HENNESSY INDUSTRIES COATS 1025, Service Manual And Troubleshooting Manual

Page 1: ...615 641 7533 800 688 6359 Manual Part 9111123 03 HENNESSY INDUSTRIES INC Manufacturer of AMMCO COATS and BADA Automotive Service Equipment and Tools Revision 11 05 Service Manual and Troubleshooting Guide 950 1025 1050 1055 950 ProRacer Computer Wheel Balancers ...

Page 2: ...ii Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Direct Drive ...

Page 3: ...uminum Back Panel and PCB Assembly 20 Hood Magnet 21 Magnetic Hood Switch 21 Mechanical Hood Interlock Switch 21 On Off Switch 21 Circuit Breakers 21 Transformer 22 Contactor 22 Auxiliary Contactor Block 22 Bridge Rectifiers 22 A D Arm Assembly 23 Fan Motor Assembly 23 Rotary Shutter 23 Optical Encoder Assembly 23 Drive Motor Assembly 24 Piezo Assembly 24 25 Capacitor Assembly 25 Capacitor 25 Sign...

Page 4: ...ry a cord with a current rating equal to or more than that of the equipment should be used Cords rated for less current than the equipment may overheat Care should be taken to arrange the cord so that it will not be tripped over or pulled 9 Keep guards and safety features in place and in working order 10 Wear proper clothing Safety toe non slip footwear and protective hair covering to contain hair...

Page 5: ...injury Servicing Service should be performed only by COATS trained and authorized service personnel The troubleshooting and service procedures in this manual are arranged to allow rapid and thorough service The steps are prelim inary inspection functional checks repair of failure replacement or adjustment and functional checks Identification of replacement parts required can be accomplished by usi...

Page 6: ...ectrical con tractor for proper installation to local electri cal codes Power outlets must be enclosed in a floor raceway or overhead drop if pedes trian or equipment traffic can damage power cord 4 Plug the balancer to a power source 5 Use an Ohmmeter to check the resistance between the frame of the Balancer and the building ground The resistance should be less than 1 ohm If the resistance measur...

Page 7: ... the SHIFT key and press GM OZ key combination to set the balancer to read in ounces 6 Install a 4 oz weight on the outer rim of the test wheel 7 Choose the DYNAMIC balancing mode 8 Lower the guard hood 9 Push the START button The machine should now cycle If the machine does not cycle see BALANCER DOES NOT CYCLE 10 The balancer should come up to speed coast for several revolutions and then brake t...

Page 8: ...e machine should now cycle This cycle is referred to as the zero spin cycle 8 The balancer should come up to speed coast for several revolutions and then brake to a stop 9 The display should now read CAL 4 10 Position the wheel so the display for the center position LED for the outside right plane is flashing 11 Add a 4 ounce weight to the 12 o clock position on the outside right of the wheel 12 P...

Page 9: ...achine will generate one of the following error codes and use the weight reading LEDs to display the error code An explanation of these codes and a troubleshooting procedure follows each code Err Displayed when an entered parameter entered is not in the acceptable range or not entered Err Hod Displayed when the hood switch is not closed the hood is up the hood switch is bad when the machine cycle ...

Page 10: ...ng and releasing the zero 0 key At this time CDE will appear in the left weight display The two digit code is then entered and appears in the right weight display There is a slight delay after the second digit is entered at which time the display blanks temporarily and the code is executed There is approximately a 10 second window from the time CDE appears for the operator to enter the 2 digit cod...

Page 11: ...eight dis play To exit this code enter code 50 52 Piezo OutputTest 300 RPM Used to verify that the output of the piezo are consistence through several spins Refer to the checking procedure piezo output 53 Piezo OutputTest 200 RPM Refer to the check ing procedure piezo output 99 Counter Reset This code resets the counter on the 950 1025 1050 and 1055 Troubleshooting Section for Models 950 1025 1050...

Page 12: ...on No Yes See the troubleshooting procedure DISPLAY DOES NOT LIGHT Does the display light No Yes No Reset the tripped breaker Did the breaker trip again Has the 1A breaker for the fan motor tripped Yes Unplug the machine and disconnect the fan motor lead from the circuit breaker and reset the breaker Plug in the machine and turn the power switch ON Did the circuit breaker trip Yes Is the fan motor...

Page 13: ...to ACCURACY PROBLEMS flow chart and test again Remove burrs and dirt and test again Replace defective parts and test again Yes Did the balancer pass the ACCURACY CHECK Yes Yes No No No No Yes Using a dial indicator check the runout on the mounting surface of the motor face plate the runout of the arbor shaft Are both total indicated runouts greater than 001 Yes Try mounting the wheel with a new ce...

Page 14: ...g at the piezo and at the P C B plug for good connections Repair defective connection s Good Yes Replace the drive motor assembly See Replacement Procedure No Replace the PCB See Replacement Procedure Did this correct the problem Adjust springs See step 19 in DRIVE MOTOR REPLACEMENT PROCEDURE Did this correct the problem Yes Check replace piezos see the procedure on page 32 Did this correct the pr...

Page 15: ...al 4 950 or terminal 64 1050 on the forward contactor Is there 220VAC between terminals 4 6 on the forward contactor Is there 220VAC between terminals 4 6 on the brake contactor Yes Yes No Yes No No Check the continuity of the power cord from the terminals to the appropriate connection on the brake contactor Repair or replace the defective wire or connection Checks Bad Checks Good Breaker Trips Ch...

Page 16: ...ure Does Not Trip Turn the power switch OFF and unplug the machine Disconnect the white violet wire from the forward contactor reset the breaker Plug in the machine turn the power switch ON press the start button Replace the PCB See Replace Procedure Trips Manually close the forward contactor check for 230 VAC on terminals 3 to 5 5 to 13 13 to 3 of the forward contactor Voltage Not Present Turn th...

Page 17: ...er to check from terminal 53 on the forward contactor to terminal 74 on the brake contactor Is this a Model 1050 No Yes If this is a single phase unit try repalcing the capicator assy See Replace Procedure After verifying the integrity of the motor connections at the contactor Replace defective motor assembly See Replace Procedure Motor Does Not Run Repair or replace defective jumper wire or conne...

Page 18: ... See Replace Procedure Disconnect the wire from A2 on the brake contactor Use an Ohmmeter to check continuity from A1 on the brake contactor to terminal 5 on the connector on the right side of the PCB Connect the wire to terminal A2 on the contactor Replace the PCB See Replace Procedure No Yes No Yes Less Than 1 Ohm Repair or replace defective wire or connection More Than 1 Ohm More Than 1 Ohm Les...

Page 19: ...defective wireorconnection s associatedwiththeterminalsjustchecked Forward contactor terminal 1 to brake contactor terminal 2 Forward contactor terminal 5 to brake contactor terminal 1 Forward contactor terminal 3 to brake contactor terminal 63 Forward contactor terminal 73 to brake contactor terminal 64 Forward contactor terminal 53 to brake contactor terminal 74 Forward contactor terminal 83 to ...

Page 20: ... machine does the Balancer Beep for 20 seconds No No Yes Return the arm to the Home position The end of the arm should be resting against the guide bushing Power cycle the machine Calibrate the A D Arm See Calibration Procedure No Yes Does the balancer hold the initial A D dimensions Key Shift 0 1 0 Does the potentiometer for A left weight display reading between 05 and 30 the D right weight displ...

Page 21: ...check the shutter disc for blockage then check the following voltages 2 When reading the voltages on the white green wires turn the faceplate slowly by hand The low volt age must be less than 7VDC The high voltages must be greater than 4 0VDC 3 Voltage readings are taken with all optical encoder wires connected Lead Color Voltage Green to Violet GND 2 4 5VDC Yellow to Violet Less than 7VDC greater...

Page 22: ...pproximately the same 4 8 ohms or 1 ohm If one leg reads different than the other two use the Forward Circuit diagram and check for a bad connection bad wire crimp or high resistance through the contactor or motor winding To check the braking circuit disconnect the rectifier from the 83 Place your ohms leads across 53 and 83 Press and hold the brake contactor and check the read ing It should be ap...

Page 23: ...isplay 1150 Right Display 1050 4 Repeat step 3 above for five more spins Remember you are looking for consistency of the read ings 5 If the Dynamic value fluctuates more than 10 check and or replace the left piezo Note The following steps will allow both right piezos to be tested individually by unpluging one at a time The 850 only has two piezos and may be tested by reviewing the left and right r...

Page 24: ...h metal plate on the bottom if not replace the contactor New Repair Procedure The models 950 1025 1050 and 1055 are different from other COATS balancers in that the Front Panel Printed Board assembly has been designed so that the PCB Assembly and the Touch Panel Aluminum Back Panel can be replaced sepa rately Refer to the Trouble Shooting section for diag nostic instructions for isolating the defe...

Page 25: ...o 2 switches are wired differ ently one is normally open and the other is normally closed Refer to the wiring diagram for correct wiring 6 Replace the sheld 7 Plug in the balancer 8 Check to make sure that the motor starts with the hood down but not with it up 9 Perform the FUNCTIONAL CHECKS On Off Switch 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Disconnect wiring to on o...

Page 26: ...ailure to perform this important step can result in damage to contactor drive motor balancer wiring and printed circuit board See Wiring Diagram Note For ease of installation the motor wires are numbered corresponding to the motor ter minal numbers on the wiring diagram 9 Install Power Panel 10 Pull power cable out of chassis and tighten power cable clamp 11 Install weight tray and weight tray shi...

Page 27: ...nstall weight tray and weight tray shield and plug in balancer 9 Perform PRELIMINARY INSPECTION and FUNC TIONAL CHECKS Rotary Shutter 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Remove rear end bell cover 4 Remove the 3 8 by 3 8 shoulder bolt and the rotary shutter Note Some motors will have a plastic shim part number 8 143988 between the rotor and the rotary shutter Leave ...

Page 28: ...ezos have the ball molded into the top casting 16 Install motor 17 Install 5 16 18 X 1 washer head screws holding flex plate to chassis 18 Install piezo springs piezo retainers and 3 8 16 Nyloc nuts 19 Tighten the Nyloc nuts until the distance from the top of the motor cradle to top of the piezo spring retainer is two 2 inches 20 Connect fan motor plug 21 Connect optical encoder plug 22 Connect dr...

Page 29: ...resis tor connected across its terminals If both new capacitors have resistors cut one out 6 Install capacitors 7 Connect plug 8 Install weight tray weight tray shield and plug in balancer 9 Perform PRELIMINARY INSPECTION and FUNC TIONAL CHECKS Signal Harness 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Remove Front panel PCB Assembly 4 Disconnect plugs from PCB assembly 5 D...

Page 30: ...of the pulley groove 7 Press and hold the SHIFT key and press 0 Press 1 and the 0 8 Using a small screw driver rotate the end of the potentiometer shaft until the left weight display reads between 10 and 20 9 Lock the pulley in place by tightening the cap screw on the pulley Do not over tighten Over tightening may cause the pulley to crack 10 See A D ARM CALIBRATION PROCEDURE on page 10 11 11 See ...

Page 31: ...ss 1 and the 0 9 Using a small screw driver rotate the end of the potentiometer shaft until the right display reads between 50 and 60 10 Lock the pulley in place by tightening the cap screw on the pulley Do not over tighten Over tightening may cause the pulley to crack 11 Turn the plunger pin out until the D pot value is 0 05 to 0 10 than the value that was obtained in step 9 of this procedure 12 ...

Page 32: ...o the same spec as the 950 1050 which is 2 All other troubleshooting proce dures remain the same as the 950 1050 CAUTION 28 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Direct Drive Motor Service Kit Instructions Hennessy now has available a service motor kit for the 950 1025 1050 1055 Contactor Solid State Balancers which will allow everyone to use one part number when ordering a m...

Page 33: ...Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 29 Direct Drive 950 Pro Racer Wiring Diagram ...

Page 34: ...30 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Direct Drive 950 Wiring Diagram Contactor Style ...

Page 35: ...Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 31 Direct Drive 1050 Wiring Diagram Contactor Style ...

Page 36: ...t the hood bracket on the balancer and hood bar have been redesigned These parts are not reverse compatible therefore you will still need to carry the previous mag netic switches magnets 8305050 8112414 in your service inventory Please use caution when installing the hood bar into the machine being careful not to damage the switch lever with the actuating rod Note a piece of Styrofoam has been ins...

Page 37: ...Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 33 Direct Drive Mechanical Hood Switch Diagram ...

Page 38: ...34 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Direct Drive 1050 Wiring Diagram Motor Controller Style Magnetic Switches ...

Page 39: ...Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 35 Direct Drive ...

Page 40: ...36 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Direct Drive 1050 Wiring Diagram Motor Controller Style Mechanical Switches ...

Page 41: ...Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 37 Direct Drive ...

Page 42: ...plying the control signal The Diagnostic Tool is connected in line with the control cable from the CPU Motor Control output to give an indication of the presence of the Control signal Mode 1 Mode 2 Mode 3 Solid State Motor Controller PCB Solid State Motor Controller PCB Solid State Motor Controller PCB SIGNAL DETECT HENNESSY SPIN STOP MOTOR CONTROLLER CONTROL FORWARD REVERSE ON OFF INDUSTRIES INC ...

Page 43: ...mer to terminal 3 of the Motor Controller Is there 220VAC between terminals 1 3 on the power supply connector on the Motor Controller pcb Is there 220VAC between terminals 1 2 on the T1 terminal ot the MC pcb Yes Yes No Yes No No Check the continuity of the power cord from the terminals to the appropriate connection on AC plug Repair or replace the defective wire or connection Checks Bad Checks Go...

Page 44: ... MC test box to MC PCB Does motor spin Replace Main PCB Yes To make this check use the MC test box to activate the spin voltage during test MC Motor Controller MC Test Box 8112078 No Check continunity of interlock switch with hood down at p7 Is there continunity No Yes Repair replace the hood switch or wiring No No Do location LEDs move when wheel is rotated No Yes Troubleshoot Encoder system Bala...

Page 45: ... the given location Yes No Yes Use MC test box will motor spin stop No Test Comm Cable Replace the Main PCB Yes Test Comm cable Replace Motor Controller Does an error message appear Do readings appear on display after wheel has stop Does wheel attempt to stop Yes No No MC Motor Controller MC Test Box 8112078 Direct Drive Balancer Does Not Brake Solid State Motor Controller Model ...

Page 46: ...onnect the black lead to the right side of the diode and the red lead to the left In this configuration your multimeter should read an open OL if the diode is good same for Ohmmeter The multimeter display should look the same as it does when the leads aren t connected to anything If the diode does not read open in this step then it is bad ICTest Use a multimeter to check for ground shorts on IC s ...

Page 47: ...z weight to make sure the balancer giving the correct reading Distance Gauge Tape Placement Also know as Optimizing A If there is a problem with the accuracy check this is the procedure to correct the problem Hub Centric Wheel A wheel that is centered to the axle by the center hole in the wheel Lug Centric Wheel A wheel that is centered to the axle by the lug bolts Rotational Check This is a proce...

Page 48: ...9111123 03 11 05 Copyright 1992 Hennessy Industries and COATS All Rights Reserved Printed in USA ...