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JohnBean B 500 Service Manual

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  • Page 1 B 500...
  • Page 2 BLANK PAGE__________________________________________________________________________...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS CHAPTER 1 INTRODUCTION PAG. 6 1.1 GENERAL PAG. 6 1.2 TOOLS REQUIRED PAG. 6 1.3 IMPORTANT SAFETY INSTRUCTION PAG. 8 1.4 ELECTRICAL SAFETY PRECAUTION PAG. 8 CHAPTER 2 AC/DC POWER DISTRIBUTION PAG. 9 2.1 LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE PAG.
  • Page 4 4.10 CHECK THE VIBRATORY SYSTEM PAG. 27 4.11 REPLACEMENT OF THE ALLOY VIBRATORY SYSTEM PAG. 28 4.12 CHECK AND REPLACEMENT OF TRANSDUCERS ON ALLOY VPM PAG. 28 4.13 CHECK AND REPLACEMENT OF ENCODER BOARD OF MAIN SHAFT PAG. 31 4.14 CHECK AND REPLACEMENT OF ENCODER BOARD OF POWER CLAMP PAG. 32 4.15 CHECK AND REPLACEMENT OF THE MOTOR PAG.

  • Page 6: Chapter 1 Introduction

    CHAPTER 1 INTRODUCTION 1.1 GENERAL This Service Manual describes maintenance, checks and repairs operations of the wheel balancer and is for use of qualifi ed personnel only. Keep this manual constantly updated, by adding Service Bulletins related to the balancers. IMPORTANT! The identifi...
  • Page 7 Spacer for transducers adjustment # EAA0470G84A. Use this tool to make the mechanical preloading of both transducers Snap-on QDRIVER 4NM / 2.95lbsft Use this torque wrench on ALLOY vibratory system only to proper tighten transducers screws. Sonar Calibration Tool # EAA0344G09A This tool allows a high accuracy sonar sensor calibration.

  • Page 8: Important Safety Instruction

    1.3 IMPORTANT SAFETY INSTRUCTIONS The units are CE or UL approved, but whenever using this equipment basic safety precautions should always be followed, including the following: 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 qualifi...

  • Page 9: Chapter 2 Ac/Dc Power Distribution

    CHAPTER 2 AC/DC POWER DISTRIBUTION 2.1 LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE 1. Notify all affected employees that a lockout or tagout system is going to be utilized and why. The authorized em- ployee should know the electrical power the machine uses and it’s hazards. 2.

  • Page 10: Dc Theory Of Operation

    2.4 DC THEORY OF OPERATION INTEGRATED DISPLAY The Integrated Display is an integrated board that contain the Main Procesor section and the Power supply section. The operating voltage for the Main Processor is 5VDC and they are generated and supplied by the Power Supply section.

  • Page 11: Installation Precautions (Floor Level)

    up only one component of the constrained forces) in the form of a periodic sine wave. The signal is not perfectly sinusoidal, due to noises from the suspension system, which add to the signal generated by the imbalance of the wheel. To determine acutal imbalance the signal must be fi ltered. To fi...

  • Page 12: Chapter 3 Balancer Components

    CHAPTER 3 BALANCER COMPONENTS 3.1 INTRODUCTION The balancer is manufactured with the following main components: Ø INTEGRATED PANEL Ø VIBRATORY ASSEMBLY Ø BRAKING SYSTEM Ø SAPE ARM Ø SONAR Ø LASER POINTER 3.2 INTEGRATED DISPLAY PANEL ASSEMBLY The Integrated display panel is a multifunctional device used to make running the Vibratory System and consists in a unique electronic board that intgrates Controller, Power Supply and Display.
  • Page 13 F1 and F2 Fuses Lead 2 (low side) Microswitch for W.G. Lead 1 (+5V) micro switch wheel guard X8 Offset potentiometer X7 Diameter potentiometer Lead 4 (OW side) pedal switch push Lead 3 (+5V) for pedal switch push Lead 2 (OW side) pedal switch pull Lead 1 (+5V) for pedal switch pull X4 Optoencoder, sonar transducers, weight laser...

  • Page 14: Power Entry Module

    3.3 POWER ENTRY MODULE (PEM) The Power Entry Module (PEM) consists in two separated units instead of one. Ø One unit includes the switch only. Ø One unit includes the the power supply inlet, suppresses noise and contains the fuses. If a transformer is required, it has to be connected between the PEM and the Power Interface Board, Connector 3.4 INTEGRATED DISPLAY BOARD The wheel balancer is equipped with integrated power supply and controller board.

  • Page 15: Transducers

    3.7 V.P.M. VIBRATORY ASSEMBLY This balancer is equipped with a V.P.M., Virtual Plane Measurement, Vibratory Assembly technology. Instead of using force measurement at widely apart positions, a compact set up is constructed . It is composed as following: - The main shaft - Two transducers - The optoencoder unit - The power clamp optoencoder (power clamp version only)

  • Page 16: Temperature Sensor

    c) Brake off the two small plugs, formed with the moulding process of the transducer case. d) The insulated wire of the ribbon cable is put in the slot at the collar of the transducer, with the end protruding about 3-mm over the collar.

  • Page 17: Encoder Board Of The Power Clamp

    integrated circuit. The light of the LED is refl ected back to the encoder by one of the 256 mirrors of the polygon ring, focused by the lens on the four detectors. During rotation of the main shaft, the mirrors or bars will tilt and defl ect the light across the detectors A, A`, B and B`.

  • Page 18: Motor Drive System

    3.13 MOTOR DRIVE SYSTEM Description: The primary functions of the motorised drive system are to accelerate the main shaft, with the wheel clamped on it, up to the measurement speed, keeping the speed constant during measurement and subsequently slowing down to a dead stop. Acceleration and deceleration should be rapid but with controlled torque, avoiding slippage of the wheel on the adaptor.

  • Page 19: Braking By Reversing The Motor Torque

    b) Indexing to the compensation location of the right-hand plane with the aid of the drive motor. c) Finding the next compensation location, with the operator slowly rotating the wheel.(so-called “sticky on top” function). 3.16 BRAKING BY REVERSING THE MOTOR TORQUE For this economical and robust brake with well-controlled torque, just the relay K4 had to be added to the drive system.
  • Page 20 Ø The motor ammeter Inputs for polling the pedal micro switches and the proximity detector. Function: Once the clamping operation has been initiated, the solenoid brake is switched on and the motion of the brake disk is monitored via incremental encoder B9. The brake locks the main shaft. The motor M1 is switched on in the direction of rotation as during the measurement run.

  • Page 21: Sonar Wheel Data System

    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/C81 service code, this procedure can be found later in this manual.

  • Page 22: Chapter 4 Service

    CHAPTER 4 SERVICE 4.1 INTRODUCTION This chapter will describe how to check and replace the components of the balancers described in Chapter 2 in the same order. NOTE: BEFORE OPENING THE MACHINE FOR SERVICE, DISCONNECT ELECTRICAL SUPPLY LINE AND USE THE LOCKOUT / TAGOUT PROCEDURE.

  • Page 23: Check Power To Integrated Display Board

    Ø Remove the lateral screws from of the weight tray Ø Remove the SAPE gauge from its arm. Ø Lift the weight tray to access to the inside of the machine. NOTE: WHEN INSTALLING THE WEIGHT TRAY, BE CAREFUL TO DO NOT CRUSH ANY WIRES. 4.4 CHECK POWER TO INTEGRATED DISPLAY BOARD "...
  • Page 24 4.5 CHECK AND REPLACEMENT OF THE MAIN SWITCH " : Voltmeter, medium fl at and Phillips screwdriver, scissors, 5mm allen key, 7 tube type key. : 1.5h : Defective power entry module may cause the following malfunctions: 1. Turning the machine on, the main switch of the shop shuts off. 2.

  • Page 25: Check And Replacement Power Entry Module

    4.6 CHECK AND REPLACEMENT OF THE POWER ENTRY MODULE " : Voltmeter, medium fl at and Phillips screwdriver, scissors, 5mm allen key. : 1h : Defective power entry module may cause the following malfunctions: 1. Turning the machine on, the main switch of the shop shuts off. 2.

  • Page 26: Check And Replacement Power Entry Module 6.3A Fuses

    4.7 CHECK AND REPLACEMENT OF THE POWER ENTRY MODULE 6.3A FUSES " : Multimeter, small fl at screwdrive. : 30’ : Defective fuses may cause the following malfunctions: Turning the machine on, the machine does not show anything. TO CHECK AND REPLACE THE FUSES Ø...

  • Page 27: Check And Replacement Of The Integrated Display

    4.9 CHECK OF THE 5VDC POWER SUPPLY VOLTAGE " : Multimeter, Medium fl at and Phillips screwdriver, scissors. : 30’ : Incorrect power supply may cause the following malfunctions: 1. After turning the machine on, the machine shows error C10810 2.

  • Page 28: Check The Vibratory System

    If it lights up, the +5 V supply voltage is OK. If not: - check mains plug, mains switch, mains fuse - check connector X1 (wiring and placement). - check the electrical connection between connector X1 and the PEM If the mains on connector X1 is 150 - 264 V~, then a short circuit or overload condition on the +5 V output may be present.

  • Page 29: Replacement Of The Alloy Vibratory System

    4.12 REPLACEMENT OF THE ALLOY VIBRATORY SYSTEM " : 2.5, 5 and 6mm allen key, 17mm wrench , Medium and big phillips screwdriver, scissors. : 2h : Defective vibratory assembly may cause the following malfunctions: 1. After the balancing cycle the machine show error 001021. 3.
  • Page 30 TO CHECK THE TRANSDUCERS: Ø Check with C64, C66, C71, C103, C104. Ø Select the C75 AdE 1 and AdE 2 are read out on a board and the voltage difference between the outputs of the unbalance signal amplifi ers N4A and N4B is indicated. AdE 2 is the channel indicating the signal of transducer B3 located in the front.
  • Page 31 setscrew. Tighten the setscrew until the transducer is centered. Ø Route the transducers with leads downward to avoid any possible condensation concentration inside of the leads them selves. Ø Screw on the locknut M10x1 (17-mm across the fl ats), but do not tie up yet. Ø...
  • Page 32 Remark: The tightening force is necessary to ensure the preload of the spring plate. Ø Turn on the machine. Ø It is required to perform the following calibration steps: C115, C84, C88. Ø Check if the machine works fi ne. Ø...
  • Page 33 Ø Clean the polygon ring with humid or dry cotton bud. Use only water. Do not use alcohol glass cleaner, degreaser or any other aggressive liquids: This kind of substances are too aggressive for the polygonal ring. NOTE: BE CAREFUL NOT TO LET FOREIGN DEBRIS FALL INSIDE THE TUBE.
  • Page 34 TO REPLACE OF THE POWER CLAMP ENCODER BOARD. Ø Disconnect power supply. Ø Remove weight tray. Ø Disconnect the 4 Pin ribbon cable from the optoencoder PCB. Ø Remove the phillip screws holding the encoder board to the bracket. Ø Turn the pulley sheave by hand making sure that it turns freely and does not rub against the encoder standoffs. If the pulley rubs against the standoffs, loosen the four screws securing the bracket and using the spacer gauge adjust the bracket so that the spacers are at 1,5mm (.063) from the pulley.

  • Page 35: Check And Replacement Of The Motor

    4.16 CHECK AND REPLACEMENT OF THE MOTOR " : Medium and big Phillips screwdriver, 5 and 6mm allen keys, 10 and 13mm wrenches, scissors. : 1.5h : Defective motor may cause the following malfunctions: 1. The balancer is noisy. 2. The balancer shows E22, E24, E27, E28. TO CHECK THE MOTOR Ø...

  • Page 36: Check And Replacement Of The Belt

    4.17 CHECK AND REPLACEMENT OF THE BELT " : Medium and big Phillips screwdriver, 5 and 6mm allen keys, 10 and 13mm wrenches, scissors. : 1h : Defective belt may cause the following malfunctions: 1. The balancer shows E22, E24, E27, E28. TO CHECK THE BELT Ø...
  • Page 37 Ø Pull out the pedal assy with the Bowden cable from the cabinet. Ø Dismount the screws to separate the pedal from the pedal bracket. Ø Pull out the Bowden cable from the pedal Ø Install the new Bowden cable on the pedal. Ø...

  • Page 38: Replacement Of The Shaft Brake Band

    4.19 REPLACEMENT OF SHAFT BRAKE BAND " : Medium and big philip screwdriver, 5mm allen key, 10 and 13mm wrenches. : 1.5h i : Defective mechanical brake cable may cause the following malfunctions: 1. Balancer does not hold the wheel in position. 2.

  • Page 39: Check And Replacement Of The Power Clamp Nut And Tie Rod

    4.20 CHECK AND REPLACEMENT OF THE POWER CLAMP NUT AND TIE ROD " : Medium Phillips and fl at screwdriver, 5 and mm allen key, 13mm wrench tire lever, scissors. : 2h : Defective power clamp may cause the following malfunctions: 1.
  • Page 40 Ø Remove the 4 screws that secure the power clamp nut to the pulley. Slide the power clamp nut with the rod off through the hole of the plastici body. Ø Check if the tie rod and its guide on the vibratory system are fi ne. If the tie rod is worn out, replace the power clamp nut kit.

  • Page 41: Check And Replacement Of The Electromagnetic Brake

    4.21 CHECK AND REPLACEMENT OF THE ELECTROMAGNETIC BRAKE " : Medium Phillips and fl at screwdriver, Voltmeter, 2.5, 5 and mm allen key, 13mm wrench seeger pliers, tire lever, scissors. : 2h : Defective electromagnetic brake may cause the following malfunctions: 1.

  • Page 42: Check And Replacement Electric/Clamping Pedal Switch

    Ø Remove the stator with the brakes. Ø Mount the new stator and the drive pulley. Ø Mount the collar and the clip ring. Ø Using a 2.5mm hex key securely tighten each set screw. This will push the pulley sheave to the right while the collar tightens securely against the C-Clip and will create a gap between the collar and the pulley sheave.
  • Page 43 TO ADJUST AND REPLACE THE SWITCH Ø Lift the balancer from the fl oor. Ø Remove the defective switch from the pedal. Ø Remove the weight tray. Ø Release the switches wires inside of the cabinet. Ø Cut the wires of the defective switch and connect them to those ones of the new switch. Ø...

  • Page 44: Check And Replacement Distance Potentiometer

    4.23 CHECK AND REPLACEMENT OF DISTANCE POTENTIOMETER " : Medium and big Phillips screwdriver, 13 and 14mm wrenches. : 1.5h i : Defective potentiometer may cause the following malfunctions: 1. Balancer show E92 turning it on. 2. Incorrect rim data entry. 3.

  • Page 45: Check And Replacement Of Diameter Potentiometer

    Ø Secure the potentiometer with the nut. Ø Mount the plastic wheel again checking the correct loop of the return cord. Ø Test SAPE assembly by pulling on the SAPE arm to it’s full out position several times. Ø With the SAPE arm in the HOME position select service code C80. Ø...

  • Page 46: Check And Replacement Of The Weight Laser Board

    Ø Remove the 13mm nut holding the potentiometer to the frame. Ø Install potentiometer onto bracket and tighten 13mm nut. Ø Install cog wheel onto potentiometer shaft and hand. Tighten nut. Ø Attach SAPE harness to Processor Board. Ø Turn on the machine Ø...

  • Page 47: Laser Pointer Check And Replacement

    Ø Connect all connectors to the board. Ø Connect the balancer to the power supply. Ø Turn the balancer on. Ø Calibrate the balancer with C81, C122, C82. Ø Check if the machine works fine. Ø Turn the balancer off. Ø...

  • Page 48: Check And Replacement Hood Switch

    Ø Mount the new laser pointer assy and proper route each cable to its connector. Ø Mount the laser plastic cover. Ø Turn on the balancer. Ø Calibrate with C122. Ø Check if the balancer works fi ne. Ø Mount the weight tray. 4.27 CHECK AND REPLACEMENT OF HOOD SWITCH "...

  • Page 49: Wheel Guard Adjustment

    Ø After adjusting and locking the mechanical end stroke that set the wheel guard inclination, proceed with cam adjustment as follows. Ø The cam should be adjusted to activate the switch within a range of 1 ° to 4 °, considering the wheel guard in fully closed position.

  • Page 50: Gas Spring: Check Adjustment And Replacement

    4.29 GAS SPRING: CHECK, ADJUSTMENT AND REPLACEMENT " : Medium and big philip screwdriver, 5, 13mm wrenches, 6mm allen key, small cone EAM0005D23A (0,5Kg / 1lbs), medium cone EAM0005D24A (1,4Kg / 3.2lbs) : 1h i : Defective hood switch may cause the following malfunctions: 1.

  • Page 51: Sonar Sensor: Check And Replacement

    TO REPLACE THE GAS SPRING Ø Turn off the balancer. Ø Remove the weight tray. Remove the lateral plug from the wheel guard holder. Ø Ø Remove the self locking nut from the bottom bolt. Ø Remove the upper bolt: HOLD THE WHEEL GUARD BECAUSE WHEN THE SCREW WILL BE OFF, IT WILL FALL DOWN.
  • Page 52 Ø Remove the sonar board cover. Ø Disconnect the sonar cable. Ø Mount the new sonar. Ø Connect the cable. Ø Install the cover. Ø Fix the sonar to wheel guard. Ø Calibrate with C82 Ø Check if the machine works fi ne.

  • Page 53: Chapter 5 Trouble Shooting

    CHAPTER 5 TROUBLE SHOOTING 5.1 INTRODUCTION This chapter represents a kind of trouble-shooting guide, which describes the different typologies of error, all system messages available and the possible causes of malfunction. In particular the following are described: Ø Error Codes: an error code appears automatically on the display when an error occurs; these codes are subdivided into H-code, E-codes and K-codes.

  • Page 54: In The Field Reprogramming Of Balancers

    IN THE FIELD REPROGRAMMING OF BALANCER After software down loading or LED display panel replacement, perform service codes in the following order: after the selection, the machine will make three audible beeps followed by the automatic turning off and on again. •...
  • Page 55 WHEEL GUARD SWITCH • - Check the wheel guard switch. The switch and the Function-Code should be checked if the balancer will not spin the wheel or if E89 is displayed Check the pedal switches. The switches and the Function-Code to lock the power clamp should be checked if the power clamp does not work.
  • Page 56 Sape Out During wheel spin Complaint After the lowering the wheel guard, the balancer does not spin the wheel and E10 comes up. Root cause Gauge arm removed from idle position during wheel spin. Service Code C80, C81, C82, C115, C84, C88, Reposition SAPE arm in home position and press STOP or ESC key to continue.
  • Page 57 Speed not reached Complaint Lowering the wheel guard the motor spins the wheel and then the display show E22 Root cause Balancing speed not reached Service Code C54, C60, C110, C115, C84, C88 Check the wing nut. Check the belt Check the capacitor, Actions to do Check the motor wiring.
  • Page 58 The rotating speed of the main shaft exceeds the safety limit Complaint During the balancing the screen shows E28 and then the wheel is stopped Root cause The main shaft is rotating at higher speed compared to the expectetionof the microprocessor Service Code C56, C74, C75 Make sure about the proper adjustment of the wheel guard switch.
  • Page 59 User Calibration Not Provised Complaint During the user calibration E50 is displayed. Calibration weight not attached to the fl ange Root cause Transducer loosened Service Code C75 (AdE1 and AdE2), C115, C84, C88 Check if the calibration weight is attached. Actions to do Check if the calibration weight is attached in the correct side.
  • Page 60 The inner gauge arm for distance and rim diameter is defective Complaint After switching on the balancer, the screen shows E92 2D sape or geodata arm not in home position. 2D sape or geodata arm not calibrated. Distance and/or diameter potentiomer are unplugged. Root cause Distance and/or diameter potentiometer are reversed on the Integrated Display.
  • Page 61 E300 Check availability of keyboard Turning the machine on the screen shows E300. It is not possible to access to any screen Complaint information. The balancers devices, such Optoencoder, HUB board and Keypad, communicate each other through the communication bus I2C. Root cause If one or more devices will not work or communicate, the communication bus I2C detects a problem showing E300.
  • Page 62 E503 Laser Power Supply Fault Complaint Turning the machine on, the display shows E503 No power supply to the laser kit. Root cause Cable from weight laser board to Laser kit is disconnected, missing or damaged. Defective Laser kit. Service Code C122, C123 Check the proper fi...

  • Page 63: H" Error Codes

    5.6 “H” ERROR CODES Optimisation Can't Improve Press ESC button and balance the wheel again without perform the optimization because the whe- el running conditions cannot be improved. Optimisation Not Recommended Further optimization not recommended but feasible Optimisation Recommend Minimisation Weight minimisation is recommended, optimisation can achieve no further improvement Power Clamp Disabled Enable power clamp with C23...
  • Page 64 5.7 ERROR CODES ON INTEGRATED DISPLAY 0X001001 PO NOT FOUND Turn off and back on the machine. If the problem still persists: Load the software. If the problem still persists: Check the main shaft Optoencoder cable If the problem still persists: Check the main shaft Optoencoder.

  • Page 65: Keyboard Display

    0X001005 PO EEP2 RD Turn off and back on the machine. If the problem still persists: Load the software. If the problem still persists: Replace the Optoencoder. If the problem still persists: Replace the IBP2 box. If the problem still persists: Call Snap On C Codes C74, C75, C85, C86, C115, C84, C88...
  • Page 66 0X001012 KEYBOARD READING The microprocessor has to fi nd the keyboard and communicate with it while balancer is working. If something is wrong with that this diagnostic codes is generated by balancing kernel software. I2C communication failure. Check the plugs, connectors and cable wiring from power interface board to the key board. May have to replace the integrated panel assembly if you can not fi...

  • Page 67: Power Fail

    0X001023 SPEED FLUCTUATION DURING THE MEASUREMENT Check the belt tension. If the problem still persists: Check the speed with C60. If the problem still persists: Check Optoencoder with C54. If the problem still persists: Check the capacitor If the problem still persists: Call Snap On C Codes C28, C54, C60...
  • Page 68 0X001032 VCC ABOVE LIMIT OF 5.2VDC Check the power supply with C110. If the problem still persists: Check the IBP box C Codes C110, C86, C115, C84, C88 0X001033 VCC BELOW LIMIT OF 5.2VDC Check VCC connectors and cables Check the power supply with C110. If the problem still persists: Check sonar sensor.
  • Page 69 0X001037 LINE BELOW LIMIT Check the main power supply with C55. If the problem still persists: Check the Power supply to wall plug If the problem still persists: Check the main power supply cord and plug. If the problem still persists: Check the main switch.
  • Page 70 0X001041 SAPE 1D HIGH VOLT Check the Distance potentiometer connector and cable. If the problem still persists: Check the Distance potentiometer If the problem still persists: Check the Integrated Display. If the problem still persists: Call Snap On C Codes C80, C81, C92, C115, C84, C88 0X001042 SAPE 2D LOW VOLT...
  • Page 71 0X001050 SIDE CAL BAR Perform the calibration C115 with weight in the correct side. If the problem still persists: Call Snap On C Codes C64, C115, C84, C88 0X001051 SIDE CAL USER Perform the User calibration with weight in the correct side. If the problem still persists: Call Snap On C Codes...
  • Page 72 0X001056 CAL2 100G WEIGHT LOW Perform the calibration with C115. If the problem still persists: Check the transducers wiring If the problem still persists: Check the transducers adjustment. If the problem still persists: Check the IBP box. If the problem still persists: Call Snap On C Codes C66, C75, C103, C104, C115, C84, C88.
  • Page 73 0X001060 C2 USER CAL TOOL LOW Perform the User calibration. If the problem still persists: Check the User Calibration weight. If the problem still persists: Check the transducers wiring If the problem still persists: Check the transducers. If the problem still persists: Check the IBP box.
  • Page 74 0X001081 NO ACCELERATION Check wing nut If the problem still persists: Check the shaft. If the problem still persists: Check the wheel clamping. If the problem still persists: Check the belt adjustment. If the problem still persists: Check the belt. If the problem still persists: Check the brake adjustment.
  • Page 75 0X001083 SPEED HIGH Check if the wheel guard is correctly adjusted. If the problem still persists: Check the main shaft Optoencoder. If the problem still persists: Check the IBP box If the problem still persists: Call Snap On C Codes C56, C60, C74, C115, C84, C88, 0X001084 REVERSE TURN...
  • Page 76 0X001091 STUCK UNCLAMP Check the Power Clamp pedal. If the problem still persists: Check the brake pads If the problem still persists: Check the electromagnetic brake If the problem still persists: Check the drive Pulley Optoencoder If the problem still persists: Check the main shaft Optoencoder.
  • Page 77 0X001094 CLAMP LOCKED Check the Power Clamp pedal. If the problem still persists: Check the drive Pulley Optoencoder If the problem still persists: Check the brake pads If the problem still persists: Check the electromagnetic brake If the problem still persists: Check the main shaft Optoencoder.

  • Page 78: E" Error Codes

    5.8 “K” CODES (KERNEL CODES) 5.8.1 STRUCTURE OF AN ERROR CODE A complete error code consists of 6 hexadecimal digits. Digit 6 Digit 5 Digit 4 Digit 3 Digit 2 Digit 1 Module ID Priority ID Error code Left Display Right Display The module ID is a 2-digit hexadecimal value and indicates the software module which detected the error.
  • Page 79 81X160 81X165 81X16A 81X161 81X166 81X16B K CODE 81X162 81X167 81X16C 81X163 81X168 81X16D 81X164 81X169 DESCRIPTION Communication with EEPROM through I2C bus is failed. When the microprocessor wants to calculate the unbalances, it needs a lot of data that EXPLANATION stored in EEPROM.
  • Page 80 K CODE C10 F02 C10 F07 C10 F08 DESCRIPTION Unsuccessful self-test on power up A software command was invalid or the hardware is set up wrong for the model EXPLANATION ACTION Restart the balancer . If these codes persist, Reset brand and model with C47 C CODE K CODE C10 800...
  • Page 81 K CODE C10 410 C10 420 C10 430 C10 410: No signal output from transducer 1 (behind main shaft) DESCRIPTION C10 420: No signal output from transducer 2 (front of main shaft) C10 430: No signal output from both transducers There are two preloaded transducers connected to the Integrated Display.

  • Page 82: B- Beeps Of The Initialisation Step

    5.9 EEP CODES The beeps codes are made to recognize the malfunction of the machine in case of display problem. 5.9.1 ABBREVIATIONS Beeps Frequency : 2000 Hz Duration : 100 ms Pause : 100 ms (Pause after beep, total length = 200 ms) Frequency : 1600 Hz Duration...

  • Page 83: C- Beeps Of The Module/Object

    5.9.5 -C- BEEPS OF THE MODULE/OBJECT Beep sequence Description ID MODULE Initialisation of the I2C bus fails. SDA or SCL level is wrong Initialisation of keyboard device driver (including STOP, 44, 45, 46, 47, 48 wheel guard, pedal) S S S S Resource not available (timer) Persistent object not available Persistent object not available...

  • Page 84: Chapter 6 Service Codes

    CHAPTER 6 SERVICE CODES 6.1 INTRODUCTION The service codes are used to: Ø Calibrate module Ø Change setting. Ø Show and check measured values of display of certain signals, system information. Ø Upgrade software WARNING! Wheel Balancer will spin in service mode when the hood is closed. Technician servicing the unit with the calibration rotor in service mode must operate in front of the machine in upright position.

  • Page 85: Saving Settings For Modes Od Operation And Calibration Data

    Description Copy content of serial EEPROM (EEP) from incremental encoder EEP to micro-controller EEP. Calibration of the 12 o’clock position for fi tting position of weights Display of actual distance and diameter of inner SAPE/geodata Conditioning of the solenoid brake Display of angular position of power clamp pulley, incremental encoder test Performing a measuring run and indication of harmonic contents of the unbalance signals Test of the transimpedance and unbalance signal amplifi...

  • Page 86: User C Codes Reference

    6.5 USER C CODES REFERENCE Load confi guration from default profi le Options: No action Set default values Special function: None Description: Pressing the Acknowledgment key resets the user settings to values defi ned under factory setting profi le (default values). The chosen mode of operation can be transferred to the permanent memory The following modes of operation are activated simultaneously by pressing the Acknowledgment key.
  • Page 87 Compensation is also cancelled by calibration, readjustment by the operator, an optimisation run or by turning off the machine. Comments: None Treshold value of suppression of minor unbalance reading in units selected with C3 Options: 3.5 - 20g (0.12 - 0.71oz) : Threshold value 3.5g (0.12oz) : Factory-adjusted value Special function: None...
  • Page 88 Recall counter - Only balancers with digital display Options (Only press the +/- key, do not turn the wheel) Total number of measuring runs Number of measuring runs where balance quality was considered OK Number of optimisations or minimisations Number of measuring runs in service mode Number of measuring runs since the last calibration Total number of clamping operations (p models only) Special function:...
  • Page 89 Unclamping of power clamp locked Options: Unclamping of power clamp device enabled Unclamping of power clamp device locked. Special function: None Description: The power clamp device is locked in clamped position. Comments: The asterisk „*“ marks the factory-adjusted default. Enable/Disable power clamp Options: Unclamping of power clamp device enabled Unclamping of power clamp device locked.

  • Page 90: Service C Codes Reference

    6.6 SERVICE C CODES REFERENCE Load confi guration from default profi le Options: No action Set default values Special function: None Description: Pressing the Acknowledgment key resets the user settings to values defi ned under factory setting profi le (default values). The chosen mode of operation can be transferred to the permanent memory The following modes of operation are activated simultaneously by pressing the Acknowledgment key.
  • Page 91 Display & clear error record Options: Do not clear the error memory Clear the error memory. Special function: none Description: The last 10 different malfunction codes are written into the error memory so that they can be called up and reported by the operator of the wheel balancer e.g. for remote diagnosis of malfunctions. The most recent malfunction code is written into memory location 1 and the previous error codes are shifted to the higher memory locations.
  • Page 92 In step 3: To reduce the acceleration of the spin avoiding excessive acceleration. Good for small wheels. Disablee the Soft Start Function Enable the Soft Start Function In step 4: Time among the reaching the balancing speed and the starting of the unbalance measurement. Measurement delay after spin up can be controlled, by chosen the preferred value.
  • Page 93 Step Description min value [%] average value [%] max value [%] A bar Avg From 40 to 60 B bar A gap Avg From 40 to 60 B gap A to B phase shift N gap channel A biggest neighbour N gap [%] of average gap around [-8...+8] of reference mark N gap channel A...
  • Page 94 Indication of the line voltage Options: None Special function: None Description: Indication of line voltage Comments: Please refer to error ID 800, 801, 804 for the limits. Indication of the circuit state of the wheel guard switch Options None Special function: None Description: The wheel guard switch is assigned to the hundreds digit, the micro-switch actuated by depressing...
  • Page 95 Special function: None Description: As soon as measured data is available, the current speed is read out. The correct speed range must be 195 to 205 Rpm. Comments: None Continuous measurements - balancers with digital display Options: Press “+/-” key to switch from step to step. Press “-”key for: 1.
  • Page 96 Front transducer: 25-135 Comments: The shown values are those ones calculated in the latest calibration performed. Display calibration values as measured with C code 83/115 (virtual dimensions) Options: None Special function: None. Description: Values for both transducers in mm. Reference mark is the zero reference of Geodata Values for both transducers in mm.
  • Page 97 Rear transducer 178-182 Front transducer 358-002 Comments: The shown values are those calculated in the latest calibration performed. Measurement of angular deviation Options: Press “+/-” key to switching over between rear and front transducers. Special function: None. Description Remove wheel or test rotor and centering cone from the adaptor. With power clamp fi...
  • Page 98 Pressing the Special Function key will reset the YZ part of the reading to 00, the X part will not be reset. Characteristic values of the status register (YZ part) after switching power on (main shaft not moved at all), or after pressing the Special function key after 2 turns backward à...
  • Page 99 Calibration of the inner SAPE gauge arm Options: None. Special function: None. Description: Step 1: Move gauge arm to calibration position 1 and adjust the distance potentiometers mechanically. The voltage of the distance potentiometer is indicated in the right 3-dig display Gauge arm fully returned to home position.
  • Page 100 Step 2: Move gauge arm to calibration position 2. Press acknowledge key to confi rm step 2. Gauge arm extended to max extension Step 3: Move gauge head to calibration position 3. Press acknowledge key to confi rm step 3. Position 1 of calibration template, or head of calibration weight Step 4:...
  • Page 101 Measuring the adaptor fl ange and the zero plane Options: None Special function: None Description: To keep the machine operative and to allow width measurement in case the gauge arm is defective, the distance SAPE will be calibrated relative to the clamping surface of the adaptor on the condition that the gauge arm has already been calibrated.
  • Page 102 Step 1 The display shows the value (distance among sonar to calibration tool) stored in the PO from the last C82. Press “RETURN” key. Step 2 Low the wheel guard. Then the sonar will try to acquire 3 valid measurement, in mm, emitting one beep every second: when acquired the display will show the green arrows.
  • Page 103 Calibration of the unbalance measurement with wheel/test rotor. Options: None Special function: In case of using of a wheel, use a 6.5”x15” steel rim with a maximum unbalance of 10g in each side. Description: With the calibration of the unbalance measurement the following are determined: the sensitivity of the transducers, the phase difference of the transducer signals, the comparative data for readjustment by the operator and temperature compensation...
  • Page 104 Step 3: Lower the wheel guard to begin the measuring run. Step 4: Remove the 100 gram calibration weight and insert it into the right hand plane of the Pruefrotor / wheel. Lower the wheel guard to begin the measuring run. Step 5: .
  • Page 105 Step 6: The ambient transducer temperature is displayed for 1 second. Step 7: Remove the 100 gram weight, lower the hood and Lower the wheel guard to start a measuring run. Step 8: . Insert the calibration weight that is supplied with the balancer on the left side of the backing plate. Lower the wheel guard to begin a measuring run.
  • Page 106 Compensation of unbalance of main shaft Options: None Special function: None Description: Compensating for residual unbalance left in the main shaft. To save balancing of the main shaft by drilling out material or by adding balance weights, the residual unbalance of the main shaft is determined and compensated for (subtracted) in all subsequent measurement runs.
  • Page 107 Step 1: Remove wheel adaptor from main shaft. Clamp the medium and big cones on the shaft and lock Close the wheel guard and press "START" key for the measurement run. Step 2: Unclamp the clamping sleeve and place the calibration ring between the cone and the sleeve.
  • Page 108 Calibration of 12 o’clock position for fi tting position of weights Options: None Special function: None Description: With this calibration code it is possible to compensate for the individual angular deviation of a machine. During the basic calibration in the factory this code will only be carried out if there is a clearly noticeable angular deviation, and not as a general procedure.
  • Page 109 Display of actual distance and diameter of inner SAPE Options: None Special function: None Description: 1. Field / left display : diameter (408-410) 2. Field / right display : distance (From machine to calibration rotor edge). Comments: Display of angular position of power clamp pulley, incremental encoder test Options : Special function: Resetting incremental register fl...
  • Page 110 8. Channel 2 2nd harmonic. 9. Channel 2 3rd harmonic. 10. Channel 2 4th harmonic. 11. Channel 2 1st harmonic wave phase Description: Test of transimpedance and unbalance signal amplifi ers. This test will take 12 seconds. Special function: All values displayed in channel 1 are related to the rear transducers and those in channel 2 are related to the front one.
  • Page 111 C115 Calibration of the unbalance measurement with test rotor. Options: None. Special function: None. Description: With the calibration of the unbalance measurement the following are determined: the sensitivity of the transducers, the phase difference of the transducer signals, the comparative data for readjustment by the operator and temperature compensation the phase shift of the unbalance signal amplifi...
  • Page 112 Step 3: Low the wheel guard to begin the measuring run. Step 4: Remove the 100 gram calibration weight and insert it into the right hand plane of the Pruefrotor. Low the wheel guard to begin the measuring run. Step 5: .

  • Page 113: Calibration Complete

    Step 6: The ambient transducer temperature is displayed for 1 second. Step 7: Remove the 100 gram weight, low the wheel guard to begin a measuring run. Step 8: . Insert the calibration weight that is supplied with the balancer on the left side of the backing plate.
  • Page 114 C120 Enable/disable laser pointer Options: None Special function: None Description: On selection the current status is displayed (0 / 1). Select 0: Disable laser pointer. Select 1: Enable laser pointer. Comments : None. C122 Laser pointer calibration Options: C122 Procedure must be done after the C80 and C81 Special function: None Description:...
  • Page 115 Rotate the wheel until the inner weight will be in front of the laser pointer. Press the "-/+" arrow button to adjust the laser dot to the correct position. IMPORTANT! The laser dot must be adjusted in front of the weight. Once the laser dot is adjusted to the correc place press the “RETURN”...
  • Page 116 C123 Laser pointer: Display of the status and execution of diagnostic tests Options: None Special function: None Description: A numeric sequence of 4 numbers that have the following meaning is displayed. 0 : off (fail) 1 : on (ok) Once selected C123, the following display is displayed Zero mark Laser sink Motor sink...

  • Page 119: Updating Guide

    UPDATING GUIDE: Author: Stefano Muzzioli REVISION M February 2019 Chapter 5.6 : Text updated Pag. Chapter 5.7 : Text - Updated Pag. Chapter 5.8 : Text - Updated Pag. Chapter 6.6 : Text - Updated Pag. REVISION L November 2018 Chapter 5.5 : Text updated Pag.
  • Page 120 309 Exchange Ave. Conway, AR 72032 Ph: 501-450-1500 Fax: 501-450-2085...

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