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Accuturn Service Manual

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1. 26 Wire assy ground EAWO240G01A 1 29 A6 gt e Power cord Display and i 8 a d keyboard unit with Euro plug O N EAA0283G14A 0024 Q F DE with UK plug 7203 0026 J Ribbon cable display and keyboard urit Input Voltage AC 50 60 Hz 2722 22222 W3 EAW0238D03A 2 Power interface board yee i Electronic X1 EAPO201D10A 5 Power supply assemblied m Miniature Ves 68V oy ti 0263045 tuse A1 Controller board 12345678910 1 y MPWM motor pwm signal E T 2 16251 FE 81 V X12 OR 2 3 gt 5 TT m N N na een VA ga 2 3 EPROM 259kx1ebt D13 for Software update only Mer ZA 32 Motor capacitor 41 513 6 5 EUR 9 AMARA j T 1 Embedded PC 5 LD4 ALE o 5V Vret 45v 10 e i aspi r n A HH Power entry FLASH Reset al al T 2 121 e module 256 X 18bit circuit Regulator Voc 5 13 ids seso KT Inner rim side lighting Yun vit
2. Hood 90 Switch vc fa xc NC t Um c M POWER SUPPLY BOARD Le ud El X43 B El Mechanical ERE B Brake Adj xi HRR gt x8 WIDTH Mtr Mounts NOTE cu DIAMETER 1400 1500 7 7 1400 1500 X8 1500 3 Rear Calibration Transoucer Weght x6 577 Threaved Shaft IMP PROCESSOR BOARD Eier CSCE IICSDDE AUX 3 x3 Backing Plate Print Captured Transducer Backspring sonic X14 41 Accu Industries Inc Accu Industries Inc P O Box 15540 Accu turn 11126 Air Park Road Richmond VA 23227 Ashland VA 23005 1500 so ie la only tow 1200 1400 1500 rev 03 2003 REV A DISPLAY BOARD RD E Bv Rod Harrison CHK BY CHK BY DC POWER DISTRIBUTION T
3. 1 1 NOTES Page 1 12 Effective 04 2003 2 THEORY OF OPERATION FUNCTIONAL DESCRIPTION The AccuTurn Wheel balancers are designed to compute static and dynamic imbalance of car light truck motorcycle and truck wheels Wheels are attached to the shaft using precision centering adapters and retainers The shaft rotates on precision bearings on the shaft support The rotating shaft is perfectly balanced The wheels attached normally represent an imbalance which creates centrifugal force and a dynamic momentum as it is spun on the balancer shaft The wheel is spun by means of a low RPM motor The centrifugal forces created by any imbalance are detected by the two transducers located between the shaft support and the machine frame These transducers contain small discs of special quartz which generate millivolts of electric current when compressed The current created is linearly proportional to the compression force Centrifugal force vectors are generated by imbalances in the rotating wheel This causes a signal to be generated by the transducers which pick up only the vertical component of the constrained forces in the form of a periodic sine wave The signal is not perfectly sinusoidal due to noises from in the suspension sy
4. 3 19 POWER SUPPLEYC iso e b E bere e e AER Ee EN M e be eA C adu D 3 19 REMOVING THE POWER ENTRY MODULE seen nn enne nnn innen nennen 3 19 INSTALLATION OF THE POWER ENTRY MODULE 3 19 VIBRATORY MEMBER 20 02001 00 nn nennen nnns inire einen enne n sss isse annua 3 21 VIBRATORY 3 21 ENCODER REMOVAL en rra vu ede Pesaro Pe EE ERE 3 21 DIAMETER SAPE POTENTIOMETER MODEL 1400 amp 1500 _ 3 22 Effective 04 2003 TABLE OF CONTENTS DIAMETER SAPE POTENTIOMETER ADJUSTMENT 3 22 SAPE GAUGE Love d dv Pr alia vb e d IR 3 22 DISTANCE SAPE POTENTIOMETER 1400 8 1500 00occcccccnccccnccncnnoncnccncnnnnnnnnononononononcnonannnnnnnnnnnnonanans 3 23 DISTANCE SAPE POTENTIOMETER INSTALLATION 1400 4 1500 3 23 WIDTH SAPE POTENTIOMETER INSTALLATION eere n nennen nenne nens 3 23 MECHANICAL BRAKE CABLE a dre eb a d rein be ta 3 24 MOTOR REMOVAL ot deese aeo acr eere 3 24 V BELT TENSION ADJUSTMENT a 3 25 VOLT
5. rada is 3 6 MANUAlEDATA ENTRY 2125 ie tt esc drea A AE A da 3 6 SAPE OPERATION ea 3 6 ioa la e ee d a Pc v 3 7 DATA ENTRY tandas rai att 3 7 SAPE WEIGHT APPLICATION 2 ri a ada 3 7 1500 0 3 7 CODES A a D e o 3 8 ACCESSING THE SERVICE CODES ara 3 8 C CODE DESCRIPTIONS id 3 8 C4 UNBALANCE COMPENSATION ALL 5 3 8 G7 VOLUME AND AUDIBEE TONES a e Pr d rn a er 3 8 C11 STOP TOP ONLY 1400 AND 1500 3 8 CIZ COUNTER INDICATION sn pe e ci un da 3 9 CI4sUSER CALIBRATION A Seb nid 3 9 C15 STICKY AT TOP ONLY 1400 1500 3 9 C28 LAST 10 KERNEL ERROR 55 3 10 RESET SPIN COUNTERS 3 10 C47 CONFIGURE THE 3 10 C66 C67 ENGINEERING AND MANUFACTURING PURPOSES 3 10 C72 MECHANICAL PHASE SHIFT OF VIBRATORY SYSTEM 3 10 C74 INDICATION OF POSITION COUN
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7. 1 1 AC THEORY OF OPERAT QN 1 e 1 2 AG DISTRIBUTION ient Feed getto t e ERR eee 1 2 DRIVEMOTOR oir dridco droit dass 1 2 DC THEORY OF OPERATION ert sorte tadas 1 2 PROCESSOR BOARD tiit lio 1 2 ENCODER BOARD 25r tel ete Eee 1 2 DISTANCE POTENTIOMETER MODEL 1400 1500 1 2 DIAMETER POTENTIOMETER MODEL 1500 1400 1 2 WIDTH POTENTIOMETER MODEL 1500 1 3 TRANSDUCERS inicie tierce atre re redet ee rete pea e t P el decr e tn Fe reete rine cato 1 3 DISPLAY BOARD ete dep tfe ee ka s esa n 1 3 O 1 3 AUTO STOP LOCK SWITCH MODEL 1500 1 3 TROUBEESHOOTINE tt an itt ue ee ped et 1 4 PHOGESSOR PGB ost waste cma unes 1 6 KEYPAD SCHEMATIC 1200 amp 1400 tiit meer ge oerte et ist db bene egt 1 10 KEYPAD SCHEMATIC 1500 nne a nnne nente ener enne enr sene nennen 1 10 CHAPTER 2 THEORY OF OPERATION FUNGTIONAE DESCRIPTION 5955 Gre anre re eat Fr Ioa a he rat 2 1 BALANCER COMPONENTS 00000000 0 esee annes 2 2 ELECTRONIC POWER BOX sitiada ola
8. balancer off and back on Balance tire and wheel assembly to check for proper operation Possible messages during calibration E6 Calibration tool was not attached in both runs calibration tool was attached in both runs E16 Calibration weight attached erroneously to flange 2 50 Factory calibration was not completed Figure 3 5 E51 Calibration failed E52 Calibration weight on opposite side to factory calibration Any operator wheel spin errors occurring during user calibration or minimisation cause the functions to exit C15 STICKY AT TOP ONLY 1400 1500 C15 in left display current setting is in right display 1 Yes 0 No Factory setting is 1 Press t key to change between 1 and 0 Press the lt F gt key to accept the displayed item and exit the code Press the FINE key to exit the code without any change 28 LAST 10 KERNEL ERROR MESSAGES A 6 hex digit error number is displayed across both displays At two second intervals this number is switched with a number from 1 10 1 being the most recent indicating which error message is currently displayed Pressing the lt gt key cycles through the list of error codes Pressing the lt FINE gt Key will exit the code Pressing the F key exits the code C43 RESET SPIN COUNTERS C43 in left display 0 or 1 in right display O will do nothing 1 resets all of the counters Pressing the x key will toggle the sta
9. pot It is supplied 5VDC from the main processor This input voltage can be measured at the Processor Board X8 pin 3 The output voltage is dependent upon the rotation of the guage from the home position TRANSDUCERS The transducers are installed in a manner that it forms a virtual transducer on each end of the shaft This configuration gives the balancer greater accuracy along with minimal amount of erroneous readings Both measuring transducers are arranged in one plane The tranducers produce a DC output The DC voltage that is generated is sent back to the processor DISPLAY BOARD The Display Board receives 5VDC from the Power Supply Board This 5 volts can be checked at the harness of the display board X2 pin 6 or at the Power Supply Board X2 pin 6 KEYPAD The keypad allows operator input to the Main Processor Board The output signal passes through the Power Supply Board directly to the Main Processor AUTO STOP LOCK SWITCH MODEL 1500 The auto lock switch receives 5VDC from the Power Supply Board when the balancer is in the ALU S mode The voltage can be measures at the Power Supply Board at X13 pin 1 amp 2 Effective 04 2003 Page 1 3 CHAPTER 1 AC DC POWER DISTRIBUTION TROUBLESHOOTING COMPLAINT CORRECTIVE ACTION Machine will not power up Is the machine plugged in at the wall NO gt Plug machine in Is the balancer plugged in at the back NO gt Plug machine in Are all connectors seated properly NO gt R
10. HIGH PERFORMANCE WHEEL BALANCER Accucturn A TURN FOR THE BETTER MODEL 1200 1400 1500 Service Manual Model 1500 Model 1400 APRIL 2003 Model 1200 PN 300935 All information contained or disclosed in this document is considered confidential and proprietary by Accu In dustries Inc All manufacturing use reproduction and sales rights are reserved by Accu Industries Inc and the information contained herein shall not be used in whole or in part without the express written consent of Accu Industries Inc Accu Turn is registered trademark of Accu Indusries Inc Table of Contents INTRODUCTION GENERAL tente s d en ER sett esf e ER eet FUNCTIONAL DESCRIPTION dando BASIC BALANGER OPERATION rafa ene tide egent haste Fee age tee aee aii WEIGHT APPLIGATION 5 ite tere Eee t is dad iracundo 2 ete e riada DISPLAY CONTROLEPANEL Rege et een ee en Pei dea ae GENERAL SPECIFICATIONS AND MACHINE FEATURES IMPORTANT SAFETY INSTRUCTIONS 2 ELECTRICAL SAFETY PRECAUTIONS 2 IV SERVICE GUIDELINES HANDLING STATIC SENSITIVE IV CHAPTER 1 AC DC POWER DISTRIBUTION LOCKOUT AND OR TAGOUT SYSTEM 1 1 ELECTRICAL REQUIREMENTS
11. The belt tension is an important factor for the lifetime of the main shaft bearings belt life and the overall measurement accuracy When the tension is too high can generate e Wrong influence on extended measurement runs and visualize several Service Codes Put unnecessary load on the ball bearings generating stress e Can produce fluctuations in the measurement When the tension is too low slipping which will cause excessive wear and longer measurement runs error codes etc e it may cause disturbing squeaking noises as well To adjust 1 adjust the tension of the v belt by using the service code C 111 available from the program version 24 this code is called up the reading is a running 2 After picking the belt a beep indicates the start of the measurement After 3 sec a second beep indicates the end of the measurement and the frequency is displayed If the harmonic analysis doesn t found any significant frequency then Err is displayed until the next measurement is started 3 The test should be repeated with different forces during picking the belt and with different sections of the belt rotating the main shaft 4 frequency is displayed a range from 100 Hz up to 300 Hz where the right value is 193 Hz 8 15 Figure 3 42 shows the relation between frequency and belt tension for a measuring head and a Poly V belt 5PJ711 DIN7867 Figure 3 42 HOOD SWITCH CAM S
12. the plate in place without movement Tighten the upper screw Ye turn then tighten the lower screw one full turn then tighten the upper screw an additional 1 2 turn Reassemble the complete balancer and perform a com plete factory calibration to ensure proper operation NOTE MOVING THE TRANSDUCER AFTER CALIBRA TION WILL CHANGE THE ACCURACY AND REQUIRE FACTORY CALIBRATION C83 amp C84 Page 3 20 Figure 3 32 Set Screw Rear Transducer Front Transducer Set Screw Encoder Figure 3 33 Effective 04 2003 VIBRATORY MEMBER REMOVAL All 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 Figure 3 34 Using 1 4 drive 6mm hex head SOT part remove the six hex bolts to the vibratory Pay special attention of spacer placement Figure 3 35 Lift up on the vibratory member and remove VIBRATORY INSTALLATION All Balancers Lift and set vibratory member into the balancer housing Insert spacers With the aid of a helper start the two lower hex bolts Install the 4 remaining hex bolts and tighten to 1 7ft lbs lbs Install the rear t
13. Check external and internal cabling Overflow Mod 41 ASS Too many time clients Mod 44 SAPE Overflow e g invalid time period Not implemented Read only Bad line Bad data type Not running still not initialised This error can occur after a measuring run if the incremental encoder of the power clamp is not able to detect the reference mark 810F17 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 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 Check C74 and C54 A malfunction of the micro controller board Check C75 if 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 ERR VOLTAGE ABOVE LIMIT ERR VOLTAGE really HIGH Keyboard No time client available Page A 3 APPENDIX A CODES Error ID Limits 101 102 120 130 131 132 133 134 140 141 142 143 144 145 146 147 148 149 14A 14B 14C 160 161 162 163 164 1
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15. This number indicates the total number of measurement runs performed Pressing the x heys displays another counter The five counters that are available C1 Total for all spins C2 Spins with OK C3 Spins with Optimisation Minimisation C4 Spins in service mode Spins since last calibration Pressing the lt FINE gt Key will exit the code C14 USER CALIBRATION When doing a User Calibration it is not necessary to use a tire and wheel assembly Use factory Calibration Weight supplied with the balancer 1 Turn balacer OFF Enter in the calibration mode by holding down the CAL key 7 seconds and restarting the machine Hold the key until the display flashes Cal Usr i 2 Press and hold CAL button then trun balancer ON 3 After approximately seven seconds CAL USR will flash on the display followed by diS 115 Release CAL button 4 Press F OPT button and the number one 1 will be displayed on right LED Lower Fl 3 4 wheel guard and spin shaft assembly with no wheel adapters or wing nut on shaft gure Figure 3 4 5 When rotation stops the number two 2 will be displayed on right LED Lift wheel guard and using the threaded hole attach factory Calibration Weight on inside of flange plate Figure 3 5 6 Lower wheel guard and spin shaft assembly After the shaft stops display will be blank for about 4 seconds then DNE will be displayed Remove Calibration Weight and place in holder
16. num 2 40348A Reset AGND Q T y 1225 dE H aa BR 5 T veste Torque capacitor RAM 4 ceu y ATQ VREF 445 2 01529A N 2x 128k x Bbit p A VOLTAGE LINE SES 1 red 202 a AMOS Miniature fuse 12 Driver Error 2211 a al 2 15351 3 i R8232E 232 lt WHEELGUARD 1 E 4 254 Serene 24 ASS 2 E 8 2 25 PEDAL S2 Miniature fu Em 4 26 4 PEDAL St Motor control unit 92 we M liniature fusa 27 NC 2 189514 gt 1r 1 0 m gt Cable power entry 44 215 2 1 gt EAWO0Z39D06A 1 N 9 DGND ains y L Driver 32 5 Ves 05v E HH power 332 06 46 EEPROM display AWP 0 95 O 3 ped 1352 Attention pei Iw Grounding L 1 36 7 48 during FS cabinet We 8 29 37 ion Resistance S00VDC mH EAWO0240G07A Vibrat tem hi VREF 38 7 nder PE igh Voltage 1000VAC tests 1 Ves 5V sn ci 3952 175 SCL serial clock X46 1 o a n 40 75 gt PCSDA serial data R93 K7 3 1 12 3 4 gt n 991 rt 1234567880123456 123 1234 1234 TT A AAA A En Es m i j ju eis 1 2 3 4 5 1 2 3 4 1 2 3 X41 1 56789 X3 X
17. pw 9 oo 55 2 T iy eurepi st lie enpow i 1 1 Ivi p x E 4 ECL 441 17 E lt lt a E tun y 1 VS T q HUM 10u00 Malla werd 9 amor 4j NOV Tc EE fasion PLX 62510 2 eoi ndo 1 5i zien f RA 2 peu 1 o arloz 9 FA Ee Ve 284 EJES 2 sien 28 A z ejnpoui DIR ZEE 19 Joyoedeo yy vxnv lt ca esmena 527 imi EN exnv Lb 9 i een premio 20 lo as pe A oly E aw 4 Te Pappoquiz gt 1 a Uos 1 rro ie vea c4 c T Hee soypedeo x T oue din 9 eyepdn esempos Jo ELC ELC xo 94 Tone d a ynb at ge xy DES MAA _ 2 5 CEI E ZIX 1 Da u 2000010204 5 9 ive AMAN gs vez
18. 2 2 5 avem voe 2 2 cb dM p UA 2 2 DISPLAY histoire dta De d ET 2 3 TEMPERATURE SENSQOH titre reta Ether beds 2 3 DRIVEMOTOR ota ia bac d E di 2 3 i RANSDUGERS i teta a eee eee teda raa dee varo deua oues da vu teas 2 3 SAPE SEMI AUTOMATIC PARAMETER ENTRY 2 3 ENCODER ES 2 3 VIBRATORY SYSTEM da ide 2 4 Effective 04 2003 TABLE OF CONTENTS CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE a doit 3 1 WHEEL SPIN FUNCTIONALITY a 3 1 BALANCING WITHOUT SLIP 00 0000 01 6 3 1 SHAFT IMBALANCE WHEEL ADAPTER TO SHAFT REMOUNT TEST 3 1 BALANCER DIAGNOSTICS 5 3 2 TROUBLESHOOT USING CORRECT DIAGNOSTICS 3 2 TOOLS REQUIRED WHEN SERVICING THE 5 4 88 3 3 DEFINETION OEF TERMS re A adt rane Pace Eu a Quad 3 4 INPUT KEYS DISPLAY WINDOWS ai e 3 5
19. AND MAINTENANCE 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 If the 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 C80 1400 1500 C82 1500 only C83 C84 C88 and retest These test can be found later in this Chapter BALANCER DIAGNOSTICS TROUBLESHOOTING Many problems may be found by process of elimination By determining the problem then eliminating poten tial problem areas starting with the most likely to fail items solutions to problems may be rapidly found The 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 operable func tions in a predetermined manner Events have to take place in the proper sequence every time A balancer must 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 Displa
20. Power Interface Board If a transformer is required it is to be connected between the PEM and the Power Interface Board Connector X41 NOTE IF ONE OF THE FUSES IN THE PEM IS BLOWN THE BALANCER WILL NOT WORK Fuses amp capacitor In the retrofit box we have two capacitors e 1 15 used for the spin e C2 is used for the works phase while the wheel is turning over the shaft In case we hear any noise coming from the motor during this operation the cause could be one of the capaci tors they get discharge automatically The protection over the power interface board is done by five fuses e F1 amp F2 are placed in the entry module to protect the complete circuit against the over tension in entrance e amp F4 are placed in the motor control unit a part of the power interface board to protect the circuit in case of wrong tension generate from the transformer e F7 protects the connector x 12 in case of video board balancer Power Interface Board The function of this module is to accept the CPU controller board that will be mounted onto it It processes the input power and distribute that to the relevant peripherals it also exchanges input signals to output signals to peripherals The Peripherals are motor Digital Display Board switches electro magnetic brake inner rim side light electromagnet for the wheel clamping device etc A malfunction in this module can generate an error code that belongs to a component that is correct i
21. SAPE wheel to the mounting bracket and slide the cog wheel off of the potetiometer shaft Figure 3 37 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 Figure 3 37 Attach SAPE harness to Power Supply Board Run C80 amp 81 for SAPE calibration SAPE GAUGE Toremove the index finger remove the phillips screw from the backside of the gauge Toremove the SAPE arm remove the phillips screw that attaches to the distance rod Toremove the distance rod disconnect the diameter string from the end of the rod Slide the distance rod completely out Reverse procedure for installation Effective Page 3 22 04 2003 DISTANCE SAPE POTENTIOMETER 1400 1500 DISTANCE SAPE POTENTIOMETER INSTALLATION 1400 amp 1500 Install 10K potentiometer onto bracket and tighten 13mm nut Disconnect the power 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 Figure 3 38 Install SAPE Wheel onto potentiometer shaft and hand tighten 10mm nut Figure 3 38 Attach SAPE thread to return spring Hook re
22. To enter a value press the appropriate key The current value will be displayed offset in left panel diameter and width in right panel Enter the value using the named keys The value can be stored and the function exited by performing any of the following actions Starting a wheel spin see below Pressing the key or the dimension key which 15 in use Only Diameter can be entered while in a hidden weight mode width and offset are not required weight offsets are entered with the sape The rim diameter range in HWM Hidden Weight Mode mode is reduced due to the mechanical constraints of using the gauge arm to apply the weights For this reason HWM modes will only allow results to be displayed if the rim diameter 15 within range Value limits are Width 80 510 mm or 3 20 inches Diameter 205 762 mm or 8 30 inches in non HWM modes 12 25 inches HWM 1 HWM 2 modes with inches selected 320 520 mm PAX mode HWM 1 and 5 selected 305 635 mm in HWM2 with mm selected Offset 1 500 mm Increments e Inch 0 25 or 0 5 depending on size of value 0 25 below 10 0 1 except for diameter in HWM 1 where increment is 20 PAX increments SAPE OPERATION There is no automatic SAPE operation for the model 1200 The SAPE on the Model 1400 and 1500 can be used for both data entry and weight application Machines fitted with a 2D SAPE allow the automatic entry of offset and Diameter D
23. Tower Integrated in tray 220V Phase YES 40 mm 190 mm Quick Nut Plastic 3 cone 43 116 mm YES full coverage Standard Standard Standard Model 1500 YES 9 YES YES YES YES 4 2 YES YES 2 static YES YES YES YES YES YES YES YES YES YES YES Effective 04 2003 IMPORTANT SAFETY INSTRUCTIONS When using this equipment basic safety precautions should always be followed including the following 1 2 10 11 12 13 14 Read all instructions Do not operate equipment with a damaged power cord or if the equipment has been damaged until it has been examined by a qualified authorized service tech nician If an extension cord is used a cord with a current rating equal to or more than that of the machine should be used Cords rated for less current than the equip ment may overheat Care should be taken to arrange the cord so that it will not be tripped over or pulled Always unplug equipment from electrical outlet when not in use Never use the cord to pull the plug from the outlet Grasp plug and pull to disconnect To reduce the risk of fire do not operate equipment in the vicinity of open containers of flammable liquids gasoline Keep hair loose fitting clothing fingers and all parts of the body away from moving parts Adequate ventilation should be provided when working on operating internal combustion engines To reduce the risk of electric shock do not use on wet surfac
24. VI Width gauge does not work Model 1500 only Is the diameter arm in the HOME position during power up NO gt Place it in the home position and retest Check pins 1 and 3 at connector X7 on the Processor Board Is the voltage reading 5 VDC 1 volt NO gt Replace Processor Board and retest Press C80 and move the SAPE gauge up does the voltage reading on the display change NO gt Check to make sure the cog wheels are meshed Replace potentiometer Check C80 with the SAPE in the home position is the voltage reading correct NO gt voltage reading to desired setting Is the width arm in the HOME position during power up NO gt Place it in the home position and retest Check pins 1 and 3 at connector X8 on the Processor Board Is the voltage reading 5 VDC 1 volt NO gt Replace Processor Board and retest Press C82 and move the SAPE to the flange does the voltage reading on the display change NO gt Check to make sure the cog wheels are meshed Replace potentiometer Check C82 with the SAPE in the home position is the voltage reading correct NO gt Readjust voltage reading to desired setting VI Machine chases weights Effective 04 2003 Are the mounting accessories in good condition NO gt Clean backing plate and all accessories Replace if necessary Has the balancer been calibrated NO gt Perform C14 and retest Perform C80 C81 C82 C83 C84 C88 and retest Pruefr
25. by pressing the foot pedal The Bowden cable clamps the brake pad s tightly on the pulley To keep the brake pad s away from the pulley while spin ning a spring 15 fitted in between the brake brackets Replacement 1 2 Remove the 2 screws that fix the clamp assy to the measuring head body 3 Replace the assy remove the pin join the 2 clamps if you need to change only one of the 2 clamps 4 Screws the assy onto the measuring head body place the 2 nuts and follow up with the adjustments Brake Cable Adjustment Adjust the 2 nuts that are on the threaded end of the Bowden cable that run through the brackets Please note that this adjustment should not require to have the foot pedal pressed down completely The play for brake bracket when moved manually should be about 1 5 2 mm approx 1 12 of a inch After adjustment the brake pads should run free from the pulley if the foot pedal is not pressed down Please note that the Bowden cable runs through a plastic tube for easier replacement and is spring loaded under the bottom brake bracket Remove the 2 nuts of the Bowden cable MOTOR REMOVAL Removing the motor 1 Switch the machine off and remove the main cable from the power inlet to prevent Figure 3 41 someone from applying power accidentally Remove the weight tray Remove the retrofit Box in order to disconnect the wiring of the motor Connector X42 Disconnect
26. eyepdn E LC 199 892 WOBdz a 2 s y E z L ZHN OL Ndo T Pa enia 1881 zumo 62510 IN E Joyoedsa T 9 v WVerEOt Zz pe HH ow fo ES MO gt bd JOJOJA Wee arto 42 1 peppequi 1 ewe dip nb 4 B 1908 A ZH losen 800010204 3 sizu bX wise Wo Ap 20001020 5 068286762 Jeonuoo LV ex A84 1 080 2A preog amod Pi 3 viSzoi z ean INS eli 19 i dnixoq 4 i Aiddns je od ZOMWS SMA ejqeo N 31 yun pyeogKex 08 08 OW yu 3200 5024 uum 9200 5024 ong pJoo 48M0d ES WLODOPZOMWa Asse am vriosezovya gt lt lt yun SOS pus gjdaic Sa oy Effective 04 2003 CHAPTER 1 AC DC POWER DISTRIBUTION
27. is done because it is not possible to apply weight to the wheel using HWM modes with a rim diameter of less than 12 inches Pressing the diameter entry key will automatically increase the diameter to the minimum required value for the HWM mode After the input of rim data by using SAPE if no measuring run was done before the data input machine will go idle or wait for data input if a measuring run was completed before the data input the unbalance will be recalculated and displayed NOTE THE INNER AND OUTER PLANES MUST BE SEPARATED BY 3 INCHES OR MORE HOLD ING THE SAPE STATIONARY IN AN ATTEMPT TO ENTER AN OUTER PLANE OFFSET LESS THAN 3 INCHES FROM THE INNER PLANE WILL NOT STORE THE PLANE OFFSET SAPE WEIGHT APPLICATION When valid results become available in a hwm mode the SAPE is configured for weight application When the SAPE is now moved from the home position the SAPE position is checked against the stored offset positions The SAPE arm is used to apply stick on weights only If a stick on weight is required for a plane and the value of the weight is above the threshold rotate the wheel so that the full application LED is lit for that plane By moving the SAPE the right led will display a minus distance value to the inner correction s plane if the SAPE is less than 100 mm left from the inner plane The machine will sound a tone when the SAPE arm is moved to within 1 0 mm of the weight position While the SAPE is in this position th
28. of range Mod 27 Temperature Out of Range Buffer full Channel not found Not found Mod 41 55 Time client not found Mod 44 SAPE Time service not found during unregister Mod C1 Self test failed result of test invalid Already exists 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 End of file Drive full Effective Page A 2 04 2003 Error ID Limits FOC FOD 10 11 12 1 F14 F15 F16 F17 F18 F20 Effective 04 2003 Description Bad name Xmit error Mod C3 User Interface Communication Error between balancing kernel and user interface BK lt Ul Machine should be restarted This error can be caused by a bad connection of the RS232 E serial line Check external and internal cabling Format failed 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 Bad medium Error in expression Mod C3 User Interface Communication Error between balancing kernel and user interface BK gt Ul This error can be cleared pressing STOP or Escape This error can caused by a bad connection of the RS232 E serial line
29. the brake by loosing the 2 nuts securing the Bowden cable to the brake top lever Release the tension from the belt by loosening the 4 distance bolts Unscrew all screws completely except the top one Support the motor to prevent it from falling into the cabinet and remove the top distance screw Take off the motor and remove the V belt Installation of the motor Pon Position the v belt over the motor pulley Position the motor guide the 4 distance bolts through the holes in the measuring head bracket Partially tighten the top screw Pace and fix the brake assy together with the motor screws the 2 nuts of the Bowden cable Tighten the screws that secure the motor not firmly Adjust the tension of the v belt check the value with the service code C 111 If needed loose and move slowly the motor left or right in order to tension plus or minus the V belt re tighten NOTE C 111 is only available starting from the program version 24 Connect the motor to the power Interface Board connector X42 Mount the retrofit Box connect all cables Ddjust and fix definitively chapter 17 10 the partially tightened nuts of the Bowden cable to the top lever of the brake Check if the brakes work properly Re connect all connectors ensure the wiring does and will not conflict with rotating parts fasten the weight tray and perform factory calibrations C83 C84 and C88 Effective Page 3 24 04 2003 TENSION ADJUSTMENT
30. very close together so that the difference in temperature has only a slight effect The current vibratory sensor has a temperature sensor The transducers can therefore be measured by one temperature sensor and taken into account in a fraction of a second The temperature sensor is attached to the vibratory plate by means of a U shaped spring This temperature sensor effects the transducers and is set during calibration DRIVE MOTOR The drive unit is mounted directly to the vibratory system by means of 4 bolts Three of the mounting holes are slotted these are used for setting the tension on the drive belt The drive belt is used to drive a large pulley which is mounted directly to the drive shaft of the vibratory system TRANSDUCERS The transducers are installed in a manner that they form a virtual transducer on each end of the shaft This gives the balancer greater accuracy along with minimal amount of erroneous readings Both measuring transducers are arranged in one plane The rear transducer picks up the alternating forces of the left hand virtual measuring plane and is supported on the machine housing The front measuring transducer is clamped between the vibratory tube and vibratory plate and transforms the alternating forces of the right hand virtual plane into electrical signals SAPE Semi Automatic PARAMETER ENTRY 2 Window Display If the distance gauge fails the machine displays an Error Code when the machine is powered on Check
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32. 0g weight and calibration rotor assumed 566 c2 value too low if a 100g weight and calibration rotor assumed 570 c1 value too high ifa calibration rotor only assumed 571 c2 value too high ifa calibration rotor only assumed 580 30 Temperature below 30 or hardware fault 581 100 C Temperature above 100 C or hardware fault 585 0 23 V Temperature Input near to ground Voltage 586 4 05 V Temperature Input near to reference Voltage 601 Internal error To many event sinks 602 Internal error Cannot register event sink 603 Internal error Invalid event level 701 ERROR_IEMS_INV_PARAM 702 Incremental encoder not initialised Software is not able to detect the reference mark 703 Incremental encoder Counter reference mark mismatch 705 2 50 V Opto electronic No voltage on shunt resistor 706 4 30 V Opto electronic VCC on shunt resistor 707 16 mA Opto electronic Current through LED below limit 708 20 mA Opto electronic Current through LED above limit Effective Page A 6 04 2003 Error ID Limits Description 710 Hand spin with electromagnetic released brake main shaft rotates backwards 800 170 V Line voltage below limit 801 265 V Line voltage above limit 804 275 Line voltage much too high 810 5 10 V VCC below limit 811 5 35 V VCC above limit 820 5 00 V Keyboard display voltage below limit 821 5 35 V Keyboard display voltage above limit 830 4 50 V External voltage pedal below limit see keyboard module 831 External voltage p
33. 6 X7 X8 123458789419 rm J UR i 1 1 4 jm 4 n d TD NS M Ie sis 4 X43 X42 X41 552 55 e ES 2 11 N gs 33 aes EE 44 Line in ni lll m SE 88 oet ameter Lo GNYE optional 825 884 E 1 1 5 BE i3 B 2 B 258 13 Potentiameter 10K MH X41 SES ol 88 55 SE B ge El EAA0266220A AM Attention 230v ov T2 388 9 28 SE E working voltage at X41 200 240 1 5 Step up transformer e LL EEE Motor ONYE 7 009024 PC BUS 1 4234567889 10 X41 B1 683 582 af 33 2 2 4 Temperature front rear Wheel guard switch a Unbalance transducers 2 07261 02500594 4kx8bit E LI LI 4 ectrical Schematic 1400 locirane board Incremental encoder main shaft 2 5 009 1891119913 yeys 2 jejusureJou leo 2140 B ew 4 18220 2 Sieonpsuen eouepqun Yous
34. 65 166 167 168 169 16A 16B 16C 16D 180 181 182 183 184 185 186 187 188 189 18A 18B 18C 18D 18E 18F 190 Page A 4 Description ERROR_KEYB_NO_HARDWARE_AVAILABLE ERROR_KEYB_ORDER_BUSY Display Digital No Hardware available Bad parameter for the frequency of beep command Bad parameter for the volume of beep command Bad parameter for the sound file of beep command Bad parameter for the repetition of a beep Sound file corrupted RS232 E Wrong parameter for ioctl call RS232 E Input buffer overrun occurred RS232 E Transmission error FIFO KORRUPT FIFO WRONG ACTION FIFO EMPTY READ FIFO FULL WRITE FIFO STRING ENDE PIPE NO COMPLETE MESSAGE AVAILABLE SER WRONG ACTION SER NO HARDWARE SER ERR RESET FIFO SER ERRORCODE EXISTS ERROR PO INIT READORDER FAILED ERROR PO INCORRECT DATA OR HEADER SIZE ERROR PO EEPROM IS FULL ERROR PO 2 WRITE ORDER ERROR PO NO TIMECLIENT AVAILABLE ERROR PO ORDER IS BUSY ERROR PO ORDER IS FULL ERROR PO PRODUCTION READ WRONG TYPE ERROR PO EEP1 2 ARE DIFFERENT ERROR PO EEP1 ERROR ERROR PO CRC EEP2 ERROR ERROR PO ORDER HAS FAILED ERROR PO NOT AVAILABLE ERROR PO EEP1 EEP2 ERROR ERROR 12 QUEUE FULL 122 ERROR ORDER NOT FOUND 122 ERROR ORDER TOO BIG 122 ERROR ORDER BUSY 12C Bus No order in I2C queue 12C Bus No active order in 2 queue 122 ERROR TOO MANY SOP 2 bad SDA 2 bad SCL 2 busy 2 no A
35. AGE MODIFIGATION Lean dead 3 26 APPENDIX A CODES KERNEL CODES i ve bed b esee ee da ee dd 3 1 ERROR CODES err RC LER 3 7 Effective 04 2003 TABLE OF CONTENTS Effective 04 2003 INTRODUCTION GENERAL The Model 1200 1400 and 1500 balancers are designed to compute static and dynamic imbalance of car light truck motorcycle and truck wheels The Model 1200 1400 and 1500 has a delay of approximately 8 to 10 seconds during power up During the delay the processor electronics are checking the status of all electronics These components include the Encoder board the transducers the thermocouple the power interface board the display board and the membrane switch After the status check is complete approxi mately 8 10 seconds the units beeps the displays all light up and then the unit goes to the idle state and displays 016 115 The unit is now ready for parameter inputs and can take measurements FUNCTIONAL DESCRIPTION BASIC BALANCER OPERATION Once the balancer reaches balancing speed 130 190 RPM calculation is done Once the weight imbalance and location is known the balancer will reverse polarity sending 230VAC via a relay on the Power Supply Board to the motor bringing the shaft to a stop Imbalance amounts and corrective weight locations will be shown on the display WEIGHT APPLICATION Rotate the wheel until all weight location LED s light up Apply the corrective weight at top dead
36. EMORIZED FACTORY CALIBRATION IS REQUIRED C86 CALIBRATION DATA TRANSER FROM ENCODER PCB TO MAIN CPU PCB Turn on the machine after the CPU replacement and C85 will be displayed Press any lt gt button to change the display to read C86 and press the lt F gt button Some beeps will be emitted an auto test and a power on will automatically be performed Data is now transferred from the Encoder PCB to the Main CPU NOTE IF THE CPU BOARD MEMORY IS EMPTY OR THE SOFTWARE RELEASE LOADED ON THE CPU MATCH WITH THE ONE OF THE ENCODER CALIBRATION DATA WILL BE AUTOMATI CALLY STORED IN THE CPU BOARD MEMORY IF THE ENCODER BOARD HAS ANOTHER RELEASE MEMORIZED FACTORY CALIBRATION IS REQUIRED C88 ANGULAR UNBALANCE POSITION NOTE A TIRE AND WHEEL ASSEMBLY MAY BE SUBSTITUDED IN PLACE OF THE PRUEFROTOR THE ASSEMBLY MUST BE BALANCED BELOW 10 GRAMS IN THE NORMAL WEIGHT PLACEMENT MODE BEFORE CONTINUING 1 Mount the Pruefrotor on the balancer shaft and enter in the parameters of the Pruefrotor using the balance screen Activate the service code 65 C88 from the service menu Press the F button to begin the measurement run Figure 3 25 gt T O 15 Figure 3 25 2 Attach the 100 gram weight to inside of the Pruefrotor and press the START button Figure 3 26 Figure 3 26 Effective 04 2003 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE 3 After the shaft comes to a complete stop rotate the shaft to locate the 100 gr
37. EROUS HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENT Always use the One Hand Rule when working with AC voltages by keeping one hand in your pocket or behind your back Before removing wires from the Balancer always verify that the unit is OFF Turn off the Main Power Switch on the back and unplug the AC power cord from the AC outlet AC DISTRIBUTION The balancer requires 230VAC Model 1500 115 VAC Model 1200 1400 for proper operation The AC voltage comes in through a switch and immediately is sent to the Power Supply PCB via X41 pin 1 The drive motor is the only component that requires the 230VAC 10 The primary voltage applies 230V 60Hz AC to the balancer via the hot side Black Wire of the AC power cable The Main Power routes to one side of the ON OFF Rear Panel Power Switch The hot wire continues to one side of the Line Filter The neutral side routes to the other side of the Line Filter The earth ground directly connects to the balancer chassis and the Line Filter It is critical to have the proper input voltage in order for the balancer to operate correctly DRIVE MOTOR The drive motor for the unit receives AC power VIA two relays mounted directly to the Power Supply Board To keep arcing at the relays to a minimum the relays are switched in synchronism The switching times of the relays are determined individually and taken into consideration for optimum pull in times The motor also utilizes a capacitor to gene
38. LE PERFORMING THESE INSTRUCTIONS When inserting PCB s Place boards on a grounded static mat after removal Remove the new PCB from the original package onto a grounded static mat Save packaging to use when returning defective boards Remove power from the machine unplug from wall before installing the PCB Avoid handling components needlessly Donot set PCBs on insulating surfaces such as paper glass rubber or plastic Static is generated by friction The following actions promote static generation Wearing silk or nylon clothing Walking on carpets Walking with rubber soled shoes Static generation is increased when certain environmental conditions exist Conditions of low humidity combined with wearing silks or nylons walking on carpets or walking with rubber soled shoes may create large electrostatic charges on your person capable of blowing a hole in the substrate of an IC Effective Page iv 04 2003 1 AC DC POWER DISTRIBUTION LOCKOUT AND OR TAGOUT SYSTEM PROCEDURE Notify all affected employees that a lockout or tagout system 15 going to be utilized and why The autho rized employee should know the electrical power the machine uses and it s hazards If the machine or equipment is running shut it down by the normal stopping procedure depress the stop button open toggle switch etc Use appropriate devices to isolate the equipment from the power source s Stored energy su
39. PRING Place the wheel guard in the lower position e Remove the top of the box of the wheel guard sup port unscrew the cam and move it to left e remove the switch and install the new one in the same position Re position the cam by placing the recess over the wheel s switch normally opened For a proper adjustment you should hear a click while lifting the wheel guard for approx 10cm 4 inches Effective 04 2003 200 150 Belt tension 100 YG S 9 55 S WW wq Frequency Hz S Figure 3 43 Page 3 25 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE VOLTAGE MODIFICATION The transformer is required to adapt the 1500 balancer to 115V main supply 1200 and 1400 come already at 115V before proceeding turn the machine off and pull out the power cable and carry out the following steps Switch the machine off 2 Take off the weight tray from machine housing 3 If missing drill four 4 5 mm mounting holes in the cabinet 4 Fasten the transformer 0026329 with the four enclosed screws M 5x10 5 Connect the green yellow wire connector D to the central grounding terminal 6 Unplug connector A X41 printed on the board from power interface board and connect it with the B cable of the transformer connector 7 Plug the connector from the transf
40. RES ARE THE SAME AS BEING IN THE SERVICE MODE NOTE ONCE THE UNIT IS POWERED DOWN THE VALUES FOR C4 WILL BE GONE ACCESSING THE SERVICE CODES NOTE IF A SERVICE CODE IS TO BE ACCESSED WHICH WILL REQUIRE THE USE OF THE PRUEFROTOR OR A WHEEL AND TIRE IT MUST BE MOUNTED AND PROPER DIMINSIONS ENTERED BEFORE TURNING THE BALANCER OFF TO ENTER THE SERVICE PROGRAM With the unit in the OFF position press and hold the FINE and the CAL buttons simultaneously and switch the power to the position After approximately 7 to 8 seconds the unit will sound a tone and the display will go blank and then display CAL FAC release the keys at this time The display will then show DIS 115 at which time the technician should press the F button Failure to press the button within 5 seconds will abort the service entry procedure and the technician must start from the beginning The first service code to appear is C4 Press the Distance x key to the desired service code once the desired code is displayed press the F key to activate that service code After the service code is per formed the technician will either press the lt F gt button to store the data or the lt STOP gt button to exit the code and enter into another service code or press the FINE key to exit the service menu If the FINE key is pressed at any time the technician must re enter in the service menu from the beginning C CODE DESCRIPTION
41. S C4 UNBALANCE COMPENSATION ALL MODELS C4 in left display 0 or 1 in right display Factory setting is 0 Spin wheel to compensate for adapter unbalance Lower the hood to commence a spin After the spin is complete the machine will store the new compensa tion values and exit to the service menu C4 is then active independent from the choice 0 or 1 e f C4 is already active when the service code is selected the Keys will toggle the status of the code between 0 and 1 Pressing the FINE with 0 displayed cancels the code and if 1 is displayed the code remains active still Press the FINE key exits the code C7 VOLUME AND AUDIBLE TONES C7 in left display 10 100 in right display Factory setting is 50 Select the required volume using the x keys Press the F to confirm the value Pressing the lt FINE gt key at any stage will act like an Escape key and exit the code without changing anything C11 STOP AT TOP ONLY 1400 AND 1500 C11 in left display current setting is in right display 1 Yes O No Factory setting is 1 e Press lt gt key to change between 1 and 0 Press the F key to accept the displayed item and exit the code Press the lt FINE gt key to exit the code without any change Page 3 8 Effective 04 2003 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE C12 COUNTER INDICATION A 6 digit number is displayed across both displays 0 999 999
42. TER ENCODER INSPECTION 3 11 C75 ENGINEERING AND MANUFACTURING PURPOSES sese eee enne nnne nnne 3 11 C76 INDICATION OF ALL ADAPTED VOLTAGES AFTER CALIBRATION WITH C88 3 11 C80 2D SAPE ARM nnne nennen essere nnn nane en entes assis nana i 3 11 GST SAPE edt te a tle cheeses t t ea AA 3 12 C82 3D SAPE CALIBRATION Fee Ha Tl qua rg 3 13 C83 FACTORY CALIBRATION 0 0 3 14 C84 COMPENSATION OF THE RESIDUAL MAIN SHAFT UNBALANCE 3 15 C85 CALIBRATION DATA TRANSER FROM CPU PCB TO ENCODER 3 16 C86 CALIBRATION DATA TRANSER FROM ENCODER TO MAIN CPU 3 16 C88 ANGULAR UNBALANCE 3 16 C111 MEASURING THE BELT enne sain 3 17 FACTORY CALIBRATION SEQUENCE 3 17 SERVICING THE BALANCER 5868888 3 18 CONTROL PANEL REMOVAL 4 REPLACEMENT 46 848000 3 18 MAIN PROCESSOR REPLACEMENT nnnm nnnnnnn nnn en esses nana nane nn enses nasa n nnda 3 18 TO ACCESS THE INSIDE OF THE
43. allows the balancer to compute shaft speed wheel accelera tion and weight location The encoder and transducer signals are multiplexed by the CPU to give weight amount and location readings The CPU board gathers the information generated from the encoder and transducer via a ribbon cable This board is powered with 5 VDC received from the Power Supply Board Calculated imbalance values are then shown on the LED display panel after a spin cycle Effective 04 2003 Page 2 1 CHAPTER 2 THEORY OF OPERATION BALANCER COMPONENTS ELECTRONIC POWER BOX The Electronic Power Box is positioned at the rear of a motor spin balancer It contains a Power Entry Module the Power Interface Board the Motor Capacitors not shown in the picture below and the CPU The main function of the retrofit Box is to allow easy retrieval and exchange of the electronic hardware to reduce servic ing efforts Therefore the electronic hardware is as much integrated into this Box as possible On the retrofit Box 15 the central earth terminal that ensures the Permanent Ground Power Entry Module The Power Entry Module receives the power cord and relays the power via a transformer if necessary to the Power Interface Board connector X41 The Power Entry Module PEM consists of one unit that accepts the power cord suppresses noise and contains the fuses and the mains switch Each balancer is protected by 2 fuses The power LEDs do not light nor the green LED on the
44. am weight at BOTTOM DEAD CENTER position Press the lt F gt key to save the data Figure 3 27 CALIBRATION COMPLETE F C111 MEASURING THE BELT TENSION Figure 3 21 Displays C 11 Lift the belt for 1cm half a inch and release it The measuring will start and a moving in the left seven segment display will appear After measuring the belt tension in Hz will be shown in the right display Right adjustment value is 193 Hz tolerance is 8 15 Hz FACTORY CALIBRATION SEQUENCE If major service is required it is recommended that a complete factory calibration be performed on the balancer Perform service codes in the following order 1 C80 only 1400 1500 2 C81 3 C82 only 1500 4 C83 5 C84 6 C88 The machine is now ready for use CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE SERVICING THE BALANCER NOTE BEFORE OPENING THE MACHINE FOR SERVICE DISCONNECT ELECTRICAL SUPPLY LINE AND USE THE LOCKOUT TAGOUT PROCEDURE The balancer is supplied with 110 230 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 the balancer will emit random beeps To check power cable Disconnect the power supply from the balancer e Using a VOM check for an output voltage at the end of the power plug 230VAC 1096 VAC Model 1500 or 110VAC x 1096 Model 1400 amp 1200 To che
45. center 12 o clock position on the wheel ALU MODES In addition to the standard Dynamic and Static modes there are 5 ALU modes each of which are illustrated by LEDs on the balancer touch panel when activated ALU modes 1 through 5 are accessed by first toggling the ALU MODE key until the balancing mode desired is displayed See the Operator s Manual for an explanation of ALU Mode balancing The last used mode will again be used even when power is cycled STATIC 1 AND 2 MODE Static mode balancing allows the operator to balance custom wheels in a true dynamic mode using concealed weights while maintaining specified weight separation See the Operator s Manual for an explanation of Static mode balancing DISPLAY CONTROL PANEL The display of the Model 1200 1400 and 1500 balancer shows weight amount and position for counterbalanc ing plus acts as a message center for the operator of the machine or for the technician who is repairing the machine Everytime the machine powers on the software automatically performs a system check The Main Processor performs a Semi Automatic Parameter Entry error check If the Semi Automatic Parameter Entry is good the machine enters idle state as normal If one of them fails for example the distance gauge fails machine displays an Error Code when the machine is powered on diameter gauge fails it displays an Error Code The operator must press the STOP button to exit the display and enter idle state Th
46. ch as that in springs elevated machine members rotating flywheels hydraulic systems and air gas steam or water pressure etc must be dissipated or restrained by methods such as repositioning blocking bleeding down etc Lockout and or tagout the energy isolating devices with individual lock s or tag s After ensuring that no personnel are exposed and as a check on having disconnected the energy Sources operate the push button or other normal operating controls to make certain the equipment will not operate CAUTION RETURN OPERATING CONTROL S TO NEUTRAL OR OFF POSITION AFTER THE TEST DE ENERGIZED STATE The equipment is now locked out or tagged out ELECTRICAL REQUIREMENTS NOTE ANY ELECTRICAL WIRING MUST BE PERFORMED BY LICENSED PERSONNEL ALL SERVICE MUST BE PERFORMED BY AN AUTHORIZED SERVICE TECHNICIAN Check on the plate of the machine that the electrical specifications of the power source are the same as that of the machine NOTE THE ACCU BALANCERS PERFORM A SELF TEST ROUTINE ON START UP THERE IS A DELAY OF SEVERAL SECONDS BEFORE THE DISPLAY IS ACTIVATED NOTE ANY ELECTRICAL OUTLET INSTALLATION MUST BE VERIFIED BY A LICENSED ELECTRI CIAN BEFORE CONNECTING THE BALANCER NOTE ENSURE THAT THE OUTLET HAS AN AUTOMATIC GROUND FAULT CIRCUIT BREAKER WITH A DIFFERENTIAL CIRCUIT SET AT 30 MA Effective 04 2003 Page 1 1 CHAPTER 1 AC DC POWER DISTRIBUTION AC THEORY OF OPERATION WARNING DANG
47. ck power to power supply box Remove the weight tray e 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 gt balancer Figure 3 28 Using a philip screw driver remove to 8 screws holding the Display Panel to the upper Display Gently pry the display lt lt 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 MAIN PROCESSOR REPLACEMENT 1 Disconnect the power from the unit A WARN 2 Locate the Main Processor PCB in the Power Supply USE STANDARD ANT STATIC PROCEDURES Box on the motorized balancer WHILE PERFORMING THESE INSTRUCTIONS 3 Insert the program EEPROM in the socket on the processor board Figure 3 29 Notch Figure 3 29 NOTE THE NOTCH ON THE END FACE OF THE 7 e EPROM MUST POINT TOWARDS THE NOTCH 1 1 2 ON THE SOCKET OF THE PCB 4 Plug the power cable into the balancer and switch the balancer to the on position The balancer will emit three beeps The upload will take appr
48. cknowledge No Acknowledge from device 122 ERROR FROM START 122 ERROR NO FROM STOP 122 ERROR NO FROM SEND 1 122 ERROR NO FROM SEND2 2C ERROR NO ACK FROM RECEIVE Effective 04 2003 Error ID Limits 191 192 193 201 202 203 204 205 206 207 208 210 211 212 213 214 215 216 300 350 351 360 361 370 371 380 381 382 383 400 401 402 403 405 Effective 04 2003 0 05 V 4 45 V 0 05 V 4 45 V 0 05 V 4 45 V 4 50 V 1 00 V 2 00 V 0 55 Description ERROR I2C SYNCHRONOUS ORDER TIMEOUT ERROR 12 ASYNCHRONOUS ORDER TIMEOUT ERROR 12 ORDER HAS FAILED 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 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 high speed Drive system Clamping device got stuck in clampe
49. connections 28 Speed limit not reached 492208 1 Check motor belt 2 Check opto encoder signals and connections 29 Start doesn t perform None 1 Start button pressed white open wheel guard 2 Checkthe micro switch regolation 50 Factory Calibration not completed 622510 Perform Factory calibration Service Code 83 Effective Page A 8 04 2003 51 52 82 Effective 04 2003 User Calibration failed 622511 1 Retry User Calibration 2 Checkif vibratory system is mounted correctly if no external vibrations are relayed etc 3 Checktransducers 4 Check opto encoder signals User Calibration on opposite side to factory calibration 622512 1 Mount User Calibration Weight on the left hand side of flange 2 Perform Factory Calibration Service Code 83 Self test disturbed None 1 Don t touch the balancer during switch on 2 Checkthe temperature sensor Page A 9 APPENDIX A CODES Effective Page A 10 04 2003 A TURN FOR THE BETTER Accu Industries Inc P O Box 15540 Richmond Va 23227 11126 Air Park Road Ashland Va 23005 phone 804 798 8922 toll free 1 800 551 2228 fax 804 798 6742 0692 9262 04 2003 Rev
50. d 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 activation of the motor First Potentiometer Voltage below measuring range AD value 0 10 First Potentiometer Voltage above measuring range AD value 1014 1024 Second Potentiometer Voltage below measuring range AD value 0 10 361 Second Potentiometer Voltage above measuring range AD value 1014 1024 Third Potentiometer Voltage below measuring range AD value 0 10 Third Potentiometer Voltage above measuring range AD value 1014 1024 ASS Voltage magnet below limit off state ASS Operating Voltage magnet below limit on state ASS Operating voltage magnet above limit on state ASS Operating Voltage magnet recharging time above limit During measuring run Data 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 cha
51. e appropriate weight LED will flash and 0 will be displayed Moving out of this position will stop the LED from flashing and a plus distance will be displayed This procedure is also used by weight application for outer plane Application mode can be cancelled by pressing the offset or diameter key when the SAPE is in the home position 3D SAPE 1500 ONLY If the 3D SAPE was used before the 2D SAPE to measure the rim data the rim width would be calculated and saved after which the left LED would flash and wait for data from the 2D SAPE After that the rim width will be recalculated and saved This would also be done if the 2D SAPE was used first Pressing the STOP key would terminate an incomplete data input Effective 04 2003 Page 3 7 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE SERVICE CODES There are only two service codes that are accessible a Users Mode These C4 Unbalance Compensation and C12 Display Counter Indication To access these service code in Users Mode 1 Press the lt F gt and the lt FINE gt key for seconds SEL will be displayed 2 seconds and than BAL SHT will be displayed Indicating C4 2 Press the plus or minus key Count 12 will be displayed and then changed between 12 and 4 3 Press the lt F gt key to select the displayed item 4 To exit the C4 or C12 function press the lt FINE gt or the lt STOP gt key NOTE THESE PROCEDU
52. e machine masks the function of the failed part after Semi Automatic Parameter Entry check For example if the diameter gauge fails the machine disables the measurement of diameter and measures the distance only Or if the distance gauge fails the machine disables the measurement of the distance gauge and measures the diameter only Effective 04 2003 INTRODUCTION GENERAL SPECIFICATIONS AND MACHINE FEATURES Performance Specifications Shipping weight Cabinet size width to end of Cabinet size depth Cabinet size height to top of display Shaft Speed in rpm Variable Cycle time 30 lb Assembly Cycle time 60 lb Assembly Cycle time 75 lb Assembly Accuracy Wheel width capacity Wheel diameter capacity Tire width capacity Tire diameter capacity Shaft capacity maximum Hardware Features Weight storage pockets Parameter entry Display positioning Cone storage Power requirements Spindle lock foot activated Shaft diameter Shaft length backing collar to end Centering Nut Cone system Wheel Hood Weight pliers Width Calipers Calibration weight Software Features Multiple Operator Distance arm holds weight Accu Stik Hidden Spoke program Weight position pulse brake Stop at Top outside plane Balancing Modes ALU Balancing Modes Motorcycle Automatic Brake after spin Balancing Modes Static amp Dynamic Match Balance Mode PAX Balancing Mode Inch mil
53. e state If the wheel rotates in the wrong direction above a preset speed E25 reverse error is generated This error resets when the speed is reduced to a near stop BALANCING WITHOUT SLIP CHECK Usually a balancing run is always with slip check to avoid a balancing run with loose wheel in case machine display E27 Balancing without slip check is a special function used to balance light wheels To use this function the operator must press and hold the START key more than seconds otherwise normal balance is started SHAFT IMBALANCE WHEEL ADAPTER TO SHAFT REMOUNT TEST This test proves the wheel balancer centering device is balanced turns true and proves the centering 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 the 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 Effective 04 2003 Page 3 1 CHAPTER 3 CHECKOUT CALIBRATION
54. ed with test functions C74 The calibration factors are stored in this location along with the Main PCB VIBRATORY SYSTEM The vibratory member is the foundation of the balancer It houses the encoder and transducers along with a temperature sensor for the tranducers Effective Page 2 4 04 2003 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE GENERAL This chapter incorporates checkout calibration and maintenance of all three Accuturn balancers The test codes for each digital display balancer are alike and so are the results however some test will not be available with the 1200 or the 1400 The Accuturn balancers use F key to begin any service procedure WHEEL SPIN FUNCTIONALITY A wheel spin can be started when the machine is idle when data is being entered manually and during user calibration minimisation and some service codes When the wheel starts to spin the display is cleared of all data and a tone is generated When the measuring run is completed successfully a tone is generated and the results are displayed and the weight placement bar graph s are enabled Errors which can be generated during a mesuring run are as follows E10 SAPE out E22 Speedup timeout E23 Speed not reached E24 Speed low E26 No Acceleration E27 Slip Detected E28 Stop by raising wheel guard E29 START pressed while hood up If one of the above errors is displayed the spin is aborted the brake is applied and the balancer returns to the idl
55. edal above limit see keyboard module 900 Power fail detected 9FF ERROR SELFTEST e01 ASA Status of an activated order has changed due to network manager or shop management software activities ERROR CODES E Code Description of Error Code amp Solution 6 Digit Code 6 User calibration failed None 1 Calibration tool not attached during factory calibration 2 Check the V belt tension 3 Check the motor 10 SAPE arm removed from the home position during None wheel spin During rotation detection an offset value gt 0 mm was detected gt Display clears after several seconds 1 Bring SAPE to its home position 2 Re spin the wheel 3 If the error appears again calibrate the SAPE offset Service Code 80 11 During power up procedure the None SAPE arm was not at its home position 1 2 3 Bring SAPE to its home position Re start the unit If the error appears again calibrate the SAPE offset ServiceCode 80 NOTE THE USER CAN CONTINUE BY ENTERING DATA MANUALLY UNTIL SERVICE ARRIVES EXIT THE ERROR CODE BY PRESSING STOP BUTTON 12 Effective 04 2003 A wheel with an entered diameter smaller than the None HWM rim diameter limit was balanced in HWM mode 1 Check the diameter entered and calibrate the SAPE diameter if required Page A 7 APPENDIX A CODES E Code Description of Error Code 8 Solution 6 Digit Code 13 During power up procedure the SAPE arm was not at None its home position 1 Bring SAPE to its home
56. eel wheel rims Two clip on weights are attached One on either rim flange A weight placement mode typically used for truck wheel rims Two clip on weights are attached One on either rim flange Displayed unbalance round in 10 gor 0 5 oz A weight placement mode typically used for alloy wheel rims Two stick on weights are attached in a variety of possible locations A weight placement mode typically used for motorcycle wheel rims Hidden Weight Mode HWM is a special ALU mode which allows the operator to enter the weight offsets exactly thereby providing more accurate ALU mode balancing Split Weight Mode SWM is a special function which allows the operator to split the weight at position 3 when using HWM a hidden weight mode described below This function allows the hiding of weights behind wheel spokes Rim data refers to the nominal wheel rim dimensions offset rim width and rim diameter These terms refer to the arm used to automatically enter offset and or diameter and apply weights in HWM modes This is a small offset 0 5 degrees to the weight application position for clip on weights and stick on weights in modes other than hwm1 which ensures that the weight application position is at exactly the 12 o clock position It is produced by a service function This is a large offset 10 30 degrees for example to the weight application position which is used internally by the machine when stick on weights are to be a
57. er the shaft comes to a stop the display 6 Figure 3 22 Attach the calibration weight to the inside of the flange plate and lower the wheel guard to begin the spin cycle After the balancer comes to a stop the new calibration factors are stored into memory CALIBRATION COMPLETE Figure 3 23 C84 COMPENSATION OF THE RESIDUAL MAIN SHAFT UNBALANCE NOTE THIS CODE MUST BE USED AFTER C83 IS PERFORMED THE VALUES PRODUCED ARE STORED AND USED FOR EVERY SUBSEQUENT UNBALANCE MEASUREMENT WHERE C4 IS DISABLED The digit 1 in the left display to indicate the step number All adaptors cones and wheels must be removed from the machine shaft Figure 3 n Lower the hood to begin a spin cycle After the spin is complete the machine will sound a tone and the function will exit The machine stores the new compensation values and exits to the service menu CALIBRATION COMPLETE Figure 3 24 85 CALIBRATION DATA TRANSER FROM CPU PCB TO ENCODER PCB Turn on the machine after the encoder replacement and C85 will be displayed Press the lt F gt button and some beeps will be emitted an auto test and a power on will automatically be performed Data is now transferred from the CPU to the Encoder NOTE IF THE ENCODER PCB MEMORY IS EMPTY OR THE SOFTWARE RELEASE LOADED ON THE CPU MATCH WITH THE DATA OF THE ENCODER CALIBRATION DATA WILL BE AUTOMATICALLY STORED IN THE ENCODER BOARD MEMORY IF THE ENCODER BOARD HAS ANOTHER RELEASE M
58. es or expose to rain Do not hammer on or hit any part of the control panel with weight pliers Do not allow unauthorized personnel to operate the equipment Use only as described in this manual Use only manufacturer s recommended attachments Always securely tighten the wing nut before spinning the shaft ALWAYS WEAR SAFETY GLASSES Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses Balancer is for indoor use only Effective 04 2003 Page iii INTRODUCTION ELECTRICAL SAFETY PRECAUTIONS Make sure the balancer is unplugged before disconnecting any wires in preparation for replacing any boards cables or other items within the unit Use the Lockout and or Tagout procedure outlined in Chapter 1 SERVICE GUIDELINES HANDLING STATIC SENSITIVE PCB S Electrostatic discharge can destroy high impedance ICs if uncontrolled Use the following techniques to avoid damaging ICs Leave new circuit boards in their antistatic bags until ready for use When replacing boards proms etc be sure to turn off power to the machine first Use anti static wrist strap Connect it to chassis ground on the equipment or to an available raw ground Touch the chassis of the equipment to put yourself at the same static potential as the equipment Grasp the PCB from opposite sides using your fingertips Do not grasp the components on the board WARNING USE STANDARD ANT STATIC PROCEDURES WHI
59. eseat connectors Are the fuse s inside the switch good NO gt Replace the fuse s Is 230VAC present at X41 pin 1 NO gt Checking wiring Is 5 VDC LED lit up on Processor Board NO gt Replace Processor Board Is 5 VDC present at pins 3 and 6 at X2 NO gt Replace Power Board Are LED lit up on Display Board NO gt Reload Software Replace Display Board Il Machine will not brake Is 230 present at X43 pins 2 during brake cycle NO gt Replace Power Board Retest Replace Processor Board Retest Replace the encoder Retest Replace the Motor Retest Ill Keypad will not function Use keypad schematic jumper pins of non working function NO gt Replace keypad Retest Replace Display Board Retest Replace Main Processor Retest IV Distance gauge does not work Is the distance arm in the HOME position during power up NO gt Place it in the home position and retest Check pins 1 and 3 at connector X6 on the Processor Board Is the voltage reading 5 VDC 1 volt NO gt Replace Processor Board and retest Effective Page 1 4 04 2003 Press C80 and pull the distance gauge out does the voltage reading on the display change NO gt Check to make sure string is attached to dis tance gauge Replace potentiometer Check C80 with the SAPE in the home position is the voltage reading correct NO gt voltage reading to desired setting V Diameter gauge does not work
60. ge Press the lt FINE gt key to exit the code C80 2D SAPE ARM CALIBRATION The Model 1200 does not have an automatic SAPE so it does not require any adjustments Both the model 1400 and 1500 have an automatic SAPE that requires periodicate adjustment and or calibration After entering in the C80 calibration the display window will display a 1 in the left display and the raw SAPE voltage in the right hand display The value should be 4 30 10 volts If the value is not correct adjustment to the distance offset potentiometer must be pl adjusted This can be done by removing the weight tray and with the SAPE rod in the home position loosen the 10mm nut holding the wheel to the potentiometer and adjusting the potentiometer using a flat blade screw driver Figure 3 9 Once the correct voltage has been obtained securely tighten the 10mm nut and press the lt F gt key to store the value in the HOME position and continue The display will i change to 2 Figure 3 9 Fully extend the distance gauge the value cannot be any lower than 0 1 05 Press the lt F gt key to store the fully extended value Figure 3 10 Figure 3 10 Place the flat portion of the calilbration weight against the face plate Extend the SAPE and touch the tip to the calibratin weight and rest the bottom portion of the weight applicator on the bell housing Figure 3 11 The value should be 3 57 05 adjust the diameter poten
61. ift of the left hand plane is shown as a floating point number in degrees from 0 360 Pressing the x keys displays the phase shift of the right hand plane Pressing the lt FINE gt or lt F gt key will exit the code Figure 3 8 Effective 04 2003 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE C74 INDICATION OF POSITION COUNTER ENCODER INSPECTION A 3 6 digit floating point number in degrees from 0 511 This represents the angular wheel position If the wheel position subsystem 15 not initialised possibly because the machine has just been turned on a buSY indication is displayed until a value is available Rotate the shaft one complete revolution to initialize the encoder Pressing the FINE or lt F gt key will exit the code C75 ENGINEERING AND MANUFACTURING PURPOSES C76 INDICATION OF ALL ADAPTED VOLTAGES AFTER CALIBRATION WITH C83 Press the F during the display of C76 adapted voltages will be displayed Eight voltages are available Press lt gt to change the display This could be requested for a check in case E24 or E27 is displayed in order for comparison to the below table LEFT DISPLAY RIGHT DISPLAY MEANING L5b 42 low speed 50Hz bottom voltage L5t 47 low speed 50Hz top voltage H5b 49 high speed 50Hz bottom voltage H5t 55 high speed 50Hz top voltage L6b 48 low speed 60Hz bottom voltage L6t 52 low speed 60Hz top voltage H6b 60 high speed 60Hz bottom voltage Het 64 high speed 60Hz top volta
62. limeter toggle Fine 10z Std 2502 round off toggle Truck round off mode Auto start with hood down Auto recalculation w changed parameters Operator Cal slug Calibration Integrated error codes Integrated counter functions Integrated instructional Info system Page ii Model 1200 293 lbs 133kg 33 5 24 43 5 130 190 Variable 5 sec 7 5 sec 9 sec 1 gr 035 02 1 20 8 24 20 9 530 mm 44 117 mm 154 Ibs 70 kg Model 1200 12 Manual keys Integrated in tray 4 left side pegs 115V 60Hz YES 40 mm 190 mm Quick Nut Plastic 3 cone 43 116 mm YES full coverage Standard Standard Standard Model 1200 YES 2 NO NO NO NO 4 2 YES YES 2 static YES YES YES YES YES YES YES YES YES YES YES Model 1400 43 5 130 190 Variable 5 sec 7 5 sec 9 sec 1 gr 035 0z 1 20 8 24 20 9 530 mm 44 117 mm 154 Ibs 70 kg Model 1400 16 2 Auto entry Integrated in tray Integrated in tray 115V 60Hz YES 40 mm 190 mm Quick Nut Plastic 3 cone 43 116 mm YES full coverage Standard Standard Standard Model 1400 YES 4 YES YES YES YES 4 2 YES YES 2 static YES YES YES YES YES YES YES YES YES YES YES Model 1500 326 lbs 148kg 65 5 130 190 5 sec 7 5 sec 9 sec 1 gr 035 02 1 20 8 24 20 9 530 mm 44 117 mm 154 Ibs 70 kg Model 1500 25 3 auto entry Raised
63. ly box marking each harness to ensure correct installation A dp 1 Remove and open the retrofit Box as described 2 Disconnect all internal wiring 3 Remove the whole PEM INSTALLATION OF THE POWER ENTRY MODULE 1 Ensure the On Off switch will be situated closest to the top of the Box after inserting the retrofit Box correctly into the balancer 2 Connect the leads to the PEM while leading the cables through the rectangular hole of the Box 3 Insert the PEM through the rectangular hole of the Box Snap it into place 4 Connect the green yellow lead to the central earth bracket next to the Protected Earth sticker 5 Connect the other 2 leads to Connector X41 6 Ensure the green yellow lead from Connector X41 is also fitted onto the central earth bracket 7 Ensure all screws and spacers are re fitted 8 Close and mount the retrofit Box Effective 04 2003 Page 3 19 CHAPTER 3 CHECKOUT CALIBRATION 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 32 Using a 13mm wrench loosen the jam nut Using a 5mm hex key back the set screw off by turning counterclockwise Figure 3 33 Do not lose the ball bearings on each end of the tranducers These allow the transducer to center easily on the vibrato
64. measuring run Figure 3 19 After the first measuring run the display will change to 2 in the left display and 100 in the right display If a tire and wheel assembly is used and a 100 gram weight 3 50z is not available press the x keys until the exact weight grams is displayed and press the lt F gt to accept this value The display will change to 3 NOTE IF USING PRUEFROTOR PRESS lt F gt AND GO TO STEP 3 BELOW Screw the 100gram 3 502 weight on the left side of the Pruefrotor Figure 3 20 and lower the wheel guard to begin the measuring run After the shaft comes to a stop the display will change to 4 Remove the 100gr 3 500z weight from the left side and screw it into the right side of the Pruefrotor Figure 3 21 NOTE IFA TIRE AND WHEEL ASSEMBLY IS USED THE TEST WEIGHT MUST BE ATTACHED ON THE OUTSIDE OF THE WHEEL EXACTLY 180 FROM THE WHERE THE INNER WEIGHT WAS ATTACHED Lower the wheel guard to begin the spin cycle After the shaft comes to a stop the display will change to 5 65 __ cl O 15 Figure 3 19 3 20 1 Figure 3 21 Effective 04 2003 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE 5 Remove the Pruefrotor from the H NOTE IF USING WHEEL AND TIRE LEAVE ON SHAFT NOTE FOR A MOTORIZED UNIT THE TECHNICIAN CAN EITHER REMOVE THE PRUEFROTOR FROM THE SHAFT OR LEAVE IT ON THE SHAFT Spin the shaft by lowering the wheel guard Aft
65. n itself MAIN PROCESSOR PCB The microcontroller normally takes its instructions from the FLASH memory A 40 pin IC socket is used to transfer the program from an EPROM to FLASH memory Unlike EPROMs FLASH memories do not require windows for UV light in order to delete data they can be cleared and programmed electronically Unless otherwise stated in the program revisions new program versions can be installed without the need for adjust ment The main processor receives its power from the power supply pcb and distributes the power to the encoder transducers and SAPE potentiometers Calibration factors are stored in this location along with the encoder PCB KEYPAD The keypad is used to input data into the Display PCB It connects directly to the display pcb via a ribbon cable Effective Page 2 2 04 2003 DISPLAY PCB The Display PCB receives power directly from the power supply pcb lt passes 5VDC to power the tone generator and the LED display lt receives the information from the Main Processor Board via the power supply pcb This information is passed back to the Main Processor routed through the Power Supply Board TEMPERATURE SENSOR The system has a new force guidance structure patent pending The forces at the measuring transducers have been reduced thus achieving long term stability and high measuring accuracy Pre tensioning of the transducers is achieved by two leaf springs On the vibratory system the measuring transducers are
66. nnel 2 Phase shift too big Page A 5 APPENDIX A CODES Error ID Limits Description 410 Transducer 1 No signal 411 Transducer 1 transimpedance to low 412 Transducer 1 RC time constant out of range 415 Transducer 1 transimpedance amplifier idle voltage out of range 416 Transducer 1 DC amplifier idle voltage out of range 418 Transducer 1 amplifier saturation 419 Transducer 1 Transfer function out of range 420 Transducer 2 No signal 421 Transducer 2 transimpedance to low 422 Transducer 2 RC time constant out of range 425 Transducer 2 transimpedance amplifier idle voltage out of range 426 Transducer 2 DC amplifier idle voltage out of range 428 Transducer 2 amplifier saturation 429 Transducer 2 Transfer function out of range 430 Transducer 182 No signal 431 Transducer 182 transimpedance to low 432 Transducer 182 RC time constant out of range 435 Transducer 182 transimpedance amplifier idle voltage out of range 436 Transducer 182 DC amplifier idle voltage out of range 438 Transducer 182 amplifier saturation 439 Transducer 182 Transfer function out of range 500 BL_BAL_ERROR_NoConverge 501 BL_BAL_ERROR_Resultinvalid 502 BL_BAL_ERROR_TooMuchLoops 510 BL_BAL_ERROR_NoCalUser 511 BL BAL ERROR FailCalUser 512 BL BAL ERROR SideCalUser NOTE 1 FRONT TRANSDUCER 560 c1 value too low if a user calibration tool assumed 2 REAR TRANSDUCER 561 C2 value too low if a user calibration tool assumed 565 c1 value too low if 10
67. on for 1 second or more will cause another tone to be generated and a new value to be displayed and stored The value is removed from the display when the SAPE is returned to the home position If a measuring run has been performed the results are recalculated and displayed when the SAPE is returned to the home position The rim data values will show in the display after measuring HWM SAPE DATA ENTRY The HWM data entry mode is entered by removing the SAPE When the SAPE is removed from the home position the appropriate inner plane weight led blinks This shows the operator where to apply the arm to the rim After the SAPE is stationary for 1 second a tone is generated the inner plane position is stored and the outer plane led blinks At this point the SAPE can be returned to the home position If this is done the results are not recalculated as the user has only partly entered the required parameters with the SAPE If the SAPE is removed again from the home position the outer plane led will flash and the user must enter this value Holding the SAPE stationary for 1 second causes the value to be entered a beep to be generated and the led to stop flashing The SAPE must now be returned to the home position If a measuring run has been per formed and the rim diameter is within limits for HWM the results are recalculated and displayed when the SAPE is returned to the home position If the rim diameter is less than 12 inches E12 will be displayed This
68. ormer cable to X41 connector of power interface board ensure the wiring does and will not conflict with rotating parts Install and fasten the weight tray 8 Replace the electrical supply wire with the correct one for the 115 volt unit To transform a 1200 or a 1400 to 220V disconnect B and C and connect A to the X41 connector and replace plug accordingly Effective Page 3 26 04 2003 APPENDIX A CODES KERNEL CODES A complete error code consists of 6 hexadecimal digits Prefix Digit 6 Digit 5 Digits Digit 3 Digit 2 Digit 1 Digital Display Left Display Right Display 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 Description 21 Time Service 22 12C bus device driver 23 Serial device driver 24 Sound device driver 25 External AD converter 26 Internal AD converter 27 Temperature measurement 28 Piezo transducer 29 Incremental encoder Main 2 Incremental encoder belt disc 2B Relay management 2C Hand spin brake 2D Electromagnetic brake 2E main supply line 2F motor 30 Supervisor 31 Watchdog timer 41 Auto stop system 42 Data conditioning 43 Rim data management 44 Sape device 45 Display device 46 Keyboard device 47 Brake device 48 Motor device 49 Drive Motor Brake 4 Power clamp 4B Incremental p
69. otentiometer 4c Rim light 61 Balancing algorithm 62 Balancing calibration 63 Behind the spokes placement 64 lt not used gt 65 Optimisation 66 Measurement control Effective 04 2003 Page A 1 APPENDIX A CODES Priority ID Error ID F01 202 203 204 205 206 207 208 209 FOA FOB Command language Commands coming from the Ul Calculator Message Server Message service from BK to Ul Message Server User messages from BK to Ul Sleep command Balancing Kernel Test statemachine eg selftest during startup Event system User management State machine complex data type Persistent objects Pipe device Power on time counter gt time stamp for error recording Counter for total spins in service in user mode Self test User interface User interface Description Critical error will be recorded in user mode Warning message For information only All of above but will not be recorded in the error record persistent objects p30 to p39 Limits Description Not complete 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 interface C28 Out of memory Out
70. otor required NOTE FINE BALANCED TIRE AND WHEEL ASSEMBLY ALONG WITH A 3 5 OUNCE WEIGHT CAN BE SUBSTITUDED Page 1 5 CHAPTER 1 AC DC POWER DISTRIBUTION PROCESSOR PCB X1 From Power Supply Board Encoder Tranducers amp Temp Sensor Pin 6 5 X6 Distance SAPE Pin 1 Gnd Pin 2 Output e Pin 3 5 VDC X7 Diameter SAPE Pin 1 Gnd Pin 2 Output Pin 3 5 VDC X8 Width SAPE Pin 1 Gnd Pin 2 Output e Pin 3 5 VDC X9 Not Used Page 1 6 NO gt NO gt NO gt Check vibratory system mounting bolts are they tight Tighten to specification and retest Are both the Front and Rear transducers tight Adjust to specification and retest Check C74 does the left display change from 010 511 Replace the Encoder Board Retest Replace the Main Processor Retest Replace the Vibratory System Retest Does the shaft spin smoothly and freely NO gt Replace vibratory system Retest 9 O e O 1 2 oo x1 1 2 X ud M y e 6 0000000 0000 gt 1 24 L 5 o zE uM E 34 5VDC TETTE ETT UT 39 40 1 1 1 2 2 2 X7 X8 Effective 04 2003 W6
71. oximately 45 seconds After the completion of the upload the balancer will continu ously emit beeps E TTT CAUTION REMOVE POWER FROM THE UNIT DURING THE UPLOAD PRO CESS PERMANENT DAMAGE TO THE MAIN PCB WILL OCCUR 5 When the upload is complete remove power from the balancer Remove the EPROM off of the socket using a screwdriver and place it in packaging for transport Reassemble the balancer and apply power and perform a complete factory calibration Effective Page 3 18 04 2003 TO ACCESS THE INSIDE OF THE MACHINE 1 Remove the screws from the front and side of the weight tray Figure 3 30 2 Standing 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 CAREFUL NOT TO CRUSH WIRES Figure 3 30 POWER SUPPLY BOX All Balancers WARNING 1 Disconnect the power from the rear of the machine DANGEROUS HIGH VOLTAGES ARE 2 Remove the weight tray PRESENT IN THIS EQUIPMENT 3 From the rear of the machine remove the two screws holding the Power Supply box Figure 3 31 simply pull the box out the back paying special attention to the wiring harness that are connected 5 Un plug each of the harnesses from the power supp
72. peog bY esn 0 1 TS 20A da Ajddns LX EX SUNEN polqwiesse ase 3 pyeoq amod 2 7 55 N NVOHOOVZOMV3 4 ZH 03 06 OW eeen yndug yun pue e dsip ejqeo 4 Bree 2024 MA 200 02 Mera pue 05 1 E MA punoib Asse ea L 7 9v j Page 1 9 Effective 04 2003 CHAPTER 1 AC DC POWER DISTRIBUTION KEYPAD SCHEMATIC 1200 amp 1400 gr oz mm inch 2 E 97702 ae ach 220 zz Z ALU INE 7 MOT STAR x 2 STOP ree e 4 6 7 S m ine KEYPAD SCHEMATIC 1500 CA 00 02 mm inch 22 E ay 2 gr o mm inch A Z DYN STAT INE START A A lt ST Effective Page 1 10 04 2003 1500 Input Wiring usvat m Main SND ACUTRAL CND NEDTRAL pj Toe 5 exwac X41
73. position 2 Re start the unit 3 If the error appears again calibrate the SAPE diameter Service Code 80 amp 81 NOTE UNTIL SERVICE WILL COME END USER CAN FOLLOW UP WORKING ENTERING DATA MANUALLY EXIT THE ERROR CODE BY PRESSING STOP BUTTON 16 User calibration failed None Calibration weight attached erroneously to the flange 22 Speed Up timeout It takes too long to reach the required 492202 wheel speed 1 Check if the shaft rotates lightly correct bearings brake adjustments etc 2 Check the signals from the opto encoder 3 Check the belt tension 4 Check the signals and power to and from the motor 23 Speed not reached 492203 1 Check if the shaft rotates lightly correct bearings brake adjustments etc 2 Check the signals from the opto encoder 3 Check the belt tension 4 Check the signals and power to and from the motor 24 Speed low 492204 1 Check if the shaft rotates lightly correct bearings brake adjustments etc 2 Check the signals from the opto encoder 3 Check the belt tension 4 Check the signals and power to and from the motor 25 Shaft rotation in wrong direction 492205 1 Hand spin turn shaft in correct direction Motor spin connect motor correctly 2 Check opto encoder signals and connections 26 No Acceleration 492206 1 Check motor belt 2 Check opto encoder signals and connections 27 Slip detected 492207 1 Tighten quick nut 2 Check motor belt 3 Check opto encoder signals and
74. pplied with the gauge arm It is rim diameter dependent Effective 04 2003 E Accu turn INPUT KEYS DISPLAY WINDOWS 11 12 13 14 1200 1400 Display 10 9 8 7 6 Figure3 2 OFFSET OFFSET CAL WIDTH WIDTH GR OZ DIAMETER DIAMETER MM INCH FINE EXIT STOP F OPT START ALU DYN STAT MOTO MOTO PAX INDICATOR LIGHTS WEIGHT PLACEMENT INDICATORS INSIDE WEIGHT AMOUNT FUNCTION DISPLAY INSIDE WEIGHT LOCATION OUTSIDE WEIGHT LOCATION OUTSIDE WEIGHT AMOUNT FUNCTION DISPLAY OPERATOR KEY OPERATOR INDICATOR 1 12 13 14 OP 15 16 10 o 8 7 6 Figure 3 3 1500 Display Effective 04 2003 Page 3 5 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE GENERAL OPERATION Pressing the relevant key performs that action Pressing the OFFSET key increases offset Pressing the WIDTH key increases rim width Pressing the key increases rim diameter To access ary functions the machine should be in Idle state press the F key and the specific key Pressing F while pressing the DIAMETER MM INCH key will toggle the MM and INCH display modes The F key on its own is mostly used as the ENTER key The FINE key is mostly used as the CANCEL Key MANUAL DATA ENTRY The nominal rim dimensions of the wheel can be entered by using the parameter entry keys These can only be used when the balancer 15 idle
75. ransducer and follow transducer installation Install mechanical brake and follow mechanical brake installation Install weight tray Connect power and follow all calibration procedures 80 81 82 83 84 88 and test ENCODER REMOVAL All Balancers 1 2 8 NOTE CAREFUL LET FOREIGN DEBRIS FALL Turn the balancer off unscrew and open the weight tray Disconnect the flat cable just the one that goes to the board same cable goes to the piezo sensors which does not needs to be disconnected Remove the black tape unscrew the screw and remove the board carefully Fix the new board connect the cable and close by placing new tape Turn the balancer on and C 85 will be displayed Press F button and few beeps will be emitted Auto test and a new switch on will be performed automati cally program version is shown on the display Perform a factory calibration C83 C84 and C88 INSIDE THE TUBE Effective 04 2003 Figure 3 35 Screw 10 Pin connector Figure 3 36 Page 3 21 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE Figure 3 37 DIAMETER SAPE POTENTIOMETER MODEL 1400 amp 1500 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 Processor Board Remove the 10mm nut holding the
76. rate a sufficient amount of torque during acceleration and braking DC THEORY OF OPERATION PROCESSOR BOARD The operating voltage for the Main Processor is 5VDC It receives this power from the Power Supply Board at X1 pins 32 and 34 This 5 volts also passes through the Processor Board and supplies the Encoder PCB and both the Distance and Diameter SAPE ENCODER BOARD The encoder receives 5VDC from the Processor Board This voltage can be measured at the Processor Board at X3 pin 6 The encoder is built so that there are no adjustments The encoder disk is built onto the shaft and cannot be replaced without replacing the vibratory member The encoder is fitted in the vibratory tube and consists of a reflective slotted sleeve which is mounted on the main shaft and the optoelectronic unit DISTANCE POTENTIOMETER MODEL 1400 1500 The distance potentiometer is a 10K pot It is supplied 5VDC from the main processor This input voltage can be measured at the Processor Board X6 pin 3 The output voltage is dependent upon the deflection of the guage from the home position DIAMETER POTENTIOMETER MODEL 1500 1400 The diameter potentiometer is a 10K pot It is supplied 5VDC from the main processor This input voltage can be measured at the Processor Board X7 pin 3 The output voltage is dependent upon the rotation of the guage from the home position Effective Page 1 2 04 2003 WIDTH POTENTIOMETER MODEL 1500 The width potentiometer is
77. ry member If the transducer is being replaced using a marker mark the front and rear transducer harnesses Cutthe two wires the transducer The positive lead of the harness is marked with a black band When using a harness and transducer assembly this step is unnecessary INSTALLATION OF TRANSDUCER The front and rear transducer must be installed correctly in order for the balancer to function correctly Figure 3 33 The rear transducer uses the last 2 wires pins 15 16 in the harness 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 without destroying the transducer Apply a small amount of grease to each end of the transducer Place the ball bearings in place on the transducer Place the transducer assembly in the vibra tory 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 move ment exists after tightening the jam nut Adjust as neces sary Hold the pre load plate in position up to the jam nut and finger tighten the set screws to just hold
78. s should be made to make sure the SAPE s are in their HOME position during start up The operator needs to press the STOP button to exit the display and enter idle state The machine masks the function of the failed part after SAPE check For example if the diameter gauge fails the machine disables the measurement of diameter and measures the distance only Or if the distance gauge fails the machine disables the measure ment of the distance gauge and measures the diameter only The potentiometers plug into the main processor at connection X6 Distance and X7 Diameter and X8 Width The potentiometers are supplied with 5VDC from the Processor Board As the SAPE is pulled out and up towards the wheel the voltage s change The distance from the balancer to the wheel is generated from the voltage output and the diameter of the wheel is generated from the amount of voltage output when the arm is moved up Adjustment are made using the C80 C82 code this procedure can be found later in this manual ENCODER The encoder disk is built onto the shaft It cannot be adjusted and can only be replaced by replacing the vibratory member The new incremental encoder is fitted in the vibratory tube and consists of a reflective slotted sleeve which is mounted on the main shaft and the optoelectronic unit To prevent dirt and light entering the opening in the vibratory tube must be sealed with black adhesive tape A red visible LED and four light detectors are fit
79. stem which add to the signal generated by the imbalance of the wheel To determine acutal imbalance the signal must be filtered To compute correct imbalance values the parameters diameter width and offset of the wheel to be bal anced must be entered Enter wheel parameters using the Distance Entry Arm Slide the gauge to touch the rim and hold The distance to the rim and the wheel diameter are entered automatically by means of two mounted potentiometers 1400 amp 1500 The rim width can be done automatically by simply pulling the width arm and touching the outside of the rim 1500 The rim width may also be done manually by using the supplied rim width calipers and entering the measured value This is done by pressing and releasing the rim width button and toggling the keys on the display panel or by rotating the tire and wheel assembly until the desired number is shown To find wheel imbalance the transducers signal magnitude and encoder timing are both required A series of timing marks on the shaft that interrupt light transmitted between two optocouplers generate a DC Square wave each time a mark moves past an optocoupler One additional mark offset from the encoders metallic strip interrupts a third optocoupler on the board creating a zero signal reset or home position The encoder detects 512 angular positions during each turn of the shaft plus the home or reset position The frequency of the DC square wave generated by the encoder
80. ted 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 Hammer drill Installation Option Pruefrotor see below 6416946 or A fine balanced tire wheel assembly 3 50 ounce 100gr wheel weight Program EPROM 0026603 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 trim to exact weight paint and label 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 Figure 3 1 Effective 04 2003 Page 3 3 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE DEFINITION OF TERMS 1100 NOT RELEASED 1200 1400 1401 NOT RELEASED 1500 NORMAL TRUCK ROUND ALU STATIC HWM SWM Rim Data SAPE Gauge Arm C88 Offset Gauge arm offset Page 3 4 Hand spin wheel balancer model designation Entry level motorised low digital wheel balancer model designator 2 User Mid Digital motorised wheel balancer model designator 4 User Mid Digital motorised wheel balancer model designator with 3D SAPE 4 User High Digital motorised wheel balancer model designator with 3D SAPE 9 User A weight placement mode typically used for st
81. ted in the encoder part of the optoelectronic unit behind the lenses Part of the light is reflected back from the webs of the slotted sleeve to the encoder part and focussed by the lens such that the web slot pattern of the sleeve is mapped on the four light detectors Two light detectors are connected to one amplifier in the encoder part The difference in brightness between the detector pairs determines the instanta neous output states of channels A and B To exclude interference from extraneous signals and to guarantee reliability the two signals are amplified by an IC One slot in the sleeve is wider than the other 255 slots Therefore the absolute angular position of the main shaft can be determined at constant rotating speed The Effective 04 2003 Page 2 3 CHAPTER 2 THEORY OF OPERATION surface of the slotted sleeve must be clean and shiny the slots must have a dull black background Should a dirt particle have settled on a web or in a slot it can be lifted off of the slotted sleeve with self adhesive tape by applying it onto a strip of strong paper so that half of the tape is on the paper and the other half overhang ing CAUTION If the slotted sleeve is twisted relative to the main shaft when being cleaned the step pensation of residual shaft unbalance must be performed with C84 A defective slotted sleeve cannot be replaced in the field because the ball bearings of the main shaft are pressed in The incremental encoder can be check
82. tiometer if the value 15 not correct adjust the diameter potentiometer Press the lt F gt key to store the value and proceed to the next step i n Figure 3 11 Place the large portion of the calibration slug down on the bell housing and pull the distance arm out and rest it on the pancake portion of the calibration slug Press the lt F gt key to store the value and proceed to the next step Figure 3 12 Figure 3 12 Place the SAPE on top of calibration slug weight by keeping the slug ER thread in the centre of the SAPE plastic round part Figure 3 13 Press oe the F key and display will show C80 and enter the value PA CALIBRATION COMPLETE ES Figure 3 13 C81 SAPE ARM ZERO Place the flat portion of the calibration weight against the face of the A flange plate Extend the SAPE arm and touch the tip to the calibration _ pA weight Press the lt F gt key to store the value Figure 3 14 gae rcg ILC CALIBRATION COMPLETE Figure 3 14 Effective 04 2003 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE C82 3D SAPE CALIBRATION The model 1500 15 the only balancer that requires this procedure both the 1200 and 1400 do not have the Width Arm Make sure that the width arm is in the home position Figure 3 15 enter C82 and verify that the voltage reading from the SAPE is 4 25 4 30VPC If the voltage is correct press the lt F gt key to enter the
83. turn sping to the lower base of the cabinet Route SAPE thread over guide roller Manually turn SAPE wheel counterclockwise and hold it into position Figure 3 39 Loop SAPE thread around SAPE wheel and release the SAPE wheel Figure 3 39 Test SAPE assembly by pulling on the SAPE arm to it s full out position several times Make sure their is no binding C80 amp C81 for SAPE calibration WIDTH SAPE POTENTIOMETER INSTALLATION Model 1500 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 potentiom eter Figure 3 40 Remove the 13mm nut holding the potentiometer Reverse procedure for installation The potentiometer comes equipped with a standoff insert the standoff into the hole in the housing Reconnect all wiring Run C82 for SAPE calibration Effective 04 2003 Fully extended Figure 3 39 Adjustment Screw Figure 3 40 Page 3 23 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE MECHANICAL BRAKE CABLE This type of brake consists of a two brake pads fitted onto a bracket assembly The friction material of the brake pads contacts and operate over the motor pulley The brake 15 activated
84. tus of the code between 0 and 1 Pressing F with 0 displayed exits the code without resetting the counters If 1 is displayed and F is held down for 10 seconds the code is exited and the counters are reset Pressing the FINE key at any stage will act like an Escape key and exit the code without changing anything C47 CONFIGURE THE FLASH 1100 or 1200 1400 1401 and 1500 in displays Pressing the x keys will toggle the selected machine model Pressing F will program the flash for the appropriate machine The machine will then reset Pressing the FINE key at any stage will act like an Escape key and exit the code without changing anything C66 C67 ENGINEERING AND MANUFACTURING PURPOSES C72 MECHANICAL PHASE SHIFT OF VIBRATORY SYSTEM Enter C72 by pressing the x keys 1 will be displayed in the left window indicating the step number Mount the Pruefrotor on the balancer and perform a measuring run A number 2 will be dis played to indicate the step number Figure 3 6 i Figure 3 6 Mount the calibration weight 100 gram on the left side of the calibration rotor Perform a measuring run Figure 3 7 The digit 3 in the left display to indicate the step number Figure 3 7 Remove the calibration weight and mount the calibration weight on the right side of the calibration rotor Perform a measuring run Figure 3 8 The phase sh
85. uring a non hwm weight application mode anything but HWM1 and HWM 2 removing the sape from the home position causes any results displayed to be removed from the display If the SAPE is removed while in manual data entry mode the data entry function is first exited see above and then the SAPE becomes functional as detailed below When the SAPE is returned to the home position the mode of entry automatically goes to parameter entry If the SAPE is removed while a measuring run is in progress the run will be terminated a beep will sound the wheel will brake and E10 is displayed After 7 seconds E10 is cleared If an attempt is made to use the SAPE while in another mode of operation the SAPE does not interrupt the function in use When the function is exited by the user the SAPE becomes active In the HWM mode 1 or 2 there are two modes of SAPE operation data entry and weight application Data entry is the default mode of operation when HWM 1 is entered When valid results are made available see recalculation above weight application is enabled Weight application is disabled by pressing the lt STOP gt key and removing the SAPE from the home position with machine in idle mode a tone is generated Effective Page 3 6 04 2003 NON HWM SAPE DATA ENTRY If the SAPE is held stationary for 1 second or more a tone is generated and the offset is shown in the left display panel and the diameter in the right Holding the SAPE stationary in another locati
86. value if it is incorrect adjustments must be made before continuing mme Figure 3 15 If the values are not correct adjustment to the 3D potentiometer must be made Remove the three philip screws from the SAPE potentiometer that is mounted on the wheel guard Holding the SAPE arm in the home position adjust the potentiometer to correct voltage Figure 3 16 Figure 3 16 Move the SAPE arm and touch the tip to the Flange Plate Figure 3 17 and press the lt F gt key to enter the value Figure 3 17 Screw the Calibration weight into the threaded hole on the Flange Plate and touch the tip of the 3D SAPE to the tip of the calibration weight Figure 3 18 and press the lt F gt key to store the value CALIBRATION COMPLETE Figure 3 18 C83 FACTORY CALIBRATION PROCEDURE NOTE THE C80 CALIBRATION MUST BE DONE BEFORE THIS OPERATION A balanced tire and wheel assembly can be substituted if a Pruefrotor is not available The calibration procedures are the same and can easily be performed The correct dimensions of the Pruefrotor or tire and wheel assembly must be entered before proceeding with this procedure After the correct dimensions have been entered recycle the power using the procedures for entering into the service menu This written procedure is done using the Pruefrotor 1 Enter C83 using the lt gt keys and press the lt F gt key Mount the Pruefrotor on the balancer shaft and lower the wheel guard to perform a
87. y proper weight amount and location The technician should watch a machine work and make performance assessments based on what is seen If 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 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 itis 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 5 Output Once all voltages and signal levels are present a proper output can be expected Effective Page 3 2 04 2003 TOOLS REQUIRED WHEN SERVICING THE ACCU BALANCERS Tools Metric Sockets 4mm Thru 15mm Metric Wrenches 6mm Thru 15mm Assor

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