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quadriga service manual do not copy nor distribute

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2. Hormann Za BONER QUADRIGA SERVICE MANUAL DO NOT COPY NOR DISTRIBUTE NO PART OF THIS DOCUMENT MAY BE PHOTOCOPI ED REPRODUCED OR TRANSLATED WITHOUT PRIOR WRITTEN CONSENT OF SNAP ON 1 QUADRIGA Service Manual 02 10 Rev C UPDATING GUIDE REVISION C February 2010 Updated parts of chapters 3 1 Electric diagram 10 4 ADJUST THE TOOLS 1 AND 2 ALIGNMENT 10 6 TO CHECK THE ALIGNMENT 11 SERVICE CODES SECTION Added C45 C55 C66 C83 C88 Modified C51 C89 12 TROUBLE SHOOTING Modified all chapter from Fault1 2 REVISION B September 2009 Updated parts of chapters 2 1 TOOLS AND SPECIAL TOOLS REQUIRED 10 4 TOOLS 1 AND 2 ALIGNEMENT CHECK AND ADJUSTMENT 11 SERVICE CODES SECTION 12 TROUBLE SHOOTING REVISION A June 2009 Issued first final edition on June 2009 Hormann ER Page 8 9 10 Page 93 Page 95 96 from Page 98 from Page 124 Page 7 Page 7 Page 7 Page 7 QUADRIGA Service Manual 02 10 Rev C TABLE OF CONTENTS CHAPTER 1 INTRODUCTION 1 1 General CHAPTER 2 TOOLS AND SAFETY 2 1 Tools and special tools required 2 2 Important safety instructions 2 3 Electrical safety precautions CHAPTER 3 ELECTRIC PNEUMATIC AND HYDRAULIC DIAGRAMS 3 1 Electric diagram 3 2 Pneumatic diagram 3 3 Hydraulic diagram CHAPTER 4 AC DC POWER DISTRIBUTION 4 1 Lockout and or tagout system procedure 4 2 Electrical requirements 4 3 AC Theoy of operation 4 4 DC Theory of o
3. Parametro configurabile 9 0 Parametro configurabile 10 Parametro impostazione Pr 61 Parametro Impostazione Pr 62 04 05 h3 T e Parametro impostazione Pr 63 Parametro impostazione Pr 64 Sovramodulazione Pr 11 Pr 11 06 Pr 11 07 10 34 Pr 11 08 10 35 Pr 11 09 4 13 Pr 11 10 Pr 1 01 Fr 1 03 Fr 2 01 Fr 5 05 Fr 5 14 Fr 5 02 Fr 5 04 Pr 4 01 2 21 Parametro impostazione Pr 65 Parametro impostazione Pr 66 Parametro impostazione Pr 67 JSN Gli DI pe LJ Ll 8 Parametro impostazione Pr 68 j Parametro Impostazione Pr 69 Parametro Impostazione Pr 70 Riferimento di frequenza selezionato ee 83 Riferimento post rampa e psn ED esse 7 87 Velocit motore 88 Corrente motore Parametri di diagnostica di sola lettura 89 Corrente attiva del motore en Fr 4 02 Fr 8 20 Pr 1 11 Pr 1 12 Pr 1 13 Pr 7 01 Fr 7 02 Parola di lettura 1 0 digitali Indicatore selezione inversione Indicatore selezione jog IRA Livello ingresso analogico 1 95 Livello ingresso analogico 2 47 QUADRIGA Service Manual 02 10 Rev C Hormann The EMC filter tab must be in out position La linguetta del filtro EMC deve essere tirata in fuori amp 2h aX Medium cross screwdriver Allen keys 4 and 5mm 7mm key calibration fixture SD card with software Defective processor board may cause the following malfunctio
4. Turn the machine Close the cylinder completely Turn the machine off Release the hydraulic pressure from the coil valve Remove the hoses Loosen the nut in the bottom under the cabinet and remove the defective cylinder 5 the new cylinder 66 QUADRIGA Service Manual 02 10 Rev C SISI HOFMANN VA Bi Bolt the new cylinder to the bottom Connect the hoses replacing the copper washers Turn the machine on and hang up the bead breaker carriage Release the bead breaker carriage Lock the nut again Check if there is there any further oil leaking Check if the machine works fine Install the bead breaker plastic protection amp 2h 3 lt End keys 19 and 24mm medium cross screwdriver Defective piston seals may cause the following malfunction 4 Low bead breaker power 5 Slow saddle sliding 6 Oilleaking TO CHECK THE RING NUT O RING AND THE PISTON ROD LIP SEAL Turn the machine on Close the bead breaker cylinder When tt is at the end of stroke keep it under pressure and verify if there is oil leaking from the piston rod or from ring nut Open the cylinder till end of stroke and verify that the piston rod would not show marks or other kind of damaging TO CHECK THE BEAD BREAKER CYLINDER PISTON SEALS Defective seals may cause low bead breaker power in one or both way Turn the machine on Open the bead breaker cylinder till end of the str
5. 12 Check if the machine works fine amp 1h30 2 lt 10 and 7mm key medium cross screwdriver multimeter Defective potentiometer may cause the following malfunction 1 Machine cannot make the bead breaking operation TO CHECK THE POTENTIOMETER Turn the machine on Go in service code C62 and select Ch5 or Ch6 12 TO REPLACE THE POTENTIOMETER Turn the machine off Remove the front plastic protection 75 1 Turn the machine on Lower or raise the completely the bead breaker disc Loosen the two 6mm top nuts Lower or raise the completely the bead breaker disc again to have the potentiometer free Loosen the four 4mm rear nuts and remove the potentiometer from the cabinet Remove the connectors Take the new potentiometer and plug the connector again Mount the potentiometer on the cabinet without lock it Turn the machine on Move the bead breaker cylinder at the end of stroke 52 QUADRIGA Service Manual 02 10 Rev C HOFMANN V Turn the machine off Connect the potentiometer to the bead breaker holder Make sure that potentiometer is not at the end of the stroke Turn the machine on Select the Service Code C C62 and select Ch5 or Che 12 Move the bead breaker cylinder Make sure that the potentiometer does not go through the 0 during the sliding and it does not reach the end of strokes Turn the machine off Lock firmly the potentiometer Mount the p
6. Enter to confirm If the misalignment among the Tool 2 and the disks is over than the maximum threshold the display will show error and the C code will be aborted In this case perform the C66 Step 15 As per Step 13 of the C80 to complete the Calibration C88 set to default POs except calibration data This C code is required after a software update Select this code and press Enter to confirm Per or to switch from NO to YES to set data to default Press Enter to confirm 121 QUADRIGA Service Manual 02 10 Rev C normanna DA C89 Format internal data This C code has been eliminated from the software 1 1 10 Erases and format to default the internal parameters Attention executing this procedure the machine looses the calibration 122 QUADRIGA Service Manual 02 10 Rev C HOFMANN CHAPTER 12 TROUBLE SHOOTING FAULT 1 Hint 1 Can t load The load procedure is not allowed because the wheel size gauge doesn t read anything The wheel size is too small to be read from the size sensor or there is nothing onto the frontal fork or the sensor is miscalibrated call service FAULT 2 Hint 02 can t unload The unload procedure is not allowed because the wheel size gauge read something on it Remove any wheel from the frontal fork before unloading the current wheel or the sensor is miscalibrated call service FAULTS 4 Jus De A automatic mount a
7. Remove the lateral covers to access Remove the pin Remove the assembly from the arm Remove the cylinder liner 79 QUADRIGA Service Manual 02 10 Rev C Replace the piston seal Replace the O rings Mount the piston on cylinder liner Mount the assembly on the tool holder Mount the rotational pin Mount the covers Mount the cylinder flange Plug the air hoses Turn the machine on Check if the machine works fine Turn the machine off Install the plastic protection 9 1 1 5h 2 lt Allen key 4 and 5mm 10mm end key seeger plyers Defective lift cylinder may cause the following malfunction 1 Air leaking 2 Lift does not raise or lower TO CHECK THE LIFTS CYLINDERS urn the machine on Lower the lift and check if the cylinder is leaking from the rear flange Raise the lift and check if the cylinder leaks air from the front flange 80 QUADRIGA Service Manual 02 10 Rev C Lower the lift and remove the hose from the front fitting If the air comes out from the fitting the piston seal is defective If the air comes out from the hose the leaking is caused by the solenoid valve Make the same operation with the rear side TO REPLACE THE LIFTS CYLINDERS Turn the machine on Lower the lift Turn the machine off and remove the air hoses from the fittings Remove the seeger ring and the bolt to remove the cylinder Take the new cylinder Lock the cylinder with t
8. 4030480 seenato in rosso sotto menire quello corretto il EA A034906824 4031035 Tutti i Manuali Operatore relativi a queste macchine verranno aggiornati al pi presto DEUTSCH Wir m chten Ihnen mitteilen dass in der Bedienungsanleitune f r die Quadri ga eine falsche Bestellnummer f r das Standard Radspannkit angegeben ist In der Anleitung ist das Standard Radspannkit mit EA A03496G044A 4030480 ange geben Abbildung 3 1 2 Seite 24 die richtige Bestellnummer ist aber EAAU349G82A 4031035 Die betroffenen Anleitungen werden umgehend itberarbeitet 132 QUADRIGA Service Manual 02 10 Rev C HOFMANN SERI 222 Equipment Service Bulletin Mo SB 705 TC February 15 2010 Models affected Quadriga based tire changer Starting from s n 0110 6028620 4 Subject New Quadriga software 1 1 10 ENGLISH Starting from the serial number above reported all Quadriga based tire changer are now equipped by the new software 1 1 0 This new software 1 1 10 replaces the forrmer one 1 0 7 and includes SW for CPU Board 1 1 10 SW for Dual DC Motor Driver 3 4 SW for Valves Control Board 3 3 The new software 1 1 10 inctudes the following new features New AWP scanner management Improved serial coommunication R5485 management Every message sent to the peripheral boards needs response ACK NACK and timeout check Indication of error in case calibration missing New C code C45 laser sensor selection This C code allows to swit
9. Am Ende von C 80 geht der Radheber in Ausgangsposition zur ck Zum Updaten der Maschine ist folgende Software erforderlich 1x 4031192 Programmierte MMC Sd Karte f r Quadriga Nach dem Updaten muss die Maschine nicht justiert werden Es ist allerdings erforderlich den C Code Css entsprechend Servicemanual durchzuf hren WICHTIG Das Updaten von Maschinen im Feld ist nur erforderlich wenn der Kunde eines der oben aufgef hrten Merkmale gegen Zahlune erwerben m chte 130 QUADRIGA Service Manual 02 10 Rev C HOFMANN Snap Z3 Equipment Service Bulletin No SB 691 TC December 03 2009 Models affected Quadriga tyre changers Starting from sn Subject ncorrect accessory number on operators manual ENGLISH We would like to inform you that the Operator s Manual of Quadriea tyre changer has been edited with an incorrect part number related to the Standard wheel clamping kit The Operator manual reports the Standard wheel clamping kit EAA0349G04A 4030480 red signed below while the correct one is EAAU349G824A 4031035 All the Operator s manuals related to these machines will be updated at soonest ITALIANO Gradiamo informarvi che i manuali dell operatore relativi allo smonta gomme Quadriea sono stati editi con il codice relativo al Kit standard fissaggio ruote non corretto manuale operatore riporta il Kit standard fissaggio ruote EAAOSJOGOAJA 4030480 seenato in rosso sotto menire quel
10. Make sure that every mobile components inspected takes about the same forward backward or upward downward motion time Press Enter button 4 to enter the Service Code Press or 2 and 3 button to scroll the test selection 101 QUADRIGA Service Manual 02 10 Rev C Press Enter button 4 to enter the test selected Press Enter button 4 to start the test Before starting with the test the machine will automatically check the homing position of all axis At the end of the control the test will start automatically At the end of the test the display will show the motion time expressed in seconds required by the axe to move forward backward or upward downward The motion time shown by the display must be about the same for both direction 102 QUADRIGA Service Manual 02 10 Rev C HOFMANN VS The bead breaker discs will take different upward downward motion time due to different cylinder size However the upward downward motion time of both cylinder must mach each others C66 Axes alignment upper and lower bead breaker disks The C code C66 is available on machine equipped with software 1 1 10 or higher e This C code verifies the axes alignment Step 1 Clamp Calibration Tool Press Enter to confirm Step 2 Front plate Calibration tool on Upper bead breaker disk Move the calibration tool in proximity of the upper bead breaker disk
11. Select the multimeter in Ohm and check if there is continuity between ends of each wire TO REPLACE THE CABLE Release cable strain relief on the electric box and on the motor 30 QUADRIGA Service Manual 02 10 Rev C HOFMANN Take the wrong cable away Insert the new cable through the strain relief IMPORTANT USE ONLY APPROVED CABLE AND GROUND WIRE MUST BE LITTLE LONGER THAN THE OTHER ONES NOTE Before connecting the wires ends tighten all terminals nuts on the motor Fix new fastons on inside cable ends and connect them to the motor and three polar meter terminals Check the rotation way of the motor If it is wrong reverse only two motor wires Mount the motor terminals cover IMPORTANT WHEN REMOUNTING THE MOTOR TERMINALS COVER BE CAREFUL NOT TO CRUSH WIRES Z 1h 30 2 lt End keys 13 17mm medium cross screwdriver 7mm tube type wrenches multimeter loctite extractor Defective chuck motor may cause the following malfunction 1 Low turntable power 2 Motor is noisy 3 Motor is burnt TO CONTROL THE TURNTABLE MOTOR WHEN IT SHOWS LOW POWER Disconnect machine from power supply Remove the motor terminals cover 5 1 Switch the machine on MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK Take the multimeter and select it in VAC Position the multimeter probes on U1 and W1 of the motor terminals and press the rotation pedal If the display shows the voltage at
12. 3 CPU board A1 check and replacement 7 4 Software installation check and replacement 7 5 Dual DC drive motor board A2 check and replacement 7 6 Valves control board A3 check and replacement 7 7 Distance laser B3 check and replacement 7 8 Bead breaker potentiometer S3 and S4 check and replacement 3 QUADRIGA Service Manual 02 10 Rev C HOFMANN Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag Pag 7 9 Turnatble carriage potentiometer B1 check and replacement 7 10 Tools carriage potentiometer B2 check and replacement 7 11 Lift size potentiometer B6 check and replacement 7 12 Lift rotation potentiometer B5 check and replacement 7 13 Lift raising potentiometer B4 check and replacement CHAPTER 8 HYDRAULIC SECTION 8 0 Hydraulic function 8 1 Access to hydraulic parts 8 2 Hydraulic oil level check and levelling 8 3 High hydraulic chuck pressure circuit check and adjustment 8 4 Hydraulic pressure of centre post cylinder check and adjustment 8 5 Centre post cylinder seals check and replacement 8 6 Bead breakers cylinders check and replacement 8 7 Bead breakers cylinder seals check and replacement 8 8 Hydraulic pump check and replacement
13. 5 1 ACCESS TO ELECTRIC BOX Turn the machine off and unplug it from the wall Open the box by using the key Sometimes the opening may result difficult because of door seal sticking when this happens the door can be easily opened by pulling it with both hands from top and bottom On the door panel there are all radio control devices and the side to side tool control Inside of the box there are all other electric components 5 2 ACCESS TO THE CONTROL PANEL Remove the screws and lift up the cover to get the access to all switches and to the QCPU board 19 QUADRIGA Service Manual 02 10 Rev C gt 5 3 ACCESS THE ROTATIONAL SWITCH Remove the two front screws and open the assy cover IMPORTANT WHEN REMOUNTING SWITCHES AND CLOSING THE ELCTRIC BOX DOOR BE CAREFUL NOT TO CRUSH WIRES 5 4 ACCESS TO THE HYDRAULIC MOTOR Remove the plastic cover to access to the hydraulic motor gt 5 5 ACCESS TO THE TURNTABLE MOTOR AND POTENTIOMETER Remove the lifts cylinders plastic protections Remove the mobile plastic top cover Go in C62 and raise the vertical lift Loosen the top cover screws and remove the cover from the front Then remove from the back the second half of the cover The turntable motor and the potentiometer are now available g gt 5 6 ACCESS TO THE 1 AND 2 VDC MOTORS The access to these motors is very easy because they covered by a plast
14. 8 To reduce the risk of electric shock do not use on wet surfaces or expose to rain 9 Donot hammer on or hit any part of the control box and portable control 10 Do not allow unauthorized personnel to operate the equipment 11 Use only as described in this manual Use only manufacturer s recommended attachments 12 Always securely lock the wheel before starting the operation 13 ALWAYS WEAR SAFETY GLASSES Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses 14 Quadriga tire changer is for indoor use only 2 3 ELECTRICAL SAFETY PRECAUTIONS Make sure the tire changer is unplugged before disconnecting any wires in preparation for replacing any electric mechanic components cables or other items within the unit CHAPTER 3 ELECTRIC HYDRAULIC AND PNEUMATIC DIAGRAMS This session is related to the electric hydraulic and pneumatic diagram configurations for CE and UL proved machines 7 QUADRIGA Service Manual 02 10 Rev C x 40 133HS OM SESHAA33 L80050 v VEN gno Ces o EB Fn d BD 430 MK pa div Lat gr 50 d3db EEAO WS MALATIA 38g 2 S VS PET QA Jo LO MCP BE EA SO MIN METRES LISA LOLLI amo12xuouso 3n fb noi dl DI LO A Od di ed 60 DL TRUST yo ER 43980060 SAL ECISIER DR HO ESC CTI TRS 90 HU Ga pf i pi gute HOFMANN 20 d Ma HE
15. 9 E At TM cui of calibration C80 i in case vem during the calibration the error is shown This error can appear during the calibration procedure only FAULT 20 Tror teo E Lol At tthe end of C81 ii in case wii during the calibration the error is shown This error can appear during the calibration procedure only on machine with software 1 1 10 or higher FAULT 21 Ss Lol rd Error fine c82 Esito in caso di errore della calibrazione cosce At tthe hi of ion C82 in case during the calibration the error is shown This error can appear during the calibration procedure only on machine with software 1 1 10 or higher FAULT 2 22 COMI DD on Error RN automatic ii if the loi Bead Breaker doesn t move or its motion is not fluid or the potentiometer doesn t detect any variation of the Lower BB position the error is shown FAULT 23 id sa Power d A Dir Error Oo ooo dui automatic coi if the fener Bead Breaker moves in the opposite direction or the potentiometer is mounted wired wrongly the error is shown 124 QUADRIGA Service Manual 02 10 Rev C HOFMANN ER automatic cestini if hei upper Bead Breaker doesn t move or its motion is not fluid or the potentiometer doesn t detect any variation of the Upper BB position the error is shown FAULT 2 aor a zx Dir Error Lita automatic o if de upper Bead Breaker moves in the opposi
16. Code 81 12 to calibrate the machine 53 QUADRIGA Service Manual 02 10 Rev C HOFMANN VS 3 lt 4 and 5mm Allen Key 10 and 14mm key medium standard screwdriver multimeter Defective potentiometer may cause the following malfunction 1 Machine does not position correctly the tools vertically TO CHECK THE 10 TURNS POTENTIOMETER Turn the machine on Go inservice code C62 and select Ch8 712 TO REPLACE THE 10 TURNS POTENTIOMETER Slide the tools carriage at the more convenient height Unplug the potentiometer Loosen the two 6mm top nuts Loosen the four 4mm rear nuts and remove the potentiometer from the table Remove the connectors Loosen the screws and remove the potentiometer from its holder Remove the toothed wheel from the potentiometer Take the new potentiometer and plug the connector again Remove the potentiometer from the bracket Mount the new potentiometer on the bracket Mount the toothed wheel on the potentiometer Plug the connector Turn the machine on Move the tool carriage at the end of top stroke Turn the machine off Turn the potentiometer manually at the end of its stroke and then make sure to turn the wheel back of a quarter of a turn IMPORTANT MAKE SURE ABOUT THE PROPER POTENTIOMETER ROTATION DIRECTION BECAUSE A WRONG END STROKE DIRECTION WILL CAUSE THE BREAKAGE OF THE POTETIOMETER WHEN WILL SLIDE Mount the potentiometer assy to the carriage ho
17. Connect the hydraulic hoses Mount all protection Check if the machine works fine Z 2 5h Each one 2 lt Allen key 4 5 6mm rubber hammer seeger pliers Q Defective lead screw nuts may cause the following malfunctions 1 Incorrect carriage or tools positioning TO CHECK THE LEAD SCREW NUT Turn the machine off Move by hand the worm screw and verify if the mobile table or the tools carriages are moving If not the nut is worn out and must be replaced Make sure that screws are well tightened TO REPLACE THE MODILE TABLE LEAD SCREW NUT Remove the plastic lifts protections 5 1 Remove the motor M1 protection 5 1 Remove the steel mobile table covers 5 1 Turn the machine off Remove the M1 belts 56 8 Remove the pulley Remove the four screws that hold the worm screw assy 88 QUADRIGA Service Manual 02 10 Rev C Remove the worm screw from the lead nut Loosen the lead nut assy screws Remove the lead nut from the support w Mount the new lead nut on the support Mount all the assembly on the mobile table securing the screws with loctite Install the worm screw Install the pulley IMPORTANT TURN THE PULLEY BY HAND TO MAKE SURE THAT THE WORM MUST TURN FREELY Install the belt Turn the machine on and check if it works fine Select Service code C 81 Check if the machine works fine Install all protections TO REPLACE THE TOOLS CARRIAGE LEAD SCREW NUT S
18. Manual 02 10 Rev C Z 2h 3 lt 13 4 and 5mm Allen Key 10 and 14mm key multimeter Defective potentiometer may cause the following malfunction 1 2 The machine does load the wheels in middle of the centre post The wheel lift does not load the wheels at all TO CHECK THE LIFT ROTATION POTENTIOMETER B5 Turn the machine on Go in service code C62 and select Ch4 12 TO REPLACE THE LIFT ROTATION POTENTIOMETER B5 Go in service code C62 and raise the rotational lift 12 Remove the lifts cylinder protection 5 1 Unplug the potentiometer Loosen the set screw and remove the defective potentiometer Install the new potentiometer Take the multimeter and select it in Ohm Make sure to have the rotation lift in home position Turn the potentiometer to read 0 20 and lock the set screw FIRMLY Plug the potentiometer Turn the machine on Move the lift to make sure that potentiometer reach the maximum voltage without go through the O Turn the machine off Route the cable Turn the machine on Select the Service Code C82 12 to calibrate the machine Mount the lifts cylinders protection 5 1 56 QUADRIGA Service Manual 02 10 Rev C HOFMANN V Z 2h 2 lt 3 4 and 5mm Allen Key 10 and 14mm key multimeter Defective potentiometer may cause the following malfunction 3 machine does load the wheels in middle of the centre post 4 The wheel lift does not load the whe
19. THE INVERTER Turn the machine on Press the rotational pedal if the motor does not run or if the tire shop shut off switch shuts off the inverter must be replaced IMPORTANT BEFORE REPLACING THE EMC INVERTER MAKE SURE THAT THE TURNTABLE MOTOR AND WIRE ARE FINE TO REPLACE THE INVERTER Turn the machine off Open the electric box 45 1 Loosen the screw and remove the front cover to access to the terminals 76 6 Disconnect the wires from the inverter terminals marking the position IMPORTANT MARK WIRES PROPERLY FOR AN EASY AND SAFE INSTALLATION Loosen the four screws in the back to and take the out the inverter Mount the new inverter Connect all wires to the terminals following the correct order Mount the front cover Turn the machine on and check the inverter set up is of the red values 7 2 MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK Check if the machine works fine Close the electric box 44 QUADRIGA Service Manual 02 10 Rev C are ne Egquigrrerri Hormann amp 7 2 EMC INVERTER T1 SET UP How to program the parameters on the SKBD200150 inverter 1 Turn on the inverter 2 Push the M button the left display will be flashing showing the number 1 3 Push the Up arrow until the left display will show Right Display 10 and the right display L1 EMEN 4 Push button L1 will be flashing Left Display 5 Push the Up arrow two time
20. The turntable motor does not run second speed The turntable motor does run in reverse speed ia rx DI 5 TO CHECK THE VALVES CONTROL BOARD Turn the machine off Open the electric box 75 1 Take the multimeter and select in VDC Turn the machine 50 QUADRIGA Service Manual 02 10 Rev C CZ Horvann MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK Position the multimeter probes on the connector X37 and verify if it correctly supplied at 48VDC and if the 24VDC output for the CPU board A1 is correct INPUT 48VDC Position the multimeter probes on two wires of a solenoid valve of the connector X45 65 Press the related switch to verify if the 24VDC output is correct Position the multimeter probes on two wires of the connector X39 Press the clamping unclamping pedal to verify if there are 230VAC output Z 90 3 lt 13mm key Defective distance laser may cause the following malfunction 1 Machine continuously scans the wheel TO CHECK THE DISTANCE LASER Turn the machine on Go in C62 and select 12 TO REPLACE THE DISTANCE LASER Turn the machine off Unplug the laser connector Loosen the 8mm nut Install the new laser 51 QUADRIGA Service Manual 02 10 Rev C Level the laser with a bubble level Turn the machine on and perform the calibration C81
21. a tire in inde scanning Batley if the rim edge is wrongly positioned for a diameter setting smaller then the proper or something nearer to the laser sensor is detected i e the tire the error is shown FAULT 4 4 MIDI 11 e coeso Danti automatic obs a tives if tire e sidewall i is not detected by the Bead Breaker sensors for a wrong diameter setting or a bare rim present the error is shown FAULTS gt Md TE zum ABSENE Dia automatic mount tof a tire in CA scanning 2s if the rim edge is wrongly positioned for a diameter setting bigger then the proper or there is nothing mounted onto the centre post the error is shown FAULT6 aot Den eee Oooo 0000 Dis start up de machine ifo one coi the switches BB sensors or pedals or sticks is engaged the error is shown FAULT 8 Hint 15 can t find rim During Bead Break and laser sensor search of the upper rim border this hint is shown if the border is not found in the expected position or the tire hides it to the sensor FAULT 9 gt cio I TM not During Lu E ihe icone thise error is du if the software detects corruption or absence of internal data FAULT 10 HOF Tue MON Linkdown cocco Cominunicias with h QPower be ers not FAULT 1 11 1 Ooo siii with h QInterface b suli not FAULT 12 Nd lad a with A AWP eru not possible or A
22. again 6 4 Take the oil previously saved in the cleaned tank and put it into the reservoir Switch the machine on and check the maximum hydraulic pressure 78 3 Make the hydraulic oil level 48 2 Remove the manometer and install the bolt with two news copper washers Mount the top cover 1 30 each one 70 QUADRIGA Service Manual 02 10 Rev C HOFMANN VS 3 Small cross screwdriver Allen wrench 4mm hydraulic oil container Defective coil valve may cause the following malfunction 1 Oil leaking 2 Oneor more hydraulic movements start themselves 3 more hydraulic movements do not work TO CHECK THE COIL VALVE Remove the top cover 5 1 Remove the coils connector Switch the machine on If the hydraulic movement start itself the coil valve is mechanically locked needs to be replaced fthe coil valve leaks oil in between with the alloy block it needs to be dismounted to replace the four rings fthe coil valve is leaking oil from the its body it must be replaced Incase of problem press the coil valve correspondent to the locked movement by screwdriver 6 13 if the machine works normally verify 6 16 TO REPLACE THE COIL VALVE IMPORTANT BEFORE REPLACING THE UPPER BEAD BREAKER COIL VALVE CLOSE THE CYLINDER COMPLETELY BEFORE REPLACING THE LOWER BEAD BREAKER COIL VALVE OPEN THE CYLINDER COMPLETELY Turn the machine off Press the coil valve by screwdriver to
23. cylinder and check if it leaks air from the lower flange 82 QUADRIGA Service Manual 02 10 Rev C Lower the cylinder and remove the hose from the lower fitting Keep pressing the control valve If the air comes out from the fitting the piston seal is defective If the air comes out from the hose the leaking is caused by the control valve Make the same operation with the rear side TO REPLACE THE CYLINDERS Disconnect ait pressure from the machine Unplug the air hoses from the cylinder Remove the bead depressor Loosen the four screws and remove the cylinder Take the cylinder lock it to the MH arm Plug the hoses Install the bead depressor Connect the air pressure and check if it works fine again 83 QUADRIGA Service Manual 02 10 Rev C 9 8 MH CYLINDER CONTROL VALVE CHECK AND REPLACEMENT amp 130 2 lt End key 5 and 22mm Allen key 3mm Defective control valve may cause the following malfunction 1 Air leaking 2 Low bead pushing pressure 3 Slow MH motion TO CHECK THE MH CONTROL VALVE Follow 79 6 TO REPLACE THE MH CONTROL VALVE Disconnect the air pressure form the machine Remove the control valve cover 9 2 Unplug the air hoses from the cylinder Loosen the screws to take out the defective valve Install the new valve and plug the air hoses Connect the air pressure again Adjust the lowering and raising cylinder speed by turning the two adjustable downloading valve Br VM
24. di distanza laser ora fuori dall algoritmo medio mobile Modificato aleoritmo del laser scan Al termine di C 80 risolto la fase di ritorno finale del sollevatore Per aggiornare le macchine richiesto il seguente software 1 x 4031192 Programmed MMC Sd card per Quadriga 129 QUADRIGA Service Manual 02 10 Rev C HOFMANN PA Dopo l aggiornamento non necessaria la taratura della macchina E necessario eseguire il codice C838 seguendo le istruzioni del manuale di riparazione IMPORTANTE Non richiesto l aggiornamento delle macchine gia operative a meno che i clienti richiedano a pagamento il software di aggiornamento DEUTSCH Wir m chten Ihnen mitteilen ab der oben aufgef hrten Seriennummer alle Versionen der Quadriga Reifenmontiermaschinen mit der neuen Softwareversion 1 0 7 ausgestattet sind Die neue Software 1 0 7 ersetzt die VorgAngerversion 1 0 6 und beinhaltet Software f r CPU Platine 1 0 7 Software f r Motorsteuerplatine 3 3 Software f r Ventilsteuerungsplatine 3 2 Die neue Software 1 0 7 umfasst die folgenden neuen Merkmale 85 zum Einstellen der Vorgabe POs mit Ausnahme der Justagewerte Drehen des zentralen Spannflansches mit zwei Drehzahlen beim Herausziehen des unteren Wulstes Die Software 1 0 7 beseitigt folgende Probleme Deranaloge Kanal f r die Laservorrichtung unterliegt jetzt nicht mehr dem flexiblen durchschnittli chen Algorithmus Gednderter Laserscann Algorithmus
25. make the adjustment following the Mechanical Section at Chapter 10 of the Service manual C80 Vertical and horizontal axes user calibration IMPORTANT BEFORE STARTING WITH THE CALIBRATION MAKE SURE THAT ALL TOOLS PLASTIC PROTECTIONS ARE FINE IF THEY ARE BAD OR NOT PRESENT REPLACE OR INSTALL THE NEW ONES WARNING DO NOT ATTEMPT ANY CALIBRATION PROCEDURE WITHOUT THE TOOLS PASTIC PROTECTION OR WITH THE PLASTIC PROTECTION WORN OUT A WRONG CALIBRATION WILL BE MADE WITH ASERIOUS RISK TO DAMAGE THE RIMS DURING THE DISMOUNTING MOUNTING OPERATION Select C80 procedure and press Enter button to start 105 QUADRIGA Service Manual 02 10 Rev C fl Im A Fuyerigr rzezrri Step 1 Tool Axis to Top position Using the vertical toolbar joystick move the vertical toolbar to its top position Touch the mechanical block gently When in position press Enter button to proceed to next step Step 2 Tool Axis to Bottom position Using the vertical toolbar joystick move the vertical toolbar to its bottom position Touch the mechanical block gently a P I x p i e al ET Press Enter button when proper position to proceed to the next step 106 QUADRIGA Service Manual 02 10 Rev C fquiprnent eae HOFMANN Step 3 Clamp Calibration Tool Clamp the Calibration tool in any position to the centre post Make sure the that the centering cone has clamped properly the calibra
26. medium cross screwdriver multimeter rubber hammer calliper Q Defective hydraulic motor may cause the following malfunction 1 Turning the switch on the hydraulic motor does not run at all Motor stops when high hydraulic pressure is required Motor noisy 2 3 27 QUADRIGA Service Manual 02 10 Rev C HOFMANN VS 4 Turning the switch on the motor turns but the machine does not make any hydraulic movements 5 The shops safety switch shuts off whenever the motor runs IMPORTANT IN CASE OF FAILURE 4 CHECK IF THE ROTATION OF THE MOTOR IS CORRECT AS FIRST TO CONTROL THE MOTOR WHEN IT DOES NOT RUN Disconnect power supply Remove the top cover protection of the hydraulic assy Remove the motor terminals cover WARNING THE CAPACITOR COULD BE STILL CHARGED OF POWER SUPPLY SHORT CIRCUIT ALL THE WIRES BEFORE DISCONNECTING TO PREVENT ANY ELECTRIC SHOCK Disconnect the capacitor wires from the terminals Select the multimeter in Ohm and positioning one probe on the motor cabinet check the continuity of all other terminals of the motor if one or more values are close to 0 the motor is in short circuit TO CONTROL THE MOTOR WHEN IT IS NOISY Disconnect power supply Remove the top cover protection of the hydraulic assy Remove the motor fan protection and check if the fan is well tightened on the shaft Mount the motor fan protection Hemove the motor terminal cover and verify if all wi
27. on and go in C61 12 to check which switch Is not working Disconnect the machine from power supply Open the control panel 55 1 Remove the suspected defective wire from the related switch Remove the related connector from the CPU board Take a multimeter and select it in Ohm Check if there is continuity between the two ends of the suspected bad cable Ade P sd TO REPLACE THE CABLE Disconnect all wires from the switches Disconnect both connectors from the CPU board Take the wires assy and connect all wires to the switches Connect the connectors to the CPU board Turn the machine on and check if it works normally Mount the control panel again TO CONTROL THE SWITCHES Disconnect the machine from power supply Open the control panel 75 1 IMPORTANT BEFORE STARTING WITH ANY REPLACEMENT VERIFY IF THE WIRES ARE WELL FITTED TO THE TERMINALS AND IF THE SWITCH IS MECHANICALLY WELL MOUNTED 36 QUADRIGA Service Manual 02 10 Rev C Remove the wires from the suspected defective switch Take a multimeter and select it in Ohm Position the multimeter probes on the switch terminals and press the switch If there is not continuity the switch must be replaced If there is not continuity the switch must be replaced TO REPLACE THE SWITCHES Take the screwdriver and lift the switch tab to remove the defective switch Install the new switch and connect the wires Turn
28. panel 5 1 Disconnect all wires from the main switch and remove it with a screwdriver Turn switch to Off Check that there is no Continuity infinity between any terminals 1 2 3 And 4 Turn switch to On Check that there is continuity between terminals 0 0 3 and discontinuity between terminals 1 3 and 1 4 as well as 2 3 and 2 4 If there is continuity the switch is in short circuit and It must be replaced TO REPLACE THE SWITCH Remove the cover and loosen the screw to remove Switch knob Remove the disc acting with a screwdriver on the side tabs Loosen the screws and remove the frame switch Install the new main switch Check that the tabs for contacts on the new switch are correctly oriented Connect wires ends FIRMLY to the new switch terminals as shown in the appropriate electric diagram 3 0 Mount the switch frame Install the disc Mount again the switch knob and cover the screw 26 QUADRIGA Service Manual 02 10 Rev C HOFMANN ES 6 3 HYDRAULIC MOTOR CABLE CHECK AND REPLACEMENT 1h 2 lt Medium screwdriver medium cross screwdriver 7mm tube type key 5mm allen key multimeter pliers Q Defective cable may cause the following malfunction 1 Low motor and hydraulic power 2 Noisy motor 3 Motor damaging burning TO CHECK THE CABLE Disconnect power supply Open the electric box 45 1 Remove the top cover
29. the machine on and check if it works fine Mount the control panel again WIRES g ith a Small and medium screwdriver 4mm allen key Defective sidewall bead breaker switches may cause the following malfunction 1 Display shows Upper lower bead breaker error during bead breaking 2 Machine does not perform the bead breaking operation IMPORTANT BEFORE STARTING WITH ANY REPLACEMENT VERIFY IF THE WIRES SWITCH IS WELL FITTED IF THE SWITCH IS MECHANICALLY IN GOOD CONDITION AND CORRECTLY ADJUSTED TO CHECK THE SWITCH Turn the machine off and unplug it from the wall Press the micro switch to verify if it make the click If not replace it Check if the micro switch is correctly adjusted if not adjust it Check if the bead breaker arm is correctly adjusted if not adjusted 10 Open the electric box 75 1 Open the Control panel 5 1 Unplug the connector X90 or X91 Take a multimeter and select it in Ohm Position the multimeter probes on the wires ends of the supposed defective switch Press the switch and verify if there is continuity If not the switch must be replaced 37 QUADRIGA Service Manual 02 10 Rev C J M Nes Wd Y x SERE l x P M n i E 4 gt TO CHECK THE SWITCH Unplug the connector X23 from the CPU board Take a multimeter and select it in Ohm Position the multimeter
30. tire lever and make sure that the disk is not going over the front plate of the calibration tool If it does make a new alignment Perform the above operation with the lower bead breaker disk TO ADJUST THE ALIGNMENT Remove the plastic protection 5 1 Remove anti rotational plate Loosen the nuts Turn the eccentric till reach the correct alignment Mount the anti rotational plate Tight the nuts Select service code 80 C83 to perform the calibration Install the plastic protection again 95 QUADRIGA Service Manual 02 10 Rev C Z 1 5h 3 lt End key 13mm allen key 6mm Incorrect bead breaker disc tilting may cause the following malfunctions 1 Display shows Upper or lower bead breaker error 2 Broken springs TO CHECK THE EXTERNAL SPRING Turn the machine on Move up or down the bead breaker arms Check if the spring is physically in good condition Check if the spring a little bit preloaded TO REPLACE THE EXTERNAL SPRING Turn the machine off Loosen the lower counter nut Loosen the screw to release the spring completely Change the spring Tight the spring till will be a little bit preloaded Lock the counter nut Place a clock base on the bead breaker carriage Position the clock on the bead breaker disc edge Loosen the screw to release the spring completely Push the disc up The disc must move upward for about 4mm If it moves l
31. yellow green Ground The machines can work at 50 or 60 Hertz according the EMC inverter tab position The 230 10 AC voltage comes in through a ON OFF Front Panel Power Switch Q1 and immediately is sent via the 20A fuses holder Q2 to an anti disturb filter to the EMC Inverter The units supplied at 100 115 VAC are equipped by a transformer before the inverter and do not have the anti disturb filter The 230 VAC is then sent to a terminal to be distributed to the following components 13 QUADRIGA Service Manual 02 10 Rev C TRANSFORMER It transforms the 230VAC in 40VACto supply the horizontal centre post and the tools carriages and the electronic boards A1 A2 and A3 The 40VAC output goes through the 20A fuses holder to the rectifier V1 EMC INVERTER 1 It supplies 230 3 to the turntable motor M3 and change the motor rotational speed from 50 to 100Hz TURNTABLE MOTOR M3 It is 3 phase single speed motor and it is supplied by the inverter that also change the rotational speed 14 QUADRIGA Service Manual 02 10 Rev C HOFMANN 4 BONER are er Egquigrnrerri HYDRAULIC PUMP MOTOR M4 It is 230 VAC single phase motor and PE wires directly go to the motor while L1 goes through electronic of the X39 connector on the Coil Valves Controls Board to control the automatic shutting off turning on LINK CONVERTER V1 Link converter transforms the 40VAC input into 48VDC be supply the following co
32. 1 Remove all coil connector from coil valves Take a multimeter and select it in Ohm Position the multimeter probes on the ends of the coil connector and verify if there is continuity between the terminals If there is not continuity the wires are defective TO REPLACE THE CABLE Disconnect all wires from the terminals block Disconnect all connectors from coil valves Release the cable strains relief Lift up the connectors by using a screwdriver to have access to the wires IMPORTANT VERIFY IF THE WIRES ARE FITTED ON THEIR TERMINALS IF THEY AREN T TIGHTEN THEM FIRMLY TO THE TERMINALS MOUNT THE CONNECTOR AGAIN AND VERIFY IF THE MACHINE WORKS FINE IF THE PROBLEM IS NOT SOLVED YET PROCED FOLLOWING THE BELOW INSTRUCTION Remove all wires from connectors Take away the defective cable Insert the new cable Tighten all wires FIRMLY on the terminals block and on the coil connectors Tighten the cable strains relief Fix the connectors to the coil valve following the correct order g ith aX Small standard and cross screwdrivers 5 mm allen key Defective wheel clamp unclamp switch may cause the following malfunction 1 The machine does not clamp or unclamp the wheels TO CHECK THE SWITCH Turn the machine on and go in C61 12 to check which switch is not working Turn the machine off Remove the pedal assy cover 75 1 Make sure that the switch is mechanically in good condition and makes a
33. 1 Frequenza massima di Pr 7 33 dI 5 18 commutazione KHz Autotaratura Pr 5 12 Pr 5 06 50 0 Numero di poli del motore Auto 5 11 Auto Frequenza nominale motore Hz 50 0 C DI c Selezione modo di tensione Url Pr5 14 Url 3 0 Pr 5 15 Boost di tensione a bassa frequenza Velocit di trasm in baud comunic Pr 11 25 seriali Indirizzo comunic seriali Pr 11 23 Soglia corrente di rilascio freno 50 12 42 soglia corrente di inserimento freno Pr 12 43 Co Frequenza di rilascio freno Hz Pr 12 44 Ritardo rilascio pre frenatura 5 1 0 Indirizzo nodo del bus di campo w e wl c co o 53 Velocit di trasm in baud bus di campo Diagnostica bus di campo Ultimo allarme 15 04 Pr 15 06 Pr 10 20 Pr 10 21 QUADRIGA Service Manual 02 10 Rev C e gt ho Allarme prima del Pr 55 I o Snap an D HOFMANN BOMER Parametro corrispondente del menu Impostazione esteso Tempo accelerazione 1 Par Descrizione Allarme prima del Pr 56 Allarme prima del Pr 57 Abilitazione programma ladder PLC Stato programma ladder PLC Parametro configurabile 1 Parametro configurabile 2 Parametro configurabile 3 64 Parametro configurabile 4 Parametro configurabile 5 Parametro configurabile 6 7 Parametro configurabile 7 z Tentativi reset automatico Parametro configurabile 8
34. 103 QUADRIGA Service Manual 02 10 Rev C Use a tire lever and lift up the bead breaker arm up to end of stroke DO NOT USE THE HANDS TO MOVE BREAKER ARM Move the centre post to get the calibration tool front plate in contact with the disk Then release the bead breaker disk again Press Enter to confirm Move the upper bead breaker disk upward out of the calibration tool range Step 3 Front plate Calibration tool on Lower bead breaker disk Perform the same procedure of step 2 with lower bead breaker disk pressing down the bead breaker arm Press Enter to confirm Now the display will show the horizontal difference in MM among the two disks If the difference is higher than the threshold 1MM not modifiable and not shown the first line of the display will show ERROR If the difference will be lower the display will show OK In the second line it will be indicated the numeric value in mm of the difference Press Enter to continue Step 4 Front plate Calibration tool on Tool 2 104 QUADRIGA Service Manual 02 10 Rev C Move the centre post to place the Tool2 to the horizontal pictures Press Enter to confirm The display will show the difference of horizontal position among the tool 2 and the upper and lower bead breaker disks The display will toggle the upper and lower bead breaker differences with the tool 2 every 12 The threshold is0to 1mm If the value is exceeding
35. 133 s y 0011215 91 01 0407 1313 06 auojzesjdse uj 013 L d gra NLA LA 4 A AAJ g Y 9 zt m N i I v _ m JOQ 091 T Y 9 i 4 aa Ko ot one a Lt J Lon d 0 J LINN 21 INVYCAH diNNd Y2INYNIQO31O VNITVYUIN3O VdMOd 010178935 OddNy9 dp I 1x02 06 s a 0199v22018S 019922019 IZ 142 qp9oqa JO 1 13395 SL9SE00 HOFMANN ES CHAPTER 4 AC DC POWER DISTRIBUTION 4 1 LOCKOUT AND OR TAGOUT SYSTEM PROCEDURE 1 Notify all affected employees that a lockout or tagout system is going to be utilized and why The authorized employee should know the electrical power the machine uses and it s hazards 2 If the machine or equipment is running shut it down by the normal stopping procedure depress the stop button open toggle switch etc 3 Use appropriate devices to isolate the equipment from the power source s Stored energy such as that in springs elevated machine members rotating flywheels hydraulic systems and air gas steam or water pressure etc must be dissipated or restrained by methods such as repositioning blocking bleeding down etc 4 Lockout and or tagout the energy isolating devices with individual lock s or tag s 5 After ensuring that no personnel are exposed and as a check on having disconnected the energy sources operate the push button or other normal operating controls to ma
36. 8 9 Coil valve check and replacement CHAPTER 9 PNEUMATCI SECTION Pag 72 9 0 Pneumatic function Pag 72 9 1 Access to pneumatic components Pag 73 9 2 Air filter lubricator assy check and replacement Pag 76 9 3 Swinging tools cylinders check and replacement Pag 77 9 4 Rotational tool cylinder check and replacement Pag 79 9 5 Lift cylinder check and replacement Pag 80 9 6 Solenoids valve check and replacement Pag 81 9 7 MH cylinder check and replacement Pag 82 9 8 MH cylinder control valve check and replacement Pag 84 9 9 Inflation spool valve check and replacement Pag 84 9 10 bead blaster valve check and replacement Pag 86 CHAPTER 10 MECHNICAL SECTION Pag 87 10 0 Mechanical section Pag 87 10 1 Gear box check and replacement Pag 87 10 2 Lead screw nuts check and replacement Pag 88 10 3 1 and 2 check and replacement Pag 90 10 4 Tool 1 and 2 alignment check and adjustment Pag 91 10 5 Bead breaker carriage check and replacement Pag 93 10 6 Bead breaker discs alignment check and adjustment Pag 94 10 7 Bead breaker arms spring check and adjustment Pag 96 CHAPTER 11 SERVICE C CODES Pag 97 CHAPTER 12 TROUBLE SHOOTING Pag 123 CHAPTER 13 SERVICE BULLETINS Pag 127 4 QUADRIGA Service Manual 02 10 Rev C HOFMANN V CHAPTER 1 INTRODUCTION 1 1 GENERAL This Service Manual describes maintenance check and repair operations of the Super automatic tire changers based on Quadriga platform under Hof
37. CHARGED OF POWER SUPPLY SHORT CIRCUIT ALL THE WIRES BEFORE DISCONNECTING TO PREVENT ANY ELECTRIC SHOCK Check the rotation way of the motor If it is wrong reverse only L1 with one of condenser wires otherwise the chuck motor will turn wrongly Mount the motor terminals cover IMPORTANT WHEN REMOUNTING THE MOTOR TERMINALS COVER BE CAREFUL NOT TO CRUSH WIRES Mount the top cover protection 2 1 30 3 lt Multimeter Defective fuse s may cause the following malfunction 1 Machine does not turn on 2 Machie does not wwork TO CONTROL AND REPLACE THE FUSES Disconnect the machine from power supply Open the electric box 5 1 Open the protection and remove the fuse Verify if there is continuity between the ends of each fuse 29 QUADRIGA Service Manual 02 10 Rev C 6 6 TURNTABLE MOTOR CABLE CHECK AND REPLACEMENT S 1h 3 lt Medium screwdrivers medium cross screwdrivers 7mm tube type wrench pliers multimeter Defective chuck motor cable may cause the following malfunction Low chuck power Noisy motor Fuses F1 F2 F3 blow up Motor damaging burning ON TO CHECK THE CABLE Remove all covers 75 1 Disconnect power supply Open the electric box 45 1 Loosen the front screw to remove the front inverter cover and disconnect the blue brown and black motor wires in bottom of the inverter Remove the motor terminals cover and all wires from terminals
38. CS 5 ra p Es as MLA Kopua pene A iat PIEESED N youbesey PLIODUE QUADRIGA Service Manual 02 10 Rev C i E 5 40 LASHS 19 g MOI LORIA TION LE mi Aj Biik tia ani pu Ma DIRLO WWE 155 HE i O FESTOH FER LIED ER rA OL WA PoP sia exces wieso ES ZH OLEI PETI aam BCP AE 0 H3 SM dO VO E E MELLA u ax n fondo dd BU LO ARE MOni e E do AL did X305 IH Li HELLS SECS 8 1 7 400 SEL POI CINE PT vESCI 3l ja cn n ja ja ja nn n p p ARB AR Exp EB iiri eas HAA HAA 28 95 Bl Badd b T EE CRED EV TE ua EE CE M Lj on get Fg B ii brs hes L J ee urn LAE A A FOU agnum Ad poi mouga FEN e jn E af T HAA illins ITE OF E iu ibis u ES ELM mi QUADRIGA Service Manual 02 10 Rev C 0 1 WOLII OHA TINY 15014 AYOLSIH 24 3 L3 6500960 Y VigEOE L 300 51400 apis S AJEAOJIIW Jake ajSel Z E 6 8 WEBEQE L 00 SJIVANVW OIDOYLOTId V ZZE vIOATVAOMNJIM 678 WEEVOE L 300 IANVA 3llOHINOJ DI L YWNaNd 8 8 WL8 0t L 00
39. ING MUST BE PLACED IN OPPOSITE POSITION COMPARED TO THE THREAD 68 QUADRIGA Service Manual 02 10 Rev C Install the new seal and the new plastic guides Lock the nut FIRMLY by using loctite Clean the piston from loctite Insert the piston into the cylinder IMPORTANT WHEN INSERTING THE PISTON INTO THE CYLINDER BE CAREFUL NOT TO CRUSH SEALS Tighten the ring screw to the cylinder IMPORTANT WHEN TIGHTENING THE RING SCREW TO THE CYLINDER BE CAREFUL NOT TO CRUSH THE O RING Lock the ring nut FIRMLY Mount the cylinder on the machine 78 6 Check the hydraulic oil level 78 2 Verify if the cylinder works fine Check if the machine works fine Mount all plastic protection 2h End wrenches 8 13 17 19 and 24mm allen wrenches 5 6 and screwdriver flat and cross medium manometer with adapter hydraulic oil container Defective hydraulic pump may cause the following malfunction Slow moving Low bead breaker and chucking power Hydraulic assy noisy Oil leaking from the motor spacer TO CHECK THE HYDRAULIC PUMP WHEN IT SHOWS HYDRAULIC PROBLEM Check the whole hydraulic pressure 8 3 If the pressure does not grow up the hydraulic pump needs be replaced TO CHECK THE PUMP WHEN IT IS NOISY Remove the hydraulic motor 6 4 Switch the motor on and listen it If it is not noisy replace the pump IMPORTANT SOMETIMES THE NOISY IS CAUSED BY A BAD JOINTS ADJUST
40. J OJILVWNINd OIO9vIOlId V Z E YIOANVA 8 8 99300 v A3u 39Y33 a es ee ee 570 WLAN 13385 QUADRIGA Service Manual 02 10 Rev C b Serer 81 10 8007 m Lie vigs92 L 00 1913 g31I081NOJ 03395 L S re I LYNN Nd 1 F_syiNony WLBVOZ L 009 OSsnid 10 3501710939 45 A n SOLO GARDINI es YZ9OLSEOYVYI J00 JAWA 9015 9 S AWLI 019938802 d YES9LSEOYW3 002 0232018 10 VIOATVA 9 5 gt PUBS 338 83101 1783839 SATIVA 43181938 ONY ONILINIT 33155359 ONILVIJNI 1 Y rd31vi Bc ee 0199 14 07 10 3N0ISS3Hd 1130 OTIOHINOJ 10 3 17181 11 11 VIOATVA ia 8002 sons NE 0328 im SET Wi gT GS SUE S dM ius 3120038 821111 pe SI LNIWTDOG SINL WE GIMIVINOI NOILVMMOGNI GUY SONIAVUC VIVO JMI In s Hi 380111018 081113 0 ef sta E E k ir TS d i o bea T Em g fe y s 1 Z3 2 Hey a t3 i j e 4 sda o ws sda sala ads s zs Fale d TTA FALLS ce a 8 Hi FIERE Vi rt orsi zi m 2 raf vs Ca indi 4 1 i er cr UL da a a Y A ir mE reacted irs THE siiis Thee ace um 7 am 8 331Y35 Ovi Jii a i eM ud 11991 uL NEC
41. LINDERS Remove rotation cylinder hoses Remove the plastic protection from the tools carriage to access QUADRIGA Service Manual 02 10 Rev C 74 gt LIFT CYLINDERS Remove all plastic protection following 5 1 gt MH CYLINDER The MH cylinder is directly available on the arm without remove any protection gt MH CONTROL VALVE To access to the valve remove the round handle and the plastic nut 75 QUADRIGA Service Manual 02 10 Rev C HECK AND REPLACEMENT Z ith 3 lt Allen key 3mm medium standard screwdriver Defective air filter lubricator assy may cause the following malfunction Air leaking Oil leaking Incorrect air lubrication Slow pneumatic motion pers TO CHECK THE AIR FILTER LUBRICATOR ASSY Air leaking and oil leaking can be solved only if they are caused by the glasses with the replacement of the glasses In all other cases the replacement of the whole assembly is required TO REPLACE THE AIR FILTER LUBRICATOR ASSY Disconnect the air pressure from the machine Unplug the hoses Loosen the bracket screws and remove the assy Install the new air filter assy Plug in the air hoses Make the oil level Connect the air pressure Make the oil lubrication adjustment Check if the machine works fine again TO REPLACE THE GLASSES Disconnect the air pressure from the machine urn counter clockwise the glass to remove it from the assy the new gl
42. MENT WHEN THEY ARE NOT WELL ADJUSTED THE MOTOR FAN STOPS VERY QUICKLY TO REPLACE THE HYDRAULIC PUMP Switch the machine on Open all cylinders completely to have less oil in the hydraulic tank and switch the machine off Take acleaned recipient x eo PONTO 69 QUADRIGA Service Manual 02 10 Rev C Disconnect the machine and the hydraulic motor from power supply 6 4 Remove the two screws shown in the picture to get the valves and hoses block separated from the hydraulic assy Remove the 2 screws under the hydraulic assy bracket and take all assembly out from the steel protection Remove the motor 76 4 Loosen the external steel belt and remove the 4 screws to take out the plastic tank Remove the screws 1 and 2 and take the pump out d l E T m ik je ir nmi PEE S SUP Ala Tua 2n ro IMPORTANT BEFORE REPLACING THE PUMP VERIFY IF THE O RINGS 1 2 AND THE SEAL 3 ARE FINE BREAKAGE OF O RING 1 MAY CAUSE SLOW HYDRAULIC MOVEMENTS AND LOW HYDRAULIC POWER BREAKAGE OF O RING 2 MAY CAUSE OIL LEAKING FROM THE ALUMINIUM MOTOR SPACER BREAKAGE OF SEAL 3 MAY CAUSE OIL LEAKING FROM THE ALUMINIUM MOTOR SPACER In case all seals and O ring will result fine the pump needs to be replaced Take a new pump and fit it on its support Tighten the pump FIRMLY Take a couple of pliers and turn the pump shaft it must turn freely Mount the oil reservoir Install the motor
43. O CHECK GEARBOX Remove the plastic lifts protections 5 1 Remove the motor M1 protection 5 1 Remove the steel mobile table covers 5 1 Turn the machine off Remove the motor and the belt 6 7 Turn the machine on Run the motor if it is run normally it means that the gearbox is noisy and must be replaced TO REPLACE THE GEARBOX urn the machine off Remove the turntable cylinder assy to access the gearbox 8 5 Disconnect the manifold revolving hose Lift the front of the machine to create the space underneath to lower the gearbox Loosen the four gearbox screws IMPORTANT BETWEEN GEARBOX AND MOBILE TABLE THERE ARE 6 SPACERS SIGN EVERY SPACER BECAUSE EVERYONE OF THESE SPACERS MUST BE REMOUNTED IN THE SAME Remove the manifold revolving Remove the pulley Install the pulley to the new gearbox Mount the manifold revolving to the gearbox 87 QUADRIGA Service Manual 02 10 Rev C Turn the set screw until it touch the shaft and then turn half of a turn back Lock the 10mm nut Grease the shaft carefully Mount the gearbox on the mobile table Make to tight the bolts FIRMLY Mount the motor Position a clock on the gearbox shaft and turn the gearbox to make sure that the shaft has not runout Mount and tension the belt Turn the machine on and check if the turntable turns normally without any noise Turn the machine off Install the two tangs Install the centre post cylinder 8 5
44. R1 8 27 LI RC CC P VNR1 2 27 ELI RC CC P COD 1282326010 di 9 COD 12 23260 Mount the control valve cover 29 2 Check if the machine works fine again 9 9 INFLATON SPOOL VALVE CHECK AND REPLACEMENT amp 1h aX Allen key 5mm 10 and 13mm key Defective inflation spool valve may cause the following malfunction 1 Air leaking 2 inflating action 3 Air leaking from the blaster jet TO CHECK THE SPOOL VALVE Open the foot pedal 5 1 Check if the mechanical components springs screws and linkage are fine 84 QUADRIGA Service Manual 02 10 Rev C ETOD Verify if the valve is leaking air from the rear springs when the pedal is in rest position Verify if the valve is leaking air from front locking nuts when the pedal is in rest position TO REPLACE THE SPOOL VALVE Disconnect the air pressure from the machine urn the machine off Unplug the hoses Remove the collar Loosen the three bracket screws the defective valve assy out and bolt the new Plug the hoses Press the pedal until it become hard to be pushed Turn the nuts to set the clearance at about 4mm between the nut and the bracket Lock the counter nut Release the pedal Now turn the linkage and the nut to set the clearance at about 8mm between the two nuts Lock the nut to the linkage Lock the valve to the pedal with the collar Plug in the air pressu
45. S o c Mu 8j a L i dows WJON 142 MM oni any Mir HM ONUNITIO 2 FEOlVAI11I05 i 3H01YA311705 9 JHJ digam 10091 1001 MHW WOOL HJHDIM t CONIINN 271150310 FIISRILO QI JJW JS DI TWO I JO 133HS 929900 11 JO 133HS SL9SE00 5303083915 000 Pp ev 10 70 6002 IUDIJON N 10 70 6002 25 ONIMYEO I1YYDIYOYNO 3 0844 ATVII 019934409 AHURU 6002 199184903 SL9SE00 Gia 1 4 a I 09 2 07 08 Z 142 0214 po3g 19807 JNI 3801YNOT11V1S 0172099 OYONI 112 v 32S10 VII 1YS 20 051 24 04 31349919 0 04 040J 19 N01123rOBd 319NV 15813 AMOISIH AJY 6900960 V 32 JUNS NO dVNS 30 4391440 NY 30 NOISSINM3d N311 UM LNOHLIM 035012510 YO 03 CIINCONdIY 38 LON AVN CNY NO dVNS 30 11814084 3105 JHL ONY 10119301 N02 51 IN3MNIOG SIHL NI GINIVINOD NOIIVNHBOJNI ONV SONIMVBO VIVO JHL Z Ajoa 211312 2 0104 0401 217 gea Y G09XGZ 0 532510 5 YLI INS e sapuryh gt 2240229 poag s3ddn 4 3801VNO11V1S 019IYU9 OYONI 11 3H2 3 Q0OM S39NVHI 1 4 rr fN 19 IY QUADRIGA Service Manual 02 10 Rev C 0 7 9EdTH 41150351A 9t dH NIISOISIA i 15 122023 yue 2101 15 OpOyequas 9 112 0 10 E ZN 3A DA J
46. WP laser not available FAULT 13 be O pum alle not dii aller Ou Bod replacement or calibration procedure aborted 123 QUADRIGA Service Manual 02 10 Rev C FAULT 14 aor 19 During the ibi of the axes misalignment of the Bead breaker axes over than the maximum threshold has cause the error This error can appear during the calibration procedure only on machine with software 1 1 10 or higher FAULT 15 D ron During the glia of dii axes the misalignment of the Bead breaker axes over than the maximum threshold has cause the error This error can appear during the calibration procedure only on machine with software 1 1 10 or higher FAULT 16 dee Poi n bai of TA id axes in misalignment of the Bead breaker axes over than the maximum threshold has cause the error This error can appear during the calibration procedure only on machine with software 1 1 10 or higher FAULT 17 EE ed 1205 podus During the dati af the wae axes the of the Bead breaker axes over than the maximum threshold has cause the error This error can appear during the calibration procedure only on machine with software 1 1 10 or higher FAULT 18 Gud Laid HOF cocco At tthe eid of diva C80i in case i due the calibration the error is shown This error can appear during the calibration procedure only on machine with software 1 1 10 or higher nl FAULT 19 OI 29
47. ard 1 0 7 SW for Dual DC Motor Driver 3 3 SW for Valves Control Board 3 2 The new software 1 0 7 includes the following new features C 88 to set to default POs except calibration data During lower bead extraction dual speed rotation of the center post The software 1 0 7 fixes the following issue Analog channel for Laser device is now out af the mobile average algorithm Modified laser scan algorithm End of C 80 fix to ending lifter homing phase To update the machines the following software is required Lx 4031192 Programmed MMC Sd card for Quadriga After the updating it is not necessary te calibrate the machine It is mandatory to perform code C85 following the service manual instructions IMPORTANT li is not required to update machines already in the field unless the customers requests under payment the software update ITALIANO Gradiamo informarvi che a partire dal numero di serie sopra riportato tutie le versioni dello smonta gomme Quadriga sono equipaggiate con il nuovo software 1 0 7 Il nuovo software 1 0 7 sostituisce il precedente 1 0 6 ed include SW per scheda CPU 1 0 7 SW per scheda controllo motori 3 3 SW per scheda controllo elettrovalvole 3 2 Il nuovo software include le seguenti novit 88 per settare i PO di default tranne I dati di calibrazione Doppia velocit dell autocentrante durante l estrazione del tallone inferiore II nuovo software risolve Canale analogico per il sensore
48. ass and tighten it IMPORTANT BEFORE TIGHTENING THE LUBRICATOR GLASS FILL IT WITH THE RECCOMENDED OIL ONLY AS REPORTED ON THE USER MANUAL AND ON TAG TO CHECK THE AIR LUBRICATION Select the Service code C62 Ch2 to move the vertical lift alone Move up and down the lift til end of stoke and make sure looking from the top transparent cap that lubricator supplies one drop of oil every complete cycle of the lift 76 QUADRIGA Service Manual 02 10 Rev C TO ADJUST THE AIR LUBRICATION Take a screwdriver and turn the regulator on top of the transparent cap Turning clockwise the oil drops will decrease Turning counter clockwise the oil drops will increase 1h aX Allen key 5mm 10 and 13mm key medium flat screwdriver 1 x0 Defective swinging tools cylinders may cause the following malfunction Air leaking 2 Tools move during mounting dismounting operation TO CHECK THE CYLINDERS Remove the cylinders protection 79 1 Turn the machine on Open the cylinder and verify if it is leaking air from the rear flange or from the fitting Close the cylinder and verify if it is leaking air from front flange or from the fitting 77 QUADRIGA Service Manual 02 10 Rev C Open the cylinder and remove the air hoses from the front flange and verify if it is leaking air from the from the fitting or from the hose If it leaking from the fitting the cylinder is defective If it leaking from the
49. aston pliers scissors pliers multimeter Defective power supply cable and plug may cause the following malfunction 1 Turning the switch on the machine does not run at all TO CHECK THE CABLE Disconnect power supply Open the electric box 5 1 Disconnect the wires form the switch Check wires continuity from power supply plug to main switch wires terminals IMPORTANT TO CHECK GROUND YELLOW GREEN WIRE DISCONNECT THE WIRE END FROM THE TERMINAL BLOCK TO REPLACE THE CABLE Disconnect the power supply Remove the main switch and disconnect the wires Disconnect the ground wire from terminal block Release cable strain relief on the electric box Remove plug from cord and take the defective cable away Insert the new cable through the strain relief IMPORTANT USE ONLY APPROVED CABLES AND PLUGS AND GROUND WIRE MUST BE LONGER THAN THE OTHER ONES Fix new fastons on inside cable ends and connect them to the switch terminals Fixthe main switch 25 QUADRIGA Service Manual 02 10 Rev C HOFFMANN Connect the ground wire to ground terminal block install plug Tighten strain relief FIRMLY 6 2 MAIN SWITCH Q1 CHECK AND REPLACEMENT amp 90 2 lt Medium cross crewdrivers and pliers Defective main switch may cause the following malfunction 1 Turning the switch on the machine does not run at all TO CHECK THE SWITCH Disconnect power supply Open the control
50. aulic oil reported on a sticker tag of the reservoir and on the user manual and fill the reservoir until to the top end of shown by the arrow IMPORTANT 1 USE SUGGESTED HYDRAULIC OIL ONLY AS REPORTED ON THE USER MANUAL AND ON TAG 2 DO NOT OVERFILL THE RESERVOIR BECAUSE THE OIL IN EXCESS WILL COME OFF THROUGH THE STOPPER WHILE MACHINE IS OPERATING hydraulic oil does not need the replacement It only must be refilled 59 QUADRIGA Service Manual 02 10 Rev C lt 130 3 lt End wrenches 17 19 and 24mm medium flat and cross screwdriver manometer This is the first operation to be do whenever there is any hydraulic force problem Incorrect pressure may cause the following malfunction Low clamping power Slow movements of the tool holder Slow lifting and lowering of the tool holder arm Low bead breaking force cs TO CHECK THE PRESSURE Remove the hydraulic assy plastic protection 5 1 Apply the manometer to any of the hose Turn the machine on Move the cylinder where it has been applied the manometer and put it under pressure sure that the maximum hydraulic pressure shown by the manometer is 160 Bar 2500 PSI TO ADJUST THE PRESSURE If the maximum pressure is lower or higher than the above one remove the nut shown by the arrow Then turn the screw clockwise to increase or counter clockwise to decrease it Remove the manometer and install the bolt with two new
51. centre post completely Turn the machine off Remove the steel hose from the centre post Loosen the locking pins and remove the flange Remove the hexagonal bar Loosen and remove 5 of the 7 flange screws and unlock the last two Loosen the screws the bottom flange The centred post is centred with two centred pins Extract the centre post assy from table hammering it around the top flange Make sure that the washer is correctly placed Remove the top flange 63 QUADRIGA Service Manual 02 10 Rev C Loosen the rear flange screws and remove the two flanges Replace the external seals and the inner O ring Remove the top spacer Pull the piston out from the top side of the cylinder IMPORTANT MAKE SURE TO PICK UP THE OIL THAT WILL COME OUT FROM THE MANIFOLD Remove the piston from the rod and replace all seals guide and O ring Mount the piston to the rod securing it with loctite 64 QUADRIGA Service Manual 02 10 Rev C Insert the piston in the centre post cylinder from the bottom of the cylinder IMPORTANT DO NOT INSERT THE PISTON INTO THE CENTRE POST CYLINDER FROM THE BECAUSE THIS OPERATION WILL DAMAGE AGAIN THE PISTON SEALS Install the two flanges in bottom securing the screws with loctite Install the spacer form the top side Mount the top flange securing the screws with loctite Make sure to lock the screws in crossing order Install the washer in the bottom of th
52. ch from Bauner to laser New C code C55 Axes durability test This C code allows the automatic motion of the axes from lowest to the maximum value of their stroke based on the calibration New C code Cob Upper and Lower bead breaker axes alignment This C code allows to verify the alignment of the Upper and Lower bead breaker axes and tool 2 C code C80 renamed as vertical and horizontal axes user calibration New C code C83 vertical and horizontal axes factory calibration This C code includes two new more steps to verify the Upper and Lower bead breaker axes alignment compared to the Tool 2 C code C89 Format internal data This C code has been removed New error codes as follow s Error 103 Qintface linkdwn Error 104 A WP linkdown Error 105 No Calibration Calibration Errors Error 120 Calibration Fail Error 121 BB Misalignment Error 122 T2 BB Misalign Error 123 Misalign Error 124 Horiz Cal Error Error 125 Vert Cal Error Error 126 Laser Cal Error Error 127 Lifter Cal Error Diagnostic check of the motion of the horizontal and vertical carriages in manual mode Wrong direction motion standing still instead of moving and motion detected instead of being still If wrong direction motion occurs all the automatic procedures are disabled The other emor are shown but do not disable the automatic modes 133 QUADRIGA Service Manual 02 10 Rev C HOFMANN PAS To update the machin
53. click 39 QUADRIGA Service Manual 02 10 Rev C HOFMANN a Press and push the pedal to make sure that the switch is well adjusted if not make a new adjustment Take a multimeter and select it in Ohm Unplug the connector X43 TO REPLACE AND AJUST THE SWITCH Position the multimeter probes on the switch wires ends and press push the pedal to verify if there is continuity if not the switch must be replaced Loosen the switch screws and remove the defective switch Mount the new switch without lock Push up press the pedal til end of stroke and make sure that the micro switch tab is close to switch end stroke If the switch tab reach the end of stroke before the pedal loosen the switch support screws and make the adjustment Lock the switch screws FIRMLY Route again the cable Plug the connector to the cable Check if the machine works fine again Mount the pedal assy cover again A 455 SI IMA IT A rf n g a ugs ue a gum AREE mo A RAFA IT 6 17 TURNTABLE H Q1 CHF DJUSTMENT AND REPLACEMENT We i awit LE t B e d a WE Ram VJ VASI ZA Los B m wu La IVI La N Z 1h 3 lt Small standard and cross screwdrivers 5 mm allen key 8mm key Defective turntable switch may cause the following malfunction mo Ic The turntable does not turn at all The turntable does not turn in first speed The turntable does not turn in se
54. cond speed The turntable does not in reverse speed TO CHECK THE SWITCH Turn the machine off Remove the pedal assy cover 75 1 Make sure that the switch is mechanically in good condition Press or push the pedal to make sure that the switch is properly adjusted if not make a new adjustment Disconnect the wires from the switch terminals IMPORTANT MARK WIRES PROPERLY FOR AN EASY AND SAFE INSTALLATION Take a multimeter and select it in Ohm In case the motor does not turn in first speed position the multimeter probes on terminals 1 and 4 and press the pedal to verify if there continuity If not replace the switch 40 QUADRIGA Service Manual 02 10 Rev C E f 7 SA LU LDO b Incase the motor does not turn in second speed position the multimeter probes on terminals 1 4 and 1 8 and press the pedal to verify if there continuity If not replace the switch Incase the motor does not turn in reversed speed position the multimeter probes on terminals 1 8 and push up the pedal to verify if there continuity If not replace the switch TO ADJUST THE SWITCH 41 QUADRIGA Service Manual 02 10 Rev C ETOD Fuyerigr rzezrri sure that the bar is more or less in the middle of the switch lever button hole when the switch is in rest position lf itis not in the middle loosen the nut 1 and remove the bolts 2 Turn half of a turn the spacer 3 and check if it is in the correct positio
55. download the remaining pressure 76 13 Loose the three screws Remove the defective valve Install the new valve and fix it FIRMLY Plug the connectors Switch the machine on and check if the machine works fine Fix the top cover 71 QUADRIGA Service Manual 02 10 Rev C are ne Egquigrrerri normann D CHAPTER 9 PNEUMATIC SECTION 9 0 PNEUMATIC FUNCTION The pneumatic section is related to all those functions and devices controlled by air pressure The working pressure required by machine to work properly must be from 8 to 12 bar and it is reported on the sticker label 9 0 1 AIR PRESSURE CIRCUIT The inlet air pressure is in the air filter lubricator assy This assembly is bolted to back of the bead breaker cabinet and it is equipped by a not adjustable air pressure regulator that reduces the over pressure to 10 Bar to avoid overstress to pneumatic components On the Quadriga tire changers all cylinders are supplied at the same pressure In some cases there air flow reducers to reduce the speed of the device only NOTE ALL PNEUMATIC CYLINDERS ARE DOUBLE ACTING TYPE 9 0 2 FUNCTIONS DESCRIPTION The description of the pneumatic functions can be grouped into 5 phases as following Air filter lubricator assy Inflation bead seating function Tools cylinders function Lifts cylinder function MH device function VVVV V 9 0 3 AIR FILTER LUBRICATOR ASSY The air pressure is controlled by the air pressure r
56. e centre post assy Make sure to place the dark side inside and the shining one outside and grease it X e r Make sure that the centring pin is not coming out from the washer Mount the centre post cylinder assy on the mobile table and secure the screws with loctite 65 QUADRIGA Service Manual 02 10 Rev C Mount the steel hose Mount the hexagonal rod Mount the flange and secure it Check if the machine works fine Mount all protections Z 1 5h 3 lt End keys 19 and 24mm medium cross screwdriver Defective piston seals may cause the following malfunction 1 Low bead breaker power 2 Slow bead breaker sliding Oil leaking NOTE THE REPLACEMENT OF THE WHOLE CYLINDER IS ONLY SUGGESTED IN CASE OF MECHANICAL DEFECTS AND OIL LEAKING THROUGHT THE WELDINGS OR THROUGHT THE PISTON ROD TO CHECK THE BEAD BREAKER CYLINDER Switch the machine on lift and lower the cylinder till end of stroke several times and verify if it show the malfunction above reported TO REPLACE THE BEAD BREAKER CYLINDER Remove the plastic protection 5 1 Switch the machine on Close completely the cylinder Turn the machine off Remove the potentiometer 7 9 Turn the machine on Open the bead breaker cylinder completely Turn the machine off Secure the bead breaker carriage to the cabinet to avoid that it will fall down after the cylinder removing Loosen and remove the top nut
57. e rotation and horizontal motion is strongly discouraged 108 QUADRIGA Service Manual 02 10 Rev C are ae Fuyer grrrzezrri EE APS VE PAT When position press Enter button to proceed to next step Automatically Tool2 will return to home position and the toolbar will move to the top home position Step 7 Both Bead Breaker arms to their top position Using upper and lower Bead Breaker joysticks move both BB arms to their top position reaching their mechanical blocks When in proper position press Enter button to proceed to next step Step 8 Both BeadBreaker arms to their bottom position Using upper and lower Bead Breaker joysticks move BB arms to their bottom position reaching mechanical blocks i When in proper position press Enter button to proceed to next step 109 QUADRIGA Service Manual 02 10 Rev C are ne Step 9 Bead Breaker arms touch the calibration tool This is an automated step and is controlled by the upper BB joystick pressing it forward the procedure starts and goes on If the joystick is released the procedure is paused The automatic procedure moves the Bead Breaker arms to a height that is for the upper BB immediately over the calibration tool and the lower BB immediately below the calibration tool The turntable rotates in order to have the calibration tool exactly in the trajectory of the BBs motion The upper BB goes down until it touches the calibrati
58. ecure the carriage to the cabinet to avoid any possibility of falling when the lead nut will be removed Loosen the lead nut screws Unscrew the lead nut and turn it to the bottom of the worm screw Loosen the worm screws bottom support IMPORTANT DO NOT REMOVE THE SET SCREWS INTO THE SUPPORT BECAUSE THE WORM SCREW ALIGNMENT WILL CHANGE 89 QUADRIGA Service Manual 02 10 Rev C HOFMANN Ba Mount the new lead nut Lock the bottom support and tight the screws FIRMLY Lock the lead nut to carriage and secure the screws with loctite Release the tools carriage IMPORTANT TURN THE PULLEY BY HAND TO MAKE SURE THAT THE WORM SCREW MUST TURN FREELY Check if the tools carriage works fine Select Service code C80 and perform the calibration Check if the machine works fine pi timis i 2h End 10 13 17 19mm allen key 3 4 5 6mm rubber hammer pliers D Defective tools may cause the following malfunctions 1 No tool rotation movement 2 Incorrect tool position 3 Excess of play in the rotational tool dae TO CHECK THE TOOL1 ROTOR Ifthe pneumatic system is fine check if all mechanical adjustment and if the tools are mechanically fine TO REPLACE THE TOOL 1 HOLDER Open the rotational cylinder 9 5 Remove the collar the tool rotor out 90 QUADRIGA Service Manual 02 10 Rev C HOFMANN a Take the new tool rotor Mount the new tool rotor M
59. educer and forwarded to water separator Two outlet forward the dry air to the inflator valve 7 2 and to the bead seating tank 8 4 One more outlet connect the water separator to the lubricator where an adjustable screw controls the oil drops to be added to the dry air to be supplied to all pneumatic cylinders 9 0 4 INFLATION BEAD BLASTER FUNCTION gt INFLATION The dry air pressure reach the inflation spool valve 7 2 Pressing the valve pedal for half of its stroke the dry air will go to the tire through to the air control valve 7 4 that controls the tire inflating pressure during the inflating process Releasing the pedal the air contained in the tire will act the manometer 7 6 showing the tire pressure Pressing the 7 7 the tire pressure will be reduced gt BEAD BLASTER The dry air pressure reach the air tank 8 4 equipped with a pressure relief valve set up at 12 bar The bead blaster valve 8 6 is basically a diaphram valve and it is directly bolted to the tank When inflator blaster pedal 7 2 is in rest position air pressure is maintained equal on both sides of the diaphram Fully depressing the inflation pedal 7 2 and the micro valve button 8 9 simultaneously air is allowed to exhaust through the controlled valve 8 8 lowering the pressure inside of the diaphragm Reduction of air pressure moves the diaphram down allowing air from tank to flow to bead blaster jet 9 0 5 TOOLS CYLINDERS gt OPENING CLOSING TOOL 1 AND 2 The air fl
60. eguire il codice C88 STRETTAMENTE PER QU le istruzioni del Manuale di Servizio Per maggiori e pi dettagliate infomazioni riguardo la nuova procedura di calibrazione e ai nuovi codici C vi preghiamo di fare riferimento al Manuale di Servizio Quadriga Service TEEWHS36A1 Rev CC ESTO AGGIORNAMENTO seguendo 134 QUADRIGA Service Manual 02 10 Rev C BLANK PAGE 135 QUADRIGA Service Manual 02 10 Rev C normann ER AUTOR Stefano Muzzioli Copyright statement This manual and the materials contained within are copyright protected The manual or any section page drawing or diagram may not be reproduced by any means without the written consent The information and specifications in this manual are based on the latest information available at the time of publication We reserve the right to change the specifications at any time without notice SNAP IN Equipment Snap on Equipment Srl unipersonale Via Provinciale per Carpi 33 42015 CORREGGIO RE ITALY Tel 39 0 522 733489 Fax 39 0 522 733610 E mail corrcs snapon com Internet http www gsboxer com SOE Digital Code SM QUADRIGA 02 10 TEEWB536A1 RC gft 2010 Snap on Equipment All Rights Reserved Rev B February 2010 P N TEEWB536A1
61. els at all TO CHECK THE LIFT RAISING POTENTIOMETER B4 Turn the machine on Go inservice code C62 and select Ch4 12 TO REPLACE THE LIFT RAISING POTENTIOMETER B4 Go in service code C62 and raise the rotational lift 12 Remove the lifts cylinder protection 5 1 Unplug the potentiometer Loosen the set screw and remove the defective potentiometer Install the new potentiometer Take the multimeter and select it in Ohm Make sure to have the rotation lift in home position Turn the potentiometer to read 0 20 and lock the set screw FIRMLY Plug the potentiometer Turn the machine on Move the lift to make sure that potentiometer reach the maximum voltage without go through the 0 Turn the machine off Route the cable Turn the machine on Select the Service Code C82 12 to calibrate the machine Mount the lifts cylinders protection 5 1 57 QUADRIGA Service Manual 02 10 Rev C normann FTO Fuyerigr rpezrri CHAPTER 8 HYDRAULIC SECTION 8 0 HYDRAULIC FUNCTION The maximum hydraulic working pressure at which each machine is carefully regulated is 160 Bar 2500 P S I and it is reported on the sticker label 8 0 1 HIGH PRESSURE CIRCUIT The high hydraulic pressure is controlled by the maximum pressure valve and its range is from 50 to 250 Bar 720 to 3600Psi This valve avoids overstress to hydraulic and mechanical components The working of this valve is very easy when the hydraul
62. es not make any movement TO CONTROL THE TRANSFORMER the multimeter and select it in VAC Switch the machine on N MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK Verify if the input among the terminals 0 230 is correct If not go to 5 2 Verify if the output among terminals 0 and 40 is correct TO REPLACE THE TRANFORMER Disconnect the machine from power supply Open the electric box 75 1 Remove all wires from terminals IMPORTANT MARK WIRES PROPERLY FOR AN EASY AND SAFE INSTALLATION Loosen its four screws Pull the transformer up and take it out Install the new transformer and tighten firmly all wires S 15 3 lt Multimeter Defective fuses may cause the following malfunction Turning the machine on the machine does not make any movement TO CONTROL THE FUSES Disconnect the machine from power supply Open the electric box 75 1 34 QUADRIGA Service Manual 02 10 Rev C ee Le te i ra i u LI A e BEN Pull out the fuse holder by hand from the transformer Verify if there is continuity between the ends of each fuse f necessary replace them with fuses of the same value 6 3A 250Volts 130 3 Multimeter Medium cross screwdriver Defective rectifier may cause the following malfunction 1 Turning the machine on the hydraulic motor run but the machine does not make any move
63. es the following software is required x 4031192 Programmed MMUC Sd card for Quadriga After the updating it is not necessary to calibrate the machine It is mandatory to perform the C code C88 STRICTLY FOR THIS UPDATE following the Service Manual instructions For more detailed informations regarding the new calibration procedures and about the new C codes please refer to the Quadriga Service Manual TEEWHSS36A1 Rev C ITALIANO A prtire dal numero di serie sopra riportato tutti gli smontagomme basati su Quadriga sono ora equipaggiati con il nuovo software 1 1 10 Questo nuovo software LL 10 sostituisce il precedente 1 0 7 ed include SW per CPU Board 1 1 10 SW per Dual DC Motor Driver 3 4 SW per Valves Control Board 3 3 Il nuovo software 1 1 10 include le seguenti nuove caratteriscti che Nuova gestione scanner AYP Gestione comunicazione seriale R5483 migliorata Ogni messaggio inviato alle schede perifieriche necessita di un responso A CE NACK e un controllo del timeout Indicazione di errore in caso di mancanza della calibrazione Nuovo codice C45 selezione sensore laser Questo codice C permette di cambiare il laser da Bauner ad AWF Nuovo codice C55 Test di durata degli assi Questo codice C permette il movimento automatico degli assi dal loro valore minimo quello massimo basato sulla calibrazione Nuovo codice C allineamento degli assi stallonatore superiore e inferiore Questo codice C permette d
64. ess Release the spring a little bit If moves more than that tight a it a little bit more Select service code C 80 to perform the calibration Check if the machine works fine again 96 QUADRIGA Service Manual 02 10 Rev C 11 SERVICE CODES SECTION To access to the Service C Codes proceed as follows gt Machine set up in Manual Mode gt Press and hold F button 5 for at least 3 seconds to enter or escape the Service C codes gt Press or 2 and 3 button to scroll the Service C codes or the calibration steps gt Press Enter button 4 to enter the Service C code and to store calibration steps C45 Laser sensor selection The C code C45 is available on machine equipped with software 1 1 10 or higher This code allow to switch the laser configuration from Baumer to AWP Press or to switch laser configuration Press Enter button to confirm C51 Operation counters Use and keys to see the following counters e Lifted wheels e Full completed e Bead breaker started e Dismount started e Mount started e Auto procedures aborted e Errors C54 Rim Scan Development use only C55 Axes motion durability test The C code C55 is available on machine equipped with software 1 1 10 or higher 97 QUADRIGA Service Manual 02 10 Rev C This code allows to perform the automatic axes motion from the lowest to the maximum
65. f hrten Maschinen einige falsche Bestellnummern f r optionales Zubeh r enthielten Mit diesem Servicebulletin m chten wir Ihnen mitteilen welche Nummem falsch waren rot markiert und welche jetzt korrigiert wurden Alle Anleitungen dieser Maschinen werden schnellstm glich berarbeitet 127 QUADRIGA Service Manual 02 10 Rev C HOFMANN PA PAGE FOR PAGINA PER SEITE FUR QUADRIGA AND OUADRIGA ATCHI 3 2 Accessories on request Fig 3 2 1 FAA0381G294 KIT FOR PICK UP WHEELS Allows pick up and light truck wheels to be clamped Fig 3 2 2 EAA0351G60A KIT FOR REVERSE WHEELS Allows wheels with reverse channel rims to be clamped Fig 3 2 3 T Im cus credano DH ii i ENTER RIMS mr LOSED C FAA0S50G 164 KIT FOR C Allows Wheels with closed center rims compact clamping device included to be clamped Fig 3 24 EAA0350G36A Bead insertion kit Far easy inflation of tubeless tires 3 2 8 128 QUADRIGA Service Manual 02 10 Rev C HOFMANN Snap Equipment Service Bulletin No SB 689 TC November 30 2009 Models affected version Quadriga tire changer Starting from s n 1009 6028521 B Subject New Quadriga software 1 0 7 ENGLISH We would like to inform you that starting from the above serial number all version of Quadriga tire changer are equipped by the new software 1 0 7 The new software 1 0 7 replaces the previous one 1 0 6 and includes SW for CPU Bo
66. he Vertical centerline of the calibration tool visible in the picture below 114 QUADRIGA Service Manual 02 10 Rev C Use the horizontal motion joystick to move the calibration tool and touch gently the Tool2 plastic protection When it is the correct position press Enter button to proceed Automatically the Tool 2 returns to home and the scanning phase will be automatically performed as described below Automatically the carriage moves up and the laser scans the calibration tool upper surface At the end of the surface scanning the procedure will save the data into internal memory and will exit from C81 Remove the calibration tool from the centre post Press button to proceed to next step 115 QUADRIGA Service Manual 02 10 Rev C are ne Egquigrrerri C82 Lifter calibration Select C82 procedure and press Enter button to start In all the steps of this procedure the user can move the two movable devices rotation device and lift device using the upper and lower BB joysticks Furthermore the user can move horizontally the turntable Carriage The upper BB joystick moves the lift device the lower BB joystick moves the rotation device Step 1 Front fork device to home position Verify to have both rotation and lift devices both to home position using the two BB joysticks If the Calibration tool is clamped please remove it using the proper clamp pedal Press Enter button when ready i
67. he seeger ring and the bolt Plug the hoses to the fittings Turn the machine on and check if it works fine again g ith 3 lt tube type key 5mm allen key medium cross screwdriver Defective coil valve may cause the following malfunction 1 Air leaking 2 Function missing 3 Turning the machine one movement starts automatically without press any switch 81 QUADRIGA Service Manual 02 10 Rev C TO CHECK THE SOLENOID VALVE HOFMANN UA urn the machine off and remove the plastic protection Unplug the air hose where it is supposed that there is not air pressure from the suspected solenoid valve Turn the machine and Check if the air is coming from the solenoid valve if yes replace the coil valve TO REPLACE THE SOLENOID VALVE Turn the machine off Disconnect the air pressure Unplug the coil of defective valve Unplug the air hoses Loosen the four front nuts Remove the defective valve Install the new valve Lock the four nuts Plug the air hoses Plug the coils Turn the machine on Check if the machine works fine Turn the machine off Mount the plastic protection ECK AND REPLACEMENT 30 End key 13mm Defective cylinder may cause the following malfunction Air leaking Low bead pushing pressure YEO I TO CHECK THE MH CYLINDER urn the machine on Lower the cylinder and check if it is leaking from the top flange Raise the
68. hose the problem is caused by the solenoid valve the same control of the rear fittings with cylinders closed TO REPLACE THE CYLINDER Disconnect the air pressure from the machine Turn the machine off Unplug the hoses Loosen the nut from the tool carriage Unscrew the piston rod from the carriage Loosen the rear screw Take the defective cylinder out and bolt the new one Plug the air hoses Connect the air pressure again Turn the machine on Check the swinging tool speed it must be 1 If necessary adjust the tool swinging speed by turning the air flow screw inside of the air fitting 78 QUADRIGA Service Manual 02 10 Rev C M Check if the machine works fine 1 5h Allen key 5mm 10mm key Defective air filter lubricator assy may cause the following malfunction Air leaking Tool move during mounting dismounting operation Tool does not turn at all FK D 1 2 3 TO CHECK THE CYLINDER Remove the cylinders protection 9 1 Plug the air hoses Turn the machine on Turn the tool and verify if it is leaking air from any flange or from the fitting TO REPLACE THE CYLINDER SEALS IMPORTANT WHEN THE CYLINDER NEEDS TO BE OPENED THE REPLACEMENT OF WHOLE SET OF SEALS IS RECCOMENDED Disconnect the air pressure from the machine Turn the machine off Unplug the hoses Loosen the nuts and remove the top flange Replace the O ring on the flange
69. i accelerazione s 100Hz 5 0 Pr 2 11 04 Tempo di decelerazione s 100Hz 10 0 Pr 2 21 05 Configurazione del convertitore Pr 11 27 Corrente nominale motore A Potenza nomin convertitore Pr 5 07 Velocit nominale motore giri min 1500 1800 Pr 5 08 Tensione nominale motore V 230 400 230 460 Pr 5 09 Dies Pr 5 10 0 75 e e wo r 2 r c Accesso ai parametri Pr 11 44 selezione logica Avviam Arresto 0 Pr 6 04 Abilitazione controller freno dis Pr 12 41 k pala CL i 15 Riferimento di jog Hz 1 5 Pr 1 05 1 5 Modo ingresso analogico 1 mA 4 0 20 Pr 7 06 UoLt 17 Abilitazione velocit negative OFF 0 Pr 1 10 OFF preimpostate 18 Velocit preimpostata 1 Hz Pr 1 21 19 Velocit preimpostata 2 Hz 0 0 1 22 100 0 Velocit preimpostata 3 Hz 0 0 1 23 Pr 1 24 Pr 4 21 Unit di visualizzazione velocit Scalatura definita da utente 1 000 1 000 ne ead 1 Velocit preimpostata 4 Hz Unit di visualizzazione carico TM MEN mn o S m d zi 2 Valori predefiniti di carico Pr 11 43 selezione modo di rampa Pr 2 04 Selezione Modo di arresto Selezione rapporto V f dinamico OFF 0 Pr 5 13 OFF Pr 6 01 selezione ripresa al volo del motore Pr 6 08 i Selezione modo terminale BT dig Pr 8 35 dig Gontrollo uscita digitale terminale c Pr 8 41 B3 Controllo uscita analogica terminale B
70. i verificare l allineamento degli assi degli stallonatori superiore inferiore e dell utensile 2 Codice C80 rinominato come Vertical and Horizontal axes user calibration Nuovo codice C83 calibarzione fabbrica degli assi verticali e orizzontali Questa codice C include due nuove fasi per verificare l allineamento dello stallonatore superiore e inferiore rispetto all utensile 2 Codice C89 Format internal data Questo codice C stato rimosso Nuovi codici errore come segue Error 103 Qintface linkdwn Error 104 A WP link own Error 105 No Calibration Errori di calibrazione Error 120 Calibration Fail Error 121 BB Misalignment Error 122 TABE Misalign Error 123 TABE Misalign Error 124 Horiz Cal Error Error 125 Vert Cal Error Error 126 Laser Cal Error Error 127 Lifter Cal Error Diagnostica del movimento dei carri verticale e orizzontale in modo manuale Direzione del movimento sbagliato rimandendo anzich muoversi e rilevamento del movimento anzich rimanere fermo Se si verifica un movimento sbagliato tutte le funzioni automatiche sono disabilitate If wrong direction motion occurs all the automatic procedures are disabled Gli altri errori vengono mostrati senza disabilitare i modi automatici Peraggiornare le macchine richiesto il seguente software xi 4031192 Programmed MMC Sd card for Quadriga Dopo l aggiornamento non necessario calibrare la macchina E obbligatorio es
71. ic pressure inside of a cylinder reaches 160 2500 5 1 the valve opens and downloads the oil directly into the reservoir The cylinders operating at high pressure are the following gt Clamping Unclamping cylinder Bead breaker cylinders NOTE ALL HYDRAULIC CYLINDERS ARE DOUBLE ACTING TYPE 8 0 2 FUNCTIONS DESCRIPTION The description of the hydraulic functions can be grouped into 4 phases as following Machine in rest position gt Raise and descent of lower bead breaker arm gt Raise and descent of upper bead breaker arm gt Open and close of the clamping centre post 8 0 3 MACHINE IN REST POSITION The oil of the reservoir is pumped through every solenoid valve which are in rest position and then it returns to the reservoir 8 0 4 LOWER BEAD BREAKER ARM RAISE DESCENT gt RAISE The oil flow arrives to the opened valve Y1N and it reaches the side B of the cylinder Z3 making the raising of the arm Oil contained in opposite side A returns to the reservoir through all others valves gt DESCENT The oil flow arrives to the opened valve Y1B and it reaches the side A of the cylinder Z3 making the raising of the arm Oil contained in opposite side B returns to the reservoir through all others valves 8 0 5 UPPER BEAD BREAKER ARM RAISE DESCENT gt RAISE The oil flow arrives to the opened valve Y2B and it reaches the side A of the cylinder Z2 making the raising of the arm Oil contained in o
72. ic protection easily accessible 1 21 QUADRIGA Service Manual 02 10 Rev C gt 5 7 ACCESS TO THE BEAD BREAKERS POTENTIOMETERS The bead breakers potentiometers are placed behind of the related hydraulic cylinders and therefore the access requires the dismounting of these cylinders gt 5 8 ACCESS TO THE SIDEWALL BEAD BREAKERS SWITCHES These switches are easily accessible because they are directly bolted to the bead breaker carriages QUADRIGA Service Manual 02 10 Rev C Mi FARINI E gt 5 10 ACCESS TO THE WHEEL DIAMETER POTENTIOMETER This potentiometer is installed on the front rotational lift Remove the plastic cover to access 23 QUADRIGA Service Manual 02 10 Rev C gt 5 11 ACCESS TO THE TOOL 1 2 CARRIAGE POTENTIOMETER The access to this potentiometer is easy because it is available in the back side of the tools carriage 24 QUADRIGA Service Manual 02 10 Rev C HOFMANN V CHAPTER 6 ELECTRIC SECTION WARNING BEFORE APPROACHING THE ELECTRIC PARTS OF THE MACHINE DISCONNECT THE MACHINE FROM ELECTRIC SUPPLY Very often electric failures are only caused by loosened wires or connectors not well fitted Therefore it is VERY IMPORTANT BEFORE STARTING WITH ANY CONTROL AND OR REPLACEMENT VERIFY IF ALL WIRES AND CONNECTORS ARE WELL FITTED 6 1 POWER SUPPLY CABLE AND PLUG CHECK AND REPLACEMENT amp 1h 3 Small and medium screwdriver medium cross screwdriver f
73. ighten the set screw till end of stroke and turn 1 8 of a turn backward Lock the counter nuts Check if the machine works fine 93 QUADRIGA Service Manual 02 10 Rev C 1 5h 3 lt End key 24 and 30mm allen key 5mm medium cross screwdriver rubber hammer Incorrect bead breaker disc alignment may cause the following malfunctions 1 Bead breaker disc works on the rim 2 bead breaker disc works on the tire sidewall TO CHECK THE ALIGNMENT Turn the machine on Clamp the calibration tool Use the turntable to place the Tool2 to the horizontal centerline of the calibration tool visible in the pictures Use the vertical toolbar joystick to place the Tool2 to the Vertical centerline of the calibration tool and use the horizontal motion joystick to move the calibration tool and touch gently the Tool2 plastic protection 94 Turn the calibration tool in proximity of the bead breaker disk IMPORTANT DO NOT MOVE FORWARD OR BACKWARD THE CENTREPOST OTHERWISE THE TOOL2 REFERENCE WILL BE LOST Low the upper bead breaker disc in till reach the front of the calibration tool plate atire lever and lift the bead breaker arm till end of stroke DO NOT USE THE HANDS TO MOVE BREAKER ARM Check if the disk touch the calibration tool If not make the adjustment till it touch it Move the upper bead breaker disk upward and when it is jus out of the calibration tool take a
74. isconnect the piston rod from the arms linkage ry to open the tool arm by hand if the alignment is correct the opening will be difficult Close the arm again by hand Connect the piston rod to the linkage la fi LE E D E E n F gs d Check if the tool arm works fine Select Service code C80 to calibrate the machine Check if the machine works fine TO ADJUST THE TOOLS 1 AND 2 PLAY Check if the linkage arms ring nut screws are well adjusted Loosen the set screws counter nuts Turn the set screw till touching the arm and then turn 1 8 of a turn backward Check by hand if the adjustment is correct and if necessary increase of decrease the adjustment 92 QUADRIGA Service Manual 02 10 Rev C Z 1 5h 3 lt End key 19mm allen key 8mm medium cross screwdriver rubber hammer Incorrect bead breaker carriage adjustment may cause the following malfunctions 1 Play in carriage 2 Difficult bead breaking operation 3 Incorrect bead breakers alignment compared to the rim edge TO CHECK THE CARRIAGE PLAY Take atire lever and check if the carriage is moves Make sure that the square bar is well locked to the top and to the bottom of the cabinet TO ADJUST THE CARRIAGE PLAY Remove the plastic protection 5 1 Loosen the slides set screws counter nuts Check if the linkage arms ring nut screws are well adjusted Loosen the set screws counter nuts T
75. ke certain the equipment will not operate CAUTION RETURN OPERATING CONTROL S TO NEUTRAL OR OFF POSITION AFTER THE TEST DE ENERGIZED STATE 6 The equipment is now locked out or tagged out 4 2 ELECTRICAL REQUIREMENTS NOTE ANY ELECTRICAL WIRING MUST BE PERFORMED BY LICENSED PERSONNEL ALL SERVICE MUST BE PERFORMED BY AN AUTHORIZED SERVICE TECHNICIAN Check on the plate of the machine that the electrical specifications of the power source are the same as that of the machine NOTE ANY ELECTRICAL OUTLET INSTALLATION MUST BE VERIFIED BY A LICENSED ELECTRICIAN BEFORE CONNECTING THE TIRE CHANGER NOTE ENSURE THAT THE OUTLET HAS AN AUTOMATIC GROUND FAULT CIRCUIT BREAKER WITH A DIFFERENTIAL CIRCUIT SET AT 30 MA A WARNING DANGEROUS HIGH VOLTAGES ARE PRESENT THIS EQUIPMENT Always use the One Hand Rule when working with AC voltages by keeping one hand in your pocket or behind your back Before removing wires from the tire changer always verify that the unit is OFF Turn off the Main Power Switch on the back and unplug the AC power cord from the AC outlet AC DISTRIBUTION All Quadriga tire changers are equipped by two VAC motors One 230 VAC single phase pump motor and one 230 VAC three phase turntable motor The voltage at which the machine is wired is printed on the serial number plate and on a tag at the end of the power cord The power cord has 3 wires N Neutral L1 Phases PE
76. key Use this key to open the hydraulic cylinders Clock with magnetic base Use this tool to adjust the bead breaker disc Ring nut socket keys There are 4 different keys 10mm 17mm 20mm and 25mm Use these keys to tight or loose the knees ring nuts 6 QUADRIGA Service Manual 02 10 Rev C normann D 2 2 MPORTANT SAFETY INSTRUCTIONS The units are CE or UL approved but whenever using this equipment basic safety precautions should always be followed including the following 1 Read all instructions 2 Do operate equipment with a damaged power cord or if the equipment has been damaged until it has been examined by a qualified authorized service technician Ifan extension cord is used a cord with a current rating equal to or more than that of the machine should be used Cords rated for less current than the equipment may overheat Care should be taken to arrange the cord so that it will not be tripped over or pulled 4 Always unplug equipment from electrical outlet when not in use Never use the cord to pull the plug from the outlet Grasp plug and pull to disconnect 5 reduce the risk of fire do not operate equipment in the vicinity of open containers of flammable liquids gasoline 6 Keep hair loose fitting clothing fingers and all parts of the body away from moving parts 7 Adequate ventilation should be provided when working on operating internal combustion engines
77. lastic protection Turn the machine on Select the Service Code C80 12 to calibrate the machine 2h Allen key 4 5 and 6mm 13 10 and 7mm key medium cross screwdriver multimeter Defective potentiometer may cause the following malfunction Machine does not position horizontally the wheel correctly TO CHECK THE POTENTIOMETER TO REPLACE THE POTENTIOMETER Turn the machine on Go in service code C62 and select Ch7 12 Turn the machine off Remove the lift cylinders plastic protection 5 1 Remove the motor M1 protection 75 1 Remove the turntable covers 75 1 Turn the machine on Slide the a little bit the carriage Loosen the two 6mm top nuts Loosen the four 4mm rear nuts and remove the potentiometer from the table Remove the connectors Take the new potentiometer and plug the connector again Mount the potentiometer on the cabinet without lock it Turn the machine on Move the carriage at the end of stroke Turn the machine off Connect the potentiometer to the carriage holder Make sure that potentiometer is not at the end of the stroke Turn the machine on Select the Service Code C C62 and select Ch7 12 Move the carriage forward and backward Make sure that the potentiometer does not go through the 0 during the sliding and it does not reach the end of strokes Turn the machine off Lock firmly the potentiometer Mount all protections Turn the machine on Select the Service
78. lder Mark the toothed wheel Turn the machine on Slide the tools carriage all way down checking that the number of revolution made by wheel are 10 and making sure that the potentiometer will not be at the of the stroke 54 QUADRIGA Service Manual 02 10 Rev C HOFMANN VS Select the Service Code C80 12 to calibrate the machine Route the wire again Z 2h 2 lt 13 4 and 5mm Allen Key 10 and 14mm key multimeter Defective potentiometer may cause the following malfunction 1 The machine does load the wheels in middle of the centre post 2 The wheel lift does not load the wheels at all TO CHECK THE LIFT SIZE POTENTIOMETER B6 Turn the machine on Go inservice code C62 and select Ch4 12 TO REPLACE THE LIFT SIZE POTENTIOMETER B6 Go in service code C62 and raise the rotational lift 12 Remove the potentiometer protection 5 1 Unplug the potentiometer Loosen the set screw and remove the defective potentiometer Install the new potentiometer Take the multimeter and select it in Ohm Make sure to have the wheel diameter gauge in home position Turn the potentiometer to read 0 20 and lock the set screw FIRMLY Move the wheel diameter gauge to make sure that potentiometer reach the maximum voltage without go though the 0 Route the cable Turn the machine on Select the Service Code C82 1 2 to calibrate the machine Mount the potentiometer protection 5 1 55 QUADRIGA Service
79. ll escape through the valves gt RAISING The air flow is forced to the side A of the cylinder 4 5 through the valve 4 2 to raise the lift Air contained in side B will escape through the valves The air flow is forced to the side B of the cylinder 6 5 through the valve 6 2 to lower the lift 9 0 7 MH DEVICE CYLINDER gt PRESSING The air flow is forced to the side A of the cylinder 6 5 through the valve 6 2 to open the cylinder and press the tire bead Air contained in side B will escape through the valves gt REALISINGThe air flow is forced to the side B of the cylinder 6 5 through the valve 6 2 to close the cylinder and release the tire bead Air contained in side A will escape through the valves Except the the access to the lift cylinders the pneumatic parts access is quite easy compared to the electric and the hydraulic ones To access to pneumatic components of the machine gt AIR FILTER LUBRICATOR This assy is bolted in the back of the bead breaker cabinet gt INFLATON SPOOL VALVE To access to the inflation spool valve open the foot pedal assy 95 1 73 QUADRIGA Service Manual 02 10 Rev C gt BEAD BLASTER VALVE AND AIR TANK Bead blaster valve is bolted to the air tank and the assy is bolted to the cabinet of the machine gt SOLENOID VALVES To access to the solenoid valves remove the rear plastic protection 8 1 gt TOOLS CY
80. lo corretto il EA A034906824 4031035 Tutti i Manuali Operatore relativi a queste macchine verranno aggiornati al pi presto DEUTSCH Wir m chten Ihnen mitteilen dass in der Bedienungsanleitune f r die Quadri ga eine falsche Bestellnummer f r das Standard Radspannkit angegeben ist In der Anleitung ist das Standard Radspannkit mit EA A03496G044A 4030480 ange geben Abbildung 3 1 2 Seite 24 die richtige Bestellnummer ist aber EAAU349G82A 4031035 Die betroffenen Anleitungen werden umgehend itberarbeitet 131 QUADRIGA Service Manual 02 10 Rev C HOFMANN Snap Z3 Equipment Service Bulletin No SB 691 TC December 03 2009 Models affected Quadriga tyre changers Starting from sn Subject ncorrect accessory number on operators manual ENGLISH We would like to inform you that the Operator s Manual of Quadriea tyre changer has been edited with an incorrect part number related to the Standard wheel clamping kit The Operator manual reports the Standard wheel clamping kit EAA0349G04A 4030480 red signed below while the correct one is EAAU349G824A 4031035 All the Operator s manuals related to these machines will be updated at soonest ITALIANO Gradiamo informarvi che i manuali dell operatore relativi allo smonta gomme Quadriea sono stati editi con il codice relativo al Kit standard fissaggio ruote non corretto manuale operatore riporta il Kit standard fissaggio ruote EAAOSJOGOAJA
81. mann John Bean and Boxer brands and is for use of qualified and trained personnel only Keep this manual constantly updated by adding Service Bulletins related to the tire changers IMPORTANT The identification datas of each machine are printed on a adhesive label attached to the cabinet of the machines The serial number is a sequence of figures standing for the manufacturing month and year the first four numbers followed by the machine part number made of 7 numbers and finally the progressive serial number of the machine manufactured with this specific part number HOD TYPE TYP MAT SER NO NET vac Mmp 1 Bar PSI kPa dBAaOtrsceh elettr CHAPTER 2 TOOLS AND SAFETY 2 1 TOOLS AND SPECIAL TOOLS To repair and or check these tire changer the following standard tools are required Keys 6mm to 30mm Tube type keys mm to 17mm Allen keys 2 5 mm to 12 mm Socket wrenches 17mm to 24mm Allen socket keys amm to 12mm Screw drivers Flat bed and Phillips from 1 to 5 Multimeter AC DC A Ohm pF Lotctite silicon and mechanical extractor opecial tools that are required for specific tasks are Manometer with adapter 4006849 Use this manometer to check the hydraulic pressure HOFMANN PS Calibration bar 4031022 EAS2111G63A Use this calibration fixture to perform all calibration and to adjust the tools and the bead breaker rollers Calliper
82. ment TO CONTROL THE CONVERTER Switch the machine on the multimeter and select it in VAC MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK Position the multimeter probes on the single black wire terminals of the converter and verify if the power displayed by the multimeter is 40 VAC Position the multimeter probes on the double wires terminals of the converter and verify if the power displayed by the multimeter is 48 VDC if not replace the converter TO REPLACE THE CONVERTER Disconnect the machine from power supply Open the electric box 75 1 Remove all wires from the converter IMPORTANT MARK WIRES PROPERLY FOR AN EASY AND SAFE INSTALLATION Lose the defective converter and replace it with a new one Fix all wires again 1heach one 35 QUADRIGA Service Manual 02 10 Rev C HOFMANN V 3 Small and medium screwdriver medium cross screwdriver allen key 4 and 5mm Defective control panel switch may cause the following malfunction 1 Turning the machine on it does not make one or more movements IMPORTANT FAILURE MAY ALSO BE CAUSED BY HYDRAULIC OR PNEUMATIC REASON TO VERIFY IF THE FAILURE IS ELECTRIC OR HYDRAULIC PNEUMATIC PRESS THE COIL VALVE CORRESPONDENTS TO THE DEFECTIVE HYDRAULIC PNEUMATIC MOVEMENT IF THE MACHINE WORKS NORMALLY BY PRESSING THE COIL VALVE THE PROBLEM IS DUE TO AN ELECTRIC MALFUNCTION TO CONTROL THE WIRES Turn the machine
83. motor and the belt Pull the motor together with belt When the is well tensioned lock the four screws FIRMLY Plug the connectors Check if the motor works fine Mount all protections 30 Multimeter small and medium cross screwdrivers pliers Defective inverter may cause the following malfunction Turntable motor does not turn at all Turntable motor turns in slow speed only Turntable motor turns in high speed only Turntable motor turns in reverse direction only The shut off switch of the tire shop shuts off 33 QUADRIGA Service Manual 02 10 Rev C SISI EET normann VA Press the rotational pedal if the motor does not run or if the tire shop shut off switch shuts off the inverter must be replaced TO REPLACE THE INVERTER Turn the machine off Open the electric box 45 1 Loosen the screw and remove the front cover to access to the terminals 75 7 Disconnect the wires from the inverter terminals marking the position Loosen the 4 screws in the back to remove the inverter Install the new inverter and wire it again as it was at the beginning Turn the machine on and check the inverter set up of the red values Z 90 2 lt Multimeter small and medium cross screwdrivers pliers Defective transformer may cause the following malfunction 8 Smoke gets out from the electric box with consequent burning of the transformer 9 Turning the machine on the machine do
84. mponents Dual DC Drive Motors board 2 for the horizontal centre post and the tools carriages VDC motors Valves Control Board PROCESSOR BOARD A1 The processor board A1 CPU is placed into the control panel and manages all input form joystick switches rotational pedal Distance laser sensor potentiometers keypad and LCD display The 24 VDC operating voltage comes to X21 connector from X37 one of the Coil Valves Controls Board A3 The CPU board A1 communicate with all other board via serial communication RS 485 connector X20 The the balancer All switches of the control platform are connected to the CPU board trough connector X24 X25 and X26 The software update can be done with an SD card like on the balancers DUAL DC DRIVE MOTOR BOARD A2 The Dual DC Drive Motors board supplies the 48 VCC to the horizontal carriage sliding motor M1 connector X32 and to the carriage tools motor M2 connector X35 and controlled by the CPU it allows to control the motor acceleration and deceleration 15 QUADRIGA Service Manual 02 10 Rev C It is directly supplied with 48 VDC by the rectifier V1 with the wider wires connector X34 and there is also an input for 24 VDC connector X33 It communicates with the CPU board A1 via serial communication RS 485 connector X27 VALVES CONTROL BOARD A3 The Valves Control Board A3 controls the hydraulic and the pneumatic coil valves and the pump motor M4 automatic shutti
85. n Press the pedal all way down and make sure that switch has already switched to the second step before the pedal has reached the end of stroke The gap between the pedal and pedal assy cabinet must be about 2mm FUE T rel has 4 FE 79 Push the pedal all way up and make sure that switch has already switched before the pedal has reached its mechanical end of stroke ATTE h a E TO REPLACE THE SWITCH 42 QUADRIGA Service Manual 02 10 Rev C Loosen the screw that hold the switch lever Push the switch lever out Loosen the screws and remove the switch Install the new switch and secure the screws Install and secure the switch lever Turn the machine on and check if the machine works fine Mount the pedal assy cover 43 QUADRIGA Service Manual 02 10 Rev C Hormann ER CHAPTER 7 ELECTRONIC SECTION WARNING BEFORE APPROACHING THE ELECTRONIC PARTS OF THE MACHINE DISCONNECT THE MACHINE FROM POWER SUPPLY 7 1 EMC INVERTER T1 CHECK AND REPLACEMENT 1h30 Multimeter small and medium cross screwdrivers pliers Defective inverter may cause the following malfunction Turntable motor does not turn at all Turntable motor turns in slow speed only Turntable motor turns in high speed only Turntable motor turns in reverse direction only The shut off switch of the tire shop shuts off Xe TO CONTROL
86. n Turning the machine on the display does not show anything Turning the machine all movements do not work Turning the machine on or while operating QPower link down is displayed Turning the machine on or while operating Qlnterface link is displayed Pressing the touch board nothing change IMPORTANT BEFORE STARTING WITH ANY REPLACEMET CHECK CAREFULLY IF ALL WIRES AND CONNECTORS ARE WELL FITTED TO CONTROL THE PROCESSOR BOARD A1 Turn the machine on Go in C63 12 to check if the CPU board is communicating with the Valves control and Dual Dc driver board Open the control panel 575 1 Turn the machine on Take the multimeter and select it in VDC Position the probes on the orange connector X21 and check if there are 24VDC Check if all connectors are well fitted to the board Check display board Check the touch board TO REPLACE THE PROCESSOR BOARD 1 Disconnect all connectors Remove the 4 screws with the screwdriver Remove all connectors Mio o9 Tert IMPORTANT MARK CONNECTORS PROPERLY FOR A EASY AND SAFE INSTALLATION Install the new board Install all connectors Install the software 7 4 Perform all calibration steps Check if the machine works properly Fix the control panel 48 QUADRIGA Service Manual 02 10 Rev C 130 aX Medium cross screwdriver Allen keys 4 and 5mm 7mm key calibration fixture SD card with software Turn the machine
87. n Za MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK Position the multimeter probes on the connector X34 and verify if it correctly supplied at 48VDC Position the multimeter probes on the connector X35 and X33 to verify if the 48VDC output for the motors M1 and M2 is correct OUTPUT 48 voc Position the multimeter probes on the connector X32 to verify if the 24VDC input for the logical part of the board is correct Check in C62 the analogical value of Ch7 12 Check in C62 the analogical value of Ch8 12 Check in C63 the communication with the CPU 12 TO REPLACE THE DUAL DRIVE MOTOR BOARD A2 Turn the machine off Remove all connectors and wires from the board IMPORTANT MARK CONNECTORS AND WIRES ROPERLY FOR AN EASY AND SAFE INSTALLATION board INPUT 24 VDC Install all connectors and wires FIRMLY Install the Valves Control board Close the electric box Check if the machine works fine again 7 6 VALVES CONTROL BOARD CHECK AND REPLACEMENT 1h 30 Medium cross screwdriver 7mm key multimeter Defective processor board may cause the following malfunction Bead breaker cylinder or clamping cylinder do not work One or more pneumatic cylinder do not work Turning the machine on the display does not show anything The pump motor does not work The turntable motor does not run at all The turntable motor does not run in first speed
88. n position 116 QUADRIGA Service Manual 02 10 Rev C HOFMANN a 5 i Step 2 Front fork device to top position Using lower BB joystick move the rotate device to the mechanical block p3 p ea bo Press Enter button when ready in position Step 3 Lift device to home position Leave the rotation device where it is and using upper BB joystick verify to have the lift device to its home position ge Press Enter button when in position Step 4 Lift device to top position Using upper BB joystick move the lift device to the top position Please verify that no collisions occur during motion of the lift arm with the rotation arm 117 QUADRIGA Service Manual 02 10 Rev C Press Enter button when in position and both lift and rotation devices go automatically to home position Step 5 Wheel size sensor to home position Verify that the frontal wheel size sensor is in its home position y E Press Enter button to store the calibration data in permanent memory and exit from C82 118 QUADRIGA Service Manual 02 10 Rev C HOFMANN V C83 Vertical and horizontal axes factory calibration This C code is available on machine equipped with software 1 1 10 or higher This calibration procedure is based on C80 with the difference that it has been added the axes alignment control with consequent automatic exit in case of error due to excessive bead breaker disk misalignmen
89. ng off turning on connector X39 It is directly supplied with 48 VDC connector X37 from the rectifier V1 with the smaller wires and it also transforms 48 VDC in 24 VDC connector X37 for the logical control part of Dual DC Drive Motors board A2 and for the CPU board A1 On this board there are the 3 control signals for the inverter T1 driving X42 slow speed clock wise rotational direction X404 X42 for high speed clock wise rotational direction X43 slow speed counter clock wise rotational direction This board communicates with the CPU board A1 via serial communication RS 485 connector X36 The first 6 output of the connector X45 to 65 goes to the hydraulic coil valve while all other ones are directed to the pneumatic VDC MOTORS M1 AND M2 These motors control the movement of the horizontal centre post and the tools carriages They are supplied at 48VDC from the Dual DC Drive Motors board 16 QUADRIGA Service Manual 02 10 Rev C BEAD BREAKERS LINEAR POTENTIOMETERS B7 AND B8 The bead breakers potentiometers B7 and B8 are 5K linear type They are supplied 5 20 VDC from the CPU board A1 This input voltage can be measured at the Processor Board X6 to X19 pin The output voltage is dependent upon the deflection of the gauge from the home position CENTRE POST CARRIAGE POTENTIOMETER 1 The bead breakers potentiometers B1 is 5K linear type It is supplied 5 20 VDC from the Dual DC motor driver board and its input v
90. ntiometer doesn t detect any variation of the rotation arm position the error is shown FAULT HOF 212 Ar MOL FORO Dir Error During if ie rotation arm moves in the opposite direction or the potentiometer is mounted wired wrongly the error is shown FAULT 33 Error 213 Size Sensor Error At the end of the loading of wheel this error is shown if the size sensor is not in the calibration home position 125 QUADRIGA Service Manual 02 10 Rev C HOFMANN FAULT 34 Error 220 Upper BB Potentiometer Error Upper BB potentiometer error To be replaced FAULT 35 Error 221 Lower BB Potentiometer Error Lower BB potentiometer error To be replaced FAULT 36 Error 222 Vertical Potentiometer Error Vertical Axis potentiometer error To be replaced FAULT 37 Error 223 Horizontal Potentiometer Error Center post potentiometer error To be replaced FAULT 38 Error 224 Lift Potentiometer Error Lift arm potentiometer error To be replaced FAULT 39 Error 225 Rotat Potentiometer Error Rotation arm potentiometer error To be replaced FAULT 40 Error 226 Size Potentiometer Error Size sensor potentiometer error To be replaced FAULTA 41 PETS SWEN automatic da if vi upper sensor is already engaged at the beginning of the procedure the error is shown FAULT A 42 HOF SI n h Engaged purses automatic Bead po if lone Bead Breaker sensor is already engaged at the beginning
91. of the procedure the error is shown FAULT ES HOF aa one NotValid m atto 126 QUADRIGA Service Manual 02 10 Rev C SISI HOFMANN VS CHAPTER 13 SERVICE BULLETIN Snap Equipment Via Provinciale per Carpi 33 42015 Correggio RE ITALY Service Gulletin SB 876 TC Date October7 2009 E HOFMANN Universal 2 Quadriga JOHN BEAN Pegasus 200 Quadriga BOXER Vulcan Quadriga SNAP ON ATC800 Quadriga ATC 1000 E E Models Affected Subject Incorrect accessories part number on Operator Manual ENGLISH We would like to inform you that the Operator s Manual of the above machines have been edited with some incorrect part number related to the accessories under request With this Service Bulletin we would like to inform you about which are the incorrect accessories part number red signed and the correct ones All the Operator s manuals related to these machines will be updated at soonest ITALIANO Gradiamo informarvi che i manuali dell operatore relative alle macchina sopra riportate sono stati editi con alcuni codici relativi agli accessori a richiesta incorretti Con questo Bollettino di Servizio gradiamo informarvi su quali sono i codici degli accessori non corretti segnati in rosso e quelli corretti Tutti i Manuali Operatore relativi a queste macchine verranno aggiornati al pi presto DEUTSCH Wir m chten Sie dar ber informieren dass die Betriebsanleitungen der oben aufge
92. off Open the control panel 5 1 Take the SD card and insert it through the slot Turn the machine on The machine will emits a sequence of 6 tone signal beepers The Downloading or Flashing of the New software will now begin It takes about 20 sec the down loading is completed the machine will start beeping constantly and will not stop till you switch off The beeping means the down loading is completed Turn the machine off Remove the SD card Close the control panel IMPORTANT IF THE SOFTWARE IS INSTALLED AFTER THE CPU BOARD REPLACEMENT THE MACHINE REQUIRES THE COMPLETE CALIBRATION IF THE SOFTWARE IS INSTALLED TO UPDATE THE MACHINE ONLY THE CALIBRATION IS NOT STRICTLY REQUIRED BUT RECCOMENDED 2 1h30 2 lt Medium cross screwdriver 7mm key multimeter Defective Dual DC drive motor board A2 may cause the following malfunction 1 or both motors M1 and 2 do not work 2 The turntable does not recognize the correct horizontal wheel position 3 The tools do recognize the correct operating position IMPORTANT BEFORE STARTING WITH ANY REPLACEMET CHECK CAREFULLY IF ALL WIRES AND CONNECTORS ARE WELL FITTED TO CHECK THE DUAL DRIVE MOTOR BOARD A2 Turn the machine off Open the electric box 5 1 Remove the Valves Control board 7 5 Take the multimeter and select in VDC Turn the machine on 49 QUADRIGA Service Manual 02 10 Rev C fai Horman
93. oke Turn the machine off Take the oil container and remove the hose from the side where it is supposed that there is no hydraulic pressure Turn the machine on Press the switch to put the cylinder under pressure If the side without the fitting will leak considerably oil the piston seal is defective Some drops of oil leaking are considered absolutely normal Perform the same operation on the other side 67 QUADRIGA Service Manual 02 10 Rev C TO REPLACE THE O RINGS AND THE SEALS IMPORTANT WHEN THE CYLINDER NEEDS TO BE OPENED THE REPLACEMENT OF WHOLE SET OF SEALS IS RECCOMENDED Remove the cylinder from the machine 778 6 Lock the cylinder on a vice Remove the ring nut When the ring screw is completely off download the oil into the oil container Lock the piston head on the vice Remove the nut Remove the seal and the plastic guides Sneo r Remove the piston Remove the O ring 1 inside of the piston Take away the ring screw Remove the O ring and the lip seal from the ring screw Verify the condition of all components Clean very accurately all parts wash the rod thread by using solvent and dry it carefully Install the new O ring and the new lip seal on the ring screw NOTE WHEN INSTALLING THE RING ON THE RING SCREW BE CAREFUL TO NOT TWIST IT Grease the seal and insert the ring screw on the piston rod Mount the piston on the rod IMPORTANT THE O R
94. oltage can be measured at the X29 connector The output voltage is dependent upon the deflection of the gauge from the home position TOOL 1 2 CARRIAGE POTENTIOMETER B2 This potentiometer is 10K 10 turns rotational type It is supplied 5 20 VDC from the Dual DC motor driver board and its input voltage can be measured at the X28 connector The output voltage is dependent upon the rotation of the gauge from the home position LIFTS AND WHEEL DIAMETER POTENTIOMETERS B4 B5 AND B6 The lifts and wheel diameter potentiometers are 5K rotational type They are supplied 5 20 VDC from the CPU board A1 and their input voltage can be measured at the CPU board A1 X6 to X19 pin The output voltage is dependent upon the deflection of the gauge from the home position 17 QUADRIGA Service Manual 02 10 Rev C DISTANCE LASER SENSOR The distance laser sensor measures the horizontal position of the rim compared to the tools and check the rim shape It is supplied by the CPU board A1 connector X89 LCD DISPLAY A4 The Display Board receives 5 20 VDC from the Main Processor Board A1 This 5 20 volts can be checked on the CPU board A1 X3 connector KEYPAD S2 The keypad allows operator input to the Main Processor Board The output signal directly goes to the CPU board 1 connector X2 18 QUADRIGA Service Manual 02 10 Rev C CHAPTER 5 ACCESS TO ELECTRIC AND ELECTRONIC COMPONENTS To access to electric parts of the machine gt
95. on tool and then goes to its home position The lower BB goes up until it touches the calibration tool and then goes to its home position Step 10 Horizontal Axis to outer position Using the horizontal motion joystick move the center post to its outer position Outer means toward the lifter Move it until it touches gently the mechanical block ATTENTION before reaching block move the carriage slowly When it is in the correct position press Enter button to proceed 110 QUADRIGA Service Manual 02 10 Rev C HOFMANN PS Step 11 Horizontal Axis to inner position Using the horizontal motion joystick move the turntable carriage to its inner position Inner means toward the Tool axis Move it until it touches gently the mechanical block ATTENTION Before reaching block move the carriage slowly n na s 4 j When it is in the correct position press Enter button to proceed Step 12 Tool2 on Calibration Tool Use the turntable to place the Tool2 to the horizontal centerline of the calibration tool visible in the pictures below 111 QUADRIGA Service Manual 02 10 Rev C Use the vertical toolbar joystick to place the Tool2 to the Vertical centerline of the calibration tool visible in the picture below er n o Use the horizontal motion joystick to move the calibration tool and touch gently the Tool2 plastic protection When it is in the correct position press Enter b
96. ount the cylinder 79 5 Check if the tool turns normally again 2h End 10 13 17 19mm allen key 3 4 5 6mm rubber hammer pliers Defective tools alignment may cause the following malfunctions Difficult mounting and dismounting operation Rim damaging Tire damaging Difficult tire hanging AONO TO CHECK THE TOOLS 1 AND 2 ALIGNMENT Turn the machine on Clamp the calibration tool Close both tools Turn the tool 1 in dismounting configuration Position the calibration tool as closest to the tools hooks Make sure that both tools are at the same distance compared to the calibration tool TO ADJUST THE TOOLS 1 AND 2 ALIGNMENT 91 QUADRIGA Service Manual 02 10 Rev C are ae Fuyerigr rzezrri Loose the tooli adjustment screw Adjust the screw in order to leave 21mm from the screw head to the machined arm surface Close the tool 2 and adjust the screw until to have a distance of 85 mm among the right sides of the tools Check if the both tools are correctly aligned Lock firmly all counter nuts Make sure that the four arms of the linkage are vertically aligned each other to make a dead point IMPORTANT IF THE ADJUSTMENT WILL BE MADE CROSSING THIS DEAD POINT THE CYLINDER WILL NOT BE ABLE TO OPEN THE TOOL ARM IF THE ADJUSTMENT WILL BE MADE BEFORE OF THIS DEAD POINT THERE IS THE POSSIBILITY THAT THE TOOL ARM WILL OPEN DURING THE MOUNTING DISMOUNTING OPERATION D
97. ow arrives to the opened valve 1 2 and 2 2 reach the side A of the cylinder 1 5 and 2 5 closing the tool1 and 2 Air contained in opposite side B will escape through the coil valve The air flow arrives to the opened valve 1 2 and 2 2 reaches the side B of the cylinder 1 5 and 2 5 opening the tool1 and 2 Air contained in opposite side A will escape through the coil valve TOOL 1 ROTATION The air flow arrives to the opened valve 3 2 and it reaches the side A of the cylinder 3 5 rotating the hook Air contained in opposite side B will escape trough the valve The air flow arrives to the opened valve 3 2 and it reaches the side B of the cylinder 3 5 rotating the hook Air contained in opposite side A will escape trough the valve 9 0 6 LIFTS CYLINDERS FUNCTION 72 QUADRIGA Service Manual 02 10 Rev C HOFMANN V gt ROTATING LIFT The air flow is forced to the side A of the cylinder 5 5 through the valve 5 2 to raise the rotating lift A lock valve 5 6 avoids the lift raising caused by the solenoid air leaking and a speed controller valve 5 7 controls the raising speed Air contained in side B will escape through the valves The air flow is forced to the side B of the cylinder 5 5 through the valve 5 2 to lower the rotating lift A further lock valve 5 6 avoids the lift lowering caused by the solenoid air leaking and a speed controller valve 5 7 controls the lowering speed Air contained in side A wi
98. peration CHAPTER 5 ACCESS TO ELECTRIC AND ELECTRONIC COMPONENTS 5 1 Access to the electric box 5 2 Access to the control panel 5 3 Access Rotational switch 5 4 Access to hydraulic motor 5 5 Access to turntable motor and potentiometer 5 6 Access M1 and M2 VDC motors 5 7 Access to Bead breaker potentiometers 5 8 Access to sidewall bead breakers switches 5 9 Access to lifts potentiometers 5 10 Access to wheel diameter potentiometer 5 11 Access to tool 1 and 2 carriage potentiometer CHAPTER 6 ELECTRIC SECTION 6 1 Power supply cable check and replacement 6 2 Main switch Q2 check and replacement 6 3 Hydraulic motor cable check and replacement 6 4 Hydralic motor check and replacement 6 5 Fuses Q2 and Q3 check and replacement 6 6 Turntable motor cable check and replacement 6 7 Turntable motor and belt check and replacement 6 8 VDC motors M1 and M2 check and replacement 6 9 EMC inverter T1 check and replacement 6 10 Transformer T3 check and replacement 6 11 Fuses F4 F5 check and replacement 6 12 Link converter check and replacement 6 13 Control panel switches S5 to 13 and cable check and replacement 6 14 Sidewall bead breaker micro switches check and replacement 6 15 Coil connectors check and replacement 6 16 Wheel clamp unclamp switch check and replacement 6 17 Turntable switch check and replacement CHAPTER 7 ELECTRONIC SECTION 7 1 EMC inverter check and replacement 7 2 EMC inverter set up 7
99. pposite side B returns to the reservoir through all others valves gt DESCENT The oil flow arrives to the opened valve Y2N and it reaches the side B of the cylinder Z3 making the raising of the arm Oil contained in opposite side A returns to the reservoir through all others valves 8 0 6 CLAMPING CENTRE POST CLAMPING UNCLAMPING gt UNCLAMPING The oil flow is forced to the check valve through the valve Y3N to unlock it When it is unlocked the oil goes in side B and that one contained in the side A of the chuck cylinder Z1 returns to the reservoir through all other valves gt CLAMPING Oil flow reaches the side B of the cylinder Z1 through the valve Y3B and when the cylinder has reached the maximum pressure the locking valve avoids dropping of hydraulic pressure Oil contained in side B returns to reservoir through all other valves 58 QUADRIGA Service Manual 02 10 Rev C CB 8 1 ACCESS TO HYDRAULIC PARTS The access to the hydraulic parts is more complicated compared to the electric ones because in some cases the dismounting of many parts is required to reach those defective ones The most important control is that one related to the hydraulic pressures at which each cylinder of the machine is called to work This controls allow to find out very quickly the reason of any hydraulic malfunction Another of the purpose of this manual is to reduce as much as possible the oil leaking during the maintenance ope
100. probes on the wires ends of the supposed defective cable on the connectors X23 and X90 or X91 and verify if there is continuity If not replace the cable TO REPLACE THE SWITCH CABLE Remove the defective cable Route the new cable and plug it to the switch and CPU board connector urn the machine and check if it works fine Mount the control panel again IMPORTANT WHEN REMOUNTING THE CONTROL PANEL BE CAREFUL TO DO NOT CRUSH WIRES TO REPLACE THE SWITCH Remove the defective switch from the support Mount the new switch on the support without lock the screws Push the bead breaker arm up til end of stroke and make sure that the micro switch tab is close to switch end stroke Lock the switch screws FIRMLY Route again the cable Plug the connector to the cable Perform the Calibration step C80 12 Check if the machine works fine again Mount the control panel IMPORTANT WHEN REMOUNTING THE CONTROL PANEL BE CAREFUL TO DO NOT CRUSH WIRES 6 15 COIL CONNECTOR CABLE CHECK AND REPLACEMENT amp 1h 3 lt Small standard and cross screwdrivers pliers multimeter Defective cable or connector may cause the following malfunction 1 One or more hydraulic oneumatic movements do not work 38 QUADRIGA Service Manual 02 10 Rev C HOFMANN 2 Fuse blows up TO CONTROL THE CABLE Disconnect the machine from power supply Open the electric box Remove the plastic cover 5
101. protection WARNING THE CONDENSER COULD BE STILL CHARGED OF POWER SUPPLY SHORT CIRCUIT ALL THE WIRES BEFORE DISCONNECTING TO PREVENT ANY ELECTRIC SHOCK Remove the motor terminals cover and remove all wires from terminals Disconnect the wires from all terminals and L1 wire from the connector of the Valves control board A3 Select the multimeter in Ohm and check if there is continuity between ends of each wire TO REPLACE THE CABLE Release cable strain relief on the electric box and on the motor the wrong cable away nsert the new cable through the strain relief IMPORTANT USE ONLY APPROVED CABLE AND GROUND WIRE MUST BE LONGER THAN THE OTHER ONES NOTE Before connecting the wires ends tighten all terminals nuts on the motor Fix new fastons on inside cable ends and connect them to the motor and breaker terminals WARNING THE CONDENSER COULD BE STILL CHARGED OF POWER SUPPLY SHORT CIRCUIT ALL THE WIRES BEFORE DISCONNECTING TO PREVENT ANY ELECTRIC SHOCK Check the rotation way of the motor If it is wrong reverse only L1 with one of condenser wires otherwise the chuck motor will turn wrongly Mount the motor terminals cover IMPORTANT WHEN REMOUNTING THE MOTOR TERMINALS COVER BE CAREFUL NOT TO CRUSH WIRES Mount the top cover protection 6 4 HYDRAULIC MOTOR CHECK AND REPLACEMENT amp 2h 3 lt tube type wrench 5mm allen key madium standard screwdriver
102. ration this will allow to operate on the machine in clean and safe condition Before approaching the hydraulic parts the following material needs to be prepared Oil container for hydraulic oil Oil absorber Paper towels IN CASE OF OIL LEAKING DRY CAREFULY THE FLOOR TO AVOID SLIPAGE AND POSSIBLE INJURY BEFORE APPROACHING THE HYDRAULIC PARTS THE MACHINE DISCONNECT THE MACHINE FROM ELECTRIC SUPPLY gt HYDRAULIC ASSY Remove the top cover and the whole assy is available 75 1 gt BEAD BREAKER CYLINDERS The cylinders are partially covered by the black plastic protection However the access is easy because it just requires the removing of this protection 75 1 CENTER POST CYLINDER This cylinder is the most complicated to be accessed because it is bolted to the mobile table Therefore to access it is required to dismount the lifts cylinders the M1 VDC motor protection and the steel mobile table covers 75 1 8 2 HYDRAULIC OIL LEVEL CHECK AND LEVELLING lt 30 aX Suggested hydraulic oil Incorrect oil level may cause the following malfunction 1 Slow or no hydraulic movements 2 Possible hydraulic pump damaging TO CHECK THE HYDRAULIC OIL LEVEL Turn the machine on Close all cylinders Turn the machine off Verify if the oil level corresponds to the top end of the steel hydraulic protection window TO MAKE THE OIL LEVEL Remove the reservoir tip Take the suggested hydr
103. re Pressing half of spool valve pedal the air has to come out from the inflator only Pressing the spool valve pedal all way down the air has to come out from the inflation hose and from the bead seating jet at the same time 85 QUADRIGA Service Manual 02 10 Rev C are ne Egquigrrerri Install the foot pedal assy cover S 1h 2 lt End key 12mm big plyers Defective bead blaster valve may cause the following malfunction 1 Air leaking from air jet 2 Air leaking from diapram TO CHECK THE BEAD BLASTER VALVE Verify if it leaking air from the diaphragm Verify it the bead seating jet is leaking air without press the pedal TO REPLACE THE BEAD BLASTER VALVE Disconnect the air pressure Remove the hoses Remove the valve from the tank nipless Mount the new valve to the nipless Install the hoses Plug the air pressure Check if the bead blaster works fine again 86 QUADRIGA Service Manual 02 10 Rev C HOFMANN V CHAPTER 10 MECHANICAL SECTION The mechanical section is connected to the mobile table the tools and to the bead breakers adjustments Usually this parts do not require the replacement and in any case their replacement is required after years of intensive working amp 4h 3 End keys 10 17 19 and 24mm allen keys 6 and 8mm Seeger pliers manometer Incorrect gearbox may cause the following malfunctions 1 Noisy rotation 2 Low rotation torque T
104. re er Fuyerigrrrzezrri TO REPLACE THE CHECK VALVE Remove all plastic and steel protections 5 1 Open the centre post cylinder Turn the machine off Take a screwdriver and release the hydraulic pressure from the hydraulic circuit Remove all screws Take the valve and install it replacing all the copper washers Turn the machine on Check the maximum pressure 8 3 Check if the machine works fine Install all protection again I I ge m IRE pum gum TRMES AID WE BOCI V NDER GEFAIS POSI UY LINDER oL LS 3 lt End keys of 10 17 19 22 and 24mm Allen keys of 5 6 8mm Socket wrench 24mm Small flat screwdriver manometer green loctite gear and hydraulic oil container rubber hammer Defective centre post cylinder seals may cause the following malfunction 1 Low clamping power 2 Decreasing of the hydraulic oil level Oil leaking from the turntable top and bottom flanges TO CHECK THE PISTON SEALS Check the maximum pressure 8 3 Turn the machine on Close the centre post cylinder and put it under pressure Verify if the turntable flange is leaking oil Turn the machine off Remove all plastic and steel protection Remove the screw from the manifold Turn the machine on Put the cylinder under pressure Verify if hydraulic is coming out from the manifold 62 QUADRIGA Service Manual 02 10 Rev C TO REPLACE THE PISTON SEALS Close the
105. res are well fitted on terminals WARNING THE CAPACITOR COULD BE STILL CHARGED OF POWER SUPPLY SHORT CIRCUIT ALL THE WIRES BEFORE DISCONNECTING TO PREVENT ANY ELECTRIC SHOCK fthe wires are well fitted on terminals mount the motor terminals cover and remove the 4 motor screws very carefully the motor may fall down suddenly Place the motor on the floor Switch the motor on and listen it if it is noisy replace it by following next step TO REPLACE THE MOTOR Remove all wires from the motor Hemove the 4 motor screws very carefully the motor may fall down suddenly Remove the aluminium spacer Take the distance of the joint compared to the motor by using a calliper Remove it from the motor shaft by using two levers 28 QUADRIGA Service Manual 02 10 Rev C Take the new motor Mount the joint following the distance previously verified and lock it IMPORTANT A WRONG ADJUSTMENT OF THE JOINTS WILL CAUSE HYDRAULIC PUMP DAMAGING OR DAMAGING OF JOINTS THEMSELVES WITH A CONSEGUENT NO HYDRAULIC MOVEMENTS Mount the aluminium spacer There is a little hole in a face and this face must be mounted downwards in order to show immediately if there is an inner oil leaking Mount the motor on the hydraulic assy Connect the wires FIRMLY to motor terminals following the voltage at which the machine is supplied NOTE Before connecting the wires ends tighten all terminals nuts WARNING THE CONDENSER COULD BE STILL
106. s tighten all terminals nuts Turn the machine on and check the parameter 09 of the inverter T1 that must be 0 75 Check the rotation way of the motor If it is wrong reverse only two chuck motor wires Mount the motor terminals cover IMPORTANT WHEN REMOUNTING THE MOTOR TERMINALS COVER BE CAREFUL NOT TO CRUSH WIRES Mount all protections x 1heach one 2 lt Multimeter allen key 4 and 5mm small and medium cross screwdrivers Defective VDC motors may cause the following malfunction 1 Turntable does not slide left and and right 2 Tools carriage does not go up and down TO CONTROL THE MOTORS Disconnect machine from power supply 32 QUADRIGA Service Manual 02 10 Rev C HOFMANN PA Remove the motors plastic protection 75 1 Unplug the motors connectors Take the multimeter and select it in VDC Turn the machine on MACHINE UNDER TENSION DANGER OF ELECTRIC SHOCK Position the multimeter probes on the connector terminals coming from the electric box Press the switch if the multimeter shows 48VDC but the motors do not run the motors are defective and must be replaced TO REPLACE THE MOTORS 3 lt D 3 4 di 6 7 TO CONTROL THE INVERTER Turn the machine on Turn the machine off Disconnect machine from power supply Loosen the four screws motor Remove the belt and the motor Remove the pulley from defective motor and install it On the new one Mount the new
107. s copper washers Mount the plastic top cover Check if the machine works fine 60 QUADRIGA Service Manual 02 10 Rev C are er Z 2h 3 lt End wrenches of 10 19 and 24mm Allen wrenches of 4 and 5mm Small flat screwdriver manometer hydraulic oil container Incorrect centre post hydraulic pressure may cause the following malfunction 1 Low clamping power TO CHECK THE CENTRE POST CYLINDER PRESSURE Turn the machine on Select Service code C62 and raise the lift Open the centre post cylinder Turn the machine off Take a screwdriver and release the hydraulic pressure from the hydraulic circuit Install the manometer on the centre post manifold steel hose Turn the machine on Close the centre post cylinder Check the maximum pressure and if necessary adjust it 8 3 Keep the centre post cylinder under maximum pressure for 10 the pressure should not decrease below than 130 Bar 2000PSl fthe pressure drops quickly or considerably over than the above one the following parts need to be checked and if necessary replaced 1 Check valve 2 Centre post cylinder piston seals 8 5 3 Centre post manifold O rings 8 5 IMPORTANT BEFORE STARTING WITH ANY REPLACEMENT VERIFY IF THE MACHINE IS LEAKING OIL FROM THE MADE ON THE CENTRE POST IN CASE OF OIL LEAKING FROM THAT IT MEANS THAT THE PROBLEM IS COMING FROM 2 OR 3 ab 61 QUADRIGA Service Manual 02 10 Rev C a
108. s until the right display will show L3 6 Push M to set the new value of parameter 10 left display will be flashing 7 Put the Smart Stick in the slot 8 Push Up arrow button until 28 is shown on the left SmartStick slot display 9 Push M button the right display will show no 10 Push Up arrow button one time the right display now will show read 11 Push the M button at this time the parameters stored in the Smart Stick will be transferred to the inverter 12 Torn off and then on the inverter to reset it 13 Push the M button to enable the left display to show the parameter numbers 14 Push the Up arrow until 38 push M the right display will show 0 15 Push the Up arrow button two time until the right display will show 2 16 Push M button until return on the normal operating condition rd on the left display 17 Be sure that the motor is free to run no load condition 18 Start the motor with a pedal command Wait until the motor stop This operation is needed to the inverter to read and tune the motor characteristics At this point the inverter programming is finished an the machine is ready to go 45 QUADRIGA Service Manual 02 10 Rev C HOFMANN PARAMETERS TABLE Impostazione Default Parametro Descrizione corrispondente del menu EUR USA esteso a Velocita minima impostata Hz Velocit massima impostata Hz Pr 1 07 50 0 Pr 1 06 100 1 Tempo d
109. sing every switch the display will show the name of the component related to that switch C62 Test analog values Check all functions related to potentiometers and laser By pressing or button we will have access to 8 channels that correspond to all analog function ChO Tocheckthe laser pointer Press Automatic mount to turn on off the laser pointer The display shows two values the value in the left is the analog control vale while the left one is the distance of object from the laser pointer expressed in mm If itis out of range a value from 7 to 101 is displayed Chi Empty Ch2 Check the vertical lift potentiometer Press Mode to enable disable the vertical Press the Upper bead breaker switch to check the vertical lift potentiometer Ch3 Check the rotational lift potentiometer Press Mode to enable disable the rotational lift Press the Lower bead breaker switch to check the rotational lift potentiometer Ch4 Check wheel diameter potentiometer Move the wheel diameter holder to check the potentiometer Ch5 Check lower bead breaker potentiometer Press the related switch to check the potentiometer Ch6 Check upper bead breaker potentiometer Press the related switch to check the potentiometer Ch7 Checkthe horizontal carriage potentiometer Press the related switch to check the potentiometer Ch8 Checkthe vertical tool carriage potentiometer Press the related switch to check the poten
110. t sa per C66 Perform the C80 till step 11 included Step 12 Upper bead breaker disk on front of Calibration tool plate O SS Move the calibration tool in proximity of the upper bead breaker disk Use a tire lever and lift up the bead breaker arm up to end of stroke DO NOT USE THE HANDS TO POSITION THE BEAD BREAKER ARM 119 QUADRIGA Service Manual 02 10 Rev C Move the centre post to get the calibration tool front plate in contact with the disk Then release the bead breaker disk again Press Enter to confirm Move the upper bead breaker disk upward out of the calibration tool range Step 13 Lower bead breaker disk on front of Calibration tool plate Perform the same procedure of step 12 with lower bead breaker disk pressing down the bead breaker arm Press Enter to confirm If the misalignment among the disks is over than the maximum threshold the display will show error Press hand button to exit and perform the C66 Step 14 Tool 2 on front of Calibration tool plate Move the centrepost to place the Tool2 to the horizontal centerline of the calibration tool as depicted as shown in the picture 120 QUADRIGA Service Manual 02 10 Rev C Use the vertical toolbar joystick to place the Tool2 to the Vertical centerline of the calibration tool and use the horizontal motion joystick to move the calibration tool and touch gently the Tool2 plastic protection Press
111. te direction or the potentiometer is mounted wired wrongly the error is shown FAULT 26 Hol nus Moron Error Lia automatic eni if the Tool Bar doesn t move or its motion is not fluid or the potentiometer doesn t detect any variation of the vertical Tool Bar position the error is shown FAULT E 29 DI eng Dir Error ecco 0 9 I O La automatic if the ToolBar moves in the opposite direction or the potentiometer is mounted wired wrongly the error is shown FAULT 2 27 a ous Motion Error CENA automatic ili if the Come Post doesn t move or its motion is not fluid or the potentiometer doesn t detect any variation of the Centre Post position the error is shown FAULT E or D conte um Wrong Dir Error Bre automatic ii if the Cenite Post moves in the opposite direction or the potentiometer is mounted wired wrongly the error is shown FAULT m EH EE sara load dn if the lift arm doesn t move or its motion is not fluid or the potentiometer doesn t detect any variation of the lift arm position the error is shown FAULT DA Error Li AI Dir Error During load ori dosi if the lift arm moves in the opposite direction or the potentiometer is mounted wired wrongly the error is shown FAULT AR rer 211 SIE MOL PANE A ii if da rotation arm doesn t move or its motion is not fluid or the pote
112. tiometer All analog values have range from 0 to 4096 and are read by the Main processor board A1 except Ch7 and Ch8 read by DUAL DC DRIVE MOTOR BOARD A2 and have range from 0 to 1024 because we have 10 bit analog to digital conversion All other ones are 12 bit conversion C63 Communication Control Protocol RS 485 This C code allows to checks the communication between Main processor board A1 and the Dual DC drive motor board A2 named POW on the display and the Solenoid valve board named INFC on the display When the communication is fine the display will show UP while it will show DN in case the communication will be bad or not available 99 QUADRIGA Service Manual 02 10 Rev C When the communication is fine the display shows the following messages POW INFC UP When the communication is bad from the Solenoid valve board A3 the display shows the following messages POW UP INFC DN When the communication is bad from the Dual DC drive motor board A2 the display shows the following messages POW DN UP When the communication is bad from both Dual DC drive motor board A2 and solenoid valve board A3 the display shows the following messages POW DN DN 100 QUADRIGA Service Manual 02 10 Rev C C65 Axes Motion Time This C code allows to tests the motion of the axes and measure the time required by each motion device to go to one side to the other one allowed mechanically
113. tion tool Press Enter button when done Step 4 Tool 1 onto the upper side of the Calibration tool Using the vertical toolbar joystick horizontal motion joystick and turntable pedal place the Tool1 onto the upper surface of the calibration tool like in the picture below touching it gently Press Enter button when in proper position Automatically the toolbar will move up enough to allow the Tool2 rotation without interference with the calibration tool and in the meantime Tool1 will return to home position 107 QUADRIGA Service Manual 02 10 Rev C Step 5 Tool 2 onto the upper side of the Calibration tool Using the vertical toolbar joystick place the Tool2 onto the upper surface of the calibration tool like in the picture below touching it gently Retreat to home position the Tool1 If the position of the previous step has been set correctly like in the step4 picture no turntable rotation nor horizontal motion is needed When in position press Enter button to proceed to next step Automatically the toolbar will move up a little in the meantime Tool2 will return to home position and then will move down enough to allow the Tool2 rotation without interference with the calibration tool to perform the next step Step 6 Tool 2 onto the lower side of the Calibration tool Rotate inward Tool2 and move it vertically in order to touch gently the lower surface of the calibration tool like in the picture below Turntabl
114. utton to procee Automatically Tool2 will return to home position and the turnte will rotate 180 112 HOFMANN VS Step 13 Calibration Tool on lifter Using the lifter joystick rotate the frontal fork of the lifter to its upper limit If needed rotate the calibration tool to meet the fork square Move horizontally the center post to have the calibration tool touching gently the bar of the lifter When in position press Enter The fork square will lower automatically The procedure will save the data into internal memory and will exit from C80 If not press F to exit C80 select C60 and lower the fork square manually Press button to proceed to next step C81 Laser calibration Select C81 procedure and press Enter button to start Step 1 Tool 1 onto the upper side of the Calibration tool 113 QUADRIGA Service Manual 02 10 Rev C g no d CORD normann amp Eganin Clamp the calibration tool in any position on the centre post Using the vertical toolbar joystick horizontal motion joystick and turntable pedal place the Tool1 onto the upper surface of the calibration tool like in the picture below touching it gently Press Enter button when in proper position Step 2 Tool2 on Calibration Tool Use the turntable to place the Tool2 to the horizontal centerline of the calibration tool visible in the pictures below Use the vertical toolbar joystick to place the Tool2 to t
115. value of the stroke based on the calibration The axis are the horizontal the vertical tools bar upper and lower bead breakers If the machine is not calibrated this service code in not useable an error code will be display and machine will exit automatically The axes can be selected singularly The procedure for every axe asks to be used or not Press or to select yes or no and Enter to confirm Ended the selection of the 4 axes the display asks to press Enter to start the procedure During the axes motion the display will toggle showing the counters Each counter will increase after having completed the forward and backward step of every axe Press Hand button to stop the procedure and Enter to restart the counters will continue the counting 98 QUADRIGA Service Manual 02 10 Rev C During the pause due to the pressure of Hand button it is possible to zero the counters pressing the button F C60 Lift test SIZE Wheel diameter potentiometer ROT Rotational lift LIFT Vertical lift Moving the bead breaker joysticks the lifts raise and lower The analog potentiometers values change from 0 to 4096 The wheel size potentiometer can be checked by moving the wheel size detector The horizontal carriage remains enabled C61 Digital switches input test To check the switches on the console bead breaker sensors and foot controls Pres
116. which the machine is supplied the motor must be replaced Perform the same controls with terminals U1 V1 and W1 V1 TO CONTROL THE TURNTABLE MOTOR AND THE BELT IF NOISY Disconnect machine from power supply Remove the motor terminal cover and verify if all wires are well fitted on the terminals If the wires are well fitted on terminals mount the motor terminals Loosen the 12mm nuts to get motor lose and remove the belt 31 QUADRIGA Service Manual 02 10 Rev C HOFMANN VS Remove the fan protection and verify if its well tightened on motor shaft Mount the fan protection turn the machine on make the turntable motor turning and verify if it s noisy TO REPLACE THE TURNTABLE MOTOR Remove the steel protection and loosen the two bolts that hold the motor Pls pay attention because the motor could fall down suddenly f eS i ca Remove the pulley set screws Remove the pulley by using an extractor tool Remove the motor from the support Take the new motor Install the pulley by using rubber hammer NOTE The mounting of the new pulley must be done very carefully in order to avoid motor bearings damaging nstall the motor on its support Install the motor assy on the machine and lock it Firmly Mount the new belt Adjust the belt tension Connect the wires FIRMLY to motor terminals following the voltage at which the machine is supplied NOTE Before connecting the wires end

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