Exalto MD1 223KGO User manual

ITEM NO. XA2125/2126
WIPER SYSTEMS
Exalto windscreen
wiper type 223KGO

Window height Up to 1100 mm Up to 1600 mm Between
1100-2500 mm
Nm range 15 23-35 40 55 85-120
Motor series 215 223
232
240 255 285
2120
Arms series LD
(LD)
MD1
(PU)
MD2
(PF)
HD1
(P10)
HD2
(P12)
Exalto window wiper systems
Complete range of products
We o er a wide range of wiper systems
for all types of vessels, both leisure and
commercial. For the leisure market we
cover all windows with our LD and MD
wipers. For commercial use we have our
HD wipers to o er perfect wiping 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, with the
help of your local dealer close by you.
Dear Customer,
Thank you for buying our products.
Exalto wiper systems are designed and manufactured to the highest standards for marine
applications. We guarantee you a clear view for many years.
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MANUAL WIPER SYSTEMS

Declaration of conformity
Safety
1.1 introduction
1.2 environmental factors
1.3 modifi ed use and warranty conditions
2.1 general
2.2 electrical data
2.3 mechanical data
6.1 wiper does not work after
switching on
6.2 wiped area or park position is not
correct
6.3 motor runs, but arms do not move
4.1 preparations for fi rst use
4.2 normal operations
3.1 preparation
3.2 installation of mechanical parts
3.3 electrical installation
3.4 fi nal 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. Troubleshooting
4. Operation and use
3. Installation
5. Maintenance
7. Drawings and schematics
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Exalto type 223KG
MANUAL WIPER SYSTEMS

Use of the manual
Read the entire manual before installation. In this manual you can fi nd the following
expressions and symbols:
Hint!
Gives you advice on how to perform a task more easily.
Aention!
Alerts you to possible problems and safety warnings.
Safety
Exalto windscreen wipers are easy to install, yet a fair amount of technical knowledge
(mechanical and electrical) is required of the installer. Please consult the manual or
contact your vendor in case of doubt during installation or operation.
Main Precaution
Disconnect all 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 infl ict any personal dangers
or damage, provided that installation is done according to the procedures
specifi ed in the manual.
• Never remove covers or other safety provisions, unless maintenance is being
performed and all safety requirements are obeyed.
• The installer must provide all necessary covers.
• Always disconnect the electrical power when performing maintenance.
Prevent the installation from being started (accidentally) by others.
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MANUAL WIPER SYSTEMS

Safety provisions
The safety provisions will protect the user against contact with moving, electrical
or hot parts. Some of these have to be provided by the installer. There are several
safety provisions:
• Cover or panel (obligatory): covers moving parts and electrical connections.
The installer MUST provide a self-made cover or place the wiper behind a panel.
• Make sure the wiper has enough ventilation when placing it behind a panel or cover.
• Place a fuse (see specifi cations) 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.
• Handle the parts with care.
• Never install or maintain the wiper with the electrical voltage applied, unless this is
specifi cally mentioned in the manual.
• Clear your tools after installation.
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Exalto type 223KG
MANUAL WIPER SYSTEMS

1. Introduction
With this user manual we want to guide you in the installation and use of the Exalto
windscreen wiper. Please follow all instructions and install all safety provisions.
1.1 Introduction
Exalto windscreen 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
spindle housings with the self-lubricating bearings are made of naval brass. The wiper is
designed to be mounted on the glass. All moving parts are protected by an aluminium
housing. 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 substances are released when using or disassembling the wiper.
1.3 Modified use and warranty conditions
All modifi cations or defects in the product are subject to the Orgalime General
Conditions of Sale. Please contact your vendor in case of any questions or if you want
to use Exalto wipers in a non-maritime environment or other applications.
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MANUAL WIPER SYSTEMS

2. Technical data
2.1 General
• Product Exalto windscreen wiper
• Type 223KGO (Glass mounted, Disc adjustable, Open housing)
• Catalogue numbers XA2125 (12V)
XA2126 (24V)
2.2 Electrical data 12 Volt
• Torque (max.) 23 Nm
• Voltage 12 Volt
• Current 3 A
• Power consumption (max.) 36 W
• Number of revolutions Low speed 40 rpm, high speed 60 rpm
• Recommended cable 5 wires, 1½ mm² (16 g) or 2½ mm² (14 g) up to 10 m
long
• Recommended fuse 6 A slow blow
• Grounding Insulated earth return
2.2 Electrical 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, 1½ mm² (16 g) or 2½ mm² (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 = 150 x 119 x 90 mm
• Shaft diameters Drive shaft Ø 11 mm/support shaft Ø 8mm
at 50 mm ctrs
• Mounting Glass mounted only (max. 17 mm)
• Bearing T316 housing, self-lubricating
• Wiper arms Model MD1 (PU) up to 450 mm
• Wiper blades Up to 500 mm
• Wipe arc 40°-90°, adjustable per 5° increments
• Weight Approx. 2,30 kg
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Exalto type 223KG
MANUAL WIPER SYSTEMS

3. Installation
Before starting the installation read the chapter on safety. Check before installation that 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 will reduce the risk of damage and
loss of parts. Make sure all parts, tools and other means are ready.
3.2 Installation of mechanical parts
1. The wipe arc of your wiper is not pre-set unless specifi ed in the order and
manufacturing process. Please follow steps described in paragraphs 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
confi guration 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 the diagram below;
L
D
E
GH
GW
W
H
D= distance top side
glass to center
of spindles
E= eye level
GH = glass height
GW = glass width
H= vertical displacement
L= length of arm
W= width of wiped area
EXAMPLE
1000
900
800
700
600
500
400
300
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
40°
45°
50°
55°
60°
65°
70°
75°
80°
85°
90°
Wipe arc
Armlength (L)
Wiped area width (W)
Determination of wipe arc
Units in mm
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MANUAL WIPER SYSTEMS

3. Determine the place where the wiper is to be installed. The dimensions are shown
below. The wiper can be installed in any position above or below the window.
4. Place the windscreen wiper in the pre-drilled holes of the bulkhead (see fi gure). A rubber sealing
gasket must be placed at both sides of the bulkhead. Hole sizes are 1x clearance on M20,
1 clearance on M8 at 50 mm centers.
• The wipe arc-line closest to the intersection, shows the wipe arc;
• Find in the table below the vertical displacement of the blade (H);
Now the wiper blade length can be calculated: Length of wiper blade = 0.9 * 2 * (E-H).
90°
86
103
117
132
146
161
176
190
205
220
234
249
264
278
293
263
250
105
85°
92
79
119
132
145
158
197
184
171
210
223
236
94
80°
82
70
105
117
129
140
175
164
152
187
199
211
222
234
83
75°
73
62
93
104
114
124
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
Armlength (L)
350
300
450
500
550
600
750
700
650
800
850
900
950
1000
Determining the vertical displacement of the wiper blade
Wipe arc
Vertical displacement of the blade (H)
Units in mm
Aention!
When installing the wiper, reserve space for a housing or cover.
Bearing
Dogbone
Nut M10
Tightening 33Nm/24ft. lbs
Nut M8
Tightening 17Nm/12ft. lbs
Nut M11 Special
tightening torque 26Nm/19ft. lbs
Glass or Bulkhead
Rubber sealing plate
Pin
Hexagon locking nut
tightening torque 16.3Nm/12ft. lbs
Stainless steel sealing plate
Bearing
Rubber sealing plate
Glass or Bulkhead
Glass or Bulkhead
Rubber weathercap
Nut M8 Special
tightening torque 16.3/12ft. lbs
M8 washer
Tightening 16.3Nm/12ft. lbs
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Exalto type 223KG
MANUAL WIPER SYSTEMS

3.3 Electrical installation
3.4 Final installation
Aention!
Do not fi t the wiper arm before fi nishing the electrical connections.
Hint!
If you have doubts regarding the park
position, make a vane with tape to
simulate the position of the arms.
1. Install the wiper switch in the
dashboard.
2. Connect the wiper to the ship’s electrical
system. Use a cable with 5 wires with a
diameter of at least 1½ mm² (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 briefl y. Wait until the motor stops after
turning o the switch. The motor will be in park position. The standard park position is
shown in the fi gure under point 5.3.2.
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MANUAL WIPER SYSTEMS