Ath W102 User manual

OPERATING INSTRUCTIONS

ATH W102

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 ................................................................................................................ - 13 -

1.5 Scale Drawing ................................................................................................................. - 14 -

2.0 INSTALLATION ................................................................................................................... - 15 -

2.1 Transport & Storage Conditions ........................................................................................ - 15 -

2.2 Unpacking the machine .................................................................................................... - 15 -

2.3 Delivery Contents ............................................................................................................ - 16 -

2.4 Location .......................................................................................................................... - 17 -

2.5 Fixing ............................................................................................................................. - 17 -

2.6 Electrical Connection ........................................................................................................ - 18 -

2.7 Pneumatic Connection ...................................................................................................... - 18 -

2.8 Hydraulic Connection ....................................................................................................... - 18 -

2.9 Assembly ........................................................................................................................ - 19 -

2.10 Completion of Work ...................................................................................................... - 23 -

3.0 OPERATION ....................................................................................................................... - 24 -

3.1 Operating Instructions ..................................................................................................... - 24 -

3.2 Basic Information ............................................................................................................ - 25 -

4.0 MAINTENANCE ................................................................................................................... - 26 -

4.1 Consumables for installation, maintenance and servicing..................................................... - 26 -

4.2 Safety Regulations for Oil ................................................................................................. - 27 -

4.3 Notes ............................................................................................................................. - 27 -

4.4 Maintenance or Service Plan ............................................................................................. - 28 -

4.5 Troubleshooting / Error Display and Solutions .................................................................... - 28 -

4.6 Maintenance and Service Instructions ................................................................................ - 30 -

4.7 Disposal .......................................................................................................................... - 31 -

5.0 EG-/EU-KONFORMITÄTSERKLÄRUNG / EC-/EU-DECLARATION OF CONFORMITY...................... - 32 -

6.0 APPENDIX .......................................................................................................................... - 33 -

6.1 Pneumatic circuit diagram ................................................................................................ - 33 -

6.2 Electric circuit diagram ..................................................................................................... - 33 -

6.3 Hydraulic circuit diagram .................................................................................................. - 33 -

7.0 WARRANTY CARD ............................................................................................................... - 34 -

7.1 Scope of the Product Warranty ......................................................................................... - 35 -

8.0 INSPECTION LOG ............................................................................................................... - 36 -

8.1 Installation and Handover Log .......................................................................................... - 37 -

8.2 Inspection Plan ................................................................................................................ - 38 -

8.3 Visual inspection (authorised expert) ................................................................................. - 39 -

9.0 SPARE PART BOOK ............................................................................................................. - 43 -

10.0 NOTIZEN ........................................................................................................................... - 55 -

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. Handwheel for lifting and lowering the balancing machine

2. Handle for operating the balancing machine

3. Display

4. Keypad

5. Weight storage

6. Brake lever

7. Main switch with emergency stop function

- for switching the balancing machine on and off

8. Housing

9. Arm

10. Fixing screws

2 1

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

Manufacturer ATH-Heinl GmbH & CO.KG

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Distance between rim and

machine

Rim width

Rim diameter

Selecting the balancing type

- Button

Button for fine display

Selection button

- 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, the following options are available for mounting the wheel.

The first way of mounting a wheel is shown

opposite.

With this method, the wheel rim is stretched onto

the balancing shaft from the exterior using a cone.

If you are using the largest cone, the extension

piece for the clamping cone must also be used.

The extension piece is secured using the screws

that are supplied.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3.3 Wheel assembly

Stand the wheel on the ground in an upright

position (vertically) and move the balancing

machine so that the balancing shaft is guided into

the centre hole on the rim.

Insert the balancing machine into the rim until the

clamping cone and/or clamping cone extension is

touching the rim.

Now position the cone from the outside and secure

it against falling off using the clamping nut.

Manufacturer ATH-Heinl GmbH & CO.KG

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If the rim is not precisely centred on the shaft, the

height can be adjusted by turning the handwheel.

The rim can then be clamped.

!!! TIP: Turn the wheel counterclockwise while

holding the rapid clamping nut in place. The weight

of the wheel will be evenly distributed on the cone.

Manufacturer ATH-Heinl GmbH & CO.KG

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The balancing unit and the wheel can then be

lifted. This should be about 2 cm above the

ground.

You can then secure the balancing machine against

rolling using the adjusting screws on the base

frame.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3.4 Selecting the balancing type

DYN

Dynamic – mode (standard WITHOUT LED):

This function calculates the radial and lateral run-

out of the wheel rim.

The balancing weights are positioned on the

exterior and interior of the stretched wheel.

STA

Static – mode:

This function calculates the radial run-out of the

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 pre-

defined points.

ALU -2-

These functions calculate the radial and lateral run-

out of an aluminium wheel rim.

The balancing weights are positioned at pre-

defined points.

ALU3

These functions calculate the radial and lateral run-

out of an aluminium wheel rim.

The balancing weights are positioned at pre-

defined points.

!!! WARNING: The positions of the adhesive

weights are fixed in the respective programmes

and must be kept at the distances shown opposite.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3.5 Entry of the tyre sizes

a) Wheel data and entries for calculating the imbalance:

The following data must be recorded for balancing:

[A] Distance between wheel and machine

[L] Rim width

[D] Rim diameter

Input using the appropriate buttons.

> >

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3.6 Starting the balancing process

The balancing process can be started by turning the wheel.

As soon as the required speed has been reached, “run” will appear

on the display. Manual turning can then be stopped.

The machine measures the wheel imbalance when idling.

The wheel imbalance will appear on the display after the balancing

process.

The braking process can now be initiated.

Now turn the wheel until the respective diodes all light up.

Position the balancing weight on the rim at the 12 o’clock position.

1.4 Technical Data

Maximum wheel weight < 200 kg

Rim diameter 12 - 24 inches

Rim width 4 - 15 inches

Maximum wheel diameter 1,200 mm

Balancing accuracy in

car mode

1 g / 0.1 ounce

Balancing accuracy in lorry mode

10 g / 0.1 ounce

Electrical system 1 / 220 V / 50 Hz

Shaft diameter 40 mm

Balancing programmes

“Dynamic” mode (standard)

“Static” mode

Standard “ALU-1”, “ALU-2” & “ALU-3” mode

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

Net/gross weight 118 / 180 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

950 mm

Length

1.150 mm

Height 980 mm

Storage temperature -10 to +50 °C

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.

Manufacturer ATH-Heinl GmbH & CO.KG

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2.3 Delivery Contents

Package #1 (23.5 x 39.5 x 25 cm):

Car calibration balancing weight 100 g

Lorry calibration balancing weight 200 g

Weight pliers

Hexagon key 6 mm

Balancing shaft Ø 40 mm x 140 mm

Cone 45 - 75

Cone 72 - 103

Cone 100 - 150

Cone 145 - 170

Cone 165 - 215

Package #2 (36 x 47 x 10.5 cm):

Double cone 198 - 225 / 270 - 287

To be used with clamping cone extension (located

on the wheel balancing machine)

Package #3 (60.5 x 43.5 x 7 cm):

Rim gauge

Measurement range: 3 - 18 inches (80 - 460 mm)

Manufacturer ATH-Heinl GmbH & CO.KG

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2.4 Location

The machine should be kept away from flammable and explosive materials, as well as from sunlight and

intense light. The machine should be placed in a well-ventilated location.

The machine must be set up on sufficiently firm ground, if necessary, according to the minimum

requirements of the information given in the foundation plan.

In addition to the ground conditions, the guidelines and instructions of the accident prevention regulations

as well as the workplace regulations must be observed when selecting an installation site.

When assembling on floor coverings, check their load-bearing capacity. A construction expert should be

consulted for inspection when mounting on floor coverings.

The machine should only be mounted and used within closed rooms. It has no corresponding safety

features (e.g. IP protection, galvanised design, etc.).

Temperature 4-40 °C

Sea level

< 1500 m

Humidity 50% at 40 °C – 90% at 20 °C

2.5 Fixing

General and local regulations must be observed. Therefore, these steps should only be

carried out by a trained professional.

The machine must be set up and fixed on sufficiently firm ground, if necessary, according to the minimum

requirements of the information given in the foundation plan.

The machine must be fastened at the points provided with suitable or specified fastening material.

In addition to the ground conditions, the guidelines and instructions of the accident prevention regulations

as well as the workplace regulations must be observed when selecting an installation site.

When assembling on floor coverings, check their load-bearing capacity. A construction expert should be

consulted for inspection when mounting on floor coverings.

Manufacturer ATH-Heinl GmbH & CO.KG

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2.6 Electrical Connection

General and local regulations must be observed. Therefore, these steps may only be

carried out by a trained professional.

Pay attention to the necessary supply line (see technical data).

The connection should be made with a 230V Schuko plug or 5-phase 16 A CEE plug (partially included).

Voltage deviations should be 0.9 - 1.1 times the nominal voltage range and the frequency deviation should

be 0.99 - 1.01 times the frequency range.

Necessary protective measures must be taken to guarantee this.

At the end of the work, the direction that the motor rotates must be checked.

2.7 Pneumatic Connection

For al

l pneumatic systems, a compressed air maintenance unit (partially included) must

be installed between the supply line and the system.

The air pressure of the supply line must at least correspond to the technical data.

The compressed air maintenance unit must be set correctly and checked.

The compressed air maintenance unit must be serviced at regular intervals.

The maximum or minimum pressure ensures perfect functioning without any damage.

2.8 Hydraulic Connection

Before the system is put into operation or operated for the first time with oil, the

following must be observed with regard to the optimal, trouble-free and almost air-free

functioning

All hydraulic lines must be connected and tightened according to the hydraulic plan and, if applicable

according to the hose designation.

All hydraulic lines and cylinders must be vented according to the hydraulic plan and, if applicable, according

to the hose designation.

In order to ensure the faultless and safe functioning of the system and the hose assemblies used, the

hydraulic fluids used must comply with the specific instructions and recommendations of the manufacturer.

Used media that do not meet the specific requirements or which have unauthorised contamination damage

the entire hydraulic system and shorten the service life of the hydraulic systems used. Warning: (system

contamination can also occur when oil is refilled)

The minimum requirement and minimum oil quantity must be checked and ensured.

Manufacturer ATH-Heinl GmbH & CO.KG

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2.9 Assembly

These instructions are not to be viewed as assembly instructions; hints and tips are

provided only for trained expert installers. Suitable clothing and personal protection must

be worn for the following work.

Incorrect installation and settings lead to exclusion of liability and warranty.

Partly pre-assembled machines must be checked, introduced and approved by a competent person before

commissioning.

Machine assembly must be carried out by a qualified and competent person.

2.9.1 Assembling the balancing shaft

Clean the entry point before assembling the

balancing shaft.

Position the balancing shaft in the corresponding

entry point and screw in place.

2.9.2 Install the fixing screws

Insert the fixing screws into the corresponding

holes in the base frame

Manufacturer ATH-Heinl GmbH & CO.KG

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Calibrating the weight sensors (car)

The machine MUST be calibrated at a minimum before the season or after a longer period of downtime.

Use the “Model” button to select car mode

Clamp a wheel that has already been balanced (14 or 15”) and

enter the wheel values (see Usage, Point 4).

> >

In order to access the calibration system, you must press the key

combination shown opposite:

1. First the F button and then the R button

2. The CAL – CAL displays will appear and the indicator lights

flash.

3. Only release the buttons when the indicator lights are

illuminated constantly.

The first pass can then be started by turning the wheel.

Manual turning can be stopped as soon as the display shows “run”.

The machine will then measure the wheel imbalance.

The display shown opposite appears after the balancing process.

The braking process can now be initiated.

Now turn the wheel until all the INTERNAL diodes light up.

Position the calibration weight (100 g) at the 12 o’clock position on

the inside of the wheel rim.

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