User manual for Exalto windshield wiper Type 280 BS 24 Volt Cat
Contents
1. 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 89 392 EEG Machines Exalto B V Nijverheidsstraat 12 3371 XE Hardinxveld Giessendam The Netherlands 31 0 184 61 58 00 Fax 31 0 184 61 40 45 hereby declares that Exalto windshield wiper type 280 BS is intended to be built into 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 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 Directive 89 392 EEG Hardinxveld Giessendam 04 15 2013 m d y 15 8 Parts list Pos CO N OV nN AUN Ko 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Qua Description 1 1 4 3 NNNNOHANNHY lt RK KRPANP RP RPK KUunNnNvon Motor 80Nm Wiper bracket Locking washer2. 8mm Hexagon bolt ISO 4017 M8 x 20 S A4 Hexagon Bolt ISO 4017 M8 x 35 S A4 Motor crank 280BS Washer 10mm din125 Rod end M10 Hexagon nut M10 din934 Threaded end Nylon tubing 010 SS Hexagon bolt M10 1SO4017 Dogbone 60mm Driven spindle 25mm SS Hexagon bolt M10 1SO4017 Washer 25x16x1mm SS Flanged nut M10 SS Hexagon bolt M10 1SO4017 Nut M8 Support spindle WD25 Liner M27x1 5mm Rubber Sealing plate Stainless steel sealing plate Nut M27x1 5mm SS Circlip for shafts 16 din471 Wheatercap 34mm Locking washer 10mm Nyloc nut M10 SS Dimensions 480x103x160 M8 M8x20 M8x35 M10 M01 M10 M10 M10x30 M10 M10x45 M8 M27x1 5mm M27x1 5mm M10 M10 Cat no 2100 PM3 0004 2197 027 2100 091 933140080020 933140080035 2197 077 2197 092 2197 070 2197 090 0975140101000 211210 093388010040 2100 938 2197 082 093388010030 2100 353 2100 069 093388010045 2100 460 2197 083 2100 344 2100 511 2100 521 2100 352 2100 411 2100 359 2100 092 2100 074 16 9 Drawings and schemes 9 1 Assembly overview 17 9 2 Internal wiring diagram The following diagram is to help understand the principle of the wiper motor FUNCTION High speed Low speed Earth Common leg Leg 53a 31b t_ 10A slow blow fuse Function Polarity Motor Switch Cable code code since 6 1999 highspeed 53b H white low speed 53 L yellow earth 31b black common leg 53e P blue self parking 53a B r
3. Exairo Parts Wipers Bearings Propulsion User manual for Exalto windshield wiper Type 280 BS 24 Volt Cat no 2178 30 24 Volt version 6 2013 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 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 Cover or panel compelled covers moving parts and electrical connections The installer MUST provide a selfmade cover or place the wiper behind a panel e Make sure the wiper has enough ventilation when placing it behind a
4. be supplied for a bulkhead thickness of 25 mm The pantograph arms are adjustable in length to set the wipe area accurately The motor of the 280 BS has IER 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 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 wipers for a non maritime environment or for another application or in case of any doubt 2 Technical data 2 1 General PROdUCE RnR E RRRA ERO Exalto windshield wiper R B o A 280 BS 24 Volt e Catalogue numbers 24V ssessssserssss 2178 30 2 2 Electrical data 24 Volt e Torque MaX atid a tees 80 Nm VONAGE a e RR 24 Volt CUMENtT eoio iiin 3 2 A e Power consumption MaXx 77W e Number of revolutions eee Low 30 rpm high 45 rpm e Recommended cable ou esses 5 wires 12 16 g or 2 mm 14 9 Slater tana atten te auaiettt up to 10 m long e Recommended FUSE cceecseececseeees 10 A slow blow Grounding ssseessssssersssseeesssseresssseressseesss Insulated earth return 2 3 Mechanical data e Dimensions ses ssssssseressssssoeresssssseeresssss I xw x h 547 x 160 x 180 mm e Bearing
5. diameters sssssesssssssssserrssseee Drive shaft 27 support shaft 27 mm MOUNTING hsrsssasnanannnanneinaii In bulkhead 25 mm Beating soeone eae Bronze housing self lubricating e WiperarmMS essessssssessssseeessssecessssessssecesss Model P12 up to 1500 mm e Wiperblades sssseessssseesssssecessssersssseesss Up to 1200 mm WIPE OIC unninn n ananin a nnak a Slotted lever 40 90 steplessly EEE E E adjustable o WEIQKE iann ano nn ERE approx 9 7 kg 3 Installation 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 lever and motor lever uninstalled please follow steps 5 3 and 5 4 to set the wiping arc prior to installation Determine the position where the wiper is to be installed The dimensions are shown below The wiper can be installed in any position 187 5 163 9 Attention When installing the wiper reserve space for a housing or cover Rubber sealing plate Bulkhead Rubber sealing plate Stainless steel sealing plate Hexagon nut Tightening torque 53Nm 39 ft lbs Stainl
6. e it PWNS PWN install the motor lever in the right park position Isolate the electrical circuit disconnect the wires and remove the wiper When replacing screw the motor on the housing Follow section 5 3 to 13 ay 6 Troubleshooting In this chapter several malfunctions are mentioned combined with possible causes 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
7. ed 18 Exairo P O Box 40 3370 AA Hardinxveld Giessendam The Netherlands e T 31 0 184 615800 e F 31 0 184 614045 e E sales exalto com e www exalto com Copyright 2013 Exalto
8. ess steel locking ring Hexagon locking nut Tightening torque 33Nm 25 ft Ibs Rubber weathercap Exalto wiper arms 2 Place the windshield wiper in the pre drilled holes of the bulkhead see figure A nitrile plate must be placed at both sides of the bulkhead 3 Make the electrical connection before fitting the wiper arm 3 3 Electrical installation 4 Install a wiper switch in the dashboard FUNCTION High speed Low speed Earth Common leg Leg 53a 31b _ 10A slow blow fuse Wiring diagram 280 BS 24 Volt 5 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 6 Place a slow blow fuse of 10 A 24 Volt in the main cable 7 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 on page 12 Hint If you have doubts regarding the park position make a vane with tape to simulate the position of the arms Attention The 280 BS is suitable for wiper arms model P12 up to 1500 mm and matching blades up to 1200 mm 9 Place the wiper arms with the blade on the shaft
9. 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 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 Warning You can hurt yourself or damage the product severly At back of manual Look at the back of the manual for a drawing Contents 1 INT OGUCEIONT sinsssscccsassaeeccdvsssts tose doscisendddvscetacnccdeccseeadedsecesevecadsscsssecedcecsses 4 1 1 Introduction sessessssssersssseeessssecessssecessssessssecesssserossseerossseeeossseresssseressseeronsseerossseees 4 1 2 Environmental factors csecsessssssssssssccscsssssssssssssssssscsucsecsscsscsssessessesecseescesseess 4 1 3 Modified Use and g
10. rking right or left see the drawing in paragraph 3 4 and the picture on page 12 for reference e place the motor lever in such a way that it forms an almost straight line with the connection lever see the drawing on page 12 e tighten the motor lever well now 11 e place the wiper in the bulkhead e adjust the wiper arm to the correct length if necessary connection lever smaller arc aS larger arc arc shaft lever SZ ranges 55 90 gt aL 40 55 33 Nm lt YG I 30 40 24 34 ft los standard park position 1 wrong park position 2 A v y 5 4 Rough determination of wipe arc and wiper blade With this method the wipe arc and the wiper blade can be i vo eee oe determined roughly Contact Boe ae your vendor to determine your configuration more accurately L GH glass height GW glass width H height displacement L length of arms W width of wiped area 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 en W in the diagram below Determination of wipe arc Wipe arc 40 45 50 55 60 65 70 75 80 85 90 Armlength L 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 Units in mm Wiped area width W 12 e the wipe arc line closest to the intersection shows the wipe arc e find in the table below the vertical displacemen
11. s Fasten the nuts onto the shafts but not too tight yet 10 Testrun the motor again to check the wiped area 11 If the wipe arc is correct adjust the position 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 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 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 chosen 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
12. ssssseressseossse 11 5 4 Rough determination of wipe arc and Wiper blade uu eeseeseeseseees 12 5 5 Disassembly and assembly sssssessesssssseeresssssseeressssssscereossssscereosssereesssssseeeeessss 13 6 Troubleshooting scsiccdscussssteaswasesbnasecassecsaesdwanedbneseccasedeorstesdebesetsdesvssneass 14 7 Declaration of conformity ssossssssooccssosooccesooooesesoooossssoooosessoooesessooo 15 8 Parts list seccisis ssscccsnescaseasdatns sasceceacascecnscatessivadeeaaabeveuscadassieaeadenbscssbancaiene 16 9 Drawings and schemes sssssssosooosooocccooocoococsccoocsocoscsossoososossoossssosoo 17 9T sASSEMIDIY OVEIVICW ceca cote EA E ROG 17 9 2 Internal wiring diagram ssss sssssseesssssersssssecessseerossseossseeeonsseceosssecesssseresssseresssee 18 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 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 280 BS is designed to be mounted in the bulkhead The wiper arc is steplessly adjustable from 40 to 90 By standard the 280 BS can
13. t of the blade H Determining the vertical displacement of the wiper blade Armlength L 300 350 400 450 500 550 600 650 700 750 800 850 900 9501000 40 19 21 25 26 30 34 37 40 43 45 48 51 40 45 51 57 62 66 74 79 85 90 96 80 87 94 100 107 114 94 102 110 117 125 133 109 118 127 136 145 154 124 135 145 155 165 176 140 152 164 175 187 199 158 171 184 197 210 223 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 54 102 121 141 163 186 211 236 264 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 94 107 113 127 134 149 157 172 181 196 e 222 234 250 263 278 293 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 bulkhead Isolate the electric circuit and disconnect the wires Remove the wiper arms Remove the nuts and rings on the outside Remove the wiper out of the holes in the bulkhead For replacing the wiper follow chapter 3 5 2 Removing the motor from the wiper assembly Disassemble the motor lever see 5 5 2 Unscrew the motor and remov
14. uarantee sssssssesssssssssscesssssssseceesssssssereossssssereesssssserresssss 4 2 Technical ccssscnsesisciesccdsanassanenonvescanconccanvestebevesseeseseocerbedustetsegdesarvecasvantees 5 Pe WR T a R A EREE AREAIS 5 22 Electrical Cala 2 VON a csscceutasransencensianeusiannonuuannsterummunMENEnG 5 223 Mecha Ca Cleat chs ccesssiacusnces ecasavesucceecaincrnoreinctsnseantteet osminsatuns ume naneriealoreen 5 3 Installati n xissiscnrvcacssdensisenbacsasevescd decnsspesteossveessse tesedivonbecassousasecnsunvexdleeds 6 3 1 Preparation ccccaacnadaccanseaaaciaewiaus aint deianuicueide 6 3 2 Installation Of mechanical parts ss essssssssscessssssssecesosssssscreosssssseresossssseeresssss 6 3 3 VEISCLIIGGI TIS bell caves sstsiesecesexuasiaseveuev a oiii eie 8 34 Faell MINS Gell Gl OUAY pet cacsuscccucso nesses ccc saccesescecsesdonccs cede edesadc iR RR 8 4 Operationand USE ss ccvsiscicsscriciereistessesedassscbeteredacentucedusiecbetenedaceediceduecer 10 4 1 Preparation for first USC sssssssscsssssssssssssscesssssssesscsscsscsscsssascascsscsscsscsssessens 10 A D NY SC ii vertu EREEREER EEC EEEE EER 10 5 MGINVCNGNCE vesissceicccicescccstcsccbacdeasceceancsivstanbscdeaassecnteaseussussensssnasoaasee 11 5 1 General maintenance sseseessssseeesssseresssserossseeesnsseresssseressseerossseerossseresssserensses 11 D PAE S EEEE AEE ee eer ar rn wenn et 11 5 3 Changing the wipe arc and park position sessessssssessssseerssssee
15. 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 system 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 arc ranges 55 90 40 55 30 40 Adjusting the wipe arc e Isolate the electrical circuit e move the screw of the motor lever to the correct wipe arc range see the upper smaller connection lever figure e move the screw in the slot from the wipe shaft lever away from the shaft for a smaller and towards the shaft for a larger wipe arc e fasten the nut again max 33 Nm 24 34 ft lbs e run the motor briefly to park it e place the motor lever in the desired park position see the text below Adjusting the park position e Place the motor lever loose on the shaft pa
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