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950/1025/1050/1055 950 ProRacer Computer Wheel Balancers

Contents

1. te od ced 9 Repeatability Problems Contractor amp Motor Controller Model s suc irr PCR RR HR on iei 10 Display Does Not Light Contactro Model 11 Balancer Does Not Cycle Contactor Model 12 13 Balancer Does Not Brake Contactor Model 14 15 AS DAm Probleme s 16 Checking Procedures a4 ee a MEC ees 17 Optical Encoder Code 44 17 Motor CIRC UE Testing se 24253454 17 Motor Circuit Diagram 18 SPISZ OUUTE ok ida aot a Senet eae 19 Replacement Procedures Section for Models 950 1025 1050 amp 1055 Balancers 20 25 Front Panel Printed Circuit Board Assembly 20 Contactor Coil Resistance Measurement 20 Front Panel Printed Circuit Board Assembly Heplacerrient xu we w ita ue op C E ed bp 20 Touch Panel Aluminum Back Panel and PCB Assembly 20 FOOL coin sak dbo hud ie eee 21 Magnetic Hood Switch 21 Mechanical Hood Interlock Switch 21 OVOM NEC e ratte de esto 21 CIFCUI BICAKElS E E Sedo s ES 21 rad 22 tere fee aient tos FE RUE E fe 22 AuxiliaFy Contactor Block 22 Bridge Rectifiers 22 amp D Arm Assembly 23 Fan Motor Assembly
2. m B ce I pere Es 185 2225 BRAK ING MOTOR CONTACTOR v x x 2 or 62 50 25 od d e Service Manual COATS Models 950 950 ProHacer 1025 1050 1055 31 Solid State Wiring Diagrams amp Troubleshooting Guides For units produced after 1 1 98 A new Solid State Motor Controller replaced the mechanical contactor and a second hood Interlock Switch was added In January of 2000 the magnetic switches were changed to mechanical switches refer to the appropri ate wiring diagram for troubleshooting and repair Mechanical Hood Switches Hennessy has introduced a new style hood switch on the 850and 950 1025 1050 1055 solid state model bal ancers Beginning with Serial 0001308154 These are mechanical rather than magnetic switches and require a different activating procedure As a result 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 amp magnets 8305050 amp 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 inserted as packing material to insure ade quate room for inserting the actuator rod Please refer to the attached
3. 5 Resistance should be 3 to 5 ohms 5 to 7 ohms on newer contactors with metal plate on the bottom if not replace the contactor New Repair Procedure 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 defective assembly Front Panel Printed Circuit Board Assembly Replacement 1 Unplug the balancer 2 Check contactor coil resistances see the proce dure on page 24 3 Remove the four 4 6 32 acorn nuts on the back of the pod 4 Disconnect the plugs on the PCB Assembly 5 Remove the Front Panel Printed Circuit Board Assembly 6 Connect the plugs to the new PCB Assembly 7 Line up the four 4 6 32 studs on the back of the Touch Panel Aluminum Back Panel with the four 4 holes in the pod and install 8 Install the four 4 6 32 acorn nuts 9 Plug in the balancer 10 Perform the 950 1050 Balancer Test Procedure 11 Perform the FUNCTIONAL CHECKS Touch Panel Aluminum Back Panel And PCB Assembly 1 Unplug the balancer 2 f the PCB is being replaced check contactor coil resistances see the procedure on page 24 3 Remove Front Panel PCB Assembly from the pod 4 Remove the eight 8 screws holding the PCB Assembly to the Touc
4. 23 aio Ecl ae ede ea ahs 23 Optical Encoder 23 Drive Motor 24 Piezo Assembly 24 25 Capacitor 0 25 Capac Oni kkn 25 Anal Hane SS t dons 25 Repair Procedures for the A amp D Arm Assembly A Pulley Removal 26 A Pulley Installation Adjustment Code 10 26 Potentiometer Replacement 26 DPI REMOVA o rue 3 8 3 5 e Cua 26 D Pulley Installation Adjustment Code 10 27 D Potentiometer 27 Motor Service Kit Instructions 28 9 50 28 950 Pro Racer Wiring Diagram 29 950 Wiring Diagram Contactor Style 30 1050 Wiring Diagram Contactor Style 31 Solid State Wiring Diagrams amp Troubleshooting Guides 32 For units produced after 1 1 98 32 Mechanical Hood Switches 32 Mechanical Hood Switch Diagram 39 1050 Wiring Diagram Motor Controller otyle Magnetic Switches 34 1050 Wiring Diagram Motor Controller style Mechanical Switches 36 Motor Controller Test Box 8112708 38 Display Does Not Light Solid State M
5. Motor Controller Test Box 8112708 Forward and In Line Control Signal Reverse Control Detection Output SIGNAL DETECT In Line Signal SPIN STOP Dectector Forward o 9 Indicator LEDs Control Reverse Power Control Indicator Power Switch Solid State Motor Controller Solid State A i Solid State PCB Motor Controller Ul Motor Controller SIGNAL DETECT SIGNAL SIGNAL SPIN STOP SPIN STOP SPIN STOP Mode 1 Mode 2 Mode 3 Forward and Reverse A Loop back plug The Diagnostic Tool buttons are used to is connected from is connected in line control signals the Control Output with the control cable to the Solid State back to the Signal from the CPU Motor Control Motor Control PCB Detection input to output to give monitor the Control an indication of the Signal output of the presence of the Diagostic Tool while Control signal manually applying the control signal 38 Service Manual COATS Models 950 950 1025 1050 1055 Display Does Not Light Solid State Motor Controller Model Is the power switch set to the ON position Is the proper voltage and ground present at the receptacle See Checking Procedure No Is there between 200 amp 230VAC between the terminals marked OV amp 230V 1 amp 3 on the No Is there 220VAC between terminals 1 amp 3 on the power supply connector on the Motor Cont
6. Only one terminal on each contactor will give a reading Brake contactor terminal 13 to 2 rectifier terminals that did not render a reading in the previous check amp D Arm Problems Heturn the arm to the Power cycle the retur Home position The end of machine does the the way to the bushing the arm should be resting Balancer Beep against the guide bushing for 20 seconds Yes Power cycle the machine Key Shift 0 1 0 Adjust the A D Arm See the Does the potentiometer e A 8 D Pulley installation for A left weight display reading between 05 and procedures 30 amp the D right weight Adjustments Completed display reading between 0 4 and 0 8 Calibrate A D Arm See Calibration Procedure Yes Does the balancer accept Does the balancer hold the entry from the A D Arm initial A amp D dimensions No Yes Check the A D Arm for proper placement of the Distance Tape Replace the PCB See See DISTANCE GAUGE TAPE Replacement Procedure PLACEMENT Does the A dimension entered by the A D arm match the distance shown on the Distance Tape Does the D dimension entered by the A D Arm match the diameter shown on the tire Yes Proceed to balance 16 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Checking Procedures Bridge Rectifiers 1 Turn the power switch OFF an
7. 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 procedure to verify if there is a problem in the balancer or the mounting of the wheel This should be done with a Hub Centric wheel Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 43 9111123 03 11 05 Copyright 1992 Hennessy Industries and COATS Rights Reserved Printed in USA
8. 1431 Q3u IHM OT 449 9 QT3IHS MOVIA UWATI Z ect p AILT 7 on INIT BULIM 2264 0414 086 31411054 qd lad HOLIMS QquvMuod Service Manual COATS Models 950 950 ProHacer 1025 1050 1055 29 iagram Contactor Style 950 W 834 3015 1 18 3015 1331 20 11 t S m en L xr EDU 5 W313M01 LN3104 34IA 03013185 3onve 135 130 2001 IN310d 33134710 NIU 82d omis T lt gt HAT mitti 02314 52 indus 1331 A 0231d L uaiH3ANOO 1 2907 3S Hd aes SOLO LU L 3 3SvHd M T p 5094 gt 5 2 1114 5 t ADCS 30 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 1050 Wiring Diagram Contactor Style LEFT SIDE PCB 11 92 SHIELOED WIRE LEFT FRONT A RIM DIAMETER POTENTIOMETER OFF SET GAUGE POTENTIOMETER a E 3 8 cC S a 71 t t 5 t H 3 1 1 il i 1 4 4 1 3 ul du gt 8 8 S 3 5 5 5 2 m ci om T gt a gt N gd 1 5 1 1 TRANSF ORMER E T m ul 23 54 ma na
9. 3 URG CT T 1 PIN 1 WHT BRN PIN 2 WHT RED GROUND 3 WHT ORG 22 110919 REF GROUND E PIN LRED DOS PIN 2CLEAR 1 111845 REF lt PIN PGREEN PIN LGREEN ROS PIN BLACK PIN 2 YELLOW PIN 3 BLUE PIN Pm WHT RED V 11838 FEF m p N R R PIEZO WHT ORG Wa NCC PIEZO TAR PIEZO WHT BLK 3 es WHT BRN MODEL 1050 SOLID STATE REV Service Manual COATS Models 950 950 ProHacer 1025 1050 1055 e 35 1050 Wiring Diagram Motor Controller Style Mechanical Switches TRANSFORMER 1e OV BREAKER 2 100 E e4 V e 7 5 ORANGE e e00 V RED e 111218 111218 24 YELLDW e 12 RED 4 DEDE BREAKER 111218 2 J RED 305015 uum xi ORANGE RED ORANGE WHITE 111066 3 20 Che 2 1 D 1 4 1 GROUND 6 GROUND 27 111142 SHIELDED CABLE 111874 BREAKER 2AMP 2 3 TERMINAL FOR 220V TERMINAL 4 FOR 440V INTER LOCK SWITCH en 3 4 NORMAL CLOSED D 144114 N 111805 2 REF fo y BLACK X 110994 REF C ORG CAPACITOR ASSY an 1 PHASE 220V 1 0 m V CONTROL 111843 REF 305802 111879 112224 JUMPER 3 PHASE 220V 3 PHASE 440V 480 3 PHASE 112556 REF PLUG 220V 1 PHASE 305076 REF X
10. BLACK Y RED G GREEN 111802 1 SWITCH PowSup POWER PLUG 220V 3 PHASE 140786 REF X BLACK Y RED Z WHITE G GREEN BROWN BLACK LINE BLACK RED LINE 106 BLUE WHITE NEUTRAL YELLOW GREEN GREEN GROUND EXPORT DOMESTIC POWER PLUG 440V 3 PHASE 4 143091 REF X BROWN Y BLACK Z BLUE G YELLOW GREEN GROUND NOTE THIS IS A 5 CONDUCTOR WIRE ONE OF THE BLACK WIRES 111848 REF IS UNUSED 36 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 MODEL 1050 MODEL 1025 MODEL 950 NOTE REMOVE NOTE REMOVE NOTE DO NOT REMOVE JUMPERS 5 17 JUMPERS 5 TO 17 JUMPERS amp 16 TO 18 1 MAIN 111886 eae Wht Org Whi 7Red B Nnt Org Wht 7Brn 2 Orange H 5 Wht Red PIN 1 SPIN PIN 3 5V 81 PIN 6 Wht Vio 6 FOR MODELS 1025 ond 1050 111846 REF 110918 REF SHIELDED 1 PIN 1 PIN e WHT RED PIN 3 WHT ORG 10919 REF PIN LRED PIN 2 CLEAR PIN 3 GREEN ut HOOD SWITCH PIN 1 iGREEN GH 57 PIN AIBLACK NORMAL OPEN PIN 2 1YELLOW 144114 PIN 3 BLUE PIN 4 PURPLE CN 1 WHT RED 1118358 REF GROUND R R PIEZO WHT ORG 2 gt L PIEZO e R F PIEZO WHT BLK TIE NC 2 3 Sa WHT BRN MEDEL 201065 61090 REV B Service Manual COATS Models 950 950 ProHacer 1025 1050 1055 e 37
11. CHECKS Service Manual COATS Models 950 950 ProHacer 1025 1050 1055 23 Drive Motor Assembly Hennessy now has available a service motor kit for the 950 1025 1050 1055 Contactor amp Solid State Balancers which will allow everyone to use one part number when ordering a motor The kit will be a com plete motor assembly hardware bag amp wiring instruc tions The hardware bag will contain wires wire nuts spade connectors amp a green phoenix connector It will require a crimping tool to crimp the spade connectors to motor wires as needed for contactor style units Refer to the Motor Service Kit instructions in this man ual for additional information 1 Unplug the balancer 2 Remove weight tray weight tray shield and motor cover 3 Disconnect fan motor plug 4 Disconnect optical encoder plug B Disconnect each motor wire where it is connected to the contactor and auxiliary contactor block 6 Remove the four 4 piezo springs and piezo spring retainers 7 Remove the two 2 5 16 18 X 1 washer head screws and lift out the motor assembly 8 Position the motor on its side or back and remove the four 4 3 8 16 washer head screws holding the flex plate to the motor 9 Remove the flex plate 10 Remove the four 4 3 8 16 washer head screws holding the cradle to the motor 11 Remove the cradle from the motor 12 Apply Loctite 242 to the threads of the 3 8 16 washer head screws and install t
12. Dx Do location LEDs move when wheel is rotated s AC correct on Motor connection of MC PCB No Yes Yes No Check wiring to motor Replace Main PCB Replace motor Check wiring connection on P4 Check replace MC Motor Controller capacitors Replace MC PCB MC Test Box 8112078 40 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Balancer Does Not Brake Solid State Motor Controller Model Balancer must spin and displaying information to proceed Does wheel attempt to stop Does an error message appear Yes Cross reference error message to N table and N troubleshoot from the given location readings appear on display after wheel has stop se MC test box will motor spin amp stop Yes Test Comm Cable Replace the Main PCB Test Comm cable Replace Motor Controller MC Motor Controller MC Test Box 8112078 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 41 PCB Checklist Addendum Hennessy has noticed a considerable increase in the amount of NAD s No Apparent Defect for the 950 1050 PCB s 8111886 Most NAD s are in the Chasing Weights category The next reason for PCB return is due to the Motor Controllers failing Some of the PCB s returned tested OK Below is a quick test
13. amp does not trip replace the breaker Breaker Trips Replace the PCB See Replacement Procedure Repair or replace the defective wire or connection Checks Bad Check the continuity of the wire from the terminal marked OV on the transformer to terminal 1 on the Motor Controller Check the continuity of 276056 Good the power switch Checks Bad Replace the power switch See Replacement Procedure Repair or replace the defective wire or connection Service Manual COATS Models 950 950 ProHacer 1025 1050 1055 39 Balancer Does Not Cycle Solid State Motor Controller Model To use the following chart you will need a tire and wheel assembly mounted on the balancer the hood closed and the proper W D dimensions entered you are unable to manually enter the proper wheel dimensions replace the touch panel Turn balancer on Press spin balancer must display info to proceed continunity o interlock switch with hood down at p7 Is there MC test box to MC PCB Does Does motor buzz or try to turn Yes Yes No Troubleshoot AC Repair replace the hood switch or wiring Is AC correct to T1 of MC PCB CPU PCB into MC test box Does Replace control cable Troubleshoot Encoder system To make this check use the MC test box to activate the Yes spin voltage during test
14. before the balancer can be considered available for service Equipment Needed 1 AC DC Volt Ohm meter 2 lest Wheel Domestic 14 15 or 16 inch diameter x 6 6 1 2 inch wide steel wheel with a center hole suitable for mounting with a back cone A new 70 senes tire properly mounted and inflated balanced to within 0 05 ounces should be part of this wheel assembly The lateral run out of this wheel should be less than 1 8 3 Mechanic s and electrician s tools Ihread locking anaerobic Loctite 242 or equiva lent 5 Retaining compound Loctite 601 or equivalent 6 Dial indicator runout gauge with magnetic base starret No 25 431 or equivalent 7 Modeling Clay 8 Motor Controller PCB tester 8112708 9 Membrane Touch Panel Tester 8112929 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 1 Voltage amp Phase Checking Procedure 1 Unplug the Balancer from the power source 2 Perform all voltage checks shown in the ate diagram and chart at the power receptacle one or all voltage measurements is faulty be sure to check the status of the circuit breakers that supply the Balancer 3 Check from one of the power terminals to the ground terminal to verify a ground is present The volt age measurement should be approximately one half of the available voltage i e 220V should read 110V If the reading is less that one half the available voltage there Is not
15. ever close remain closed No No Replace the optical encoder See Replace Procedure Has one of the 1A breakers on the rear of the machine tripped Yes Disconnect the wire from terminal A2 Replace the contactor See of the brake contactor amp check the coil Replace Procedure resistance from A1 A2 Is the resistance of the coil between 3 amp 5 Ohms 5 to 7 on new contactors Replace Procedure Turn the power switch OFF amp unplug the machine Disconnect the white blue wire from A1 on the More Than brake contactor Use 1 Ohm ter to check from A2 on the brake contactor to terminal A2 on the Repair or replace defective wire or connection forward contactor Connect the white blue wire Less Than 1 Ohm Disconnect the wire from A2 on More Than the brake contactor Use an 1 Ohm Ohmmeter to check continuity from A1 on the brake contactor to Less terminal 5 on the connector on Than 1 the right side of the PCB Ohm Replace the PCB See Replace Procedure Connect the wire to terminal A2 on the contactor Does the forward No Replace the optical encoder contactor ever open See Replace Procedure Yes Manually close the brake Is this a Model 950 contactor Is there a 230VAC Replace the contactor See between terminals 3 to 5 5 to Replace Procedure No 13 8 13 to 3 Yes Check the connections from Bad Repair or replace the def
16. less than four 4 turns and the hub nut is firmly tightened before spinning the wheel Read and understand this manual before operat ing Abuse and misuse will shorten the functional life Be sure the balancer is properly connected to the power supply and electrically grounded Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged until it has been examined by a qualified serv Iceman Do not let cord hang over edge of table bench or counter or come in contact with hot manifolds or moving fan blades If an extension cord is necessary 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 Keep guards and safety features in place and in working order 10 20 21 22 29 Wear proper clothing Safety toe non slip footwear and protective hair covering to contain hair is recommended Do not wear jewelry loose clothing neckties or gloves when operating the balancer Keep work area clean and well lighted Cluttered and or dark areas invite accidents Avoid dangerous environments Do not use power tools or electrical equipment in damp or wet loca tions or expose them to rain Avoid unintentional starting Be sure the balancer is turned off before servicing Disconne
17. of capacitor C15 or C16 see fig 1 3 lake the multimeter positive lead and check the pins on the IC s above Figure 2 Pin Configuration Note e Pin 7 is GND on the IC s You will hear a continu ous beep e Pin 14 is VCC on the IC s You will hear a short beep or read 5 7 on the Diode Scale This is OK Only if you measure 0 Ohms or hear a continuous beep is the IC bad C U19 pins 7 11 14 and 13 are the only pins where you should read 0 Ohms or hear a continuous beep If any other pins not listed are shorted to ground read 0 Ohms or you hear a continuous on the IC s listed above THE PCB IS DEFECTIVE DO NOT INSTALL PCB BACK INTO THE BALANCER If the IC s and the diodes check out OK but the PCB does not display any lights THE PCB IS DEFECTIVE DO NOT INSTALL PCB BACK INTO THE BALANCER Rev 1 42 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Glossary Of Terms Accuracy Check Also referred to as Plane Separation When a weight is placed on one side plane of a wheel the opposite side plane should not change Balancer Calibration Also know as Weight Sensor Calibration This process uses a specified size wheel and a 4 oz 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
18. or 2 Service Manual COATS Models 950 950 ProHacer 1025 1050 1055 Preliminary Inspection 1 Check the power supply to the balancer See the procedure on page 6 2 Balancer should sit on all three 3 legs Make sure the legs have not filled with dirt wheel weights or other foreign matter that may prevent a leg from making contact with the floor 3 The floor should be a solid flat surface that does not allow the balancer legs to set into a recess in the floor or sink into the floor itself 4 Check the operation of the cooling fan on the drive motor The fan should run as soon as the balancer is powered the fan fails to run check the 1A breaker on the rear of the machine to see if it has tripped If it has tripped reset it If it will not reset see FAN MOTOR DOES NOT RUN 5 Inspect cones hub nut pressure cup s and threaded stud for damage Missing cones or acces sories should be replaced Functional Checks Operational Check 1 Turn the power switch ON The display should read as follows AW D 0 0 Weight Display _ 00 Mode Dynamic Operator A Model 1050 only Grams Ounces Last Selection If the display fails to light see DISPLAY DOES NOT LIGHT 2 Mount your test wheel described in EQUIPMENT NEEDED on the balancer 3 Enter the wheel parameter data Note If this is a Model 950 and the machine will not accept keypad entries replace the keypad If this does not correct
19. plugs to assembly 11 Install Front Panel PCB assembly 12 Install weight tray and weight tray shield 13 Perform the FUNCTIONAL CHECKS Repair Procedures for the A amp D Arm Assembly A Pulley Removal 1 Rotate the pulley counterclockwise and remove the brass stop and cable from the catch groove on the pulley 2 Loosen the cap screw on the pulley and carefully slide the pulley and return spring from the shaft of the potentiometer A Pulley Installation Adjustment Code 10 1 Locate the return spring onto the A pulley Install the tension spring to the retaining pin on the pulley ensuring that the spring coils counterclockwise from the inside to the outside 2 Catch the outside loop on the end of the return spring onto the tension pin on the amp D bracket 3 Slide the A pulley onto the shaft of the poten tiometer 4 Rotate the A pulley counterclockwise one 1 turn and loop the cable from the distance gauge around the pulley 5 Install the cable and brass stop assembly into the groove on the pulley 6 Locate the A pulley on the shaft of the poten tiometer such that the cable assembly from the dis tance gauge is located in the center of the pulley groove and the cable is not contacting the edge of the pulley groove 7 Press and hold the SHIFT key and press 0 Press 1 and the O 8 Using a small screw driver rotate the end of the potentiometer shaft until the left weight display reads
20. the problem replace the PCB and put the original keypad back in Note If this is a Model 1025 1050 or 1055 and you do not get proper wheel parame ters from the A amp D Arm see A amp D ARM PROBLEMS f the balancer is in round off mode press and hold the SHIFT key and press ROUND OFF to enter the non round off mode 5 If the balancer is in gram mode press and hold the SHIFT key and press GM OZ key combination to set the balancer to read in ounces Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 3 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 to a stop If the machine fails to brake and continues to coast see BAL ANCER DOES NOT BRAKE 11 he balancer should now have weight values and position lights displayed 12 Position the wheel so the display for the center position LED for the outside right plane is flashing 13 Note the position of the 4 oz weight and the weight readings for both planes 14 Perform five 5 spin cycles and note the posi tions and weight readings after each spin cycle The weight readings should repeat within 2 oz and the position within 1 2 inch If they do not see REPEAT
21. to help determine if the PCB is defective This test does not pertain to any other PCB s Remove PCB from Touch Panel Tools Needed Digital Multimeter with leads Diode Test Using a multimeter set the function indicator to the diode function and check Diodes D9 Rev D boards and D10 D11 Rev E and above to see if they are shorted Perform the following procedure for each diode 1 Connect the multimeter s black lead to the left side of the diode and the red end on the right If the diode Is good you will hear a short beep and the reading on the meter should be between 5 and 7 if you re using an Ohmmeter the reading will be about 5 Meg Ohms If the diode is bad you will hear a continuous tone and the multimeter reading will be O same for ohm scale unless it s open no tone reading 2 Next switch the multimeter leads Connect 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 1 bad IC Test Use a multimeter to check for ground shorts on IC s U8 U12 and U19 1 Set the multimeter up for continuity or diode checking 2 Connect the common lead of the multimeter to a ground point on the PCB good place is the negative end
22. 0V WHITE y BLACK 111803 1 505050 REF ORG CAPACITOR ASSY eae 1 PHASE 220V SWITCH ORG C7 NEREA JUMPER 3 PHASE 220 3 PHASE 440V POWER PLUG 220V 1 PHASE 305076 REF X BLACK Y RED G GREEN POWER PLUG 220V 3 PHASE 140786 REF X BLACK Y RED Z VHITE G GREEN BROWN XBLACKO BLACK lt RED LINE BLUE WHITE NEUTRAL YELLOW GREEN GREEN GROUND POWER PLUG 440V 3 PHASE 143091 REF X BROWN Y BLACK Z BLUE G YELLOW GREEN 41 3 EXPORT DOMESTIC Th 12 GROUND 11142 11874 BREAKER 2 111218 111218 BREAKER 2 2 7 2 1 Tr Lt Tr n m RED WHITE l HI GROUND 13 111 25 2 REF E s FA 110994 REF 8 3 PHASE 480V 3 PHASE 111802 1 5 O GROUND NOTE THIS IS 5 CONDUCTOR 7 WIRE OF THE BLACK WIRES IS UNUSED 34 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 MODEL 1050 MODEL 1025 MODEL 930 DIE FEMOVE 5 TO 17 IS 10 17 8 1 4 AUTO A amp D MAIN 111886 FPFE PRERE PIN 1 SPIN PIN 3 5V PIN 6 BRAKE FOR MODELS 1025 and 1050 111845 REF 110918 LL H 88 PIN
23. 50 oz weight on the outside enter the wheel parameters 2 Enter the piezo test code for the model balancer being tested Ignore the initial set of values displayed 3 Spin the wheel by closing the wheel guard and or pressing the spin button When the balancer stops write down the values when the Dynamic and Alloy 1 LED s are on These values will be slightly different on each balancer Typical readings for 950 1050 balancer Left Display 1150 Right Display 1050 4 Repeat step 3 above for five more spins Remember you are looking for consistency of the read Ings 5 f 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 readings If the Alloy 1 reading fluctuates more than 10 test the right front piezo by unplugging the right rear piezo and repeating step 4 7 f the reading is stable the right front piezo is good Check and or replace the right rear piezo after testing 8 f the reading in step 7 fluctuates check and or replace the right front piezo 9 Reverse steps 6 and 7 to test the right rear piezo Both piezos should be checked individually before replacing either piezo Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 19 Replacement Procedures Section for M
24. A BILITY PROBLEMS Note If the customer had problems with a specific wheel assembly only make sure there is no water or debris inside the tire Accuracy Check Plane Separation 1 Remove the 4 oz weight from the wheel 2 Fine balance the test wheel to obtain 0 00 40 02 weight readings on both displays It may be necessary to use modeling clay to counter balance small imbal ances 3 Place a 4 oz weight on the outside of the wheel 4 Press start The readings for this cycle should be as follows Inner Left Plane 0 00 0 20 oz Outer Right Plane 4 00 0 10 oz Outer Position 407 at bottom dead center x 1 2 inch 5 Move the 4 oz weight to the inside plane Press start reading should be as follows Inner Left Plane 4 00 0 10 oz Outer Right Plane 0 00 0 20 oz Inner Position flashing 407 at bottom dead center 1 2 inch 6 f the above results are not achieved check the A W and D dimensions and perform the A amp D ARM CAL IBRATION and the WEIGHT SENSOR CALIBRATION 7 Check the placement of the distance tape see the DISTANCE GAUGE TAPE PLACEMENT PROCEDURE 8 specified results are not achieved see ACCU RACY PROBLEMS Rotational Check Use a Hub Centric Wheel 1 Remove the 407 weight from the inner rim and perform a fine balance to obtain 0 00 4 02 weight readings on inner and outer plane 2 Position valve stem at 6 o clock Loosen hub nut jus
25. Hood Installation Instructions and wiring dia grams The operators manuals have been updated with current parts lists and addi tional copies can be ordered through our order entry department Old Part New Part Number Number 8305050 8144114 Switch 8110014 8112843 Hood Bar 8112731 Actuator Rod 924724 Serrated Nut 8111812 850 Operator Manual 8111868 950 thru 1055 Operators Manual 32 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Mechanical Hood Switch Diagram 109945 109949 Retainer Cap Plug a 301122 Hex Nut 301121 Washer 4 ON 1 2 1 0 p 109944 Washer 1 1 2 I D 307014 Bearing Flanged 112731 Actuator Rod 24724 Nut Serrated 111813 VN 24724 Hood Assy 4 Serrated r V 4 144114 Switch d Mechanical f S 23603 Screw 8 32 x 1 2 w Kep 6 32 308062 Spring Hood 309008 Molding 8 c Ne 301120 Bolt 1 2 13 x 2 1 2 P Service Manual COATS Models 950 950 ProHacer 1025 1050 1055 33 1050 Wiring Diagram Motor Controller Style Magnetic Switches LEC TRANSFORMER ORANGE 100 24 V 7S AMP ces ORANGE e RED gt ir BREAKER 111218 RED 2 AMP 305015 up DAE a LE ERIGI 111066 3 mc 7 Pa ai gt 1 l 2 o op 1 gt TERMINAL 3 FOR 220V TERMINAL 4 FOR 44
26. J Ae MOTOR 1838 ZAIN 950 Pro Racer Hennessy is proud to announce the 950 Pro Racer Balancer This machine is a 950 contactor style machine with new software for racing wheels and utilizes a 1001 balancer motor The 950 1050 Service Manual and Calibrating instructions should be used when servicing this unit along with the attached wiring diagram and parts list Part No Description 950 CONTACTOR WITH DC BRAKE 3112945 Motor Replacement Kit Remember to unplug the balancer before servicing 700 59 24 STATE LLV NIO 440V 2 W ww N 0 N The part number is Different due to the software 8112850 The CPU chip may be changed with a standard 950 1050 PCB 8110946 8111886 in the event you have a machine down condition for a PCB problem Note The piezo spring tension should be adjusted to the same spec as the 950 1050 which is 2 All other troubleshooting proce dures remain the same as the 950 1050 28 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 950 Pro Racer Wiring Diagram 00 2 V QuyMUO OIA LHM 9 YIG LHM G AIg LDBM b 5 19 6 6 aLIHM dNVC 1 quud b HNI 2 11 Hess 02314 lHDIMN Nug 1HM 6 ees o 02314 LNOWS LHOLY lu i 2 09 1 8 AOZT
27. LE d Le 950 1025 1050 1055 950 ProRacer Computer Wheel Balancers Service Manual and Troubleshooting Guide Vinousrrics mc 3002 1601 J P Hennessy Drive LaVergne USA 37086 615 641 7533 800 688 6359 HENNESSY INDUSTRIES INC Manufacturer of AMMCO COATS and BADA Automoti ii Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 1 Safety Notes 1 2 15 a cof B ur te ord dod 1 Equipment Needed 1 Voltage amp Phase Checking Procedure 2 Preliminary Inspection 3 Functional Checks Operators 3 Accuracy Check Plane Separation 3 4 Rotational Check Use a Hub Centric Wheel 4 Calibration Procedures Weight Sensor Calibration 4 A amp D Arm Calibration Code 10 4 5 otop On Top Calibration Code 20 21 5 Distance Gauge Placement Optimize 5 Error CodeS uuu 5 6 Function 6 7 Troubleshooting Section for Models 950 1025 1050 amp 1055 Balancers 7 16 7 Fan Motor Does Not Contactor Model 9 Accuracy Problems Plane Separation 9 Rotational Problems Contractor amp Motor Controller 1
28. Rectification 7 9 96 ohms Motor Wiring J Forward Circuit Forward 2 1 4 3 6 5 14 13 54 53 64 63 74 73 84 83 2 1 L R 4 3 I2 B 6 5 13 W 14 13 54 53 64 63 Braking 84 83 Braking Circuit Forward 2 1 4 3 6 5 l4 13 a Bridge 64 63 Rectifiers 74 73 84 83 2 1 4 3 6 5 14 13 54 53 Braking 9 84 83 Disconnect power before taking readings he motor may be checked individually using the motor wiring diagram above The complete spin circuit may be checked by placing your ohm leads across L1 amp L2 L2 amp L3 L1 amp L3 Press and hold the spin contac tor in while taking the reading The readings should be approximately 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 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 approximately 24 ohms 5 x 4 8 If the reading is incorrect use the Brake Circuit diagram to check for a bad connection bad wire crimp or high resistance through the cont
29. a ground present Normal acceptable deviation 1 plus and minus 1096 damage can occur when voltage or amperage is beyond 1096 design specs Note If any faults are found in the above procedure it is the responsibility of the owner COATS authorized service personnel are not responsible for wiring within the building Consult a licensed electrical 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 GROUND X Y Z THREE PHASE VOLTAGE REQUIREMENTS INFORMATION 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 measurement is greater that one 1 ohm check the power plug and frame connection for proper contact Operation with a defective ground circuit will create a shock hazard for the operator and could damage the balancer s electron ics Operation with a defective ground cir cuit may void warranty GROUND A B GREEN BLACK SINGLE PHASE VOLTAGE REQUIREMENTS INFORMATION 208V 220V 230V 380V 460V 195 250 370 420 420 480 195 250 370 420 420 480 195 250 370 420 420 480 Y Z Plug Required Hubbell 2420 or Hubbell 2430 or 208V 220V 230V 195 250 Plug Hubbell Required Hubbell 5462
30. actor While the contactor is closed also check terminals 1 to 2 on the brake contactor If your meter fails to register any resistance replace the primary contactor Use an Ohmmeter to check the following connections If your meter fails to register 0 0 ohms repair or replace the defective wire or connection s associated with the terminals just checked 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 brake contactor terminal 73 After verifying the integrity of the motor connections to the contactor replace the motor assembly See Replacement Procedure Service Manual COATS Models 950 950 ProHacer 1025 1050 1055 15 Use an Ohmmeter to check for continuity on the following connections your meter fails to register any resistance repair or replace the defective wire or connection s associ ated with the terminals just checked Forward contactor terminal 13 to brake contactor terminal 84 Forward contactor terminal 54 to brake contactor terminal 54 Brake contactor terminal 83 to both rectifiers terminal Brake contactor terminal 53 to both rectifiers terminal Brake contactor terminal 5 to all 4 rectifier terminals
31. actor or motor winding 18 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Piezo Output Note Rust corrosion and trash under the The piezo out put test can be used to help diagnose piezo ball or between the piezo and the problems or failures with piezos on the 950 1050 1025 chassie can cause a bad ground and make Limited Edition 850 and 700 balancers When the the readings fluctuate Cleaning reinstalla test is activated the weight display will show four dif tion adjusting to proper torque and cali ferent readings as the Dynamic RV Alloy 1 and Alloy 2 brating may be all that is necessary for LED s alternately light up The values needed are the repair Dynamic 1st LED and Alloy 1 8rd LED Dynamic value is the amplitude or signal strength of the left piezo Alloy 1 is the amplitude of the right front and rear piezo added together except for 850 that only has two For the 700 balancer use the Dynamic LED for the left piezos It is the consistency of the readings through Alloy LED for the two right piezo s five or six spins that is important not the value of the Note For 850 use the Dynamic LED for the left reading and Static LED right reading When checking these two balancers only use the left readings display readings rounded off to 3 places To use the codes perform the following steps Code 52 Shift 0 52 Code 27 1 Mount a balanced wheel on the balancer with a 4 950 1050 1025 700 8
32. ate tightly against faceplate Is the hub nut broken or Replace the damaged the cones damaged part s Move balancer to a another location in the shop Is the balancer located near a piece of equipment that causes the floor to vibrate Check the tension adjustment on the motor springs See step 19 in the DRIVE MOTOR REPLACEMENT PROCEDURE Where they adjusted properly Adjust springs See step 19 in DRIVE MOTOR REPLACEMENT Yes PROCEDURE Did this correct the problem Check the piezo wiring at the piezo and at the PC B plug for good connections Repair defective connection s heck replace piezos see the procedure on page 32 Did this correct the problem Check replace the optical Return to FUNCTIONAL encoder See the procedure on CHECKS page 30 31 Did this correct the problem Replace the PCB See Replacement Procedure Did this correct the problem Replace the drive motor assembly See Replacement Procedure 10 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Display Does Not Light Contactor Model Is the power switch set Turn the power to the ON position switch ON Yes Have the voltage supply to the machine corrected Is the proper voltage and ground present at the receptacle See AC CheckingProcedure Has one of the 3A breakers on ves the power panel tripped No Reset the tripped breaker If the breaker trips again replace the PCB S
33. 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 amp D ARM CALIBRATION PROCEDURE on page 10 11 11 5ee WEIGHT SENSOR CALIBRATION PROCE DURE on page 9 10 A Potentiometer Replacement 1 Remove the A pulley see the procedure under topic A PULLEY REMOVAL on page 34 2 Unplug the three 3 wires form the A potentiome ter from the wiring harness 3 Remove the wires for the A potentiometer from the A amp D Bracket 4 Remove the potentiometer retaining nut lock washer and the potentiometer 5 Install the new potentiometer lockwasher and retaining nut 6 Install the potentiometer wires to the A amp D Bracket using a small mount of silicone sealer adhe Sive 7 Connect the wires for the A potentiometer to the wiring harness 8 Install the A pulley see the procedure under A PULLEY INSTALLATION in this guide D Pulley Removal 1 Rotate the pulley clockwise and remove the brass stop and cable from the catch groove on the pulley 2 Loosen the cap screw on the pulley and carefully slide the pulley and return spring trom the shaft of the potentiometer 26 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 D Pulley Installation Adjustment Code 10 1 Completely back off the plunger stop pin 2 Locate the return spring onto the D pulley Install the tension
34. bly see Replacement Procedure Return to FUNCTIONA CHECKS 89 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Rotational Problems Contactor amp Motor Controller Model Is the test wheel balanced No Fine balance test wheel to 0 00 0202 and test again Yes baart nasie Perform WEIGHT SENSOR CALIBRA ACCURACY CHECK TION procedure or refer to ACCURACY l PROBLEMS flow chart and test again Yes Are there burrs dirt and or grease on faceplate test wheel R emove burrs and dirt cones or pressure cup prevent ing perfect centering of the wheel Are there worn or defective cones pressure cup threaded Replace defective parts stud backcone spring or hub and test again nut Using a dial indicator check the runout on the mounting surface of the Replace drive motor see motor face plate amp the runout of the arbor shaft Are both total indicated Test again runouts greater than 001 Try mounting the wheel with a new centering cone and spring Does the balancer now pass the rotational test Return to FUNCTIONA CHECKS Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 9 Repeatability Problems Contactor amp Motor Controller Model Mark the wheel amp faceplate with a piece of chalk and check after each spin Is the wheel slipping Clean the faceplate and or remove all nicks Make sure wheel is chucked against the face pl
35. cer 2 Remove weight tray and weight tray shield 3 Disconnect plug to capacitor assembly 4 Remove three 3 6 32 X 1 2 screws holding capac clamps to capacitor panel and remove capacitor clamps 5 Remove capacitors Note wire locations discon nect wires from capacitors and transfer wires to new capacitors Note Only one capacitor should have a resis tor connected across its terminals 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 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 25 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 Disconnect signal harness connections inside chassis 6 Cut tie wrap securing signal harness to chassis 7 Pull harness out of hole in back of chassis and then up through pod support tube and out through pod 8 Install new signal harness 9 Connect signal harness connections inside chas sis Refer to wiring diagram Note All signal harnesses come wired for the model 950 When installing a signal har ness in a model 1025 remove the jumper between 15 to 17 For a1050 55 remove the jumpers from terminals 15 to 17 and 16 to 18 on the 18 pin connector 10 Connect
36. ct the balancer before servicing Use only manufacturer s recommended acces sories Improper accessories may result in per sonal injury or property damage Repair or replace any part that is damaged or worn and that may cause unsafe balancer operation Do not operate damaged equipment until it has been examined by a qualified service technician Never overload or stand on the balancer Do not allow untrained persons to operate machinery To reduce the risk of fire do not operate equip ment in the vicinity of open containers or flamma ble liquids gasoline Adequate ventilation should be provided when working on operating internal combustion engines Keep hair loose clothing fingers and all parts of body away from moving parts Use equipment only as described in this manual Use only manufacturers recommended attach ments SAVE THESE INSTRUCTIONS iv Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Introduction This service manual contains the functional checks troubleshooting adjustment and part replacement instructions for COATS Models 950 950 Pro Racer 1025 1050 and 1055 Wheel Balancers Exploded views illustrations and an indexed parts list facilitate parts location ordering and replacement All adjustments and replacements can be rendered with mechanic s or electrician s tools Safety Notes High voltages high torque motors and high speed rotating whe
37. d unplug the machine 2 are several type of rectifiers with different types of terminal identification Use the drawing below that best represents the type oof rectifier you are checking Red 45 pk OL BIk Red Volt Leads Typical readings your VOM readings may very slightly AC AC 3 Remove all wires from the rectifier being checked 4 Set Ohmmeter to the diode check mode if so equipped 1 your meter does not have this mode use the highest range ohm scale 5 Plug the red lead into the meter in the connection marked ohms 6 Plug the black lead into the meter connection marked common or ground 7 Place the black lead of your meter on the terminal marked 8 Use the red lead of your meter to check to the other two 2 AC terminals 9 he readings from these terminals should not rep resent a short 0 00 If at any time during this proce dure you obtain a reading that represents a short the rectifier must be replaced 10 Place the red lead of your meter on the terminal marked 11 Use the black lead of your meter to check to the other two 2 AC terminals Service Manual COATS Models 950 950 1025 1050 1055 17 Optical Encoder Code 44 1 Press and hold the SHIFT key and press O Then press 4 followed by 4 Rotate the wheel the readings in the display window should change from 000 to 255 If not check the shutter di
38. e open try resetting and rechecking If the breaker remains open amp does not trip replace the breaker Breaker Trips Replace the PCB See Replacement Procedure Repair or replace the defective wire or connection Checks Bad Check the continuity of the wire from the terminal marked OV on the transformer to terminal 6 on the forward contactor Checks Check the continuity of 2225 the power switch Checks Bad Replace the power switch See Replacement Procedure Repair or replace the defective wire or connection Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 11 Balancer Does Not Cycle Contactor Model To use the following chart you will need a tire and wheel assembly mounted on the balancer the hood closed and the proper A W and D dimensions entered If you are unable to manually enter the proper wheel dimensions replace the touch panel Has one of the 1A circuit Does Not Proceed to balance breakers on the rear of the press the start button Proceed to balance machine tripped Trips Turn the power switch OFF and unplug the machine Disconnect the white violet wire from the forward Trips Replace the PCB See Replace Procedure contactor reset the breaker Plug in the machine turn the power switch ON amp press the start button Does Not Trip Replace the contactor See Replace Procedure Does the forward contactor Will the ba
39. ec the contactor to the motor tive wire or connections Good NEXT PAGE Replace the drive motor See Replace Procedure 14 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 CONTINUED FROM LAST PAGE Does the Balancer trip a circuit breaker on the electrical panel when it starts the brake cycle Check the bridge rectifiers See Checking Procedure Manually closing the contactor to check voltage may cause the wheel to spin at high speeds To avoid this from happening disconnect the wires going from the contactor to the motor Manually close the brake Manually close the brake contactor Is there 220VDC on contactor Is there 220VAC No Replace the contactor See between terminals 13 amp 54 on between terminals 3 amp 5 on Replace Procedure the forward contactor the lower contactor Turn the power switch OFF and unplug the balancer from the power source Manually close the brake contactor Use Replace the auxiliary an Ohmmeter to check between termi brake contactor See nals 53 amp 54 and between terminals 83 Replacement Procedure and 84 on the brake contactor 1 there less than 1 Ohm on both checks Turn the power switch OFF Manually close the brake contac tor Use an Ohmmeter to check these connections for conti nuity on the brake contactor 63 to 64 amp 73 to 74 If your meter fails to read 0 0 ohms replace the auxiliary piggy back contactor on the brake cont
40. ee Replacement Procedure Disconnect the 2 RED wires from the circuit breakers Is there 20VAC between these 2 RED wires Reconnect wires Is there between 200 amp 230VAC between the terminals marked OV amp 230V on the transformer Checks Turn the power off and unplug the s machine Check the continuity of the two 2 3A circuit breakers Checks Good Connect the machine to a power source and turn the power switch ON Is there 20VAC between pins 1 amp 2 on the connector on the right side of the PCB Yes Checks Good Turn the power off and unplug the machine Check the continuity of the RED wires from the trans former pins 1 amp 2 on the connec tor on the right side of the PCB Checks Bad Turn the power off and unplug the machine Turn the power switch to the ON position Check the continuity of the wire from the 230V terminal on the transformer to terminal 4 950 or terminal 64 1050 on the forward contactor Checks Is there 220VAC between Good terminals 4 amp 6 on the forward contactor Checks Bad Replace or repair the defec tive jumper wire from the Is there 220VAC between forward to brake contactor terminals 4 amp 6 on the brake contactor Check the continuity of the power cord from the terminals to Bad the appropriate connection on the brake contactor Replace the transformer See Replacement Procedure If either of the breakers ar
41. els are present in coats wheel balancers Follow the safety rules below while servicing a bal ancer 1 Disconnect balancer from power source before starting any part replacement or internal adjustment 2 Lower guard hood before starting cycle 3 Do not wear neckties or loose clothing while serv icing the balancer 4 Be aware of hair length If hair is long wear it up under a hat 5 Mounting cones must be centered in wheel before tightening The wheel must be forced up firmly against the faceplate The hub nut must be engaged by a mini mum of four 4 full threads Tighten hub nut by rotating the wheel and striking a spoke of the hub nut with the heel of the hand Failure to tighten the hub nut could result in serious 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 using the pictorial breakdown and index in this manual It is important that the functional checks be performed in sequence and the problem iso lated prior to attempting any adjustments or replace ments an adjustment or replacement is made the entire functional checks must be performed success fully
42. error Check for a defective ground circuit or line filter prob lem Note The machine should be on a dedicated circuit Err 8 Displayed when The most likely cause is noise interference Check for a defective encoder cable or defective PCB Check for a defective ground circuit or line filter problem Note The machine should be on a dedicated circuit Err 9 his message is displayed when the speed of the wheel has decreased at too fast a rate This could occur if the machine is extremely cold and a small wheels mounted on the shaft Err 10 his message is displayed when a sequence error has occurred with the calibration of the A amp D arm See the A amp D ARM CALIBRATION PROCEDURE Err 11 his message is displayed when an unac ceptable A dimension was entered during the A amp D arm calibration process See the A amp D ARM CALI BRATION PROCEDURE Err 12 his message is displayed when an unac ceptable D dimension was entered during the A amp D Arm calibration process See the A amp D ARM CALI BRATION PROCEDURE Err 13 his message is displayed when the A pot is not adjusted properly See REPAIR PROCEDURES FOR A amp D ARM ASSEMBLY Err 14 his message is displayed when the D pot is not adjusted properly See REPAIR PROCEDURES FOR A amp D ARM ASSEMBLY Err 15 Displayed when the motor has gone over speed prior to breaking This could be caused by a defective PCB encoder contactor or mot
43. ezo output 53 Piezo Output Test 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 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 7 Troubleshooting Section for Models 950 1025 1050 amp 1055 Balancers Introduction For balancers with Solid State Motor Controllers refer to that section only in the flow charts and wiring dia grams located in the back of this manual The trou bleshooting section of this manual makes use of flow charts These flow charts will enable you to more quickly and accurately locate the problem with the bal ancer main topics covered by these flow charts FAN MOTOR DOES NOT RUN ACCURACY PROB LEMS ROTATIONAL PROBLEMS REPEATABILITY PROBLEMS DISPLAY DOES NOT LIGHT BALANCER DOES NOT CYCLE and BALANCER DOES NOT BRAKE These flow charts may refer you to another section of the manual If after a repair has been com pleted you encounter another or similar problem refer to the section that best describes the problem cur rently encountered The flow charts are designed to lead you to the most likely problems towards the top of the chart where possible Hennessy Industries Inc hopes this manual will help you provide the best and most thorough service to our customers The flow charts will refer to several voltage checks at various points To avoid lengthy and confusing charts the vol
44. feature there is no jumper between pins 16 18 the right weight display will show SOT to indicate the presence of the stop on top hardware otherwise the display will show NST It should be noted that the presence or absence of the arm and stop on top is not detected directly so if the jumpers are improperly installed incorrect information will be displayed 42 Keyboard Test After the code is entered all dis plays will be blank When a key is pressed the number of the key or a description of the function is activated MODE and SHIFT keys is displayed on the wheel parameter display Io exit the test press and hold the SHIFT key and press the zero 0 key 43 Display Test All display segments are turned on simultaneously including decimal points and individual LED s test be terminated by pressing and holding the SHIFT key and then pressing and releasing the zero 0 key If the test is not terminated manually it will terminated automatically 44 Encoder TEST encoder count is displayed on the right weight display and the left display is blanked The count should be zero 0 when the top dead center 6 Service Manual COATS Models 950 950 ProHacer 1025 1050 1055 indicators are flashing As the shaft is rotated forward the count should increase At the point where the bot tom dead center indicators are flashing the count should be 128 and should continue to increase as the shaft is rotated i
45. grease on back of the bridge rectifier and install the new bridge rectifier 7 Connect wiring The wires must be transferred to new bridge rectifier exactly as connected previously 8 Plug in the balancer 9 Check bridge rectifier as outlined in TROU BLESHOOTING SECTION 10 Install weight tray and weight tray shield 11 Perform the FUNCTIONAL CHECKS 22 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 A amp D Arm Assembly Note The Model 950 uses a manual Distance Gauge Assembly The model 1050 uses an automatic Distance A and Diameter D Gauge Assembly These assemblies are repairable Refer to the illustrated parts breakdown and parts lists in the back of this manual for individual parts identification 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Model 1050 disconnect plugs 4 Remove three 3 1 4 20 flange nuts holding gauge assembly 5 Remove gauge assembly 6 Install new or repaired gauge assembly 7 Model 1050 connect plugs 8 Plug in the balancer 9 Model 1050 perform A amp D Arm Calibration Procedure 10 Install weight tray and weight tray shield 11 Perform the FUNCTIONAL CHECKS Fan Motor Assembly 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Disconnect fan motor plug 4 Remove rear end bell cover 5 Remove the two 2 8 32 nuts holding the fan motor to the drive motor and remove the fan motor a
46. h Panel Aluminum Back Panel 5 Disconnect the plug going to the PCB Assembly 6 Replace the defective Touch Panel Aluminum Back Panel or PCB Assembly and connect the plug trom the Touch Panel Aluminum Back Panel to the PCB Assembly Note Make sure there are no twists or kinks in the cable 7 Install the eight 8 screws holding the PCB assem bly to the Touch Panel Aluminum Back Panel 8 Install Front Panel PCB Assembly to the pod 9 Plug in the balancer 10 Perform the FUNCTIONAL CHECKS 20 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 Hood Magnet 1 Remove the rubber hood stop from the hood bracket on the chassis 2 ean the hood back as far as it will go 3 Remove the magnet from the hood bar 4 Install the new magnet 5 Place the hood in the down position and install the rubber hood stop 6 Check to make sure that the motor starts with the hood down but not with it up 7 Perform the FUNCTIONAL CHECKS Magnetic Hood Switch 1 Unplug the balancer 2 Remove two 2 6 32 x 1 2 screws holding hood switch to hood bracket and remove hood switch 3 Disconnect two 2 wires going to hood switch 4 Connect wires to new hood switch and install 5 Plug in the balancer 6 Check to make sure that the motor starts with the hood down but not with it up 7 Perform the FUNCTIONAL CHECKS Mechanical Hood Interlock Switch 1 Unplug the balancer 2 Drill out the four 4 pop riv
47. he cradle on the new motor 13 Clean and apply Loctite to the surface of the flex plate and the cradle where they mate 14 Apply Loctite 242 to the threads of the 3 8 16 washer head screws and install the flex plate on the cradle 15 Ensure balls are inserted into each piezo assembly Note Current piezos 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 drive motor wires to the contactor and auxiliary contactor block Note Each motor wire is numbered corre sponding to the motor terminals on the wiring diagram 22 Install the weight tray weight tray shield and motor cover and plug in the balancer 23 Perform the FUNCTIONAL CHECKS Piezo Assembly Note See checking procedure in this manual before replacing piezos 1 Unplug the balancer 2 Remove weight tray weight tray shield and motor 3 Remove the four 4 3 8 16 Nyloc spring retaining nuts spring retainers and piezo springs 4 Remove the two 2 5 16 18 X1 washer head screws 5 Disconnect the fan motor and optical encoder plugs 6 Note wire colors and discon
48. he previous See WHEEL DOES NOT SPIN Err 2 Similar to Err 1 this message is displayed when the time to reach measurement speed is too long This can be caused by a defective motor defec tive contactor motor control board or incorrect wiring of either See WHEEL DOES NOT SPIN Err 3 Displayed when no encoder pulse is detected after the start button is pressed the motor did not spin This can be caused by incorrect wiring to the encoder contactor motor control board motor PCB or safety interlock switch the drive motor did not start see the troubleshooting procedure for WHEEL DOES NOT SPIN If the drive motor does begin to spin See OPTICAL ENCODER CHECKING PROCEDURE Err 4 Displayed when the machine detects the wheel rotation in the reverse direction This can be caused by incorrect encoder or motor phasing motor control board or a bad PCB See WHEEL DOES NOT STOP Err 5 his message Is displayed when the time to brake the wheel to a stop at the end of the cycle is too long This can be caused by bad contactor motor con trol board or a bad PCB See WHEEL DOES NOT STOP Err 6 Displayed when there is no power to the LEDs on the encoder This can be caused by a defective encoder or PCB or improper encoder wiring See OPTICAL ENCODER CHECKING PROCEDURE Err 7 Displayed when a time out occurs within the software This can be caused by noise interference in the encoder circuit causing a signal sequencing
49. ide out contactor 8 Install new contactor and connect wiring Contactor wiring must be transferred to new contactor exactly as connected previously Failure 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 shield and plug in balancer 42 Perform the FUNCTIONAL CHECKS Auxiliary Contactor Block 1 Perform steps 1 through 4 of Contactor Replacement Procedure 2 Disconnect wiring trom auxiliary contact block 3 Lift the white lever that is on the top of the contac tor block and slide the contactor block off the contactor 4 Install new contactor block and connect wiring Follow the same precautions as outlined in step 8 of the CONTACTOR REPLACEMENT PROCEDURE 5 Perform steps 9 through 12 of CONTACTOR REPLACEMENT PROCEDURE Bridge Rectifiers Note See checking procedure on page 23 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Identify and record wire locations 4 Disconnect wiring from bridge rectifier 5 Remove the 8 32 x 3 4 screw holding the bridge rectifier to the power panel 6 Place a small amount of thermal
50. is connect the wires going from the contactor to the motor CONTINUED ON NEXT PAGE 12 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 CONTINUED FROM Manually closing the contactor to check voltage may cause the LAST PAGE wheel to spin at high speeds To avoid this from happening dis connect the wires going from the contactor to the motor Is there 230VAC from terminals Is this Model 1050 64 to 74 74 to 84 amp 84 to 64 on Kio the forward contactor Repair or replace defective jumper wire or connections Voltage Manually close the forward contac wo tor amp check for 230VAC on terminals Present Replace the forward 63 to 73 73 to 83 amp 83 to 63 of the auxiliary contactor See Replace Procedure forward contactor Voltage Present Turn the power switch OFF amp unplug the machine Use an Ohmmeter to More Than Repair or replace 1 Ohm check from terminal 53 on the defective jumper wire forward contactor to terminal 74 on the brake contactor Less Than 1 Ohm or connections More Than Use an Ohmmeter to check from 1 Ohm terminal 74 on the brake contactor to terminal 2 on the forward contactor Less Than 1 Ohm Manually close the forward More Than contactor Use an Ohmmeter to 1 Ohm check from terminal 2 to terminal 1 on the forward contactor Replace the contactor See Replace Proce dure Less Than 1 Ohm After verifyi
51. ition L E D for the outside right plane should be flashing when the weight is at bottom dead center A amp D Arm Calibration Code 10 1 Press and hold the SHIFT key and press O Then press 1 followed by O The A pot reading is displayed on the left weight display and the D pot reading is dis played in the right weight display The reading for the A pot should be between 0 05 and 0 30 and the D read ing should be between 0 40 and 0 80 when the arm is in the park position If the readings are not between the given values see A and or D PULLEY INSTALLATION 2 Rotate the arm to the maximum diameter position While holding the arm in this position press the MODE key 3 Return the arm to the park position and press the MODE key 4 Pull the arm out to the test wheel and position it into the radius of the wheel While holding the arm against the wheel you must enter the distance dimension to the test wheel enter as 2 digits 1 6 5 8 Before releasing the arm from this position enter the diameter of the wheel D dimension as 3 digits 1 e 4 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 14 0 After these parameters have been entered the weight displays will show 0 and the machine returns to normal operating mode 5 Return the arm to the park position Then pull the arm out and position into the radius of the wheel The correct A and D readings should appear on the wheel parameter display The
52. its holdint the sheld in place 3 Remove the screw and nut holding the switch 4 Disconnect two 2 wires going to hood or interlock switch 5 Connect wires to new hood or interlock switch and install Note The two 2 switches are wired differ ently one is normally open and the other 1 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 off switch 4 Squeeze the retainers at the top and bottom of the switch and push it through the opening in the power panel and chassis B Install new on off switch 6 Connect wires 7 Install weight tray and weight tray shield and plug in balancer 8 Perform the FUNCTIONAL CHECKS Circuit Breakers There are four 4 circuit breakers three 3 breakers if the unit has a Motor Controller PCB located on the top of the Power Panel Refer to the Wiring Diagrams for circuit location The replacement procedure for each is the same 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Disconnect wiring to circuit breaker 4 Squeeze the retainers on both sides of the circuit breaker and push it through the power panel and chas SIS B install new circuit breake
53. lancer cycle with close when the start button both the hood switch wires Replace the hood switch is depressed on the same terminal N Is there 27VAC between the two No Replace the transformer See Orange wires on the transformer Replace Procedure o Yes Turn the power switch OFF and unplug Is there continuity from A1 of the machine Disconnect the connector the forward contactor to from the right side of the PCB Is there terminal 6 of the connector on continuity between A2 of each contactor the right side of the PCB Is the proper voltage and ground present at the Correct the voltage receptacle See page 6 for supply to the machine Is there 3 to 5 or 5 to 7 new the checking procedure contactors Ohms resistance between A1 amp A2 on the forward contactor Is there 230VAC on terminals 4 to 6 6 to 14 amp 14 to 4 on the brake contactor Repair or replace defective power cord or connections Replace the PCB See Replace Procedure Is there 230VAC on terminals 4 to 6 6 to 14 amp 14 to 4 on the forward contactor Repair or replace defective jumper wire or connections Yes Manually close the forward Voltage Not contactor amp check for 230 VAC on Present 5 terminals 3 to 5 5 to 13 amp 13 to 3 of the forward contactor Manually closing the contactor Voltage to check voltage may cause the Present wheel to spin at high speeds To avoid this from happening d
54. n the forward direction The maximum count should be 255 which occurs just before the top dead indicator begin to flashing as the shaft is being rotated forward If the shaft is being rotated in the reverse direction the above comments apply to top dead center and bottom dead center Ihe count will decrease from 255 to zero 0 as the shaft is being rotated in the reverse direction from top dead center he test may be terminated by pressing and holding the SHIFT key and then pressing and releasing the zero 0 key 47 Cycle Count This code displays the cycle count of the board The cycle count is displayed in the weight display The weight displays are treated as a single 6 digit display when displaying the count 50 Exit Code Code to escape from continues loop such as when displaying the transducer outputs 51 A amp D Arm Adjustment This code represents subset of code 10 A amp D arm calibration It allow the A amp D potentiometers to be continuously monitored with out having to do a complete calibration The pri mary purpose is to enable the pulleys to be adjusted on the potentiometer shaft The A potentiometer voltage 1 displayed on the left weight display and the D poten tiometer voltage is displayed on the right weight dis play exit this code enter code 50 52 Piezo Output Test 300 RPM Used to verify that the output of the piezo are consistence through several spins Refer to the checking procedure pi
55. nect wires to piezo assemblies 7 Lift up on the motor and twist and lift the piezo assemblies to remove from the chassis Note The piezo assemblies used in the mod els 950 and 1050 balancers are different from other Coats balancers in that they are held in position by studs in the bottom of the piezo carriers that fit into holes in the chas sis New piezos have the ball molded into the top casting 8 Use emery cloth to clean the mounting surfaces of the piezo assemblies and chassis install new piezo assemblies and connect wires 9 Install the two 2 5 16 18 X1 washer head screws 10 Install piezo springs spring retainers and Nyloc nuts 11 lighten the Nyloc nuts until the distance from the top of the motor cradle to the top of the retainer is two 2 inches 12 Connect the fan motor and optical encoder plugs 24 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 13 Install weight tray weight tray shield and motor and plug in balancer 14 Perform the FUNCTIONAL CHECKS Capacitor Assembly 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Disconnect plug to capacitor assembly 4 Remove four 4 6 32 X 1 2 screws holding capac itor panel to chassis 5 Install new capacitor assembly 6 Connect plug 7 Install weight tray weight tray shield and plug in balancer 8 Perform PRELIMINARY INSPECTION and FUNC TIONAL CHECKS Capacitor 1 Unplug the balan
56. ng the integrity of If this is a single phase unit try 2 the motor connections at the repalcing the capicator assy contactor Replace defective See Replace Procedure motor assembly See Replace Procedure Manually close the forward Yes contactor 15 there 230 on No Repair or replace defective terminals 3 to 5 5 to 13 amp 13 to 3 on the forward contactor Yes Check connections at the wire B529 Connection Repair or replace nut where the three motor a defective connection wires are joined Good Connection After verifying the integrity of If this is a single phase unit try 227 the motor connections at the contactor Replace defective motor assembly See replacing the capicator assy See Replace Procedure Replace Procedure Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 13 Balancer Does Not Brake Contactor Model CAUTION Does the wheel rotate clockwise Manually closing the contactor to when the forward S Reverse any two power leads check voltage may cause the wheel to engage at power source and re test spin at high speeds To avoid this from Is there 27VAC between A2 on the brake contactor amp terminal 4 No on the connector on the right side of the PCB CONTINUED ON Yes happening disconnect the wires going from the contactor to the motor Does the brake contac Yes Does the brake contactor Yes tor
57. odels 950 1025 1050 amp 1055 Balancers The procedures in this section will aid in replacing major sub assemblies of the balancer Do not disassemble adjust or replace any part before performing the PRELIMINARY INSPECTION and FUNCTIONAL CHECK PROCEDURES proce dures along with the troubleshooting flow charts will isolate the necessary adjustment or replacement Perform checks in the order listed and exactly as spec ified Refer to the illustrated parts breakdowns and parts lists in the back of the manual for parts identification Standard commercial fittings and fasteners are used throughout and should be obtained locally Check all interconnecting wiring and connectors when an electrical malfunction is indicated Check all fittings and fasteners when a mechanical malfunction is indicated Front Panel Printed Circuit Board Assembly Important Never replace the printed circuit board without first checking the contactor coil resistance whenever any of the follow ing symptoms occur Shorted contactor coils will result in failure of the new printed circuit board 1 Displays do not light 2 Drive motor does not start 3 Drive motor does not stop Contactor Coil Resistance Measurement 1 Unplug the balancer 2 Disconnect the plug from the right side of printed circuit board assembly 3 Set ohmmeter to lowest scale 4 Measure the resistance from terminals A1 to A2 on both the start and brake contactors
58. on Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 5 Error Codes The following is a list of error codes When the bal ancer is cycled several operating parameters are checked one of these parameters is not within toler ance the machine 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 is started Iry closing the hood if the machine still gives this error See WHEEL DOES NOT SPIN Err Hub Displayed when the machine detects no load condition on the motor at start up If there is a wheel mounted on the arbor check the mounting of the wheel to make sure it is not slipping See REPEATABILITY PROBLEMS Err Cal Displayed when an error has occurred dur ing the calibration process It can be caused by not placing the calibration weight on the wheel for one or both spins or a defective PCB The code is generated by equal piezo outputs in consecutive spins Err 1 Displayed when the wheel moves slowly when the start button is depressed This can be caused by a defective motor defective contactor motor control board or incorrect wiring of either of t
59. or control board or incorrect wiring of either of the previous Function Codes The following is a list of function codes with it s description Codes are entered into the balancer by pressing and holding the SHIFT key and then pressing 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 code If the code is not entered in this time the code entry routine will automatically be ter minated 10 Calibrate the A amp D arm 20 Toggle stop on top ON or OFF 211 Calibrate stop on top 40 Displays the software revision on the weight dis play The revision letter s is are shown on the left dis play and the revision level is shown on the right weight display 41 Indicates presence or absence of A amp D arm and stop on top hardware as dictated by the electronics If there is no jumper connected between pins 15 and 17 on the 18 pin connector in the harness the left display will show AR to indicate an A amp D arm is present If there is a jumper between these pins the left weight display will show NAR to indicate the absence of an A amp D arm An analogous method is used for the stop on top
60. otor Controler Model ESEE TEE 39 Balancer Does Not Cycle Solid State Motor Contmolerdvigdel merer vida e debi PPP Eee S e 40 Balancer Does Not Brake Solid State Motor Ong ole VIOdel FUE OE S ok 41 PCB Checklist Addendum 42 at 4 a tle Aine ooo ota 42 et eet A PIED 42 Glossary of Terms 43 his manual has been updated to include all related models Items that are new are high lighted by an asterick for your convenience Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 iii IMPORTANT SAFETY INSTRUCTIONS READ ALL INSTRUCTIONS Eye and face protection recommendations Protective eye and face equipment is required to be used where there is a reasonable probability of injury that can be prevented by the use of such equipment O S H A 1910 133 a Protective gog gles safety glasses or a face shield must be pro vided by the owner and worn by the operator of the equipment Care should be taken to see that all eye and face safety precautions are followed by the operator ALWAYS WEAR SAFETY GLASSES Everyday glasses only have impact resistant lenses they are not safety glasses Do not disable hood safety interlock system or in any way shortcut safety controls and operations Be sure that wheels are mounted properly the hub nut engages the arbor for not
61. r 6 Connect wires 7 Install weight tray and weight tray shield and plug in balancer 8 Perform the FUNCTIONAL CHECKS Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 21 Transformer 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Remove the two 2 8 32 x 1 2 screws and remove the transformer from the Power Panel 4 Record wire color and corresponding transformer terminal numbers B Disconnect wiring to transformer 6 Connect wiring to transformer Transformer wiring must be transferred to new transformer exactly as connected previ ously Failure to perform this important step properly may result in damage to trans former balancer wiring or printed circuit board See Wiring Diagram 7 Install new transformer to Power Panel 8 Install weight tray and weight tray shield and plug balancer 9 Perform the FUNCTIONAL CHECKS Contactor 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Loosen the power cable clamp on the back of the chas sis and push one or two feet of cable into the chassis 4 Remove three 3 6 32 x 1 2 screws holding power panel to chassis and set power panel on top of bracket in center of balancer to facilitate wire removal 5 Record the wire numbers and the corresponding contactor terminal location 6 Disconnect wires at contactor 7 Loosen two 2 8 32 x 3 4 screws holding contac tor and sl
62. re under topic D PULLEY REMOVAL 2 Unplug the three 3 wires form the D potentiome ter from the wiring harness 3 Remove the wires for the D potentiometer from the A D Bracket 4 Remove the potentiometer retaining nut lock washer and the potentiometer 5 Install the new potentiometer lockwasher and retaining nut 6 Install the potentiometer wires to the A D Bracket using a small mount of silicone sealer adhesive 7 Connect the wires for the D potentiometer to the wiring harness 8 Install the D pulley see the procedure under D PULLEY INSTALLATION Motor Service Kit Instructions Hennessy now has available a service motor kit for the 950 1025 1050 1055 Contactor amp Solid State Balancers which will allow everyone to use one part number when ordering a motor The kit will be a com plete motor assembly hardware bag amp wiring instruc tions hardware bag will contain wires wire nuts spade connectors amp a green phoenix connector It will require a crimping tool to crimp the spade connectors to motor wires as needed for contactor style units TO BRAKING CONTACTOR 13 0 TO BRAKING D 3 TO BRAKING CONTACTOR 5 4 5 6 220 CONTACTOR TO BRAKING CONTACTOR 13 OID TO BRAKING OD CONTACTOR 3 TO BRAKING OI CONTACTOR 5 950 CONTACTOR 2 0 CONTACTOR WITH BRAKE 440V 21 WIN NIO
63. roller pcb Is there 220VAC between terminals 1 amp 2 on the T1 terminal ot the MC pcb Turn the power switch ON Have the voltage supply to the machine corrected Reset the tripped breaker If the breaker trips again replace the PCB See Replacement Procedure Disconnect the 2 RED wires from the circuit breakers 18 there 24VAC between these 2 RED wires Reconnect wires Yes Turn the power off and unplug the machine Check the continuity of the two 2 2A circuit breakers Checks Good Connect the machine to a power source and turn the power switch ON Is there 20VAC between pins 1 amp 2 on the connector on the right side of the PCB Turn the power off and unplug the machine Check the continuity of the RED wires from the trans former pins 1 amp 2 on the connec tor on the right side of the PCB Turn the power off and unplug the machine Turn the power switch to the ON position Check the continuity of the wire from the 230V terminal on the transformer to terminal 3 of the Motor Controller Replace the Motor Controller pcb Check the continuity of the power cord from the terminals to the appropriate connection on AC plug Checks Bad Yes Checks Good Checks Bad Checks Good Checks Bad Checks Bad Replace the transformer See Replacement Procedure If either of the breakers are open try resetting and rechecking If the breaker remains open
64. sc for blockage then check the following voltages 2 When reading the voltages on the white amp 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 greater than AVDC Blue to Violet Less than 7VDC greater than AVDC Motor Circuit Testing following diagram will be useful when trou bleshooting the motor circuit of a 1004 1050 or 6401 balancer contactor style It allows you to troubleshoot just the motor using the motor wiring diagram or the complete circuit using the Forward or Braking diagrams The readings may vary slightly depending on your ohm meter but the three readings should be consistently the same It may be useful to check the readings on a working balancer so you will know what your meter reads before trying to repair a nonworking balancer oolid State Balancer motors may be checked in a sim manner by unplugging the motor connector reading across the three motor wires you should have the same readings across L1 to L2 L2 to L3 L1 to L3 Remember to unplug the balancer before using this procedure Motor Circuit Diagram 3 6 48 ohms 2 5 48 ohms 1 4 48 ohms 7 8 96 ohms 8 9 96 ohms Bridge
65. se values would be within 0 20 of the values entered in calibration If the readings are not within tolerance check for slippage of the pot pul leys If they are tight see A amp D ARM PROBLEMS Stop On Top Calibration Code 20 21 1 f the test wheel is not mounted to the machine mount it 2 Press and hold the SHIFT key and press 0 Then press 2 followed by 0 This will toggle the machine into otop on Top feature The weight display should now read SOT ON If the display now reads SOT OFF repeat the key sequence shown above 3 Add a 4 oz weight to the outside of the test wheel 4 Press the START button 5 When the wheel stops press and hold the SHIFT key and press O Then press 2 followed by 1 to cali brate Repeat steps 4 and 5 until the wheel stops with the 4 oz weight at approximately 6 o clock Distance Gauge Tape Placement Optimize A If the ACCURACY CHECK fails try entering A dimen sion 1 higher than the one used originally If the plane separation gets worse try using an dimension 1 lower than the one used originally If the plane separation gets better keep increasing or decreasing the dimension until acceptable value is achieved Calibrate the machine and perform the ACCURACY CHECK Repeat this procedure until the ACCURACY CHECK produces an acceptable result Move the distance tape to the posi tion to allow proper A dimension entry Calibrate the bal ancer using the new A dimensi
66. spring to the retaining pin on the pulley ensuring that the spring coils clockwise from the inside to the outside 3 Slide the D pulley onto the shaft of the poten tiometer 4 Catch the outside hook on the end of the return spring onto the tension pin on the A amp D bracket 5 Rotate the D pulley clockwise approximately 3 4 of a turn and loop the cable from the distance gauge around the pulley 6 Install the cable and brass stop assembly into the groove on the pulley 7 Locate the D pulley on the shaft of the poten tiometer such that the cable assembly from the dis tance gauge is located in the center of the pulley groove and the cable is not contacting the edge of the pulley groove 8 Press and hold the SHIFT key and press O Press 1 and the O 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 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 See the A amp D ARM CALIBRATION PROCEDURE on page 10 11 13 See the WEIGHT SENSOR CALIBRATION PRO CEDURE on page 9 10 Service Manual COATS Models 950 950 ProRacer 1025 1050 1055 27 D Potentiometer Replacement 1 Remove the D pulley see the procedu
67. ssembly 6 Install new fan motor assembly and tighten nuts 7 Connect fan motor plug 8 Install 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 this shim in place when replacing the rotary shutter 5 Install the new rotary shutter 6 Put Loctite 242 or equivalent on the 3 8 shoulder bolt threads install and tighten 7 Install rear end bell cover 8 Install weight tray and weight tray shield and plug in balancer 9 Perform the FUNCTIONAL CHECKS Optical Encoder Assembly 1 Unplug the balancer 2 Remove weight tray and weight tray shield 3 Remove rear end bell cover 4 Remove rotary shutter 5 Disconnect optical encoder plug 6 Slide optical encoder from aluminum rear end bell casting Note Some motors will have a plastic shim behind the optical encoder Leave this shim in place when replacing the optical encoder 7 Install new optical encoder 8 Install rotary shutter 9 Install rear end bell 10 Connect optical encoder plug 11 Install weight tray and weight tray shield and plug in balancer 12 Perform the FUNCTIONAL
68. t enough to allow the wheel to move While holding the faceplate so it cannot turn rotate the wheel 90 degrees relative to the faceplate Tighten hub nut 3 Press START Weight readings should be 0 30 oz or less 4 Repeat steps 2 amp 3 At 180 and 270 degrees weight readings should be 30 oz or less B If the specified results are not achieved see ROTA TIONAL PROBLEMS Calibration Procedures Weight Sensor Calibration 1 Turn the power switch ON 2 Mount the test wheel to the machine 3 Enter the wheel parameters f the machine is in ROUND OFF mode toggle it OFF by pressing and holding the SHIFT key and press ing ROUND OFF 5 f the machine is not in ounce mode put it into ounce mode by pressing and holding the SHIFT key and pressing GM OZ 6 Press and hold the SHIFT key and press CALI BRATE to enter the calibration mode Ihe display should read CAL O 7 Push the START button The 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 Push the START button 13 he outer right weight display should read 4 00 0 02 oz and the center pos
69. tages shown on the blocks of the chart are nom inal To better define these voltages see the range chart below 120VAC 98 to 125VAC 220VAC 198 to 240VAC 27VDC 22 to 32VDC Fan Motor Does Not Run Contactor Model Turn the power switch ON See the troubleshooting procedure DISPLAY DOES NOT LIGHT Has the 1A breaker for Yes Reset the tripped breaker Yes the fan motor tripped Did the breaker trip again Is the fan motor running Yes Return to FUNCTIONAL CHECKS Is the power switch set to the ON position Yes Does the display light Is there 120VAC between the terminals marked OV amp 120V on the transformer Replace the transformer see Replacement Procedure Accuracy Problems Plane Separation Did you perform weight Perform weight sensor amp A D arm sensor and A D arm calibration see Calibration calibration Procedures Check Replace piezo Is weight reading No sensors Did this correct accurate problem Yes 2 Replace optical encoder Is position accurate Check for loose shutter Yes wheel Did this correct the problem Replace the circuit breaker see Replacement Procedure 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 Replace the fan motor see Replacement Procedure Replace PCB Assem

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