EM8540 N.A.

Cod. 4-104006 - 1.0 del 06/05

English Technical service manual

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Sperimentale Equilibratrici

May 2005

TECHNICAL SERVICE MANUAL EM 8540

Version with roller-driven wheel spin

CONTENTS
ELECTRICAL CONNECTION ................................................................................................................................... 2
SERVICE PROGRAMS ............................................................................................................................................... 2
87 Working environments:............................................................................................................................................ 2
88 Sensitivity calibration (2 spins): .............................................................................................................................. 2
90 Automatic position search (RPA):........................................................................................................................... 3
91 Cancel/reset:.............................................................................................................................................................. 3
93 Display current software version ............................................................................................................................. 4
95 Display phase calibration coefficient ...................................................................................................................... 4
96 Display pickup signal and phase. ............................................................................................................................ 4
97 Display search circuit board operation (encoder)................................................................................................... 5
98 Display sensor operation .......................................................................................................................................... 5
99 Preset speed wheel spin setting: .............................................................................................................................. 6
100 Electrical actuator control function: ...................................................................................................................... 6
101 Counters: ................................................................................................................................................................. 6
MBE161 MOTHERBOARD SWITCH CONFIGURATION.................................................................................... 6
DIAGNOSTICS PROGRAMS ..................................................................................................................................... 7
REMOVING THE WEIGHT-HOLDER LID ............................................................................................................. 7
MBE161 MOTHERBOARD UPDATES .................................................................................................................... 7
REPLACING THE INSIDE SENSOR (DISTANCE AND DIAMETER) REED MICROSWITCH AND
ENCODERS................................................................................................................................................................... 7
Replacing and adjusting the reed microswitch ............................................................................................................ 7
Checking the operation of the diameter encoder [di] .................................................................................................. 8
Checking the operation of the distance sensor [d]....................................................................................................... 8
Replacing the diameter encoder.................................................................................................................................... 8
Replacing the distance encoder..................................................................................................................................... 9
REPLACING AND ADJUSTING THE OUTSIDE SENSOR POTENTIOMETER (WIDTH
POTENTIOMETER)..................................................................................................................................................... 9
Sensor errors: ............................................................................................................................................................... 10
REPLACING AND ADJUSTING THE PICKUPS .................................................................................................. 10
REPLACING THE BRAKE PEDAL SWITCH ....................................................................................................... 11
REPLACING THE ENTIRE CENTRAL UNIT ....................................................................................................... 11
REPLACING THE QUICK LOCK CENTRAL UNIT PNEUMATIC CYLINDER GASKETS ......................... 11
SPIN UNIT................................................................................................................................................................... 12
Replacing the electrical actuator................................................................................................................................. 12
Replacing the friction roller ........................................................................................................................................ 12
Replacing the brake shoe............................................................................................................................................. 13
Replacing the motor..................................................................................................................................................... 14
TROUBLE SHOOTING ............................................................................................................................................. 15
TROUBLE SHOOTING ............................................................................................................................................. 15
ERROR MESSAGES .................................................................................................................................................. 19

-1-
ELECTRICAL CONNECTION
All EM85XX balancing machines operate on single-phase power and are supplied preset for
the specified power supply (115 V, 280V or 230 V AC). To modify this setting, the
transformer primary must be adjusted to the available mains voltage.

SERVICE PROGRAMS
The purpose of these programs is to provide the information required for quickly and
efficiently testing the various parts of the machine.
The selection procedure is as follows:
• press either of the two arrow keys, and then, within two seconds, the wheel size setting
key. This selects the first service program (number 87).
• press the arrow keys to select the next (or previous) available program, until you have
selected the program you wish to use. Each selection results in display of the code
8X...9X (X varies with the program) on the LH display and a flashing "Ent" on the RH
display to indicate the need to confirm the selection by pressing "Enter";
• press the "Enter" key to confirm.
If the presetting is not confirmed within about three seconds, the system automatically exits
the Utility environment.

The various selectable programs (each with a different X) are described below.

87 Working environments:
allows three different operators to work at the same time;
Selecting the program results in the machine displaying:
- message 1, 2 or 3 on the RH display;
- message OP (operator) on the LH display.
This service program allows selection of the operator (1, 2 or 3)
by pressing "Enter".
To confirm selection of another operator, press F.
For each working environment, the following data are stored:
- balancing mode;
- wheel size;
- the last step in the optimization procedure (OPT).
To exit from the program (and the service environment) press F.

88 Sensitivity calibration (2 spins):

Allows calibration of the sensitivity.
This must be done when the user considers that the calibration is outside the tolerance range,
or when the machine itself prompts the procedure by displaying "Err CAL".
When the program is selected the machine displays “ d F ”, hence:
- fit the calibration disc on the balancing machine;
- place the inside sensor touching the calibration disc in line with the hole with the blue outline.
- press F to confirm, and then move the inside sensor to the rest position.
- the displays will show "CAL --I".
- fit the calibration weight to the outside of the disc (position 1);
- run a first spin;
- at the end of the spin the displays will show "CAL --I";
- fit the calibration weight to the outside of the disc again, but this time at 180° to the
previous position (position 2);
- run a second spin;

2
- at the end of the wheel spin, if the calibration has run successfully the message "END
CAL" will be displayed; otherwise, the message "Er3 CAL" will appear for a short time;
- press F to exit the calibration function.

NOTES
- On completion of the calibration procedure, remove the calibration weight and remove
the automatic calibration disc from the balancing machine;
- the user can interrupt the program at any moment by pressing F;
- if the machine displays "ER3 GE2", this indicates an error in performing the calibration
procedure; repeat the calibration;
- message "d 212" displays if the inside sensor has failed; to continue with calibration,
place the inside sensor against the blue hole on the calibration disc and enter the distance
value read on the sensor ruler in manual mode.
- the calibration procedure described above is valid for any type of wheel!

90 Automatic position search (RPA):

Selecting the program results in the machine displaying:
- message RPA on the LH display;
- message ON or OFF on the RH display.
When this program is selected it is possible to enable automatic weight position search by
pressing Enter.
Select:
- OFF to disable automatic position search;
- ON to enable automatic position search;
To exit from the program (and the service environment) press F.

91 Cancel/reset:
- display of the first gram of unbalance;
- rounding to the nearest inch of the diameter and width measured with the automatic
sensors.
Selecting the program results in the machine displaying:
- message "1 oF" on the RH display;
- message "on .5" on the LH display.
In normal operation, even when unbalance display in "gr x 1" is selected, the first gram of
unbalance is not displayed. In this condition, when program "91" is selected the machine
displays "1 oF" on the RH display. Pressing Enter enables display of the first gram and
amplification of the machine's sensitivity (the RH display reads "1 on"). When Enter is
pressed again, the system switches from one mode to the other in alternation.
At switch-on the machine presets to display the diameter and width measured with the
automatic sensors rounded to the nearest inch. In this condition, when program "91" is
selected the machine displays "on .5" on the LH display. Pressing Enter enables displaying
the diameter and width measured with the automatic sensors with a precision of a tenth of an
inch (the LH display reads "oF .5"). Press Enter again to switch between the two modes.

Important
Press Enter to change the display setting when the central element of the position centered indicator
is on. Press either of the two arrow keys to transfer control from one display to the other.

To exit from the program (and the service environment) press F.

3
The program is used for:
- maximum precision display of the unbalance values so as to be able to balance the wheel
perfectly and run further checks on it;
- maximum precision display (tenth of an inch) of the correspondence between the diameter
and width values measured with the automatic sensors and the nominal wheel dimensions.

93 Display current software version

Selecting the program results in the machine displaying:
- message "rEL" (release) on the LH display;
- numeric message "XX.Y" on the RH display, which is the version of the program
currently running on the machine.
- Pressing Enter displays: the date of the software version (day, month, year), the balancing
machine model and the country of destination.
To exit from the program (and the service environment) press F.

The program is used for:

checking the version of the CPU software and updating it, if necessary.

95 Display phase calibration coefficient

Selecting the program results in the machine displaying:
• "F" on the LH display
• the phase calibration coefficient on the RH display;
The data is expressed in encoder marks (integer part) and eighths of a mark (decimal part)
(each mark corresponds to approximately 1.4 degrees).
Press Enter to display the result of the disk calibration procedure.

To exit from the program (and the service environment) press F.

The program is used for:

- checking the values of the phase calibration coefficient are in the allowed range, from -
2.0 to +2.0.
- checking that the disk calibration values are between 97 and 103 grams;

96 Display pickup signal and phase.

Selecting the program results in the machine displaying:
- message "96" on the LH display;
- message "GO" flashing on the RH display.
Before selecting the program, proceed as follows:
- fit the simulator disc to the balancing machine;
- apply a sample weight to the outside of the rim;
- run a spin cycle.
The machine acquires the unbalance signals and then displays in sequence:
- the phase difference F between the pickup signals relative to the ideal value of 180° (RH
display). The data is expressed in encoder marks (integer part) and eighths of a mark
(decimal part) (each mark corresponds to approximately 1.4 degrees);
- values proportional to the levels of the signals from the inside and outside pickups.
- the signal amplifier calibration value;
- the spin speed;
- rejected periods.

4
Notes
• The values displayed are independent of the set dimensions.
• With the wheel stationary, the measured data can be displayed alternately by pressing
Enter.
• It is possible to run additional spin cycles while still in the program.
• To exit from the program (and the service environment) press F.

The program is used for:

checking that the displayed values are within the correct range:
- phase difference F from -2.0 to +2.0
- inside pickup signal I from 200 to 280
- outside pickup signal E from 110 to 170
- signal amplifier calibration from 55.8 to 57.8
- n. rejected periods from 0 to 6

97 Display search circuit board operation (encoder).

Selecting the program results in the machine displaying:
- message "Pos" on the LH display;
- a numerical value from 0 to 255, depending on the shaft angle, on the RH display.
If the program is evoked immediately after the machine is switched on, the display reads "Pos
rot" to indicate the need for turning the shaft until the encoder zero reference passes in front
of the search circuit board: when this is done the message cancels from the display.
It is also possible to run a spin cycle (the displays read "97 GO") during which the pulses
measured by the search circuit board are totaled. On termination of the spin cycle the LH
display shows the expected count (384) and RH display flashes the actual total. These values
are displayed for 5 seconds after which the current angular position of the shaft is again
displayed.
To exit from the program (and the service environment) press F.

The program is used for:

checking the operation of the search circuit board. When the shaft is turned in either direction
the count should run continuously from 0 to 255, and at the end of a spin cycle the two
displayed values should coincide.

98 Display sensor operation

Selecting the program results in the machine displaying:
- message "di" on the LH display;
- the value in marks of the signal from the diameter sensor on the RH display.
As the sensor is retracted, the value is continuously updated.
Press the keypad wheel data setting button, and the following display:
- message "d" on the LH display;
- the value in marks of the signal from the distance sensor on the RH display.
The value changes as the sensor is moved in/out.
Press the keypad wheel data setting button, and the following display:
- message "Lr" on the LH display;
- the converted voltage from the width potentiometer.
This value also changes as the outside sensor is moved in/out.

To exit from the program (and the service environment) press F.

5
The program is used for:
checking the operation of the sensors used for automatic data input. When the sensors are
moved, the displayed values should vary continuously within the following ranges:
diameter sensor from 0 to 1000 (+/-10) from standby to full stroke (see
“replacing the diameter sensor”);
distance potentiometer from 0 to 490 (+/-10) from standby to full stroke;
width potentiometer from 5 to 245 (+/-10) from standby to full stroke.

99 Preset speed wheel spin setting:

Selecting this program displays the set default speed value (rpm). The arrow keys can be used
to modify the speed setting at which the data will be acquired in subsequent wheel spins
performed in the context of this program.
To exit from the program (and the service environment) press F.

The program is used for:

checking that the unbalance values are calculated precisely for all allowed spin speeds.

100 Electrical actuator control function:

Selecting the program results in the machine displaying:
- message "Pos" on the LH display;
- a numerical value which shows the position (in marks) of the electrical actuator, on the
RH display.
The program enables:
• moving the actuator to the spin or brake position with the START/STOP buttons
respectively.
• moving the actuator gradually with the arrow keys. This function is particularly important
when servicing or replacing the actuator;
• moving the actuator to mid-stroke with ENTER;
To exit from the program (and the service environment) press F.

The program is used for:

- Checking the operation of the electrical actuator and its control logic.
- Servicing the spin/brake unit.
- The no load current values (in marks) read by the electrical actuator also appear, both in
spin and brake modes.

101 Counters:
Selecting the program results in the machine displaying the following counters:
• [LAN TOT] n. of spin cycles run;
• [LAN CAL] n. of spin cycles run since the most recent sensitivity calibration,
• [N° PIS] n. of electrical actuator cycles.

Press Enter to select the counter you wish to display.

MBE161 MOTHERBOARD SWITCH CONFIGURATION

The circuit boards on the balancing machine are equipped with hardware and software to
enable their use on a variety of models. They are already configured to operate correctly and
do not require configuration.

6
DIAGNOSTICS PROGRAMS
These programs serve primarily for repairing the circuit boards and should be used with
reference to the boards' circuit diagrams. We recommend using them exclusively for this
purpose; the service programs described above are generally sufficient for service staff to
identify malfunctions.
In case of need, the documentation for the diagnostics programs can be requested from
Corghi.

REMOVING THE WEIGHT-HOLDER LID

Remove in sequence:
- mini-anvil;
- diameter and distance sensor arm;
- sensor arm support disk (A in the
figure);
- four bolts securing the weight-holder A
lid;
- remove the weight-holder lid taking
care not to stress the sensor rod.

Refit the parts in reverse order, making

sure to check that:
- the sensor lever touches only the support disk in standby, without touching the weight-
holder lid;
- the support disk (A in the figure) does not touch the weight-holder lid.

MBE161 MOTHERBOARD UPDATES

A portable programmer "PRG161" is required to update the control unit (MBU) of the
MBE161 motherboard. The firmware is stored in a special memory card (MEMSTICK),
which inserts into a slot in the PRG161.
For the use of the programmer and hence also for programming the MBE161 motherboard,
refer to the PRG161 programmer user manual.

REPLACING THE INSIDE SENSOR (DISTANCE AND DIAMETER) REED

MICROSWITCH AND ENCODERS
To ensure correct wheel size measurements, the inside sensor must be mounted in such a way
that its aluminum mount is perfectly supported by the block (to which are mounted the
central unit's leaf springs) and the inside pickup leaf spring.
The reed sensor which sets the standby position must also be correctly adjusted.
Function 98 displays the encoder signals.

Replacing and adjusting the reed microswitch

In case of replacement or disassembly of
the microswitch, its trip distance must be
adjusted.
The setting is correct when:
- when the sensor arm is moved 2.5
mm away from the standby position,
the microswitch is open;

7
- if this condition obtains, when the machine is switched on it displays "ERR10";
- when the sensor arm is moved 2 mm away from the standby position, the microswitch is
closed; at this point the "ERR10" message is cancelled.
- To adjust the position of the sensor, move it on its axis with the two nuts securing it to the
mount.

Checking the operation of the diameter encoder [di]

To check the operation of the diameter sensor, proceed as follows:
- move the inside sensor to the standby
position (the arm is snug against the
support disk);
- rotate and extend the arm until it rests
against the turntable shaft in the
position shown in the figure; check that
1000 +/- 10 marks have been read.

If the sensor does not read correctly,

check in sequence:
1) the flat cable;
2) the mounting of the sensor in its
housing;
3) the adjustment of the reed microswitch;
4) that reed sensor cable is connected correctly;
If the above checks do not reveal any defects, replace the encoder.

Checking the operation of the distance sensor [d]

Check that the total stroke is 490 +/- 10 marks;
If the sensor does not read correctly, check in sequence:
1) the flat cable;
2) the mounting of the sensor in its housing;
3) the adjustment of the reed microswitch;
4) that reed sensor cable is connected correctly;
If the above checks do not reveal any defects, replace the encoder.

Replacing the diameter encoder

- Remove the diameter encoder complete with gear.
- Remove the gear and fit it to the new encoder; tighten down the mounting nut.
- Fit the new encoder plus gear to the sensor mount gear in such a way that the play
between the two gears is minimal at all positions.
- Reconnect the cable to the diameter sensor (RP2).

Warning: to reduce diameter reading

errors due to mechanical play, the
spring (A in the figure) must be
correctly preloaded. To check the
preload, immobilize the diameter
sensor arm and move the large gear
wheel (B in the figure) by hand in both
directions. If the spring is correctly
installed, when the wheel is released it

8
should return to its position in such a way as to recover the entire play in the
gearwheel/sliding rod slot coupling.
Check this throughout the range of possible diameter measurements.
If the preload is insufficient, disengage one of the ends of the spring, rotate it 360° in the
direction which increases the load, and refit it in the hole in the gearwheel or mount.

Replacing the distance encoder

- Press the keyboard wheel data entry key to display the data for this encoder on the RH
display (the distance led on the control panel will light up).
- Remove the drive wire from the pulley seats.
- Slacken off the bolt securing it to the sensor shaft and remove the large pulley.
- Remove the distance encoder.
- Fit the new encoder.
- Tighten down the bolt to secure the pulley to the encoder shaft.
- Refit the drive wire in the pulley seat.
- Reconnect the cable to the distance encoder (RP1).
- Move the sensor to its full stroke position and check the encoder reading.
- Refit the complete sensor with the two M6 bolts securing it to its aluminum mount.

REPLACING AND ADJUSTING THE OUTSIDE SENSOR POTENTIOMETER

(WIDTH POTENTIOMETER)
- Select service program "98" to display the sensor data. The first datum displayed refers to
the diameter (the respective led on the control panel will light up).
- Press the keyboard wheel data entry key twice to display the data for this potentiometer
on the RH display (the width led on the control panel will light up).
- Unscrew the bolts securing the outside sensor cover and remove it;
- Disconnect the potentiometer cable;
- Disengage the spring from the eye-ring on the potentiometer mount plate;
- Undo the bolts securing the potentiometer mount plate;
- Remove the gear and fit it to the new potentiometer with its bolt tightened down so that it
is friction fit to the shaft for subsequent adjustment.
- Refit the new potentiometer and gearwheel to the plate and secure the assembly in such a
way that the teeth of the two gearwheels are meshed;
- Refit the spring into its hole;
- Reconnect the cable to the potentiometer;
- To adjust the potentiometer, remove the sensor mount box cap and use a screwdriver to
turn the potentiometer shaft until the value 5 +/- 1 appears on the RH display
- Tighten down the bolt securing the gearwheel to the potentiometer shaft.
- Turn the sensor fully towards the wheel flange and check that the potentiometer's electrical
connection is good and that the gearwheels mesh correctly throughout the sensor's stroke.
Since the full stroke of the potentiometer is around 250 digits, if the potentiometer has
been adjusted to read 5 in standby, it should read approximately 255 at full stroke.
- Calibrate the sensor as described in the user manual.
- Check the sensor's width readings with the wheels of a known size. To have the readings
precise to a tenth of an inch, select function "oF .5" in service program "91" before
running the checks. The maximum allowed error for a calibration wheel is +/- 0.1 inches.

Notes
Bear in mind that the wheel's nominal diameter and width (e.g.: 6", 14") refer to the planes on
which the tire bead rests, which are obviously inside the rim. On the other hand, the data

9
measured refer to external planes, so they will be lower than the nominal values because of
the thickness of the rim. These differences are compensated by the sensor calibration
procedure, so that the values measured are the same as the nominal values, a consolidated
reference for the user. Obviously, compensation is done with reference to the rim thickness
used in the calibration procedure, so the data measured later on wheels of different thickness
may vary slightly (maximum 2 or 3 tenths of an inch) from the nominal values. This is not an
error in the precision of the devices; it simply reflects the real situation.

Sensor errors:
ERR10:
1. When the machine is switched on, the contacts of the reed microswitch, which indicates
the standby position of the distance and diameter sensors, are open. Check that the sensor
is in its standby position.
2. With the sensor at standby, check that the microswitch cable contacts are closed with a
tester.
If not, check the adjustment of the microswitch (see above, "Replacing and adjusting the
reed microswitch"). If the problem cannot be resolved, replace the microswitch.
3. Check the connection of the cable connecting the microswitch to the circuit board.

ERR12:
1. When the machine is switched on, the outside sensor standby position reference value is
not 5 +/-1 marks (use function 98 to check) or the outside sensor is not in the standby
position;
2. Check that the outside sensor connector is connected to the balancing machine's
connector panel;
3. If the outside sensor is not mounted, simply select the sensor calibration function to
cancel the error message.

REPLACING AND ADJUSTING THE PICKUPS

- Remove the weight-holder lid and the side casing to access the machine's interior.
- Disconnect the two pickups.
- Remove the pickup by undoing the two M8 stud bolts (to better access the inside pickup,
you can undo the M8 locknut to remove the automatic brake lever);
- Fit the new set of pickups, making sure that the balls fit correctly into their seats, then
tighten down the stud bolts so that the pickups are lightly friction fit.
- The pickup marked with the letter I (inside) mounts on the right and that marked with E
(outside) on the left (when facing the machine).
- Reconnect the pick up connector.
- Set the "1 On" mode in service program "91" to display the unbalance value at maximum
precision.
- Fit the calibration disc to the balancing machine shaft.
- Apply a sample weight to the outside of the rim.
- Select service program "96" and run a spin cycle to check the values of the pickup signal
and phase.

The correct values should be as follows:

- phase difference F from -2.0 to +2.0
- inside pickup signal I from 200 to 280
- outside pickup signal E from 110 to 170

10
If the values displayed after the spin cycle are not within the specified ranges, use the stud
bolts to tighten down the pickups until the readings are correct.
The correct values are usually obtained at a tightening torque of 2 Nm.
- Fully tighten down the locknuts and then release them slightly (about one sixth of a turn)
to load the Belleville washers.
During this operation, immobilize the stud bolts so as to avoid altering the pickup
preloads.
- Refit the side casing and the weight-holder lid.
- Run a three spin cycle sensitivity calibration.

REPLACING THE BRAKE PEDAL SWITCH

- Remove the side panel;
- unscrew the ring nuts securing the switch to its mount;
- disconnect the cable from the switch's terminal block;
- connect the cable to the new switch;
- fit the new switch to the mount (the position is unequivocal since no adjustment is required);
- tighten down the two ring nuts (nut and locknut).

REPLACING THE ENTIRE CENTRAL UNIT

After making sure that the unit is really the cause of the machine's malfunctions, replace it as
described below:
- Remove the weight-holder lid.
- Remove the search circuit board complete with mount by undoing the two M8 screws
securing it.
- Remove the central unit by undoing the two M12 bolts with a 19 wrench.
- Fit the new central unit, locating it to ensure perfect coupling between the spin unit base
(front reference plane) and the block to which the leaf springs are mounted. Also make
sure that the drive roller is centered on the pulley.
- Fit the search circuit board with its two M8 bolts, making sure that the encoder disk teeth
can run inside the fork without collisions.
- Reconnect the pickup cable and the search circuit board.
- Close the weight-holder lid again.
- Run a three spin cycle sensitivity calibration.

REPLACING THE QUICK LOCK CENTRAL UNIT PNEUMATIC CYLINDER

GASKETS
The cylinder gaskets
must be replaced
whenever there are air
leaks or piston operation
is defective.
• Remove the weight-
holder lid;
• Undo the two bolts
securing the rear
flange of the
pneumatic cylinder;
• Recover the inside
spring (B);

11
• Extract the piston (C);
• Replace the O-ring (A) with a new one;
• Undo the nut securing the piston to the rod;
• Replace the piston (C) with a new one;
• If necessary, also replace the rod guide (D);
• Refit all parts in reverse order.

SPIN UNIT

Replacing the electrical actuator

- Disconnect the power
and actuator signal cable
(brush mount side);
- Remove the two caps
on the side panel next
to the spin unit;
- Screw a 5 x 50 bolt into
the cylindrical stud (A);
- Extract the cylindrical
stud;
- Unscrew the two actuator
fulcrum screws (B);
- Remove the electrical
actuator;
- Check that the rear
block of the new
actuator (C) is located
27 mm away from the stop (D);
- Fit the new actuator, positioning its various components in the sequence shown in the figure.
- Apply medium strength threadlocker (loctite243) to the two fulcrum screws (B) and
screw them onto the actuator.
- Fit the cylindrical stud (A).
- Close the weight-holder lid again.

Replacing the friction roller

- Remove the weight-holder lid.
- Remove the circlip (C);
- Unscrew the stud bolt (B);
- Extract the shaft and friction roller
(A);
- From the old part, recover the
other circlip and the thrust
washers, which must be mounted
in the same positions in which
they were before replacement of
the roller;
- Refit the new shaft in reverse
order, making sure that the hole in
stud bolt B is aligned with the flat
seat on the shaft.

12
- Apply medium strength threadlocker (loctite243) to stud bolt B and screw it onto the
pulley.

Replacing the brake shoe

- Remove the weight-holder lid and the side casing;
- Select function 100 and press the down arrow key to move the electrical actuator so that
the roller is touching the bell;
- Unscrew the M6 locknut (D);
- Extract the pin and recover the Belleville washers;
- Fit the new brake shoe with the washers removed in the previous step;
- Tighten down the locknut on the fulcrum pin so that there is no play between the shoe and
the lever; the shoe should be friction fit to the lever.
- Switch the machine off and on again to enable the balancing machine to calibrate itself
with the new stroke of the spin unit;
- Run a number of trial spin cycles.
- Fit the side casing and close the weight-holder lid.

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Replacing the motor

- Remove the weight-holder lid and the side casing;

- Remove the entire linear actuator assembly as described in the appropriate section of this
manual;
- Undo the four M8 bolts securing the spin unit to the body beam and remove the unit from
the balancing machine;
- On a work bench, undo the four M6 bolts and the single M8 bolt securing the brake lever
and control lever (A);
- Remove the outside circlip from the motor shaft (B);
- Slacken off the stud bolt securing the small pulley (C);
- Unscrew the four bolts securing the motor to its mount (D).
- Remove the motor and recover the connecting rod assembly spacers (F);
- Before installing the new motor, fit the inside circlip to the motor shaft (E);
- Fit the motor shaft into the first connecting rod bearing (F) and then into the small pulley
and so on, as shown in the figure;
- Tighten down the engine mounting bolts (D);
- Tighten the stud bolt (C);
- Fit the circlip (B);
- Reinstall the brake lever and control lever with bolts (A);
- Refit the unit to the balancing machine beam, taking care to position the front reference
on the aluminum casting perfectly snug against the central unit block;
- Reinstall the linear actuator.

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TROUBLE SHOOTING
TROUBLE SHOOTING
The EM 85XX balancing machine is equipped with self-test and self-diagnostics programs
which cover the majority of faults and how to solve them (see the list of error messages and
"troubleshooting" in the user manual).
There are however some malfunctions which the machine is unable to identify; these are
listed below.

WARNING!
For all electrical faults, before replacing any circuit boards:

- check that the power cable is correctly connected to the transformer primary, depending
on the mains voltage;
- check that the secondary transformer voltages correspond to their specified nominal
values (use a tester set to AC voltmeter and refer to the attached transformer diagram);
- check the condition of the cabling between the components probably involved in the
malfunction. In particular, check:
- that all connectors are correctly inserted in their sockets;
- that all contacts are correctly secured at the ends of the wires of the various cables;
- that the mains power supply is stable and that the ground plant is operational;
- that the transformer and power board fuses are not burnt, and that the leds on the power
board have lit up to indicate that the power phases are available.
We give a summary troubleshooting table below, with reference to the general wiring
diagram.

The machine does not switch on

Use a voltmeter to check that there is power to the transformer primary terminal block.

1) If there is no primary voltage check:

- the condition of the voltage connector and the fuses;
- that the power supply lead is connected correctly to the plug;
- the condition of the mains cable;
- the operation of the master switch.
2) If there is primary voltage check:
- the transformer fuses;
- the transformer secondary voltages;
- the operation of the PEAL "power and control board", and check:
• the board fuses and that the respective leds are on;
• the power voltages available at the Jalsk connector (refer to the attached wiring diagram
for the board);
- that the motherboard power supply cable is wired correctly and its connectors properly
fitted;
- check for short circuits on the peripheral equipment. To do this, disconnect all cables from
the motherboard connectors, except for the power cable, and try switching the machine on in
this condition.

If the above checks do not identify any defective components, replace the motherboard.

When the START button is pressed the machine does not run a spin cycle
In this case the possible causes depend on the monitor display.

15
1) If the display is still showing the previously calculated unbalance values.
The motherboard is not receiving or detecting the START signal from the keyboard or
microswitch.
Check:
• the operation of the automatic start microswitch on the wheel guard (lowering the guard
should close the switch's contact);
• the cabling of the automatic start microswitch;
• the operation of the START key.
If the above checks do not identify any defective components, replace the motherboard.
2) If the display is showing the wheel geometric data.
The motherboard is receiving the signal from the START button or microswitch, but the
command is not executed.
Check:
- that the Control cable which connects the motherboard to the power and control board is
correctly fitted and wired;
- that the power and control board is operational, and in particular that fuse FU4 and the spin
motor relay are in good condition.
Proceed as follows:
• disconnect the motor power supply cables;
• apply the terminals of a tester in DC voltmeter mode to the terminals of the disconnected
cables;
• press the START button. If the control upline of the measurement point (including
relay) operates correctly, the tester should read approximately 28 Volt.
- the condition of the spin motor.
If the above checks do not identify any defective components, replace the motherboard.

When the machine is switched on, the display reads "ttt"

- Switch off the machine;
- Set microswitch 2 of the "SW 2" pair next to the upper edge of the motherboard between
the LH display and the corresponding position indicator to ON. The microswitch is
accessible without having to disassemble the board from its panel;
- switch on the machine.

When the machine is switched on, the displays are blank

Check that the switch for programming the CPU is in the correct position
- Switch off the machine;
- open the rear panel of the display head by undoing the four M4 bolts;
- on the top right, turn microswitch 2 of the "SW 1" couple (the first from the right) to
OFF. The microswitch is accessible without having to disassemble the board from its
panel;

When it is switched on, the machine is locked (not accepting commands)

Check:
- that all the keyboard keys are undamaged, i.e. that none of them is remaining constantly
depressed due to a breakage. In this case, replace the faulty key or the entire motherboard;
- that no keys are permanently depressed due to incorrect installation of the motherboard to
its panel;
Whenever mounting a circuit board to its panel, make sure that the keys, which are mounted
directly on the motherboard, operate correctly. Proceed as follows:

16
- tighten down the four circuit board mounting nuts located at the corners;
- finger tighten the two nuts located next to the keys;
- check that all keys work by pressing them one at a time;
- gradually tighten the two nuts so that the keys stay in contact with the polyester film
without being overloaded.

The balancing machine supplies different unbalance values in successive

spin cycles (differences greater than 3 grams with unbalance of 30 grams)
Check in the following order:
- that the machine is resting stably on the floor and its feet are in good condition;
- that the weight-holder lid is correctly located, without rubbing against the central unit bell
during the spin cycle;
- that the brake shoe and spin unit drive roller are not touching the pulley during signal
acquisition
- that the wheel is properly mounted to the shaft, so that there is no slippage between the
wheel and the flange during the spin cycle.
- To check this latter requirement, make two reference marks in chalk, one on the flange
and one on the wheel, aligned with each other. Run a number of spin cycles and check
that the two marks are still aligned.
- check that the pickups are correctly tightened, with reference to the signal values
displayed with service program "96";
- check the operation of the motherboard by replacing it with a new one.

If the above checks do not reveal any faults, replace the central unit and check for running
noise in the bearings.

The motor continues driving the wheel and the spin cycle does not
terminate
Run all the checks on the search circuit board listed in the previous paragraph. Also check the
operation of the power and control circuit board with special reference to the motor power
relay.

The automatic sensor diameter/distance values are different from the real
dimensions
Check with function 98 that the sensors are operational by checking (see inside digital sensor
paragraph):
If the sensors are not malfunctioning it may be sufficient to recalibrate the outside sensor.
For small differences (at most one inch) above all with thicker than normal alloy rims, the
remarks of the abovementioned paragraph may apply.

Impossible to balance the wheel: when the weights specified by the

balancing machine are applied and a new spin cycle is run, new random
unbalance values are measured
Run all the checks listed in the previous paragraph.
Also check:
- the geometrical dimension settings;
- whether the machine is out of calibration, by running the sensitivity calibration
procedure;

17
- that the brake shoe and spin unit drive roller are not touching the pulley during signal
acquisition;
- that the cable connecting the search circuit board (encoder) to the motherboard is
correctly fitted and wired;
- the operation of the search circuit board (encoder) by means of the values displayed in
service (see "Service programs"). Malfunction of the search circuit board prevents the
machine from calculating the unbalance positions correctly. In this case:
• check that the search circuit board photo-diodes are clean;
• check that the fork is correctly registered relative to the search disk.

If the fault persists, replace the search circuit board.

If the fault persists even after this, replace the motherboard.

During a spin cycle:

* the machine locks up with the beeper on;
* the machine resets itself.
This fault, which is usually intermittent, can be due to a temporary power failure to the
motherboard, or to disturbance or malfunction of the motherboard.
Check:
- that the motherboard power supply cable is wired correctly and its connectors properly
fitted;
- the operation of the power and control board, and especially the power voltages available
at the Jalsk connector (refer to the attached wiring diagram for the board);
- that the motor power cables are decoupled from the signal cables;

If the above checks do not identify any defective components, replace the motherboard.

The braking sequence at the end of the spin cycle is too long or noisy
Check:
- brake shoe wear.
check for play between the shoe and lever; if there is any, tighten down the locknut on the
fulcrum pin (the shoe should be friction fit to the lever).

The spin unit is noisy in operation:

Check in the following order:
- that the drive roller is not too worn;
- that the linear actuator control screw is properly lubricated; use multipurpose grade 2
grease to lubricate it;
- the mechanical condition of the motor;
- that the connecting rod bearings are running freely.

The mechanical parts of the balancing machine give an electric shock when
touched
Check the operation of the power socket ground plant (a good ground connection is essential
for the correct functioning of the machine as well as for reasons of safety).
- check that the power cable is correctly connected to the transformer primary, depending
on the mains voltage;

18
ERROR MESSAGES
The machine is able to recognize a certain number of malfunctions and inform the user of
their occurrence by displaying the respective messages on the screen.
Err 1
Sensitivity calibration error
- Perform sensitivity calibration.
- The MBC161 board has been changed. Perform sensitivity calibration.
Err 4
- Outside sensor calibration error: perform outside sensor calibration.
- Outside sensor not present: click on the Sensor Calibration icon (utility menu) to disable
the sensor check and clear the display of the error.
Err 5
- Dimensions entered for an ALU program are not correct. Enter the dimensions correctly.
Err 6
Error detected in execution of the optimization program. Repeat the procedure from the start.
Err 7
- The machine is temporarily unable to select the program requested.
- Carry out a spin and repeat the request.
Err 8
Printer out of service; no printer; printer fault.
Err 9
- Unbalance value above 999 grams.
- Reduce the unbalance and repeat the spin.
Err 10
- When the machine is switched on, the contacts of the reed microswitch, which indicates
the standby position of the distance and diameter sensors, are open. Check that the sensor
is in its standby position.
- With the sensor at standby, check that the microswitch cable contacts are closed with a
tester.
- If not, check the adjustment of the microswitch (see above, "Replacing and adjusting the
reed microswitch"). If the problem cannot be resolved, replace the microswitch.
- Check the connection of the cable connecting the microswitch to the circuit board.
Err 11
- Diameter sensor not in standby (fully retracted) position when machine switched on.
Return the sensor to the correct position.
- Distance sensor failure. Press the handle to disable the sensors and enter the data using
the keyboard. Contact after-sales service.
Err 12
- When the machine is switched on, the sensor standby position reference value is not 5 +/-
1 marks (use function 98 to check) or the sensor is not in the standby position;
- Check that the outside sensor connector is connected to the balancing machine's
connector panel;
- If the outside sensor is not mounted, simply select the sensor calibration function to
cancel the error message.
Err 20
Outside sensor calibration error
- Repeat the calibration procedure correctly;

19
- Check that the outside sensor is at 5 +/- 1 marks in the standby position.
- Check in service mode that when the outside sensor probe is touching the central unit
flange, around 220 +/-30 marks are displayed.
- If the above conditions are not satisfied, register or replace the potentiometer.
Err 23
Incomplete or invalid data entry in ALU P. Enter correct values.
Err 25
Program not available on this model.
Err 27
Wheel did not stop within maximum allowed time.
Err 28
Encoder count error.
Err 29
This error displays when there is an electrical piston fault.
- Switch on the machine and calibrate the electrical piston;
- Check that the power supply/signal cable is connected correctly;
- Check fuse FU5 on the power board.
Err 30
Error condition referring to failure of the unit to turn after the START button is pressed.
If the wheel spins:
- check the operation of the encoder board;
If the motor does not start:
- Check fuse FU4 on the Peal board.
- check that the motor power lead is connected correctly;
- check the operation of the Peal board;
- check the operation of the motor.
ERR31
Optimization procedure already started by another user.
ERR32
The balancing machine runs checks on disturbances; if during an unbalance reading the
machine is jolted violently, this error displays.
If no such disturbance is present, check the machine as follows:
- the brake shoe must not touch the bell during the reading;
- the machine must be resting firmly on the ground;
- the central unit bearings must run silently.
ERR Cr
The microswitch contact on the wheel guard is open:
- check the operation of the automatic start microswitch on the wheel guard (lowering the
guard should close the switch's contact);
- If the above checks do not identify any defective components, replace the motherboard.
- Wheel spin run with guard raised.
- Lower the guard to carry out the spin.
ERR STP
The spin stopped before the entire acquisition cycle terminated;
- Check that the ring nut is fully tightened down;
- A spin cycle has been run without a wheel mounted;
- Check that the drive roller, brake shoe and weight-holder lid are not touching the unit

20
 during the spin cycle.
CCC
This message appears when the unbalance values are excessive, or when the balancing
machine has been jolted during the reading stage.

21
EM8540 N.A.
Cod. 4-104006 - 1.0 del 06/05

UPT - Cod. 4-104006 - 1.0 06/05

CORGHI S.p.A. - Strada Statale 468 n.9

42015 CORREGGIO - R.E. - ITALY
Tel. ++39 0522 639.111 - Fax ++39 0522 639.150
www.corghi.com - info@corghi.com