Jema Autolifte DWC-9-E User manual

Wheel balancer
DWC-9-E
OPERATING MANUAL

Manual
Wheel balancer for passenger car wheels, trucks and
(optionally) motorcycle wheels.
DWC-9-E
Serial number .........................................................................................
Production date ......................................................................................
SUPPLIER
Jema Autolifte A/S
Industrihegnet 2
Tel. [phone]
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_________________________ Table of Content__________________________
1. Introduction ........................................................................................ 5
1.1 The manual......................................................................................... 5
1.2 Preliminary work with the wheel balancer......................................... 5
1.3 Machine's identification data.............................................................. 6
1.4 Technical specification....................................................................... 6
2. Description of the wheel balancer...................................................... 7
2.1 Machine equipment ............................................................................ 8
2.2 Keyboard description.......................................................................... 9
3. Safety.................................................................................................... 10
3.1 General precautions.............................................................................. 10
4. Maintenance and scrapping of wheel balancer..................................... 12
4.1 Maintenance.......................................................................................... 12
4.1.1 Periodical maintenance......................................................................... 12
4.2 Machine scrapping................................................................................ 13
4.2.1 Fire protection....................................................................................... 13
4.2.2 Accident prevention.............................................................................. 13
4.2.3 Safety designing provided in the wheel balancer................................. 13
4.2.4 Noise evaluation................................................................................... 13
5. Installation of the wheel balancer......................................................... 14
5.1 Installation requirements ...................................................................... 14
5.1.1 Power supply source requirements....................................................... 14
5.2 Place of installation .............................................................................. 15
5.2.1 Required working area ......................................................................... 15
5.3 Mounting car wheels'holder ................................................................. 16
5.3.1 Description of the holder's elements .................................................... 16
5.3.2 The clamp nut....................................................................................... 16
5.4 Holder's elements.................................................................................. 17
5.5 Mounting motorcycle wheels'holder.................................................... 18
5.6 Mounting the hood................................................................................ 18
5.7 Fixing wheels on wheel balancer's holders.......................................... 19
5.7.1 Car or delivery truck wheel.................................................................. 19
5.7.2 Mounting the spike holder.................................................................... 22
5.7.3 Car wheel in a spike holder.................................................................. 23
5.7.4 Motorcycle wheel................................................................................. 24
6. Working with the machine ................................................................... 25
6.1 Connecting the machine to a power outlet........................................... 25
6.2 Activating the wheel balancer.............................................................. 25
6.3 Selecting weight placement (ALU)...................................................... 25
6.4 Other icons on the display.................................................................... 26
6.5 Changing of threshold .......................................................................... 27
6.6 Input of parameter values..................................................................... 27
6.6.1 User memory ........................................................................................ 28
6.6.2 Imbalance recalculation........................................................................ 28
6.6.3 AUTOSTART function........................................................................ 28
6.7 Balancing a wheel................................................................................. 29
6.8 Automatic wheel positioning................................................................ 29
6.9 Optimisation ......................................................................................... 30
6.10 "Hidden weight" program - 3P............................................................. 31
6.11 Calibration............................................................................................ 32
6.11.1 Calibration using the device................................................................. 32
6.11.2 Calibration using a wheel..................................................................... 32
6.11.3 Balancing a wheel before calibrating with it........................................ 32
7. Diagnostics and fault detection ............................................................ 33
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Packing, transportation and storage information
ATTENTION: All operations concerning packing, lifting, moving,
transporting and unpacking must be carried out by qualified personnel only.
Packing
The wheel balancer is sent as a complete piece of equipment (quick change holder,
wheel balancer, protective hood, operating manual). The wheel balancer can be
packed in a few different ways:
-pallet + stretch foil + carton box
-pallet + stretch foil
-palet + carton box
Transport
The package can be lifted or displaced by fork-lift or pallet trucks. Once the cargo arrives
at its destination, it is recommended to check if its contents have not been damaged during
transportation. It is also recommended to check the conformity of the delivery with its bill
of landing. In case of non-conformity or transportation damages it is necessary to inform
without delay the responsible person or carrier about it. Moreover, the loading should be
done with extreme precautions and consideration.
Storage
The machine should be stored in a dry room free of dust.
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1. Introduction
WARNING: This manual is intended for personnel licensed to service
the wheel balancer (operator) and those who carry out current
maintenance. Before starting any operations concerning the balancing
machine or the package, one should carefully study the manual. It contains
important information concerning personal security of the operators and
maintenance personnel as well as wheel balancer’s operation.
1.1 The manual
For proper usage of this manual, the following should be applied:
-The manual must be kept in the proximity of the machine in a place of easy access.
-The manual must be kept in a dry place.
-The manual must be used properly with care not to damage it.
It is forbidden for operators who have not studied this manual to work with a balancing
machine.This manual is an integral part of the wheel balancer and should always
accompany the machine even if it is going to be sold.
ATTENTION: It is strongly advised to read carefully and repeatedly chapter
3 in which very important information and warnings concerning safety are
contained.
1.2 Preliminary work with the wheel balancer
ATTENTION: Lifting, transportation, unpacking, assembly, installation,
putting in motion, preliminary adjustment and testing, maintenance repairs,
technical inspections, do not require the presence of service personnel but
must be carried out with extreme precaution.
The manufacturer does not bear any responsibility for personnel injuries or
vehicle and other object damages if any of the above mentioned operations
will be performed not according to the service manual or the balancing
machine was used in an improper way.
In the manual only the aspects of the servicing and security which can help operators and
servicing personnel in a better understanding of the construction and working of the
wheel balancer and to allow them to use it the best way possible were enumerated.
To understand the vocabulary used in the manual, operators must possess specific
experience in servicing, maintenance, repairs, workshop works and ability to correctly
decode all drawings and descriptions contained in the manual. Operators must also know
general and detailed safety requirements obligatory in the installation country. The word
"operator" used in this manual should be understood in the following manner: Operator: a
person licensed to service a wheel balancer.
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1.3 Machine's identification data
When contacting our authorized service, providing the model and serial number aids
getting help from service Staff and quickens the process of sending spare parts.
For convenience and clarity, a table is presented below.
If any differences between the table below and the name plate on the machine, data on
name plate apply. - Fig. 1.1
1.4 Technical specification
Wheel diameter
10"-30"
Wheel width
2"-15”
Imbalance indication accuracy
lg
Imbalance location signal accuracy
3°
Measurement time
approx. 7s
Wheel weight
up to 60kg
Drive motor rating
80W
Spindle rotation speed during measurement
Overall dimensions
160 rpm
No hood, with wheel holder
1000 x 580 x 900 mm
With hood opened
1170 x 1000 x 1450 mm
Total machine weight
approx. 85 kg
Power supply
230V/50Hz
Average level of acoustic pressure Lav
65 dBA
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2. Description of the wheel balancer
DWC-9-E wheel balancer are designed for balancing of car and motorcycle wheels
in a single measurement cycle. Original construction solutions assure safe, simple and
comfortable operating of the machine as well as reliability and fast wheel balancing.
The wheel balancer is equipped with:
•quick mounting holder
•hood
•LCD display
•sound speaker
•automatic calibration program
•"Hidden weight" program
•optimisation program
•imbalance recalculation
•ALU program for working with aluminum rims
•user memory bank
The wheel balancer has following attributes:
•modem measurement system with a computer system for data processing to ensure
fast and complete measurement with great accuracy,
•the possibility to choose a program for wheel handling (also for light aluminium
rims) with every type of balancing weights - hammered or adhesive,
•the possibility of regulating balancing accuracy, according to the wheel’s mass and
state,
•easy programming and measurement with an ergonomic keyboard design,
versatility of special holders enabling attachment of almost all wheel types,
•automatic calibration system that allows the machine to regulate the measurement
system on its own if operator assumes incorrect imbalance indications of the
•machine,
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2.1 Machine equipment
Fig. 2.1 Wheel balancer and its elements
1Hood
2Arm of the hood
3Collar of hood's axis
4LCD display
5Keyboard
6Adjuster
7Machine's main switch
8Power cable
9Holders for additional elements
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2.2 Keyboard description
Fig. 2.2 shows the wheel balancer's keyboard
(5 in fig. 2.1). All functions of each button have been described in table 2.2.
Description of buttons' functions (from fig. 2.2)
1
START
Starting of measurement cycle
2
STOP
Stopping a measurement cycle / imbalance correction place
movement
3
Q
Changing of threshold
4
3P
Activate "Hidden weight" program
5
CAL
Calibration
6
OPT
Optimisation
7
Left
Turn the wheel to left imbalance point
8
Distance
Setting distance parameter
9
Diameter
Setting diameter parameter
10
Width
Setting width parameter
11
ALU
Weight placement selection
12
Right
Turn the wheel to right imbalance point
13
Plus
Increase selected value
14
Minus
Decrease selected value
15
M
User memory
16
(?)
Recalculate imbalance of the wheel
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3. Safety
WARNING: This chapter should be read carefully because it contains
important information for operators and other persons concerning hazards of
using the wheel balancer in an inappropriate way.
Below are explanations concerning hazards and risks which can occur during balancing
machine operating and maintenance. General and detailed precautions are given for
avoiding potential hazards.
WARNING: The DWC-9-E wheel balancer was designed for the
balancing of car and motorcycle wheels in one measurement cycle. Any work
with the wheel balancer should be preceded by comprehensive reading
and understanding of this manual. Any other type of usage of this balancing
machine is not allowed. In particular, the wheel balancer is not intended
for balancing other elements.
ATTENTION: The manufacturer and the dealer do not bear any
responsibility for personnel injuries or vehicle and other objects' damages in
case of improper or unauthorized use of the wheel balancer!
Any operation of the wheel balancer is not allowed without prior closing
of tiie hood. Not satisfying the above mentioned recommendations can result
in serious human injuries and irreparable wheel balancer's damages and
wheel damages.
3.1 General precautions
It is required that the operator and the maintenance technician adapt safety rules obligatory
in the country of installation. Moreover, the operator and the maintenance staff should read
all the information regarding safety placed on the machine and all the information included
in this manual.
Risk of electric shock - hazard of electric shock can occur in those wheel balancer
areas, where electric cables are placed. Use of water sprayers, vapour sprayers (high
pressure washing units), dissolvers and painting equipment is not allowed in vicinity of the
wheel balancer and in particular they should not be in contact with the control unit.
Impact risk - during operation of the machine here is a risk of some parts of the balancing
machine hitting the operator. With the protective screen open, personnel must preserve all
precautions to avoid hitting against machine parts.
Risk of wheel easing - before balancing starts, one should check if the wheel is properly
and firmly fixed in the machine's holder.
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ATTENTION: It is forbidden to unscrew the wheel during machine work!
It is forbidden to use wheels excising the maximum wheel weight - 60 kg!
It is forbidden to leave the machine unattended during work!
It is forbidden to initiate a measurement with an incorrectly mounted wheel!
Skid risk - this hazard can be caused by floor contamination with grease in the proximity
of the wheel balancer. The area under the wheel balancer, the holders and the area
near them must be kept clean at all times. All the oil spots should be removed instantly.
Hazard caused by poor illumination - the operator and the maintenance technician must
have the possibility to check if all areas of the wheel balancer are properly and
uniformly illuminated according to the regulations applied in the installation place.
Risk of wheel balancer defect during work - to produce a reliable and safe balancing
machine, the manufacturer applied suitable materials and manufacturing techniques that
are necessary for this type of equipment. Nevertheless the wheel balancer should be
operated according to the producer's recommendations. Technical service (after warranty
period) and other maintenance works described in chapter
4.1 - "Maintenance" should be carried out with specified periodicity.
ATTENTION: All operations of the wheel balancer contrary to its
function can cause danger, serious damage or accidents to anybody near the
machine. It is crucial to scrupulously observe all recommendations contained
in this manual concerning maintenance and safety.
Risk involving machine's moving parts - During any kind of operations all limbs should
be kept as far from moving parts as possible at all times. Necklaces, bracelets and loose
clothes as well as long hair may cause potential danger to the operator. It is mandatory to
take any jewellery off, wear clothes fit close to body and use headgear. The operator should
use appropriate shoes to prevent any lower limb injuries.
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4. Maintenance and scrapping of wheel balancer
4.1 Maintenance
Maintenance should be conducted by experienced personnel with knowledge concerning
the principles of wheel balancer's operation. During the maintenance process one
should preserve all precautions in order to avoid any accidental start of the balancing
machine. The master switch should be pushed out and its light should be off. One should
also adhere to all instructions given in chapter 3 "Safety".
4.1.1 Periodical maintenance
In order to keep the wheel balancer in a good operational state one should observe the
below mentioned indications:
•Clean your wheel balancer at least once a month without using any chemical
washing agents or high pressure spray guns.
•Check the operational state of all equipment periodically.
•Lubricate all holders periodically and keep them clean.
•Check the state of all cords once a year.
ATTENTION: Disregard of these recommendations will dismiss the
manufacturer from any responsibility included in warranty.
WARNING: Always remove all dirt from the area near the wheel balancer.
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4.2 Machine scrapping
ATTENTION: During machine scrapping one should preserve all
precautions described in chapter 3, also applied during assembly.
As well as assembly, disassembly has to be executed by trained personnel only. All metal
parts should be utilized as metal scrap. In all cases of machine scrapping, the utilization of
all materials has to be conducted according to the rules applied in the country of
installation.
One should also notice that for tax purposes, effective machine scrapping should be
documented in reports and forms according to the rules applied in the installation country.
4.2.1 Fire protection
This machine does not constitute fire hazard. Nevertheless, room in which the balancing
machine is installed, has to fulfill requirements of fire protection regulations applied in the
country of installation.
Always keep one or more portable fire extinguishers within the operator's reach (operator
zone), in order to prevent any fire hazard.
4.2.2 Accident prevention
During lifling/lowering, shifting, installing, assembling and disassembling of the balancing
machine, one should preserve all precautions provided in regulations concerning accident
prevention applied in the installation country. Moreover, all regulations concerning fork-lift
trucks have to be preserved.
4.2.3 Safety designing provided in the wheel balancer
The machine has been equipped with a hood, which protects the operator with revolving
parts of the balancer. The machine has been designed in such manner as not to initiate a
measurement by accident or start one with the hood opened.
Each measurement initiation has to be preceded with pressing the , button, which
starts only a single measurement (assured by software).
Due to many safety design constructs, it is impossible for the machine to initiate any kind
of measurement sequence on its own.
If any other incidental situations not mentioned in this operating manual occur, the operator
is to immediately stop working with the machine, call authorized service and describe the
problem.
4.2.4 Noise evaluation
Noise emission approximations where conducted in ordinary surroundings for a wheel
wheel balancer using environmental correction, defined and simplified by norm PN-EN
ISO 11202. Measurements where made using a 20” wheel, weight approximately 30kg and
in correct working conditions, i.e. nominal power supply conditions.
Measurements using a calibrated microphone where performed during a period from start
of measurement and reaching maximal rotation speed to turning the drive motor off and
stopping the wheel completely. For evaluation purposes an average from a couple of
maximised measurements has been taken.
Average level of acoustic pressure Lav = 65 dBA
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5. Installation of the wheel balancer
WARNING: These operations can be executed by persons who were earlier
trained in servicing equipment described in this manual. To avoid possible
wheel balancer damage or causing human injuries, it is necessary to
preserve mentioned instructions. One must make sure nobody is within the
working area of the machine.
5.1 Installation requirements
The wheel balancer has to be installed at a safe distance from walls, columns or any
equipment. The room must be equipped with an electric power source. The balancing
machine can be positioned on any surface, provided it is hard and perfectly horizontal. All
parts must be uniformly illuminated, for the light intensity assures safe completion of all
regulations and maintenance works specified in this manual. The presence of shaded
places, light reflections or dazzling light is unacceptable. One must avoid any situations
leading to eye fatigue. Illumination must be installed according to the regulations
obligatory at the installation place (it is the responsibility of the light installation
contractor).
Before starting the installation process, it is recommended to unpack all parts and check for
any type of damage. All matters concerning displacing and lifting were discussed in chapter
"Packing, transportation, storage".
ATTENTION! THE MACHINE MUST NOT BE PERMANENTLY
SCREWED TO ANY SURFACE!
HOLES IN THE BOTTOM PART OF THE MACHINE ARE FOR
TRANSPORTING PURPOSES ONLY!
5.1.1 Power supply source requirements
Wheel balancer is powered using a single phase alternating current 230V/50Hz. It
should be connected to a power socket using an appropriate plug and secured with a 30mA
residual-current fuse. Additionally the machine is protected from over current using a 2A
fuse.
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2.1 Place of installation
The wheel balancer should be installed in a locked, dry and heated (during
autumn/winter season) room. Humidity should be between 30-95% with no vapor
condensation. Temperature should be kept between 0-55 °C. The surface on which the
wheel balancer will be standing should be hard and horizontal (best if concrete).
The machine should be placed on four rubber backings provided with the equipment. They
should be placed under four legs welded to the wheel balancer's base.
2.1.1 Required working area
Fig. 5.1 Machine surroundings: minimal distance from walls and
operator's working setting.
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5.3 Mounting car wheels' holder
WARNING: The wheel balancer may be delivered with an already
mounted holder.
An assembled holder for car wheels with rims having a central mounting hole is shown in
fig. 5.2.
Before mounting the holder, clean the cone surface of the spindle and the surface of the
holder (1, 2). Place the holder on the spindle so the position of the markers (3) on the
spindle's snug and on the holder is aligned as shown in the figure. Lastly, screw the holder
onto the spindle with the bolt (4).
Fig. 5.2 Holder for car wheels (with no nut, cone or bushings)
1: Spindle 3: Markers
2: Holder 4: Bolt
5.3.1 Description of the holder's elements
The fast mounting holder was designed for car wheels with rims having a central hole.
Figure 5.5 shows all of the holder's elements with their description.
5.3.2 The clamp nut
Figure 5.3 shows the clamp nut in two positions: (a) (CLEARANCE) - one can freely
move the nut along the thread, (|j) (CLAMP) - the nut can be screwed on the thread of the
shaft.
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ATTENTION: Careful cleaning of the cone surface and maintaining the
position of the holder's markers is a crucial condition for accurate
measurement.

Fig. 5.3 Clamp nut
Fig. 5.4 Nut with mounted clamp.
5.4 Description of the holder's elements
1: holder with flange 7: centering cone no. 2
2: clamp nut 8: centering cone no. 3*
3: bolt used for mounting the holder on the 9: centering cone no. 4*
spindle 10: centering cone no. 5 (110-125mm)*
4: cone spring 11: centering cone no. 6 (125-145mm)*
5: nut clamp 12: centering cone no. 7 (145-165 mm)*
6: centering cone no. 1 * _ extra equipment
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Fig. 5.5 Elements of the holder:

5.5 Mounting motorcycle wheels' holder
ATTENTION: Motorcycle wheels' holder is not standard equipment and -
if needed - can be purchased separately
WARNING: The wheel balancer may be delivered with an already
mounted holder.
Mounting motorcycle wheels' holder is very similar to mounting car wheels' holder, which
was described in chapter 5.3. In fig. 5.6 the holder has been presented and all of its parts
described.
For proper holder mounting, the holder's bar with a matching base (1) should be placed on
the machine's spindle (1 in fig. 5.2). Secondly, the holder's axis (3) is to be screwed to the
spindle using the shorter thread and tightened using a size 22 wrench.
Fig. 5.6 Motorcycle wheel's holder elements:
1 : holder's bar with a base 4: cone muff - 2 pcs.
2: tyre clamps 5: distance muff - 6 pcs.
3: holder's axis 6: holder's screw.
5.6 Mounting the hood
The description and numeration below is based on figure 2.1.
-Unscrew all bolts from the collar (3),
-While holding the hood (1) set it in such position that holes in arm of the hood (2)
are aligned with holes in the collar (3),
-Screw the arm (2) to the collar (3).
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5.7 Fixing wheels on wheel balancer's holders
5.7.1 Car wheel
Figure 5.7 shows four stages of mounting a car wheel on the wheel balancer's holder.
Firstly, one has to slide the wheel on the radix of the holder (fig. 5.7(a)) and hang its hole's
edge on the centering cone (fig. 5.7(2)). Secondly, place the collar of the nut in
CLEARANCE position and slide the nut on the radix until there is no more space
(fig. 5.1(c)). Then, using left hand to lift the wheel, place the thumb on the stud of the nut,
move the collar to the left to CLAMP position and screw the nut pressing to the flange of
the holder (fig. 5.7(2)).
Fig. 5.7 Mounting a car wheel in the holder.
Figure 5.8 shows two stages of dismounting a car wheel from the wheel balancer's
holder. In order to dismount the wheel, place the holder's collar in CLEARANCE position
(fig. 5.8(a)) and then turn the nut a little (fig. 5.8(2))- When it becomes loose, one can
slide the nut and the wheel from the holder.
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Fig. 5.8 Dismounting the wheel from the holder.

Construction and equipment of the holder make it possible to mount wheels with different
rim shapes and different central hole diameters which is shown in figure 5.9. If using оде
of the centering cones, the wheel should be mounted from the outer side like in fig. 5.9(a)
and 5.9(д), without using nut clamp 5 nor cone spring 4 (fig. 5.5). If due to the rim
mounted the cone is to be placed from the inner side, the nut clamp should be put onto the
clamp nut (fig. 5.4), spring with a matching cone slid to the handle in such manner that
bigger basis is facing the machine. Lastly, slide the wheel onto the cone and screw it firmly
to the holder using the clamp nut.
Fig. 5.9 Various methods of using the holder and its equipment.
When centering disks and cones are used for centering from the external edge of the rim, one
should take the clamp off the nut. In order to do so, pull the clamp along the axis so it goes
off the detent. One can gently dent it with a screwdriver. In order to put the clamp on, push
it in the nut's detent.
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