s Tyremaster Operation Guide - UK 2026 v1.1

Operation Guide

Hydraulic Wheel Changer

Model: Tyremaster 1200-2400

Document: Operation Guide – Tyremaster UK – 2026 v1.1

Date: February 2026

Manufacturer: HydraLoad ApS, Denmark

1. Introduction2

2. Safety Requirements2

3. Machine Overview3

4. Controls4

5. Before You Start5

6. Operating Procedures6

6.1 Wheel Removal6

6.2 Wheel Mounting7

7. Adjusting the Gripper Arms8

8. Troubleshooting9

1. Introduction

The Tyremaster 1200-2400 is a hydraulic wheel changer designed for the safe and efficient handling of large wheels on trucks, agricultural machinery, construction equipment, and military vehicles.

The standard configuration handles wheels with diameters from 920mm to 1,700mm, widths up to 800mm, and weights up to 1,200kg. Optional kits extend the range:

Configuration	Wheel Diameter Range
Standard (included)	920 – 1700 mm
Large Wheel Kit (optional)	1600 – 2400 mm
Brake Drum Kit (optional)	300 – 1000 mm

Intended Use: The Tyremaster is designed for use in workshops, garages, and field conditions. It can be suspended from overhead cranes or truck-mounted cranes. The standard 920mm minimum diameter provides compatibility with standard truck wheel setups.

This guide covers daily operation only. For maintenance procedures, refer to the separate Service Guide.

2. Safety Requirements

2.1 Required Personal Protective Equipment (PPE)

The following PPE must be worn at all times when operating the Tyremaster:

🦺

Safety Footwear
Steel-toe boots required

⛑️

Hard Hat
Required during lifting operations

2.2 Safety Warnings

⚠️ DANGER – Crushing Hazard
Contact with moving parts can cause crushing or severing of body parts. Keep hands and body clear of the gripper arms and tilting mechanism during operation.

⚠️ DANGER – Falling Load
Never position yourself or others beneath a suspended wheel. Always secure the wheel with the safety strap before lifting.

⚠️ WARNING – Single Operator Only
The Tyremaster must only be operated by one person at a time. The crane operator is responsible for all lifting movements.

2.3 Prohibited Uses

Do not use for lifting personnel
Do not use for horizontal pulling of loads
Do not use near electrical power lines
Do not use in explosive atmospheres
Do not climb or stand on the machine
Do not operate with guards removed

3. Machine Overview

Figure 1: Tyremaster component overview

Key Components

Component	Description
Lifting Point	Connection point for crane hook or lifting equipment
Frame	Main structural frame with handles for manual positioning
Hydraulic Cabinet	Contains pump, tank (2.5L), and control valves
Electrical Cabinet	Houses PLC, battery, and charger
Tilt Cylinder	Hydraulic cylinder for tilting wheel vertical/horizontal
Gripper Cylinders	Three hydraulic cylinders that drive the gripper arms
Gripper Arms	Adjustable arms that grip the wheel (3 or 4 arms depending on model)
Safety Strap	Securing strap to prevent wheel from falling during transport
Depth Stop	Adjustable stop for consistent wheel positioning

4. Controls

4.1 Pendant Control

The Tyremaster is operated via a handheld pendant with five control buttons. All buttons are "hold-to-run" – the movement stops immediately when you release the button.

Figure 2: Pendant control layout

Button	Function
1 + 4 (Press together)	Open gripper arms
5	Close gripper arms
3	Tilt to vertical position (for lifting)
2	Tilt to horizontal position (for laying wheel down)

Note: Opening the gripper arms requires pressing two buttons simultaneously (1 + 4) as a safety measure to prevent accidental release.

4.2 Emergency Stop

The red emergency stop button is located on the side of the electrical cabinet. When pressed:

All machine movement stops immediately
The motor is de-energised
Hydraulic pressure is maintained (wheel stays gripped)

To reset: Twist the emergency stop button clockwise to release, then resume operation.

4.3 Battery Status

The battery level indicator is on the left side of the electrical cabinet. The machine should have at least 40% charge before use. The machine uses two 20Ah 12V lead-acid batteries connected in series for a 24V system.

Figure 3: Battery status indicator location

5. Before You Start

5.1 Pre-Operation Checks

Before each use, perform the following checks:

Check	Action
Battery level	Confirm at least 40% charge on indicator
Emergency stop	Verify it is not engaged (button released)
Visual inspection	Check for visible damage, leaks, or loose parts
Safety strap	Confirm strap is present and undamaged
Gripper arms	Verify arms move freely and are properly secured
Crane connection	Ensure lifting equipment is properly rated and connected

5.2 Wheel Compatibility

Confirm the wheel to be handled falls within the machine's specifications:

Configuration	Wheel Diameter
Standard	920 – 1,700 mm
Large Wheel Kit (optional)	1,600 – 2,400 mm
Brake Drum Kit (optional)	300 – 1,000 mm

Parameter	Limit
Max Wheel Width	800 mm
Max Wheel Weight	1,200 kg

⚠️ Do not attempt to handle wheels outside these specifications. Ensure you have the correct kit fitted for the wheel diameter.

6. Operating Procedures

6.1 Wheel Removal

Use this procedure to remove a wheel from a vehicle.

Tilt the Tyremaster to the vertical position using the pendant (button 3).

Position and centre the Tyremaster over the wheel to be removed.

Close the gripper arms (button 5) to grip the wheel. Ensure all arms make contact with the tyre.

Verify centring: Slightly release the grippers, check all arms have equal spacing to the wheel, then re-grip at full pressure.

Remove the wheel bolts from the vehicle hub.

Pull the wheel away from the hub using the crane.

Attach and tighten the safety strap around the wheel.

Tilt the wheel to the horizontal position (button 2) for transport.

Transport the wheel to the desired location and lower it to the ground.

Release the safety strap, then open the gripper arms (buttons 1 + 4) to release the wheel.

Figure 4: Ensure the gripper is centred over the wheel before gripping

6.2 Wheel Mounting

Use this procedure to mount a wheel onto a vehicle.

Position the wheel flat on the ground in the pickup area.

Tilt the Tyremaster to the horizontal position (button 2).

Position and centre the Tyremaster over the wheel.

Close the gripper arms (button 5) to grip the wheel securely.

Attach and tighten the safety strap around the wheel.

Lift and tilt the wheel to the vertical position (button 3).

Transport the wheel to the vehicle and position it in front of the hub.

Release the safety strap once aligned with the hub.

Slide the wheel onto the hub and install the wheel bolts.

Open the gripper arms (buttons 1 + 4) and move the Tyremaster away.

⚠️ CRITICAL: The wheel must be in the vertical position and resting on the two lower gripper arms before lifting and transporting. Never transport a wheel in the horizontal position while elevated.

7. Adjusting the Gripper Arms

The gripper arms can be adjusted to accommodate different wheel sizes. Adjustment holes are provided at multiple positions along each arm.

Configuration Options

Configuration	Wheel Diameter Range	Notes
Standard	920 – 1700 mm	Included – suits trucks and medium agricultural
Large Wheel Kit	1600 – 2400 mm	Optional – large agricultural, forestry, mining
Brake Drum Kit	300 – 1000 mm	Optional – for brake drum service

⚠️ Perform adjustment with the machine unloaded and on a stable surface.

Adjustment Procedure

Remove the split pin from the locking bolt.

Pull out the locking bolt.

Slide the gripper arm to the desired position.

Re-insert the locking bolt and secure with the split pin.

Step 1: Remove split pin

Step 2: Pull out bolt

Step 3: Adjust position

Step 4: Secure with pin

Tip: All gripper arms should be set to the same position to ensure balanced gripping.

8. Troubleshooting

If the machine does not respond as expected, check the following before contacting support:

Symptom	Possible Cause	Solution
No movement	Low battery	Check battery indicator. Charge if below 40%.
No movement	Emergency stop engaged	Twist and release the emergency stop button.
No movement	Low hydraulic oil	Check oil level in the hydraulic tank. Top up if needed (ISO 32 oil).
Slow or jerky movement	Air in hydraulic system	Contact service technician to bleed the system.
Gripper won't open	Buttons not pressed correctly	Press buttons 1 AND 4 together to open.
Unusual noise/vibration	Air in hydraulic oil	Contact service technician.

Contact Information

For technical support or spare parts:

Manufacturer	HydraLoad ApS
Address	Østergårdsvej 15, 7840 Højslev, Denmark
Phone	+45 97 53 52 00
Email	info@hydraload.dk
Website	https://hydraload.dk

TYREMASTER – Hydraulic Wheel Changers

Operation Guide – Tyremaster UK – 2026 v1.1

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