Exalto windshield wiper
Contents
1. 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 a dk e au 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 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 12. 700 Heer EE Eee Tee eee E soo LE PREECE EEE lt 500 400 300 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 Units in mm Wiped area width W e amu 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 Armlength LJ 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 30 37 40 43 45 38 46 50 53 57 47 56 61 66 70 57 66 74 79 85 67 80 87 94 100 79 94 102 110 117 90 109 118 127 136 104 124 135 145 155 132 158 171 184 197 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 remember 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 Disconnect all the electric connections of the wiper e 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 If you 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
3. 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 Motorruns 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 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 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
4. shall be complete and conforms to all aspects of Directive 89 392 EEG Hardinxveld Giessendam 4 22 2011 m d y N 10 11 12 13 15 16 17 18 19 20 21 22 23 24 Parts_list Qua Part 1 N N b N b m N Motor 12 V 23 Nm Motor 24 V 23 Nm Wiper housing for 223 BD Cross recessed countersunk head screw DIN 965 Wipe arc disc Sticker for Wipe arc disk Nut s s DIN 934 Nut s s Nut s s Connecting pin Shaft with lever bh 20 mm Shaft with lever bh 35 mm Shaft with lever bh 55 mm Shaft with lever bh 75 mm Sleeve bearing bush plastic Bearing bush Nut s s flat Retaining ring Push rod Nut s s Plain washer s s Bearing house bh 20 mm Bearing house bh 35 mm Bearing house bh 55 mm Bearing house bh 75 mm Retaining ring for shaft Gasket rubber Gasket s s Nut s s Dust cap rubber Nut s s nylock A4 Support shaft bh 20 mm Support shaft bh 35 mm Support shaft bh 55 mm Support shaft bh 75 mm Dimensions 180x105x85 180x105x85 150x90x40 M6x16 70x5 M8 M8 5 M10 6 5 M8x26 O12x102 12x117 O12x137 O12x157 13x14 10x10 M8x4 6mm 110x24x10 M20 18x12x1 M20x65 M20x80 M20x100 M20x120 12x4 90x45x3 90x45x3 M20 O26x20 MB M8x75 M8x90 M8x110 M8x130 Cat no 2100 2312 2100 2324 2100 104 2100 050 2100 930 2100 931 2100 460 2100 355 2100 354 2100 920 2100 364 2100 360 2100 3
5. Make sure 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 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 e amu 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 E Introduction sisia aa AN AA ANNA EN GRA NE NENGGE NANANG E GAN GANG NG Na Kas ANG 4 kah TIGO TON aana aa raaa tt aapa eter eee aa tne 4 1 2 ETNIK ODINENTAl TACIONS kakak agak aa AN NGANG NG GARENG AN EOR 4 k3 MOGITEG USe and GUalantee as asia Da Ta a A A EN A AB aa Ba a 4 2
6. ere up to 10 m long Recommended fuse eesecesseeeseseees 4 A slow blow GrounGING sinan cds Insulated Earth Return 2 4 Mechanical data DIMENSIONS isan a aaa ga Ixwxh 173 x 107 x 100 mm Bearing diameters_ oooooooeeooeeoeene Drive shaft 20 support shaft 8 mm MOUNTING aging aana ababaka kan a a aaa In bulkhead 20 35 55 or 75 mm BENG asira Bronze housing self lubricating WIPE ell RA Model PU up to 750 mm WiperDladesS asauran anana ana aaa nana Up to 800 mm Wipe arC srno nanana Wipe arc disc 40 90 adjustable per 5 MAS sanggi KT TERE approx 2 3 kg 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 100 Attention When installing the wiper reserve space for a housing or cover ahten 25 6 Nm 16 3 Nm tightening torque 1
7. 66 2100 368 2100 925 2100 926 2100 760 2197 097 2100 936 2100 349 2100 400 2100 326 2100 321 2100 327 2100 328 2100 410 2100 491 2100 481 2100 350 2100 361 2100 071 2100 446 2100 441 2100 447 2100 448 Type 223 BD 9 Drawings and Schemes 9 1 Assembly overview o E i 7 E a hE o S Of 66 9 2 Internal wiring diagram The following diagram explains the way the wiper motor works Function high speed low speed earth common leg Self parking O 1 Ko NG lh glej P IN 53a Polarity Motorcode Switch code 53b 53 31b 53e 53a H L OD OB Cable 12 24V white yellow black blue red Exairo e P O Box 40 3370 AA Hardinxveld Giessendam The Netherlands e T 31 0 184 615800 e F 31 0 184 614045 lt E sales exalto com e www exalto com Copyright 2012 Exalto
8. 8 88 ft lbs 12 02 ft Ibs 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 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 Too much space N i y n Al lo sel Li 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 Colours Function yellow low speed black minus earth blue common leg red selfparking White high speed _ SLOW BLOW FUSE 6A for 12V SLOW BLOW FUSE 4A for 24V 8 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 112 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 or 4 A 24 Volt in the main cable Connect a switch to the wiper refer to that specific manual for installation 3 4 FinaL installation 9 10 Test the motor briefly Wai
9. Exairo Parts Wipers Bearings Propulsion User manual for Exalto windshield wiper Type 223 BD 12 24 Volt Cat no 2165 30 32 35 40 12 volt Cat no 2166 30 32 35 40 24 volt version 9 2012 e amu au y 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
10. TecNNICAl ayasa yes anaa GA AN GAN n A NENG aa ENENG DN TEN iai 5 21 GNT agaca Na a a a a Nn 5 2 2 EICCtrICal data T2 VOIT sasasi sakaki ana gana sae eaaa a anaa akasa ake aka 5 23 E CCtKICal Gata 24 Lo hg aa Nana NE a E E EN NE EEN EEN EN 5 2 4 Mechanical data w cccccccccccssssssssssssssescsscsssssssssssssesessesesssssssssssesessesesssessssesesess 5 3 INAU O ccccestsssesvasaceccerstesesssucdevenssdeness ANE GG BEN Na Aa 6 3A TAKO DATAN aana a aan aan aan AT a A A a a a ab a at ab a ah da ah aab a aa a aa a a Na Ah ag 6 32 IfstallatiOM OL mechanical Parts ecesisscecscsesessssszssseseszsosasasacasasasesezesesesescstacacics s 6 33 Electrical nstallatiOIN arsana cavacacicscesecasasaseczcecazevarerasscsesvavaccsseeescasave osanesasarasactussle 8 3 4 Final installation wu eesscsssssssssssssesecsessssssssssssssseesesessssssssssseseseesesessssssessesees 8 4 Operatlon GIG Use sssiccescsdecvesciaessiaaieccccsscccseeenicesacieeatiaiauseendeieaaseiwssian 10 AV PRE DAATION TOR MYSEUSE kaa ka a AA NGANG NG NA GG NGA ONG A DG a AG ANG NG ANENG 10 A2 MSO sage an naa KN NG iei GE NGGAE TE TANGGA a 10 5 MANtenanGe siarsio an a 11 Bil General maena NCE arrani aa a a aaa aa Ng aaa a DG Na a NGA aga 11 D2 SENGGAKAN BAG AAN teint a a a Bada aa ak Ta a aaa nana 11 5 3 Changing the wipe arc and park position ssessessesseseeseesessessessessessessesses 11 5 4 Rough determination of wipe arc and wiper blade 0e00e00eeeee0ee00ee 12 5 5 Disassembl
11. per 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 runthe motor briefly to park it e move the disc to the desired park position see the text below Wishoeken Wiper arcs OOA 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 park position 4 O 5 4 Rough determination of wipe arc and wiper blade With this method the wipe arc lengths of the wiper blade and wiper arm can be determined roughly Contact your vendor to calculate your configuration more accurately D distance top side glass to center of spindles E eye level L GH glass height GW glass width H vertical displacement L length of arm 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 and W in the diagram below ae tito of ee af 1000 Wipe arc 50 59 80 85 90 of aa eee Bares A s Herer aa eA T
12. rong 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 can be changed Always disconnect the power supply before opening the housing Adjusting the wipe arc e Disconnect the power supply e remove the wi
13. ronmental 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 wipers for a non maritime environment or for another application or in case of any doubt 2 Technical data 2 1 General PROOUICE perseae aE Exalto windshield wiper TYDES uar 223 BD 12 Volt and 24 Volt Catalogue numbers 12V ues 2165 30 32 35 40 Catalogue numbers 24V ou eee 2166 30 32 35 40 2 2 Electrical data 12 Volt Torgue MaX essccsssssecssesesesseeseesseees 23 Nm VONAGE teases 12 Volt CUNEN creer a a D 3A Power consumption max seses 36 W Number of revolutions ou Low 38 rpm high 59 rom Recommended Cable uu 5 wires 1 16 g or 2 2 mm 14 9 Sie aaa eae cece eater aa aaa up to 10 m long Recommended fuse esesscesseeeeeeeees 6 A slow blow GOUGING aram Insulated Earth Return 2 3 Electrical data 24 Volt Torque mak eesessesesessesesesesreseseesesesees 23 Nm VOOG aE 24 Volt CUCL anana dan aaa ana aka aaa pa a u s 1 5A Power consumption mak eses 36 W Number of revolutions ou eee Low 35 rpm high 56 rom Recommended Cable uu 5 wires 11 16 g or 2 mm 14 9
14. t until the motor stops after turning off the 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 page 17 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 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 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 shafts go through the bulkhead if the wipe arc cleans the entire window if the park position is correct If the wipe arc or the park position is w
15. y and assembly ou sssssessssssssssesescsescscscssssssssssssssssesesesesesesceeees 13 6 lt TEOUDICSNOOUING sisa kasa a a a ei ag NGAGAS GAE TANG 14 7 Declaration Of conformity s060000006000000000000000000000000 00000000000000 000000000 15 8 Parts USE sasanga naka ANANGENG ERa 16 9 Drawings and Scdhemes sooo0000000000000000000000000000000000000000 0000000000000000 00000e 17 9T ASSEMDIY OVEIVIEW siirre SUNAR NGANA DAGANGANE Ga AG GN Gaga aga A 17 92 JANG Ra Wining adagra sasasi an ang aana aan ang aaa an aab aan gana 18 e au 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 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 223BD has IER Insulated Earth Return 1 2 Envi
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