John Bean EEWB304B, Service Manual

Page 1: ...WHEEL BALANCER Service Manual EEWB502B C EEWB503B EEWB304B ...

Page 2: ...ed confidential and proprietary by Snap on Equipment All manufacturing use reproduction and sales rights are reserved by Snap on Equipment and the information contained herein shall not be used in whole or in part without the express written consent of Snap on Equipment ...

Page 3: ... READ OR RESET PRODUCTIVITY OF USER 1 6 F P 50 READ OUTPUT VOLTAGE OF THE DISTANCE POTENTIOMETER OF SAPE 1 6 F P 51 READ OUTPUT VOLTAGE OF THE DIAMETER POTENTIOMETER OF SAPE 1 6 F 52 READ OUTPUT VOLTAGE OF THE WIDTH POTENTIOMETER 1 7 F P 53 DISPLAY TEST 1 7 F P 55 CHECK AC AND DC VOLTAGES 1 7 F P 56 CHECK PEDAL AND HOOD SWITCHES ON POWER CLAMP 1 7 F P 59 DISPLAYS THE UNBALANCE OF THE BARE SHAFT 1 ...

Page 4: ...CTRIC BRAKE PEDAL ADJUSTMENT 1 23 ELECTROMAGNETIC MOTOR BRAKE ADJUSTMENT 1 23 MECHANICAL BRAKE CABLE ADJUSTMENT 1 23 MECHANICAL BRAKE CABLE 1 23 MOTOR REMOVAL 1 23 HOOD SWITCH CAM SPRING 1 23 VPI SYSTEM III IV 1 23 HOOD SWITCH CAM SPRING 1 24 VPI SYSTEM II SOT Low Digital 1 24 HOOD SWITCH CAM SPRING 1 24 VPI SYSTEM I 1 24 chapter 2 diagnostic codes 2 1 In Field Reprogramming of Balancer 2 2 2 2 Re...

Page 5: ... oz TEST PRODUCES READINGS OUT OF TOLERANCE 5 Remove the tire and wheel assembly from the balancer 6 Check the tapered surfaces of the basic centering device and balancer shaft They should be clean and smooth Clean and retest Check all mounting accessories cones wingnut etc making sure each fit on the shaft snug there should be no play between the shaft and mounting accessories 7 If the test still...

Page 6: ...for ripple or drift may indicate faulty regulation or failing PCB s Ensure there is enough power and a good ground Inputs Check for proper Encoder and Transducer signals 4 Output Once all voltages and signal levels are present a proper output can be expected 5 Check for any registered diagnostic codes using F P 28 in most cases these codes will point to a solu 6 tion TOOLS REQUIRED WHEN SERVICING ...

Page 7: ...ck to the dynamic mode 19 Enter ALU S 1 plane mode press the balancing mode key to exit back to the dynamic mode 21 Check revision of balancing kernel software 22 Power clamp lock JBC 3 power clamp model only 28 Check last 10 kernel error messages Clean all recorded error codes 36 Toggle reading the positions and angles of left and right weights 43 Read or reset re setable counter 44 Read or reset...

Page 8: ...plays SPN 1 Operator spins the shaft just like ordinary balancing When the machine is taking data and calculation it displays CAL BAL to tell the operator the machine is working on the balancing procedure Once the calibration is done machine displays ADP FIN to indicate the calibration is successful Once the shaft stops machine displays and exits the F P4 automatically The machine is now in an idl...

Page 9: ...s the calibration result is FINE Displays when shaft stops and machine is in the idle state CALIBRATION COMPLETE NOTE THE BALANCER WILL NOT FUNCTION UNTIL A VALID CALIBRATION HAS BEEN PER FORMED ERROR MESSAGES WOULD BE DISPLAYED IN THE EVENT PROBLEMS OC CUR DURING THE CALIBRATION PROCESS F P 18 ALU S MODE Aluminum Static See the operation manual for a detailed explanation F P 19 ALU S ONE PLANE BA...

Page 10: ...total number of spins for either operator A B C or D depending what is chosen on the main display Choose the operator that you would like to read or reset from the main PCB by pressing the operator 1 mode key A B C or D Press and release the 2 F P key turn the shaft until the display reads F P 44 is displayed and press enter The balancer will display A Ctr or B Ctr or C Ctr or D Ctr The next displ...

Page 11: ...ype of vibratory will depend on the status Power Clamp vibratory will measure the status of the Hood switch and both pedal switches Units without the power clamp vibratory will measure the status of the hood switch only Display Left Window Status Display Right Window Status Hd Hood Up Ped Pedal Up Pedal static Hood Down Pedal Down F P 59 DISPLAYS THE UNBALANCE OF THE BARE SHAFT Press and release t...

Page 12: ...9 3 The display will change to SAP E 2 FIN for one second followed by a tone indicating a successful calibration Unit will then go into an idle state CALIBRATION COMPLETE F79 CALIBRATION OF WIDTH SAPE Note This procedure is part of the F80 Press and release the F key toggle the UP DOWN ar 1 row keys until F 79 is displayed and press ENTER to ac tivate function of F79 Once activated the display wil...

Page 13: ...2 hold it steady for about 1 second a tone will sound Display will read 5 bAC H POS followed by a beep Return the arm to the home position NOTE STEP 5 IS THE final STEP FOR A VPI SYS TEM i BALANCER Display changes to 6 dIA 18 POS Gently pull the SAPE out and rest the arm of the SAPE 7 gauge on the bell housing 80 3 A tone will sound and the display will change to bAC H POS Return the arm to the ho...

Page 14: ...13 tO CAL SLG Screw the calibration weight onto the outside of the flange Touch the tip of the width gauge to the tip of the calibration slug and hold it for one second or press the F button 80 7 The display will change to SAP E 2 FIN for one second followed by a tone indicating a successful calibration Unit will then go into an idle state CALIBRATION COMPLETE Touch the tip of the width gauge to t...

Page 15: ...ion must be done before this operation A balanced tire and wheel assembly can be substituted if a Pruefrotor is not available The calibration proce dures are the same and can easily be performed However custom parameters must be used for this proce dure if using a balanced tire and wheel assembly Beginning with a balanced Tire and Wheel assembly Mount the tire and wheel assembly on the shaft For t...

Page 16: ...ress the F P key to continue calibration or operator can press the STOP key to exit out of calibration basic calibra tion is all that is performed NOTE IF THIS IS THE FIRST TIME FOR FACTORY CALI BRATION AND THE OPERATOR PRESSES THE STOP KEY TO STOP THE REMAINDER OF CALIBRA TION F14 WILL NOT BE AVAILABLE TO THE OPERA TOR Press 9 F P to continue calibration Displays SPN 4 Remove the Pruefrotor Tire ...

Page 17: ...AL 1 when the shaft reaches calibration speed The machine is taking data and doing calculations After taking data shaft is automatically braked to a stopped Then displays CAL SHF FIN for one second The machine displays the shaft resident unbalances in fine mode The fine mode LED indicator is automatically on By pressing STOP key to exit F84 and return to idle state The fine mode LED indicator is a...

Page 18: ... Press and release the 1 F key toggle the UP DOWN button or press and hold the P key while turning the Diameter Function Knob until F P 95 is displayed The machine displays CLN EEP imme diately The user can press the STOP button at anytime before step 5 to abort this procedure Press 2 F P button the balancer displays 1 1 1 Press 3 F P button again the balancer displays 2 2 2 Press 4 F P button aga...

Page 19: ...TROL PANEL REMOVAL REPLACEMENT The Digital Display Board is mounted directly to and behind the keypad on each balancer Figure 3 22 Using a 4mm Hex Key remove to 4 screws holding the Display Panel to the upper Display on VPI and the SOT Low Digital is held in place with velcro gently pry the display forward To remove the Display Board unplug the membrane panel and simply remove the 4 8mm nuts holdi...

Page 20: ...12 V JBC System 2 3 08 3 12 V 2 80 2 90 V 3 05 3 15 V JBC System 3 3 08 3 12 V 2 80 2 90 V 3 05 3 15 V 3 10 3 20 V Snapon Low Digital 3 08 3 12 V 2 80 2 90 V 3 05 3 15 V Remove the power from the balancer 1 Remove the weight tray from balancer 2 Disconnect all wiring harnesses from the Electronic box and remove the old electronic box 3 Partially insert the new Electronic box into the back of the b...

Page 21: ...d from 5 0V to 3 3V therefore it will be necessary to reset the value of PO 220 Place the distance gauge in the home position and program F P 50 Verify the home position voltage mentioned in step 12 Press the F P button the display changes to 1 1 press it again the display will change to 2 2 and then finally 3 after the final press Set dis 220 will be displayed saving the home voltage to PO 220 Co...

Page 22: ...ead to the transducer The positive lead is marked with a black band Insert the clip into the transducer firmly snapping it into place Once the wire is installed it cannot be removed without destroying the transducer Apply a small amount of grease to each end of the trans ducer Place the ball bearings in place on the transducer Place the transducer assembly in the vibratory system Finger tighten th...

Page 23: ...ower Supply box Remove the rear transducer Remove the access plugs from the front of the balancer Using 1 4 drive 6mm hex head SOT part TMAM6E remove the six 6mm hex bolts to the vibratory Pay special attention of spacer placement Lift up on the vibratory member and remove VIBRATORY INSTALLATION All Balancers Lift and set vibratory member into the balancer housing Insert spacers Apply Loctite 242 ...

Page 24: ...nto bracket and tighten 13mm nut Install cog wheel onto potentiometer shaft and hand tighten 10mm nut Attach SAPE harness to Power Supply Board With the SAPE arm in the home position program F P 51 Pull out the SAPE arm and rest it on the vibratory tube Figure 3 32 using a flatblade screwdriver turn the poten tiometer to a voltage reading of 3 10VDC 05 Run F P C 80 for SAPE calibration SAPE GAUGE ...

Page 25: ...tentiometer onto bracket and tighten 13mm nut Install SAPE Wheel onto potentiometer shaft and hand tighten 10mm nut Attach SAPE belt to the guide roller Route SAPE belt over guide roller Loop SAPE belt through the auto lock mechanism and attach the SAPE belt to the distance rod Test SAPE assembly by pulling on the SAPE arm to it s full out position several times Make sure their is no binding With ...

Page 26: ...wheel firmly using a flatblade screw driver turn the potentiometer to a voltage reading of 3 10 02V Run F P 80 for SAPE calibration WIDTH SAPE POTENTIOMETER INSTALLATION JBC VPI SYstem III IV Disconnect the power from the rear of the machine Remove the weight tray Disconnect the 3D SAPE wire from the Power Supply box and gently pull the wire through the hood tube Remove the three screws holding th...

Page 27: ...d wheel assembly has a little resistance MECHANICAL BRAKE CABLE Disconnect the power from the rear of the machine Remove the Display panel Remove the weight tray Disconnect the brake cable from the vibratory member Make note of the location of the springs and washers Remove the two 5mm bolts holding the pedal to the frame Separate the pedal from the pedal bracket Pull the cable through the protect...

Page 28: ...UNDER PRESSURE TO RELEASE PRESSURE RAISE THE HOOD TO THE OPEN POSITION Remove the screw from the shaft that attaches the hood spring Reverse pocedures for installation HOOD SWITCH CAM SPRING VPI SYSTEM I Disconnect the power from the rear of the machine Remove the weight tray Disconnect the Hood Switch from the Power Supply Board and remove the wiring from the connector Remove the cover plate from...

Page 29: ...at the code type be properly identified before calling technical support for assistance In most cases the problem may be quickly determined and corrected by properly using the diagnostics codes to troubleshoot This Chapter contains codes for ALL Y2k balancers 2 1 In Field Reprogramming of Balancer 2 2 2 2 Recommended service steps 2 2 2 3 Self test during start up CRT HNA HWT 2 3 2 4 H codes CRT H...

Page 30: ...performed 8 Perform service codes in the following order 9 C47 Select machine model BFH Optima C80 Calibration of inner SAPE gauge arm C81 Measurement of flange to zero plane distance C82 Calibration of outer gauge arm Optima C83 Basic calibration of vibratory system C84 Measurement of residual main shaft unbalance C88 Adjustment of 12 h position C90 Saving calibration data The machine is now read...

Page 31: ...Models with 3D P SAPE Service Codes C82 to calibrate SAPE Outer SAPE gauge arm not in home position Re place SAPE gauge arm in home position and press STOP or ESC key to continue 4 Check weights usage database E50 Affected models Models with AWP Service Codes C125 to format the weights usage database An attempt to access the weights usage database has failed restart the balancer to re initialise t...

Page 32: ...fected models Models with optima hardware Service Codes C123 The optima hardware requires wheel profiler position calibration When the camera controller board is replaced on the machine the SW detected that calibration data are missing Calibration procedure C122 is required to calibrate the actual position of the laser scanners with respect to the balancer reference plane 13 Check Optima Hardware ...

Page 33: ...optima hardware Service Codes C123 Possible causes the cable connecting the camera controller board and the motor power supply board is unplugged damaged or missing the motor power supply is not configured properly there is a fault in the motor power supply board the cable connecting the mains supply and the motor power supply board is un plugged damaged or missing Corrective actions check all ite...

Page 34: ...board switch power off and on again should the problem not go away please call ser vice 22 4 Check Optima inner scanner calibration E373 Affected models Models with optima hardware Service Codes C123 Possible causes the inner scanner has not been factory calibrated Corrective actions please call service and replace the inner scanner 22 5 Check Optima inner motor power supply E374 Affected models M...

Page 35: ...self there is a fault in the camera controller board laser driversCorrective actions check all items above 22 9 Check Optima inner laser modulation E378 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the inner scanner CCD board is unplugged missing or damaged the cable of the laser module of the inner scanner...

Page 36: ...r power supply E384 Affected models Models with optima hardware Service Codes C123 Possible causes the cable connecting the camera controller board and the outer scanner motor is unplugged damaged or missing the motor power supply is not configured properly there is a fault in the motor power supply board the cable connecting the mains supply and the motor power supply board is unplugged damaged o...

Page 37: ...ulation E388 Affected models Models with optima hardware Service Codes C123 Possible causes the flat cable connecting the camera controller board and the outer scanner CCD board is unplugged missing or damaged the cable of the laser module of the outer scanner is damaged or there is a fault in the laser module itself there is a fault in the camera controller board laser drivers Corrective actions ...

Page 38: ...able connecting the camera controller board and the rear scanner motor is unplugged damaged or missing the motor power supply is not configured properly there is a fault in the motor power supply board the cable connecting the mains supply and the motor power supply board is un plugged damaged or missing there is a fault in the rear scanner motor there is a fault in the camera controller board mot...

Page 39: ...era controller board and the rear scanner CCD board is unplugged missing or damaged the cable of the laser module of the rear scanner is damaged or there is a fault in the laser module itself there is a fault in the camera controller board laser drivers Corrective actions check all items above 25 1 Check Optima rear shift motor power supply E404 Affected models Models with optima hardware Service ...

Page 40: ...vice codes C47 the machine will remain in service code mode 27 Check calibration E901 Affected models All models Service Codes C80 C81 C82 C83 C84 C88 C90 Machine was not calibrated For calibration the following calibration codes will have to be carried out in the sequence as given below C80 Calibration of inner SAPE gauge arm C81 Measurement of flange to zero plane distance C82 Calibration of out...

Page 41: ...ow or above a limit the error code is displayed Refer to section 2 3 4 Error ID 30 4 Hardware test Current of opto electronic LED C10705 C10706 C10707 C10708 Affected models All models Service Codes C75 AdC1 to check LED If the current voltage is below or above a limit the error code is displayed Refer to section 2 3 4 Error ID 30 5 Hardware test Transducer signals C10410 C10420 C10430 Affected mo...

Page 42: ...nnot be re located using the gauge arm H21 Indexing position does not match correction plane H22 0x492215 Unclamping of power clamp device is disabled H23 Unclamping of wheel not allowed H26 The gauge arm was pulled out too quickly normal operation ASS calibra tion H28 NEW The gauge arm was pulled out too slowly ASS calibration 80 H80 0x810510 No provision was made for readjustment H82 Self test d...

Page 43: ...too wide E14 The power clamping device is not clamped E15 Corrective terms for readjustment are out of range E16 0x812570 0x812571 Calibration weight attached erroneously to flange E17 0x492207 Wheel slipped on adapter 20 E28 0x492205 Wrong direction of rotation hand spin E29 Speed too high hand spin 30 E30 Run out measurement failed E31 Rim only mounted during geometric matching when rim and tyre...

Page 44: ...IMA left side scanner self test fail or CCD not calibrated or zero mark not detected E364 OPTIMA right side scanner self test fail or CCD not calibrated or zero mark not detected E365 OPTIMA rear scanner self test fail or CCD not calibrated or zero mark not detected E366 OPTIMA main camera board memory self test failure E367 OPTIMA motor power supply missing or out of range E368 OPTIMA main camera...

Page 45: ...rear scanner zero mark not detected E396 OPTIMA rear motor missing steps E397 OPTIMA rear laser current sink or power supply failure E398 OPTIMA rear laser modulation failure 400 E400 OPTIMA pull index user calibration failure E404 OPTIMA rear shift motor current sink or power supply failure E405 OPTIMA rear shift scanner zero mark not detected E406 OPTIMA rear shift motor missing steps 600 E623 0...

Page 46: ...the kind of the fault Module ID Priority ID Error ID 81 0 511 2 7 2 Module ID Module ID Description 21 Time Service 22 I2C bus device driver 23 Serial device driver 24 Sound device driver 25 External AD converter 26 Internal AD converter 27 Temperature measurement 28 Piezo transducer 29 Incremental encoder Main shaft 2A Incremental encoder belt disc 2B Relay management 2C Hand spin brake 2D Electr...

Page 47: ... UI 84 Message Server User messages from BK to UI 85 Sleep command 86 Balancing Kernel Test state machine eg self test during start up A1 Event system A2 User management A3 State machine A4 complex data type A5 Persistent objects A6 Pipe device A7 Power on time counter time stamp for error recording A8 Counter for total spins in service in user mode C1 Self test C2 User interface C3 User interface...

Page 48: ...und Mod 44 SAPE Time service not found during unregister Mod C1 Self test Self test failed result of test invalid F08 Already exists F09 In use Mod 44 SAPE AWP already in use Mod 49 Drive system Internal error command not valid in actual mode of operation Many 490F09 errors in the error record indicates a malfunction of the pedal F0A End of file F0B Drive full F0C Bad name F0D Xmit error Mod C3 Us...

Page 49: ...amp F18 Timeout Mod 31 Watchdog Recorded during start up Watchdog causes last reset Please check error record C28 Mod 42 Data cond Can t get data from external AD converter This error can caused by a malfunction of the incremental encoder Please check C74 and C54 a malfunction of the micro controller board Check C75 if ADE1 and ADE2 displays valid results Mod 44 SAPE Communication timeout No answe...

Page 50: ...HARDWARE 14B SER_ERR_RESET_FIFO 14C SER_ERRORCODE_EXISTS 160 ERROR_PO_INIT_READORDER_FAILED 161 ERROR_PO_INCORRECT_DATA_OR_HEADER_SIZE 162 ERROR_PO_EEPROM_IS_FULL 163 ERROR_PO_I2C_WRITE_ORDER 164 ERROR_PO_NO_TIMECLIENT_AVAILABLE 165 ERROR_PO_ORDER_IS_BUSY 166 ERROR_PO_ORDER_IS_FULL 167 ERROR_PO_PRODUCTION_READ_WRONG_TYPE 168 ERROR_PO_EEP1_EEP2_ARE_DIFFERENT 169 ERROR_PO_CRC_EEP1_ERROR 16A ERROR_PO...

Page 51: ...Incremental encoder main shaft 207 Drive system Slip detected speed up to fast 1 Wheel not clamped strong enough 2 no wheel or wheel mass to low 208 Drive system Speed limit exceeded speed exceeds security limit mainly wheel guard open and drive management set to high speed 210 Drive system Clamping device got stuck in clamped position 211 Drive system Clamping device got stuck in unclamped positi...

Page 52: ... measuring run Can t perform transducer correction 405 Channel 1 channel 2 Phase shift too big 410 Transducer 1 No signal 411 Transducer 1 transimpedance to low 412 Transducer 1 RC time constant out of range 415 Transducer 1 transimpedance amplifier idle voltage out of range 416 Transducer 1 DC amplifier idle voltage out of range 418 Transducer 1 amplifier saturation 419 Transducer 1 Transfer func...

Page 53: ...perature Input near to reference Voltage 601 Internal error To many event sinks 602 Internal error Cannot register event sink 603 Internal error Invalid event level 701 ERROR_IEMS_INV_PARAM 702 Incremental encoder not initialised software is not able to detect the reference mark 703 Incremental encoder Counter reference mark mismatch 705 2 50 V Opto electronic No voltage on shunt resistor 706 4 30...

Page 54: ...K_ERROR_PO_EEP1_WR new 001 007 BK_ERROR_PO_EEP2_WR new 001 010 BK_ERROR_KBD_DISPLAY internal 001 011 BK_ERROR_KBD_VOLTAGE 46x xxx 001 012 BK_ERROR_KBD_READING 46x xxx 001 020 BK_ERROR_DC_OVERRUN xxx 401 E83 001 021 BK_ERROR_IEM_ZERO_MISMATCH 290 703 001 022 BK_ERROR_IEP_ZERO_MISMATCH 2A0 703 001 030 BK_ERROR_POWER_FAIL xxx 900 001 031 BK_ERROR_TEMP_SENSOR xxx 58x 001 032 BK_ERROR_VCC_ABOVE_LIMIT x...

Page 55: ..._ERROR_C2_0G_HIGH xxx 571 E16 001 059 BK_ERROR_C1_USERCALTOOL_LOW xxx 560 E6 001 060 BK_ERROR_C2_USERCALTOOL_LOW xxx 561 E6 001 070 BK_ERROR_SPOKE_SAME_POS internal 001 071 BK_ERROR_UG_NOT_BET_SPOKES internal 001 072 BK_ERROR_ANG_SPOKES_TOOHIGH internal 001 073 BK_ERROR_ANG_SPOKES_FAIL internal 001 080 BK_ERROR_SPINUP_TIMEOUT 490 202 H90 001 081 BK_ERROR_NO_ACCELERATION 490 206 H90 001 082 BK_ERRO...

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Page 57: ... Equipment shall not be liable for errors contained herein or for incidental consequential damages in connection with furnishings performance or use of this material This document contains proprietary information which is protected by copyright and patents All rights are re served No part of this document may be photocopied reproduced or translated without prior written consent of Snapon Equipment...