Exalto windshield wiper type 235 KK 12/24 Volt
Contents
1. standard parkside 1 wrong parkside 2 LY 00 o0 O0 connection lever of wipe arc and wiper blade With this method the wipe arc and the wiper blade can be determined J D distance top side glass to center roughly Contact your vendor to o Spindles ey I determine your configuration more L GH glass height GW glass width accurately L length of arms e Determine length of panto graph am L LZ E D e get the maximum wiped area width W W 0 9 GW e find the intersection of L en W in the diagram below Determination of wipe arc o o BRE et A ee Armlength L EH zeae TAAA REAA Goad Boe eee 7227277277 24 88 ooo gece gt daa eer sooo eed 2 ELE G 00 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 Units in mm Wiped area width W e the wipe arc line closest to the intersection shows the wipe arc H height displacement W width of wiped area 5 4 R 12 m m a AOE a l e find in the table below the vertical displacement of the blade H Determining the vertical displacement of the wiper blade Armength L 300 350 400 450 800 550 600 650 700 750 800 850 900 950 1000 51 54 57 60 45 23 65 68 72 76 50 26 80 84 89 94 55 34 96 102 107 113 60 40 114 121 127 134 65 47 133 141 149 157 70 55 154 163 172 181 75 62 176 186 196 207 80 70 199 211 222 234 85 79 223 232. Tee SER CEOULHE LOTO acces sonst sep ctt cde aces md ater Naat cass ahs pe dcr DLE 1 2 dErdironhenbebT goose estesa tte soe cot teatro titii 1 3 Modified use and guarantee usse mm ero ur n ud HE RE Pe Edit UR 2 T OTOP A usd cui uL ARP D LLL LE LEN A Ad 2 2 Electrical data 12 Volt t deti be erecto rt ree irse ctore 23 Electrical data 2A Voll 5t steps tete oe ote t toi elati ec tbeicitele 244 Mechanical data feiss er t e etu are ete ce E a be e EN PRu dE Installation e Dab PPeDOLaHOTl oscnnammiiptet wt DH URN UII ee PEORES REIS Tiaia 3 2 Installation of mechanical parts 5 con tonto eter tapete rit 3 9 ublectnoalipstall so oos bre aee t oen RE ale 3 4 Finalinstallation 230 decet eoa eMe dE EE Operation and use 09090000000000000000000000000000000000000000000000000000000000000000000000000000 0 4 1 Preparation for first use uudacsennendies RR EH er ER 122 S ssa a ce rere o e Eus o P cu c et E o P IRL Maintenance Meet 5 1 General maintenance aeeandher trado d RAPTI GEPUR EE RR 3 2 OCLVICING 2 ata ermtn cama n E rasan Ac commen Aet D naL 5 3 Changing the wipe arc and park position eene 5 4 Rough determination of wipe arc and wiper blade 5 9 Disassembly and assembly sese tnt Troubleshooting oue e RHEROS HA EOHEPRS EH RR NI RR WIO HA ER Declaration of conformity eere eene rennen rnnt nn tonno Parts St a c RR COR UR
3. 89 392 EEG Machines Exalto B V Nijverheidsstraat 12 3371 XE Hardinxveld G iessendam The Netherlands 31 0 184 61 58 00 Fax 31 0 184 61 40 45 hereby declares that Exalto windshield wiper type 235 KK is intended to be built into another machine or as a component or is to be integrated with other machines to a machine where D irective 89 392 EEG applies to does not fully comply to the requirements of mentioned Directive complies to the following harmonised standards Pleasure yachts e NEN EN ISO 10133 Extra low voltage D C installations 1997 regarding color codes and declares that the sub assembly in question shall not be set into operation until the complete machine into which the sub assembly is fitted shall be complete and conforms to all aspects of D irective 89 392 EEG Hardinxveld G iessendam 6 15 2000 m d y 15 AT 8 Parts list Nr Qua Part 1 CO 1 O C1 EW P2 10 11 12 13 14 15 16 17 18 19 21 22 23 1 Rr NO WF BDO e N e e W e WwW e e RR N e EE M Motor 12 V 15 Nm Motor 24 V 15 Nm Socket screw s s countersunk DIN 965 Half wiper shell motor side Socket screw s s countersunk DIN 965 Arc disc Nut s s DIN 934 Linking pin Spindle spindle lever Spindle spindle lever Spindle spindle lever Spindle spindle lever Spindle spindle lever Filling bushing plastic Linking lever Nut s s flat Bearing shell
4. minus earth blue common leg red selfparking white high speed L 4 6 A slow blow fuse Electrical connection scheme 235 KK 24 Volt L 4 A slow blow fuse 6 7 Colour Function since 1 7 1999 yellow low speed minus earth common leg selfparking high speed Connect the wiper to the ship s electrical installation see the schemes above Use a cable consisting of 5 wires with cross sections of at least 1 mm 16 g up to a maximum of 10 m Use larger cross sections when using longer cables Place a slow blow fuse of 6 A 12 Volt resp 4 A 24 Volt in the main cable Connect the switch to the wiper refer to that specific manual for installation 3 4 Final installation 8 Testrun the motor briefly Wait until the motor stops after turning the switch off If the wiper is well installed the motor will be in park position The standard park position is shown in the figure under point 9 Hint If you have doubts regarding the park position make a vane with tape to simulate the position of the arms Attention The 235 KK is suitable for wiper arms modd PU up to 600 mm and matching blades up to 600 mm Place the wiper arms with the blade on the shafts Fasten the nuts onto the shafts but not too tight yet tightening torque 16 3 Nm 12 02 ft lbs 10 Testrun the motor again to check the wiped area 11 If the wipe arc is correct adjust the pos
5. 28 mm Mounting 3o eu abate In bulkhead 20 55 75 100 125 mm Dea sacs Portus A NR rS Bronze housing self lubricating WiperarmS 6cosseseeta tera rit qiti Model PU up to 600 mm Wiperblades a Mte M bU Up to 600 mm Wipe GIO eet eI ER EDI Wipe arc disc 40 90 adjustable per 5 Number of revolutions Low 54 rpm high 76 rpm W ICD asunst eani SO ra ER RR 1 5 kg 3 nstallation Read the chapter on safety Check before installation if the parts are all present and undamaged In case of errors contact your vendor 3 1 Preparation The complete wiper with packaging can be handled and transported by hand Leave the wiper in the packing until you re ready to install it this to reduce the risk of damage Make sure all parts tools and other means are ready 3 2 Installation of mechanical parts 1 If your wiper is supplied with the wipe arc disc uninstalled please follow the steps 5 3 and 5 4 pages 11 12 to set the wiping arc prior to installation Determine the spot where the wiper is to be installed The dimensions are shown below The wiper may be installed in any position 96 68 Attention W hen installing the wiper reserve space for a housing or cover 2 Plac 3 Nov 7 Lip R g optional tightening 25 6 Nn 16 3 Nm torque 18 88 ft lbs 12 02 ft lbs llation 4 nstall a wiper switch in the dashboard Electrical connection scheme 235 KK 12 Volt since 1 7 1999 black
6. 6 250 263 90 86 249 264 278 293 Units in mm Vertical displacement of the blade H e Now the wiper blade can be calculated Length of wiper blade 0 9 2 E H 5 5 Disassembly and assembly Prevent injuries when disassembling isolate the wiper from the electrical installation Keep all necessary tools within reach and remember the chapter on safety Provide a protecting packaging if you re going to stock or transport the wiper 5 5 1 Removing the wiper assembly from the window Isolate the electric circuit and disconnect the wires Remove the wiper arms Remove the nuts 13 19 22 and plates 17 18 on the outside Remove the wiper out of the holes in the window For replacing the wiper follow chapter 3 pube eh A 5 5 2 Disassembling the wipe arc disc 1 Isolate the electrical circuit 2 Unscrew the housing 3 20 wiper should be removed first see 5 5 1 3 Unscrew the nut 6 on the motor shaft and remove the disc 5 4 For adjusting the wipe arc and replacing follow section 5 3 5 5 8 Removing the motor from the wiper assembly Isolate the electrical circuit and disconnect the wires Disassemble the wipe arc disc 5 see 5 5 2 Unscrew the motor and remove it When replacing screw the motor on the housing Follow section 5 3 to install the wipe arc disc in the correct park position PONP 13 6 Troubleshooting In this chapter several malfunctions are mentioned combined with possible caus
7. E UR CEU ER UAR ERU UAR UU Drawings and schemes 0909000000000000000000000000000000000000000000000000000000000000000000000 9 1 Assembly OVERVIEW fossato ipn dance OI oa pe PEN ARARCAR 9 2 Intemal wiring diagram 3suserecudeemavetveetvount tre terrenis tied rer eig 11 11 11 11 12 13 14 l Introduction With this user manual we want to guide you in the installation and use of the Exalto windshield wiper Follow all instructions and install all safety provisions 1 1 Introduction The Exalto windshield wipers are especially designed to keep working even with the most extreme weather conditions at sea All external parts are made of corrosion resistant materials The housing of the self lubricating bearings is made of bronze All arms and blades have a black weather resistant coating to prevent reflection Wiper type 235 KK is designed to be mounted in the bulkhead The wiper arc is adjustable from 40 to 90 with steps of 5 By standard the 235 KK can be supplied for bulkhead thicknesses of 20 55 75 100 and 125 mm The pantograph arms are adjustable in length to set the wipe area accurately The 12V motor of the 235 KK is not insulated and has a negative earth The 24V motor has an insulated earth return 1 2 Environmental factors In the wiper materials are used that are harmful for the environment e g copper At disposal of the wiper parts can be re used or recycled well No harmful materials can get off when u
8. Exalto USER MANUAL catalogue number 2154 00 05 10 15 20 12 Volt catalogue number 2155 00 05 10 15 20 24 Volt version 3 2000 Exalto B V Nijverheidsstraat 12 e 3371 XE Hardinxveld G iessendam P O Box 40 e 3370 AA Hardinxveld G iessendam Telephone 31 0 184 615800 e Fax 31 0 184 614045 The Netherlands sales ex alto com Copyright 2000 Exalto B V Safety Although Exalto windshield wipers are easy to install a fair amount of technical knowledge mechanical and electrical is required of the technician Consult the manual or your vendor in case of doubt on installation or functioning Safety symbols An exclamation mark in front of the text warns that injury or damage can occur if a procedure is badly performed Dangers The installation and use of Exalto wipers doesn t inflict any personal dangers or damage provided that installation is done according to the requirements e Never remove covers or other safety provisions unless maintenance is being performed and all safety requirements are obeyed e The installer must provide all necessary covers e Always isolate the electrical circuit when performing maintenance Prevent the installation from being started accidentally by others Safety provisions Safety provisions protect the user against contact with moving electrical or hot parts Some of them must be provided by the installer There are several safety provisions e housing covers m
9. em functions normally and is kept in good shape see section 5 1 servicing the drive is not necessary Check yearly monthly when used intensively if the wiper blades are worn Replace blades when worn or when the blades leave many stripes across the glass In case of failure or adjustments have servicing done solely by qualified mechanics In chapter 6 Troubleshooting a listing is given of possible troubles 5 3 Changing the wipe arc and park position If the wiped area is not optimal the wipe arc and park position can be changed Always isolate the electrical circuit before opening the housing A djusting the wipe arc e Isolate the electrical circuit e open the housing e remove the wipe arc disc see figure on the right from the motorshaft e move the pin to the hole of the desired wipe arc see section 5 4 e fasten the nut on the pin not too tight max 9 78 Nm 7 21 ftlbs to prevent damage of the plastic spacer e run the motor briefly to park it e place the disc in the desired park position see the text below Wishoeken Wiper arcs A djusting the park position e Place the disc loose on the shaft parking right or left see the drawing in paragraph 3 4 and below for reference e place the disc in such a way that the connection lever forms a straight line with the pin and the central hole of the disc see the drawing below e tighten the disc well now e place and fasten the housing 11 9 78 Nm
10. es Please leave servicing to qualified mechanics 6 1 Wiper doesn t run after switching on e Possible causes 1 Wiper switch has failed 2 Burned or incorrectly sized fuse 3 Electrical connections are miswired or damaged 4 Motor failed e Solutions 1 Test and replace it Check if the current is and keeps being too high 2 See solution 1 3 Test for a charge on the motor and check all connections 4 Replace the motor and check for drag or a current that is too high 6 2 Wiped area or park park position wrong e Possible causes 1 The wiper arms were placed without parking the motor first 2 The wipe arc is set wrong or changed due to high loads e g spring tension arms to high drag 3 The wires are connected wrong e Solutions 1 Remove the wiper arms Run the motor shortly to park it and re install the arms according to chapter 3 2 Determine the wipe arc if needed see section 5 4 and set the wipe arc again see chapter 5 3 3 Check and reconnect the wiring see the scheme in section 3 3 6 3 Motor runs but arms don t move e Possible causes 1 Mechanical joints are loose 2 Parts are broken 3 Grooves of shafts are worn e Solutions 1 Check if the arms are well fastened If not open the housing follow chapter 5 and check all joints and parts to see if they are loose broken or worn 14 7 Declaration of conformity MANUFACTURER S DECLARATION according to Appendix II sub B of Directive
11. ition and the length of the arm if necessary Tighten the nuts properly now 12 To complete the installation the wiper must be enclosed by means of a panel or cover Provide the wiper with enough ventilation 4 Operation and use 4 1 Preparation for first use If the wiper has been installed and been adjusted the system can be prepared for first use We recommend a thorough inspection of the system to ensure proper operation Check If there are no leaks where the bearings go through the window if the set wipe arc cleans the entire window if the park position is correct If the wipe arc or the park position is wrong adjust them again Follow the procedure in section 5 3 4 2 Use All Exalto windshield wipers are provided with the following functions e low speed e high speed e self parking Don t run the wiper on a dry window excessive wear of the blades and the motor can occur Clean the wiper frequently see also paragraph 5 1 Because of the big variety of wiper switches refer to the user manual of the applied switch to learn about the functions of that specific switch 10 5 Maintenance 5 1 General maintenance To keep the Exalto wiper in good condition you are advised to e clean wiper arms and blades with fresh water after every journey in salt water to prevent salt from clogging moving parts e prevent running the wiper on a dry window 5 2 Servicing As long as the wiper syst
12. llowing diagram is to help understand the principle of the wiper motor I eM es e a een Gee re EIE RR MEET ER e I RN weg pee ia MEE Qo a EN CE Po eed eons dee e I 0 1 ec N e e e e e mum mum mem e e mem i m l Function Polarity Motor Switch Cable code code since 6 1999 high speed 53b H white low speed 53 L yellow earth 31b black common leg 53e P blue selfparking T 53a B red Some older wipers may have different wire colours Check the diagram below to compare the colour combinations Function Current cable Previous cables since 6 1999 before 6 1999 high speed white red red 6 low speed yellow yellow or white yellow 5 earth black blue blue 4 common leg blue green grey 3 selfparking red black black 7 18 Exalto B V Nijverheidsstraat 12 e 3371 XE Hardinxveld Giessendam P O Box 40 e 3370 AA Hardinxveld G iessendam Telephone 31 0 184 615800 e Fax 31 0 184 614045 The Netherlands Sales ex alto com Exalto
13. nut s s Ring s s Bearing shell complete bulkhead 20 mm Bearing shell complete bulkhead 55 mm Bearing shell complete bulkhead 75 mm Bearing shell complete bulkhead 100 mm Bearing shell complete bulkhead 125 mm Locking ring Rubber locking plate S s locking plate Rubber dust cap Rounded nut s s special Half wiper shell spindle side Support spindle bulkhead 20 mm Support spindle bulkhead 55 mm Support spindle bulkhead 75 mm Support spindle bulkhead 100 mm Support spindle bulkhead 125 mm Support spindle nut s s Ring s s DIN 125A 24 V only Dimensions Cat nr 170x95x95 170x95x95 M6x35 180x96x22 M6x16 70x5 M6 M8x26 012x102 012x137 012x157 012x182 012x207 213x14 110x24x2 M8x4 M20 18x12x1 M20x65 M20x100 M20x120 M20x145 M20x170 212x4 82x35x3 82x35x3 26x20 M8 180x96x22 M8x70 M8x110 M8x130 M8x155 M8x180 M20 M6 2100 310 2100 300 2100 055 2100 902 2100 050 2100 930 2100 080 2100 920 2100 364 2100 366 2100 368 2100 370 2100 372 2100 925 2100 935 2100 760 2100 350 2100 400 2100 326 2100 327 2100 328 2100 329 2100 331 2100 410 2100 490 2100 480 2100 361 2100 346 2100 901 2100 446 2100 447 2100 448 2100 449 2100 451 2100 460 2100 690 16 9 Drawings and schemes O 9 1 Assembly overview W5 aN a 7 D o o SOB 9 DA L O Ee Sg 7 L TI Yo o AK JE Co 17 9 2 Internal wiring diagram The fo
14. oving parts of the drive e plastic cover optional covers the motor and electrical connections If not used the installer must provide another cover or place the wiper behind a panel e Make sure the wiper has enough ventilation when it is placed behind a panel or when a cover is applied e Place a fuse see specifications in the main cable Safety requirements Before the Exalto wiper is installed we strongly recommend the following Read the entire manual before installation Keep your working environment as well as the wiper parts clean Check to be sure no parts are missing or damaged Use only well maintained tools and have them within reach when installing Handle the parts with care Never install or maintain the wiper with the electrical voltage applied unless this is specifically mentioned in the manual e Clear your tools after installation Use of the manual Read the entire manual before installation In this manual you can find the following expressions and symbols Hint Gives you advice on how to perform a task more easily Attention Alerts you to possible problems and safety warnings Careful Warns if the product can be damaged when working carelessly Waming You can hurt yourself or damage the product severly Look at folding page at back of manual Unfold the folding page or look at the back of the manual for a drawing Contents 1 Introduction ice ave celts eterna sere here eset adie eee hel
15. sing or disassembling the wiper 1 3 Modified use and guarantee conditions All modifications or defects in the product are subject to the O rgalime G eneral Conditions of Sale Contact your vendor if you want to use Exalto wipers for a non maritime environment or for another application or in case of any doubt 2 Technical data 2 1 General PIDOUCL Queues Mendes EAA Exalto windshield wiper TIPOS Lr REPRE NEC RERO 235 KK 12 Volt and 24 Volt Catalogue numbers 12V 2154 00 05 10 15 20 Catalogue numbers 24V 2155 00 05 10 15 20 2 2 Electrical data 12 Volt Torque MaX caido tesoros 15 Nm NOMA resorni 12 Volt CUED E S Sescitseesesteiesalbsotatvaninabiaceies 3A Power consumption max 36 W Recommended cable 5 wires 17 16 g or 27mm 14 g re up to 10 m long Recommended fuse 6 A slow blow Grounding oddentushtio bad ROG dU Not insulated negative earth 2 3 Electrical data 24 Volt Torque max oce EORR 15 Nm MO aot eR NEHME HRS 24 Volt GUI TOI rininis 15A Power consumption max 36 W Recommended cable 5 wires 17 16 g or 27mm 14 g EP up to 10 m long Recommended fuse ss 4 A slow blow Grounding aeo dice RD OR IRO DEBER RA Insulated earth return 2 4 Mechanical data Dimensions 44e ite vetere espe lxwxh 180x 113x 120 mm Bearing diameters Drive shaft 220 support shaft
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