
2. Tighten valve and wheel electronics unit.
2.1. Block the valve at the bore in the base of the valve using a suitable assembly pin. This is necessary in order to counter while tightening the union nut. Tighten the union nut to 4 Nm (3 ftlb.). The union nut must be tightened in one step (without interruption until the prescribed tightening torque is reached). It must not be tightened again afterwards!
2.2. After fitting the valve, remove the assembly pin (used to counter the valve)!
2.3. Press the wheel electronics unit -A- slightly into the rim bed (this adjusts the angle of inclination of the valve with respect to the wheel electronics unit).
Carefully tighten the self-locking fastening screw (Torx T 20) to the required tightening torque of 4 Nm (3 ftlb.). The wheel electronics unit should now be lying evenly against the rim.
Countering TPM valve while tightening
Removing/mounting tires (removing and installing tires)
Removing tires
For correct tire removal/mounting, follow the instructions provided for the tire removal/mounting machine.
See Requirements/information on removing/mounting tires!
1. Fit and clamp a clean disc wheel on the tire removal/mounting machine.
Check that the tire is seated securely and without damage (as described in the instructions provided for the tire removal/mounting machine).
2. Unscrew the valve insert and release the air so that the tire is depressurized.
3. Set the tire bead press-off tool (in accordance with the tire size).
Setting the tire bead press-off tool
3.1. Set the tire bead press-off tool to the inch graduation (rough setting in accordance with the tire size).
3.2. Then adjust the setting precisely (the press-off roller must not touch the rim when positioned on the tire). If this is not the case, the rim flange may be damaged by the press-off rollers.
4. Loosen the lower and upper tire bead (press the tire off the rim).
4.1. The wheel must be turned anti-clockwise (anti-clockwise rotation of the mounting table) when pressing the tire off the rim (loosening the tire bead). Otherwise, excessive forces occur on the fastening bolts of the machine which can break the bolts. First press off the lower tire bead and then the upper tire bead (to ensure that the wheel remains seated securely on the machine). Coat the tire beads with mounting paste even at this stage of the procedure to make it easier to press the tire bead off.
4.2. Loosen the two bead press-off tools again (by moving them back to their original position).
5. Before removing the tire, coat the tire beads with mounting paste again if necessary to facilitate removal.
Information
* Always use a bead holding-down device for removing the upper tire bead (second tire bead).
* Use the Wulstboy bead holding-down device (type 2 in section 6.2) for tire/wheel combinations that are difficult to remove.
6. Removal
6.1. Removing upper tire bead - type 1
Valve/wheel electronics unit at 12 o'clock position.
Fit the mounting head on the rim flange.
The mounting lever (with plastic protection) is pushed into the deep bed underneath the upper tire bead, and then guided over the mounting shoe and pushed down.
Lift the tire bead out of the rim bed by turning the wheel clockwise. Check the following while doing this:
* Check that the bead lip is facing outwards and is fully visible. Otherwise, the tire bead can become jammed and be damaged irreparably.
* The mounting lever must be the same distance from the inside of the tire and the valve during the entire removal procedure.
* Constantly check that the plastic protection (on the mounting lever) is positioned correctly in order to protect the rim.
* The lower (second) tire bead must be in the deep bed during removal.
* The tire bead must not be pressing against the wheel electronics unit.
Removal using Wulstboy
6.2. Removing upper tire bead using bead holding-down device type 2 = Wulstboy
Valve/wheel electronics unit at approx. 12 o'clock position.
Use the upper plastic press-off roller on the mounting machine to press the upper tire bead approx. 4 to 5 cm below the rim flange (max. 5 cm/the belt edge of the tire must not be deformed by the plastic press-off roller). This makes space for the bead holding-down device blocks.
Fit the bead holding-down device (Wulstboy) into the middle of the "wheel/rotary plate". Move the arm of the bead holding-down device to the 1 o'clock position.
Turn the wheel slowly in a clockwise direction (clockwise rotation) and insert the blocks of the bead holding-down device.
Remove the upper press-off roller on the mounting machine from the tire and fit the mounting head on the rim flange. Insert the mounting lever (with plastic protection) -1- and lever the upper tire bead over the mounting head.
Continue turning the disc wheel slowly (clockwise rotation) until the bead holding-down device (Wulstboy) is just in front of the mounting head. Remove the Wulstboy using holding-down device 9539. Continue turning the disc wheel slowly (clockwise rotation) until the upper bead is completely removed.
6.3.
7. Removing lower tire bead:
Removing tires
Valve/wheel electronics unit at 12 o'clock position.
Pull the tire upwards and push it into the rim bed underneath the second tire bead using the mounting lever (plastic protection).
Make sure that the valve/wheel electronics unit is not damaged.
Check the position of the mounting lever. The mounting lever must be the same distance from the inside of the tire and the valve during the entire removal procedure. Constantly check that the plastic protection (on the mounting lever) is positioned correctly in order to protect the rim.
Turn the wheel slowly clockwise until the tire is removed.
8. Set the mounting lever and tire aside (in a safe/clean place).
Detach the disc wheel from the machine, remove it and lay it carefully aside (store in a safe place).