Instructions for use CONTENTS

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Damian Chambers
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1 Instructions for use I CONTENTS 1 - GENERAL GENERAL SAFETY REGULATIONS STANDARD SAFETY DEVICES FIELD OF APPLICATION OVERALL DIMENSIONS (standard guard) TECHNICAL DATA HANDLING, FITTING START - UP ANCHORING ELECTRICAL CONNECTION ADAPTER MOUNTING WHEEL GUARD ASSEMBLY AND ADJUSTMENT (optional) WD/DC SPACER (optional) CONTROLS AND COMPONENTS MANUAL DISTANCE MEASUREMENT GAUGE CONTROL PANEL AND DISPLAY OPERATION FUNCTIONS MENU MANUAL DIMENSION PRESETTING STANDARD WHEELS ALUM WHEELS ALU 3M WHEELS COMBINED ALU RIMS PRESETTING WITH GAUGE EXTENSION RESULT OF MEASUREMENT RECALCULATION OF THE UNBALANCE DOUBLE OPERATOR PROGRAM SPLIT FUNCTION (HIDDEN WEIGHT) UNBALANCE OPTIMIZATION ALU AND STATIC MODES MINISTAT - AUTOMATIC MINIMIZATION OF STATIC UNBALANCE SET UP SELF-DIAGNOSTICS SELF-CALIBRATION ERRORS INCONSISTENT UNBALANCE READINGS ROUTINE MAINTENANCE TO REPLACE THE FUSES 17 I 0575 GB - 1

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3 1 - GENERAL GENERAL SAFETY REGULATIONS - The machine should only be used by authorized and suitably trained personnel. - Do not use the machine for purposes other than those specified in this manual. - The machine should not be modified in any way except for those modifications explicitly carried out by Butler. - Never remove the safety devices. Any work on the machine should only be carried out by specialist personnel. - Avoid using strong jets of compressed air for cleaning. - Use alcohol to clean the plastic panel or shelves (AVOID LIQUIDS CONTAINING SOLVENTS). - Before starting the wheel balancing cycle, make sure that the wheel is securely locked on the adapter. - The machine operator should avoid wearing clothes with flapping edges. Make sure that unauthorized personnel do not approach the machine during the work cycle. - Avoid placing objects inside the base as they could impair the correct operation of the machine STANDARD SAFETY DEVICES - Stop key that stops the motor when an emergency arises. - The wheel guard is not compulsory since the rotation speed is less than 100 min FIELD OF APPLICATION The machine is designed for balancing wheels of car, light commercial vehicles or motorcycle, weighing less than 75 Kg. It can be operated in the temperature range of 0 to + 45 C. The following functions are provided: ALUM; ALU 3M; SPLIT; Unbalance optimization; Double operator; Self diagnostics; Self calibration OVERALL DIMENSIONS (standard guard) 1 I 0575 GB - 3

4 1.4 - TECHNICAL DATA Weight with guard (excluding adapter) ~ 84 Kg. Single-phase power supply 115 / 230 V 50/60 Hz Protection class IP 54 Max.power consumption 0,8 Kw Balancing speed 100 min-1 Cycle time for average wheel (14 kg) 6-8 seconds Max.resolution of measurement 1 gram Position resolution ± 1.4 Average noise < 70dB (A) Rim-machine distance mm Rim width setting range or mm Diameter setting range or mm 2 - HANDLING, FITTING 2 2a NOTE: NEVER USE OTHER POINTS TO LIFT THE MACHINE. 3 - START - UP ANCHORING The machine can operate on only fl at non resilient fl oor. Make sure that the machine rests on the 3 mounting points provided (Fig. 2). N.B.: It is advisable to secure the system to the ground using the specific feet (see fig. 2a) in the event of continual use with wheels weighing over 35 Kg ELECTRICAL CONNECTION The machine is supplied with an electrical cable plus earth (ground). The supply voltage (and mains frequency) is given on the machine nameplate. It cannot be changed. Connection to mains should always be made by expert personnel. The machine should not be started up without proper earthing. Connection to the mains should be through a slow acting safety swich rated at 3 A (230V) or 8 A (115V). I 0575 GB - 4

5 3.3 - ADAPTER MOUNTING The wheel balancer is supplied complete with cone adapters for fi xing wheels with a central hole. Other optional adapters can be mounted: a) Remove the threaded end-piece A after unscrewing the screw B. b) Mount the new adapter (see attached sheets). 3 Note: carefully clean the coupling surfaces before performing any operation WHEEL GUARD ASSEMBLY AND ADJUSTMENT (optional) a) Fasten the components to the base as illustrated in the specifi c exploded drawing. b) N.b.: The tip of the microswitch must fi t into the relative seat when the guard is closed. Note: Do not lean on the guard during the wheel balancing cycle WD/DC SPACER (optional) When balancing very wide wheels (9 ), there is not enough space to turn the distance gauge. To move the wheel away from the machine side, fi t the WD spacer on the fl ange body and secure it with the standard issue nuts. When centring the wheel with cone from the inside, mount the DC spacer to obtain spring thrust. 3a DC WD Cone Spring 4 - CONTROLS AND COMPONENTS MANUAL DISTANCE MEASUREMENT GAUGE This gauge serves to manually measure the distance between the point of application of the counterweight and the machine. I 0575 GB - 5

6 4.2 - CONTROL PANEL AND DISPLAY Digital readouts, AMOUNT OF UNBALANCE, inside/outside 3-4 Digital readouts, POSITION OF UNBALANCE, inside/outside 5 Indicators, correction mode selected 6 Indicators, selection made 7 Push button, unbalance reading < 5 g (.25 oz) 8 Push button, operator selection 9 Push button, selection of mode of correction 10 Push button, SPLIT (unbalance spread) 11 Push button, FUNCTIONS MENU 12 Push button, menu selection confi rmation 13 Push button, cycle start 14 Push button, emergency/home 15 Manual dimension setting buttons 16 Push button, unbalance optimization Note: Only use the fi ngers to press the push buttons. Never use the counterweight pincers or other pointed objects. I 0575 GB - 6

7 OPERATION FUNCTIONS MENU diameter mm/inch width mm/inch p start from guard closing CONFIRM CONFIRM CONFIRM approximates 1-5g oz CONFIRM See SELF-DIAGNOSTICS * * * See SELF-CALIBRATION g/oz unbalance unit Calibration of automatic RIM DISTANCE gauge (see SETUP) Calibration of automatic DIAMETER gauge (see SETUP) see CHANGE OF GAUGE CHARACTERISTIC CONFIRM RETURN TO MEASUREMENT SCREEN * N.B. If such indications appear, contact Technical Service. I 0575 GB - 7

8 5 - MANUAL DIMENSION PRESETTING STANDARD WHEELS - Press until a symbol is shown. - Use the ruler to measure the distance and then set the value which has been measured. - Select by pressing - Set the nominal diameter indicated on the tyre. - Select by pressing - Set the nominal width, which is normally stamped on the rim, or proceed to measure the width with the caliper gauge (supplied as standard). N.B.: This setting is also valid for the other ALU correction modes. I 0575 GB - 8

9 5.2 - ALUM WHEELS Measure the values according to the diagram hereunder 3 4 Reading SETTING: Select the value to be set by pressing N.B.: Not setting the value of the outside diameter ( ) the system automatically measures: outside diameter ( ) = inside diameter ( ) - 1. I 0575 GB - 9

10 5.3 - ALU 3M WHEELS Measure the values according to the diagram hereunder 3 4 Reading SETTING: Select the value to be set by pressing N.B.: Not setting the value of the outside diameter ( ) the system automatically measures: outside diameter ( ) = inside diameter ( ) OTHER ALU MODES Put in the wheel data as for steel rims described in MANUAL DIMENSION PRESETTING. Make the measuring spin. Press as many times as the LEDs come on for the desired correction method. Fix the weights at the indicated positions. Make a control spin. To balance more tyres of the same type and dimension the machine automatically stores the current wheel data. I 0575 GB - 10

11 5.5 - PRESETTING WITH GAUGE EXTENSION A Extension + 60 B 60 cm mm The extension increases the distance measuring range of the gauge by 60 mm (fi g. A) and allows measuring the distance also when the rim is of special shape (fi g. B). Proceed as follows: - Insert the extension on the distance gauge. - Measure the distance as already described in the above procedures. - After reading value a on the scale, return the gauge to 0 and preset the value a + 60 in manual mode. - Preset the diameter and width in manual mode RESULT OF MEASUREMENT Inside correction Outside correction After performing a balancing spin, the amounts of unbalance are shown on the digital readouts. Digital readouts with LED s 3-4 lit up indicate the correct angular wheel position to mount the counterweights (12 o clock position). If the unbalance is less than the threshold selected, 0 is displayed instead of the unbalance; with it is possible to read the values below the threshold chosen gram by gram. N.B.: For wheel diameters less than or equal to 13 and at temperatures around 0 C, the wheel balancer automatically initiates a special measurement cycle involving two consecutive measurements. The precision of unbalance values and the reliability of the wheel balancer are unaffected. This type of operation is reset every time the wheel balancer is switched on RECALCULATION OF THE UNBALANCE Press after new setting of the measurement DOUBLE OPERATOR PROGRAM This program allows memorizing the dimensions of two types of wheels. Thus two operators can work simultaneously on two differents cars using the same balancing machine. The system memorizes two programs with various present dimensions. 1 - Press for more than 3 seconds to select the operator (1 or 2). The current USER is displayed by briefl y pressing the button. 2 - Enter the dimensions 3 - Press to carry out the balancing as usual and to store the program. Press for more than 3 seconds to select program 1 or 2 for subsequent balancing operations without setting the dimensions again. I 0575 GB - 11

12 5.9 - SPLIT FUNCTION (HIDDEN WEIGHT) The SPLIT function is used to position the adhesive weights behind the wheel spokes so that they are not visible. This function should be used only in the case of static unbalance or where the hidden adhesive weight is to be applied on the outside. Input the wheel dimensions and do a spin. Start the SPLIT function as follows: Example of display prior to SPLIT function - Place the wheel in the outside unbalance correction position. - Set one of the top spokes (preferably the one to the left of the unbalance) to 12 o clock. - Press the button - Follow the UP/DOWN indication of the positioning LEDs and set the second top spoke to 12 o clock. - Press button Set the fi rst split unbalance to correction position Correction position Set the second split unbalance to correction position Correction position 2 N.B.: If error 24 is displayed, repeat the SPLIT function ensuring that the minimum distance between the spokes is greater than 18 degrees. If error 25 is displayed,repeat the split function ensuring that the maximum distance between the spikes is smaller than 120 degrees. To return to normal unbalance display, press any button. To carry out a new spin, press the button. I 0575 GB - 12

13 UNBALANCE OPTIMIZATION - This function serves to reduce the amount of weight to be added in order to balance the wheel - It is suitable for static unbalance exceeding 30g. - It improves the residual eccentricity of the tyre. No previous unbalance measurement Unbalance already measured unbalance measurement - Mark with chalk a reference point on the adapter and rim - With the aid of a tyre remover, turn the rim on the tyre by Refi t the wheel with the reference mark coinciding between rim and adapter - RH display: percentage reduction - LH display: actual static unbalance which can be reduced by rotation TYRE POSITION - Mark the two positions of the rim and tyre, and turn the rim on the tyre until the positions correspond in order to obtain the optimization on the display RIM POSITION CANCEL OPTIMISATION IN ANY PHASE. I 0575 GB - 13

14 ALU AND STATIC MODES From the measurement screen, press or button to select the type required. The 5-LED displays show the position where to apply the weights. If a spin has already been performed, the processor automatically recalculates, for each change of mode, the amounts of unbalance according to the new calculation. Button DYNAMIC Balancing of steel or light alloy rims with application of clip-on weights on the rim edges. Button STATIC The static mode is necessary for motorcycle wheels or when it is not possible to place the counterweights on both sides of the rim. ALU M Balancing of light alloy rims with application of adhesive weights on the rim shoulders. ALU 3M Combined application: clip-on weight inside and hidden adhesive weight on outside (Mercedes). Combined application of alloy rims with application of adhesive weights on the rim shoulders. Combined application: adhesive weight outside and clip-on weight inside. Combined application: adhesive weight inside and clip-on weight outside MINISTAT - AUTOMATIC MINIMIZATION OF STATIC UNBALANCE Initial unbalance sx dx g g phase shift 50 Possible approximations sx dx sx dx sx dx sx dx g g g g g g g g residual static residual static residual static residual static 4 g 3 g 1 g 6 g With conventional Choice with minimum wheel balancer static residual This program is designed to improve the quality of balancing without any mental effort or loss of time by the operator. In fact by using the normal commercially available weights, with pitch of 5 in every 5 g, and by applying the two counterweights which a conventional wheel balancer rounds to the nearest value, there could be a residual static unbalance of up to 4 g. The damage of such approximation is emphasized by the fact that static unbalance is cause of most of disturbances on the vehicle. This new function, resident in the machine, automatically indicates the optimum entity of the weights to be applied by approximating them in an intelligent way according to their position in order to minimize residual static unbalance. I 0575 GB - 14

15 6 - SET UP SELF-DIAGNOSTICS performs tests useful for maintenance staff SELF-CALIBRATION For machine self-calibration proceed as follows: - Fit a wheel with steel rim on the shaft. Example: 6 x 15 (± 1 ) - Preset the exact dimensions of the wheel mounted. CAUTION!! Presetting 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 spin under normal conditions. - Add a 60 g. sample weight (2.00 oz) on the outside in any position. - Shift the sample weight from the outside to the inside keeping the same position. - Rotate the wheel so to have the sample weight to the 12 o clock position. END OF SELF-CALIBRATION CANCEL SELF-CALIBRATION IN ANY PHASE. I 0575 GB - 15

16 7 - ERRORS During machine operation, various causes of faulty operation could occur. If detected by the microprocessor, they appear on the display as follows: ERRORS CAUSES CONTROLS Black The wheel balancer does not come on. 1. Check proper connection to the mains. 2. Check and if necessary replace the fuses on the power board. 3. Replace the computer board. Err. 1 No rotation signal. 1. Check belt tautness. 2. Check functioning of the phase generator and, in particular, the reset signal. 3. Replace the phase generator. 4. Replace the computer board. Err. 2 Too low speed during measurement. During the unbalance measurement 1. Check that a vehicle wheel has been mounted on the wheel balancer. revolutions, the wheel speed has fallen to 2. Check belt tautness. below 42 rpm. 3. Check functioning of the phase generator and, in particular, the reset signal. 4. Replace the computer board. Err. 3 Too high unbalance. 1. Check the wheel dimension setting. 2. Check the sensor connections. 3. Run the machine calibration function. 4. Mount a wheel with a more or less known unbalance (less than 100 grams) and check the machine response. 5. Replace the computer board. Err. 4 Err. 5 Err. 7 / Err. 8 / Err. 9 Err. 11 Err.14/ Err.15/ Err.16/ Err.17/ Err. 18/ Err. 19 I 0575 GB - 16 Rotation in opposite direction. After pressing [START], the wheel starts turning in the opposite direction (anticlockwise). Guard open The [START] pushbutton was pressed without fi rst closing the guard. 1. Verify the connection of the UP/DOWN - RESET signals on the phase generator. 1. Reset the error. 2. Close the guard. 3. Verify the function of the protection Switch. 4. Press the [START] button. NOVRAM parameter read error 1. Repeat machine calibration 2. Shut down the machine. 3. Wait for at least ~ 1 min. 4. Restart the machine and check proper functioning. 5. Replace the computer board. Too high speed error. The average spinning speed is greater than 240 rpm. 1. Check if there is any damage or dirt on the timing disc. 2. Check functioning of the phase generator and, in particular, the reset signal. 3. Replace the computer board. Unbalance measurement error. 1. Check functioning of the phase generator. 2. Check the sensor connections. 3. Check the machine earthing connection. 4. Mount a wheel with a more or less known unbalance (less than 100 grams) and check the machine response. 5. Replace the computer board. Err.21 Motor on for more than 15 seconds. 1. Check functioning of the phase generator. 2. Check the connections on the power board. 3. Replace the computer board. Err.22 Err. 24 Err. 25 Maximum number of spins possible for the unbalance measurement has been exceeded. Distance between the spokes smaller than 18 degrees. Distance between the spokes greater than 120 degree 1. Check that a vehicle wheel has been mounted on the wheel balancer. 2. Check belt tautness. 3. Check functioning of the phase generator and, in particular, the reset signal. 4. Replace the computer board. 1. The minimum distance between the spokes where to split the unbalance must be greater than 18 degrees 2. Repeat the SPLIT function increasing the distance between the spokes. 1. The minimum distance between the spokes where to split the unbalance must be smaller than 120 degrees 2. Repeat the SPLIT function increasing the distance between the spokes.

17 Err.32/ Err.33/ Err.34/ Err.35/ Err.36/ Err.37 Errors related to test functions of the wheel balancer. 1. Cancel the error and continue using the wheel balancer as normal INCONSISTENT UNBALANCE READINGS Sometimes after balancing a wheel and removing it from the balancing machine, it is found that, upon mounting it on the machine again, the wheel is not balanced. This does not depend on incorrect indication of the machine, but only on faulty mounting of the wheel on the adapter, i.e. in the two mountings the wheel has assumed a different position with respect to the balancing 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 tightened, 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 grams (0.4 oz) are to be considered normal in wheels locked by a cone; the error is normally greater for wheels fastened with screws or studs. If, after balancing, the wheel is found to be still out-of-balance when refi tted on the vehicle, this could be due to 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 using the balancing machine with the wheel mounted. 8 - ROUTINE MAINTENANCE Switch off the machine from the mains before carrying out any operation TO REPLACE THE FUSES Remove the weight holder shelf to gain access to the power supply board where the fuses are located (see Exploded Drawings). If fuses require replacement, use ones of the same current rating. If the fault persists, contact the Technical Service Department. NONE OF THE OTHER MACHINE PARTS REQUIRE MAINTENANCE I 0575 GB - 17

TABLE OF CONTENTS 1 - GENERAL...3

TABLE OF CONTENTS 1 - GENERAL...3 Instructions for use I TABLE OF CONTENTS Page 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