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Service Manual 40 - 60 - 80

1. Note the width as read off the rim or measured with a manual gauge Example Actual 7 5 Enter C19C Press and release the width button Hold the width gauge against the rim as taking a measurement The left display indicates the measured width Example Measured 6 5 Note the difference between the Actual rim width and the width Measured using the automatic gauge Example Actual 7 5 Measured 6 5 1 Enter the difference noted through the keypad Example Press 1 If the gauge measurement was higher than the actual rim width press the S D key If the gauge measurement was lower as in the example go to step 9 Example go to step 9 Press the C key Press the STOP key 11 Test the rim width gauge to insure it is reading correctly If not repeat steps 12 1 10 Store the setting into the computer memory See G Revised 3 00 Page 38 Service Manual 40 60 80 ADJUSTMENT PROCEDURES Cont Readout Adjustment Basic Re calibration All Models A Mount a wheel and set corresponding rim width distance and diameter B Balance the wheel to within 1 00 ounce in each plane C Select a test weight of 3 5 ounces 99 grams or any size between 3 and 4 ounces 1 ounce 28 35 grams D Enter C 83 C 1 Press start the machine will run through a cycle Ze Enter the size of the selected test weight in grams then press C 3 Attach the test weight on the left side of the wheel Press
2. 4 To adjust remove the screws from the display panel and for the 60 80 Series remove the display housing and weight tray For the 60 80 Series reconnect display panel and go through steps 2 amp 3 again After steps 2 amp 3 have been done unplug the opto electronic cable 5 Enter C 20 C Reconnect the opto electronic cable A number will appear in the right hand display If the weight is before 6 00 enter a number higher than the displayed default number press the C button If the weight is after 6 00 enter a number lower than the displayed default number press the C button Press the START button and check to see if the location is correct if not perform adjustment again 6 Continue on step G storing the calibration data into the permanent memory Revised 3 00 Page 40 Service Manual 40 60 80 ADJUSTMENT PROCEDURES Cont AFTER PERFORMING THE ADJUSTMENT PROCEDURES THE CALIBRATION DATA MUST NOW BE STORED IN THE COMPUTER MEMORY SO THAT IT WILL BE RETAINED WHEN THE POWER IS SWITCHED OFF To store the adjustments into the computer memory G Store adjustments and function codes into the machine memory 1 Enter C 10 C a 2 Press buttons 1 and 3 at the same time The Processor circuit board issues three tone signaling the code setting has been stored in the memory Revised 3 00 Page 41 Service Manual 40 60 80 Operator Calibration Intended for the user to fine tune the balancer calibration it can also
3. display Rim distance setting is impractical for balancing using the selected ALU 2 or 3 mode The distance between the rim center flange and left correction plane is too narrow El with gt display Rim width entered is out of range E1 with display Rim diameter entered is out of range E2 Wheel guard is not closed ES Distance gauge is not in the rest position E4 Width gauge is not in the rest position Symptom After pressing start key an E3 and or E4 appears Cause Remedies On a machine with automatic distance diameter and or rim width gauges these codes occur because one of the gauges is not in the rest position See Adjustment codes C80C C81C C82C On a machine without automatic measuring gauges these codes can be caused by a defective processor board interface board Or a micro residue build up on the interface board Replace Defective board E5 Wheel is too far out of balance for zero balance compensation during function code C4 or calibration weight was inserted by mistake during CAL 1 E6 Calibration weight was not inserted during Cal 2 step of the user calibration or both pick ups are disconnected E7 ALU mode was selected after rim dimensions have been entered in mm Dimensions must be entered in inches width amp diameter to use the ALU modes Revised 3 00 Page 10 Service Manual 40 60 80 E8 E9 E15 E30 E31 ERROR CODE DIRECTORY cont During tire matching the valve position
4. 80 C63 C65 C68 C69 USING THE DIAGNOSTIC CODES cont Use this code to set the machine into the continuous display mode As the shaft turns the display will blink each 40 revolutions as updated imbalance inputs are averaged This code is helpful while trouble shooting for a intermittent or erratic read out Enter C 6 3 C Press start TO END THE TEST PRESS THE STOP BUTTON Use this code to check the phase difference between the two Pick ups For the computer to correctly calculate the imbalance correction weight needed it is necessary that the output voltages from the Pick ups are in phase Error message E34 will display during a Code C83 adjustment if the Pick ups are detected to be out of phase by more than 3 degrees Enter C 6 5 C The phase difference will display Seres TO END THE TEST PRESS THE STOP BUTTON Use this code to check the operation of the electrical system Enter C 68C The left display shows the number of shaft revolutions required to reach measurement speed during the last measurement The right display shows the number of shaft revolutions required to reach the speed where the motor start capacitor switching relay dropped out during the last measurement cycle rec TO END THE TEST PRESS THE STOP BUTTON Use this code to set up the automatic measurement cycle This cycle can be used to allow an unattended machine to measure brake to a stop sit at rest then measure brake to a stop cont
5. B Place the rim distance diameter gauge downwards against the rim hold in this position and press the C key 6 Final Adjustment made with C18C Eprom versions 1 52 and above Revised 3 00 Page 35 Service Manual 40 60 80 ADJUSTMENT PROCEDURES Cont Rim Width Gauge Adjustment _Geodyna 80 E Series The distance gauge has to be adjusted prior to calibration of the rim width gauge 1 Enter code C82C The left display shows the slider voltage of the rim width potentiometer in volts The right display shows the adjustment step In the home position right limit position the voltage should be set to between 0 12 and 0 50 volts If adjustment is necessary remove cover by removing 3 screws Loosen the nut Using a screwdriver change the position of the slotted potentiometer shaft in the center of the gear until the left display shows between 0 12 and 0 50 volts Re tighten the nut Press the C key the value of the home position is stored In the right display 2 is displayed Rim Width Gauge Arm Pull out the distance gauge and the rim width gauge gauges will not touch so that both gauges are at their maximum extension as shown below and press the C key again This completes the C82C adjustment The final adjustment to compensate for mechanical differences from machine to machine is made with C19C Eprom Version 1 52 and above Revised 3 00 Page 36 Service Manual 40 60 80 ADJUSTMENT PROCEDURES Co
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7. Description Fuse 8 0A 250 volts Fuse 0 8 A 250 volts Fuse 12 0A 250 volts Fuse 0 4 A 250 volts Relay 24 volt coil Capacitor 56 67 MFD 250 VAC Motor Start type Capacitor 43 52 MFD 330 VAC Motor Start type Capacitor 45 MFD 330 VAC Motor Run type Capacitor 50 MFD 330 VAC Motor Run type Rectifier 15 A Page 43 Service Manual 40 60 80 Testing of individual components on electric board A CAUTION DISCONNECT MACHINE FROM POWER SOURCE gt BEFORE PERFORMING ANY OF THE FOLLOWING TESTS Dir 1 Transformer 1 To test transformer resistance remove fuse F2 from electric board Set your multimeter to ohms and select appropriate scale A Transformer primary resistance Place meter leads on L2 terminal and load side of fuse F2 Resistance should be approximately 22 26 ohms B Transformer secondary resistance Remove ribbon cable leads 12 and 11 from the interface board Place meter leads across these wires 12 and 11 Resistance should be approximately 0 8 1 4 ohms 2 To test output voltage of the transformer install fuse F2 set meter to Vac and select the appropriate range Leaving ribbon cable leads 12 and 11 disconnected from the interface board place meter leads across the wires and turn on machine Voltage should be approximately 19 26 vac 2 Relays To test the relays remove them from the board and set meter to ohms Measure across the terminals indicated below A
8. Reading open circuit NOTE A properly functioning diode will show low resistance in one direction only 7 Motor To test the motor disconnect the motor leads from the electric Set the meter to ohms and measure as indicated below For this test polarity does not matter Blue to white wire 4 8 ohms Red to white wire 4 8 ohms Any color to green open circuit NOTE All of these values should fluctuate if motor shaft is turned while measuring with meter Revised 3 00 Page 46 Service Manual 40 60 80 Electric Board Trouble Shooting Table symptom Diagnostic Test Check Probable Fault Fuse is blown Machine does Is there voltage at the Defective transformer not have a output of the Defective ribbon cable display transformer leads 11 8 12 Fuse on processor board is blown Processor board is defective E74 Press start then spin Fuse F1 is blown Wheel will not wheel by hand Does Check motor Spin wheel continue to spin NO Defective relay K1M Defective ribbon cable leads 9 amp 10 Defective motor red to white Defective relay K3M Defective capacitor YES Defective ribbon cable leads 5 amp 6 Defective motor blue to white E31 Press start Defective capacitor Wheel will spin Does wheel continue to backwards Spin backwards after Defective relay K2M E31 No brake Normal start but no brake Defective relay K2M at end of cycle Defective
9. T Co U 8 A BL A OFZ a E MAWHOASNV YL LL o MS E eae IDO Didde SE SE SE A OSE Aner E SE jose Z YOLISVdVO VO O Gil 8 4 Y 0 Z4 La OO O d a Y CTL t4 4 14 6 sasn4 ud yon ogg Alddnsuemog Service Manual 40 60 80 Page 58 Revised 3 00 Service Manual Revision Updates 10 13 97 10 28 97 2 25 98 4 24 98 6 12 98 9 11 98 9 21 98 4 25 99 11 19 99 12 07 99 3 00 US version Service Manual created Pages 1 26 27 Pages 1 2 3 4 5 7 8 9 10 11 12 15 16 20 21 24 26 27 28 29 30 31 32 33 34 39 Pages 1 2 4 5 6 26 27 28 29 30 32 33 34 40 41 Pages 1 2 4 5 6 7 9 15 26 33 34 41 42 Pages 1 2 5 8 22 25 26 27 28 29 37 43 44 53 Pages 2 3 4 5 6 11 12 13 14 15 23 24 25 26 27 46 47 48 Pages 1 31 37 Pages 1 2 8 9 14 22 29 31 33 34 35 41 48 Page 28 Pages 1 2 29 37 38 41 Revised 3 00 Page 59 Service Manual 40 60 80
10. a number which may fluctuate two numbers This number should be within the range of 40 60 Press the e button 3 will show in the left display This is the zero reference test The right display will show a number which may fluctuate two numbers This number should be within the range of 40 60 Press the e button 4 will show in the left display The right display will show a number which may fluctuate two numbers This number should be within the range of 20 35 You may monitor each test repeatedly by pressing the e key If any of these tests display readings which are not within the specified range the Opto electronic may need replacing It is only recommended to replace the Opto electronic if an out of tolerance reading is found along with a machine malfunction It is not recommended to replace the Opto electronic if the above tests indicated a reading slightly out of tolerance FER END THE TEST PRESS THE STOP BUTTON e Revised 3 00 Page 23 Service Manual 40 60 80 C55 C59 C60 USING THE DIAGNOSTIC CODES cont Use this code to check for proper D C voltage at the Circuit Board A function of the Processor circuit board is to provide a DC power supply Depending on operating voltage either 115 or 230 volts AC is supplied to the transformer primary The transformer reduces the voltage at the secondary to approx 18 2 volts AC The secondary voltage is converted by the power supply portion of the
11. be used by the service technician rather than Readout Adjustment if only a slight readjustment to the readout accuracy is required The basic theory During certain steps of the Readout Adjustment C 8 3 C procedure imbalance forces created with and without a calibrated weight called the Calibration Weight attached to the wheel centering adapter are measured as an output voltage from each pick up These voltages are measured with a calibrated weight threaded into the centering adapter at an exact Known distance and diameter from each pick up The voltages are also measured without the calibrated weight During Readout Adjustment C 8 3 C step 5 the voltage output from the pick ups without the calibrated weight and during step 6 the voltages from the pick ups with the calibrated weight are measured and memorized by the computer This information is stored on a EEPROM located on the Interface circuit board Completing operator calibration requires two operations one with and one without the calibration weight attached to the wheel adapter similar to following steps 5 amp 6 of the Readout Adjustment The computer compares the voltages with those stored during the Readout Adjustment When necessary the computer adjusts the readouts to match the original Readout Adjustment accuracy Operator Calibration procedure Without a wheel on the balancer remove the cones ringnut and pressure cup from the adapter Leave only the threade
12. circuit Board does not recognize that the balancer shaft is turning Does the shaft turn If yes test using codes C54 amp C74 Opto electronic or Processor circuit board may be defective If not the error code is not caused by the Opto electronic Check the power to the machine internal electrical system motor relay fuses and connections If the motor can be heard turning but the balancer shaft does not check the drive belt and tension assembly If the motor hums only and E74 comes on after a few seconds it may be a defective start capacitor It may be also a incorrectly wired wheel guard switch especially if the C13C code is set to 1 Remedy Replace wheel guard switch Revised 3 00 Page 15 Service Manual 40 60 80 ERROR CODE DIRECTORY cont E76 Left Pick up reference voltage incorrect To trouble shoot see E77 E77 Right Pick up reference voltage incorrect To trouble shoot 1 Switch the power off Unplug both Pick ups from the Interface circuit board Switch the power on If E76 77 still displays replace the Interface circuit board If not go to 2 2 Switch the power off Plug the left Pick up into the right terminal and the right Pick up into the left Switch the power on If the error code follows the Pick up replace the Pick up If not replace the Interface circuit board Symptom After turning on power E76 and or E77 appears These error codes indicate a wrong D C voltage on the left and or right transducer Pick
13. for anything under the machine Check for a wheel weight lodged in or along side the vibratory structure Check the Pick up connections at the Interface circuit board If E36 displayed with E34 it s likely the problem is a defective pick up Check that the Pick ups are tightly mounted under the shaft in the vibratory system They should not turn by hand Check that the four vibratory system mounting bolts are tight Try C83 Readout adjustment again using another wheel and tire assembly or only a wheel If C83 adjustment was attempted using a thick alloy wheel try adjustments again using a steel wheel Revised 3 00 Page 12 Service Manual 40 60 80 E50 E51 E52 ESO E54 E55 E56 E58 E60 E61 E62 E63 ERROR CODE DIRECTORY cont Eprom defective The Eproms are mounted on the Processor circuit board sockets ROM 1 and ROM 2 and are field replaceable When this error code appears both Eproms should be replaced Ram defective The Ram is not field replaceable replace the Processor circuit Board Left A D Converter defective The A D converter is not field replaceable replace the Processor circuit Board Right A D Converter defective The A D converter is not field replaceable replace the Processor circuit Board Power supply to the machine measured at the Processor circuit board is low See Error Diagnosis section C55 Power supply to the machine measured at the Processor circuit board
14. increase or decrease erratically If it does see notes below meses TO END THE TEST PRESS THE STOP BUTTON seenen Notes for Codes C50 C51 C52 1 A voltage which is out of tolerance with the gauge in its rest position indicates that the gauge needs to be adjusted following the Adjustment Procedures 2 A voltage which does not change or changes erratically indicates that the potentiometer is defective or there is a mechanical problem such as the potentiometer shaft is loose at the gear or loose or broken wire etc Revised 3 00 Page 22 Service Manual 40 60 80 USING THE DIAGNOSTIC CODES cont C53 Use this code to check the display circuit board Enter C53C All LED segments will light lf one or more segments are defective error message E60 would have displayed when the machine was switched on To correct for a missing segment it is recommended to replace the display circuit board teca TO END THE TEST PRESS THE STOP BUTTON eene C54 Use this code to check the Opto electronic The complete test consists of four sections and is done with the motor turning the shaft Also see test code C74 Enter C 5 4 C Press start This is the A channel test 1 will show in the left display The right display will show a number which may fluctuate two numbers This number should be within the range of 40 60 Press the e button 2 will show in the left display This is the B channel test The right display will show
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16. off Operate the balancer a few times and insure that no more than 0 05 oz is displayed Using the supplied 14 mm Allen wrench loosen the Allen bolt located in the center of the threaded sleeve Rotate the wheel adapter with the balanced tire 180 on the balancer shaft then tighten the Allen bolt Operate the balancer The new imbalance displays should not be larger than 0 25 oz This test proves the wheel balancer shaft is balanced turns true and that the wheel mounting adapter and balancer conical shaft mating surfaces are true If the test produces readings out of tolerance Remove the complete wheel adapter and operate the balancer The display should indicate zero If not balance the shaft following Code C84 see Adjustment Procedures Remove the wheel adapter and check the mating surfaces of the wheel adapter and balancer shaft They should be clean and smooth After cleaning if a further test still produces unacceptable results Run the above test using a known good wheel adapter If another test produce the same results go to B If not replace the threaded sleeve portion of the wheel adapter Using a dial indicator measure the run out at the balancer shaft conical surface The acceptable tolerance is 0 0015 If out of tolerance replace the balancer shaft Revised 3 00 Page 17 Service Manual 40 60 80 ACCURACY TESTS cont WHEEL ADAPTER COMPONENTS CENTER CONE ADAPTER REMOUNT TEST Important note Ple
17. ribbon cable leads 7 8 Machine Defective relay K1M hums when Defective relay K2M turned on Or Processor circuit board Machine is Is start capacitor Check mechanics of drive running louder abnormally hot system belt tension pulleys etc than normal Defective relay K3M No Position Fuse F3 is blown check rectifier brake Defective brake rectifier Defective relay K4M Defective resistor 230 volts HP machine only Revised 3 00 Page 47 Service Manual 40 60 80 Program Updates Eprom Versions Version 1 2 Date 1 93 Geodyna 40 only Version 1 3 Date 3 94 Models Geodyna 60 80 added Code C47C will display these modes Geodyna 40 60 80 95 Version 1 4 Date 7 94 Software Improvements only no new features Version 1 5 Date 12 95 Software Improvements Version 1 51 Date 1 96 Model Geodyna 80 E added Code C47C will display these modes Geodyna 40 60 80 80 E Automatic entry of standard wheel dimensions upon switching machine on 6 for gt 14 for i 7 0 cm for gt Codes 17 18 19 where added C17C Selects number of revolutions for a measuring run The number selected cannot be stored in the permanent memory C18C Increases the measured rim width C19C Decreases the measured rim width To adjust make sure each code is set to zero Enter C 18 C press 0 then press the C button Enter C 19 C press O then press the C button Measure a rim if the measured width is lower
18. than the actual width use code C18C if the measured width is higher than actual width use code C19C Enter C 18 C Enter the offset value required to allow proper rim width measurement To correct the offset value must be entered in millimeters mm then press the C button 1 0 inch 25 mm Enter C 19 C Enter the offset value required to allow proper rim width measurement To correct the offset value must be entered in millimeters mm then press the C button 1 0 inch 25 mm Now these adjustments must be stored in the permanent memory by using the code C10C Revised 3 00 Page 48 Service Manual 40 60 80 Program Updates Eprom Versions cont Version 1 52 Date 2 96 Code C17C the number selected now can be stored in the permanent memory using C10C Codes C18 C19 the operation was changed C18C now corrects for rim diameter measurements C19C now corrects for rim width measurements Correction value for C18 C19 is now entered in inches Version 1 53 Date 3 96 When using Codes C18 C19 the value displayed in the left hand display can be reset by pressing their respective diameter amp width buttons Version 1 60 Date 1 98 Model Geodyna 40 Limited Edition GEO 40 P has been added Codes COC C46C have been deleted Code C15C has been added It is a LED light show 0 disabled 1 on after 5 minutes of non use 2 test always on Codes C18C amp C19C cannot be accessed when in Geodyna 40 amp 60 modes C
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21. 0 d9 pIDOg 2090 J19 U KSE CoS L168L9G0 7 OZLOZL9 VO T LLEVOLO YSN PuDOG JOSSSIDOIJ 6 8 4 9 S v 8 Z 1 L ZGE 9719 VO WSN papog Aojdsiq Service Manual 40 60 80 Page 54 Revised 3 00 Qde 989 PIT senbiuyoo Bujuojog uuowsoH AQ UOlHOZIJOYPND Ua UM ZOS8Z96 E19 pi 8216796 19 Ud noya pay used jou Aja nNjosqo AINO 3 08 AINO 08 YNAGORZS d e Xq p yoayg si auupe ey yo Bu doa Jo Buiysiqng ee S n Ald O ER cee e oe penssi DOT senbiuyos Buroudjog uuowjoy jo STD OL MO eo IUuoel ID JOH 96 20 48 9100 Kysodosd au sulowes BUIMOJP SIUL IO LLOd UO SE IA a 09 Ya HOA engl 309 08 o bu posg HLOIM Niy 43 NYLSIG YALAWNVId si E j ET gl Ta YO P S GAR GEO el N de e gt j C O pesibd e L je E vez HEI ER SE e 2 puonbjesyy See SE ran Ka E EE ee ee D ee ee bt ee n See o T O ne CALO3LOYA ATIVWUSHL Een KE Ai l 7 l mn i n 1 gt i BEE SS GU US ER eZ I eZ bic egrecl D N A UOI1010 eet EEN Y L 3 E Es He 1 uo 27 C LEEOTLG VOS VSN be pee Ge E PADOG 990419 U RS E rf ERE e ea el O FEI cher 119 Ae pe elelelelelzlz Ses dal A ot ir WD eiz i v z a E E A E E SI i reek bbbbtcbletstetz aare oA E 8 oO Svea T KKK Lil6ezgcrezi i O R D gt S SCH Se S DESIELO e eg K dal dog s LECPOLS ESO al la sae oe O 1 O NSI nee A E PIDOJ 108SSIDOIJ 3 SE gt t t UA o
22. COC 07 30 1 2 Deleted after 1 60 E1 10 C1C 03 1 2 E2 10 C2C 03 1 2 E3 10 C3C 03 152 E4 10 C4C 03 09 20 40 1 2 E5 10 C5C 03 1 2 E6 10 C8C 04 1 2 E7 10 C9C 04 1 2 E8 11 C10C 03 04 41 1 2 E9 11 C11C 04 1 3 E15 11 C12C 04 1 2 E30 11 C13C 04 1 2 E31 11 47 C14C 08 42 1 2 E34 12 C15C 04 09 1 60 E35 12 C17C 04 1 5 E36 12 C18C 08 37 15 E50 13 C19C 08 38 1 5 E51 13 C20C 05 08 40 1 61 E52 13 C24C 05 30 12 E53 13 C43C 06 1 2 E54 13 C46C 07 30 1 2 Deleted after 1 60 E55 13 C47C 07 30 31 1 2 E56 13 C50C 09 22 1 3 E58 13 C51C 09 22 1 3 E60 13 C52C 09 22 1 5 E61 13 C53C 09 23 1 2 E62 13 C54C 09 23 1 2 E63 13 C55C 09 24 1 2 E64 14 C59C 09 24 1 2 E65 14 C60C 09 24 1 2 E70 14 C61C 09 25 1 2 E71 14 C62C 09 1 2 E72 15 C63C 09 26 1 2 E73 15 C64C 09 1 2 E74 15 47 C65C 09 26 1 2 E76 16 C66C 09 12 E77 16 C68C 09 26 1 2 E78 16 C69C 09 26 1 2 E79 16 C74C 09 27 1 2 E80 16 C75C 09 28 1 2 E136 16 C80C 08 32 33 1 2 C81C 08 34 1 3 C82C 08 36 15 C83C 08 39 1 2 C84C 08 40 1 2 Revised 3 00 indicates code can only be accessed by unplugging the opto cable Page 2 Service Manual 40 60 80 SETTING FUNCTION CODES Function codes are verified selected and changed as follows Enter a code by pressing C the code number then C again The right display will show one of the numbers that follows the codes below After verifying or changing the code press the RED stop button Unless stored in the computer memory located on the Interface circu
23. Coil resistance measured across terminal 1 amp 2 should be approximately 1000 ohms 3 4 5 B Normally closed contacts measured across roy terminal 3 amp 4 TII should be approximately 0 ohms CG Normally open contacts measured across Relay bottom view terminal 4 amp 5 should be an open circuit l o 2 mo 3 Start Capacitor To test the start capacitor remove the black leads at the capacitor Set the meter to ohms low to middle scale Touch the meter leads across the terminals of the capacitor The resistance should jump towards zero then gradually increase Now reverse the meter leads and the meter should do the same again This test can give an indication that the capacitor is defective by telling if it is open or shorted It cannot tell if the capacitor is the proper capacitance value A capacitor tester or the following procedure should be used MFD 2650 X Measured Current At the capacitor Measured Line Voltage MFD The Capacitor Value Revised 3 00 Page 44 Service Manual 40 60 80 Testing of individual components on electric board cont Example For this example a Geodyna 80 115 Volts machine was used The capacitor on the electric board is a 56 67 MFD cap The measured line voltage is 122 Volts and the measured current at the capacitor is 3 Amps 2650 X 3 A 122 V 65 MFD 4 Ribbon Cable To test the continuity of the ribbon cable disconnect the cable from the interface board S
24. HOFMANN USA 7 GEODYNA 40 40 Limited Edition 60 80 Series WHEEL BALANCER SERVICE MANUAL SET Service Manual Contents Quick guide for Function and Error codes Setting Function Codes Diagnosis and Test Code List Error Code Directory Accuracy Tests Shaft Imbalance Wheel Adapter Shaft Remount Wheel Adapter Components Readout Accuracy Using the Diagnostic codes Adjustment procedures Parts Replacement Is Readjustment necessary Setup for Eprom Versions 1 2 1 53 Setup for Eprom Versions 1 60 1 61 Rim Distance Gauge Geodyna 40 60 Rim Distance Gauge Geodyna 40 Limited Edition 80 Series Rim Diameter Gauge Geodyna 40 Limited Edition 80 Series Rim Width Gauge Geodyna 80 E Series Readout Adjustment Basic Calibration Balancing the Shaft Adjust the Imbalance location Operator Calibration Trouble Shooting the Electric Control Board Program Updates Eprom Updates Notes Geodyna 40 60 80 Series Wiring diagrams Service Manual Revision Updates USA VERSION Created 10 13 97 Revised 10 28 97 2 25 98 4 24 98 6 12 98 9 11 98 9 21 98 4 25 99 11 22 99 12 07 99 3 00 Revised 3 00 Page 1 Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page zech ch SEH Service Manual 40 60 80 Quick guide for Error and C Functions Errors Page Functions Page Codes available starting in version number EO 10
25. Only from Eprom program version 1 51 and above With this function you can select 5 through 10 revolutions for a measuring run Factory set to 10 revolutions If the PRO MATCH program is in use the measuring revolutions are automatically set to 10 Press the e button to change Revised 3 00 Page 4 Service Manual 40 60 80 C20 SETTING FUNCTION CODES cont Adjusts location imbalance This code can only be accessed by unplugging the opto electronic unit The default value is 20 To check location imbalance Mount and balance a wheel to within 1 ounce Then enter C4 C AO will show in the right display C4 In the left Press the START button The balancer will run through a cycle stop and display a 1 in the right hand display Press the STOP button Attach a weight to the outside of the wheel Press the START button After the wheel stops rotate it until only the center bar is on in the right hand display the weight should be at 6 00 If the weight is not at 6 00 then it will need to be adjusted To Adjust C24 Remove the screws from the display panel and for the 60 80 Series remove the display housing and weight tray For the 60 80 Series reconnect display panel and go through the procedure as described above To check location imbalance Unplug the opto electronic cable from the Interface board Enter C 20 C Reconnect the opto electronic cable A number will appear in the right hand display If the weight is before 6 00 e
26. ZOSSZ96 E19 XDY 86 4 1 6 pesiAgy 28216796 19 Ud Kq peyosug MUO UOISJaA 3 HTA Sdn ADld O O N a SC on pee 1 es e db y w n esny SCH Z dALDALOYA ATIVAYIHL ES j a EVIS FV rf I y T Mi 09 530133 U1 el ig PeZ Pezi rezi UA a ug ES HAEE ER y 2 F id d P H 1 HU 2 Ai a cs EE k 2 E zer e Ae pb di o cleleclozlz bb alee dated feleli o elriezi i S 2 O DO O P e Om Y D e D p pe gt a a rehogar ES D SV d d e EELS eZeCTTTTTETTI IIL RINNEN Oo gt r bs z o EE dd d ds E ewech LLEVOLY gis O e wow WLM p bog Joseso014 Ke Sp ie 2 wyo ou S g y 1 Meee ee RARE ou E bs e e LEE Etienne gt sae E JAVI Jad Died LS UI be db d Dd 181S e Ge OU Uri yY GILOTLO Yun 91479813 ZIZIZ ITS ISI p ILL LIL ULI L 618 29 1S wag E Mi 00 e Te oOo Be E A A A A A A A a eS ee ee c 7 Sp Q A BL AA Oez D a YINYJOISNVAL 11 P e 9CL9 Y GEZ we ER A Off An ZG Ep pane eee YOLIOVAVO VO Sech A 4 Y O Z4 A SSS aS al 8 4 Y OTI v4 4 l4 Sasn4 ud FHO0A oez Alddnsuemod Service Manual 40 60 80 Page 5 Revised 3 00 Py senbiuyos Bujouojpg UUDUUOD az dyag AQ LOIJDZIJOUINMO UOJ ZO 8Z96 19 pi 96 L 1 6 D se r NoYYM pajypuused you AjopNjosgo KUO
27. ase read first The test will check the wheel as well as the wheel adapter Most wheels are manufactured to less exact tolerances than the wheel adapter The majority of the measured remount error is usually caused by the wheel not the wheel adapter It is best to use a wheel that is known to be true The wheel must have a round smooth center hole and the surface that presses against the wheel adapter backing plate must be flat and smooth Because remount error is a function of mechanical tolerances the heavier the wheel assembly the larger the mounting error Use a mid size 14 or 15 wheel and tire about 30 to 40 pounds Usually OEM alloy wheels will remount best 1 First make sure the results of the SHAFT IMBALANCE WHEEL ADAPTER TO SHAFT REMOUNT TEST are acceptable 2 Electronic imbalance compensation must be off Check by entering code C4 O must be displayed If 1 appears switch the balancer off and then back on after a few seconds 3 Balance a 30 to 40 Ib wheel to exactly 0 00 in each plane with the small imbalance suppression C2 turned off 4 Operate the balancer a few times and insure that no more than 0 05 oz is displayed 5 Loosen the wing nut hold the centering cone in place and rotate wheel 180 degree Tighten the wing nut 6 Operate the balancer through a cycle The new display is the remount error A reading not larger than 0 50 ounce is generally acceptable If the readings are not acceptable d Are you u
28. d shaft and faceplate attached to the balancer shaft A calibration weight will be found threaded into the rear wall of the balancer chassis EnterC 14C Press Start N 57 Thread the calibration weight into the wheel adapter backing plate 4 Press Start CAL At the completion of calibration the machine will stop and emit three beeps Operator Calibration is completed Remove the calibration weight and return it to the rear of the balancer Revised 3 00 Page 42 Service Manual 40 60 80 SUBJECT Trouble Shooting the Electric Control Boards Although the electric boards for the above mentioned machines have proven to be very reliable and trouble free most of the components can be easily exchanged should trouble occur For this reason we strongly suggest that every possible attempt be made to repair these boards on site by substitution of components The only circumstance in which a board change should be required is if the transformer ribbon cable or relay diodes are defective Each technician should be sure to have all interchangeable components in stock These when used in conjunction with the attached trouble shooting guide should allow almost any electric board repair to be carried out on site Recommended parts for inventory Part 1001036 1 1001035 1 1001036 3 1001035 2 3440068 3762010 1 3762010 4 4481432 3762010 5 3300050 Revised 3 00 Quantity 22xx x 4h00001
29. e computer The measured imbalance will be subtracted from the next measurement runs The test wheel imbalance will remain stored in the computer memory until the machine is switched off or until C4 is again selected and the 1 is changed to a O by pressing the e button Press and hold the STOP red button The right and left display will each show 0 00 Release the STOP button Select a hammer on type wheel weight of about 3 ounces for this test It is important that you are sure that the actual weight agrees with what is marked on the weight Be sure that the weight has not been clipped Attach the weight to the right side of the wheel then operate the balancer When the balancer stops press and hold in the STOP red button A weight reading corresponding to the test weight is shown in the right display The allowable tolerance is 0 15 ounce A weight reading is also shown in the left display The maximum allowable reading is 0 15 ounce If it s out of tolerance see A on next page Release the STOP red button Example lf a 3 ounce test weight was selected It is acceptable if the display shows between 2 85 and 3 15 for test weight side and no more than 0 15 for the opposite side Revised 3 00 Page 20 Service Manual 40 60 80 A B ACCURACY TEST cont Position the test weight at exactly 6 o clock The center bar of the right location display should be on The allowable tolerance is one bar from center I
30. e to be completely re adjusted When replacing this version with versions 1 53 or 1 60 the only codes that will have to be set are C47C amp C20C Revised 3 00 Page 50 Service Manual 40 60 80 Notes Revised 3 00 Page 51 Service Manual 40 60 80 Geodyna 40 115 Volt diagram 19 307 ZOS8Z96 19 XDY 8216796 19 ud OLDJUO oJ lA9 J9g J98143 A9SSNQ 6F DI senbiuyos Buldubjpg UUDUIJOH Y 06 09 Ud da192110e8dd ATIY NYAH NEA Nom tv YOUMS abbol al NLY LaL NN a K N ome Prd iN LIOA Stl Ajddnsuemod 96 90 45 HOA GLE OF BUADOS S9C97L9 PUN 2Uu12e1 py sanbiuyos Buldudjog uuowyoy AQ YOHOZUOYUIND Ue11LN pnoy paypuued zou Ajoynjosqo si eluoSs ay jo Du do Jo Bulysiiqna Py senbiuyos Buloudjog uubUYOH Jo Kysedoud y sulowies Buimoup siul Aq pexoeyo penssi 930Q posIby apta ta pionbjesuym o Ele HA IA Ch E 3 veo esn4 eng E eras ous Di Ss ODIO Y ioo he E EC eene JAYE 1 Vad 1971S Lal A 81 A Sil YINYJO SNYAL 11 A OGZ AN 89 94 yO IDU dVI VW0 m N L oo Iil N bb g D SN ag SS Le ge IS s dn Sole a kor wk OTS r1v0L9 i Le puo wen u01399 20349 da SOL la H AU p a Word 33 LESIZTLI YO YSN PUDOgG 22bJ193 u ean Kei WI LLP LIL PRP LY AR daran
31. ed is 220 230 RPM nominal teca TO END THE TEST PRESS THE STOP BUTTON Revised 3 00 Page 24 Service Manual 40 60 80 USING THE DIAGNOSTIC CODES cont C61 Use this code to check for changes in the Pick up outputs Each time the balancer readouts are adjusted using the service code C83C a reference value of 1 0000 is stored in the memory for the left and right Pick ups separately Whenever the readouts are adjusted using operator calibration code C14C each value of 1 0000 will change to a higher or lower value The new value reflects the compensation made by the processor circuit board depending on the condition of the each individual pick up output as measured at the processor circuit board Slight variations are acceptable and are the result of aging and temperature or changes in the circuit component path Large variations may not be acceptable and can yield error codes or balance problems The Pick up outputs and the circuit component path determine readout location accuracy and imbalance readout separation between correction planes To monitor the reference outputs Enter C61C The left location LED s will light and the display will show the left Pick up reference voltage Pressing the decimal key will light the right location LED s and the right pick up reference voltage displays Pressing the decimal key will toggle between the left and right reference voltage The code can be helpful for troubleshooting a machine that may co
32. election and entry in grams of the readout suppression of small imbalances Factory set to 3 5 grams All imbalance of the selected weight or less will display O grams To enter a new value enter C8C key in the new value press the C button Selection and entry in ounces of the readout suppression of small imbalances Factory set to 0 25 ounce All imbalance of the selected weight or less will display 0 00 ounces To enter a new value enter C9C key in the new value press the C button Stores selected codes data and adjustments into the computer memory located on the Interface circuit board Enter C 10 C then press buttons 1 amp 3 atthe same time Listen for a 3 tone audible acknowledgment Selects index position brake operation Press the e button to turn on and off Does not apply to Geodyna 40 1 Shaft stops at the wheel weight position as the tire is rotated 0 Shaft does not stop at the wheel weight position Total balancing cycles Entry of this code displays the total number of measuring runs the balancer has operated The maximum count is 999 999 see Code C43C to Reset Counter Selects operation by start button or wheel guard Press the e button to change 1 Machine starts as the wheel guard is closed or when the start button is pushed O Machine starts only when the start button is pushed Led Light Show Press the e button to change O disabled 1 enabled after 5 minutes of non use 2 test always on
33. et the meter to ohms and measure across the indicated wires in both directions The meter should read the indicated value in at least one direction Leave in the relays for this test Wires 12 8 411 0 8 1 40hms Wires 6 amp 5 1000 ohms Wires 10 amp 9 1000 ohms Wires 13 amp 5 1000 ohms Wires 8 amp 7 1000 ohms 5 Brake Rectifier Positionin 1 To test brake rectifier remove rectifier diode or bridge from the electric board Set meter to ohms or diode test if meter is so equipped Measure across the terminals of the device as indicated below observing polarity en nin Reading 500 700 ohms Rb Rb L1 L2 O BU RD WH GS e Lid ge Red to Black to Old style X 7y Reading open circuit ae Red to Black to E Reading ircuit New style E eading open circui O 2 When installing new 2 lead rectifier diode for older 3 lead style use the two left most terminals only Revised 3 00 Page 45 Service Manual 40 60 80 Testing of individual components on electric board cont 6 Relay Diodes To test the relay diodes mounted on the board set meter to ohms or diode test if meter is so equipped With the relays removed measure across the device as indicated below observing the polarity Diode White strip Red to Black to Reading 500 600 ohms IO E Black to Red to KM
34. f it s out of tolerance see B Remove the test weight from the right side of the wheel and attach it to the left side then operate the machine When the machine stops press and hold in the STOP red button The allowable tolerance is 0 15 ounce as shown in the example above Release the STOP red button First check the rim distance gauge setting following code C80C Then follow the ADJUSTMENT PROCEDURES If the imbalance read out accuracy was found out of tolerance follow as per A If only the location accuracy was found to be out of tolerance the wheel has probably slipped on the balancer shaft while braking it There is also a slight possibility that there is a problem with a pick up or Opto electronic If these two components are suspected substitution with known good parts is the only method of trouble shooting TO END THE TEST PRESS C 4 C THE e KEY 8 THE STOP BUTTON Revised 3 00 Page 21 Service Manual 40 60 80 USING THE DIAGNOSTIC CODES To use the codes enter C code then C C50 Use this code to check the rim distance gauge potentiometer Geodyna 40 Limited Edition 80 Series Only To use Enter C50C A voltage reading corresponding to the position of gauge is shown in the left display A measurement in millimeters mm corresponding to the position of the gauge is shown in the right display With the gauge lever in its rest position a voltage reading of between 0 12 0 25 should be displayed As the lever is exte
35. fference between Pick ups is more than 3 See codes C61 C65 amp C75 1 Check the Pick up connections at the Interface circuit board Are they connected to the correct terminals 2 Check that the Pick ups are tightly mounted under the shaft in the Vibratory assembly 3 Check that the four vibratory assembly mounting bolts are tight 4 Replace the Pick ups one at a time The display is the phase difference found during the last C83 adjustment In order to display another value it is necessary run C83 again after replacing each Pick up Left Pick up output voltage does not correspond to rim width or distance settings during code C83 adjustment See E36 for troubleshooting Right Pick up output voltage does not correspond to rim width or distance settings during code C83 adjustment To trouble shoot 1 2 3 4 9 6 1 8 9 see Code C61C Check that the actual rim width use Hofmann calipers and distance has been set Has the C80 procedure rim distance adjustment been properly followed Check that the machine is sitting solidly on the floor and only resting on the three mounting pads Tilt the machine back to check underneath for wheel weights etc If the machine is bolted to the floor make sure either all bolts are tight or all are loose to eliminate the possibility that one mounting pad is not solidly touching the floor It is best to loosen all three mounting bolts and tilt the machine back to check
36. form these codes C47C C80C C81C C82C C18C C19C C83C C84C C20C C10C Note B After replacement perform these codes C83C C84C C20C C10C Note C After replacement perform these codes C82C C19C C10C Note D After replacement perform these codes C81C C18C C10C Note E After replacement perform these codes C80C C10C Revised 3 00 Page 29 Service Manual 40 60 80 ADJUSTMENT PROCEDURES IMPORTANT DO NOT TURN OFF THE POWER THROUGHOUT THE ADJUSTMENTS AFTER COMPLETING THE FOLLOWING PROCEDURES THE DATA MUST BE STORED IN THE COMPUTER MEMORY SO THAT IT IS RETAINED WHEN THE POWER IS SWITCHED OFF SET FUNCTION CODES TO ORIGINAL FACTORY SETTINGS The Setup for Eprom versions 1 60 and above are on the next page Note Setup for Eprom versions 1 2 1 53 Enter C 47 C For Eprom program version 1 51 to 1 53 the display will show GEO 40 GEO 60 GEO 80 GEO 80 E Press the e button repeatedly until the machine model is displayed Press the STOP button For balancer modes in previous Eprom program versions refer to Program Updates Enter C 46 C 0 or 1 will appear in the right display If 1 appears press the STOP red button lf O appears press the e key 1 will appear Press the STOP button EnterC e C CO will display briefly Enter C 46 C 1 will appear in the right display Press the 0 key 0 will appear Press the STOP button Note Always set C46 back to O after using the CO code otherwise the keyb
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38. ies 1 Place a heavy rubber band around the shaft housing and the distance diameter gauge pointer as shown in the diagram 3 Set the center point In the left display is a voltage reading 2 50 corresponding to the setting of the rim diameter gauge potentiometer It should be between 2 40 and 2 60 Adjust 2 Enter C81C If adjustment is necessary For the Geodyna 40 Limited Edition Turn power off remove the gauge lever front panel and weight tray Then place front panel on a non conductive surface and reconnect front panel Turn power on and enter C 81 C Replace the gauge lever Loosen the nut Using a screwdriver change the position of the slotted potentiometer shaft in the center of the gear Re tighten the nut For the Geodyna 80 Series Turn power off remove the gauge lever display housing and weight tray Reassemble the display housing Replace the gauge lever Turn power on and enter C 81 C Loosen the nut Using a screwdriver change the position of the slotted potentiometer shaft in the center of the gear Re tighten the nut 4 Remove the rubber band and mount a wheel onto the machine Revised 3 00 Page 34 Service Manual 40 60 80 ADJUSTMENT PROCEDURES Cont Rim Diameter Gauge Adjustment Geodyna 40 Limited Edition 80 Series o Set the linearity A Place the rim distance diameter gauge upwards against the rim as if making a normal measurement Hold in this position and press the C key
39. inuously The rest intervals can be selected This code is helpful while troubleshooting any intermittent problem especially in an equipment repair shop environment Enter C69C The left display will show 1 This is rest interval one The right display will show 50 This is the preset rest interval in seconds To change the interval key in a new interval in seconds then press the C key The left display will show 2 This is preset rest interval two The right display will show 170 To change the interval key in a new interval in seconds Press the start button The machine will cycle continuously rece TO END THE TEST PRESS THE STOP BUTTON Revised 3 00 Page 26 Service Manual 40 60 80 USING THE DIAGNOSTIC CODES cont C74 Use this code as a quick check of the Opto electronic without the shaft turning under power For the complete Opto electronic test use code C54 Enter C 7 4 C The left display will show C74 The right display will show a number from O to 255 Rotate the shaft the numbers will change counting in ascending order as the shaft is turned clockwise and descending as the shaft is turned counterclockwise teca TO END THE TEST PRESS THE STOP BUTTON Revised 3 00 Page 27 Service Manual 40 60 80 C75 C75 USING THE DIAGNOSTIC CODES cont Use this code to check the Pick ups The Pick ups are mounted into the imbalance measuring structure of the machine They are made of a material that when fo
40. is high see Error Diagnosis section C55 A D reference voltage incorrect Replace the Processor circuit board Processor circuit board error PIO Replace the Processor circuit board Display error One of the seven segment displays or LED s is defective Replace the Display circuit board Start stop or keyboard key is stuck closed Can be the Display circuit board or the Processor circuit board defective If replacement of either board is necessary connect a wire from the panel ground to the machine chassis ground Use a panel circuit board hold down stud Memory defective Replace the Processor or Interface circuit board Ifa replacement board is not at hand adjust the machine following adjustment procedures then leave the power on until the defective part can be replaced Adjustment amp or function code data memory on Interface circuit board is incorrect When the power is switched on the computer program transfers stored data from the Interface circuit board data memory to the Processor circuit board memory If an error is detected code E63 displays It is possible this error can occur because of loss of stored data caused by large voltage variations in the balancer power source This could occur during lightning storms or by power distribution problems Readjust and set function codes If E63 reoccurs replace the Interface circuit board Revised 3 00 Page 13 Service Manual 40 60 80 ERROR CODE DIRECTORY cont E64 24 vdc
41. is not available on the Interface circuit board Check the 0 8 amp fuse on the Interface circuit board If the fuse continues to blow there can be short at one of the contactor coils Disconnect one ata time to trouble shoot The problem may also be the Interface or Processor circuit board E65 Power supply voltage to the Processor circuit board dropped too low during the balancing cycle to ensure accurate readings Measure the line voltage connections to the balancer and the internal connections See code C55 E70 Distance gauge defective 40 Limited Edition 80 Series Only a The potentiometer slider voltage of the distance gauge is less than 0 1 or more than 4 9 volts b After pressing the STOP button it is possible to balance wheels with dimension input via the keyboard C For precise trouble shooting enter the test code C50C and check the following items 1 Is the gauge in its rest position 2 Is the gauge calibrated 3 Is the connector on interface board plugged 4 Does the voltage on the potentiometer slider increase steadily while moving the gauge lever If items 1 to 3 are O K but the error code is displayed again after power on replace the potentiometer and adjust the gauge 5 Is the handle lever from the distance gauge off E 71 Rim diameter gauge defective 40 Limited Edition 80 Series Only a The potentiometer slider voltage of the diameter gauge Is less than 0 1 or more than 4 9 volts b After pres
42. it board a function code that has been changed returns to the original state when the power is turned off To store code settings in the computer memory Enter C 10 C Then press keys 1 3 at the same time The Processor circuit board issues three tones signaling the code setting has been stored in the memory Gl C2 C3 C4 C5 Readout resolution round off Press the e decimal button to change 1 0 05 Ounce 1 Gram 0 0 25 Ounce 5 Gram Factory set to 0 Readout suppression of small imbalances as selected using C9 or C8 Press the e button to turn on or off 1 On Factory set to 1 0 Off If the readout is set to read in ounces the suppression value used is from C9 If the readout is set to read in grams the suppression value used is from C8 Readout in ounces or grams Press the e button to change 1 Ounces Factory set to 1 0 Grams Electronic compensation of the residual imbalance Enter C 4 C then press the Start button to go through a cycle Press the stop button to continue Compensation cannot be stored in the computer memory and retained when power is off It resets to 0 whenever power is turned off 1 On O Off Machine brakes or coasts when the wheel guard is lifted Press the e button to change 1 Brakes Factory set to 1 0 Coasts Revised 3 00 Page 3 Service Manual 40 60 80 C8 C9 C10 C11 C12 C13 GTO C17 SETTING FUNCTION CODES cont S
43. n mm Reset any individual Function Codes if necessary See Setting Function Codes Continue on with the Rim Distance Gauge Adjustment Revised 3 00 Page 31 Service Manual 40 60 80 ADJUSTMENT PROCEDURES Cont Rim Distance Gauge Adjustment _Geodyna 40 60 1 2 Enter C 80 C A number will appear in the right display Hold a straight edge against the wheel contact surface of the wheel adapter backing plate Measure the distance in mm from the wheel contact side of the straight edge to the flat surface of the distance gauge in the rest position Record the measurement Subtract 25 The remainder will be used in step 5 Enter the remainder found in step 4 It will replace the number shown in step 2 Press the C button Example The scale reading was 185 185 25 is 160 C80 160 Enter 160 press the C button Continue on with Readout Adjustment Revised 3 00 Page 32 Service Manual 40 60 80 ADJUSTMENT PROCEDURES Cont Rim Distance Gauge Adjustment _Geodyna 40 Limited Edition 80 Series 1 Enter code C 80C With the gauge in the rest position the left display must 0 18 1 indicate between 0 12 0 25 Ss If adjustment is necessary For the Geodyna 40 Limited Edition Adjust Turn power off remove the gauge lever front panel and weight tray Then place front panel on a non conductive surface and reconnect front panel place gauge lever back on Then turn power on and enter C 80 C Loosen
44. nded the voltage reading should increase proportional to the distance moved up to a maximum of about 5 00 volts Be sure that the voltage does not increase or decrease erratically If the voltage is out of tolerance see notes below rece TO END THE TEST PRESS THE STOP BUTTON C51 Use this code to check the rim diameter gauge potentiometer Geodyna 40 Limited Edition 80 Series Only To use Enter C51C A voltage reading corresponding to the position of the gauge is shown in the right display A measurement in millimeters mm corresponding to the position of the gauge is shown in the right display As the gauge lever is rotated 360 degrees the voltage should change evenly through the range of 0 volts to 5 00 volts If the voltage does not change or changes erratically see notes below EEE TO END THE TEST PRESS THE STOP BUT TON C52 Use This Code to check the rim width potentiometer Geodyna 80 E Series Only Enter C52C A voltage reading corresponding to the position of the gauge is shown in the left display A measurement in millimeters mm corresponding to the position of the gauge is shown in the right display with gauge lever in its rest position a voltage of between 0 12 0 50 should be displayed If the voltage is out of tolerance see Notes below As the lever is moved toward the machine the voltage should increase proportional to the distance as moved up to a maximum of about 5 00 Volts Be sure that the voltage does not
45. nt Final Adjustment of Rim Diameter Geodyna 40 Limited Edition 80 Series EPROM VERSION 1 53 and higher For Eprom Versions 1 51 amp 1 52 See Program Updates Mount a rim with or without a tire on the machine Rim diameter 1 Ole IS D 9 10 Note the diameter as read off the tire or rim Example Actual 15 Enter C18C Press and release the diameter button H Hold the diameter gauge against the rim as taking a measurement The left display indicates the measured diameter Example Measured 155 Note the difference between the Actual rim diameter from step 1 and the Measured diameter using the gauge from step 5 Example Actual 15 Measured 15 5 5 Enter the difference noted through the keypad Example Press 3 If the gauge measurement was higher than the actual rim diameter as in the example press the S D key If the gauge measurement was lower go to step 9 Example Press the S D key Press the C key Press the STOP key 11 Test the rim diameter gauge to insure it is reading correctly If not repeat 12 steps 1 10 Store the setting into the computer memory See G Revised 3 00 Page 37 Service Manual 40 60 80 ADJUSTMENT PROCEDURES Cont Final Adjustment of Rim Width Geodyna 80 E Series EPROM VERSION 1 53 and higher For Eprom Versions 1 51 amp 1 52 See Program Updates Mount a rim with or without a tire on the machine Rim Width 1 Ole IS O 9 10
46. nter a number higher than the displayed default number press the C button If the weight is after 6 00 then enter a number lower than the displayed default number press the C button Press the START button and check to see if the location is correct if not perform adjustment After location is properly adjusted it must be stored in the permanent memory using the procedure for code C10C X Selects rim distance entry in millimeters mm or centimeters cm through the key panel The machine is factory set for cm Eprom version 1 61 now the code can only be accessed by unplugging the opto electronic To check for the correct setting Enter code ZAC 1 distance entry must be made in cm This is the correct setting 0 distance entry must be made in mm This is the incorrect setting If O displays press the e key to change to 1 Press the stop button 22 MI To enter rim distance To enter rim distance in centimeters in millimeters Correct Setting Incorrect Setting Revised 3 00 Page 5 Service Manual 40 60 80 SETTING FUNCTION CODES cont C43 X Resets the cycle counter Built into the software of the balancer is a counter that records each time the balancer is operated When code C12C is entered the total number of recorded measuring runs is displayed To reset the counter to zero Unplug the balancer from line voltage Remove the screws from the display panel and for the 60 80 Series remove the display housing and
47. ntinually require readjustment via user calibration code C14C or a machine that develops a measurement related error code or chases weights during operation Example The customer complains that the machine usually does not balance a wheel to zero in one or two spins The operator is chasing weights around the rim After running the machine through C14C the technician using code C61C finds that the value for the right Pick up is 1 0030 little change from the reference of 1 0000 but the value for the left pick up is 9000 a larger change This indicates the likely cause of the problem is a faulty or loose left pick up When troubleshooting be aware that the reference voltage is measured by the processor circuit board and not directly read at the Pick up This means that the large difference in output can have a cause other than the pickup Be aware that in series with the Pick up output path to the processor is the interface circuit board Tip Whenever a machine is out of calibration chases weights or will not go through C14C or C83C procedures without an error code always check for anything touching the internal balancing structure It is always necessary to remove the weight tray and check carefully for foreign material such as a stray wheel weight It is also necessary to check under the wheel balancer making sure only the three intended points touch the floor Revised 3 00 Page 25 Service Manual 40 60
48. oard will be reversed Enter code C 2 4 C 1 should display If O displays press e key to change Press the Stop button 22 MI To enter rim distance To enter rim distance in centimeters in millimeters Correct Setting Incorrect Setting Reset any individual Function Codes if necessary See Setting Function Codes Continue on with the Rim Distance Gauge Adjustment Revised 3 00 Page 30 Service Manual 40 60 80 ADJUSTMENT PROCEDURES Cont Setup for Eprom version 1 60 amp 1 61 E Enter C 47 C The display will show GEO 40 GEO 60 GEO 80 GEO 80 E GEO 40 P Press the e button repeatedly until the machine model is displayed Press the STOP button GEO 40 Geodyna 40 Balancer GEO 60 Geodyna 60 Balancer GEO 80 Geodyna 80 80HP Balancers GEO 80 E Geodyna 80E 80 EHP Balancers GEO 40 P Geodyna 40 Limited Edition Note When this code is accessed it will automatically set the following to these default values C1 0 Readout Resolution 0 25 oz 5 gr C2 1 Readout suppression on C3 1 Readout display in ounces C5 1 Brakes when wheel guard lifted C8 3 50 Suppression value in grams C9 0 25 Suppression value in ounces C11 1 N A Geo 40 Index position brake on C13 0 Wheel guard start off C15 1 LED light show on C17 10 Number of revolutions for measurement C20 20 Version 1 61 only Angle correction C24 1 Distance entry in cm C80 160 Geo 40 amp 60 only Adapter flange distance i
49. ode C19C cannot be accessed when in Geodyna 40 P amp 80 Code C47C now displays 40 60 80 80 E 40 P It was changed so that when entered it automatically sets up the following codes to these default values C1C 0 C11C 1 N A for Geo 40 C2C 1 C13C 0 C3C 1 C15C 1 CSC 1 C17C 10 C8C 3 50 C24C 1 C9C 0 25 C80C 160 Geo 40 amp 60 only There is a 8 second delay before machine will start when pressing the start button or by lowering the wheel guard A B Operator was added Pressing button will toggle between operator A amp B wheel dimensions Revised 3 00 Page 49 Service Manual 40 60 80 Program Updates Eprom Versions cont Version 1 61 Date 5 98 Code C83C will not accept a value of 85 grams or less in step 2 The 8 second delay before the machine starts was changed to 5 seconds Code C20C was added This code adjusts the imbalance location It can only be accessed by unplugging the opto electronic unit When C47C is entered it will be automatically set to the default value of 20 Code C24C was changed Now it can only be accessed by unplugging the opto electronic cable from the interface board Error codes E3 amp E4 now cannot appear in models 40 amp 60 Error code E4 now cannot appear in models 80 amp 40 P Error code E54 now will not appear until C55C is below 16 volts It was 23 volts in previous versions When replacing this version with versions 1 2 1 52 the machine will hav
50. processor circuit board to DC voltage filtered and regulated The DC voltage is used to operate the electronic circuits and motor control relays Enter C 55 C The right display indicates the DC voltage The allowable working voltage is 16 to 37 VDC for Eprom version 1 61 amp 23 to 37 VDC for Eprom version 1 2 1 60 If error E54 was displayed when the machine was turned on less than the allowable voltage will be measured If error E55 was displayed when the machine was turned on more than 37 VDC will be measured SWITCH THE POWER OFF Disconnect the Processor circuit board 34 pin connector for further troubleshooting To trouble shoot check the voltage at the wall receptacle the input voltage to the balancer at the transformer primary and the output voltage from the secondary TO END THE TEST PRESS THE STOP BUTTON Use this code to display the shaft imbalance compensation value stored in the memory The value is determined during the Shaft Balance procedure C84 Enter C 59C The displayed value is the shaft compensation in kg mm eee O END THE TEST PRESS THE STOP BUT TON Use this code to measure the speed of the balancing shaft The Processor circuit board counts pulses received from the Opto electronic These pulses are the result of a slotted disc read by the Opto electronic as the shaft turns The pulses are routed through the Interface circuit board Enter C60C Press start The RPM is displayed Balancing spe
51. rce is applied generate a voltage proportional to the force Upon entering this test exactly 2 5 volts is applied to each Pick up The test measures the voltage drop across the Pick ups Enter C 7 5 C then press 5 The left and right displays will each show a voltage This voltage is a reference voltage about 2 50 v less the voltage drop The left display shows the left Pick up reference voltage The right display shows the right reference voltage The acceptable tolerance is 2 45 to 2 55 A voltage below 2 20 will display an error message during the self test when power is applied to the balancer The pick ups are further tested by pressing down on the balancer shaft while watching the displays The displays should vary above and below the nominal 2 50 volts This test proves if the Pick ups are shorted open or disconnected from the Interface circuit board A successful test also proves that the output voltage path from the pick ups through the Interface to the Processor circuit board is in order The test does not prove that the Pick ups are producing the proper output voltage that they are in phase or properly installed mechanically Further troubleshooting is by substitution with a known good part Note Voltage readings below 2 45 are suspect especially when erratic or intermittent measurement problems have been noticed or error codes have appeared such as E34 E35 E36 during Adjustment procedures or E76 E77 E78 E79 during Operato
52. reversed the numbers will not match the display Example 3 is pressed and 9 will display Setup for Eprom versions 1 60 amp 1 61 C47 Sets the computer to operate in a specific balancer mode either Geodyna 40 60 80 80 E 40 P The display will show GEO 40 or GEO 60 or GEO 80 or GEO 80 E or GEO 40 P Press the e key to change When this code is accessed it will automatically set the following to these default values C1 0 C11 1 N A Geo 40 C80 160 Geo 40 amp 60 only C2 1 C13 0 C3 1 C15 1 C5 1 C17 10 C8 3 50 C20 20 Version 1 61 only C9 0 25 C24 1 Revised 3 00 Page Service Manual 40 60 80 SETTING FUNCTION CODES cont ADJUSTMENT CODE LIST C14 Operator Calibration EPROM VERSION 1 52 AND ON C18 Adjustment of automatic measuring gauge for rim diameter Note Geodyna 40 Limited Edition 80 Series For Eprom program version 1 51 refer to Program Updates EPROM VERSION 1 52 AND ON C19 Note C20 C80 C81 C82 C83 C84 Adjustment of automatic measuring gauge for rim width Geodyna 80 E Series For Eprom program version 1 51 refer to Program Updates Imbalance location adjustment or angle correction Eprom Version 1 61 only Adjustment of rim distance gauge Adjustment of rim diameter gauge Geodyna 40 Limited Edition 80 Series Adjustment of rim width gauge Geodyna 80 E Series Basic adjustment of the imbalance readout Shaft imbalance correc
53. rs Calibration e TO END THIS TEST PRESS THE STOP BUTTON Use this code to test the Opto electronic whenever an E73 appears Enter C75C then Press 6 The left display shows the voltage across IR led The proper voltage is approximately 1 20 Volts If displays shows 0 00 volts unplug opto If the Voltage changes to 5 00 volts then opto is defective If the Voltage does not change then the Interface or Processor board is defective If the display shows 5 00 volts with opto plugged in then using a screwdriver short the 2 3 mm screws on the opto If the voltage drops to 0 00 volts then opto is defective If the voltage does not drop then opto cable is damaged interface or processor board is defective TO END THIS TEST PRESS THE STOP BUTTON Revised 3 00 Page 28 Service Manual 40 60 80 ADJUSTMENT PROCEDURES PARTS REPLACEMENT WHICH READJUSTMENT IS NECESSARY Many machine components with the following exceptions can be replaced without resetting the function codes or readjusting the machine Exceptions Eproms see Note A Processor circuit board See Note B Interface circuit board See Note A Pick up s See Note B Machine shaft bearings or drive components See Note B Rim Width potentiometer Geodyna 80 E Series See Note C Rim Diameter potentiometer Geodyna 40 Limited Edition 80 Series See Note D Rim Distance potentiometer Geodyna 40 Limited Edition 80 Series See Note E Note A After replacement per
54. sing a wheel known to be true See Important Note above Try the test using another wheel 2 Are the mating surfaces of the wheel adapter backing plate and the threaded sleeve clean and smooth 3 Is there a large amount of play between the center cone and threaded sleeve Check against another cone in the set Run the same test but this time only rotate the cone 180 degree Revised 3 00 Page 18 Service Manual 40 60 80 ACCURACY TESTS cont 4 Using a dial indicator measure the radial run out of the threaded sleeve at the point where the threads end The acceptable tolerance is 0 0015 oy Using a dial indicator measure the lateral run out of the wheel adapter face plate as the shaft is rotated 360 degree The acceptable tolerance is 0 0015 6 Use known good wheel adapter components individually to localize the cause of the unacceptable remounting error Revised 3 00 Page 19 Service Manual 40 60 80 C4 ACCURACY TESTS cont Use this code to check the balancer imbalance read out accuracy to insure that the proper size and location of the correction weight is called for To use Mount a wheel enter rim sizes and then balance the wheel to within 1 ounce on each side Enter C4C AO will show in the right display C4 in the left Press START green The balancer will run through a cycle stop and display a 1 in the right display The 1 displayed means that the out of balance wheel has been measured by th
55. sing the STOP button it is possible to balance wheels with dimension input via the keyboard C Enter the test code C51C and check the following items 1 Is the gauge calibrated 2 Is the connector on interface board plugged in 3 Does the voltage on the potentiometer slider increase steadily while turning the gauge lever If items 1 to 2 are O K but the error code is displayed again after power on replace the potentiometer and adjust the gauge Revised 3 00 Page 14 Service Manual 40 60 80 ERROR CODE DIRECTORY cont E 72 Rim width gauge defective 80 E Series Only E73 E74 a The potentiometer slider voltage of the rim width gauge is less than 0 1 or more than 4 9 volts b After pressing the STOP button it is possible to balance wheels with dimension input via the keyboard C For precise trouble shooting enter the test code C52C and check the following items 1 Is the gauge in its rest position 2 Is the gauge calibrated 3 Is the connector on the interface board plugged in 4 Does the voltage on the potentiometer slider increase steadily while moving the gauge lever If items 1 to 3 are O K but the error code is displayed again after power on replace the potentiometer and adjust the gauge Transmitter IR LED of Opto electronic defective Test using codes C54 amp C74 amp C75 Opto electronic Processor board may be defective No pulses are measured from the Opto electronic The Processor
56. start 4 Remove the test weight from the left and attach it on the right Press start ef Remove the wheel and wing nut pressure cup cone and spacer ring Leave only the threaded sleeve and backing plate on the balancer shaft Press start 6 Thread the calibration weight into the wheel adapter backing plate Press start CAUTION IF ERROR CODE E34 E35 OR E36 APPEARED DURING THE C83 ADJUSTMENT IT IS NECESSARY TO FIND AND CORRECT THE CAUSE OF THE ERROR BEFORE STORING INTO MEMORY Following the above procedure cancels the value stored in the memory to compensate for shaft imbalance It is always necessary to balance the shaft Continue on to step E Revised 3 00 Page 39 Service Manual 40 60 80 ADJUSTMENT PROCEDURES Cont E Balance the Shaft l Remove the wheel and wheel adapter including the cones threaded sleeve and adapter backing plate 2 Enter C 84 C MM 3 Press start F Imbalance Location Adjustment Eprom Version 1 61 only Je Mount and balance a wheel to within 1 ounce 2 Enter C 4 C then press the START button The balancer will run through a cycle stop and display a 1 in the right display Press the STOP button 3 Attach a weight to the outside of the wheel Press the START button After the wheel stops rotate it until only the center bar is on in the right hand display weight should be at 6 00 If the weight is not at 6 00 proceed to step 4 If it is proceed to step G
57. the nut Change the position of the slotted potentiometer shaft in the center of the distance gauge pulley until the left display shows 0 18 between 0 12 0 25 Re tighten nut For the Geodyna 80 Series Turn power off remove the gauge lever display housing and weight tray Reassemble the display housing and front panel Replace the gauge lever Turn power on and enter C 80 C Loosen the nut Change the position of the slotted potentiometer shaft in the center of the distance gauge pulley until the left display shows between 0 12 0 25 Re tighten nut With the display indicating between 0 12 and 0 25 press the C key Hold a straight edge against the wheel contact surface of the wheel adapter backing plate measure the distance in mm from the wheel contact side of the straight edge to the flat surface of the distance gauge in the rest position Record the measurement and subtract 25 The remainder will be used in step 5 Example The measured distance was 185 mm 185 25 160 mm Slide the distance gauge out until the distance gauge scale reads the remainder found during step 4 example 160 mm Hold the gauge exactly in this position and press the C key Reassemble the weight tray front panel display housing gauge lever and continue on to Rim Diameter Gauge Adjustment Revised 3 00 Page 33 Service Manual 40 60 80 ADJUSTMENT PROCEDURES Cont Rim Diameter Gauge Adjustment Geodyna 40 Limited Edition 80 Ser
58. the weight tray For the 60 80 Series reconnect the display panel Unplug the Opto electronic cable from the connector on the Interface circuit board Connect the machine to power and turn machine on Press Stop to delete E73 Enter C43C Unplug the balancer from line voltage Reconnect the Opto electronic cable and reassemble the display panel and for 60 80 Series reassemble weight tray Revised 3 00 Page 6 Service Manual 40 60 80 SETTING FUNCTION CODES cont Setup for Eprom versions 1 2 1 53 C46 sets computer to North American or European standards as necessary to use code CO Press the e or 0 button to change 1 North America 0 Europe Note Always set C46 back to O after using C e code otherwise the keyboard will be C47 Note CO reversed Sets the computer to operate in a specific balancer mode either Geodyna 40 60 80 or 80 E For version 1 51 to 1 53 the display will show GEO 40 or GEO 60 or GEO 80 or GEO 80 E Press the e key to change For balancer modes in previous Eprom program versions refer to Program Updates Sets the Function Codes to the factory recommendation if C46 is set to 1 TosetpressC e C C46 must 1 C1 0 25 OZ Resolution C5 1 Brakes w wheel guard C2 1 Suppression on C8 3 5 gr Suppression value C3 1 Displays ounces C9 0 25 oz Suppression value Note Always set C46 back to 0 after using C e code otherwise the keyboard will be
59. tion Revised 3 00 Page 8 Service Manual 40 60 80 C4C C15 C50 C51 C52 C53 C54 C55 C59 C60 C61 C62 C63 C64 C65 C66 C68 C69 C74 C75 DIAGNOSIS AND TEST CODE LIST Imbalance compensation LED light show Rim distance potentiometer Geodyna 40 Limited Edition 80 Series only Rim diameter potentiometer Geodyna 40 Limited Edition 80 Series only Rim width potentiometer Geodyna 80 E Series only Display test Opto electronic test Unregulated D C voltage at Processor circuit board Value of the shaft imbalance compensation stored in the Memory Shaft RPM Reference imbalance Value determined during last C83 adjustment Imbalance location displayed in degrees Continuous high resolution imbalance measurement averaged and displayed each 40 revolutions Pick up sensitivity Pick up phase difference in percent Virtual vibratory system dimensions determined during last C83 adjustment Number of revolutions required to reach measuring speed Automatic testing measurement cycle intervals Position disc Opto electronic test Also see C54 Pick up test Opto Electronic test Revised 3 00 Page 9 Service Manual 40 60 80 ERROR CODE DIRECTORY Many of the error codes are followed by the most probable cause of the error amp or action to be taken This action assumes proper electrical electronic wiring connections EO Keyboard entry of a non existent error code El with
60. up These voltages can be observed using code C75C then press 5 The proper voltage should be 2 50 0 05 volts Cause These error codes can be caused by a defective interface board or a build up of film on the board The latter fault will become evident in very humid conditions E78 Incorrect output is measured from the left Pick up See code C75 Left Pick up Processor or Interface circuit board may be defective E79 Incorrect output is measured from the right Pick up See code C75 Right Pick up Processor or Interface circuit board may be defective E80 Basic calibration data was not found in the memory Can be that steps 5 and 6 were not stored in the memory during basic adjustment C83 Reset the Function codes and then follow the adjustment procedures C83 4 C84 If error code E80 repeats replace the Interface circuit board E136 Computer data line defect Check ribbon cable to Processor board loose plug Replace the Processor or Interface Circuit board Revised 3 00 Page 16 Service Manual 40 60 80 ACCURACY TESTS SHAFT IMBALANCE WHEEL ADAPTER TO SHAFT REMOUNT TEST Make sure electronic compensation is off Check by entering code C4 0 must be displayed If 1 appears switch the balancer off and then back on after a few seconds Set the corresponding rim dimensions and balance a medium size 14 tire to 0 00 ounce in both planes Balance to exactly 0 00 in both planes with the small imbalance suppression C2 turned
61. was not entered Tire matching error e An error was made following the procedure or e The wheel was incorrectly centered on the adapter or e The tire was incorrectly mounted on the rim During operator calibration C14C The correction factors used for calibration are incorrect Causes The Geodyna 40 60 80 Series uses a wheel adapter that is different than many earlier model Hofmann balancers The machines use a longer threaded center sleeve The backing plate the surface the wheel presses against is extended about 3 4 from previous versions Both types of wheel adapters can be used but it is necessary to set the Distance Gauge Adjustment to match the adapter used See Adjustment Distance Gauge Follow instructions using code C 80 C Also Readjust using codes appropriate for each balancer model C81 C82 C83 C84 The value determined must be stored in the memory see Store Adjustments in Memory The Pick up output voltage has changed Check and replace pickups if necessary There may be a wheel weight lodged in or along side the vibratory structure The shaft did not reach measuring speed within 120 revolutions Check the drive motor Opto electronic using codes C54 amp C74 The balancer shaft attempted to turn in the wrong direction Check the drive motor connections and start capacitor Revised 3 00 Page 11 Service Manual 40 60 80 E34 Note E35 E36 ERROR CODE DIRECTORY cont Phase di

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