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Hofmann Megaplan MS400-2 Technical Maintenance Manual

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TECHNICAL
MAINTENANCE
MS400-2 Version C (Type 0967)
MS400-2P Version D (Type 1001)
Hauptstraße, 67 - Tel. (+43) 6214 646612
Fax (+43) 6214 646622 - EMail: HM-mail@hofmann-megaplan.com
Hofmann Megaplan GmbH
A 5302 HENNDORF - AUSTRIA
19.08.2013
English

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Summary of Contents for Hofmann Megaplan MS400-2

  • Page 1 TECHNICAL MAINTENANCE MS400-2 Version C (Type 0967) Hofmann Megaplan GmbH MS400-2P Version D (Type 1001) A 5302 HENNDORF - AUSTRIA Hauptstraße, 67 - Tel. (+43) 6214 646612 19.08.2013 Fax (+43) 6214 646622 - EMail: HM-mail@hofmann-megaplan.com English...
  • Page 3 SHEET 001 POWER SUPPLY VOLTAGE CHANGE Models: M400-2(C) - M400P-2(C) - M400P-2(D) The wheel balancer can operate at 115 V – 50/60 Hz or 230 V – 50/60 Hz To change the power supply voltage, make the following modifications: Description Image Replace the motor Replace the capacitor...
  • Page 4 SHEET 002 LOGIC BOARD INITIALISATION Models: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image Turn on the machine while holding down the button Press to confirm Initialisation done...

  • Page 5: Self-Diagnostics

    SHEET 003 SELF-DIAGNOSTICS Models: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image Press Press Press...
  • Page 6 Press All the LEDs and the display must light up for 1 second After 1 second [Pos 137] appears; the current wheel position is shown on the right-hand display with a number between 0 and 255. Turning the wheel in the rotation direction, the number displayed must increase.
  • Page 7 Indicates the output of the piezo sensor R1. It must be equal to 200 +/-30 with the shaft bare. Press Indicates the output of the piezo sensor R2. It must be equal to 200 +/-30 with the shaft bare. Press Displays the DISTANCE sensor value Press Displays the DIAMETER sensor value...
  • Page 8 Displays the WIDTH sensor value Press End of self-diagnostics. To end self-diagnostics at any time press...
  • Page 9 SHEET 004 SPINDLE UNBALANCE RESET Models: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image Press Press Press...
  • Page 10 Press Press in sequence To proceed with the unbalance reset: Press (spin with the shaft bare) Spindle unbalance reset complete...
  • Page 11 To view the unbalance and timing values used to reset the spindle unbalance, continue as follows: Press Press Press Press...
  • Page 12 Press in sequence The unbalance value (left-hand display) and the timing value (right-hand display) used to reset the inside unbalance are shown (IN LED on) Press The unbalance value (left-hand display) and the timing value (right-hand display) used to reset the outside unbalance are shown (OUT LED on) Press...
  • Page 13 SHEET 005 TO ENABLE AUTOMATIC GAUGES Models: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image Press Press Press...
  • Page 14 Press in sequence (within 5 seconds from when has been pressed Press Press select ON by pressing...
  • Page 15 Press to confirm Press to cancel self-diagnostics in any phase...

  • Page 16: Distance Sensor Adjustment

    SHEET 006 DISTANCE SENSOR ADJUSTMENT Models: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image Remove the weight tray (see the relative instructions) Press Press...
  • Page 17 Press Press Press Press...
  • Page 18 Press Press The wording [diS.] appears on the left display while a number appears on the right display, which varies when the distance gauge is moved Back-off the screws fastening the pulley on the potentiometer shaft...
  • Page 19 Leave the gauge in rest position Turn the potentiometer shaft with a screwdriver holding the pulley firm until reading a number between 5 and 15 Tighten the screw...
  • Page 20 Refit the weight tray Calibrate the automatic gauges...
  • Page 21 SHEET 007 DIAMETER SENSOR ADJUSTMENT Models: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image After DISTANCE SENSOR ADJUSTMENT press The wording [dIA] appears on the left display, a number appears on the right display, which varies when the gauge is turned Pull out the gauge and rest it on the adapter surface...
  • Page 22 Back-off the screw that secure the potentiometer on the pulley Turn the potentiometer shaft with a screwdriver holding the pulley firm until reading a number between 5 and 15 Tighten the screw...
  • Page 23 Refit the weight tray Calibrate the automatic gauges...
  • Page 24 SHEET 008 THREADED TERMINAL ASSEMBLY Models: M400-2 (C) Description Image The wheel balancing machine is packed with the threaded terminal removed Carefully clean the inside of the adapter where the terminal will be secured Allen wrench (provided) + threaded terminal...
  • Page 25 Insert the threaded terminal in the adapter Lock the threaded terminal by fully screwing down the hexagonal screw using the wrench provided (tighten it well) Fitted threaded terminal...

  • Page 26: Guard Assembly

    SHEET 009 GUARD ASSEMBLY Models: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image The wheel balancing machine is shipped with the microswitch already fitted in the correct position. Insert the guard pipe in the bushing Hold the bushing in position while inserting the pipe...
  • Page 27 If the bushing is free to move, the microswitch may be damaged!! Close the guard Position the ring with the head of the microswitch in the slot Tighten the first grub screw...
  • Page 28 Open the guard Tighten the second grub screw Fit the spring Fitted guard...
  • Page 29 SONAR WIDTH If present, connect the cable to the relative connector on the rear of the base...
  • Page 30 SHEET 010 WEIGHT TRAY REMOVAL Models: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image Remove the 2 front caps of the weight tray Remove the rear cap of the weight tray Undo the 2 front screws of the weight tray...
  • Page 31 Undo the rear screw of the weight tray Push the weight tray slightly to the left and then lift it (to prevent it from jamming against the pulley of the automatic gauge) Completely remove the weight tray Weight tray removed...
  • Page 32 SHEET 011 MAGNETIC PHASE GENERATOR REPLACEMENT Models: M400-2 (C) Description Image Disconnect the flat cable connector Detach the anti-rotation spring Remove the phase generator by undoing the hexagonal screw turning it clockwise...
  • Page 33 To refit it, operate in reverse order from removal...
  • Page 34 SHEET 011 MAGNETIC PHASE GENERATOR REPLACEMENT Models: M400P-2(C) - M400P-2(D) Description Image Fit the SE spacer on the terminal complete with collar Close the spindle (the encoder becomes visible through the window on the plate) Detach the anti-rotation spring...
  • Page 35 Remove the encoder by undoing the hexagonal screw turning anticlockwise Disconnect the flat cable Detach the board from the Nylon spacers Remove the encoder passing the board through the rectangular hole of the plate positioned near the spacers...
  • Page 36 To refit, perform the operations in reverse order...
  • Page 37 SHEET 012 GAUGE UNIT AND CYLINDER UNIT REPLACEMENT Models: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image Remove the weight tray (see the relative instructions) Remove the encoder (see the relative instructions) Mark (with a felt-tip pin) the position of the plate on the base (this will allow correctly aligning the plate when refitting it)
  • Page 38 Undo the 2 screws A. M400P-2 If the wheel balancing machine is fitted with a pneumatic spindle, also undo the 3 screws B. Undo the 2 screws C Disconnect the 2 potentiometer cables from the board...
  • Page 39 Remove the gauge unit M400P-2 CYLINDER UNIT REMOVAL Close the compressed air and disconnect the tube 90° Turn the cylinder unit 90°...
  • Page 40 To remove the cylinder unit, the internal plate must be positioned with one of the two round sides facing Remove the cylinder unit pulling upward REFITTING Fit the cylinder unit vertically...
  • Page 41 90° Turn the cylinder unit 90° Reposition the gauge unit (use the mark previously made on the base) Screw in the 2 screws A and the 2 screws C...
  • Page 42 Screw in the 3 screws B that support the cylinder unit (without tightening them) SPESSORE PER ALLINEAMENTO 22FP85322 Alignment shim (part no.: 22FP85322) Fit the alignment shim into place...
  • Page 43 Reconnect the tube and open the compressed air Open the spindle Tighten the 3 screws...
  • Page 44 Close the spindle Remove the shim Reconnect the potentiometer cables...
  • Page 45 Refit the encoder Refit the weight tray...
  • Page 46 SHEET 013 PIEZO SENSOR REPLACEMENT Models: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image Remove the weight tray (see the relative instructions) Remove the gauge unit and the cylinder unit (see the relative instructions) Remove the encoder (see the relative instructions) Disconnect the motor, capacitor and power supply cables, and the flat cable Disconnect the piezo extension cable...
  • Page 47 Undo the 4 upper retaining screws Undo the 6 remaining spindle unit retaining screws Gently remove the spindle unit...
  • Page 48 Spindle unit Unscrew and remove the nut with relative washer pack of the dynamic piezo Loosen the internal nut of the static piezo...
  • Page 49 Unscrew and remove the nut with relative washer pack of the static piezo Undo the spindle plate retaining screws Remove the spindle unit from the box...
  • Page 50 Replace the piezo sensors Position the static piezo Position the dynamic piezo...
  • Page 51 Reposition the spindle unit in the box Align the plates with the box and lock the two retaining screws To lock the piezo, position the following parts in sequence: large flat washer, 4 Belleville washers with the concave side facing the large washer, small flat washer, nut These must be tightened with a 400 kg.cm torque wrench...
  • Page 52 Lock the nut (and relative washer pack) of the dynamic piezo (with a 400 kg.cm torque wrench) Tension the tie-rod of the static piezo screwing down the nut and then turn it a further 180° 180° Check that the nut that joins the threaded bars is locked with a 400 kg.cm torque wrench...
  • Page 53 Lock the nut (and relative washer pack) of the static piezo (with a 400 kg.cm torque wrench) Cover both piezos with an abundant layer of silicone Gently refit the spindle unit in the base...
  • Page 54 Screw in (without tightening) the 4 upper self- threading screws Screw in (without tightening) the 6 side self- threading screws Tighten the 4 upper screws with a 120 kg.cm torque wrench...
  • Page 55 Tighten the 6 side screws with a 120 kg.cm torque wrench Reconnect the motor, capacitor and power supply cables, and the flat cable Reconnect the piezo extension cable Refit the encoder, the gauge unit, the cylinder unit and the weight tray Recalibrate the wheel balancing machine...

  • Page 56: Power Board Replacement

    SHEET 014 POWER BOARD REPLACEMENT M400-2(C) - M400P-2(C) - M400P-2(D) Modeo: Description Image Remove the weight tray (see relative instructions) Disconnect the motor cable Disconnect the power cable...
  • Page 57 Disconnect the potentiometer cables Disconnect the flat cable Disconnect the relay board cable (if present)
  • Page 58 Disconnect the sonar cable Disconnect the computer board power cable (sonar signals) Disconnect the protection microswitch cable...
  • Page 59 Detach the board from the Nylon spacers Fit the new power board performing the operations in reverse order...
  • Page 60 SHEET 015 BALANCING MACHINE CALIBRATION Models: M400-2(C) - M400P-2(C) - M400P-2(D) Image Description Fit a medium-sized wheel with steel rim on the shaft. Example: 6” x 15” (± 1”) Take the exact measurements of the wheel mounted Caution!! Presetting incorrect dimensions would mean that the machine is not correctly calibrated, therefore all subsequent measurements will be incorrect until a new self-...
  • Page 61 Press Press Press Press...
  • Page 62 Press Add a 60 g. sample weight on the outside in any angular position Press Shift the sample weight from the outside to the inside keeping the same angular position. Press Turn the wheel until the sample weight is in the 12 o’clock position.
  • Page 63 End of calibration.
  • Page 64 SHEET 016 ENCODER COUNT TEST Models: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image Press Press Press...
  • Page 65 Press All the LEDs and the display must light up for 1 second After 1 second [Pos 137] appears; the current wheel position is shown on the right-hand display with a number between 0 and 255. Turning the wheel in the rotation direction, the number displayed must increase.
  • Page 66 SHEET 017 BALANCING MACHINE CALIBRATION TEST Models: M400-2(C) - M400P-2(C) - M400P-2(D) With the wheel perfectly balanced, first apply 60g on the outside and then on the inside. The wheel balancer must read: IN=0 OUT=60 OUT POS = at low at 6 o’clock IN=60 OUT=0 IN POS =...
  • Page 67 SHEET 018 MACHINE OSCILLATION TEST Models: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image Press Press Press...
  • Page 68 Press in sequence (in maximum 5 sec.) Press Press The machine runs a cycle of 10 spins with automatic calculation and display of the maximum oscillation (If you wish to run more than 10 automatic spins press to select the desired number in the range 5%999) Oscillation (max.

  • Page 69: Distance Gauge Calibration

    SHEET 019 DISTANCE GAUGE CALIBRATION M400-2(C) - M400P-2(C) - M400P-2(D) Model: Description Image Mount the calibration tool on the shaft Press Press...
  • Page 70 Press Press Press Press...
  • Page 71 Press Leave the distance gauge in rest position and press Move the gauge up against the calibration tool (in line with the adapter surface) and press Return the gauge to rest position...
  • Page 72 Calibration done...
  • Page 73 SHEET 020 DIAMETER GAUGE CALIBRATION M400-2(C) - M400P-2(C) - M400P-2(D) Model: Description Image Mount the calibration tool on the shaft Press Press...
  • Page 74 Press Press Press Press...
  • Page 75 Move the gauge to the 80mm measuring position (bottom notch) and press Move the gauge to the 150mm measuring position (top notch) and press Return the gauge to rest position Calibration done...
  • Page 76 SHEET 021 WIDTH SONAR CALIBRATION M400-2(C) - M400P-2(C) - M400P-2(D) Model: Description Image Press Press Press...
  • Page 77 Press Press With the gauge in rest position, measure the distance from the 0 of the distance gauge to the 0 of the width sonar Enter the distance measured by pressing...
  • Page 78 Press to confirm If after calibration the control detects a measuring error of more than ½“, repeat the calibration changing the distance value (tolerance + 20 mm with respect to the value measured with a rule) until obtaining a correct width value.
  • Page 79 SHEET 022 MECHANICAL BRAKE REMOVAL Model: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image Remove the weight shelf (see relative instructions) Remove the gauge unit (see relative instructions) Remove the encoder (see relative instructions) Detach the spring Detach the pedal rod...
  • Page 80 Pull the brake rod out from the top Unscrew the fastening nut Remove the brake Mechanical brake removed...
  • Page 81 SHEET 023 DISTANCE GAUGE CHECK M400-2(C) - M400P-2(C) - M400P-2(D) Model: Description Image Mount the calibration tool on the shaft Move the gauge up against the calibration tool (in line with the adapter surface) and press After acquiring the dimensions, hold down...
  • Page 82 Check that the distance measured is 212 ±3...

  • Page 83: Belt Tension Check

    SHEET 024 BELT TENSION CHECK Model: M400-2(C) - M400P-2(C) - M400P-2(D) Description Image Machine without weight tray (see "Weight tray removal") Hold the wheel locked and press...
  • Page 84 If the belt tension is correct, the motor pulley must not turn.

  • Page 85: Belt Tension Adjustment

    SHEET 025 BELT TENSION ADJUSTMENT Model: M400-2(C) - M400P-2(C) - M400P-2(D) Tools required Pin wrench UNI/ISO 2982/2983 Description Image Remove the weight tray Release the power plate cables from the clips...
  • Page 86 Loosen the 3 power plate retaining screws Place the power plate on the bottom of the base Accessing the motor...
  • Page 87 Loosen the two fastening nuts on the left-hand side of the motor Use the pin wrench illustrated Position the pin wrench on the socket wrench and then adjust the belt tension...
  • Page 88 After adjusting the belt tension, lock the motor fastening nuts If possible, check the belt tension with suitable instruments In service conditions, the belt tension is between 380 and 400 Hz When installing a new belt, overtension it up to 450 Hz to recover the natural belt elongation that occurs in the first 48 hours...
  • Page 89 SHEET 026 PIEZO INSULATION TEST M400-2(C) - M400P-2(C) - M400P-2(D) Model: Description Image Use a megohmmeter with a full scale of min. 3000 MΩ Test the insulation between the dynamic sensor poles between the blue and the yellow wires MIN 2000 MÙ Test the insulation between the yellow wire and the machine body MIN 2000 MÙ...
  • Page 90 Test the insulation between the blue wire and the machine body MIN 2000 MÙ Test the insulation between the static sensor poles between the white and the yellow wires MIN 2000 MÙ Test the insulation between the yellow wire and the machine body MIN 2000 MÙ...
  • Page 91 Discharge the piezo sensors before connecting them to the electronic circuit...
  • Page 92 SHEET 027 AIR SPRING REPLACEMENT M400-2(C) - M400P-2(C) - M400P-2(D) Model: Description Image Remove the weight tray (see relative instructions) Remove the encoder (see relative instructions) Remove the SE terminal (see relative instructions) Remove the gauge unit and the cylinder unit (see relative instructions) Remove the 2 grub screws that fasten the external ring nut...
  • Page 93 Use an adjustable toothed-jaw wrench to act on the external ring nut Hold the rod locked with a flat-jaw wrench Remove the ring nut. You will need to use force when removing the ring nut, as the rod threading will have been scratched by the fastening grub screws...
  • Page 94 Remove the air springs and plate Using a needle file, file off the burr on the rod threading in the ring nut locking area Fit the air springs...
  • Page 95 Fit the plate Fit the ring nut holding the rod locked with the flat- jaw wrench Lock the ring nut by screwing it down with the adjustable toothed-jaw wrench...
  • Page 96 Lock the ring nut fastening grub screws Refit the gauge unit and the cylinder unit (see relative instructions) Refit the SE terminal (see relative instructions) Refit the encoder (see relative instructions) Refit the weight shelf. (see relative instructions)
  • Page 97 SHEET 028 VDD UNIT REFASTENING Model: M400-2(C) - M400P-2(C) - M400P-2(D)
  • Page 98 SHEET 029 VDD BELT REPLACEMENT Model: M400P-2 (C) - M400P-2 (D) Description Image Continue with: Weight tray removal Magnetic encoder replacements Gauge unit and cylinder removal Gauge units and cylinder removed Remove the motor fastening nuts...
  • Page 99 Remove the motor Remove the belt Replace the belt...
  • Page 100 Fit the motor without locking the nuts Identify the hole on the wall for belt tension Insert the screwdriver and tension the belt (also see the specific instructions)
  • Page 101 If there is no hole in the wall, act on the motor tie- rods using a jaw wrench Lock the motor Insufficient tautness may cause rapid belt wear The specific instructions for the belt tensioning and slipping check procedures are given in the maintenance manuals...
  • Page 102 SHEET 030 POWER LAYOUT DIAGRAM Model: M400-2(C) - M400P-2(C)
  • Page 103 SHEET 030 POWER LAYOUT DIAGRAM Model: M400P-2 (D)

This manual is also suitable for:

Ms400-2p