Rim Clamp® Tire Changers
For servicing single piece automotive and most light truck tire/wheel
assemblies.
Model 200 Shown
See
RIM Safety page iii
ÌOperating
Instructions
on page 2.
Operation Instructions
Safety Instructions
Maintenance Instructions
Set-up Instructions
READ these instructions before placing unit in
service. KEEP these and other materials delivered
with the unit in a binder near the machine for ease
of reference by supervisors and operators.
Manual Part No.: 85607260 04
Revision: 4/13
Safety Instructions
Owner’s Responsibility
To maintain machine and user safety, the responsibility
of the owner is to read and follow these instructions:
• Follow all installation instructions.
• Make sure installation conforms to all applicable
Local, State, and Federal Codes, Rules, and Regulations; such as State and Federal OSHA Regulations
and Electrical Codes.
• Carefully check the unit for correct initial function.
• Read and follow the safety instructions. Keep them
readily available for machine operators.
• Make certain all operators are properly trained,
know how to safely and correctly operate the unit,
and are properly supervised.
• Allow unit operation only with all parts in place and
operating safely.
• Carefully inspect the unit on a regular basis and
perform all maintenance as required.
• Service and maintain the unit only with authorized
or approved replacement parts.
Definitions of Hazard Levels
Identify the hazard levels used in this manual with the
following definitions and signal words:
DANGER
Watch for this symbol:
DANGER
It Means: Immediate hazards, which will result in
severe personal injury or death.
WARNING
Watch for this symbol:
WARNING
It Means: Hazards or unsafe practices, which could
result in severe personal injury or death.
CAUTION
Watch for this symbol:
CAUTION
• Keep all instructions permanently with the unit
and all decals/labels/notices on the unit clean and
visible.
• Do not override safety features.
Operator Protective Equipment
Personal protective equipment helps make tire servicing safer. However, equipment does not take the
place of safe operating practices. Always wear durable
work clothing during tire service activity. Loose fitting
clothing should be avoided. Tight fitting leather gloves
are recommended to protect operator’s hands when
handling worn tires and wheels. Sturdy leather work
shoes with steel toes and oil resistant soles should be
used by tire service personnel to help prevent injury
in typical shop activities. Eye protection is essential
during tire service activity. Safety glasses with side
shields, goggles, or face shields are acceptable. Back
belts provide support during lifting activities and are also
helpful in providing operator protection. Consideration
should also be given to the use of hearing protection if
tire service activity is performed in an enclosed area, or
if noise levels are high.
It Means: Hazards or unsafe practices, which may
result in minor personal injury or product or property
damage.
Watch for this symbol! It means BE ALERT! Your
safety, or the safety of others, is involved!
ii • Important: Always read and follow operating instructions.
Safety Notices and Decals
Remember R.I.M.
Three Simple Steps To Help Keep Shops Safe
WARNING
Failure to follow danger, warning, and caution
instructions may lead to serious personal
injury or death to operator or bystander or
damage to property. Do not operate this
machine until you read and understand all
the dangers, warnings and cautions in this
manual. For additional copies of either, or
further information, contact:
Hennessy Industries, Inc.
1601 JP Hennessy Drive
LaVergne, TN 37086-3565
(615) 641-7533 or (800) 688-6359
www.ammcoats.com
For additional information contact:
Rubber Manufacturers Association
1400 K Street N. W., Suite 900
Washington, DC 20005
(202) 682-4800
www.rma.org
Tire Guides, Inc.
The Tire Information Center
1101-6 South Rogers Circle
Boca Raton, FL 33487-2795
(561) 997-9229
www.tireguides.com
READ INSPECT
R.I.M. is a training program developed by Hennessy
Industries to help keep tire technicians safe. By following the basic principles of R.I.M., technicians can avoid
situations that can cause catastrophic accidents like tire
explosions.
R.I.M. stands for read, inspect, and mount:
Read the tire size on a new tire before mounting to
make sure it is the proper size for the wheel.
Inspect the wheel for cracks, rust, and or other damage that could cause an unsafe situation.
Mount the tire safely, making sure not to put any part
of your body over the tire during inflation.
The most serious of possible accidents is a tire explosion. This is often caused by a tire/rim mismatch.
If a tire explodes on a tire changer, pressure causes it
to fly straight up at tremendous speed. If a technician
is standing over the tire, he can be seriously injured or
killed.
Hennessy’s R.I.M. program allows the technician to
avoid situations that can cause tire explosions and other
accidents. The full program, including training videos,
brochures, posters, and other materials, is available
from Coats distributors nationwide.
MOUNT
For more details, contact your Coats distributor or e-mail us.
Important: Always read and follow operating instructions. • iii
Table of Contents
Safety Instructions .................................................. iii
Owner’s Responsibility .............................................ii
Operator Protective Equipment ................................ii
Definitions of H azard Levels .....................................ii
Safety Notices and Decals ......................................iii
Remember R.I.M. .................................................... iii
Principle Operating Parts ......................................... 1
Know Your Unit ........................................................ 1
Operating Instructions ........................................ 2 - 7
Bead Loosening and Demounting ...................... 2 - 5
Mounting ............................................................ 6 - 7
Inflation .............................................................. 8 - 11
Bead Sealing ............................................................ 9
Bead Seating ..........................................................10
Inflation...................................................................11
Stages of Inflation on a Conventional Tire
and Rim ................................................................... 12
Bead Sealing .......................................................... 12
Bead Seating ......................................................... 12
Inflation.................................................................. 12
Mismatched Tires and Wheels ............................... 13
Tube Type Tires ........................................................ 14
Mounting ............................................................... 14
Demounting........................................................... 14
Maintenance Instructions ............................... 15 - 17
Mount/Demount Tool Cleaning .............................. 16
Mount/Demount Tool Adjustment ......................... 16
Pressure Limiter Maintenance ........................16 - 17
Oil Injector Maintenance ........................................17
Installation Instructions .................................. 18 - 19
Location ................................................................. 18
Workspace Requirements ..................................... 18
Tower Installation ............................................18 - 19
Air Source .............................................................. 19
Electrical Source .................................................... 19
Floor Mounting ...................................................... 19
Operating Instructions
(with Robo-Assist™) ....................................... 20 - 17
Bead Loosening and Demounting ......................... 20
Mounting ............................................................... 23
Robo-Assist™ Maintenance .................................. 24
Critical Safety Instructions ...................... Back Cover
NOTICE
Read entire manual before assembling,
installing, operating, or servicing this
equipment.
iv • Important: Always read and follow operating instructions.
Principal Operating Parts
Do It Now!
Now is a good time to fill out the Owner’s
✔
Registry Card.
Know Your Unit
Compare this illustration with the unit before placing it
into service. Maximum performance and safety will be
obtained only when all persons using the unit are fully
trained in its parts and operation. Each user should learn
the function and location, of all controls.
Prevent accidents and injuries by ensuring the unit is
properly installed, operated and maintained.
21
1
2
9
3
8
4
7
6
5
1 Pressure Safety Valve — The high pressure safety
valve is set to exhaust at line pressures above 185 PSI.
2 Air Inflation Gauge — Registers tire pressure when
clip-on chuck is attached to tire valve stem and inflation
pedal is released.
3 Tower — Support for horizontal and vertical slides,
also air storage tank.
4 Important Safety Decal — Important safety informa-
tion for the operator. DO NOT obstruct with tire stickers
or other materials.
5 Inflation Pedal — Three-position pedal that allows
inflation of tires through air hose and clip-on chuck.
6 Bead Loosener Handle — Controls operation of bead
loosener shoe.
7 Clamps — Holds wheel to table top for tire changing.
Position outward to allow outside clamping of wheels.
8 Table Top — Rotating chuck for tire changing.
9 DuckHead® (Mount/Demount Head) — Mounts
and demounts tire from wheel.
10
19
20
(If equipped)
11
12
18
14 15 16 17
13
11 Bead Sealing Nozzles — Expands tire sidewall
to bead seat area of rim to seal tire to rim and allow
inflation.
12 Lube Bottle — Dispenser for rubber lubricant.
13 Clamp Control Pedal — Three-position pedal that
opens, holds or closes rim clamps.
14 Bead Loosener Control Pedal — Controls operation
of bead loosener shoe.
15 Table Top Pedal — Three-position pedal that controls
rotation of table top (forward, off, reverse).
16 Bead Lifting Tool — Used to lift and position tire
bead correctly on duckhead (mount/demount tool).
17 Tire Bumper Guards — Provides protective surface
when bead loosening tires.
18 Bead Loosener Shoe — Pivoting shoe for loosening
tire beads.
19 Vertical Slide Locking Handle — Locks and unlocks
vertical slide and sets correct vertical position to maintain head/wheel clearance.
10 Swing Arm Adjustment Knob — Adjusts swing
arm/vertical slide assembly for proper horizontal positioning of mount/demount head.
20 Robo-Assist™ — Provides extra leverage when
mounting/demounting tires.
21 Robo-Assist Control Valve — Controls vertical
movement of robotic arm cylinder.
Important: Always read and follow operating instructions. • 1
Operating Instructions
This unit must be properly operated and properly
maintained to help avoid accidents that could damage
the unit and injure the operator or bystanders. This
section of the Operating Instructions manual review
basic operations and use of controls. These instructions
should be reviewed with all employees before they are
allowed to work with the machine. Keep these instructions near the machine for easy reference.
Bead Loosening and Demounting
CAUTION
This machine may operate differently from
machines you have previously operated.
Practice with a regular steel wheel and tire
combination to familiarize yourself with the
machine’s operation and function.
A. Remember to remove all weights from both sides
of the wheel. Weights left on backside of wheel
may cause the wheel to be clamped unleveled.
This may result in the combination mount/demount
head contacting the rim causing scratches. On alloy
wheels, always rotate the wheel one turn after setting the Duckhead to insure proper wheel chucking.
B. Always review with the owner any nicks and
scratches on expensive wheel and tire combinations prior to servicing.
CAUTION
Loosening the beads on a partially or fully
inflated tire is unsafe and causes excess
movement and friction against the bumper
pads and excessive wear on pivots. Deflate
the tire completely to prolong the life of
your machine.
1. Deflate the tire completely by removing the valve
core from the valve stem (figure 1). Be cautious and
do not smoke as a flammable gas could have been
introduced into the tire at some time.
Figure 1 - Remove Valve Core to Deflate Tire
CAUTION
Tires are always installed and removed from
the rim’s narrow side.
D. Always loosen the bead on the narrow side of
the wheel’s drop center first (tire removed in figure
2 for clarity).
Narrow Side
Drop Center
Long Side
Figure 2 - Determine Narrow Side of Wheel
E. The clamps on the table top may extend beyond
the table top itself. To avoid damaging the clamps,
move them to their full inward position before
positioning a tire for bead loosening.
F. Use extra care in positioning the bead loosener
shoe on larger wheels/tires, and on alloy wheels.
Make sure the shoe rests next to but not on the
rim, and not on the tire sidewall.
2. Pull the bead loosener shoe away from the machine
and roll wheel into position. The valve stem should be
in the 2 o’clock position to accommodate a possible
asymmetric safety hump type rim. Position the bead
loosener shoe against the tire next to, but not on, the
rim. Press the bead loosener foot pedal to actuate the
shoe and loosen the bead. It may be necessary to
loosen the bead in multiple locations around the tire
(figure 3).
2 • Important: Always read and follow operating instructions.
Valve Stem
Figure 3 - Position Tire and Bead Loosener Shoe
3. Turn the wheel around and repeat loosening pro-
cedure on the other side of the wheel (figure 4). This
should be the long side of the drop center (figure 2).
5. Determine the mounting side of the wheel. The
mounting side is the narrow side of the drop center. See
figure 2 for more information on the drop center.
6. Place tire/wheel assembly on table top with mount-
ing side up (figure 6). Use the clamp control pedal to
move the clamps inward (push pedal down) or outward
(toggle pedal up). Clamp steel wheels from the inside
(clamps push outward against wheel). Clamp mag and
custom wheels from the outside (clamps push inward
against the outside rim edge).
Figure 4 - Position Tire and Bead Loosener Shoe With Wheel
Turned Around
G. It will be easier to outside clamp the wheel to
the table top if the long side of the rim is loosened
last.
4. Apply tire manufacturer’s approved rubber lubricant
liberally to entire circumference of both tire beads after
loosening (figure 5).
Figure 6 - Place Tire/Wheel Assembly on Table top
7. Move the swing arm into position. Pull the locking
handle forward to release the slide. Push down on the
top of the vertical slide to move the demount head into
contact with the rim edge. Push the locking handle back
and lock the slide into place (figure 7).
Figure 7 - Position Mount/Demount Tool
Figure 5 - Apply Rubber Lubricant to Tire Beads
Important: Always read and follow operating instructions. • 3
8. The mount/demount head should be in contact
with the rim edge. Turn the swing arm adjusting knob to
move the mount/demount head away from the rim 1/8
to 1/4 inch (figure 8).
K. Table top rotation can be stopped at any time by
removing your foot from the rotation pedal.
CAUTION
At times during the mounting and demounting procedure, the bead lifting tool may
encounter resistance and can be thrown.
Keep one hand firmly on the tool to avoid
possible tool disconnect. Use the reversing
feature to back out of jam-ups. A thrown
tool can cause injury.
10. Insert the smooth curved end of the bead lifting
tool over the forward end of the demount head and
below the top bead of the tire. Lift the bead up and
over the knob on the Duckhead (figure 10). Also, note
the valve stem position to the Duckhead. Use your free
hand to press down on the tire opposite the Duckhead
to allow the bead to utilize the drop center area of the
rim, this position reduces stresses in the bead and
allows an easier bead lift.
Figure 8 - Adjust Swing Arm to Position Head Roller
9. Check metal head positioning. Mount/demount
metal head should be positioned with 3/16 to 1/8 inch
clearance between the top of the rim edge and the bottom of the head, and 1/8 to 1/4 inch clearance between
the rim edge and the head roller. This clearance will be
maintained as long as the locking handle and adjustment knob are not changed. The operator may swing
the arm out of the way and back into place again
without needing to reposition the head (when changing
a like set of wheels) (figure 9).
3/16" to 1/8"
1/8" to 1/4"
Figure 9 - Proper (Metal) Mount/Demount Head Position
H. The tool clearance may change with machine use
and should be inspected often. Failure to maintain
the proper clearance may result in damage to the
wheel rim and/or tire.
Valve Stem
Figure 10 - Insert Bead Lifting Tool
11. Push the bead lifting tool down towards the
wheel to lift the tire bead up and over the knob portion
of the demount head. Hold the tool and bead in this
position (figure 11).
J. Normal table top rotation for demounting is clockwise. Depress the table top pedal to rotate this
direction. To rotate the table top counterclockwise,
lift the pedal up with your toe.
Figure 11 - Lift Bead Over Demount Head
4 • Important: Always read and follow operating instructions.
12. Depress the table top pedal to rotate the wheel.
The Duckhead will guide the tire bead up and over the
edge of the wheel. Continue rotation until the upper
bead is demounted.
14. Depress the table top pedal to rotate the wheel.
The demount head will guide the bead up and over the
edge of the wheel. Continue rotation until lower bead
is demounted.
L. Push down on the tire across from the demount
head during table top rotation to utilize the drop
center area of the wheel. This reduces the tensional
force on the top or first bead during demount (figure
10).
Figure 12 - Demounting Lower Bead
13. Lift and hold the tire at an angle so that the lower
bead is resting in the drop center directly across from
the demount head, and is loose below the demount
head (figure 12). Insert the smooth curved end of the
bead lifting tool down over the forward end of the
mount/demount tool and below the lower bead. Lift
the bead up and over the knob on the demount head
(figure 13).
M. With tube-type tires, demount the upper bead
and remove the tube before demounting the lower
bead.
After successfully completing the demount
process, proceed to Mounting (page 6).
✔
Figure 13 - Guide Lower Bead Over Tool Head
Important: Always read and follow operating instructions. • 5
Mounting
This information must be read and followed carefully
to prevent accidents and injuries during mounting.
DANGER
Attempts to force a bead seat on mismatched tires and wheels can cause the
tire to violently explode, causing serious
personal injury or death to operator and/or
bystanders.
WARNING
Check tire and wheel carefully before mounting. Make sure the tire bead diameter and
wheel diameter match exactly. Consult the
Tire Guide and/or Rubber Manufacturer’s
Association for approved rim widths for tire
sizes.
WARNING
1. Before any mounting, inspect tire for damage and
verify size match between tire and wheel (fig. 14).
Figure 14 - Verify Size Match Between Tire and Wheel
2. Inspect wheel closely for damage. Clean the wheel
and remove any light corrosion or rubber residue (figure
15). Do not attempt to service a heavily corroded wheel,
damaged wheel, or bent wheel.
Never mount a damaged tire. Never mount a
tire on a rusty or damaged wheel. Damaged
tires and/or wheels may explode.
CAUTION
When in doubt do not mount.
CAUTION
Never mount a tire and wheel handed to
you by anyone without checking both tire
and wheel for damage and to be certain the
sizes match. Do not let untrained persons
operate tire changer and keep bystanders
out of service area.
CAUTION
Forcing the tire onto the rim can cause bead
damage. If you damage the tire bead during
mounting, STOP!, remove tire and mark it
as damaged. Do not mount a damaged tire.
Figure 15 - Inspect and Clean the Wheel
3. Inspect valve stem and replace if necessary. Next
lubricate tire beads liberally with tire manufacturer’s
approved rubber lubricant (figure 16).
Figure 16 - Lubricate Tire Beads Liberally
6 • Important: Always read and follow operating instructions.
4. Place tire over wheel and move swing arm into
position making sure the valve stem is at the 9 o’clock
position in front of bead lock. Position tire so that lower
bead is above the rear extension of the mount/demount
tool and below the front knob (figure 17).
Figure 17 - Position Tire Against (Mount/Demount Tool)
5. Depress table top pedal and rotate wheel to mount
lower bead. Use drop center of wheel by forcing down
on tire just ahead of the mounting tool, and follow as tire
rotates. Rotate table top until lower bead is mounted.
N. If table top rotation stalls, reverse the table top
momentarily until tire bead is again loose on the
wheel. Reposition tire on Duckhead, make sure
bead is correctly positioned in drop center of the
wheel; then attempt mounting again.
P. For low profile or stiff sidewall tires, it may be
advantageous to use the bead lifting tool to initially
hold the upper bead down in the drop center.
R. For tube type tires, mount lower bead first, move
swing arm out, install tube, and then mount upper
bead.
6. For top bead installation, rotate the table top
until the valve stem is directly across from the mount
head. Lift the upper bead up and over the rear of the
mount head. With your left hand press down on the tire
between the mount head and the valve stem to hold
the tire in the drop center. Depress table top pedal and
rotate tire until bead is mounted. Be careful to ensure
bead stays in the rim drop center in the area ahead of
Duckhead (figure 18).
Figure 18 - Mounting Top Bead
Important: Always read and follow operating instructions. • 7
Infl ation
Tire inflation is performed in three steps: BEAD SEAL,
BEAD SEAT, and INFLATION. These steps are explained
in detail on page 12. Read the explanation of each step
and understand them thoroughly before proceeding.
DANGER
Tire failure under pressure is hazardous.
This tire changer Will Not Restrain Exploding Tires, rims or other related equipment.
Inspect tire and wheel carefully for match,
wear, damage, or defects before mounting.
Always use approved tire bead lubricant
during mounting and inflation.
CAUTION
The clip-on chuck allows the operator to
keep hands and entire body back from inflating tire. The chuck must be an open/freeflow
style with all parts in proper working order.
CAUTION
Check for proper inflation gauge operation.
Accurate pressure readings are important
to safe tire inflation. Refer to the Operating Maintenance section of this manual for
instructions.
The inflation pedal, located at the rear of the left side
of the machine, controls the flow of air through the
inflation hose, and has three positions.
Note: The clip-on chuck on the end of the hose should
always be an open/freeflow style with all parts in proper
working order.
Position 1 - Tire Pressure – With the inflation hose
attached to the tire valve and the pedal in this position,
the air gauge will register the air pressure in the tire.
Whenever your foot is removed from the pedal, it will
return to this position.
Position 2 - Tire Inflation – This is the first activated
position. With the inflation hose attached to the tire
valve and the pedal in this position, line pressure is
allowed to flow through the valve system and into the
tire for inflation. Correct tire pressure is not indicated on
the gauge in this position.
Position 3 - Bead Sealing – This is the second and last
activated position. With the inflation hose attached to
the tire valve and the pedal in this position, line pressure
is allowed to flow through the valve and to the air-flate
bead seal jets on the table top for bead sealing.
1. If the rim has been clamped from the outside for
tire mounting, release the clamps, lift the tire, and move
the clamps to the center of the table top.
Note the Inflation Pedal Positions (See Diagram)
Tire Pressure Tire Inflation Bead Sealing
CAUTION
If the rim has been clamped from the outside
for tire mounting, release the clamps, lift the
tire, and move the clamps to the center of
the table top.
CAUTION
If the wheel/tire has a diameter larger than
14-inches and is difficult to bead seal, the
clamps should be moved to the center of the
table top for the bead seal operation.
Inflation Pedal Positions
8 • Important: Always read and follow operating instructions.
CAUTION
Use of bead sealing jets without a tire in
place can cause dirt and debris to be blown
into the air with enough force to injure
operator and/or bystander. Do not use the
bead sealing control position to inflate a tire.
S. This unit is equipped with a pressure limiter to
assist the operator with proper tire inflation. When
the inflation pedal is held in position 2, the pressure
limiter cycles the machine between position 2 (inflation) and position 1 (at rest, no airflow to tire). This
cycling helps to prevent over inflation of the tire.
Tires can still be over inflated and explode with the
use of this pressure limiter if all of the instructions
in this manual are not followed completely. The
pressure limiter will keep most car and light truck
tires from inflating beyond 60 PSI (smaller tires
may reach higher pressures). It is the operator’s
responsibility to follow all instructions and to control
inflation pressure as specified in these instructions.
Check the function of the pressure limiter regularly
and maintain it according to the instructions provided in this manual for safe and proper operation.
Do not tamper with or attempt to adjust the pressure limiter. Tires requiring inflation beyond 60 PSI
should be inflated in a safety cage.
Bead Sealing
1. Remove the valve core from the valve stem to
allow more air flow into the tire to assist with bead seal.
2. Position valve stem in front of operator and con-
nect the inflation hose with the clip-on chuck. Hold
tire up against upper edge of the wheel. Be sure tire’s
top bead does not cover the bottom of the valve stem
(figure 19).
Figure 19 - Lift Tire Upwards for Bead Sealing
3. Depress inflation pedal to position 2 and hold about
one second to begin air flow through tire valve, then
depress pedal to position 3 and hold briefly — less than
one full second. The blast of air from the jets will expand
tire and seal the beads.
4. Release the inflation pedal and allow it to return to
position 1. Verify that both beads are completely sealed
to the wheel. Repeat these steps if beads have not
sealed. It may be necessary to wait a few seconds for
the air storage tank pressure to recover before attempting again.
5. After bead seal is achieved, remove the clip-on
chuck and reinstall the valve core. Reattach the clip-on
chuck after core is installed.
Important: Always read and follow operating instructions. • 9
Bead Seating
DANGER
NEVER exceed 40 PSI to seat beads while
using this tire changer. If more than 40 PSI
is permitted by tire manufacturer, ALWAYS
use safety cage and clip-on chuck. NEVER
exceed recommended pressure after seating
beads. ALWAYS keep hands and entire body
back from inflating tire.
An exploding tire, wheel, or bead sealing
equipment may propel upward and outward
with sufficient force to cause serious injury
or death to operator or bystander.
WARNING
Check tire pressure frequently. If operator is
unable to obtain Bead Seat, something is
wrong. Deflate tire completely, inspect tire
and wheel, correct any problems found, relubricate both tire beads, and reattempt Bead
Seal and Seat procedures. Follow all safety
instructions in this manual and on machine.
1. Once tire pressure is indicated on the air gauge
(inflation pedal in position 1; foot removed from pedal),
continue to inject air into the tire (inflation pedal position 2) in short intervals. Check the pressure frequently.
Stand back during bead seat. Keep hands, arms, and
entire body away from tire during this procedure (figure
20).
Tire beads should move outward and “pop” into their
bead seat position as pressure inside the tire increases.
If this does not happen, a problem exists. Investigate
carefully.
Figure 20 - Stand Back during Bead Seat
10 • Important: Always read and follow operating instructions.
Inflation
WARNING
NEVER exceed tire manufacturer’s recommended air pressure. Tires can explode,
especially if inflated beyond these limits.
Use clip-on air chuck, keep hands, arms
and entire body back from inflating tire.
Avoid distraction during inflation. Check
tire pressure frequently to avoid over inflation. Excessive pressure can cause tires to
explode, causing serious injury or death to
operator or bystander.
1. Make sure both beads are seated. When both
beads are seated, the tire is ready for inflation.
2. Replace the valve core if it was removed.
3. Depress the inflation pedal to position 2 to inflate
the tire. The pressure limiter will cycle the air flow as
described earlier. On most tires, the pressure limiter
will cease air flow at approximately 60 PSI. On smaller
volume tires the pressure may be higher.
Figure 21 - Do Not Use a Hand-held Style Air Chuck
4. Important: When inflating tires that require more
than 60 PSI, always use a safety cage and air hose with
a clip-on air chuck and in-line valve. The air hose must
have enough length between the chuck and the operation/in-line valve to allow the operator to stand outside
the trajectory.
U. If you change tires defined as truck tires, they
must be inflated per OSHA instructions.
DANGER
Explosion Hazard
DANGER
Explosion Hazard
Never exceed 40
PSI while seating
beads.
Remember R.I.M.
(see page iv and back cover)
Never infl ate tire
above
manufacturer’s
recommended
pressure after bead
is seated.
Important: Always read and follow operating instructions. • 11
Stages of Infl ation on a
Conventional Tire and Rim
Review these descriptions and diagrams carefully. Refer to them as
necessary during bead sealing, bead seating, and inflation to verify that
you are proceeding properly and safely.
Bead Sealing
Bead sealing is the process of capturing air pressure between the
tire and the rim. The tire will usually contain about 1/2 to 2 PSI at initial
bead seal.
Bead Seating
Bead seating usually occurs on the long tapered side of the wheel
first and the shorter side last. Bead seating will usually require at least
7 PSI in the tire. 40 PSI is the maximum safe pressure at this stage
regardless of tire operating pressure.
Most European import cars and many aftermarket alloy wheels are
very tight and can be difficult to bead seat. Also note that asymmetrical
hump and run-flat tires are extremely difficult to bead seat. Follow tire
manufacturer’s recommended procedure for bead seating.
Inflation
After the beads are seated, the tire is ready to be inflated. Do not
inflate the tire above the manufacturer’s recommended pressure as
stamped on the tire sidewall. The typical inflation pressure for automobile tires is between 24 and 45 PSI. Light truck inflation pressure
typically covers a wider range.
12 • Important: Always read and follow operating instructions.
Mismatched Tires and Wheels
Never attempt to mount and inflate mis-matched tires
and wheels.
DANGER
Mismatched tire and wheel combinations can explode,
causing personal injury or death to operator and/or
bystanders.
Important: Always read and follow operating instructions. • 13
Tube Type Tires
Mounting
1. Avoid pinching or forcing the tube.
2. Apply rubber lubricant to the beads of the tire.
3. Mount the bottom bead.
4. Round out the tube with a small amount of air.
5. Apply rubber lubricant to the tube.
6. Insert the tube into the tire.
7. Mount the top bead.
Demounting
1. After tire beads are loosened, lubricate the beads
and rim liberally.
2. Position demount head and bead lifting tool as
described in steps 7 through 10 on pages 3 and 4.
Depress table top pedal and rotate only a short distance
at a time. This allows you to stop the process should the
tube get pinched.
3. After upper bead is demounted, remove tube and
demount lower bead.
✔
Do It Now
Make sure the instruction and warning decal
is clean and clearly visible to operator.
14 • Important: Always read and follow operating instructions.
Maintenance Instructions
Read and follow all the maintenance instructions provided in this manual to keep the machine in good operating condition. Refer to the other materials received
with the unit and to the service bulletins from the
manufacturer for additional instructions on proper maintenance and service. Regular inspections and proper
maintenance are essential to preventing accidents and
injuries.
Important: These instructions will help you service
the unit. Instructions are for a person with some
mechanical ability and training. No attempt has been
made to describe all basic steps. For example, how to
loosen or tighten fasteners. Also basic procedures such
as cycling systems and checking operation of the equipment are not fully described since they are known to
anyone who does mechanical and service work. Do not
attempt to perform work beyond your ability or at which
you have no experience. If you need assistance, call an
authorized service center.
WARNING
Always DISCONNECT ELECTRICAL POWER
and block out all moving parts before making any inspection, adjustment, or repair to
the machine. This prevents electrical shock
or accidental movement of the systems
operated by the electrical power.
WARNING
Always DISCONNECT AIR SUPPLY before
servicing machine. This prevents accidental
movement of systems operated by compressed air which may result in personal
injury. BLEED AIR SYSTEM by actuating all
the valves.
WARNING
Keep the machine and the immediate work
area clean. Do not use compressed air to
remove dirt and debris from the machine.
Foreign material may be propelled into the
air and into operator or bystander causing
personal injury.
WARNING
Wear protective clothing, equipment and
eye protection when making any adjustments or repairs to the machine.
A. The vertical slide should be cleaned with a vapor-
izing solvent and then lubricated with chassis grease
once a month.
B. Check the adjustment of the Duckhead® (mount /
demount tool) once a month.
C. Check the fluid level in the table top transmission
once every 3 months. If fluid shows on dipstick, level
is satisfactory. If no fluid shows, add an SAE 80 gear
lubricant until fluid shows on dipstick.
D. The table top, clamps, steel Duckhead (mount /
demount tool), and other working surfaces should be
cleaned with a vaporizing solvent every month.
E. The clamps should be inspected and metal chips
and dirt from the serrations with a wire brush every
month.
F. Check the tire pressure gauge function daily, and
check the accuracy monthly. Use a pressurized tire and
a high quality stick-type pressure gauge. If necessary,
adjust the dial of the machine gauge. If the gauge is
defective, replace it immediately (part number 8107985).
Check function of the pressure limiter weekly. Always
reinstall the lens after adjusting the gauge.
G. Make sure all fasteners are securely tightened.
H. Make certain that all guards and covers are in place.
I. Check for worn, damaged or missing parts including
grips and protective covers. Replace them before allowing the unit to be used.
J. On a daily basis, inspect the unit and check to be
certain that all systems are operating normally. Detailed
inspection and testing procedures are specified for various components at regular intervals. Set up a chart and
assign responsibility for these items.
CAUTION
Replace any damaged or missing safety
decals. They are available from COATS, (800)
688-6359.
Important: Always read and follow operating instructions. • 15
Mount/Demount Tool Cleaning
Clean dirt and debris from the mount/demount tool
(duckhead) roller with small screw driver or pick.
Figure 22 - Clean Mount/demount Tool Using Small Screwdriver
Pressure Limiter Maintenance
DANGER
Operating a tire changer with a defective,
improperly adjusted, or by-passed pressure
limiter could cause an operator to accidentally over pressurize a tire, resulting in a tire
explosion with severe injury or death to the
operator or bystanders.
Always be sure that the pressure limiter is
present and is operating properly.
Mount/Demount Tool Adjustment
To Adjust Lock Tightness
With lock handle unlocked, loosen jam nut (ref. 1) and
adjust pin (ref. 2) until a slight firmness is obtained, then
tighten jam nut and check. Also recheck tool head lift at
this time.
DANGER
Never inflate tire above manufacturer’s recommended pressure after bead is seated.
Pressure limiter is set at 60 PSI. Any required
inflation above 60 PSI should be performed
in an inflation chamber/safety cage or
securely mounted on the vehicle if an inflation chamber is not available. A tire explosion may cause personal injury or death to
operator or bystanders.
The pressure limiter helps prevent inflation of standard
size or larger tires or tubes beyond 60 PSI to minimize
risk of explosion. This device is for the safety of the
operator and bystanders. Proper operation of the pressure limiter is essential to safe operation of the machine.
Check operation of the pressure limiter as shown and
described below at least monthly:
1. Remove tires and/or wheels from the machine.
2. Connect the inflation hose to an empty service
tank with a pressure gauge (gauge should read 0). Use
a certified tank with at least 250 PSI pressure rating.
3. Depress inflation pedal to position 1 to start airflow
through the hose and into the tank. Maintain a steady
pressure for constant flow.
16 • Important: Always read and follow operating instructions.
4. Watch the rising pressure on the tank gauge and
the gauge on the machine. Machine gauge should
cycle between check and inflation pressures while tank
gauge climbs steadily. As tank pressure reaches 60 PSI,
the pressure limiter should stop the airflow automatically. Both gauges should read 60 PSI ± 5 PSI.
5. Replace pressure limiter if it fails to cycle properly
during inflation, if it fails to shut air supply off at 60 PSI,
or if it malfunctions in any other way. Do not operate
machine with a faulty pressure limiter.
Watch
Pressure on
Both Gauges
250 PSI Tank
with Gauge
Oil Injector Maintenance
The oil injector typically require annual service. The
oil level in the oil reservoir tank should be checked
regularly.
Add oil to oil reservoir tank when fluid level is a quarter
full or below. Remove cap from the oil reservoir tank
and add Chevron Regal
oil is an acceptable substitute). Replace cap and clean
up any spilled oil.
Important: An air lock will form if the hose between
the reservoir and injector is ever empty of oil. In this
case, after filling the reservoir tank, the line must be
bled of air at the injector connection as follows:
1. Disconnect all power sources, both air and electric-
ity inputs. Allow any stored air in the reservoir to escape
by depressing the inflate pedal.
2. Remove the side panel and locate the oil injector.
3. Prime the oil injector. Loosen bleeder plug until oil
drips from screw and all air is relieved from the oil line
hose. Retighten the bleeder screw.
®
R & O 32 oil to full line (air tool
Tire Changer
Infl ation Hose
Connected to
Tank
4. Reconnect air/electric sources and cycle the clamp
control pedal a few times checking for oil and air leaks.
5. Test the machine for full function before returning
the machine to operation.
6. Monitor oil consumption to ensure oil is being used
in system.
Important: Always read and follow operating instructions. • 17
Installation Instructions
Tower Installation
CAUTION
Proper unit installation is necessary for safe
use and efficient operation. Proper installation also helps protect the unit from damage and makes service easier. Always place
safety poster and instructions near the unit.
Location
Select a location using the drawings below. The area
should provide the operator with enough space to use
the equipment in a safe manner. The area selected
should be well lit, easy to clean and should be away
from oil, grease, brake lathe chips, etc. Avoid areas
where bystanders and customers may be present.
Workspace Requirements
CAUTION
STAY CLEAR OF MOVING PARTS when
reconnecting the unit to the air supply. The
position of control valves may have changed
during the servicing of the machine.
CAUTION
Be careful of pinch point at swing arm spring.
Tools Required:
Screw Driver
14mm Open-ended Wrench
19mm Open-ended Wrench
24mm Open-ended Wrench
1. Carefully remove carton and packaging from unit.
2. Using a 14mm wrench, remove shipping bolts
holding tower, swing arm and chassis to the pallet.
50"
41.5"
3. Using a 19mm wrench, remove the four bolts
and washers from the chassis; reserving the bolts and
washers.
4. With the aid of a helper holding the tower, connect
hose from chassis to tower barb fitting (figure 26). Position and tighten hose clamp.
5. Use reserved bolts and washers to attach tower to
chassis (figure 26). Torque to 15 - 20 ft. lbs.
Connect Hose To
Tower Fitting
Use Reserved
Bolts & Washers
Figure 26 - Assemble tower onto chassis.
18 • Important: Always read and follow operating instructions.
6. Remove swing arm bolt, washers and nut from
tower. Then, with the aid of a helper, position and attach
swing arm using bolt, washers and nut just removed
(figure 27). Torque to 55 - 75 ft. lbs.
Swing Arm
Install Swing
Arm Bolt
Figure 27 - Install swing arm onto tower.
7. Install air line and/or plug into power supply. Test
functionality (oil injector, pressure gauge function, etc.).
Air Source
The model 200 requires a 5 CFM air source at 120 PSI.
The operating pressure range is between 110 PSI and
175 PSI at the machine.
The unit is furnished with a 1/4” pipe thread male fitting for easy connection. This connection is located on
the right side of the rear of the machine. A 1/4” ID hose
(or pipe) for connection to the machine is satisfactory.
Sufficient air pressure ensures good performance.
Electrical Source
Electrical models require power as follows:
15 amp, 115V electrical circuit
15 amp, 220V electrical circuit (Export)
Refer to the caution decal that is located by the unit’s
power cord.
Refer to the serial tag located on the lower part of
the machine for specific electrical requirements for
the unit. Have a licensed electrical technician perform
any necessary changes to the power source before
plugging in the unit. The electrical source must have a
solid connection (less than 1 ohm) between ground and
building ground.
Floor Mounting
The machine should be securely bolted to the floor
with suitable anchors using the hole at each corner of
the machine base.
Important: Always read and follow operating instructions. • 19
Operating Instructions (with
Robo-Assist™)
This unit must be properly operated and properly
maintained to help avoid accidents that could damage
the unit and injure the operator or bystanders. This
section of the Operating Instructions manual review
basic operations and use of controls. These instructions
should be reviewed with all employees before they are
allowed to work with the machine. Keep these instructions near the machine for easy reference.
Bead Loosening and Demounting
CAUTION
This machine may operate differently from
machines you have previously operated.
Practice with a regular steel wheel and tire
combination to familiarize yourself with the
machine’s operation and function.
A. Remember to remove all weights from both sides
of the wheel. Weights left on backside of wheel
may cause the wheel to be clamped unleveled.
This may result in the combination mount/demount
head contacting the rim causing scratches. On alloy
wheels, always rotate the wheel one turn after setting the Duckhead to insure proper wheel chucking.
B. Always review with the owner any nicks and
scratches on expensive wheel and tire combinations prior to servicing.
CAUTION
Loosening the beads on a partially or fully
inflated tire is unsafe and causes excess
movement and friction against the bumper
pads and excessive wear on pivots. Deflate
the tire completely to prolong the life of
your machine.
1. Deflate the tire completely by removing the valve
core from the valve stem (figure 1). Be cautious and
do not smoke as a flammable gas could have been
introduced into the tire at some time.
Figure 1 - Remove Valve Core to Deflate Tire
CAUTION
Tires are always installed and removed from
the rim’s narrow side.
D. Always loosen the bead on the narrow side of
the wheel’s drop center first (tire removed in figure
2 for clarity).
Narrow Side
Drop Center
Long Side
Figure 2 - Determine Narrow Side of Wheel
E. The clamps on the table top may extend beyond
the table top itself. To avoid damaging the clamps,
move them to their full inward position before
positioning a tire for bead loosening.
F. Use extra care in positioning the bead loosener
shoe on larger wheels/tires, and on alloy wheels.
Make sure the shoe rests next to but not on the
rim, and not on the tire sidewall.
20 • Important: Always read and follow operating instructions.
2. Pull the bead loosener shoe away from the machine
and roll wheel into position. The valve stem should be
in the 2 o’clock position to accommodate a possible
asymmetric safety hump type rim. Position the bead
loosener shoe against the tire next to, but not on, the
rim. Press the bead loosener foot pedal to actuate the
shoe and loosen the bead. It may be necessary to
loosen the bead in multiple locations around the tire
(figure 3).
Valve Stem
Figure 3 - Position Tire and Bead Loosener Shoe
3. Turn the wheel around and repeat loosening pro-
cedure on the other side of the wheel (figure 4). This
should be the long side of the drop center (figure 2).
4. Apply tire manufacturer’s approved rubber lubricant
liberally to entire circumference of both tire beads after
loosening (figure 5).
Figure 5 - Apply Rubber Lubricant to Tire Beads
5. Determine the mounting side of the wheel. The
mounting side is the narrow side of the drop center. See
figure 2 for more information on the drop center.
6. Place tire/wheel assembly on table top with mount-
ing side up (figure 6). Use the clamp control pedal to
move the clamps inward (push pedal down) or outward
(toggle pedal up). Clamp steel wheels from the inside
(clamps push outward against wheel). Clamp mag and
custom wheels from the outside (clamps push inward
against the outside rim edge).
Figure 6 - Place Tire/Wheel Assembly on Table top
Figure 4 - Position Tire and Bead Loosener Shoe With Wheel
Turned Around
G. It will be easier to outside clamp the wheel to
the table top if the long side of the rim is loosened
last.
Important: Always read and follow operating instructions. • 21
7. Depress the tire sidewall downward with the aid
of the assist foot providing clearance for the mount/
demount head to be positioned (figure 7). Move swing
arm into place. Increase the horizontal distance between
the demount head and the wheel an additional 1/16 to
1/8 inch with the adjustment knob.
10. Place the assist foot opposite the demount head
and push the bead into drop center. Insert bead lifting
tool between knob on demount tool and tire bead
(Figure 10).
Figure 10 - Insert Bead Lifting Tool
Figure 7 - Assist Foot Depressing Sidewall of Tire
8. Lubricate upper bead liberally (Figure 8).
Figure 8 - Lubricate Upper Bead
9. Locate the valve stem just before the demount
head before proceeding (Figure 9).
11. Rotate lifting tool down over wheel to lift bead
up and over the knob and at the same time remove
assist foot.
12. Hold lifting tool in place, depress the table top
rotation pedal momentarily to jog the wheel a short
distance. Check the wheel and tire to verify that operation is not causing damage. The lifting tool can usually
be removed after jogging the wheel a short distance
(Figure 11). Continue to jog the wheel to allow the tire
sidewall to flex as it crosses the rim edge. Continue
short rotations until top bead is completely demounted.
Valve Stem
Demount Head
Figure 9 - Position Valve Stem Under Demount Head
Figure 11 - Holding Lifting Tool in Place and Rotate Wheel
22 • Important: Always read and follow operating instructions.
13. Demount lower bead. Pay close attention to sen-
sor/transmitter location, and position it just before the
demount tool when starting the lower bead demount
procedure (Figure 12).
Sensor
Figure 12 - Sensor/Transmitter Location
14. Lift and hold the tire at an angle so the lower
bead is resting in the drop center directly across from
the demount head, and is loose below the demount
head. Insert bead lifting tool down over demount tool
and below the lower bead. Lift the lower bead over the
demount tool (Figure 13). Hold the lifting tool in place.
Depress the table top rotation pedal momentarily to jog
the wheel short distances to complete the demounting
process.
Mounting
1. Lubricate both tire beads liberally. Performance
tires will require more lubrication than standard passenger car tires.
2. Mount the lower bead. In most cases, the lower
bead will mount easily.
AE: Mounting the top bead can be very difficult
when mounting new tires on performance and custom
wheels. Proceed slowly and cautiously.
3. Position the valve stem 90 degrees clockwise in
front of the mount/demount tool for top bead mounting. Lift the bead over the rear of the mounting head.
Use the assist tool to hold the bead in the drop center
(Figure 14). Rotate the wheel in short steps and apply
extra lubricant to mount upper bead.
Valve
Figure 13 - Lower Bead in Drop Center
Figure 14 - Mount Upper Bead, Use Assist
4. On extremely tight tire and wheel combinations, it
may be necessary to use the bottom of the assist foot
to flip the tire bead over the rim flange (Figure 15)
Figure 15 - Assist Foot to Flip Bead Over Rim Flange
Important: Always read and follow operating instructions. • 23
Robo-Assist™ Maintenance
A. Grease the Robo-Assist to maintain smooth rota-
tion. Grease fittings have been provided at the pivot
joints.
B. Check bolt torque periodically at pivot joints. Proper
Torque is 240 ft. lbs.
Maintain Bolt Torque
at 240 ft. lbs.
Grease Fittings
24 • Important: Always read and follow operating instructions.
NOTES
Important: Always read and follow operating instructions. • 25
ONE WORD FOR SAFETY
R.I.M.
READ INSPECT MOUNT
READ…
Mounting and inflating the
wrong size tire can get
you hurt. Read the size on
the tire and make sure it
matches the rim. Be especially careful about putting
a smaller tire on a larger
rim, such as a 16-inch tire
on a 16.5-inch rim.
Inflation of a mismatched
tire and rim can cause an
explosion.
BE CAREFUL OF THESE SITUATIONS:
1. Damaged Bead or
Beads.
2. Rusty Wheels.
(particularly in the
bead seat area)
3. Bent or Cracked
Wheels.
4 A. Mismatched.
(A mis-match of a
16-inch tire to a 16.5inch rim causing an
explosion)
4 B. Mismatched.
(16.5-inch tire on a
16-inch rim)
INSPECT…
Before you put any tire
on a rim, inspect the rim
for rust, tough spots, bent
edges, or cracks that could
prevent the tire from seating right. If you spot any
of these problems, don’t
mount the tire until the rim
has been checked by your
shop foreman.
Inspect the tire for bead
damage.
5. Walk-In Tire and
Rim.
6. Back Injuries.
7. Hand or Finger
Injuries.
(Hands or fingers too
close to inflating tire
or bead seats which
may cause injury.)
MOUNT…
Once you’ve made sure the tire is OK
and the right size and the rim is OK,
mount the tire safely. NEVER, ever lean
over the tire when you’re inflating it. If
a tire does explode, it will go straight
up. You don’t want to be over the tire
if that happens. Also, never over-inflate
the tire, even if the bead doesn’t seat.
Never inflate over 40 PSI. If the tire
hasn’t seated, something is wrong.
Deflate the tire and check it and the
rim again. If it doesn’t work the second
time, try another tire.
8. Standing Clear.
(Never put any part
of your body over the
tire changer during
inflation.)
9. Beads will not
Seat at 40 PSI.
10. Improper
Inflation.
Remember R.I.M. (Read, Inspect, Mount) for every tire.
TIRE FAILURE UNDER PRESSURE IS HAZ-
FAILURE TO READ AND FOLLOW ALL WARNINGS AND INSTRUCTIONS IN THIS MANUAL
CAN LEAD TO SERIOUS PERSONAL INJURY
OR DEATH TO OPERATOR OR BYSTANDER.
THE OWNER IS RESPONSIBLE FOR MAINTAINING THE OPERATION INSTRUCTIONS
AND DECALS FOR OPERATOR REFERENCE.
FOR ADDITIONAL COPIES, CONTACT THE
COATS® COMPANY, 1601 J.P. HENNESSY
DRIVE, LAVERGNE, TENNESSEE, 37086 - (800)
688-6359.
85607260 04 4/2013 © Copyright 2011 Hennessy Industries and COATS® All Rights Reserved. Printed in USA
DANGER
ARDOUS! This tire changer Will Not Restrain
Exploding Tires, rims or other related equipment.
TIRES CAN EXPLODE, ESPECIALLY IF
INFLATED BEYOND SPECIFIED LIMITS. DO
NOT EXCEED TIRE MANUFACTURERS RECOMMENDED AIR PRESSURE.
AN EXPLODING TIRE, RIM, OR BEAD SEATING EQUIPMENT MAY PROPEL UPWARD
AND OUTWARD WITH SUFFICIENT ENERGY
TO CAUSE SERIOUS INJURY OR DEATH TO
OPERATOR AND/OR BYSTANDERS.
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