Read 521 WARRANTY text version

150/250 Wheel Balancer

Instruction Manual and Parts List

Kwik-Way Products Inc. 500 57th Street, Marion, IA 52302 USA

800-553-5953

Copyright 2005 All Rights Reserved

Equipment specifications, options and accessories subject to change without

521 WARRANTY

Brake Lathes Tire Changers · Wheel Balancers

Kwik-Way Products Inc. (Kwik-Way) provides a limited 521 Warranty on products when purchased in a new

and unused condition to be free from defective material or workmanship from date of purchase as per the following: Product BENCH MODEL Category LATHES Spindle, spindle bearing and housing PASSENGER CAR TIRE CHANGERS WHEEL BALANCERS Frame, welding construction All other mechanical parts Motor, electronic components and labor TRUCK LATHES AND TIRE CHANGERS N/A

ON-CAR-LATHES Cast iron components, excluding guide rods

5 Years

Transmission

2 Years

All other mechanical All other mechanical All other mechanical parts parts parts Motor, electronic components and labor Motor, electronic components and labor Motor, electronic components and labor

N/A Machine, components and labor

1 Year

Kwik-Way will repair and/or replace, free of charge (FOB factory) all such defective parts, only when returned to factory with shipping charges prepaid. This warranty does not cover parts and supplies (nylon inserts, nylon mount-demount heads, breaker blade covers, and mount-demount covers) consumed in normal operation of the machine. Kwik-Way disclaims all other warranties, expressed or implied, as to the quality of any goods, including implied warranties of MERCHANTABILITY and FITNESS FOR PARTICULAR PURPOSES. UNDER NO CIRCUMSTANCES WHATSOEVER, SHALL Kwik-Way BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, WHETHER BASED ON LOST GOODWILL, LOST RESALE PROFITS, WORK STOPPAGE, IMPAIRMENT OF OTHER GOODS OR ARISING OUT OF BREACH OF ANY EXPRESS OR IMPLIED WARRANTY, BREACH OF CONTRACT, NEGLIGENCE OR OTHERWISE, EXCEPT ONLY IN THE CASE OF PERSONAL INJURY. Because of Kwik-Way's constant program of product improvement, specifications are subject to change without notice. This warranty does not apply to a product that has been purchased in used condition, that has failed due to improper installation, repairs, service or that has sustained damage caused by accident, improper use or shipment. For further information or questions, please contact Kwik-Way Products Inc at 800/553-5953 or 319/377-9421, fax 319/377-9101, email [email protected]

Kwik-Way Products Inc. 500 57th Street, Marion, IA 52302 USA Copyright 2005 All Rights Reserved

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150/250 Wheel Balancer RECEIVING SHIPMENT

Upon taking delivery of your machine, carefully inspect the assembly before removing the rating and packing materials. If evidence of damage exists, contact the shipper and Kwik-Way Products Inc. immediately. Although Kwik-Way Products Inc. is not responsible for damage incurred during transit, you will be provided assistance in preparation and filing of any necessary claims. CAREFULLY READ THIS MANUAL BEFORE ATTEMPTING TO SETUP O OPERATE THIS MACHINE.

IMPORTANT NOTE

Always have your serial number ready when communicating with Kwik-Way Products Inc. regarding parts or service. Keep this manual in a safe place.

Date Received:

Serial Number:

(Serial Number location: Upper left corner at rear of unit)

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150/250 Wheel Balancer SAFETY FIRST

This manual has been prepared for the owner and those responsible for the maintenance of this machine. It's purpose aside from proper maintenance and operations, is to promote safety through the use of accepted practice. READ THE SAFETY AND OPERATING INSTRUCTIONS THOROUGHLY BEFORE OPERATING THE MACHINE. In order to obtain maximum life and efficiency from your machine, follow all the instructions in the operating manuals carefully. The specifications put forth in this manual were in effect at the time of publication. However, owing to Kwik-Way Products' policy of continuous improvement, changes to these specifications may be made at any time without obligation.

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150/250 Wheel Balancer SAFETY INSTRUCTIONS

1. Read, understand and follow the safety and operating instructions found in this manual. Know the limitations and hazards associated with operating the machine. 2. Eye Safety: Wear an approved safety face shield, goggles or safety glasses to protect eyes when operating the machine. 3. Grounding the Machine: Machines equipped with three prong grounding plugs are so equipped for your protection against shock hazards and should be plugged directly into a properly grounded three-prong receptacle in accordance with national electrical codes and local codes and ordinances. A grounding adapter may be used. If one is used, the green lead should be securely connected to a suitable electrical ground such as a ground wire system. Do not cut off the grounding prong or use an adapter with the grounding prong removed. 4. Work Area: Keep the floor around the machine clean and free of tools, tooling, stock scrap and other foreign material and oil, grease or coolant to minimize the danger of tripping or slipping. Kwik-Way recommends the use of anti-skid floor strips on the floor area where the operator normally stands and that each machine's work area be marked off. Make certain the work area is well lighted and ventilated. Provide for adequate workspace around the machine. 5. Guards: Keep all machine guards in place at all times when machine is in use. 6. Do Not Overreach: Maintain a balanced stance and keep your body under control at all times. 7. Hand Safety: NEVER wear gloves while operating this machine. 8. Machine Capacity: Do not attempt to use the machine beyond its stated capacity or operations. This type of use will reduce the productive life of the machine and could cause the breakage of parts, which could result in personal injury. 9. Avoid Accidental Starting: Make certain the main switch is in the OFF position before connecting power to the machine. 10. Careless Acts: Give the work you are doing your undivided attention. Looking around, carrying on a conversation and horseplay are careless acts that can result in serious injury. 11. Job Completion: If the operation is complete, the machine should be emptied and the work area cleaned. 12. Disconnect All Power and Air to Machine before performing any service or maintenance. 13. Replacement Parts: Use only Kwik-Way Products replacement parts and accessories; otherwise, warranty will be null and void. 14. Misuse: Do not use the machine for other than its intended use. If used for other purposes, Kwik-Way Products Inc. disclaims any real or implied warranty and holds itself harmless for any injury or loss that may result from such use.

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150/250 Wheel Balancer TECHNICAL CHARACTERISTICS

Metric Dimensions Max height (with cover open) Depth (with cover open) Width (without adapter) Width (with adapter) Weight Net Weight (SBM 150/250) Gross Weight (SBM 150/250) Electrical Supply Power supply (3 models) Power Phases Protection Balancing speed Imbalance reading resolution Noise level 1800mm 1260mm 860mm 900mm 187 kg 192 kg 115V 1~ 60Hz 0.7 kW 1~ IP 22 200 rpm at 60Hz 1/5 g (0.01/0.25 oz) < 75 db English 75" 71" 50" 34" 411 lbs. 422 lbs.

RANGE OF APPLICATIONS

The 150/250 Balancer is designed for balancing car wheels up to a weight of 154 lbs. and motorcycle wheels up to a weight of 44 lbs. The operating capacity of the machine is the following: Rim width Rim diameter Max. wheel diameter Max wheel weight (150/250) min/max 1" ­ 20" 10" ­ 26" 900mm 70 kg

44" 154 lbs.

NOTE: The minimum and maximum figures given above refer to the dynamic imbalance on the two compensating planes, or to static imbalance alone. Imbalance is indicated in grams in three digital figures, If readings in ounces are preferred to grams, the transformation can be programmed (see "Wheel Balancer Configuration" section).

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150/250 Wheel Balancer UNPACKING

On receipt of the packed machine, remove the straps (taking care when cutting them) and packing as in Figure 1. After removing the packing check the machine for missing or damaged parts. If in doubt contact your sales representative or Kwik-Way direct. Please open and inspect the accessories provided. NOTE: Discard all non-biodegradable packaging at the appropriate collection points. All packaging materials potentially hazardous to children. Dispose of all materials in a responsible way.

Figure 1

LOCATION OF THE MACHINE

The machine must be placed on a solid floor surface, and should not be any closer to a wall or any fixed object than 20". This is to provide for a safe and ergonomic operation of the machine. Figure 2

Figure 2

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150/250 Wheel Balancer INSTALLATION

Check the voltage at the wall outlet to be used to verify voltage supply matches the voltage on the electrical tag located at the rear of the machine by the cord set. Attach the air supply to the air regulator at the rear of the machine. Check to verify that there are no air leaks and the regulator is adjusted to 115 psi minimum. (P Model only)

MACHINE DESCRIPTION

Figure 3

:

KEY: A: Main Switch B: Power Supply Cable C: Weight Holder Panel D: Control Panel E: Wheel Guard Cover (small cover shown) F: Adapter G. Automatic Gauges H: Brake Pedal I: Adapter and Accessories Support L: Pneumatic Supply (on P version only)

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150/250 Wheel Balancer ACCESSORIES PROVIDED

Figure 4 Key 1 2 4 5 5a 5b 5c 5d 5e 5f 5g 5h 6 N/S

504-6065-00 504-6027-00 504-6294-00 504-6024-00 504-6162-00 504-6161-00 504-6165-00 504-6325-00 504-6528-62 504-6056-00 504-6123-00 504-6528-61 504-6053-00 504-6241-00

Wheel weight pliers Rim caliper Aluminum wheel gauge Bell flange ad cone (set) Kwik-release nut Nylon ring Pressure cup #1 Cone #2 Cone #3 Cone #4 Cone Bell flange Wrench L-Hex M-14 Calibration wheel weight, 3.5 oz/100g

Kwik-Way Products Inc. 500 57th Street, Marion, IA 52302 USA Copyright 2005 All Rights Reserved

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150/250 Wheel Balancer OPTIONAL ACCESSORIES

Figure 5

Key 1 1b 2 3 4 5

504-6276-00 504-6281-00 504-6062-00 504-6063-00 504-6000-00 504-6358-00

Universal flange mount (with standard nuts) Universal flange mount (with Kwik-nuts) Spacer plate (truck cone) Truck cone (4.8-6.70") Truck cone set (includes 504-6062-00/504-6063-00) Motorcycle wheel clamp

Kwik-Way Products Inc. 500 57th Street, Marion, IA 52302 USA Copyright 2005 All Rights Reserved

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150/250 Wheel Balancer INSTRUCTIONS FOR USE

CONTROL PANEL

Figure 6

Key 1. Data display 2. Luminous diode imbalance direction indicators 3. Imbalance point (LED) 4. Rim distance setting buttons 5. Rim diameter setting buttons 6. Rim width setting buttons 7. Unit of measurement selection button for rim width or diameter (mm/ inch) 8. Balancing program selection button (MODE) 9. Select user button 10. Data increase/decrease buttons 11. Data confirm button 12. Optimization button 13. SPLIT button 14. Control functions button (MENU) When the wheel is not being driven by the electrical motor, pressing the brake pedal locks the rotation of the wheel. To read the positions for weight application with the ALUDATA gauge, push the pedal up. Figure 3

Kwik-Way Products Inc. 500 57th Street, Marion, IA 52302 USA Copyright 2005 All Rights Reserved

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150/250 Wheel Balancer WHEEL BALANCING

Switch the machine on with the main switch. When switched on, the machine displays its software version for a few seconds. After this the displays read 0 0. Figure 6 (1) Mount the tire and wheel to be balanced on the spindle using the correct centering cone and adapters and tighten with the Kwik-Nut. To balance a wheel the following data must be entered: a) Select wheel type and balancing program, which is correct for the type of wheel and where the placement of weight will be made. b) Set the wheel measurements: 1. Nominal width 2. Nominal diameter 3. Set the distance from the machine to the internal side of the wheel. For more in-depth instructions on entering wheel data, refer to the paragraph on "Setting the Wheel Data." Close the hood to begin the wheel balancing cycle. When the balancing cycle is completed, the machine will automatically brake to a stop. The amount and position of the imbalance is measured and then shown in the left and right displays. The luminous arrows will indicate the direction in which the wheel must be turned to reach the correct position for balance correction. There are separate indicators for the inside and outside position. When the green center LED is illuminated, it indicates the correct position where the weights are to be attached (twelve o'clock). Attach the correct amount of weight and in the position as indicated by the LED's (inside and outside planes). Close the hood and run a balance cycle to check that the correction is completed. The display will now read 000.

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150/250 Wheel Balancer SELECTING BALANCING PROGRAM

The use of different types of counterweights for balancing different types of wheels (in steel or light alloy) results in variations in the nominal measurements set for the wheel to be balanced and the actual measurements of the correction planes. The wheel balancer offers a variety of balancing programs in order to accommodate these differences. The operator must set the operating mode required on the basis of the type of wheel being balanced, the type of counterweights to be used, and the selected correction planes. Pressing the MODE button Figure 6 (8) scrolls through all the balancing programs available: Standard dynamic balancing with clip weights (with spring). 5 ALU programs for dynamic balancing with adhesive weights. 3 static balancing programs (with spring or adhesive weights). 2 special ALU programs for balancing PAX Michelin tires with adhesive weights and measurements in mm. The LED's on the control panel indicate the position of weights on the rim on the basis of the selected balancing program. When the machine is switched on it automatically configures itself for the standard dynamic program.

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150/250 Wheel Balancer SETTING WHEEL DATA

Setting with the Automatic Gauge Testing is achieved by moving the internal gauge (Figure 7) and external gauge (Figure 8) against the rim. Wait for the confirmation "beep". The figures to set (distance, width, and diameter) are entered automatically. It is a single, quick, error-free operation. NOTE: If the automatic gauges malfunction (and for the "aluminum" and "light alloy" programs) manual programming is possible (see following section).

Figure 7

Figure 8

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150/250 Wheel Balancer SETTING WHEEL DATA (continued)

Manual Setting of Wheel Data On the front panel use the +/- buttons to set the figures for width (Figure 6 (6), diameter (Figure 6 (5) and distance (Figure 6 (4), for the wheel being balanced. The rim width figures are generally given on the rim itself, otherwise it can be measured using the gauge supplied with the machine. Figure 9 The rim diameter is generally given on the rim itself, or can be read from the tire. The rim distance is measured on the internal side of the rim with the cursor gauge fitted on the machine (Figure 10). The distance to be set can be read from the scale. NOTE: For wheels of small dimensions (for example motorcycle wheels) only the static imbalance has to be established. In these cases the STATIC balancing program is used and the correct figures only have to be set for the rim diameter Figure 6 (5). The rim distance and width can be set to any figures.

Figure 9

Figure 10

Entering Measurements in mm The default unit of measurement for rim width and diameter is inches. In order to set wheel measurements in mm press the MM/INCH button and enter the figures in mm as they appear on the wheel. The LED lights up to indicate that the figures are set to mm. Distance is always set in mm (LED on). NOTE: For PAX programs the default unit of measurement of rim width and diameter is mm.

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150/250 Wheel Balancer USING ALUDATA THE PROGRAM

Selecting Balancing Program Pressing the MODE button opens the program selection page. The ALUDATA programs are: 3. ALU 2 4. ALU 3 9. Pax 2 Select the ALUDATA mode balancing program. When the most suitable balancing program has been selected, press the OK or STOP button to return to the main page. Setting Wheel Data When the inside gauge is extracted from its rest position the LED for the selected position starts flashing on the control panel. Position the gauge in the first position selected for balancing, keep it still and lift the pedal up to confirm the position. The corresponding panel LED flashes for the selected position. If the pedal is not enabled wait for the confirmation "beep". Next, locate the gauge at the second position selected for balancing, keep it still and lift the pedal up to confirm the position. The corresponding panel LED flashes for the selected position. If the pedal is not enabled wait for the confirmation "beep". Finally, moving the gauge back to the rest position returns automatically to the main page. Wheel Balancing Close the guard cover and press the START button to begin a measuring cycle. When the readings have been established the wheel will automatically brake until it stops. The scale and position of imbalance on the two sides of the wheel are established in a single measuring cycle and are shown separately on the displays. The arrows indicate the direction the wheel must be turned for the positioning at the point of imbalance (separate indications for the two sides of the wheel). Turn the wheel manually until the imbalance point LED lights up. Figure 6 (1). If the sound signal is enabled it also indicates when the correct position is reached. Insert the required adhesive weight into the relevant seat on the measuring probe with the adhesive part facing up. Remove the protective film, extract the probe towards the balancing position. The arm is automatically stopped when the correct position is reached. Rotate the gauge to bring the weight into contact with the rim and press the extruder to fit the weight.. During this stage the LED relative to the selected position for the application of the weight will flash on the panel and the display shows the position of the arm in relation to the selected balancing planes. When the correct balancing position is reached the displays show a symbol corresponding to the conditions: The wheel is in the correct angular position for balancing. The arm is positioned on the corresponding balancing plane. In these conditions the arm is automatically locked in the correct position and the weight can be fitted.

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150/250 Wheel Balancer USING ALUDATA THE PROGRAM (continued)

NOTE. The arm does not lock if: It is moved too quickly. It has not been moved far enough away from its last locking position. The wheel is not in position. Repeat operations E and F for the opposite side. NOTE: In the WEIGHT SEPARATION program, the E and F operations must be repeated for both weights to be fitted on the outside in the correct positions behind the spokes.

PROGRAMMING AND FITTING ADHESIVE WEIGHTS WITH THE SPECIAL GAUGE FOR ALUMINUM OR LIGHT ALLOY RIMS

Figure 11

Key A: Gauge Base Cursor B: Weight Positioning Gauge Head C: Outside Claw D: Screw Knob E: Scale Plate in Millimeters F: Extruder G: Inside Claw for Fixing Weights H: Grip with Scale Plate Insert A SPECIAL GAUGE is supplied with the machine for the ALU programs and for fixing weights to aluminum and light alloy rims. This gauge, designed for use in the ALU 2, ALU 3 and Pax 2 programs, allows maximum precision (also in relation to the rim shape) when determining the position for attaching adhesive weights.

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150/250 Wheel Balancer PROGRAMMING AND FITTING ADHESIVE WEIGHTS WITH THE SPECIAL GAUGE FOR ALUMINUM OR LIGHT ALLOY RIMS (continued)

Look at Figures 11, 12 and 13. Proceed as follows: Set the machine program to ALU 2. Figure 6. Position the gauge with its base at (A) on the inside edge of the rim. Slide the base A on the millimeter scale (E) and move the outside claw (C) to the required and optimum position for fixing the weight. Fix the base (A) using the screw knob (D). Read the measurement in mm and enter it as the rim width using the keyboard. Run a balancing cycle: the weight figures are given (internal and external). Move the wheel into position and locate the weight (as read on the external display) on the outside claw (C). Move the base (A) to the edge of the rim (12 o'clock) and fix the weight using the extruder (F). Figure 12 Move the wheel into position and locate the weight (as given on the internal display) on the inside claw (G). Move the gauge head (B) to the edge of the rim and attach the weight using the extruder (F). Figure 13 NOTE: For the ALU-3 program the external procedure is the same, while for the internal reading, attach the clip-on weight on the rim flange.

Figure 12

Figure 13

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150/250 Wheel Balancer SPLIT WEIGHT PROGRAM

The Split Weight Program can be used in the Alu 2 and Alu 3 portions of the Balancing Program Selections. To select either ALU 2 or ALU 3, press the Program Selection Key (Figure 6 (8) until the LED combination for the program you wish to use is illuminated on the wheel diagram (center of the display panel). Figure 14.

Figure 14

NOTE: Be sure that the PAX LED is NOT illuminated when selection is made. Once the ALU 2 or ALU 3 program is selected, proceed as follows: Establish the Weight Placement Locations: Move the inside data arm slowly toward the inside flange of the wheel. The inside LED on the wheel diagram will begin to flash, continue to move the arm until it is in the correct position for the weight placement. Lift up on the brake pedal, the LED will stop flashing and become solid, the inside position is set. The outside LED will now begin flashing, continue to move the internal data arm inward into the wheel until the arm is in the correct position for the outside weight placement. Lift up on the brake pedal, the LED will stop flashing and become solid. The outside position is set. Close the hood and run a cycle. Balancing Procedure: Once the cycle is complete, rotate the tire and wheel, watching the left direction indicators (Figure 6(2), continue until the center green LED (Figure 6(3) is lit. The left display will give the correction weight required for this placement. If in ALU 2 Mode: Slowly move the internal distance arm until the left LED on the wheel diagram flashes, the arm will stop automatically. Attach the weight. If in the ALU 3 Mode: Simply place clip-on weight at the twelve o'clock position. Press the split weight key (Figure 6 (13); the right display indicates the number of spokes from the last balance sequence. If this number is incorrect, use the +- key (Figure 6 (10) to enter the correct number of spokes. Rotate the tire and wheel so as to have a spoke at the twelve o'clock position. Press the split weight key again and one of the LED's on the key will become illuminated. Rotate the tire and wheel until the right directional indicator green LED is lit. The right display (Figure 6 (1) will give the correction weight required, move the internal arm in until it locks, and apply the first weight at this position. Rotate the tire and wheel until the opposite LED on the split weight key becomes illuminated. Continue to rotate the tire and wheel until the right directional indicator green LED (Figure 6 (3) is lit. The right display (Figure 6 (1) will give the correction weight required, move the internal arm in until it locks, and apply the second weight at this point. Close the hood and run a cycle. If tire requires additional weight, repeat the procedure from spoke at the twelve o'clock position forward.

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150/250 Wheel Balancer OPTIMIZING IMBALANCE

When the imbalance measured on a wheel is very high (e.g., static imbalance > 1.75 ounces) the imbalance optimization procedure is recommended. This program allows the reduction of the total imbalance of the wheel by compensating, when possible, the static imbalance of the tire with that of the rim. The following operations are required: an initial measuring cycle, rotation the tire on the rim by 180°, a second measuring cycle, another rotation of the tire on the rim to the extent indicated by the machine, and a final check measuring cycle. To activate the static imbalance reduction procedure press the OPTIMIZATION button (Figure 6 (12) and release it immediately: the display reads oPt1. Stage 1: Press the START button to run the first cycle with the wheel to be optimized: at the end of the cycle the display reads oPt2. Stage 2: Rotate the wheel by hand to bring the valve to the twelve o'clock position. Press the SPLIT key (which has both LED's on) to memorize the wheel reference position for the first run. The display reads oPt3. Mark a reference point on the tire itself at the valve position. Stage 3: Remove the rim from the adapter and rotate the tire on the rim by 180° (refer to the mark made on the tire, moving it to a position directly opposite the valve). Remount the rim on the adapter and once more reposition the valve at 12 o'clock. Keeping the wheel in this position, press the SPLIT key (which has both LED's on) to memorize the new position of the rim on the adapter. The display reads oPt 4. Stage 4: Press the START button to run a new cycle. At the end of the cycle the display reads oPt5. IMPORTANT: For best imbalance reduction results it is important that the operations described above are carried out with the maximum precision. Pressing the STOP button at the end of the second cycle displays the following information: Right display: current static imbalance reading for the wheel. Left display: minimal residual imbalance that can be achieved by applying the recommended imbalance reduction. Displaying these figures is useful for deciding if it is worth continuing the imbalance reduction procedure (for the same reason, also after the first cycle the STOP button can be pressed to view the static imbalance on the right display and thus check if it is effectively worth following the reduction procedure). Stage 5: To proceed with reduction of imbalance, rotate the wheel by hand to bring the positioning LED's on the display into a central position and mark the tire at the top (the same position the weight is normally located). To reduce imbalance remove the rim from the adapter and rotate the tire on the rim until the new mark is at the valve position. Remount the rim on the adapter and again position the valve at twelve o'clock. Keeping the wheel in this position press the SPLIT key (with both LED's on) to memorize the new position of the rim on the adapter. The display reads oPt 6.

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150/250 Wheel Balancer OPTIMIZING IMBALANCE (continued)

Stage 6: Press the START key to run a test cycle. At the end of the test cycle the wheel imbalance is automatically compared with the minimum residual imbalance figure. If the difference between these two values is less that the maximum permitted tolerance, the display reads oPt yES. By pressing the STOP button it is in any case possible to display the new static imbalance figure in order to verify the success of the procedure. Stage 7: If the first imbalance reduction cycle has not been satisfactory, the display again reads oPt 5. In this case it is possible to continue imbalance reduction by repeating the steps described above, starting from Stage 5. When it is not possible to further reduce imbalance the procedure terminates: If the procedure was completed with success the display reads oPt yES. If the procedure was unsuccessful the display reads oPt Err indicating that it is necessary to repeat the entire procedure from the beginning. At the end of optimization operations press the STOP button to return to wheel imbalance measuring and the display shows the imbalance for the current wheel. Pressing the OPTIMIZATION button at any time interrupts the imbalance reduction procedure and the system reverts to wheel imbalance measuring mode.

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150/250 Wheel Balancer BALANCER CONFIGURATION

The configuration program allows the user to customize the machine according to their own requirements. Press and hold the MENU button. As soon as SEt appears in the left display, immediately release the button. The machine enters the customizing program, which allows the following parameters to be set. The functions will appear as follows: Zeroing Small Grams. The left display will read toL and the right display gives the current setting in the corresponding unit measurement (grams or ounces). To change the setting, use the keys on Figure 6 (10). The highest setting is 25.0 grams or 1 ounce. Press the OK/MENU button to move to the next parameter. Imbalance Display Interval. The left display reads rES and the right display reads the current imbalance resolution setting in grams or in ounces depending on the unit of measurement programmed. To change the setting, use the keys on Figure 6 (10). The possible settings in grams are: 1: Imbalance displayed is the fine resolution, or at an interval of 1 g. 5: Imbalance displayed is the standard resolution, or at an interval of 5 g The possible settings in ounces are: 0.05: imbalance displayed is the fine resolution, or at an interval of 0.05 ounces. 0.25: imbalance: displayed is the standard resolution, or at an interval of 0.25 ounces. Press the OK/MENU button to move to the next parameter. Imbalance Unit of Measurement: The display reads unb and the right display gives the current imbalance unit of measurement. To change the setting, use the keys on Figure 6 (10). GrA: display currently reads in grams Oun: display currently reads in ounces Press the OK/MENU button to move to the next parameter. Sound Signal: The left display reads Snd and the right display gives the current state, enabled or disabled, of the sound system. The possible settings are: On: sound signal enabled OFF: sound signal is disabled Press the OK/MENU button to move to the next parameter. Start Up By Lowering Guard: The left display reads CAr and a menu opens with the enabled or disabled for activation with the guard lowered. To change the settings, use the keys on Figure 6 (10). The possible settings are: On: start by simply lowering the guard OFF: start by pressing the START button with the guard in the lowered position. Press the OK/MENU button to move to the next parameter.

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150/250 Wheel Balancer BALANCER CONFIGURATION (continued)

Wheel Width Display Interval: The left display shows Lar and the right display shows the present value of the width in inches. Use the keys on Figure 6 (10) to introduce a new value. The possible values are: 0.50: displays the value in ½" increments 0.25: displays the width values in ¼" increments Press the OK/MENU button to move to the next parameter. NOTE: To save changes in the parameters, you must press the OK/MENU button. If the STOP button is pressed before confirming the new setting, or if the unit is switched off, the machine will revert back to its previous settings.

BASIC MACHINE CALIBRATION

Press and hold down the MENU button. As soon as the left display reads CAL immediately release the button and press (within 1.5 sec) the MM/INCH button. The left display reads C-1. NOTE: Use of the MENU button now permits you to scroll through the various calibration menus and choose the one for shaft imbalance calibration (C-1), wheel balancer self-calibration (C-2), or calibration of the automatic gauges (D-1). To exit a menu at any time press STOP. First Stage of Calibration: Shaft Imbalance Correction: Have the bell flange attached to the spindle, but without adapters or tire and wheel. Run a balancing cycle. At the end of the run the measured imbalance is saved. This allows any residual imbalance in the machine's shaft to be compensated electronically. The left display now reads C-2. Second Stage of Calibration: Wheel Balancer Self-Calibration: Install a 5.5" or 6.0" wide, 13" or 14" diameter tire and steel wheel assembly onto the spindle and tighten into place using the correct centering cone and adapters. Carefully set the tire and wheel dimensions using the corresponding pairs of buttons Figure 6 (4,5,6,10). (Manually enter data.) Run a balancing cycle. C-3 will appear on the left display, 100 or 3.50 on the right. Using the 100g (3.5 ounces) calibration weight provided, attach it to the inside wheel flange. NOTE: The 100 or 3.50 is a calibration default setting, if any other value of weight is to be used during calibration, using the buttons +/- move the value up or down in the right display until it shows the corrected value of the weight to be used.

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150/250 Wheel Balancer BASIC MACHINE CALIBRATION (continued)

Run a balancing cycle. At the end of the run C-4 will appear on the left display and 100 or 3.50 on the right. Rotate the tire and wheel until the weight is at the 12:00 o'clock position, then remove and reattach the weight to outside flange exactly at the 12:00 o'clock position. Run a balancing cycle. C-5 will appear in the left display and the calibration angle in the right, rotate the tire and wheel until the wheel weight is exactly in the 6:00 o'clock position. While holding the wheel in this position, press the Split weight button. Figure 6 (13). The calibration settings are automatically and permanently saved. Two test procedures are necessary to ensure that wheel balancing is conducted accurately. Balancing Accuracy Test: Balance the two sides of a wheel according to the instructions. Artificially create an imbalance by fitting a weight of 50 grams (1.75 ounces) on one side of the wheel. The machine should identify this imbalance precisely, both for weight and position. A reading up to a maximum of 5 g (.25 ounce) is possible for the other side. In order to check the position of the imbalance, turn the wheel to the balancing position as indicated by the arrows on the monitor. In this position the test weight should be vertically below the rotation axle (6 o'clock). If there is an obvious angular error the indicators have to be rectified. If there is an unacceptably big weight error on the side with the test weight, or an excessive figure for the opposite side of the wheel, the machine has to be recalibrated. Centering Precision (Balancing Quality): The wheel balanced in the previous test can be used. Remove the test weight. Release the wheel from the adapter and retighten it, but rotated by about 35°. In a test cycle the imbalance must not exceed a maximum of 10 g (.5 ounce) on each side, 15 g (.75 ounce) in the case of particularly heavy wheels. This error is due to the rim centering tolerance. Precise centering is essential both for this test and during normal balancing operations. If this test run produces a high imbalance reading check the parts used for centering the wheel for wear, play, and dirt.

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150/250 Wheel Balancer DATA ARM CALIBRATION

To enter the data arm program, press the MENU key (14), and then within 1.5 seconds, press the IN/MM key (Item 7). Cal 1 will appear in the left display, press the MENU key again until: D-1 appears in the left display. Using the +- key (Item 10) enter the number to match the beginning number on the internal distance arm. Move the arm back to the retract position and then press OK (Item 11).

Figure 15

NOTE: Each graduation on the internal arm scale is one mm. The "beginning number" for this arm is 3 mm. Your beginning number may be different, it is important to use the correct beginning number. D-2 appears in the left display. Move the arm to the full extended position, and while holding in that position, use the +/- key (Item 10) and enter the number which appears on the scale, press OK (Item 11).

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150/250 Wheel Balancer DATA ARM CALIBRATION (continued)

Figure 16

L-1 appears in the left display. Move the external distance arm to the right position (Figure 16) and while holding it in position, measure the distance from the stop surfaces on the contact points of the internal and external arms in mm. While still holding the arm L-2 appears in the left display. Move the external distance arm to the left position and while holding it in position, measure the distance from the stop surfaces on the contact points of the internal and external arms in mm. While holding the arm in the aligned position, use the +/- key (Item 10) enter that measurement and press OK (Item 11).

Figure 17

H-1 appears in the left display. Mount a 14 inch tire and wheel, move the internal arm into position for measuring wheel diameter, while holding in position. Using the +/- key (Item 10) enter the diameter of the wheel and press OK (Item 11). Figure 17 C-2 appears on the left screen. Data arm calibration is complete and data is saved.

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150/250 Wheel Balancer AUTO-DIAGNOSIS

Auto-diagnostic functions are included to check that the balancing machine is working properly. Press and hold down the MENU button. As soon as tSt appears on the left display, immediately release the button and press (within 1.5 sec) the MM/INCH button. This opens the auto-diagnosis menu with the following functions (press the MENU button to scroll through the functions): Pick-up voltage display (recorded during the last measuring cycle): the display reads MSr. To display the figures for the last measurement press the distance button on Figure 6 (4). The right display shows the sequence of readings from the inside pick-up, the outside pick-up, (from 0 to 4095), the phase difference (in °), and the gain employed. To check on pick-up operation, proceed as follows: Mount a test wheel on the machine and balance it perfectly. Fit a single test weight on the outside (e.g. 100 g or 3.5 ounces) and run a test cycle. When completed, check the readings. The inside pick-up voltage figure must always be lower than the outside pick-up voltage figure. Also, the ratio (outside ÷ inside = 1.2 to 1.8) between the outside and inside pick-up figures must always be between 1.2 and 1.8. The phase difference must be 180° ± 1°. Shaft Angular Position Display: The display reads EnC. When the shaft is rotated, the right display varies constantly from 0 to 255 or from 0 to 200, depending on the model. Shaft Speed Check: The display reads SP. By pressing the START button it is possible to check the machine running speed in rpm (200±5rpm @ 60Hz). Reading Signals: To scroll through the menus use the buttons. Figure 6 (4 and 5). The left display reads in sequence An0, An1, ..., An10; figures from 0 to 4095. Pressing the + button moves to the analogue input readings for DISTANCE, WIDTH, and DIAMETER in the corresponding units of measurement. Cycle Counter: The display reads Cnt. To display the cycle count press the distance button (Figure 6 (4) and the right display gives in sequence the total number of cycles and partial number of cycles (from the last time the machine was switched on). Test Display: The display reads LEd; test lighting up of LED's. To scroll the menus use the distance and diameter buttons. Figure 6 (4,5). Self-Calibration Data Display: The display reads tAr. To scroll the menus use the buttons. Figure 6 (4, 5).

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150/250 Wheel Balancer AUTO-DIAGNOSIS (continued)

I/O Test: The display reads i_o; various inputs and outputs are rested: Magnet Output: the left display reads mag; the right display reads on if the magnet is active and oFF if the magnet is inactive. Adapter Enable Output:: the left display reads fla; the right display reads on if the enable output is active and oFF if it is inactive. Pedal Microswitch Input: the left display reads ped; the right display. Reads on is pushed up and oFF if the pedal is in the neutral position. Wheel Guard Microswitch Input: the left display reads inP; the right display reads on if the guard is closed and oFF if the guard is open. Temporary Balancing of a Wheel: The display reads rEL; relative balancing tests can be run on a wheel without actually balancing it using counterweights; Mount the test wheel and launch a first cycle; on completion of the cycle the display shows the real imbalance of the wheel and automatically records the imbalance data and annuls the same for all subsequent measurements. NOTE: The imbalance figures displayed in all the subsequent measurements after activation of this function are not real and are relative to the initial imbalance of the test wheel. This function cannot be memorized and is cancelled when the machine is switched off or by returning to the same function and pressing the decrease button - : the right display reads on if the function is active and oFF if it is inactive.

WARNINGS

The present instructions booklet is an integral part of the product. Carefully study the warnings and instructions contained in it. This information is important for safe use and maintenance. Conserve this booklet carefully for further consultation. The Wheel Balancer SBM 150/250 is a machined designed and constructed for the balancing of car, van and motorcycle wheels. The machine has been designed to operate within the limits described in this booklet and in accordance with the manufacturer's instructions. The machine must be used only for the purpose for which it was expressly designed. Any other use is considered wrong and therefore unacceptable. The maker cannot be held responsible for eventual damage caused by improper, erroneous, or unacceptable use. This symbol is used in the present manual to warn the operator of particular risks associated with the use of the machine.

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150/250 Wheel Balancer TROUBLE SHOOTING GUIDE

Display

Displays do not come on.

Malfunctioning

The card is not powered up.

Causes

1. External supply off or phase not working. 2. Fuse blown in the electrical plant. 3. Control panel fuse blown.

Troubleshooting

1. Check that positive/negative and neutral are connected up to balancer. 2. Replace fuses in electrical plant (blown fuses; indicate fault in electric plant). 3. Replace fuses on control panel (blown fuses indicate fault in electronic fault) 1. Repeat all calibration and balancer configuration stages. 2. Perform missing programming or setting operations. 1. Wait for end of measuring launch before raising guard. 1. Ascertain that the wheel is still before start-up and in any case avoid rotating wheel backwards on START. 2. Check for correct motor connection. 1. Check mains voltage (it is probably low). 2. Replace electronic card. 3. Replace electrical part. 1. Repeat calibration from beginning and apply the calibration weight when instructed in the calibration procedure. (See "Basic Machine Calibration") 2. Check pick-up connections. 1. Lower guard with wheel mounted. 2. Replace microswitch. 1. Check that the calibration weight has been correctly applied. 2. Check machine location, it is probably not stable and is vibrating excessively. 3. If the problem persists after having stabilized the machine correctly, check the sensor and electronic card connections and replace if necessary. 4. Replace pick-ups. 5. If after replacing pick-ups the problem is not solved, replace the card. 1. Check left pick-up connection and replace if necessary.

Err 1

Err 1 appears on power-up.

Err 2 Err 3

During the measuring cycle the Err 2 message appears. During the measuring cycle the Err 3 message appears.

1. The card has lost the calibration data and factory configuration setting. 2. One or more calibration or setting phases have not been carried out. 1. The guard has been raised before completion of measurements. 1. On start-up (using START key or lowering guard) the wheel was rotating backwards. 2. Motor winding inverted. 1. The motor cannot reach the revolutions needed for effective balancing. 2. Electronic card malfunctioning. 3. Electrical plant malfunctioning. 1. Calibration weight has not bee applied on the wheel. 2. The pick-ups have not been connected. 1. The guard has not been lowered. 2. Guard microswitch broken. 1. Phase difference between the 2 pick-ups is too large.

Err 4

The motor does not turn (with START pressed) or after about 20 seconds the Err 4 message appears. At end of second calibrating run with the wheel Err 5 appears on the display.

Err 5

Err 6 Err 7

Message Err 6 appears when pressing the START key. At end of second calibrating run with the wheel Err 7 appears on the display.

Err 8

At end of second calibrating run wit the wheel Err 8 appears on the display.

1. The left pick-up has not been correctly connected or is defective or the cable is disconnected.

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150/250 Wheel Balancer TROUBLE SHOOTING GUIDE (continued)

Err 9 Err 10 At end of second calibrating run with the wheel Err 9 appears on the display. During launch Err 10 appears on the display. 1. The right pick-u has not been correctly connected or is defective or the cable is disconnected. 1. Position sensors in optoelectronics defective. 2. The motor will not turn. 1. Check right pick-up connection and replace if necessary. 1. Check optoelectronic card connection. 2. Check the optoelectronic card is protected from daylight and cover if necessary. 3. If the defect persists check and if necessary replace the optoelectronic card. 4. Check electrical part. 1. Check optoelectronic card connection. 2. Check the optoelectronic card is protected from daylight and cover if necessary. 3. If the defect persists, check and if necessary replace the optoelectronic card. 4. Check the electrical part. 1. Check that the wheel is correctly fixed on the flange. 2. Find the external position, apply a 100 gram weight and launch a run. 1. The connections to the two pickups might be inverted. Check and exchange if necessary. 1. Avoid pressing the brake pedal when the motor is operating. 2. Beware of knocking the machine during the measuring cycle. Check mains voltage ­ probably low. 1. Switch off the machine, lower the guard and switch the machine back on without moving the wheel. 2. If the error persists, check and replace if necessary the electric or electronic part (control panel or encoder card). 1. Check the optoelectronic card is protected from daylight and cover if necessary. 2. If the defect persists, check and if necessary replace the optoelectronic card. 3. Check and if necessary replace the control panel electronic card.

Err 11

During launch Err 11 appears on the display.

1. Passage through zero sensors defective in optoelectronics. 2. The motor will not turn.

Err 17

At end of launch Err 17 appears on display. Err 19 is displayed after the second calibration cycle. During measuring cycle Err 20 appears on display. The wheel speed has gone below the minimum for measurability. During measuring cycle Err 21 appears on display. Possible electrical fault.

1. Weight out of regulation field (weight necessary for balancing the wheel is above 500 grams) 1. The signal reading at the right pick-up is lower than that at the left pick-up. 1. Brake pedal operated during the measurement. 2. Motor rotation speed irregular.

Err 19 Err 20

Err 21

Err 22

During the launch Err 22 appears on display.

1. The electronic card has found a condition of danger connected to a too high wheel speed during an inactive machine phase. 2. The shaft rotates at high speed without the operator having pressed the START command. 3. The electric power is deactivated. 1. Some fault in the optoelectronic signals.

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150/250 Wheel Balancer ROUTINE MAINTENANCE

To ensure proper operation of the machine, it is essential to perform periodic maintenance. MECHANICAL PARTS: Keep the moving parts of the machine clean, wash them with naphtha or a similar product, lubricate them with oil or grease. LUBRICATOR: Check and maintain the oil level in the lubricator, the level must always be within the min/max listed on the outside.

TECHNICAL ASSISTANCE AND SPARE PARTS

For any malfunctions, consult the Troubleshooting Guide in this manual. Any malfunctions other than those listed should be checked by a qualified technician. For prompt assistance, please have the machine mode and serial number ready when you place your call. Any SPARE PARTS must be ordered from Kwik-Way Products or an authorized distributor the manufacturer denies all responsibility for damage or malfunctions resulting from use of nonoriginal substituted parts.

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150/250 Wheel Balancer PART NUMBER REFERENCES

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150/250 Wheel Balancer PART NUMBER REFERENCES

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150/250 Wheel Balancer PART NUMBER REFERENCES

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150/250 Wheel Balancer PART NUMBER REFERENCES (OPTIONALS)

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150/250 Wheel Balancer ELECTRIC DIAGRAM (115V)

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500 57th St., Marion, IA 52302 USA 319/377-9421 319/377-9101 (FAX) 800/553-5953 www.kwik-way.com [email protected]

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