COATS 9500 Electro-Hydraulic Tire Changer User Manual
1601 J. P. Hennessy Drive, LaVergne, TN USA 37086-3565 615/641-7533 800/688-6359 Manual Part No.: 8184344 02
HENNESSY INDUSTRIES INC. Manufacturer of AMMCO
®
, COATS®and BADA®Automotive Service Equipment and Tools. Revision: 01/04
9500
Electro-Hydraulic Tire Changer
For Medium and Large Size Tires
®
Installation Instructions
Operating Instructions
Safety 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.
ii • COATS 9500 Tire Changer
Table of Contents
Safety Instructions . . . . . . . . . . . . . . . . . . . .ii-iv
Definitions of Hazard Levels . . . . . . . . . . . . . . .ii
Operator Protective Equipment . . . . . . . . . . . .iii
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Important Safety Instructions . . . . . . . . . . . . . .iii
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . .iii
Bead Loosening Safety . . . . . . . . . . . . . . . . . . .iv
Demounting & Mounting Safety . . . . . . . . . . .iv
Inflation Safety . . . . . . . . . . . . . . . . . . . . . . . . . .iv
1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . .1-4
1.1 Use Limitations . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 General Safety Instructions . . . . . . . . . . . . .1
1.4 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . .1
1.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . .2
1.6 Dimensions Of The Machine . . . . . . . . . . . .2
1.7 Standard Accessories . . . . . . . . . . . . . . . . . .2
1.8 Optional Accessories . . . . . . . . . . . . . . . . . .3
2.0 Carriage Instructions . . . . . . . . . . . . . . . . . .4
2.1 Uncrating Instructions . . . . . . . . . . . . . . . . .4
2.2 Installation Area . . . . . . . . . . . . . . . . . . . . . .4
3.0 Installation Instructions . . . . . . . . . . . . . . .5
3.1 Electric Installation . . . . . . . . . . . . . . . . . . . .5
3.2 Motor Rotation Check . . . . . . . . . . . . . . . . . .5
Operating Instructions . . . . . . . . . . . . . . . . .6-17
4.0 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
5.0 Mounting And Demounting - General
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . .7
5.1 Locking Rims . . . . . . . . . . . . . . . . . . . . . . . . .7
5.2 Demounting T ubeless Truck Tires
(Up To 13” Wide) . . . . . . . . . . . . . . . . . . . .8-9
5.3 Mounting T ubeless Truck Tires
(Up To 13” Wide) . . . . . . . . . . . . . . . . . . .10-11
5.4 Demounting Duplex And Supersingle
Tubeless Truck Tires (Over 13” Wide) . . . .12
5.5 Mounting Duplex And Supersingle
T ubeless Truc k Tires (Over 13” Wide) . .12-13
5.6 Demounting Tires From Multi-Piece
Rim/Wheel Assemblies . . . . . . . . . . . . . . . .14
5.7 Mounting Tires Onto Multi-Piece
Rim/Wheel Assemblies . . . . . . . . . . . . . . . .15
5.8 Demounting Tractor And O.T.R.
Wheels With One-Piece Rims . . . . . . . .15-17
5.9 Mounting Tractor And O.T.R.
Wheels On One-Piece Rims . . . . . . . . . . . .17
6.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . .18
7.0 Moving The Machine . . . . . . . . . . . . . . . . .18
8.0 Storing The Machine . . . . . . . . . . . . . . . . .18
10.0 Trouble Shooting . . . . . . . . . . . . . . . . . . .19
Safety Instructions
Failur e to f ollow dang er, 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 J.P. Hennessy Drive
LaVergne, TN 37086-3565
(615) 641-7533 or (800) 688-6359
www.ammcoats.com
Definitions of Hazard Levels
Identify the hazard levels used in this manual with the
following definitions and signal words:
DANGER
Watch for this symbol:
It Means: Immediate hazards, which will result in
severe personal injury or death.
WARNING
Watch for this symbol:
It Means: Hazards or unsafe practices, which could
result in severe personal injury or death.
CAUTION
Watch for this symbol:
It Means: Hazards or unsafe practices, which may result
in minor personal injury or product or property damage.
SAFETY ALERT
Watch for this symbol! It means BE ALERT!
Your safety, or the safety of others, is
involved!
Read entire manual
before assembling,
installing, operating,
or servicing this
equipment.
WARNING
WARNING
DANGER
WARNING
CAUTION
COA TS 9500 Tire Changer • iii
Operator Protective Equipment
Personal protective equipment helps make tire servicing safer. However, equipment alone 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.
Safety Devices
This machine has several protectors to prevent compression or crushing hazards to body areas. Keep these
devices properly maintained and do not disable or in
any way shortcut the safety controls and opertations.
There is a micro-switch protection under the chuck
arm to prevent compression.
The rotation speed of the chuck has been limited to a
maximum of 8 rpm to prevent dragging or en-trapping
hazards.
There is an emergency button on the portable control
unit.
Important Safety Instructions
Only properly tr ained personnel should service tires on the 9500. Read all safety and
operating instructions thoroughly before
using the tire changer.
ALWAYS
remove all wheel weights and the valve core
to deflate the tire before servicing.
ALWAYS
cover the electric motor and switch box
before hosing down the tire changer. Be sure water
does not enter the motor or switch box.
ALWAYS
disconnect the electric power and air supply
before attempting any maintenance.
ALWAYS
keep all working surfaces clean and free of
tire lube buildup.
ALWAYS
be aware of what each person is and will do
before attempting any two-person operation.
Safety Precautions
A. Before servicing any tires, wheels or rims all personnel should receive thorough training for the proper
servicing of truck tires, wheels and rims. Consult with
your local city, country state, and national safety and
health administrators to receive clarification of any publications available governing this serious matter.
B. During the use and maintenance of the machine it
is mandatory to comply with all laws and regulations for
accident prevention.
C. The electric power source must have a ground
cable and the ground cable of the machine (yellow and
green) must be connected to the ground cable of the
power source.
D. Before any maintenance or repairs are accomplished the machine must be disconnected from the
electric supply. The unit should only be serviced by a
qualified service technician.
E. Never wear ties, chains or other loose articles
when using, maintaining or repairing the machine. Long
hair is also dangerous and should be kept under a hat.
The user must wear proper safety attire, i.e. gloves,
safety shoes and glasses.
F. Maintain all electric cords in good repair.
G. Keep safety features in place and in w orking order.
H. Keep working area clean. Cluttered areas invite
accidents.
I. Avoid dangerous environments. Don’t use power
tools or electrical equipment in damp or wet locations,
or expose them to rain.
L. Nobody should be allowed to stand next to or near
the wheel, when mounting/demounting a tire or clamping a wheel.
M. Keep the work area well lighted.
N. Properly anchor the machine to the floor.
WARNING
iv • COATS 9500 Tire Changer
Bead Loosening Safety
NEVER
place any part of your body between the bead
loosener disc and the tire/wheel, severe bodily injury
may result.
NEVER
place anything between the bead loosener
disc and the tire/wheel as damage may result.
NEVER
allow the bead loosener to contact the wheel,
wheel damage may occur.
Demounting & Mounting Safety
NEVER
stand on the working table while demounting
or mounting a tire, as personal injury may result.
ALWAYS
keep hands, feet, and other objects away
from moving parts while the machine in turned on.
ALWAYS
place the narrow bead seat to the outside
when clamping. Failure to demount the tire from the
narrow bead seat side may cause damage to the tire
beads.
ALWAYS
apply an approved rubber lubricant to rim
flanges and both tire beads before demounting or
mounting and seating the beads.
NEVER
use
antifreeze, silicone, or petroleum base lubricants.
ALWAYS
clean and inspect the wheel before servic-
ing.
NEVER
mount a tire on a damaged or rusty wheel.
Wheel damage or rust may cause tire or wheel failure
during inflation. Explosion from failure may result in
severe injury or death of the operator and bystanders.
ALWAYS be sure the bead opposite the tool is in the
drop center before rotating the tire when demounting
or mounting to avoid damage to the tire beads.
Inflation Safety
ALWAYS follow all applicable Local, State, and Federal
Codes, Rules, and Regulations; such as the Federal
OSHA Standard Number 1910.177.
NEVER
seat beads or inflate a tire on the tire changer.
This tire changer is not designed as a safety device or
stand for bead seating or inflation.
ALWAYS
use an approved inflation chamber or infla-
tion cage.
The following safety instructions are for one piece
wheels only. Refer to the manuf acturer’s or R.M.A. procedures for multipiece wheels.
ALWAYS
use an approved inflation chamber or inflation cage equipped with a grip chuck and a remote inflation gauge and valve. DO NOT OVER INFLATE! Tire or
wheel failure during and after inflation may result in an
explosion capable of causing severe injury or death.
ALWAYS
inflate the tire to manufacturer’s recom-
mended cold operating pressure.
NEVER
reinflate a tire that has been run underinflated
or flat without first demounting the tire and checking for
wheel and tire damage.
ALWAYS
inspect the tire interior for loose or broken
cords, cuts, penetrating objects, and other damage to
the carcass. Discard tires that cannot be properly
repaired.
NEVER
rework, weld, heat or braze wheels.
NEVER
strike the tire or wheel with a hammer.
ALWAYS
be sure the tire diameter exactly matches
the wheel diameter.
Tire f ailur e under pr essur e can be hazar dous.
Place the wheel inside an approved inflation
chamber or cage before inflating. Use an
approved remote inflation valve, hose, and
gauge. ALWAYS wear safety goggles for eye
protection.Do not stand beside the wheel or
cage during inflation. Keep hands and other
parts of the body out of the cage during
inflation. Observe the tire pressure frequently. Do not exceed the manufacturer’s
recommended maximum inflation pressure.
Failure to follow these instructions may
cause the tire and rim to separate with
tremendous force, resulting in serious personal injury or death.
DANGER
COA TS 9500 Tire Changer • 1
1.0 Introduction
Congratulations on purchasing the COATS®9500
Electro-Hydraulic Tire Changer.
This tire changer is designed for ease of operation,
safe handling of rims, reliability and speed.
With a minimum of maintenance and care, your tire
changer will provide many years of trouble-free operation.
Instructions on use, maintenance and operational
requirements of the machine are covered in this manual.
Store this manual in a convenient place for
future reference. Read this manual thoroughly before using the machine.
1.1 Use limitations
The CO ATS model 9500 tire changer is intended to be
used as a device to demount and mount tubeless tr uck
tires with the following specifications:
Maximum Tire Diameter: 90 1/2 inches (2300 mm)
Maximum Tire Width : 43 inches (1100 mm)
This device shall be used in the application for which
it is specifically designed. Any other use shall be considered as improper, and not WITH THE SPECIFICATIONS OF THIS UNIT. In particular, this device is not
suitable to inflate tires. Inflation of tires shall be carried
out in an approved inflation safety cage. The manufacturer shall not be considered liable for possible damage
caused by improper, wrong or non-SPECIFIED use.
1.2 Notice
This manual is a part of the product. Read carefully
the warnings and instructions of this manual since they
provide important information concerning safety and
maintenance.
1.3 General Safety Instructions
Any misuse or modification of this device or of its
parts or components not previously authorized by the
manufacturer relieves the manufacturer from any damage consequent or related to the above mentioned
misuse.
No modifications should be made without consulting
COATS®. Removing or bypassing any safety devices or
warning labels of the machine is a violation of the
safety regulations.
The use of this device is allowed only in locations
with no explosion or fire hazards, consistent with state
and local fire codes.
This equipment is designed to use original or manufacturer supplied spare parts and accessories only.
The installation shall be carried out only by qualified
personnel and within the scope of the instructions provided in this manual.
Check for possible dangerous conditions during the
operation of the machine. If suc h a case e xists stop the
machine immediately. In case a defective functioning
condition stop using the machine, immediately and call
the authorized distributor for assistance.
All electrical connections shall be performed by a licensed electrician. All service
must be performed b y an authorized service
technician.
1.4 Nomenclature
Before installing and using the tire changer it is suggested that you become familiar with the nomenclature of the machine’s components (fig.1).
Fig.1
1-
8 Position Switch
2-
Chuck Switch
3-
Emergency Stop
4-
Tool Holder Arm
5-
Main Switch
6-
Tool Holder Carriage
7-
Foot Board
8-
Jaws
9-
Self-centering Chuck
10 -
Chuck Arm
11 -
Chuck Rotation Control Pedal
12 -
Mount/Demount T ool
13 -
Electric Cabinet
14 -
Tool Holder Arm & Release
WARNING
WARNING
1.5 Specifications
Electro-hydraulic tire changer for tubeless truck tires.
Weight with Standard Acc. 2079 lbs. (945 kg)
Electric Specifications 220VAC, 3Ph, 60Hz, 22A
Hydraulic Motor Power 2 HP (1.5 kW)
Chuck rotation Motor Power 3-4 HP (2.2 - 3 kW)
Chuck Capacity 14” - 56”
Max. Tire Diameter 90 1/2 inches (2300 mm)
Max. Tire Width 43 inches (1100 mm)
Max. Chuck Torque 2268 ft./lbs. (310 0 mm)
Clamping Power 13,513 lbs. (60 kN)
Chuck Rotation Speed 4 - 8 rpm
Acoustic Pressure <70dBA
1.6 Dimensions Of The Machine
Fig.2
1.7 Standard Accessories
#870001418 Short Tire T ool
#874004461 Long Tire T ool
#874002354 Bead Pushing Lever
Fig.3
#874009472 Mounting Clamp (fig.4).
To hold the bead when mounting tires on steel rims.
Instructions for use is in section 5.3.
Fig.4
2 • COATS 9500 Tire Changer
COA TS 9500 Tire Changer • 3
1.8 Optional Accessories
#874021852 Clamp for Light-Alloy Rims (fig.5).
To hold the bead when mounting tires on light-alloy
rims. Instructions for use is in section 5.3.
Fig.5
#874007611 O.T.R. Clamp (fig.6)
Useful when breaking the bead from the rim on multi-
piece wheels (O.T.R.).
Instructions for use is in section 5.6.
Fig.6
#874008257 Protectors for Alloy Rims (fig.7).
Suitable for rims with a center hole of 220 and 280
mm.
Fig.7
#874008264 Protectors for Alloy Rims (fig.8)
Suitable for rims with a center hole of 280 mm only.
Fig.8
#874014974 Tubeless Roller (fig.9).
Facilitates mounting and dismounting tubeless tires
up to 13” wide.
Fig.9
#874019161 Extensions for 56” (fig.9/A).
Necessary when clamping rims without flange and
with a diameter exceeding 44”.
Fig.9/A
2.0 Carriage Instructions
The mac hine is crated in a w ooden bo x of appropriate
strength.
The box is mounted on a pallet.
Handling of the machine must be performed with an
appropriate lifting device (fork lift) (fig.10).
Fig.10
2.1 Uncrating Instructions
Always wear gloves when uncrating the
machine to prevent scratches, abrasions, or
cuts due to the contact with packing materials.
Uncrate the machine pa ying at tention when remo ving
the nails or during any other operation which may be
hazardous.
After removing the crate, check for any visible damage to the machine and its components.
If in doubt, call qualified personnel for assistance.
The pac king materials (plastic bags, poly styrene, nails,
screws, wood etc.) must be properly disposed of.
Place the above-mentioned materials into a trash container and dispose per local regulations.
2.2 Installation Area
Install the machine in a covered and dry area.
The installation of the machine requires a free space
of at least cm 16’ 5” x 16’ 5” (500cm x 500cm) (fig.1 1).
Fig.11
Make sure that from the operating position (fig. 11)
the user can see all of the machine and the surrounding area.
Only authorized operators of the equipment should
be in the work area. Keep the work area clean and clear
of objects which may create possible hazards.
It is the responsibility of the facility owner to properly
designate work areas and areas where by-standers are
not permitted.
Install the machine on a horizontal floor, preferably
even. Do not install the machine on a sinking or irregular floor.
In case the machine is installed on a raised floor or on
a service vehicle, the floor must have a capacity of at
least (330 lbs. x sq. ft.). Please contact COATS directly
at 1-800-688-9240 to discuss options and other precautions that may apply.
The machine must be secured to the floor through
the holes provided in the cabinet. Expansion screws
(1/2” x 4 3/4”), or bolts (1/2” x 3 1/8”) shall be used.
Drill (1/2”) holes in the floor flush with the holes provided in the cabinet.
Place the lags into the holes drilled in the floor and
move the machine so that the holes of the cabinet are
flush with the holes in the floor.
Tighten the screws to (50 ft. lbs.).
4 • COATS 9500 Tire Changer
CAUTION
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