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Hofmann geodyna 7600, Service Manual

The Hofmann geodyna 7600 Service Manual is a comprehensive and essential resource for users of this exceptional product. Packed with detailed instructions and troubleshooting tips, this manual is available for free download from manualshive.com. Enhance your experience with the geodyna 7600 by accessing this invaluable resource today.

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76

K CODE

81X160
81X161
81X162
81X163
81X164

81X165
81X166
81X167
81X168
81X169

81X16A
81X16B
81X16C
81X16D

DESCRIPTION

Communication with EEPROM through I2C bus is failed.

EXPLANATION

When the microprocessor wants to calculate the unbalances, it needs a lot of 
data that stored in EEPROM. If the communication with EEPROM failed, it can 
not do calculation.

ACTION

Check the plugs, connectors and cables between microprocessor control 
board and main shaft encoder board. May need to change encoder board or 
microprocessor board

C CODE

C74

K CODE

81X510 

 Calibration slug is missing

81X511  

The mass of calibration slug is wrong

81X512

  The calibration slug is put on wrong side.

DESCRIPTION

The user calibration fail.

EXPLANATION

The user calibration uses calibration slug to calibrate the balancer. The calibra-
tion slug should be properly used in different steps. If it is not properly used, 
or the mass of calibration slug is not right, or it is put wrong side, one of these 
code will be generated.

ACTION

Follow the user manual to repeat user calibration procedure. 
Reload software, maybe the software collapses. 
Check the output of transducers.

C CODE

C14, C64

K CODE

81X560

  c1 value too low, if a user calibration tool assumed

81X561

  c2 value too low, if a user calibration tool assumed

81X565 

 c1 value too low, if a 100g weight and calibration rotor assumed

81X566

  c2 value too low, if a 100g weight and calibration rotor assumed

81X570

  c1 value too high, if a  calibration rotor only assumed

81X571

 c2 value too high, if a  calibration rotor only assumed

DESCRIPTION

The vectors c1 and c2 generated by transducers are no correct in factory cali-
bration procedure.

EXPLANATION

In factory calibration procedure, a very precise and accurate instrument called 
proof rotor and 100 gram calibration weigh are used. These calibration tools 
make the transducers produce certain outputs, we call them as vector c1 and 
c2. If something is wrong, for example, the tools are used improperly, or the 
transducer work improperly, the vectors c1 and c2 will out of their range. If the 
software detected the c1 and c2 are not right, these diagnostic codes will be 
generated.

ACTION

Followed instruction on the manual repeat the factory calibration carefully. 
Make sure every step is right. If still can not pass the calibration and got dia-
gnostic code, it will be the transducer problem. Use C64 to check the outputs 
of transducers. 
In most case should re-torque the transducers. Or transducer(s) is bad, need 
replace the transducer(s). 

C CODE

C64, C115, C84, C88

SM HOF GEODYNA 7600 Rel.D

Summary of Contents for geodyna 7600

Page 1: ...geodyna 7600 Service Manual ...

Page 2: ...2 BLANK PAGE__________________________________________________________________________ SM HOF GEODYNA 7600 Rel D ...

Page 3: ...STEM PAG 17 3 13 BELT TENSION PAG 18 3 14 THE BRAKES PAG 18 3 15 BRAKING BY REVERSING THE MOTOR TORQUE PAG 18 3 16 THE SHAFT LOCKS OF THE MOTOR DRIVE VIBRATORY ASSY PAG 19 3 17 THE ELECTROMAGNETIC BRAKE PAG 19 3 18 POWER CLAMPING DEVICE PAG 19 3 19 SD SAPE SEMI AUTOMATIC PARAMETER ENTRY PAG 20 3 20 SONAR WHEEL DATA SYSTEM PAG 21 3 18 SONAR SENSOR PAG 21 CHAPTER 4 SERVICE PAG 22 4 1 INTRODUCTION PA...

Page 4: ...4 29 SONAR SENSOR CHECK AND REPLACEMENT PAG 49 4 30 TOUCH SCREEN CHECK AND REPLACEMENT PAG 50 CHAPTER 5 TROUBLE SHOOTING PAG 51 5 1 INTRODUCTION PAG 51 5 2 TO UPDATE THE SOFTWARE PAG 51 5 3 IN THE FIELD REPROGRAMMING OF BALANCER PAG 52 5 4 RECOMMENDED SERVICE STEPS PAG 52 5 5 SELF TEST DURING STARTUP PAG 53 5 6 H ERROR CODES PAG 60 5 7 X ERROR CODES PAG 62 5 8 K CODES KERNEL CODES PAG 75 5 8 1STRU...

Page 5: ...5 BLANK PAGE__________________________________________________________________________ SM HOF GEODYNA 7600 Rel D ...

Page 6: ... keys 2 5 mm to 8 mm 6 mm with a length or adapter of at least 140 mm ratchet advised Screw drivers Flat bed 1 to 3 Phillips 1 to 3 Magnetized Phillips 300mm long Multimeter AC DC A Ohm pF User Calibration Weight supplied with the unit Special tools that are required for specific tasks are Test Rotor EAA0277D12A Use this test rotor to perform a Factory Calibration Service Code C115 C88 This is requ...

Page 7: ... transducers screws Sonar Calibration Tool EAA0344G09A This tool allows a high accuracy sonar sensor calibration Use this calibration tool to calibrate C82 the sonar sensor It is required after Ø Sonar sensor replacement Ø BP box replacement Ø Distance and or diameter potentiometer s replacement Ø Vibratory assy replacement Ø Wheel guard replacement Electronic inclinometer and spirit level SM HOF ...

Page 8: ...and pull to disconnect 5 To reduce the risk of fire do not operate equipment in the vicinity of open containers of flammable liquids gasoline 6 Keep hair loose fitting clothing fingers and all parts of the body away from moving parts 7 To reduce the risk of electric shock do not use on wet surfaces or expose to rain 8 Do not hammer on or hit any part of the control panel with weight pliers 9 Do not al...

Page 9: ... UP THERE IS A DELAY OF SEVERAL SECONDS BEFORE THE MONITOR IS ACTIVATED NOTE ANY ELECTRICAL OUTLET INSTALLATION MUST BE VERIFIED BY A LICENSED ELECTRICIAN BEFORE CONNECTING THE BALANCER NOTE ENSURE THAT THE OUTLET HAS AN AUTOMATIC GROUND FAULT CIRCUIT BREAKER WITH A DIFFERENTIAL CIRCUIT SET AT 30 MA 2 3 AC THEORY OF OPERATION Always use the One Hand Rule when working with AC voltages by keeping on...

Page 10: ...rge that is gene rated is sent back to the processor SONAR SENSOR The sonar sensor is supplied and connected to X1 of the IBP ELECTROMAGNETIC BRAKE The PCB sends 150VDC to the Electromagnetic brake on the motor stopping the tire and wheel assembly at TDC for the outside weight location The voltage can be measured at X43 on the IBP box WEIGHT LASER POINTER It is used to place the adhesive weights o...

Page 11: ...he Processor section gathers the information generated from the encoder and transducer via a ribbon cable This board is powered with 5VDC received from the Power Supply section of the IBP box Calculated imbalance values are then shown on the screen after a spin cycle 2 6 INSTALLATION PRECAUTIONS Floor Level All models of Wheel Balancers have to be placed on a well levelled floor 1º tolerance If you...

Page 12: ...cludes more functions and easy software installation or update since it can be done via MMC SD card Software installation or update on all kind of balancers with new IBP board can be done with a unique MMC SD card because the software downloading is automatically performed according to the type of keyboard installed on the ba lancer The IBP box controls Power supply 5 VDC Potentiometers Motor capa...

Page 13: ...er X7 Diameter potentiometer X3 Optoencoder and transducers X4 Wheel guard X1 Sonar X14 Laser pointer X42 Motor X2 Stop Button X13 Brake pedal wheel guard switch inner rim light X15 Laser stepper motor X43 Power clamp SM HOF GEODYNA 7600 Rel D ...

Page 14: ... 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 The motor The vibratory assembly is the central module of all wheel balancers It consists of the force guidan...

Page 15: ...ibratory plate and converts the alternating forces of the right hand virtual plane into a proportional electrical charge Charge amplifiers on the processor board convert the transducer outputs to alternating voltages A transducer consists of a single piezo disc with contact plates insulation discs and thrust spreading members at both sides of it This sandwiched arrangement is encapsulated by a moul...

Page 16: ...s The output signals A and B have about the shape and relationship shown An intended irregularity Nullmarke is detected with the main shaft rotating at constant speed On detection of the irregularity the position counter is set to zero thus providing absolute angular reference to the shaft 3 10 ENCODER BOARD OF THE MAIN SHAFT The incremental encoder B8 is located between the ball bearings inside t...

Page 17: ...ider zone of the zero reference has to be positioned to the edge of the pulley The small encoder board carries four SMT reflective interrupters some resistors an integrated circuit Hex Schmitt Trigger and a 4 position ribbon cable with receptacle The reflective interrupters A and A respectively B and B are placed with a radial offset of half an increment so the interrupters work in a push pull arran...

Page 18: ...150 RPM of main shaft speed the torque capacitor CT is switched off by relay under program control With increasing speed the effect of CT on torque drops and reactive current increases Direction of rotation of the main shaft is appointed by the order of wires attached to its connector 3 13 BELT TENSION With the drive system belt tension is crucial as it has great influence on friction Friction can ...

Page 19: ...h the winding behind the brake lining and the brake disc fastened axially movable to the hub by an annular leaf spring Without power there is no friction at all since the brake disc is separated from the stator by an air gap With current applied to the solenoid the disc is pulled to the stator by magnetic force With rotary motion of the hub friction will develop between the brake disc and both the...

Page 20: ...tarting position causing the clamping jaws to retract in the adaptor sleeve thus releasing the clamping sleeve As with clamping motion is monitored by the encoder Motor and brake are switched off in succession Releasing a wheel from the power clamping device in the event of a power failure Behind a 15 mm hole in the front of the cabinet closed by a black plastic cap two pegs project axially out of...

Page 21: ...the presence of an object within the nominal flow On the wheel balancer the sonar must work in conjunction with the inclination of the wheel guard rim offset and diameter This because it must make a board of returned echo signals to be converted through a specific trigonometry recalculation to the rim width 3 21 SONAR SENSOR The Sonar Sensor is used to detect all information required by the IBP abou...

Page 22: ...est but the display does not show anything Turning the balancer on it showsC10800 Ø Go to C55 to check the power supply Ø Disconnect the power supply from the balancer or from the screen Ø Using a VOM check for an output voltage at the end of the power plug 10 VAC VPI compared to the nominal Ø If there is not the correct output voltage the cable must be replaced 4 3 TO ACCESS TO THE INSIDE OF THE ...

Page 23: ...POWER TO IBP BOX Big and Medium Phillips screwdriver Plastic panel with keypad EAA0408G40A 6 30 i Ø Remove the weight tray Ø Check if the wires are well fitted to the connector Ø Turn the machine on Ø Using a VOM check for 230VAC at the power supply board X41 pins 2 and 3 all balancers 4 6 CHECK AND REPLACEMENT OF THE POWER ENTRY MODULE Multimeter medium flat and Phillips screwdriver scissors 6 1h i...

Page 24: ...e is fine and the problem is caused by IBP box TO REPLACE THE POWER ENTRY MODULE Ø Turn the balancer off Ø Disconnect the power supply from the machine Ø Remove the cover from the IBP Ø Disconnect the the cables from Power Entry Module Ø Remove the screws that secure the PEM to the bracket and take it out Ø Take the new module and secure it to the bracket Ø Plug the new module to the main switch Ø ...

Page 25: ...CHECK AND REPLACEMENT OF THE IBP BOX F1 AND F2 F FUSE Multimeter big and medium Phillips screwdriver 6 30 i Defective fuses may cause the following malfunctions Turning the machine on the machine does not show anything TO CHECK AND REPLACE THE FUSES Ø Turn the balancer off Ø Unplug the power supply cable from the balancer Ø Remove the weight tray Ø Access to the IBP board Ø Lift the fuse with the ...

Page 26: ...ay shows 001034 5 Turning the balancer on the display shows 001035 6 After the wheel spin the display shows error 001080 7 After the wheel spin the display shows error 001081 8 After the wheel spin the display shows error 001082 CONTROLLER SECTION 1 After the balancing cycle the machine show error with module 81 2 After the balancing cycle the machine show error with module C10 3 After turning the...

Page 27: ... signal flow from connector to connector Some signals run straight from connector to connector 4 11 CHECK OF VIBRATORY SYSTEM Calibration rotor electronic or spirit inclinometer 6 1h i Both bearings are bonded into place in the main shaft In between the two positions the polygon ring is positioned It is not possible to replace the bearings or the polygon ring the only solution is replacing the comp...

Page 28: ...ut on a board and the voltage difference between the outputs of the unbalance signal amplifiers N4A and N4B is indicated AdE 2 is the channel indicating the signal of transducer B3 located in the front AdE 1 is the channel indicating the signal of transducer B2 located in the back Normally the readings are fluctuating around 0 005x volts Ø Standing in front of the balancer push at the end of the mai...

Page 29: ...th black band must be fitted on the positive lead Ø The two setscrews M10x1x29 with ball sockets inverse cones should be screwed into the vibratory plate of 20 mm 0 79inch thickness and the rigid support plate welded to the cabinet Ø Put some stiff grease in the recesses at both ends of the transducer Put 8 mm Ø ball bearing in the recesses Ø Insert the transducer in the slot of the vibratory plate...

Page 30: ...etscrew to turn hold it with the hexagon wrench 5 mm inserted Ø Drive in the screws M4 so that the leaf spring is in equal distance at both ends but not bend in the middle Ø Place the spacer EAA0470G84A on the spring plate as shown in the picture Ø Tighten the screws red arrows at 1 00 0 05 Nm 8 4 0 4 lbs in then remove the spacer Remark The tightening force is necessary to ensure the preload of t...

Page 31: ... Disconnect the 10 Pin ribbon cable from the encoder PCB Ø Remove all dirt from the region where the Optoencoder is positioned preferably with a moisturized cloth Ø Remove the phillip screw holding the encoder PCB to the shaft tube Ø Clean the encoder board lens Ø Clean the polygon ring Ø Clean the polygon ring with humid or dry cotton bud Use only water Do not use alcohol glass cleaner degreaser ...

Page 32: ... error code 0x1090 0x1091 0x1092 0x1093 0x1094 0x1095 TO CHECK THE POWER CLAMP ENCODER BOARD Ø Check the encoder with service code C98 Ø Remove the weight tray Ø Verify if the board sensors are at 1mm above the pulley Ø Verify if the encoder sensor read the wider strip zone Ø Make sure that the cable and connection are fine Ø Make sure that the optoencoder is well tightened TO REPLACE OF THE POWER ...

Page 33: ...f the screw check again the gap Ø Connect the 4 pin ribbon cable to the encoder PCB Ø Mount the weight tray Ø Turn on the machine Ø Perform C code C84 Ø Check if the machine works fine 4 16 CHECK AND REPLACEMENT OF THE MOTOR Medium and big Phillips screwdriver 5 and 6mm allen keys 10 and 13mm wrenches scissors 6 1 5h i Defective motor may cause the following malfunctions 1 The balancer is noisy 2 T...

Page 34: ... tray Ø Turn on the balancer Ø Check if the balancer works fine 4 17 CHECK AND REPLACEMENT OF THE BELT Medium and big Phillips screwdriver 5 and 6mm allen keys 10 and 13mm wrenches scissors 6 1h i Defective belt may cause the following malfunctions 1 The balancer shows E22 2 The balancer shows E23 3 The balancer shows E24 4 The balancer shows E25 5 The balancer shows E26 TO CHECK THE BELT Ø Check i...

Page 35: ...ouch the motor pulley during the balancing cycle Ø Disconnect the power supply from the rear of the machine Ø Remove the weight tray Ø Disconnect the brake cable from the vibratory assy Ø Make note of the location of the springs and washers Ø Remove the two 5mm bolts holding the pedal to the frame Ø Pull out the pedal assy with the Bowden cable from the cabinet Ø Dismount the screws to separate th...

Page 36: ...se to apply tension to the brake or clockwise to loosen the brake Ø The cable is properly adjusted when the tire and wheel assembly has a little resistance Ø Lock firmly with the counter nut Ø Mount the weight tray 4 19 REPLACEMENT OF SHAFT BRAKE BAND Medium and big philip screwdriver 5mm allen key 10 and 13mm wrenches 6 1 5h i Defective mechanical brake cable may cause the following malfunctions 1...

Page 37: ...OWER CLAMP NUT AND TIE ROD Medium Phillips and flat screwdriver 5 and mm allen key 13mm wrench tire lever scissors 6 2h i Defective power clamp may cause the following malfunctions 1 E14 after the wheel clamping 2 001090 after wheel clamping 3 001091 after wheel unclamping 4 Wheel sleapage TO CHECK AND REPL ACE THE POWER CLAMP Ø Diconnect the power supply from the machine Ø Remove the weight tray Ø...

Page 38: ...ews 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 fine If the tie rod is worn out replace the power clamp nut kit If the guides inside of the vibratory system are worn out replace the complete vibratory system SM HOF GEODYNA 7600 Rel D ...

Page 39: ...ke may cause the following malfunctions 1 Machine does not brake the wheel 2 001090 during wheel clamping 3 001091 during wheel unclamping 4 Noisy brakes during braking 5 The stator is noisy when it holds the wheel in position TO CHECK THE ELECTROMAGNETIC BRAKE Ø Check if make noise during the braking action Ø Check if pressing the pedal the electromagnetic brake works or not Ø Check if pressing t...

Page 40: ...es 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 SM HOF GEODYNA 7600 Rel D ...

Page 41: ...e switches with service code C56 Ø Remove the two screws securing the brake pedal assembly Ø Remove the weight tray Ø Remove the cover from the electronic box Ø Rotate either the microswitch activator or the micro switch on the brake pedal assembly until the circuit is open Ø Make sure that the circuit closes when the brake pedal is depressed or pressed TO ADJUST AND REPLACE THE SWITCH Ø Lift the ...

Page 42: ... connector X13 Ø Fit the pedal assy to the balancer Ø Turn on the machine and check if the brake and the power clamp switches work fine If the functions are reversed reverse the wires on the connector X13 Ø Mount the pedal assy Ø Mount the weight tray 4 23 CHECK AND REPLACEMENT OF DISTANCE POTENTIOMETER Medium and big Phillips screwdriver 13 and 14mm wrenches 6 1 5h i Defective potentiometer may ca...

Page 43: ...Remove the conical bushing Ø Remove the 13mm nut holding the potentiometer to the frame Ø Remove the potentiometer from the back of the plastic frame Ø Install 10K potentiometer onto bracket and tighten 13mm nut Ø Make sure to insert the antirotational pin into the hole on the rakcket Ø Secure the potentiometer with the nut SM HOF GEODYNA 7600 Rel D ...

Page 44: ...tentiometer may cause the following malfunctions 1 The laser pointer does not work 2 Turning the balancer on the display show E50X when C120 is 1 3 The laser pointer is on but it does not move 4 Turning the balancer on the display shows E300 TO CHECK THE POTENTIOMER Ø Check with service code C75 C80 and C92 TO REPLACE THE POTENTIOMETER Ø Disconnect the power supply from the machine Ø Remove the we...

Page 45: ...se the following malfunctions 1 Turning the machine on several error 50X are displayed 2 The laser does not work at all 3 Laser shoots the dot in one point only TO CHECK THE LASER POINTER Ø Turn on the balancer Ø Check with C123 Ø Turn of the balancer and disconnect it from power supply Ø Remove the weight tray Ø Check if the cable and connector are fine TO REPLACE THE LASER POINTER Ø Turn off the ...

Page 46: ...E SWITCH Ø Check with service code C56 When the wheel guard is lowered it should show 100 TO REPLACE THE SWITCH Ø Disconnect the power supply from the back of the machine Ø Remove the weight tray Ø Remove the cover from wheel guard holder Ø Disconnect the Hood Switch from the PCB and remove the wiring from the connector Ø Remove the two 2 screws holding the switch to the wheel guard box Ø Install ...

Page 47: ...e hood switch may cause the following malfunctions 1 Lowering the wheel guard the wheel does not start 2 The balancer shows E2 3 Machine shows H33 4 Machine shows H35 5 Machine take wrong rim data Ø Disconnect the power supply from the back of the machine Ø Remove the weight tray Ø Remove the cover from wheel guard holder Ø To adjust the the wheel guard inclination lower completely the wheel guard...

Page 48: ...CK THE GAS SPRING Ø Remove the cover of the wheel guard pipe Ø Adjust the eye screw until the free thread distance protruding from the nut outside the backpack is in the range of 10 12 mm Ø Attach the EAA0470G24A weight support to the hose tube Ø Apply the weight of 1 4Kg 3 2lbs medium cone EAM0005D24A the wheel guard has to go down otherwise it means that the gas spring is too hard Ø Apply the we...

Page 49: ...g malfunctions 1 The balancer shows H33 lowering the wheel guard 2 The balancer shows incorrect rim with data 3 The balancer chases weight TO CHECK THE SONAR 1 Make sure that the gauge arm is correctly calibrated taking rim data input of a wheel with steel rim or performing the C92 with the calibration rotor 2 If the rim data entry ARE NOT CORRECT perform the C codes C80 C81 and where available C9...

Page 50: ... not show anything 3 Monitor does not change working function TO CHECK THE TOUCH SCREEN Ø Make sure that the monitor is turned on Ø Make sure that the monitor is well supplied Ø Make sure that all cables are well fitted Ø If the monitor shows E89 go to C56 and check the status of the switches TO REPLACE THE TOUCH SCREEN Ø Turn off the balancer Ø Disconnect all wires from the monitor Ø Remove the fo...

Page 51: ...ngular positions are related to the mass to balance the wheel they are not the positions of the imbalance mass itself 5 2 TO UPDATE THE SOFTWARE The software update must be performed by using the SD card Before starting with any software update make sure that software version in the SD card is the last one or however higher compared to that one running on the balancer The software update must be p...

Page 52: ...alibration data The machine is now ready for use 5 4 RECOMMENDED SERVICE STEPS In case of an error it is recommended to perform some service code to check the system The following are some common service codes for this job C28 Indicate the content of the error record C54 Some more testing for the incremental encoder of the main shaft C55 Check lines Voltage C56 Check the pedal switches The switche...

Page 53: ...1 at the end of the balancing cycle Balancer shows E1 at the end of rim data entry Root cause Inner SAPE gauge arm not in home position Service code C92 C80 C81 C122 C123 C90 Actions to do Re position SAPE gauge arm in home position and press STOP or ESC key to conti nue E2 Wheel guard is not closed Code C28 Complaint After the lowering the wheel guard the balancer does not spin the wheel and E2 c...

Page 54: ...5 812566 Complaint During the calibration C115 or C83 at the end of one of the step 3 or 4 is displayed E6 Root cause Calibration weight not attached to the flange Transducer loosened Service Code C75 AdE1 and AdE2 C115 C84 C88 C90 Actions to do Perform the calibration C115 with the weight on the flange Re adjust the transducer and calibrate with C115 C84 C88 C90 E8 Valve position was not entered Co...

Page 55: ...ttached erroneously to flange Code C28 812570 812571 Complaint During the calibration C115 the balancer shows E16 Root cause Calibration weight attached erroneously to flange Service Code C115 C84 C88 C90 Actions to do Repeat the calibration C115 C84 C88 C90 E17 Wheel slipped on adapter Code C28 492207 Complaint After the wheel spin the wheel stops and the balancer shows E17 Root cause Wheel slipped...

Page 56: ...ns to do Make sure that the vibratory system is properly secured to the cabinet Make sure that the balncer is properly installed E88 The rotating speed of the main shaft exceeds the safety limit Code C28 492208 Complaint During the balancing the screen shows E88 and then the wheel is stopped Root cause The main shaft is rotating at higher speed compared to the expectetionof the micro processor Ser...

Page 57: ... C80 C81 C82 C115 C84 C88 C122 C90 Actions to do Make sure about the proper communication with C74 Perform the C47 changing model and then One more C47 with the correct model Replace the IBP box E144 Check sums of both EEPROMs are wrong Code C28 00016D Complaint After switching on the balancer the screen shows E144 Root cause EEprom of IBP box and Optoencoder are defective IBP box and Optoencoder ...

Page 58: ... the there si not fluctution of power supply during balancer booting Perform the C85 if Optoencoder has been replaced E500 Laser kit failure Code C28 Complaint Turning the machine on the display shows E500 Root cause Incorrect set up of the balancer Laser kit disconnected Defective Laser kit Weight laser board not supplyed Defective weight laser board Service Code C120 C123 C122 C90 C85 C80 C81 C82...

Page 59: ...roper fitting of the laser kit cable Check and replace the laser kit adjust with C123 and calibrate with C122 E623 Virtual dimensions wrong Code C28 620530 Complaint During the C115 the balancer shows E623 Root cause The IBP board has encountered a reversed signal from one or both transducers Service Code C115 C84 C88 C90 Actions to do Check the transducers wiring Perform the C codes above reported...

Page 60: ...place the IBP box 5 6 H ERROR CODES H0 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 H1 Optimisation Not Recommended Further optimization not recommended but feasible H2 Optimisation Recommend Minimisation Weight minimisation is recommended optimisation can achieve no further improve...

Page 61: ... attached If the problem still persists Check if the calibration weight is attached in the correct side If the problem still persists Check if the calibration weight is correct H82 Selftest Disturbed Turn the machine off and back on without touch the unit H90 Measuring Speed Not Reached Check if the brake is released If the problem still persists Make sure that the shaft with clamped wheel can rot...

Page 62: ...em still persists Replace the IBP2 box If the problem still persists Call Snap On C Codes C74 C75 C86 C115 C84 C88 C90 0X001003 PO WRITING 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 Replace the IBP2 box If the problem still persis...

Page 63: ...codes C74 C75 C86 C115 C84 C88 C90 0X001007 PO EEW2 WR 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 Check the IBP box If the problem still persists Call Snap On C codes C74 C75 C85 C86 C122 C115 C84 C88 C90 0X001020 DC OVERRUN Check if the main shaft turns free If the problem sti...

Page 64: ...m still persists Call Snap On C Codes C98 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 0X001024 NOISY SIGNAL FROM TRANSDUCERS DURING MEASURING RUN ...

Page 65: ...0 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 C90 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 If the problem still persists Check the main shaft Optoencoder If the problem still persists Check ...

Page 66: ...Codes C74 C75 C85 0X001039 MAINSHAFT OPTOENCODER LED CURRENT LESS 16 mA TOO LOW Check the main shaft Optoencoder flat cable If the problem still persists Clean the main shaft Optoencoder band If the problem still persists Check the main shaft Optoencoder If the problem still persists Call Snap On C Codes C74 C75 C85 0X001040 SAPE 1D LOW VOLT Check the Distance potentiometer connector and cable If t...

Page 67: ...ter connector and cable If the problem still persists Check the Distance potentiometer If the problem still persists Check the IBP box If the problem still persists Call Snap On C Codes C80 C81 C92 C115 C84 C88 C90 0X001047 2D SAPE INVALID CAL Check the Diameter potentiometer connector and cable If the problem still persists Check the Diameter potentiometer If the problem still persists Check the ...

Page 68: ...C86 C115 C84 C88 C90 0X001055 CAL1 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 C90 0X001056 CAL2 100G WEIGHT LOW Perform the calibration with ...

Page 69: ...Codes C66 C75 C103 C104 C115 C84 C88 C90 0X001059 C1 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 If the problem still persists Call Snap On C Codes C66 C75 C103 C104 C115 C84...

Page 70: ...ill persists Check the IBP box If the problem still persists Call Snap On C Codes C60 C74 C54 C115 C84 C88 C90 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 a...

Page 71: ...eck the motor 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 C60 C74 C54 C115 C84 C88 C90 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 st...

Page 72: ...e problem still persists Check the drive Pulley Optoencoder 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 C74 C98 C115 C84 C88 C90 0X001091 STUCK UNCLAMP Check the Power Clamp pedal If the problem still persists Check the brake pads If the problem still persists Check the electro...

Page 73: ...roblem 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 If the problem still persists Check the IBP box If the problem still persists Call Snap On C Codes C56 C74 C97 C98 C115 C84 C88 C122 C90 0X001094 CLAMP LOCKED Check the Power Clamp pedal If the problem still persists Check the drive...

Page 74: ...ists Call Snap On C Codes C56 C74 C97 C98 C115 C84 C88 C122 C90 0X001096 CLAMP FALL BACK Check the drive pulley If the problem still persists Check the power clamp tie rod If the problem still persists Check the electromagnetic brake 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 ...

Page 75: ...er C functions or P or F functions in some digital balancers to locate the problems Module 81 Command Language This part is a large chunk of the diagnostic codes The command language is used inside software and can not be seen by the operator Some electronic and mechanical failures can introduce grammar conflict in command language then the diagnostic codes started with 81 are generated by software...

Page 76: ...lue too low if a user calibration tool assumed 81X561 c2 value too low if a user calibration tool assumed 81X565 c1 value too low if a 100g weight and calibration rotor assumed 81X566 c2 value too low if a 100g weight and calibration rotor assumed 81X570 c1 value too high if a calibration rotor only assumed 81X571 c2 value too high if a calibration rotor only assumed DESCRIPTION The vectors c1 and...

Page 77: ...d to alert the operator to check mains power line voltage ACTION Check the power line voltage The balancer must be on a dedicated 230 Volt Main Avoid use of long extension cords or share the power source with large electric machinery If the mains power line is OK check the mains power con nections inside the unit C CODE C55 CODE C10 801 C10 804 DESCRIPTION AC power supply is above 265V 15 above 23...

Page 78: ...the microprocessor can not get these signals the balancer does not work ACTION Check the cable and connectors from transducers to microprocessor control board Re torque the transducers A transducer is bad and can not output signal C CODE C103 C104 K CODE C10 705 C10 706 C10 707 C10 708 DESCRIPTION C10705 Optoencoder voltage on shunt resistor is less 2 50 V too low C10706 Optoencoder voltage on shu...

Page 79: ...initialisation step Ø C Beeps which indicates the module object Ø D Pause between the cycle 5 9 3 A PREFIX BEEP Each beep will be indicated by a prefix beep Ø P0 5 5 9 4 B BEEPS OF THE INITIALISATION STEP Beep sequence Description ID MODULE S P1 Error during basic initialisation I2C bus Keyboard keyboard cable 22 Message server 83 Command language 81 S S P1 Error during PO persistent objects based ...

Page 80: ...ource not available timer L L 4S Incremental encoder of power clamp 2A Persistent object not available L L 5S Data conditioning 42 Persistent object not available 3L Extensions keyboard display SAPE brake motor 44 45 46 47 48 Persistent object not available Resource not available timer 3L S Extensions Drive system 49 Persistent object not available Resource not available timer 5 9 6 D PAUSE BETWEE...

Page 81: ...eters 47 Select machine model 54 Checking the incremental encoder on the main shaft 55 Indication the line voltage 56 Indication of the circuit state of the wheel guard switch 57 Indication of temperature 59 Indication of the residual unbalance compensated for using code C84 60 Motor Indication of RPM of main shaft 61 Indication of correction values for user calibration 63 Continuous measurement w...

Page 82: ... Display the dignostic status of weigh laser board 130 Touch screen calibartion 6 3 ENTERING SERVICE C CODES AND OPTIONS Ø C code Enter the FUNCTION screen The service menu is accessed by pressing and holding the STOP button for 5 The Service code will be displayed in the screen Ø Note The service menu is for service personnel only Not for customers The last service code used since power on is dis...

Page 83: ...d simultaneously by pressing the Acknowledgment key FUNCTION STATUS VALUE CODE Unbalance display Dynamic Wheel Dimansion distance 115mm SAPE diameter 15 width 6 5 Wheel type Car in inches Type 1 Weight placement Normal Resolution of unbalance readings Low 0 C1 Suppression of minor unbalance readings On 1 C2 Measurement units of the unbalance readings Grams Ounces 0 1 C3 Compensation of adaptor unb...

Page 84: ...red balance quality for a correction plane has been reached the unbalance below the threshold set using C8 will be read out as zero In some cases this suppression may not be useful and can therefore be switched off temporarily using the precision FINE key or permanently using code C2 The chosen mode of operation can be transferred to the permanent memory Comments None C3Measurement units of unbala...

Page 85: ...e permanent memory Comments The asterisk marks the factory adjusted default C6 Number of revolutions for measurement Options 5 to 25 Number of revolutions per measuring run 10 revs run Factory adjusted value Special function None Description WARNING Reducing the number of measurement revolutions will reduce the accuracy of measurement Measurement accuracy can be evaluated using test mode C63 The c...

Page 86: ...unbalance suppression in grams ounces 3 5 20 g 0 12 0 71 oz C8 Position brake and indexing Off On C11 Start of measurement by closing wheel guard Of f On C13 Unclamping of power clamp locked Off On C22 Actuation direction of pedal for clamping releasing Off On C26 C11 Position brake after measuring run Power Clamp Options 0 No position brake after measuring run 1 Position brake after measuring run...

Page 87: ...g the wheel guard Options 0 No start of measurement by closing the wheel guard 1 Start of measurement by closing the wheel guard Special function None Description The chosen mode of operation can be transferred to the permanent memory Comments The asterisk marks the factory adjusted default C14User calibration Options None Special function None Description Re calibration serves to compensate for s...

Page 88: ...o initiate the second Remove calibration weight and place in storage location Press ESC key to escape the C code Comments None C21Indication of the program version model number Options Indication of model designation Special function None Description Indication of program version number Press Option key to read out the model designation Comments None C22Unclamping of power clamp locked Options 0 U...

Page 89: ... 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 C29 Language selection ...

Page 90: ...on lifting the wheel guard On 1 C5 Number of revolutions for measurement 5 25 10 C6 Threshold for unbalance suppression in grams ounces according to C3 3 5 20 g 0 12 0 71 oz C8 Position brake and indexing On 1 C11 Start of measurement by closing wheel guard On 1 C13 Actuation direction of pedal for clamping releasing Lifting 0 C26 Comments None C28 Display clear error record Options 0 Do not clear...

Page 91: ...ry number of revolution for measurement The Special function can be read out one below the other In step 1 The balancing time is reduce automatically in case the machine is able to measure it in the firsts revolutions of the spin 0 Disable the Adaptive Measuring Cycle 1 Enable the Adaptive Measuring Cycle In step 2 Alternative algoritm to measure the 1st Harmonic of the unbalance Faster then the pr...

Page 92: ...is released This should be done when the final speed is reached Once the START key is released the starting capacitor is turned off and motor voltage is reduced so that speed can be easily maintained If no signal is identified in one or both channels no reading is given for the relative channel and for the phase shift Step Description min value average value max value 1 A bar min Avg From 40 to 60 m...

Page 93: ... marks fall inside the 1 5 revolutions range is 50 With only one zero mark detected inside the range the data recorded cannot be analyzed LH display group Reading Meaning 8 __ Step 8 of Test function C54 active __ _ Divergence between channel A and channel B ___A RH display is count of channel A ___B RH display is count of channel B C55 Indication of the line voltage Options None Special function ...

Page 94: ...C84 Options None Special function None Description Indication of the residual unbalance of the main shaft and drive pulley compensated for using C84 Channel 1 corresponds to front transducer Channel 0 corresponds to rear transducer Maximum unbalance allowed Comments None C60 Indication of RPM of main shaft Options None Special function None Description As soon as measured data is available the cur...

Page 95: ...ane is signalled by the direction indicator inner side 3 The mean of unbalance plus angular location in degrees of the measurements carried out so far whereby the plane is signalled by the direction indicator outer side 4 The mean of vectorial deviation of the measured mean of unbalance after the number of measurements exceeded 9 5 The maximum vectorial deviation of the measured mean of unbalance ...

Page 96: ...ssive measuring runs with pauses Options In step 1 0 to 50 First pause which simulates the weight application init value 50 seconds In step 2 0 to 170 Second pause which simulates the un clamping of the wheel init value 170 seconds In step 3 Only models with power clamp 0 Do not unclamp clamp the wheel 1 Unclamp Clamp the wheel after the second pause Special function please refer to the service fu...

Page 97: ...tion Reset of incremental encoder flags Description Once this code is called up the angular position and incremental encoder status register are display continuously On digital machines the angular position is displayed in initially Pressing the Option key toggles the right hand display between angular location and status register For a short test turn the main shaft at least 2 turns in both direct...

Page 98: ...r in backward direction Comments If this test fails no 23F please check the cabling of the optoencoder micro controller the connectors of the cable clean the incremental encoder sleeve C75Display values from AD converter Options Choosing the AD channel Special function None Description AD input Channel Description AdC 0 0 0 Free AdC 1 1 0 fLED CW LED current control AdC 2 2 0 Free AdC 3 3 0 fBAL T...

Page 99: ...mechanically The voltage of the distance potentiometer is indicated in the right 3 dig field Gauge arm fully returned to home position The reading for distance sape must be 3 10 3 15V Place the gauge arm to the flange edge and adjust the diameter potentiometers mechanically the voltage of the diameter potentiometer is indicated in the left 3 digit field Place the arm to flange edge The reading must be...

Page 100: ...e arm fully returned to home position Step 2 Move gauge arm to calibration position 2 Press acknowledge key to confirm step 2 Gauge arm extended to max extension Step 3 Move gauge head to calibration position 3 Press acknowledge key to confirm step 3 Position 1 of calibration template or head of calibration weight SM HOF GEODYNA 7600 Rel D ...

Page 101: ... relative to the clamping surface of the adaptor on the condition that the gauge arm has already been calibrated Having applied the gauge arm to the outer edge of the adaptor flange press the Acknowledgment key to acknowledge the input No further inputs are necessary Comments Save the calibration data in the the permanent memory using code C90 C82 Calibration of the outer SONAR Options None Special...

Page 102: ... 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 screen will show the green arrows Take a ruler and make sure that distance shown in the screen will be comparable with the one done manually Reapeat the acquiring procedure 3 times to make sure that the value acquired will be stable Press OK to confirm the value Comme...

Page 103: ... difference of the transducer signals the comparative data for readjustment by the operator and temperature compensation the phase shift of the unbalance signal amplifiers and the angular deviation After the 1st step that is the measuring run a beep signal is heard After acknowledgement setting of weight size in step 2 a beep signal is heard in addition to the beep made by the key In step 6 the amb...

Page 104: ...eight is displayed ROTATE THE CALIBRATION TOOL WHEEL WITH 100GR AT 12 O CLOCK Press the ENTER key to enter the value of the test weight Step 3 Press the START button 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 Press the START key to begin the measuring run Step 5 Step Number 5 has not been programmed Press...

Page 105: ... lower the hood and press the START button 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 Press the START button to begin a measuring run Comments Complete this calibration with C84 C88 and C90 SM HOF GEODYNA 7600 Rel D ...

Page 106: ... Complete this calibration with C88 and C90 C84 Compensation of unbalance of main shaft Power Clamp Options None Special function None Description 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 Since the angular position of the drive pu...

Page 107: ... Description To make sure the content is not overwritten by mistake first set display from 0 to 1 by using the option selection Then the copying operation is started by pressing the Acknowledgment key Once copying has been completed the machine is started again automatically Comments None C86 Copy content of serial EEPROM EEP from optoencoder to IBP Options 0 No action 1 Copy from optoencoder EEP t...

Page 108: ... parallel to and vertically above the main shaft The second possibility is to attach the weight in the right hand rim flange and to turn the weight in step 3 so that it is exactly vertical below the main shaft In this position a plumb line can be used as the reference point Possible angle correction is read out in 5 degrees used to be called increments If the angular deviation is more than 5 degree...

Page 109: ...ft still rotates when the wheel guard is open Enter code C97 and then press the START key to run the motor with brake activated in order to remove contamination such as fingerprints from the brake lining thus improving the braking effect of a new solenoid brake As this function causes the brake to heat up quickly it is deactivated automatically after one minute The motor speed is held constant by c...

Page 110: ... screen will show the value of the channel selected 0 Channel 1 Offset DC analog signal 1 Channel 1 1st harmonic wave 2 Channel 1 2nd harmonic 3 Channel 1 3rd harmonic 4 Channel 1 4th harmonic 5 Channel 1 1st harmonic wave phase 6 Channel 2 Offset DC analog signal 7 Channel 2 1st harmonic wave 8 Channel 2 2nd harmonic 9 Channel 2 3rd harmonic 10 Channel 2 4th harmonic 11 Channel 2 1st harmonic wav...

Page 111: ... The frequency is displayed in a range from 100 Hz up to 300 Hz The begin of a new measurement will be detected automatically Comments Only for belt driven balancer 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 di...

Page 112: ... ENTER VALUE key and rotate the shaft until the custom weight is displayed ROTATE THE CALIBRATION TOOL WITH 100GR AT 12 O CLOCK Press the OK key to enter the value of the test weight Step 3 Press the START button to begin the measuring run Step 4 Remove the 100 gram calibration weight and insert it into the right hand plane of the Pruefrotor Press the START key to begin the measuring run SM HOF GE...

Page 113: ...ogrammed Press the ENTER key to advance to the Step 6 The ambient transducer temperature is displayed for 1 second Step 7 Remove the 100 gram weight lower the hood and press the START button to begin a measuring run SM HOF GEODYNA 7600 Rel D ...

Page 114: ...ete C84 after this function CALIBRATION COMPLETE Comments Save the calibration data in the the permanent memory using code C90 C120Enable 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 The setting can be stored to persistent memory by performing code C90 SM H...

Page 115: ...Attach two adhesive weights in the balancing place 4 Set rim dimensions using the gauge arm following the pictures below 5 Enter service code C122 6 Press OK The laser pointer will shot the dot to the inner rim edge 7 Press the left right arrow button to adjust the laser dot to the correct position IMPORTANT The laser dot must be adjusted in front of the weight SM HOF GEODYNA 7600 Rel D ...

Page 116: ...OK to store the outer laser position 12 Press STOP button to exit the service code Comments The setting can be stored to persistent memory by performing code C90 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 t...

Page 117: ...escription On selection the current status is displayed 0 1 Select 0 Standard Screen Select 1 Touch screen First Step Second Step Third Step At the end of the calibration process the machine will reboot itself Comments The setting must be stored to persistent memory by performing code C90 SM HOF GEODYNA 7600 Rel D ...

Page 118: ...118 SM HOF GEODYNA 7600 Rel D ...

Page 119: ...t updated Pag 93 Chapter 6 6 Text and pitcures updated Pag 96 REVISION B May 2015 Chapter 4 28 Text and pitcures updated Pag 46 Chapter 4 29 Text Pag 47 Chapter 5 2 Text and pitcures updated Pag 49 Chapter 5 7 Text updated Pag 62 REVISION A December 2014 Author Stefano Muzzioli Copyright statement This manual and the materials contained within are copyright protected The manual or any section page...

Page 120: ...120 BLANK PAGE__________________________________________________________________________ SM HOF GEODYNA 7600 Rel D ...

Page 121: ...nnection with furnishings performance or use of this material Snapon Equipment Services 309 Exchange Avenue Conway AR 72034 SOE Digital Code SM_HOF GEODYNA 7600 US_18 06_EN_F_TEEWB751AU Snap on Equipment SrL Manufacturing Facility Via Per Carpi 33 42015 Correggio RE Italy Technical alterations reserved All information contained or disclosed in this document is considered confidential and proprietar...

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