5060 A/E 5060 AX/EX - Automotive Equipment Service co

1601 J. P. Hennessy Drive, LaVergne, TN USA 37086-3565 615/641-7533 800/688-6359 Manual Part No.: 8182883 01HENNESSY INDUSTRIES INC. Manufacturer of AMMCO®, COATS® and BADA® Automotive Service Equipment and Tools. Revision: 12/96

Safety InstructionsOperating Instructions

Installation InstructionsMaintenance Instructions

READ these instructions before placing unit inservice. KEEP these and other materials deliveredwith the unit in a binder near the machine forease of reference by supervisors and operators.

®

5060 A/E5060 AX/EXRim Clamp®

Tire ChangerFor servicing single pieceautomotive and most lighttruck tire/wheel assemblies

Table of Contents

Definitions of Hazard Levels ................................1

Owner’s Responsibility ........................................1

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

Operating Instructions .........................................3

Bead Loosening and Demounting ....................3

Mounting ...........................................................6

Inflation ..................................................................7

Bead Sealing ....................................................7

Bead Seating ....................................................8

Inflation .............................................................8

Performance, Custom, and Aluminum Wheels ..9

Aluminum and Custom Wheels ........................9

Performance Tires and Wheels • Demounting .9

Performance Tires and Wheels • Mounting ....11

Custom and Special Wheels ..............................12

Tube Type Tires ..................................................12

Stages of Inflation ...............................................13

Bead Seal .......................................................13

Bead Seat .......................................................13

Inflation ...........................................................13

Mis-Matched Tires and Wheels ..........................13

Maintenance Instructions ...................................14

Installation Instructions .....................................15

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

Failure to follow danger,warning, and cautioninstructions may lead to

serious personal injury or death to operator orbystander or damage to property. Do notoperate this machine until you read andunderstand all the dangers, warnings andcautions in this manual. For additional copiesof either, or further information, contact:

Hennessy Industries, Inc.P.O. Box 3002, 1601 J.P. Hennessy DriveLaVergne, TN 37086-1982(615) 641-7533 or (800) 688-6359

WARNING

Operator Protective Equipment

Personal protective equipment helps make tirechanging safer. However, equipment does not takethe place of safe operating practices. Always weardurable 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 toprotect operator’s hands when handling worn tiresand wheels. Sturdy leather work shoes with steeltoes and oil resistant soles should be used by tireservice personnel to help prevent injury in typicalshop activities. Eye protection is essential duringtire service activity. Safety glasses with sideshields, goggles, or face shields are acceptable.Back belts provide support during lifting activitiesand are also helpful in providing operatorprotection. Consideration should also be given tothe use of hearing protection if tire service activityis performed in an enclosed area, or if noise levelsare high.

Important Addresses

RUBBER MANUFACTURERS ASSOCIATION1400 K Street N.W.Washington, DC 20005

TIRE GUIDES, INC.The Tire Information Center1101-6 South Rogers CircleBoca Raton, FL 33487-2795

Definitions of Hazard Levels

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

DANGERWatch for this symbol:

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

WARNINGWatch for this symbol:

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

CAUTIONWatch for this symbol:

It Means: Hazards or unsafe practices which mayresult in minor personal injury or product or propertydamage.

Watch for this symbol! It means BE ALERT!Your safety, or the safety of others, is involved!

Owner’s Responsibility

To maintain machine and user safety, theresponsibility of the owner is to read andfollow these instructions:

• Follow all installation instructions.

• Make sure installation conforms to allapplicable Local, State, and FederalCodes, Rules, and Regulations; such asState and Federal OSHA Regulations andElectrical Codes.

• Carefully check the unit for correct initialfunction.

• Read and follow the safety instructions.Keep them readily available for machineoperators.

• Make certain all operators are properlytrained, know how to safely and correctlyoperate the unit, and are properlysupervised.

• Allow unit operation only with all parts inplace and operating safely.

• Carefully inspect the unit on a regularbasis and perform all maintenance asrequired.

• Service and maintain the unit only withauthorized or approved replacementparts.

• Keep all instructions permanently with theunit and all decals on the unit clean andvisible.

COATS 5060A/E/AX/EX Rim Clamp Tire Changer • 1

DANGER DANGER

Explosion HazardNever exceed 40PSI while seatingbeads.

Explosion HazardNever inflatetire abovemanufacturer’srecommendedpressure after beadis seated.

DANGER

CAUTION

WARNING

Principal Operating Parts

Know Your UnitCompare this illustration with the unit before placingit into service. Maximum performance and safety willbe obtained only when all persons using the unit arefully trained in its parts and operation. Each usershould learn the function and location of all controls.Prevent accidents and injuries by ensuring the unitis properly installed, operated, and maintained.

Tower — Support for horizontal and verticalslides, also air storage tank.

Air Inflation Gauge — Registers tire pressurewhen clip-on chuck is attached to valve stem

and inflation pedal is released.

Inflation Pedal — Three position pedal thatallows inflation of tires through air hose and

clip-on chuck.

Clamp Control Pedal — Three position pedalthat opens and closes rim clamps.

Table Top Pedal — Three position pedal thatcontrols rotation of table top.

Table Top — Rotating chuck for tire changing.

Clamps — Secures wheel to table top for tirechanging.

Adjustable Clamp (AX/EX) — Adjusts outwardto allow outside clamping of wheels up to 21”.

Lube Bottle — Dispenser for rubber lubricant.

Combination Mount/Demount Head —Mounts and demounts tire from wheel.

Do It NowNow is a good time to fill out the Owner'sRegistry Card.

Swing Arm Adjustment Knob — Adjustsswing arm/vertical slide assembly for proper

horizontal positioning of mount/demount head.

Vertical Slide Locking Handle — Locks andunlocks vertical slide and sets correct vertical

position to maintain head/wheel clearance.

Bead Lifting Tool — Used to lift and positiontire bead correctly on mount/demount head.

Bead Loosener Shoe — Pivoting shoe forloosening tire beads.

Bead Loosener Handle/Button — Controlsoperation of bead loosener shoe.

Oil Check Dipstick — For transmission oillevel.

Bead Sealing Nozzles — Expands tiresidewall to bead seat area of rim to seal and

allow inflation.

Pressure Safety Valve — The high pressuresafety valve is set to exhaust at line pressures

above 185 PSI.

Release Valve — Allows the manual release ofair pressure from tire.

2 • COATS 5060A/E/AX/EX Rim Clamp Tire Changer

1

2

8

7

6

5

4

3

✓

9

10

11

12

13

14

15

16

17

18

1

2

3 4

5

6

7 89

10

11 12

13

14

15

16

17

18

19

19

OPERATING INSTRUCTIONS

The unit must be properly operated and properlymaintained to help avoid accidents that coulddamage the unit and injure the operator orbystanders. This section of the OperatingInstructions manual review basic operations and useof controls. These instructions should be reviewedwith all employees before they are allowed to workwith the machine. Keep these instructions near themachine for easy reference.

BEAD LOOSENING AND DEMOUNTING

This machine may operatedifferently from machinesyou have previously

operated. Practice with a regular steel wheel andtire combination to familiarize yourself with themachine’s operation and function.

A. Remember to remove all weights from both sidesof the wheel. Weights left on back side of wheel maycause the wheel to be clamped unlevel. This mayresult in the combination mount/demount headcontacting the rim causing scratches. On alloywheels, always rotate the wheel one turn aftersetting the head to insure proper wheel chucking.

B. Always review nicks and scratches with owners ofexpensive wheel and tire combinations prior toservicing.

C. Review the performance wheel section of thismanual prior to servicing performance tire/wheelcombinations.

1. Deflate tire completely by removing the valvecore from the valve stem (Figure 1).

Figure 1 – Remove Valve Core to Deflate Tire

NOTE: Loosening the beads on a partially orfully inflated tire is unsafe and causes excessmovement and friction against the bumper padsand excessive wear on pivots. Deflate the tirecompletely to prolong the life of your machine.

D. Always loosen the bead on the narrow side ofthe wheel’s drop center first. See Figure 4 formore information on the drop center.

E. The clamps on the table top may extendbeyond the table top itself. To avoid damagingthe clamps, move them to their full inwardposition before positioning a tire for beadloosening.

F. Use extra care in positioning the beadloosener shoe on larger wheels/tires, and onalloy wheels. Make sure the shoe rests next tobut not on the rim, and not on the tire sidewall.

2. Pull the bead loosener shoe away from themachine and roll wheel into position. The valvestem should be in the 3 o’clock posit ion.Position the bead loosener shoe against the tirenext to, but not on, the rim. Press the button onthe bead loosener to actuate the shoe andloosen the bead. It may be necessary to loosenthe bead in multiple locations around the tire

(Figure 2).

Figure 2 – Position Tire and Bead Loosener Shoe

3. Turn wheel around and repeat looseningprocedure on the other side of the wheel. Thisshould be the long side of the drop center (seeFigure 4).

G. It will be easier to clamp the wheel to thetable top if the lower bead is loosened last.


CAUTION

4. Apply tire manufacturer’s approved rubberlubricant liberally to entire circumference of bothtire beads after loosening (Figure 3).

Figure 3 – Apply Rubber Lubricant to Tire Beads

5. Determine the mounting side of the wheel. Themounting side is the narrow side of the dropcenter. (Tire removed in Figure 4 for clarity.)

Figure 4 – Determining Mounting Side of Wheel

6. Place tire/wheel assembly on table top withmounting side up (Figure 5). Use the clampcontrol pedal to move the clamps inwards (pushpedal down) or outwards (toggle pedal up).

Clamp steel wheels from the inside (clampspush outwards against wheel). Clamp mag andcustom wheels from the outside (clamps pushinwards against the outside rim edge). Refer tothe Performance Tires and Wheels section.

Figure 5 – Place Tire/Wheel Assembly on Table Top

7. Move the swing arm into position. Pull thelocking handle forward to release the slide.

Push down on the top of the vertical slide to

move the demount head into contact with therim edge. Push the locking handle back to lockthe slide into place. As the slide is locked, themount/demount head wil l move upward

approximately 1/8 inch from rim edge (Figure 6).

Figure 6 - Position Mount/Demount Tool

8. The mount/demount head roller should be incontact with the rim edge. Turn the swing armadjusting knob to move the roller away from therim 1/8 to 1/4 inch (Figure 7).

Figure 7 - Adjust Swing Arm to Position Head Roller

9. Check head positioning. Mount/demount headshould be positioned with 1/8 to 3/16" clearance

between the top of the rim edge and the bottomof the head, and 1/8 to 1/4 inch clearancebetween the rim edge and the head roller. Thisclearance will be maintained as long as thelocking handle and adjustment knob are notchanged. The operator may swing the arm outof the way and back into place again withoutneeding to reposition the head (when changinga like set of wheels) (Figure 8).

Figure 8 - Proper Mount/Demount Head Position

H. The vertical tool clearance may change withmachine use and should be inspected often.Failure to maintain the proper clearance mayresult in damage to the wheel rim and/or tire.

10. Insert the smooth curved end of the bead liftingtool over the forward end of the demount headand below the top bead of the tire. Use your free


Narrow Side

Long Side

Drop Center

1/8" to 1/4"

1/8" to 3/16"

hand to press down on the tire opposite thehead to help with tool insertion (Figure 9).

Figure 9 - Insert Bead Lifting Tool

11. Push the bead lifting tool down towards thewheel to lift the tire bead up and over the knobportion of the demount head. Hold the tool andbead in this position (Figure 10).

Figure 10 - Lift Bead Over Demount Head

12. Depress the table top pedal to rotate the wheelclockwise. The demount head will guide theupper bead up and over the edge of the wheel.

J. Push down on the tire across from thedemount head during table top rotation to utilizethe drop center area of the wheel. This reducesthe tensional force on the top or first bead

during demount (Figure 9).

13. Lift and hold the tire at an angle so that thelower bead is resting in the drop center directlyacross from the demount head, and is loosebelow the demount head (Figure 11). Insert the

smooth curved end of the bead lifting tool downover the forward end of the mount/demount tooland below the lower bead. Lift the bead up andover the knob on the demount head (Figure 12).

Figure 11 - Demounting Lower Bead

14. Depress the table top pedal to rotate the wheel.The demount head will guide the bead up andover the edge of the wheel. Continue rotationuntil lower bead is demounted.

Figure 12 - Guide Lower BeadOver Tool Head

K. With tube-type tires,demount the upper bead and remove the tubebefore demounting the lower bead.

L. Table top rotation can be stopped at any time byremoving your foot from the rotation pedal.

M. Normal table top rotation fordemounting is clockwise. Depress thetable top pedal to rotate this direction. Torotate the table top counterclockwise, lift

the pedal up with your toe.

At times during the mounting and demountingprocedure, the bead lifting tool may encounterresistance or come under load. Keep one handfirmly on the tool to avoid possible tooldisconnect. Use the reversing feature to backout of jam ups.

After successfully completing the demount process,proceed to Mounting (page 6).


✓

CAUTION

MOUNTINGThis information must be read and followed carefullyto prevent accidents and injuries during mounting.

Check tire and wheelcarefully before mounting.Make sure the tire bead

diameter and wheel diameter match exactly.Consult the Rubber Manufacturer's Associationfor approved rim widths for tire sizes.

Attempts to force a beadseat on mis-matched tiresand wheels can cause the

tire to violently explode, causing seriouspersonal injury or death to operator and/orbystanders.

Never mount a tire andwheel handed to you byanyone without checking

both tire and wheel for damage andcompatibility. Be extra cautious of personswithout knowledge of tire service. Keep by-standers out of service area.

Never mount a damagedtire. Never mount a tire ona rusty or damaged wheel.

Damaged tires and/or wheels may explode.

If you damage the tirebead during mounting,STOP!, remove the tire

and mark it as damaged. Do not mount adamaged tire.1. Inspect the wheel closely for damage. Clean the

wheel and remove any light corrosion or rubberresidue (Figure 13). Do not attempt to serviceheavily corroded wheels.

Figure 13 - Inspect and Clean the Wheel

2. Inspect tire for damage, paying close attentionto the beads. Verify size match between tire andwheel (Figure 13).

3. Lubricate t ire beads l iberally with t iremanufacturer approved lubricant (Figure 14).

Figure 14 - Lubricate Beads

4. Place tire over wheel and move swing arm intoposition. Position tire so that the lower bead isabove the rear extension of the mount/demounthead and below the front knob (Figure 15).

Figure 15 - Position Tire Against Mount/Demount Head

5. Depress table top pedal and rotate the wheel tomount the lower bead. Use the drop center ofthe wheel to reduce the tensional force on thebead by pressing down on the tire directlyacross from the mount head. Rotate table topuntil lower bead is fully mounted.

Figure 16 - Mounting Top Bead

6. For top bead, rotate the table top until the valvestem is directly across from the mount head. Liftthe upper bead up and over the rear of themount head. With your left hand press down onthe tire between the mount head and the valvestem to hold the tire in the drop center. Depresstable top pedal and rotate tire until the bead ismounted. Continue to press down on tire duringthe remaining mounting process (Figure 16).

Do not force the tire ontothe rim. Bead damagecould result making the

tire unsafe and/or creating the risk of injury.

N. If table top rotation stalls, reverse the table topmomentarily until the tire bead is again loose on thewheel. Reposition the tire on the mount head, makesure the bead is correctly positioned in the dropcenter of the wheel, then attempt mounting again.

P. For low profile or stiff sidewall tires, it may beadvantageous to use the bead lifting tool to initiallyhold the upper bead down in the drop center, or usedrop center tools as shown in Figure 32, page 11.

R. For tube type tires, mount the lower bead first,move swing arm out, install the tube, and thenmount the upper bead.


WARNING

CAUTION

WARNING

CAUTION

WARNING

DANGER

INFLATION

Tire inflation is performed in three steps: Bead Seal,Bead Seat, and Inflation. These steps are explainedin detail on page 13. Read the explanation of eachstep and understand them thoroughly beforeproceeding.

Check for proper inflationgauge operation.Accurate pressure

readings are important to safe tire inflation.Refer to the Operating Maintenance section ofthis manual for instructions.

If the rim has beenclamped from the outsidefor tire mounting, release

the clamps, lift the tire, and move the clamps tothe center of the table top.

If the wheel/tire has adiameter larger than 14inches and is difficult to

bead seal, the clamps should be moved to thecenter of the table top for the bead sealoperation.

Tire failure underpressure is hazardous.This tire changer is not

intended to be a safety device to containexploding tires, tubes, wheels, or bead sealingequipment. Inspect tire and wheel carefully formatch, wear, or defects before mounting. Alwaysuse approved tire bead lubricant duringmounting and inflation.

The inflation pedal, located at the rear of the left sideof the machine, controls the flow of air through theinflation hose.

NOTE: The clip-on chuck on the end of the hoseshould always be an open style with all parts inproper working order.

Position 1 - Tire Pressure – With the inflation hoseattached to the tire valve and the pedal in thisposition, the air gauge will register the air pressurein the tire. Whenever your foot is removed from thepedal, it will return to this position.

Position 2 - Tire Inflation – This is the firstactivated position. With the inflation hose attachedto the tire valve and the pedal in this position, linepressure is allowed to flow through the valve andinto the tire for inflation. Tire pressure is notindicated on the gauge in this position.

Position 3 - Bead Sealing – This is the second andlast activated position. With the inflation hoseattached to the tire valve and the pedal in thisposition, line pressure is allowed to flow through thevalve and to the air-flate bead seal jets on the tabletop for bead sealing.

Use Position 3 for beadsealing only. Do not usethis position without a tire

and wheel positioned on the table top. Dirt anddebris could be blown into the air with enoughforce to injure the operator or bystanders. Donot use this position to inflate a tire.

S. The unit is equipped with a pressure limiter toassist the operator with proper tire inflation. Whenthe inflation pedal is held in position 2, the pressurelimiter cycles the machine between position 2(inflation) and position 1 (at rest, no air flow to tire).This cycling helps to prevent over inflation of the tire.Tires can still be over inflated and explode with theuse of this pressure limiter if all of the instructions inthis manual are not followed completely. Thepressure limiter will keep most car and light trucktires from inflating beyond 60 PSI (smaller tires mayreach higher pressures). It is the operator'sresponsibility to follow all instructions and to controlinflation pressure as specified in these instructions.Check the function of the pressure limiter regularlyand maintain it according to the instructionsprovided in this manual for safe and properoperation. Do not tamper with or attempt to adjustthe pressure limiter. Tires requiring inflation beyond60 PSI should be inflated in a safety cage.

Bead Sealing

1. Position valve stem in front of operator andconnect the inflation hose. Hold tire up againstupper edge of the wheel. Be sure tire’s top beadis over the bottom of the valve stem (Figure 17).

Figure 17 - Lift Tire Upwards for Bead Sealing


Tire Pressure Tire Inflation Bead Sealing

Inflation Pedal Positions

CAUTION

CAUTION

CAUTION

DANGER

CAUTION

Explosion Hazard

Never inflatetire abovemanufacturer'srecommendedpressure after bead isseated.

2. Depress inflation pedal to position 2 and holdabout 1 second to begin air flow through tirevalve, then depress pedal to position 3 and holdbriefly – less than 1 full second. The blast of airfrom the jets will expand tire and seal the beads.

3. Release the inflation pedal and allow it to returnto posit ion 1. Verify that both beads arecompletely sealed to the wheel. Repeat thesesteps if beads have not sealed. It may benecessary to wait a few seconds for the airstorage tank to recover before attempting again.

T. If tire and wheel are properly lubricated andoperator cannot achieve bead seal after 3 or 4attempts, the valve core may be removed from thevalve stem to allow more air flow into the tire toassist with bead seal. After bead seal is achieved,remove the chuck and reinstall the valve core.

Bead SeatingOperator should keephands, arms, and entirebody away from the tire

during the remaining bead seat and inflationprocedures. Do not stand over tire, as personalinjury could result.

NEVER increase airpressure to exceed 40 PSIwhen attempting Bead

Seat. If operator is unable to obtain Bead Seat,something is wrong. Deflate tire completely,inspect tire and wheel, correct any problemsfound, relubricate both tire beads, and reattemptBead Seal and Seat procedures. Follow all safetyinstructions in this manual and on machine.

1. Once tire pressure is indicated on the air gauge(inflation pedal in position 1; foot removed frompedal), continue to inject air into the tire in shortintervals. Check the pressure frequently. Standback during bead seat. Keep hands, arms, andentire body away from tire during this procedure.

Tire beads should move outward and "pop" intotheir bead seat position as pressure inside thetire increases. If this does not happen, aproblem exists. Investigate carefully.

Check tire pressurefrequently. Never exceed40 PSI while seating

beads. Once seated, never exceed tiremanufacturer's recommended air pressure. Tirescan explode, especially if they are inflatedbeyond their limits. At all pressure levels wheninflating through the valve stem, keep hands,arms, and entire body away from inflating tire.An exploding tire, wheel, or bead sealingequipment may propel upward and outward withsufficient force to cause serious injury or deathto operator or bystander.

InflationNEVER exceed tirem a n u f a c t u r e r ' srecommended air

pressure. Tires can explode, especially if inflatedbeyond these limits. Keep hands, arms, andentire body back from inflating tire. Avoiddistraction during inflation. Check tire pressurefrequently to avoid over inflation. Excessivepressure can cause tires to explode, causingserious injury or death to operator or bystander.

1. Make sure both beads are seated. When bothbeads are seated, the tire is ready for inflation.

2. Replace the valve core if it was removed.

3. Depress the inflation pedal to position 2 toinflate the tire. The pressure limiter will cycle theair flow as described earlier. On most passengercar tires, the pressure limiter will cease air flowat approximately 60 PSI. On smaller volumetires the pressure may be higher.

U. Release air pressure from tire by pressing themanual release valve button (inflation hose must beattached to the valve stem, Figure 18).


DANGER DANGER

Explosion Hazard

Never exceed 40 PSIwhile seating beads.

WARNING

WARNING

DANGER

DANGER

Figure 18 - Location of Manual Release Valve

PERFORMANCE, CUSTOM, ANDALUMINUM WHEELS

Only tire technicians withexperience and trainingon custom wheels should

attempt to service expensive custom alloy oraluminum wheels and high-performance low-profile tires.

Pre-Operation Notes:• Ensure all weights have been removed.

• Assistance will be required on wide wheels.

• Clamp wheel from the outside.

• Use ample lubricant for mount and demounting

• Always review wheel nicks and/or scratcheswith the owner before servicing.

Aluminum and Custom WheelsFollow instructions provided for standard steelwheels, except:

AA. After loosening and lubricating both beads,rotate the table top until the clamps are in the12, 3, 6, and 9 o'clock positions.

Figure 19 - Rotate Table Top to 12 O'clock

AB. The normal position for all clamps is position 1(or the most inward position). This providesoutside clamping of wheels 10 to 17.5 inches indiameter, and inside clamping of wheels from 12to 20 inches in diameter

Use position 2 only on large diameter wheels.This provides outside clamping of wheels 14 to21 inches, and inside clamping of wheels from16 to 24 inches in diameter.

Figure 20 - Adjustable Clamp Positions

AC.Clamp wheel from the outside. Position rimedge into clamp at 12 o'clock position. Lowerthe wheel and depress the clamp control pedal.Slowly move the clamps inward until theysecurely contact the outside edge of the rim.

TIP: This is usually accomplished by crouchingdown in front of the tire changer, holding thewheel with the right hand, and operating theclamp control pedal with the left hand. Thisallows the operator to watch the clamps as theymove to ensure proper, damage-free clamping.

Performance Tires and Wheels • DemountingFollow these instructions for performance type tiresand wheels, including run-flat t ires and theirassociated wheels, and asymmetrical hump wheels.

1. Remove valve core and completely deflate tire.

2. Pull the bead loosener shoe away from themachine and roll the tire into position against thebumper pads. Position the tire with the valvestem in the 3 o'clock position (in direct line withthe bead loosener shoe). Reposition the beadloosener positioning pin for wheels over 10inches wide. Always loosen the bead on thenarrow/mounting side of the wheel first (Figures4 and 21).

Figure 21 - Position Tire for Bead Loosening and PlacePositioning Pin in Proper Location for Wide Wheels


Position 1

Position PinValve Stem

CAUTION

Position 2

AD: Wheels with an asymmetrical hump have alarger "ledge" type hump around the wheelexcept at the valve hole making them moredifficult to mount and demount (Figure 22).

Figure 22 - Asymmetrical Hump Wheel

AE: Some wheels have a low pressuresensor/transmitter strapped to the wheel. This isespecially true on run-flat tire/wheel systems. Thesensor is positioned directly opposite from the valvestem. To avoid damaging the sensor, always loosenthe top bead at the valve stem first, then loosen thebottom bead at the valve stem, and then continue toloosen the remaining circumference of the beads asnecessary (Figure 23).

Figure 23 - Wheel with Low Pressure Sensor/Transmitter

3. Loosen bottom bead, starting with valve stempositioned directly next to the loosener shoe(Figure 24).

Figure 24 - Loosen Bottom Bead

4. Liberally lubricate the bottom bead of the tire(Figure 25).

Figure 25 - Lubricate Bottom Bead

5. Clamp the wheel to the table top as described initems AB and AC on page 9. Always clampcustom wheels from the outside.

6. Lubricate upper bead liberally. Use the beadlifting tool to help push the tire bead down sobead area is easier to reach for lubrication(Figure 26).

Figure 26 - Lubricate Upper Bead

7. Move swing arm into place and adjust asdescribed on page 4, steps 7, 8, and 9. Increasethe distance between the demount head and thewheel an additional 1/16 to 1/8 inch with theadjustment knob. Locate the valve stem directlyunder the demount head before proceeding(Figure 27).

Figure 27 - Position Valve Stem Under Demount Head

8. Insert bead l i f t ing tool between knob ondemount tool and tire bead. Pull lifting tool downover wheel to lift bead up and over the knob(Figure 28).

AF: On asymmetrical hump wheels and stiffsidewall performance tires, it may be necessaryto use 2 optional drop center tools (part#435685) to hold tire in the drop center so thatthe bead can be lifted over the demount tool.


SmoothHump At

ValveHole

LedgeHump -Rest ofWheel

Valve Stem

Senso

r

Valve Stem

Demount Head

Valve Stem

Figure 28 - Insert Bead Lifting Tool (Optional Drop CenterTools Shown)

9. Hold lifting tool in place and depress the tabletop control pedal momentarily to jog the wheel ashort distance. Check the wheel and tire toverify that operation is not causing damage.

Figure 29 - Pull Lifting Tool Down and Rotate Wheel

10. The lifting tool can usually be removed afterjogging the wheel a short distance. Continue tojog the wheel to allow tire to flex where itcrosses the rim edge. Continue short rotationsuntil top bead is completely demounted.

Figure 30 - Remove Drop Center Tools Before Tool Head

11. Demount lower bead. In most cases whendemounting performance tires, the lower beadwill be less difficult. Use help to lift, position, andhold t ire. Pay close attention to sensor/transmitter location, and position it directlybelow the demount tool when starting the lowerbead demount procedure (Figure 31).

Figure 31 - Use Help on Lower Bead, Watch Sensor

Performance Tires and Wheels - Mounting1. Lubricate both tire beads liberally. Performance

tires will require more lubrication than standardpassenger car tires.

2. Mount the lower bead. In most cases, the lowerbead will mount easily.

Figure 32 - Mount Upper Bead, Use Lifting Tool

3. Position the valve stem directly across from themount/demount tool for top bead mounting. Liftthe top bead over the rear of the mount head.Use the lifting tool to help push and keep the topbead in the drop center during mounting, or usean optional drop center tool to help hold thebead in the drop center (Figures 32 and 33).Rotate the wheel in short steps and apply extralubricant to mount upper bead.

AG: Mounting the top bead can be very difficultwhen mounting new tires on performance andcustom wheels. Proceed slowly and cautiously.

Figure 33 - Mounting Top Bead


Sensor

4. Mount the top bead using short rotations of thewheel. On stiff sidewall tires, add a second dropcenter tool to keep the bead in the drop center.

Figure 34- Add Second Drop Center Tool

5. On extremely tight tire and wheel combinations,it may be necessary to use the hooked end ofthe bead lifting tool to flip the tire over the rimflange (Figure 35).

Figure 35 - Use Hooked End of Bead Lifting Tool

6. After beads are mounted, unclamp wheel, lift itslightly, and move the clamps to the center ofthe table top. With the tire/wheel loose on thetable top, fol low the detailed instructionsprovided in the Inflation section of this manualfor bead sealing, bead seating, and inflation.

CUSTOM AND SPECIAL WHEELS

If a custom wheel isdamaged in mounting ordismounting, STOP, and

avoid damaging the other wheels. Continue onlywhen the cause is identified and corrected.

Alloy WheelsSome manufacturers offer wheels with little or nodrop center. These are not DOT approved. The tireor wheel - or both - can be damaged and the tirecould explode under pressure, resulting in seriousinjury or death. If you attempt to mount/demount thistype of wheel, use extreme caution (Figure 36).

Figure 36 - No DropCenter

European Performance Wheels (Asymmetrical Hump)

Some European wheels have very large humpsexcept near the valve hole. On these wheels, thebeads should be loosened at the valve hole on boththe upper and lower sides first (Figure 37).

Figure 37 - Asymmetrical Hump on European Wheels

Wheels with Low Pressure Warning SensorsPerformance wheels on some vehicles (includingCorvette, BMW, Lamborghini Diablo) have apressure sensor strapped to the rim opposite thevalve hole. On these wheels, the beads should beloosened at the valve hole on both upper and lowersides first (Figure 38).

Figure 38 - Wheels with Low Pressure Sensor

TUBE TYPE TIRES

Mounting1. 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.

Demounting1. After tire beads are loosened, lubricate the

beads and rim liberally.

2. Position demount head and bead lifting tool asdescribed in steps 7 through 11 on pages 4 and5. Depress table top pedal and rotate only ashort distance at a time. This allows you to stopthe process should the tube get pinched.

3. After upper bead is demounted, remove tubeand demount lower bead.

Do it NowMake sure the instruction andwarning decal is clean and clearlyvisible to operator.


No DropCenter

SlightHump

LargeHump

Valve Hole

Transmitter

MountingStrap

Valve Hole

✓

CAUTION

STAGES OF INFLATION

Review these descriptions and diagrams carefully.Refer to them as necessary during bead sealing,bead seating, and inflation to verify that you areproceeding properly and safely.

Bead SealingA 140 PSI air blast from the table top jets creates anair curtain to aid in bead sealing. Never exceed 10PSI in the tire during bead sealing. The tire willcontain about 1/2 to 2 PSI when bead seal isobtained.

Bead SeatingBead seating usually occurs on the long taperedside of the wheel first and the shorter side last. Beadseating will usually require at least 7 PSI in the tire.40 PSI is the maximum safe pressure at this stageregardless of tire operating pressure.

Most European import cars and many aftermarketalloy wheels are very tight and can be difficult tobead seat. Also note that asymmetrical hump andrun-flat tires are extremely difficult to bead seat.Follow tire manufacturer's recommended procedurefor bead seating.

InflationAfter the beads are seated, the tire is inflated. Donot inflate the t ire above the manufacturer'srecommended pressure as stamped on the tiresidewall. The typical inflation pressure forautomobile tires is between 24 and 45 PSI. Lighttruck inflation pressure typically covers a widerrange.

MIS-MATCHED TIRES AND WHEELSNever attempt to mount and inflate mis-matchedtires and wheels.

Mis-matched tire andwheel combinationsexplode, causing personal

injury or death to operator and bystanders.

For safety, do not attempt to mount and inflatemis-matched tires and wheels.


Requires rubber lubricant onboth upper and lower beads

Air flow through valve requiresabout 140 PSI air pressure drop toinsure sufficient flow on difficulttires.

Lift tire up toassist seal ontop side

Table top jets

Usually last to "pop" is top side

Requires visual confirmation of bead seat

Do not stand overtire during inflation.

Do not stand overtire during inflation.

Note the gapin this area

Note 15°Bead Seat

Even SIze Wheels14.0, 15.0, 16.0,

17.0, etc.

Even Size Tires14.0, 15.0, 16.0,

17.0, etc.

Bead will notseat properly

Half Size Tires14.5, 15.5, 16.5,

17.5, etc.

Half Size Wheels14.5, 15.5, 16.5,

17.5, etc.

DANGER

MAINTENANCE INSTRUCTIONS

Read and follow all the maintenance instructionsprovided in this manual to keep the machine in goodoperating condition. Refer to the other materialsreceived with the unit and to the service bulletinsfrom the manufacturer for additional instructions onproper maintenance and service. Regularinspections and proper maintenance are essential topreventing accidents and injuries.

Before making anyinspection, adjustment, orrepair, disconnect the

power source and block out all moving parts toprevent injury.

Keep the machine and theimmediate work areaclean. Do not use

compressed air to remove dirt and debris fromthe machine. Foreign material may be propelledinto the air and into operator or bystandercausing personal injury.

Wear protective clothingand use eye protectionwhen making any

adjustments or repairs to the machine.

A. The vertical slide should be cleaned with avaporizing solvent and then lubricated withchassis grease once a month.

B. Check the adjustment of the mount/demounthead once a month. See instructions this page.

C. Check the fluid level in the table toptransmission once every 3 months. If fluidshows on dipstick, level is satisfactory. If no fluidshows, add an SAE 80 gear lubricant until fluidshows on dipstick.

D. The table top, clamps, mount/demount head,and other working surfaces should be cleanedwith a vaporizing solvent every month.

E. The clamps should be inspected and metalchips and dirt removed from the serrations witha wire brush once a month.

F. Check the tire pressure gauge function daily,and check the accuracy monthly. Use apressurized tire and a high quality stick-typepressure gauge. If necessary, adjust the dial ofthe machine gauge. If the gauge is defective,replace it immediately (part number 107985).Contact COATS at (615) 641-7533. Checkfunction of the pressure limiter weekly. Alwaysreinstall the lens after adjusting the gauge.

G. Make sure all fasteners are securely tightened.

H. Make certain that all guards and covers are inplace.

I. Check for worn, damaged or missing partsincluding grips and protective covers. Replacethem before allowing the unit to be used.

J. On a daily basis, inspect the unit and check tobe certain that al l systems are operatingnormally. Detailed inspection and testingprocedures are specif ied for variouscomponents at regular intervals. Set up a chartand assign responsibility for these items.

Replace any damaged ormissing safety decals.They are available from

COATS, (615) 641-7533.

IMPORTANT: These instructions will help youservice the unit. Instructions are for a person withsome mechanical ability and training. No attempthas been made to describe all basic steps. Forexample, how to loosen or tighten fasteners. Alsobasic procedures such as cycling systems andchecking operation of the equipment are not fullydescribed since they are known to anyone who doesmechanical and service work. Do not attempt toperform work beyond your ability or at which youhave no experience. If you need assistance, call anauthorized service center or contact COATS directly.

Mount/Demount Tool Head Adjustment

To Adjust Tool Head LiftLoosen jam nut (ref. 1) and adjust screw (ref. 2) untillift clearance is 1/8" to 3/16". Tighten jam nut andcheck.

To Adjust Lock TightnessWith lock handle unlocked, loosen jam nut (ref. 3)and adjust pin (ref. 4) until a slight firmness isobtained, then tighten jam nut and check. Alsorecheck tool head lift at this time.


Lock Plate

This will be thesame as tool head

Cam

WARNING

WARNING

CAUTION

CAUTION

Separator/Lubricator MaintenanceCheck oil and water levels regularly, and performthese maintenance items weekly:

A. Disconnect air supply to machine.

B. Drain water from the separator by unscrewingthe petcock on the bottom of bowl. Allow waterto drain and tighten petcock securely by hand.

C. Add oil to the lubricator if the fluid level is morethan 1/4” from the top of the gauge. Remove thefiller plug on top of the lubricator and add SAE10W non-detergent oil or an air tool oil to bringthe level up to 1/4” from the top of the gauge.Replace filler plug and clean up any spilled oil.

D. Adjust the oil f low by pull ing the red flowadjustment ring up and turning it to increase ordecrease the flow. Push the ring down to lock.Watch the formation of oil drops in the see-through oil chamber. Reconnect the air supplyand continually cycle the bead loosener throughfull strokes and count the drips during thecycles. The delivery of oil to the air line shouldbe about 1 drop per 10 cylinder cycles. Adjustflow as required.

Mount/Demount Head CleaningClean dirt and debris from the mount/demount tool(duckhead) roller with small screw driver or pick.

Pressure Limiter MaintenanceThe pressure limiter helps prevent inflation ofstandard size of larger tires or tubes beyond 60 PSIto minimize risk of explosion. This device is for thesafety of the operator and bystanders. Properoperation of the pressure limiter is essential to safeoperation of the machine.

Check operation of the pressure limiter as shownand described below at least monthly:

1. Remove tires and/or wheels from the machine.

2. Connect the inflation hose to an empty servicetank with a pressure gauge (gauge should read0). Use a tank with a 250 PSI pressure rating.

3. Depress inflation pedal to position 1 to start airf low through the hose and into the tank.Maintain a steady pressure for constant flow.

4. Watch the rising pressure on the tank gaugeand the gauge on the machine. Machine gaugeshould cycle between check and inflationpressures while tank gauge climbs steadily. Astank pressure reaches 60 PSI, the pressurelimiter should stop the air flow automatically.Both gauges should read 60 PSI ± 5 PSI.

5. Release inflation pedal. Check manual releasevalve function by pressing the button andreleasing pressure from the tank until it reaches50 PSI. Disconnect inflation hose, and releaseair inside tank.

6. Replace pressure limiter if it fails to cycleproperly during inflation, if it fails to shut airsupply off at 60 PSI, or if it malfunctions in anyother way. Do not operate machine with a faultypressure limiter.

Operating a tire changerwith a defective,improperly adjusted, or

by-passed pressure limiter could cause anoperator to accidentally over-pressurize a tire,resulting in a tire explosion with severe injury ordeath to the operator or bystanders. Always besure that the pressure limiter is present and isoperating properly on the machine at all times.

Never inflate tire abovem a n u f a c t u r e r ’ srecommended pressure

after bead is seated. Pressure limiter is set at 60PSI. Any required inflation above 60 PSI shouldbe performed in an inflation chamber/safetycage or securely mounted on the vehicle if aninflation chamber is not available. A tireexplosion may cause personal injury or death tooperator or bystanders may occur.


DrainPetcock

Air In Air Out

Oil FillOil FlowAdjust

Lubr

icat

or

Sep

arat

or

250 PSI Tankwith Gauge

Watch Pressureon Both Gauges

Tire ChangerInflation HoseConnected to Tank

DANGER

DANGER

INSTALLATION INSTRUCTIONS

Proper unit installation isnecessary for safe useand efficient operation.

Proper installation also helps protect the unitfrom damage and makes service easier. Alwaysplace safety poster and instructions near theunit.

LocationSelect a location using the drawings below. Thearea should provide the operator with enough spaceto use the equipment in a safe manner. The areaselected should be well lit, easy to clean and shouldbe away from oil, grease, brake lathe chips, etc.Avoid areas where bystanders and customers maybe present.

Workspace Requirements

Air SourceThe 5060A/AX all-air models require a 14 to 15 CFMair source at 150 PSI. The 5060E/EX air/electricmodels require a 5 CFM air source at 150 PSI. Thesafe operating pressure range for all models isbetween 110 PSI and 175 PSI at the machine.

The unit is furnished with a 1/4" pipe thread malefitting for easy connection. This connection islocated on the right side of the rear of the machine.A 1/4" ID hose (or pipe) for connection to themachine is satisfactory. Sufficient air pressureassures good performance.

Electrical SourceThe 5060E/EX models require power from a 15 ampelectrical circuit. Refer to the serial tag located onthe lower part of the machine for specific electricalrequirements for the unit. Have a licensed electricaltechnician perform any necessary changes to thepower source before plugging in the unit. Theelectrical source must have a solid connection (lessthan 1 ohm) between ground and building ground.

Floor MountingThe machine should be securely bolted to the floorwith suitable anchors using the hole at each cornerof the machine base.


86"

66" 66"

CAUTION

Notes


8182883 12/96 © Copyright 1995, 2001 Hennessy Industries and COATS® All Rights Reserved Printed in USA

FAILURE TO READ AND FOLLOW ALL WARN-

INGS AND INSTRUCTIONS IN THIS MANUAL

CAN LEAD TO SERIOUS PERSONAL INJURY OR

DEATH TO OPERATOR OR BYSTANDER.

THE OWNER IS RESPONSIBLE FOR MAINTAIN-ING THE OPERATION INSTRUCTIONS ANDDECALS FOR OPERATOR REFERENCE. FORADDITIONAL COPIES, CONTACT THE COATS®

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

TIRE FAILURE UNDER PRESSURE IS HAZ-

ARDOUS! This tire changer Will Not Restrain

Exploding Tires, rims or other related equipment.

TIRES CAN EXPLODE, ESPECIALLY IF INFLATED

BEYOND SPECIFIED LIMITS. DO NOT EXCEED

TIRE MANUFACTURERS RECOMMENDED AIR

PRESSURE.

AN EXPLODING TIRE, RIM, OR BEAD SEATING

EQUIPMENT MAY PROPEL UPWARD AND OUT-

WARD WITH SUFFICIENT ENERGY TO CAUSE

SERIOUS INJURY OR DEATH TO OPERATOR

AND/OR BYSTANDERS.

DANGER

READ…Mounting and inflating thewrong size tire can getyou hurt. Read the size onthe tire and make sure itmatches the rim. Be espe-cially careful about puttinga smaller tire on a largerrim, such as a 16-inch tireon a 16.5-inch rim.

Inflation of a mismatchedtire and rim can cause anexplosion.

INSPECT…Before you put any tire ona rim, inspect the rim forrust, tough spots, bentedges, or cracks thatcould prevent the tire fromseating right. If you spotany of these problems,don’t mount the tire untilthe rim has been checkedby your shop foreman.

Inspect the tire for beaddamage.

MOUNT…Once you’ve made sure the tire is OKand the right size and the rim is OK,mount the tire safely. NEVER, everlean over the tire when you’re inflatingit. If a tire does explode, it will gostraight up. You don’t want to be overthe tire if that happens. Also, neverover-inflate the tire, even if the beaddoesn’t seat. Never inflate over 40PSI. If the tire hasn’t seated, some-thing is wrong. Deflate the tire andcheck it and the rim again. If it doesn’twork the second time, try another tire.

1. Damaged Beador Beads.

2. Rusty Wheels.(particularly in thebead seat area)

3. Bent orCrackedWheels.

4 A. Mismatched.(A mis-match of a 16-inch tire to a 16.5-inch rim causing anexplosion)

4 B. Mismatched.(16.5-inch tire on a16-inch rim)

5. Walk-In Tireand Rim.

6. Back Injuries.

7. Hand or FingerInjuries.

(Hands or fingers tooclose to inflating tireor bead seats whichmay cause injury.)

8. Standing Clear.(Never put any part ofyour body over thetire changer duringinflation.)

9. Beads will notSeat at 40 PSI.

10. ImproperInflation.

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

BE CAREFUL OF THESE SITUATIONS:

ONE WORD FOR SAFETY

R.I.M.READ INSPECT MOUNT

Documents

5060 A/E 5060 AX/EX - Automotive Equipment Service co