Hunter DSP7700 Service Manual

4443T, 01-00
Service Manual
DSP 7700 Wheel Balancer
 Copyright 2000 Hunter Engineering Company

Contents
1 .Introduction............................................................................................ 1-1
Purpose........................................................................................................ 1-1
Operation ..................................................................................................... 1-1
Hazard Definitions........................................................................................ 1-1
Related Publications .................................................................................... 1-2
Purpose Of Components ............................................................................. 1-2
2 .Initial Installation ................................................................................... 2-1
Placement .................................................................................................... 2-1
Floor Requirements ..................................................................................... 2-1
Installation Procedure .................................................................................. 2-2
3 .Removal, Installation, and Adjustment of Components..................... 3-1
Purpose........................................................................................................ 3-1
Weight Tray, 69-933-1 ................................................................................. 3-1
ON/OFF Switch, 18-270-2 ........................................................................... 3-2
DC Drive Board, 45-861-1 ........................................................................... 3-2
Spindle Encoder Board and Bracket Assembly, 45-863-1 .......................... 3-3
“EPROM”...................................................................................................... 3-4
Cables .......................................................................................................... 3-4
Force Transducer......................................................................................... 3-5
Manual Dataset Arm .................................................................................... 3-5
Optional Auto Dataset Arm .......................................................................... 3-5
Motor, Belt, and Pulley................................................................................. 3-7
Spindle and Threaded Shaft Assembly ....................................................... 3-9
Spindle Encoder (Slotted Aperture) Disk (Part of Kit 20-976-1) ................ 3-11
Manual Input Knob, 34-86-2 ...................................................................... 3-11
Knob Board, 45-675-1................................................................................ 3-11
4 .Diagnostics Mode .................................................................................. 4-1
Enabling the Diagnostics Mode ................................................................... 4-1
Screen Viewable Diagnostic Values ............................................................ 4-1
Calibrating In Diagnostics Mode .................................................................. 4-2
Setup Procedure in Diagnostics Mode ........................................................ 4-3
5 .Troubleshooting..................................................................................... 5-1
Pre-Troubleshooting Checklist..................................................................... 5-1
Auto Dataset Troubleshooting ..................................................................... 5-2
Inner Auto Dataset ....................................................................................... 5-2
Troubleshooting Chart ................................................................................. 5-4
Display Error Codes..................................................................................... 5-6
Quick Calibration Check Procedure ............................................................ 5-9
Troubleshooting Transducers .................................................................... 5-10
Troubleshooting Drifting Transducers ....................................................... 5-11
Motor Drive Board LED Data ..................................................................... 5-12
6 .Appendix ................................................................................................ 6-1
CPU/Display Board Test Pad Voltages: ...................................................... 6-1
Wiring Schematics and Diagrams................................................................ 6-1
Knob Board, 45-675-1.................................................................................. 6-2
Encoder Board, 45-863-1 ............................................................................ 6-3
CPU/Display Board, 45-867-1 ..................................................................... 6-4
CPU/Display Board, 45-867-1 ..................................................................... 6-5
DC Drive Board, 45-861-1 ........................................................................... 6-6
DSP 7700 Wheel Balancer Service Manual Contents • i

ii • Contents DSP 7700 Wheel Balancer Service Manual
1 .Introduction
Purpose
This manual will assist service personnel in troubleshooting and repairing the
DSP 7700 Wheel Balancer.
Operation
When service is requested, it is important to verify that the unit is being used
properly. Always check for proper AC line voltage. For proper line voltages, refer to
“CPU/Display Board Test Pad Voltages,” page 6-1.
Read and become familiar with the contents of this manual before servicing the
DSP 7700 wheel balancer. It is also essential to have read and understood the
operation manual. Refer to “Operation Instructions DSP 7700 Wheel Balancer,” Form
4244T. Hands-on operation experience is recommended; try all the features, balance
a wheel, etc. Understanding the operation of the balancer will make servicing easier
and safer.
Hazard Definitions
Watch for these symbols:
CAUTION: Hazards or unsafe practices, which could result in minor

personal injury, or product or property damage.
WARNING: Hazards or unsafe practices, which could result in

severe personal injury or death.
DANGER: Immediate hazards, which will result in severe personal

injury or death.
These symbols identify situations that could be detrimental to your safety and/or
cause equipment damage.
Because components in this manual are referred to by Hunter part numbers, refer to
parts drawing 12-13, for parts identification.
WARNING: To prevent the possibility of electrical shock injury or

damage to the equipment, POWER MUST BE
DISCONNECTED BY PULLING THE PLUG FROM THE AC
POWER SUPPLY.
WARNING: Make sure that a 115V, 15 amp electrical supply circuit

and the appropriate receptacle are installed with the
proper grounding. Plugging the 115V balancer into a
230V electrical supply circuit will damage the
equipment.
DSP 7700 Wheel Balancer Service Manual Introduction • 1-1

Related Publications
Additional information can be found in:
Form 4244T Operation Instructions DSP 7700 Wheel

Balancer
Form 4280T Installation Instructions for DSP 7700 Wheel
Balancer
Form 3667T Installation Instructions for Bolt-Down Kit
Form 12-13 DSP 7700 Parts Drawing
Purpose Of Components
The spindle encoder board, 45-863-1, operates with the movement of the slotted
spindle encoder disk, 17-63-2, providing two square waves and a home pulse to the
CPU/Display board, 45-867-1. The two square waves occur in “quadrature” or 90
degrees out of phase with each other. Refer to illustration.
1/128
REVOLUTION
SQUARE
WAVES
1/512
REVOLUTION
0V
0V
The CPU/Display board senses the order and frequency of the edges to determine
the direction and speed of the shaft. Each passing of a slot in the disk through a
detector causes a high (+5V) and low (0V) edge on each channel. There are 128
slots in the disk, so the position of the shaft is determined to 128 x 2 edges x 2
channels, or 512 positions. There are three, red LED’s on the board for visual
checking of the two channels and the home pulse.
There are two force transducers, 109-87-3. A ceramic element located between the
two steel caps, produces voltage change when the force upon the caps is changed.
The transducers receive force vibrations (due to the rotating imbalance) through the
welded steel structure. Also on each transducer is a temperature sensor. The change
in temperature (since calibration) is calculated at every spin. The signals are then
compensated for any temperature-dependent system effects. The force transducer
signals are sent through the cables (these cables are a permanent part of the
transducers) to the CPU/Display board.
The knob board, 45-675-1, has a rotary encoder for manual entry of wheel
dimensions. The rotary encoder produces the same kind of signal as the spindle
encoder board, with the exception that the device uses mechanical switches (rather
than optics), and there is no home pulse. The direction and speed of the knob is
noted by the CPU/Display board for update of the dialed-in wheel settings.
The keypad overlay provides “key pressed” signals to the CPU/Display board by
connecting pins 1 through 9 to pin 10 (ground) of J2 on the CPU/Display board.
Refer to Appendix, “Wiring Diagrams and Schematics.”
The CPU/Display board, 45-867-1, performs the following operations:

Drives the display and beeper.
Scans the knob and keypad for change via J1 and J2.
Receives unregulated power and monitors/controls the DC drive via J3.
Tracks the spindle movement via J5.
1-2 • Introduction DSP 7700 Wheel Balancer Service Manual

Reads the imbalance signals from the left and right force transducers via
J8 and J7.
The manual input knob is scanned for change by the DSP (digital signal processor)
chip 800 times-per-second. The turning rate is noted and the digits are updated by
larger increments for faster rates. This is why a large range of values can be quickly
dialed across before slowly tuning-in an exact value as the knob is slowed down.
The nine keys are scanned and the display is updated 200 times-per-second. One
LED display update requires 96 shifts of data “bits” (one for each LED). These 96
shifts occur every 1/200 of a second, while the DSP is scanning and responding to
the knob and switches.
When a spin starts, the DSP chip checks for locked rotor, excessive time to forward
rotation, excessive time to minimum speed, etc. The DSP chip also makes sure that
the following conditions are met during the spin:
Spindle encoder signals are functioning perfectly.

Both force pickup temperature sensors are functioning properly.
The knob and keypad are ignored during the spin. Once the wheel is at
minimum speed to take data, eight revolutions (of the wheel) worth of
force transducer data are fed to the DSP chip. The DSP chip extracts the
rotating imbalances from the noise in the signal, due to the motor and
floor vibrations, determines, and displays the correction weight angles
and positions based on the dialed-in wheel data. It then initiates the
wheel braking sequence. Once the wheel stops, the knob and keypad
functions are restored.
DSP 7700 Wheel Balancer Service Manual Introduction • 1-3

1-4 • Introduction DSP 7700 Wheel Balancer Service Manual
2 . Initial Installation
Placement
The balancer should be placed in a dry area, which is not subjected to water spray.
Clearance for the operator at the front of the balancer should be at least 3 feet. The
electrical power cord should be positioned so that it cannot be walked on, driven
over, or tripped over.
Floor Requirements
The balancer should be placed on a solid concrete floor. Any floor condition, which
might allow the balancer to move during a spin, is unacceptable.
PROBLEM CORRECTIVE ACTION

Very fine finished Rough up the floor area at the three point
concrete. supports or bolt the unit down to the floor.
Painted concrete. Remove floor paint at the three point supports or
bolt the unit down to the floor. Do not grind the
paint off with the three point supports by simply
jerking the balancer about . . . this will leave
flakes of paint under the supports (making
matters worse).
Floor is angled. Bolt the unit down. (The fact that the balancer is
installed tilted will not affect it’s performance.)
Floor is not clean. Clean the floor.
If the balancer cannot be moved easily by pulling on the spindle with one’s index
finger, the floor condition is acceptable. Also be sure that the three point supports are
on flat surfaces and not on “bumps” or “pits” in the concrete floor.
NOTE: This floor condition requirement is not unique to the

DSP 7700. All balancers must remain stationary during the
measurement spin. Balancer movement may be
undetectable, but the force transducers of a balancer cannot
sense the true rotating imbalance forces, if the entire
balancer is moving due to those same forces (even if only by
tiny fractions of an inch).
If the location selected is a cement floor that is hollow underneath, place the balancer
over a supporting beam or close to a supporting wall.
With the proper floor requirements, the DSP 7700 will perform well, with or without
being bolted to the floor. If desired, three of the hold-down hooks used during
shipment can be placed in the slots next to the feet to bolt the unit to the floor. Refer
to “Installation Instructions for Bolt-Down Kit,” Form 3667T.
DSP 7700 Wheel Balancer Service Manual Initial Installation • 2-1

Installation Procedure
Unpack the balancer and check for shipping damage.
Verify proper grounding of the unit by taking an ohm reading between the frame and
the ground pin of the power cord.
Remove the motor panel assembly and check the belt tension. Adjust to 50 lbs. + 5
lbs., if necessary. Refer to “Motor, Belt, and Pulley,” page 3-7.
Be certain that the balancer is turned off (“O” is depressed on the ON/OFF switch,
located on the motor panel assembly).
Plug the balancer into the proper electrical service.
Turn the unit on by depressing the “I” side of the ON/OFF switch.
Check for proper operation of the balancer controls:
Press the START key. Verify that the shaft is turning clockwise when
viewing it from the end of the shaft.
Verify that the unit completes a balance cycle and the shaft brakes to a
stop.
If the shaft turns the wrong way, unplug the unit, unplug the motor wires
from the power board, and swap positions.
Check if each of the remaining keys function, causing a short beep. The
NEXT and ENTER keys can be checked by performing the “Set-Up”
procedure.
Check if the knob causes changes to the corresponding display wheel
dimension indicators.
Calibrate the balancer per the operation manual. Refer to “Operation
Instructions DSP 7700 Wheel Balancer,” Form 4244T.
Perform the “Calibration Check” procedure. Refer to “Quick Calibration
Check Procedure,” page 5-9.
If desired, perform the “Set-Up” procedure, programming the balancer
settings to the customer’s needs. Refer to “Operation Instructions DSP
7700 Wheel Balancer,” Form 4244T.
Check the spindle threads and lubricate them, if necessary. Clean the
spindle threads by running the edge of a rag between the threads, while
turning the spindle by hand. Lubricate the spindle shaft and wing nut
threads. A lubricant containing Teflon®, which evaporates leaving a long
lasting film of lubricant, such as SuperLube® by Permatex is
recommended.
Initial installation procedure is complete.
2-2 • Initial Installation DSP 7700 Wheel Balancer Service Manual

3 .Removal, Installation, and
Adjustment of Components
Purpose
The intent of this section is to provide helpful information during servicing that may
not be obvious from part drawings.
WARNING: To prevent the possibility of electrical shock injury or

damage to the equipment, POWER MUST BE
DISCONNECTED BY PULLING THE PLUG FROM THE AC
POWER SUPPLY.
To prevent damage to static sensitive components, a grounded static wrist strap

must be used when servicing circuit boards or cables. Any board shipped in an anti-
static bag should remain in the bag until it is necessary to install it in the balancer.
Use the same bags when returning defective boards to Hunter so that anti-static
damage during shipment is not mistaken for a problem with the balancer.
CAUTION: Wait 30 seconds after turning off the balancer before

unplugging any of the cables. There are capacitors on the
DC drive board, which hold a charge although power is
turned off. There are resistors across these capacitors to
bleed-off the charge, however, it takes about 30 seconds for
this to happen after the power is turned off.
Weight Tray, 69-933-1

Remove the four screws that hold the weight tray down and the five Keps nuts that
attach the display to the weight tray.
CAUTION: Removal of the radius arm will result in the loss of the
manual and optional auto dataset calibration and will break
the factory Loctite seal.
DSP 7700 Wheel Balancer Service Manual Removal, Installation, and Adjustment of Components • 3-1
ON/OFF Switch, 18-270-2
NOTE: When replacing the ON/OFF switch, making wiring harness

connections will be easier from the outside of the balancer
with the wires pulled through the mounting hole.
To remove the ON/OFF switch, reach inside the cabinet and push out on the switch,
while depressing one of the molded plastic tabs on the switch. This will disengage
the switch from the mounting hole. Pull out a portion of the wiring harness through
the mounting hole and disconnect the old switch.
Connect the new switch to the wiring harness. On the new switch, there are two sets
of terminals separated by a plastic rib. Plug the black wire (from L1 on the DC drive
board) and white wire (from L2 on the DC drive board) into one set of terminals, and
plug the tan and gray wires (from power source) into the other. Refer to illustration
below for connections.
GRAY WIRE 2 5 TAN WIRE

CONNECTS HERE CONNECTS HERE
N L
BLACK WIRE 1 4 WHITE WIRE

CONNECTS HERE CONNECTS HERE
N L
3 6
OPEN TERMINAL
Install the new switch in the mounting hole so the “I” (ON) side is up and “O” (OFF) is
down.
DC Drive Board, 45-861-1

Service to the DC drive board consists of checking and replacing fuses at F1, F2,
and F3, and adjusting potentiometers R31, R42, and R49. Fuses at F1 and F2 are
250 volt, MDA-10 amp fuses. F3 uses a 250 volt, GMC-3 amp fuse.
R31 is Motor Speed Control. Refer to “Motor, Belt, and Pulley,” page 3-7.
R42 is Torque Limit and is always rotated fully clockwise (maximum).
R49 is “I-R Compensation.” It is set such that the motor comes up to speed, but does
not overshoot the intended rpm. R49 may be adjusted from 1/3 clockwise to 2/3
clockwise with no materially adverse effects.
NOTE: There is little chance this potentiometer will need to be

adjusted.
3-2 • Removal, Installation, and Adjustment of Components DSP 7700 Wheel Balancer Service Manual
Spindle Encoder Board and Bracket Assembly, 45-863-1
When plugging-in and unplugging the connector to the encoder board bracket
assembly, support the board by hand to avoid deflecting the bracket. This could
make the optical switches on the board press against the brass encoder disk and
possibly bend the encoder disk.
It is important that the cable be secured properly to prevent contact with the pulley
and belt.
Do not remove the two screws holding the board to the mounting bracket, as they are
pre-adjusted at the factory. To install the assembly, slide the three optical switches
on the PC board over the brass spindle encoder disk, 17-63-2, inside the pulley
section of the spindle.
SPINDLE ENCODER BOARD
SPINDLE
MOUNTING
SCREWS
Turn the spindle by hand, looking, and listening for any contact between
components. Bend the bracket, if necessary, to ensure that the board does not rub
on the spindle and that the encoder disk does not rub on the optical switches.
Turn the balancer on and check for proper optical switch operation by observing the
three LED’s on the PC board while turning the spindle clockwise as viewed from the
end of the spindle. The LED’s should flash as shown in the illustration below.
SPINDLE ENCODER BOARD
LED-1
OFF
ON
ON
OFF LED-2
OFF OFF
OFF
ON
LED-3 ON
ON OFF
ON
ON
ON
ON
LED-3 (home pulse) is always ON, except for a short duration, OFF once per
revolution of the spindle.
If the LED’s do not operate correctly, remove the bracket assembly, but leave the
cable plugged-in. While holding the encoder assembly by the bracket, turn on the
balancer and block each optical switch with a business card. The LED corresponding
to each switch should turn ON when blocked.
If the board functions, but the installed assembly does not produce the proper LED
sequence, the position of the assembly must be adjusted. If LED-3 sequences with
LED-1 and LED-2, the board is too close to the spindle centerline. Loosen the two
mounting screws of the bracket and adjust the assembly until LED-3 turns off once
per revolution of the shaft. If LED-3 never turns off, the board is located too far from
the spindle centerline. If the board must be moved closer to the spindle centerline,
loosen the two mounting screws of the bracket and adjust the assembly.
The DSP 7700 has automatic encoder signal checking at every spin. Refer to
“Display Error Codes,” page 5-6.
“EPROM”
Remove and discard the old EPROM (Erasable Programmable Read Only Memory)
from U2 position on the CPU/Display board, 45-867-1. Install the new EPROM with
the notched end facing in the same direction as indicated by the notch printed in
white ink on the PC board. Refer to illustration.
U2
NOTCH PRINTED IN
WHITE INK ON PC
EPROM BOARD
NOTCH IN EPROM
PIN #1
Verify the program version is correct by pressing and holding the ENTER key while
turning the machine on.
The software version number (such as 1.0.0) appears on the outer weight amount
indicators. The displayed software version number should agree with the label on the
EPROM.
Calibrate the unit per the Operation Manual. Refer to “Operation Instructions DSP
7700 Wheel Balancer,” Form 4244T.
Perform the Set-Up Procedure (select the display programmables) per the Operation
Manual. Refer to “Operation Instructions DSP 7700 Wheel Balancer,” Form 4244T. If
error codes appear, refer to “Display Error Codes,” page 5-6.
Cables
If replacing a cable, which is routed through the weight tray, be sure to re-route the
new cable through the same hole in the same manner.
The spindle encoder cable should be installed with end marked “This end to DSP BD
J5” at J5 of the CPU/Display board. This ensures that the cable shield connection
originates at the CPU/Display board and not the encoder board.
Force Transducer
Clean the mounting surfaces so that the ball sockets and ceramic ball are completely
free of any dirt or debris. Install the new transducer, making sure that the flat surface
area (if present) of the ball is not contacting the ball seat as illustrated below:
YES NO NO
Tighten the setscrew 1/4 turn after finger tightening.
Move the transducer in small arcs to allow the ball and transducer to become seated.
Position the assembly so that the long edge of the board is parallel with the floor
(excessive angle will cause the board to contact the weight tray, upsetting the
imbalance vibration readings).
Tighten the setscrew another 1/4 turn.
Tighten the locknut to prevent the adjustment from changing.
Plug the cable connector into J8 of the DSP board for a left transducer, or into J7 for
a right transducer.
Manual Dataset Arm

Calibrate the arm to a reading of 295 per the Operation Manual. Refer to “Operation
Instructions DSP 7700 Wheel Balancer,” Form 4244T.
The sliding Dataset arm must be installed parallel with the main shaft to operate
properly. Rotate the arm to the down position to verify that the reading is still within
one digit of the 295 calibration reading.
Optional Auto Dataset Arm

Remove weight tray, 69-933-1, from housing assembly.
Unplug Dataset cable from J11 on CPU/Display board. Remove cable tie securing
cable to housing.
Remove the two screws, 75-312-2, that attach the optional Auto Dataset arm
assembly, 103-89-1, to the housing assembly.
Install the Auto Dataset system using the same screws previously removed.
If Auto Dataset potentiometers are faulty, the Auto Dataset Potentiometer Assembly
should be replaced as a unit. Refer to “Inner Auto Dataset Potentiometer Assembly
Replacement,” page 3-6.
Cable routing and mechanical adjustments:

It is important that the cable be looped and secured properly to prevent
binding and scraping of the cable jacket when the arm is pulled in and
out.
Work the arm back and forth, checking that the loop moves freely. The
loop should not rub against the welded balance structure, but it can rub
against the outer wrapper of the unit.
Route the cable up through the weight tray. Plug the connector into J11
“Inner Dataset" of the CPU/Display board.
The rim diameter potentiometer is the one located at the left end of the
Dataset arm shaft.
The rim distance potentiometer is the one that rides on the plastic rack
as the arm is moved in and out.
Potentiometer guide, 104-117-2, slides along the formed metal guide rail.
Pull the arm from full in to the full out position, making sure that the
potentiometer guide does not bind anywhere along its travel.
To calibrate the Auto Dataset arm, refer to “Operation Instructions DSP 7700 Wheel
Balancer,” Form 4244T
Place a wheel on the balancer and take a rim lip measurement. Verify that the
diameter acquired agrees with the wheel to within 0.1 inch (3 mm) and with the scale
reading to within 1 mark (1 mm) of the tape scale.
Inner Auto Dataset Potentiometer Assembly Replacement, 93-52-1

Remove weight tray.
Unplug Dataset cable from J11 on CPU/Display board. Remove cable tie securing
cable to housing.
Hold the spring that wraps the dataset arm shaft back, and loosen the two setscrews
securing the potentiometer assembly to the dataset arm shaft.
Slide the old potentiometer assembly off the shaft and slide the new assembly onto
the shaft. Verify that the potentiometer guide slides along the guide rail.
Perform “Inner Auto Dataset Centering Adjustments,” page 3-6, then tighten the two
setscrews securing the potentiometer assembly to the dataset arm shaft.
To calibrate the Auto Dataset arm, refer to “Operation Instructions DSP 7700 Wheel
Balancer,” Form 4244T
Place a wheel on the balancer and take a rim lip measurement. Verify that the
diameter acquired agrees with the wheel to within 0.1 inch (3 mm) and with the scale
reading to within 1 mark (1 mm) of the tape scale.
Inner Auto Dataset “Centering” Adjustments

To “Center” the diameter potentiometer (adjust potentiometer shaft for mid-rotation
when the radius arm is at half travel):
Put the balancer in diagnostic mode and advance to display variable 27
(diameter potentiometer reading). This will give a real-time reading of the
diameter potentiometer value, followed by an “H” (which indicates
hexadecimal format).
Before installing the potentiometer assembly onto the Dataset shaft,
rotate the upper potentiometer shaft until the display shows between
00 00H and 00 09H.
Rotate the Dataset arm until it is pointing directly away from the spindle.
DATASET ARM IN
LINE WITH
SPINDLE SHAFT
SPINDLE SHAFT
While the arm is in this position, insert the potentiometer into the end of
the dataset shaft. Rotate the arm, making sure that the display shows
00 00H when the arm is pointing away from the spindle.
It is also possible to use the potentiometer test pad voltages on the DSP
board to “center” the potentiometers. Display reading 00 00H
corresponds to zero volts at the potentiometer test pad. “POT 1” test pad
is the diameter (TP10) potentiometer, “POT 2” is the distance (TP9)
potentiometer.
To “Center” the distance potentiometer (adjust potentiometer shaft for mid-rotation
when the Dataset arm is pulled halfway out):
Put the balancer in diagnostic mode and advance to display variable 26.
This will give a real-time reading of the distance potentiometer value,
followed by an “H” (which indicates hexadecimal format).
Pull the arm out to scale at 230.
With the scale at 230, lift the distance potentiometer off the rack just
enough to rotate the gear. Rotate the gear to obtain display reading
between 00 00H and 00 09H.
Set the potentiometer and gear back onto the rack. Pull the arm in and
out, making sure that the display shows 00 00H at approximately mid
rack travel.
Motor, Belt, and Pulley
Check and Adjust Belt Tension

Disconnect AC power cord from the power supply.
Remove the two screws securing the motor panel assembly to the base assembly.
Check belt tension as follows:
1. Position the end of the indicator flush with the scale of the belt
tension tool.
BELT TENSION TOOL, INDICATOR

25-104-2
READ SCALE HERE
2. Place the index finger inside the rubber finger strap of the belt
tension tool.
3. Position the belt tension tool on the section of belt between the
motor and the spindle.
4. Push down on the belt tension tool until the tool clicks.
5. Read belt tension where the top edge of the arm crosses the scale.
Refer to the above illustration.
6. Belt tension should be set to 50 ft-lb., ± 5 ft-lb.
If necessary, adjust belt tension as follows:
1. Loosen four motor mount bolts.
DRIVE BELT
DRIVE MOTOR
INSERT PRY BAR

HERE TO ADJUST MOTOR MOUNT
BELT TENSION BOLTS
2. Using a small pry bar, move the motor to obtain the correct tension
on the belt. To decrease belt tension, move the motor upward. To
increase belt tension, move the motor downward.
3. Hold the motor in place and tighten four motor mount bolts.
4. Verify proper belt tension and readjust, if necessary.
5. Secure the motor panel assembly to the base assembly using two
screws previously removed.
Connect AC power cord to the power supply.
Verify the motor’s rpm as follows:
1. Press and hold the “Next” and “Enter” keys while turning the unit on.
2. Press the “Start” key.
3. The rpm of the motor will display on the console. It should be 150
rpm ± 2 rpm.
If necessary, adjust the motor speed as follows:
1. Remove two screws securing the motor panel assembly to the base
assembly.
CAUTION: Do not touch any components of the circuit board, other than
the potentiometer, while the balancer is plugged into the
electrical supply.
2. Locate the potentiometer (R31) and adjust using a small slotted
screwdriver. Turning the potentiometer clockwise will increase the
motor speed. Turning it counterclockwise will decrease the motor
speed.
POTENTIOMETER,
(R31)
3. Verify motor speed. Readjust as necessary.

4. Reinstall two screws previously removed to secure the motor panel
assembly to the base assembly.
5. Turn off the unit to cancel “rpm display” mode.
The electrical connections to the motor consist of one ground to be connected to tab
5 (also labeled motor 2) and a power wire to tab 3 (also labeled motor 1) of the DC
drive board, 45-861-1. A ground wire is connected to the “N” terminal of the DC drive
board and a welded stud on the chassis of the balancer.
If replacing the pulley, torque the two pulley setscrews to 70 in-lbs., while the motor is
out of the unit. This torque is not achievable with a simple hex wrench (use a torque
wrench with a hex bit).
Set the belt tension to 50 lbs. ±5 lbs. Refer to “Check and Adjust Belt Tension,” page
3-7. Turn the spindle a few times and then recheck the belt tension.
Spindle and Threaded Shaft Assembly

Clean the taper of the spindle with a clean cloth and verify that it is free of dirt and
debris. Apply a light coat of oil to prevent rust.
TAPERED
SPINDLE
Position the hub/shaft assembly, 97-367-3, on the tapered surface.
HUB/SHAFT
ASSEMBLY,
97-367-3
Gently shake the hub/shaft assembly to seat the assembly on the tapered surface.
Tighten the bolt located inside the hub/shaft assembly to approximately 50 ft-lbs.
using the 14mm Allen wrench provided.
14MM ALLEN
WRENCH
HUB/SHAFT
ASSEMBLY,
97-367-3
The threaded shaft loosens counterclockwise (as viewed from the end of the shaft)
and tightens clockwise.
Spindle Encoder (Slotted Aperture) Disk (Part of Kit 20-976-1)
Remove the spindle encoder bracket assembly, remove the spindle assembly, pull
off the old encoder disk, and scrape off any old adhesive from the spindle. Clean the
spindle contact area and the new encoder disk with lacquer thinner. DO NOT use
parts cleaner or anything that leaves a residue.
Use either Hunter adhesive, 162-69-2, or “Loctite-426” and spread a thin coat on the
spindle contact area. Place the disk in position and press it firmly over the adhesive
all the way around. The orientation of the home pulse slot does not matter. Add more
adhesive to the outside of the disk and spindle lip to form a fillet as shown in the
following illustration.
NOTE: Be careful to not get adhesive into the encoder disk slots.
SPINDLE
ENCODER DISC
ADHESIVE FILLET
THIN FILM OF
ADHESIVE
Re-install the spindle and spindle encoder board.
Manual Input Knob, 34-86-2

Pry off the gray plastic knob cap, 34-87-2, from the knob. Loosen the brass collet nut
to allow the knob to slide off the knob stem.
BEZEL
COLLET NUT
KNOB STEM
KNOB
KNOB CAP
When installing the new knob, the knob will bind against the display if it is held
against the display while tightening the collet nut. Hold the knob slightly away from
the display (the thickness of a piece of paper is about right) while tightening the brass
collet nut. The knob should be installed as close to the display as possible without
binding.
Knob Board, 45-675-1

Unplug the knob board cable connector from J1 of the DSP board.
Remove the gray plastic cap, brass nut, and washer to remove the knob from the
knob shaft.
Remove the lock nut to remove the knob board from the assembly.
4 . Diagnostics Mode
Enabling the Diagnostics Mode

Press and hold the two keys while turning the balancer on. It is important to
remember that once the balancer is turned on in diagnostic mode, it remains in the
diagnostic mode until turned off. All balancer operations work identically while in
diagnostic mode, with three exceptions:
Screen Viewable Diagnostic Values

If a balancer problem cannot be corrected by normal service measures, it is possible
to show diagnostic values on the display screen. These values are used internally by
the DSP chip for use elsewhere in this manual or for analyzing at a Hunter Service
Center. Before calling the service center with these values, have the balancer serial
number and software version number available, to prevent the need for a second
telephone call. To access the software version number, press and hold the ENTER
key while turning the balancer on. The software version number will appear on the
display.
The DSP 7700 uses the Hexadecimal system to show diagnostic values instead of
the decimal system. The Hexadecimal system is based on units of sixteen rather
than units of ten that the decimal system uses:
DECIMAL SYSTEM:
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17...
HEX SYSTEM:
1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, F, 10, 11...
EX: DECIMAL SYSTEM 6298
(6 X 1000) + (2 X 100) + (9 X 10) + (8 X 1) = 6298

EXAMPLE: CONVERTING
HEX SYSTEM TO DECIMAL 189A
(1 X 4096) + (8 X 256) + (6 X 16) + (10 X 1) = 6298

IF RESULT IS GREATER THAN 32,767, THE HEX NUMBER
IS NEGATIVE. SUBTRACT 65,536 FROM THE TOTAL TO
GET THE DECIMAL NEGATIVE NUMBER.
Hexadecimal-to-decimal calculators are available, identifiable by the letters “A, B, C,

D, E, F” appearing across one of the rows of keys.
Press the NEXT key while the “Standard” LED is lit to see the first diagnostics value
(1 should appear, alternating with a five character value across the weight amount
indicators). If the NEXT key does not respond this way, both outer keys were not held
down firm enough during power-up, (the balancer responded to only one of the keys,
initiating normal balancer operation).
DSP 7700 Wheel Balancer Service Manual Diagnostics Mode • 4-1

NOTE: The diameter knob can be used to dial to the desired display
variable, once the NEXT key is pressed to show the first
variable.
Each press of the NEXT key will present a five character value across the weight
amount indicators. The corresponding index will alternate with that number.
Each character of a displayed value can be the numbers 0 through 9 or the letters A,
b, C, d, E, or F. The last character is always “H” which stands for “hex” format
characters.
The following is an example of the characters as they appear on the display screen:
For example, DSP 7700 software version 1.0.0, has twenty-nine diagnostics
variables which might show on the screen as shown in the table below:
DIAMETER WEIGHT HEX VALUE DECIMAL VALUE

DIGITS DIGITS
1 01 1bH O11b 283
2 02 00H 0200 512
3 0E AFH 0EAF 3,759
. 00 01H 0001 1
. 00 00H 0000 0
. FF FFH FFFF -1
After the last diagnostics value has been presented, pressing the NEXT key will return
the unit to the normal weight displays. Be sure to turn the balancer off and then back
on when finished with the diagnostics mode.
Calibrating In Diagnostics Mode

Diagnostic calibration will be saved even if the calibration fails (“CAL Err” is displayed
on the screen). This might allow the balancer to function until a faulty transducer can
be replaced. A transducer that has a weak output may be failing the regular
calibration. For example, try calibrating while in diagnostics and then perform the
quick cal check.
In diagnostic calibration, all the limits are tighter, especially for the temperature
sensors on each transducer. “CAL Err” is acceptable to appear on a balancer that
always shows “CAL rdy” if calibrating while not in diagnostics mode.
4-2 • Diagnostics Mode DSP 7700 Wheel Balancer Service Manual

Setup Procedure in Diagnostics Mode
When the balancer is in diagnostic mode, the “Setup” procedure presents some
setup programmables not available in the non-diagnostic mode “Setup” selections.
Selection Purpose Settings Factory

Settings
Rnd Round 0.01, 0.05, 0.25 0.25 oz
Increment oz
Bli Blind 0, 0.15, 0.29, 0.29 oz
Amount 0.58 oz
Lan Language DSP (English DSP
U.S.)
05 (English
Export)
09 (German)
18 (Spanish LA)
19 (Spanish
Spain)
DSP 7700 Wheel Balancer Service Manual Diagnostics Mode • 4-3

4-4 • Diagnostics Mode DSP 7700 Wheel Balancer Service Manual
5 .Troubleshooting
Pre-Troubleshooting Checklist
When service is requested, it is important to verify that the balancer is being used
properly.
Verify that the “blind” is set to a value larger than the “round.” Refer to “Setup
Procedure in Diagnostics Mode,” page 4-3.
Verify that the calibration weight studs are not loose or bent.
Was the “enter TDC” step 2 of the calibration procedure performed correctly?
Is the wheel shifting position during the spin without the operator realizing it? The
wing nut may not be tight enough. A two handed “rocking” motion of the wheel is
recommended.
Is the wheel shifting its position during the spin because of dry spindle and wing nut
threads? When the threads are not well lubricated, a large portion of the effort to turn
the wing nut goes into overcoming the thread friction, instead of pushing the wheel
against the balancer hub faceplate. It may feel tight, but it is not pushing the wheel
against the hub to nearly the same degree as if the threads were lubricated.
Is the wheel shifting position during the spin because of excessive oil or debris on the
hub faceplate or wheel? Make sure these surfaces are clean and dry.
NOTE: The customer should not coat the hub surface with oil to
keep it from rusting.
Is the wheel (especially a large wheel) centered properly? Check for proper centering
by holding the Dataset arm tip near, but not touching the rim lip while turning the
wheel. Look for up and down movement of the rim with respect to the stationary
Dataset arm tip. Large wheels are more difficult to center due to the extra weight
having to travel up the cone.
Make sure the cones are not dry and that the wheel is “rolling” as the wing nut is
tightened. This lets the pilot hole roll, instead of slide, while it travels up the wheel
cone.
Try lifting the wheel as the wing nut is being tightened.
On very heavy wheels, try wheel coning from the outside of the wheel. This forces
the cone into the pilot hole by the full wing nut force instead of just the spring
pressure.
Is the wheel bent? Check by holding the Dataset arm tip close-to, but not touching
the rim lip while turning the wheel. Look for left and right movement of the rim with
respect to the stationary Dataset arm tip. If the wheel is bent, the dialed-in Dataset
reference setting on the display is only correct for one spot (where the wheel was
measured). A weight placed at any other angular location will be in error and result in
residual imbalance amounts.
Check for debris accumulating inside of the spindle spring mechanism.
DSP 7700 Wheel Balancer Service Manual Troubleshooting • 5-1

Ask the customer if the problem re-occurs on different wheels (water or other matter
inside the tire will cause trouble). Tires should always be inflated to proper
specifications.
Check the floor condition. Refer to “Initial Installation,” page 2-1.
Check for physical damage to wheel cones, cup, and wing nut.
Auto Dataset Troubleshooting

Test pins on the power board are provided to access the wiper voltages with a meter.
A distance potentiometer wiper voltage can read from almost -5 to almost +5 volts if
the potentiometer is not installed in the Dataset arm. For the distance potentiometer
(TP9), mechanical limiting of the arm is set to allow only a percentage of the possible
10 turns of the potentiometer to occur. The distance wiper voltages on a correctly
assembled Dataset arm should not exceed ±1.9 volts. The diameter potentiometer
(TP10) is a single-turn potentiometer and should read up to ±1.95 volts, with about
40 degrees rotation of “dead area” where the voltage will not change. The dead area
will not be accessible in an installed dataset arm because the spindle will inhibit the
arm movement. The best situation is to have a potentiometer “centered” for the arm
travel. This means that the inner Auto Dataset diameter wiper voltage should be zero
when the arm is at mid angular travel. The distance wiper voltages should be zero
when the inner and outer arms are at mid linear travel. A potentiometer can be “off
center” by quite a bit without impairing Dataset arm performance because this is
compensated for at calibration.
NOTE: Test pads TP9 and TP10 are coated, therefore it will be
necessary to “poke” through the coating with the meter
probe.
Inner Auto Dataset

Potentiometer 1, TP10 (diameter), should go from negative to positive voltage as the
arm is pivoted from touching the top of the threaded shaft to touching the bottom of
the threaded shaft. Ideally, the voltage should be zero with the arm pointing directly
away from the spindle (mid angular travel). This is not required, but if the voltage
clips (sticks at a maximum or minimum value) within the endpoints of the arm travel,
“center” the potentiometer. Refer to “Inner Auto Dataset “Centering” Adjustments,”
page 3-6.
Potentiometer 2, TP9 (inner Auto Dataset distance), should go from negative to

positive voltages as the arm is pulled from the rest position to fully extended. Ideally,
the voltage should be zero with the arm at the half-travel point. This is not required,
but if the voltage clips (sticks at a maximum or minimum value) within the endpoints
of the arm travel, “center” the potentiometer. Refer to “Inner Auto Dataset “Centering”
Adjustments,” page 3-6.
The balancer spindle travel from steps 1 and 2 is used in the calibration, so the
spindle encoder board must be plugged-in to obtain a successful Dataset calibration.
Spindle angle travel between cal steps 1 and 2 is used to determine to high accuracy
the distance between the spindle centerline and Dataset arm shaft centerline. This
makes the diameter reading accurate to 0.1 inch, yet does not require a fixed vertical
or horizontal mounting distance of the arm relative to the spindle. The arm does
need to be parallel with the spindle, however. To check for parallel, touch the arm tip
to the back of a cone with the arm in the up position, and then in the down position.
If the scale readings vary by 3mm or more, report this to the Service Center. The arm
can be repositioned by filing a slot in the leftmost mounting hole on the front of the
balancer, allowing the rear of he Dataset arm to be moved up or down.
5-2 • Troubleshooting DSP 7700 Wheel Balancer Service Manual

Binding Dataset Shaft
Lubricate main shaft with grease or “white lube” to eliminate shaft binding during arm
rotation.
If the inner arm refuses to trigger by distance potentiometer movement or inputs

incorrect distances:
Refer to “Diagnostics Mode,” page 4-1. Write down the value in variable
30. This is the potentiometer value recorded from the last arm
calibration, at which the trigger should occur due to the distance
potentiometer.
Change to display variable 26 (real time inner distance potentiometer
reading) and observe if reading 30 occurs when the arm is pulled slightly
to the right of the home (storage) position. If so, the problem is
somewhere else.
If the inner arm refuses to trigger by diameter potentiometer movement or inputs

incorrect distances:
Refer to “Diagnostics Mode,” page 4-1. Write down the value in variable
31. This is the potentiometer value recorded from the last arm
calibration, at which the trigger should occur due to the diameter
potentiometer.
Change to display variable 27 (real time inner diameter potentiometer
reading) and observe if reading 31 occurs when the arm is rotated
slightly upward from the home (storage) position. If so, the problem is
somewhere else.

Troubleshooting Chart
SYMPTOM POSSIBLE CAUSE REMEDY
Motor will not run, display dead, No AC power. Check customers AC power line
spindle encoder LED is dead. service.
Fuse F1/F2 open on power board.
Replace fuse.
Motor starts, but will not cycle, Defective spindle encoder cable. Replace cable, 38-627-1.
spindle encoder LED’s sequence
correctly. Defective CPU/Display board. Replace CPU/Display board,
45-867-1.
Motor starts, but will not cycle, Defective or out of adjustment Replace or adjust assembly.
spindle encoder LED’s do not spindle encoder assembly.
sequence correctly.
Everything appears dead, except Balancer software is not running Try re-inserting EPROM, then try a
for spindle encoder LED’s. due to intermittent EPROM known good EPROM.
connection.
Defective CPU/Display board. Replace CPU/Display board,

45-867-1.
Motor runs and cycles, but the Defective CPU/Display board. Replace CPU/Display board,
display is dead. 45-867-1.
Wheel starts, but freewheels Intermittent cable connections. Replace cable, 38-860-1.
instead of braking to a stop.
Defective DC drive board. Replace DC drive board, 45-861-1.
Wheel and/or wing nut come loose Threads on spindle shaft and wing Clean the spindle by running the
during the spin. nut are not lubricated and/or dirty. edge of a rag between the threads,
Too much of the turning force on while turning the spindle by hand.
the wing nut is being used to Lube the spindle shaft and wing
overcome the thread friction, nut threads using Teflon®
instead of pushing the wheel containing evaporating lubricant
against the hub faceplate. i.e. SuperLube® by Permatex.
Wheel and/or balancer hub Clean with non-residue solvent

faceplate not clean and dry. such as lacquer thinner.
Wingnut is not tight enough. Tighten wingnut.

Spindle starts by itself. START switch is sticking near the Replace the keypad/overlay
closed position. Try a known, good assembly, 51-1579-1.
keypad/overlay assembly and
observe if the problem persists.
Fuses loose in fuse clips of power Remove fuses and tighten clips
board. (compress together).
CPU/Display board has conductive Blow off debris.

debris near the start sensing
circuits (near U9, 13, and 14.)
CPU/Display board “start” sensing Replace CPU/Display board,

circuits are defective. 45-867-1.
Intermittent shorts to “start” Replace cable, 38-627-1.

sensing lines in DC power cable.

Troubleshooting Chart (continued)
Weight positions or amount Incorrect calibration of top-dead- Re-calibrate balancer.
indicators are incorrect, or non- center (step 2 of Cal Procedure).
repeatability from spin to spin.
Loose or defective force Clean, adjust, or replace
transducer. transducer.

45-867-1.
Dirt in spindle encoder disk. Clean and check the encoder

board operation.
Wheel can be balanced, but is Shaft has runout. Check shaft for runout:
then out by more than 0.30 ounces Shaft runout should be <0 .0015”
if remounted on the balancer. Plate runout should be <0 .002”
Cone is worn or dry, preventing Inspect cone for excessive wear or

proper wheel centering. lack of lubrication film.
Wheel is not centering properly Use the outside wheel cone

due to excessive weight, even if mounting method for larger
the wheel is turned while tightening wheels.
the wing nut.
Weights and angles repeat from Wheel is bent or has run out. Replace wheel.
spin to spin, but cannot balance
the wheel (chasing weights). Wheel is not centering properly Use the outside wheel cone
due to excessive weight, even if mounting method for larger
the wheel is turned while tightening wheels.
the wing nut.
Cone is worn or dry, preventing Inspect wheel cone for excessive

proper wheel centering. wear or lack of lubricating oil.
Angle location at calibration was Re-calibrate the balancer.

not accurate.
Calibration weight stud is loose or Replace the calibration weight.

bent.
Setup “blind” is set to 0.00 ounce Change “blind” to 0.29 oz and

and/or “rounding” is set to 0.01 rounding to 0.25 oz.
ounce (used for “weight trimming” Refer to page 4-3 for “Setup
precision balancing). Procedure in Diagnostics Mode.”
Setup “blind” is smaller than the Only use one of the following
“rounding.” Example: 0.25 ounce combinations:
round; 0.15 ounce blind. rnd blind usage
0.05 0.15, 0.29, weights
0.58 in 0.05 ounce
increments.
0.25 0.29, 0.58 weights

in 0.25 ounce
increments.

Troubleshooting Chart (continued)
Keypad or knob functions happen CPU/Display board has conductive Blow off debris.
by themselves. debris near the knob and switch
detect circuits (near U7, U8, CR43,
and J2).
CPU/Display board knob and Replace CPU/Display board,

switch detect circuits are defective. 45-867-1.
Defective knob encoder. Replace knob board, 45-675-1.

The keypad is too sensitive or Defective keypad/overlay Replace the keypad/overlay
responds to a number of key assembly. assembly, 51-1579-1.
presses that were not actually
executed.
Keypad not responding. Defective keypad/overlay Replace the keypad/overlay
assembly. assembly, 51-1579-1.

45-867-1.
Display Error Codes
“Err -1-” blinks on the display, “no Spindle encoder assembly or Replace assembly, 45-863-1, or
rotation signal detected.” cable is defective. cable, 38-627-1.

45-867-1.
Spindle really is not turning. Verify that balancer is plugged into

Drive or motor problem. power supply.
CPU/Display board has conductive Blow off debris.

debris near the encoder sense
circuits (near U8, RN2, and J5).

“Err -2-” blinks on the display, Wheel is too heavy. Give the wheel a helping push
“excessive time elapsed to achieve before pressing the START switch.
minimum measuring speed.” Advise Hunter of wheel and tire
type for evaluation.
Wheel was turning the wrong way Do not allow larger wheels to turn
when the START switch was in the wrong direction before
pressed, taking extra time for the pressing the START switch.
motor to reverse it’s rotation.
No home pulse detected. Check spindle encoder board,

cable, and CPU/Display board.
Incoming power voltage sagging Improve the incoming power

when spinning large tire. service or convert the balancer to
a different power service. Advise
Hunter if this occurs.
“Err -3-” blinks on the display, Motor leads reversed. Reverse motor leads.
“forward rotation not detected.”

Display Error Codes (continued)
“Err -4-” blinks on the display, Intermittent DC drive cable Replace cable, 38-627-1.
“excessive time to decelerate.” connections.

“Err -5-” blinks on the display, Not applicable to a DSP 7700. Advise Hunter of wheel and tire
“unexpected reverse rotation.” type if this occurs.
“Err -6-” blinks on the display, Spindle encoder board bracket Loosen encoder bracket mounting
“no home pulse detected.” assembly adjusted too close to screws and move the assembly
shaft centerline. away from the shaft centerline.
Dirt in encoder ring home pulse Clean encoder ring.

slot.
Bad encoder board. Replace encoder board, 45-863-1.
Home pulse wire (pin 4) of Replace cable, 38-627-1.

encoder cable is shorted to ground
(pin 5).
Replace encoder board and check
Spindle encoder ring scraped spindle for end play problems.
against detectors on encoder
board, damaging the home pulse
detector.
“Err -7-” blinks on the display Spindle encoder board bracket Loosen encoder bracket mounting
“home pulse erratic.” assembly adjusted too close to screws and move the assembly
shaft centerline. away from the shaft centerline.
Dirt in encoder ring home pulse Clean encoder ring.

slot.
Bad encoder board. Replace encoder board.

“Err -8-” blinks on the display Spindle encoder board bracket Loosen encoder bracket mounting
“multiple home pulses detected.” assembly adjusted too far from screws and move the assembly
shaft centerline. closer to the shaft centerline.
Home pulse wire (pin 4) is open or Replace encoder cable, 38-627-1.

intermittent.
“Err -9-” blinks on the display Spindle encoder board bracket Try repositioning encoder
“spindle encoder erratic.” assembly adjusted. assembly.
Pins 1 and/or 3 of encoder cable Replace encoder cable, 38-627-1.

are intermittent shorts or opens.
Spindle encoder ring scraped Replace encoder board and check

against detectors on encoder spindle for end play problems.
board, damaging the phase A
and/or phase B detector.
“Err -10-” blinks on the display, “left Transducer is unplugged (if you Plug in transducer.
transducer temperature out of unplug it as a test, turn power off
range.” to allow temperature “reading” to
discharge from a capacitor on the
CPU/Display board).

“Err -11-” Blinks on the display, Temperature sensor in transducer Replace transducer, 109-87-3.
“right transducer temperature out is bad.
of range.”
Bad U10 on CPU/Display board. Replace CPU/Display board,
45-867-1.
Bad transducer cable connections. Replace transducer, 109-87-3.

“Err -12-” blinks on the display, Problem with CPU/Display board Replace CPU/Display board. If
“problem reading calibration data.” permanent memory. unable to replace board, calibrate
balancer and leave power on.
“Err - 13-” blinks on the display, Problem with CPU/Display board Replace CPU/Display board. If
“problem writing calibration data.” permanent memory. unable to replace board, leave
power on.
“Err - 14-” blinks on the display, Problem with auto dataset. Replace CPU/Display board. If
“problem writing calibration data.” (Optional equipment) unable to replace board, leave
power on.
“Err - 15-” blinks on the display, Problem with auto dataset. Replace CPU/Display board. If
“problem writing calibration data.” (Optional equipment) unable to replace board, leave
power on.
“problem reading setup data.” permanent memory. unable to replace board, perform
“Setup” and leave power on.
“problem writing setup data.” permanent memory. unable to replace board, leave
power on.
“problem reading from multiple permanent memory. unable to replace board, calibrate
areas of data storage.” balancer, perform “Setup,”
calibrate Auto Dataset arm, and
leave power on.
NOTE: Errors 12 through 20 may appear at power up after installing
new software. This is normal. Perform “Calibration” and
“Setup.” Turn balancer OFF, then ON. Error message should
be gone.

“CAL Err” appears on the display Calibration weight was not placed Re-calibrate the balancer per the
after the last calibration spin. at the proper position for each Operation Manual. Refer to
calibration spin. “Operation Instructions DSP 7700
Wheel Balancer,” Form 4244T.
Left or right channel imbalance Try new transducers first, then try
signal was out of correct range a new CPU/Display board.
because of a bad transducer or
CPU/Display board.
Transducer has grown weaker with Calibrate the balancer while in

time, failing the calibration weight diagnostics mode. This forces the
sequence test in software. balancer to accept calibration,
which in most cases will let the
user continue to use the balancer.
Before turning the unit off, record
and send diagnostic display
variables 1-13 to Service Center
for evaluation.

Quick Calibration Check Procedure
Turn the balancer off and then on again.
The purpose of doing this is to obtain the default knob settings (where the inner and
outer weight placement planes coincide with the center of gravity of the left and right
installed calibration weight positions) as illustrated below.
POWER-UP POWER-UP
DEFAULT DATASET
DISTANCE SETTING “W” SETTING
CAL. WEIGHT
SPINDLE
Disable Blind and Rounding by pressing the right key once to light the
middle LED above the key as illustrated below.
MIDDLE
DISPLAY
LED ON
Install the calibration weight on the right side of the hub faceplate (using either
hole).
Since the center of the installed calibration weight coincides with the dialed in
settings for the outer plane, all of the imbalance amount caused by the calibration
weight should appear on the outer plane imbalance amount indicator as shown
below. The reading should be within 0.05 oz of 4.31 oz.
gm
oz
mm
in
To verify the weight angle, turn the spindle shaft until the Green Arrow and the
Center LED on the outer plane imbalance amount indicator are both on (as if to
position a wheel for correction weight placement at Top Dead Center).
The calibration weight should be at Bottom Dead Center.
Move the calibration weight to the left side of the hub faceplate.
Since the center of the installed calibration weight coincides with the dialed in
settings for the inner plane, all of the imbalance caused by the calibration weight
should appear on the inner plane imbalance amount indicator as shown below. The
reading should be within 0.05 oz of 4.31 oz.

gm
oz
mm
in
To verify the weight angle, turn the shaft until the Green Arrow and the Center
LED on the inner plane imbalance amount indicator are both on (as if to
position a wheel for correction weight placement at Top Dead Center).
The calibration weight should be at Bottom Dead Center.
The “Quick Calibration Check Procedure” is complete.
The “Quick Calibration Check Procedure” can be performed at any time, but the 0.05
tolerance on the weight amounts can only be expected on a balancer that has just
been calibrated. If the calibration check readings are off by more than 0.10, re-
calibrate the unit and perform the “Quick Calibration Check Procedure” again. Report
any chronic calibration check problems to the Hunter Engineering Service Center.
NOTE: Both calibration and the quick calibration check should be

performed at the same conditions as when the balancer is in
use. If the ambient temperature has changed dramatically,
(heat or air conditioning turned off overnight), wait until the
room has returned to working conditions before using the
feature.
Troubleshooting Transducers
Variable Description Limits
Decimal Hex
3 Left transducer magnitude due to cal weight position 2. 94 -> 1,649 005EH -> 0671H
7 Right transducer magnitude due to cal weight position 2. 398 -> 6,971 018EH -> 1b3bH
14 Left transducer range value.
15 Left transducer magnitude due to spin.
16 Engineering use.
17 Left transducer temperature reading due to spin. 0 -> 2752 0H -> 0AC0H
18 Right transducer range value.
19 Right transducer magnitude due to spin.
20 Engineering use.
21 Right transducer temperature reading due to spin. 0 -> 2752 0H -> 0AC0H
Turn balancer off, then back on while pressing the outer two keys to enable
diagnostics mode, let warm up for five minutes, and calibrate while in the diagnostic
mode.
Leave cal weight installed and spin again. Remember that “cal err” may appear since
all limits are tighter, but this is not a problem because the calibration is saved in the
diagnostic mode (pass or fail).
Check limits of variables 3 and 7 as shown above. This must be done after
calibration to be of diagnostic value.

Check repeatability of transducers:
Check that variables 14 (L) and 18 (R) are 000F. If not, replace the
corresponding transducer.
Select variable 15 (L) or 19 (R) and spin four times. The number should
not fluctuate more than twenty counts.
Test the temperature probes:

Select variable 17 (L) or 21 (R) and spin four times. The number should
be within limits shown above and should not fluctuate more than twenty
counts.
Spin repeatedly (the temperature is only read during a spin) while
blowing warm air on the transducer, the number should decrease.
Remove the heat source and continue spinning, the number should
gradually return to the original reading.
Troubleshooting Drifting Transducers

Calibrate (not in diagnostics mode). If “CAL Err” appears, refer to “Troubleshooting
Transducers,” page 5-10.
Turn balancer off, then back on while pressing the outer two keys to enable
diagnostics mode.
Press NEXT key to view variables 3 and 7. Record the variables.
Turn the balancer off to cancel diagnostic mode.
Balancer may be used until drift symptoms reappear.
After drift symptoms reappear, repeat steps and compare new variables for 3 and 7
to previously recorded variables. It is important that the ambient temperature be
close to that at the time of the beginning of the test. If not, normal temperature effects
on the force crystals will be mistaken for drift.
The numbers should not be different by more than 1%. Replace corresponding
transducer if required.
NOTE: Newly installed transducers may “settle in” for a week after
being compressed. Calibration may be required daily for the
first week.

Motor Drive Board LED Data
COLOR FUNCTION NUMBER DESCRIPTION

Green Start CR13 START signal is on (from CPU). If the motor does not
rotate, and the BRAKE FAULT LED is lit, check the
BRAKE FAULT information below. Check the motor
and its wiring. If the FIRE LED is not lit, check fuse
F3 on the drive board. If F3 is okay, replace the drive
board.
Amber Fire CR14 FIRE Indicates the SCR fire signal is being
produced. This checks the majority of the run
circuitry. If the GREEN LED is ON, and the FIRE
LED is not ON, there is a board fault.
Red Stop CR15 STOP signal is on (from CPU). Braking is being
applied. This is never on when the GREEN and/or
AMBER LEDs are on, unless there is a fault, which is
most likely to be the cable has pulled partly out of its
connector, or the CPU is faulty.
Orange Brake Fault CR22 This LED is ON during normal braking, but is always
OFF after rotation stops. If the ORANGE LED stays
lit, there is a fault in the brake circuit, usually caused
by a bad cable, as above. Usually this has harmed a
component in the drive, and requires replacement of
the drive board. This replacement MUST be
preceded by repair/replacement of the cable, or the
new board will be harmed. NOTE: Verify that the
wires are properly seated into the IDC connector.
Due to the stiffness of the wire, repeated
exercising of the cable/connector may cause the
wire to roll up and out from between the arms of
the connector contact. If this occurs, it may give
the same symptoms as a bad cable.
WIRE ROLLED OUT OF

SEATED POSITION,
MAKING INTERMITTENT
OR NO CONNECTION
CONNECTOR CONTACT
WIRE IN SEATED POSITION

6 .Appendix
CPU/Display Board Test Pad Voltages:

When checking the power supply output voltages, use the test pads located on the
CPU/Display Board.
CPU/DISPLAY BOARD,
45-867-1
TEST PADS
LABEL NAME VOLTAGE TO GND.
GND. Ground 0V
24U + 12V Unregulated * + 14V to + 15.5V
+ 5D + 5 Digital + 5V
+ 5A + 5 Analog + 5V
-5 - 5 Analog - 5V
A OUT Analog Out Not Used
* “24U” is 24 Unregulated on 8500 version of DSP/Display board.
Wiring Schematics and Diagrams

Encoder Board, 45-863-1
CPU/Display Board, 45-867-1
DSP 7700 Wheel Balancer Service Manual Appendix • 6-1


Encoder Board, 45-863-1




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4443T, 01-00

 Copyright 2000 Hunter Engineering Company

DSP 7700 Wheel Balancer Service Manual Contents • i

CAUTION: Hazards or unsafe practices, which could result in minor

WARNING: Hazards or unsafe practices, which could result in

DANGER: Immediate hazards, which will result in severe personal

WARNING: To prevent the possibility of electrical shock injury or

WARNING: Make sure that a 115V, 15 amp electrical supply circuit

DSP 7700 Wheel Balancer Service Manual Introduction • 1-1

Form 4244T Operation Instructions DSP 7700 Wheel

The CPU/Display board, 45-867-1, performs the following operations:

1-2 • Introduction DSP 7700 Wheel Balancer Service Manual

Spindle encoder signals are functioning perfectly.

DSP 7700 Wheel Balancer Service Manual Introduction • 1-3

PROBLEM CORRECTIVE ACTION

NOTE: This floor condition requirement is not unique to the

DSP 7700 Wheel Balancer Service Manual Initial Installation • 2-1

Plug the balancer into the proper electrical service.

Check for proper operation of the balancer controls:

Initial installation procedure is complete.

2-2 • Initial Installation DSP 7700 Wheel Balancer Service Manual

WARNING: To prevent the possibility of electrical shock injury or

To prevent damage to static sensitive components, a grounded static wrist strap

CAUTION: Wait 30 seconds after turning off the balancer before

Weight Tray, 69-933-1

NOTE: When replacing the ON/OFF switch, making wiring harness

GRAY WIRE 2 5 TAN WIRE

BLACK WIRE 1 4 WHITE WIRE

DC Drive Board, 45-861-1

R42 is Torque Limit and is always rotated fully clockwise (maximum).

NOTE: There is little chance this potentiometer will need to be

SPINDLE ENCODER BOARD

SPINDLE ENCODER BOARD

Tighten the setscrew 1/4 turn after finger tightening.

Tighten the setscrew another 1/4 turn.

Tighten the locknut to prevent the adjustment from changing.

Manual Dataset Arm

Optional Auto Dataset Arm

Cable routing and mechanical adjustments:

Inner Auto Dataset Potentiometer Assembly Replacement, 93-52-1

Inner Auto Dataset “Centering” Adjustments

Motor, Belt, and Pulley

Check and Adjust Belt Tension

Check belt tension as follows:

BELT TENSION TOOL, INDICATOR

READ SCALE HERE

1. Loosen four motor mount bolts.

INSERT PRY BAR

3. Verify motor speed. Readjust as necessary.

Spindle and Threaded Shaft Assembly

Re-install the spindle and spindle encoder board.

Manual Input Knob, 34-86-2

Knob Board, 45-675-1

Enabling the Diagnostics Mode

Screen Viewable Diagnostic Values

(6 X 1000) + (2 X 100) + (9 X 10) + (8 X 1) = 6298

(1 X 4096) + (8 X 256) + (6 X 16) + (10 X 1) = 6298

Hexadecimal-to-decimal calculators are available, identifiable by the letters “A, B, C,

DSP 7700 Wheel Balancer Service Manual Diagnostics Mode • 4-1

DIAMETER WEIGHT HEX VALUE DECIMAL VALUE