40-6537 Auto-leveling Rotating Laser Service Manual
Contents
1. pe ZAN oO Press the key one time and verify that the X direction LED on the keypad of the 40 6537 flashes indicating that it has entered the self calibration mode on the X direction Press the ZX Vi key to adjust the laser beam up or down to coincide with the reference line 3 Y axis calibration Rotate the 40 6537 90 so that the Y axis is now facing the wall N key one time and verify that the Y direction LED on the keypad of the 40 6537 C gt flashes i Press the indicating that it has entered the self calibration mode on the Y direction Press the A V key to adjust the laser beam up or down to coincide with the reference line 4 Self calibration confirmation Prepared By Tim Wojo Revision Date 0 03232009 Press the te Sgi Ho TIRE can key after finishing self calibration on both the X and Y axis and verify that the Self Calibration LED R extinguishes The instrument will exit the self calibration mode automatically after finishing self calibration Power off the unit to store the calibration values into the 40 6537 s memory Repower the 40 6537 and confirm the units accuracy Repeat procedure as required i Py Pa omama al sho LASER DRO 40 6537 Service Manual Coarse Adjust Calibration via Internal Leveling Sensors If the error is more than 0 5mm m it will need to make calibration by adjusting the sensor The details a2. 2 2 Housing Assembly AP1944 11 2 11 3 11 4 11 5 11 6 Item JLT Part Description Qty 11 1 AP1949 Keypad 2 1 11 2 AP1950 M2 5 x 8 Cross Sunk Screw 8 11 3 AP1951 2 PCB Key Pad 2 1 11 4 AP1538 M2 5 Nut 8 11 5 AP1952 Connecting Nut 4 11 6 AP1953 3 PCB Keypad 1 1 11 7 AP1954 Housing 1 11 8 AP1989 Keypad 1 1 1 Remove keypads 1 and 2 11 1 and 11 7 respectively by peeling off of housing 2 Remove 2 PCB 11 3 by loosening retaining nuts 11 4 3 Remove 3 PCB 11 6 by loosening retaining nuts 11 4 and 11 5 respectively x te ISIN ie fF BCL easyPDF Printer Driver Prepared By Tim Wojo Revision Date 0 03232009 Page omama al sho LASER DRO 40 6537 Service Manual 2 3 Main Body Assembly AP1941 Item JLT Part Description Qty 6 1 AP1513 M3 x 8 Cross Plate Screw 12 6 2 AP1955 Top Plate Assembly 1 6 3 AP1883 3MM Elastic Gasket 12 6 4 AP1956 Core Assembly 1 6 5 AP1957 Tension Spring 2 6 6 AP1958 1 Main PCB 1 6 7 AP1616 M2 5 x 5 Cross Plate Screw 10 6 8 AP1959 Frame Part 1 1 6 9 AP1960 Bottom Plate 1 6 10 AP 1961 8 Alarm PCB 1 6 11 AP1962 Spacer 2 6 12 AP 1493 M2 5 x 8 Cross Plate Screw 2 6 13 AP 1963 4 PCB 1 6 14 AP1964 Connecting Staff Part 1 6 15 AP1965 5 PCB 1 6 16 AP1915 2 5MM Elastic Gasket 2 6 17 AP 1966 Frame Part 2 1 6 18 AP1967 4MM Elastic Gasket 1 6 19 AP1968 M4 x 14 C
3. Service Manual 2 5 Base Assembly AP1942 Item JLT Part Description Qty 7 1 AP1690 ST2 9 x 10 Cross Plate Tapping 5 Screw 1 2 AP1985 Cover 1 7 3 AP1986 10 Connecting PCB 1 7 4 AP1987 Bottom Seat Assembly 1 7 5 AP1988 Feeler Part 2 Disassemble Cover 7 2 by removing 5 retaining screws 7 1 2 Remove 10 Connecting PCB 7 3 by sliding it out of the guide slot of the Bottom Seat Assembly 7 4 3 Disassemble Bottom Seat Assembly 7 4 by desoldering the wires of 2 Feeler Parts 7 5 Press out Feeler Parts as required 3 0 Calibration Calibration is a process that is used to correct for accuracy and or functional errors above and beyond those stated in published specifications While Manual leveling Self leveling and Automatic leveling motor driven devices have different mechanisms that require calibration there are similarities with optics that is consistent regardless of the leveling mechanism This section of the service manual discusses calibrations specific to the 40 6537 Each item discussed is shown below 3 1 Horizontal Mode Operation 3 1 1 Quantifying Accuracy Error 3 1 2 Characterize the type of error 3 1 2 1 Oblique Error 3 1 2 2 Taper Error 3 1 2 3 Wave Error 3 2 Vertical Mode Operation 3 3 Leveling Range Alarm Calibration Prepared By Tim Wojo Revision Date 0 03232009 omama al sho LASER DRO 40 6537 Service Manual 3 1 Horizonta
4. 2 6 4 11 AP1974 Electric Motor 1 6 4 12 AP1975 6 PCB 1 6 4 13 AP1976 Base Assembly 1 6 4 14 AP1977 Indicator 1 6 4 16 AP1978 9 Connecting PCB 1 6 4 17 AP1979 M4 x 12 Inner Hex Column 1 Screw 6 4 18 AP1967 M4 Elastic Gasket 1 6 4 19 AP1980 Compression Spring 1 6 4 20 AP 1981 Sensor Assembly 2 6 4 21 AP1982 Spacer 1 6 4 22 AP1983 Ball Gimbal Assembly 1 6 4 23 AP1984 M2 5 flat spacer 2 1 Disassemble Ball Gimbal Assembly 6 4 22 and Compression Spring 6 4 19 by removing retaining screw 6 4 17 and respective elastic gasket 6 4 18 2 Disassemble 2 Sensor assemblies 6 4 20 by removing 4 retaining screws 6 4 1 3 Disassemble 6 PCB 6 4 12 by removing 2 retaining screws 6 4 9 4 Disassemble 9 PCB 6 4 16 by removing 2 retaining screws 6 4 9 5 Disassemble Electric Motor 6 4 10 by removing 2 retaining screws 6 4 9 2 elastic gaskets 6 4 10 and 2 flat spacers 6 4 23 6 Disassemble Rotary Head 6 4 2 by removing 2 retaining screws 6 4 1 Disassemble Prism Assembly 6 4 4 by removing 4 retaining screws 6 4 3 Disassemble 12mm Bearing 6 4 7 Big Gear Assembly 6 4 8 and second 12mm Bearing 6 4 7 by loosening retaining screw 6 4 6 and turning locking nut 6 4 5 counter clockwise until it is removed 9 Disassemble Indicator 6 4 14 by removing 4 retaining screws 6 4 15 Prepared By Tim Wojo Revision Date 0 03232009 omama al sho LASER DRO 40 6537
5. acy meets published published specification specification Aand B lt 0 but dD lt gt 0 but Oblique Error Can i A B 0 C D 0 Aand B lt 0 but peat wa C and D lt 0 but _ Taper Error A B C D AandB S 0and Section 2 1 2 1 C and D lt gt 0 and EEEN Oblique Error D Taper Error A B lt C D Section 2 1 2 3 Wave Error j BCL easyPDF Printer Driver Click here to purchase a license to remove this image _ Prepared By Tim Wojo Revision Date 0 03232009 Pa omama al sho LASER DRO 40 6537 Service Manual 3 1 2 1 Oblique error This type of error occurs when leveling compensator does not hang straight as illustrated to the right AT X i e is not properly balanced When the laser spins it actually rotates on a plain that is not level i e perfectly horizontal whose rotating axis is not plumb So value A on the left target does not has the same sign as that on the right target like A 2 Aig0 2 A number of factors can cause this situation to exist e Normal use Depending upon how careful the user is with the instrument finely tuned adjustments can be altered by very large changes in temperature vibrations due to handling and transportation e Shock The instrument was dropped and components of the leveling system gimbal compensator weight and shaft screw adjustments have either been damaged or came out of alignment If defective componen
6. ame of sh oom hee ee ee ee OY au LASER LEVELS aaa 40 6537 Auto leveling Rotating Laser Service Manual agmg of schoo r T ee r G L amp E LEYEL amp Item Description Pages 1 0 Introduction 2 2 0 Overall Unit Assembly 2 2 1 Upper Cover Assembly 3 2 2 Housing Assembly 3 2 3 Main Body Assembly 4 24 Core Assembly 5 2 5 Base Assembly 6 3 0 Calibration 6 14 3 1 Horizontal Mode Calibration 7 3 1 1 Quantifying Accuracy Error 7 3 12 Characterizing Accuracy Error 8 3 1 2 1 Oblique Error 9 11 3 1 2 2 Taper Error 12 3 1 2 3 Wave Error 13 3 2 Vertical Mode Operation 14 3 3 Alarm Calibration 14 4 0 Electrical Connections 14 5 0 Trouble Shooting Guide 15 Revision Date 0 03232009 Pa Prepared By Tim Wojo 40 6537 Service Manual omama al sho LASER LEVELS PRO 1 0 Introduction This rotating laser is a highly accurate instrument Out side of a few customer adjustments outlined in the owners manual all performed only by authorized service personnel Authorized personnel should adhere to the guidelines described within this service manual for all repairs and or service work This manual is written with the assumption that a unit is disassembled or assembled from start to finish In reality only component parts or modules would be replaced during a repair Given this procedures discussed in this manual should be adjusted according to the
7. ble one 1 As shown in the figure below put the table vice on the debugging platform 2 Fix the core part without prism on the adjustment fixture and Install the adjustment fixture on the table vice to make the laser spot towards the wall 3 Turn the core part to make the laser revolve around the rotary axis Adjust the 4pcs of adjustment crews which are used for fixing the laser indicator in order to make the diameter of the laser spot circle no more than 1cm 4 Spread the screw and laser source part with shellac Adjusting fixture Core part Table vic S Prepared By Tim Wojo Revision Date 0 03232009 Pa rit Driver omama al sho LASER DRO 40 6537 Service Manual 3 2 Vertical Mode Operation In this mode of operation the rotating laser surface is a plumb plane while the laser line projected from the top is in projecting horizontal While in this mode the instrument is manually level meaning that accuracy is a function of how accurately the vial is calibrated The 40 6537 is not designed for Vertical Mode Operation 3 3 Alarm Calibration The alarm function is made up of 3 components the 2 alarm PCB s 7 15 17 7 14 13 and the buzzer 10 3 Calibrating it is a matter of centering the contact ring of 7 14 13 to the spring post of 7 15 17 When the spring post makes contact with the contact ring of 7 14 13 the buzzer 10 3 sounds Centering the post be
8. emove the top cover as discussed in section 1 of this document b Screw the wedge out of its base with special spanner as shown in the Optical wedge figure to the right c Adjust the laser to the zero position of the target d Loc tight adjust after it has been set Note Only one direction X or Y is necessary for the adjustment BCL easyPDF Printer Driver Prepared By Tim Wojo Revision Date 0 03232009 Pa g omama al sho LASER DRO 40 6537 Service Manual 3 1 2 3 Wave Error lt This error occurs when the rotating laser surface is not a plane but a turn up one as S 5 shown in the figure to the right The rotating beam projected on the wall is crooked similar to waviness which is caused by the unbalance of rotating head The value A Wave error checked in the X direction deviates upwards while the one in the Y direction downwards or the value A in the Y direction upwards while the one in the X direction downwards Meanwhile you can see the laser point above the head is mobile and its orbit is inclined to be a circle The error can be removed by adjusting the balance block of the Rotating head as follows a Remove the top cover as discussed in section 1 of this document b Regulate the adjusting screws on the four balance block as shown in the figure to the right until the laser point above the head becomes stable namely the laser point projected on the ceiling being a sta
9. ge repair cabling beyond tolerance loose defective Cabling between PCB 1 and PCB 9 is y Change repair cabling loose defective 4 alarm when tilted beyond Buzzer is defective Repair Replace Buzzer tolerance but no sound Cabling from Buzzer is defective Change repair cabling Cabling to laser is defective Change repair cabling 8 Unit powers but no laser Laser is defective Repair Replace Laser Cabling between PCB 1 PCB 4 and i Change repair cabling 9 Unit doesn t auto level PCB 5 is loose defective Core Spring is loose spring is tightened Adjust spring Prepared By Tim Wojo Revision Date 0 03232009 iy a Pa
10. l Mode Operation In this mode of operation the instrument is self leveling where by a major factor of accuracy is how well the leveling compensator is balanced Different types of errors require different methods of calibration These errors are easily characterized by placing the instrument on a flat surface following the guidelines below and running the instrument with the rotating head continuously rotating 360 3 1 1 Quantifying Accuracy Error Establish the test set up shown in the following illustration and confirm that it meets the following requirements 1 The debugging platform should be horizontal with a error less than 0 1 6 2 The distance L from the center of the debugging clamp to the wall should be L gt 10m 3 The accuracy of the reference marking is no less than 0 05mm m 4 The adjacent light ruler should be put within 0 3m 12 of the instrument the zero position of the ruler should be located at the same height as that of the laser line at the emitting hole Far Target placed on wall at least 10m 33ft from Test Stand where 0 corresponds to them same height as 0 on the target next to the aperature of the instrument Laser line Instrument for test laser spinning 360 rotation Distance L gt 10m 33ft Accuracy A Difference between laser line height and reference line height divided by the Flat Surface Test Stand i distance that the laser is fro
11. m the wall L Near Target placed within 0 3m 12 of instrument Note that 0 of the target corresponds to the height of laser line at the aperature of the instrument 1 Place the instrument for test on the test stand preconfigured from the illustration above with handle facing the far target 2 Power the laser and function in full rotation mode head rotates 360 Note the errors in all four quadrants of the instrument as read on the far target i e x axis A 0 and B 180 y axis C 90 and 270 e You should end up with 4 numbers i AO __ ii B 80 lt iii C 90 iv D 270 4 Since all of the errors are referenced against 0 on the far target essentially the largest number from the data collected A D the distance should be equal to or less than the published specification for the product If not characterize the error and determine method of calibration as defined by section 4 1 2 of this document Prepared By Tim Wojo Revision Date 0 03232009 omama al sho LAGER LEVELS PRO 40 6537 Service Manual 3 1 2 Characterize the type of error Use the following rules to determine what to of accuracy error the instrument for test has and reference the stated section to adjust for it Note that the unit my have a combination of different types of errors to adjust for in which case multiple calibration must be performed Accuracy is beyond Accur
12. mptom Cause Corrective Action Battery case is loose Change battery box 1 control board is defective Change 1 control board Battery is low Charge Change Battery p Power switch is defective Change Power Switch 1 Unit doesn t turn on Cabling between PCB 1 PCB 3 and Change repair cabling PCB 5 is loose defective Cabling between PCB 1 and PCB 10 is i Change repair cabling loose defective PCB 1 is Defective Repair Replace PCB PCB 11 is Defective Repair Replace PCB Remote control does not Cabling between PCB 1 PCB 3 and 2 Change repair cabling work PCB 5 is loose defective Cabling between PCB 3 and PCB 11 is f Change repair cabling loose defective Alarm Sounds when power Cabling from 12 PCB is defective Change repair cabling 3 comes on Ball switch from 12 PCB is defective Repair Replace PCB Switch Cabling between PCB 1 PCB 3 and Change repair cabling PCB 5 is loose defective Indicators don t light upon A P 4 k PCB 1 is defective Repair Replace PCB ey press uP PCB 2 is defective Repair Replace PCB PCB 3 is defective Repair Replace PCB Incorrect Quadrant PCB 6 is defective Repair Replace PCB 5 Shield incorrect rotating Cabling from PCB 6 is defective Change repair cabling speed Reflective Plane is Dirty Clean Reflective Plane Cabling between PCB 5 and PCB 12 is f Change repair cabling loose defective No Alarm when tilted Cabling between PCB 4 and PCB 81 is 6 Chan
13. re as follows Reference poit _ Reflected prism d ON y US T bET OA F l J Display of the adjusting fixture for sensor N Connecting plate YY F 7 a V A V X A A i A A A i D D AS Se fos Display of the well adjusted sensor Adjustable tribrach base oa ae Fixture used for adjusting the sensor Fixture Setup See Above 1 Fix a square reflected prism on the debugging platform and affix a label paper that having a light emitting aperture in center on the prism the diameter of the aperture is about 1mm Put an auto leveling rotating laser that having plumb up point on the platform Power on the unit and the plumb up point will pass through the prism and the light emitting aperture of the label paper and then to reflect on the wall Take the center of the reflected laser point on the wall as a point A 2 Turn the unit by 90 and take the center of the laser spot on the wall as points B C D in turn The center of internally tangent circle of these four points A B C D is used as the reference point Core Module Leveling Sensor Calibration 1 Fix the core part on the special clamp By supplying the laser source with a power of DC 3V the laser spot will pass through the aperture on the laser paper and to reflect on the wall Adjust the three leveling knob on the tribrach base shown above in order to make the center of the reflected la
14. repair being made 2 0 Overall Unit Assembly 40 6537 40 6537 Service Manual Item JLT Part Description Qty 1 AP1690 ST2 9 x 10 Cross Plate Tapping 2 Screw 2 AP1939 Upper Cover Assembly 1 3 AP 1940 Handle 1 4 AP1742 M2 5 x 12 Cross Plate Screw 6 3 AP1026 ST2 9 x 13 Cross Plate Tapping 2 Screw 6 AP1941 Main Body Assembly 1 7 AP1942 Base Assembly 1 8 AP1565 M3 x 14 Cross Plate Screw 4 9 AP1943 Battery Case Assembly 1 10 AP1677 ST2 9 x 8 Cross Plate Tapping 2 Screw 11 AP1944 Housing Assembly 1 12 AP1945 Stopper 1 1 Remove Rechargeable Battery Pack 9 by turning retaining screw counter clockwise 2 Remove Upper Cover Assembly 2 and Housing Assembly 11 by removing retaining screws 8 3 Carefully disconnect ribbon cable of Keypad PCB 4 Remove Handle 3 by removing rubber screw plug 12 and retaining screw 1 5 Disassemble housing assembly 11 by removing retaining screws 4 6 Remove Main Body Assembly by removing retaining screws 10 and 5 Prepared By Tim Wojo Revision Date 0 03232009 omga ol sho Re gece _ 40 6537 Service Manual eee PRO 2 1 Upper Cover Assembly AP1939 Item JLT Part Description Qty 2A AP1947 Upper Cover 1 2 2 AP1948 11 Connecting PCB 1 2 3 AP1843 ST2 2 x 6 5 Cross Plate Tapping 1 Screw 1 Remove Rechargeable 11 PCB 2 2 by removing retaining screws 2 3
15. ross Plate Screw 1 1 Remove 4 PCB 6 13 and 5 PCB 6 15 by loosening removing retaining 6 screws 6 7 and 2 elastic gaskets 6 16 respectively 2 Remove 1 PCB 6 6 by loosening removing 4 retaining screws 6 7 Disassemble top plate assembly 6 2 by removing retaining screw 6 19 and respective elastic gasket 6 18 as well as 6 retaining screws 6 1 and respective elastic gaskets 6 3 4 Remove Core Assembly 6 4 from Frame Parts 1 and 2 6 8 and 6 17 respectively by removing 2 tension springs 6 5 5 Disassemble Frame Parts 1 and 2 6 8 and 6 17 respectively by removing 6 retaining screws 6 12 and they re respective elastic gaskets 6 3 6 Disassemble 8 Alarm PCB 6 10 by removing 2 retaining screws 6 12 and they re respective spacers 6 11 Prepared By Tim Wojo Revision Date 0 03232009 omama al sho LASER DRO 40 6537 Service Manual 2 4 Core Assembly AP1956 Item JLT Part Description Qty 6 4 1 AP1647 M2x 5 Cross Plate Screw 6 6 4 2 AP1969 Rotary Head Part 1 amp 6 4 3 AP1696 M2x 10 Cross Plate Screw 12 643 64 4 AP1970 Prism Assembly 1 1t 5a 6 4 5 AP1971 Locking Nut 1 Os 6 4 6 AP1592 M3 x 4 Inner Hexagon 1 6 4 23 SH Tightening Screw 6 4 7 AP1972 12MM Bearing 2 6 4 8 AP1973 Big Gear Assembly 1 6 4 9 AP1449 M2 5x 6 Cross Plate Screw 4 6 4 10 AP1915 M2 5 Elastic Gasket
16. ser spot coincident with the reference point Fix the sensors of X amp Y direction to the proper positions on the core part using 2 crosshead plate screw M2x5 3 Adjust the position of the sensors by connecting a specially designed instrument developed for sensor levelling position and adjusting until the signal shows that sensor is level i e the upper amp lower arrows occupy no more than one grid And then tighten the screws on leveling sensor securing it to the core module 4 After the sensors of both X amp Y directions have been calibrated loc tight the heads of the tightening screws to the sensors so that they cannot come loose Prepared By Tim Wojo Revision Date 0 03232009 Pa F omama al sho LASER LEVELS PRO 40 6537 Service Manual 3 1 2 2 Taper Error A Taper error results when the prism base module discussed in section 2 4 item 6 4 4 does e not reflect the laser light exactly 90 i e non perpendicularity between the rotating line and the rotating axis The end result is a laser rotating surface that is not a plane but a Taper error tapered one as shown in the figure to the right The value A in the left target shares the same symbol as the one in the right target during the check that is Aj 2 and Ajgo 2 The error is removed by adjusting the optical wedge of the laser output window to make the rotating laser beam and rotating axis plumb beam The details are listed as follows a R
17. ts are present they will need to be repaired or replaced prior to the calibration procedures defined below being initiated Depending upon the magnitude of the error 5mm or 0 0005 in only fine adjustments need to be made i e calibration via the remote control Larger errors gt 5mm m or 0 0005 in require coarse adjustment to get close then fine adjustment to bring the unit within specification Both adjustments are defined below Fine Adjust Calibration via The Remote Control If the error is within the range of 0 5mm m it only needs to make calibration with the aid of remote control The details are as follows lt I Shield key Sleep key SLOPE key TILT key Confirm key of self calibration Direction key of Adjust key of self calibration yu y self calibration la B la TILT key ooo A Slope direction LED N YA eee pea Weak battery LED Slope mode LED A A Power LED Yi ao Slope key Power key Prepared By Tim Wojo Revision Date 0 03232009 Pa 7 omama al sho LAGER LEVELS PRO 40 6537 Service Manual 1 Enter self calibration mode Power off the instrument and direct the X axis towards wall 7 JO D U key remove finger from Press the Once this key observe the main display s LED s flash 3 time laser is now in calibration mode 2 X axis calibration
18. tween the ring offers equal angular alarming in all directions Adjustments are made as follows Adjustment screw 2pcs a Remove the Upper housing assembly as shown in section 2 1 Locate the adjustment screws 6 10 reference section 2 3 c Loosen the adjustment screws 6 1 land 6 12 to manually center ISS the contact ring to the spring post d Tighten the adjustment screws and reassemble the upper VBH alarm circuit board part housing assembly to the base assembly 4 0 Electrical Connections 9 ie on m o fe o oa Th l Prepared By Tim Wojo Revision Date 0 03232009 omama al sho ee fee ee LASER LEVELS PRO 5 0 Troubleshooting Guide 40 6537 Service Manual No Sy
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