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WHEEL BALANCER - Snap

1. D Power Clamp System T NL 83 5 M 83 6 Power Clamp System Checkout and Maintenance F P 84 EMPTY SHAFT CALIBRATION PROCEDURE Press and release the F P key turn the shaft until the display reads F P 84 is displayed The display changes to CAL SHF for one second Then it displays SPN 4 Spin the empty shaft by pressing the ENTER button or lower the hood The board displays the following information Displays CAL 1 when the shaft reaches calibration speed The machine is taking data and doing calculations After taking data shaft is automatically braked to a stopped Then displays CAL SHF FIN for one second The machine displays the shaft resident unbalances in fine mode The fine mode LED indicator is automatically on By pressing STOP key to exit F84 and return to idle state The fine mode LED indicator is automatically turned off NOTE UNITS WITH A POWER CLAMP REQUIRE A SPACER 2 1 0033D53A BE INSTALLED BETWEEN THE AND CLAMPING SLEEVE AND A SECOND SPIN CYCLE BE COMPLETED F P 88 TDC CALIBRATION Mount the Pruefrotor on the balancer shaft and enter in the parameters of the Pruefrotor
2. AAA AAA ES Oo ojojojojojojoj oj jojo jo jo BBR BIBIBIBI IR Chapter 2 Diagonostic Codes 2C busy 2C no Acknowledge No Acknowledge from device 2C ERROR NO ACK FROM START 2C ERROR NO ACK FROM STOP 2C ERROR FROM SEND1 2C ERROR NO ACK FROM SEND2 2C ERROR NO ACK FROM RECEIVE ERROR 12 SYNCHRONOUS ORDER TIMEOUT ERROR 12 ASYNCHRONOUS ORDER TIMEOUT ERROR 12 ORDER HAS FAILED e wip S S ssl gt ERROR DS USER BREAK Drive system Timeout during speed up hand spin only speed does not settle after start command ERROR DS SPEED NOT REACHED Drive system Speed slows down during measuring speed falls below limit while measuring Drive system Wheel speeds up in reverse turn Hand spin only main shaft rotating backwards on start command eo Co Drive system No acceleration during speed up or braking detected 1 Motor 2 Belt mounted 3 Incremental encoder main shaft Drive system Slip detected speed up to fast 1 Wheel not clamped strong enough 2 no wheel or wheel mass to low Drive system Speed limit exceeded speed exceeds security limit mainly wheel guard open and drive management set to
3. 2 The user selected to proceed with a bare measurement the ma chine actually detects that a complete wheel is on the machine Mount a bare rim 50 An attempt to access the weights usage database has failed restart the balancer to re initialise the database or call service if the problem persists E83 Vibration of the machine disturbed the unbalance measurement fess Power clamp service interval expired E88 0x492208 The rotating speed of the main shaft exceeds the safety limit Jesa Key contact or pedal switch closed 2 15 Chapter 2 Diagnostic Codes E93 0x441370 The outer gauge arm for rim width is defective 0x441371 aof T management software activities Che au of EEPROM wrong ox00076D Check sums ofboth EEPROMs arewong Ei45 0 000168 Contents of the EEPROMsarediferent Bof O D a aii tween micro controller and ChecksumofEEPROM2iswong 1 Bef S OPTIMAnardware wheel profiler position calibration required E361 OPTIMA wheel profiler is not present or is not responding during test E362 MEN OPTIMA main camera board power on self test failure E363 OPTIMA left side scanner self test fail or CCD not calibrated or zero mark not detected E364 OPTIMA right side scanner self test fail or CCD not calibrated or z
4. Corrective actions Models with optima hardware the cable connecting the camera controller board and the rear scanner motor is unplugged damaged or missing the motor power supply is not configured properly there is a fault in the motor power supply board the cable connecting the mains supply and the motor power supply board is un plugged damaged or missing there is a fault in the rear scanner motor there is a fault in the camera controller board motor drivers check all items above Models with optima hardware the flat cable connecting the camera controller board and the rear scanner CCD board is unplugged missing or damaged there is a fault in the rear scanner CCD board the rear scanner is locked the rear scanner zero mark is missing bent locked or damaged the cable connecting the camera controller board and the rear scanner motor is unplugged damaged or missing there is a fault in the motor power supply board there is a fault in the rear scanner motor there is a fault in the camera controller board motor drivers check all items above Check Optima rear motor missing steps E396 Affected models Models with optima hardware C123 Service Codes 2 10 Chapter 2 Diagonostic Codes Possible causes the rear scanner movement is not smooth or it is striking the frame the motor power supply is not configured properly there is a fault in the motor power supply board there is a fault in the rear scann
5. gt key turn the shaft until the display reads F P F 59 is displayed and press enter Display should read 0 10 or less Anything greater than 10 requires bare shaft calibration F84 Press STOP to exit this function Hd F P 60 READ SHAFT RPM This test displays the motor RPM a reading of 190 RPM s 10 on a VPI III and SOT Low Digital or 90 RPM s on a VPI 11 It is recommended that a tire and wheel be used for this test Press STOP to exit this function F P 63 CONTINUOUS BALANCING Mount a tire and wheel assembly Activating this code puts the balancer in a continuous spin cycle and up dates the amount of imbalance every 5 seconds Press lt gt to cancel this test F P 64 DISPLAYS THE TRANSDUCER OUTPUT Transducer output should be steady Any slight vibration of the unit should cause the readings to fluctuate After activating F P 64 the display will change to ADE 1 2 forone second By forcing the shaft rear ward the read should display negative forcing the shaft forward the reading should display a positive voltage Press the F P key to toggle to the front transducer 2 1 7 Checkout and Maintenance F79 CALIBRATION OF WIDTH SAPE Note This procedure is part of the F80 1 Press and release the lt F gt key toggle the UP DOWN ar row keys until F 79 is displayed and press ENTER to tivate function of F79 Once activated the display will change
6. 3 10 The voltage should read 3 15VDC x 0 05 in the home position and greater than 0 20VDC when p the tip of the SAPE arm is touching the backing collar RX eS 1 NN A ANNUS LV F P 53 DISPLAY TEST Used to diagnose the display panel Once activated the display will either scroll a message or all LED s will light up Pressing STOP displays Goo _d_ ByE and cancels this test F P 55 CHECK AC AND DC VOLTAGES Press and release the F P key turn the shaft until the display reads F P 55 and press enter Machine displays VOL tSt for one second the display toggles between AC voltage and DC voltage Example AC 230 5 15 Although some machines require only 120VAC the machine still displays 230 volts the step up transformer generates 230VAC on these units Press STOP button to exit this function F P 56 CHECK PEDAL AND HOOD SWITCHES ON POWER CLAMP Press and release the lt gt key turn the shaft until the display reads 56 and press enter Depend ing on the type of vibratory will depend on the status Power Clamp vibratory will measure the status of the Hood switch and both pedal switches Units without the power clamp vibratory will measure the status of the hood switch only Display Left Window Status Display RightWindow Status Pedal static F P 59 DISPLAYS THE UNBALANCE OF THE BARE SHAFT Press and release the lt
7. 14 Calibration by user 18 Enter ALU S 2 plane mode press the balancing mode key to exit back to the dynamic mode 19 Enter ALU S 1 plane mode press the balancing mode key to exit back to the dynamic mode 21 Check revision of balancing kernel software 22 Power clamp lock JBC 3 power clamp model only 28 Check last 10 kernel error messages amp Clean all recorded error codes 36 Toggle reading the positions and angles of left and right weights 43 Read or reset re setable counter 44 Read reset productivity of user Display counter number of default user only 50 Read output voltage of potentiometer of distance measurement of SAPE 51 Read output voltage of potentiometer of the diameter measurement of the SAPE 52 Read output voltage of potentiometer of the width measurement of the SAPE 53 Display test 55 Check AC and DC voltages 59 Read resident imbalances of shaft in fine mode The fine mode LED indicator is automatically turned on and off if the machine is in the regular accuracy mode 60 Read shaft speed RPM 63 Continuous spin 64 Read outputs of transducers 79 Calibration of the width SAPE 80 Calibration of SAPE 83 Manufacture calibration Pruefrotor required 84 Empty Calibration of the bare shaft 88 Top Dead Center calibration TDC 90 Enter match balancing mode 91 Optimization balancing mode 92 Split weight mode 94 Spoke mode 95 Clean and reset EEPROM 1 amp 2 97 Sticky at Top 1 3
8. Ground These machines depend on proper Grounding for proper and safe function Improper or poor ground will create problems that are quite difficult to diagnose and may create a dangerous condition Check never assume ground is correct 3 DC Power The microprocessor will not run correctly if at all if it is not supplied with proper DC power and ground Check DC power for ripple or drift may indicate faulty regulation or failing PCB s Ensure there is enough power and a good ground 4 Inputs Check for proper Encoder and Transducer signals Output Once all voltages and signal levels are present a proper output can be expected Check for any registered diagnostic codes using F P 28 in most cases these codes will point to a solu tion TOOLS REQUIRED WHEN SERVICING THE Y2K BALANCERS Tools Metric Sockets 4mm Thru 15mm Metric Wrenches 6mm Thru 15mm Assorted Hex Wrenches metric standard Inch Pound Torque Wrench Foot Pound Torque Wrench 2 Phillips Screwdriver 2 Flat Head Screwdriver Digital Volt ohm Meter Small Screwdriver Hilti Rotor hammer drill Installation Option Pruefrotor H6416946 or fine balanced tire wheel assembly 3 50 ounce 100gr wheel weight Programmed Secure Disk Loading Balancer Software Loctite 242 and 272 or 609 Silicone based grease Used for transducer ball placement Putty for fine wheel balancing 1 2 and 3 ounce weights verified accurate weigh on postal scales and
9. 5 The display changes to rSt A or rSt b for 1 second F P 50 READ OUTPUT VOLTAGE OF THE DISTANCE POTENTIOMETER OF SAPE Slide the SAPE in the home position Press and release the lt gt key turn the shaft until the display reads F P 50 is displayed and press enter 3 Displays 3 10 0 02 3 10 With the Distance guage in the home position the voltage in the right hand display should read 3 10VDC 0 02 If the voltage setting is not within the tolerance the balancer will not function correctly N F P 51 READ OUTPUT VOLTAGE OF THE DIAMETER L POTENTIOMETER ww P 1 Move the SAPE in the losest position 2 Press release the F P key turn the shaft until the display reads HE F P 51 and press enter ene 3 Displays 3 10 0 05 3 10 The voltage should read 3 10VDC 0 05 pos TN point A when the SAPE is on the vibratory tube or 2 85VDC 0 05 point B when placed on the bell housing 1 6 Checkout and Maintenance F 52 READ OUTPUT VOLTAGE OF THE WIDTH POTENTIOMETER This function is only available with the JBC VPI System III balancer NN WN X NAN WS 1 Slide the SAPE in the home position Press and release the lt F gt key toggle the UP gt arrow keys until 52 is displayed and press enter 3 Displays dTH and then changes to 3 15 0 05
10. Checkout and Maintenance F P CODE DESCRIPTIONS OF THE BALANCER F P 1 TOGGLE FINE WEIGHT MODE When F P 1 is activated the machine displays FIN for one second round off 0 05 oz or 1 gram Toggle F P 1 again changes back to the normal round off and display changes to FIN OFF for one sec ond round off 0 25 oz or 5 gram F P 2 RIM WIDTH INCH MILLIMETER Selecting F P 2 toggles the balancer between inch and millimeters for rim width Unit will display I for inches pressing F P 2 again toggles to millimeters and the display changes to DtH for millimeters F P 3 GRAM OUNCE Selecting F P 3 toggles the balancer between Grams and Ounces Unit will display for ounce pressing F P 3 again toggles to Grams and the display changes to GR GR GR F P 4 CALIBRATION WITH ADAPTER OR DISABLE ADAPTER COMPENSATION Some special tires and those wheels whose center holes are not the primary reference but are lug centric re quire an adapter Lug centric identifies that the tire and wheel assembly to be centered on it s axis of rotation must be mounted using the lug pattern instead of the center hole of the wheel In this case the adapter may introduce an unbalance to the spin system This means that this unbalance has to be compensated for after tire unbalance is measured This F P code is used to measure the unbalance of shaft and adapter together and saves it in memory and set an adapte
11. If the current voltage is below or above a limit the error code is displayed Refer to section 2 3 4 Error ID 30 5 Hardware test Transducer signals C10410 C10420 C10430 Affected models All models Service Codes C103 C104 CRT only to check transimpedance and signal amplifiers and transducer values If no signals from the transducers are detected the error code is displayed Refer to section 2 3 4 Error ID 30 6 Hardware test Auto stop system C10380 C10381 C10382 C10383 Affected models Models with auto stop system Service Codes C75 Adc21 to check voltage on capacitor of the auto stop system If the voltage is below or above a limit or the recharging time is above a limit the error code is displayed Refer to section 2 3 4 Error ID 2 13 Chapter 2 Diagnostic Codes SERVICE CODES 2 4 H CODES CRT HNA HWT ui error h revision 1 11 LL Whee rumning conditons cannot be improved by optimisation m Further optimisation not recommended butfeasible AMNEM improvement The correction plane cannot be relocated using the gauge 21 __ Indexing position does not match correction plane of wheel notalowed The gauge arm was pulled out too quickly normal operation ASS calibra tion H8 NEW The gauge arm was pulled out too slowly ASS calibration H80 0x810510 No provision was made for readjustment Jae Self test distu
12. TRANSDUCER I 1 18 ENCODER REMOVAL e 1 18 VIBRATORY MEMBER REMOVAL center ttt ttti 1 19 VIBRATORY INS TALLA TION RAT 1 19 DIAMETER SAPE POTENTIOMETER VPI II IIl IV amp SOT LD ns 1 19 DIAMETER SAPE POTENTIOMETER ADJUSTMENT 1 20 GNIS S 1 20 DISTANCE SAPE POTENTIOMETER VPI Ill IV tette ttti 1 21 DISTANCE SAPE POTENTIOMETER INSTALLATION 1 21 DISTANCE SAPE POTENTIOMETER VPI Il amp SOT 1 22 DISTANCE SAPE STRING ROUTE INSTALLATION VPI Il amp SOT LD 1 22 WIDTH SAPE POTENTIOMETER INSTALLATION 1 22 JEC IPI ETIE oe sass 1 22 ELECTRIC BRAKE PEDAL ADJUSTMENT 1 23 ELECTROMAGNETIC MOTOR BRAKE ADJUSTMENT ettet tette ttt 1 23 MECHANICAL BRAKE CABLE ADJUSTMENT ettet ttt tt ttt ttti 1 23 MECHANICAL BRAKE CABLE crise qur a a a Xin ED reor RR S aree 1 23 MOTOR BEMOVAL 1 23 HOOD SWITCH CAM SPRING itecto descen 1 23 VPIS VS TEM I N A tdm 1 23 HOOD STC CAMI SPRING 1 24 VPIS YS TEM IS SOT COW DIGITAL rcbus eTR tasto tcr cate 1 24 HOOD SWITCH CAM SPRING tret tte ttt tte ttr ttt ttt ennnen 1 24 teh NEN MEME 1 24 CHAPTER 2 DIAGNOSTIC CO
13. the flat cable connecting the camera controller board and the rear scanner CCD board is unplugged missing or damaged there is a fault in the rear scanner CCD board there is a fault in the camera controller board 3 8 4 1 2 9 Chapter 2 Diagnostic Codes Corrective actions check the connections check the rear scanner CCD board check the camera controller board Switch power off and on again should the problem not go away please call ser vice Check Optima rear scanner memory E392 Affected models Models with optima hardware Service Codes C123 Possible causes Corrective actions 4 4 the flat cable connecting the camera controller board and the rear scanner board is partially unplugged or damaged there is a fault in the rear scanner CCD board check the connectionsS check the rear scanner CCD board switch power off and on again should the problem not go away please call ser vice Check Optima rear scanner calibration E393 Affected models Models with optima hardware Service Codes C123 Possible causes Corrective actions the rear scanner has not been factory calibrated please call service and replace the rear scanner Check Optima rear motor power supply E394 Affected models Service Codes C123 Possible causes Corrective actions Check Optima rear scanner zero mark E395 Affected models Service Codes C123 Possible causes
14. there is a fault in the motor power supply board the cable connecting the mains supply and the motor power supply board is un plugged damaged or missing there is fault the rear shift scanner motor there is a fault in the camera controller board motor drivers Corrective actions check all items above Check Optima rear shift scanner zero mark E405 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the rear shift scanner CCD board is unplugged missing or damaged there is a fault in the rear shift scanner CCD board the rear shift scanner is locked the rear shift scanner zero mark is missing bent Chapter 2 Diagnostic Codes Corrective actions locked or damaged the cable connecting the camera controller board and the rear shift scanner mo tor is unplugged damaged or missing there is a fault in the motor power supply board there is a fault in the rear shift scanner motor there is a fault in the camera controller board motor drivers check all items above Check Optima rear shift motor missing steps E406 Affected models Models with optima hardware Service Codes C123 Possible causes Corrective actions the rear shift scanner movement is not smooth or it is striking the frame the motor power supply is not configured properly there is a fault in the motor power supply board there is a fault in the rear s
15. Affected models Models with power clamp Service Codes All codes available for the model Check Keyboard E89 Affected models All models Service Codes No service code available One of the keys F1 to F6 HELP ESC START supplies a key code The machine will proceed with the next step only if the trouble is remedied TA Check Pedal switches E85 Affected models Models with power clamp or electromagnetic brake Service Codes C56 to check the pedal switches C75 AdC16 to check voltage to external switches Models with solenoid brake only and power clamp One or if available both pedal switches are actuated The user can now remedy the trouble Press STOP or ESC key to check the pedal switch once again and to delete the error code reading If the trouble cannot be remedied the pedal is made inoperative C5 i AR Chapter 2 Diagnostic Codes Disable left SAPE E92 Affected models Models with 1D 2D SAPE or geodata Service Codes C80 amp C81 to calibrate SAPE C92 to check distance and diameter of actual calibration During the second attempt the inner SAPE gauge arm was again not re placed to home position Inner and outer SAPE gauge arms are turned off Wait for 5 seconds or press STOP or ESC key to continue Disable right SAPE E93 Affected models Models with 3D P SAPE Service Codes C82 to calibrate SAPE During the second attempt the outer SAPE gauge arm was again not re placed to home position Outer SAP
16. Corrective actions check the camera controller board check the encoder check the connections 22 1 Check Optima inner CCD signals E370 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the inner scanner CCD board is unplugged missing or damaged P B B 2 5 Chapter 2 Diagnostic Codes Corrective actions there is a fault in the inner scanner CCD board there is a fault in the camera controller board the supply voltage is configured too high on the power interface board check all items above Switch power off and on again should the problem not go away please call ser vice Check Optima inner scanner memory E371 Affected models Models with optima hardware Service Codes C123 Possible causes Corrective actions the flat cable connecting the camera controller board and the inner scanner CCD board is unplugged missing or damaged there is a fault in the inner scanner CCD board there is a fault in the camera controller board check the connectionsS check the inner scanner CCD board check the camera controller board switch power off and on again should the problem not go away please call ser vice 22 3 Check Optima inner scanner memory E372 Affected models Models with optima hardware Service Codes C123 Possible causes Corrective actions 2 4 the flat cable connecting th
17. Reverse procedure for installation The potentiometer comes equipped with a standoff insert the standoff into the hole in the housing Reconnect all wiring With the Width SAPE arm in the home position program lt F gt lt 52 gt System IV lt C82 gt Losen the 10mm nut and hold the gear Using a flat blade screwdriver turn the potentiometer to a voltage reading of 3 15 05VDC or greater than 0 20 when the tip of the SAPE is touching the backing collar Run lt F79 for SAPE calibration System IV lt C82 gt 1 22 Checkout and Maintenance ELECTRIC BRAKE PEDAL ADJUSTMENT Early model JBC VPI System III balancers Remove the two screws securing the brake pedal assembly Remove the weight tray Remove the cover from the electronic box Attach a VOM to each lead of the microswitch Rotate either the microswitch activator or the micro switch on the brake pedal assembly until the circuit is open Check to make sure that the circuit closes when the brake pedal is depressed ELECTROMAGNETIC MOTOR BRAKE ADJUSTMENT Remove power from the balancer Remove weight tray assembly Losen hex set screw from the motor pulley Adjust the distance between the magnetic brake and clutch plate to 0 2mm by moving the motor pulley Apply power to the balancer and retest braking capability by pressing on the brake pedal MECHANICAL BRAKE CABLE ADJUSTMENT Mount a standard 15 tire and wheel assembly Using your foot apply pressu
18. SAP for one second Do not move the arm at this point this means CALibration SAPE Then it displays SAP OUT FUL The SAPE calibration procedure is activated Gently pull the SAPE arm OUT until it is fully extended 80 2 hold it steady for about 1 second a tone will sound Display will read POS followed by a Return the arm to the home position NOTE STEP 515 THE FINAL STEP FORA VPI SYS TEM I BALANCER Display changes to 18 POS Gently pull the SAPE out and rest the arm of the SAPE gauge on the bell housing 80 3 A tone will sound and the display will change to bAC H POS Return the arm to the home position The display will change to 42 1 POS Locate the Calibration Weight Place the calibration weight with the large end oriented on the bell collar Extend the SAPE arm outward and rotate the extension to just touch the end of the calibration weight 80 4 A tone will sound and the display will change to POS Return the SAPE arm to the home position NOTE THE REMAINING STEPS APPLY ONLY TO THE VPI SYSTEM Ill BALANCER 1 9 Checkout and Maintenance 10 11 12 13 The display will change to SAP 1 FIN for one sec ond and the changes to dis to FLA Pull the distance gauge to the outside flange of the backing collar use the flat head of the calibration
19. The front and rear transducer must be installed correctly in order for the balancer to function correctly The rear transducer uses the last 2 wires pins 15 16 in the har ness Connect the positive and negative lead to the transducer The positive lead is marked with a black band Insert the clip into the transducer firmly snapping it into place Once the wire is installed it cannot be removed Set Screw iN without destroying the transducer Apply a small amount of grease to each end of the trans ducer Place the ball bearings in place on the transducer Place the transducer assembly in the vibratory system Finger tighten the set screw to position the transducer The wire connection should be on the bottom A properly installed transducer will be able to rotate freely but must have no side to side motion Snug the jam nut that holds the setscrew This nut should be tightened solidly but need not be extremely tight Recheck the transducer to ensure that no lateral Set movement exists after tightening the jam nut Adjust as necessary Screw Hold the pre load plate in position up to the jam nut and finger tighten the set screws to just hold
20. codes available for the model There is an error occurred during the hardware test The four hyphens replace the digits 0 to 9 and the letters A to which all characterize an error defect The following test will be performed 5V line Power supply voltage 235V Incremental encoder Current of opto electronic LED Transducer signal available Auto Stop System Voltage for relay 2 12 Chapter 2 Diagonostic Codes Hardware tests Common Errors C10F02 C10F07 C10F18 Affected models All models Service Codes All codes available for the model A hardware tests couldn t executed successfully C10F02 Test returned with an error No valid test results available 10 07 Test function reported an unknown error C10F18 Test timed out No valid test results available 30 2 Hardware test Power supply voltage C10800 C10801 C10804 Affected models Models with motor Service Codes C55 to check line voltage If the line voltage is below or above a limit the error code is displayed Refer to section 2 3 4 Error ID 30 3 Hardware test 5V line C10810 C10811 Affected models All models Service Codes C110 to heck 5V voltage If the 5V voltage is below or above a limit the error code is displayed Refer to section 2 3 4 Error ID 30 4 Hardware test Current of opto electronic LED C10705 C10706 C10707 C10708 Affected models All models Service Codes C75 AdC1 to check LED
21. have been manufactured since 2000 contain diagnostic codes to aid the technician in trouble shooting and repair of the balancer There are 5 different types of diagnostic codes Start up Errors Error Codes H Codes E Codes and IBP Codes It is important that the code type be properly identified before calling technical support for assistance In most cases the problem may be quickly determined and corrected by properly using the diagnostics codes to troubleshoot This Chapter contains codes for ALL Y2k balancers 2 1 IN FIELD REPROGRAMMING OF BALANCER cinta ee eee 2 2 2 2 RECOMMENDED SERVICES TEPS eel gau uu tanti DUI A MALI 2 2 2 3 SELF TEST DURING START UP CR TPRINBPINNT 2 3 24H CODES 2 13 2 2 CODES Rae eet 2 15 2 0 STRUCTURE OF AN ERROR 2 18 2 IR CN EHE EPIDEMIC 2 18 2 8 3 S 2 19 2 9 4 ERROR ID a CEPR QUA PEN UN rr qu VPE SEMI NER 2 20 210 IBP CODES iraran 2 26 2 1 Chapter 2 Diagnostic Codes Some notes about the operations of the wheel
22. high speed Drive system Clamping device got stuck in clamped position Drive system Clamping device got stuck in unclamped position Drive system Displacement limit exceeded during un clamping Drive system Belt disc rotates backward after clamping Drive system Main shaft rotates during clamping e g EMB defective Drive system Clamp device is locked Drive system Time limit for clamping process exceeded Motor over current detected by hardware Over current LED on the power interface board will be cleared on the next activa tion of the motor 0 05 V First Potentiometer Voltage below measuring range AD value 0 10 0 037 V for IBP 4 45V 3 36 First Potentiometer Voltage above measuring range AD value 1014 1024 V for IBP 2 23 Chapter 2 Diagnostic Codes Second Potentiometer Voltage below measuring range AD value 0 10 4 45 V 3 36 Second Potentiometer Voltage above measuring range AD value 1014 1024 V for IBP 0 05 V Third Potentiometer Voltage below measuring range AD value 0 10 0 037 V for IBP 4 45 V 3 36 Third Potentiometer Voltage above measuring range AD value V for IBP 1014 1024 4 50 V ASS Voltage magnet below limit off state 1 00 V ASS Operating Voltage magnet below limit on state 2 00 V ASS Operating voltage magnet above limit on state ASS Operating Voltage magnet recharging time above limit During measuring run Dat
23. lower hex bolts Install the 4 remaining hex bolts and tighten to 22ft Ibs 3 in Ibs Install the rear transducer and follow transducer installa tion Install mechanical brake and follow mechanical brake installation Install weight tray Connect power and follow all calibration procedures F P C 83 84 and 88 and test Checkout and Maintenance DIAMETER SAPE POTENTIOMETER VPI II IV amp SOT LD Disconnect the power from the rear of the machine Remove the Display panel Remove the weight tray Disconnect the 2D SAPE harness from the Main Proces sor Board Remove the 10mm nut holding the SAPE wheel to the mounting bracket and slide the cog wheel off of the poteti ometer shaft Remove the 13mm nut holding the potentiometer to the frame Reverse procedure for installation DIAMETER SAPE POTENTIOMETER ADJUSTMENT Install 5K potentiometer onto bracket and tighten 13mm nut Install cog wheel onto potentiometer shaft and hand tighten 10mm nut Attach SAPE harness to Power Supply Board With the SAPE arm in the home position program lt F P gt lt 51 gt Pull out the SAPE arm and rest it on the vibratory tube Figure 3 32 using a flatblade screwdriver turn the poten tiometer to a voltage reading of 3 10VDC 05 Run F P C lt 80 gt for SAPE calibration SAPE GAUGE To remove the index finger remove the phillips screw from the backside of the
24. o 801 800 x 5 T Qo o 2 26 Chapter 2 Diagonostic Codes E92 E92 001 048 E93 001 050 E16 001 05 E16 001 052 H80 001 058 E15 001 054 E623 001 055 EG 001 056 EG 001 057 E16 001 068 E16 001 059 EG 00 060 001 070 001 071 001 072 001 073 001 080 001 08 H90 001 082 HS 001 083 001 084 E28 001 085 E17 001 090 001 09 001 092 Sp 001 093 001 094 H22 2 27 Notice The information contained in this document is subject to change without notice Snapon Equipment makes no warranty with regard to this material Snapon Equipment shall not be liable for errors contained herein or for incidental consequential damages in connection with furnishings performance or use of this material This document contains proprietary information which is protected by copyright and patents All rights are re served No part of this document may be photocopied reproduced or translated without prior written consent of Snapon Equipment TEEWB502B 05 2014 rjh Printed in the U S A
25. series of audible signals is given or anerror code is read out On HNA HWT or CRT models a three tone signal is given once if the machine is operative In case there is a functional error it must be acknowledged by pressing the STOP or ESC key and there is no three tone signal 1 Communication between microcontroller and embedded PC Blue screen Affected models CRT models Service Codes No service code available Communication between micro controller and embedded PC is not OK check serial cables This can also indicate a bad connection to the keyboard 2 Check home position of left SAPE Affected models Models with 1D 2D SAPE or geodata Service Codes C80 amp C81 to calibrate SAPE C92 to check distance and diameter of actual calibration Inner SAPE gauge arm not in home position Re place SAPE gauge arm in home position and press STOP or ESC key to continue 3 Check home position of right SAPE Affected models Models with 3D P SAPE Service Codes C82 to calibrate SAPE Outer SAPE gauge arm not in home position Re place SAPE gauge arm in home position and press STOP or ESC key to continue Check weights usage database E50 Affected models Models with AWP Service Codes C125 to format the weights usage database An attempt to access the weights usage database has failed restart the balancer to re initialise the data base or call service if the problem persists 5 Power clamp service interval expired E85
26. the left weight position So working with number and position LEDs it is very easy to find the left weight s position value and angle value This function is very useful to check the position accuracy Press the STOP key to exit this function F P 48 RESETTING THE COUNTERS The counter can be reset using this code 1 Press and release the lt gt key turn the shaft until the display reads 43 is displayed and press enter 2 The balancer will display Ctr rSt 3 The display shows the total number of spins since last reset Press the STOP key while this number is displayed 4 The total number of spins since the last reset has been reset to zero 5 The display changes to rE Set for one second F P 44 READ OR RESET PRODUCTIVITY OF USER This displays or resets the total number of spins for either operator A B C or D depending what is chosen the main display 1 Choose the operator that you would like to read or reset from the main PCB by pressing the operator mode key A B C or D 2 Press and release the lt gt key turn the shaft until the display reads F P 44 is displayed and press lt enter gt The balancer will display A Ctr or B Ctr or C or D Ctr 3 The next display shows the total number of spins for the operator chosen Press the lt STOP gt key while this number is displayed 4 The total number of spins for that operator is now reset to zero
27. the plate in place without movement Tighten the upper screw 2 turn then tighten the lower screw full turn then tighten the upper screw an additional 75 turn Reassemble the complete balancer and perform a complete factory calibration to ensure proper opera tion NOTE MOVING THE TRANSDUCER AFTER CALIBRATION WILL CHANGE THE ACCURACY AND REQUIRE FACTORY CALIBRATION Checkout and Maintenance ENCODER REMOVAL Balancers Disconnect power Remove weight tray Disconnect the 10 Pin ribbon cable from the encoder PCB 4 Remove the phillip screw holding the encoder to the m shaft tube 229 NOTE CAREFUL TO LET FOREIGN DEBRIS FALL INSIDE THE TUBE Rear VIBRATORY MEMBER REMOVAL Balancers Disconnect the power from the rear of the machine Remove the weight tray Disconnect the mechanical brake at the vibratory system Disconnect the motor and encoder harness from the Power Supply box Remove the rear transducer Remove the access plugs from the front of the balancer Using 1 4 drive 6mm hex head SOT part TMAMGE remove the six 6mm hex bolts to the vibratory Pay special attention of spacer placement Lift up on the vibratory member and remove VIBRATORY INSTALLATION Balancers Lift and set vibratory member into the balancer housing Insert spacers Apply Loctite 242 to the hex bolts With the aid of a helper start the two
28. trim to exact weight paint and label A test tire and wheel balanced to within 0 10 oz 2 8 gr on both inside and outside planes or 0 20 oz stati cally mode 7 is required during some troubleshooting procedures In the event of vibratory system replacement the use of a certified Pruefrotor Figure 3 1 will be required to confirm conformance to design specifications and certification requirements 1 2 Checkout and Maintenance FUNCTIONS OF SNAPON JBC VPI BALANCERS All the service codes are entered using F P codes The procedure for activating an F P code is described below 1 Press and release the lt gt key the left window displays letter F P and right window displays current F P code number 2 Press and release the lt gt key rotate the shaft to increase or decrease the number in the RH display until the desired code number is reached 3 In general the F P code will display some brief information to the operator for 1 2 seconds and the machine enters the corresponding function SERVICE CODES The JBC balancer requires that the F button be pressed while the Snapon balancer uses the P button 1 Toggle switch between fine and normal balancing mode 2 Toggle switch between inch and millimeter display of width 3 Toggle switch between gram and ounce display 4 Calibration with adapter or disable adapter compensation 7 Toggle switch of millimeter and inch for diameter measurement 12 Read counters
29. weight as an in dex 80 5 After a short the machine displays POS and changes to tO FLA Touch the tip of the width gauge to the backing collar and hold it for one second or press the F button 80 6 The display will change to H POS followed by a tone Return the SAPE arm to the home position Display will then change to tO CAL SLG Screw the calibration weight onto the outside of the flange Touch the tip of the width gauge to the tip of the calibration slug and hold it for one second or press the F button 80 7 The display will change to SAP E 2 FIN for one second followed by a tone indicating a successful calibration Unit will then go into an idle state CALIBRATION COMPLETE Checkout and Maintenance F P 83 FACTORY CALIBRATION PROCEDURE NOTE THE F80 CALIBRATION MUST BE DONE BEFORE THIS OPERATION A balanced tire and wheel assembly can be substituted if a Pruefrotor is not available The calibration proce dures are the same and can easily be performed However custom parameters must be used for this proce dure if using a balanced tire and wheel assembly Beginning with a balanced Tire and Wheel assembly Mount the tire and wheel assembly on the shaft For this example a 14 X 5 5 wheel will be used Enter the distance diameter and width user defined Press and release the lt F P gt key turn th
30. 83 Basic calibration of vibratory system C84 Measurement of residual main shaft unbalance e C88 Adjustment of 12 h position C90 Saving calibration data The machine is now ready for use 2 2 RECOMMENDED SERVICE STEPS In case of an error it is recommended to perform some service code to check the system The following are some common service codes for this job C28 Indicate the content of the error record C74 Check the incremental encoder of the main shaft C54 Some more testing for the incremental encoder of the main shaft C98 Check the incremental encoder of the power clamp C63 Continuous measurements for test of valid results C56 Check the pedal switches The switches and the Function Code to lock the power clamp should be checked if the power clamp does not work C75 Check Voltages of SAPE potentiometers AD8 AD9 AD10 or perform STEP 1 of C80 and C82 C80 Check Voltages for left SAPE ATTENTION This is a calibration function interrupt this function after the test in STEP 1 with the STOP or ESC key e C82 Check Voltages for right SAPE ATTENTION This is a calibration function interrupt this function after the test in STEP 1 with the STOP or ESC key C55 Check lines Voltage C110 Check VCC Voltage Chapter 2 Diagonostic Codes 2 3 SELF TEST DURING START UP CRT HNA HWT A series of tests is accomplished after the machine has been turned on If a test is not successful e
31. DES 2 1 IN FIELD REPROGRAMMING OF BALANCER annaia Ora ttis 2 2 2 2 RECOMMENDED SERVICE STEPS E Ea 2 2 2 3 SELF TEST DURING START UP 2 3 SERVICE CODES ZATICODES CRTIHNA HWT I aao EI uS sii Les qub C at tua n IUUD NEU EIE 2 14 2 9 E CODES pre MMm 2 15 2 6 1 STRUCTURE OF AN ERROR CODE pA RUMP VA oea NA NEEE NEEE E EEEN 2 18 2 7 2 MODULE aa a a E E AE 2 18 CK S PRIORITY ID 2 19 TR 2 20 2 10 IBP CODES n 2 26 CHECKOUT CALIBRATION AND MAINTENANCE GENERAL This book incorporates all motorized Y2Kb c balancers manufactured in Conway Arkansas The test codes for each digital display balancer are alike and so are the results The JBC balancer uses F to begin any service procedure the Snapon balancer begins all service procedures with a P code All F P codes run parrallel If a service routine is not available for any particular balancer the result will be displayed as NOt USE SHAFT IMBALANCE WHEEL ADAPTER TO SHAFT REMOUNT TEST This test proves the wheel balancer centering device is balanced turns true and proves the centeri
32. E gauge arms are turned off Wait for 5 seconds or press STOP or ESC key to continue 0 Check content of permanent memories E145 Affected models All models Service Codes C85 C86 to copy content of permanent memory Contents of both permanent memories are different but both contain valid data If the trouble signalled by the error code is not remedied using service codes C85 or C86 the machine will remain in service code mode Check availability of keyboard E300 Affected models CRT models Service Codes No service code available The microcontroller was not able to detect a keyboard Check cabling between microcontroller and key board 2 Check Optima Calibration E360 Affected models Models with optima hardware Service Codes C123 The optima hardware requires wheel profiler position calibration When the camera controller board is replaced on the machine the SW detected that calibration data are missing Calibration procedure C122 is required to calibrate the actual position of the laser scanners with respect to the balancer reference plane 3 Check Optima Hardware E360 Affected models Models with optima hardware Service Codes C123 Wheel profiler is not present or is not responding during self test The balancer controller board was not able to communicate with the camera controller board during start up self test Possible causes The camera controller board is missing or dead The flat cable connecting the bala
33. ION WITH ADAPTER OR DISABLE ADAPTER 1 4 F P 7 TOGGLE MILLIMETER AND INCH FOR DIAMETER inepta enne Deut aba ni boc eot 1 4 12 READ COUNTERS T 1 4 F P 34 USER CALIBRATION PROCEDURE 1 5 F P 18 ACUS MODE O e A EA Ta 1 5 F P 19 ALU S ONE PLANE BALANCING 1 5 FAP 21 KERNEL SOFTWARE c 1 5 28 KERNELERROR MESSAGES iine ead acta eee eh ede 1 5 36 TOGGLE ANGLES OF LEFT AND RIGH T WEIGH 1 6 F P 43 RESETTING THE GOLEINTEPIS 1 6 F P44 READ OR RESET PRODUCTIVITY OF USER 1 6 F P 50 READ OUTPUT VOLTAGE OF THE DISTANCE POTENTIOMETER OF 5 1 6 51 READ OUTPUT VOLTAGE OF THE DIAMETER POTENTIOMETER OF 1 6 52 READ OUTPUT VOLTAGE OF THE WIDTH POTENTIOMETER sees eee Tr FAP 53 DISPLAY TEST c 1 7 F P 55 CHECKAC AND DCO VOLTAGE Ems 152 56 CHECK PEDAL AND HOOD SWITCHES ON POWER CLAMP sese eee ee 1 7 F P 59 DISPLAYS THE UNBALANCE OF THE BARE SHAFT sse eee lez F P 60 READ SHAFT RPM sccssicesscsssunnccisseasiennatwnusovnnssuvnaantarkauionea enpiri aip i aa E aa SE
34. SUBSTITUTED BALANCER DIAGNOSTICS TROUBLESHOOTING Many problems may be found by process of elimination By determining the problem then eliminating po tential problem areas starting with the most likely to fail items solutions to problems may be rapidly found The Y2k balancer is composed of subsystems each requiring several inputs for proper function With proper inputs the subsystem performs as expected and produces an output Every piece of equipment when oper able functions in a predetermined manner Events have to take place in the proper sequence every time A balancer must Checkout and Maintenance Be supplied with correct power and ground Give a display output Accept Keypad input Process commands through the Computer Receive and process encoder transducer inputs Brake Display proper weight amount and location The technician should watch a machine work and make performance assessments based on what is seen subsystem failure is suspected use diagnostic tests to confirm the failure Remember every part requires input to produce the expected output These outputs in turn become inputs for further use by the system TROUBLESHOOT USING CORRECT DIAGNOSTICS PROCEDURES Balancers are relatively simple pieces of machinery With proper diagnostic procedures balancer problems should be quickly resolved The Basics that the technician must never overlook are 1 AC Power The unit must be supplied with correct AC power
35. WHELL BALAM ER EEWB502 Service Manual All information contained or disclosed in this document is con sidered confidential and proprietary by Snap on Equipment All manufacturing use reproduction and sales rights are reserved by Snap on Equipment and the information contained herein shall not be used in whole or in part without the express written consent of Snap on Equipment Table of Contents CHECKOUT CALIBRATION AND MAINTENANCE GENERAL We MO E Y 1 SHAFT IMBALANCE WHEEL ADAPTER TO SHAFT REMOUNT 1 BALANCER DIAGNOSTICS TROUBLESHOOTING ss see ripara tact Spr pub md rue 1 TROUBLESHOOT USING CORRECT DIAGNOS TIGS PROGEDURES 1 2 TOOLS REQUIRED WHEN SERVICING THE Y2K BALANCERS eee eee 1 2 FUNCTIONS OF SNAPON JBC 1 3 SERVICE CODES A ee ee A re 1 3 F P CODE DESCRIPTIONS OF THE BALANCER 1 4 F P 1 TOGGLE FINE WEIGHT MODE tT 1 4 F P 2 RIM WIDTH INGE MILEIMETER 1 4 RUIN Gates casa antes da 1 4 4 CALIBRAT
36. a EE NEENA 1 7 F P CONTINUOUS BALANCIN rcoC anne ina E 1 7 F P 64 DISPLAYS THE TRANSDUCER OUTPUT sse 1 7 F79 CALIBRATION OF WIDTH SAPE 1 8 F P 80 SAPE GAUGE CALIBRATION EEEE UN RIA Paa EEan 1 9 F P FACTORY CALIBRATION PROCEDURE Reiten oli Oe euo RS ui 1 11 F P 84 EMPTY SHAFT CALIBRATION PROGEDUNRE neta 1 13 F P 88 TDC CALIBRATION x cU 1 13 90 MATCH BALANCE 1 14 ixi Re dp eec m 1 14 F P 92 NIIT 1 14 FP 94 SPOKE MODE gen eee 1 14 F P 95 GLEAN amp RESET EEPROM 1 amp 2 1 14 FIPSZSHORYTAULTOP STOP AT TOP 55 1 14 SERVICING THE BALAN GEIR 2 1415 CONTROL PANEL REMOVAL amp REPLACEMENT eee 1 15 MAIN PROCESSOR aN A ensa 1 16 TOACCESS THE INSIDE OF THE MACHINE 2 a 1 17 TRANSDUCER REMOVAL MENT ha ea alu 1 18 INSTALLATION
37. a conditioning can t get proper speed information During measuring run User break Measuring run stopped by user During measuring run Temperature information invalid 20 used instead During measuring run Can t perform transducer correction Channel 1 channel 2 Phase shift too big Transducer 1 No signal Transducer 1 transimpedance to low Transducer 1 RC time constant out of range Transducer 1 transimpedance amplifier idle voltage out of range alae o AB A o 6 A o c po AB Hrs 405 HEN 45 45 9 420 423 A A A ho ho o A ojo A 2 24 Chapter 2 Diagonostic Codes Ee Internal error Invalid event level software is not able to detect the reference mark Incremental encoder Counter reference mark mismatch Hand spin with electromagnetic released brake main shaft rotates backwards Line voltage below limit Line voltage above limit Line voltage much too high VCC below limit VCC above limit Keyboard display voltage below limit Keyboard display voltage above limit 4 50 V External voltage pedal below limit see keyboard module External voltage pedal above limit see keyboard module 2 25 Chapter 2 Diagnostic Codes Power fail detected OPTIMA hardware
38. ation basic calibra tion is all that is performed NOTE IF THIS IS THE FIRST TIME FOR FACTORY CALI BRATION AND THE OPERATOR PRESSES THE STOP KEY TO STOP THE REMAINDER OF CALIBRA TION F14 WILL NOT BE AVAILABLE TO THE OPERA TOR 9 Press lt gt to continue calibration Displays SPN 4 10 Remove the Pruefrotor Tire amp Wheel from the shaft Spin the empty shaft by lowering the hood or pressing the enter key Figure 83 5 The board displays the information in the following order NOTE 2 CONES AND THE POWER CLAMP NUT MUST USED ON A POWER CLAMP SYSTEM Displays CAL 4 when the shaft reaches calibration speed The machine is taking data and doing calculations After taking data shaft is automatically braked to a stopped Displays SPN 5 when shaft stops 11 Install the calibration slug on the left side of the bell housing Figure 3 18 Spin the shaft by lowering the hood or by pressing the enter key Displays CAL 5 when the shaft reaches calibration speed The machine is taking data and doing calculations After taking data shaft is automatically braked to a stopped Displays CAL FIN ISH after a successful calibration e Displays when shaft stops and machine is in a stand by mode Must complete F P 84 after this function CALIBRATION COMPLETE i S ha Li Ex _
39. balancer All measured angular positions are related to the mass to balance the wheel they are not the positions of the imbalance mass itself If the balancer is in service mode some of the normal behavior is changed gt Ao Some error codes will be written into the error record in normal operation mode This is disabled in service mode errors will not be recorded The number of revolution for a measurement run in service mode is set to 20 turns GS JBEG models two times of the C6 setting but minimum 20 turns CRT HNA HWT models 2 1 IN FIELD REPROGRAMMING OF BALANCER Turn off balancer Place EEPROM in micro controller socket with flat end at bottom of socket close to large blue connector Notched end is 3 spaces short of other end of socket IBP Remove dummie plug and place secure disk into opening Turn on balancer Three audible beeps accompanied by three flashes of the led on the micro controller board indicate that pro gram is loading A continuous sequence of beeps and flashes indicates that program loading is complete Turn off balancer Remove EEPROM and turn on balancer IBP Remove secure disk The normal start up procedure will be performed Perform service codes in the following order e C47 Select machine model BFH Optima C80 Calibration of inner SAPE gauge arm C81 Measurement of flange to zero plane distance C82 Calibration of outer gauge arm Optima C
40. ble connecting the camera controller board and the outer scanner CCD board is unplugged missing or damaged the cable of the laser module of the outer scanner is damaged or there is a fault in the laser module itself there is a fault in the camera controller board laser drivers Corrective actions check all items above Check Optima outer laser modulation E388 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the outer scanner CCD board is unplugged missing or damaged the cable of the laser module of the outer scanner is damaged or there is a fault in the laser module itself there is a fault in the camera controller board laser drivers Corrective actions check all items above Check Optima rear CCD signals E390 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the rear scanner CCD board is unplugged missing or damaged there is a fault in the rear scanner CCD board there is a fault in the camera controller board the supply voltage is configured too high on the power interface board Corrective actions check all items above switch power off and on again should the problem not go away please call service 24 2 Check Optima rear scanner memory E391 Affected models Models with optima hardware Service Codes C123 Possible causes
41. bove Check Optima inner laser modulation E378 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the inner scanner CCD board is unplugged missing or damaged the cable of the laser module of the inner scanner is damaged or there is a fault in the laser module itself there is a fault in the camera controller board laser driversCorrective actions check all items above Check Optima outer CCD signals E380 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the outer scanner CCD board is unplugged missing or damaged there is a fault in the outer scanner CCD board Sthere is a fault in the camera controller board the supply voltage is configured too high on the power interface boardCorrective actions check all items above Switch power off and on again should the problem not go away please call ser vice 23 2 Check Optima outer scanner memory E381 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the outer scanner CCD board is unplugged missing or damaged 2 7 Chapter 2 Diagnostic Codes there is a fault in the outer scanner CCD board there is a fault in the camera controller board Corrective actions check the connections check the ou
42. braked to a stopped Displays SPN 2 when shaft stops Checkout and Maintenance Attach the 3 5 ounce weight 100 gr on the inside of the Prue frotor Tire amp Wheel Figure 3 15 T Spin the Pruefrotor Tire amp Wheel by lowering the hood or pressing the enter key Displays CAL 2 when the shaft reaches 90 RPM s The ma chine is taking data and doing calculations After taking data shaft is automatically braked to a stopped Displays SPN 3 when shaft stops Attach the 3 5 ounce weight 100 gr on the outside of the Prue frotor Tire amp Wheel Figure 3 16 NOTE IF USING A TIRE AND WHEEL ASSEMBLY ATTACH THE 3 5 OZ WEIGHT ON THE OUTSIDE 180 DE GREES OPPOSITE THE INSIDE WEIGHT LOCATION Spin the Pruefrotor Tire amp Wheel by lowering the hood or pressing the enter key Displays CAL 3 when the shaft reaches calibration speed The machine is taking data and doing calculations After taking data shaft is automatically braked to a stopped Displays CAL GOO d when the third step of calibration is finished and the calibration is successful or displays CAL FAL L if the calibration fails Display then changes to to prompt operator to press the lt F P gt key to continue calibration or operator can press the STOP key to exit out of calibr
43. e camera controller board and the inner scanner CCD board is partially unplugged or damaged there is a fault in the inner scanner CCD board check the connections check the inner scanner CCD board switch power off and on again should the problem not go away please call ser vice Check Optima inner scanner calibration E373 Affected models Models with optima hardware Service Codes C123 Possible causes Corrective actions the inner scanner has not been factory calibrated please call service and replace the inner scanner 22 5 Check Optima inner motor power supply E374 Affected models Models with optima hardware Service Codes C123 Possible causes Corrective actions the cable connecting the camera controller board and the inner scanner motor is unplugged damaged or missing the motor power supply is not configured properly there is a fault in the motor power supply board the cable connecting the mains supply and the motor power supply board is unplugged damaged or missing there is a fault in the inner scanner motor there is a fault in the camera controller board motor drivers check all items above Check Optima inner scanner zero mark E375 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the inner scanner CCD board is unplugged missing or damaged there is a fault in the inner scanner CCD board the inn
44. e shaft until the display reads 83 is displayed and press ENTER to activate function of F P 83 After entering the F P83 function the balancer will automatically switch to default parameters 15 X 6 5 Press lt gt button to change from default parameters to user defined parameters The display will change to USE CST for one second and then display SPN 1 Pressing the lt F P gt button again will toggle the unit back to factory defaults NOTE IFA TIRE AND WHEEL ASSEMBLY IS USED PROCEED TO STEP 6 SH Beginning with a Pruefrotor 1 Mount the Pruefrotor on the balancer shaft Figure 83 1 i 2 Pull the distance gauge arm out and touch the Pruefrotor 7 Figure 83 2 3 Return the Distance Gauge to the home position i 4 Press and release the lt gt key turn shaft until the 83 1 display reads 83 is displayed The display changes to CAL BAL for one second 5 The display then changes to SPN 1 6 Spin shaft with the Pruefrotor Tire amp Wheel by lowering the hood or pressing the enter key The board displays the information in the following order Displays CAL 1 when the shaft reaches calibration speed The machine is taking data and doing calcula tions After taking data shaft is automatically
45. er from the rear of the machine Remove the weight tray Disconnect the 1D SAPE return spring from the lower base assembly Remove the 10mm nut holding the SAPE wheel to the frame Remove the 13mm nut holding the potentiometer to the frame DISTANCE SAPE STRING ROUTE INSTALLATION PE I 1 amp SOT LD Install 10K potentiometer onto bracket and tighten 13mm nut Install SAPE Wheel onto potentiometer shaft and hand tighten 10mm nut Attach SAPE thread to distance rod Route SAPE thread over guide roller and around the spool as shown by blue arrows Attach the spring from the SAPE bracket to the spool Test SAPE assembly by pulling on the SAPE arm to it s full out position several times Make sure their is no binding With the SAPE arm in the HOME position program F P gt lt 50 gt Hold the SAPE wheel firmly using a flatblade screw driver turn the potentiometer to a voltage reading of 3 10 02V Run lt F P gt lt 80 gt for SAPE calibration WIDTH SAPE POTENTIOMETER INSTALLATION JBC VPI SYSTEM IV Disconnect the power from the rear of the machine Remove the weight tray Disconnect the 3D SAPE wire from the Power Supply box and gently pull the wire through the hood tube Remove the three screws holding the top cover on the SAPE arm Remove the three screws holding the bottom cover on the SAPE arm Remove the 10mm nut holding the gear to the potenti ometer Remove the 13mm nut holding the potentiometer
46. er motor there is a fault in the camera controller board motor drivers the cable connecting the camera controller board and the rear scanner motor is partially unplugged or damaged Corrective actions check all items above Check Optima rear laser power supply E397 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the rear scanner CCD board is unplugged missing or damaged the cable of the laser module of the rear scanner is damaged or there is a fault in the laser module itself there is a fault in the camera controller board laser drivers Corrective actions check all items above Check Optima rear laser modulation E398 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the rear scanner CCD board is unplugged missing or damaged the cable of the laser module of the rear scanner is damaged or there is a fault in the laser module itself there is a fault in the camera controller board laser drivers Corrective actions check all items above 25 1 Check Optima rear shift motor power supply E404 Affected models Models with optima hardware Service Codes C123 Possible causes the cable connecting the camera controller board and the rear shift scanner mo tor is unplugged damaged or missing the motor power supply is not configured properly
47. er scanner is locked the inner scanner zero mark is missing bent locked or damaged the cable connecting the camera controller board and the inner scanner motor is unplugged damaged or missing 2 6 Chapter 2 Diagonostic Codes there is a fault in the motor power supply board there is a fault in the inner scan ner motor there is a fault in the camera controller board motor drivers Corrective actions check all items above Check Optima inner motor missing steps E376 Affected models Models with optima hardware Service Codes C123 Possible causes the inner scanner movement is not smooth or it is striking the frame the motor power supply is not configured properly there is a fault in the motor power supply board there is a fault in the inner scan ner motor there is a fault in the camera controller board motor drivers the cable connecting the camera controller board and the inner scanner motor is partially unplugged or damaged Corrective actions check all items above Check Optima inner laser power E377 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the inner scanner CCD board is unplugged missing or damaged the cable of the laser module of the inner scanner is damaged or there is a fault in the laser module itself there is a fault in the camera controller board laser driversCorrective actions check all items a
48. ero mark not detected E365 OPTIMA rear scanner self test fail or CCD not calibrated or zero mark not detected Esr OPTIMA motor power supply missing or out ofrange fesse main camera board A D converter failure Ese main shaft encoder zero mark detection failure or missing cable BO C fen oPmMAmmerGCDsgnastaue oPmMAimerscemermemoymotrespondng ewe oPmMAmmerscemermemeymotvald ess oPmMAmmerscemernotcaibraed Es inner motor current sink or power supply failure fess OPTIMA inner scanner zero mark not detected _ fess OPTIMA inner motor missing stees esm OPTIMA inner laser current sink or power supply failure fess OPTIMAinner laser madulationfaiure LLL 5o esr oPmMAeuwerscamermemenynotrespondimg OPTIMA outer scanner memory 2 16 Chapter 2 Diagonostic Codes OPTIMA outer scanner not calibrated 390 Eo oPmWApuldexusercalbratontalue Ep shit motor current sink or power supply failure tns __ OPTIMA shift scanner ze
49. errors will occur SAPE voltage readings in the HOME position F50 Distance F51 Diameter F51 Diameter F52 Width on Bell Housing On Vibratory Tube 308 3 12V 12 80 290 3 05 3 15 V 3 08 3 12 Y 2 80 290V 305 345 3 10 320 3 08 3 12 V 280 290 305 315V Qro e Nc Remove the power from the balancer Remove the weight tray from balancer Disconnect all wiring harnesses from the Electronic box and remove the old electronic box Partially insert the new Electronic box into the back of the balancer Feed all the harnesses out the back of the cabinet through the Ebox access hole This will make it much easier to make the connections Secure the new Ebox using the existing screws Embedded PC Hood Pedal Display Encoder Distance Diameter Width Pot Switch Pot Pot Incoming Motor Electric Brake Power Power Clamp 11 12 13 TO ACCESS THE INSIDE OF THE MACHINE 1 2 Checkout and Maintenance Make sure all the SAPE arms are in the home position Remove the dummy plug from the secure disk slot and install the new software Please NOTE that the secure disk will only go in one way DO NOT FORCE the media into the opening Power up the balancer When the unit begins to continually emit beeps the download process is com plete Turn off the balancer remove the software and reinstall the dummy plug and re boot After the re boot process the balancer wil
50. g the cam to the hood shaft and slide the cam off of the shaft NOTE THE HOOD SPRING IS UNDER PRESSURE TO RELEASE PRESSURE RAISE THE HOOD TO THE OPEN POSITION Remove the screw from the shaft that attaches the hood spring Reverse procedures for installation 1 23 Checkout and Maintenance HOOD SWITCH CAM SPRING PE SYSTEM Il amp SOT LOW DIGITAL Disconnect the power from the rear of the machine Remove the weight tray Disconnect the Hood Switch from the Power Supply Board and remove the wiring from the connector Remove the two 2 screws holding the switch to the mounting bracket Remove the set screw holding the cam to the hood shaft and slide the cam off of the shaft NOTE THE HOOD SPRING IS UNDER PRESSURE TO RELEASE PRESSURE RAISE THE HOOD TO THE OPEN POSITION Remove the screw from the shaft that attaches the hood spring Reverse pocedures for installation HOOD SWITCH CAM SPRING 046 SYSTEM 1 Disconnect the power from the rear of the machine Remove the weight tray Disconnect the Hood Switch from the Power Supply Board and remove the wiring from the connector Remove the cover plate from the wheel guard box Remove the two 2 screws holding the switch to the wheel guard box Install the new switch and route the wiring harness through the access hole Install the wiring into the connector Reverse procedure for installation 1 24 CHAPTER 2 DIAGNOSTIC CODES GENERAL OVERVIEW Balancers that
51. gauge To remove the SAPE arm remove the phillips screw that attaches to the distance rod To remove the distance rod disconnect the diameter string from the end of the rod Slide the distance rod completely out Reverse procedure for installation 1 20 Checkout and Maintenance DISTANCE SAPE POTENTIOMETER VPI III IV Disconnect the power from the rear of the machine Remove the weight tray Disconnect the 1D SAPE belt from the distance rod Remove the 10mm nut holding the SAPE wheel to the frame NOTE DO NOT LET THE RETURN SPRING UN COIL Remove the 13mm nut holding the potentiometer to the frame DISTANCE SAPE POTENTIOMETER INSTALLATION Install 10K potentiometer onto bracket and tighten 13mm nut Install SAPE Wheel onto potentiometer shaft and hand tighten 10mm nut Attach SAPE belt to the guide roller Route SAPE belt over guide roller Loop SAPE belt through the auto lock mechanism and attach the SAPE belt to the distance rod Test SAPE assembly by pulling on the SAPE arm to it s full out position several times Make sure their is no binding With the SAPE arm in the HOME position program lt F gt 50 System IV C80 Hold the SAPE wheel firmly using a flatblade screw driver turn the potentiometer to a voltage reading of 3 10 02 Run lt F C gt lt 80 gt for SAPE calibration 1 21 Checkout and Maintenance DISTANCE SAPE POTENTIOMETER VPI Il amp SOT LD Disconnect the pow
52. he software 1 Press and release the lt F gt key toggle the UP DOWN button or press and hold the P key while turning the Diameter Function Knob until 95 is displayed The machine displays CLN EEP imme diately The user can press the STOP button at anytime before step 5 to abort this procedure Press F P button the balancer displays 1 1 1 Press F P button again the balancer displays 2 2 0 2 Press F P button again the balancer displays 3 3 3 If user press F button again balancer displays CLN EEP and erases all information in the EEPROM and resets the machine NOTE ALL FACTORY CALIBRATION PROCEDURES ARE REQUIRED F P 97 STICKY AT TOP STOP AT TOP Used to turn Sticky at Top on or off Press F 97 ENTER display changes to STY ON sticky at top is now on Pressing F 97 ENTER again changes the display to read STY TOP OFF sticky at top is now off Checkout and Maintenance SERVICING THE BALANCER NOTE BEFORE OPENING THE MACHINE FOR SERVICE DISCONNECT ELECTRICAL SUPPLY LINE AND USE THE LOCKOUT TAGOUT PROCEDURE WARNING DANGEROUS HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENT The balancer is supplied with 110 230 VAC It is critical to have the proper input voltage in order for the balancer to operate correctly The balancer performs a systems check on initial power up If a problem is detected t
53. he balancer will emit random beeps To check power cable Disconnect the power supply from the balancer Using a VOM check for an output voltage at the end of the power plug 230VAC 1096 VAC VPI Sys tem or 110VAC 10 VPI System I Il and SOT Low Digital To check power to power supply box Remove the weight tray Using a VOM check for 230VAC at the power supply board X41 pins 2 amp 3 all balancers CONTROL PANEL REMOVAL amp REPLACEMENT The Digital Display Board is mounted directly to and behind the keypad on each balancer Figure 3 22 Using a 4mm Hex Key remove to 4 screws holding the Display Panel to the upper Display on VPI and the SOT Low Digital is held in place with velcro gently pry the display forward To remove the Display Board unplug the membrane panel and simply remove the 4 8mm nuts holding it onto the backing plate Once the keypad is removed from the backing panel it cannot be reused The keypad can be removed by gently peeling back at a corner If a keypad is suspect for replacement it is suggested testing a new keypad before replacement Checkout and Maintenance MAIN PROCESSOR REPLACEMENT Before flashing the new Main PCB on an IBP Processor check and adjust the SAPE potentiometers for the correct voltage settings F P 50 51 F52 see chart below The distance setting is very critical for correct operation before flashing The voltage setting must be within the specified range or
54. hift scanner motor there is a fault in the camera controller board motor drivers the cable connecting the camera controller board and the rear shift scanner mo tor is partially unplugged or damaged check all items above 26 Check model information E900 Affected models All models Service Codes C47 to set model The stored machine model is not known If the trouble signalled by the error code is not remedied using service codes C47 the machine will remain in service code mode 27 calibration E901 Affected models All models Service Codes C80 C81 C82 C83 C84 C88 C90 Machine was not calibrated For calibration the following calibration codes will have to be carried out in the sequence as given below C80 Calibration of inner SAPE gauge arm C81 Measurement of flange to zero plane distance C82 Calibration of outer gauge arm C83 Basic calibration of vibratory system C84 Measurement of residual main shaft unbalance C88 Adjustment of 12 h position C90 Saving calibration data 28 Hardware test disturbed H 82 Affected models All models Service Codes All codes available for the model A self test was disturbed e g wheel was rotated during the transducer test The code is read out for 3 seconds then measurement is repeated 10 times maximum or aborted using the STOP or ESC key 29 Check Optima main shaft encoder zero mark 1 Affected models All models Service Codes All
55. l identify itself Press the ENTER button to confirm the model number The balancer will reboot f the balancer is Snapon Low Digital or JBC System the tech nician will need to use the P or F to toggle and select the correct model If the balancer is a System III it will be necessary to program either 3 b basic vibratory or press the to toggle 3 for a power clamp unit Press the ENTER key to confirm the model selected If the wrong model is selected the technician will need to perform an F P 95 to clear the EEprom It may be necessary to perform an extended F50 digital balancer The supply voltage from the old sys tem to the new system has changed from 5 0V to 3 3V therefore it will be necessary to reset the value of PO 220 Place the distance gauge in the home position and program F P 50 Verify the home position voltage mentioned in step 12 Press the lt F P gt button the display changes to 1 1 press it again the display will change to 2 2 and then finally 3 after the final press Set dis 220 will be displayed saving the home voltage to PO 220 Complete all necessary factory calibration procedures use the service manual for proper procedures C80 Distance Diameter gauge calibration Distance F50 3 08 3 12 Small Cabinet 3 08 3 12 Medium Large Cabinet Diameter F51 3 05 3 15 On the Vibratory Tube A 2 80 2 90 On Bell Housing B Width F52 3 10 3 20 C83 Vibratory calibra
56. main board fault detected OPTIMA hardware inner scanner fault detected OPTIMA hardware outer scanner fault detected OPTIMA hardware rear scanner fault detected ERROR SELFTEST ASA Status of an activated order has changed due to network manager or shop management software activities 5 NENNEN 2 10 IBP CODES Y2K error User error internal internal 001 001 001 002 001 003 001 004 001 005 001 006 001 007 001 010 001 011 001 012 001 020 001 021 001 022 001 030 001 031 001 032 001 033 001 034 001 035 001 036 001 037 001 038 001 039 001 040 001 041 001 042 BK ERROR PO NOTFOUND BK ERROR PO READING BK ERROR PO WRITING BK ERROR PO EEP1 RD BK ERROR PO EEP2 RD BK ERROR PO EEP1 WR BK ERROR PO EEP2 WR BK ERROR KBD DISPLAY BK ERROR KBD VOLTAGE BK ERROR KBD READING BK ERROR DC OVERRUN BK ERROR IEM ZERO MISMATCH BK ERROR ZERO MISMATCH BK ERROR POWER FAIL BK ERROR TEMP SENSOR BK ERROR VCC ABOVE LIMIT BK ERROR VCC BELOW LIMIT BK ERROR VDISP ABOVE LIMIT BK ERROR VDISP BELOW LIMIT BK ERROR LINE ABOVE LIMIT BK ERROR LINE BELOW LIMIT BK ERROR OPTO SHORT HIGH CUR BK ERROR OPTO OPEN LOW CUR BK ERROR SAPE 1D LOW VOLT BK ERROR SAPE 1D HIGH VOLT BK ERROR SAPE 2D LOW VOLT internal internal o D gt gt gt 5 o lt x x S internal o x x 5 e ELE IE S S X x 5 T
57. n changes to B 2 0 10 for 3 seconds this is the balancer kernel revision The display will then change to JBC or SOT SYS 1 2 or 3 this is the brand The display will then display EEb XXX X this is the model number The unit will then display the user interface revision UI 1 0 The last is the date code for the revision Dat 112 607 11 26 07 F P 28 KERNEL ERROR MESSAGES Enter F P 28 the machine will display Err for 2 seconds and then display Err 0 for 1 second fol lowed by the error code Pressing the lt F gt again will toggle the machine to the 2nd recorded error code and so forth The balancer can display up to 10 error codes after which the display will display CLN ERR allow ing the operator to clean all recorded error codes by pressing the lt gt the final time and clearing all codes or pressing the STOP key will cancel the Clean operation for further diagnostics 1 5 Checkout and Maintenance F P 36 TOGGLE ANGLES OF LEFT AND RIGHT WEIGHTS Begin procedure by mounting a tire and wheel assembly Enter all wheel parameters and spin the tire and wheel assembly After F P36 is activated machine displays POS ANG first Once the shaft moves machine displays encoder position in integer form from 0 to 511 in left window and angle in floating form from 0 00 to 359 in right window Meanwhile machine lights on the position bars to indicate
58. ncer controller board and the camera controller board is unplugged damaged or missing 4 Check Optima Hardware E362 Affected models Models with optima hardware Service Codes C123 Main camera board self test fail Balancing is not possible since wheel data cannot be scanned Problem during power up Switch power off and on again Should the problem not go away please call service S 15 Affected models Models with optima hardware Service Codes C123 Left side scanner self test fail or CCD not calibrated or zero mark not detected Balancing is not possible since wheel data cannot be scanned Problem during power up Switch power off and on again Should the problem not go away please call service E363 2 4 Chapter 2 Diagonostic Codes 6 Check Optima outer scanner E364 Affected models Models with optima hardware Service Codes C123 Right side scanner self test fail or CCD not calibrated or zero mark not detected Balancing is not possible since wheel data cannot be scanned Problem during power up Switch power off and on again Should the problem not go away please call service T Check Optima rear scanner E365 Affected models Models with optima hardware Service Codes C123 Rear scanner self test fail or CCD not calibrated or zero mark not detected Wheel data can be scanned balancing is possible Run out measurement of the wheel is no
59. ng device inside taper and balancer shaft outside taper mating surfaces are true 1 Mount a medium size wheel assembly 14 input the rim dimensions and balance the wheel assembly to 0 00 ounces imbalance in both planes This must be fine balanced to exactly 0 05 in both planes 2 Spin balancer several times Verify that no more than 0 05 oz imbalance is displayed 3 Loosen the Speed nut and rotate the tire and wheel assembly 180 degrees making sure the cone does not rotate NOTE DO NOT REMOVE THE WHEEL ASSEMBLY 4 Operate the balancer The new imbalance displayed should not exceed 0 25 oz TEST PRODUCES READINGS OUT OF TOLERANCE 5 Remove the tire and wheel assembly from the balancer 6 Check the tapered surfaces of the basic centering device and balancer shaft They should be clean and smooth Clean and retest Check all mounting accessories cones wingnut etc making sure each fit on the shaft snug there should be no play between the shaft and mounting accessories 7 test still produces unacceptable results use a dial indicator measure runout of the balancer shaft tapered mounting surface Acceptable tolerance is 0 0015 T I R Total Indicated Runout If the surface measures out of tolerance replace the vibratory system 8 Perform a F P 80 F P 83 F P 84 and a F P 88 and retest These test can be found later in this Chapter NOTE AFINE BALANCED TIRE AND WHEEL ASSEMBLY ALONG WITH A 3 5 OUNCE WEIGHT CAN BE
60. r compensation flag to tell the program to use adapter compensa tion after tire balance is done 4 is a toggle it is used to turn this flag off After 4 is activated machine displays CAL ADP for one second And then it displays SPN 1 Operator spins the shaft just like ordinary balancing When the machine is taking data and calculation it displays CAL BAL to tell the operator the machine is working on the balancing procedure Once the calibration is done machine displays FIN to indicate the calibration is successful Once the shaft stops machine displays and exits the F P4 automatically The machine is now in an idle state When the machine is working under the application of an adapter the balancing mode display is differ ent than ordinary balancing In ordinary balancing the machine displays 2PL while the machine is taking data In balancing with an adapter the machine displays AdP 2PL as it takes data This reminds the operator he is under adapter compensation mode So if the operator does not use an adapter and the machine displays in left the window the operator should turn off the adapter compensation by toggling lt F gt 4 or by cycling power F P 7 TOGGLE MILLIMETER AND INCH FOR DIAMETER If a metric tire is to be balanced the diameter can be changed to enter the tire parameters in millimeters in stead of inches The default is se
61. rbed during execution H90 0x492203 acceleration during start or stop too slow measuring speed not reached 0x492204 Speed too low during measuring run m N o 2 14 Chapter 2 Diagonostic Codes 2 5 E CODES CRT HNA HWT ul error h revision 1 11 je mmaa Rim dimensions entered incorrectly amp guara is not closed Gauge arm not in home position E4 Outer gauge arm not in home position E5 Range of electrical unbalance compensation exceeded residual adapter unbalance E6 0x812560 Calibration weight not attached to flange 0x812561 0x812565 0x812566 No balancing mode for this wheel type Valve position was not entered Optimisation was carried out incorrectly MET Wheel guard is not open wheel may not be clamped unclamped E12 Not available to Pedal is operated measuring run not possible date wa Not available to The clearance of the solenoid brake is too wide date ME The power clamping device is not clamped Et5 Corrective terms for readjustment are out of range E16 0x812570 Calibration weight attached erroneously to flange 0x812571 Eu oxao2207 Wheel sipped on adapter rA oxao2205 Wrong direction ofrotaton _9 E E T Rim oniy mounted during geometric matching when rim and tyre expected
62. re to the foot pedal assembly Using a 13mm wrench hold the nut located at the top of the cable as indicated on Using a flatblade screwdriver turn the cable counterclockwise to apply tension to the brake or clockwise to loosen the brake The cable is properly adjusted when the tire and wheel assembly has a little resistance MECHANICAL BRAKE CABLE Disconnect the power from the rear of the machine Remove the Display panel Remove the weight tray Disconnect the brake cable from the vibratory member Make note of the location of the springs and washers Remove the two 5mm bolts holding the pedal to the frame Separate the pedal from the pedal bracket Pull the cable through the protective flex tubing Reverse pocedures for installation MOTOR REMOVAL Disconnect the power from the rear of the machine Remove the weight tray Disconnect the Motor wiring harness from the Power Supply box Remove the setscrew securing the motor pulley to the motor Remove the 4 bolts securing the motor from the vibratory system Reverse procedure for installation Using a pry bar pry against the motor spacers to tighten belt HOOD SWITCH CAM SPRING SYSTEM Ill IV Disconnect the power from the rear of the machine Remove the weight tray Disconnect the Hood Switch from the Power Supply Board and remove the wiring from the connector Remove the two 2 screws holding the switch to the mounting bracket Remove the set screw holdin
63. rface C28 POutof memory F04 Out of range Mod 27 Temperature Out of Range Fo Bue ful Channel not found F07 Not found Mod 41 ASS Time client not found Mod 44 SAPE Time service not found during unregister Mod C1 Self test Self test failed result of test invalid Already exists 9 In use Mod 44 SAPE AWP already in use Mod 49 Drive system Internal error command not valid in actual mode of operation Many 490 09 errors in the error record indicates a malfunction of the pedal TE offi ros rive tui toc FOD Xmit error Mod C3 User Interface Communication Error between balancing kernel and user interface BK lt Ul Machine should be restarted This error can caused by a bad connection of the RS2 32 E serial line Check external and internal cabling FOE Format failed FOF Bad parameter Mod 41 ASS Invalid time specified Mod 44 SAPE Bad parameter during calling time service Mod 81 cmd Parameter of a kernel command is bad Such an error can occur as a result from a hardware malfunction Fio Badmedium 2 20 Chapter 2 Diagonostic Codes Error in expression Mod C3 User Interface Communication Error between balancing kernel and user interface BK UI This error can be cleared by pressing STOP or Escape This error can caused by a bad connection of the RS2 32 E serial line Check e
64. ro mark not detected Eis oPTMArearshitmetormissimgsteps 4 2 17 Chapter 2 Diagnostic Codes 2 6 1 STRUCTURE OF AN ERROR CODE A complete error code consists of 6 hexadecimal digits EXAMPLE 810 511 81 Command language Commands coming from the UI Critical error will be recorded in user mode BL BAL ERROR FailCalUser ou tl 511 Module ID 2 digit hexadecimal value and indicates the software module which detected the error Priority ID Represents the kind of error message only critical error Error ID Determines the kind of the fault Module ID Priority ID o O A 2 7 2 MODULE ID 2 18 main supply line Chapter 2 Diagonostic Codes s6 Balancing Kerel Test state machine eg selftest during startup 2 8 3 PRIORITY ID Prior ID Description S Critical error will be recorded in user mode For information only 2 19 Chapter 2 Diagnostic Codes 2 9 4 ERROR ID The table lists the error codes and gives some examples for an error ums S SSS F02 Invalid job Mod 2D Brake Module gets invalid event Mod 49 Drive system Internal error command not valid in actual mode of operation Mod 66 Meas Control Internal error Module gets invalid user event command not valid in actual mode of operation Mod C1 Self test Self test failed see error record for more information kernel register errO err9 or User inte
65. s above Check Optima outer scanner zero mark E385 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the outer scanner CCD board is unplugged missing or damaged there is a fault in the outer scanner CCD board the outer scanner is locked the outer scanner zero mark is missing bent locked or damaged the cable connecting the camera controller board and the outer scanner motor is unplugged damaged or missing there is a fault in the motor power supply board there is a fault in the outer scanner motor there is a fault in the camera controller board motor drivers Corrective actions check all items above Chapter 2 Diagonostic Codes Check Optima outer motor missing steps E386 Affected models Models with optima hardware Service Codes C123 Possible causes the outer scanner movement is not smooth or it is striking the frame the motor power supply is not configured properly there is a fault in the motor power supply board there is a fault in the outer scan ner motor there is a fault in the camera controller board motor drivers the cable connecting the camera controller board and the outer scanner motor is partially unplugged or damaged Corrective actions check all items above Check Optima outer laser power supply E387 Affected models Models with optima hardware Service Codes C123 Possible causes the flat ca
66. t possible Problem during power up Verify if the scanner is on its rail Switch power off and on again Should the problem not go away please call service 8 Check Optima main camera board memory E366 Affected models Models with optima hardware Service Codes C123 Possible causes there is a fault in the camera controller board Corrective actions check the camera controller board 9 Check Optima motor power supply E367 Affected models Models with optima hardware Service Codes C123 Possible causes the cable connecting the camera controller board and the motor power supply board is unplugged damaged or missing the motor power supply is not configured properly there is a fault in the motor power supply board the cable connecting the mains supply and the motor power supply board is un plugged damaged or missing Corrective actions check all items above 20 Check Optima main camera board A D converter E368 Affected models Models with optima hardware Service Codes C123 Possible causes there is a fault in the camera controller board Corrective actions check the camera controller board Check Optima main shaft encoder zero mark E369 Affected models Models with optima hardware Service Codes C123 Possible causes there is a fault in the camera controller board there is a fault in the encoder the cable connecting the camera controller board and the encoder board is un plugged missing or damaged
67. t to inches Pressing F P7 again toggles the balancer and forth between inches and millimeters DIA 1 NCH inches DIA millimeters F P 12 READ COUNTERS The balancer has 4 counters that keeps track of total number of cycles for a certain parameter The balancer will automatically cycle through the counters after lt F P12 gt is activated The order of the counters 1 Display Ctr ALL for one second Total number of spins 2 Display Ctr CAL for one second Total number of spins since last calibration 3 Display Ctr SrV for one second Total number of service spins 4 Display Ctr USR for one second Total number of user spins 5 The display will cycle through continuously through each step until STOP is pressed Checkout and Maintenance F P 14 USER CALIBRATION PROCEDURE The JBC VPI and SOT balancers feature a user calibration program which requires only a few minutes to complete Perform this procedure when the balancer has been moved disturbed or whenever accuracy is questioned Occasional field calibration will ensure years of reliable service 1 Activate Calibration Press and release the lt gt key turn the shaft until the display reads F P 14 Once F P14 activates the display will read CAL for one second The display will then read 1 2 Spinshaft F14 1 Lower the wheel guard and or press the en
68. ter key The shaft will spin n Displays CAL 1 when the shaft reaches speed RPM s machineis o 144 j IB taking data and doing calculations After taking data shaft is automatically braked to a stopped Displays 2 when shaft stops m 3 Spin shaft with calibration slug on the left side Mount calibration slug EAMO0005D40A to the shaft F14 2 Lower the wheel guard and or press the enter key The shaft will spin i lr Displays CAL 2 when shaft reaches speed At this mo ment the machine is taking data and doing calculation work After taking data shaft is automatically stopped T Displays CAL FIN ISH when the second step of calibration is fin ished and machine says the calibration result is FINE Displays when shaft stops and machine is in the idle state CALIBRATION COMPLETE NOTE THE BALANCER WILL NOT FUNCTION UNTIL A VALID CALIBRATION HAS BEEN PER FORMED ERROR MESSAGES WOULD BE DISPLAYED IN THE EVENT PROBLEMS OC CUR DURING THE CALIBRATION PROCESS F P 18 ALU S MODE Aluminum Static See the operation manual for a detailed explanation F P 19 ALU S ONE PLANE BALANCING MODE Aluminum Static See the operation manual for a detailed explanation F P 21 KERNEL SOFTWARE When F P21 is activated the machine display changes to REV ISI ON for 1 second The display the
69. ter scanner CCD board check the camera controller board Switch power off and on again should the problem not go away please call ser vice 23 3 Check Optima outer scanner memory E382 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the outer scanner CCD board is partially unplugged or damaged there is a fault in the outer scanner CCD board Corrective actions check the connectionsS check the outer scanner CCD board switch power off and on again should the problem not go away please call ser vice Check Optima outer scanner calibration E383 Affected models Models with optima hardware Service Codes C123 Possible causes the outer scanner has not been factory calibrated Corrective actions please call service and replace the outer scanner Check Optima outer motor power supply E384 Affected models Models with optima hardware Service Codes C123 Possible causes the cable connecting the camera controller board and the outer scanner motor is unplugged damaged or missing the motor power supply is not configured properly there is a fault in the motor power supply board the cable connecting the mains supply and the motor power supply board is unplugged damaged or missing there is a fault the outer scanner motor there is a fault in the camera controller board motor drivers Corrective actions check all item
70. tion C84 Empty shaft calibration C88 Top Dead Center TDC calibration Mount a Tire and Wheel assembly Using the SAPE assembly verify all data taken matches the tire and wheel being used Balance the Tire and Wheel assembly to verify operation F51 Remove the screws from the front and rear of the weight tray Standing at the front of the machine rotate the SAPE arm to it s full most outward position Lift and remove the weight tray Avoid breaking or damaging wire harnesses Harnesses may be held in place with various retainer clips NOTE WHEN INSTALLING THE WEIGHT TRAY BE FUL NOT TO CRUSH WIRES Checkout and Maintenance TRANSDUCER REMOVAL The transducers are held in place with setscrews and jam nuts Disconnect the power from the rear of the machine Remove the display panel Remove the weight tray Using a 2 5mm hex key remove the preload plate Figure 3 26 Using a 13mm wrench loosen the jam nut Using a 5mm hex key back the set screw off by turning counterclockwise Do not lose the ball bearings on each end of the tranducers These allow the transducer to center easily on the vibratory member If the transducer is being replaced using a marker mark the front and rear transducer harnesses Cut the two wires at the transducer The positive lead of the harness is marked with a black band When using a harness and transducer assem bly this step is unnecessary INSTALLATION OF TRANSDUCER
71. to CAL SAP E2 for one second and the changes to DIS FLA 2 Pull the distance gauge to the outside flange of the backing collar use the flat head of the calibration weight as an index Figure 79 1 After a short beep the machine displays H POS and changes to tO FLA NGE 3 Touch the tip of the width gauge to the face plate and hold it for one second or press the lt F gt button Figure 3 5 The display will change to H 5 followed by a tone Return the SAPE arm to the home position 4 Display will then change to CAL SLG Screw the calibration weight onto the outside of the flange Touch the tip of the width gauge to the tip of the calibration slug and hold it for one second or press F button Figure 79 3 The display will change to SAP E 2 FIN for one second followed by a tone indicating a successful calibration Unit will then go into an idle state CALIBRATION COMPLETE 1 8 1 D F P 80 SAPE GAUGE CALIBRATION To calibrate the SAPE gauge Checkout and Maintenance Make sure the SAPE arm is in the home position as shown in 80 1 NOTE WEIGHT TRAY MUST BE INSTALLED Activate the gauge calibration program Press and re lease the lt F P gt key turn the shaft until the display reads F P 80 is displayed on right display window and press enter The right display will read CAL 3 D
72. using the balance screen c S lt Press and release the lt F P gt key turn the shaft until the display reads F P 88 is displayed The display changes to CAL ANG for one second Press the START but ton to begin the measurement run N Attach the 100 gram weight to outside of the Pruefrotor and press the START button After the shaft comes to a complete stop rotate the shaft to _ locate the 100 gram weight at BOTTOM DEAD CENTER position Press the ENTER key F6 Optima BFH 9 4 J press the lt F P gt button digital balancers to save the data CALIBRATION COMPLETE Checkout and Maintenance F P 90 MATCH BALANCE Matches the tire to the wheel See operators manual for detailed information F P 91 OPTIMIZATION See operators manual for details F P 92 SPLIT WEIGHT See operators manual for details F P 94 SPOKE MODE See operators manual for details F P 95 CLEAN amp RESET EEPROM 1 amp 2 Care should be taken before running this function All information in the EEPROM will be lost including manufacture calibration which can not be reversed once performed However this function can be very use ful if data is corrupted on the EEPROM s Performing this function can be much quicker than re flashing t
73. xternal and internal cabling Overflow Mod 41 ASS Too many time clients Mod 44 SAPE Overflow e g invalid time period Not running still not initialised This error can occur after a measuring run if the incre mental encoder of the power clamp is not able to de tect the reference mark 810F 17 Please check the incremental encoders with C54 C74 main shaft and C98 power clamp Timeout Mod 31 Watchdog Recorded during start up Watchdog causes last reset Please check error record C28 Mod 42 Data cond Can t get data from external AD converter This error can caused by a malfunction of the incremental encoder Please check C74 and C54 a malfunction of the micro controller board Check C75 if ADE1 and ADE2 displays valid results Mod 44 SAPE Communication timeout No answer from AWP Mod C1 Self test Self test failed test function does not response timed out Access denied Mod 49 Drive system Access denied e g use of the clamp device if it is not available not a power clamp machine Requested action not allowed UT_CMPLX_ERROR_MatrixSingular ERR_VOLTAGE_ZERO ERR_VOLTAGE_BELOW_LIMIT lG GO IM 2 21 Chapter 2 Diagnostic Codes RS232 E Wrong parameter for ioctl call pM 2 22 S PN k lk A A AYA 02 lG CB AIIN 1 O

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