Wheel balancer with microprocessor for cars, light commercial vehicles and motorcycles S 449 C/2 Ed. 01/10 Operating and maintenance instruction manual - Original Instructions - Cod. 3013571
DECLARATION DE CONFORMITE CE CE DECLARATION OF CONFORMITY DICHIARAZIONE DI CONFORMITA CE CE - ÜBEREINSTIMMUNG DECLARACIÓN CE DE CONFORMIDAD GIULIANO S.p.A. - Via Guerrieri, 6-42015 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 S449 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 - 2006/95/CE - 2004/108/CE ed alle Norme: as well as to the following norms: ainsi qu aux normes suivantes: und folgender Vorschrift gemäß: EN 12100-1:2005 - EN 13850:2007 - EN 61000-6-3:2007 - EN 12100-2:2005 - EN 7731:2009 - EN 61000-6-1:2007 - EN 294:1993 - EN 60204-1:2006 - EN 61000-6-4:2007 - EN 349:2008 - EN 60439-1:2000 - EN 61000-6-2:2006 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 17050-1 The model of present declaration is in conformity with directive EN ISO/IEC 17050-1 Le modèle de cette déclaration est conforme à la Norme EN ISO/IEC 17050-1 Das Modell dieser Erklärung übereinstimmt mit der Bestimmung EN ISO/IEC 17050-1 El modelo de esta afirmación está en consonancia con la norma EN ISO/IEC 17050-1 GIULIANO S.p.A Il Presidente G. Maselli
DICHIARAZIONE DI CONFORMITA RAEE RAEE DECLARATION OF CONFORMITY DECLARATION DE CONFORMITE RAEE RAEE - ÜBEREINSTIMMUNG GIULIANO S.p.A. - Via Guerrieri, 6-42015 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
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 DATA...4 2 - HANDLING AND LIFTING...4 3 - STARTUP...4 3.1 - ANCHORING...4 3.2 - ELECTRICAL CONNECTION...4 3.3 - FLANGE MOUNTING...5 3.4 - WHEEL GUARD ASSEMBLY AND ADJUSTMENT (OPTIONAL)...5 3.5 - WD SPACER...5 4 - CONTROLS AND COMPONENTS...5 4.1 - MANUAL DISTANCE MEASUREMENT GAUGE...5 4.2 - KEYBOARD AND DISPLAY...6 4.2.1 FUNCTION MENU MANAGEMENT...7 5 - INSTRUCTIONS FOR USE OF THE WHEEL BALANCER...8 5.1 - SETTING THE WHEEL DIMENSIONS...8 5.2 - RECALCULATION OF THE UNBALANCE VALUES...12 5.3 - MEASUREMENT RESULT...12 5.3.1 - SPLIT FUNCTION (unbalance spread)...13 5.3.2 - OUT OF BALANCE OPTIMIZATION...14 5.3.3 - AUTOMATIC MINIMISATION OF STATIC UNBALANCE...15 6 - SET-UP...16 6.1 - AUTODIAGNOSTICS...16 6.2 - AUTOCALIBRATION...17 7 - ERRORS...18 7.1 - INCONSISTENT UNBALANCE READINGS...19 8 - ROUTINE MAINTENANCE...19 8.1 - REPLACING THE PROTECTION FUSES...19 I 0538 GB - 1
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1 - General 1.1 - 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 GIULIANO. - 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. 1.1.1 - Standard safety devices - Stop push button for stopping the wheel under emergency conditions. - The wheel guard is not compulsory since the balancing speed is less than 100 min -1. 1.2 - 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: ALUS; PAX; SPLIT; Unbalance optimisation; Autodiagnostics; Autocalibration. 1.3 - Overall dimensions (with guard 34") 1 1174 1162 1048 1384 I 0538 GB - 3
1.4 - Technical data Weight (excluding flange)... Single-phase power supply 115 / 230 V - 50/60 Hz Protection class IP 54 Max. power absorbed 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 0-265 mm Rim width setting range 1.5-20 or 40-510 mm Diameter setting range 10-26 or 265-665 mm 2 - Handling and lifting 2 2a Note: DO NOT LIFT THE WHEEL BALANCER USING OTHER GRIPS. 3 - Startup 3.1 - 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). If possible, it is advisable to anchor to the floor using relative mounting feet (see fig. 2a) in the event of continual use with wheels weighing over 35 Kg. 3.2 - Electrical connection The machine is supplied with a single-phase mains cable plus earth (ground). 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 3 A (230V) or 8 A(115 V). See enclosed diagram. I 0538 GB - 4
3.3 - Flange 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. 3 3.4 - Wheel guard assembly and adjustment (optional) a) Fasten the components to the base as illustrated in the specific exploded drawing. b) 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. 3.5 - 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. DC WD Cone 3a Spring 4 - Controls and components 4.1 - Manual distance measurement gauge This gauge serves to manually measure the distance between the point of application of the counterweight and the machine. I 0538 GB - 5
4.2 - Keyboard and display 4 10 7 1/2 15 18 9 8 17 11 12 PAX 16 14 13 6 3 5 4 1-2 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 PAX selection. 9 Correction mode selection pushbutton 10 Push button, SPLIT (unbalance resolution) 11 Push button, FUNCTION MENU 12 MENU selection confirmation pushbutton 13 Push button, cycle start 14 Push button, emergency/home 15 Push button, manual setting 16 DIAMETER selection button 17 WIDTH selection button 18 DISTANCE selection button Note: - Press buttons only with your fingers. Do not use the counterweight grippers or other pointed objects. I 0538 GB - 6
4.2.1 - Function menu management MENU See chapter on unbalance optimisation diameter mm/inch CONFIRM mm/inch width CONFIRM start from guard closing CONFIRM approx. -5 g or 0.1-0.25 oz CONFIRM See chapter on AUTODIAGNOSTICS See chapter on AUTOCALIBRATION g/oz unit of measure unbalance CONFIRM STOP RETURN TO MEASUREMENT FRAME I 0538 GB - 7
5 - Instructions for use of the wheel balancer 5.1 - Setting the wheel dimensions a) DYNAMIC balancing of steel or light alloy rims with application of clip-on weights on the edge of the rim. From the measuring frame press ALU, to select the desired correction mode. The illuminated LEDs indicate the position where the weights should be applied. If a spin has already been carried out, each time the mode is changed, the processor automatically recalculates the unbalance values on the basis of the new setting. - MEASURING 5 b Reading - SETTING - Set the distance a between the inside of the wheel and the machine a + b + - Set the nominal width, normally indicated on the rim, or measure the width b using the caliper gauge supplied. d + - Set the nominal diameter d indicated on the tyre. This setting is also valid for the following correction modes: The STATIC mode is required for motorcycle wheels or when it is not possible to place the counterweights on the two sides of the rim. Balancing of light alloy rims with application of adhesive weights on the shoulders of the rims. The position of the weights is fixed from the edges of the rim to the inside of the rim. Combined balancing: adhesive weight on the outside and clip-on weight on the inside. The position of the outside weight is fixed from the outside edge of the rim to the inside of the rim. Combined balancing: adhesive weight on the inside and clip-on weight on the outside. The position of the inside weight is fixed from the edge of the rim to the inside of the rim. I 0538 GB - 8
b) Balancing of alloy rims with hidden application of the outside adhesive weight. The position of the weights can be set. - MEASURING 6 0 gauge SETTING: a + b + d + (Nominal) d + Note: Hold the button down for more than 2 seconds when the value of the diameter -dappears on the display. d Note: not setting de as it is automatic, de = 0.8 d I 0538 GB - 9
c) Combined balancing: clip-on weight on the inside and hidden adhesive weight on the outside (Mercedes). The position of the weights can be set. - MEASURING 7 0 gauge SETTING: a + b d + + (Nominal) d + Note: not setting de as it is automatic, de = d - 2. Note: Hold the button down for more than 2 seconds when the value of the diameter -dappears on the display. d I 0538 GB - 10
d) PAX-type wheel balancing - MEASURING 8 0 gauge SETTING: a + b d + + (Nominal) d + Note: Hold the button down for more than 2 seconds when the value of the diameter -dappears on the display. d Note: - the diameters must always and only be set in mm - not setting de as it is automatic, de = 0.8 d. I 0538 GB - 11
5.2 - Recalculation of the unbalance values Press STOP after new setting of the measurement. 5.3 - Measurement result 9 Inside correction Outside correction 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). If the unbalance is less than the threshold value selected, is displayed instead of the unbalance value; with FINE the values below the threshold can be read, selected gram by gram. Note : in the case of wheels with a diameter less than or equal to 13 and at temperature conditions near 0, the wheel balancer automatically inserts a special measuring cycle composed of two successive measurements. The accu racy of the unbalance values and the reliability of the wheel balancer remain unchanged. This type of operation is reset each time the wheel balancer is started. I 0538 GB - 12
5.3.1 - SPLIT function (unbalance spread) 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. To start the SPLIT function, input the following data: Display example before the SPLIT function Input the number of spokes ( 3 12 ) - Move a spoke at random to the 12 o clock position 15 30 - Place the first Split unbalance in correction position 1 15 30 - Correction position 1 30 15 - Set the second split unbalance to correction position 2 30 15 - Correction position 2 To return to normal unbalance display, press the button To perform a new spin, subsequently press the button I 0538 GB - 13
5.3.2 - Out of balance 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 greater than 30 g. - It improves the residual eccentricity of the tyre. - 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 180 - Refit the wheel in such a way that the reference marks on the rim and the flange coincide. - RH display: percentage reduction value - LH display: actual static unbalance value which can be reduced by rotation TYRE POSITION 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 START OF OPTIMISATION RETURN TO MEASUREMENT FRAME I 0538 GB - 14
5.3.3 - Automatic minimisation of static unbalance Initial unbalance Phase shift Possible approximations static residue static residue static residue static residue With traditional wheel balancer Choice with minimum static unbalance This program is designed to improve the quality of balancing without any mental effort or waste of time by the operator. In fact, using the normal weights available on the market (pitch of 5 in every 5 g) and applying the two counterweights which a conventional wheel balancer rounds to the nearest value, a residual static unbalance of up to 4 g may result. The damage of such approximation is emphasized by the fact that static unbalance is the cause of most disturbances on vehicles. This new function automatically indicates the optimum entity of the weights to apply by approximating them in an intelligent way according to their position in order to minimize residual static unbalance. I 0538 GB - 15
6 - Set-up 6.1 - Autodiagnostics DISPLAY TEST - All the LEDs and the displays should light up simultaneously. - On the right-hand display the current position of the wheel is indicated with a number from 0 to 127. Turning the wheel in the direction of rotation, the number displayed should increase. Turning the wheel in the opposite direction of rotation the number displayed should decrease. With one full turn of the wheel the number zero should appear only once. - Press: - Control parameter - Checking parameter for technical service - Checking parameter for technical service END OF AUTODIAGNOSTICS STOP CANCEL AUTODIAGNOSTICS IN ANY PHASE. I 0538 GB - 16
6.2 - 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!! - Perform a spin under normal conditions. START - Add 100 g. (3.5 oz) on the outside in any angular position. START - Shift the 100 g weight from the outside to the inside keeping the same angular position. START - Turn the wheel until the 100 g weight is in the 12 o clock position. END OF AUTOCALIBRATION STOP CANCEL AUTOCALIBRATION IN ANY PHASE. I 0538 GB - 17
7 - Errors During machine operation there may be various causes of malfunctioning which, if detected by the microprocessor, are indicated on the display: 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 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 uswitch. 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.32/ Err.33/ Err.34/ Err.35/ Err.36/ Err.37 Maximum number of spins possible for the unbalance measurement has been exceeded. Errors related to test functions of the wheel balancer. 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. Cancel the error and continue using the wheel balancer as normal. I 0538 GB - 18
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. 8.1 - 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 0538 GB - 19
PR 0538 - Recommended spare parts list R SHAFT ASSEMBLY POWER UNIT CODE DESCRIPTION 080077004 Rigid belt Poly V 181206560 Distance gauge spring 511242101 Two pole switch 16A 05PR62046 Lexan panel 86SC61693 Computer board 67M60192A Position pick-up board with cable 86SB72093 Cable with microswitch for GP wheel guard 86SB72089 Cable with microswitch for 34 wheel guard 50FG59009 1-ph Motor 230V/50-60 Hz 50FG61456 1-ph Motor 115V/50-60 Hz 020600503 Bearing 6005-2Z 181198630 Spring 86SZ72076 Complete power plate 230V 86SZ72078 Complete power plate 115V 67M70968O Power board 230V 67M70968P Power board 115V 568001058 Capacitor 10 MF (230V) 568003558 Capacitor 35 MF (115V)
Extraordinary maintenance M TABLE OF CONTENTS Page 1 - TO CHANGE SUPPLY VOLTAGE...3 2 - DISTANCE GAUGE CHECK...3 3 - PIEZO SENSOR ASSEMBLY...4 4 - TROUBLESHOOTING LOGIC SEQUENCE...5 5 - POWER BOARD REPLACEMENT...6 6 - FUNCTIONING AND ACCURACY TEST...7 7 - WHEEL MEASUREMENT AND SETTING ON THE WHEEL BALANCER...8 M 0538 GB - 1
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1 - To change supply voltage (See recommended spare lists and power layout diagram) The machine can run on 115 V - 50/60 Hz or 230 V - 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 power board 2 - Distance gauge check Check that the ruler used for measuring the DISTANCE of the wheels reads 210 mm as measurement of the distance from the adapter plane. If the graduated strip is replaced, position it with the line indicating 210 at the fixed index limit (reading point) when the prod coincides with the adapter plane. 1 Reading point: 210 mm Adapter plane M 0538 GB - 3
3 - 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 50 Mohm). 8. Reassemble the various parts. 9. Again carry out the automatic calibration. 2 3 2 5 4 6 yellow blue yellow white 1 M 0538 GB - 4
4 - Trouble shooting logic sequence Is fuse F1 on the power board in a good state? NO Replace the power board YES Replace the fuse and power the machine YES Does F1 work? NO Disconnect CN1 on the power board. Replace F1 again and power the machine. Does F1 work? NO YES Replace the computer board Is the position sensor working? ( see AUTODIAGNOSTICS) NO YES Replace the position sensor board N.B. : Do not remove the mounting brackets. Replace the computer board M 0538 GB - 5
5 - Power board replacement 3 1 1A 2 2A F1 T1 CN6 WHEEL GUARD CN19 CN1 COMPUTER BOARD CN4 M M 0538 GB - 6
6 - Functioning and accuracy test If not clearly identifiable faults or inaccuracies are encountered, it may be useful to run the functioning and accuracy test. PRELIMINARY CHECKS Thorough cleaning of the flange and cones Spring cover sliding Shaft terminal locking ENCODER TEST (see AUTODIAGNOSTICS) POS = outside display: 0/127 turning the shaft by hand WHEEL BALANCING MACHINE CALIBRATION (see AUTOCALIBRATION) Use a wheel of average dimensions. Ex.: 6 x 14 (± 1 ) Manually set precise measurements Perform autocalibration MACHINE CALIBRATION CHECK 1) Mount an average-sized iron wheel (Ex.: 6 x 14 (± 1 ) and carefully set the Distance / Diameter / Width. 2) Spin 10 consecutive times and measure the repeatability error (normally ± 1 g; acceptable ± 2 g). 3) Balance the wheel as well as possible. 4) Apply 100 g on the outside; you should have: F.E. = 100 ± 5 F.I. 5 gr Weight F.E. = vertical down 5) Remove the 100 g weight from the outside and apply it to the inside; the following should be true : F.I. = 100 ± 5 F.E. 5 gr Weight F.I. = vertical down 6) If the values are out of tolerance, proceed with autocalibration and repeat points 3), 4), 5). FLANGE CHECK With the wheel perfectly balanced, tilt 180 and measure the unbalance values MAX ERR = Especially for this check, it is advisable to use a sample wheel with known max. unbalance errors caused by centring, which for iron wheels are normally less than 10 g. M 0538 GB - 7
7 - 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 throughplanes 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 a b h NOTE : I = INSIDE E = OUTSIDE 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 - 1 de = d preset - 2 0 0gauge Calibro ai di ae de a = ai preset b = ae - ai - 5 mm di = d preset de = d preset - 2 0 gauge ai d ae de a = ai preset - 8 mm b = ae - ai di = d preset de = d preset - 1 M 0538 GB - 8
GIULIANO S.p.A. Via Guerrieri, 6-42015 CORREGGIO - ITALY Tel. +39. 522. 73.11.11 - Fax. +39. 522. 63.31.09 E-mail: giuliano@giuliano.it http://www.giuliano.it