Robo-Assist Accessory - PDF Free Download

Robo-Assist Accessory Kit 85607617 For use with BaseLine by COATS Tire Changers This is a supplement to your operating manual and covers the installation and use of the Robo-Assist accessory. If you do not have your original operating manual, please call BaseLine by Coats at 1-800-688-6359 to request an additional copy. Installation Instructions Operating Instructions with Parts Identification 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. 1601 J. P. Hennessy Drive, LaVergne, TN USA 37086-3565 615/641-7533 800/688/6359 www.baselinebycoats.com Manual Part No.: 85607624 01 HENNESSY INDUSTRIES INC. Manufacturer of AMMCO, COATS, BaseLine and BADA Automotive Service Equipment and Tools. Revision: 02/12

Installation Instructions 1. Before beginning any work, clear the area and position the machine for easy access. Disconnect all power sources, both air and electricity inputs. Allow any stored air in the reservoir to escape by depressing the inflate valve. 4. Next, remove nut on the bolt supporting the swing arm pivot system. With the new 14-inch (356 mm) long bolt push the old bolt out. Make sure the small washer is on the head of the new bolt. Pivot Pin Spacer Figure 1 - Disconnect power and air sources. 2. Verify the stored air pressure is zero by completely depressing the inflation foot valve located on the side of the machine. Next with a 9/16-inch wrench remove the safety valve (reserve for later use). Safety Valve Figure 4 - Use new long bolt to push old bolt out. 5. Next, install the large spacer, the swing arm (note position of the decal) with pivot pin spacer, swing arm sleeve, large washer and the lock nut. Next, using large wrenches, tighten the assembly to 240 ft. pounds torque (very tight). If the swing arm rotation is too tight, loosen the lock nut until the swing arm assembly rotates with a slight amount of resistance. Figure 2 - Remove safety valve. 3. Install the manifold; then assemble the safety valve (reserved) and barbed hose fitting onto the manifold. Tighten until the barbed fitting is positioned as shown in photo. Safety Valve Figure 5 - Tighten swing arm to rotate with some resistance. Manifold Barbed Fitting Figure 3 - Install manifold, safety valve and barbed fitting. 2 Tire Changers

6. Locate arm with valve assembly, install the 10 1/2- inch (267 mm) long bolt with head through the bottom side, slide pivot pin over bolt and attach nut with only one turn. 8. Next, using large wrenches, tighten the assembly to 240 ft. pound torque (very tight). Again, even though the bolt is very tight, the assembly should be free to rotate. Figure 8 - Tighten the swing arm bolt. Figure 6 - Locate and position arm with cylinder. 7. Slide the cylinder arm pivot pin through the swing arm bushing, hold in position, remove nut and place washer over bolt threads and assemble nut to bolt. 9. Slide the cylinder through the cylinder arm bushing, aligning the cylinder for set screw installation. Tighten the set screw. Set Screw Figure 9 - Slide cylinder through cylinder arm bushing. 10. Install the external snap ring. Figure 7 - Hold swing arm in position to install nut to bolt Figure 10 - Install external snap ring. Tire Changers 3

11. Grease the steel ball and place it in the bottom of the assist tool. 14. Attach hose clamps to arms. Next, unwrap the hose from valve, guide through hose clamps; and, with the hose pushed over the barbed fitting, tighten hose clamps by pulling clamp tabs off. Route and Connect Hose C C Figure 11 - Place greased ball in bottom of assist tool. 12. Next, install the assist tool onto the cylinder shaft using the roll pin. Roll Pin Figure 14 - Route hose and tighten hose clamps. 15. Next, reconnect the air pressure source and check for leaks. Cycle the cylinder on the Robo-Assist several times to make sure cylinder operates correctly (valve up for cylinder up - valve down for cylinder down). Figure 12 - Install assist tool onto cylinder shaft. 13. Connect 1/8-inch nylon tubes from robo cylinder to cylinder arm valve fittings, as shown in figure 13. Attach cable tie around tubes to bottom cylinder fitting. A Nylon Tube Use Cable Tie To Nest Tubing Nylon Tube B B A Figure 13 - Connect nylon tubes. 4 Tire Changers

Operating Instructions (with Robo-Assist ) This unit must be properly operated and properly maintained to help avoid accidents that could damage the unit and injure the operator or bystanders. This section of the Operating Instructions manual review basic operations and use of controls. These instructions should be reviewed with all employees before they are allowed to work with the machine. Keep these instructions near the machine for easy reference. Bead Loosening and Demounting CAUTION This machine may operate differently from machines you have previously operated. Practice with a regular steel wheel and tire combination to familiarize yourself with the machine s operation and function. A. 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 combination mount/demount head contacting the rim causing scratches. On alloy wheels, always rotate the wheel one turn after setting the Duckhead to insure proper wheel chucking. B. Always review with the owner any nicks and scratches on expensive wheel and tire combinations prior to servicing. CAUTION 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 1 - Remove Valve Core to Deflate Tire CAUTION Tires are always installed and removed from the rim s narrow side. D. Always loosen the bead on the narrow side of the wheel s drop center first (tire removed in figure 2 for clarity). Drop Center Figure 2 - Determine Narrow Side of Wheel Narrow Side Long Side E. The clamps on the table top may extend beyond the table top itself. To avoid damaging the clamps, move them to their full inward position before positioning a tire for bead loosening. F. 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. Tire Changers 5

2. Pull 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. Press the bead loosener foot pedal to actuate the shoe and loosen the bead. It may be necessary to loosen the bead in multiple locations around the tire (figure 3). 4. Apply tire manufacturer s approved rubber lubricant liberally to entire circumference of both tire beads after loosening (figure 5). Valve Stem Figure 5 - Apply Rubber Lubricant to Tire Beads Figure 3 - Position Tire and Bead Loosener Shoe 3. Turn the wheel around and repeat loosening procedure 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. 6. Place tire/wheel assembly on table top with mounting side up (figure 6). Use the clamp control pedal to move the clamps inward (push pedal down) or outward (toggle pedal up). Clamp steel wheels from the inside (clamps push outward against wheel). Clamp mag and custom wheels from the outside (clamps push inward against the outside rim edge). Figure 4 - Position Tire and Bead Loosener Shoe With Wheel Turned Around Figure 6 - Place Tire/Wheel Assembly on Table top G. It will be easier to outside clamp the wheel to the table top if the long side of the rim is loosened last. 6 Tire Changers

5. Depress the tire sidewall downward with the aid of the assist foot providing clearance for the mount/ demount head to be positioned (figure 7). Move swing arm into place. Increase the horizontal distance between the demount head and the wheel an additional 1/16 to 1/8 inch with the adjustment knob. 8. Place the assist foot opposite the demount head and push the bead into drop center. Insert bead lifting tool between knob on demount tool and tire bead (Figure 10). Figure 10 - Insert Bead Lifting Tool Figure 7 - Assist Foot Depressing Sidewall of Tire 6. Lubricate upper bead liberally (Figure 8). 9. Rotate lifting tool down over wheel to lift bead up and over the knob and at the same time remove assist foot. 10. Hold lifting tool in place, depress the table top rotation pedal momentarily to jog the wheel a short distance. Check the wheel and tire to verify that operation is not causing damage. The lifting tool can usually be removed after jogging the wheel a short distance (Figure 11). Continue to jog the wheel to allow the tire sidewall to flex as it crosses the rim edge. Continue short rotations until top bead is completely demounted. Figure 8 - Lubricate Upper Bead 7. Locate the valve stem just before the demount head before proceeding (Figure 9). Valve Stem Demount Head Figure 11 - Holding Lifting Tool in Place and Rotate Wheel Figure 9 - Position Valve Stem Under Demount Head Tire Changers 7

11. Demount lower bead. Pay close attention to sensor/transmitter location, and position it just before the demount tool when starting the lower bead demount procedure (Figure 12). Sensor Mounting 1. Lubricate both tire beads liberally. Performance tires will require more lubrication than standard passenger car tires. 2. Mount the lower bead. In most cases, the lower bead will mount easily. AE: Mounting the top bead can be very difficult when mounting new tires on performance and custom wheels. Proceed slowly and cautiously. 3. Position the valve stem 90 degrees clockwise in front of the mount/demount tool for top bead mounting. Lift the bead over the rear of the mounting head. Use the assist tool to hold the bead in the drop center (Figure 14). Rotate the wheel in short steps and apply extra lubricant to mount upper bead. Figure 12 - Sensor/Transmitter Location 12. Lift and hold the tire at an angle so the lower bead is resting in the drop center directly across from the demount head, and is loose below the demount head. Insert bead lifting tool down over demount tool and below the lower bead. Lift the lower bead over the demount tool (Figure 13). Hold the lifting tool in place. Depress the table top rotation pedal momentarily to jog the wheel short distances to complete the demounting process. Valve Figure 14 - Mount Upper Bead, Use Assist 4. On extremely tight tire and wheel combinations, it may be necessary to use the bottom of the assist foot to flip the tire bead over the rim flange (Figure 15) Figure 13 - Lower Bead in Drop Center Figure 15 - Assist Foot to Flip Bead Over Rim Flange 8 Tire Changers

Robo-Assist Maintenance A. Grease the Robo-Assist to maintain smooth rotation. Grease fittings have been provided at the pivot joints. B. Check bolt torque periodically at pivot joints. Proper Torque is 240 ft. lbs. Maintain Bolt Torque at 240 ft. lbs. Grease Fittings Tire Changers 9

Parts Identification Kit 85607617 Robo-Assist Accessory ITEM PART NO. DESCRIPTION 1 85607622 Plastic Hold Down Foot 2 905563 Roll Pin, 1/4" Dia x 1-1/2" 3 8301017 Dia. Steel Ball, 1/2" 4 7000230 Rubber Hand Grip, 1/2" 5 8183637 2" Ext. Retaining Ring 6 8181983 10-24 x 3/4 Lg. BHSCS 7 *** Robo-Assist Valve Assembly 8 85607946 Cyl Assem 2" Dia x 8-inch Stroke 9 8181996 1/4 NPT x 1/8 Tube St. Fitting 10 8106301 1/4-20 x 3/4" HWHST Screw 11 8182044 Neoprene Cushion Clamp 12 8183649 1/4-20 x 5/16" Soc Hd Set Screw 13 8184226 1/4-28 Grease Fitting 14 8182016 3/4-10 Hex Nylock Lock Nut 15 8100994 Flat Washer, 3/4" 16 8560761802 Front Arm Weldment 17 8560761901 Rear Arm Weldment 18 8181038 Swing Arm Pivot Pin 19 8183703 3/4-10 x 10-1/2 Hex HD Cap Srw 21 8182457 Flat Washer, 3/4 SAE ITEM PART NO. DESCRIPTION 25 8183635 Screw, 3/4-10 x 14, HHCS, Gr.5 32 8181997 90º Elbow 33 8184208 Pivot Pin Spacer 34 * Hose, Rubber, 1/4, 58" Black 35 * Plastic Tube, 1/8 x 6" 36 * Plastic Tube, 1/8 x 16" 37 85607633 Swing Arm Sleeve 38 Wire Tie 39 871101642 1/4 NPTM x 1/4 F Straight Fitting 40 8000378 1/4 NPT Brass Straight Fitting * Hose Reels LENGTH PART NO. DESCRIPTION 50-ft. 85000375 1/4 ID x 1/2 OD Black Rubber Hose 50-ft. 85000376 1/8 OD x 0.25 Plastic Tube 10 Tire Changers

7 45 1 46 2 47 3 48 4 49 5 Robo-Assist Assy Valve ROBO ARM ASSEMBLY VALVE ITEM PART NO. DESCRIPTION 45 8000378 Brass Straight Fitting, 1/4 NPT 46 8105615 Small Muffler 47 8185585 3 Position Valve 48 8109481 RDCR Fitting, 1/4 NPT x 1/8 NPT 49 8181997 Male Elbow, 1/8 NPT x 1/8" Tire Changers 11