User manual for Exalto windshield wiper
Contents
1. it 2 Check if the current is and keeps being too high See solution 1 3 Measure the voltage across the motor and check all connections if there is none 4 Replace the motor and check for drag or a high current 6 2 Wiped area or park position not correct 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 pressure of arms too high drag 3 The wires are connected incorrectly 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 do not 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 instructions of chapter 5 and check all joints and parts to see if they are loose broken or worn 7 Declaration of conformity MANUFACTURER S DECLARATION In accordance to Appendix II sub B of Directive 89 392 EEG Machines Exalto B V Nijverheidsstraat 12 3371 XE Hardinxveld Giessendam The Netherlands T 31 0 184 61 58 00 F 31 0 184 61 40 45 hereby declares that Exalto windshield wiper type 223 BD is intended to be built i2. M20 2100 349 2 Plain washer s s 18x12x1 2100 400 1 Bearing house bh 20 mm M20x65 2100 326 Bearing house bh 35 mm M20x80 2100 321 Bearing house bh 55 mm M20x100 2100 327 Bearing house bh 75 mm M20x120 2100 328 1 Retaining ring for shaft 12x4 2100 410 2 Gasket rubber 90x45x3 2100 491 1 Gasket s s 90x45x3 2100 481 1 Nut s s M20 2100 350 1 Dust cap rubber 26x20 2100 361 1 Nut s s nylock A4 M8 2100 071 1 Support shaft bh 20 mm M8x75 2100 446 Support shaft bh 35 mm M8x90 2100 441 Support shaft bh 55 mm M8x110 2100 447 Support shaft bh 75 mm M8x130 2100 448 Type 223 BD 9 Drawings and Schemes 9 1 Assembly overview 2100 930 2100 931 7 See partslist for part no 2100 050 3x 1 See partslist for part no 8 See partslist for part no 24 See partslist for part no 9 2 Internal wiring diagram The following diagram explains the way the wiper motor works pro crc cece I 0 1 i 1 1 D lt N k mm mm mm mm m mm m m m m m m m m m d Function Polarity Motor Switch Cable code code 12 24V high speed 53b H red grey lowspeed 53 L green yellow earth 31b black common 53e P brown bl wh leg Self 53a B black white parking Exairo e P O Box 40 3370 AA Hardinxveld Giessendam The Netherlands eT 31 0 184 615800 e F 31 0 184 614045 e E sales exalto com e www exalto com Copyright 2011 Exalto 19
3. User manual for Exairo Parts Wipers Propulsion Exalto windshield wiper Type 223 BD 12 24 Volt er Catalogue no 2165 30 32 35 40 12 Volt Catalogue no 2166 3032 35 40 24 Volt version 7 2011 ay 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 indicates if a procedure is executed incorrectly injury or damage may occur 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 Cover or panel compelled covers moving parts and electrical connections The installer MUST provide a self made cover or place the wiper behind a panel e Make su
4. ccsscsscesscssccsscssccsscssccsscssccsscsscessesses 17 9 2 InternalWirna diagiara r actions rosaire Tetor 18 y 1 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 te 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 of the sunlight Wiper type 223 BD is designed to be mounted in the bulkhead The wiper arc is adjustable from 40 to 90 with steps of 5 Standard the 223 BD can be supplied for a bulkhead thickness of 20 35 50 or 75 mm The pantograph arms are adjustable in length to set the wipe area accurately The motor of the 223 BD is not insulated and has a negative earth 1 2 Environmental factors In the wiper materials are used that are harmful for the environment e g copper Upon disposal of the wiper parts can be re used or recycled No harmful materials are released when using or disassembling the wiper 1 3 Modified use and guarantee conditions All modifications or defects in the product are subject to the Orgalime General Conditions of Sale Contact your vendor if you want to use Exalto wip
5. e Determine length of panto graph arm L L E D e get the maximum wiped area width W W 0 9 GW e find the intersection of L and W in the diagram below Determination of wipe arc Wipe arc 45 50 55 60 65 70 75 80 85 90 EEE EEE T S ee S Armlength L 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 Units in mm Wiped area width W mmp e the wipe arc line closest to the intersection shows the wipe arc e find in the table below the vertical displacement of the blade H Determining the vertical displacement of the wiper blade 30 34 37 40 43 45 B 54 57 60 27 30 35 38 42 46 50 53 57 61 65 68 72 76 33 36 43 47 52 56 61 66 70 75 80 84 89 94 40 45 51 57 62 66 74 79 85 90 96 102 107 118 47 54 60 67 74 80 87 94 100 107 114 121 127 134 55 63 71 79 86 94 102 110 117 125 133 141 149 157 63 73 81 90 100 109 118 127 136 145 154 163 172 181 73 83 93 104 114 124 135 145 155 165 176 186 196 207 82 94 105 117 129 140 152 164 175 187 199 211 222 234 92 105 119 132 145 158 171 184 197 210 223 236 250 268 103 117 132 146 161 176 190 205 220 234 249 264 278 293 Units in mm Vertical displacement of the blade H e Now the length of the wiper blade can be calculated Length of wiper blade 0 9 2 E H 5 5 Disassembly and assembly To prevent injuries when disassembling disconnect the wiper from the power supply Keep all necessary tools within reach and remembe
6. ers for a non maritime environment or for another application or in case of any doubt 2 Technical data 2 1 General POGUE Tera RR BRR ARDER Exalto windshield wiper TYPES ari ic nE te eT TEE 223 BD 12 Volt and 24 Volt Catalogue numbers 12V 2165 30 32 35 40 Catalogue numbers 24V 2166 30 32 35 40 2 2 Electrical data 12 Volt e Torque Max eres 23 Nm Voltage eccsscsresscssessnsstvansasaitoaccactaccass anes 12 Volt O CUETO RIG sacar gavin ea 3A e Power consumption max 36 W e Number of revolutions Low 38 rpm high 59 rpm e Recommended cable 5 wires 14 16 g or 2 mm 14 9 ETR PR DR RSS PENNE AD up to 10 m long e Recommended fuse 6 A slow blow Grounding DESSE ERON TN NO Not insulated negative earth 2 3 Electrical data 24 Volt e Torque Max sss 23 Nm Voltage qmsagupasanaRasasugads 24 Volt 6 CUIDE apensmanidodnna da indicada 1 5 A e Power consumption max 36 W e Number of revolutions Low 35 rpm high 56 rpm e Recommended cable 5 wires 1 16 g or 2 mm 14 9 NMRA ANAM SRNR an A TN TT up to 10 m long e Recommended fuse 4 A slow blow e Grounding es Not insulated negative earth 2 4 Mechanical data e DIMENSIONS aniaentanatanio ninar andina Ixwxh 173x107x100mm e Bearing diameters sss Drive shaf
7. fts go through the bulkhead if the wipe arc cleans the entire window ifthe 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 use the wiper on a dry window excessive wear of the blades and the motor may occur in this case Because of the big variety of wiper switches we refer to the user manual of the installed switch to learn about the functions of that specific switch 5 Maintenance 5 1 General maintenance To keep the Exalto wiper in good condition you are advised to e clean wiper arms and wiper 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 system functions normally and kept in good shape see section 5 1 servicing the motor 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 problems 5 3 Changing the wipe arc and park position If the wiped area is not optimal the wipe arc and park position ca
8. n be changed Always disconnect the power supply before opening the housing Adjusting the wipe arc e Disconnect the power supply e remove the wiper from the bulkhead e remove the wipe arc disc see figure on the right from the motor shaft e relocate the pin into 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 ft lbs to prevent damage of the plastic spacer e run the motor briefly to park it e move the disc to the desired park position see the text below Wishoeken Wiper arcs Adjusting the park position e Place the disc on the shaft parking right or left see the drawing in paragraph 3 4 and the next page for reference e place the disc in such a way that the connection lever forms an almost straight line with the pin and the central hole of the disc see the drawing below e tighten the disc well e mount the wiper motor assembly e adjust the wiper arm to the correct length if necessary standard E park poston wrong park position 2 588 D 5 4 Rough determination of wipe arc and wiper blade With this method the wipe arc A Do Mo ace al e D dist t id lengths of the wiper k RE H i f spindl wiper arm can be determined E roughly Contact your vendor to calculate your configuration L GH glass height GW glass width more accurately H vertical displacement L length of arm W width of wiped area
9. nnuadasenardeiveiseedssenaeveaosnee 5 DA General oases a a taeda E aini 5 22 Electrical data 12 Volt dccckmussgussuaacuumuncanuaeaonueeneuse 5 2 3 Electrical data 24 Volt paras no 5 ZA Mechanical data ai 5 3 Installation inicisccecsccsscnasanssesincsesdessencssuinessecensosssaccussinaeeonsatastoeosnacosseesagess 6 3 1 e e Tes gle aH 6 3 2 Installation of mechanical parts sss 6 3 3 Electrical installation sss 8 24 MEIAS Cell FEU EE 8 4 Operation GING USE aussiccccesccsicssasansscsspececsseseonsussvonndunsodoaicasacesecspenonsoepeats 10 4 1 Preparation for first USe ccsssesnssensenssecsdssnssaxsonssssnnscnnsrassaonnsohconsehdsdeonesobenisentanses 10 EZ NISC o id 10 5 Maintenance T 11 5 1 General maintenance gas aa o 11 52 O CTN GINO TTT 11 5 3 Changing the wipe arc and park position eee 11 5 4 Rough determination of wipe arc and wiper blade se sss 12 5 5 Disassembly and assembly sssssssssecsscssccsecssscssessccsscssccnsesscessessccssessceseses 13 6 Troubleshooting ascisscssssssssscsonsers socscenndsvscsensvessesiuesssesesuivosieetiavesssescooies 14 7 Declaration of conformity scccccsccccccsscccccsscccccsccccsssccccscsccsessccoees 15 8 Parts list cisiusscsscscvtessssccsaazagdsseceaunnssedgcadecssacsacvesscecaducesshoccneiedideceuscasageeade 16 9 Drawings and Schemes sssoessssoooesecoooocsscococecooocsscoooocsccocoosesoooocessoso 17 9 1 Assembly overview sessssssssssscsscsscsscssccsscss
10. nto another machine or as a component or is to be integrated with other machines to a machine where Directive 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 colour 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 Directive 89 392 EEG Hardinxveld Giessendam 4 22 2011 m d y Parts list N 10 11 12 13 15 16 17 18 19 20 21 22 23 24 Qua Part Dimensions Cat no 1 Motor 12 V 23 Nm 180x105x85 2100 415 Motor 24 V 23 Nm 180x105x85 2100 425 1 Wiper housing for 223 BD 150x90x40 2100 104 Cross recessed countersunk head M6x16 2100 050 screw DIN 965 1 Wipe arc disc 70x5 2100 930 1 Sticker for Wipe arc disk 2100 931 2 Nut s s DIN 934 M8 2100 460 1 Nut s s M8 5 2100 355 1 Nut s s M10 6 5 2100 354 1 Connecting pin M8x26 2100 920 1 Shaft with lever bh 20 mm 12x102 2100 364 Shaft with lever bh 35 mm 12x117 2100 360 Shaft with lever bh 55 mm O12x137 2100 366 Shaft with lever bh 75 mm 12x157 2100 368 1 Sleeve bearing bush plastic 13x14 2100 925 1 Bearing bush 10x10 2100 926 1 Nut s s flat M8x4 2100 760 2 Retaining ring 6mm 2197 097 1 Push rod 110x24x10 2100 936 1 Nut s s
11. r the chapter on safety Provide a protective packaging if you re going to stock or transport the wiper 5 5 1 Removing the wiper assembly from the bulkhead 1 Disconnect all the electric connections of the wiper 2 Remove the wiper arms 3 Remove the nuts 5 23 21 and plates 19 20 on the outside 4 Remove the wiper from the bulkhead 5 Ifyou want to replace the wiper follow the instructions of chapter 3 5 5 3 Disassembling the wipe arc disc 1 Disconnect all the electric connections of the wiper 2 Remove the wiper from the bulkhead see 5 5 1 3 Unscrew the nut 5 on the motor shaft and remove the disc 4 4 For adjusting the wipe arc and replacing follow the instructions of section 5 3 5 5 4 Removing the motor from the wiper assembly 1 Disconnect all the electric connections of the wiper Disassemble the wipe arc disc 4 see 5 5 2 Unscrew the motor and remove it When replacing screw the motor on the housing Follow the instructions of section 5 3 to install the wipe arc disc in the correct park position RWD 6 Troubleshooting In this chapter several malfunctions are mentioned combined with possible causes Please leave servicing to qualified mechanics 6 1 Wiper does not work after switching on e Possible causes 1 Wiper switch is not working properly 2 Burned fuse 3 Electrical connections are incorrect or damaged 4 The wiper motor has failed e Solutions 1 Test and replace
12. re the wiper has enough ventilation when placing it behind a panel or cover e Place a fuse see specifications in the main cable Safety requirements Before the Exalto wiper is installed we strongly recommend the following e Read the entire manual before installation e Keep your working environment as well as the wiper parts clean e Check to be sure no parts are missing or damaged e Use only well maintained tools and have them within reach when installing e Handle the parts with care e 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 will 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 Warning You could hurt yourself or damage the product severely At the back of the manual Look at the back of the manual for a drawing Contents 1 Iniroductioh ss dasecisavasiscssscchekessseccussiediecasnuisssansubacssosssusssvaalessseselestacesciseceus 4 E 13 efe Te 9 Te T manaa a a a a A E A ARNA 4 1 2 Environmental factors sss 4 1 3 Modified use and guarantee e 4 2 Technical sss ccisisvssasetusevesenauavisshenedasssssccanacvacanusvevade
13. switch If the motor is installed correctly and a switch with park feature is used it will stop in the 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 223 BD is suitable for wiper arms model PU up to 750 mm with wiper blades up to 800 mm 10 Place the wiper arm with the blade on the shafts Fasten the nuts onto the shafts but not too tight yet 11 Test the motor again to check the wiped area 12 If the wipe arc is correct adjust the position and the length of the arm if necessary Tighten the nuts properly now ya lt i Pe I IN N gt z d i by R mR 17 7 22 Pas VAN Ql WF Va ra S a sgiot 4 Td T vo NONO j 1 yi us T N OSS i ORIN yy N L Ar ff MA Nas a it 2 MN wa On A I i SN l fy Sy JAW Aer Sy park position 16 3 Nm tightening torque 12 02 ft lbs 13 To complete the installation the wiper must be enclosed by means of a panel or cover Provide the wiper motor with sufficient ventilation Place a protection cover or panel Provide sufficient 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 sha
14. t 20 support shaft 8 mm s MOuUnting arcadas In bulkhead 20 35 55 or 75 mm lt T Ta carsssrstrsscarsatcacessiseatnisnasienanacten Bronze housing self lubricating e WIperarms saia aa Reais Model PU up to 750 mm e Wiperblades canina anna Up to 800 mm Wipe arC ir trataaratainas Wipe arc disc 40 90 adjustable per 5 e Weight aptas o e approx 2 3 kg 3 Installation Read the chapter on safety Check before installation if all parts are 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 are 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 steps 5 3 and 5 4 pages 11 12 to set the wiping arc prior to installation Determine the place where the wiper is to be installed The dimensions are shown below The wiper can be installed in any position Co 100 Attention When installing the wiper reserve space for a housing or cover l 25 6 Nm 16 3 Nm tightening torque 18 88 ft lbs 12 02 ft lbs 2 Place the windshield wiper in the pre drilled holes of the bulkhead see above figure A nitrile plate must be placed at both sides of the bulkhead 3 To ensure that the arm has
15. the right spring pressure install the wiper arm in such a way that the shaft makes a 90 angle with the window and fuse a spacer from the inside when there is too much space between the bulkhead and the rubber dust cap o Too much L Tr Eae l IT space L Tr 1 RI im F E p H Ah Ah PS Hd be 90 Pa B 90 19 LT Spacer h H H 5 p n n all aul U N N Correct Correct Not Correct Correct 4 Do not fit the wiper arm before finishing the electrical connections 3 3 Electrical installation 5 Install a wiper switch in the dashboard Wiring diagram 223 BD 12 24 Volt Earth for 12V only gt gt Colours 12V Colours 24V Function yellow low speed see diagram black minus earth brown black white common leg white selfparking grey high speed SLOW BLOW FUSE 6A for 12V SLOW BLOW FUSE 4A for 24V 6 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 2 mm 16 9 up to a maximum of 10 m Use larger cross sections when using longer cables 7 Place a slow blow fuse of 6 A 12 Volt or 4 A 24 Volt in the main cable 8 Connect a switch to the wiper refer to that specific manual for installation 3 4 Final installation 9 Test the motor briefly Wait until the motor stops after turning off the
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