KATOOL KT-830 Tire Changer

Installation, Operation and Maintenance User's Manual

Model: KT-830

Website: ITSK.COM

Important Safety Instructions

Read Before Operating Unit:

Overview

1.1 Important Note

Thank you for your purchase and use of this product. Please read and follow the safety instructions. Keep them readily available for machine operators.

Service and maintain the unit only with authorized or approved replacement parts.

1.2 Qualified Users

Make certain all operators are properly trained, know how to safely and correctly operate the unit, and are properly supervised.

Electrical appliances must be operated by a qualified electrician.

Do not attempt to operate this equipment if you have never been trained on basic tire service and mounting/dismounting procedures.

1.3 Notes

Equipment Description

2.1 Product Introduction

This semi-automatic swing arm tire changer is convenient and quick for disassembling and installing wheels from 10" to 28". It handles tire widths from 110-380mm and tire diameters up to 1040mm.

2.2 Technical Parameters

Special Points Technical Parameters
Outer rim 10" - 22"
Inner rim 12" - 24"
Maximum tire diameter 1040mm (41")
Maximum tire width 380mm (15")
Pressing force (10bar) 5510 lbs. (2500kg)
Operating air pressure 8bar - 10bar (116 - 145psi)
Maximum charge pressure 3.5bar (50psi)
Power supply voltage 120V 1ph / 220V 3ph
Motor power 1.1kw / 0.75kw / 1.5kw
Outline dimension 1120 × 750 × 860
Net weight 485 lbs. (220kg)
Working state noise <70dB(A)

2.3 Transportation

Handling of the machine must be performed only with an appropriate lifting device such as a forklift or pallet jack. Only personnel who are experienced and qualified on material handling procedures should handle any transportation or moving of the machine.

2.4 Figure and Part Name

Diagram showing the packed dimensions of the tire changer unit, with labels for 1120mm, 900mm, and 750mm.

Part Identification:

Diagram illustrating the main components of the tire changer with labels corresponding to the part names listed above.

Installation and Commissioning Instructions

3.1 Installation Preparation

3.1.1 Installation Location

Diagrams illustrating recommended installation space and dimensions for the tire changer.

3.1.2 Installation Equipment and Tools

List of required installation equipment and tools.

3.1.3 Inspection Products

The shipment should be thoroughly inspected upon receipt. The signed Bill of Lading acknowledges receipt by the shipping carrier. If any goods are missing or damaged, do not accept them until the shipping carrier notes the issue on the freight bill. This is for your protection.

3.1.4 Unpacking

Illustration of the tire changer unit in its packaging box.

3.2 Precautions During Installation

3.3 Main Installation Procedure

3.3.1 Standard Configuration Installation

  1. First step: Unscrew wooden pallet fixing screws. Place the tire changer at the installation site, ensuring it conforms to requirements.
  2. Second step: Unscrew the bolts from the box. Install the column in the machine box at the specified position and tighten the bolts.
  3. Third step: Fix the inflation box on the left side of the tower with the box.
  4. Fourth step: Fix the turbo blast at the back of the machine box.

Images depicting installation steps: securing the inflation box, and attaching the turbo blast.

3.4 Check the Project Table After Installation

No. Inspection Item Yes No Remarks
1 Whether the power supply voltage is consistent with the requirements of the equipment
2 Whether the components are installed correctly
3 Whether the bolts, screws, nuts are tightened

Note: Please fill in the inspection item list after the installation is finished.

3.5 Commissioning and Debugging

3.5.1 Commissioning

3.5.2 Debugging

  1. Step 1: Turn on the power and gas supply. Depress the Turntable Rotation pedal; the turntable should rotate clockwise. Raise the Turntable Rotation pedal; the turntable should rotate anti-clockwise. (If the turntable rotates in the opposite direction, exchange the position of the two lines in the three-phase plug.)
  2. Second step: Depress the Bead Breaker Pedal to start the Bead Breaker device. When the pedal is released, the Bead Breaker device should return to its original position.
  3. Third step: Depress the Jaw Clamp Pedal to open the 4 clamps. Release the Jaw Clamp Pedal; the Jaw Clamps return to the original position.
  4. Fourth step: Swing Arm / Vertical Shaft / Mount-Demount Head Assembly.

Operation

4.1 Operating Notes

4.2 Disassemble Operation Process

4.2.1 Bead Loosening

Diagram of "WHEEL CONFIGURATION" showing Narrow Side, Drop Center, Wide Side.

4.2.2 Wheel Clamping

Use the Wheel Clamp Foot Pedal to move the clamps inward (pedal down) or outward (pedal up).

4.2.3 Tire Mounting

Diagrams illustrating the correct clearance (1/8" to 3/16" and 1/8" to 1/4") between the mount/demount head roller and the rim edge.

NOTE: This clearance will be maintained as long as the vertical shaft remains locked. The operator may swing the arm out of the way and back into place again without needing to reposition the head when changing a like set of wheels. The tool clearance may change with machine use and should be inspected often.

CUSTOM AND SPECIAL WHEELS

If a custom wheel is damaged while demounting, stop and avoid damaging other wheels. Continue only when the cause is identified and corrected.

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. If you attempt to mount/demount this type of wheel, use extreme caution.

Diagram illustrating an alloy wheel with "No Drop Center", highlighting the absence of a drop center.

4.2.4 Demount Tube Type Tires

REMEMBER: Table top rotation can be stopped at any time by removing your foot from the rotation pedal. Normal table top rotation for demounting is clockwise. Depress the table top pedal to rotate in this direction. To rotate the table top counter-clockwise, lift the pedal.

4.3 Mounting

WARNING: The rim and bead must be liberally lubricated. Failure to use adequate lubricant can lead to bead binding on the rim and damage to the motor or void the warranty.

WARNING: The information in this section must be read and followed carefully to prevent accidents.

WARNING: Check tire and wheel carefully before mounting. Make sure the tire bead diameter and wheel diameter match exactly. Consult the rubber manufacturer's association for approved rim widths for tire sizes.

WARNING: Attempts to force a bead seat on mismatched tires and wheels can cause the tire to violently explode, leading to serious personal injury or death.

WARNING: Never mount a tire and wheel handed to you by anyone without checking both tire and wheel for damage and compatibility. Be extra cautious of mismatched tires. Never mount a damaged tire. Never mount a tire on a rusty or damaged wheel. Damaged tires and/or wheels can cause the tire to violently explode, leading to serious personal injury or death.

NOTE: Low profile tires may require use of the bead assist tower.

NOTE: The following procedures show the assist tower being used; the tire changer you are using may not have the assist tower installed.

WARNING: Do not force the tire onto the rim. Bead damage could result, making the tire unsafe and/or creating the risk of injury.

Mounting Tube Type Tires

Inflation

Review the following descriptions and diagrams carefully. Refer to them as necessary during wheel restraint, bead sealing, bead seating, and inflation to verify that you are proceeding properly and safely.

WARNING: Check inflation gauge for proper operation. Accurate pressure readings are important to safe tire inflation. Refer to the operating maintenance section for instructions. If the rim has been clamped from the outside for tire mounting, release the clamps once bead seal is obtained, lift the tire, and move the clamps to the center.

The clip-on air chuck on the end of the inflation hose and all inflation-related components should be checked weekly for proper operation. Do not use this machine for tire inflation if any parts are damaged or appear not in proper working order.

WARNING: Tire failure under pressure is hazardous. This tire changer is not intended to be a safety device to contain exploding tires, tubes, wheels, or bead sealing equipment. Inspect tire and wheel carefully for match, wear, or defects before mounting. Always

Diagram illustrating the tire inflation process, showing a tire connected to an air fill hose.

WARNING: Check the function of the pressure limiter regularly. 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 only be inflated in a safety cage.

Image showing the pressure gauge and pressure relief valve.

Stage of Inflation

WARNING: This machine is not intended to be a restraining device for exploding tires, tubes, or rims. Keep hands and body clear at all times and as far back as possible during inflation. Do not lean over the tire while inflating. An exploding tire, rim, or other wheel component can cause death to the operator.

WARNING: This object is a restraint device only. It will not protect operators in the event of catastrophic tire/wheel rupture or failure. Always use extreme caution during the inflation procedure. As an added safety precaution, safety cages that conform to OSHA standard 1910.177 are recommended.

Bead Sealing

Images showing the Turbo Blast Nozzle in 'Closed' and 'Open' states, with arrows indicating operation.

WARNING: To seal low profile or difficult beads, use the turbo nozzle. Never point the nozzle towards yourself or other persons. Inspect the nozzle, tire, and wheel for debris. The nozzle must be pointed toward the tire bead area. Hold the nozzle securely with both hands at all times. Never operate the nozzle without a tire and wheel positioned on the table.

Position the Turbo Blast Nozzle to direct air towards the rim center, just under the rim lip.

Image showing the Turbo Blast Nozzle positioned to direct air towards the rim center.

Bead Seating

Bead seating usually occurs on the long-tapered side of the wheel first and the shorter side last. Bead seating typically requires at least 7 PSI in the tire. 40 PSI is the maximum safe pressure at this stage, regardless of tire operating pressure. Most European import cars and many aftermarket alloy wheels are very tight and can be difficult to bead seat. Asymmetrical hump and run-flat tires are extremely difficult to bead seat. Follow the tire manufacturer's recommended procedure for bead seating.

WARNING: Operators should keep hands, arms, and entire body away from the tire during bead seat and inflation procedures. Do not stand over the tire, as personal injury could result from inflating the tire.

WARNING: Never attempt to mount and inflate mismatched tires and wheels. Mismatched tire and wheel combinations can explode, causing personal injury or death to the operator and bystanders.

WARNING: Check tire pressure frequently. Never exceed 40 PSI while seating beads. Once seated, never exceed the tire manufacturer's recommended air pressure. Tires can explode, especially if inflated beyond their limits. At all pressure levels when inflating through the valve stem, keep hands, arms, and entire body away from the inflating tire. An exploding tire, wheel, or bead sealing equipment may propel upward and outward with sufficient force to cause injury or death.

Stage Four / Tire Inflation

WARNING: Check tire pressure frequently. Never exceed 40 PSI while seating beads. Once seated, never exceed tire manufacturer's recommended air pressure. Tires can explode, especially if inflated beyond their limits. At all pressure levels when inflating through the valve stem, keep hands, arms, and entire body away from inflating tire. An exploding tire, wheel, or bead sealing equipment may propel.

Image of a safety cage used for tire inflation.

NOTE: 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 hose must have enough length between the chuck and the operation/in-line valve to allow the technician to operate safely.

BEFORE MAKING ANY INSPECTION, ADJUSTMENT, OR REPAIR: Disconnect the power source and/or air supply and block out all moving parts to prevent injury.

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

Maintenance

WARNING: Wear protective clothing and use eye protection when making any adjustments or repairs to the machine.

5.1.1 Maintenance

5.1.2 Tending

As shown in Figure 15-c, if machine horsepower is insufficient, check the triangle belt of the motor. Before any operation, cut off power. First, unscrew the 4 screws on the side of the box and remove the left side protective plate. Second, use the special adjustment screw X (Figure 15-c) in the motor support base to adjust the triangle belt.

As shown in Figure 15-d, if the lock (I) is not good or cannot be stopped at the top by 2mm, adjust the nut on the operating arm.

As shown in Figure 15-e, when cleaning or replacing the silencer that controls the opening or closure of the clamps (G), follow these steps: first, unscrew the 4 screws on the side of the box and remove the left side protective plate. Second, in the pedal (V1, V2) system controlling clamp opening/closure, unscrew the silencer. Clean with a compressed air nozzle; if damaged, replace with the same parts.

Figures 15-a, 15-c, 15-d, 15-e showing maintenance details.

5.2 Storage and Scrap

5.2.1 Storage

If the machine is to be stored for a long time, disconnect all energy supply and lubricate the skidway of the clamps on the turntable to prevent oxidation.

5.2.2 Scrap

In accordance with the law of metal and nonmetal for scrap processing, release the oil inside the machine in the specified place.

Fault Causes and Solutions

Note: If you cannot solve the failure, please contact the manufacturer for assistance. Provide relevant fault information and fault pictures so the manufacturer can resolve the issue quickly.

Failure Phenomenon Failure Cause Resolvent
Unidirectional rotation of the turntable Universal steering switch damage Replace universal steering switch
Triangle damage Replace triangle belt
Rotary table does not rotate Universal steering switch damage Replace universal steering switch
Motor fault or line fault Check motor and external plug or socket
Rotary clamp opening / closing speed is slow Muffler blockage Clean or replace muffler
Clamps have trouble Replace clamps
The turntable can't lock the rim correctly Rotary cylinder has trouble Replace cylinder or repair cylinder sealing ring
Working head can touch the rim Lock plate adjustment is not correct or faulty Adjust or replace the locking plate (Figure 18/d)
Working head screw loose Tighten screws (Figure 12/a)
The pedal is not located at work position. Return spring has trouble Replace return spring
Operating difficulties of the tire device Muffler blockage To clean or replace the silencer (Figure 18/f)
Cylinder sealing ring damage of pressure device Replace sealing ring

Parts List and Exploded Drawings

Exploded view diagram of the tire changer, with numbered parts corresponding to the parts list below.

Part Number Description
1 88013000 Box Weld
2 620+310A Tower Weld
3 6206000 Turntable ASSY
4 6207000 Gear Box ASSY
5 8808000 Pedals ASSY
6 8805100 Φ200 Aluminum Cylinder Unit
7 8805200 Φ200 Aluminum Cylinder piston
8 5804000 Universal Blade Weld
9 620B420 Bead Breaker Weld
10 210 210 Helper Arm ASSY
11 310 310 Helper Arm ASSY
12 5704200 Inflation Box Unit
13 8803000 Horizontal Arm Unit
14 580A111 Side Cover
15 5621012 Bead Breaker Pad
16 8801013 Soap Bucket
17 8802008 Hand Wheel
18 8803007 Column Limit Rod
19 5622500 Hexagon Shaft Unit
20 62013404 Bead Breaker Blade Arm
21 301300 Air Drier Unit

Limited Warranty

Lenox® Wheel Service Equipment is warranted for a period of one year on all operating components to be free of defects in material and workmanship. Lenox® shall repair or replace, at their option, those parts returned to the factory freight prepaid which prove upon inspection to be defective. Lenox® will pay labor costs for the first 12 months only on parts returned as previously described. These warranties do not extend to defects caused by ordinary wear, abuse, misuse, shipping damage, improper installation, or lack of required maintenance. This warranty is exclusive and in lieu of all other warranties expressed or implied. In no event shall Lenox® be liable for special, consequential, or incidental damages for the breach or delay in performance of the warranty. Lenox® reserves the right to make design changes or add improvements to its product line without incurring any obligation to make such changes on product sold previously. Warranty adjustments within the above stated policies are based on the model and serial number of the equipment. This data must be furnished with all warranty claims.

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