Exalto MD1 223KGC, Manual

Page 1: ...ITEM NO XA2123 2124 WIPER SYSTEMS Exalto windscreen wiper type 223KGC ...

Page 2: ...ing of large window sizes We also can provide linked or straight line systems Please see the below table as an overview After sales support We have an excellent after sales support Our wiper specialists can provide a comprehensive advice to ensure the system works accurately and to your wishes Should problems occur with the product it is always our main priority to solve it quickly and accurately ...

Page 3: ... use 4 2 normal operations 3 1 preparation 3 2 installation of mechanical parts 3 3 electrical installation 3 4 final installation 5 1 general maintenance 5 2 servicing 5 3 changing the wiping arc and park position 5 4 disassembly and assembly 7 1 assembly overview 7 2 parts list 7 3 connection table 7 4 wiring diagrams for switches and control systems 1 Introduction 2 Technical data 6 Troubleshoot...

Page 4: ...the electric connections of the wiper before making any change to the wiper system Safety symbols An exclamation mark in front of the text warns you that injury or damage can occur if a procedure is badly performed Dangers The installation and use of Exalto wipers will not inflict any personal dangers or damage provided that installation is done according to the procedures specified in the manual Ne...

Page 5: ...el or cover Place a fuse see specifications sized to protect the motor Safety requirements Before the Exalto wiper is installed we strongly recommend the following Read the entire manual before installation Make sure your working environment as well as the wiper parts are clean Check to be sure no parts are missing or damaged Use only high quality tools and have them within reach when installing Ha...

Page 6: ... The wipe arc is adjustable from 40 to 90 with steps of 5 The matching Exalto MD1 PU pantograph arms are adjustable in length up to 450mm to set the wipe area accurately The motor has insulated earth return 1 2 Environmental factors Some materials used in the construction of the wiper motor maybe harmful to the environment e g copper These parts of the wiper may be re used or recycled No harmful s...

Page 7: ...rical data 24 Volt Torque max 25 Nm Voltage 24 Volt Current 1 5 A Power consumption max 36 W Number of revolutions Low speed 40 rpm high speed 60 rpm Recommended cable 5 wires 1 mm 16 g or 2 mm 14 g up to 10 m long Recommended fuse 4 A slow blow Grounding Insulated earth return 2 3 Mechanical data Dimensions L x w x h 180 x 113 x 108 mm Shaft diameters Drive shaft Ø 11 mm support shaft Ø 8mm at 50...

Page 8: ...ragraphs 5 3 and 5 4 to set the wiping arc prior to installation 2 Rough determination of wiping arc and wiper blade With this method the wiping arc and the wiper blade length can roughly be determined Please contact your vendor to calculate your configuration more accurately Determine length of pantograph arm L L E D Get the maximum wiped area width W W 0 9 GW Find the intersection of L en W in th...

Page 9: ... 155 145 135 165 176 186 196 207 73 70 63 55 81 90 100 109 136 127 118 145 154 163 172 181 63 65 55 47 71 79 86 94 117 110 102 125 133 141 149 157 54 60 47 40 60 67 74 80 100 94 87 107 114 121 127 134 45 55 40 34 51 57 62 66 85 79 74 90 96 102 107 113 36 50 33 26 43 47 52 56 70 66 61 75 80 84 89 94 30 45 27 23 35 38 42 46 57 53 50 61 65 68 72 76 25 40 21 19 26 30 34 37 45 43 40 48 51 54 57 60 400 ...

Page 10: ...ble with 5 wires with a diameter of at least 1 mm 16 g up to a maximum length of 10 m Use larger diameters when using longer cable lengths greater than 10 m 3 Fit a slow blow fuse of 6 A 12 Volt or 4 A 24 Volt in the main cable positive 4 Connect the switch to the wiper refer to the switch manual for installation 1 Switch on the power and test the motor briefly Wait until the motor stops after turn...

Page 11: ...rm and blade assembly on the shafts Fasten the nuts loosely onto the shafts 9 0 9 0 Bearing Dogbone Nut M10 Tightening 33Nm 24ft lbs Nut Tightening 17 pindle Lever Half Nut M8 Tightening 17Nm 12ft lbs Pin exagon socket head cap screw Tightening 8Nm 6ft lbs Bearing Spacer Glass or Bulkhead Glass or Bulkhead Glass Glass Retaining Ring Tightening 16 3Nm 12ft lbs 3 Switch on the power and test the mot...

Page 12: ...park position is wrong adjust them again Follow the procedure in paragraph 5 3 4 2 Normal operation All Exalto windscreen wipers are provided with the following functions low speed high speed self parking Do not use the wiper on a dry window excessive wear of the blades and the motor will occur in this case Because of the wide variety of wiper switches refer to the user manual for the installed sw...

Page 13: ...one solely by qualified mechanics In chapter 6 Troubleshooting a list is given of possible problems and their solutions 5 3 Changing the wiping arc and park position If the wiped area is not optimal the wipe arc and park position can be changed Always disconnect the electric before opening the housing 5 3 1 Adjusting the wipe arc 1 Remove the wiper from the glass 2 Remove the countersunk screws hol...

Page 14: ... disc well and mount the wiper on the glass 4 Run the motor briefly to check performance 5 Adjust the wiper arm to the correct length if necessary 6 Install the wiper arm in correct parking position 7 If necessary repeat steps 5 and 6 to position wiper arm in correct parking position Dogbone Hexagon screw M5x10 Tightening 4 5Nm 3 3ft lbs Retaining Ring Disc Sticker Nut M8 Tightening 17Nm 12ft lbs S...

Page 15: ...replace the wiper follow chapter 3 1 Disconnect all the electric connections to the wiper 2 Remove the wiper from the glass see 5 4 1 3 Unscrew the nut see 7 1 on the motor shaft see 7 1 and remove the disc 4 For adjusting the wipe arc follow section 5 3 1 Disconnect all the electric connections to the wiper 2 Remove the wiper arm see 5 4 1 3 Disassemble the wiper system as detailed in section 5 3...

Page 16: ...the voltage across the motor and check all connections are correct 4 The wiper motor has failed Solution Replace the motor and check for excessive drag or high current 6 2 Wiped area or park position is not correct Possible causes 1 The wiper arm was placed without parking the motor first Solution Remove the wiper arm Run the motor to the park position and re install the arm 2 The wipe arc is set w...

Page 17: ...ints are loose Solution Replace worn parts or tighten as required 2 Parts are broken Solution Replace broken parts re adjust as required 3 Splines of shafts are worn Solution Replace all loose broken or worn parts and adjust as required 17 Exalto type 223KGC MANUAL WIPER SYSTEMS ...

Page 18: ...7 Drawings Schematics 7 1 Assembly overview 19 23 11 24 17 18 21 8 9 6 10 5 14 15 11 12 3 2 26 22 20 1 4 7 25 13 16 27 18 MANUAL WIPER SYSTEMS ...

Page 19: ...5 1 Connecting rod Ø10 L 85mm 2100 936 0 050 4 1 Leverpin Ø8mm 2100 920 1 4401 SS316 0 013 3 1 Wishoekschijf sticker 2100 931 PE High Density 0 000 2 1 Wipe arc plate 2100 930 1 0037 S235JR 0 269 1 1 Motor 12Volt 23Nm 2100 023012 Material not specified 1 100 7 2 Parts list Pos QTY Description Part nr Note 1 1 Motor 12Volt 23Nm 2100 023012 1 Motor 24Volt 25Nm 2100 025024 2 1 Arc disc for wiper235KK...

Page 20: ...to complex controllers Below you will find some connection wiring diagram examples of Exalto switches and controllers Please refer for detailed instructions to the specific switch or controller manual Function Polarity Motorcode Switch code Cable High speed 53b H White Low speed 53 L Yellow Negative 31 Black Stop self park 31b P Blue Positive 53a B Red 20 MANUAL WIPER SYSTEMS ...

Page 21: ... 2134 2135 Function Polarity Motorcode Switch code Cable High speed 53b H White Low speed 53 L Yellow Negative 31 Black Stop self park 31b P Blue Positive 53a B Red 21 Exalto type 223KGC MANUAL WIPER SYSTEMS ...

Page 22: ...06425 SET as per following details which is wiper switch specific Function Polarity Motorcode Switch code Cable High speed 53b H White Low speed 53 L Yellow Negative 31 Black Stop self park 31b P Blue Positive 53a B Red 22 MANUAL WIPER SYSTEMS ...

Page 23: ...scheme can also be used for the case of digital switching modules with only simple output channels Function Polarity Motorcode Switch code Cable High speed 53b H White Low speed 53 L Yellow Negative 31 Black Stop self park 31b P Blue Positive 53a B Red 23 Exalto type 223KGC MANUAL WIPER SYSTEMS ...

Page 24: ...Stop self park 31b P Blue Positive 53a B Red To touch pad PS Wiper SB Wiper Red Black Self park Negative White High speed Yellow Low speed Battery Battery To pump solenoid Connector for wiper on relay box Viewed from cable side of connector Low speed Yellow Negative Black High speed White Self park Red 24 MANUAL WIPER SYSTEMS ...

Page 25: ...41 Switch 210342 Function Polarity Motorcode Switch code Cable High speed 53b H White Low speed 53 L Yellow Negative 31 Black Stop self park 31b P Blue Positive 53a B Red 25 Exalto type 223KGC MANUAL WIPER SYSTEMS ...

Page 26: ...umps heaters is not supplied in standard equipment Function Polarity Motorcode Switch code Cable High speed 53b H White Low speed 53 L Yellow Negative 31 Black Stop self park 31b P Blue Positive 53a B Red Switch panel 210321224 210351224 26 MANUAL WIPER SYSTEMS ...

Page 27: ... CONTROL 210351224 2 4 1 3 5 Additional relay box for heated window operation PUMPS HEATERS OUTPUT M F S P Positive 53a Slow 53 Fast 53b Negative 31 Stop 31b Function Polarity Motorcode Switch code Cable High speed 53b H White Low speed 53 L Yellow Negative 31 Black Stop self park 31b P Blue Positive 53a B Red 27 Exalto type 223KGC MANUAL WIPER SYSTEMS ...

Page 28: ...he Netherlands 31 0 184 615 800 wipers exalto com Hereby declares that Exalto windscreen wiper type 223KGC formerly 235KG complies to the following harmonised standards Pleasure yachts electric systems NEN EN ISO 10133 2017 Extra low voltage D C installations regarding color codes Version 01 2022 ...