Coats gts series, GTS70, GTS50, GTS90, GTS60 Operation Instructions Manual

Page 1

GTS50/60/70 and GTS90

Rim Clamp® Tire Changers

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

Any other type, including tube type and agricultural, require special handling. Tires identiﬁ ed as truck tires need to adhere to OSHA standard 1910.177.

See

RIM Safety page vi.

Operating

Instructions

on page 4.

1601 J. P. Hennessy Drive, LaVergne, TN USA 37086 615/641-7533 800/688/6359 www.coatsgarage.com Manual Part No.: 85610001 06 HENNESSY INDUSTRIES INC. Manufacturer of AMMCO

Safety Instructions Set-up Instructions

Operation 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.

, COATS® and BADA® Automotive Service Equipment and Tools. Revision: 09/17

Page 2

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

ii • Important: Always read and follow operating instructions.

NOTICE

Page 3

Table of Contents

Tire Specifications Diagram ..............................................iv

Safety Instructions ..............................................................v

Owner’s Responsibility.......................................................v

Operator Protective Equipment .........................................v

Definitions of Hazard Levels ..............................................v

Safety Notices and Decals ................................................ vi

Remember R.I.M. .............................................................vi

Setup Instructions ...............................................................1

Location ..............................................................................1

Workspace Requirements ..................................................1

Air Source ...........................................................................1

Electrical Source .................................................................1

Floor Mounting ...................................................................1

Principal Operating Parts ....................................................2

Know Your Unit ...................................................................2

Operating Instructions ........................................................5

Tire Bead Loosening and Demounting ...............................5

Tire Mounting .....................................................................9

Inflation .............................................................................. 11

Bead Sealing ....................................................................12

Bead Seating .................................................................... 13

Inflation.............................................................................14

Stages of Inflation on a Conventional Tire and Rim ......15

Bead Sealing ....................................................................15

Bead Seating .................................................................... 15

Inflation.............................................................................15

Mismatched Tires and Wheels ..........................................16

Custom and Special Wheels .............................................17

Alloy Wheels .....................................................................17

European Performance Wheels (Asymmetrical Hump) .... 17

Wheels with Low Pressure Warning Sensors .................. 17

Tube Type Tires ................................................................... 17

Mounting .......................................................................... 17

Demounting......................................................................17

Maintenance Instructions .................................................18

Duckhead® Mount/Demount Tool Cleaning .....................19

Pressure Limiter Maintenance (if equipped) ....................19

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

Decal Locations .................................................................21

Important: Always read and follow operating instructions. • iii

Page 4

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)

Rim diameter code

Load index & speed symbol

U.S. DOT tire

identification number

Severe snow conditions

Tire ply composition and materials used

Treadwear, traction and temperature grades

iv • Important: Always read and follow operating instructions.

Max. load rating

Page 5

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:

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:

• 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. • v

Page 6

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.coatsgarage.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

vi • Important: Always read and follow operating instructions.

For more details, contact your Coats distributor or e-mail us.

Page 7

Setup Instructions

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

Air Source

The all-air models require a 14 to 15 CFM air source at 150 PSI. The air/electric models require a 5 CFM air source at 150 PSI. The operating pressure for all models is 120 PSI at the machine.

The unit is furnished with a 1/4-inch pipe thread male fitting for easy connection. This connection is located on the right side of the rear of the machine. A 1/4-inch 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, single phase

15 amp, 230V electrical circuit, single phase (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

As Hennessy can not be certain of the environment and conditions of the locations where the equipment will be installed, it is recommended that the safety manager review the shop floor conditions and local regulatory practices to determine if bolting of the equipment to the shop floor is necessary or advisable.

GTS90 with Robo-Arm®

Important: Always read and follow operating instructions. • 1

Page 8

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.

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.

Single-Point Nozzle

*5 Bead Sealing Nozzle — Some models are equipped

with a single-point nozzle bead sealer. Expands tire sidewall to bead seat area of rim to seal tire to rim and

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

1 Tilt Tower — Support for horizontal and vertical

slides.

2 Release Valve — Allows the manual release of air

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

3 Air Inflation Gauge — Registers tire pressure when

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

4 Important Safety Decal — Important safety infor-

mation for the operator. DO NOT obstruct with tire stickers or other materials.

2 • Important: Always read and follow operating instructions.

allow inflation.

6 Inflation Pedal — Three-position pedal that registers

tire pressure, allows inflation of tires through air hose and clip-on chuck or allows air flow through bead sealing nozzle.

7 Robo-Arm® (if equipped) — Provides extra leverage

for runflat and low profile tires.

8 Robo-Arm Valve (if equipped) — Controls verti-

cal movement of robo-arm slide cylinder. Used to set correct vertical position to maintain robo-arm disk-asist wheel clearance.

Page 9

9 Slide Locking Valve — Locks and unlocks hori-

zontal/vertical slide and sets correct vertical/horizontal position to maintain Duckhead® mount/demount tool to wheel clearance.

10 DuckHead Mount/Demount Tool — Used to

mount and demount tire from wheel.

11 Clamps — Holds wheel to table top for tire chang-

ing. Position outward to allow outside clamping of wheels.

12 Table Top — Rotating chuck for tire changing.

13 Clamp Control Pedal — Three-position pedal that

opens, holds or closes rim clamps.

14 Tower Tilt Pedal — Two-position pedal that moves

tower forward or back.

17 Tire Bumper Guards — Provides protective sur-

face when bead loosening tires.

18 Bead Loosener Shoe — Pivoting shoe for loosen-

ing tire beads.

*19 Lube Bucket — Dispenser for rubber lubricant.

20 Bead Loosener Handle — Pull handle up or down

to control operation of bead loosener shoe.

21 Horizontal Disk-Assist Control Lever — Locks

and unlocks horizontal slide. Used to position disk-assist for bead lubrication, assist with tire mounting, and demounting lower bead without tire tool.

22 Disk-Assist Hitch Pin (if equipped) — Allows

extra clearance when tire changing large diameter wheel assembles.

15 Table Top Pedal — Four-position pedal that controls

rotation of table top (forward-fast, forward-slow, off, reverse).

16 Bead Lifting Tool — Used to lift and position tire

bead correctly on Duckhead mount/demount tool.

23 Disk-Assist Position Lock (if equipped) — Locks

and unlocks horizontal slide to flip the disk-assist for either upper or lower bead positioning.

*Not Shown

14 15

Important: Always read and follow operating instructions. • 3

Page 10

GTS-90

24 Robotic Arm Control Valve — Controls vertical movement of robotic arm cylinder.

25 Robo-Arm® — Provides extra leverage for runflat and low profile tires.

26 Leverless Bead Lifter Tool — Used to hook under tire bead lip for top bead removal

when demounting tire from wheel. Used as a helper device when mounting tire on wheel.

27 Leverless Bead Lifter Control — Controls vertical movement of Leverless Bead

Lifter

Tool.

28 Robo-Assist™ — Roller provides extra leverage for runflat and low profile tires.

4 • Important: Always read and follow operating instructions.

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Operating Instructions

This unit must be properly operated and properly maintained to help avoid accidents that could injure the operator or bystanders, or damage the unit. 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

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.

Note: 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 Duckhead® mount/demount tool contacting the rim causing scratches. On alloy wheels, always rotate the wheel one turn after setting the mount/demount tool to insure proper wheel clamping.

Note: Always review with the owner any nicks and scratches on expensive wheel and tire combinations prior to servicing.

Figure 1 - Remove Valve Core to Deflate Tire

Tires are always installed and removed from the rim’s narrow side.

Note: 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

Note: Review the performance wheel section of

this manual prior to servicing performance tire/ wheel combinations.

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 2 - Determine Narrow Side of Wheel

Note: The clamps on the table top may extend beyond the table top itself. To avoid damaging 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.

2. Actuate valve (or pull) to position 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. Actuate the bead loosener hand valve to position the shoe and loosen the bead. It may be necessary to loosen the bead in multiple locations around the tire (figure 3).

Important: Always read and follow operating instructions. • 5

Page 12

Valve Stem at

2 o’clock Position

Figure 3 - Position Tire and Bead Loosener Shoe with Valve Stem in 2 o’clock Position.

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.

Note: The wheel clamps can be positioned in one of two different ranges:

• Use inner holes for 6-22-inch diameter wheels

• Use outer holes for 8-24-inch diameter wheels

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

ing side up (figure 6).

Mounting Side Up

Narrow Side

Figure 6 - Place Tire/Wheel Assembly on Table top

Valve Stem at

2 o’clock Position

Figure 4 - Position Tire and Bead Loosener Shoe With Wheel Turned Around and Valve Stem in 2 o’clock Position.

Note: 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).

Clamp control pedal must be in the full up or full down position (detent position) to maintain clamping force on wheel.

7. If equipped, use Robo-Arm with cone to apply

pressure to aid in clamping rim (figure 7). Use the clamp control pedal to move the clamps inward (push pedal down) or outward (toggle pedal up). Engage the detent position (pedal in full up or full down position) to maintain clamped or unclamped pedal position.

Clamp steel wheels from the inside (clamps push outward against wheel). Clamp alloy and custom wheels from the outside (clamps push inward against the outside rim edge). Refer to the Performance Tires and Wheels section.

Figure 5 - Apply Rubber Lubricant to Tire Beads

6 • Important: Always read and follow operating instructions.

Figure 7 - Robo-Arm® Aids Clamping

Page 13

8. Take time to experiment with the Duckhead®

mount/demount tool locking system (figure 8).

A B C

Figure 8 - Position slide lock as shown, A - Slide/duckhead locked in fully retracted position, B - Slide/duckhead unlocked for positioning, and C - Slide/duckhead locked into position

Before tilting tower forward, always be sure Duckhead mount/demount tool is in the fully retracted position. 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.

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.

11. Apply tire manufacturer’s approved rubber lubri-

cant liberally to entire circumference of both beads after bead loosening and clamping wheel on table top.

9. Using foot pedal,

position tower forward (figure 9). See figure 8 for mount/demount tool movement and locking. With tower forward, press the slide lock valve button to allow mount/demount tool to descend on the tire sidewall (figure 9). Then move the mount/ demount tool toward rim and release the locking button.

Figure 9 - Position Mount/ Demount Tool

10. Check mount/demount tool positioning. A metal

Duckhead mount/demount tool will move up and back about 1/8-inch from the rim edge after it is locked. This clearance will be maintained as long as the slide locking valve remains locked. The operator may move the tower back out of the way and back into place again without needing to reposition the mount/demount tool (when clamping a like set of wheels).

Note: If equipped, when positioning the mount/ demount tool toward rim, use disk-assist in upper position to press down on tire sidewall (figure 10). Once the bead lifting tool is in place, raise the Disk-assit off the tire.

Figure 10 - Apply Rubber Lubricant to the Beads

Note: If equipped, use disk-assist in upper position to hold down the top bead (figure 10), while rotating wheel to make tire lubrication easier.

Note: Normal table top rotation for demounting is clockwise. Depress table top pedal to rotate this direction. To rotate table top counterclockwise, lift pedal up with your toe.

Note: Table top rotation can be stopped at any time by removing your foot from the rotation pedal.

12. Insert the smooth curved end of the bead lifting

tool over the forward end of the demount tool and below the top bead of the tire. Lift the bead up and over the knob on the demount tool (figure 11). Also, note the valve stem position to the demount tool.

Push down

Valve Stem

Figure 11 - Insert Bead Lifting Tool

Important: Always read and follow operating instructions. • 7

Page 14

Note: If equipped, use disk-assist in upper position to press down on tire sidewall in front of mount/ demount tool. It will aid in locating the bead lifting tool over forward end of mount/demount tool and below the top bead of the tire (figure 11).

13. Depress the table top pedal to rotate the wheel.

The Duckhead demount tool will guide the tire bead up and over the edge of the wheel. Continue rotation until the upper tire bead is demounted.

Figure 12 - Demount Upper Bead

Note: Push down on tire (if equipped, use RoboArm®) across from the demount tool during table top rotation to utilize drop center area of the wheel. This reduces tensional force on the top or first bead during demount.

14. Lift and hold the tire at an angle so that the lower

bead is resting in the drop center directly across from the demount tool, and is loose below the demount tool (figure 14). 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 tool (figure 13).

Note: If equipped, use disk-assist in lower position and clear of table top rotation to aid in pushing up on lower bead of the tire (figure 14. This helps the tire to not slide out of drop center and back on to the rim.

Figure 14 - Disk-assist Aiding Lower Bead Demount

Note: If equipped, use the disk-assist to aid in changing large diameter tires. When moving the disk-assist from the upper position to the lower position, it may be necessary to stow the diskassit away (figure 15) by removing the hitch pin.

Disk-assist Hitch Pin

Hitch Pin

Disk-assist Stowed

Figure 13 - Guide Lower Bead Over Knob On Demount Tool

8 • Important: Always read and follow operating instructions.

Figure 15 - Stow the Disk-assist Away

15. Depress the table top pedal to rotate the wheel.

The demount tool will guide the bead up and over the edge of the wheel. Continue rotation until lower bead is demounted.

16. Depress the tower pedal to move the tilt tower in

the backward position to remove the tire.

Page 15

Tire Mounting

This information must be read and followed carefully

to prevent accidents and injuries during mounting.

Mounting a mismatched tire and wheel will cause an explosion before it bead seats during inflation. Attempts to force a bead seat, by increasing air pressure, on mismatched tires and wheels will cause the tire to violently explode, causing serious personal injury or death to operator and/or bystanders if standing over tire and wheel.

1. Before any mounting, inspect tire for damage and

verify size match between tire and wheel (figure 16).

Figure 16 - Verify Size Match Between Tire and Wheel

WARNING

Check tire and wheel carefully before mounting. Make sure the tire bead diameter and wheel diameter match exactly. Consult the tire manufacturer’s recommendations, Tire Guide and/or Rubber Manufacturer’s Association for approved rim widths for tire sizes.

WARNING

Never mount a damaged tire. Never mount a tire on a rusty or damaged wheel. Used tires may have bead and/or tread damage. Used rims may have flange damage where the tire/rim was run down the road on a flat tire. Run-flat tires are not meant to be reused! Damaged tires and/or wheels may explode.

When in doubt do not mount. 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. Used tires may have road hazard damage or mount/demount damage, inspect carefully. Do not let untrained persons operate tire changer and keep bystanders out of service area.

2. Inspect wheel closely for damage. Clean the wheel

and remove any light corrosion or rubber residue (figure

17). Do not attempt to service a heavily corroded wheel, damaged wheel, or bent wheel.

Figure 17 - 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 18).

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.

Important: Always read and follow operating instructions. • 9

Figure 18 - Lubricate Tire Beads Liberally

Page 16

4. Place tire over wheel and move tower arm into

position. Position tire so that lower bead is above the rear extension of the Duckhead® mount/demount tool and below the front knob (figure 19). Make sure the valve stem is at the 9 o’clock position in front of bead lock to prevent TPMS sensor damage.

Figure 19 - Position Tire Against Mount/Demount Tool

5. Depress table top pedal and rotate wheel to mount

lower bead. Use drop center of wheel by pushing down on tire just ahead of the mounting tool, and follow as tire rotates. Rotate table top until lower bead is mounted.

7. Depress table top pedal and rotate tire until the

top tire bead is mounted. Continue to press down on the tire to ensure bead stays in the rim drop center area ahead of mount/demount tool.

Note: If equipped, use Robo-Arm to press down on tire sidewall between Robo-Arm and disk-assist to hold tire in rim drop center. When the Robo-Arm is 180 degrees from the mounting tool, begin to lift the disk-assist off the tire.

Note: If table top rotation stalls, reverse the table top momentarily until tire bead is again loose on the wheel. Reposition tire on mount/demount tool making sure bead is correctly positioned in drop center of the wheel; then attempt mounting again.

8. Depress the tower pedal to move the tilt tower

in the backward position to remove the tire/wheel assembly.

6. For top bead installation, rotate table top until

the valve stem is directly across from the mount/ demount tool. Lift the upper bead up and over the rear of the mount/demount tool. Press down on tire sidewall between mount/demount tool and valve stem to hold tire in rim drop center (figure 21).

Note: If equipped, use disk-assist in upper position to press down on tire sidewall in front of mount/ demount tool. This helps keep the upper tire bead in the drop center of the rim (figure 21).

Note: If equipped, use Robo-Arm

to push down on tire (figure 21) 90 degrees clockwise from mount/demount tool to allow bead to utilize drop center area of rim.

Fig 21 - Hold Tire Bead In Rim Drop Center

10 • Important: Always read and follow operating instructions.

Page 17

Inﬂ ation

Tire inflation is performed in three steps: BEAD SEAL, BEAD SEAT, and INFLATION. These steps are explained in detail on page 14. Read the explanation of each step and understand them thoroughly before proceeding.

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.

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.

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 is a safety item that must 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 (using the clip-on chuck) 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.

Note: Some models use a single-point nozzle bead sealer.

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.

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.

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.

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

Inflation Pedal Positions

Important: Always read and follow operating instructions. • 11

Page 18

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.

Note: 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 system 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, when using 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 24).

Figure 24 - 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 jet(s) 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.

12 • Important: Always read and follow operating instructions.

Page 19

Bead Seating

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.

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

25).

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.

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.

Important: Do not continue to add air pressure to

force bead seat.

Figure 25 - Stand Back during Bead Seat

Important: Always read and follow operating instructions. • 13

Page 20

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.

WARNING

If you change tires defined as truck tires, they must be inflated per OSHA instructions.

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.

Manual Release Valve

Figure 26 - Location of Manual Release Valve

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.

4. Release air pressure from tire by pressing the

manual release valve button (inflation hose must be attached to the valve stem, Figure 26). Never add or adjust tire pressure using an air hose without a clip-on air chuck and in-line valve. Do not use a hand-held style chuck (figure 27).

5. 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.

Explosion Hazard

Never exceed 40 PSI while

seating beads. If you use more than 40 PSI always

use safety cage.

Remember R.I.M.

(see page vi and back cover)

Figure 27 - Do Not Use a Hand-held Style Air Chuck

Explosion Hazard Never inﬂ ate tire

above

manufacturer’s

recommended pressure after

bead is seated.

14 • Important: Always read and follow operating instructions.

Page 21

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. For tires requiring more than 40 PSI to bead seat use safety cage.

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.

Important: Always read and follow operating instructions. • 15

Page 22

Mismatched Tires and Wheels

Never mount and inflate mis-matched tires and wheels.

Mismatched tire and wheel combinations will explode, if you attempt to force a bead seat, causing personal injury or death to operator and/or bystanders.

16 • Important: Always read and follow operating instructions.

Page 23

Custom and Special Wheels

Only tire technicians with experience and training on custom wheels should attempt to service expensive custom alloy or aluminum wheels and high-performance lowprofile tires.

Alloy Wheels

Some manufacturers offer wheels with little or no drop

center. These are not DOT approved. The tire or wheel

- or both - can be damaged and the tire could explode under pressure , resulting in serious injury or death. Do not mount/demount this type of wheel (figure 28).

Figure 28 - No Drop Center

European Performance Wheels (Asymmetrical Hump)

Some European wheels have very large humps except near the valve hole. On these wheels, the beads should be loosened at the valve hole on both the upper and lower sides first (figure 29).

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 tool and bead lifting tool as

described in steps 8 through 12 on pages 6 and 7. 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.

Figure 29 - Asymmetrical Hump on European Wheels

Wheels with Low Pressure Warning Sensors

Performance wheels on some vehicles (including Corvette, BMW, Lamborghini Diablo) have a pressure sensor strapped to the rim opposite the valve hole. On these wheels, the beads should be loosened at the valve hole on both upper and lower sides first (figure

30).

Figure 30 - Wheels with Low Pressure Sensor

Important: Always read and follow operating instructions. • 17

Page 24

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.

WARNING

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 or contact COATS directly, (800) 688-6359.

Before making any inspection, adjustment, or repair, disconnect the power source and block out all moving parts to prevent injury.

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.

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

1. The vertical slide should be cleaned with a

vaporizing solvent and then lubricated with chassis grease once a month.

2. Check the adjustment of the Duckhead demount tool once a month. See instructions on page 18.

3. The table top, clamps, steel Duckhead mount/ demount tool, and other working surfaces should be cleaned with a vaporizing solvent every month.

4. Inspect clamps. Remove metal chips and dirt from the serrations with a wire brush every month.

5. 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). Contact COATS at (615) 641-7533. Check function of the pressure limiter weekly. Always reinstall the lens after adjusting the gauge.

6. Make sure all fasteners are securely tightened.

7. Make certain that all guards and covers are in

place.

8. Check for worn, damaged or missing parts including grips and protective covers. Replace them before allowing the unit to be used.

mount/

18 • Important: Always read and follow operating instructions.

9. 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.

Page 25

Maintenance Instructions

Read and follow all the maintenance instructions pro-

vided 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.

WARNING

Before making any inspection, adjustment, or repair, disconnect the power source and block out all moving parts to prevent injury.

WARNING

Watch Pressure on Both Gauges

Air Service Tank

Tire Changer Inﬂ ation Hose Connected to Tank

you have no experience. If you need assistance, call an authorized service center or contact COATS directly, (800) 688-6359.

1. The vertical slide should be cleaned with a vaporizing solvent and then lubricated with chassis grease once a month.

2. Check the adjustment of the Duckhead demount tool once a month. See instructions on page 18.

mount/

Wear protective clothing, equipment and eye protection when making any adjustments or repairs to the machine.

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

Important: Always read and follow operating instructions. • 19

3. The table top, clamps, steel Duckhead mount/ demount tool, and other working surfaces should be cleaned with a vaporizing solvent every month.

4. Inspect clamps. Remove metal chips and dirt from the serrations with a wire brush every month.

6. Make sure all fasteners are securely tightened.

Page 26

Maintenance Instructions

WARNING

Before making any inspection, adjustment, or repair, disconnect the power source and block out all moving parts to prevent injury.

WARNING

Wear protective clothing, equipment and eye protection when making any adjustments or repairs to the machine.

Injector Barb Fitting

1. The vertical slide should be cleaned with a vaporizing solvent and then lubricated with chassis grease once a month.

2. Check the adjustment of the Duckhead demount tool once a month. See instructions on page 18.

3. The table top, clamps, steel Duckhead mount/ demount tool, and other working surfaces should be cleaned with a vaporizing solvent every month.

4. Inspect clamps. Remove metal chips and dirt from the serrations with a wire brush every month.

6. Make sure all fasteners are securely tightened.

7. Make certain that all guards and covers are in

place.

8. Check for worn, damaged or missing parts including grips and protective covers. Replace them before allowing the unit to be used.

mount/

Clamp Control Pedal Valve

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

20 • Important: Always read and follow operating instructions.

Page 27

DECAL LOCATION

8183597



8182373

8184736

8181285

8182373FR

8

8181970

8184736

85609716

85609717 (GTS70) 85610213 (GTS50) 85610214 (GTS60) 85610482 (GTS90)

85610079

8181967

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

Important: Always read and follow operating instructions. • 21

85607835

8180237

8180237FR

8

Page 28

22 • Important: Always read and follow operating instructions.

Page 29

8183597

85611205

Decal Locations

Important: Always read and follow operating instructions. • 23

Page 30

ONE WORD FOR SAFETY

R.I.M.

READ INSPECT

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.

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.

MOUNT

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.

BE CAREFUL OF THESE SITUATIONS:

1. Damaged Bead or Beads.

2. Rusty Wheels.

(particularly in the bead seat area)

3. Bent or Cracked Wheels.

Remember R.I.M. (Read, Inspect, Mount) for every tire.

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)

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.)

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.

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 HENNESSY INDUSTRIES, INC., 1601 J. P. HENNESSY DRIVE, LAVERGNE, TENNESSEE, 37086 - (800) 688-6359.

TIRE FAILURE UNDER PRESSURE IS HAZARDOUS! 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.

Coats gts series, GTS70, GTS50, GTS90, GTS60 Operation Instructions Manual

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