KATOOL KT-830 Tire Changer

Product Overview

This document provides detailed instructions for the installation, operation, and maintenance of the KATOOL KT-830 semi-automatic swing arm tire changer. It is designed for efficient and safe tire mounting and demounting.

Important Safety Instructions

FAILURE TO OPERATE THIS EQUIPMENT AS DIRECTED MAY CAUSE INJURY OR DEATH. READ THIS ENTIRE MANUAL PRIOR TO INSTALLATION AND OPERATION. BY USING THIS PRODUCT, YOU AGREE THAT YOU FULLY UNDERSTAND AND COMPREHEND THE FULL CONTENTS OF THIS MANUAL. MAKE SURE ALL OPERATORS READ AND UNDERSTAND.

• Do not operate until all dangers, warnings, and cautions in this manual are understood.
• Follow all installation instructions.
• Carefully check the unit for correct initial function.
• Keep safety instructions readily available for operators.
• Ensure all operators are properly trained, know how to operate safely, and are properly supervised.
• Allow unit operation only with all parts in place and operating safely.
• Inspect the unit regularly and perform maintenance as required.
• Service and maintain the unit only with authorized or approved replacement parts.
• Keep the machine away from moist, corrosive, and hot surroundings.
• Always wear safety glasses or a face shield.
• Keep guards and safety features in place and in working order.
• Wear proper protective clothing, safety toe, non-slip footwear, and hair covering. Avoid loose clothing or jewelry.
• Use extension cords with a current rating equal to or greater than the equipment's.
• Read and understand this manual before operating.
• Do not operate damaged equipment or if the power cord is cut or worn.
• Keep the work area clean and well-lighted.
• Avoid dangerous environments (damp, wet locations, rain, moisture).
• Avoid unintentional starting; ensure the tire changer is turned off before servicing.
• Disconnect the tire changer before servicing.
• Use only manufacturer's recommended accessories.
• Repair or replace damaged or worn parts immediately.
• Never overload or stand on the tire changer.
• Do not allow untrained persons to operate the machinery.
• To reduce the risk of fire, do not operate near open containers of flammable liquids.
• Ensure adequate ventilation when working on operating internal combustion engines.
• Keep body parts away from moving parts.
• Use equipment only as described in this manual and with manufacturer's recommended attachments.

Equipment Description

The KATOOL KT-830 is a semi-automatic swing arm tire changer designed for convenient and quick disassembly and installation of wheels. It handles wheel sizes from 10" to 28", tire widths from 110-380mm, and tire diameters up to 1040mm.

Technical Parameters

Transportation

Handle the machine using an appropriate lifting device like a forklift or pallet jack. Only experienced and qualified personnel should handle transportation or moving.

Figure and Part Name

The machine components are identified by letters:

• G: Wheel Clamp
• P: Tower
• U: Bead Breaker Pedal
• I: Mounting / Dismounting head
• R: Bead Breaker
• V2: Turntable Pedal
• V3: Pedal Inflatable
• Z: Bead Breaker Pad
• Y: Turntable
• N: Horizontal Pendulum arm
• K: Locking Handle
• Q: Oil Drier
• V1: Wheel Clamp Pedal
• C: Turbo Blast Hose Assembly
• E: Hand Wheel
• M: Vertical Reverse Spring

A diagram shows the overall assembly with these parts labeled.

Installation and Commissioning Instructions

Installation Preparation

Installation Location

• Ensure adequate space for safe operation.
• The area should be well-lit, easy to clean, and free from oil, grease, or brake chips. Avoid areas with bystanders.
• The installation location must meet specified dimensions to ensure normal operation and prevent restrictions on machine parts.
• The tire changer is forbidden for use in explosive gas environments.

Installation Equipment and Tools

Ensure proper fittings for air supply, as tire machines often come with Japanese-style fittings.

Inspection of Products

Thoroughly inspect the shipment upon receipt. The Bill of Lading serves as acknowledgment of receipt. If goods are missing or damaged, do not accept them until the shipping carrier notes the damage on the freight bill.

Unpacking

Check packaging for damage. Use appropriate tools for unpacking and dispose of the packaging responsibly to prevent environmental pollution. Inspect the machine for any damage or lost parts against the packing list. Contact the dealer or manufacturer immediately if issues are found. Do not use the machine if leakage is present but still installed.

Precautions during Installation

• All bolts must be tightened.
• Ensure the power cord has no broken skin, broken pipes, or other damage.

Main Installation Procedure

1. Unscrew wooden pallet fixing screws and place the tire changer at the installation site, ensuring the site meets requirements.
2. Unscrew bolts from the box, install the column in the machine box at the specified position, and tighten the bolts.
3. Fix the inflation box on the left side of the tower.
4. Fix the turbo blast at the back of the machine box.

Check the Project Table after Installation

Complete the following inspection checklist:

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

Commissioning and Debugging

Commissioning

• Before connecting power, verify the user's power supply, gas source, and machine requirements are consistent.
• The machine must be connected to a circuit with a fuse compliant with operating rules. An automatic circuit breaker of 25A is required and should be operated by professional personnel.
• The compressed air system connects via a pipe joint on the right side of the tank.

Debugging

1. Turn on power and gas supply. Depress the Turntable Rotation pedal; the turntable should rotate clockwise. Release the pedal; it should rotate counter-clockwise. If rotation is reversed, exchange the phase wires in the three-phase plug.
2. Depress the Bead Breaker Pedal to start the bead breaker device; it should return to its original position when released.
3. Depress the Jaw Clamp Pedal to open the 4 clamps; release it to return the clamps to their original position.
4. Swing Arm / Vertical Shaft / Mount-Demount Head Assembly: Raise the Vertical Shaft/Mount-demount head assembly to its highest position and lock it with the Locking Handle. Check the Socket Head Cap Screw on the Cap and tighten if necessary. Check the operation of the Vertical Shaft and Locking Handle.

Operation

Operating Notes

• Ensure air pipes are properly connected and there are no air leaks. Confirm sufficient operation space.
• Before any operation, release the gas from the tire and remove the balance block from the tire balancing device.

Disassemble Operation Process

Bead Loosening

• Deflate the tire completely by removing the valve core. Move clamps to their full inward position before bead loosening to avoid damaging the clamps or wheel.
• Pull the bead breaker blade away from the machine and position the wheel. Ensure the valve stem is at the 12 o'clock or 6 o'clock position, especially for wheels with Tire Pressure Sensors.
• Position the bead breaker blade against the tire, next to but not on the rim or sidewall. Press the breaker pedal to loosen the bead. This may require multiple locations around the tire. Use extra care on larger wheels/tires and alloy wheels.
• Turn the wheel around and repeat the procedure on the other side. The long side of the drop center should be loosened last for easier clamping.
• Determine the mounting side of the wheel, which is the narrow side of the drop center.

Wheel Clamping

• Fix the block in the left helper arm.
• Place the tire/wheel assembly on the turntable with the mounting side up.
• Use the Wheel Clamp Foot Pedal to move the clamps inward (pedal down) or outward (pedal up).

Tire Mounting

• Apply tire manufacturer's approved rubber lubricant liberally to the entire circumference of both upper and lower beads after loosening and placing the wheel on the table.
• With the wheel secured, swing the Vertical Arm into position. Use the adjusting knob to position the Mount/Demount Head over the rim edge.
• Push the Vertical Shaft down to bring the Mount/Demount Head into contact with the rim edge.
• Pull the locking handle to lock the Vertical Shaft. The Mount/Demount Head will move upward approximately 1/8 inch and backward 1/8 inch from the rim edge. The head roller should not contact the rim edge.
• Rotate the wheel using the Turntable Pedal until the valve stem is at the 3 o'clock position relative to the Mount/Demount Head.
• Insert the smooth curved end of the Bead Lifting Tool over the tab side of the Mount/Demount Head and under the top bead of the tire.
• Push the Bead Lifting Tool down and away from the wheel to lower the bead into the drop center while lifting the Table Top Pedal to rotate the turntable counter-clockwise.
• Push the Bead Lifting Tool down toward the wheel to lift the tire bead up and over the demount head tab. Hold it in position. Depress the Table Top Foot Pedal to rotate the wheel clockwise.
• Hold the Bead Lifting Tool down until the upper bead is above the rim. Continue rotating clockwise until the upper bead is demounted.
• Lubricate the lower bead again if needed.
• Insert the Bead Lifting Tool under the lower bead and push down toward the wheel to lift the bead over the Mount/Demount Head tab. Hold the tool in position.
• Depress the Table Top Pedal to rotate the wheel. The Mount/Demount Head will guide the bead over the rim edge. Continue rotation until the lower bead is demounted.

Custom and Special Wheels

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

Alloy Wheels

Some manufacturers offer wheels with little or no drop center, which may not be DOT approved. These can be damaged, and the tire could explode under pressure, causing injury or death. Use extreme caution when mounting/demounting these wheels.

Wheels with Tire Pressure Warning Sensors

After loosening both tire beads, attempt to remove the tube. Lubricate beads and rim liberally if removal is difficult.

Demounting Tube Type Tires

• After loosening beads, try to remove the tube. Lubricate beads and rim liberally if removal is difficult.
• Position the demount head and bead lifting tool carefully to avoid pinching the tube. Depress the table top pedal and rotate in short increments, stopping if the tube appears pinched.
• After the upper bead is demounted, remove the tube and then the lower bead.

Remember: Table top rotation can be stopped by removing your foot from the rotation pedal. Normal rotation for demounting is clockwise. Depress the pedal for clockwise rotation; lift the pedal for counter-clockwise rotation.

Mounting

• Inspect the wheel for damage, clean it, and remove any corrosion or residue. Do not service heavily corroded wheels.
• Inspect the tire for damage, paying close attention to the beads. Verify the tire and wheel size match.
• Lubricate both tire beads liberally with tire manufacturer's approved lubricant.
• WARNING: The rim and bead must be liberally lubricated. Failure to use adequate lubricant can lead to bead binding and damage to the rim.
• WARNING: Read and follow information carefully to prevent accidents.
• WARNING: Check tire and wheel carefully before mounting. Ensure tire bead diameter and wheel diameter match exactly. Consult the rubber manufacturer's association for approved rim widths. Forcing a bead seat on mismatched tires/wheels can cause violent explosion, leading to serious injury or death. Never mount a tire/wheel provided by someone else without checking both for damage and compatibility. Never mount a damaged tire or a tire on a rusty or damaged wheel.
• If the tire bead is damaged during mounting, stop, remove the tire, mark it as damaged, and do not mount a damaged tire.
• Place the tire over the wheel and position the Vertical Arm and Mount/Demount Head.
• Manually push the tire into the drop center of the wheel opposite the Mount/Demount Head to reduce bead tension. Depress the Table Top Pedal and rotate the wheel to mount the lower bead. Continue rotating until the lower bead is fully mounted.
• NOTE: Low profile tires may require the use of the bead assist tower.
• NOTE: The following procedures show the assist tower being used; your tire changer may not have this feature.
• Swing the Assist Tower into position and lower the Roller Arms to hold the upper bead in the drop center. The Upper Arm must be locked next to the Mount-demount Head.
• Depress the Table Top Pedal. As the turntable rotates, the Lower Arm follows the tire. Continue rotating until the bead is mounted.

Mounting Tube Type Tires

• Lubricate beads and rim liberally.
• Position the Mount/Demount Head. Mount the bottom bead first.
• Apply rubber lubricant to the tube. Insert the tube into the tire, being careful not to pinch it. Round out the tube with a small amount of air.
• Lower the Arm Rollers onto the tire.
• Round out the tube with a small amount of air and apply lubricant.
• Depress the Table Top Pedal and rotate in short increments.
• Mount the top bead.

Inflation

Review descriptions and diagrams carefully for wheel restraint, bead sealing, bead seating, and inflation.

• WARNING: Check inflation gauge for proper operation. Accurate pressure readings are vital for safe tire inflation. Refer to the operating maintenance section for instructions. If the rim was clamped from the outside for mounting, release clamps once bead seal is obtained.
• WARNING: Tire failure under pressure is hazardous. This tire changer is not a safety device for exploding tires, tubes, wheels, or bead sealing equipment. Inspect tire and wheel for match, wear, or defects before mounting.
• Position One - Tire Pressure: With the Inflation Hose attached to the tire valve and the pedal in this position, the air gauge registers tire pressure. Releasing the pedal returns it to this position.
• Tire Inflation: With the Inflation Hose attached and the pedal depressed, line pressure flows through the valve into the tire for inflation. Tire pressure is not indicated on the gauge in this position.
• WARNING: Regularly check the pressure limiter function. 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.
• The unit has a Pressure Limiter/Regulator to assist with proper tire inflation, typically limiting pressure to 60 PSI for car and light truck tires. The operator is responsible for following all instructions and controlling inflation pressure.

Stage of Inflation

WARNING: This machine is not 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. An exploding tire, rim, or wheel component can cause death.

WARNING: This object is a restraint device only and will not protect operators from catastrophic tire/wheel rupture or failure. Use extreme caution during inflation. Safety cages conforming to OSHA standard 1910.177 are recommended.

Bead Sealing

• Position the valve stem in front of the operator and connect the inflation hose after removing the valve core.
• Step on the inflation pedal to allow air to flow into the tire and seal the beads.

To Seal Low Profile or Difficult Beads, Use the Turbo Blast

• WARNING: Never point the nozzle towards yourself or others. Inspect nozzle, tire, and wheel for debris. Point the nozzle toward the tire bead area. Hold the nozzle securely with both hands at all times. Never operate the nozzle without a tire and wheel on the table.
• To open the Slide Valve, PUSH the Slide Valve forward.
• To close, PULL the Slide Valve closed.
• Position the Turbo Blast Nozzle to direct air towards the Rim Center just under the Rim Lip.
• Depress the inflation pedal and open the Turbo-Blast Valve for less than one second. The blast of air will expand the tire and seal the beads.
• Repeat steps if beads have not sealed. Wait for the air storage tank to recover. If bead seal is not achieved after several attempts, check if the valve core is removed to allow more air flow. After bead seal, remove the chuck and reinstall the valve core.

Bead Seating

Bead seating typically occurs on the long-tapered side of the wheel first, then the shorter side. It usually requires at least 7 PSI. 40 PSI is the maximum safe pressure at this stage. European import cars and many aftermarket alloy wheels can be tight and difficult to bead seat. Asymmetrical hump and run-flat tires are also difficult. Follow tire manufacturer's recommendations.

WARNING: Keep hands, arms, and body away from the tire during bead seating and inflation. Do not stand over the tire, as personal injury could result.

• Once tire pressure is indicated on the air gauge, continue injecting air in short intervals, checking pressure frequently. Stand back during bead seat. Keep hands, arms, and body away from the tire. Tire beads should move outward and 'pop' into their seat position as pressure increases. If not, investigate the problem.
• Release air pressure using the manual Pressure Relief Valve.
• WARNING: Never attempt to mount and inflate mismatched tires and wheels. Mismatched combinations can explode, causing injury or death.
• 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 if inflated beyond limits. Keep hands, arms, and body away from the tire during inflation.
• If bead seat cannot be obtained, something is wrong. Deflate the tire, inspect tire and wheel, correct any problems, re-lubricate beads, and reattempt bead seal and seat procedures. Follow all safety instructions.

Stage Four / Tire Inflation

• Ensure both beads are seated. The tire is ready for inflation.
• Replace the valve core if removed.
• Depress the Inflation Pedal to inflate the tire. DO NOT STAND OVER TIRE DURING INFLATION.
• Do not inflate the tire above the manufacturer's recommended pressure. Typical automobile tire pressure is 24-45 PSI; light truck pressure varies. Release excess pressure using the manual Pressure Relief Valve.

Maintenance

WARNING: Wear protective clothing and eye protection when making adjustments or repairs.

Maintenance

• Prohibit unauthorized personnel from maintenance operations.
• Perform maintenance according to the manual to extend service life. Neglecting maintenance can compromise operation and reliability, causing danger.
• Before any maintenance, disconnect power and gas supply, and turn off the switch. Press the pedal 3-4 times to release air pressure.
• Only professional staff should replace damaged parts with original spare parts. Unauthorized removal or replacement of safety devices is a violation of work safety regulations. The manufacturer is not responsible for damage caused by non-manufacturer parts or disassembly of safety devices.

Tending

• Regularly use diesel oil to clean the turntable and prevent dirt formation. Apply lubricating oil to the clamp skidways.
• Check oil mist level in the oil mist device. If low, unscrew oil F and add recommended oil (e.g., ESSO Febis K32, MOBIL Vacouline 1405, KLUBER32). Step the pedal 3-4 times and check for oil drops in cup F; adjust screw D if necessary.
• 20 days after the first use, re-tighten screws A and B in the clamps.
• If machine horsepower is insufficient, check the motor's triangle belt. First, cut off power, unscrew 4 screws on the side of the box, remove the left side protective plate, and then use the special adjustment screw X to adjust the belt.
• If the 'I' lock is not good or cannot stop at 2mm, adjust the nut on the operating arm.
• When cleaning or replacing the silencer controlling clamp opening/closure (G): unscrew 4 screws on the side of the box, remove the left side protective plate. Then, in the pedal (V1, V2) system, unscrew the silencer. Clean with compressed air; replace if damaged.

Storage and Scrap

Storage

For long-term storage, disconnect all energy supplies and lubricate the clamp skidways on the turntable to prevent oxidation.

Scrap

Dispose of the machine according to metal and nonmetal scrap processing laws. Release the oil inside the machine in a specified place.

Fault Causes and Solutions

If a failure cannot be resolved, contact the manufacturer with relevant fault information and pictures for assistance.

Parts List and Exploded Drawings

Refer to the provided exploded view diagram and parts list for component identification and part numbers.

A detailed list of parts is available, including item numbers, part numbers, and descriptions such as 'Box Weld', 'Tower Weld', 'Turntable ASSY', 'Gear Box ASSY', 'Pedals ASSY', 'Aluminum Cylinder Unit', 'Aluminum Cylinder piston', 'Universal Blade Weld', 'Bead Breaker Weld', 'Helper Arm ASSY', 'Inflation Box Unit', 'Horizontal Arm Unit', 'Side Cover', 'Bead Breaker Pad', 'Soap Bucket', 'Hand Wheel', 'Column Limit Rod', 'Hexagon Shaft Unit', 'Bead Breaker Blade Arm', and 'Air Drier Unit'.

Limited Warranty

KATOOL (Lenox®) Wheel Service Equipment is warranted for one year on all operating components against defects in material and workmanship. KATOOL will repair or replace defective parts. Labor costs for the first 12 months are covered for returned parts. Warranties do not cover defects from wear, abuse, misuse, shipping damage, improper installation, or lack of maintenance. KATOOL is not liable for special, consequential, or incidental damages. KATOOL reserves the right to make design changes without obligation.