S 448s C/2. Wheel balancer with microprocessor for cars, light commercial vehicles and motorcycles

Transcription

1 Wheel balancer with microprocessor for cars, light commercial vehicles and motorcycles S 448s C/2 Ed. 01/10 serie C Operating and maintenance instruction manual - Original Instructions - Cod

2 DECLARATION DE CONFORMITE CE CE DECLARATION OF CONFORMITY DICHIARAZIONE DI CONFORMITA CE CE - ÜBEREINSTIMMUNG DECLARACIÓN CE DE CONFORMIDAD GIULIANO S.p.A. - Via Guerrieri, Correggio (RE) ITALY dichiara sotto la propria esclusiva responsabilità che il prodotto: declare on our own responsibility that the product: Déclare sous son propre responsabilité que le produit: erklärt unter ihrer eigenen Verantwortung, daß das Erzeugnis: declara bajo su exclusiva responsabilidad que el producto: Equilibratrice Balancer Equilibreuse Auswuchtmaschine Equilibradora S448 S C/2 Matricola al quale questa dichiarazione si riferisce E' CONFORME ALLE SEGUENTI DIRETTIVE: to which declaration refers is in conformity with the FOLLOWING DIRECTIVES: au quel cette déclaration se rapporte EST CONFORME AUX DIRECTIVES SUIVANTES: darauf diese Erklärung Bezug nimmt, mit den folgenden Bestimmungen übereinstimmt: 2006/42/CE /95/CE /108/CE ed alle Norme: as well as to the following norms: ainsi qu aux normes suivantes: und folgender Vorschrift gemäß: EN : EN 13850: EN : EN : EN 7731: EN : EN 294: EN : EN : EN 349: EN : EN :2006 Il firmatario della presente dichiarazione è la persona autorizzata a costituire il fascicolo tecnico The signer of this declaration of conformity is the person authorized to provide for the technical file literature Le signataire de cette déclaration de conformité est la personne autorisée à produire le dossier technique Der Unterzeichner dieser CE-Übereinstimmung ist dazu ermächtigt, das technische Aktenbündel vorzulegen El firmante de esta declaración es la persona autorizada para elaborar el expediente técnico Correggio, 07/01/2010 Il modello della presente dichiarazione è conforme alla Norma EN ISO/IEC The model of present declaration is in conformity with directive EN ISO/IEC Le modèle de cette déclaration est conforme à la Norme EN ISO/IEC Das Modell dieser Erklärung übereinstimmt mit der Bestimmung EN ISO/IEC El modelo de esta afirmación está en consonancia con la norma EN ISO/IEC GIULIANO S.p.A Il Presidente G. Maselli

3 DICHIARAZIONE DI CONFORMITA RAEE RAEE DECLARATION OF CONFORMITY DECLARATION DE CONFORMITE RAEE RAEE - ÜBEREINSTIMMUNG GIULIANO S.p.A. - Via Guerrieri, Correggio (RE) ITALY dichiara sotto la propria esclusiva responsabilità che il prodotto: declare on our own responsibility that the product: Déclare sous son propre responsabilité que le produit: erklärt unter ihrer eigenen Verantwortung, daß das Erzeugnis: Equilibratrice ruote Equilibreuse de roue Wheel-balancer Radauswuchtmaschine al quale questa dichiarazione si riferisce E CONFORME ALLA DIRETTIVA: to which declaration refers is in conformity with the FOLLOWING DIRECTIVE: au quel cette déclaration se rapporte EST CONFORME À LA DIRECTIVES SUIVANTES: darauf diese Erklärung Bezug nimmt, mit der folgenden Bestimmungen übereinstimmt: 2002/96/CE e 2003/108/CE (RAEE) Raccolta differenziata Specific garbage collection Collecte sélective getrennte Müllsammlung La presente macchina/apparecchiatura rientra nelle prescrizioni della Direttiva 2002/96/CE e 2003/108/CE (RAEE) e non può essere smaltita come rifiuto urbano generico ma attraverso raccolta separata; Il simbolo del bidone barrato riportato sul prodotto indica questa prescrizione. Lo smaltimento della stessa e dei suoi componenti dovrà avvenire secondo quanto previsto dalle Direttive 2002/96/CE e 2003/108/CE (RAEE) e le disposizioni di Legge del Paese di destinazione della macchina/apparecchiatura; il mancato rispetto della direttiva è sanzionabile secondo le disposizioni di Legge del Paese di dstinazione. L abbandono o smaltimento non corretto delle macchine/apparecchiature sottoposte alla Direttiva 2002/96/CE può provocare gravi danni all ambiente ed alle persone. Il costruttore è disponibile, ai sensi della Direttiva, allo smaltimento della macchina/apparecchiatura; per questo servizio contattare il costruttore o i rivenditori autorizzati secondo il Paese di destinazione della macchina/apparecchiatura. This equipment is subject to the regulations foreseen by Directives 2002/96/CE and 2003/108/CE (RAEE) and therefore it cannot be scrapped as a generic scrap material but through specific collection circuits; the symbol with barred tank marked on the product refers to this prescription. Scrapping must be made in accordance with Directives 2002/96/CE and 2003/108/CE (RAEE) as well as with the local Regulations in force in the Country of installation, the non-respect of the Directive is subject to sanctions according to the national Laws of the Country of destination. Abandonment or wrong scrapping of the equipment subject to Directive 2002/96/CE can cause serious damage to the environment. The manufacturer is available, according to the Directive, to scrap the equipment; for this service, please contact the manufacturer or your dealer. Ce produit rentre dans les prescriptions des Directives 2002/96/CE et 2003/108/CE (RAEE) et il ne peut donc pas être mis à la ferraille comme du matériel générique mais à travers un circuit de collecte sélective; le symbole du «bidon barré» reproduit sur la machine se réfère à cette prescription. Le traitement de la machine et de ses composants devra se réaliser en conformité aux Directives 2002/96/CE et 2003/108/CE (RAEE) ainsi qu aux dispositions de Loi en vigueur dans le Pays de destination de la machine, le non-respect de la Directive est passible de sanctions par rapport aux Lois nationales du Pays de destination. L abandon ou un traitement erroné des produits sujets à la Directive 2002/96/CE peut provoquer de graves dégâts à l environnement. Le constructeur est disposé, aux termes de la Directive, à s occuper du traitement de la machine; pour ce service contacter le constructeur ou les revendeurs autorisés. Die vorliegende Maschine/Gerät fällt in den Vorschriften der 2002/96/CE Richtlinie, und kann nicht als allgemeiner Stadtmüll sondern durch getrennte Müllsammlung beseitigt werden; das Symbol mit der durchgestrichenen Mülltonne weist auf diese Vorschrift hin. Die Entsorgung des Gerätes und seiner Bestandteilen muss nach den 2002/96/CE und 2003/108/CE (RAEE) Richtlinien und nach den Vorschriften des Bestimmungslandes der Maschine/Gerätes erfolgen, die Nicht-Beachtung der Vorschrift ist sanktionierbar laut dem Gesetz des Bestimmungslandes Die unkorrekte Entsorgung oder Verlassen der zu der 2002/96/CE vorgelegenen Richtlinie Maschine/ Gerätes kann die Umwelt und die Personen schwer beschädigen. Gemäß der Richtlinie, steht der Hersteller für die Entsorgung der Maschine/Gerätes zur Verfügung; dazu setzen Sie sich mit dem Hersteller oder mit den berechtigten Händlern nach dem Bestimmungsortes der Maschine/Gerätes in Verbindung. Correggio, 01/07/06

4 Instructions for use I Contents 1 - GENERAL GENERAL SAFETY REGULATIONS STANDARD SAFETY DEVICES FIELD OF APPLICATION OVERALL DIMENSIONS TECHNICAL DATA HANDLING AND LIFTING STARTUP ANCHORING ELECTRICAL CONNECTION ADAPTER MOUNTING GUARD MOUNTING AND ADJUSTMENT (OPTIONAL) WD SPACER CONTROLS AND COMPONENTS AUTOMATIC DISTANCE AND DIAMETER GAUGE KEYBOARD AND DISPLAY FUNCTION MENU MANAGEMENT INSTRUCTIONS FOR USE OF THE WHEEL BALANCER USING THE GAUGE INSTALLED ON THE MACHINE DATA SETTING AUTOMATIC PRESETTING STEEL OR ALUMINUM WHEEL RIMS. SPRUNG COUNTERWEIGHTS STATIC & COMBINED MODES RIMS WITH INTERNAL COUNTERWEIGHT DOUBLE OPERATOR PROGRAM MEASUREMENT RESULT RECALCULATION OF THE UNBALANCE INDICATION OF THE EXACT ADHESIVE WEIGHT APPLICATION POSITION SPLIT FUNCTION (HIDDEN WEIGHT) UNBALANCE OPTIMISATION AUTOMATIC MINIMIZATION OF STATIC UNBALANCE SET UP AUTODIAGNOSTICS AUTOCALIBRATION MANUAL DIMENSION PRESETTING STEEL WHEEL RIMS ALUS RIMS ALUS VARIANT WITH INSIDE CLAMP WEIGHT AUTOMATIC GAUGES CALIBRATION DISTANCE GAUGE DIAMETER GAUGEE40 MM ERRORS INCONSISTENT UNBALANCE READINGS ROUTINE MAINTENANCE REPLACING THE PROTECTION FUSES 18 I 0549 GB - 1

5 I 0549 GB - 2

6 1 - General General safety regulations -The wheel balancer may only be used by duly authorized and trained personnel. - The wheel balancer must not be used for purposes other than those described in the instruction manual. - The wheel balancer must not be modified in any way except for those modifications made explicitly by the manufacturer. - Do not remove the safety devices. Any work on the machine must be carried out by specialised personnel only. - Avoid using strong jets of compressed air for cleaning. - Use alcohol to clean plastic panels or shelves (AVOID LIQUIDS CONTAINING SOLVENTS). - Before starting the wheel balancing cycle, make sure that the wheel is securely locked on the flange. - The machine operator must not wear clothes with flapping parts. Do not allow unauthorized personnel to approach the wheel balancer when the cycle is running. - Avoid placing objects in the base which could impair the correct operation of the wheel balancing machine Standard safety devices - Stop push button for stopping the wheel under emergency conditions. - 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 cars, light commercial vehicles or motorcycles weighing less than 75 kg. It can be operated in a temperature range of 0 to + 45 C Overall dimensions Technical data Single-phase power supply 230 V - 50/60 Hz or 115V - 50/60 Hz Protection class IP 54 Max. power absorbed 0,8 KW Breakaway Current 6 A (115V) Balancing speed < 100 min -1 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 I 0549 GB - 3

7 2 - Handling and lifting 2 2a NOTE: DO NOT LIFT THE WHEEL BALANCER USING OTHER GRIPS. 3 - Startup Anchoring The machine can operate on any flat non resilient floor. Make sure that the machine rests solely on the three support points provided (fig. 2a) Electrical connection The machine is supplied with a single-phase mains cable plus earth (ground). (any extension cables must have a cross-section of no less than 1.5 mm 2 ). The power supply voltage (and mains frequency) is indicated on the machine identification plate and cannot be changed. Connection to the mains must always be made by expert personnel. The machine must not be set up without proper earthing. Connection to the mains should be through a slow acting safety switch rated at 3A (230V) or 8A (115V). See enclosed diagram Adapter mounting 3 A B The wheel balancer is supplied complete with cone flanges for fixing wheels with a central hole. To mount other optional flange adaptors : a) Remove the threaded end-piece A after unscrewing the screw B. b) Mount the new flange (see attached sheets). NOTE: CAREFULLY CLEAN THE COUPLING SURFACES BEFORE PERFORMING ANY OPERATION Guard mounting and adjustment (optional) a) Fasten the components to the base as illustrated in specifi c exploded view. b) The position of the wheel guard when closed can be adjusted with relative screw accessible at the back. Correct position is the one which keeps the tube exactly horizontal with wheel guard closed. c) Check that the microswitch is held down when the guard is closed. d) Adjust the angular position of microswitch control. I 0549 GB - 4

8 3.5 - WD spacer 3a DC WD Cone Spring To move the wheel away from the machine side (e.g. for very wide wheels), fit the WD spacer on the flange 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. These devices are optionals (see flange details enclosed). 4 - Controls and components Automatic distance and diameter gauge Allows automatic measurement of the distance from the machine and the wheel diameter at the counterweight application point. The same gauge can be used to position the counterweights correctly inside the wheel, using the specific function that suggests the position memorised during measurement inside the rim Keyboard and display b a d a b d 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, selection confirmation 13 Push button, cycle start 14 Push button, emergency 15 Push buttons, manual DISTANCE/ DIAMETER/WIDTH setting 16 Maximize/MENU button 17 Position repeater push button 18 Minimize/MENU button 19 Push button, unbalance optimisation Note: - Press buttons only with your fingers. Do not use the counterweight grippers or other pointed objects. I 0549 GB - 5

9 Function menu management on/off beep signal diameter mm/inch mm/inch width start from guard closing approx.1-5 g or oz CONFIRM CONFIRM CONFIRM CONFIRM CONFIRM See chapter on AUTODIAGNOSTICS See chapter on AUTOCALIBRATION * * g/oz unit of measure unbalance Calibration of automatic RIM DISTANCE gauge (see SETUP) Calibration of automatic DIAMETER gauge (see SETUP) CONFIRM RETURN TO MEASUREMENT FRAME * N.B.: If such indications fail to appear, contact Technical Service. I 0549 GB - 6

10 5 - Instructions for use of the wheel balancer Using the gauge installed on the machine Data setting 5 POS. A For clamp weights, use the gauge in the top position A. For adhesive weights, use the gauge as preferred in top position A or bottom position B. Note: Always use the round part of the striker plate resting on the rim. POS. B 5a Indication of gauge in movement Automatic presetting The machine automatically detects the correct balancing program for steel and aluminium rims (ALUS). The counterweight position proposed may be changed using the two / buttons Steel or aluminum wheel rims. Sprung counterweights 5b 5c Pull out the gauge as far as the inner edge of the rim. Hold it in this position until the symbol shown in Fig. 5d is displayed. 5d Indication of dimensions acquired Return the gauge to rest position. The machine has automatically detected DISTANCE + DIAMETER and goes to MANUAL WIDTH SETTING. - The nominal width is normally stamped on the rim; if not, proceed to measure dimension b with the calibre gauge (supplied as standard). b b 5e I 0549 GB - 7

11 Static & combined modes After calibration as per STEEL OR ALUMINUM WHEEL RIMS. SPRUNG COUNTERWEIGHTS, it is possible to modify the position of the correction weights using the / buttons. STATIC button: button: Balancing of light alloy rims with application of adhesive weights on the shoulders of the rims. Combined balancing: adhesive weight on the outside and clip-on weight on the inside. Combined balancing: adhesive weight on the inside and clip-on weight on the outside Rims with internal counterweight 6 Slide out the gauge on the LH side, at the point where a weight is to be fitted. Wait until the symbol shown in Figure 5d is displayed. Pull it out further towards the right plane and wait until the symbol shown in Figure 6A is displayed. The wheel balancer automatically identifi es ALU S mode. 6a Counterweight position automatically suggested. resting surface resting surface can be used to set the alternative position indicated. I 0549 GB - 8

12 5.3 - 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 to select operator (1 or 2). Selection of USER 2 is confirmed by the LED on the panel. 2 - Enter the dimensions (see DATA SETTING ). 3 - Press to carry out the balancing as usual and to store the program. With program 1 or 2 is called for subsequent balancing operations without having to newly enter the dimensions Measurement result After performing a balancing spin, the amounts of unbalance are shown on the digital readouts. The illuminated LEDs 3 and 4 indicate the correct angular position of the wheel to mount the counterweights (12 o clock). 7a F Fig. 7a - Inside correction 7b Fig. 7b - Outside correction If the unbalance is less than the threshold value selected, the values below the threshold can be read. is displayed instead of the unbalance value; with Recalculation of the unbalance Press after new setting of the dimensions. I 0549 GB - 9

13 5.6 - Indication of the exact adhesive weight application position In ALU S, STATIC correction mode, approximations in the application of the counterweights can be cancelled operating as follows: - press - Fit the correction weight in the specific gauge seat with the adhesive part facing upwards - bring the wheel into correct angular position for the plane to be corrected The gauge should be pulled further out The left display gives the indications to reach the position for the inside, while the right display that for the outside. The gauge should be returned to rest position 3 4 INSIDE CORRECTION POSITION OUTSIDE CORRECTION POSITION Rotate the gauge until the correction weight adheres to the rim - The fact that the weight application position is no longer vertical (Fig. 8) is automatically compensated. - To cancel this function, press button again N.B. : It is not possible to put automatically the correction weight in the Fig.5b position; always rotate the rim in Fig.5a upwards. I 0549 GB - 10

14 5.7 - 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 30 - Set the first 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 0549 GB - 11

15 5.8 - Unbalance optimisation - This function serves to reduce the amount of weight to be added in order to balance the wheel - It is suitable for static unbalance greater than 30 g. - It improves the residual eccentricity of the tyre. No previous unbalance measurement Unbalance already measured unbalance measurement - With a piece of chalk make a reference mark on the flange and the rim - With the aid of a tyre remover, turn the tyre on the rim by Refit the wheel in such a way that the reference marks on the rim and the adapter coincide. - RH display: percentage reduction value - LH display: actual static unbalance value which can be reduced by rotation RIM IN POSITION INDICATION - Mark the tyre (12 o clock position) TYRE IN POSITION INDICATION - Mark the rim (12 o clock position) Turn the tyre on the rim until the marks correspond to obtain the optimization shown on the display. RETURN TO MEASUREMENT SCREEN. CANCEL OPTIMISATION IN ANY PHASE I 0549 GB - 12

16 5.9 - Automatic minimization of static unbalance Initial unbalance phase shift Possible approximations residual static residual static residual static residual static With conventional wheel balancer Choice with minimum static residual 6 - Set up Autodiagnostics 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. performs tests useful for maintenance staff Autocalibration For autocalibration proceed as follows: - Fit a wheel with steel rim of average dimensions on the shaft. Example 6 x 14 (± 1 ) - Set the exact dimensions of the wheel mounted. CAUTION!! Setting incorrect dimensions will result in the machine not being properly calibrated and hence all the subsequent measurements will be incorrect until a new autocalibration is performed with the correct dimensions!! N.B.: Use steel wheel rims detection from MANUAL DIMENSION PRESETTING. - Perform a spin under normal conditions. - Add a 60 g. sample weight (2.00 oz) on the outside in any angular position. - Shift the sample weight from the outside to the inside keeping the same angular position. - Turn the wheel until the sample weight is in the 12 o clock position. END OF AUTOCALIBRATION CANCEL AUTOCALIBRATION IN ANY PHASE. I 0549 GB - 13

17 6.3 - Manual dimension presetting (Use only in particular cases or for test) Steel wheel rims (use for setting dimensions in AUTOCALIBRATION) 9 b a - Setting: d a - Set the distance a between the inside of the wheel and the machine b - Set the nominal width, normally indicated on the rim, or measure the width b using the caliper gauge supplied (see fig. 5e). d - Set the nominal diameter d indicated on the tyre. N.B.: This setting is also valid for the correction modes indicated at STATIC & COMBINED MODES ALUS rims 10 0 gauge - Setting: a b d + d Note: not setting de as it is automatic, de = di - 1 I 0549 GB - 14

18 ALUS variant with inside clamp weight 11 0 gauge - Setting: a b d (Nominal) + d Note: not setting de as it is automatic, de = di Automatic gauges calibration Distance gauge - Shift the distance gauge to position 0, keeping it quite still, press - Move the gauge to position 150, press CORRECT CALIBRATION - Return the gauge to rest position. - The wheel balancer is ready for operation. N.B.: In the event of errors or faulty operation, the writing "P.O appears on the display : shift the gauge to position 0 and repeat the calibration operation exactly as described above. If the error persists, contact the Technical Service Department. In the event of incorrect input in the rim distance gauge calibration function, press to cancel it. I 0549 GB - 15

19 Diameter gaugee40 mm Place the round part of the gauge terminal on the fl ange as shown in the figure and press. - The number 353 ± 1 appears on the left display. - Turn the gauge downward position the round part of the gauge terminal at 40 mm (radial distance) from the fl ange as indicated in the figure. 40 mm 40 mm - The number 256 ± 3 should appear on the left display. - If not, press the button holding the gauge still at 40 mm: the number 256 appears on the left display. - Return the gauge to rest position. In the event of incorrectly accessing the diameter gauge calibration function, press to cancel it. I 0549 GB - 16

20 7 - Errors During machine operation there may be various causes of malfunctioning which, if detected by the microprocessor, are indicated on the display: 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 revolutions, the wheel speed has fallen to below 42 rpm. 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. 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. 24 Err. 25 Err.30 Rotation in opposite direction. After pressing [START], the wheel starts turning in the opposite direction (anticlockwise). Guard open The [START] pushbutton was pressed without first 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. Distance between the spokes smaller than 18 degrees. Distance between the spokes greater than 120 degree Error related to test functions of the wheel balancer. 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. 1. Cancel the error and continue using the wheel balancer as normal. I 0549 GB - 17

21 7.1 - Inconsistent unbalance readings It may occur that after balancing a wheel, when removing it from the wheel balancer and then remounting it, the wheel is not balanced. This is not the result of an incorrect indication by the machine, but only of incorrect mounting of the wheel on the flange, i.e. in the two mountings the wheel has assumed a different position with respect to shaft axis of the wheel balancer. If the wheel has been mounted on the flange with screws, it may be that the screws have not been tightened correctly in gradual criss-cross manner one after the other, or (as often occurs) holes have been drilled in the wheel with too wide tolerances. Small errors, up to 10 grams (0.4 oz), are to be considered normal in wheels locked with a cone: the error is normally greater for wheels locked with screws or studs. If, after balancing, the wheel is still unbalanced when refitted on the vehicle, this could be due to the unbalance of the brake drum or very often is due to the screw holes in the rim and the drum drilled with too wide tolerances. In this case a readjustment would be advisable using the wheel balancer with the wheel mounted. 8 - Routine maintenance Before carrying out any operation on the machine, cut the power supply to the machine Replacing the protection fuses A protection fuse is fitted on the power board, accessible by dismantling the weight shelf (see Exploded Drawings). If fuses require replacement, use ones with an identical current rating. If the fault persists, contact Technical Service. NONE OF THE OTHER MACHINE PARTS REQUIRE MAINTENANCE. I 0549 GB - 18

22 S448 S (C) Extraordinary maintenance M Contents 1 - TO CHANGE SUPPLY VOLTAGE DISTANCE GAUGE CHECK CALIBRATION OF AUTOMATIC GAUGES TO ENABLE THE GAUGES CALIBRATION OF THE DISTANCE POTENTIOMETER CALIBRATION OF THE DIAMETER POTENTIOMETER AUTODIAGNOSTICS PIEZO SENSOR ASSEMBLY 6 9. AGAIN CARRY OUT THE AUTOMATIC CALIBRATION TROUBLE SHOOTING LOGIC SEQUENCE POWER LAYOUT DIAGRAM (230 V CONNECTION) TO REPLACE THE POWER BOARD (CHECK VOLTAGE) FUNCTIONING AND ACCURACY TEST WHEEL MEASUREMENT AND SETTING ON THE WHEEL BALANCER 11 M 0549 GB - 1

23 M 0549 GB - 2

24 1 - To change supply voltage (see recommended spare parts lists and power layout diagram) The wheel balancer can operate at 115 V - 50/60 Hz or 230V - 50/60Hz. To change the supply voltage, proceed as follows: 1) Replace the motor. 2) Replace the entire power board or else modify the board as follows: A) Replace the capacitor B) Replace the two transformers. 2 - Distance gauge check 1 Reading point: 205 mm Adapter plane Check that the ruler used for measuring the DISTANCE of the wheels reads 205 mm as measurement of the distance from the adapter plane. If the graduated strip is replaced, position it with the line indicating 205 at the fixed index limit (reading point) when the prod coincides with the adapter plane. 3 - Calibration of automatic gauges To enable the gauges In the event of faulty operation or replacing a P.C. board, proceed to set the gauges as follows: press in sequence and within 5 seconds from when has been pressed. - always select ON using buttons - Confirm - cancels enabling in any phase. M 0549 GB - 3

25 3.2 - Calibration of the distance potentiometer - Remove the weight shelf and refi t the tip on the gauge rod. - Back-off the screws fastening the pulley on the potentiometer shaft. - Select on the FUNCTIONS MENU CONTROL OF THE FUNCTIONS MENU SET UP SELF-DIAGNOSTICS - Scroll until the wording (dis) appears on the left display while a number appears on the right display, which varies when the distance gauge is moved and represents a reference for calibrating the potentiometer. - With the gauge fully retracted, turn the potentiometer shaft keeping the pulley still until a number between 50 and 100 is read. - Decrease by two numbers, then retighten the screws to secure the pulley on the shaft. - Carry out the DISTANCE GAUGE SET UP Calibration of the diameter potentiometer - After CALIBRATION OF THE DISTANCE POTENTIOMETER press. - The wording [dia] appears on the left display, a number appears on the right display, which varies when the gauge is turned and represents a reference for calibrating the potentiometer. - Remove the diameter gauge from the gauge rod after backing off relative screw. - Slightly pull out the gauge rod and rest its stop on the machine shaft in external position near the base. - Turn the potentiometer shaft until a number between 50 and 100 is read, then place it back in its correct work position. - Lock the potentiometer with relative set screw - Carry out the DIAMETER GAUGE SET UP M 0549 GB - 4

26 4 - Autodiagnostics In Setup, selecting diagnosis gives: DISPLAY TEST - On the right-hand display the current position of the wheel is indicated with numbers from 0 to Turning the wheel in the direction of rotation for the unbalance measurement, the word UP must appear on the left-hand display. - With one full turn of the wheel the number zero (0) should appear only once on the right-hand display. - Test parameter - Displays values of rim DISTANCE sensor - Displays values of DIAMETER sensor END OF SELF-DIAGNOSTICS CANCEL SELF-DIAGNOSTICS IN ANY PHASE. M 0549 GB - 5

27 5 - Piezo sensor assembly ASSEMBLY INSTRUCTIONS Problems of excessive compensation and out-of-phase sometimes depend on a fault in the piezo measurers. To replace them, proceed as follows: 1. Remove the weight shelf. 2. Remove nuts 1 and 2 with relative cup springs and washers. 3. Back-off screws 3, 4, 6 and 5 then disassemble the various parts. 4. Reassemble the various parts without tightening the nuts being careful to follow the correct sequence. N.B.: Mount the piezo units in accordance with the position of the coloured wires shown in the drawing. 5. Keeping the spindle perfectly aligned, tighten the nuts 5 and 6 with a spanner, and nuts 3 and 4 by hand (by half a turn with the spanner if necessary). 6. Refit the washers, cup springs and nuts 1 and 2. Tighten the nuts fully in order to fully regain the elasticity of the cup springs, then loosen them by half a turn. This will automatically ensure correct preloading on the piezo (a torque wrench can be used set to 400 kg. cm.). 7. Cover the piezo units with a generous layer of silicone (N.B.: for correct operation, insulation of the piezo crystals should be greater than 2000 Mohm). 8. Reassemble the various parts. 9. Again carry out the automatic calibration yellow blue yellow white 1 M 0549 GB - 6

28 6 - Trouble shooting logic sequence Are fuses FS1 - FS2 on the power board in a good state? NO Replace the power board YES Replace the fuses and switch on YES Are FS1 - FS2 working? NO Disconnet CN1 on the power board. Again replace FS1 - FS2 and switch on. Are FS1 -FS2 working? NO YES Replace the computer board Does the voltage across points 1-3 and the earth on CN4 correspond to that shown in the layout diagram? YES NO Check that the transformer primary be energized with the mains voltage and that there is not damage in the wiring. If everyting is OK, replace the transformer. Is the position sensor working? ( see SELF-DIAGNOSTICS) NO YES Replace the position sensor board. Note: Do not remove the mounting brackets. Replace the computer board M 0549 GB - 7

29 7 - Power layout diagram (230 V connection) 3 1 1A 2 2A M 1 2 CN5 CN2 MICROSWITCH WHEEL GUARD Vca 9Vca FS2-2A FS1-2A CN1 COMPUTER BOARD CN4 POWER BOARD 8 - To replace the power board (check voltage) M 0549 GB - 8

30 9 - Functioning and accuracy test If faults or inaccuracies are encountered which are not readily identified, it may be useful to perform the function and precision check. PRELIMINARY CONTROLS Carefully clean the flange and cones Spring cover sliding Shaft terminal locking TEST OF PROPER ENCODER FUNCTIONING 1. Cleaning the encoder Remove the snap cover on the chuck side. Insert a tool until it touches the phase disc (use a soft brush to prevent damaging the decals). Slowly turn the wheel by hand several times to allow the tool to remove any residual dust. Never force the tool on the phase generator. After cleaning, close the snap cover. 2. Positioning the encoder card It is recommended to position the encoder card in the following cases: - If replacing the encoder card; - If replacing, cleaning or generally working on the encoder decals; - In the event of repeated errors 1,2,11,12,13,14,15,16,17,18 detected by the wheel balancer during the unbalance measurement phase; - In the event of unjustified unbalance oscillation. Before running the encoder test, ALWAYS check that there is a maximum distance of 1 mm between the decal and the encoder card and that the retaining nuts of the encoder card are adequately tightened. Use a wheel of average dimensions. Press: [MENU] [ ] The word [Setup] appears [ENTER] The word [Diagn.] appears [MENU]+[STOP]+[MENU] Press in sequence in maximum 5 sec. [ ] The word [Enc.] appears [ENTER] [START] The word [Start] appears The test cycle is run after which the following results must be obtained for the encoder to function properly: [ 32] [ 32] Number of encoder pulses A/B [Min.] [0.15] The number displayed must be in a range of 0.12%0.25. [xxx] [xxx] The number shown on the left-hand display must be higher by as much as possible than the right-hand number and both values must be as far as possible away from 0. MEANING OF ENCODER TEST ERRORS Err. 1 No reset signal. 1. Check the connection cable between the encoder card and the CPU board. 2. Check positioning of the encoder card. 3. Clean the encoder decal. 4. Replace the encoder card 5. Replace the CPU board Err. 2 Encoder test speed not reached. 1. Check positioning of the encoder card. 2. Clean the encoder decal. 3. Replace the encoder card 4. Replace the CPU board Err. 4 Incorrect direction of rotation. 1. Check the encoder card connection cable. Err. 33 Rising edge fault detected for ENCA. 1. Check positioning of the encoder card. 2. Clean the encoder decal. Err. 34 Err. 35 Falling edge fault detected for ENCB. Falling edge fault detected for ENCA. 1. Check positioning of the encoder card. 2. Clean the encoder decal. 1. Check positioning of the encoder card. 2. Clean the encoder decal. Err. 36 Rising edge fault detected for ENCB. 1. Check positioning of the encoder card. 2. Clean the encoder decal. Err. 37 Detected irregular behaviour of the ENCA falling edge with respect to the reset rising edge. 1. Check positioning of the encoder card. 2. Clean the encoder decal. 3. Move the encoder card up or down. M 0549 GB - 9

31 Err. 38 Detected irregular behaviour of the ENCB falling edge with respect to the reset rising edge. STOP [STOP] button pressed during test. 1. Repeat the test. 1. Check positioning of the encoder card. 2. Clean the encoder decal. 3. Move the encoder card up or down. 3. Encoder count test Press: [MENU] [ ] [ENTER] The word [diagn.] appears [ENTER] Confirm After a brief LED and display test, the wheel position appears on the right-hand display, which must vary in the range 0%127 in a full turn. On the left-hand display UP must appear in clockwise direction and nothing in anticlockwise direction. WHEEL BALANCING MACHINE CALIBRATION (see SELF CALIBRATION) Use a wheel with steel rim of average dimensions e.g. : 6 x 14 (± 1 ) Set precise measurements (input by hand if necessary) Perform self-calibration CHECKING MACHINE OSCILLATION After running autocalibration, press [STOP] to return to the standard measuring frame. Without locking the wheel, measure the machine oscillation as follows: [MENU] [ ] [ENTER] [MENU]+[STOP]+[MENU] Press in sequence in maximum 5 sec. The words [Lan] [ci] appear [ENTER] Confirm. The letters [t.l.] [ 10] appear [START] A cycle of 10 spins is run with automatic calculation and display of the maximum oscillation (max. permitted +/- 2 g). [ENTER] The following appears [Ini] [~120]: indicates the average unbalance measurement start speed in rpm. [ENTER] The following appears [End] [~100]: indicates the average unbalance measurement end speed in rpm. N.B.: The difference between the unbalance measurement start and end speed must never be more than 30 rpm. [ENTER] End of test. [STOP] Return to the standard measuring frame If you wish to run more than 10 automatic spins, when [t.l.] [10] appears press the buttons [+]/[-] to select the desired number in the range 5%999. CHECKING MACHINE CALIBRATION With the wheel perfectly balanced, apply 100 g first on the outside and then on the inside. The wheel balancer must measure: FI=0 FE=100 Weight F.E. = position = 6 o clock FI=100 FE=0 Weight F.I. = position = 6 o clock Max. permitted tolerance 100 g = 5%. CHECKING THE FLANGE When the wheel is perfectly balanced, tip over by 180 and measure the unbalanced values. MAX ERR = Above all for this check, it is advisable to use a sample wheel with known max. unbalanced errors caused by centering which, for metal wheels, are less than 10 gr. M 0549 GB - 10

32 10 - Wheel measurement and setting on the wheel balancer The need for ever more accurate calibration and the use of the ALU buttonsmakes it important to define how the rims must be measured and how the wheel balancer interprets the data set. Hence we indicate how the set dimensions are automatically changed in order to obtain the distances of the correction planes which are defined as through-planes for the centres of gravity of the correction weights. Let us consider a typical rim: The measurement l given as rim width by the manufacturer differs from the distance measured between the correction planes for the rim thickness and the physical dimensions of the counterweight whose centre of gravity is at distance h from the resting point on the edge of the rim. The wheel balancer automatically corrects the set measurement by adding 2 x h = 6 mm to the measurement. The measurement b made with the gauge is normally more accurate even if very similar to the measurement l known by the user. The two measurements differ only by the thickness of the plate, usually about 2 mm per side. This minimal difference allows obtaining accurate calibration by indifferently setting the inside width l or the outside width b of the rim. It is a good rule to add 1/4 inch to the value given by the rim manufacturer. As regards the ALU functions, the machine performs the following approximations in addition to systematic correction of the centre of gravity of the counterweight as seen above. I E NOTE : I = INSIDE E = OUTSIDE a b h I I I E E E a = a preset + ¾ b = b preset - 1 1/2 dl = d preset - 1 de = d preset - 1 a = a preset b = b preset -¾ dl = d preset de = d preset - 1 a = a preset + ¾ b = b preset -¾ dl = d preset - 1 de = d preset 0 gauge 0 Calibro ai di ae de a = ai preset - 8 mm b = ae - ai di = d preset de = di preset gauge 0 Calibro ai di ae de a = ai preset b = ae - ai - 5 mm di = d preset de = di preset - 2 M 0549 GB - 11

33 PR Recommended spare parts list R SHAFT ASSEMBLY POWER UNIT CODE DESCRIPTION Rigid belt Poly V Distance gauge spring Two pole switch 16A 05PR47974 Lexan panel 86SC72067 Computer board 67M38954N Position pick-up board with cable 86SB34144 Cable with microswitch for wheel guard 50FG ph Motor 230V/50-60 Hz 50FG ph Motor 115V/50-60 Hz Braking spring 86SB36493 Cable, automatic diameter gauge 86SB38988 Cable, automatic distance gauge Bearing Z Spring 86SZ50867 Complete power plate 230V 86SZ50868 Complete power plate 115V 67M36950A Power board Power transformer 40VA (230V) Braking Transformer 40VA (230V) Power transformer 40VA (115V) Braking Transformer 40VA (115V) Fuse 5x20-2A (CSA) Capacitor 10 MF (230V) Capacitor 35 MF (115V)

34 S448S (C) E S-GB.PDF D MANDRINO SHAFT ASSEMBLY MOTORE+DATORE DI FASE+ MOTOR+POSITION PICK-UP+ D TRASDUTTORI PIEZO PIEZO TRANSDUCER D FRENO BRAKE D BASAMENTO (1) CASING (1) CALIBRO AUTOMATICO: DISTANCE + 22 DIAMETER D DISTANZA + DIAMETRO 22 AUTOMATIC GAUGE D POTENZA POWER UNIT D PROTEZIONE RUOTA WHEEL GUARD * Particolari reperibili in commercio * Parts on the market

35 S448S (C) E S-D.PDF D DORN BROCHE MANDRIL D MOTOR+PHASENGEBER+ MOTEUR+DONNEUR DE PHASE+ MOTOR+CAPTADOR DE FASE+ PIEZOGEBER TRANSDUCTEURS PIEZO TRANSDUCTORES PIEZOELECTRICOS D BREMSE FREIN FRENO D SOCKEL (1) BASE (1) BASE (1) D AUT. MESSLEHRE: ABSTAND CALIBRE AUTOMATIQUE: CALIBRE AUTOMATICO: UND 22 DURCHMESSER DISTANCE + DIAMETRE 22 DISTANCIA + DIAMETRO 22 D NETZEINHEIT PUISSANCE POTENCIA D RADSCHUTZVERKLEIDUNG PROTECTION ROUE PROTECCION RUEDA * Handelsübliche Teile * Pièces se trouvant dans le commerce * Piezas que se encuentran en el mercado

36 D N. CODE DATA N. CODE DATA N. CODE DATA * 11 04FM * * 12 42FM41391 Ø * * * 4 42FM * 5 04FM * * 16 42FM51744 Ø 40 L = * * 8 42FM FP * *

37 D F G E D D=WHITE E=YELLOW F=YELLOW G=BLUE N. CODE DATA N. CODE DATA N. CODE DATA 1 86SD * * FG V/50-60 Hz * 3 42SD FG V/50-60 Hz * * M38954N 14 07FG V * * 14 07FG V-EUR-USA * * * * * * *

38 D N. CODE DATA N. CODE DATA N. CODE DATA FB * * * 5 42FB * * *

39 D N. CODE DATA N. CODE DATA N. CODE DATA 1 86PR FB PR BV PR * * * 6 86SC * * * * * * * 10 14FB * 549-4

40 D B A N. CODE DATA N. CODE DATA N. CODE DATA 2 42FB FC FC * * 16 86SB * 8 21FC SB * * 28 18FC * * 29 21FC A 46FC * 30 21FC B 46FC FC40276 * 31 21FC * *

41 D N. CODE DATA N. CODE DATA N. CODE DATA VA (230V) VA (115V) 3 86SZ V VA (230V) 3 86SZ V VA (115V) 4 42SZ MF (230V) * MF (115V) 6 67M36950A * * * * * *

42 D N. CODE DATA N. CODE DATA N. CODE DATA * * * * 4 42FW * * 18 86SB * * * 8 42FW FW *

43

44 GIULIANO S.p.A. Via Guerrieri, CORREGGIO - ITALY Tel Fax giuliano@giuliano.it