Ath-heinl Ath 1200 User manual

USER´S MANUAL

TRUCK WHEEL BALANCER

ATH 1200

CONTENT

1. DESCRIPTION

1.1 General information

1.2 Technical data

1.3 Recommendations

1.4 Standard safety devices

2. TRANSPORT AND ASSEMBLING

3. ELECTRICAL CONNECTION

4. COMPLETION

4.1 Fixing of balancing shaft

4.2 Adjustment and calibration

5. CONTROL PANEL

6. OPERATION MANUAL

6.1 Self test

6.2 Clamping of wheel

6.3 Input of parameters

6.4 Selection of balancing type

6.5 Standard mode „Dynamic“

6.6 Mode „Static“

6.7 Mode „ALU 1-3“

6.8 Mode „ALU-S“

6.9 Mode motorcycle

7. ADJUSTMENTS

7.1 System adjustmens

7.2 Service calibration

8. ERRORS

8.1 Different balancing results

9. MAINTENANCE

9.1 Adjustment of drive belt tension

9.2 Changing fuses

10. CHECKING OF PIEZO TRANSDUCER

11. MOUNTING OF PIEZO TRANSDUCER

12. OPERATION INSTRUCTION

13. DECLARATION OF CONFORMITY

14. FUNCTION SCHEME

14.1 Electric diagrams

15. TECHNICAL DOCUMENTATION

15.1 Exploded drawing ATH 1200

15.2 Spare parts list ATH 1200

As a descriptive help you can see under the indicated addresses in the internet different videos:

Calibration ATH 1200

http://www.youtube.com/watc

h?v=GLo3kNeApQ0

Operation ATH 1200

http://www.youtube.com/watch

?v=Ub-XB25I9-U

1. DESCRIPTION

1.1 General Information

This microprocessor controlled machine is intended for the balancing of wheels with a weight of up to 160 kg. The key-

controlled system enables a balancing of all types of wheels from standard wheels up to wheels for motorcycles and

racing cars. Due to special functions it is also a balancing of wheels with non-standard rims possible.

General safety information

Only skilled persons are allowed to operate the machine.

If the operator makes unauthorized reconstructions and/or changes on the machine the CE verification will be overridden

and a liability of ATH-Heinl for damages, which are resulting from this reconstructions/changes, is also excluded.

Only use the machine according to its intended and specified use.

If there are occuring errors during operation or during the working process then the machine must be switched-off from

the current before eliminating them.

All electrical connecting and reconnecting works are only to be done by skilled personal under consideration of the

regulations of VDE and/or the responsible power company.

As there is always a residual risk which can not be foreseen while working with technical work equipment, there are

different self-explanatory warning symbols (triangle yellow/black) on the balancing machine.

This warning symbols signalise the operator a possible residual risk and shall provoke a special care to avoid accidents

and/or damages of the product to be treated.

In general the operator shall eliminate possible residual risks before by a proper and careful attitute.

Here it must be especially considered:

Always use correct and proper working materials.

Wearing suitable protective clothing respectively protective agents (e.g. protective glasses, ear protection,

safety shoes and so on).

Considering given information, instructions and technical data of the machine producer respectively of the

producer from the treated product:

-The balancer shall only be used according to its intended use.

-Only skilled personal is allowed to operate the machine.

-Power-operated balancing machines are only allowed to be operated in Germany with a protective bow.

-Safety devices are not allowed to be removed respectively taken out of operation.

-Necessary reparation works are only allowed to be done by skilled service personal. Unauthorized changes

on the machine exclude ATH-Heinl from liability for damages which are arising from this.

-Works on the electrical installation are only allowed to be done by skilled electricians.

-The balancing machine is not allowed to be used in explosive atmosphere (rooms).

-The balancing machine must be firmly fixed on the ground.

Further safety instructions in detail are indicated in the single chapters.

1.2 Technical data

Maximum wheel weight

160

Motor performance

550

Stromversorgung

V / Hz / A

3x400 / 50 / 16

Balancing accuracy

Balancing rpm

U/min

120

Rim diameter

Inch / mm

13 –24 / 330 –610

Rim width

Inch / mm

5 –20 / 127 –508

Cycle time

Sec

Appr. 18

Max. wheel diameter

1200

Net weight

255

Dimension of machine (W x D x H)

1640 x 730 x 1450

Noise level at operation

dB(A)

<70

Operating temperature

°C

0 –50

Shaft diameter

Pneumatic working pressure

bar

4 –8

Cones diameter

50 –82

75 –130

120 –154

151 –171

192 –204

204 –220

270 –290

1.3 Recommendations

Read the operation manual carefully before use.

Keep the operation manual safe.

To guarantee a correct operation, machine parts are not allowed to be removed or modified. If reparations are

necessary, the technical service has to be notified or asked.

Clean the plastic faces with alcohol (do not use solvents).

Take care that the wheel is fixed firmly on the adapter before starting balancing.

The user is not allowed to wear clothing with sagging parts The user has to take care that there are no further

persons are nearby the machine during balancing process.

Do not put big parts on the machine, as this could affect the accuracy of balancing

Do only use the balancing machine for purposes which are described in the operation manual.

The balancing machine must be fixed firmly on the ground to achieve an exact balancing result.

1.4 Standard safety devices

Emergency stop button

Protective bow is made of high-strength plastic. In form and size it is so designed that the balancing weights will not

expel but at most can fall on the ground. .

A micro switch prevents that the machine can be operated when the protective bow was not let down and the wheel

will be decelerate when the protective bow will be raised.

Pneumatic deceleration of the wheel.

2. TRANSPORT AND ASSEMBLING OF THE MACHINE

To raise the machine, only the four support points which are foreseen for this are to be taken. Do not raise under no

circumstances the machine on other points as e.g. the shaft, the display or the plate for accessories. The machine must

stand on the foreseen support points at the ground and must be fixed firmly.

3. ELECTRICAL CONNECTION

The machine shall only be connected to the power supply by skilled personal.

Necessary for the function = L1 –L2 –L3 - PE

Before the machine will be connected to the power supply via a cable it has to be checked if the supply voltage is

identical with that indicated on the name plate. The name plate is on the back of the machine. The connection shall

correspond with the power consumption of the machine. (see name plate).

On the main connection cable of the machine has to be made a plug which corresponds to the needed standard.

It is recommendable to connect the machine via an own connection and a suitable circuit breaker.

4. COMPLETION

4.1 Fixing of balancing shaft

Before the thread shaft will be put on the balancing shaft it has to be checked, if the area around the shaft and the thread

shaft is clean. The thread shaft will be fixed to the balancing shaft by a socket screw.

4.2 Adjustment and calibration

Please refer to point 7 ADJUSTMENTS

5. CONTROL PANEL

AIndicator: Position of inner unbalance

BDigital display: Inner unbalance

CDigital display: Static unbalance

DIndicator: Position of weights

EDigital display: Outer unbalance

FIndicator: Position of outer unbalance

GLamp: Dynamic

HLamp: Static

ILamp: ALU

JLamp: ALU S

KLamp: Optimizatioin unbalance

LLamp: mm/inch

MLamp: Mode „CAR“

NLamp: Mode „TRUCK“

OButton: Change of input parameters

PButton: Minus

QButton: Plus

RButton: Enter

SButton: Wechsel DYNAMISCH/STATISCH

TButton: ALU program selection

UButton: Optimization unbalance

VButton:Recalculation

WButton: Start

XButton: Mode change CAR-TRUCK

YButton: Indication of exact unbalance <5g

ZButton: Emergency stop

AA Wheel lifter down

AB Wheel lifter up

Push the buttons only with the fingers.

Do not use under no circumstances the tongues for the compensating weights or other sharp objects.

6. OPERATION MANUAL

6.1 Self test

After switching on the machine makes a self test and

changes automatically in the mode „Dynamic“.

6.2 Clamping of wheel

The standard equipment of the balancer is a clamping shaft, 6 cones and a clamping nut.

There are different possibilities to clamp the wheel. It is possible to clamp the wheel with the suitable cone and clamping

nut from the front (see picture). It is also possible to clamp the wheel with a cone from behind and to fix it with a five-star

flange. It must always paid attention to that an unsufficient centering leads to a wrong balancing result.

6.3 Input of wheel parameters

Except of the program "ALU-S", which needs 4

parameters, all other programs need only 3 parameters.

The parameters are shown in figure 10, figure 11 shows

the parameters for the program „ALU-S”.

Dynamic, Static, ALU 1-3,

Mode

ALU-S

Mode

6.4 Selection of balancing type

The standard mode after switching on is the Dynamic

mode.

By pressing the corresponding button can be selected

any mode as shown adjacent.

OPT is an additional function.

OPT can be used in the dynamic and in the static

mode.

With CAR/TRUCK can be changed between truck

and car mode.

6.5 Standard mode "Dynamic"

This function determines the parameter of the unbalance on the outer and inner side of the clamped wheel and shows then

the weight and the exact position of the counterweight.

After the wheel is clamped properly and the wheel parameters are entered follow the steps described below.

Input wheel parameters

Or close

protective bow

Stopps while opening the protective bow or with button "STOP"

Balancing finished

The measuring is finished and the

results of the unbalance are shown in

the display.

Turn the wheel until all LED´s at the

indicator „Outer“ illuminates and fix the

corresponding weight at the position 12

o´clock. (here 70 g).

Turn the wheel until all LED´s at the

indicator „Inner“ illuminates and fix the

corresponding weight at the position 12

o´clock. (here 40 g).

6.6 Mode "Static"

After the measuring in the mode „Dynamic“ it can be selected directly the mode „Static“. The wheel balancer will then

calculate automatically the result fort he mode „Static“.

If the mode “Static” was selected from the beginning, follow after the wheel clamping and exact input of the wheel

parameters the following instructions:

Input of wheel parameters

Or close protective bow

Open protective

bow

The measuring is finished and the results will be shown in

the display

Turn the wheel until all LED´s in the indicator „Outer“

illuminate and fix the corresponding weight at the position

12 o´clock. (here 60 g).

Balancing finished

6.7 Mode ALU 1 - ALU 3

In the programs ALU 1-3 there are different possibilities

to place the counterweights as shown adjacent.

In the mentioned symbols are always used the

parameters as for steel rims. Thereby can occure

inexactnesses when placing the weights.

After the balancing process the counterweights must be

fixed at the position 12 o´clock. Adjacent figure 18

shows the dimension for fixing the weights.

6.8 Mode ALU-S

This special function can be used for aluminium rims if there was no satisfied result in the standard ALU-programs. By

determining of two exact distance dimensions for placing the weights there will be achieved considerably more exact

results (Abb. 1).

By pressing the button ALU (out of the standard mode 4

times) the mode ALU-S will be reached.

Input of wheel parameters (see Abb. 2):

Press button (Change of wheel parameters) and in

the display appears AI (Inner distance).

Determine with the gauge the dimension and enter it.

Press button (Change of wheel parameters) and

in the display appears AE (Outer distance).

Determine with the gauge the dimension and enter it.

Press button (Change of wheel parameters) and in

the display appears DI (Inner diameter).

Input diameter which is indicated on the rim.

Press button (Change of wheel parameters) and

in the display appears DE.

The program takes as standard parameter 80% of the

entered value for DI. This can be changed according to

the type of rim.

Now the balancing process starts and thus the unbalance

of the wheel will be determined.

Following the needed adhesive weights will be placed on

the determined distance measures at the position 12

o´clock and a new balance process will be started to

achieve the balancing result.

By pressing the button the residual unbalance can

be displayed in a 1 g –separation.

Abb. 1

Abb. 2

7. ADJUSTMENTS

7.1 System adjustments

With help of the system adjustment can be determined the basic adjustments, which will remain also after switching-off of

the machine (e.g. Auto-Start, exactness of display, unit of measurements and weights and so on.)

Press button for appr. 5 sec

Auto-Start oor with Start button

Display measuring result:

CAR: 1 g or 5 g steps

TRUCK: 10 g or 50 g steps

Threshold unbalance display:

Possilbe values CAR: 1 g to 50 g

Possible values TRUCK: 10 g to 100 g

Signal tone On or Off

Input unit for width:

0 = mm 0,0 = Inch

Input unit for diameter:

0 = mm 0,0 = Inch

Unit for weights:

Gram or ounce

Saving & End

End

7.2 Service-calibration of wheel balancer ATH 1200 (Operation in both modes)

Fort he calibration must be clamped a

wheel with steel rim ≥ 15 inches (CAR-

mode) resp. ≥ 22,5 inchesl (TRUCK-

mode) and the wheel parameters

must be entered.

With adjacent key combination will be

called the standard calibration:

Press button FINE, then additionally

ENTER, release FINE, release

ENTER only after the display „CAL 1“

appears.

With the following key combination can

now be called the service calibration:

Press ENTER, then FINE, hold both

keys until „CA.2“ appears in the

display, then release first ENTER and

then FINE.

After pressing the button ENTER

appears „CAL-Add-0“ in the display.

By pressing the button START the

balancing process for the calibration

will be started.

After the balancing process appears in

the display „CAL-Add-100“. Turn the

wheel until all LED´s of the display

unbalance illuminate and fix the 100g

weight at the position 12 o´clock

outside.

By pressing the button START the

balancing process for the calibration

will be started newly.

After the balancing process appears

„100-Add-CAL“ in the display. Remove

the 100 g weight outside. Turn the

wheel until all LED´s of the display

unbalance illuminate and fix the 100g

weight at the position 12 o´clock

inside.

By pressing the button START the

balancing process for the calibration

will be started newly.

After the balancing process is finished

the measuring data will be memorized

and the calibration is finished.

8. ERROR AND REMEDY

The wheel balancer can shown the following errors:

Display

Meaning

Remedy

Ccc ccc

The measuring result is outside of the

display area

OFF OFF

During the balancing process was

pressed the button STOP

Err 01

While protective bow function was

activated the protective bow was

opened during the balancing process or

while protective bow was open the

button START was pressed.

Close protective bow or deactive the

protective bow function.

ATTENTION: The corresponding

regulations for protective bows in the

corresponding country must be

observed.

Err 02

The needed number of revolutions for

the measuring was not achieved or was

underrunned during measuring.

Problems on the electromotor or on the

drive belt. Check and adjust.

Also a too low wheel weight can cause

this error.

ERR CAL

Machine wrong or not calibrated.

Calibrate machine newly.

Further errors

Different balancing results during balancing process:

Wheel balancer is not fixed firmly on the ground

Erroneous calibration

Balancing shaft not fix; shaft twisted

Piezo transducer not fix

Rim is not clean or warped

Buttons do not work

Key board is not connected to the control board or cable connection is defect.

Motor electric

Circuit breaker of the house fuse is blown: Main switch of machine is not connected correctly or there is a contact

error. Main board is defect.

8.1 Different balancing values

It can happen that it will be determined that a wheel after it has been balanced and was clamped again to check the

balancing, was balanced wrong.

The reason for that is not that the machine display is wrong but that the wheel was clamped wrongly on the adaptor, that

means that the wheel was clamped wrongly at one of the two balancing processes.

If the wheel is clamped on the adapter it can be that the screws are not tightened correctly. The screws are to be

tightened crosswise in succession. It has often happened that boreholes with too big tolerances has led to an incorrect

clamping.

Smaller errors of up to 10 g can be seen as normal if the wheels are clamped with a cone.

If a wheel, after it was mounted on the car, has still an unbalance it can be that the brake drum of the vehicle is the

reason or that the boreholes in the rim or at the brake drum have a too big tolerance. In such a case a readjustment is

recommendable without demounting the wheel before.

9. MAINTENANCE (For non-skilled personal)

Disconnect the machine from the power supply before any maintenance work.

9.1 Adjustment of drive belt tension

1. Remove carefully the cover (weights rack). It has to be paid attention to that no cables will be damaged.

2. Loosen the 4 fixing screws of the motor, then move the motor until the correct belt tension is done.

3. Retighten the 4 screws again. While the belt is running, check that the belt does not go off lateral. Mount the cover

again.

9.2 Changing fuses

Remove carefully the cover ( weights rack) in order to obtain access to the power board and to the two fuses on the

board. If the fuses must be changed then use only fuses with the same values.

If the error persists, you should contact the ATH Service.

10. CHECKING OF POSITION SENSOR

To check the function of the position sensor the following must be done:

1. Make sure that none of the three photocells have contact with the phase plate and the RESET-tooth.

2. Check with a DC voltmeter the following voltages (machine is on but no revolution

*between earth and red wire: +5 V DC

*between earth and yellow wire (RESET): + 4,5 - 4,8 V DC, if the RESET-tooth is in the photocell TCST 2000;

and 0 V DC if the RESET-tooth is outside of the photocell.

*between earth and green wire (CLOCK) and between earth and white wire (U/D): If the machine shaft is turned

very slowly, the voltage should change from 0 V DC to 4,5/4,8 V DC.

WIf the position sensor must be changed, only the two fixing screws must be loosened and the board taken out. As

the holder must not be taken out, a new positioning is easier.

11. MOUNTING OF PIEZO TRANSDUCER

Einbauanweisungen:

Übermäßige Asynchronität und Kompensation können durch einen defekten Piezoaufnehmer verursacht werden. Um die

Piezoaufnehmer auszutauschen, ist wie folgt vorzugehen.

1. Remove the cover (weights rack) carefully.

2. Remove the nuts 1 and 2 together with lock washers and washers.

3. Loosen the nuts 3, 4 and 5, then remove the corresponding parts.

4. Put together again the corresponding parts without tigthening the screws. Pay attention to the correct order.

Pay attention to the colours of the wires, as indicated in the drawing, while mounting the piezo

transducer.

5. Tighten nut 5 with a wrench. Tighten nuts 3 and 4 by hand (plus a half turn with a wrench, if necessary). The shaft

must be exactly aligned here.

6. Put on the lock washers for the nuts 1 and 2. Tighten the nuts strongly so that the lock washers will be pressed

together. Then loosen the nuts a half turn. With that a correct pre-tension of the piezo transducer will be ensured.

Alternatively also a torque wrench can be used ( 400 kg / cm).

7. Coat the piezo transducer with silicone.

For a correct operaton the isolation of the crystals must be at least 50 MOhm.

8. Mount the cover again.

9. Make a service calibration.

12. OPERATION INSTRUCTIONS

OPERATION INSTRUCTION

TRUCK WHEEL BALANCER

1. Application

This operation instruction is valid for working with truck wheel balancer

2. Danger for human and environment

Risk of tilting or slipping of the machine

Risk of slackened wheels

Risk of flying away dirt or dust particles

Risk of loose hanging clothing or long hair

Trip hazard and falling down

Hardness of hearing by hurtful noise

Disease of the backbone by lifting and carrying heavy loads

3. Protective measures and directives

Ensure proper stability

Wear personal protective clothes:

Safety shoes,

Protective goggles and gloves,

ear protection

Put protective device in operation

Use proper adapters

Clean the wheel from dirt (wet cleaning, do not use compressed air!)

Wear close-fitting working clothes, possibly with Velcro fastener on

arms and legs

Protective cap for long hairs

If possible, use transport devices and lifting devices and transport in

pairs

Pay attention to an ergonomic workplace design

Right lifting and carrying for the backbone

4. Behaviour in case of error and danger

In case of security relevant errors stop immediately the operation and

secure it against use.

Inform responsible person in case of defects

Remedy of deficiencies only by experts!.

5. Behaviour in case of accidents –first aid

Secure the scene of accident.

Render first aid, inform first-aider and your boss.________________

Take care of the person injured.

Place of first aid kit and first aid book: ________________

EMERGENCY CALL:

________________

Record all information in the first aid book ________________

6. Maintenance, Disposal

Maintenance works on the lift are made by: ________________

Responsible for disposal (e.g. used oil):: ________________

13. DECLARATION OF CONFORMITY

Seriennummer / Serial number:

Konformitätserklärung

Declaration of conformity

Déclaration de conformité

Declaración de conformidad

Für / for / pour / para

Typ / Type / Type / Tipo

Reifenmontiermaschine

Tyre Changer

Démonte-pneus

Desmontadora

ATH 1200

Wurden folgende einschlägige Bestimmungen beachtet

The following EG-directives are considered

Les Directives suivantes de l’Union européenne ont été respectées

Los siguientes directivas pertinentes de la Unión Europa fuen cumplido

Maschinenrichtlinie (Machine-Directive):

73/23/EEC

93/68/EEC

Folgende harmonisierten Normen und Vorschriften wurden eingehalten

The following harmonized standards are applied

Les normes harmonisées suivantes ont été appliquées

Los siguientes normas y reglamentos armonizados fuen cumplido

DIN EN 60204-1: 2000

Hersteller

Manufacturer

Fabricant

Fabricante

ATH-Heinl GmbH &Co. KG

Kauerhofer Straße 2

D-92237 Sulzbach-Rosenberg

Germany

Prüfinstitut

Institut of Quality

Institut de qualité

Instituto de calidad

TÜV Rheinland Product Safety GmbH

Am Grauen Stein

D-51105 Köln

Germany

Referenznummer der technischen Daten:

Reference number for the technical data:

Numéro de référence des données techniques:

Número de referencia de los datos técnicos:

16700486 001

Typ / Type / Type / Tipo

Herstellerbezeichnung

Designation of producer

Désignation du producteur

Denominación del fabricante

ATH 1200

Nummer des Zertifikats:

Number of the certificate:

Numéro du Certificat

Número del certificado

AM 50076547 0001

Hiermit wird bestätigt, dass die oben bezeichneten Maschinen den genannten EG-Richtlinien entsprechen.

Herewith we confirm that the above named machines are according to the named EC-directives.

Nous certifions par la présente la conformité des machines décrites ci-dessus aux Directives de l’Union européennes citées.

Confirmamos con esto de que la mercancía denominada arriba cumple las directivas llamadas de la Unión Europea.

ATH-Heinl GmbH &Co. KG

Kauerhofer Straße 2

D-92237 Sulzbach-Rosenberg

Germany

Im September 2008

ATH-Heinl GmbH & Co. KG/ Hans Heinl (Geschäftsführer)

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