Instructions for use I 0375 GB - 1

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1 Instructions for use I INDEX pae 1 - GENERAL GENERAL SAFETY REGULATIONS STANDARD SAFETY DEVICES FIELD OF APPLICATION OVERALL DIMENSIONS TECHNICAL DATA HANDLING, HOISTING START-UP ANCHORING ELECTRICAL CONNECTION ADAPTER MOUNTING WHEEL GUARD ASSEMBLY AND ADJUSTMENT (Dw. 4 - Exploded views) CONTROLS AND COMPONENTS MANUAL RIM DISTANCE GAUGE CONTROL PANEL AND DISPLAY OPERATION FUNCTIONS MENU INDICATION AND USE OF THE WHEEL BALANCER DOUBLE OPERATOR PROGRAM PRESETTING OF WHEEL DIMENSIONS STANDARD WHEELS ALU-M WHEELS RECALCULATION OF THE UNBALANCE RESULT OF MEASUREMENT SPLIT FUNCTION UNBALANCE OPTIMIZATION ALU AND STATIC MODES AUTOMATIC MINIMIZATION OF STATIC UNBALANCE SET UP SELF-DIAGNOSTICS SELF-CALIBRATION ERRORS INCONSISTENT UNBALANCE READINGS ROUTINE MAINTENANCE TO REPLACE THE FUSES RECOMMENDED SPARE PARTS LIST...17 I 0375 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 usin stron jets of compressed air for cleanin. - Use alcohol to clean the plastic panel 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 avoid wearin clothes with flappin edes. Make sure that unauthorized personnel do not approach the machine durin the work cycle. - Avoid placin 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 emerency arises. - The wheel uard is not compulsory since the rotation speed is less than 100 min FIELD OF APPLICATION The machine is desined for balancin wheels of car, liht commercial vehicles or motorcycle, weihin less than 75 K. It can be operated in the temperature rane of 0 to +45 C. The followin functions are provided: Double operator; ALU-M;SPLIT; Unbalance optimization; Self dianostics; Self calibration OVERALL DIMENSIONS (standard uard) I 0375 GB - 3

4 1.4 - TECHNICAL DATA Weiht with uard (excludin adapter)... ~ 84 K. Sinle-phase power supply / 230 V 50/60 Hz Protection class...ip 54 Max.power consumption...0,8 Kw Balancin speed min-1 Cycle time for averae wheel (14 k) seconds Max.resolution of measurement...1 ram Position resolution...± 1.4 Averae noise...< 70dB (A) Rim-machine distance Rim width settin rane or mm Diameter settin rane or mm 2 - HANDLING, HOISTING 2 2a NOTE: NEVER USE OTHER POINTS TO HOIST THE MACHINE 3 - START - UP ANCHORING The machine can operate on only flat non resilient floor. Make sure that the machine rests on the 3 mountin points provided (Fi. 2). It is advisable to secure the system to the round usin the specific feet (see Fiure 2a) in the event of continual use with wheels weihin over 35 K ELECTRICAL CONNECTION The machine is supplied with an electrical cable plus earth (round). The supply voltae (and mains frequency) is iven on the machine nameplate. It cannot be chaned. Connection to mains should always be made by expert personnel. The machine should not be started up without proper earthin. Connection to the mains should be throuh a slow actin safety swich rated at 3 A (230V) or 8 A (115V). I 0375 GB - 4

5 3.3 - FLANGE MOUNTING The wheel balancer is supplied complete with cone flanes for fixin wheels with a central hole. Other optional flanes can be mounted: a) Remove the threaded end-piece A after unscrewin the screw B. b) Mount the new flane (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 specific exploded drawin. b) For the GP model, also refer to the GUARD ASSEMBLY SEQUENCE card at the end of the manual. c) N.b.: The tip of the microswitch must fit into the relative seat when the uard is closed. Note: Do not lean on the uard durin the wheel balancin cycle WD SPACER When balancin very wide wheels (9 ), there is not enouh space to turn the distance aue. To move the wheel away from the machine side, fit the WD spacer on the flane body and secure it with the standard issue nuts. When centrin the wheel with cone from the inside, mount the DC spacer to obtain sprin thrust. 3a 4 - CONTROLS AND COMPONENTS MANUAL DISTANCE MEASUREMENT GAUGE This aue serves to manually measure the distance between the point of application of the counterweiht and the machine. I 0375 GB - 5

6 4.2 - CONTROL PANEL AND DISPLAY START 9 FINE 11 MENU ALU USER HOME STOP USER 1 USER 2 ALUM mm Diital readouts, AMOUNT OF UNBALANCE, inside/outside 3-4 Diital readouts, POSITION OF UNBALANCE, inside/outside 5 Indicators, correction mode selected 6 Indicators, selection made 7 Push button, unbalance readin < 5 (25 oz) 8 Push button, operator selection 9 Push button, selection of mode of correction 10 Push button, SPLIT (unbalance resolution) 11 Push button, FUNCTIONS MENU 12 Push button, menu selection confirmation 13 Push button, cycle start 14 Push button, emerency/home 15 Push buttons, manual DISTANCE settin 16 Push buttons, manual DIAMETER settin 17 Push buttons, manual WIDTH settin 18 Push button, unbalance optimization Note: - Only use the finers to press the push buttons. Never use the counterweiht pincers or other pointed objects. In case of audible alarm connected (see par. OPERATION FUNCTIONS MENU), any push button operation sounds with a beep alarm. I 0375 GB - 6

7 OPERATION FUNCTIONS MENU MENU' on/off audible alarm CONFIRM diameter mm/inch CONFIRM width mm/inch p CONFIRM uard on/of CONFIRM start from uard closin CONFIRM approximates oz CONFIRM See SELF-DIAGNOSTICS See SELF-CALIBRATION HOME STOP RETURN TO MEASUREMENT SCREEN /oz unbalance unit CONFIRM I 0375 GB - 7

8 5 - INDICATION AND USE OF THE WHEEL BALANCER DOUBLE OPERATOR PROGRAM This proram allows memorizin the dimensions of two types of wheels. Thus two operators can work simultaneously on two differents cars usin the same balancin machine. The system memorizes two prorams with various present dimensions. USER 1 - Press to select operator (1 or 2). Selection is confirmed by panel-mounted Led. 2 - Enter the dimensions (see PRESETTING OF WHEEL DIMENSIONS ). 3 - Press START to carry out the balancin as usual and to store the proram. With USER proram 1 or 2 is called for subsequent balancin operations without havin to newly enter the dimensions PRESETTING OF WHEEL DIMENSIONS STANDARD WHEELS 5 Readin - Preset distance of the inside of the wheel from the machine. - Preset the nominal width which is normally stamped on the rim; if not, measure dimension with the capelier aue (supplied as standard). - Preset the nominal diameter indicated on the tyre. I 0375 GB - 8

9 - Wheel ALU-M - Measure the dimensions as shown in the followin diaram aue 1 2 PRESETTING: Note: if the outside diameter is not preset ( ) the system automatically calculates the followin: FINE outside diameter ( ) = 0.8 x inside diameter ( ) PRESETTING WITH GAUGE EXTENSION 6a Extension +6 6b cm The extension increases the distance measurin rane of the aue by 6 cm (fi. 6a) and allows measurin the distance also when the rim is of special shape (fi. 6b). Proceed as follows: - Insert the extension on the distance aue. - Measure the distance as already described in the above procedures. - After readin value a on the scale, return the aue to 0 and preset the value a + 6 in manual mode. - Preset the diameter and width in manual mode. I 0375 GB - 9

10 5.3 - RECALCULATION OF THE UNBALANCE Press HOME STOP after new settin of the measurement RESULT OF MEASUREMENT 7 Inside correction Outside correction After performin a balancin spin, the amounts of unbalance are shown on the diital readouts. Diital readouts with LED s 3-4 lit up indicate the correct anular wheel position to mount the counterweihts (12 o clock position). In case of audible alarm connected (see par. OPERATION FUNCTIONS MENU), the correction position will sound with a beep alarm. If the unbalance is less than the threshold selected, 0 is displayed instead of the unbalance; with FINE it is possible to read the values below the threshold chosen ram by ram. 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 involvin 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. If the mobile symbol should appear at the end of any balancin start operation, turn the wheel by hand until the unbalance values are displayed. I 0375 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 utilise this function only in the event of static unbalance or with ALU-M functions. 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) Place any spoke in the vertical position. - Place the first Split unbalance in correction position 1. - Correction position 1 - Place the second Split unbalance in correction position 2. - Correction position 2 To return to normal unbalance display, press the button To perform a new spin, subsequently press the button START I 0375 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 It improves the residual eccentricity of the tyre. A) - 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 Refit the wheel with the reference mark coincidin between rim and adapter TYRE POSITION - RH display: percentae reduction - LH display: actual static unbalance which can be reduced by rotation RIM 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 RETURN TO MEASUREMENT SCREEN If before pressin the button no spin was performed, the machine requires one, as follows: The procedure resumes from point A). I 0375 GB - 12

13 ALU AND STATIC MODES From the measurement screen, press ALU or button to select the type required. The 5-LED displays show the position where to apply the weihts. If a spin has already been performed, the processor automatically recalculates, for each chane of mode, the amounts of unbalance accordin to the new calculation. 8 Button DYNAMIC DYNAMIC STATIC DYNAMIC Balancin of steel or liht alloy rims with application of clip-on weihts on the rim edes. STATIC The static mode is necessary for motorcycle wheels or when it is not possible to place the counterweihts on both sides of the rim. Button ALU ALU M ALU 1 ALU 2 ALU 3 ALU 4 ALU M ALU - 1 Balancin of liht alloy rims with application of adhesive weihts on the rim shoulders. ALU - 2 Balancin of liht alloy rims with hidden application of the outer adhesive weihts. Outer weiht position is fixed. Restin surface ALU - 3 ALU - 4 Combined application: clip-on weiht inside and hidden adhesive weiht on outside (Mercedes). Outer weiht position is the same as ALU- 2. Combined application: adhesive weiht outside and clip-on weiht inside AUTOMATIC MINIMIZATION OF STATIC UNBALANCE Initial unbalance sx dx Position 50 Possible approximation sx dx sx dx sx dx sx dx 4 static residual static residual static residual static residual With a traditional balancin machine Choice with minimum static residual This proram is desined to improve the quality of balancin without any mental effort or loss of time by the operator. In fact by usin the normal commercially available weihts, with pitch of 5 in every 5, and by applyin the two counterweihts which a conventional wheel balancer 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 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 in order to minimize residual static unbalance. If it is not possible to minimize completely the static unbalance keepin in tolerance the dynamic unbalance, this function has the solution to minimize the static unbalance. I 0375 GB - 13

14 6.1 - SELF-DIAGNOSTICS 6 - SET UP DISPLAY TEST - All displays, readouts and LED s should liht up in sequence. - Turn the wheel in direction of rotation. - Turn the wheel in reverse direction of rotation. - In one complete rev.of the wheel (in direction of rotation) this should appear once - Test parameter END OF SELF-DIAGNOSTICS HOME STOP CANCEL SELF-DIAGNOSTICS IN ANY PHASE I 0375 GB - 14

15 6.2 - SELF-CALIBRATION For machine self-calibration proceed as follows: - Fit a medium-sized metal wheel on the shaft. Example: 6 x 14 (± 1 ) - 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 spin under normal conditions. START - Add 100. (3.5 oz) on the outside in any position. START START - Shift the 100.weiht from the outside to the inside keepin the same position. - Rotate the wheel so to have the 100. weiht to the 12 o clock position. END OF SELF-CALIBRATION HOME STOP CANCEL SELF-CALIBRATION IN ANY PHASE I 0375 GB - 15

16 7 - ERRORS Durin machine operation, various causes of faulty operation could occur. If detected by the microprocessor, they appear on the display as follows: ERRORS CAUSES CONTROLS Err. 1 No rotation sinal. 1. Verify belt tautness. 2. Verify the function of the phase pick-up board and, in particular, the reset sinal. 3. Replace the phase pick-up board. 4. Replace the computer board. Err. 2 Speed too low durin detection. 1. Make sure that a vehicle wheel is mounted on the wheel balancer. Durin unbalance measurement rotation, wheel speed 2. Verify belt tautness. is less than 42 rpm. 3. Verify the function of the phase pick-up board and, in particular, the reset sinal. 4. Replace the computer board. Err. 3 Unbalance too hih. 1. Verify wheel dimension settins. 2. Check detection unit connections. 3. Perform machine calibration. 4. Mount a wheel with more or less known unbalance (less than 100 rammes) and verify the response of the machine. 5. Replace the computer board. Err. 4 Err. 5 Err. 7 / Err. 8 Rotation in opposite direction. After pressin [START], the wheel beins to rotate in the opposite direction (anticlockwise). Guard open The [START] pushbutton was pressed without first closin the uard. 1. Verify the connection of the UP/DOWN RESET sinals on the phase pick-up board. 1. Reset the error by pressin pushbutton [7]=End. 2. Close the uard. 3. Verify the function of the protection uswitch. 4. Press the [START] pushbutton. NOVRAM parameter read error 1. Repeat machine calibration 2. Shut down the machine. 3. Wait for a minimum time of ~ 1 Min. 4. Re-start the machine and verify correct operation. 5. Replace the computer board. Err. 9 NOVRAM parameter write error. Replace the computer board. Err. 10 Measured width too small. 1. Repeat the distance measurement. N.B.: Minimum width accepted by the 2. Repeat the width measurement. wheel balancer is 1.5 or 40 mm. 3. Verify the calibration of the distance aue and replace the distance aue potentiometer as necessary. 4. Verify the calibration of the width aue and replace the width aue potentiometer as necessary. 5. Replace the computer board. Err. 11 Speed too hih error. Durin unbalance measurement rotation, wheel speed is more than 270 rpm. 1. Check if there is any damae or dirt on the timin disc. 2. Verify the function of the phase pick-up board and, in particular, the reset sinal. 3. Replace the computer board. Err. 12 Unbalance measurin cycle error. 1. Verify phase pick-up board function. 2. Verify correct motor operation. 3. Verify belt tautness. 4. Replace the computer board. Err.13/ Err.14/ Err.15/ Err.16/ Err.17/ Err.18 Unbalance measurement error. 1. Verify phase pick-up board function. 2. Check detection unit connections. 3. Verify machine earth/round connection. 4. Mount a wheel with more or less known unbalance (less than 100 rammes) and verify the response of the machine. 5. Replace the computer board. Wheel reset wait 1. Turn the wheel until the imbalance is displayed I 0375 GB - 16

17 7.1 - INCONSISTENT UNBALANCE READINGS Sometimes after balancin a wheel and removin it from the balancin machine, it is found that, upon mountin it 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 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 Switch off the machine from the mains before carryin out any operation TO REPLACE THE FUSES Remove the weiht holder shelf to ain access to the power supply board where the fuses are located (see Exploded Drawins). If fuses require replacement, use ones of the same current ratin. If the fault persists, contact BUTLER Technical Service Department. NONE OF THE OTHER MACHINE PARTS REQUIRE MAINTENANCE 9 - RECOMMENDED SPARE PARTS LIST (For references, see exploded drawins) CODE DESCRIPTION Bearin Z Ø 25/47/ Sprin 19863P Riid belt - Poly V - TB Vee s 67M38954H Position pick-up board with cable 05PR38651 LEXAN panel Switch KL Q M36950A Power board Fuses DM5x20-2A 86SC44478 Computerboard Sprin, rim distance aue 20656P 86SB40113 Cable with standard protective microswitch 86SB55636 Cable with "GP" protective microswitch SPECIAL PARTS FOR 230 V MACHINE 50FG41254 Sinle phase motor V/50-60 Hz Kw 63-B3-4p. BIMA 86SZ50867 Complete power board Brakin transformer 30 VA -0/ Capacitor 10MF 450V FASTON screw M Power supply transformer 30 VA 230 9/9 SPECIAL PARTS FOR 115 V MACHINE 50FG41255 Sinle phase motor V/50-60 Hz Kw 63-B3-4p BIMA 86SZ50868 Complete power board Brakin transformer 30 VA 115-0/ Capacitor 35MF 450V FASTON screw M Power supply transformer 30 VA 115-9/9 I 0375 GB - 17

2 - HANDLING, HOISTING START-UP...4

2 - HANDLING, HOISTING START-UP...4 Instructions for use I INDEX 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 (standard protection)...3