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caution - Automotive Garage Equipment

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1. Heatshrink Hangs free on 1250 Balancer P3 1 Red 5V E Black GND 8114236 Laser Unregulated DC 19V 36V belween Natura l Red and Red Black a ge Penida NOTE 1 85000264 and 850 x atura l Clear 7 orange w screw end Sonar gt A f Black GND Regular 1250 parts 811420 i 2 Video needs 85000116 850 7 24v Brown Sp as A fo 1 85000304 gt o ko a O Ll x IN fa NO D All wire is 22AWG unle Black GND Red 24V DC 850003051 sonar and LCD harness 24 e Important Always read and follow the information box instructions 81144121 Motor Control Board Spin Spin 220 VAC Molor RT Cooling Fan ne 8112444 Fans cl MOTOR FAN VAC2 VAC Common a VAC1 D VACI Tine voltage ON OFF 8114208 VAC2 Line Voltage White 3 phase only L3 Red LF Capacilor Single L2 Phase Only Black Li Cc o 2 y T lt H 8114249 8111860 EE Motor C1 C2 oO 00 mM Jumper 3 mM a phase only N N E gt wo N N Oo wH wH C3 x y ra O d LAA 00 00 O Counting Crom Lop of board to bottom USF Cc ROUND WHEN MEASURING 3 PHASE 1 PHASE One phas 11 be ine voltage al line vollage Two secs will ba less than 100 volts xf 2 85000704 three EA 7 z phase Motor Protection x Relay 85000705 White wires go to single phase the silver tin oe connectors White 2 Wh
2. n nN amp Sus lt 0 ii py e nN lanl an N o lt N WA Check for power through cord Check for power through jumper Check for power through pover PCB Check for power through pover PCB Check for power through pover PCB Check for power through pover PCB Power PCB i S o 29 1250 Touch Display Panel 1250 Touch Display Panel Vacuum Fluorescent Display PCB VFD 8 pin phone style connector Ribbon Cable to VFD to Processor PCB Not currently used AA ER e gt OA p2 A gt e i i Jis u bd Pa e b Aln ES CLERIEY 4 Spade connector to Chassis Ground Touch Panel Assembly Ribbon Cable from Touch Panel Display PCB 1250 3DV Touch Display Panel Single Board ma Computer SBC cece a Ribbon Cable to Touch Panel A yeaeel AVA A DC AC gt Inverter A E d E 5 JE P Power PCB to Motor Connections 1250 220V 1P Power PCB to Motor Connections Pr From Motor Yellow Purple Black From Motor VVhite From PCB Black From Motor Pink Blue From PCB VVhite From Motor Orange Grey From PCB Red 30 e Important Always read and follow the information box instructions Safety Guard Hood Switch Connections 1250 Balancer Safety Guard Hood Switch Connections Note orientation position A of switches unused terminals amp routing with
3. 2 4 Floor and Space Requirements 2 Unpack and Setup e a E E 3 Safety Guard Hood Installation 3 Sonar Width Installation 4 Control Pod Set UP asta siadsis dde db ee bes 4 Operation isis 5 End User Training 0 0 lt lt lt lt 5 Balancer Description 5 6 Computer Balancer System Diagram 5 POWer SYSICIN 4 6 ec da is 5 INDUL SYSTOND 2 bbdd da ld 404 6 TOU CM RANEI eur eres arcs 6 Ubiical EnNCOder sad a da 6 A amp D Potentiometers 2 sca ce sii ricette sni yoi ey 6 POZO dur EEE SEE E 6 Safety Guard Hood Switch i320 sti dsas 6 Processor oys lEn tok 4h eiii het Sede tas 6 DISPARES 6 PAS CUS Bina oie crea eas eit wea ne Re eee ea 6 Wheel Mounting amp Drive System 6 Chassis ste stb nio oie dy debe Gace ee dd 6 3DV Differences 00000 7 8 AUTO WIAT ENT A Bee anes eave we Raton A 7 Sonar Cala HON aso bai 7 WIE DON cr idas deta ac aoe 3 7 Touch Panel Display Assembly F TOUGH PANG ers dio da 7 FOWEr PANG earar E a as ik be awe 8 O O tees hs ot oie Web eek hed ites ee 8 Processor POD ck eee aid So eee ee See 8 Motor Protection Relay 2 8 vi e Diagnostics 8 Troubleshooting 8 12 Preliminary Inspection o o o oo 8 9 Functional GHECKS lt s tog av nk Bk tl ONS de 9 Opera tonces oa dee eae eee 9 Repeatability Check o o
4. Mount Sonar In Bracket MULA Align Cable 10 Replace hood onto hood bar Control Pod Set Up 1 Use a 1 2 inch wrench socket to loosen the four Nyloc nuts that secure the u bolts to the support bracket and raise the control pod support arm Raise it high enough to allow room for the pod to rotate into position 2 Lightly tighten the control pod support arm retainer nuts on the side of the support bracket Arm will be adjusted and tightened later 3 Loosen the two adjustment knobs on the back of the control pod C Adjustment Knobs 4 Rotate the pod into operating position and retighten the knobs 5 Loosen the nuts on the support arm retainers G Raise or lower the control pod into the desired position and tighten the retainer nuts enough to secure the pod but allow the arm to be pivoted Important Always read and follow the information box instructions Operation See the Operator s Manual for this unit Be sure you completely understand all of the functions and fea tures of the wheel balancer End User Training 1 Begin by having the end user do a typical two clip on weight dynamic balance This should make the end user comfortable with the balancer because it oper ates like most other computer wheel balancers and the operator is immediately successful 2 Then demonstrate all of the touch panel functions like operator A amp B Round off etc 3 Demonstrate an
5. 6 Verify that the On Off Switch is good as described in the Power Signal Systems Checks section of this manual 7 Verify that the Processor PCB is good as described in the Power Signal Systems Checks sec tion of this manual 8 Verify that all of the sonar power and signal cables are securely connected 9 Plug in and turn on the balancer 10 With the hood up enter Command Code Shift 0 73 This turns the sonar on for continuous readings and displays them in the information box on the LCD 11 With the hood up and nothing in front of the sonar reflector it should display 44 inches and a TOF Time of Flight of 65535 A2 44 000in TOF 65535 Temp 24 3 C Samps 48 Min 44 000in TOF 65535 Max 44 000in TOF 65535 Total Static Outboard inboard 12 Ignore the Temperature reading It probably will not agree with the current ambient temperature This is O K as long it is calibrated 13 Place a smooth opaque flat object like a clip board in front of the sonar reflector and watch the dis play for a change in values for inches and TOF 1 4 If no initial display is given or if it fails to change replace the sonar See appropriate Replacement Procedures sections of this manual Important Always read and follow the information box instructions Touch Display Panel A Perform the functional checks described in this manual 2 Verify that the power source is good
6. e Carefully check the unit for correct initial function e Read and follow the safety instructions Keep them readily available for machine operators e Make certain all operators are properly trained know how to safely and correctly operate the unit and are properly supervised e Allow unit operation only with all parts in place and operating safely e Carefully inspect the unit on a regular basis and perform all maintenance as required e Service and maintain the unit only with authorized or approved replacement parts e Keep all instructions permanently with the unit and all decals labels notices on the unit clean and visi ble e Do not override safety features Operator Protective Equipment Personal protective equipment helps make tire serv icing safer However equipment does not take the place of safe operating practices Always wear durable work clothing during tire service activity Loose fitting clothing should be avoided Tight fitting leather gloves are recommended to protect operator s hands when handling worn tires and wheels Sturdy leather work shoes with steel toes and oil resistant soles should be used by tire service personnel to help prevent injury in typical shop activities Eye protection is essential dur ing tire service activity Safety glasses with side shields goggles or face shields are acceptable Back belts provide support during lifting activities and are also helpful in providing operato
7. 7 Plug in the balancer and test the switch for proper functions 8 If good unplug the balancer and install the Weight Tray and Shield Power PCB 1 Unplug the balancer from the power source 2 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 3 Remove all of the cable wire connectors from the Power PCB 4 Remove the Power PCB from its stand offs 5 Install the new Power PCB on the stand offs 6 Connect all of the cable wire connectors to the new Power PCB Refer to the appropriate section of the Wiring section in this manual Y Install the Weight Tray and Shield 8 Plug in the balancer 9 Perform the appropriate functional checks 36 e 4 1 aa 4 f gt r y a n gi 4 1 p b Sonar LCD Power PCB MN E AAA A DA O MA vet A ieee won Sonar LCD Power PCB 3DV 1 Unplug the balancer from the power source 2 Remove the weight tray See appropriate replace ment procedure in this manual 3 Remove the heat shield See appropriate replace ment procedure in this manual 4 Note locations and routing and disconnect the cables from the Sonar LCD Power PCB 5 Remove the Sonar LCD Power PCB from its stand offs on the power panel 6 Install in reverse order 7 Perform a functional check Capacitors Capacitor Assembly 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Disc
8. When performing any of the power signal systems checks always follow all of the safety procedures and observe all of the cautions found in this manual Power Source Perform steps 1 and 2 of Preliminary Inspection found in Diagnostics amp Troubleshooting section Power Cord and Plug A Verify that the power source is good as described in the Preliminary Inspection section of this manual 2 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 3 Use a Volt Ohm meter to check the black and red wires from the power cord to the Power PCB spade ter minals as described in the Power PCB Test Points and Connectors table and illustration in the Wiring sec tion of this manual 4 l no voltage is present check the power cord and plug for continuity 5 f continuity is not found repair or replace the faulty part See Replacement Procedures section of this manual Motor Protection Relay 1 Verify that the power source is good as described in the Preliminary Inspection section of this manual 2 Verify that the Plug and Power Cord are good 3 If power is reaching relay red LEDs will be blinking 4 l not replace the PCB Contactor assembly 5 Functional check the balancer Power PCB A Verify that the power source is good as described in the Preliminary Inspection section of this manual 2 Verify that the Power Cord and Plug are
9. O N Heat Sink 1 8 VDC Processor PCB voltages if no voltage present check power PCB VREFHI VREFLO converter Must use T9 as ground C82 _ _ ma na ____ GroundforT78T8 RROUT Heat Sink 1 5 VDC Right Rear Piezo when shaft is NOT spinning 11 ines le Heat Sink 1 5 VDC Right Front Piezo when shaft is NOT spinning H 1 5 VDC Reference voltage for analog to digital converter Must use T9 as ground 0 0487 vdc Reference voltage for analog to digital rr gt E C na Fi 1 l A T O Al LOUT Heat Sink 1 5 VDC Left Piezo when shaft is NOT spinning HOOD T13 eat Sink 0 6 VDC Hood Up Check on function and proper wiring of Safety or 3 3 VDC Hood Guard Interlock Switches Down _ de WIN T14 T15 SPIN SPIN BRAKE 4 0 VDC to 5 0 Test for start and stop signal from processor BRAKE VDC Positive voltage when spinning and negative voltage when braking Plane weight display when in arm calibration mode check to verify Processor PCB T16 Optical Encoder working Red LED should be blinking when balancer shaft is turning slowly or appear steady when shaft is rotating fast T OUTERA i i Should be same VDC reading shown in Left 17 ui T Heat Sink variable VDC 18 OUTERDIA Heat Sink variable VDC 1 2 7 8 Should be same VDC reading shown in Right Plane weight display when in arm calibration mode check to verify Processor PCB Important Always read and
10. Unplug the balancer from the power source 7 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 8 Remove the Processor PCB Cover See Replacement Procedures section of this manual 9 Disconnect the Safety Guard Hood Switch Connector from the Processor PCB 10 Plug in the balancer and turn the power switch on 11 Mount a test wheel amp tire and enter A D and W dimensions 12 Press start 13 if the wheel cycles unplug the balancer and check the cable and switches for continuity See the illustration in the Reference Materials section of this manual 14 Identify the failed component s and repair or replace it them Note that if the cable is replaced it must be routed from inside the balancer to the switch assembly See the necessary Replacement Procedures sections of this manual e 15 15 Connect the switch cable connector to the Processor PCB 16 Plug in the balancer 17 Perform the appropriate functional checks 138 Unplug the balancer and re assemble It Laser A Perform the functional checks described in this manual 2 Verify that the power source is good as described in the Preliminary Inspection section of this manual 3 Verify that the Power Cord and Plug are good as described in the Power Signal Systems Checks sec tion of this manual 4 Verify that the Power PCB is good as described in the Power Signal
11. Usually a symptom of capacitor failure is when the motor doesn t spin but hums or gets up to speed with a helping push 1 Verify that the power source is good as described in the Preliminary Inspection section of this manual 2 Verify that the Power Cord and Plug are good as described in the Power Signal Systems Checks sec tion of this manual 3 Verify that the Power PCB is good as described in the Power Signal Systems Checks section of this manual 4 Verify that the On Off Switch is good as described in the Power Signal Systems Checks section of this manual 5 Verify that the Processor PCB is good as described in the Power Signal Systems Checks sec tion of this manual 6 Verify that the Motor is good as described in the Power Signal Systems Checks section of this man ual 7 Unplug the balancer from the power source 8 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 9 Check the capacitor connection to the Power PCB 10 If all of the above checks are good replace the Capacitor pack See necessary Replacement Procedures sections of this manual Fan The fan starts a 30 minute run cycle each time the balancer is powered up or each time the balancer initi ates a spin cycle The fan can be turned on and off manually by using the appropriate extended Command Code Either Shift 0 24 to turn it on or Shi
12. appears in the LEFT PLANE weight display 2 Depress the number 4 key and then the num ber 3 key Code 43 3 All LEDs will light Those in the position dis plays will only remain on if the balancer shaft does not rotate 4 Depress the Next key or the Stop Exit key to leave the check mode 5 If any of the LEDs do not light replace the Display PCB See appropriate section of Repair amp Replacement Procedures in this manual Vacuum Fluorescent Display Check The Vacuum Fluorescent Display will either show information or not If not perform a physical inspection of the PCB wiring and connections and then perform the checks described in the appropriate section of Power Signal systems Checks in this manual 120 LCD 3DV Functional Check The LCD will have either an easily seen image a very faint image or no image An easily seen image is an indication of proper oper ation A very faint image is an indication of a failed DC AC Inverter or LCD Back Light Assuming the power and signal paths have checked as functional up to the LCD Panel no image is an indi cation of a failed LCD Panel Laser Check Follow all of the Laser safety instructions and cautions in the Safety Instructions section of this manual A With a test wheel mounted on the balancer depress the Direct Select Weight key T2 Tape This will activate the laser 2 lurn the k
13. depress the 0 key CdE appears in the LEFT PLANE weight display Variation Largest Value minus Smallest Value 2 Depress the number 4 key and then the num ber 2 key Code 42 42 will appear in the RIGHT PLANE weight display 3 Now when each pressure sensitive switch Is depressed except for the Shift key a character will appear in the Vacuum Fluorescent Display Intormation Box as shown in the following table 4 Depress each key to see if it is functioning 5 Depress and hold the Shift key while you depress the 0 key to exit this mode As you do this the Vacuum Fluorescent Display Information Box will briefly display Shift 0 before returning to normal displays 6 If any of the switches are inoperative replace the touch panel See appropriate section of Repair amp Replacement Procedures in this manual Important Always read and follow the information box instructions e 11 witc ey Description Clip 1 T1 Tape Patch Static T2 Tape T3 Tape Clip 2 Dynamic Static Behind Spoke Spoke 1 Spoke 2 Stop amp Exit Displayed Charater Next 1 Cal Mach 2 Cal Laser 3 Cal Arm 4 RV Lite Truck 5 Tire Match 6 Round Off 7 Operator A B 9 Ounce Gram Shift Start Total Static Pressure Switch Table LEDs Check To check the LEDs 41 Depress and hold the Shift key while you depress the 0 key CdE
14. pull the poten tiometer shaft out of the rod just enough to grip it with needle nose pliers 3 Carefully rotate the shaft to achieve the desired reading in the right plane weight display 0 40 through 0 70 4 Carefully slide the shaft back into the rod 5 Check to make sure the reading did not change and tighten the set screw to secure the shift in the rod G Rotate the arm simulating a rim measurement to make sure the reading changes and then returns to your same setting in the home position 7 Reassemble the balancer in reverse order A Dimension Potentiometer 1 Use a 2 mm Allen wrench to slightly loosen the set screw that secures the pulley to the potentiometer shaft 2 With the arm in home position use a small flat blade screw driver to carefully rotate the potentiome ter shaft to achieve the desired reading in the left plane weight display 0 40 through 0 70 3 While holding the position of the shaft with the screw driver tighten the set screw that secures the pulley to the shaft 4 Pull out the arm simulating a rim measurement to make sure the reading changes and then returns to your same setting in the home position 5 Reassemble the balancer in reverse order Important Always read and follow the information box instructions Replacement Procedures Do not disassemble adjust or replace any part before performing the appropriate Functional Checks and Power Signal System Ch
15. section of this manual 4 Verify that the On Off Switch is good as described in the Power Signal Systems Checks section of this manual 5 Verify that the Processor PCB is good as described in the Power Signal Systems Checks sec tion of this manual 6 Unplug the balancer from the power source 7 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 8 Remove the Processor PCB Cover See Replacement Procedures section of this manual 9 Check test point 114 115 as described in the Processor PCB Test Points table and illustration in the Wiring section of this manual 10 f the spin signal is present at the Processor PCB check the wiring connections to the motor from the Power PCB and the continuity of the wires 11 If all of the above are good replace the motor assembly See necessary Replacement Procedures sections of this manual Reference Materials Command Codes 250 1250 3DV Shift Command Codes Depress and hold the Shift ke Depress hb Cal Mach Laser 1 3 Cal Arm 4 RV Lite Truck Match Balance Round Off Oo 7 Operator A B Hood Start Ounce Gram Extended Command Codes nitiates acceptance of extended command codes nitiates 4 ounce calibration procedure Initiates dot laser calibration as additional step to 4 ounce calibration Only necessary after replacing processor PCB
16. A potentiometer value voltage changes When the arm Is rotated in the Diameter plane the value voltage for the D potentiometer changes This information tells the processor where the inside weight will be placed and where 2 will be placed when using that location Piezos The three piezos between the motor and the chassis each measure the amount of imbalance in the wheel When pressure is applied to a piezo it generates a volt age When pressure Is applied in the opposite direction a voltage of the opposite polarity is generated This is called an AC voltage If more pressure is applied you get a larger AC signal When a wheel rotates the plezos generate an AC signal proportional to the pres Sure applied The larger the imbalance in the tire wheel assembly the larger the signal generated Safety Guard Hood Switch Two switches make up the safety interlock system They send signals to the processor that allow It to know if the hood is in the up position or down position and prevent the motor from getting power to spin when the hood Is up Processor System The actual CPU Central Processing Unit is mounted on the Processor PCB along with the necessary com ponents to convert analog signals to digital signals and back 6 Note Processor PCB revision H and backward will only drive 1250s Revision and forward will drive both 1250 and 1250 3DV Display Panel The display PCB is part of the Touch Panel assembly
17. Motor and or dot laser bracket itiates Arm calibration procedure oggles to 0 50 ounce round off itiates match balancing procedure Toggles weight amount display between round off and fine balance 1 4 ounce round off or hundredths of an ounce displa oggles between wheel dimensions and values for either operator A or operator B oggles Hood Start on or off oggles weight amount display between units in ounces or grams After Depressing Shift 0 CdE appears in Left Plane weight amount displa Cal A amp D Arm Set Date amp Time Show Date amp Time Bypass 4 ounce Cal oggle stop on top oqgle Laser ogale Fan how Revision 42 Same as shift 3 stamp events entering urns laser on amp off Shows software revision est Displa how Encoder Count le ee a KR D lt Jo Q a 4 18 e n for 30 minutes or off Used to set date amp time when processor board is assembled Calendar Clock is used to date time Reset should only be required if battery falls out or fails Used to show date amp time of processor board la urns stop on top feature on amp off Each key when depressed displays a unique character on the vacuum fluorescent display in the Information Box See pressure switch table for characters ights all of the LEDs on the display PCB 8DV simulates lighted LEDs lays the optical encoder count from 0 255 in the right plane weight displa Important Always read and follow th
18. SUD OOM TUDE sonrisa rana ena 34 HIOZOS ato Ba a BES Gre cto BONES 34 FOLE omelo etario 34 35 D Dimension Potentiometer 35 A Dimension Potentiometer 35 Replacement Procedures 35 45 Power SysteM a Toa radd e e a e oo 35 36 Replace PCB Contactor Assembly 36 ON OR VIC Ira nda 36 POWER PGE oy fot doused te ista 36 Sonar LCD Power PCB BDV osuna 36 EA E ss bee 36 37 INPUE SISTE sio sddl tadas dsp es 37 38 Optical Encoder amp Rotary Shutter 38 39 POLOS Narro arta e ode Se ea 38 39 A e a a E a Gots dus eons 39 40 Safety Guard Hood Switch discs acia a Satna dez 40 TOUGH aNe ardor Ea 40 oe AA eens Soak ae ee 40 41 PrOCESSOMOYSTEM sia ads rr 41 Display Syste rs abia 41 42 Single Board Computer SBC BDW 42 DC AC Inverter BDV 42 PS DY hoa te asst ce or abreast tees aie ae ean Sih 43 44 Wheel Mounting amp Drive System 44 45 Chassis Syo le ei event cued e ore ade ete en ke 45 Display Pod Assembly 45 Important Always read and follow the on screen operating instructions o 1 Servicing Service should be performed only by COATS trained and authorized Service Technicians The troubleshoot ing and service procedures in this manual are arranged to allow rapid and thorough service The steps are PRE LIMINARY INSPECTION FUNCTIONAL CHECKS REPAIR OF FAILUR
19. as described in the Preliminary Inspection section of this manual 3 Verify that the Power Cord and Plug are good as described in the Power Signal Systems Checks sec tion of this manual 4A Verify that the Power PCB is good as described in the Power Signal Systems Checks section of this manual same for Sonar Display Power PCB on 3DV 5 Verify that the On Off Switch is good as described in the Power Signal Systems Checks section of this manual G Verify that the Processor PCB is good as described in the Power Signal Systems Checks sec tion of this manual 7 Unplug the balancer from the power source 8 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 9 Remove the Touch Display Panel from the pod See Replacement Procedures section of this man ual 10 Refer to the Processor PCB Connections and Touch Display Panel Connections sections in the Wiring section of this manual and check all of the connectors and cables for a positive connection and for continuity 11 if all of the above tests are good replace the malfunctioning component s Touch Panel Display PCB and or Vacuum Fluorescent Display PCB 3DV single board computer SBC PCB DC AC Inverter PCB and or LCD see necessary Replacement Procedures sections of this manual Important Always read and follow the information box instructions Capacitors
20. generates a sound wave signal that bounces off a metal reflector It then bounces off the tire sidewall back to the reflec tor and back to the sonar This dimension along with the A dimension is then used to calculate rim width Touch Panel Display Assembly LCD The 1250 3DV display features a liquid crystal display LCD panel This eliminates the need for the LED display and Vacuum Fluorescent Display found on the 1250 The Information Box Weight Amount and Location Indicators Mode Selection Indicators and Weight Location Indicators all appear on the LCD panel Important Always read and follow the information box instructions The LCD is protected by a sheet of thin Lexan in front of the panel Display PCB The display PCB is different from that used on the 1250 4 x we de y H lt y gt Inverter a TE gT ny The fluorescent backlight in the LCD requires a power supply mounted on the back of the touch panel The inverter connects to the display PCB This inverter pro duces 3 000 Volts It will blow its fuse if you ground it via your body and It will need to be replaced The 1250 3DV has a single board computer SBC to supply the additional computing capability to drive the LCD panel and the animated graphics it displays The Single Board Computer SBC PCB is piggy backed onto the display PCB and can be replaced without replacing the main PCB The display PCB pl
21. located in the Pod and displays weight amounts weight locations service codes and Indicates active functions using LEDs A Vacuum Fluorescent Display with its own PCB is used to communicate messages instructions error codes and wheel dimensions etc and is labeled the Information Box Lasers When weight location 12 is activated a laser displays a red dot for use on the inside of the wheel to indicate T2 weight location A manually operated line laser is used to precisely match the A2 dimension to the desired weight location plane Wheel Mounting amp Drive System A 220 Volt Motor with 220 Volt Cooling Fan provides direct rotation of the balancer shaft 220 Volt single ohase units use a capacitor The motor shaft is the bal ancer shaft and extends trough the balancer faceplate A threaded shaft screws into the balancer shaft to pro vide a means of securing the wheel tire assembly to the unit Various mounting adapters cones pin plates hub nuts etc are available individually and in sets to mount the wheel tire assembly in a manner to accu rately simulate its centering and plane of rotation on the vehicle Chassis System The chassis system consists of the balancer cabinet with safety guard pod bracket Weight Tray and Shield processor PCB Cover motor cover gasket amp shield safety guard hood assembly and display pod assem bly The chassis contains a pound sack of rock that serves as ballast so the balancer d
22. o oooooooooo 9 Calibration GCNECkS ecos hve 2 eee tel 9 10 Rotational Check Mounting 10 Potentiometer CHECK estamos AV 10 AL o A A th weed TEE G2 11 Optical Encoder nec ccoo 11 Touch Panel CMECK marica rr matte eta 11 12 LEDS CHECKE su tia a o as 12 Vacuum Fluorescent Display Check 12 LCD 3DV Functional Check taciones 12 EI codra e a eerie Aes Meson ae 12 Sonar 3DV Functional Check 12 Power Signal Systems Checks 13 18 POWER SOUCO eroa n e a 13 Power Cord and Plug 0 00005 13 OVE EE sees eng he eae edit Seaton ak Aas oe ante a 13 Sonar LCD Power PCB 3DV Power System SIGN ali eha CK 2 dtc asian da dd 13 DC AC Inverter 3DV Power SST SIM GHECK ermita dis dea 13 OMOTO sacan cia diria a a pi 14 Processor E CDS adas didas Aa 14 EZ ics ia a A a tidad 14 Potentiometers tia aa ed 15 Optical Encoder 2 dada id 15 Safety Guard Hood Switches 15 16 WES EN 2 25 dike be os oh akon ste coerce boy s edhe te de wean pee teak 1 Hed bes 16 sonar 3DV Power System Signal Check 16 TOUCHADISDIAV Panel yd oa 17 Capacitan pica 17 FM srt dotan Bete cies ay eT e ease 17 18 Mo AA ch ar ash dh a Hct at ea he Gatun dare 18 Reference Materials 18 21 Command Codes 00 0000 18 19 Failure Mode Possible Cause s Verification Test s Solution S 20 ENMOFEDIES citas span 21 1250 Processor PCB Compatibi
23. or below floor level THIS EQUIPMENT MUST BE EARTH GROUNDED The earth ground connector built into the power cord provides protection to reduce the risk of electrical shock Do not use below garage floor or grade level Disconnect power before servicing this equipment To prevent electrical shock do not remove cover No user servicable parts inside Refer servicing to qualified service personnel May Be Protected by one or more of the following patents USA 4 423 632 4 499 768 4 939 941 5 311 777 5 337 256 AUSTRALIA 564038 8113547 01 Standard Safety Devices e Stop key for stopping the wheel under emergency conditions e A hood guard of high impact plastic that is designed to prevent the counterweights from flying out in any direction except towards the floor e A hood switch interlock system that prevents the machine from starting if the guard is not lowered and stops the wheel whenever the guard Is raised Important Always read and follow the information box instructions ev Table of Contents Safety Instructions ii v Important Safety InStructi0NS ii Owner s Responsibility isso dadas iii Operator Protective EquipMent jii Definitions of Hazard Levels III safety Notices and Decals iV V Standard Safety Devices anat are V Servicing ica eee Bee 2 Required Tools 000coooo or 2 Installation amp Set Up
24. piezo springs 6 Remove two 2 5 16 18 X1 washer head screws Y Disconnect fan motor and optical encoder plugs 8 Disconnect the motor wires from the power board PCB motor plug wires See illustration in the Wiring section of this manual Important Always read and follow the information box instructions 9 Lift out the motor assembly 10 After noting the wire colors disconnect the wires to the piezos 11 Remove the piezo assemblies trom the chassis Note The piezo assemblies used in the models 950 and 1050 balancers are different from other Coats bal ancers in that they are held in position by studs in the bottom of the piezo carriers that fit into holes in the chassis New piezos have the ball molded into the top casting 12 Use emery cloth to clean the mounting surfaces of the piezo assemblies and chassis install new piezo assemblies and connect wires 13 Install the motor assembly 14 Install two 2 5 16 18 X1 washer head screws 15 Install piezo springs spring retainers and Nyloc nuts 16 lighten the Nyloc nuts until the distance from the top of the motor cradle to the top of the retainer is two 2 inches 17 Install the laser assembly 118 Install the motor wires to the wires coming from the motor connector on the Power PCB See illustra tion in Wiring section of this manual 19 Connect fan motor and optical encoder plugs 20 Install motor cover shield motor cover ga
25. still at the edge of the face plate enter the A offset dimension shown on the arm rod Depress the Next key 5 Move the arm to its home position and depress the Next key 6 Move the arm to the Clip 1 position on the rim flange and hold it there while you manually enter the D dimension Depress the Next key 7 VVhile still holding the arm at the Clip 1 position on the wheel depress the A key and enter the dimen sion on the arm rod Depress the Next key 8 Return the arm to the home position and calibra tion Is complete Note If you did not complete the A amp D arm calibra tion successfully you can bypass the 4 ounce calibra tion with code Shift O 19 to try again without having to repeat the 4 ounce calibration Important Always read and follow the information box instructions Adjustments Laser Use of controls adjustments or perform ance of procedures other than those speci fied herein may result in hazardous radiation exposure Focus A Mount a 16 inch wheel on the balancer 2 Depress and hold the Shift key while depress ing the number 2 Cal Laser key to turn on the laser with a steady beam 3 Rotate the knurled knob on top of the laser assembly to move the beam to the position where a right plane Tape A Weight would go on the inside of the wheel 4 Use a medium wide flat blade screw driver to slightly turn the set screw where the laser p
26. the correct tension it will not be necessary to loosen them and retighten them to move and maintain the desired position VFD or LCD 3DV Brightness There are various brightness levels that the VFD or LCD backlight can be set at Use and repeat Command Code Shift 0 61 to scroll through the choices The balancer will automatically save and then power up at the level it is set at when it is shut off Pod Support Tube e Pivot the pod tube to bring the Touch Panel Display to the desired position by pushing or pulling on the left edge of the display panel while gripping the support tube with your other hand e f the pod resists movement use a 1 2 inch wrench socket to slightly loosen the four Nyloc u bolt nuts that retain the support tube to the chassis support bracket and try again Note that if the nuts are tight ened to the correct tension It will not be necessary to loosen them and retighten them to move and maintain the desired position Piezos The preload on the piezos is adjusted by tightening or loosening the Nyloc nuts that retain the piezo springs The desired setting for each spring height is 2 inches plus or minus 1 16th inch from the bottom spring seat to the top of the piezo spring retainer 1 Unplug the balancer 2 Remove the Weight Tray and Shield See appropri ate Replacement Procedures section in this man ual 3 Remove the motor cover and gasket enough to access the right sid
27. 17 Perform an A amp D arm calibration Refer to the Calibration section of this manual 38 o Optical Encoder amp Rotary Shutter Optical Encoder 41 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Remove rear end bell cover from motor 4 Remove rotary shutter 5 Disconnect optical encoder plug 6 Slide optical encoder from aluminum rear end bell casting Y Install new optical encoder 8 Install rotary shutter 9 Install rear end bell 10 Connect optical encoder plug 11 Install weight tray and weight tray shield 42 Plug in balancer 13 Perform Functional Checks Rotary Shutter 4 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Remove rear end bell cover from motor 4 Remove 3 8 x 3 8 shoulder bolt and rotary shutter 5 Install the new rotary shutter 6 Put Loctite 242 or equivalent on the 3 8 shoulder bolt threads install and tighten 7 Install rear end bell cover 8 Install weight tray and weight tray shield 9 Plug in balancer 10 Perform Functional Checks Piezos 1 Unplug the balancer 2 Remove A amp D Arm from rod 3 Remove weight tray weight tray shield motor cover motor cover gasket and motor cover shield 4 Remove the laser assembly by removing the two inch Allen screws that retain the laser bracket to the front of the motor 5 Remove the four 4 3 8 16 Nyloc spring retain ing nuts spring retainers and
28. 50 Processor PCB Compatibility Matrix PCB 8113907 Model 1250 Model 1250 3DV Revsion Hand backward X O X land forward 1250 Spin History Data Key If you access about the last 50 spin cycles on a 1250 by entering Shift 0 CDE 45 Dump Event Log you will see a display as follows in the Information Box Example Display 00 02 13 42 37A 2 765 3 063 2 556 00 is the record number 00 is the most recent spin 33 would be 33 spins ago etc The next four fields are the time that the spin was recorded 02 is the day of the month 13 Is the hour 42 is min 37 is seconds A is operator either A or B 2 65 is the left amplifier gain 3 063 is the right front amplifier gain 2 556 is the right rear amplifier gain Note Amplifier gain readings are inversely related to the piezo outputs The smaller the piezo output the larger the gain A maximum gain reading of 11 800 Important Always read and follow the information box instructions Message Suggested Action s would indicate a disconnected broken or shorted plezo wire or a bad piezo 3DV Spin History Data Key If you access about the last 50 spin cycles on a 1250 by entering Shift 0 CDE 45 Dump Event Log you will see a display as follows on the LCD Example Display i E AGLA DA KA e Spin In Ang Ang LP Ang RFP Ang RR Ang LG RFG RRG 13 13 36 82 0 236 0 154 3 866 0 243 1 667 1 230 1 7330 3 953 1 6960 4
29. 838 2 556 2 556 2 282 13 13 36 Is Time 82 Is Spin count 0 236 Is Inner weight magnitude 0 154 is Inner weight angle in radians 3 866 is Outer weight magnitude 0 243 is Outer weight angle 1 667 is Left piezo magnitude 1 230 is Left piezo angle 1 733 is Right Front piezo magnitude 3 953 Is Right Front piezo angle 1 696 is Right Rear piezo magnitude 4 838 Is Right Rear piezo angle 2 556 is Left piezo gain 2 556 Is Right Front piezo gain 2 282 Is Right Rear piezo gain Note Amplifier gain readings are inversely related to the piezo outputs The smaller the piezo output the larger the gain A maximum gain reading of 11 800 would indicate a disconnected broken or shorted plezo wire or a bad piezo e21 Diagnostic Flow Charts Balancer Chases Weights Does not return zero on check spin Perform Operation Check OK NO accurately OK Perform 4 ounce Calibration Check Perform Repeatability Check Accuracy check BAD BAD OK Perform Piezo Check Perform 4 ounce Calibration OK BAD AD c ER Replace Piezos Perform A amp D Dimensions Check B BAD oK Perform Potentiometer Check Perform A D Calibration Replace Potentiometers Balancer Will Not Spin Does Light Up Refer to the Power Signal System Checks Wiring 8 Failure Mode Table sections in this manual BAD Check Power PCB Repair or replace faulty component OK BAD Repair or replace
30. E REPLACEMENT or ADJUST MENT and FUNCTIONAL CHECKS Identification of replacement parts required can be accomplished by using the parts identification manual for this unit It is important that the functional checks be per formed in sequence and the problem isolated prior to attempting any adjustments or replacements Do not assume anything f an adjustment or replace ment is made all functional checks must be performed successfully before the balancer can be considered available for service Required Tools e AC DC Volt Ohm meter e Test Wheel Domestic 14 15 or 16 x 6 steel wheel with a center hole suitable for mounting with a back cone A new tire properly mounted and inflated balanced to within 0 05 ounces should be part of this wheel assembly The lateral run out of this wheel should be less than 1 8 e Typical Mechanic s and electrician s tools e Thread locking anaerobic Loctite 242 or equiva lent e Retaining compound Loctite 601 or equivalent e Dial indicator run out gauge AMMCO No 929752 or equivalent e Modeling Clay e Z ounce or 100 gram calibration weight e Static discharge wrist strap to ground device Failure to wear this when handling testing or replacing any of the PCBs in this balancer may result in damage to a PCB which Hennessy Industries Inc is not responsible for 20 Installation amp Set Up e A factory trained COATS Service Technician must perform th
31. Goats 1250 Series Wheel Balancer 250 eaats eee E DRIVE e GUIDED OPERATI LASER 1250 30V Shown Service Manual and Troubleshooting Guide READ these instructions before placing unit in service KEEP these and other materials delivered with the unit in a binder near the machine for ease of reference by supervisors and operators HENNESS Vinvusrries inc 1601 J P Hennessy Drive LaVergne TN USA 37086 3565 615 641 7533 800 688 6359 www ammcoats com HENNESSY INDUSTRIES INC Manufacturer of AMMCO COATS and BADA Automotive Service Equipment and Tools Revision Manual Part No 8114353 02 07 07 Safety Instructions IMPORTANT SAFETY INSTRUCTIONS READ ALL INSTRUCTIONS Eye and face protection recommendations Protective eye and face equipment Is required to be used where there is a reasonable probability of injury that can be prevented by the use of such equipment O S H A 1910 133 a Protective gog gles safety glasses or a face shield must be pro vided by the owner and worn by the operator of the equipment Care should be taken to see that all eye and face safety precautions are followed by the operator ALWAYS WEAR SAFETY GLASSES Everyday glasses only have impact resistant lenses they are not safety glasses Do not disable hood safety interlock system or in any way shortcut safety controls and operations Be sure that wheels are mounted properly the hub nut engages the arbor
32. Loads baseline 4 ounce calibration into volatile memory Reverts to last calibration values if shut off Load baseline A amp D calibration Loads baseline A amp D calibration into volatile memory Reverts to last calibration values if shut off 76 77 78 Clear calibration Clears 4 ounce baseline calibration values from non volatile memory Clear A amp D calibration Clears A amp D baseline calibration values from non volatile memory gnore noise error Used to fine tune noise filter settings if code 94 does not solve problem Contact RSM for usage Write baseline calibration Writes current 4 ounce calibration values to non volatile memor i i Used to fine tune noise filter settings if code 94 does not solve problem Contact RSM for usage Write baseline A amp D calibration Writes current A amp D calibration values to non volatile memory storage 81 82 83 84 85 87 88 Used to fine tune noise filter settings if code 94 does not solve problem Contact RSM for usage feat inal floating decimal Adjusts noise filter settings to production noise filter 91 Adjust float tolerance Allows setting range for floating potion chosen using code 89 Contact RSM for usage 94 Set to High Noise defaults Adjusts noise filter to settings found successful in most high noise environments Reset Counters Resets all counters Important Always read and follow the information box instructions o 19 Failure Mode Possible Cause s Verif
33. Systems Checks section of this manual 5 Verify that the On Off Switch is good as described in the Power Signal Systems Checks section of this manual G Verify that the Processor PCB is good as described in the Power Signal Systems Checks sec tion of this manual 7 Unplug the balancer from the power source 8 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 9 Remove the Processor PCB Cover See Replacement Procedures section of this manual 10 Inspect the laser connector and wiring 11 l good replace the laser sub assembly See Parts Identification manual for this unit See the neces sary Replacement Procedures sections of this man ual 12 Re assemble plug in the balancer and perform the necessary functional checks Adjust the laser focus If necessary 16 e Sonar 3DV Power System Signal Check A Perform the functional check described in this manual 2 Verify that the power source is good as described in the Preliminary Inspection section of this manual 3 Verify that the Power Cord and Plug are good as described in the Power Signal Systems Checks sec tion of this manual 4A Verify that the Power PCB is good as described in the Power Signal Systems Checks section of this manual 5 Verify that the Sonar Power PCB is good as described in the Power Signal Systems Checks sec tion of this manual
34. ag and for RRAngle 9 Depress the Next key to exit the code mode 10 Depress the Start key and cycle the balancer 11 Repeat the process of writing down the read ings for a total of 5 cycles 412 Mag and Angle readings should not vary by more than 0 0500 for a specific piezo Example values may be different depending on wheel size used L Angle RFMag RFAngle RRMag RRAngle 3 7835 5 0438 3 4221 1 4457 3 3996 2 3454 3 8118 5 0542 3 4567 3 4361 2 355 VIAJUV VOI IATA NT TAS ATA II AAA ATT ITA TIAS 14 29 28 109 0 04302 513 4 01303 425 1 7120 4 349 1 7750 0 791 1 7280 1 675 2 084 2 282 2 084 14 29 36 110 0 056002 504 4 00303 477 1 7100 4 399 1 774 0 841 1 7270 1 725 2 556 2 556 2 282 09 24 25 111 0 314 5 899 3 839 6 137 1 768 0 772 1 8090 3 501 1 7680 4 37313 063 3 063 3 339 09 24 40 112 0 548 5 860 3 823 6 137 1 7680 0 770 1 8110 3 498 1 7700 4 370 2 084 2 084 2 556 09 24 48 113 0 34305 852 3 82106 087 1 7670 0 722 1 8100 3 450 1 7690 4 323 2 282 1 909 2 282 09 24 55 114 0 32706 000 3 82006 129 1 7640 0 769 1 8060 3 498 1 7680 4 372 2 282 2 556 2 556 09 25 03 115 0 371 5 929 3 796 6 136 1 7630 0 771 1 808 3 499 1 7690 4 372 2 556 2 282 2 282 1 09 28 53 116 0 35605 851 3 80806 090 1 7640 0 724 1 8100 3 452 1 767 4 32012 a i 0 Note Alternative method for 3DV model piezo check follow steps 1 amp 2 above cycle the balancer fi
35. air or replace faulty component Repair or replace faulty component ON BAD Check VFD PCB Repair or replace faulty component Perform Functional Checks Important Always read and follow the information box instructions e 23 Check Processor PCB O O O A A A Check Display Panel PCB Schematic Diagram Power amp Signal Flow 8113907 Processor 8114259 SV Spin 5V Spin RAT RT2 lack 1 TT rea 213 mtural ciesr 5 Red 5V 6 Black Fan 7 Silver Silver VAC en 8114259 VAC D Silva LX Black 3 ETC TO racer 2 Red 1 85000116 85000115 Single Board Compuler Output Snaps onto Display DC AC inverter Ta 8114211 i 2 2 3 3 m EN e EN EN E A yl 16 NA A E A YE PE 7 A _ A CAT b Patch Cable Display Board a Drain Ed 850000491 ME Jl c 2 oh 3 3 4H 8114262 x 5 8 6 i Unregulated DC 197 36 secweer Natural Red anc Red 3 Leck 85000392 Jumper phase Teft Piezo CS Right Front Piezo L Black Righl Rear Piczo Silve FEE lg LShield A RES 5 RF 6 RF Shield R 7 RR ack gt 8 RR Red Red Heatshrink 9 RR Shield Silver O 8114260 81142663 three piezos 85000305 Silver POT ry 8114257 INNER DIA Nakural Clear Green Heal sheink mE 85000264 ei Tares Sonar Video Power Supply Black OANOnNAWNDM
36. alancer Is a specialized com puter system A computer has a system of inputting information processing the information and displaying the input and the output results Of course electron ics need a power system A wheel balancer also requires a system to make a wheel rotate simulating the centering of the wheel and its plane of rotation on the vehicle Computer Balancer System Diagram Inputs System Touch Panel Power System Power PCB Piezos Potentiometers Optical Encoder Hood Switch Sonar Mounting amp Rotation System Motor amp Faceplate Processor System Assembly CPU Center Processing Unit Chassis System Cabinet Outputs System Vacuum Fluorescent LED Laser LCD Power System The balancer is typically configured to be powered by a 220 VAC 15 Amp 3 Phase or 220 VAC 15 Amp Single Phase source If the balancer is Single Phase a capacitor pack is required If the balancer is 3 Phase a jumper plug is used Power goes to the Power PCB Printed Circuit Board sometimes called the Motor Controller Board Power is controlled and routed through this board to the 220 VAC components like the Motor and the Motor Cooling Fan The Power PCB has an integral transformer to step down the voltage to 6 5 VAC as required by other components This 6 5 VAC is supplied to and powers the Processor PCB The Power PCB has two non replaceable fuses to prevent the board from literally burning if it fai
37. allet for damage Take pic Be sure the hood bracket properly engages the switch tures if damaged assembly 2 Move the pallet as close as possible to the work 5 Slide the other flanged bearing and the other hood ing location of the balancer bar washer into position followed by the 1 1 2 retainer washer and hood bar cap 3 Remove the carton from the pallet 7 Raise the hood all the way and verity that the 4 Inspect the contents for hidden damage Take pic hood stop bracket on the side of the hood contacts the tures if damaged rubber hood stop solidly 3 Remove the safety Guard Hood literature 8 Lower the hood and verify that the other end of packet skin pack s and any accessories shipped with the hood stop bracket contacts the rubber hood stop the balancer solidly 6 Unbolt the balancer from the pallet 9 Raise the hood and hold it up 7 Carefully remove the balancer from the pallet and position It in its working location A CAUTION A CAUTION Use help to hold the hood while attaching the hood spring Attaching the spring with Do not use the control pod control pod out holding the hood in place may cause it arm faceplate hood or stub shaft to lift the to snap open suddenly resulting in per balancer Use help to remove the balancer sonal injury from the pallet The unit is heavy and the 10 Hook one end of the hood spring under the back weight is not evenly distributed Dropping of balancer chassis in line w
38. ample noise filtering codes 86 through 89 Adjust EB dynamic limit Toggle EB mode Toggles access to operator of EB mode On non EB 1250s a PIN will be required to enable access to the feature and this is achieved by using codes 76 77 amp 78 Note that all 3DV models come with it enables but toggled off by default Detect Sonar Turns on sonar Example after replacing processor PCB MUST be turned on before attempting calibration Show Sonar diagnostic Shows Distance reading in inches TOF time of flight number and Celsius temperature Ignore O t 71 72 Q information temperature It may not agree with current ambient temperature This is O K as long it is calibrated 74 Run graphics demonstration Starts looped program of balancer operations on LCD display Toggle when to load W dimension Toggles between loading the W dimension with every hood closure or only on the first close after A amp from Sonar D dimensions have been entered Default setting is only after A amp D has been entered Every hood closure loading is only necessary for diagnostic reasons N oO Enter Balancer Serial Number Used to enable EB mode on 1250s after customer purchase of EB mode feature Enter Processor Board Serial Used to enable EB mode on 1250s after customer purchase of EB mode feature Number Enter Feature Ke Used to enable EB mode on 1250s after customer purchase of EB mode feature Load baseline calibration
39. as described in the Preliminary Inspection section of this manual 2 Verify that the Power Cord and Plug are good as described in the Power Signal Systems Checks sec tion of this manual 3 Verify that the Power PCB is good as described in the Power Signal Systems Checks section of this manual 4 Unplug the balancer from the power source Power is still flowing to the Power PCB and the On Off Switch when the balancer is plugged in 5 Remove the Weight Tray and Shield See appropri ate section in Replacement section of this manual G Remove the black wires from the spade terminals on the power switch 7 Check the switch for continuity as described in the Power PCB Test Points and Connectors table and illustration in the Wiring section of this manual 8 l the switch fails the continuity test in either the on or off position replace the switch See Replacement Procedures section of this manual Processor PCB 1 Verify that the power source is good as described in the Preliminary Inspection section of this manual 2 Verify that the Power Cord and Plug are good as described in the Power Signal Systems Checks sec tion of this manual 3 Verify that the Power PCB is good as described in the Power Signal Systems Checks section of this manual 4 Verify that the On Off Switch is good as described in the Power Signal Systems Checks section of this ma
40. be a A T 8 Note the one shorter spacer on the standoff near est the direct connector This shorter spacer must NEVER be replaced with one of the longer ones as it helps insure a reliable connection between the Display PCB and LCD 9 Install in reverse order 10 Perform a functional check Vacuum Fluorescent Display 1 Unplug the balancer from the power source 2 Use a 1 Phillips screw driver to remove the four screws and spacer bushings if so equipped on the back of the pod that retain the Touch Panel 3 From the front of the pod carefully pull out the Touch Display Panel assembly 4 Disconnect the 8 pin phone style connector cable on the back of the Display PCB See illustration in the Reference Materials section of this manual 5 Disconnect the green ground wire from its spade terminal on the back of the Display PCB 6 Disconnect the Vacuum Fluorescent Display VFD PCB ribbon cable connector from the back of the VFD PCB 7 Use a 1 Phillips screw driver to remove the screws that attach the VFD PCB to Its Touch Panel stand offs 8 Properly position the new VFD PCB on the Touch Panel and attach it to Its stand offs 9 Connect the VFD PCB ribbon cable connector to the VFD PCB 10 Connect and install the assembly in the pod 1 1 Plug in the balancer and perform the appropriate functional checks Single Board Computer SBC 3DV 1 Unplug the balancer from the power sourc
41. cable ties of wires Unused terminal terminal P 4 Qe O EAA re Switch 2 on Switch 1 on Schematic Schematic Piezo Wire Heat Shrink Color Codes Left Cable Insulation BLACK Right Front N l Right Rear Cable Insulation J amp Cable Insulation Fach TOP wire RED amp BOTTOM wire BLACK Important Always read and follow the information box instructions e31 Calibration Machine Calibration 4 ounce 100 gram Calibrate the machine only after verifying that the machine is out of calibration as shown by functional checks Of course If you adjust or replace parts like piezos or potentiometers calibration is also necessary 1 Mount a 14 15 or 16 inch steel tire wheel assem bly on the balancer A balanced tire wheel is required Note Position wheel so that no weights on either flange are at the top dead center location Turn the machine OFF then ON 2 Enter DIMS A W and D wheel dimensions 3 Press and hold the SHIFT key and press 1 to select the CAL MACHINE mode 4 Lower the hood and press START 5 After spin raise the hood Rotate wheel until the right plane center bar blinks attach test weight to the outside flange at top dead center 4 ounce 100 grams Aa y i Figure 19 Test Weight On Outside Flange At Top Dead Center 6 Lower the hood and press START Important lt is critical that the inner weight be placed accurately to achieve p
42. calibration In fact the balancer will not permit you to do other wise This is because when you do the 4 ounce calibra tion the balancer actually calculates the A dimension and the W dimension If fact the A and or W dimension displayed may change during calibration The Arm calibration gives the balancer a reference point to the edge of the faceplate and home position When you enter the A dimension from the arm rod it calculates the difference from the 4 ounce calibration A and uses that as a factor for manual A entry Arm calibration also gives the D dimension a reference point trom home position Important Always read and follow the information box instructions Perform the 4 ounce calibration Note A amp D Arm calibration is NOT available to end users and must be accessed with an extended Command Code only published in the service manual 1 Depress and hold the Shift key and depress the number 3 key Cal Arm CdE will appear in the LEFT PLANE weight display 2 Enter Code 96 A brief version of the following calibration steps will now appear in the Information Box 3 Bring the edge of the tip of the arm precisely to the outer edge of the faceplate and hold it there while you depress the Next key It may be necessary to loosen the calibration wheel temporarily to do this depending on the wheel size and configuration 4 With the arm
43. ch Panel ribbon cable connec tor from the back of the Display PCB Y Disconnect the Vacuum Fluorescent Display VFD PCB ribbon cable connector from the back of the Display PCB 8 Use a 1 Phillips screw driver to remove the screws that attach the Display PCB to its Touch Panel stand offs 9 Properly position the new Display PCB on the Touch Panel and attach them to the stand offs 10 Connect the ribbon cable connector from the Touch Panel to the Display PCB 11 Connect the ribbon cable connector from the VFD PCB to the Display PCB 12 Connect and install the assembly in the pod 13 Plug in the balancer and perform the appropriate functional checks Display PCB 3DV 1 Unplug the balancer from the power source 2 Remove the Touch Panel Display Assembly from the Pod See appropriate replacement procedure in this manual 3 Note and mark the location and routing of the cables to the Display PCB 4 Disconnect the cables to Display PCB 5 Remove the piggy back Single Board Computer PCB from the Display PCB See appropriate replace ment procedure in this mz tual 6 Remove the four r ats that attach the PCB to Its standoffs 7 Carefully disconnect the PCB from the direct con nector on the back of the LCD 41 Connector on Mi Display PCB Spacer Connector y E ia e eee on LCD PCB avasit gy MM n a 4 DDN y PNY gt wea ts yt he fas yi CN P AELS we y Alea tie fi Sn
44. chassis support bracket and the back of the hood switch housing because the connector to the Processor PCB is too large to fit through these holes 9 l replacing the cable pull it into the chassis and disconnect it from the Processor PCB 10 After re assembly plug in the balancer 411 Perform the appropriate functional checks Touch Panel 1 Unplug the balancer from the power source 2 Use a 1 Phillips screw driver to remove the four screws and spacer bushings if so equipped on the back of the pod that retain the Touch Panel 3 From the front of the pod carefully pull out the Touch Display Panel assembly 40 o 4 Disconnect the 8 pin phone style connector cable on the back of the Display PCB See illustration in the Reference Materials section of this manual 5 Disconnect the green ground wire from its spade terminal on the back of the Display PCB G Disconnect the Touch Panel ribbon cable connec tor from the back of the Display PCB 7 Use a 1 Phillips screw driver to remove the screws that attach the Display PCB and the Vacuum Fluorescent Display VFD PCB to the Touch Panel stand offs 8 Properly position the Display PCB and VFD PCB on the new Touch Panel and attach them to the stand offs 9 Connect the ribbon cable connector from the Touch Panel to the Display PCB 10 Connect and install the assembly in the pod 1 1 Plug in the balancer and perform the appropriate functional check
45. connect the associated cable from the Sonar Display Power PCB 8 Remove the touch panel assembly 9 Disconnect the associated cable from the display 10 Note the routing and pull the cable into the bal ancer 141 Assemble in reverse order 12 Perform a functional check 39 Sonar Bracket 1 Unplug the balancer from the power source 2 Remove the sonar See appropriate replacement procedure in this manual 3 Remove the two bolts that fasten the sonar bracket to the hood bar A Assemble in reverse order 5 Plug in the balancer 6 Perform a 4 ounce calibration to calibrate the sonar 7 Perform a functional check Safety Guard Hood Switch 1 Unplug the balancer from the power source 2 If replacing the cable remove the Weight Tray and Shield and the Processor PCB Cover See Replacement Procedures section of this manual 3 Remove the safety guard hood assembly See the appropriate section of the Replacement Procedures in this manual 4 Pull off the switch cam cover 5 Note the orientation position of the switches wire terminal connections cable routing and tie downs See appropriate section of Wiring in this manual 6 Use a small flat blade screw driver to carefully pry out the switches 7 Remove the wires from the switches 8 Remove the wire tie downs and pull off the hood switch housing Note The cable must be removed and installed through the
46. d have the operator do a tape a weight balance using the laser for T2 Be sure he understands that the more accurately he matches the arm line laser position to the laser point position the more successful he will be on the check spin Also that the laser must stop blinking before placing the weight at the laser point of light on the wheel 4 Instruct the end user on a behind the spoke 2 balance 5 Instruct the end user on the match mount proce dure G Have the end user do a 4 ounce calibration follow ing the instructions on the display and emphasize how critical correct weight amount amp placement are during calibration and when balancing any wheel Explain why the A amp W dimensions may change slightly during cali bration on this particular balancer 7 Emphasize that the balancer only needs calibra tion If it begins to consistently chase weights It does not need to be calibrated very often 8 Instruct the end user on why proper wheel mounting Is so critical 9 Instruct the end user on all standard and optional accessories shipped with the unit 10 Instruct the end user on proper balancer and adapter maintenance 411 Address specific shop issues that may affect operation of the unit 12 Review all documentation enclosed with the unit Operator s Manual Warranty information etc Important Always read and follow the information box instructions Balancer Description A computerized wheel b
47. e 2 Remove the Touch Panel Display Assembly trom the Pod See appropriate replacement procedure in this manual 3 Carefully disconnect the Single Board Computer from the Display PCB It is a piggy back plug in com ponent MN Connector on SBC PCB A Install in reverse order 5 Perform a functional check DC AC Inverter 3DV 1 Unplug the balancer from the power source Remember the inverter is the component that pro duces 3 000 Volts 2 Remove the Touch Panel Display Assembly trom the Pod See appropriate replacement procedure in this manual 3 Note and mark location and routing of the cables to the inverter PCB To avoid interference it is critical that the 5 wire cable from the Inverter to the Display PCB be routed behind the eee PCB standoff TET iz A Note Cable Routing Under PCB amp Behind Off _ 4 Remove the two Philips head screws that nee the PCB to its standoffs 5 Install in reverse order G Perform a functional check Important Always read and follow the information box instructions LCD 3DV 1 Unplug the balancer from the power source 2 Remove the Touch Panel Display Assembly trom the Pod See appropriate replacement procedure in this manual 3 Remove the DC AC Inverter See appropriate replacement procedure in this manual 4 Remove the Single Board Computer PCB and the Display PCB as an assembly See appropriat
48. e information box instructions Command Codes Cont 45 Dump Event Log Shows data from approximately 50 of the last spins from oldest to newest 1250 Depressing Next gives one at a time advance of these readings and depressing Shift Next goes back one at a time Depressing Start skips forward about 11 readings at a time Depressing Stop Exit or reaching most current spin data exits this mode See Reference Materials section of manual for keys to 1250 3DV data sequences 47 Show Spin Count Cal count amp Displays spin count calibration count amp arm calibration count in Information Box Arm Cal count Upload new firmware Can load new display board firmware versions via a the USB port and a memory stick that was loaded from the HNY Document Library on the internet Cannot use for new processor firmware at this time 52 Show Cal High Speed Shows numbers stored during high speed calibration routine in Information Box 53 Show Cal Low Speed Shows numbers stored during low speed calibration routine in Information Box 4 Show last piezo values Raw reading from piezos Use to check for bad piezo if piezos are wired correctly and value from last spin peak magnitude and phase 55___ Show Arm Cal 61 Scroll VFD or LCD brightness Allows cycling through brightness levels on VFD display 1250 or LCD display on 3DV 65 Set Admin Access PASSWORD is 69 Allows access to restricted extended command codes highlighted in gray Ex
49. e install setup and initial test proce dures on this 1250 balancer e Read the Operating Manual for this unit e Be sure you completely understand and comply with all of the Receiving Installation Set Up Connecting to Power and Initial Testing instruc tions e Be sure to perform the Preliminary Inspection and Operational Check described in this manual elf necessary perform any functional checks required Floor and Space Requirements e The balancer must be located on a flat floor of solid construction preferably concrete e The balancer must sit solidly on its 3 feet e f the balancer is not level does not sit solidly on its 3 feet or is placed on an unstable floor the bal ancer will not function properly and will produce inaccurate balance readings e The balancer is not designed to be bolted down nor will it function properly if left on the pallet e Select a location for the balancer that provides a level solid floor and adequate clearance around and above the balancer JR 5 Ft _____ gt 6 5 Ft e Make sure the location selected has enough room above and behind the unit so the hood can be raised completely e The location must also provide working room tor mounting and removing wheels Important Always read and follow the information box instructions Unpack and Setup 4 Install the hood assembly into the hood bracket 4 Inspect the carton and p
50. e piezo spring assemblies 4 Measure each spring height and use a 9 16th inch wrench socket to tighten or loosen the Nyloc retaining nut to achieve the above dimensional requirement 5 Assemble the balancer 6 Perform the 4 ounce calibration procedure for welght amount and location Potentiometers The potentiometers are adjusted to have the correct base value when the arm Is in the home position This will prevent them trom over rotating crossing their zero point during normal usage of the arm Each potentiometer should display a value trom 0 40 through 0 70 in Its weight display when the arm Is in the home position 1 Remove the Weight Tray and Shield See appropri ate Replacement Procedures section in this man ual Important Always read and follow the information box instructions 2 Depress Shift 0 then enter code 19 to bypass A ounce calibration and access the A amp D arm calibra tion 3 Depress and hold the Shift key while you depress the number 3 key Cal Arm 4 Depress 96 5 Do not perform the calibration 6 The LEFT PLANE Weight display now shows volt ages for the A offset potentiometer and the RIGHT PLANE Weight display shows voltages for the D diameter potentiometer D Dimension Potentiometer 1 Use a 3 mm Allen wrench to slightly loosen the set screw that secures the potentiometer shaft in the rod 2 With the arm in home position
51. e replace ment procedures in this manual 5 Disconnect the cables to the LCD Short o Spacer a GD Fa Connector on MA Display PCB Connector A a cti on LCD PCB Op 083 2 082 BD DURCAL UE URRACA cra i 7 MIMIIARA MA 9Z 822290 o gosean 8907279 W x NS poros a O n y VA E aa AA POISIZIO aja i j y K 4e 4 ma i G Remove the four nuts that retain the LCD to its stand offs Remove the LCD 7 Assemble in reverse order 8 Perform a functional check Laser Use of controls adjustments or perform ance of procedures other than those speci fied herein may result in hazardous radiation exposure 1 Unplug the balancer from the power source 2 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 3 Remove the Processor PCB Cover See Replacement Procedures section of this manual 4 Unplug the laser cable connector from the Processor PCB See appropriate illustration in the Wiring section of this manual Note The routing of the laser cable and the tie down points for installation 5 Remove the cable from the balancer chassis 6 l removing the entire assembly use a 1 4 inch Allen wrench to remove the 2 cap screws that hold the laser bracket to the front end bell of the motor Important Always read and follow the information box instructions 7 l only replacing the cylindrical laser housing ass
52. e the Weight Tray and Shield See Replacement Procedures section of this manual 9 Remove the Processor PCB Cover See Replacement Procedures section of this manual Important Always read and follow the information box instructions 10 Plug in the balancer and turn the power switch on 11 Check test point 116 as described in the Processor PCB Test Points table and illustration in the Wiring section of this manual 42 Check the encoder connectors and wires 13 Check to be sure the encoder disc is secured to its shaft and clean 14 f the all of the above are good replace the encoder Remember they are replaced as a set with cable on this unit See necessary Replacement Procedures sections of this manual and the neces sary Adjustments section of this manual Safety Guard Hood Switches 1 Verify that the power source is good as described in the Preliminary Inspection section of this manual 2 Verify that the Power Cord and Plug are good as described in the Power Signal Systems Checks sec tion of this manual 3 Verify that the Power PCB is good as described in the Power Signal Systems Checks section of this manual 4 Verify that the On Off Switch is good as described in the Power Signal Systems Checks section of this manual 5 Verify that the Processor PCB is good as described in the Power Signal Systems Checks sec tion of this manual 6
53. eadings should stay within plus or minus 0 10 ounces of its original reading If not per form the piezo check Calibration Checks Calibration checks are used to verify that the balancer is calibrated 4 ounce Amount amp Location Accuracy Check A Balance a hub centric steel wheel to 0 03 ounces or lower per side in the fine balance non round off mode 2 Place a 4 ounce weight on the outside wheel flange 3 Cycle the balancer 4 Readings should be LEFT PLANE 0 00 plus or minus 0 12 ounces RIGHT PLANE 4 00 plus or minus 0 12 ounces RIGHT POSITION FLASHING 4 00 ounce weight at Bottom Dead Center plus or minus 0 50 inches 5 Move the 4 00 ounce weight to the inside wheel flange 6 Cycle the balancer Y Readings should be RIGHT PLANE 0 00 plus or minus 0 12 ounces LEFT PLANE 4 00 plus or minus 0 12 ounces LEFT POSITION FLASHING 4 00 ounce weight at Bottom Dead Center plus or minus 0 50 inches 9 8 l above parameters are not met perform a 4 ounce 100 gram calibration See Operator s Manual Calibration Section in this manual or use Instructions on display A 8 D Dimensions 1 louch the A amp D arm to the rim at the clip on weight location C1 2 Note the dimensions on the display 3 Verify the dimensions by reading the A dimension on the gauge rod scale and the D dimension on the tire sidewall 4 l automatic A dimension is not plus or minus 0 2 of the scale
54. ecks described in this man ual These procedures used in conjunction with the material found in the Reference section of this man ual will isolate the necessary adjustment or replace ment Perform checks exactly as specified Refer to the Parts Identification manual Parts List for this unit for parts identification and assembly structure Some standard commercial fittings and fasteners are used in this unit and can be obtained locally if necessary Power System Plug 1 Unplug the balancer from the power source 2 Loosen or remove the fasteners that join the 2 parts of the plug 3 Note which wires are used and their locations 4 Remove the wires from their terminals 5 Remove the power cord from the plug 6 Insert the power cord into the new plug part 7 Connect the wires to their terminals 8 Join the 2 plug parts and tighten the fasteners 9 Plug in the balancer and functional test Power Cord 1 Unplug the balancer from the power source 2 Loosen or remove the fasteners that join the 2 parts of the plug 3 Note which wires are used and their locations 4 Remove the wires from their terminals 5 Remove the power cord from the plug 6 Remove the Weight Tray and Shield See appropri ate Replacement Procedures section in this man ual 7 Disconnect the power cord wires trom the Power PCB and the Chassis Ground Refer to the appropriate Wiring section in this manual 8 No
55. ect the motor wires from the power board PCB motor plug wires See illustration in the Wiring section of this manual 9 Lift out the motor assembly 10 Position the motor on its side or back and remove the four 4 3 8 16 washer head screws hold ing the flex plate to the motor 11 Remove the flex plate 12 Remove the four 4 3 8 16 washer head screws holding the cradle to the motor 13 Remove the cradle trom the motor 14 Apply Loctite 242 to the threads of the 3 8 16 washer head screws and install the cradle on the new motor 15 Clean and apply Loctite to the surface of the flex plate and the cradle where they mate 16 Apply Loctite 242 to the threads of the 3 8 16 washer head screws and install the flex plate on the cradle 17 Ensure balls are inserted into each piezo assem bly Note Current piezos have the ball molded into the top casting 18 Install motor 19 Install 5 16 18 X 1 washer head screws holding flex plate to chassis 20 Install piezo springs piezo retainers and 3 8 16 Nyloc nuts 21 Tighten the Nyloc nuts until the distance trom the top of the motor cradle to top of the piezo spring retainer is two 2 inches 22 Connect fan motor plug 23 Connect optical encoder plug 24 Connect the motor wires to the wires coming from the motor connector on the Power PCB See illustration in Wiring section of this manual 25 Install motor cover shield motor co
56. embly use a 1 8 inch Allen wrench to loosen the set screw in the housing assembly that retains the knob dowel 8 Pull the knob and dowel from the housing 9 Use a 3 16 inch Allen wrench to loosen the set screw in the bottom of the laser bracket enough to remove the housing Be careful to capture the 1 4 inch ball that the bottom of the housing pivots on and the plastic washer at the top as you remove the laser housing from the bracket 10 Back the bottom set screw down enough to hold the 1 4 inch ball in place and install the ball 411 Install the laser housing and with the plastic washer on top and the cable to the back side of the balancer 42 Install the knob and dowel 13 Adjust the rotational force required to turn the laser housing as described in the Adjustments sec tion of this manual 14 Route the laser cable to the Processor PCB with appropriate tie downs and plug in the connector 15 Install the Processor PCB Cover Weight Tray Shield and Weight Tray 16 Plug in the balancer 47 Perform a functional check on the laser and adjust the focus if necessary Battery On Line Laser A Use a flat blade screw driver inbetween the end of the laser and the plastic rod to help slide the line laser out of Its housing 2 Unscrew the end cap from the line laser 3 Remove the two old button cell batteries 4 Replace with two new 1 5 Volt LR44 L1154 but ton cell batteries negative pole
57. essor PCB in this manual Safety Guard Hood Switches and See Powe System Signal Checks for Repair or replace Saftey Guard cable Safety Guard Hood in this manual Hood switches Motor connections amp wires Repair or replace faulty component Motor in this manual Capacitor in this manual Power PCB in this manual Processor PCB in this manual Optical Encoder See Optical Encoder Check in this manual Error Codes 250 Error Codes ode h SPIN UP IS TOO SLOW Verify power supply to balancer amp power connection SPIN UP TIME TOO LONG Check wheel diameter and power supply Depress Stop Exit NO ROTATION SIGNAL Check motor Power PCB encoder amp wiring probably encoder if balancer spins probably power PCB if does not spin Depress Stop Exit WHEEL ROTATION DIRECTION IS REVERSED Disconnect power amp correct wiring STOP TIME TOO LONG Verify power supply amp motor connection Depress Stop Exit ENCODER IS NOT CONNECTED OR HAS FAILED Test for encoder prescence Disconnect power supply and repair or replace WHEEL COAST SPEED IS TOO SLOW Light tire or mechanical problem in motor bearings CORRECT SEQUENCE NOT FOLLOWED DURING ARM CALIBRATION Recalibration required EEPROM READ ERROR 24 LOWER HOOD TO SPIN LOOSE HUB NUT Tighten hub nut and spin 26 CAL ERROR Repeat 4 ounce calibration 27 UNDEFINED 3 Pm a E10 23 N a 1250 Processor PCB Compatibility Matrix 12
58. faulty component Repair or replace faulty component Repair or replace faulty component Repair or replace faulty component Repair or replace faulty component Perform Functional Checks Check Processor PCB OK Check Safety Guard Hood Switches and cable OK BAD Motor connections amp wires OK Check Motor OK Check Capacitor 220 Volt single phase 220 Important Always read and follow the information box instructions Balancer Will Not Brake Refer to the Power Signal System Checks Wiring amp Failure Mode Table sections in this manual BAD Check Processor PCB for Brake Signal Repair or replace faulty component Check Optical Encoder Repair or replace faulty component OK BAD Power PCB Repair or replace faulty component Perform Functional Checks Balancer Does Not Light Up Refer to the Power Signal System Checks Wiring 8 Failure Mode Table sections in this manual Is Balancer Plugged In Plug in balancer YES NO Is Power Source Good Have end user repair power source Repair or replace faulty component Repair or replace faulty component Repair or replace faulty component BAD Check All Connectors amp Cables Repair or replace faulty component BAD Check Plug and Power Cord m 109 Check Motor Protection Relay Check On Off Switch BAD Check Power PCB Repair or replace faulty component BAD Rep
59. follow the information box instructions o 27 Processor PCB Connectors Power PCB AC Power In s gt Touch Display Panel Currently A ro E AA Not Used jde Tr aw i IO 1 Controls gt Signal Out Safety Interlock Hood Switch 1717 aa i Optical Encoder i x i R i Ta gt a 4 h Y Titiite as ya 44 ay bs aid gt J Sonar 3DV ye M p ala a a TE Y e rr irnos o q an 4 iy p f f d a ay suse es Laser Ab i e p n eno f j a ae m A A 5N s y e zi 5 w gt a s w age E fe Sr y qe Pa R g 512 5 E 5 all E A resi a hai H utut n s i a y Y Y ar J fi 1 d AA AAA e eTA 2 4 E Ie yj w s y f e A i 9 we oe gt D i E z a y mk REN mes a a freee ebebeds amp 5 S8eeeeen6 re Ve ie re eontlometels 7 AITEITE TT Eii Power PCB Test Points amp Connectors 28 Power out to Processor PCB amp control Kot signals in from Processor PCB Power through Power Switch and power out to Fan Power through Power Switch and power out to Fan Capacitor in replaced with jumper on 3 phase units Chassis Ground Integral Transformer Power cord in Green wire to chassis ground amp white wire not used in single phase units On 3 Phase units white wire from power cord goes to this
60. for not less than four 4 turns and the hub nut is firmly tightened before spinning the wheel Read and understand this manual before operat ing Abuse and misuse will shorten the functional life Be sure the balancer is properly connected to the power supply and electrically grounded Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged until it has been examined and repaired by a quali fied serviceman Do not let cord hang over edge of table bench or counter or come in contact with hot manifolds or moving fan blades If an extension cord is necessary a cord with a cur rent rating equal to or more than that of the equip ment 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 Keep guards and safety features in place and in working order 10 11 12 13 14 TD 16 17 18 19 20 21 22 23 Wear proper clothing Safety toe non slip footwear and protective hair covering to contain hair is recommended Do not wear jewelry loose clothing neckties or gloves when operating the balancer Keep work area clean and well lighted Cluttered and or dark areas invite accidents Avoid dangerous environments Do not use power tools or electrical equipment in damp or wet loca tions or expose them to rain Avoid unintentional starti
61. ft 0 25 to turn it off If the fan does not run as described above 1 Verify that the power source is good as described in the Preliminary Inspection section of this manual 2 Verify that the Power Cord and Plug are good as described in the Power Signal Systems Checks sec tion of this manual 3 Verify that the Power PCB is good as described in the Power Signal Systems Checks section of this manual 4 Verify that the On Off Switch is good as described in the Power Signal Systems Checks section of this manual 77 5 Verify that the Processor PCB is good as described in the Power Signal Systems Checks sec tion of this manual 6 Unplug the balancer from the power source 7 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 8 Remove the Processor PCB Cover See Replacement Procedures section of this manual 9 Check the connector and wires from the Power PCB to the fan 10 if all of the above are good replace the fan See necessary Replacement Procedures sections of this manual Motor 4 Verify that the power source is good as described in the Preliminary Inspection section of this manual 2 Verify that the Power Cord and Plug are good as described in the Power Signal Systems Checks sec tion of this manual 3 Verify that the Power PCB is good as described in the Power Signal Systems Checks
62. good as described in the Power Signal Systems Checks sec tion of this manual The voltage check in this verifica tion assures power is flowing to the Power PCB 3 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 4 Remember that power is still flowing to Power PCB and On Off Switch when the balancer is plugged in Even if the power switch is in the off position 5 Use a Volt Ohm meter to perform all of the power out and fuse checks as described in the Power PCB Test Points and Connectors table and illustration in the Wiring section of this manual Important Always read and follow the information box instructions 6 lf any of required voltages are not found or if fuses are blown no continuity replace Power PCB See Replacement Procedures section of this manual Sonar LCD Power PCB 3DV Power System Signal Check Verify that the power source is good as described in the Preliminary Inspection section of this manual Verify that the Power Cord and Plug are good as described in the Power Signal Systems Checks sec tion of this manual The voltage check in this veritica tion assures power is flowing to the Power PCB Remove the Weight Tray and Shield See the Replacement Procedures section of this manual Remember that power is still flowing to the Power PCB and the On Off Switch when the balancer is plugged in Even if the po
63. good as described in the Power Signal Systems Checks section of this manual 5 Verify that the On Off Switch is good as described in the Power Signal Systems Checks section of this manual G Verify that the Processor PCB is good as described in the Power Signal Systems Checks sec tion of this manual 7 Unplug the balancer from the power source 8 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 9 Remove the Processor PCB Cover See Replacement Procedures section of this manual 10 Plug in the balancer and turn the power switch on 11 Check test points 111 112 4 113 as described in the Processor PCB Test Points table and illustration in the Wiring section of this manual 112 If any of the required voltages are not present inspect the piezo connector and wiring 13 l good replace the piezos See necessary Replacement Procedures sections of this manual Important Always read and follow the information box instructions Potentiometers A Perform the functional check described in this manual 2 Verify that the power source is good as described in the Preliminary Inspection section of this manual 3 Verify that the Power Cord and Plug are good as described in the Power Signal Systems Checks sec tion of this manual 4 Verify that the Power PCB is good as described in the Power Signal Systems Checks
64. he front of the pod carefully pull out the Touch Display Panel assembly 4 Disconnect the 8 pin phone style connector cable on the back of the Display PCB See illustration in the Reference Materials section of this manual 5 Disconnect the green ground wire from its spade terminal on the back of the Display PCB G Set aside the Touch Display Panel assembly Y Loosen the four 3 8 inch carriage bolts that secure the pod mounting brackets and pod to the pod support tube and slide the pod assembly off the tube 8 Remove the rear harness cover from the chassis 9 Pull the 8 pin phone connector cable and the green ground wire out of the bottom of the pod sup port tube 10 Use a 3 8 inch wrench socket to loosen the four Nyloc u bolt nuts that retain the support tube to the chassis support bracket 11 Lift the pod support tube out of the u bolts and support bracket 12 Slide the convoluted boot off of the tube 13 Install in reverse order 14 Plug in the balancer 15 Perform the appropriate functional checks e 45 8113830 02 07 07 O Copyright 2005 Hennessy Industries and COATS All Rights Reserved Printed in USA
65. ication Test s Solution s Failure Modes Possible Cause s Verification Test s Solution s 20 o Does not light up Chases Weights Does not return Zeros on check spin Will Not Spin assuming balancer liahts up Will Not Brake Important Always read and follow the information box instructions Balancer is not plugged in Check if balancer is plugged in Plug in balancer Power Source Breaker is open Check breaker Reset breaker Outlet Use Volt Ohm Meter to check outlet Have end user get outlet repaired Check for correct wiring loose Repair or replace plug connection continuity Power Cord Check for correct wiring loose Repair or replace cord connection continuity Motor Protection Relay ___ _________________ SeePower System Signal Checks connection continuity or replace connector Power PCB in this manual Processor PCB in this manual Display Panel PCB See Power System Signal Checks for Replace Display Panel PCB Display Panel PCB in this manual Vacuum Fluorescent Display PCB See Power System Signal Checks for Replace Vacuum Fluorescent Vacuum Fluorescent Display PCB in Display PCB this manual Technician is not positioning weights Watch technician balance several Train technician ee AA Not calibrated See Calibration Checks in this manual Calibrate balancer Amount Position amp Arm See Piezo Checks in this manual Adjust or replace piezos manual manual Power PCB in this manual Proc
66. inward positive pole outward 5 Install the end cap 6 Slide the laser back into the housing Be sure the on off push button is oriented correctly in the open slot and that the laser beam aperture Is pointing at the plas tic rod in the bottom of the slot o 43 Line Laser Housing A Remove the Allen head screw BN that retains the EM housing to the arm ey 2 Be sure to cap ture the tensioning spring under the head of the Allen screw 3 When installing the housing be 7 sure that the ten sion on the retaining screw is sufficient 4 to allow the housing f A to pivot but with B77 72a some resistance Wheel Mounting amp Drive System Motor Assembly Hennessy has a service motor kit for the 1250 Balancer The kit will be a complete motor assembly motor 220V fan optical encoder rotary shutter Refer to the Motor Service Kit instructions for additional information 1 Unplug the balancer 2 Remove A amp D Arm from rod 3 Remove weight tray weight tray shield motor cover motor cover gasket and motor cover shield 4 Remove the laser assembly by removing the two 1 4 inch Allen screws that retain the laser bracket to the front of the motor 5 Remove the four 4 3 8 16 Nyloc spring retain ing nuts spring retainers and piezo springs G Remove the two 2 5 16 18 X1 washer head screws 7 Disconnect the fan motor and optical encoder plugs 8 Disconn
67. iometers are func tioning properly 10 Depress the Stop End key to exit this mode without performing an Arm calibration 11 if the readings are present but do not act as described above perform a physical inspection of the potentiometers to be sure they are not loose or dam aged and that their wiring and connections are good It they are loose refer to the Potentiometer Adjustments section in this manual 112 f there is no voltage reading in either of the dis plays perform a physical inspection as described above and then perform the checks described in the appropriate section of Power Signal Systems Checks in this manual Important Always read and follow the information box instructions Piezo Check This check is to verify consistency of piezo outputs 4 Mount a balanced steel test wheel on the bal ancer and enter the dimensions 2 Attach a 4 ounce weight on the wheel s outer rim 3 Cycle the balancer 4 Depress and hold the Shift key then depress the 0 key CdE appears in the LEFT PLANE welght display 5 Depress the 5 key then the 4 key Code 54 54 appears in the RIGHT PLANE weight display 6 Write down the values in the Information Box for L Mag and for L Angle 7 Depress the Next key and write down the val ues for RFMag and for RFAngle 8 Depress the Next key and write down the val ues for RRM
68. ite Black Black wires go to p 4 Black LI 12 copper contacts Motor Protection Module 8113101 8114208 and 85000305 are needed if unit has Video OR Sonar a 8114200 116 85000115 85000308 85000305 8500264 85000307 WG unless otherwise specified itle lt Title gt Size Document Number Rev e lt Doc gt lt RevoHe gt Date Monday May 14 2007 Sheet 1 of 1 2 1 Important Always read and follow the information box instructions e25 Processor PCB Test Points E na ea Processor PCB Test Points o a aay P Fe 13 sarees Gian 11 11 46 000000000004 y VIARIA TF 2000000000000 Note Processor PCB revision H and backward will only drive 1250s Revision and forward will drive both 1250 and 1250 3DV 26 Important Always read and follow the information box instructions 1250 Processor PCB Test Points Key points on the permanent damage to the board est Point Label V O Meter V O Meter on Processor Red Lead Black Lead i PCB Location Location Test Point Voltage Test Description T1 T2 Power supply from power PCB if no voltage present check power PCB amp cable Processor PCB voltages if no voltage present check power PCB Processor PCB voltages if no voltage present check power PCB Processor PCB voltages if no voltage present check power PCB tt 82 OO O O aa a7 oa oat a T 3 0 at 49 o 2 sa
69. ith the pin on the hood the unit may cause personal injury or equip stop bracket ment damage 11 Hook the other end of the spring over the pin in Safety Guard Hood Installation the rear of the hood stop bracket Make sure the spring 1 Locate the hood assembly hardware and hood fits into the groove in the pin spring 2 Locate the hood assembly 3 Slide one hood bar washer and one flanged bear ing onto the stationary hood bar flange to cam Hood fy O Bracket lee ey Stationary Hood Bar ITEM DESCRIPTION 8109944 Hood Bar Washer 8307014 Flanged Nylon Bearing 8113332 Hood Switch Cam Cover 8113334 Limit Switch 8113333 Hood Switch Housing 8109945 1 1 2 Retainer Washer 8109949 Hood Bar Cap YN 0 0d S ON gt Important Always read and follow the information box instructions 3 Sonar Width Installation 1 Install hood assembly onto the balancer 2 Next remove hood from the hood bar 3 Uncoil sonar cable located at back of balancer 4 Now slice an X in the end cap see below Slice End Cap To Route Cable 5 Route cable through hood bar to sonar location 6 Remove sonar and bracket from tem plate Y Install sonar bracket on hood bar with hardware provided 8 Attach cable to sonar Sonar N Bracket PR MKC A 4 4 o 9 Mount sonar in bracket aligning cable to hole hood bar N
70. le deviation is plus and minus 10 damage can occur when voltage or amperage Is beyond 10 design specs Note f any faults are found in the above procedure it is the responsibility of the owner COATS authorized service personnel are not responsible for wiring within the building Consult a licensed electrical contractor for proper installation to local electrical codes Power out lets must be enclosed in a floor raceway or overhead drop if pedestrian or equipment traffic can damage power cord 2 Plug the balancer into its power source Use an ohmmeter to check the resistance between the frame of the Balancer and the building ground The resistance should be less than 1 ohm If the resistance measure ment is greater that one 1 ohm check the power plug and frame connection for proper contact Operation with a defective ground circuit will create a shock hazard for the operator and could damage the balance s electron ics Operation with a defective ground cir cuit may void warranty 3 Ihe Balancer should sit on all three 3 legs Make sure the legs have not filled with dirt wheel weights or other foreign matter that may prevent a leg from making contact with the floor Important Always read and follow the information box instructions GROUND X Y RED THREE PHASE VOLTAGE REQUIREMENTS INFORMATION 208v 220vi230v___ 380v_ 460v A Xz 195 250 370 420 420 480 Plug Installed Hubbell 2421 Hubbe
71. lity Matrix 21 1250 Spin History Data Key suicidas 21 3DV Spin History Data Key 21 Important Always read and follow the information box instructions Diagnostic Flow Charts 22 23 Balancer Chases Weights Does not return zero on check spin 22 Balancer Will Not Spin Does Light Up 22 Balancer Will Not Brake 23 Balancer Does Not Light Up 23 WINING ius 24 31 Schematic Diagram Power amp SINFO A arp dre eats 24 25 Processor PCB Test Points 26 27 Processor PCB Connectors 5 28 Power PCB Test Points amp Connectors 28 29 POVVER PANG sa isa Be ies ee tte te Golesi node Peat did 29 1250 Touch Display Panels esoo iia 30 1250 3DV Touch Display Panel 30 Power PCB to Motor Connections 30 Safety Guard Hood Switch Connections 31 Piezo Wire Heat Shrink Color Codes 31 Calibration 000o0oo0 lt lt 32 33 Machine Calibration sas ceca papu bid a 32 Sonar SDV Calibration 24 4 242405 acta dada ees 32 Laser Dot Calibration cccvar saciar 32 ACD AIM rr eA 32 33 Adjustments 0 0ccooocooo o 33 35 KASEI A cetera teats amp dota i a a on Act i 33 34 LIME NOSE seso ito dr deve eh does 34 Display Pod Touch Panel Display 34 VEDSOr ECD ASIDV BIiOnin SS 2 2 vases aaa 34 FOd
72. ll 2431 GROUND A B GREEN RED BLACK SINGLE PHASE VOLTAGE REQUIREMENTS INFORMATION 208V 220V 230V 195 250 A B Plug NEMA Installed L6 20P 4 The floor should be a solid flat surface that does not allow the balancer legs to set into a recess in the floor or sink into the floor itself 5 Inspect cones hub nut pressure cup s and threaded stud for damage Missing cones or acces sories should be replaced Functional Checks Functional checks are used to determine if the bal ances components are adjusted calibrated and or functioning correctly They should not be performed until AFTER the preliminary inspection has been com pleted Operation Check A Mount a Test Wheel on the balancer 2 With the balancer set up to do a two clip on weight dynamic balance Clip 1 amp Clip 2 weight locations proceed to balance the wheel 3 If the wheel does not zero on the check spin in round off mode proceed to do a repeatability check and a calibration check Repeatability Check 1 Put the balancer in non round off fine mode 2 Cycle the balancer 3 Note the readings for each plane 4 Cycle the balancer five 5 more times and note the readings after each cycle Important Always read and follow the information box instructions Required Hubbell 2420 or Hubbell 2430 or Mating Outlet Equivalent Equivalent Required NEMA Mating Outlet L6 20R 5 Each planes r
73. ls The Processor PCB supplies power to other components like the Display PCB The Processor PCB has its own integral rectifier to convert the AC voltage to DC voltage for those components that require direct current 05 Input System The input system supplies the required information to the processor that is needed to calculate the correct weight amounts and locations to display tor wheel bal ancing It also supplies the information to select the options for the displays In addition it supplies the sig nals for the safety interlock and to start and stop the balancing cycle Touch Panel The Touch Panel is equipped with pressure sensitive switches that allow manual input of wheel dimensions and selection of desired functions Optical Encoder The optical encoder delivers signals to the processor that provide rotational information From these signals the processor can calculate rotational soeed and wheel locations It consists of a rotary shutter attached to the motor shaft with 64 open windows that allow an opti cal signal through with a single window at a different diameter on the wheel that identifies a complete revo lution 360 degrees The processor calculates 256 positions including zero for the wheel This results in very accurate weight placement of 1 4 degrees of res olution A amp D Potentiometers There are two potentiometers connected to the A amp D arm When the arm is pulled out in the Distance plane the
74. ng Be sure the balancer is turned off and power disconnected before serv ICING Disconnect the balancer before servicing Use only manufacturer s recommended acces sories Improper accessories may result in per sonal Injury or property damage Repair or replace any part that is damaged or worn and that may cause unsafe balancer operation Do not operate damaged equipment until it has been examined by a qualified service technician Never overload or stand on the weight tray or any part of the balancer Do not allow untrained persons to operate machin ery To reduce the risk of fire do not operate equip ment in the vicinity of open containers or flamma ble liquids gasoline Adequate ventilation should be provided when working on or operating internal combustion engines Keep hair loose clothing fingers and all parts of body away from moving parts Use equipment only as described in this manual Use only manufacturer s recommended attach ments and accessories SAVE THESE INSTRUCTIONS Important Always read and follow the information box instructions Owner s Responsibility To maintain machine and user safety the responsibil ity of the owner is to read and follow these instruc tions e Follow all installation instructions e Make sure installation conforms to all applicable Local State and Federal Codes Rules and Regulations such as State and Federal OSHA Regulations and Electrical Codes
75. nnessy Drive LaVergne IN 37086 3565 615 641 7533 or 800 688 6359 www ammcoats com The motor unit of this machine contains a Class llla laser with a maximum output less than bmW at a wave length of 650 670 nm Avoid Exposure Laser radia tion is emitted from its aperture Use of controls adjustments or perform ance of procedures other than those speci fied herein may result in hazardous radiation exposure In case of failure the entire motor unit must be replaced LASER RADIATION Avoid Direct Eye Exposure Max Output Less Than 5mW Wave Length 650 670 nm 8113892 03 Class Illa Laser Product This product incorporating a laser has been tested to the requirements of CDRH 21CFR and complies with standards 21CFR1040 10 and 21CFR1040 11 Hennessy Industries Inc Manufactured 1601 J P Hennessy Drive LaVergne TN 37086 8113909 01 LISTED GARAGE C UL US equipment 7812 8111519 04 Important Always read and follow the on screen operating instructions Risk of Injury This machine is provided with a wheel guard interlock Do not defeat it s purpose 8111840 02 Maximum Size of Wheel Rating Weight Diameter Width 160 lbs 44in 20 in Maximum Duty Cycle 30 Wheels Hour 160 Ibs 8113570 01 RISK OF EXPLOSION This equipment has internal arcing or sparking parts which should not be exposed to flammable vapors Do not locate in a recessed area
76. nual 5 Unplug the balancer from the power source G Remove the Weight Tray and Shield See Replacement Procedures section of this manual 7 Remove the Processor PCB Cover See Replacement Procedures section of this manual 8 Plug in the balancer and turn the power switch on 9 Check test points 11 amp 12 as described in the Processor PCB Test Points table and illustration in the Wiring section of this manual 10 if 11 and T2 fail unplug the balancer then remove and check the power supply cable to the con nector between 11 and T 2 for continuity 11 f the cable fails the continuity test replace the cable 14 0 12 Plug in the balancer and turn the power switch on 13 Mount a test wheel on the balancer enter the dimensions and cycle it once 14 Use a Volt Ohm meter to check test points T3 through T8 as described in the Processor PCB Test Points table and illustration in the Wiring section of this manual 15 l any of the test points fail replace the Processor PCB See Replacement Procedures sec tion of this manual Piezos A Perform the functional check described in this manual 2 Verify that the power source is good as described in the Preliminary Inspection section of this manual 3 Verify that the Power Cord and Plug are good as described in the Power Signal Systems Checks sec tion of this manual 4 Verify that the Power PCB is
77. nurled knob on the laser assembly to position the dot on the interior of the test wheel if it is not already there The laser dot should be in focus 3 It will be blinking if the Right Plane weight posi tion is other than 12 00 When the Right Plane weight position Is precisely at 12 00 the laser will stop blinking and have a steady dot 4 if the Laser does not come on perform a physical inspection of the Laser wiring and connections and then perform the checks described in the appropriate section of Power Signal Systems Checks in this manual 5 l the Laser is not in focus perform the proce dures described in the appropriate section of Adjustments in this manual Sonar Check 3DV Functional Check With a test wheel mounted on the balancer start a new balancing cycle by using the A amp D arm to enter its dimensions Close the hood to start a spin cycle The W dimension should appear on the display If not perform a physical inspection of the Sonar components If no fault is found then perform the procedures described in the appropriate section of Power Signal system Checks in this manual If necessary refer to the 3DV schematic in the reference section of this manual Important Always read and follow the information box instructions Power Signal Systems Checks Always perform the related Functional Check before performing the Power Signal System Check
78. nut and washer G Remove the A potentiometer bracket from the housing 7 Remove the A potentiometer from its bracket 8 Remove the 3 mm cap screw and washer that retains the string bracket on the back end of the A amp D rod It may be necessary to remove the arm to allow the rod further back for access 9 Use a 3mm Allen wrench to loosen the set screw that retains the D potentiometer shaft in the end of the A amp D rod and remove the potentiometer and A amp D pendulum assembly 10 Remove the nut and washer from the D poten tiometer 11 Remove the cable ties and then remove the pendulum 42 Install in reverse order Important During installation pay close attention to the routing of the cables and their tie down points as well as the string routing and seating on the A pulley Be sure the slot on the bottom of the A amp D pendulum engages the bottom lip of the housing 13 Plug in the balancer and perform an A amp D potentiometer adjustment procedure Refer to the Adjustments section of this manual 14 Unplug the balancer 15 Install the Processor PCB cover and the weight tray and shield 16 Plug in the balancer 17 Perform Functional Checks 18 Perform an A amp D arm calibration Refer to the Calibration section of this manual o 37 Rod Tube 8 Bushings 1 Unplug the balancer from the power source 2 Remove the Weight Tray and Shield See Replacement Procedure
79. o the appropriate illustration in the Wiring section of this manual Remove the A amp D arm from the A amp D rod 5 Remove the motor cover fasteners and pull the motor cover gasket and shield away from the side of the balancer This will allow space to remove the A amp D Arm assembly later 6 Use a 7 16 inch wrench to remove the 3 nuts that fasten the assembly to its chassis member Y lo remove the assembly hold the motor cover and shield out of the way as you lift upward and pull rear ward on the assembly to slide the A amp D tube out of the chassis cutout 8 Install in reverse order 9 Plug in the balancer 10 Perform required Functional Checks Important Always read and follow the information box instructions Potentiometers Note Potentiometers are replaced in sets with cable on the 1250 1 Unplug the balancer from the power source 2 Remove the Weight Tray and Shield See Replacement Procedures section of this manual Note The routing and the tie down points and dis connect the potentiometer cable trom the Processor PCB Refer to the appropriate illustration in the Wiring section of this manual 3 Remove the spring from the edge of the A amp D arm housing to release the tension on the string A Use a 2mm Allen wrench to loosen the set screw in the A pulley and remove the pulley from the poten tiometer shaft 5 Remove the A potentiometer retaining
80. oes not have to be bolted to the floor Important Always read and follow the information box instructions 3DV Differences 3DV Unique Functionality Auto Width Entry The main functional difference between the 1250 and the 1250 3DV is the use of a hood mounted sonar unit for auto matic width entry When the C2 weight location Is selected and after entering A amp D dimensions when the hood is lowered the sonar reading Is used to calculate W dimension Reflector The W dimension will not be calculated again until the C2 location is exited and chosen again or the A amp D dimensions are re entered In other words the W dimension is not calculated every time the hood is lowered For diagnostic purposes you can use Command Code 75 to toggle between normal operation and width sonar calculations every time the hood is closed Sonar Calibration The width sonar is self calibrating and calibration is performed every time a 4 ounce calibration is per formed Remember that the balancer s computer cal culates the true A dimension during the 4 ounce calibration If a sonar unit is replaced a 4 ounce calibration must be performed before balancer is returned to service If automatic width readings are inaccurate perform a 4 ounce calibration and then an A amp D Arm calibration This assumes all the components involved are good 3DV Unique Components Width Sonar The width sonar mounted to the hood bar
81. onnect plug to capacitor assembly trom Power PCB 4 Remove four 4 6 32 X 1 2 screws holding capacitor panel to chassis 5 Install new capacitor assembly 6 Connect plug Y install weight tray weight tray shield and plug in balancer 8 Perform Preliminary Inspection amp Functional Checks Capacitor 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Disconnect plug to capacitor assembly 4 Remove three 3 6 32 X 1 2 screws holding capacitor clamps to capacitor panel and remove capac itor clamps Important Always read and follow the information box instructions 5 Remove capacitors Note wire locations discon nect wires from capacitors and transter wires to new capacitors Note Only one capacitor should have a resistor con nected across its terminals If both new capacitors have resistors cut one out 6 Install capacitors 7 Connect plug 8 Install weight tray weight tray shield and plug in balancer 9 Perform Preliminary Inspection amp Functional Checks Input System A D Arm Assembly 1 Unplug the balancer from the power source 2 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 3 Remove the Processor PCB Cover See Replacement Procedures section of this manual Note he routing and the tie down points and discon nect the potentiometer cable from the Processor PCB Refer t
82. pair amp Replacement Procedures in this man ual 10 e 4 Dial indicate the balance s face plate shaft non threaded shaft It should have 0 001 inch or less run out Replace motor face plate assembly if necessary See appropriate section of Repair Replacement Procedures in this manual 5 l face plate amp shaft are good dial indicate the bal ancer cone that was used for mounting the wheel while it is on the smooth portion of the balancer shaft It should have 0 002 inch or less run out Replace the cone if necessary Potentiometer Check 1 Depress Shift 0 then enter code 19 to bypass A ounce calibration and access the A amp D arm calibra tion 2 Depress and hold the Shift key while you depress the number 3 key Cal Arm 3 Depress 96 4 Do not perform the calibration 5 The LEFT PLANE Weight display now shows volt ages for the distance potentiometer and the RIGHT PLANE Weight display shows voltages for the Diameter potentiometer 6 With the arm in the home position each reading should be between 0 400 and 0 700 If this is not the case adjust the potentiometers as described in the Adjustments Section of this manual 7 Move the arm as if you were measuring a wheel 8 Each of these voltages should increase as the arm is moved from the home position and return to the original readings when the arm Is returned home 9 f this is the case the potent
83. r 5 Lift off the weight tray shield 6 Assemble in reverse order Processor PCB Cover 1 Unplug the balancer 2 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 3 Use a 3 8 inch wrench socket to remove the four cap screws that retain the processor PCB Cover Two screws on top and two screw on bottom of cover 4 Lift off the cover 5 Assemble in reverse order Safety Guard Hood Assembly 1 Unplug the balancer 2 Remove the red end cap from the end of the safety guard hood bar at the rear of the balancer 3 Use a medium flat blade screw driver and pry the retainer off by alternating from one side to the other 4 Remove the flat washer 5 Remove the white flanged bearing 6 Note how the safety guard hood flange engages the hood switch assembly Important Always read and follow the information box instructions Note he safety guard is fairly heavy and awkward to carry Be careful when removing it and have a place ready to set It aside 7 Pull the safety guard out of the bracket and set it aside see the Installation amp Set Up section of this man ual for installation Perform a functional check after installation Display Pod Assembly 1 Unplug the balancer from the power source 2 Use a 1 Phillips screw driver to remove the four screws and spacer bushings if so equipped on the back of the pod that retain the Touch Panel 3 From t
84. r protection Consideration should also be given to the use of hear ing protection if tire service activity is performed in an enclosed area or if noise levels are high Definitions of Hazard Levels Identify the hazard levels used In this manual with the following definitions and signal words DANGER Watch for this symbol 44 DANGER It Means Immediate hazards which will result in severe personal injury or death WARNING Watch for this symbol A WARNING It Means Hazards or unsafe practices which could result in severe personal injury or death CAUTION Watch for this symbol It Means Hazards or unsafe practices which may result In minor personal Injury or product or property damage Watch for this symbol lt means BE ALERT Your safety or the safety of others is involved A NOTICE Read entire manual before assembling installing operating or servicing this equipment Important Always read and follow the information box instructions Safety Notices and Decals 44 WARNING Failure to follow danger warning and cau tion instructions may lead to serious per sonal injury or death to operator or bystander or damage to property Do not operate this machine until you read and understand all the dangers warnings and cautions in this manual For additional copies of either or further information con tact Hennessy Industries Inc 1601 J P He
85. reading perform the arm calibration If the D dimension is not plus or minus 0 25 inches of the dimension on the tire sidewall perform the arm cali bration See appropriate Calibration section in this manual Rotational Check Mounting The rotational check is used to verify the wheel is mounted correctly and the adapters balancer face plate and shaft are not damaged A Balance a hub centric steel wheel to 0 05 ounces or less per side in the fine balance non round off mode 2 Position the valve stem at 12 00 3 Loosen hub nut just enough to allow the wheel to move 4 While holding the faceplate so it cannot turn rotate the wheel 90 degrees relative to the faceplate valve stem at 3 00 5 Tighten hub nut G Press START New weight readings should be 0 30 oz or less 7 Repeat steps 3 through 6 at 180 degrees valve stem at 6 00 and 270 degrees valve stem at 9 00 Weight readings should be 30 oz or less If the weight readings exceed 0 30 ounces in either plane in any of the positions A Remove the wheel from the balancer 2 Inspect the mounting contact points of the wheel the balancer adapters used for mounting the balancer shaft and the balancer faceplate for damage nicks burrs rust etc Repair or replace as necessary 3 Dial indicate the balancer s face plate It should have 0 001 inch or less run out Replace motor face plate assembly if necessary See appropriate section of Re
86. rojects from This will cause the dot on the wheel to get larger or smaller Adjust until the dot is about 1 8 inch to 3 16 Inch in maximum diameter Note with the wheel on unless you have a stubby screw driver it may be necessary to turn the knurled knob on top of the laser to bring the adjustment screw to an accessible posi tion Then return the beam to the desired position in the wheel to check the result number 2 key Cal Laser 2 times to take the balancer out of the Cal Laser mode 33 Rotational Force If the laser is difficult to turn using the knurled knob or If it is too loose and will not hold position e Use a 3 16 inch Allen wrench to loosen or tighten the set screw on the bottom of the laser bracket until the cylindrical laser housing assembly rotates but with sufficient drag to hold position Loctite 242 is applied to the threads of this set screw during assembly to prevent it from backing out as the laser is rotated Line Laser Loosen or tighten the Allen head screw and spring that fasten the housing to the arm until the housing will pivot with some resistance Display Pod Touch Panel Display Touch Panel Display Vertical Plane e Pivot the pod to the desired angle by pushing on the top and pulling on the bottom or visa versa e f the pod resists movement slightly loosen the two 3 wing knobs on the back of the display pod and try again Note that if the knobs are tightened to
87. roper calibration lf the test weight is not moved from the outside flange directly across to the inside flange an inner weight placement error will occur To correct follow the infor mation box instructions 7 After spin raise hood Rotate wheel until left plane center bar blinks move and attach test weight to inside flange at top dead center 4 ounce 100 grams Figure 20 lest Weight Moved Directly Across To Inside Flange 32 o 8 Lower the hood and press START 9 Calibration complete Press NEXT Sonar 3DV Calibration Each time a 4 ounce 100 gram calibration is per formed the width sonar is automatically calibrated If a width sonar calibration is required as in after replacing a sonar unit simply perform a 4 ounce or 100 gram calibration Laser Dot Calibration This calibration only needs to be performed if the motor laser housing or processor PCB is replaced Follow the steps for a normal 4 ounce calibration EXCEPT enter Shift 2 laser then the 96 service access code One additional step is added to the 4 ounce calibra tlon procedure The laser dot will automatically turn on Position the dot on the inner rim flange With the 4 ounce weight on the inside flange rotate the wheel until the dot is at the center of the weight and then press the Next key A amp DArm You must always perform the 4 ounce calibration just prior to doing the A amp D arm
88. s Touch Panel 3DV 1 Unplug the balancer from the power source 2 Remove the Touch Panel Display Assembly from the Pod See appropriate replacement procedure in this manual 3 Remove the DC AC Inverter See appropriate replacement procedure in this manual 4 Remove the Single Board Computer PCB and the Display PCB as an assembly See appropriate replace ment procedures in this manual ed A Inverter 5 Remove the four spacers from the Touch Panel Display PCB stand offs Note and mark the location of the short spacer Remember that its location is critical for a reliable connection between the Display PCB and the LCD Important Always read and follow the information box instructions 6 Remove the LCD See appropriate replacement procedures in this manual Short Spacer amp for Display PCB 7 Remove the four spacers from LCD stand offs LCD Spacer gt 8 Remove the Lexan shield 9 Assemble in reverse order 110 Perform a functional check Processor System Main PCB Note Processor PCB revision H and backward will only drive 1250s Revision and forward will drive both 1250 and 1250 3DV 1 Unplug the balancer from the power source 2 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 3 Remove the Processor PCB Cover See Replacement Procedures section of this manual A Remove all of the cable wire connector
89. s section of this manual 3 Disconnect the return spring from the front edge of the housing A Remove the arm 5 Remove the string bracket from the back end of the rod Refer to the potentiometer replacement sec tion above G Remove the D potentiometer from the rod Refer to the potentiometer replacement section above Y Slide the rod out of the front of the tube 8 Remove the bushings Bushings may be more easily removed after removing the tube 9 Remove the 2 hose clamps that secure the tube to the housing 10 Remove the tube by pulling it out of the chassis cutout and lifting it out of the balancer 41 Install in reverse order Important During installation be sure the string Is fully seated and correctly routed on the A pulley and the slot on the bottom of the A amp D pendulum is prop erly engaged on the lip of the housing Before tighten ing the hose camps to secure the tube be sure that the back edge of the tube is lined up with the front edge of the positioning cutout in the housing as shown in the illustration NR ae E Paka y f This defines the A home position of the arm 12 Plug in the balancer and perform an A amp D potentiometer adjustment procedure Refer to the Adjustments section of this manual 13 Unplug the balancer 14 Install the Processor PCB cover and the weight tray and shield 15 Plug in the balancer 16 Perform Functional Checks
90. s from the Power PCB 5 Remove the Processor PCB from Its stand offs 6 Install the new Processor PCB on the stand offs 7 Connect all of the cable wire connectors to the new Processor PCB Refer to the appropriate section of the Wiring section in this manual 8 Install the Processor PCB Cover 9 Install the Weight Tray and Shield 10 Plug in the balancer 11 After replacing board turn balancer on to pick up the model from the Display PCB then reboot the bal ancer by shutting the balancer off waiting about 5 sec onds and then turning the balancer on 12 Enter code Shift 0 72 to detect the hood sonar If so equipped Perform all calibrations neces Important Always read and follow the information box instructions sary for model i e 4 0z laser A amp D arm sonar Perform the appropriate functional checks Display System Display PCB LEDs 1 Unplug the balancer from the power source 2 Use a 1 Phillips screw driver to remove the four screws and spacer bushings If so equipped on the back of the pod that retain the Touch Panel 3 From the front of the pod carefully pull out the Touch Display Panel assembly 4 Disconnect the 8 pin phone style connector cable on the back of the Display PCB See illustration in the Reference Materials section of this manual 5 Disconnect the green ground wire from its spade terminal on the back of the Display PCB 6 Disconnect the Tou
91. section of this manual 5 Verify that the On Off Switch is good as described in the Power Signal Systems Checks section of this manual G Verify that the Processor PCB is good as described in the Power Signal Systems Checks sec tion of this manual 7 Unplug the balancer from the power source 8 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 9 Check the potentiometer connector and wires 10 l the all of the above are good replace the potentiometers Remember they are replaced as a set with cable on this unit See necessary Replacement Procedures sections of this manual and the neces sary Adjustments section of this manual Optical Encoder A Perform the functional check described in this manual 2 Verify that the power source is good as described in the Preliminary Inspection section of this manual 3 Verify that the Power Cord and Plug are good as described in the Power Signal Systems Checks sec tion of this manual 4 Verify that the Power PCB is good as described in the Power Signal Systems Checks section of this manual 5 Verify that the On Off Switch is good as described in the Power Signal Systems Checks section of this manual G Verify that the Processor PCB is good as described in the Power Signal Systems Checks sec tion of this manual 7 Unplug the balancer from the power source 8 Remov
92. sket motor cover weight tray shield weight tray and A amp D arm 21 Plug balancer in 22 Perform Functional Checks amp 4 oz calibration Sonar 3DV Sonar 1 Unplug the balancer from the power source 2 Disconnect the sonar cable from the bottom of the sonar unit 3 3 Remove the large top nut that holds the sonar unit In Its bracket 4 Slide the sonar unit from the bracket 5 Remove the top nut from the new unit 6 Position the bottom nut on the new unit at the same height as the bottom nut on the old unit 7 Connect the cable 8 Slide the new unit into the bracket 9 Check to be sure the sonar cable is still in line with the hole in the hood bar 10 lighten the top nut on the sonar unit Important Always read and follow the information box instructions 1 1 Plug in the balancer 12 Perform a 4 ounce calibration to calibrate the sonar 13 Perform a functional check Sonar Cable Note The sonar cable is part of an assembly that includes three cables Replacement of any of the cables requires replacement of the entire cable assem bly 1 Unplug the balancer from the power source 2 Disconnect the sonar cable from the bottom of the sonar unit 3 Pull the sonar cable out of the hood bar Remove the balancer s weight tray and heat shield 5 Note the routing and pull the sonar cable into the balancer 6 Disconnect the sonar cable from the Processor PCB 7 Dis
93. spade terminal 3 Black 1 Power PCB Test Points amp Connectors 220V Important Always read and follow the information box instructions 1250 Power PCB Test Points amp Connectors VIO Meter Rec hem ProbeLocation VIO Meter Blac Probe Location Voltage Test Description Power Switch Each black wire Chassis Ground 120 VAC Check for power through Power PCB terminal Power Switch Switch terminal with Other switch terminal Continuity with wires off with wires off switch in on position amp no Check for good switch Each fuse terminal Chassis Ground 120 VAC Check for power through Power PCB Fuse terminal with Other Fuse terminal Continuity Check for good fuse balancer with balancer unplugged unplugged Power Cord Black Chassis Ground 120 VAC Check for power through cord Power Cord Red Chassis Ground 120 VAC Check for power through cord Each Red wire in power out to power switch and to fan connector Black jumper wire in power out to power switch and to fan connector Power Panel Important Always read and follow the information box instructions PAS PEE Power Cord White Chassis Ground 120 VAC Chasis Ground 120 VAC Each wire terminal Chassis Ground 120 VAC Each wire terminal Chassis Ground 120 VAC Each Red wire Chassis Ground 120 VAC terminal 60 VAC Each Black wire Chassis Ground terminal i E p a q Eg a e PD e a ty how f
94. stead of directly to the power PCB A temperature sensor is used in the motor and is connected to the relay printed circuit board The con tactor PCB assembly is attached to a capacitor pack bracket On three phase units the capacitor pack bracket is used without the capacitors and a 3 pole contactor Is 8 o used to enable connection of the white wire in the power cord Two red LEDs on the lower left corner of the PCB blink in the following patterns Slow Alternating Blinking Indicates open power cir cuit as when motor is cooling down and power Is interrupted or computer is booting up Faster Alternating Blinking Indicates closed power circuit normal operation Simultaneous Blinking Indicates open power circuit motor temperature exceeds limit Diagnostics amp Troubleshooting Preliminary Inspection 1 Check the power supply to the balancer Unplug the Balancer from the power source Perform all volt age checks shown in the appropriate diagram and chart at the power receptacle If one or all voltage measure ments is faulty be sure to check the status of the cir cuit breakers that supply the Balancer Check from one of the power terminals to the ground terminal to verify a ground is present The voltage measurement should be approximately one half of the available voltage i e 220V should read 110V If the reading is less that one half of the available voltage there is not a ground pres ent Normal acceptab
95. te the distance from the strain relief bushing to the chassis end of the old power cord 9 Remove the strain relief bushing and then the old power cord from the back of the chassis 10 Position the strain relief bushing on the new cord at the noted distance from the chassis end 1 1 Install the cord and strain relief bushing into the chassis e35 12 Connect the power cord wires to the Power PCB and the Chassis Ground 13 Insert the new power cord into the plug 14 Connect the wires to their terminals 15 Join the 2 plug parts and tighten the fasteners 16 Install the Weight Tray and Shield 17 Plug in balancer and perform a functional test Replace PCB Contactor Assembly 1 Unplug the balancer from the power source 2 Remove the weight tray and shield 3 Note their locations and disconnect the wires from the relay s PCB Contactor Assembly 4 Remove fasteners that hold assembly to Capacitor Bracket 5 Install the new assembly in reverse order 6 Functional test the balancer 7 if good install the shield and weight tray On Off Switch 1 Unplug the balancer from the power source 2 Remove the Weight Tray and Shield See Replacement Procedures section of this manual 3 Disconnect the wiring to the on off switch 4 Squeeze retainers at the top and bottom of the switch and push it through the opening in the chassis 5 Install the new on off switch G Connect the wires to the switch
96. ugs directly into the back of the LCD no cable Touch Panel The touch panel switches are relocated to match with the information locations as shown on the LCD panel Extra care must be taken when removing or installing the touch panel assembly The LCD has a glass front which may break if the assembly is flexed during removal or Installation o7 Power Panel Sonar LCD Power PCB The sonar and LCD panel require additional power This takes the form of a sec ond PCB mounted next to the regular Power PCB on a longer mounting plate Sonar LCD Power PCB eee ddl SILO JAS AS A wen wee pa or ED Be Kye Shas ve a a LA FELE p j 4 gt gt gt wes a Y A vy Y yf j AE are IM qe A TRS won Pod The 3DV has a deeper Pod to accommodate the addi tional depth of the Pod components Processor PCB The 3DV processor PCB revisions and up have been modified but are backward compatible to the 1250 However the 1250 processor PCB revision H and back are not forward compatible to the 3DV Motor Protection Relay 7 Bda N Rags 120050 JE The 1250V is equipped with a motor protection relay If the motor temperature reaches about 150 degrees Centigrade the balancer power circuit is opened for about 4 5 minutes to allow the motor to cool down At that time the balancer power will be restored by the circuit automatically closing The power cord connects to the relay contactor in
97. ve times then access the event log shift O 45 The piezo mag nitude and angle for the last five spins will be displayed at the bottom of the screen for comparison Permitted variation is still 0 0500 Optical Encoder Check 1 Depress and hold the Shift key while you depress the 0 key CdE appears in the LEFT PLANE weight display 2 Depress the 4 key two times Code 44 With the first push the number 4 appears in the RIGHT PLACE weight display With the second push the encoder count appears in the RIGHT PLANE weight display 3 Slowly rotate the wheel a full revolution while watching the display The count should go from O to 255 without missing a value and then start over 4 l the count skips numbers or is missing a section of numbers or a signal does not appear perform a physical inspection of the encoder wiring and connec tions and then perform the checks described in the appropriate section of Power Signal Systems Checks in this manual Touch Panel Check To check the pressure sensitive switches keys 0 0283 0 0162 0 0387 0 0131 0 0382 0 0171 13 If the variation is greater than 0 0500 perform a physical inspection of the piezo spring height adjust ment piezo wiring and connections and then perform the checks described in the appropriate section of Power Signal Systems Checks in this manual 1 Depress and hold the Shift key while you
98. ver gasket motor cover weight tray shield weight tray andA amp D arm 26 Plug balancer in 27 Perform Functional Checks and 4 ounce calibra tion 28 Perform Functional Checks and a 4 ounce cali bration Motor Fan 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Disconnect fan motor plug 4 Remove rear end bell cover 5 Remove the two 2 8 32 nuts holding the fan motor to the drive motor and remove the fan motor assembly 6 Install new fan motor assembly and tighten nuts 7 install rear end bell cover Important Always read and follow the information box instructions 8 Connect fan motor plug 9 Install weight tray and weight tray shield 10 Plug in balancer 1 1 Perform fan functional check Stub Shaft 1 Prevent the face plate from rotating by placing a large screw driver through one of the holes in the rim of the face plate 2 Use a large adjustable wrench on the flats of the stub shaft to unscrew the shaft Note On the 40mm version the connecting threaded rod may come off with the stub shaft Chassis System Weight Tray and Shield 1 Unplug the balancer 2 Use a 3 8 inch wrench socket to remove the four cap screws that retain the weight tray Two screws on each side of the balancer 3 Lift off the weight tray 4 Use a 3 8 inch wrench socket to remove the four cap screws that retain the weight tray shield Two screws on each side of the balance
99. wer switch is in the off posi tion Verify that the Power PCB Motor Controller Board is good as described in the Power Signal Systems Checks section of this manual Each red wire from the Power PCB to the Sonar LCD Power PCB should read 110 Volts to chassis ground 220 Volts across REFER TO THE 3DV WIRING SCHEMATIC IN THE REFERENCE SECTION OF THIS MANUAL These wires provide the power to the PCB The red and black to the processor PCB are red 24 volts DC Black ground The wires going to the Display PCB are unregulated and should read from 19 volts DC to 36 volts DC between the Natural and Red as well as between the Red and Black DC AC Inverter 3DV Power System Signal Check Verify power is good from the power source outlet all the way to the display PCB Refer to the appropriate information in this manual The two black wires pins one amp two from the Display PCB should each be 12 volts DC across either of the two white wires which are ground REFER TO THE 3DV WIRING SCHEMATIC IN THE REFERENCE SECTION OF THIS MANUAL Outgoing from inverter to the LCD is 3 000 volts AC Most volt ohm meters DO NOT measure in the 3 000 volt range If the inverter is getting power but the LCD is only dis playing a very faint image It is most likely that the inverter has failed and needs to be replaced The other possibility is LCD back light failure e 13 On Off Switch 1 Verify that the power source is good

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