2 - HANDLING AND HOISTING COMMISSIONING...5

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1 Instructions for use I CONTENTS pae 1 - GENERAL GENERAL SAFETY REGULATIONS STANDARD SAFETY DEVICES FIELD OF USE OVERALL DIMENSIONS SPECIFICATION HANDLING AND HOISTING COMMISSIONING ANCHORING ELECTRICAL CONNECTION PNEUMATIC CONNECTION ADAPTER MOUNTING WHEEL MOUNTING CONTROLS AND COMPONENTS MANUAL RIM DISTANCE GAUGE CONTROL PANEL AND DISPLAY FUNCTIONS MENU CONTROL INDICATIONS AND USE OF THE BALANCING MACHINE DOUBLE OPERATOR PROGRAM PRESETTING OF WHEEL DIMENSIONS STANDARD WHEELS PRESETTING WITH GAUGE EXTENSION RECALCULATION OF THE UNBALANCE MEASUREMENT RESULT SETTING THE STATIC UNBALANCE TO ZERO SPLIT FUNCTION UNBALANCE OPTIMIZATION ALU AND STATIC MODES SET-UP SELF-DIAGNOSTICS SELF-CALIBRATION ERRORS INCONSISTENT UNBALANCE READINGS ROUTINE MAINTENANCE TO REPLACE THE FUSES RECOMMENDED SPARE PARTS LIST...17 I 0195 GB - 1

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3 1 - GENERAL GENERAL SAFETY REGULATIONS - The balancin machine should only be used by duly authorized and suitably trained personnel. - Do not use the machine for purposes other than those specified in the instruction manual. - The balancin should not be modified in any way whatsoever unless for those modifications explicitly carried out by the manufacturer. - Never remove the safety devices. Only specialized personnel should be allowed to carry out maintenance operations on the machine. - Do not use stron jets of compressed air for cleanin. - Use alcohol to clean plastic panels or shelves (AVOID LIQUIDS CONTAINING SOLVENTS). - Before startin the wheel balancin cycle, make sure that the wheel is securely locked on the adapter. - The machine operator should not wear clothes with flappin edes. Make sure that unauthorized personnel do not approach the balancin machine durin the work cycle. - Avoid placin objects in the base as they could impair the correct operation of the balancin machine STANDARD SAFETY DEVICES - Anti-squash safety tubes on the lift pedestal FIELD OF USE The machine is desined for balancin wheels of heavy vehicles and cars up to 200 k. It can be used within an operatin temperature rane between 0 C and +45 C. It is provided with the followin functions: ALU-M; SPLIT; Unbalance optimization; Self dianostics; Self-calibration. Motor spinner OVERALL DIMENSIONS Fi I 0195 GB - 3

4 1.4 - SPECIFICATION Sinle phase power supply V Protection class IP 54 Max. power consumption 300 W Balancin speed 72 rpm TRUCK 100 rpm CAR Cycle time for averae wheel (14 k) 6 seconds Max. measurement resolution 1 ram Position resolution ± 1.4 Averae noise level < 70dB (A) Rim-machine distance mm (385 with extension) Rim width settin rane 1.5" to 20" or 40 to 510 mm Diameter settin rane 10" to 26.5" or 265 to 665 mm Max. wheel diameter 1285 mm - Provision for settin the balancin machine in car or truck mode by pressin button ; LED lihts up when the machine set to car mode. - Unbalance display pitch Car = 1/5 (.1/0.25 Oz) When Truck = 10/50 (.25/1 Oz) is pressed, the unbalance is displayed with pitch: Car = 1 Truck = 10.1 Oz.25 Oz - Unbalance display threshold Car = 5 (.4 Oz) Truck = 50 (2 Oz) Fi HANDLING AND HOISTING N.B. NEVER HOIST THE MACHINE USING OTHER LIFTING POINTS. THE BALANCING MACHINE FITS A REMOVABLE DEVICE FOR ITS DISPLACEMENT. I 0195 GB - 4

5 3 - COMMISSIONING ANCHORING The machine can operate on any flat non resilient floor. Make sure that the machine rests only on the 3 mountin points provided (fi. 2) ELECTRICAL CONNECTION The machine is provided with net supply (AC) and cable for battery supply (12-24VDC). The supply voltae (and mains frequency) is iven on the machine nameplate. It cannot be chaned. The machine must not be started up within proper earthin (roundin). Connection to the mains should be throuh a slow actin safety switch rated at 2 A (230 V) or 4 A (115 V). See enclosed wirin diaram PNEUMATIC CONNECTION Connect the machine to the compressed air main. Do not use the machine if there is no pressure. Max. permissible inlet pressure is 10 k/cm 2 (approx. 10 Bar or 145 PSI or 1MPa). Connection is throuh the pressure limitin unit at the back of balancin machine. The pneumatic circuit is desined to ive the Lift considerable "flexibility" of movement in any position of its stroke; thanks to this the wheel position can be adjusted accordin to requirements with minimum manual effort ADAPTERS MOUNTING The wheel balancer is supplied complete with cone type adapter for fastenin wheels with central bore. Other optional adapters can be mounted: a) Remove threaded end piece A after backin off screw B. b) Mount the new adapter (see enclosed brochures) A B I 0195 GB - 5

6 4 - CONTROLS AND COMPONENTS MANUAL RIM DISTANCE GAUGE Desined for manual measurement of the distance of the point of application of the counterweiht from the machine CONTROL PANEL AND DISPLAY Fi Diital readouts, AMOUNT OF UNBALANCE on inside/ outside 3-4 Indicators, UNBALANCE POSITION on inside/outside 5 Indicators, correction mode selected 6 Indicators, selection made 7 Push button, unbalance readin < 5 (0.25 oz) 8 Push button, operator selection 9 Push buttons, selection of correction mode 10 Push button, SPLIT (resolution of unbalance) 11 Push button, FUNCTIONS MENU 12 Push button, MENU selection confirm 13 Home push button 14 Push button, car/truck selection 15 Push buttons, manual DISTANCE settin 16 Push buttons, manual DIAMETER settin 17 Push buttons, manual WIDTH settin 18 Push button, unbalance optimization control N.B.: - Only use the finers to press the push buttons. Never use the counterweiht pincers or other pointed objects. - When the beep sinal is enabled (see section FUNCTIONS MENU CONTROL), pressin of any push button is accompanied by a "beep". I 0195 GB - 6

7 FUNCTIONS MENU CONTROL on/off senale Beep acustico sinal on/off mm/inch diametro diameter mm/inch larhezza width Approssima Approximates 1/5 1/5 o.1/.25 or.1/.25 Oz per Oz vettura for car Approximates Approssima 10/50 10/50 o.25/1.0 or.25/1.0 Oz per Oz autocarro for truck CONFERMA CONFIRM CONFERMA CONFIRM CONFERMA CONFIRM CONFERMA CONFIRM CONFERMA CONFIRM Vedi capitolo autodianosi See SELF-DIAGNOSTICS chapter See SELF-CALIBRATION chapter Vedi capitolo autotaratura /oz unit of /oz unità unbal. misura squil. measurement CONFIRM CONFERMA TORNA RETURN AL TO QUADRO MEASUREMENT DI MISURA SCREEN I 0195 GB - 7

8 5 - INDICATIONS AND USE OF THE BALANCING MACHINE DOUBLE OPERATOR PROGRAM This proram allows memorizin the dimensions of two types of wheels. Thus two operators can work simultaneously on two different vehicles usin the same balancin machine. The system memorizes two prorams with the various preset dimensions. 1 - Press to select operator (1 or 2). Choice is confirmed by the panel-mounted LED: LED lit up = User Enter the dimensions (see PRESETTING OF WHEEL DIMENSIONS). 3 - Carry out the balancin normally. With call proram 1 or 2 for subsequent balancin operations without settin the dimensions aain PRESETTING OF WHEEL DIMENSIONS Standard wheels Fi. 5 lettura readin - Preset the distance "a" of the inside of the wheel from the machine. - Preset the nominal diameter marked on the tyre. - Preset the nominal width which is normally stamped on the rim or else measure the width with the calliper aue (standard accessory). I 0195 GB - 8

9 - Wheel ALU-M - Measure the dimensions accordin to the diaram iven below. Fi Gaue 1 2 for car 20 mm for truck PRESETTING: N.B.: Do not preset the outer diameter ( ) the system calculates automatically: - outer diameter ( ) = 0.8 x inner diameter ( ) PRESETTING WITH GAUGE EXTENSION The extension increases the distance measurin rane of the aue by 10 cm (fi. 6A). Proceed as follows: - Insert the extension on the distance aue. - Measure the distance as already described in the above procedures. - After readin value on the scale, return the aue to 0 and preset the value + 10 in manual mode. - Preset the diameter and width in manual mode as illustrated in fi. 5 Fi. 6A extension readin I 0195 GB - 9

5.3 - RECALCULATION OF THE UNBALANCE Press after a new measurement presettin. 5.

7 Correction on inside Correction on outside After makin a balancin spin, the unbalance values appear on the displays.

10 5.3 - RECALCULATION OF THE UNBALANCE Press after a new measurement presettin MEASUREMENT RESULT To spin the wheel, turn relative lever in the direction indicated by the arrow until the display oes out. Fi. 7 Correction on inside Correction on outside After makin a balancin spin, the unbalance values appear on the displays. Displays with LED's 3-4 lit up indicate correct anular position of the wheel for mountin the counterweihts (12 o'clock). When the beep sinal is enabled (see section FUNCTIONS MENU CONTRO), reachin of the correction position is indicated by a "beep" MINIMIZATION OF STATIC UNBALANCE Initial unbalance sx phase shift dx 50 Possible approximations (car) sx dx sx dx sx dx sx dx residual static residual static residual static residual static With conventional balancin machine Selection with minimum residual static unbalance This proram is desined to improve the quality of balancin without any mental effort, or loss of time by the operator. In fact when usin the normal commercially available weihts, with pitch of 5 in every 5 (.25 in.25 Oz) and applyin the two counterweihts which a conventional balancin machine rounds to the nearest value, there could be a residual static unbalance of up to 4. The damae of such approximation is emphasized by the fact that static unbalance is cause of most of the disturbances on the vehicle. This new function automatically indicates the optimum entity of the weihts to be applied by approximatin them in an "intellient" way accordin to their position. (Pitch 5 rams/0.25 ounce for cars, 50 rams/1 ounces for trucks. - Press to display the actual unbalance (Pitch 1 ram/0.1 ounce). - The instruments indicate "0" for unbalance less than 5 rams/0.4 for cars and 50 rams/2 ounces for trucks; to display the residual unbalance press. I 0195 GB - 10

11 SPLIT FUNCTION (unbalance spread) The SPLIT function is used to position the adhesive weihts behind the wheel spokes so that they are no loner visible. It is advisable to use this function only in the event of static unbalance or in the ALU M function. Input the wheel dimensions and start the spin. To start the SPLIT function, input the followin data: Display example prior to SPLIT function Input the number of spokes ( 3 12 ) - Move any spoke to the 12 o clock position Place the first Split unbalance in correction position Correction position Place the second Split unbalance in correction position Correction position 2 To return to normal unbalance display, press the button I 0195 GB - 11

12 UNBALANCE OPTIMIZATION - This function serves to reduce the amount of weiht to be added in order to balance the wheel. - It is suitable for static unbalance exceedin 30 in the case of cars or 300 in the case of trucks - It improves the residual eccentricity of the tyre. Perform a manual spin A) - Mark (with chalk) a reference sin on the adapter and rim. - With the aid of a tyre remover, turn the tyre on the rim by Refit the wheel with the reference sin coincidin between rim and adapter TYRE POSITION RIM POSITION - Riht display: percentae reduction. - Left display: actual static unbalance in rams which can be reduced with the rotation. - Mark the two positions, of the rim and tyre, and turn the tyre on the rim until the positions coincide in order to obtain the optimization indicated on the display. RETURN TO THE MEASUREMENT SCREEN If, before pressin button to be carried out as follows:, a spin had not already been performed, the machine will request one Perform a manual spin The procedure is resumed from point A) I 0195 GB - 12

13 ALU AND STATIC MODES From the Measurement screen, press button or to select the required type. LED displays 5 indicate the prescribed position for application of the weihts. If a spin has already been made, each time the mode is chaned, the processor automatically recalculates the unbalance values on the basis of the new settin. Fi. 8 Button DYNAMIC STATIC DYNAMIC DYNAMIC Balancin of steel or liht alloy rims by applyin clip-on weihts on the rim edes. STATIC Button ALU - 1 The STATIC mode is required for motor cycle wheels or when it is not possible to place counterweihts on both sides of the rim. ALU M ALU 1 ALU 2 ALU 3 ALU 4 ALU M Balancin of liht alloy rims with application of adhesive weihts on the rim shoulders. 12/13 mm restin surface ALU - 2 ALU - 3 Balancin of liht alloy rims with hidden application of the outer adhesive weiht. Outer weiht position is fixed. Combined application: clip-on weiht inside and hidden adhesive weiht on outside (Mercedes). Outer weiht position is the same as ALU-2. ALU - 4 Combined application: adhesive weiht outside and clip-on weiht inside. N.B.: ALU1/2/3/4 are not available for machine set to truck mode. I 0195 GB - 13

14 6.1 - SELF-DIAGNOSTICS 6 - SET-UP DISPLAY TEST - All LED's and displays should liht up in sequence. - Turn the wheel in direction of rotation. It appears: - Turn the wheel in reverse direction of rotation. It appears: - In one complete rev. of the wheel (in direction of rotation), the followin should appear once: - Test parameter END OF SELF-DIAGNOSTICS CANCEL SELF-DIAGNOSTICS IN ANY PHASE I 0195 GB - 14

15 6.2 - SELF-CALIBRATION For self-calibration of the machine, proceed as follows: - Mount any wheel on the shaft, even if not balanced; better still if of an "averae" size (see N.B.). - Preset the exact dimensions of the wheel mounted. CAUTION!! Presettin of incorrect dimensions would mean that the machine is not correctly calibrated, therefore all subsequent measurements will be incorrect until a new self-calibration is performed with the correct dimensions! - Perform a manual spin under normal conditions Perform a manual spin - Add a reference weiht on the outside in any position. Reference weiht = 100 (3.5 oz) for car 350 (12.0 oz) for truck - Shift the reference weiht from the outside to the inside keepin the position unaltered Perform a manual spin - Move the reference weiht to 12 o'clock position END OF SELF-DIAGNOSTICS CANCEL SELF-CALIBRATION IN ANY PHASE N.B.: It is hihly important not to knock the wheel durin the spins when in selfcalibration. It is advisable to perform the calibration with the balancin machine set to car mode and with a iron wheel 6" x 14" ( ± 1" ). I 0195 GB - 15

16 7 - ERRORS Various abnormal conditions can arise durin machine operation. When detected by the microprocessor, they appear on the monitor as: ERROR MEANING 1 No sinal of rotation. Could be caused by faulty position transducer or by somethin preventin the wheel from turnin. 2 Durin the measurement spins, wheel speed had dropped to below 42 r.p.m. Repeat the spin. 3 Too hih value of unbalance. 4 Direction of rotation incorrect. 7 Fault in readin of machine calibration parameters. Repeat the self-calibration. 8 Fault in writin of machine calibration parameters. Repeat the self-calibration. 9 General fault in memory of machine calibration parameters. Contact Technical Service. 11 Speed too hih durin unbalance measurin revs. 12/13/14 Difficulty in readin analo sinal. Contact Technical Service. 15/17 Analo sinal inside/outside too hih. Contact Technical Service. 16/18 Analo sinal inside/outside too low. Contact Technical Service INCONSISTENT UNBALANCE READINGS Sometimes after balancin a wheel and removin it from the balancin machine, it is found that, upon mountin the wheel on the machine aain, the wheel is not balanced. This does not depend on incorrect indication of the machine, but only on faulty mountin of the wheel on the adapter; i.e. in the two mountins, the wheel has assumed a different position with respect to the balancin machine shaft centre line. If the wheel has been mounted on the adapter with screws, it could be possible that the screws have not been correctly tihtened, i.e. crosswise one by one, or else (as often occurs) holes have been drilled on the wheel with too wide tolerances. Small errors, up to 10 rams (0.4 oz) are to be considered normal in wheels locked by a cone; the error is normally reater for wheels fastened with screws or studs. If, after balancin, the wheel is found to be still out-of-balance when refitted on the vehicle, this could be due to the unbalance of the car brake drum or very often due to the holes for the screws on the rim and drum sometimes drilled with too wide tolerances. In such case a readjustment could be advisable usin the balancin machine with the wheel mounted. 8 - ROUTINE MAINTENANCE Before carryin out any operation, disconnect the machine from the mains TO REPLACE THE FUSES On the power board access to the power supply cable on the computer board on which the fuses are installed. If the fuses need replacement, use ones of the same current ratin (2A). If the fault persists, contact the Technical Service Department. NONE OF THE OTHER MACHINE PARTS REQUIRE MAINTENANCE. I 0195 GB - 16

17 9 - RECOMMENDED SPARE PARTS LIST (For references, see exploded drawins) CODE DESCRIPTION Bearin Z dia. 40/80/18 67M38954E Position pick-up board with cable Sprin, rim distance aue 05PR38749 LEXAN panel A Two-pole Switch 86SC M40387D Computer board Supply board x20-2A fuse Piston T DUOP Supply 230 V AC I 0195 GB - 17

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Instructions for use I 0375 GB - 1

Instructions for use I 0375 GB - 1 Instructions for use I INDEX pae 1 - GENERAL...3 1.1 - GENERAL SAFETY REGULATIONS...3 1.1.1 - STANDARD SAFETY DEVICES...3 1.2 - FIELD OF APPLICATION...3 1.3 - OVERALL DIMENSIONS...3 1.4 - TECHNICAL DATA...4