AccuLine 40-6640 User manual

Prepared By: Peter Brandt Version: 08 – 20080415 Page 1 of 26
40-6640 Service Manual
40-6640
Self Leveling Laser Marker
SERVICE MANUAL
Main Instrument
Bracket
Item Description Page(s)
1.0 Overall Instrument Assembly 2 - 8
1.1 Central Unit Assembly 5
2.0 Component Assembly 9 - 15
2.1 Core Module Assembly 9
2.2 Base Plate Module Assembly 10
2.3 Platform Module Assembly 12
2.4 Bracket Assembly 15
3.0 Electrical Connections 17
4.0 Calibration 18 – 23
4.1 Checking Accuracy 18
4.2 Calibration Adjustments 19
4.2.1 Linearity (curvature) error 20
4.2.2 Oblique error 21
4.2.3 Height error 23
5.0 Alarm Adjustment 24
6.0 Troubleshooting Guide 25 - 26

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40-6640 Service Manual
1. Overall Instrument Assembly
9
Fig. 1-A
Item JLT Part # Description Qty
1AP1682 Cross Plate Screw M2.5x14 4
2AP1572 Cross Plate Screw M2.5x10 4
3AP1681 Back Housing 1
4AP1683 Front Housing 1
5AP1684 Central Unit (see Sec. 1.1) 1
6AP1572 Cross Plate Screw M2.5x10 1
7AP1685 On-Off Turn Knob 1
8AP1686 Rubber Jacket 1
9AP1687 Battery Cover 1
7

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40-6640 Service Manual
General Assembly Instructions
[Note: Refer to section 3.0 for information on electrical connections.]
1. Connect the battery compartment plug from the Back Housing (3) to the Main Circuit Board. (See Fig. 1
Main Circuit Board
Back Housing
Plug connected
Fig. 1-B
2. Connect the plug coming from the Main Circuit Board to the Alarm Switch Circuit Board located on the inside
of the Front Housing (4). (See Fig. 1 C.)
Front Housing
Main Circuit Board
Plug connected
Fig. 1-C

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40-6640 Service Manual
3. Before moving the Front and Back Housing units in place, position the Rubber Jacket (8) over the instrument
so that the matching hole is located over the Crank Shaft and the on-off indicator light (from the Power Switch
Circuit Board) is through a smaller hole in Rubber Jacket. (See Fig. 1 D.)
Front Housing Back Housing
Indicator light Crank Shaft
Fig. 1-D
4. Now bring both Front and Back Housing units together over the edges of the Rubber Jacket. Use the four
Cross Plate Screws (2) to secure the units. [Note: It may be necessary to use a thin nail placed into the screw
holes to center the nuts found inside the instrument so that a straight path is achieved for the screws.]
5. Holding the instrument up-side- down, further secure the housing units using the four Cross Plate Screws (1).
Rotate the bottom portion of the base in order to locate the screw holes through the access hole. Drop the
screws into the hole and screw into housing units until tight. [Note: It may be necessary to use a thin nail
placed into the screw holes to center the nuts found inside the instrument so that a straight path is achieved for
the screws.]
The instrument can be disassembled using the reverse order described above.

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40-6640 Service Manual
1.1 Central Unit Assembly(AP1684)
Fig. 1-1-A
Item JLT Part # Description Qty
5-1 AP1513 Cross Plate Screws M3×8 4
5-2 AP1688 Support Seat Ring 1
5-3 AP1689 Core Module 1
5-4 AP1690 Cross Plate Tapping Screws ST2.9×10 3
5-5 AP1691 Base Plate Module 1
5-6 AP1692 Platform Module 1
5-7 AP1475 Cross Plate Screws M2×5 2
5-8 AP1693 On-Off Switch Assembly (includes Circuit Boards #3 and #7) [Fig. 1-1-B.] 1
5-9 AP1548 Cross Plate Tapping Screws ST2.2×6.5 3
5-10 AP1694 Circuit Board #1 (Main) 1
5-11 AP1516 M3 Flat Washers (NOT shown in diagram) 4
5-12 AP1695 Cross Plate Tapping Screws ST2.2×5 (shown in Fig. 1-1-G) 3
5- 6
5- 8
5- 7
5- 1
5- 5
5- 3
5- 4
5- 2
5- 9
5- 10
Indentation
covers
Protrusion

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40-6640 Service Manual
General Assembly Instructions
1. Attach Base Plate Module (5-5) to Platform Module (5-6) using the three Cross Plate Tapping Screws (5-4).
2. Snap on the Support Seat Ring (5-2) making sure that the inside indentation fits over the protrusion of the
Gimbal ring. Using the four Cross Plate Screws (5-1) attach the Support Seat Ring [together with the Core
Module (5-3)] onto the four Support Pillars (see Fig. 2-2-A) of the Platform Module (5-6). Place Flat Washers
(5-11) on top of Support Pillars so that the Core Module will rest on top of washers. The arm of the pendulum
(bottom piece of Core Module) must be forced through the Locking Ring (see Fig. 2-2-A).
3. Attach the On-Off Switch Assembly (5-8) [see Fig. 1-1-B for view of complete assembly] by first attaching
the switch portion of assembly using the two Cross Plate Screws (5-7). See Fig. 1-1-C for view of switch
portion attached. This portion of assembly is oriented directly above Crank Shaft (item 5-5-7 of Fig. 2-2-A).
Connecting Circuit Board Attached here Connecting Circuit Board
Crank Shaft
Fig. 1-1-B Fig. 1-1-C
Plug

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40-6640 Service Manual
4. Now attach the connecting circuit board to the underside of the supporting plate of the Core Module (5-3).
The two bolts on the underside must first be removed and then used to attach the circuit board. See Fig. 1-1-D.
Nuts for securing circuit board
Fig. 1-1-D
5. Connect plug (Fig. 1-1-B) to the top connection on found on the back side of the Main Circuit Board (5-10).
See Electrical Connections figure in Section 3 for further help.
6. First connect the plug from the A/C Receptor Circuit Board (item 5-6-9 of section 2.3)
to the middle front connection of the Main Circuit Board. Then attach the Main Circuit Board (5-10) to the
Base Plate Module (5-5) using the three Cross Plate Tapping Screws (5-9). See Fig.1-1-F. Also see Electrical
Connections figure in Section 3 for further help.
Connected Plug (from Connecting Circuit Board)
Fig. 1-1-E
Fig. 1-1-F Connected Plug from
A/C Receptor Circuit Board
7. Now attach the Alarm Loop Circuit Board to the top of the Support Seat Ring (5-2) using the three Cross Plate
Tapping Screws (5-12). The alarm loop must fit around the alarm rid. See Fig. 1-1-G.

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40-6640 Service Manual
Alarm Rod positioned inside
Alarm Loop
Three Screws
used to attach
Circuit Board
Fig. 1-1-G
The Central Unit assembly can be disassembled using the reverse order described above.

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40-6640 Service Manual
2.0 Component Assembly
2.1 Core Module Assembly
Regarding General Assembly of Core Module
NOTE OF CAUTION
This module should not be assembled by anyone other than
professional service technicians with appropriate equipment.
Cutting the hairspring wires or any other wires is NOT
recommended.
If repairs / replacements are needed for this module, it is
recommended to send the unit to the appropriate repair facility.
Call the main office of Johnson Levels for further information.

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40-6640 Service Manual
2.2 Base Plate Module Assembly (AP1691)
Fig. 2-2-A
See parts list on next page
5- 5- 13
5- 5- 10
5- 5- 11
5- 5- 12
5- 5- 9
5- 5- 8
5- 5- 3
5- 5- 7
5- 5- 6
5- 5- 5
5- 5- 4
5- 5- 2
5- 5- 1

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40-6640 Service Manual
Item JLT Part # Description Qty
5-5-1 AP1696 Cross Plate Screws M2x10 2
5-5-2 AP1697 M2 Lock Washers 2
5-5-3 AP1698 Support Post Type A (w. 1 hole through side of post) 2
5-5-4 AP1699 Support Post Type B (w. 2 holes through side of post) 2
5-5-5 AP1700 Locking Ring 1
5-5-6 AP1701 Compression Springs 2
5-5-7 AP1702 Crank Shaft 1
5-5-8 AP1703 Magnets: 10 mm x 4 mm 4
5-5-9 AP1704 Fixture Support 1
5-5-10 AP1705 Base Plate 1
5-5-11 AP1677 Cross Plate Tapping Screws ST 2.9x8 3
5-5-12 AP1658 M3 Lock Washers 4
5-5-13 AP1513 Cross Plate Screws M3x8 4
General Assembly Instructions
1. Attach Support Post Type B (5-5-4) to Base Plate (5-5-10) using Cross Plate Tapping Screws (5-5-13).
Make sure that concave impression of plate is facing up with indentation of plate to the right side of the two
posts (when looking down upon the plate).
2. Attach Support Post Type A (5-5-3) to other remaining holes in Base Plate (5-5-10) using Cross Plate Tapping
Screws (5-5-13).
3. Insert Crank Shaft (5-5-7) through inside the matching opening in Fixture Support (5-5-9). Make sure that
grease is applied to Crank Shaft. Set Crank Shaft in uppermost position.
4. Place Fixture Support (5-5-9) onto Base Plate (5-5-10) so that it fits among the four support posts. The
Crank Shaft should be oriented between the two Type B Support Posts (5-5-4). Secure the Fixture Support
from below the Base Plate using the three Cross Plate Tapping Screws (5-5-11).
5. Place the four Magnets (5-5-8) in the four matching openings of the Fixture Support (5-5-9). The magnets
will attach themselves to the Base Plate (5-5-10) below.
6. Place Locking Ring (5-5-5) down upon Type B Support Posts (5-5-4). Make sure that Locking Ring fits in
place with Crank Shaft (5-5-7).
7. Slide the two Compression Springs (5-5-6) over each of the Type B Support Posts (5-5-4). Push the
Compression Springs down far enough to insert the Cross Plate Screws (5-5-1) and Lock Washers (5-5-2).
Screw both screw in all the way and then release the Spring.
The Base Plate Module can be disassembled using the reverse order described above.

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40-6640 Service Manual
2.3 Platform Module Assembly (AP1692)
The off-center hole
needs to match
the indentation circle
on the bottom of the
Degree Scale.
Item JLT Part # Description Qty
5-6-1 AP1706 Lock Ring 1
5-6-2 AP1707 Wave-form Gasket 1
5-6-3 AP1708 Gasket 1
5-6-4 AP1709 Rotation Platform 1
5-6-5 AP1616 Cross Plate Screws M2.5×5 3
5-6-6 AP1710 Degree Scale 1
5-6-7 AP1711 Bottom Axle (metal) 1
5-6-8 AP1548 Cross Plate Tapping Screws ST2.2×6.5 2
5-6-9 AP1712 #2 A/C Receptor Circuit Board 1
5- 6- 3
5- 6- 2
5- 6- 7
5- 6- 1
5- 6- 9
5- 6- 6
5- 6- 8
5- 6- 5
5- 6- 4
Fig. 2-3-Ax

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40-6640 Service Manual
General Assembly Instructions
1. Using three Cross Plate Screws, attach the Bottom Axle (5-6-7) into the bottom of the Degree Scale (5-6-6).
2. Place the Rotation Platform (5-6-4) onto the Bottom Axle (5-6-7). Place the Gasket (5-6-3) and then
Wave-form Gasket (5-6-2) onto the Bottom Axle. Attach Lock-Ring (5-6-1) using ring pliers to secure all parts.
3. Attach #2 A/C Receptor Circuit Board by first inserting only the tip of indicator bulb into matching hole in
Rotation Platform (5-6-4). Apply a little grease on the indicator bulb before inserting. Then pivot the circuit
board downward so that the A/C plug receptor is matching the slot in the Rotation Platform. Make sure that the
receptor is flush with outside of Base. (See Fig. 2-3-B).
Plug Receptor
Fig. 2-3-B
4. Then gently place 1/8-inch flat head screwdriver between the second and third wire prong and gently leverage
the indicator light forward until it protrudes out from the hole in the Rotation Platform. (See Fig. 2-3-C.)
Fig. 2-3-C

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40-6640 Service Manual
5. Then push plug receptor down and attach #2 A/C Receptor Circuit Board (5-6-9) using two Cross Plate Screws
(5-6-8). (See Fig. 2-3-D.) Make sure that wires are fit into inside groove along edge of Rotation Platform.
Fig. 2-3-D
The Base assembly can be disassembled using the reverse order described above.
[NOTE: To remove the A/C Receptor Circuit Board, remove Cross Plate Screws (5-6-8) and gently lift the
power plug receptor out while indicator light is still in place. Then gently use a small nail head to push the
indicator light until it releases from the hole. (See Fig. 2-3-E.)
Fig. 2-3-E

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40-6640 Service Manual
2.4 Bracket Assembly (40-6356)
Fig. 2-4-A
See Parts List on next page.
9-8
9-10
9-4
9-12
9-6 9-7
9-2
9-1
9-5
9-16
9-11
9-14
9-13
9-15
9-12
9-3
9-9

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40-6640 Service Manual
Item JLT Part # Description Qty
9-1 AP1717 Bracket 1
9-2 AP1718 Cover Board #1 1
9-3 AP1719 Cover Board #2 1
9-4 AP1720 Cover Board #3 1
9-5 AP1721 Fastening Knob 1
9-6 AP1722 Magnet Holders 2
9-7 AP1723 Rubber Pad 1
9-8 AP1724 Cushion Rings 1
9-9 AP1725 Magnet Plate 2
9-10 AP1726 Magnet 14x4 2
9-11 AP1727 Magnet 18x4 2
9-12 AP1493 Cross Plate Screw M2.5×8 6
9-13 AP1728 Cross Plate Tapping Screw ST2.2×4.5 1
9-14 AP1548 Cross Plate Tapping Screws ST2.2×6.5 5
9-15 AP1677 Cross Plate Tapping Screws ST2.9×8 3
9-16 AP1729 Cross Plate Tapping Screws ST2.9×9.5 3
General Assembly Instructions
NOTE:
This bracket unit is similar to the bracket of the instrument 6620 (or 6625).
Refer to that service manual for instructions.

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40-6640 Service Manual
3.0 Electrical Connections
Fig. 3 A
Fig. 3-A
#1 Main
Circuit Board
#4 Alarm Loop
Circuit Board
(outside ring)
Power Source
(Batteries)
#3 Power Switch
Circuit Board
#7 Connecting
Circuit Board
#6 Alarm Switch
Circuit Board
#5 Alarm Rod
Circuit Board
(inside ring)
#2 A/C Receptor
Circuit Board

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40-6640 Service Manual
4.0 Calibration
Calibration is a process used to correct for accuracy and/or functional errors above and beyond those stated in
published specifications. While Manual-leveling, Self-leveling, and Automatic-leveling (motor driven) devices
have different mechanisms that require calibration, there are similarities with optics that are consistent regardless
of the leveling mechanism. This service manual discusses calibration specific to the 40-6640.
All accuracy checking and calibration adjustments described below must be made while laser instrument is
secured on a leveled platform.
4.1 Checking Accuracy
Note diagram below and follow instructions on next page.
Laser Lines
Horizontal Reference
Line AOB
Vertical Reference
Line COD
Fig. 4-1-A

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40-6640 Service Manual
A true and correct reference standard must first be established:
1. Use a wall surface 5 meters (16.5 feet) away from the level platform which supports the laser instrument.
2. Establish and mark a level horizontal line and a plumb vertical line as Reference Lines. The horizontal
reference line is named AOB, while the vertical reference line is named COD.
NOTE: Point “O” should share the same height as the laser output source of the instrument.
3. Mark lines on both sides of each reference line that are 0.5 mm from the lines. (see Fig. 4-1-A)
4. Now check the accuracy of the lasers against the reference.
If the laser lines are within the range created by the lines drawn 0.5 mm out from the reference lines, the laser
instrument is operating within the accuracy specification of the instrument.
[Accuracy specification is the same for the 40-6640 Self-leveling Laser: +1/8”/35 ft. (+ 3mm / 10m).]
If accuracy does not fall within specification, continue to review the following sections and make the needed
calibration adjustments.
4.2 Calibration Adjustments
There are three types of error described in the following sections:
4.2.1 Linearity (or curvature) error.
4.2.2 Oblique error.
4.2.3 Height error.
When making adjustments with the errors described below, a pair of screws must be turned in
a certain manner. One of the screws needs first to be loosened slightly. The other screw then needs to be
tightened by an equal amount. Continue loosening one screw and tightening the other (or go in the reverse
direction) depending on the adjustment needed. When adjustment is completed, make sure both screws are
tight.
NOTE: When all accuracy checks and needed corresponding calibrations have been made, it may be necessary to
adjust the position of the alarm (see section 5.0).

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4.2.1 Linearity (or curvature) error.
Either the horizontal or vertical line is not straight (i.e. there is curvature).
Adjustment required: Adjust the needed screws in the diagram below depending on which laser lines show
curvature. [NOTE: The housing needs to be removed. For the vertical linearity adjustment, the Main
Circuit Board will also need to be detached to provide access to the screws.]
Fig. 4-2-B Fig. 4-2-C
for horizontal linearity for vertical linearity
Adjustment screws
Adjustment screws
- other screw is on other side
Vertical
Reference Line
(COD)
Fig. 4-2-A Linearity (or curvature)
Horizontal
Reference Line
(AOB)