Ath-heinl W42 User manual

OPERATING INSTRUCTIONS

ATH W42

Manufacturer ATH-Heinl GmbH & CO.KG

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Contents

1.0 INTRODUCTION ................................................................................................................... - 3 -

1.1 General Information ........................................................................................................... - 3 -

1.2 Description ........................................................................................................................ - 4 -

1.3 Operation.......................................................................................................................... - 7 -

1.4 Technical Data ................................................................................................................ - 15 -

1.5 Scale Drawing ................................................................................................................. - 16 -

2.0 INSTALLATION ................................................................................................................... - 17 -

2.1 Transport & Storage Conditions ........................................................................................ - 17 -

2.2 Unpacking the machine .................................................................................................... - 18 -

2.3 Delivery Contents ............................................................................................................ - 19 -

2.4 Location .......................................................................................................................... - 21 -

2.5 Fixing ............................................................................................................................. - 22 -

2.6 Electrical Connection ........................................................................................................ - 23 -

2.7 Pneumatic Connection ...................................................................................................... - 23 -

2.8 Hydraulic Connection ....................................................................................................... - 23 -

2.9 Assembly ........................................................................................................................ - 24 -

2.10 Completion of Work ...................................................................................................... - 34 -

3.0 OPERATION ....................................................................................................................... - 35 -

3.1 Operating Instructions ..................................................................................................... - 35 -

3.2 Basic Information ............................................................................................................ - 36 -

4.0 MAINTENANCE ................................................................................................................... - 37 -

4.1 Consumables for installation, maintenance and servicing..................................................... - 37 -

4.2 Safety Regulations for Oil ................................................................................................. - 38 -

4.3 Notes ............................................................................................................................. - 39 -

4.4 Maintenance or Service Plan ............................................................................................. - 39 -

4.5 Troubleshooting / Error Display and Solutions .................................................................... - 40 -

4.6 Maintenance and Service Instructions ................................................................................ - 42 -

4.7 Disposal .......................................................................................................................... - 43 -

5.0 EG-/EU-KONFORMITÄTSERKLÄRUNG / EC-/EU-DECLARATION OF CONFORMITY...................... - 44 -

6.0 APPENDIX .......................................................................................................................... - 45 -

6.1 Pneumatic circuit diagram ................................................................................................ - 45 -

6.2 Electric circuit diagram ..................................................................................................... - 45 -

6.3 Hydraulic circuit diagram .................................................................................................. - 45 -

7.0 WARRANTY CARD ............................................................................................................... - 46 -

7.1 Scope of the Product Warranty ......................................................................................... - 47 -

8.0 INSPECTION LOG ............................................................................................................... - 48 -

8.1 Installation and Handover Log .......................................................................................... - 49 -

8.2 Inspection Plan ................................................................................................................ - 50 -

8.3 Visual inspection (authorised expert) ................................................................................. - 51 -

9.0 SPARE PART BOOK ............................................................................................................. - 55 -

10.0 NOTES ............................................................................................................................... - 78 -

Manufacturer ATH-Heinl GmbH & CO.KG

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1.0 INTRODUCTION

1.1 General Information

THESE INSTRUCTIONS ARE AN INTEGRAL PART OF THE MACHINE.

THEY MUST BE READ AND UNDERSTOOD BY THE USER.

NO LIABILITY IS ASSUMED FOR ANY DAMAGES CAUSED BY FAILURE TO

FOLLOW THESE INSTRUCTIONS OR THE VALID SECURITY PROVISIONS.

WARNING: Follow the instructions to prevent injury or damage.

TIP: Provides more information on functionality and tips for using the device efficiently.

Appropriate protective clothing must be worn for all work on the described system.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.2 Description

1. Main switch with emergency stop function

used to switch the balancing machine on and off

2. Cone intake

3. Weight storage

4. Wheel protector

5. Plunge

6. Balancing shaft

7. Display

8. Control

9. Brake pedal

10. Broad-measurement (optional)

Manufacturer ATH-Heinl GmbH & CO.KG

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1) Display INTERNAL imbalance 2) Display EXTERNAL imbalance

3) Display position of the INTERNAL imbalance 4) Display position of the EXTERNAL imbalance

5) Display mode 6) Indicator light for measurement unit – mm or

inches

7) Display STATIC imbalance 8) Indicator light for measurement unit – g or

ounces

9) Display weight position

3 4

Manufacturer ATH-Heinl GmbH & CO.KG

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Distance between rim and

machine

Rim width

Rim diameter

Calibration button

Self test

Change between

DYNAMIC/STATIC

ALU programme selection

Optimisation programme

Display precise imbalance < 5 g

Change size entries

- Button

Only operate the buttons with your fingers. Under no circumstances should sharp objects be used.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3 Operation

1.3.1. Self test

After it is switched on, the device carries out a self

test and then automatically switches to “dynamic”

mode

1.3.2. Wheel assembly

Select the correct cone to centre the wheel on the balancing flange.

As shown below, there are 2 easy ways to mount the wheel.

a. The first way of mounting a wheel is

shown opposite.

Using this method, the wheel rim is stretched

onto the balancing shaft from the exterior.

If you are using the largest cone, the

extension piece for the clamping cone must

also be used.

This method increases the risk of

clamping errors and is therefore only

recommended for use with steel rims.

b. When using the second method, first

position the tension springs on the

balancing shaft and then a suitable

cone. The wheel rim can be stretched

onto the balancing shaft using a

pressure hood.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3.3. Selecting the balancing type

DYN

Dynamic – mode (standard):

This function calculates the radial and lateral

run-out of an aluminium or steel wheel rim.

The balancing weights are positioned on the

exterior and interior of the wheel.

STA

Static – mode:

This function calculates the radial run-out of a

steel wheel rim.

The balancing weights are positioned centrally

on the wheel rim.

ALU -1-

These functions calculate the radial and lateral

run-out of an aluminium wheel rim.

The balancing weights are positioned at a pre-

defined point.

ALU -2-

These functions calculate the radial and lateral

run-out of an aluminium wheel rim.

The balancing weights are positioned at a pre-

defined point.

ALUS

These functions calculate the radial and lateral

run-out of an aluminium wheel rim.

The balancing weights are positioned at a

location that has been pre-defined by the user.

We recommend selecting the ALUS mode to balance aluminium wheel rims. This mode not only

takes into account the exact cross section of your wheel rim, but also helps you to precisely position the

adhesive weight.

If using ALU 1, the following measurements must be observed when attaching adhesive weights:

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3.4. Entry of the tyre sizes

a) Basics:

In motorcycle mode, an optional measuring tip (+ 100 mm) must be used.

Manufacturer ATH-Heinl GmbH & CO.KG

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b) Wheel data and entries for calculating the imbalance:

The following data must be recorded in the DYN, STA and

ALU1 modes:

[A] Distance between wheel and machine

[B] Rim width

[D] Rim diameter

This data is recorded by positioning the gauge on the

wheel rim. The [A] and [D] data is automatically recorded

by the machine.

The rim width must then be entered using the [B+] / [B-]

buttons.

The following data must be recorded in ALU2 and ALUS

mode:

[A] Distance between the machine and the first adhesive

point

[B] Distance between the machine and the second

adhesive point

[D] Rim diameter

[dE] Rim diameter at the second adhesive point

All wheel values are recorded by the automatic plunge.

During the measurement process, firstly move the plunge

to the first point and then, after a brief wait, it can be

moved to the second point.

The [A]; [B]; [D] and [De] data is then automatically

recorded by the machine.

In this process, the ALUS programme does not need to be

selected in advance.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3.5. Starting the balancing process

Start the balancing process using the

STARTbutton or by closing the wheel protector

Turn the wheel until all the diodes on the display

light up

The weight must then be applied to the wheel.

The machine provides you with the following aids

to ensure precise positioning:

Programme

Internal

weight

External

weight

DYN

12 o'clock

position

(laser)

12 o'clock

position

STA 12 o'clock position (laser)

ALU1

12 o'clock

position

(laser)

12 o'clock

position

ALU2

12 o'clock

position

(laser)

Weight

recording on

the gauge

arm

ALUS

Weight

recording on

the gauge

arm

Weight

recording on

the gauge

arm

a) HID function

- The HID function allows you to position the external balancing weight in a hidden spot behind the

spokes.

- This function is available in ALU2 and ALUS mode.

After the balancing process, the HID programme

can be started by pressing the T + OPT buttons +

The display then shows SPO – 12H.

Turn the wheel until all the diodes on the display

for the external position light up.

Confirm this position using ALU

Manufacturer ATH-Heinl GmbH & CO.KG

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The display will then show SPO – -1-.

Now turn the wheel until the left spoke is at the 12

o'clock position.

Confirm this position using ALU

The display will then show SPO – -2-.

Now turn the wheel until the right spoke is at the

12 o'clock position.

Confirm this position using ALU

The

display will then show the INTERNAL

IMBALANCE and SPL in the third field.

By turning the wheel until all the diodes for the

external position light up, the respective value will

also be displayed.

Next, position the weight against the gauge and

use this to position the weight on the wheel rim.

Manufacturer ATH-Heinl GmbH & CO.KG

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Continue to turn the wheel until all the diodes for

the external position light up in order to pinpoint

the second value. The respective value will then

also be displayed.

Next, position the weight on the gauge and use

this to position the weight on the wheel rim.

b) Optimisation

- It is possible to minimise the static imbalance of the wheel using the OPT function. The unbalance

of the wheel rim is evened out with the unbalance of the tyre.

After a balancing run, you can test the static

imbalance by pressing the F button.

If the imbalance is over 30 g, an optimisation

process is recommended.

Make a mark at the position of the valve on the

tyre, the entry cover of the balancing machine and

the wheel rim so that the mark lines up with the

valve.

Press the OPT button to start the optimisation

process.

A display then appears which tells you to turn the

tyre 180° on the wheel rim.

Remove the wheel from the balancing machine.

Measure the air pressure and remove the tyre

using a suitable tyre changer.

Manufacturer ATH-Heinl GmbH & CO.KG

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Fit the tyre on the wheel rim again and turn it

180°.

Fill the wheel with the same air pressure.

The wheel can then be mounted on the balancing

machine again. Pay attention to the marks on the

entry cover when doing so.

Start the balancing process using the STARTbutton

or by closing the wheel protector

The optimisation that has been calculated will then

appear on the display.

Turn the wheel when stretched until the display

opposite appears.

Mark the TYRE at the 12 o’clock position.

Turn the wheel when stretched until the display

opposite appears.

Mark the WHEEL RIM at the 12 o’clock position.

Remove the wheel from the balancing machine.

Measure the air pressure and remove the tyre

using a suitable tyre changing machine.

Fit the tyre on the wheel rim again and, whilst

doing so, turn the tyre until both marks on the tyre

and the wheel rim line up.

Fill the wheel with the same air pressure.

Start the balancing process using the STARTbutton

or by closing the wheel protector

Manufacturer ATH-Heinl GmbH & CO.KG

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1.4 Technical Data

Maximum wheel weight < 65 kg

Rim diameter 12-24 inches

Rim width

1.5

20 inches

Maximum wheel diameter

800 mm

Balancing accuracy +/- 1 g / 0.1 ounce

Measurement accuracy > 99 %

Cycle time 7 - 12 s

Motor 0.25 kW

Electric system

1 / 220 V / 50 Hz

Power

consumption

< 15 W in standby mode

Balancing speed 180 rpm

Protection type IP 54

Sound pressure level during

operation < 70 dB(A)

Shaft diameter 40 mm

Balancing programmes

“Dynamic” mode (standard)

“Static” mode

Standard “ALU-1”, “ALU-2” mode

“ALU-S” mode

Additional functions

OPT (optimisation) mode

HID mode (positioning behind spokes)

Setting the measurement units to g / ounces, mm / inches

Floor anchor Bolt anchor: M8 x 100

Number of anchors 3

Machine dimensions

(L x W x H) approx. 1330 x 800 x 1700 mm

Net/gross weight 113/176 kg

Manufacturer ATH-Heinl GmbH & CO.KG

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1.5 Scale Drawing

800 mm

1330 mm

1700 mm

Manufacturer ATH-Heinl GmbH & CO.KG

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2.0 INSTALLATION

The machine must be installed by an authorised person according to the instructions.

The operating instructions (including the log) are an important part

of the machine / product.

!!!PLEASE STORE CAREFULLY!!!

The product must be checked after completion of the installation, handover, if necessary, briefing and then

regularly in accordance with the applicable regulations and legal provisions in the country of operation by a

suitable and approved company or facility.

2.1 Transport & Storage Conditions

When transporting and positioning the machine, always use suitable lifting and material handling

equipment and consider the machine’s centre of gravity.

The machine should only be transported with the original packaging.

Data: ----

Width

850 mm

Length

750 mm

Height 1.160 mm

Storage temperature -10 to +50 °C

Manufacturer ATH-Heinl GmbH & CO.KG

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2.2 Unpacking the machine

Remove the top cover of the packaging and make sure that no damage has occurred

during transport.

Remove the safety bolt to remove the machine from the pallet / rack.

Use a suitable lifting device (possibly with a stopping rope) to lower the machine from the

pallet / frame.

The packaging material used for the machine should be stored carefully.

Keep the packaging material out of the reach of children as it may be hazardous.

You can view the current contents of the

packaging in the image opposite.

There is also an accessory pack INSIDE the

balancing machine.

In order to retrieve this, tip the machine slightly

and remove the pack.

If something is missing from the delivery (see

packing slip), please contact our sales

department.

Manufacturer ATH-Heinl GmbH & CO.KG

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2.3 Delivery Contents

Wheel protector

Consists of two plastic arcs and a frame with

handle

LED monitor with holder

Manufacturer ATH-Heinl GmbH & CO.KG

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Wheel rim gauge

Measurement range diameter: 10-23 inches

Measurement range width: 3-14 inches

Packaging dimensions: 455 x 430 x 50 mm

Protector mechanism

Fixing screw for protector

Fixing

Packaging dimensions: 350 x 230 x 160 mm

Accessories box

Packaging dimensions: 385 x 240 x 280 mm

Adhesive weight remover

5 g impact weight

10 g impact weight

35 g impact weight

50 g impact weight

100 g impact weight

Weight pliers

Hexagon key

Tensioned cover

Rubber lip for tensioned cover

Tension spring

Fixing anchor

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