COATS 5040 A-E Tire Changer User Manual

®

5040 A/E

Rim Clamp® Tire Changer

For servicing single piece automotive and most light
truck tire/wheel assemblies.

See

RIM Safety page iv

ÌOperating

Instructions

on page 4.

Operation Instructions

Set-up Instructions

Maintenance 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.

Safety Instructions

1601 J. P. Hennessy Drive, LaVergne, TN USA 37086-3565 615/641-7533 800/688/6359 www.ammcoats.com Manual Part No.: 8184829 04
01HENNESSY INDUSTRIES INC. Manufacturer of AMMCO

®

, COATS® and BADA® Automotive Service Equipment and Tools. Revision: 05/13

Tire Specifi cations Diagram

Nominal width of
tire in millimeters

Passenger
car tire

Max.
permissible
inflation
pressure

Radial

Ratio of height to
width (aspect ratio)

1

2

P

E

L

A

I

D

A

R

I

S

P

5

0

0

3

1

D

A

O

L

.

X

A

N

O

I

T

E

R

I

T

A

E

R

N

U

T

A

A

R

E

M

X

P

M

E

R

P

.

A

M

3

.

S

S

E

S

B

L

T

5

A

C

Rim diameter
code

Load index &
speed symbol

U.S. DOT tire

1

R

5

6

/

S

E

L

E

B

U

T

M

D

R

O

C

A

R

T

0

2

5

9

5

H

D

O

S

T

M

A

L

9

A

B

L

L

2

P

L

I

E

S

2

X

X

X

X

X

E

A

D

W

E

A

2

R

C

0

3

6

T

R

E

S

I

D

E

W

A

T

R

identification number

M

+

S

A

D

4

O

R

D

P

L

I

E

X

X

C

M

A

S

2

X

X

X

N

U

F

A

C

T

U

R

E

R

Severe snow
conditions

Tire ply
composition
and materials
used

Treadwear, traction
and temperature grades

ii • Important: Always read and follow operating instructions.

Max. load rating

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, 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 or bypass 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!

Important: Always read and follow operating instructions. • iii

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
[phone] or [phone]
www.ammcoats.com

For additional information contact:

Rubber Manufacturers Association

1400 K Street N. W., Suite 900
Washington, DC 20005
[phone]
www.rma.org

Tire Guides, Inc.

The Tire Information Center
1101-6 South Rogers Circle
Boca Raton, FL 33487-2795
[phone]
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.

iv • Important: Always read and follow operating instructions.

Table of Contents

Tire Specifications Diagram ..................................... ii

Safety Instructions .................................................. iii

Owner’s Responsibility ............................................iii

Operator Protective Equipment ............................... iii

Definitions of H azard Levels .................................... iii

Safety Notices and Decals ......................................iv

Remember R.I.M. ....................................................iv

Principle Operating Parts .................................... 2 - 3

Know Your Unit ................................................... 2 - 3

Operating Instructions ........................................ 4 - 8

Tire Bead Loosening and Demounting ............... 4 - 6

Tire Mounting ..................................................... 7 - 8

Inflation .............................................................. 9 - 11

Bead Sealing ...........................................................10

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

Performance, Custom, and Aluminum Automotive &

Light Truck Wheels ........................................... 14 - 17

Performance Tires and Wheels •

Demounting.....................................................14 - 16

Performance Tires and Wheels • Mounting ............17

Custom and Special Wheels .................................. 18

Tube Type Tires ........................................................ 18

Maintenance Instructions ............................... 19 - 21

Duckhead™ (Mount/Demount Tool) Cleaning ........ 19

Duckhead (Mount/Demount Tool)

Adjustment ............................................................ 20

Oil Injector Maintenance ....................................... 20

Pressure Limiter Maintenance .............................. 21

Setup Instructions .................................................. 22

Location ................................................................. 22

Workspace Requirements ..................................... 22

Air Source .............................................................. 22

Electrical Source .................................................... 22

Floor Mounting ...................................................... 22

Critical Safety Instructions ...................... Back Cover

NOTICE

Read entire manual before assembling,
installing, operating, or servicing this
equipment.

Important: Always read and follow operating instructions. • 1

Principal Operating Parts

Do It Now!

Now is a good time to contact product service to
start warranty, otherwise warranty starts at time of
shipment.

17

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.

18

2

10

11

1

9

7

16

6

15

8

12

3

13

5

4

14

2 • Important: Always read and follow operating instructions.

CAUTION

Replace any damaged or missing safety
decals. They are available from COATS, (800)
688-6359.

1 Tower — Support for horizontal swing arm, also air

storage tank.

2 Air Inflation Gauge — Registers tire pressure when

clip-on chuck is attached to tire valve stem and infla­tion pedal is released.

3 Inflation Pedal — Three-position pedal that allows

inflation of tires through air hose and clip-on chuck.

4 Clamp Control Pedal — Three-position pedal that

opens and closes rim clamps.

5 Tabletop Rotation Pedal — Three-position pedal that

controls rotation of tabletop.

6 Tabletop — Rotating chuck for tire changing.

7 Clamps — Secures wheel to table top for tire chang-

ing.

8 Lube Bottle — Dispenser for rubber lubricant.

9 Duckhead® Mount/Demount Tool — Mounts and

demounts tire from wheel.

10 Swing Arm Adjustment Knob — Adjusts swing

arm/vertical slide assembly for proper horizontal
positioning of Duckhead mount/demount tool.

11 Vertical Slide Locking Handle — Locks and

unlocks vertical slide and sets correct vertical posi­tion to maintain head/wheel clearance.

12 Bead Lifting Tool — Used to lift and position tire

bead correctly on Duckhead mount/demount tool.

13 Bead Loosener Shoe — Pivoting shoe for loosen-

ing tire beads.

14 Bead Loosener Handle/Button — Controls opera-

tion of bead loosener shoe.

15 Oil Check Dipstick — For transmission oil level.

16 Bead Sealing Nozzles (In Slides) — Expands tire

sidewall to bead seat area of rim to seal tire to rim
and allow inflation.)

17 Pressure Safety Valve — The high pressure safety

valve is set to exhaust at line pressures above 185
PSI.

18 Release Valve — Allows the manual release of air

pressure from tire when clip-on chuck is attached
to tire valve.

Important: Always read and follow operating instructions. • 3

Operating Instructions

The 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.

Tire Bead Loosening and Demounting

NOTE: Always loosen the bead on the narrow side

of the wheel’s drop center first. See Figure 4 for more
information on the drop center.

REMEMBER: 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.

NOTE: 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.

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.

Remember to remove all weights from both sides
of the wheel. Weights left on back side of wheel may
cause the wheel to be clamped unlevel. This may result
in the combination mount/demount tool contacting the
rim causing scratches. On alloy wheels, always rotate
the wheel one turn after setting the tool to insure proper
wheel chucking.

NOTE: Always review nicks and scratches with own­ers of expensive wheel and tire combinations prior to
servicing.

IMPORTANT: Review the performance wheel section
of this manual prior to servicing performance tire/wheel
combinations.

1. Deflate tire completely by removing the valve core

from the valve stem (Figure 1).

2. Pull the bead loosener shoe away from the machine

and roll wheel into position. The valve stem should be in
the 3 o’clock position. Position the bead loosener shoe
against the tire next to, but not on, the rim. Depress 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 2).

Figure 2 - Position Tire and Bead Loosener Shoe

3. Turn wheel around and repeat loosening procedure

on the other side of the wheel. This should be the long
side of the drop center (see Figure 4).

TIP: It will be easier to clamp the wheel to the table

top if the lower bead is loosened last.

4. Apply tire manufacturer’s approved rubber lubricant

liberally to entire circumference of both tire beads after
loosening.

Figure 1 - Remove Valve Core to Deflate Tire

NOTE: Loosening the beads on a 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.

Figure 3 - Apply Rubber Lubricant to Tire Beads

4 • Important: Always read and follow operating instructions.

5. Determine the mounting side of the wheel. The

mounting side is the narrow side of the drop center.
(Tire removed in Figure 4 for clarity.)

Narrow Side

Drop Center

Long Side

Figure 4 - Determining Mounting Side of Wheel

6. Place tire/wheel assembly on table top with mount-

ing side up (Figure 5). Use the clamp control pedal to
move the clamps inwards (push pedal down) or out­wards (toggle pedal up). Clamp steel wheels from the
inside (clamps push outwards against wheel). Clamp
mag and custom wheels from the outside (clamps push
inwards against the outside rim edge). Place rim flange
into rear clamp and slowly move the other clamps
inward until they contact the rim. Observe closely to
prevent tire/wheel damage.

8. The mount/demount tool roller should be in contact

with the rim edge. Turn the swing arm adjusting knob
to move the tool away from the rim 1/8 to 1/4 inch.
On expensive and polished rims, it is recommended a
plastic bootie (p/n 8183373) be used over the mount/
demount tool roller.

Figure 7 - Adjust Swing Arm to Position Tool Roller

9. Check tool positioning. Mount/demount tool should

be positioned with 1/8 to 3/16” clearance between the
top of the rim edge and the bottom of the tool (with
plastic mount/demount tool it is recommended the ver­tical clearance be limited to a maximum of 1/16-inch),
and 1/8 to 1/4 inch clearance between the rim edge and
the tool. 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
tool (when changing a set of the same wheels).

Figure 5 - 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 tool into
contact with the rim edge. Push the locking handle
back to lock the slide into place. As the slide is locked,

the mount/demount tool
will move upward approxi­mately 1/8 inch from the
rim edge.

Note: On plastic mount/

demount tool, the upward
movement should be
limited to 1/16-inch maxi­mum.

Figure 6 - Position Mount/
Demount Tool

1/8" to 3/16"

1/8" to 1/4"

Figure 8 - Proper Mount/Demount Tool Position

IMPORTANT: The vertical 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.

Important: Always read and follow operating instructions. • 5