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Hofmann Megaplan MS400-2, Technical Maintenance Manual

The Hofmann Megaplan MS400-2 Technical Maintenance Manual is a comprehensive resource for maintaining and servicing your vehicle. This detailed manual covers all aspects of the MS400-2, allowing you to ensure optimal performance and longevity. Download this manual for free from manualshive.com, and keep your vehicle in top shape for years to come.

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Hofmann Megaplan GmbH

 

A 5302 HENNDORF - AUSTRIA 

Hauptstraße, 67 - Tel. (+43) 6214 646612 

Fax (+43) 6214 646622 - EMail: [email protected]

 

TECHNICAL 

MAINTENANCE

MS400-2 Version C (Type 0967)

MS400-2P Version D (Type 1001)

19.08.2013

English

Summary of Contents for MS400-2

Page 1: ...n GmbH A 5302 HENNDORF AUSTRIA Hauptstraße 67 Tel 43 6214 646612 Fax 43 6214 646622 EMail HM mail hofmann megaplan com TECHNICAL MAINTENANCE MS400 2 Version C Type 0967 MS400 2P Version D Type 1001 19 08 2013 English ...

Page 2: ......

Page 3: ... 2 C M400P 2 D The wheel balancer can operate at 115 V 50 60 Hz or 230 V 50 60 Hz To change the power supply voltage make the following modifications No Description Image 1 Replace the motor 2 Replace the capacitor SHEET 001 3 Replace the power board ...

Page 4: ...LOGIC BOARD INITIALISATION Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Turn on the machine while holding down the button 2 Press to confirm 3 Initialisation done SHEET 002 ...

Page 5: ...SELF DIAGNOSTICS Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Press 2 Press 3 Press SHEET 003 ...

Page 6: ...he right hand display with a number between 0 and 255 Turning the wheel in the rotation direction the number displayed must increase Turning the wheel in the opposite direction the number must decrease In one full turn of the wheel the number 0 must appear once only Press 7 Statistical control parameter for internal use not important Press ...

Page 7: ... R1 It must be equal to 200 30 with the shaft bare Press 9 Indicates the output of the piezo sensor R2 It must be equal to 200 30 with the shaft bare Press 10 Displays the DISTANCE sensor value Press 11 Displays the DIAMETER sensor value Press ...

Page 8: ...12 Displays the WIDTH sensor value Press 13 End of self diagnostics To end self diagnostics at any time press ...

Page 9: ...SPINDLE UNBALANCE RESET Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Press 2 Press 3 Press SHEET 004 ...

Page 10: ...4 Press 5 Press in sequence 6 To proceed with the unbalance reset Press spin with the shaft bare 7 Spindle unbalance reset complete ...

Page 11: ...8 To view the unbalance and timing values used to reset the spindle unbalance continue as follows Press 9 Press 10 Press 11 Press ...

Page 12: ...d the timing value right hand display used to reset the inside unbalance are shown IN LED on Press 14 The unbalance value left hand display and the timing value right hand display used to reset the outside unbalance are shown OUT LED on Press 15 End of value reading ...

Page 13: ...TO ENABLE AUTOMATIC GAUGES Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Press 2 Press 3 Press SHEET 005 ...

Page 14: ...4 Press in sequence within 5 seconds from when has been pressed 5 Press 6 Press 7 select ON by pressing ...

Page 15: ...8 Press to confirm 9 Press to cancel self diagnostics in any phase ...

Page 16: ...DISTANCE SENSOR ADJUSTMENT Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Remove the weight tray see the relative instructions 2 Press 3 Press SHEET 006 ...

Page 17: ...4 Press 5 Press 6 Press 7 Press ...

Page 18: ...ress 10 The wording diS appears on the left display while a number appears on the right display which varies when the distance gauge is moved 11 Back off the screws fastening the pulley on the potentiometer shaft ...

Page 19: ...12 Leave the gauge in rest position 13 Turn the potentiometer shaft with a screwdriver holding the pulley firm 14 until reading a number between 5 and 15 15 Tighten the screw ...

Page 20: ...16 Refit the weight tray 17 Calibrate the automatic gauges ...

Page 21: ...00P 2 D No Description Image 1 After DISTANCE SENSOR ADJUSTMENT press 2 The wording dIA appears on the left display a number appears on the right display which varies when the gauge is turned 3 Pull out the gauge and rest it on the adapter surface SHEET 007 ...

Page 22: ...4 Back off the screw that secure the potentiometer on the pulley 5 Turn the potentiometer shaft with a screwdriver holding the pulley firm 6 until reading a number between 5 and 15 7 Tighten the screw ...

Page 23: ...8 Refit the weight tray 9 Calibrate the automatic gauges ...

Page 24: ...M400 2 C No Description Image 1 The wheel balancing machine is packed with the threaded terminal removed 2 Carefully clean the inside of the adapter where the terminal will be secured 3 Allen wrench provided threaded terminal SHEET 008 ...

Page 25: ...4 Insert the threaded terminal in the adapter 5 Lock the threaded terminal by fully screwing down the hexagonal screw using the wrench provided tighten it well 6 Fitted threaded terminal ...

Page 26: ...C M400P 2 D No Description Image 1 The wheel balancing machine is shipped with the microswitch already fitted in the correct position 2 Insert the guard pipe in the bushing 3 Hold the bushing in position while inserting the pipe SHEET 009 OK ...

Page 27: ...4 If the bushing is free to move the microswitch may be damaged 5 Close the guard 6 Position the ring with the head of the microswitch in the slot 7 Tighten the first grub screw ...

Page 28: ...8 Open the guard 9 Tighten the second grub screw 10 Fit the spring 11 Fitted guard ...

Page 29: ...12 SONAR WIDTH If present connect the cable to the relative connector on the rear of the base ...

Page 30: ...RAY REMOVAL Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Remove the 2 front caps of the weight tray 2 Remove the rear cap of the weight tray 3 Undo the 2 front screws of the weight tray SHEET 010 ...

Page 31: ...ar screw of the weight tray 5 Push the weight tray slightly to the left and then lift it to prevent it from jamming against the pulley of the automatic gauge 6 Completely remove the weight tray 7 Weight tray removed ...

Page 32: ...NERATOR REPLACEMENT Models M400 2 C No Description Image 1 Disconnect the flat cable connector 2 Detach the anti rotation spring 3 Remove the phase generator by undoing the hexagonal screw turning it clockwise SHEET 011 ...

Page 33: ...4 To refit it operate in reverse order from removal ...

Page 34: ...MENT Models M400P 2 C M400P 2 D No Description Image 1 Fit the SE spacer on the terminal complete with collar 2 Close the spindle the encoder becomes visible through the window on the plate 3 Detach the anti rotation spring SHEET 011 ...

Page 35: ...ndoing the hexagonal screw turning anticlockwise 5 Disconnect the flat cable 6 Detach the board from the Nylon spacers 7 Remove the encoder passing the board through the rectangular hole of the plate positioned near the spacers ...

Page 36: ...8 To refit perform the operations in reverse order ...

Page 37: ...00P 2 D Nr Description Image 1 Remove the weight tray see the relative instructions Remove the encoder see the relative instructions 2 Mark with a felt tip pin the position of the plate on the base this will allow correctly aligning the plate when refitting it SHEET 012 ...

Page 38: ...ndo the 2 screws A M400P 2 If the wheel balancing machine is fitted with a pneumatic spindle also undo the 3 screws B 4 Undo the 2 screws C 5 Disconnect the 2 potentiometer cables from the board A A B C C ...

Page 39: ...6 Remove the gauge unit 7 M400P 2 CYLINDER UNIT REMOVAL Close the compressed air and disconnect the tube 8 Turn the cylinder unit 90 90 ...

Page 40: ...9 To remove the cylinder unit the internal plate must be positioned with one of the two round sides facing up 10 Remove the cylinder unit pulling upward 11 REFITTING Fit the cylinder unit vertically ...

Page 41: ...12 Turn the cylinder unit 90 13 Reposition the gauge unit use the mark previously made on the base 14 Screw in the 2 screws A and the 2 screws C 90 A C ...

Page 42: ...15 Screw in the 3 screws B that support the cylinder unit without tightening them 16 Alignment shim part no 22FP85322 17 Fit the alignment shim into place SPESSORE PER ALLINEAMENTO 22FP85322 B ...

Page 43: ...18 Reconnect the tube and open the compressed air 19 Open the spindle 20 Tighten the 3 screws ...

Page 44: ...21 Close the spindle 22 Remove the shim 23 Reconnect the potentiometer cables ...

Page 45: ...24 Refit the encoder Refit the weight tray ...

Page 46: ... the weight tray see the relative instructions Remove the gauge unit and the cylinder unit see the relative instructions Remove the encoder see the relative instructions 2 Disconnect the motor capacitor and power supply cables and the flat cable Disconnect the piezo extension cable SHEET 013 ...

Page 47: ...3 Undo the 4 upper retaining screws 4 Undo the 6 remaining spindle unit retaining screws 5 Gently remove the spindle unit ...

Page 48: ...6 Spindle unit 7 Unscrew and remove the nut with relative washer pack of the dynamic piezo 8 Loosen the internal nut of the static piezo ...

Page 49: ...9 Unscrew and remove the nut with relative washer pack of the static piezo 10 Undo the spindle plate retaining screws 11 Remove the spindle unit from the box ...

Page 50: ...12 Replace the piezo sensors 13 Position the static piezo 14 Position the dynamic piezo ...

Page 51: ...h the box and lock the two retaining screws 17 To lock the piezo position the following parts in sequence large flat washer 4 Belleville washers with the concave side facing the large washer small flat washer nut These must be tightened with a 400 kg cm torque wrench ...

Page 52: ...of the dynamic piezo with a 400 kg cm torque wrench 19 Tension the tie rod of the static piezo screwing down the nut and then turn it a further 180 20 Check that the nut that joins the threaded bars is locked with a 400 kg cm torque wrench 180 ...

Page 53: ...21 Lock the nut and relative washer pack of the static piezo with a 400 kg cm torque wrench 22 Cover both piezos with an abundant layer of silicone 23 Gently refit the spindle unit in the base ...

Page 54: ...24 Screw in without tightening the 4 upper self threading screws 25 Screw in without tightening the 6 side self threading screws 26 Tighten the 4 upper screws with a 120 kg cm torque wrench ...

Page 55: ...cm torque wrench 28 Reconnect the motor capacitor and power supply cables and the flat cable Reconnect the piezo extension cable 29 Refit the encoder the gauge unit the cylinder unit and the weight tray 30 Recalibrate the wheel balancing machine ...

Page 56: ...POWER BOARD REPLACEMENT Modeo M400 2 C M400P 2 C M400P 2 D Nr Description Image 1 Remove the weight tray see relative instructions 2 Disconnect the motor cable 3 Disconnect the power cable SHEET 014 ...

Page 57: ...4 Disconnect the potentiometer cables 5 Disconnect the flat cable 6 Disconnect the relay board cable if present ...

Page 58: ...7 Disconnect the sonar cable 8 Disconnect the computer board power cable sonar signals 9 Disconnect the protection microswitch cable ...

Page 59: ...10 Detach the board from the Nylon spacers 11 Fit the new power board performing the operations in reverse order ...

Page 60: ...rim on the shaft Example 6 x 15 1 2 Take the exact measurements of the wheel mounted Caution Presetting of incorrect dimensions would mean that the machine is not correctly calibrated therefore all subsequent measurements will be incorrect until a new self calibration is performed with the correct dimensions 3 Press SHEET 015 ...

Page 61: ...4 Press 5 Press 6 Press 7 Press ...

Page 62: ... weight on the outside in any angular position Press 10 Shift the sample weight from the outside to the inside keeping the same angular position Press 11 Turn the wheel until the sample weight is in the 12 o clock position Press ...

Page 63: ...12 End of calibration ...

Page 64: ...ENCODER COUNT TEST Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Press 2 Press 3 Press SHEET 016 ...

Page 65: ...position is shown on the right hand display with a number between 0 and 255 Turning the wheel in the rotation direction the number displayed must increase Turning the wheel in the opposite direction the number must decrease In one full turn of the wheel the number 0 must appear once only Press to exit self diagnostics ...

Page 66: ... OUT 60 OUT POS at low at 6 o clock IN 60 OUT 0 IN POS at low at 6 o clock Permitted tolerance on 60g 5 Residual tolerance max 5g ADAPTER TEST With the wheel perfectly balanced tilt 180 and measure the unbalance values MAX ERR 6 gr It is advisable to use a new wheel of good quality for this test The error due to tilting should be less than 6g Replace the centring cones if necessary SHEET 017 ...

Page 67: ...MACHINE OSCILLATION TEST Models M400 2 C M400P 2 C M400P 2 D No Description Image 1 Press 2 Press 3 Press SHEET 018 ...

Page 68: ... 10 spins with automatic calculation and display of the maximum oscillation If you wish to run more than 10 automatic spins press and to select the desired number in the range 5 999 7 Oscillation max permitted 2 g i e 4 grams on the indicator To return to the measuring frame press ...

Page 69: ...DISTANCE GAUGE CALIBRATION Model M400 2 C M400P 2 C M400P 2 D No Description Image 1 Mount the calibration tool on the shaft 2 Press 3 Press SHEET 019 ...

Page 70: ...4 Press 5 Press 6 Press 7 Press ...

Page 71: ...8 Press 9 Leave the distance gauge in rest position and press 10 Move the gauge up against the calibration tool in line with the adapter surface and press 11 Return the gauge to rest position ...

Page 72: ...12 Calibration done ...

Page 73: ...DIAMETER GAUGE CALIBRATION Model M400 2 C M400P 2 C M400P 2 D No Description Image 1 Mount the calibration tool on the shaft 2 Press 3 Press SHEET 020 ...

Page 74: ...4 Press 5 Press 6 Press 7 Press ...

Page 75: ...8 Move the gauge to the 80mm measuring position bottom notch and press 9 Move the gauge to the 150mm measuring position top notch and press 10 Return the gauge to rest position 11 Calibration done ...

Page 76: ...WIDTH SONAR CALIBRATION Model M400 2 C M400P 2 C M400P 2 D No Description Image 1 Press 2 Press 3 Press SHEET 021 ...

Page 77: ...4 Press 5 Press 6 With the gauge in rest position measure the distance from the 0 of the distance gauge to the 0 of the width sonar 7 Enter the distance measured by pressing and ...

Page 78: ...If after calibration the control detects a measuring error of more than repeat the calibration changing the distance value tolerance 20 mm with respect to the value measured with a rule until obtaining a correct width value ...

Page 79: ...C M400P 2 C M400P 2 D No Description Image 1 Remove the weight shelf see relative instructions Remove the gauge unit see relative instructions Remove the encoder see relative instructions 2 Detach the spring 3 Detach the pedal rod SHEET 022 ...

Page 80: ...4 Pull the brake rod out from the top 5 Unscrew the fastening nut 6 Remove the brake 7 Mechanical brake removed ...

Page 81: ... 2 C M400P 2 C M400P 2 D No Description Image 1 Mount the calibration tool on the shaft 2 Move the gauge up against the calibration tool in line with the adapter surface and press 3 After acquiring the dimensions hold down SHEET 023 ...

Page 82: ...4 Check that the distance measured is 212 3 ...

Page 83: ...BELT TENSION CHECK Model M400 2 C M400P 2 C M400P 2 D No Description Image 1 Machine without weight tray see Weight tray removal 2 Hold the wheel locked and press SHEET 024 ...

Page 84: ...3 If the belt tension is correct the motor pulley must not turn ...

Page 85: ...LT TENSION ADJUSTMENT Model M400 2 C M400P 2 C M400P 2 D Tools required Pin wrench UNI ISO 2982 2983 Nr Description Image 1 Remove the weight tray 2 Release the power plate cables from the clips SHEET 025 ...

Page 86: ...3 Loosen the 3 power plate retaining screws 4 Place the power plate on the bottom of the base 5 Accessing the motor ...

Page 87: ...6 Loosen the two fastening nuts on the left hand side of the motor 7 Use the pin wrench illustrated 8 Position the pin wrench on the socket wrench and then adjust the belt tension ...

Page 88: ...ts 10 If possible check the belt tension with suitable instruments 1 1 In service conditions the belt tension is between 380 and 400 Hz When installing a new belt overtension it up to 450 Hz to recover the natural belt elongation that occurs in the first 48 hours ...

Page 89: ...escription Image 1 Use a megohmmeter with a full scale of min 3000 MΩ 2 Test the insulation between the dynamic sensor poles between the blue and the yellow wires MIN 2000 MÙ 3 Test the insulation between the yellow wire and the machine body MIN 2000 MÙ SHEET 026 ...

Page 90: ... 2000 MÙ 5 Test the insulation between the static sensor poles between the white and the yellow wires MIN 2000 MÙ 6 Test the insulation between the yellow wire and the machine body MIN 2000 MÙ 7 Test the insulation between the white wire and the machine body MIN 2000 MÙ ...

Page 91: ...8 Discharge the piezo sensors before connecting them to the electronic circuit ...

Page 92: ...emove the weight tray see relative instructions Remove the encoder see relative instructions Remove the SE terminal see relative instructions 2 Remove the gauge unit and the cylinder unit see relative instructions 3 Remove the 2 grub screws that fasten the external ring nut SHEET 027 ...

Page 93: ...wrench to act on the external ring nut 5 Hold the rod locked with a flat jaw wrench 6 Remove the ring nut You will need to use force when removing the ring nut as the rod threading will have been scratched by the fastening grub screws ...

Page 94: ...7 Remove the air springs and plate 8 Using a needle file file off the burr on the rod threading in the ring nut locking area 9 Fit the air springs ...

Page 95: ...10 Fit the plate 11 Fit the ring nut holding the rod locked with the flat jaw wrench 12 Lock the ring nut by screwing it down with the adjustable toothed jaw wrench ...

Page 96: ...ng grub screws 14 Refit the gauge unit and the cylinder unit see relative instructions 15 Refit the SE terminal see relative instructions Refit the encoder see relative instructions Refit the weight shelf see relative instructions ...

Page 97: ...VDD UNIT REFASTENING Model M400 2 C M400P 2 C M400P 2 D SHEET 028 ...

Page 98: ...Model M400P 2 C M400P 2 D No Description Image 1 Continue with Weight tray removal Magnetic encoder replacements Gauge unit and cylinder removal 2 Gauge units and cylinder removed 3 Remove the motor fastening nuts SHEET 029 ...

Page 99: ...4 Remove the motor 5 Remove the belt 6 Replace the belt ...

Page 100: ...7 Fit the motor without locking the nuts 8 Identify the hole on the wall for belt tension 9 Insert the screwdriver and tension the belt also see the specific instructions ...

Page 101: ...ll act on the motor tie rods using a jaw wrench 11 Lock the motor 12 Insufficient tautness may cause rapid belt wear The specific instructions for the belt tensioning and slipping check procedures are given in the maintenance manuals ...

Page 102: ...POWER LAYOUT DIAGRAM Model M400 2 C M400P 2 C SHEET 030 ...

Page 103: ...POWER LAYOUT DIAGRAM Model M400P 2 D SHEET 030 ...

Page 104: ......

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