Wheel balancer machine for trucks, bus and car wheels with manual ...

Wheel balancer machine for
trucks, bus
and car wheels with manual
spin
or motor-driven spin
S 444
Ed. 01/10
Operating and maintenance instruction manual
- Original Instructions -
Cod. 3006250

DECLARATION DE CONFORMITE CE
CE DECLARATION OF CONFORMITY
DICHIARAZIONE DI CONFORMITA CE
CE - ÜBEREINSTIMMUNG
DECLARACIÓN CE DE CONFORMIDAD
GIULIANO S.p.A. - Via Guerrieri, 6 - 42015 Correggio (RE) ITALY
dichiara sotto la propria esclusiva responsabilità che il prodotto:
declare on our own responsibility that the product:
Déclare sous son propre responsabilité que le produit:
erklärt unter ihrer eigenen Verantwortung, daß das Erzeugnis:
declara bajo su exclusiva responsabilidad que el producto:
Equilibratrice Balancer Equilibreuse Auswuchtmaschine
Equilibradora
S 444
Matricola
al quale questa dichiarazione si riferisce E' CONFORME ALLE SEGUENTI DIRETTIVE:
to which declaration refers is in conformity with the FOLLOWING DIRECTIVES:
au quel cette déclaration se rapporte EST CONFORME AUX DIRECTIVES SUIVANTES:
darauf diese Erklärung Bezug nimmt, mit den folgenden Bestimmungen übereinstimmt:
2006/42/CE - 2006/95/CE - 2004/108/CE
ed alle Norme:
as well as to the following norms:
ainsi qu’aux normes suivantes:
und folgender Vorschrift gemäß:
EN 12100-1:2005 - EN 13850:2007 - EN 61000-6-3:2007 - EN 12100-2:2005 -
EN 7731:2009 - EN 61000-6-1:2007 - EN 294:1993 - EN 60204-1:2006 -
EN 61000-6-4:2007 - EN 349:2008 - EN 60439-1:2000 - EN 61000-6-2:2006
Il firmatario della presente dichiarazione è la persona autorizzata a costituire il fascicolo tecnico
The signer of this declaration of conformity is the person authorized to provide for the technical file literature
Le signataire de cette déclaration de conformité est la personne autorisée à produire le dossier technique
Der Unterzeichner dieser CE-Übereinstimmung ist dazu ermächtigt, das technische Aktenbündel vorzulegen
El firmante de esta declaración es la persona autorizada para elaborar el expediente técnico
Correggio, 07/01/2010
Il modello della presente dichiarazione è conforme alla Norma EN ISO/IEC 17050-1
The model of present declaration is in conformity with directive EN ISO/IEC 17050-1
Le modèle de cette déclaration est conforme à la Norme EN ISO/IEC 17050-1
Das Modell dieser Erklärung übereinstimmt mit der Bestimmung EN ISO/IEC 17050-1
El modelo de esta afirmación está en consonancia con la norma EN ISO/IEC 17050-1
GIULIANO S.p.A
Il Presidente
G. Maselli

DICHIARAZIONE DI CONFORMITA’ RAEE
RAEE DECLARATION OF CONFORMITY
DECLARATION DE CONFORMITE RAEE
RAEE - ÜBEREINSTIMMUNG
GIULIANO S.p.A. - Via Guerrieri, 6
- 42015 Correggio (RE) ITALY
dichiara sotto la propria esclusiva responsabilità che il prodotto:
declare on our own responsibility that the product:
Déclare sous son propre responsabilité que le produit:
erklärt unter ihrer eigenen Verantwortung, daß das Erzeugnis:
Equilibratrice ruote
Equilibreuse de roue
Wheel-balancer
Radauswuchtmaschine
al quale questa dichiarazione si riferisce E’ CONFORME ALLA DIRETTIVA:
to which declaration refers is in conformity with the FOLLOWING DIRECTIVE:
au quel cette déclaration se rapporte EST CONFORME À LA DIRECTIVES SUIVANTES:
darauf diese Erklärung Bezug nimmt, mit der folgenden Bestimmungen
übereinstimmt:
2002/96/CE e 2003/108/CE (RAEE)
Raccolta differenziata
Specific garbage collection
Collecte sélective
getrennte Müllsammlung
La presente macchina/apparecchiatura rientra nelle prescrizioni della Direttiva 2002/96/CE e 2003/108/CE (RAEE) e non può essere smaltita
come rifiuto urbano generico ma attraverso raccolta separata; Il simbolo del bidone barrato riportato sul prodotto indica questa prescrizione.
Lo smaltimento della stessa e dei suoi componenti dovrà avvenire secondo quanto previsto dalle Direttive 2002/96/CE e
2003/108/CE (RAEE) e le disposizioni di Legge del Paese di destinazione della macchina/apparecchiatura; il mancato
rispetto della direttiva è sanzionabile secondo le disposizioni di Legge del Paese di dstinazione.
L’abbandono o smaltimento non corretto delle macchine/apparecchiature sottoposte alla Direttiva 2002/96/CE può
provocare gravi danni all’ambiente ed alle persone.
Il costruttore è disponibile, ai sensi della Direttiva, allo smaltimento della macchina/apparecchiatura; per questo servizio contattare il costruttore
o i rivenditori autorizzati secondo il Paese di destinazione della macchina/apparecchiatura.
This equipment is subject to the regulations foreseen by Directives 2002/96/CE and 2003/108/CE (RAEE) and
therefore it cannot be scrapped as a generic scrap material but through specific collection circuits; the symbol with
“barred tank” marked on the product refers to this prescription.
Scrapping must be made in accordance with Directives 2002/96/CE and 2003/108/CE (RAEE) as well as with the
local Regulations in force in the Country of installation, the non-respect of the Directive is subject to sanctions
according to the national Laws of the Country of destination.
Abandonment or wrong scrapping of the equipment subject to Directive 2002/96/CE can cause serious damage to
the environment.
The manufacturer is available, according to the Directive, to scrap the equipment; for this service, please contact
the manufacturer or your dealer.
Ce produit rentre dans les prescriptions des Directives 2002/96/CE et 2003/108/CE (RAEE) et il ne peut donc pas
être mis à la ferraille comme du matériel générique mais à travers un circuit de collecte sélective; le symbole du
« bidon barré » reproduit sur la machine se réfère à cette prescription.
Le traitement de la machine et de ses composants devra se réaliser en conformité aux Directives 2002/96/CE et
2003/108/CE (RAEE) ainsi qu’aux dispositions de Loi en vigueur dans le Pays de destination de la machine, le non-respect de la
Directive est passible de sanctions par rapport aux Lois nationales du Pays de destination.
L’abandon ou un traitement erroné des produits sujets à la Directive 2002/96/CE peut provoquer de graves dégâts à
l’environnement.
Le constructeur est disposé, aux termes de la Directive, à s’occuper du traitement de la machine; pour ce service contacter le
constructeur ou les revendeurs autorisés.
Die vorliegende Maschine/Gerät fällt in den Vorschriften der 2002/96/CE Richtlinie, und kann nicht
als allgemeiner Stadtmüll sondern durch getrennte Müllsammlung beseitigt werden; das Symbol
mit der durchgestrichenen Mülltonne weist auf diese Vorschrift hin.
Die Entsorgung des Gerätes und seiner Bestandteilen muss nach den 2002/96/CE und 2003/108/CE
(RAEE) Richtlinien und nach den Vorschriften des Bestimmungslandes der Maschine/Gerätes
erfolgen, die Nicht-Beachtung der Vorschrift ist sanktionierbar laut dem Gesetz des Bestimmungslandes
Die unkorrekte Entsorgung oder Verlassen der zu der 2002/96/CE vorgelegenen Richtlinie Maschine/
Gerätes kann die Umwelt und die Personen schwer beschädigen.
Gemäß der Richtlinie, steht der Hersteller für die Entsorgung der Maschine/Gerätes zur Verfügung;
dazu setzen Sie sich mit dem Hersteller oder mit den berechtigten Händlern nach dem
Bestimmungsortes der Maschine/Gerätes in Verbindung.
Correggio, 01/07/06

0123
1 - DESCRIPTION OF THE BALANCING MACHINE
1.1 - GENERAL
The machine is designed for precision balancing of truck, bus and cars wheels, weighing up to 200 Kg.
The machine is complete with a built-in pneumatic lift mounted on castors in order to facilitate clamping of
the wheel on the adapter and to ensure greater mounting accuracy.
Technical features
· Wheel spinning is powered by a single phase electric motor and is actuated by shifting a lever which
moves the driver pulley in contact with the driven pulley and then presses the START push-button.
· Pad type brake operated by the very same spinning lever displaced to the opposite direction.
· Brake can be locked for easier wheel mounting.
· Measurement can be made with any speed of rotation, therefore it is not necessary to wait to reach a
preset speed.
· The amount of unbalance and relative position are shown on digital displays after just one measuring
spin.
· Easy selection of static balancing only or for balancing light alloy wheels of unusual shape (1 STATIC
function and 2 ALU functions). Furthermore, the unique ALU S function allows calibration to be performed
for special light alloy wheels with direct presetting of the measurements.
· Self-calibration of the machine can be easily and quickly carried out with any wheel, even if not balanced.
1.2 - TECHNICAL DATA
⎯ Max wheel weight...............................................................................200 Kg
⎯ Max power consumption....................................................................500W
⎯ Standard power supply.......................................................................230 V single phase (or 115 V)
⎯ Balancing accuracy............................................................................1 gr
⎯ Min/max balancing speeds.................................................................42/120 r.p.m.
⎯ Rim diameter......................................................................................from 10" to 26" or from 255 to 660 mm
⎯ Rim width............................................................................................from 1.5" to 20" or from 40 to 510 mm
⎯ Cycle time...........................................................................................8 to 20 sec
⎯ Net weight..........................................................................................210 Kg
⎯ Overall dimensions of machine..........................................................1880 x 840 x h = 970
⎯ Sound pressure level in cycle.............................................................< 70 d B (A)
⎯ Operating temperature range.............................................................from 0 to 50° C
⎯ Min/max compressed air pressure (LIFT)..........................................from 8 to 10 Kg/cm² ~ 0,8 ÷ 1Mpa
................................................................................................................8 ÷ 10 BAR; ~ 115 ÷ 145 PSI
- UNBALANCE DISPLAY PITCH:
CARS = 5 g (0.25 oz)
TRUCKS = 50 g (1 oz)
When FINE (END) is pressed, the unbalance is displayed with pitch: 1 g for CARS
10 g for TRUCKS
- UNBALANCE DISPLAY THRESHOLD:
CARS = 5 g (.3 Oz)

5
CONTENTS
PAGE
1 - DESCRIPTION OF THE BALANCING MACHINE...........................................................................................................4
1.1 - GENERAL.........................................................................................................................................................4
1.2 - TECHNICAL DATA............................................................................................................................................4
1.3 - USER RECOMMENDATIONS..........................................................................................................................5
1.4 - STANDARD SAFETY DEVICES.......................................................................................................................5
2 - HOISTING AND INSTALLATION.....................................................................................................................................5
3 - POWER SUPPLY.............................................................................................................................................................5
4 - PNEUMATIC CONNECTION ...........................................................................................................................................6
5 - ADAPTER MOUNTING....................................................................................................................................................6
6 - WHEEL MOUNTING........................................................................................................................................................6
7 - CONTROL PANEL...........................................................................................................................................................7
8 - PRESETTING OF DIMENSIONS.....................................................................................................................................8
8.1 - OPTIONS..........................................................................................................................................................9
8.2 - PRESETTING WITH GAUGE EXTENSION.....................................................................................................9
9 - WHEEL BALANCING......................................................................................................................................................10
9.1 - MEASUREMENT OF UNBALANCE.................................................................................................................10
9.2 - RECALCULATION OF UNBALANCE...............................................................................................................10
9.3 - STATIC - ALU....................................................................................................................................................11
9.4 - "ALU S" SPECIAL FUNCTION..........................................................................................................................12
10 - SELF-CALIBRATION.....................................................................................................................................................13
10.1 - FOR CAR AND TRUCK WHEELS..................................................................................................................13
10.2 - FOR TRUCK WHEELS ONLY.........................................................................................................................13
11 - ERRORS.........................................................................................................................................................................14
11.1 - INCONSISTENT UNBALANCE READINGS...................................................................................................14
12 - ROUTINE MAINTENANCE............................................................................................................................................15
12.1 - REPLACEMENT OF FUSES..........................................................................................................................15
12.2 - REPLACEMENT OF DRIVER PULLEY..........................................................................................................15
12.3 - TO REPLACE THE BRAKE PAD....................................................................................................................15
13 - RECOMMENDED SPARE PARTS LIST........................................................................................................................16

0123
TRUCKS = 50 g (2 Oz)
1.3 - RECOMMENDATIONS
- Before starting to use the balancing machine, carefully read the operating instruction manual.
- Keep the manual in a safe place for future reference.
- Refrain from removing or modifying machine parts which would impair correct operation. Please
get in touch with the technical Service when needing repairs.
- Do not use strong jets of compressed air for cleaning.
- Use alcohol to clean plastic panels or shelves (AVOID LIQUIDS CONTAINING SOLVENTS).
- Before starting the wheel balancing cycle, make sure that the wheel is securely locked on the
adapter.
- The machine operator should not wear clothes with flapping edges; make sure that unauthorized
personnel do not approach the machine during the work cycle.
- Avoid placing counterweights or other bodies in the base which could impair the correct operation
of the balancing machine.
- The balancing machine should not be used for purposes other than those described in the instruction
manual.
- It is forbidden to use wheel locking devices other than those approved by the manufacturer. It is
also forbidden to balance objects other than vehicle wheels.
Caution: if the machine is left idle for more than two minutes, the system automatically
switches off all displays and the LEDs, apart from the car/truck selector LED which
stats flashing. To return to normal operation conditions, press any push-button or
move the wheel.
1.4 - STANDARD SAFETY DEVICES
- Low speed of rotation
- Protection on LIFT control.
2 - HOISTING AND INSTALLATION
To hoist the machine, lever the base only with the 3 support points. Under no circustances apply
force to other points such as spindle, head or accessory shelf.
Check that the balancing machine rests on the floor at the three points. There is no need to anchor the
machine to the floor for correct operation.
3 - POWER SUPPLY
WARNING: Electrical connection must be made by specialized personnel.
Connection to the single phase mains must be between phase and neutral and under
no circumstances between phase and earth. Earthing is essential for correct machine
operation.
The firm declines all responsibility and warranty in the event of incorrect connection.
Before connecting the machine to the mains through the relative cable, check that the mains voltage matches
that shown on the nameplate at the back of the balancing machine. Rating of the electrical connection
should be on the basis of the machine electrical power consumption (see nameplate).
- The machine mains supply cable should be fitted with a plug complying with current regulations.
- It is advisable to provide the machine with its own electrical connection incorporating a suitable circuit
breaker. Connection to the mains should be through a slow acting safety switch rated at 4A (230V) or
10A (115V).
- When connection is made directly to the main control panel, without using any plug, it is advisable to
padlock the main switch of the balancing machine so that its use is limited only to authorized personnel.

4 - PNEUMATIC CONNECTION
Connection to the pneumatic system is on the back of the balancing machine. Adjustment can be carried
out according to lifting and lowering requirements. The pneumatic system has been studied so that great
movement "elasticity" is provided to the lift in any position of its stroke. In this way, the position of the
wheel can be adjusted according to requirements and with minimum manual effort. Max input pressure 10
Kg/cm 2 ( ~ 10 BAR; 145 PSI; ~ 1 MPa) adjusted through a pressure switch.
7
5 - ADAPTER MOUNTING
Fig. 1
The wheel balancer is supplied complete with
cone type adapter for fastening wheels with central
bore. Other optional adapters can be mounted:
a) Remove threaded end piece A after backing off
screw B.
b) Mount the new adapter (see enclosed brochures)
6 - WHEEL GUARD ASSEMBLY AND ADJUSTMENT
Assembly the components in the order indicated in the specific exploded drawing.
The guard position can be adjusted using the appropriate screw. Adjust the angular position of ring 6 so
that the wheel enters the relative seat when the guard is closed.

0123
7 - CONTROL PANEL
Fig. 2
1 = Digital display, AMOUNT OF UNBALANCE, inside
2 = Digital display, AMOUNT OF UNBALANCE, outside
3 = Indicator, POSITION OF UNBALANCE, inside
4 = Indicator, POSITION OF UNBALANCE, outside
5 = Indicators, correction mode selected
6 = Push-button for selecting STATIC/DYNAMIC - g/ounce - mm/inch; self-calibration
7 = Push-button, recalculation and self-calibration
8 = Push-button, correction mode selection, ALU
9 = Push-buttons, manual DISTANCE input
10 = Push-buttons, manual WIDTH input
11 = Push-buttons, manual DIAMETER input
12 = Push-button, car selection
13 = Push-button, truck selection
14 = Indicators, car - truck selection
15 = Threshold push-button
N.B.: Press buttons only with the fingers. Do not use the counterweight pincers or other pointed objects.

9
8 - PRESETTING OF DIMENSIONS
FIG. 3 : DIAMETER
- Preset the nominal diameter shown on the tyre
FIG. 4: WIDTH
- Preset the nominal width which is generally given on the rim, or else measure width " b " with the gauge
supplied.
FIG. 5: DISTANCE
- Preset distance " a " of the inside of the rim.
8.1 - OPTIONS

0123
PRESETTINGS MEMORIZED ALSO WITH INOPERATIVE MACHINE:
+
+
F ↑ a ↓ a
- UNIT of measurement of unbalance grams/ounces
PRESETTINGS LOST WHEN MACHINE IS SWITCHED OFF:
F
F
+
or
+
↑ b
↓ b
- UNIT OF MEASUREMENT OF WIDTH mm/inch
(from "PRESETTING OF DIMENSIONS"
by selecting WIDTH)
N.B.: in inches each time the machine is switched on.
F
+
or
↑ d
- UNIT OF MEASUREMENT OF DIAMETER mm/inch
(from "PRESETTING OF DIMENSIONS"
by selecting DIAMETER).
N.B.: In inches each time the machine is switched on.
F
+
↓ d
DISPLAY OF UNBALANCE:
F
ALU
Dynamic Static Dynamic
ALU1 ALU2 ALUS ALU1
8.2 - PRESETTING WITH GAUGE EXTENSION
The extension increases the distance measuring range of the gauge by 10 cm (fig. 5A).
Proceed as follows:
- Insert the extension on the distance gauge.
- Measure the distance as already described in the above procedures.
- After reading value “a” on the scale, return the gauge to 0 and preset the value “a + 10” in manual
mode.
- Preset the diameter and width in manual mode as already illustrated.

11
9 - WHEEL BALANCING
9.1 - MEASUREMENT OF UNBALANCE
a) The spinning of the wheel is motorized. Move the special motor control lever upwards. When displays
go out, release the control. The driving force is disengaged and the motor stops.
b) Measurement can be made at any speed as soon as the wheel stops accelerating.
c) When the displays show the values, brake the wheel by acting on the lever in the opposite sense of
spinning (Wait at least 2 seconds before a new spin). Displays 1 and 2 show the amount of unbalance.
Displays 3 and 4 indicate through LEDs the correction position. When all the LEDs light up, it means
that the correction weight should be placed at the top in the vertical position.
FIG. 6: CORRECTION ON THE OUTSIDE
FIG. 7: CORRECTION ON THE INSIDE
9.2 - RECALCULATION OF THE UNBALANCE
- Preset the new dimensions following the procedures described above.
- Without repeating the spin, press
C
- The new recalculated unbalance values are displayed.

0123
9.3 - STATIC - ALU
(Balancing of motorcycle wheels, in light alloy or unusually shaped)
CAUTION: for a correct operation, the wheel to be balanced must be mounted on an adapter for
car wheels. Calibrate the machine following the procedure described in section 8.
Functions available can be selected from the measurement control panel and permit the displaying of
correction weights in different positions with respect to normal positions.
Press push-button [F] or [ALU] and select the required function, (see 8.1). For each function, the microprocessor
processes and displays the real values of the compensation weights corrected on the basis of
the correction weight position.
FIG. 8
NORMAL - Balancing of steel or light alloy rims
by applying clip-on weights on the rim
edges.
STATIC - STATIC correction is required for
motorcycle wheels or when it is not
possible to place the counterweights
on both sides of the rim.
ALU 1 - Balancing of light alloy rims with application
of adhesive weights on the rim
shoulders.
ALU 2 - Balancing of alloy rims with hidden
application of the outer adhesive
weight.
The position of the outer weight is
indicated in the figure.

9.4 - SPECIAL "ALU S" FUNCTION
This function is used for unusually shaped alloy rims where ALU2 is not able to guarantee sufficient accuracy.
- Select the S option by pressing the push-button [ALU] (LEDs ALU1 - ALU 2 both light up together).
- Measure the sizes according to the following scheme:
13
Sequence:
a) To modify al press
b) To modify aE press
c) To modify dl press
N.B.: dE is = 0.8 dl by default
d) To modify dE press
Attention: by selecting dl the system automatically resets dE = 0.8 dl
The system automatically calculates the distance between the centre of gravity of the two weights by
considering the width of the weights to be approx. 14 mm. To display the unbalance associated with the
preset dimensions, press the push-button [C]; the system will automatically proceed to recalculate the
unbalance, otherwise perform the new spin.
If it is not possible to insert the gauge into the rim (13”-14” car wheels), measure aI and aE with a precision
ruler.
It is often possible to take measurements using the gauge extension (8.2).

0123
For machine self-calibration, proceed as follows:
10 - SELF-CALIBRATION
10.1 - FOR CAR AND TRUCK WHEELS
1 Fit a medium-sized metal car wheel on the shaft. Example: 6" x 14" (± 1")
2 Preset the exact dimensions of the wheel mounted. Caution!! Presetting of incorrect dimensions
can mean the machine is not correctly calibrated and therfore all subsequent measurements will be
incorrect until a new self-calibration is performed with the correct dimensions!
F
3 First press push-button . While keeping it pressed, press also until the positioning
LEDs pass from flashing to being steady.
4 Release the push-buttons and turn the wheel until all displays go out. Then wheel can be released.
(The self-calibration spin can also require a couple of minutes. It is important not to knock the
wheel during this spin or else accelerate again after being released, otherwise it is not possible
to perform the self-calibration and the machine will stop with an error message).
5 At the end of the first spin, the following message appears on the display "Add 100 (Add 3.5)" while
the outside positioning LEDs flash. At this point add a weight of 100 grams (3.5 oz) on the OUTSI-
DE in any angular position.
6 Again bring the wheel up to speed (until the display "Add 100" goes out). Likewise this spin can require
a couple of minutes. Leave the wheel to rotate freely until the wording "END CAL" appears.
At the end of this operation, the machine will be calibrated. Remove the master weight from the
wheel and with a new spin proceed to balance the mounted wheel.
The values measured by the machine with self-calibration cycle are automatically memorized in a special
memory which retains them even when the machine is switched off. Hence when the machine is switched
on again, it is ready to operate correctly. However, self-calibration can be carried out whenever required
or when there is some doubt whether the machine is operating correctly.
C
10.2 - USE FOR TRUCK WHEEL ONLY
It does not matter whether car wheels (if car adapter is available) or truck wheels are used. With truck
wheels, it is recommended to preset the wheel dimensions with great care especially the width and distance
to be referred to the centre of gravity of the counterweight to be applied.
The procedure is identical to that described for car wheels, except for:
1) Select "truck wheels"
2) At the end of the first spin, add a master weight of 350 grams (12 oz).

15
11 - ERRORS
Various fault conditions may arise during machine operation. If detected by the microprocessor, they
appear on the display with the message "ERR:" followed by a number with one of the meanings listed
below:
ERROR
MEANING
1 Could be caused by a faulty position transducer, or something preventing the
wheel from turning or else too slow speed of rotation.
2 During the measurement spins, wheel speed had drop to below minimum (90
r.p.m. for CARS - 42 r.p.m. for TRUCKS).
3 Wheel unbalance too high or incorrect calibration.
4 Wheel turning in opposite direction.
7 Faulty self-calibration values.
8 Error during self-calibration. Could be due to the second spin made without
adding reference weight, or else by a break in the transducer cable.
Further error indications are given by the LED "ALU2" during measurement.
When the wheel has been brought up to speed, a rapid flashing of this LED means the speed of rotation
is too high; the machine will wait for the speed to fall, LED ALU2 will go out and the measurement will be
made.
If during the measuring spin there is a random flashing of the above LED, the system is in a dwell status,
probably due to a knock received by the machine. However, the measurement is repeated automatically
without errors. Errors in balancing can be due to rubbing of the reduction gear on the spindle gear. After
spinning the wheel, always allow the crank handle to return to rest position.
11.1 - INCONSISTENT UNBALANCE READINGS
Sometimes after balancing a wheel and removing it from the balancing machine, then again mounting it
on the balancing machine, it is found that the wheel is not balanced.
This does not depend on incorrect indication of the machine, but only on a faulty mounting of the wheel
on the adapter, i.e. in the two mountings, the wheel has assumed a different position with respect to the
balancing machine shaft centre line.
If the wheel is mounted on the adapter with screws, it could be possible that the screws have not correctly
tightened - they should be tightened one by one crosswire or else (as often happens) holes have been
drilled on the wheel with too wide tolerances.
Small errors, up to 10 grams (4 oz) are to be considered normal in wheels locked by a cone; the error is
normally greater for wheels locked with screws or studs.
If, after balancing, when the wheel is refitted on the vehicle, it is still out-of-balance, this could be due to
unbalance of the car brake drum or very often due to the holes for the screws of the rim and drum drilled
sometimes with too wide tolerances. In such case a readjustment could be dvisable using the balancing
machine with the wheel mounted.

0123
12- ROUTINE MAINTENANCE
(Non specialized personnel)
WARNING: Before carrying out any operation, disconnect the machine from the mains.
12.1 - TO REPLACE THE FUSES
Remove the weight holder shelf to gain access to the power supply PC board and the two fuses mounted
on this board. Should replacement be required, use fuses of the same current rating. If the failure persists,
contact the Technical Service Department.
12.2 - REPLACEMENT OF DRIVER PULLEY
- Remove the weight holder shelf being careful not to pull on the electrical cables.
- Untight the pulley mounting screw and change the pulley.
12.3 - TO REPLACE THE BRAKE PAD
Back-off the two screws fastening the worn brake pad to the motor mounting brake. Securely fix the new
brake pad by tightening the screws.
NONE OF THE OTHER MACHINE PARTS REQUIRE MAINTENANCE.

17
13 - LIST OF RECOMMENDED SPARE PARTS
(references on the exploded drawings)
CODE
DESCRIPTION
182185730 Balancing spring
07FG33406
Rubber covered driving pulley
42FB37113
Complete brake pad
020620803 Bearing 6208-2Z Ø 40/80/18
67M38954M
Position pick-up board c/w cable and plug
86SB44557
Cable with microstart
181270080 Spring, rim distance gauge
050144103 Display panel
940603137 Complete power plate 230/115V
511231002 Switch KL 1002 + Q 555
86PR36224
Complete panel
86SC36223
Computer board
611018463 Transformer 115/230 - 9/9
940512124 Supply board
681002000 Fuses DM 5x20 2A
162368905 Pneumatic control 368-905
181198630 Spindle spring
SPECIAL PARTS FOR 230V MACHINES
568001458 Capacitor 14MF 450V Faston screw M8
SPECIAL PARTS FOR 115V MACHINES
568003558 Capacitor 35MF 450V Faston screw M8

0123
SPECIAL MAINTENANCE
(Only for specialized personnel)
14 - TO CHANGE SUPPLY VOLTAGE
- Always check the required voltage on the machine nameplate.
- Standard power supply 220 - 240 V / 50 Hz single phase.
- For 115 V power supply, the components must be replaced as indicated in the attached exploded
drawing.
15 - SELECTING OF MACHINE PARAMETERS
To preset the machine parameters (DF; I; S), press push-buttons and as in
self-calibration. When the position LEDs stop flashing, instead of performing the spin, press the following
push-buttons within 5 seconds and in the correct sequence:
[ ↓ a ] then [ ↑ a ] then [ F ]
After pressing [ ↓ a ] and [ ↑ a ], the displays go out. After pressing [ F ], the current value of " DF " appears;
it can be modified with [ ↑ b ] and [ ↓ b].
Press [ ↑ a ] to modify parameter " I ". The current value (in %) appears on the right display, while the
wording "in" and the symbol " ⎯ " appear on the left display if the correction is negative or else " " if it
is positive. Modify with [ ↑ b ] and [ ↓ b ]. Press [ ↑ a ], the value of parameter " S " appears on the right
display; modify with [ ↑ b ] and [↓ b]. To finish, press [ ↑ a ].
N.B.: when [ FINE ] is pressed during any one of the parameter presetting phases, the system interrupts
such function and sets the parameters with basic values.
After modifying such values, the machine requires self-calibration again.
CAUTION! The basic configuration values: " DF "= 120
" I " = +0
" S " = 330
The values at which the machine is factory set are given on a special nameplate inside the machine.
F
C

16 - CHECKING OF THE RIM DISTANCE GAUGE
Check that the ruler used for measuring the DISTANCE of the wheels reads 26.5 cm as measurement of
the distance from the adapter plane. If the graduated scale is changed, position it with the line indicating
26.5 at the fixed index limit (reading point) when the gauge tip coincides with the adapter plane.
Fig. 10
19
Reading point :26.5 cm
Adapter plane
17 - ASSEMBLY TO THE PIEZO MEASURES
Problems of excessive compensation and out-of-phase sometimes depends on a fault in the piezo measurers.
To replace them, proceed as follows:
1. Remove the weight shelf.
2. Remove nuts 1 and 2 with relative cup springs
and washers.
3. Back-off screws 3, 4 and 5 then disassemble the
various parts.
4. Reassemble the various parts without tightening
the nuts being careful to follow the correct sequence.
N.B. Mount the piezo units in accordance with the
position of the coloured wires shown in the drawing.
5. Keeping the spindle perfectly aligned, tighten nut
5 with a spanner, and nuts 3 and 4 by hand (by half
a turn with the spanner if necessary).
6. Refit the washers, cup springs and nuts 1 and
2. Tighten the nuts fully in order to fully regain the
elasticity of the cup springs, then loosen them by half
a turn. This will automatically ensure correct preloading
on the piezo (a torque wrench can be used set
to 400 kg. cm.).
7. Cover the piezo units with a generous layer of
silicone.
(N.B. For correct operation, insulation of the piezo
crystals should be greater than 50 Mohm).
8. Reassemble the various parts.
9. Again carry out the automatic calibration.
yellow
blue
yellow
white
Fig. 11

0123
18 - LOGIC TROUBLE SHOOTING SEQUENCE
When PC boards require replacement, repeat the self-calibration operation after having again preset the
machine parameters.

0123
19.1 - CHECKING AND SETTING OF STATIC VALUE (STI)
(To be performed with car wheel of average size)
Carry out self-calibration
Wheel balancing.
Tolerance 1 gram.
Select STATIC.
Apply 100 grams on inside.
Perform the spin.
Is the STATIC value on
the inside between 98 and
102 grams?
YES
NO
Select function "SELECTING OF
MACHINE PARAMETERS".
Increase value "I" if the inside STATIC
value is too low, decrease if it is too
high (2 digits of "I" are equivalent to
approx. 1 gram).
END

23
19.2 - CHECKING AND SETTING OF UNBALANCE POSITION
(To be performed with car wheel of average size)
Carry out self-calibration
Wheel balancing.
Tolerance 1 gram.
Apply weight of 100 grams
on the outside.
Perform the spin.
Is the 100 gram
counterweight in the six
o'clock position?
NO
Select function "SELECTING OF MA-
CHINE PARAMETERS".
Modify value "S" by making various
attempts ("S" is expressed in degrees)
YES
END

0123
19.3 - CHECKING AND CALIBRATION OF FIXED DISTANCE VALUE (DF)
(Perform with car wheel of average size)

20 - WHEEL MEASUREMENT AND PRESETTING ON THE BA-
LANCING MACHINES
25
The ever increasing need for more accurate calibration and use of the ALU functions means that it is
important to establish how to measure the rims and how the balancing machine interprets the preset data.
Hence a description is now given of how to modify the preset dimensions automatically in order to obtain
the distances of the correction planes which are defined as through planes for the centres of gravity of
the corrective weights. Consider a typical rim: size "l", given as width by the rim manufacturer, differs from
the measurement of the distance between the correction planes for the rim thickness and physical dimensions
of the counterweight, whose centre of gravity is located at distance “h” from the resting point of
the rim edge. The balancing machine automatically corrects the measurement preset by adding 2 x h = 6
mm to the measurement. Measurement “b” made with the gauge is generally more accurate even if very
similar to the measurement "l" known to the rim user. The two measurements differ only by the thickness
of the sheet metal, usually about 2 mm per side. Such insignificant distance means that an accurate
calibration can be obtained regardless of whether the inner rim with "l" or outer width “b” is preset. It is a
good rule to add ¼ inch to the value given by the manufacturer. As regards the ALU functions, the machine
performs the following approximations in addition to the systematic correction regarding the centre of
gravity of the counterweight as seen above.
ALU 1

0123
21 - HOW TO CHECK FUNCTIONING AND ACCURACY
Further to some notices informing us of defects and unaccuracies not clearly traceable, we are explaining
hereunder the procedure how to check functioning and accuracy to help us to detect problems.
FIRST CHECKS
Accurate wiping of adapter and cones
Spring cover sliding
Shaft end blocking
CALIBRATION (see 10)
Use the wheel indicate
Set accurate measures, in manual mode if necessary
Make self-calibration
CHECKING MACHINE CALIBRATION
Make 10 spins without loosening the wheel and detect MAX oscillations
F.I. (Inner side)= F.E. (Outer side)= (tolerance ± 2)
Put 100 gr. on FE first and then on FI using an accurately balanced wheel) Detect rates
F.I.= F.E.= POS.E.= F.I.= F.E.= POS.I=
(tolerance 3%)
CHECKING THE ADAPTER
Turn a fine balanced wheel upside down (180°) and detect unbalance rates
ERR.MAX =
This check-out in particular must be made with a sample wheel whose max unbalance errors due to
centering are well known (generally lower than 10 gr. for iron wheels).
SCRAPPING
Attention! For a correct waste disposal, consult the declaration of conformity to RAEE and ROHS (where applicable)
MAINTENANCE
At the achievement of 5 years from the date of installation and commissioning, the product must be reviewed
in its entirety

0123 0123
GIULIANO S.P.A.
Via Guerrieri, 6 - 42015 CORREGGIO (RE) ITALY
Tel. +39 0522 731.111 - Fax +39 0522 633.109
http://www.giuliano.it
E-Mail: giuliano@giuliano.it