40-6640 Self Leveling Laser Marker SERVICE MANUAL
Contents
1. 7 Connecting Circuit Board T E Tz im d ied 3 Power Switch Circuit Board 1 Main Circuit Board 4 Alarm Loop Circuit Board outside ring Power Source Batteries I 56 2 A C Receptor EH Circuit Board 6 Alarm Switch Circuit Board Fig 3 A Prepared By Peter Brandt Version 08 20080415 Page 17 of 26 a A agen oll w ma ii ik inns PRO 40 6640 Service Manual 4 0 Calibration Calibration is a process used to correct for accuracy and or functional errors above and beyond those stated in published specifications While Manual leveling Self leveling and Automatic leveling motor driven devices have different mechanisms that require calibration there are similarities with optics that are consistent regardless of the leveling mechanism This service manual discusses calibration specific to the 40 6640 All accuracy checking and calibration adjustments described below must be made while laser instrument is secured on a leveled platform 4 1 Checking Accuracy Note diagram below and follow instructions on next page Laser Lines Horizontal Reference Line AOB Vertical Reference I Line COD Fig 4 1 A 0 5mm Prepared By Peter Brandt Version 08 20080415 Page 18 of 26 LH En LEYEL amp ASSE 40 6640 Service Manual A true and correct reference standard must first be established 1 Use a wall2. Vertical Reference Line COD Adjustment required First attempt a small error adjustment using a hexagonal wrench key 3 mm Adjust the horizontal laser line until it matches the reference line AOB If further adjustment is needed use the two screws indicated in the figure below The middle screw needs to be loosened first only by little Then move the horizontal laser line toward the reference line by either tightening or loosening the two outer screws Then secure the adjustment be tightening the middle screw If needed make small adjustments again using the hexagonal nuts Fig 4 2 I Screws for large range adjustment Center screw Hexagonal bolts for small adjustments Prepared By Peter Brandt Version 08 20080415 Page 23 of 26 A 5 ol ELA 40 6640 Service Manual 9 0 Alarm Adjustment After one or more calibrations have been completed 1f may be necessary to adjust the alarm range If the alarm rod is not centered within the alarm loop make adjustments as follows 1 Remove all housing to clearly view the top portion of Central Unit Assembly see Fig 5 A 2 Loosen the 3 screws on the Alarm Loop Circuit Board outer ring and move the circuit board until the alarm rod is centered inside the alarm loop Tighten the screws and attach all housing Fig 5 A Top view of Central Unit Assembly Three Screws Alarm Loop Alarm Rod NOTE If alarm rod needs to be further centered beyond adjusting the o
3. 3 E Prepared By Peter Brandt Version 08 20080415 Page 14 of 26 S S BCL easyPDF Printer Driver Click here to purchase a license to remove this image 40 6640 Service Manual 2 4 Bracket Assembly 40 6356 9 9 9 13 9 14 9 11 9 15 BS eic Fig 2 4 A See Parts List on next page Prepared By Peter Brandt Version 08 20080415 Page 15 of 26 e LH GE LEYEL amp 40 6640 Service Manual 93 _arinio Cover Board 1 x4 Ammo GweBemdi 1 9s Apr FswwngKwb 3 Ls Amm MameHedes oa 95 Arms miberpad 3 9s aa ewhonRins 3 s Amms MamePae 2 910 Arme Mameri 2 su Amm Manera 2 Lus Apu S Cross Pite Sew M23 5 m NINI N N General Assembly Instructions NOTE This bracket unit is similar to the bracket of the instrument 6620 or 6625 Refer to that service manual for instructions Prepared By Peter Brandt Version 08 20080415 Page 16 of 26 LH htm LE VYELE ASEULINE PRO 40 6640 Service Manual 3 0 Electrical Connections 5 Alarm Rod Circuit Board inside ring
4. 5 using the three Cross Plate Tapping Screws 5 9 See Fig 1 1 F Also see Electrical Connections figure in Section 3 for further help Connected Plug from Connecting Circuit Board Fig 1 1 F Connected Plug from A C Receptor Circuit Board 7 Now attach the Alarm Loop Circuit Board to the top of the Support Seat Ring 5 2 using the three Cross Plate Tapping Screws 5 12 The alarm loop must fit around the alarm rid See Fig 1 1 G Prepared By Peter Brandt Version 08 20080415 Page 7 of 26 y Created usil d BCL easyPDF Printer Driver Click here to purchase a license to remove this image sg ol ah ge sanen Levers DRO 40 6640 Service Manual Alarm Rod positioned inside Alarm Loop Three Screws used to attach Circuit Board Fig 1 1 G The Central Unit assembly can be disassembled using the reverse order described above Prepared By Peter Brandt Version 08 20080415 Page 8 of 26 e BCL easyPDF Printer Driver Click here to purchase a license to remove thisimage Laben Levers PRO 40 6640 Service Manual 2 0 Component Assembly 2 1 Core Module Assembly Regarding General Assembly of Core Module NOTE OF CAUTION This module should not be assembled by anyone other than professional service technicians with appropriate equipment Cutting the hairspring wires or any other wires is NOT recommended If repairs replacements are needed for this module it is recommended to send the un
5. on the adjustment needed When adjustment is completed make sure both screws are tight NOTE When all accuracy checks and needed corresponding calibrations have been made it may be necessary to adjust the position of the alarm see section 5 0 Prepared By Peter Brandt Version 08 20080415 Page 19 of 26 Se s of ah oae ii ik Sinan PRO 4 2 1 Linearity or curvature error 40 6640 Service Manual Either the horizontal or vertical line 1s not straight 1 e there 1s curvature Horizontal Reference Line AOB Linearity or curvature Vertical Reference Line 1 cop Adjustment required Adjust the needed screws in the diagram below depending on which laser lines show curvature NOTE The housing needs to be removed For the vertical linearity adjustment the Main Circuit Board will also need to be detached to provide access to the screws Fig 4 2 B for horizontal linearity Adjustment screws Prepared By Peter Brandt Fig 4 2 C for vertical linearity Adjustment screws other screw is on other side Version 08 20080415 Page 20 of 26 agma ol ah ge 4 2 2 Oblique error Either vertical or horizontal line is not plumb 40 6640 Service Manual Fig 4 2 D Oblique Error Horizontal Reference Line AOB Vertical li Reference Line COD Adjustment required If the laser lines are perpendicular to each other and only a small ad
6. Mmm of sah ge CR iu e Re EE 7C n SUPRO 40 6640Service Manual x PRO 40 6640 Self Leveling Laser Marker SERVICE MANUAL Main Instrument HBracket Item Description Page s 1 1 Central Unit Assembly 5 21 CoreModuleAssembly 9 18 23 4 2 2 2 4 2 3 Height error 23 5 0 Alarm Adjustment 24 6 Troubleshooting Guide 25 26 15 17 18 19 20 l Prepared By Peter Brandt Version 08 20080415 Page 1 of 26 Se LH htm LEYEL amp 40 6640 Service Manual 1 Overall Instrument Assembly Fig 1 A 3 API8I BackHousing Po do 4 API6B FrontHousins o Po do s arises Centr Unie Ge Sel 3 6 an tGesPesaewMisdo O Too 7 nes OxOrTeskmb 3 s ARS Rubberhaket E 3 Co Aries Basey Cover E Prepared By Peter Brandt Version 08 20080415 Page 2 of 26 Se s aem m al sh ge oa PRO 40 6640 Service Manual General Assembly Instructions Note Refer to section 3 0 for information on electrical connections 1 Connect the battery compartment plug from the Back Housing 3 to the Main Circuit Board See Fig 1 Main Circuit Board Back Housing Plug connected Fig 1 B 2 Connect the plug coming from the Main Circuit Board to the Alarm Switch Ci
7. cuit board Repair accordingly Replace LED Page 26 of 26
8. in Contol circuit board does not work Version 08 20080415 Repair connecting wires Replace LED Replace circuit board Repair connecting wires Replace LED Replace circuit board Page 25 of 26 LH hE LEYEL amp 5 No laser No buzzer when 6 instrument is tilted beyond tolerance On Off keypad for Alarm Switch does not work On Off keypad indicator 8 light for Alarm Switch does not work Prepared By Peter Brandt Hairspring wire is broken Connecting wires between circuit boards 1 and 4 are broken Core connection wire to laser is cut 1 Main Contol circuit board does not work Laser light source is broken Buzzer is broken 4 Alarm Loop Circuit Board is loose or not aligned properly Connecting wires between circuit boards 1 and 4 are broken 1 Main Contol circuit board does not work Connecting wires between circuit boards 1 and 6 are broken 6 Alarm Switch circuit board does not work 1 Main Contol circuit board does not work See reasons listed in above No 7 LED of circuit board 2 1s damaged Version 08 20080415 40 6640 Service Manual Replace the hairspring wire Repair connecting wires Replace the connection wire Replace circuit board Replace the laser Replace buzzer Adjust and tighten circuit board Repair connecting wires Replace circuit board Repair connecting wires Replace circuit board Replace cir
9. it to the appropriate repair facility Call the main office of Johnson Levels for further information Prepared By Peter Brandt Version 08 20080415 Page 9 of 26 LABEM LEvELIB PRO 40 6640 Service Manual 2 2 Base Plate Module Assembl AP1691 5 5 1 55 2 5 5 6 3 3 5 HU 5 5 4 ee ES 9 3 Fig 2 2 A See parts list on next page Prepared By Peter Brandt Version 08 20080415 Page 10 of 26 LH htm LE VELE 40 6640 Service Manual General Assembly Instructions 1 Attach Support Post Type B 5 5 4 to Base Plate 5 5 10 using Cross Plate Tapping Screws 5 5 13 Make sure that concave impression of plate is facing up with indentation of plate to the right side of the two posts when looking down upon the plate 2 Attach Support Post Type A 5 5 3 to other remaining holes in Base Plate 5 5 10 using Cross Plate Tapping Screws 5 5 13 3 Insert Crank Shaft 5 5 7 through inside the matching opening in Fixture Support 5 5 9 Make sure that grease 1s applied to Crank Shaft Set Crank Shaft in uppermost position 4 Place Fixture Support 5 5 9 onto Base Plate 5 5 10 so that it fits among the four support posts The Crank Shaft should be oriented between the two Type B Support Posts 5 5 4 Secure the Fixture Support from below the Base Plate using the three Cross Plate Tapping Screws 5 5 11 5 Place the four Magnets 5 5 8 i
10. justment is needed adjust the hexagonal nut shown Fig 4 2 E using a hexagonal wrench key 3 mm NOTE The nut can be accessed by removing the Plastic Screw see Fig 4 2 F and 4 2 G The outer housing on the instrument does NOT need to be removed Fig 4 2 E Hexagonal Nut found inside hole Prepared By Peter Brandt Version 08 20080415 Page 21 of 26 x Created using amp Fe BCL easyPDF Printer Driver Click here to purchase a license to remove this image sg ol ah ge ctt PRO 40 6640 Service Manual Fig 4 2 F Fig 4 2 G m C Remove plastic screw to provide access Use 3 mm hexagonal wrench key If the lines are not perpendicular to each other or a larger adjustment is needed the housing needs to be removed The Main Circuit Board will also need to be detached to provide access to the screws Adjust the appropriate screws indicated in figure below Screws for horizontal error Screws for vertical error Fig 4 2 H Prepared By Peter Brandt Version 08 20080415 Page 22 of 26 A BCL easyPDF Printer Driver __ Gliek here to purchase a license to remove this image of ala inks isa PRO 4 2 3 Height error Point O does share the same height as the laser output source of the instrument 40 6640 Service Manual but the height of the laser height needs to be corrected Fig 4 D Height Error Reference point O Horizontal Reference Line AOB
11. n the four matching openings of the Fixture Support 5 5 9 The magnets will attach themselves to the Base Plate 5 5 10 below 6 Place Locking Ring 5 5 5 down upon Type B Support Posts 5 5 4 Make sure that Locking Ring fits in place with Crank Shaft 5 5 7 7 Slide the two Compression Springs 5 5 6 over each of the Type B Support Posts 5 5 4 Push the Compression Springs down far enough to insert the Cross Plate Screws 5 5 1 and Lock Washers 5 5 2 Screw both screw in all the way and then release the Spring The Base Plate Module can be disassembled using the reverse order described above Prepared By Peter Brandt Version 08 20080415 Page 11 of 26 Si LANCA LEYEL amp ASEULINE PRO 40 6640 Service Manual 2 3 Platform Module Assembl AP1692 5 6 1 5 6 8 C us 5 6 2 5 6 9 Fig 2 3 A The off center hole needs to match the indentation circle on the bottom of the Degree Scale Prepared By Peter Brandt Version 08 20080415 Page 12 of 26 sg ol ah ge ii ik inns PRO 40 6640 Service Manual General Assembly Instructions 1 Using three Cross Plate Screws attach the Bottom Axle 5 6 7 into the bottom of the Degree Scale 5 6 6 2 Place the Rotation Platform 5 6 4 onto the Bottom Axle 5 6 7 Place the Gasket 5 6 3 and then Wave form Gasket 5 6 2 onto the Bottom Axle Attach Lock Ring 5 6 1 using ring pliers to secure all parts 3 A
12. n top of washers The arm of the pendulum bottom piece of Core Module must be forced through the Locking Ring see Fig 2 2 A 3 Attach the On Off Switch Assembly 5 8 see Fig 1 1 B for view of complete assembly by first attaching the switch portion of assembly using the two Cross Plate Screws 5 7 See Fig 1 1 C for view of switch portion attached This portion of assembly is oriented directly above Crank Shaft 1tem 5 5 7 of Fig 2 2 A Connecting Circuit Board Attached here Connecting Circuit Board MAA X Crank Shaft Fig 1 1 B Fig 1 1 C Plug Prepared By Peter Brandt Version 08 20080415 Page 6 of 26 Y created using m n BCL easyPDF Printer Driver Click here to purchase a license to remove this image agmg of ah ge oo PRO 40 6640 Service Manual 4 Now attach the connecting circuit board to the underside of the supporting plate of the Core Module 5 3 The two bolts on the underside must first be removed and then used to attach the circuit board See Fig 1 1 D Nuts for securing circuit board Fig 1 1 D 5 Connect plug Fig 1 1 B to the top connection on found on the back side of the Main Circuit Board 5 10 See Electrical Connections figure in Section 3 for further help 6 First connect the plug from the A C Receptor Circuit Board item 5 6 9 of section 2 3 to the middle front connection of the Main Circuit Board Then attach the Main Circuit Board 5 10 to the Base Plate Module 5
13. rcuit Board located on the inside of the Front Housing 4 See Fig 1 C Front Housing ITE Main Circuit Board WS Plug connected EFES Es M Fig 1 C Prepared By Peter Brandt Version 08 20080415 Page 3 of 26 Y created using fe s BCL easyPDF Printer Driver Click here to purchase a license to remove this image s alb sah oae il ik inns PRO 3 Before moving the Front and Back Housing units in place position the Rubber Jacket 8 over the instrument so that the matching hole is located over the Crank Shaft and the on off indicator light from the Power Switch Circuit Board is through a smaller hole in Rubber Jacket See Fig 1 D 40 6640 Service Manual Front Housing Back Housing Indicator light Crank Shaft Fig 1 D 4 Now bring both Front and Back Housing units together over the edges of the Rubber Jacket Use the four Cross Plate Screws 2 to secure the units Note It may be necessary to use a thin nail placed into the screw holes to center the nuts found inside the instrument so that a straight path is achieved for the screws 5 Holding the instrument up side down further secure the housing units using the four Cross Plate Screws 1 Rotate the bottom portion of the base in order to locate the screw holes through the access hole Drop the screws into the hole and screw into housing units until tight Note It may be necessary to use a thin nail placed into the screw holes
14. surface 5 meters 16 5 feet away from the level platform which supports the laser instrument 2 Establish and mark a level horizontal line and a plumb vertical line as Reference Lines The horizontal reference line is named AOB while the vertical reference line is named COD NOTE Point O should share the same height as the laser output source of the instrument 3 Mark lines on both sides of each reference line that are 0 5 mm from the lines see Fig 4 1 A 4 Now check the accuracy of the lasers against the reference If the laser lines are within the range created by the lines drawn 0 5 mm out from the reference lines the laser instrument is operating within the accuracy specification of the instrument Accuracy specification is the same for the 40 6640 Self leveling Laser 1 8 35 ft 3mm 10m If accuracy does not fall within specification continue to review the following sections and make the needed calibration adjustments 4 2 Calibration Adjustments There are three types of error described in the following sections 4 2 1 Linearity or curvature error 4 2 2 Oblique error 4 2 3 Height error When making adjustments with the errors described below a pair of screws must be turned in a certain manner One of the screws needs first to be loosened slightly The other screw then needs to be tightened by an equal amount Continue loosening one screw and tightening the other or go in the reverse direction depending
15. to center the nuts found inside the instrument so that a straight path is achieved for the screws The instrument can be disassembled using the reverse order described above Prepared By Peter Brandt Version 08 20080415 Page 4 of 26 LH hE LE VYELE ASEULINE PRO 40 6640 Service Manual 1 1 Central Unit Assembly AP1684 Indentation covers 5 7 Protrusion a Fig 1 1 A 5 7 AP1475 Cross Plate Screws M2x5 o 2 ss _API693 On Off Switch Assembly includes Circuit Boards Band Fi IB 55 Asi Cross Plate Tapping Serows STL6S 3 Circuit Board 1 Main ERU M3 Flat Washers NOT shown in diagram 4 5 12 Cross Plate Tapping Screws ST2 2x5 shown in Fig 1 1 G Prepared By Peter Brandt Version 08 20080415 Page 5 of 26 am cl nah ge oa PRO 40 6640 Service Manual General Assembly Instructions 1 Attach Base Plate Module 5 5 to Platform Module 5 6 using the three Cross Plate Tapping Screws 5 4 2 Snap on the Support Seat Ring 5 2 making sure that the inside indentation fits over the protrusion of the Gimbal ring Using the four Cross Plate Screws 5 1 attach the Support Seat Ring together with the Core Module 5 3 onto the four Support Pillars see Fig 2 2 A of the Platform Module 5 6 Place Flat Washers 5 11 on top of Support Pillars so that the Core Module will rest o
16. ttach 2 A C Receptor Circuit Board by first inserting only the tip of indicator bulb into matching hole in Rotation Platform 5 6 4 Apply a little grease on the indicator bulb before inserting Then pivot the circuit board downward so that the A C plug receptor is matching the slot in the Rotation Platform Make sure that the receptor is flush with outside of Base See Fig 2 3 B Plug Receptor Fig 2 3 B 4 Then gently place 1 8 inch flat head screwdriver between the second and third wire prong and gently leverage the indicator light forward until it protrudes out from the hole in the Rotation Platform See Fig 2 3 C Fig 2 3 C Prepared By Peter Brandt Version 08 20080415 Page 13 of 26 RS BCL easyPDF Printer Driver Click here to purchase a license to remove this image agmg of ah ge SUPRO 406640Service Manual 5 Then push plug receptor down and attach 2 A C Receptor Circuit Board 5 6 9 using two Cross Plate Screws 5 6 8 See Fig 2 3 D Make sure that wires are fit into inside groove along edge of Rotation Platform Fig 2 3 D The Base assembly can be disassembled using the reverse order described above NOTE To remove the A C Receptor Circuit Board remove Cross Plate Screws 5 6 8 and gently lift the power plug receptor out while indicator light is still in place Then gently use a small nail head to push the indicator light until it releases from the hole See Fig 2 3 E Fig 2
17. uter circuit board the inner circuit board holding alarm rod can be loosened and adjusted This will help only for minimal further adjustment Prepared By Peter Brandt Version 08 20080415 Page 24 of 26 reatec SII Se BCL easyPDF Printer Driver Click here to purchase a license to remove this image Li htt LEYEL amp 40 6640 Service Manual 6 a 0 Tro u b es h ooti n Q G u id e see Section 3 for visual display of circuit boards mo Symptom Game O orenean O Failure to start using batteries instrument does not turn on Failure to start using A C adapter instrument does not turn on Low batteries On Off Switch does not work Wires are disconnected or broken 1 Main Contol circuit board does not work _ Wires are disconnected or broken 2 A C Receptor Circuit Board does not work Recharge or replace batteries Replace On Off Switch Assembly Repair connecting wires Replace circuit board Repair connecting wires Replace circuit board Power is on but indicator light above On Off Turnknob is not working Indicator light of 4 A C Receptor Circuit Board is not working Prepared By Peter Brandt Connecting wires between circuit boards 3 7 and 1 are broken LED of circuit board 3 1s damaged 1 Main Contol circuit board does not work Connecting wires between circuit boards 1 and 2 are broken LED of circuit board 2 1s damaged 1 Ma
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