COATS Extended Mobility (EMT) RunFlat Tires User Manual

Extended Mobility (EMT)

RunFlat Tires

Training Manual

Bead Loosening, Demounting, Sensor Installation,

Mounting, and Inflation Procedures

prepared and presented by

FOR DISTRIBUTION

HENNESSY Part No.: 183708B

Name: Date:

Instructor: Location:

Table of Contents

EMT Training Objectives……………………………………………………………ii

Course Timetable…………………………………………………………………iii

Overview……………………………………………………………………Section A

Safety………………………………………………………………………Section B

Tools & Equipment…………………………………………………………Section C

Bead Loosening……………………………………………………………Section D

Demounting

–

Valve-Type Sensor…………………………………………Section E

Sensor Inspection & Installation

–

Valve-Type………………………Section F

Mounting

–

Valve-Type Sensor……………………………………………Section G

Inflation……………………………………………………………………Section H

First Half…Test for Performance Certification for EMT

……………………

Section I

Demounting–Strap-Type Sensor…………………………………………Section J

Sensor Inspection & Installation

–

Strap-Type

……

………………………Section K

Mounting

–

Strap-Type Sensor……………………………………………Section L

Second Half…Test for Performance Certification for EMT

…………………

Section M

Quick Reference……………………………………………………………Section N

EMT Training Objectives

1. Given a lecture and demonstration, job aid, EMT tire/wheel assembly, tire machine, accessories and tools the associate will be able to safely remove various sizes of EMT tires from the wheels without damage to the tire, wheel or band-type sensor.

2. Given a lecture and demonstration, job aid, EMT tire/wheel assembly, tire machine, accessories and tools the associate will be able to safely remove various sizes of EMT tires from the wheels without damage to the tire, wheel or valve-type sensor.

3. Given a lecture and demonstration, job aid, EMT tire/wheel assembly, tire machine, accessories and tools the associate will be able to safely install

various

sizes of EMT tires from the wheels without damage to the tire, wheel or band-type sensor.

4. Given a lecture and demonstration, job aid, EMT tire/wheel assembly, tire machine, accessories and tools the associate will be able to safely install

various

sizes of EMT tires from the wheels without damage to the tire, wheel or valve-type sensor.

5. Given a lecture and demonstration, job aid, wheel, tools and a band-type

sensor

assembly, the associate will be able to safely install the sensor on the wheel with the counter weight in the proper position and tighten the band clamp to the proper specification.

6. Given a lecture and demonstration, job aid, wheel, tools and a valve-type

sensor

assembly, the associate will be able to safely install

the sensor on the wheel with the

retaining nut tightened to the proper specification.

7. Given a lecture and demonstration, job aid, EMT tire/wheel assembly, tire machine, accessories, tools, and adequate practice time, the associate will be able to complete the tasks

as outlined on the Performance Certification document.

8. Given a lecture and demonstration, job aid, EMT tire/wheel assembly, tools,

inflation safety cage

, the associate will be able to safely seat the beads and adjust the

tire inflation pressure to specification.

Course Timetable

iii

Before starting the program,appoint a time keeper to help maintain a schedule.The time keeper can fill in the blank spaces below and at the beginning of each study session. Only fill in the time blanks to the first break as the practice and certification periods can vary

with number of students and available equipment.

…………………………………………………………………Start Time

15 min……………………………………………………Overview of EMT

15 min………………………………………………………………Safety

10 min………………………………………Tools & Equipment Required

10 min……………………………………………………Bead Loosening

10 min……………………………………………Demounting–Valve-Type

10 min……………………………………Sensor Installation–Valve-Type

10 min………………………………………………Mounting–Valve-Type

15 min……………………………………………………………Inflation

15 min………………………………………………………………Break

15 min…Per Student/Per Tire Changer……………………………Practice

15 min…Per Student/Per Tire Changer…Performance Certification–Valve-Type

…………………………………………………………………Start Time

15 min……………………………………………Demounting–Strap-Type

10 min……………………………………Sensor Installation–Strap-Type

10 min………………………………………………Mounting–Strap-Type

15 min………………………………………………………………Break

15 min…Per Student/Per Tire Changer……………………………Practice

15 min…Per Student/Per Tire Changer…Performance Certification–Strap-Type

5 min…………………………………………………Certificate Signing

………………………………………………………………End (estimate)

Description

Lecture

Time

Clock

Time

The Objective of this Section:

To provide an introduction to tires that remain usable with little to no air pressure inside the tire

and the necessary changes to the mounting, demounting, and inflation procedures for these tires.

Safety Issues Related to this Section:

This manual is intended to supplement the Operator’s Manual provided with your tire changer only and is not meant as a replacement. ALL safety issues contained in your original Operator’s Manual remain in effect when changing this type of tire. The safety information contained in this manual is to be used in addition to the safety information in your Operator’s Manual.

What is this new technology?

The principle behind this new technology is to provide a tire that will remain “operable” even with a total loss of air pressure inside the tire, thus allowing the vehicle to be driven for some additional distance without stopping. These tires will be referred to as Run Flat and/or Extended Mobility Tires (EMT).

What is the difference in these new tires?

These tires are manufactured with exceptionally stiff sidewalls. These stiff sidewalls are designed to support the wheel for limited periods of time without air pressure inside the tire. Of course, stiffening the sidewalls to this degree creates problems for the wheel service technician.

How can I tell when the tire is flat?

Because the stiff sidewalls support the wheel in a drivable posture even without air pressure, it is nearly impossible to tell when this type of tire “goes soft.” Regular verification of air pressure inside the tire is critical. Tire manufacturers are required to install low pressure sensors on the wheels (inside the tires) to provide electronic notification of low tire pressure. These sensors transmit their low pressure warnings to a remote readout inside the vehicle.

This low pressure system is available on some new cars, and will be available on even more models in the near future. Today, customers can purchase an aftermarket system and have it installed on their current vehicle. These systems use either a valve-stem mounted sensor (O.E.M. only), or a sensor that straps onto the wheel (aftermarket & O.E.M.).

How is this type of tire serviced?

As any tire service technician can tell you, the stiffer the sidewall, the tougher the tire changing. These new tires are so exceptionally stiff that they require special handling. This special handling is not only to ease installation and prevent any damage to these expensive tires, but to help prevent damage to the wheel and the tire changing equipment. These tires require extra time and patience to service and to prevent injury to the tire technician. Be prepared to take your time and not rush the procedures..

Rotate Pause Rotate

Overview

A–1

min

Stop Time

A–2

Overview

These tires also require the tire service technician to be extra cautious. In every case, there will be a low pressure sensor of some type installed on the wheel. When standard tire changing procedures are used on these tires the sensors will be damaged. If not properly serviced, these sensors are easily damaged and expensive to replace. Knowing the proper method of changing a tire on a wheel equipped with a sensor, and how the sensors themselves are installed, will save the technician valuable time and resources and avoid headaches and frustration.

Before you begin, take a good look at the tire and wheel.

There are things that the technician may take for granted when changing standard tires that can have a dramatic effect when changing these new tires. For example: on steel wheels, watch for curb damage on the wheel rim flange that is rough or sharp. The beads on these tires are pulled tightly across this flange, and rough, sharp edges can seriously damage the beads.

The tire service technician will also need to spend increased time cleaning and polishing the wheel. These tires are very inflexible, and will pull and slide against the wheel surfaces much more than a standard tire. Keeping the wheel clean and polished smooth will reduce friction and allow the tire to move easier during the mounting and bead sealing process.

These tires made their debut on specialty vehicles like the Corvette. Because of their “high performance” nature, these tires are, in many cases, position–and directional–specific. This means that they may be designed to roll in one direction only, or to be placed in a front or rear position only. Or, in some cases, they are totally position-specific, designed for placement as right front, left rear, etc. This information is included on the sidewall of the tire. The technician needs to be aware of these specifics to ensure that tires are properly mounted and positioned.

Many alloy wheels today are location-specific as well. These wheels may have additional offsets to compensate for brakes or other suspension requirements. This information is usually included on the inside of the wheel. The technician must also be aware of “reverse mount” wheels–where the drop center (or short side of the wheel) is toward the inner plane of the wheel instead of outer. Tires are always mounted from the short side, so reverse mount wheels will be mounted to the tire changer “upside down” from normal–with the inside of the wheel facing upwards.

Safe tire inflation is of the utmost importance.

These new tires are much tougher to bead seat and inflate. Because they are so stiff, a bead seating pressure that exceeds 40 PSI may be required. For this reason, a safety

cage must be used for bead seating and inflation of EMT/RunFlat Tires. Read and follow ALL the safety instruc-

tions provided in this publication and your tire changer manual.

This completes Section A.

The Objective of this Section:

To clearly identify the safety issues related to tire service and inflation procedures.

Safety Issues Related to this Section:

• Operator Protective Equipment.

• Definitions of Hazard Levels.

• ALWAYS use a safety cage for bead seating and inflation of EMT/RunFlat Tires.

• NEVER inflate tire above manufacturer’s recommended pressure after bead is seated.

This instruction manual is intended to supplement the Operating Instructions manual provided with your tire changer. Read and understand the entire manual before servicing any tire or wheel. Read and follow all the CAUTION, WARNING, and DANGER notations in the manual as they apply to these instructions as well. This manual is intended to act only as an information supplement, and does NOT replace your Operating Instructions manual.

These exceptionally stiff sidewall tires use super-reinforced sidewalls and stiffer composition materials. It is very difficult to mount and demount. These tires may be used on expensive custom wheels that are easily scratched or damaged. These tire/wheel assemblies will include a low-pressure sensor affixed to the inside of the wheel–either as a strap on addition or a one-piece valve stem sensor. The operator must use extra care and caution when working with these tire/wheel/sensor combinations to avoid costly damage to any of the individual components. These special combinations require changes to the standard mount/demount instructions for your tire changer.

OPERATOR PROTECTIVE EQUIPMENT

Personal protective equipment helps make tire changing safer. However, equip-

ment does not take the place of safe operating practices. Always wear durable

work clothing during tire service activity. Shop aprons or shop coats may also be worn, however 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.

Definitions of Hazard Levels

Identify the hazard levels used in this manual with the following definitions and signal words:

Watch for this symbol:

It Means: Immediate hazards which will result in severe personal injury or death.

Watch for this symbol:

It Means: Hazards or unsafe practices which could result in severe personal injury or death.

Watch for this symbol:

It Means:Hazards or unsafe practices which may result in minor personal injury or product or property damage.

READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE BEGINNING. KEEP THESE INSTRUCTIONS IN A BINDER NEAR THE MACHINE FOR REFERENCE BY SUPERVISORS AND OPERATORS.

Safety

B–1

min

Stop Time

DANGER

WARNING

CAUTION

DANGER

Explosion Hazard Never inflate

tire above manufacturer’s recommended pressure after bead is seated.

DANGER

Explosion Hazard

A safety cage must be used for bead seating and inflation of EMT/RunFlat Tires. Never exceed 80 PSI to seat beads on EMT/RunFlat Tires.

B–2

Safety

The low-pressure sensors used on these tire/wheel assemblies are very expensive to replace. Do NOT use

the bead loosener where it may come in direct contact with the sensor. Do NOT use full strokes of the bead loosener to avoid pushing the tire bead into the sensor. ALWAYS check sensor position before starting any procedure.

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 DANGER, WARNING and CAUTION notations in this manual.

This tire changer 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.

The tire changer must be properly operated and main-

tained to help avoid accidents that could damage the

unit and injure the operator or bystanders.

CAUTION

WARNING

CAUTION

This completes Section B.

The Objective of this Section:

To provide a basic list of the tools and equipment that will be required to change exceptionally stiff sidewall tires.

Safety Issues Related to this Section:

This manual is written based on the use of COATS Rim Clamp®Tire Changers. This includes models 5030, 5050, 5060, 5065, 6060, and 6065.

Equipment and Tool list:

• Safety Glasses

• Tire Lubricant (slow drying)

• Lube Swab

• Tire Marking Crayon

• Plastic booties (for metal duckheads)

• Drop Center Tool

• Lift Tool

• Shop Towels

• Air Pressure Gauge

• Valve Core Tool

• Valve Stems

• Valve Stem Puller

• Nut Driver (5/16 for strap-type sensor)

• Wrench (7/16 for valve-type sensor)

• Tin Snips

• Air Hose with Remote Valve and Clip On Chuck

• Safety Cage (for inflation)

• Inch Pound Torque Wrench

This completes Section C.

Tools & Equipment

C–1

min

Stop Time

The Objective of this Section:

To identify the safe and proper loosening of both inner and outer tire beads.

Safety Issues Related to this Section:

• ALWAYS wear eye protection during tire service activity.

• ALWAYS wear durable work clothing (i.e.; tight-fitting leather gloves, steel-toed shoes, back belts).

• NEVER wear loose fitting clothing or articles, jewelry, or long hair.

• NEVER smoke or have open flames or other ignition sources in or near tire changing area.

Use a crayon to mark both the tire and wheel with their

location on the vehicle (i.e.; RF, LR, etc.). Check the sidewall of the tire for any rotation and position indicators. Remember that some low-pressure sensors are locationspecific as well. Note any offsets that may exist between the front and rear wheels, or any difference in tire width. Marking the tire and wheel will help you reinstall them in the correct location later.

Inspect the wheel and tire for damage. Pay close atten-

tion to the rim flange–nicks or burrs here may interfere with the mounting process or damage the tire bead. Make a note of any damage found, and review with the customer before continuing.

Safety glasses must be worn at all times. Air is released from the tire with sufficient force to propel dirt and debris into the eyes.

Never smoke or have open flames and/or other ignition sources in or near tire changing area. A flammable gas may have been used to pressurize the tire, and severe

personal injury or death could result.

Remove the valve core and allow the tire to completely

deflate. Remove all wheel weights from the wheel at this

time.

Roll the tire and wheel into position at the bead loosener,

with the top bead facing outward and the wheel seated firmly against the rubber pads. The valve stem should be positioned towards the top of the bead loosener shoe. This position works best for wheels with existing pressure sensors, and those wheels with asymmetrical safety humps..

Bead Loosening

D–1

min

Stop Time

CAUTION

WARNING

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