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Tyremaster Service Guide - UK 2026 v1.1
Service Guide
Inspection & Maintenance Manual
Contents
1. Introduction2
2. Safety During Maintenance2
3. Maintenance Schedule4
4. Pre-Use Inspection Checklist5
5. Annual Inspection Checklist6
6. Hydraulic System8
7. Electrical System9
8. Battery Care10
9. Storage11
10. Troubleshooting12
11. Consumables & Spare Parts13
1. Introduction
This Service Guide provides maintenance and inspection procedures for the Tyremaster 1200-2400 hydraulic wheel changer. Following these procedures will ensure safe operation and maximise the service life of your equipment.
Expected Service Life: The Tyremaster is designed for 20 years of service when properly maintained. After 20 years, a full inspection and risk assessment must be performed before continued use.
Who Should Use This Guide
Maintenance and service tasks should only be performed by:
- Qualified maintenance technicians
- Trained mechanics with hydraulic system experience
- Qualified electricians (for electrical work)
Operators may perform pre-use visual inspections only.
2. Safety During Maintenance
2.1 Lockout / Tagout Procedure
Before performing any maintenance work, the machine must be isolated from all energy sources:
β οΈ DANGER β Energy Isolation Required
Failure to properly isolate energy sources before maintenance can result in serious injury or death.
1
Bring the machine to a complete stop.
2
Release hydraulic pressure (see Section 6.2).
3
Disconnect the power supply by unplugging the mains cable.
4
Turn the isolator switch to OFF and remove the key.
5
Attach a lockout tag to the isolator.
6
Verify zero energy state before starting work.
2.2 Required PPE for Maintenance
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Oil-Resistant Gloves
2.3 Hydraulic Oil Safety
β οΈ Hydraulic Oil Hazards
- Repeated skin contact may cause irritation and dermatitis
- Eye contact may cause damage
- Always wear protective gloves and safety glasses when handling hydraulic oil
- Refer to the Safety Data Sheet for ISO 32 hydraulic oil
2.4 Electrical Safety
β οΈ DANGER β Electrical Hazard
The machine operates on 230V AC (charging) and 24V DC (controls). All electrical work must be performed by a qualified electrician. Verify zero voltage with a suitable meter before working on electrical components.
2.5 Safe Working Practices
- Place the machine on a stable, level surface
- Support/secure the tilt mechanism before working underneath
- Use adequate lighting
- Establish barriers or signage if working in a shared area
- Keep the work area clean and free of oil spills
- Use appropriate lifting equipment for components over 25 kg
3. Maintenance Schedule
| Task |
Frequency |
Performed By |
| Visual inspection (damage, leaks, loose parts) |
Before each use |
Operator |
| Check battery level |
Before each use |
Operator |
| Check safety strap condition |
Before each use |
Operator |
| Test emergency stop function |
Monthly / Min. annually |
Technician |
| Check hydraulic oil level |
Monthly |
Technician |
| Inspect hydraulic hoses and fittings |
Annually |
Technician |
| Inspect electrical cables and enclosures |
Annually |
Electrician |
| Check grounding/earthing connections |
Annually |
Electrician |
| Inspect welds for cracks |
Annually |
Technician |
| Check all bolts and fasteners |
Annually |
Technician |
| Inspect guards and safety covers |
Annually |
Technician |
| Check safety labels and pictograms |
Annually |
Technician |
| Test isolator switch function |
Annually |
Electrician |
| Replace hydraulic oil |
As needed / per oil condition |
Technician |
| Replace hydraulic hoses |
Per date marking or condition |
Technician |
Documentation: All inspections and maintenance must be recorded in a maintenance log. The log should be kept accessible to all users of the machine.
4. Pre-Use Inspection Checklist
Complete this checklist before each use. If any item fails, do not use the machine until the issue is resolved.
Battery level β Indicator shows β₯40% charge
Emergency stop β Button is released (not engaged)
Visual condition β No visible damage, cracks, or deformation
Hydraulic system β No visible leaks or wet spots
Safety strap β Present, undamaged, and functional
Gripper arms β Move freely, securely fastened with split pins
Pendant control β Cable undamaged, buttons function correctly
Lifting point β No damage or wear to hook attachment
Guards β All safety guards in place and secure
Work area β Clear of obstructions and hazards
β All items passed: Machine is approved for use.
β Any item failed: Do not operate. Report issue and arrange repair.
| Inspected by: ______________________ |
Date: ______________________ |
| Signature: ______________________ |
Machine ID: ______________________ |
5. Annual Inspection Checklist
This comprehensive inspection must be performed at least once per year by qualified personnel.
5.1 Safety Systems
Emergency stop β Activate during operation; machine must stop immediately. Reset and verify restart.
Isolator switch β Can be locked in OFF position; machine cannot start when isolated.
Hold-to-run controls β Movement stops immediately when button is released.
Safety labels β All warning labels present, legible, and undamaged. Replace if needed.
5.2 Electrical System
Cables β No damage to insulation, strain reliefs intact, no exposed conductors.
Enclosures β Electrical cabinets intact, seals good, no water ingress.
Earth bonding β All earthing connections secure and continuous.
Pendant cable β No cuts, kinks, or damage. Connectors secure.
5.3 Hydraulic System
Oil level β Within marked range on tank.
Oil condition β Clear, no milky appearance (water contamination) or dark discoloration.
Hoses β No cracks, bulges, chafing, leaks, or soft spots. Check date markings.
Fittings β No leaks at connections. Fittings tight.
Cylinders β No external leaks. Rods clean and undamaged.
Hose protection β Guards and clamps in place.
5.4 Mechanical Components
Welds β No cracks, breaks, or signs of fatigue. Inspect all structural welds.
Bolts and fasteners β All present, tight, and undamaged. Replace if worn.
Gripper arm pins β Secure with split pins. No excessive wear.
Guards β All safety guards fitted correctly and undamaged.
Lifting point β No wear, cracks, or deformation.
5.5 Annual Inspection Sign-Off
| Machine Information |
| Machine Type: Tyremaster 1200-2400 |
Serial Number: _______________ |
| Inspection Details |
| Inspection Date: _______________ |
Next Inspection Due: _______________ |
| Issues Found: _______________________________________________ |
| Corrective Actions: _______________________________________________ |
| Certification |
| Inspector Name: _______________ |
Company: _______________ |
| Signature: _______________ |
Date: _______________ |
β οΈ If any safety-critical defect is found, the machine must be taken out of service until repaired and re-inspected.
6. Hydraulic System
6.1 Hydraulic Specifications
| Parameter |
Value |
| Operating Pressure |
175 bar |
| Flow Rate |
2.1 L/min |
| Tank Volume |
2.5 litres |
| Oil Type |
ISO 32 mineral hydraulic oil |
| Viscosity |
15-32 cSt at 40Β°C |
| Filtration |
Particles <10ΞΌ |
6.2 Releasing Hydraulic Pressure
Before any hydraulic maintenance, pressure must be released:
1
Open the gripper arms fully to release cylinder pressure.
2
Place the tilt frame in the "over-centre" (rest) position.
4
The hydraulic system is now depressurised.
6.3 Checking and Topping Up Oil
Check the oil level monthly or if movement becomes slow or erratic.
- Place the machine on a level surface with grippers open
- Check the oil level on the tank sight glass or dipstick
- Top up with ISO 32 hydraulic oil if below the minimum mark
- Do not overfill
6.4 Bleeding the Hydraulic System
If air enters the system (indicated by jerky movement or noise), the system must be bled by a qualified technician.
Note: Hydraulic component replacement and system bleeding should only be performed by trained mechanics.
7. Electrical System
7.1 Electrical Specifications
| Parameter |
Value |
| Mains Supply (Charging) |
230V AC, 50Hz, 10A |
| System Type |
TN-S (earthed) |
| Battery Voltage |
24V DC |
| Battery Capacity |
2x20Ah 12V |
| Control Voltage |
24V DC |
| Pump Motor |
24V DC |
7.2 Electrical Cabinet Components
| # |
Component |
| 1 | PLC Controller |
| 2 | Battery |
| 3 | Battery Charger |
| 4 | Isolator Switch / Emergency Stop |
| 5 | Battery Status Indicator |
β οΈ All electrical work must be performed by a qualified electrician. Always verify zero voltage before opening cabinets or working on electrical components.
7.3 Earthing / Grounding
The mains cable must include an earth connection (3-pin Schuko or CEE plug). Check annually that all earth bonding connections are secure.
After any maintenance or repair, earth bonding connections must be re-checked and reconnected correctly.
8. Battery Care
8.1 Charging
- Connect to 230V AC mains supply using the supplied cable
- The charger will automatically manage the charging cycle
- Charge when battery indicator drops below 40%
- The machine can be used during charging if needed
8.2 Battery Maintenance
- Keep battery terminals clean and free of corrosion
- Do not deep-discharge the battery repeatedly
- If storing for extended periods, charge to ~50% and recharge every 3 months
- Replace battery when it no longer holds sufficient charge for normal operation
β οΈ Battery Disposal: Batteries must be disposed of according to local WEEE (Waste Electrical and Electronic Equipment) regulations. Do not dispose of in general waste.
9. Storage
9.1 Storage Conditions
| Parameter |
Requirement |
| Temperature |
-30Β°C to +40Β°C |
| Humidity |
40% β 70% (non-condensing) |
| Surface |
Stable, level (max 5Β° incline) |
| Environment |
Avoid prolonged direct sunlight |
9.2 Storage Position
Store the machine with the tilt frame in the "over-centre" rest position as shown:
10. Troubleshooting
| Symptom |
Possible Cause |
Action |
Who |
| No movement at all |
Battery flat |
Check battery indicator; charge if low |
Operator |
| No movement at all |
Emergency stop engaged |
Release emergency stop (twist clockwise) |
Operator |
| No movement at all |
Low hydraulic oil |
Check oil level; top up if needed |
Operator |
| Slow movement |
Low battery |
Charge battery |
Operator |
| Slow movement |
Hydraulic oil low/degraded |
Check and top up or replace oil |
Technician |
| Jerky movement |
Air in hydraulic system |
Bleed hydraulic system |
Technician |
| Unusual noise/vibration |
Air in hydraulic oil |
Bleed system; check for leaks |
Technician |
| Grippers won't open |
Wrong button combination |
Press buttons 1 AND 4 together |
Operator |
| Hydraulic leak |
Damaged hose or fitting |
Stop use; repair/replace component |
Technician |
| Won't hold position |
Internal valve/seal failure |
Contact manufacturer |
Technician |
Unknown Faults: If you experience a fault not listed above, contact the manufacturer with details of the issue, machine serial number, and any error indications.
11. Consumables & Spare Parts
11.1 Consumables
| Item |
Specification |
| Hydraulic Oil |
ISO 32 mineral hydraulic oil (e.g., Biltema ISO 32) |
11.2 Spare Parts
Contact HydraLoad for genuine spare parts. When ordering, provide the machine serial number.
| Component |
Notes |
| Hydraulic pump station |
HPI-MICRO3G |
| Tilt cylinder |
β |
| Gripper cylinders (Γ3) |
β |
| Hydraulic hoses (various lengths) |
Replace per date or condition |
| Control valves |
β |
| Pendant control station |
Techno Elettrica Ravasi ALPHA |
| Battery |
24V |
| Charger |
β |
| PLC |
β |
| Gripper arms (standard) |
920 β 1700 mm range |
| Large Wheel Kit |
1600 β 2400 mm (optional) |
| Brake Drum Kit |
300 β 1000 mm (optional) |
| Safety strap |
β |
| Split pins, bolts |
Use equivalent grade |
β οΈ Replacement parts must have at least equivalent strength and specifications to the originals.
Contact Information
| Manufacturer |
HydraLoad ApS |
| Address |
ΓstergΓ₯rdsvej 15, 7840 HΓΈjslev, Denmark |
| Phone |
+45 97 53 52 00 |
| Email |
info@hydraload.dk |
| Website |
https://hydraload.dk |
TYREMASTER β Hydraulic Wheel Changers
Service Guide β Tyremaster UK β 2026 v1.1
Β© 2026 HydraLoad ApS. All rights reserved.
