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HTC 500 Service Manual - Runyon Surface Prep Supply

1. soo e wasuERTERSBMeGA sois oooO es SHAFT BELTTENSIONER moms _ t es SCREW 3105 es GAMMA RING RB 2033 nox nem BALL BEARING moo J BEARING CUP PULLEY UPPER HTC 110032 500 Te FECIT ON RM Eu 9 Parts list HTC 500 Pos Description Remarks 77 SHAFLPULLEY 199 78 WEDGERK8x7x25Ho 7 31003 79 WEDGE RK 8x7x25Ho _ 31023 80 50032X150 90 e omcuesGas mam es BEARING CUP PULLEY LOWER HTOS00 11004 es omcuPsAso jo er BALL BEARING 601028 CS noa oS Les PULLEYHUBHTC 500 nos es EDGING STRIP HTC 500 110846 0 oweRcovRHTOSo nos O e C not cover mos 7 es SCREW MET TT Mex2s 8 8 6ALV stops J e CYLINDER PIN aoo omcuesaaeo Jj SGRINDING HOLDER UPPER 600 110080 er HOLDER POLYCORD OUTER nos es
2. HTC SWEDEN AB www htc sweden com BI PAS Service Manual HTC 500 650 amp 800 Introduction Contact HTC or your nearest reseller if you have questions or comments Make sure to have the serial number of your machine available when you call since all machines are registered and this helps us provide you with the best possible service The serial number is located on the right hand side of the chassis seen from behind and on the right hand fixing lug It is also found on the machine sign located on the electrical housing It is possible to read the manufacture date of the machine from the serial number In the example of 89704240 8 represents the model this is an HTC 800 The next six numbers are the date of manufacture The last number is a sequence number and 0 indicates that this is the first machine built on this day Best wishes HTC Sweden AB CONTENTS e ER TUR 3 Technical data HTC 500 HTC 650 and 800 5 Exploded diagram HTC 500 a a 6 Exploded diagram HTC 500 J 7 Pants sionis 8 Exploded diagram 6050 11 Exploded diagram grinding holder HTC 6 12 Parts MISE TAG GSO ceti he vd S OU e apt se de e 13
3. 310088 18 SCREW 65 25 GALV 910 19 TANKBRACKET 20 WASHER BRB M6 GALV 310082 21 SCREWMC6S MeXi288GALV 310080 specification 23 SCREWMeSMi2xe5GALV 810084 24 M12 GALV DIN985 310004 25 CHASSIS HTC 650 BOTTOM 110848 26 WHEELFITTINGKIT 1108 27 WHEEL HTC 650 WKCP 28086558 1110350 28 waren VALVE TO GRINDER 110007 29 SCREW M6S M5X20 GALV 3090 S 30 WATER TANK HTC 60 80 31 MOTOR7 5DPIG182M 4200 40 1126 _ 31 MOTOR 5 5KW DPIG132S 4 400 690 31 MOTOR 5 5KW DPIG132S 4 200 400 1182 32 SCREWMeSMI2X5GALV daon 33 WASHERBRBMI2GALV o 310008 34 SCREW 65 M6X25 129GALV 3905 35 WASHERBRBM6GALV 3 36 COVERHTC650COMPLETE 37 FXINGLUG 2 13 Parts list HTC 650 Pos ss moron PLAteno ss SCREW moes 129 40 WASHER BRB 2 GALM scnewweswipasGAw O 4s BELT UPPER S140 44 scRewwrrrTMexiose GAY 4s scnewweswi
4. 99 0 k fa 110 CROSS PIECE PART 2 111 SCREW 5 M5X8 GALV 20 Exploded diagram HTC 800 E HTC 800E1 2001A 21 Exploded diagram HTC 800 E HTC 800 2 2001 22 Exploded diagram HTC 800 E HTC 200 23 Exploded diagram grinding holder HTC 800 HTC 800E4 2001A 24 Parts list HTC 800 E Description CHASSIS 650 800 HANDLE SHRINK TUBING HTC HANDLE COVER PLUG TO HTC HANDLE CONSOLE CONTROL PANEL SCREW RXS B10X16 GALV CONTROL PANEL COMPLETE EMERGENCY STOP COMPLETE XB4 POTENTIOMETER COMPLETE ON OFF KNOB COMPLETE LAMP GREEN RESET BUTTON COMPLETE FRONT BACK KNOB COMPLETE SCREW MC6S M6X12 8 8 GALV WASHER BRB M6 GALV SCREW MC6S M6X12 8 8 GALV WASHER BRB M6 GALV WIRING HOLDER CLIP JR12 SCREW 68 6 12 8 8 GALV WASHER BRB M6 GALV WIRING HOLDER CLIP JR12 CHASSIS HTC 650 800 POST SCREW M6S M16X120 GALV WASHER BRB M16 GALV NUT NYLOCK M16 GALV DIN985 WASHER BRB M16 GALV SPRINT CHASSIS HTC 650 800 HAIR PIN GALV 3 5X75 21 SCREW MC6S M6X12 8 8 GALV WASHER BRB M6 GALV TANK BRACKET FREQUENCY CONVERTER 7 5 kW 4A RUNNING TIME METRE CURTIS CHASSIS HTC 650 800 PROTECTIVE CAGE SCREW MF6S 8 25 GALV WALL SOCKET 16A 200 250V 3P BLUE SCREW 6 M5X20 GALV WALL INLET 16A 346 415V 5P RED PHASE INDICATOR 4 DIODES 16A 400 VOLTS PHASE INDICATOR 3 DIODES 200V SCREW 6 5 20 GALV WA
5. CROSS PIECE PART 1 HTC EZ SCREW 8 16 8 8 GALV 1040 CROSS PIECE PART 2 CROSS PIECE PART 2 HTC EZ SCREW MF6S 5 8 GALV 28 Exploded diagram HTC 800 HD Exploded diagram HTC 800 HD HTC 00 2 2001 30 Exploded diagram HTC 800 HD HTC B OT3 20014 31 Exploded diagram grinding holder HTC 800 HD HTC 800E4 2001A 32 Parts list HTC 800 HD Description O 2 4 12 13 i 1A 3 5 5A 5B 5C 5D 5E 5F 7 10 12 13 14 17 18 0 1 2 3 4 4 5 6 7 8 9 30 31 32 33 34 k cO 2 2 2 2 2 2 WALL SOCKET 16A 200 250V 3P BLUE CONNECTOR FEMALE MOTOR as specified 2 2 2 2 2 33 Parts list HTC 800 HD Description No MOTOR 11KW 400 690V 132M 4 HOSE POLYURETHANE TUBE 10 7 BLACK WIRING HOLDER CLIP JR14 SCREW MC6S 8 25 12 9 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 61 62 63 64 65 67 70 71 72 73 74 75 76 77 Parts list HTC 800 HD m O O 78 79 82 m a5 87 as 30A 08 OE OF 0 OH 2 2B 2 2E 2F 3 4 5 7 C D SCREW MFT TT M6X16 8 8 GALV 100 101 102 103 104 105 35 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 Parts list HTC 800 HD Pos Description Nos 7 GRINDING HOLDER COMPLETE H
6. js es s SCREW 65 6 20109 stia 32 BELT RING Discontinued motor plate and the belt ring are one piece BELT UPPER 5 140 HTC 500 110016 522222277 SCREW M6X16 8 8 GALV 310014 Parts list HTC 500 Pos Description PartNo Remarks 35 MOTORPLATEHTC500 noor 36 SCREWMeS 8 25 310001 37 WASHERTBRSBMBGALV 31005 7 38 CIRCLIPSGA20 306 39 SHAFTBELTTENSIONER 110018 40 BALL BEARING 6005 2RSC3 110019 41 TENSIONING WHEEL HTC 500 ioo 42 BELT INNER S 250HTC 500 110028 43 BALL BEARING 6005 2RSC3 io 44 CIRCLIPSGA20 306 45 6 16 8 8 3004 46 UPPERCOVERHTC500 102 47 FIXING BOSS NONZINC ios 48 SCREWMFFTTMOX258 8GALV 3009 J 49 BEARING CUP CENTRE HTC 500 10024 50 BALLBEARINGGO 22RS CS 110000 51 BEARING BOTTOM CENTRE 500 1927 52 CIRCLIPSGA60 81008 S EE BEARING CUP PULLEY UPPER HTC 110032 500 KA C T Uu CIT pA ss SCREWMETTT M6X16 8 8 GALV aoma SCREW mioxe 129 e covemcewmEHUBHTCSO now 2 SCREW MET TT M6X25 8 8 GALV sos SSS es scnewweswexes Gay
7. 2 kW 10 Amp 220 V 120 kg 500 mm 100 kg 300 1300 rpm 171 3x220 mm Motor output Current Voltage Weight Grinder diameter Grinding pressure Revolutions per minute Water tank volume Grinding wheels Model Motor output Current Voltage Weight Grinder diameter Grinding pressure Revolutions per minute Water tank volume Grinding wheels HTC 504E 4 0 kW 16 Amp 3x380 V 140 kg 500 mm 120 kg 300 1300 rpm 171 3x220 mm HTC 650E 7 5 kW 16 Amp 3x380 V 240 kg 650 mm 210 kg 300 1300 rpm 401 3x220 mm HTC 800HD 11 kW 25 Amp 3x380 V 315 370 kg 800 mm 280 335 kg 300 1300 rpm 401 3x270 mm HTC 504S 4 0 kW 16 Amp 3x380 V 120 kg 500 mm 100 kg 750 rpm 171 3x220 mm HTC 650S 5 5 kW 16 Amp 3x380 V 220 kg 650 mm 190 kg 750 rpm 401 3x220 mm HTC 800E 7 5 kW 16 Amp 3x380 V 280 kg 800 mm 240 kg 300 1300 rpm 401 3x270 mm Exploded diagram HTC 500 Exploded diagram HTC 500 66 64 63 49 Parts list HTC 500 The grinding machine s design may vary based on the year s model Machines produced be tween 1992 and 1995 for example have a drive system that is simple to upgrade Do not forget to quote the serial number when ordering spare parts The serial number is located on the right hand side of the chassis seen from behind and on the right hand fixing lug It can also be found on the namepla
8. SCREW MC6S M6X16 88 GALV sog PAD POLYCORD GREEN team 110970 2 per grinding hoder 100 HOLDER POLYCORD INNER 101 SCREWMET TT M6X16 8 8 GALV aoma rio nee 103 GRINDING HOLDER LOWER HTC 500 1088 O ao 105 CROSS PIECE PARTS 7 106 CROSS PIECE PART 1M6 107 SCREW MCES Mox 129 sog J we CROSS PIECE gt nose Jj we scnewwreswsxeomy soos 10 Exploded diagram HTC 650 Exploded diagram grinding holder HTC 650 Parts list HTC 650 Description PartNo Remarks 1 CHASSIS 650 800 HANDLE 2 CONSOLECONTROLPANEL SCREWRXSBIOXIGGALV 81009 4 SCREWMC6S M6X128 8GALV 300 j 5 WASHERBRBM6GALV 3902 j 6 WIRING HOLDER CLIP JR12 qo 7 WASHERBRBMeGAV 310082 1 8 SCREWMCeSMOXI288GAIV 310080 9 WIRING HOLDER CLIP JR12 110059 10 wasuERBRBMeGAIW tow 11 SCREW MC6S MOX128 8 GALV 310090 12 CHASSISHTC650 800POST mooo 18 SCREW mes 16 120 810 14 WASHER BRB M16 GALV 31002 15 SPRINT CHASSIS 650 800 16 WASHER BRB M16 GALV 31002 17 NUTNYLOCKM16 GALV DIN985
9. bearing s inner ring 6312 ball bearings are bonded with Fig 1 Pulley Assembly Loctite 603 against the shaft for machines after 2000 HTC 800 18 Position the three pulleys on the bench exactly as they were when you removed the 19 Place the can over the three pulleys 20 Apply grease to the bearings and fit the covers 21 Secure the covers by tightening the screws in sequence 22 Turn over the can with the pulleys now mounted and refit the motor plate hub 23 Fitthe circlip 24 Apply grease to the motor shaft and then fit the centre hub The machine should now look the same as in Fig 3 It is now time to fit the belt 37 26 Unscrew the fixing bosses by the pulleys if necessary NOTE If repairing an HTC 800 year 2000 model or later screw on the belt tool now 27 Soak the belt in hot water for about 15 minutes Fig 4 28 Arrange the belt according to figure 4 29 Once the belt is fitted according to figure 4 the belt tensioning tool should be used to press down the belt 30 Screw the tool onto the drive Fig 5 6 Fig 7 31 Turn the tool while pressing down the belt Once the belt is in position remove the tool and turn the belt while pressing it down NOTE This step requires two people figures 5 7 Fig 8 38 32 Once this is done Fig 8 fit the bearing cup to the centre hub and screw the fixing bosses in place 33 Clean the inside of the machine making sure
10. that no loose items such as screws have been left there before replacing the cover A foreign object could negate the entire service Fig 9 Locating pin M6 For bearing cups Fig 10 Locating pin M10 For tensioning wheel HTC HTC 500 650 and 800 Art No 310050 650 and 800 Not available as Art Produced by cutting the head off a M10 screw 34 Locating pins facilitate closing Order locating pins from HTC or make your own by cutting the heads off long M6 screws 35 Thread the locating pins 2 pins per bearing cup 1 per tensioning wheel See Fig 8 Fig 11 36 Position the cover Fig 11 Using a crowbar helps NOTE The cover on a HTC 500 can only be fitted in one way Make sure that all the holes are correctly positioned 39 37 38 39 40 41 Fig 12 Apply a flange seal to the edge of the edging strip to seal the machine The machine must be sealed so that dust and water cannot get in Use Loctite 5970 flange sealant See Fig 12 Fig 14 Once the machine is sealed press down the cover It can be difficult to get the tensioning wheel shafts in the right place The simplest solution is to use a rigging screw as illustrated in Fig 13 Thread the rigging screw into a fixing boss and then pull the tensioning wheel shaft into its correct position It may be necessary to give it a light tap with a non rebounding hammer to get it into position An alternative is to strike the tensioning wheel into
11. the shafts the upper belt runs on Change as needed On the HTC 800 models built after year 2000 only the shaft journal can be changed Test run and listen for any sounds from the bearings 45 Troubleshooting Machine does not start Emergency stop Cable OK Full voltage in all phases Error message on the display Cable OK Speed setting Not on the highest The machine shuts down often Reduce speed Error message on the display Cable OK Full voltage in all phases The machine sways or does not run smoothly on the floor Check the grinding holders Check the upper belt Check the tools wear The screws that fasten the grinding head to the chassis may be too tight The tools wear unevenly more than 3mm difference Overhaul the grinding holders 46 Electronic error codes Hitachi An error code is automatically displayed if a fault causes the frequency converter to trip out The following list contains error codes and their possible causes For resetting see page 45 Error Explanation Description of possible fault code Overload during continuous operation The most common codes in this category are E01 and This error may arise in the event of momentary overload This may be due to the machine being run too quickly or with a high load Try reducing the speed alleviating the load by moving the position of the weights and checking your tools If the error is an E03 you can try startin
12. C 800 models built before year 2000 Pos Description 1 Artno Remarks 41 SCREWMeSMI2X45GALV 310007 42 BELTRINGHTC800 43 110106 44 310014 7 MES r o o o UR o BALL BEARING 6207 2860 uos TENSIONING WHEEL 660 Oo BALL BEARING 6207 RS 03 nos OmcuPSGAs ss FIXING BOSS NONZING CO O sT 1 1ll 01 BALL BEARING 6214 2881 EE O now BALL BEARING 6207 2R803 ee GG x r oo e o F O K O o EE F 5 AB 4 SCREW MC6S M12X60 12 9 70 7 72 74 SCREW MFT TT M6X25 8 8 GALV 310025 N 2102100 Oo1T O1I O1 O1 O1 O1 O1 O1 O1 O1 Jo ro SHAFT COVER BALL BEARING 6207 2RS C3 110078 1 BEARING CUP PULLEY UPPER HTC 650 110086 CIRCLIP SGA 40 310043 3 SHAFT PULLEY 110093 NININININ N Parts list HTC 800 models built before year 2000 Pos Description GA Remis WEDGE RK TEXBXA0 PCS ss WwepgERKimexs ss PULLEVHTC 650 50x180 a7 8 1010 1010 02 03 04 N 90 96 98
13. EW 110316 88F SGA 35 310038 SCREW 65 M8X25 GALV 310071 BELT INNER HTC 800 NEW 7 5KW 110288 CENTRE HUB 10293 BALL BEARING 6207 2RS C3 10078 EDGING STRIP HTC 800 NEW 110326 FIXING BOSS 110314 SCREW MFT TT M6X16 8 8 GALV 310014 BEARING CUP CENTRE HTC 800 110140 LOWER COVER HTC 800 NEW 110324 SCREW 65 8 16 GALV 8 8 10080 COVER INSPECTION HOLE HTC 800 10141 SCREW M6S 5 10 10052 SCREW MC6S M12X95 12 9 10051 102 TERMINATION PLUG BRASS M25 M25 10138 SCREW 65 M6X12 8 8 GALV 10030 104 GRINDING HOLDER COMPLETE HTC 800 10603 GRINDING HOLDER COMPLETE HTC 800EZ 11244 AJOJN A RE o I gt UJ i gt lt cO cO cO N e n i Se eee iu x I G t i p po SSS po REN pm pl x F C 7 p 110078 100326 02 310014 0140 2 2 110324 310080 310052 310051 310030 i008 SCREW MC6SMBX16GALV8 8 WASHERTBRSBMIOGALV SCREW MF6S M10X20 O TENSIONING WHEEL COMPLETE HTC 800 PULLEY ASSEMBLY COMPLETE HTC 800 SHAFT JOURNAL I VRSEAL4030 95A i O RADIAL SEAL CR20X35X7 HMSA 10RG BEARIN
14. G CUP UPPER HTC 800 650 NEW BALL BEARING 6312 2RSV C3HT PULLEY HTC 800 NEW MODEL BEARING CUP LOWER HTC 800 650NEW RADIAL SEAL CR 60 75 8 HMSA7R SCREW MF6S M10X20 O WASHER TBRSB MIO GALV O SHAFT BELT TENSIONER 880 BEARING 6207 2RSC3 88E TENSIONING WHEEL HTC 800 650 NEW CIRCLIPSGA35 SCREW MF6S 8 25 GALV BELT INNERHTC800NEW7 5KW CENTRE HUB O BALL BEARING 62072885 EDGING STRIP HTC 800NEW FIXINGBOSS SCREW MFT TT M6X16 8 8 BEARING CUP CENTRE 800 _ LOWER COVER 800 NEW SCREWMC6S 16 GALV 88 COVER INSPECTION HOLE 800 SCREWMeSM5XIO SCREW MC6S M12X95 12 9 TERMINATION PLUG BRASS M25 M25 SCREW MC6S M6X12 8 8 GALV GRINDING HOLDER COMPLETE HTC 800 GRINDING HOLDER COMPLETE HTC 800 2 27 Parts list HTC 800 E Pos Description 310046 110098 104C 10099 310082 PAD POLYCORD BLACK 184 110371 PAD POLYCORD GREEN 184MM 110369 PAD POLYCORD GREEN 184MM 110369 104F HOLDER POLYCORD INNER 104G SCREW 6 16 8 8 GALV 104H SPRING 110397 10014 10100 10111 10027 110148 110054 110937 110257 110930 310070 110056 110955 310028 1041 GRINDING HOLDER LOWER HTC 800 SCREW MC6S M6X20 12 9 VELCRO GRINDING HOLDER 270MM 104L CROSS PIECE PART 3 CROSS PIECE PART 3 HTC EZ 104M CROSS PIECE PART 1 M8
15. LACK 110145 WIRING HOLDER CLIP JR14 os POPRIVET48XI27 faoa PIPEPEHSOLK 1103 VELCRO MALE WIDTH 38MM 110264 SPLASHGUARD HTC 800 3MX6OMM 10114 J FOAM 25 2500 20 ETHAFOAM 220E 10241 MOTOR PLATE 800 NEWMI32 oss 10072 4 10036 10037 10008 10004 BELT RING 800 nos 77 UPPER 800 NEW MODEL 110126 26 O Pos Hi 4 a7 60 66 68 69 m Parts list HTC 800 E Description PartNo Remarks SCREW MFT TT M6X16 8 8 GALV 310004 BEARING CUP MOTOR PLATE HTC 800 110151 BALL BEARING 6314 2RS C3 10174 UPPER COVER HTC 800 NEW 110325 SCREW 65 8 16 GALV 8 8 10080 WASHER TBRSB M10 GALV 10042 SCREW 5 M10X20 10078 TENSIONING WHEEL COMPLETE HTC 800 10568 PULLEY ASSEMBLY COMPLETE HTC 800 10567 SHAFT JOURNAL 10318 6 VR SEAL 4030 25A 110531 86C RADIAL SEAL CR20X35X7 HMSA 10RG 110291 BEARING CUP UPPER HTC 800 650 NEW 110296 BALL BEARING 6312 2RS1 C3 HT 110289 PULLEY HTC 800 NEW MODEL 10295 BEARING CUP LOWER HTC 800 650 NEW 10297 RADIAL SEAL CR 60X75X8 HMSA7 R 110290 CREW 65 8 60 12 9 310076 OUNTERWEIGHT HTC 650 800 NEW 110315 ENSIONING WHEEL COMPLETE HTC 800 110568 SCREW 5 M10X20 310078 WASHER TBRSB M10 GALV 310042 SHAFT BELT TENSIONER 10317 BALL BEARING 6207 2RS C3 110078 8 TENSIONING WHEEL HTC 800 650 N
16. Parts list HT 650 nae vont ein tr Hd eer debita I bond 14 Parts Shy HTG 650 oco da p vef 15 Exploded diagram HTC 800 models built before year 2000 16 Parts list HTC 800 models built before year 2000 18 Exploded 21 Parts list PES 25 Exploded diagram HTC ote b elec 29 SOG LIP L Pp He 33 Changing the inner belt HTC 500 650 800 37 Changing the upper belt HTC SOO reb eet RSKR t 41 Changing the upper belt HTC 650 800 42 Overhauling the grinding oodd e rr rr rr RR RR KRK ee rr nn 43 TEE 45 e tne LT 46 Electronic error codes bee 47 Checking the latest error Code Hitachi 48 Specialtool QN M u RAI ID 49 Technical data HTC 500 HTC 650 and HTC 800 HTC 650 HTC 500 HTC 800 Model Motor output Current Voltage Weight Grinder diameter Grinding pressure Revolutions per minute Water tank volume Grinding wheels Model HTC 502E 2
17. SHER BRB M5 GALV NUT M6M M5 GALV CONNECTOR FEMALE MOTOR 110057 110308 110357 110058 310029 110122 110481 110500 110499 110491 10498 10485 10030 10012 10030 A 10012 110059 310030 310012 110059 110060 310031 310032 310033 10032 10061 10125 10030 10012 10062 0 Pos 5 _ 8 9 21 N 10309 10158 10071 184 2504 10010 as specified 10229 2 10944 10010 22 10194 10193 j O IO Parts list HTC 800 E WATER TANK HTC 650800 a1 NUT 1259 018 HOSE CONNECTOR HOSE CONNECTOR 2601 12 38 HOSE CONNECTOR 26011214 T mue ww osELAmGEREFORCEDPVO H ei p Remarks 47 SCREWMeSM5Xe0GALV 810010 8 CHASSIS HTC 800 BOTTOM 110619 SCREW M6S M12X65 310034 WASHER BRBMI2GALV 310003 M12 GALV DIN985 310004 WHEELHTCSBO0 15582 CIRCLIPSGA20 306 BALL BEARING HTC800 WHEEL OUTER 110279 O BALL BEARING HTC800 WHEEL INNER 110278 MOTOR 7 5 DPIG 132M 4 200 346 110226 SCREWMe SMi2X25GALV faon WASHERBRBMI2GALV 310009 COVER 800 NEW MODEL HIGH __ 110133 HMOMA PO HOSE POLYURETHANE TUBE 10 7 B
18. TC 800EZ 111244 1088 108C 108D PAD POLYCORD BLACK 184MM PAD POLYCORD GREEN 184MM PAD POLYCORD GREEN 184MM 108F HOLDER POLYCORD INNER 1089 SCREW MFT TT M6X16 8 8 GALV 108H GRINDING HOLDER LOWER HTC 800 108J CREW MC6S M6X20 12 9 108K VELCRO GRINDING HOLDER 270MM 108L CROSS PIECE PART 3 CROSS PIECE PART 3 HTC EZ 108M CROSS PIECE PART 1 M8 CROSS PIECE PART 1 HTC EZ SCREW MFT M8X16 8 8 GALV 1080 CROSS PIECE PART 2 CROSS PIECE PART 2 HTC EZ 108P SCREW MF6S M5X8 GALV 36 Changing the inner belt HTC 500 650 800 When changing the belt on the HTC 650 800 certain steps are easiest if performed by two people NOTE Never use the same screw twice To open the machine Disconnect the chassis from the grinding head Disconnect the motor cable make a note of the connections Remove the cover Turn the grinding head upside down and stand it on the motor Remove the cross from the grinding holders Remove the grinding holders Remove all the upward facing screws approx 35 40 pcs Remove all the small covers and finally the large cover may require a crowbar When the machine is open it is possible to see what is broken Is the belt broken Is there a lot of dirt in the machine Remove the upper belt Spin the pulley to make sure it turns freely and smoothly without making a noise Try tipping the pulley If it can be tipped the upper ball bearing is broken If one ball b
19. WER 650 SCREWMCES 20129 3 107 CROSS PIECEPART3 54 j 108 CROSS PIECEPARTiM8 110257 j 109 SCREWMFTM8X1688GAV 110 CROSSPIECEPART2 o 111006 1 111 SCREWMFGS 310088 15 Exploded diagram HTC 800 models built before year 2000 Exploded diagram HTC 800 models built before year 2000 Parts list HTC 800 models built before year 2000 CHASSIS 650 800 HANDLE PS CONSOLE CONTROL PANEL ros SCREW BIOXIGGALV s 310080 soa WIRING HOLDER CLIP JAI E 810080 moss SS gi SCREW mces M6X128 8 GAL GO pz 1 SCREW MC6S M6X12 8 8 GALV WHEEL FITTING KIT 110008 Only for use with solid wheels 27 WHEEL HTC 800 110382 More alternatives available 110007 310010 110069 110226 310011 1 p x x I 1 Sl 7 21 22 22 WASHER BRB M12 GALV 310003 SCREW MC6S M6X25 12 9 310035 WASHER BRB M6 GALV COVER HTC 800 COMPLETE NEW RIGHT 110228 available FIXING LUG 110072 MOTOR PLATE HTC 800 pa SCREW 65 M8X25 12 9 WASHER BRB M12 GALV 310003 18 22 22a Parts list HT
20. a chine Check the starting operation in the manual The Start Stop knob must be in the position Stop before the key is turned Earth fault Earth fault on motor side May be due to jammed or damaged motor cable or motor breakdown Check the motor and its con nections E15 Overvoltage If the mains voltage volts is higher than permitted the converter is disconnected Occurs rarely E16 Mains undervoltage Main voltage volts is too low for the time being May be due to lightning or a loose contact in the cables Could occur if some one connected to the mains is using a powerful welder Check the cables and con nections Overheating Temperature too high in the electronics See item E 08 May also be due to having poor mains voltage and the current being too high which generates heat in the electronics Ventilate the cabinet and turn the machine off for a while with the door open Phase fault One of the incoming phases is missing Check the fuses cables and connections 8888 Processor error Contact service if this is the case The con verter must be reset Checking the latest error code Hitachi Press FUNC 001 on the display Press the arrow up key until you come to 008 Press FUNC and the error code appears on the display Press FUNC again and the relevant frequency is shown when an error occurs Press FUNC again and the motor current is shown when an error occurs Press FUNC again to view the voltage when an err
21. be ground down before fitting the grinding holder 10 Refit the grinding holders and the cross Fig 20 Fig 21 Fig 22 43 Use the right line as a guide when overhauling the grinding holders The right line means turning the various parts of the grinding holder to the correct position in relation to each other during assembly D Inner polycord holder Upper grinding holder Inner grinding holder polycord and upper grinding holder Lower grinding holder 44 Maintenance Daily Clean the machine if it has been used for wet grinding or mist spray Check wear on the tools abnormal or uneven wear can indicate damage to the grinding holders Weekly Clean the machine Check the grinding holders Remove the tools and run the machine off the ground on the lowest speed If the grinding holders oscillate or wobble considerably they are damaged Overhaul all grinding holders at the same time Check that the upper belt is intact Try to turn the large disk in any direction It should be stiff If it turns freely then the belt has broken Each month or 100 hours Clean the machine Check the grinding holders Screw into place everything that can have vibrated loose Lift off the cover and check that it is intact Scrape and vacuum the parts that are enclosed by the cover Check the upper belt Change as needed Check the seals of
22. earing is broken change all the ball bear ings since the cost of parts is low compared with time it takes to dismantle the machine If the belt has broken this should be returned as defective to HTC Slip marks on the belt however can arise from removing carpet adhesive and due to carelessness when start ing up the machine see the machine manual Qu O Ol ER NIS A Br E To dismantle the machine further proceed as follows 9 Remove the screw from the centre hub requires electric or s 81 compressed air nut runner oy 82 84 10 Use crowbars to remove the centre hub s lt 2 2 8 11 Remove the circlip from the motor plate hub located under ws 83 TN the centre hub 2 S9 85 12 Remove the can from the motor and motor plate EN me Use the special tool and a sledgehammer if required T4 y B 13 Put the can on a workbench with the open end down NOTE Exercise care so that the pulley assembly does 87 not fall out JE gt EE 14 Undo the screws securing the three shaft covers and re D amp move these Lift off the can The pulley should remain on F an the bench may require tapping out with a non rebounding F 81 hammer Fig 2 Pulley 16 Press the ball bearings off the shafts with an extractor or a Assembly HTC 500 hydraulic press and HTC 650 17 Press on new ball bearings Make sure to press on the ball H
23. first threading it over the shafts and then prising it down over the edge of the motor plate as illustrated in Fig 19 Refit all parts The machine is now ready to be used Fitting the upper belt HTC 650 800 Fig 19 42 Overhauling the grinding holders These instructions describe how to overhaul or repair a grinding holder The polycord and spring are the parts that are normally changed It is vital to overhaul all grinding holders at the same time so that the tools are not subjected to uneven wear Never use the same screw twice Clean all components in the grinding holder thoroughly Since the design varies between machine models the machine pictured in the illustra tions may look slightly different from your machine 1 Remove the grinding holder from the machine remove the cross and then undo the three screws J beneath 2 Turn the grinding holder so that you can undo the screws D 3 The grinding holder is now split The spring and polycord can be changed H E 4 Remove the old spring 5 Remove the polycord by undoing the screws G that are now visible on the top part 6 Glue the spring to the lower grinding holder 1 It must be positioned in the centre Use Loctite 406 or equivalent 7 the polycord E Thread and tighten the screws G into the top grinding holder B see Fig 20 8 Thread and tighten the screws D into the lower grinding holder 1 see Fig 21 9 Protruding screws must
24. g the machine on another surface Overload during retardation See E01 Overload during acceleration See E01 Overload Occurs during prolonged overloads If the overload lamp has been lit for a length of time this will be the result when the elec tronics cannot handle the load any more Drop the speed or reduce the load by ad justing the weights or tools Overvoltage May arise if there is a mechanical fault and the motor generates current back to the electronics Check the mechanical function ality such as belts and bearings E08 EEPROM error Occurs rarely but may arise from high tem peratures in the electrical housing Open the housing and air out Check filters and cool ing fans in the housing E09 Undervoltage Occurs if the voltage is too low May occur where there are long cables or poor con nections contacts May also arise if there are many users in the network Try chang ing outlets shortening cables and reducing speed E10 Current transformer interference Contact service if this is the case The inter nal transformer needs replacing 47 Error Explanation Description of possible fault code Processor interference The processor experiences interference generates errors and needs to be reset Comes from interference from the mains or other disruptive equipment Try resetting the electronics by keeping the RESET button pressed for two seconds Restart protection tripped Operating fault when starting up the m
25. or occurs Voltage on the DC bus To view previous errors choose 209 which matches item 2 in list above For previous errors you cannot view data with respect to current or voltage 48 Special tools Special tools may be required to perform some repairs Extractor for dismantling ball bearings Hydraulic press for mounting Belt tensioning tool HTC 500 ej hub article 110232 Belt tensioning tool HTC 650 three grinding holders article 110231 Belt tensioning tool HTC 800 models built before year 2000 article 110230 Belt tensioning tool HTC 800 models built after year 2000 article 110634 Special tool hammer 500 article 110212 To move the motor plate out of the centre position Special tool hammer 650 and 800 models built before year 2000 article 110213 To move the motor plate out of the centre position Locating pin M6x70 article 310050 To assist in closing the can 49 HTC SWEDEN AB Box 69 SE 614 22 S derk ping Sweden Phone 46 0 121 294 00 Fax 46 0 121 152 12 www htc sweden com 50
26. pesGay _ 46 WASHERTBRSBMIOGALV _ sioe 4r omcuesoass OO 8 4s BELTTENSIONER noy 4s 6207 25509 so TENSIONINGWHEELHTC660 BELT NNERSesoHTC s0 5 BELT INNER S 250HTC 650 SOFT STAT 2 BALL BEARING 6207 RS 08 to omcuPSGass o SCREWMFT TT M6XI6 88 eav so ss FIXING Boss ss opper cover 60 sr scnewwerwexessGAy 5s BEARING CUP TOP CENTRE n BALL BEARING 6242 O toes BEARING BOTTOM CENTRE 650 e oRcuPsca70 e CENTRE SOFT START foose BALL BEARING 6207 BAS 03 BEARING CUP PULLEY UPPER HTC 680 5 65 EDGINGSTRIPHTC650 O es er screw moss maxo r20 sod 6s COVER CENTRE HUB HTC 650800 110088 es SOREWMFT TT M6X25 BB 1 FIXING BOSS NONZING fos 71 SOREWMFT TT GAY sou 7 scnewweswipesGay sona 7s WASHERTBRSBMIOGALV sto 74 COUNTERWEIGHTHTC 650800 o 7s SCREWMETTTM6X2558GAV ss 7e omcumsaaz
27. s O 7s SHAFTOOVER _ GS 14 Parts list HTC 650 Description PartNo Remarks poe 80 BALLBEARINGG2072RS 03 111008 81 BEARING CUP PULLEY UPPER 650 1196 82 CIRCLIPSGA40 83 SHAFL PULLEY 11093 84 WEDGERK12X8X40 o 310044 85 WEDGERK12X8X30 o 310045 1 86 PULLEYHTC65050X180 87 CIRCLIPSGA40 y y odao BEARING CUP PULLEY LOWER 9 89 CIRCLIPSGAGO0 o 90 BALLBEARING60122RS 03 91 PULLEYHUBHTCGS0 11105 92 LOWER COVER HTC 650 mows 93 SCREWMFTTTMeXi688GALV 31004 HUB COVER PROCESSING HTC 650 800 1110097 95 SCREWMFTM6X308 8GAIV 310087 96 CIRCLIPSGA70 o 97 GRINDING HOLDER UPPER 650 800 1115986 98 CYLINDERPINCPex20Hs 8106 99 HOLDER POLYCORD OUTER 110008 100 SCREWMC6S MeX168 8GALV 31002 100a POLYCORD BLACK 184MM tsa 101b POLYCORD GREEN 184MM tte 101 POLYCORD GREEN 184MM 110309 102 HOLDER POLYCORD INNER 103 SCREWMFTTTMeXi688GALV 3114 104 SPRING toto 1 105 GRINDING HOLDER LO
28. te Shown below is a parts list corresponding to the exploded diagram on the previous pages Pos 1 CHASSISHTOSOOHANDLE nem s SCREW Gay moo 4 sgg 75 2 5 12 sta 7 NUT GALVDING S stp s semwrcHassisHTOSO noo 79 sme 10 WATERTANKHTC 500 110008 wa PROTECTIVECAGE 5 _ _ 19 SCREW Mes jo 14 CHASSISHTC 500 BOTTOM ner 16 NUTNYLOCK spe 1 WATERVALVETOGRINDER noy O 19 scnewweswexGav jo m Moron A ier 22 sonewweswimesGAw jo 7 zs WASHER aoo a sts ss wasuERERBMeGAy aona ss COVERHTC 500 COMPLETE jio C mos zs WASHER sa 29 SCREW MI0X35 GALV
29. the correct position according to Fig 14 Once everything is in place apply grease to the ball bearings and fit the cover Replace the screws that were originally removed with new screws and make sure they are tightened NOTE Never use the same screw twice Refit the grinding holders Turn the grinding holders several turns before turning over the grinding head 40 Changing the upper belt HTC 500 Changing the upper belt on the HTC 500 is more complicated than the HTC 650 Changing the belt takes 1 2 hours based on how experienced you are in performing the change NOTE Only use rounded screwdrivers when fitting the belt 1 Disconnect the chassis from the grinding head 2 Disconnect the motor cable make a note of the connections 3 Remove the cover 4 Undo and remove the screws securing the motor Fig 15 5 Remove the split plates with the lugs Fig 16 6 Check the seals and change if they are damaged Check if the shafts are worn They should be approx 17 mm If they are worn more than 2 mm the entire pulley shaft must be changed See pages 37 40 Changing the inner belt for dismantling instructions 7 Removing the split plates exposes three shafts 8 The belt should run on the three shafts and on the edge of the motor plate NOTE Make sure that the belt is not fouled on the sharp edges of the shafts The belt can crack or break 9 Stretch the belt over the three shafts and allow it to take a short cut
30. under the motor Fig 17 10 Use rounded screwdrivers to pry the belt out onto the edge Fig 18 11 Once the bet is fitted refit the split plates 12 Refit the screws securing the motor 13 Refit the cover 14 Connect the motor cable 15 Refit the chassis on the head The machine is now ready to be used Lm M KS 1 j s Fig 15 Fig 16 am eT um Wi _ e Al UE J H s B EX ay 4 lt TE 2 pe Fig 17 Fig 18 41 Changing the upper belt HTC 650 800 Changing the upper belt on an HTC 650 800 takes approx 30 minutes to 1 hour NOTE Only use rounded screwdrivers when fitting the belt pom cm Disconnect the chassis from the grinding head Disconnect the motor cable make a note of the connections Remove the cover Remove all that remains of the old belt Check the seals and change if they are damaged Check if the shaft journals are worn On the HTC 650 and 800 models built before year 2000 the shaft is approx 20 mm If it is worn more than 2 mm the entire pulley shaft must be changed See pages 37 40 Changing the inner belt for dismantling instructions On the newer HTC 800 models built after year 2000 the upper section of the shaft can be changed It is fastened from above with a socket head cap screw Fit the new belt by

HTC 500 Service Manual - Runyon Surface Prep Supply

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