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

Transcription

1 Instructions for use I INDEX Page 1 - GENERAL GENERAL SAFETY REGULATIONS STANDARD SAFETY DEVICES FIELD OF APPLICATION OVERALL DIMENSIONS (standard protection) TECHNICAL DATA HANDLING, HOISTING START-UP ANCHORING ELECTRICAL CONNECTION ADAPTERS MOUNTING WHEEL GUARD ASSEMBLY AND ADJUSTMENT (optional) WD SPACER CONTROLS AND COMPONENTS AUTOMATIC DISTANCE MEASURING GAUGE CONTROL PANEL AND DISPLAY OPERATION FUNCTIONS MENU INDICATION AND USE OF THE WHEEL BALANCER USE OF THE GAUGE INSTALLED IN THE MACHINE AUTO SELECT AUTO SELECT FOR STEEL RIMS AUTO SELECT FOR ALU M RIMS ALU 3M RIMS PAX RIMS ALU 1 AND ALU 4 RIMS RESULT OF MEASUREMENT DOUBLE OPERATOR PROGRAM SPLIT FUNCTION 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 RECOMMENDED SPARE PARTS LIST...22 I 0374 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 the manufacturer. - Never remove the safety devices. Any work on the machine should only be carried out by speciali 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 balancing 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. The following functions are provided: ; AUTO SELECT; ALU-M; ALU 3M; PAX; SPLIT; Unbalance optimization; Double operator; Self diagnostics; Self calibration OVERALL DIMENSIONS (standard protection) I 0374 GB - 3

4 1.4 - TECHNICAL DATA Weight with guard (excluding adapter)... ~ 84 Kg. Single-phase power supply / 230 V 50/60 Hz Protection class... IP 54 Max.power consumption... 0,8 Kw Balancing speed min-1 Cycle time for average wheel (14 kg) 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, HOISTING 2 2a NOTE: NEVER USE OTHER POINTS TO HOIST THE MACHINE 3 - START - UP ANCHORING The machine can only be operated on a flat non resilient floor. Make sure that the machine rests on the 3 mounting points provided (see above) N.B.: It is advisable to secure the system to the ground using the specific feet (see above) 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 0374 GB - 4

5 3.3 - ADAPTER MOUNTING The wheel balancer is supplied complete with cone flanges for fixing wheels with a central hole. Other optional flanges can be mounted: 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 WHEEL GUARD ASSEMBLY AND ADJUSTMENT (OPTIONAL) a) Fasten the components to the base as illustrated in the specific exploded drawing. 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 guard is closed. Note: Do not lean on the guard during the wheel balancing cycle WD SPACER 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, 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. 3a 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 0374 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 confirmation 13 Push button, cycle start 14 Push button, emergency/home 15 Push button AUTO SELECT 16 Push buttons, manual DIAMETER setting 17 Push buttons, manual WIDTH setting 18 Push button, unbalance optimization Note: - Only use the fingers to press the push buttons. Never use the counterweight 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 0374 GB - 6

7 OPERATION FUNCTIONS MENU MENU' on/off audible alarm CONFIRM diameter mm/inch CONFIRM width mm/inch CONFIRM guard on/of CONFIRM start from guard closing CONFIRM approximates 1-5g oz CONFIRM See SELF-DIAGNOSTICS See SELF-CALIBRATION g/oz unbalance unit CONFIRM DISTANCE automatic gauge calibration HOME STOP RETURN TO MEASUREMENT SCREEN I 0374 GB - 7

8 5 - INDICATION AND USE OF THE WHEEL BALANCER USE OF THE GAUGE INSTALLED IN THE MACHINE 5 For clip-on weights use the gauge in the upper position A. For adhesive weights use the gauge either in the upper position A or the lower position B. It is recomended to use Position B. As here one can see where the adhesive weights will be placed. POS A. Note: Always use the round part of the striker plate. POS B AUTO SELECT The machine automatically detects the right balancing program for steel and ALU M rims AUTO SELECT FOR STEEL RIMS 6 Pull out the gauge to the edge of the rim. Keep it there until you hear a beep Push back the gauge to the resting position. The machine automatically has detected the mode for steel rims. Set the diameter indicated on the rim. Set the width indicated on the rim, or measure the width with the calliper (standard accessory). Make a measuring spin, turn the wheel to the right angles, fix the clip-on weights, and make a control spin. To balance more tyres of the same type and dimension the machine automatically stores the current wheel data. I 0374 GB - 8

9 AUTO SELECT FOR ALU M RIMS 7 FI FE Pull out the gauge to the left plane, where you want to fix an adhesive weight. Keep the gauge there until you hear a beep. Pull it further out to the right plane and wait for the second beep. The machine automatically has detected the ALU M mode. Push back the gauge to the resting position. Set the diameter indicated on the rim. Make a measuring spin For the adhesive weight on the left position turn the wheel to the correct angle and simply fix the weight by hand at the 12 o' clock position or use the gauge for repositioning as described below. For the adhesive weight on the right position turn the wheel to the correct angle. Pull out the gauge for repositioning and re-adjust the angle. Move the gauge further to the right until you hear a beep. Move the gauge further to the left until you hear a beep. Make a control spin To balance more tyres of the same type and dimension the machine automatically stores the current wheel data. To put in other dimensions or to change the balancing program press I 0374 GB - 9

10 5.3 - ALU 3M RIMS Press until the correct weight positions are indicated. To indicate the free choice of the position planes the ALU M LED is also lighting up at the same time. 8 FI FE Pull out the gauge to the edge of the rim, where you want to fix the clip-on weight. Keep the gauge there until you hear a beep. Pull it further out to the right plane, where you want to fix the adhesive weight. Wait for the second beep. The machine confirms with ALU 3M Push back the gauge to the resting position. Set the diameter indicated on the rim. Make a measuring spin For the clip-on weight on the left position turn the wheel to the correct angle (see RESULT OF MEASUREMENT) and simply fix the weight by hand at the 12 o' clock position or use the gauge for repositioning as described below. For the adhesive weight on the right position turn the wheel to the correct angle. Pull out the gauge for repositioning and re-adjust the angle. Move the gauge further to the right until you hear a beep. Move the gauge further to the left until you hear a beep. Make a control spin To balance more tyres of the same type and dimension the machine automatically stores the current wheel data. To put in other dimensions or to change the balancing program press I 0374 GB - 10

11 5.4 - PAX RIMS Press 9 FI FE Pull out the gauge to the left plane, where you want to fix an adhesive weight. Keep the gauge there until you hear a beep. Pull it further out to the right plane and wait for the second beep. The machine confirms with PAX Push back the gauge to the resting position. Set the diameter indicated on the rim in mm. Make a measuring spin For the adhesive weight on the left position turn the wheel to the correct angle (see RESULT OF MEASUREMENT) and simply fix the weight by hand at the 12 o' clock position or use the gauge for repositioning as described below. For the adhesive weight on the right position turn the wheel to the correct angle. Pull out the gauge for repositioning and re-adjust the angle. Move the gauge further to the right until you hear a beep. Move the gauge further to the left until you hear a beep. Make a control spin To balance more tyres of the same type and dimension the machine automatically stores the current wheel data. To put in other dimensions or to change the balancing program press I 0374 GB - 11

12 5.5 - ALU 1 AND ALU 2 RIMS Put in the wheel data as for steel rims described in AUTO SELECT FOR STEEL RIMS. Make the measuring spin. Press ALU as often as the LEDs for ALU 1 or ALU 2 are lighting up. 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. Note for ALU M/PAX programs: For the outer/right diameter the machine automatically calculates 80% of the value of the inner/left diameter. Note for ALU 3M programs: For the outer/right diameter the machine automatically calculates - 2" of the value of the inner/left diameter. For very special shaped rims you can adjust the right diameter as follows: Press one of the widths buttons for 3 seconds. Adjust the right diameter to the shape of the rim. I 0374 GB - 12

13 5.6 - RESULT OF MEASUREMENT 10 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). In case of audible alarm activated (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 gram by gram. To enable automatic distance acquisition for a new wheel to be balanced, press 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. If the mobile symbol should appear at the end of any balancing start operation, turn the wheel by hand until the unbalance values are displayed 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 preset dimensions. 1 - Press USER to select operator (1 or 2). Selection is confirmed by panel-mounted Led. 2 - Enter the dimensions (see AUTO SELECT ). 3 - Press START to carry out the balancing as usual and to store the program. With USER program 1 or 2 is called for subsequent balancing operations without having to newly enter the dimensions. I 0374 GB - 13

14 5.8 - SPLIT FUNCTION (unbalance spread) The SPLIT function is used to position the adhesive weights behind the wheel spokes so that they are no longer visible. It is advisable to utilise this function only in the event of static unbalance or with ALU-M, ALU-3M or PAX functions. Input the wheel dimensions and start the spin. To start the SPLIT function, input the following 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, press the button START I 0374 GB - 14

15 5.9 - 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. 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 coinciding between rim and adapter TYRE POSITION RIM POSITION - RH display: percentage reduction - LH display: actual static unbalance which can be reduced by rotation - 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 pressing the button no spin was performed, the machine requires one, as follows: The procedure resumes from point A). I 0374 GB - 15

16 ALU AND STATIC MODES On the control panel, press ALU or button to select the type required. The 5-LED display shows 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 STATIC DYNAMIC DYNAMIC Balancing of steel or rims with application of clipon weights on the rim edges. STATIC Button ALU 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 ALU 3M ALU 1 ALU 2 ALU M ALU M Balancing of alloy rims with hidden application of adhesive weights. ALU 3M Combined application: clip-on weight inside and hidden adhesive weight on outside (Mercedes). ALU - 1 Balancing of alloy rims with application of adhesive weights on the rim shoulders. ALU - 2 Combined application: adhesive weight outside and clip-on weight inside. PAX PAX type wheel balancing I 0374 GB - 16

17 MINISTAT - AUTOMATIC MINIMIZATION OF STATIC UNBALANCE Initial unbalance sx dx g g Position 50 Possible approximation sx g dx sx dx sx dx sx dx g g g 4 g static residual 3 g 1 g 6 g static residual static residual static residual g g g g With a traditional balancing machine Choice with minimum 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 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. If it is not possible to minimize completely the static unbalance keeping in tolerance the dynamic unbalance, this function has the solution to minimize the static unbalance. I 0374 GB - 17

18 6.1 - SELF-DIAGNOSTICS 6 - SET UP DISPLAY TEST - All displays, readouts and LED s should light 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 (Values are not relevant) - Displays the DISTANCE sensor values END OF SELF-DIAGNOSTICS HOME STOP CANCEL SELF-DIAGNOSTICS IN ANY PHASE I 0374 GB - 18

19 6.2 - SELF-CALIBRATION For machine self-calibration proceed as follows: - Fit a medium-sized steel wheel on the shaft. Example: 6 x 14 (± 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. START - Add 100 g. (3.5 oz) on the outside in any position. START - Shift the 100 g.weight from the outside to the inside keeping the same position. START - Rotate the wheel so to have the 100 g. weight to the 12 o clock position. END OF SELF-CALIBRATION HOME STOP CANCEL SELF-CALIBRATION IN ANY PHASE I 0374 GB - 19

20 7 - ERRORS During machine operation, various causes of faulty operation could occur. If detected by the microprocessor, they appear on the display as follows: ERROR CAUSES CONTROLS Black The wheel balancer does not switch 1. Verify correct connection to the mains. on. 2. Check and if necessary replace the fuses on the power board. 3. Verify display function in self-diagnostics mode. 4. Replace the computer board. Err. 1 No rotation signal. 1. Verify belt tautness. 2. Verify the function of the phase pick-up board and, in particular, the reset signal. 3. Replace the phase pick-up board. 4. Replace the computer board. Err. 2 Speed too low during detection. During unbalance measurement rotation, wheel speed is less than 42 rpm. 1. Make sure that a car wheel is mounted on the wheel balancer. 2. Verify belt tautness. 3. Verify the function of the phase pick-up board and, in particular, the reset signal. 4. Replace the computer board. Err. 3 Unbalance too high. 1. Verify wheel dimension settings. 2. Check the connection of the piezo sensors. 3. Perform machine calibration. 4. Mount a wheel with more or less known unbalance (less than 100 grammes) and verify machine result. 5. Replace the computer board. Err. 4 Err. 5 Rotation in opposite direction. After pressing [START], the wheel begins to rotate 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 pick-up board. 1. Reset the error by pressing pushbutton HOME/STOP. 2. Close the guard. 3. Verify the function of the protection Switch. 4. Press the [START] pushbutton. Err. 7 / Err. 8 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. 11 Speed too high error. During unbalance measurement rotation, wheel speed is more than 270 rpm. 1. Check if there is any damage or dirt on the timing disc. 2. Verify the function of the phase pick-up board and, in particular, the reset signal. 3. Replace the computer board. Err. 12 Unbalance measuring 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 the connection of the piezo sensors. 3. Verify machine earth/ground connection. 4. Mount a wheel with more or less known unbalance (less than 100 grammes) and verify machine result. 5. Replace the computer board. Procedure error in automatic distance acquisition in ALU M, ALU 3M and PX mode. 1. Pull out the gauge and measure the outer side distance. 2. Check distance gauge calibration. 3. Check function of distance potentiometer. No unbalance value shown. 1. Turn the wheel until the imbalance is displayed I 0374 GB - 20

21 7.1 - 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 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 using the balancing machine with the wheel mounted. I 0374 GB - 21

22 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 Technical Service Department. NONE OF THE OTHER MACHINE PARTS REQUIRE MAINTENANCE 9 - RECOMMENDED SPARE PARTS LIST (For references, see exploded drawings) CODE DESCRIPTION Bearing Z Ø 25/47/ Spring 19863P Rigid belt - Poly V - TB Vee s 67M38954H Position pick-up board with cable 05PR55985 LEXAN panel Oscillating switch 16A 67M36950A Power board Fuses DM5x20-2A 86SC58670 Computerboard Spring, rim distance gauge 86SB40113 Cable with standard protective microswitch 86SB55636 Cable with "GP" protective microswitch 86SB36752 Cable, automatic distance gauge SPECIAL PARTS FOR 230 V MACHINE 50FG54366 Single phase motor 230V/50-60 Hz Kw HB63B-4 86SZ50867 Complete power board Braking transformer 30 VA -0/ Capacitor 10MF 450V FASTON screw M Power supply transformer 30 VA 230 9/9 SPECIAL PARTS FOR 115 V MACHINE 50FG54283 Single phase motor 115V/50-60 Hz Kw HB63B-4 86SZ50868 Complete power board Braking transformer 30 VA 115-0/ Capacitor 35MF 450V FASTON screw M Power supply transformer 30 VA 115-9/9 I 0374 GB - 22