Exalto 255BSS User manual

Exalto type 255BSS - 1
Exalto windscreen wiper type 255BSS
(Item no. 211255.35S/211255.65S -12V - 212455.35S/212455.65S - 24V)
User manual for

- Exalto type 255BSS
2
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.
Complete range of products
We oer a wide range of wiper systems for all types of vessels, both leisure and com-
mercial. 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.

Exalto type 255BSS - 3
Contents
Safety
1. Introduction
1.1 introduction
1.2 environmental factors
1.3 modied use and warranty conditions
2. Technical data
2.1 general
2.2 electrical data
2.3 mechanical data
3. Installation
3.1 preparation
3.2 installation of mechanical parts
3.3 electrical installation
3.4 nal installation
4. Operation and use
4.1 preparations for rst use
4.2 normal operations
5. Maintenance
5.1 general maintenance
5.2 servicing
5.3 changing the wiping arc and park position
5.4 disassembly and assembly
6. Troubleshooting
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
7. Drawings and schematics
7.1 assembly overview
7.2 parts list
7.3 connection table
7.4 wiring diagrams for switches and control systems
Declaration of conformity

- Exalto type 255BSS
4
Use of the manual
Read the entire manual before installation. In this manual you can nd 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.
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 inict any personal dangers
or damage, provided that installation is done according to the procedures
speci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.

Exalto type 255BSS - 5
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 speci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 specically mentioned in the manual.
• Clear your tools after installation.

- Exalto type 255BSS
6
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 re-
sistant materials. The spindle housings with the self-lubricating bearings are made of
naval brass. The wiper is designed to be mounted through the bulkhead above or be-
low the window. The wipe arc is step less adjustable from 45° to 90°. By standard the
model can be supplied for a bulkhead thickness of 35 mm and 65 mm. The matching
Exalto MD1 Pendulum arms have adjustable lengths between 300 mm and 750 mm
in length (suitable for wiper blades upto 750 mm). The wiper arm 2143.1000B is suita-
ble for length between 750 mm and 1000 mm in length and suitable for wiper blades
850-1000 mm. 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 Modied use and warranty conditions
All modications or defects in the product are subject to the Orgalime General Con-
ditions 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.

Exalto type 255BSS - 7
2. Technical data
2.1 General
• Product Exalto windscreen wiper
• Type 255BSS (Bulkhead tting, step less adjustable)
• Catalogue numbers 211255.35S - 211255.65S (12V)
212455.35S - 212455.65S (24V)
2.2 Electrical data 12 Volt
• Torque (max.) 55 Nm
• Voltage 12 Volt
• Current 7 A
• Power consumption (max.) 85 W
• Number of revolutions Low speed 38 rpm, high speed 60 rpm
• Recommended cable 5 wires, 1½ mm² (16 g) or 2½ mm² (14 g) up to 10 m
length
• Recommended fuse 8 A slow blow
• Grounding Insulated earth return
Electrical data 24 Volt
• Torque (max.) 55 Nm
• Voltage 24 Volt
• Current 4 A
• Power consumption (max.) 96 W
• Number of revolutions Low speed 38 rpm, high speed 60 rpm
• Recommended cable 5 wires, 1½ mm² (16 g) or 2½ mm² (14 g) up to 10 m
length
• Recommended fuse 6 A slow blow
• Grounding Insulated earth return
2.3 Mechanical data
• Dimensions L x w x h = 250 x 126,7 x 126 mm
• Shaft diameters Drive shaft Ø 20 mm no support shaft
• Mounting Through glass or bulkhead (35 mm and 65 mm)
• Bearing Bronze housing, self-lubricating
• Wiper arms Model MD1 pendulum or HD1 pendulum
• Wiper blades Up to 1200 mm
• Wipe arc Slotted lever 40°-90°, step less adjustable
• Weight Approx. 4,80 kg

- Exalto type 255BSS
8
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 specied in the order and manu-
facturing 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 con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;
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
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

Exalto type 255BSS - 9
Bearing
Dogbone
Nut M10
Tightening 33Nm/24ft. lbs
Nut M8
Tightening 17Nm/12ft. lbs
Hexagon nut
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
tightening torque 16.3/12ft. lbs
M8 washer
Nut M8
Tightening 16.3Nm/12ft. lbs
Hexagon nut
Tightening 26Nm/19ft. lbs
• The wipe arc-line closest to the intersection, shows the wipe arc;
• Find in the table below the vertical displacement of the blade (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
Now the wiper blade length can be calculated: Length of wiper blade = 0.9 * 2 * (E-H).
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.
Attention!
When installing the wiper, reserve space for a housing or cover.
4. Place the windscreen wiper in the pre-drilled holes of the bulkhead (see gure). A
rubber sealing gasket must be placed at both sides of the bulkhead. A second-
ary xing is required and we advise to bond or mechanically install a secondary
xing at the opposite end of the housing.

- Exalto type 255BSS
10
Attention!
Do not t the wiper arm before nishing the electrical connections.
3.3 Electrical installation
1. Install the wiper switch in the
dashboard.
2. Connect the wiper to the
ship’s electrical system; see
from page 18 and the colour
codes at page 19. 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.
3. Fit a slow blow fuse of 8A (12 Volt) or 6A (24 Volt) in the main cable (positive).
4. Connect the switch to the wiper (refer to the switch manual for installation).
3.4 Final installation
1. Switch on the power and test the motor briey. Wait until the motor stops after
turning o the switch. The motor will be in park position. The standard park posi-
tion is shown in the gure under point 5.3.2.
Hint!
If you have doubts regarding the park position,
make a vane with tape to simulate the position
of the arms.

Exalto type 255BSS - 11
90°
90°
Bearing
Dogbone
Nut M10
Tightening 33Nm/24ft. lbs
Nut M8
Tightening 17Nm/12ft. lbs
Arc Disc
Spindle Lever
Half Nut M8
Tightening 17Nm/12ft. lbs
Pin
Tightening 16.3Nm/12ft. lbs
Hexagon 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
Attention!
This wiper model 255 is suita-
ble for wiper arms model MD1
pendulum or HD1 pendulum up to 1000
mm and wiperblades up to 1200 mm.
Attention!
To ensure the arm has the right
spring pressure, install the wip-
er arm in such a way that the shaft makes
a 90° angle with the window (gure left)
and that the shaft makes a 90° angle with
the wiper arm (gure right). If this is not
the case, please install spacer(s) to make
the 90° angles.
1. Place the wiper arm and blade as-
sembly on the shafts. Fasten the nuts
loosely onto the shafts.
2. Switch on the power and test the mo-
tor briey again to check the wiped
area.
3. When the wipe arc is correct, adjust the position and the length of the arm if nec-
essary. Tighten the nuts to the correct torque (33Nm/25ft.lbs).
4.0 Operation & Use
4.1 Preparation for rst use
When the wiper has been installed and adjusted, the system can be prepared for rst
use. We recommend a thorough inspection of the system to ensure proper operation.
Check:
• there are no leaks where the shafts go through the bulkhead;
• the wiping arc cleans the entire window;
• the park position is correct.
If the wiping arc or the park position is wrong, adjust them again. Follow the procedure
in paragraph 5.3.

- Exalto type 255BSS
12
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 switch to learn about the functions of that specic
switch. In the back of this manual you will nd some general controls and its wiring
instructions.
5.0 Maintenance
5.1 General maintenance
To keep the Exalto wiper in good condition, you are advised to:
• clean wiper arms and blades with fresh water after every journey in salt water
(to prevent salt from clogging moving parts);
• never use the wiper on a dry window.
5.2 Servicing
As long as the wiper system functions normally and is kept in good shape (see
paragraph 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 qualied 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 arms from the shafts;
2. Move the screw in the slot from the shaft lever away from the shaft for a smaller
and towards the shaft for a larger wipe arc;
3. Fasten the nut again (33Nm/25 ft.lbs);
4. Place the motor lever in the desired park position (see paragraph 5.3.2).

Exalto type 255BSS - 13
Retaining Ring
Half Nut M8
Tightening 17Nm/12ft. lbs
Drive Shaft
Pin
Nordlock
Bearing
Dogbone
Bolt M10x35
Dogbone
Washer
Motorlever
Nordlock
Nut M6
Tightening 6.8Nm/5ft. lbs
Nordlock
Bolt M6x25
Nut M10
tightening 33Nm/24ft. lbs
Nordlock
Bolt M10x35
Half Nut M10
tightening 33Nm/24ft. lbs
Nut M10
tightening 33Nm/24ft. lbs
5.3.2 Adjusting the park position
1. Place the motor lever loose on the shaft, parking right or left (see drawing in para-
graph 3.4 and below for reference);
2. Place the motor lever in such a way that it forms an almost straight line with the
connection lever (see drawing);
3. Tighten the motor lever well;
4. Place the wiper in the bulkhead;
5. Install the wiper arm in correct parking position.
Not correct Not correct
Correct Correct

- Exalto type 255BSS
14
5.4 Disassembly and assembly
Prevent injuries when disassembling by disconnecting the wiper from the power
supply. Keep all necessary tools within reach and remember the chapter on safety.
Provide protective packaging, if you’re going to store or transport the wiper assembly.
5.4.1 Removing the wiper assembly from the bulkhead
1. Disconnect all the electric connections to the wiper;
2. Remove the wiper arms;
3. Remove the nuts (see 7.1, nr 24) and plates (nr 21 and 22) on the
outside;
4. Remove the wiper from the holes in the bulkhead;
5. If you want to replace the wiper, follow chapter 3.
5.4.2 Disassembling the drive crank lever
1. Disconnect all the electric connections to the wiper;
2. Remove the wiper from the bulkhead (see 5.4.1);
3. Unscrew the nut (see 7.1, nr 18) and bolt (nr 17) on the shaft (nr 16) and remove
the lever;
4. For adjusting the wipe arc, follow section 5.3.
5.4.3 Removing the motor from the wiper assembly
1. Disconnect all the electric connections to the wiper;
2. Remove the wiper arm (see 5.4.1);
2. Disassemble the drive crank lever (nr 16) from the motor;
3. Unscrew the three bolts of the motor (see 7.1, nr 4) and remove the motor;
4. When replacing, bolt the motor on the housing and follow section 5.3 to
install the drive crank lever and set to the correct park position.
Bearing
Dogbone
Nut M10
Tightening 33Nm/24ft. lbs
Nut M8
Tightening 17Nm/12ft. lbs
Arc Disc
Spindle Lever
Half Nut M8
Tightening 17Nm/12ft. lbs
Pin
Tightening 16.3Nm/12ft. lbs
Hexagon socket head cap screw
Tightening 8Nm/6ft. lbs
Bearing
Spacer
Glass or Bulkhead
Glass or Bulkhead
Glass
Glass
Tightening 4.5Nm/3.3ft. lbs
Tightening 16.3Nm/12ft. lbs

Exalto type 255BSS - 15
Troubleshooting
In this chapter, several malfunctions are mentioned combined with possible causes
and solutions. Please leave servicing to qualied mechanics.
6.1 Wiper does not work after switching on
• Possible causes:
1. Wiper switch is not working properly.
Solution: Test and replace it. Check if the current is (and keeps being) too high.
2. Burned or incorrectly sized fuse.
Solution: Test and replace it. Check if the current is (and keeps being) too high
3. Electrical connections are wired incorrectly or might be damaged.
Solution Measure 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 rst.
Solution: Remove the wiper arm. Run the motor to the park position and re-install the
arm.
2. The wipe arc is set wrong or has changed due to high loads (e.g. spring pressure
of arms too high, excessive drag).
Solution: Determine the wiping arc if needed (see paragraph 5.4) and set the wiping arc
again (see paragraph 5.3).
3. The wires are connected incorrectly.
Solution: Check and reconnect the wiring (see the scheme in paragraph 3.3).
6.3 Motor runs, but the wiper arm does not move
• Possible causes:
1. Mechanical joints 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.

- Exalto type 255BSS
16
Drawings & Schematics
7.1 Assembly overview
21 18 20 13 9 7 17 16 8 3 1
6
4
12
22
14
7
5
6
2
6
11
79 22
15 12 23 19
Pos.
Park/QTY.
Description
PartNo/Note
Material
Weight
23 1 Lock washer 10mm Large
2100.412L
1.4401 - SS316
0.004
22 2
Hexagon bolt
0933A410035
1.4401 - SS316
0.034
21 1
Self-locking nut
0985A408 1.4401 - SS316
0.006
20 1
Weathercap M20
2100.361
Rubber
0.005
19 1
Washer
0125A410 1.4401 - SS316
0.004
18 1
Washer
0125A408 1.4401 - SS316
0.002
17 1
Washer
0125A420 1.4401 - SS316
0.017
16 2
Rubber ring Ø36.5×21×2mm
2197.095
Rubber
0.001
15 1
Wisas 255 WD 35
2197.103_A
1.4404 - SS316 L
0.28
14 1
Connecting rod Ø10 L=175
2100.939
-
0.181
13 1
circlip 12mm
0471A2012
1.4401 - SS316
0.000
12 2
Nut M10
0934A410 1.4401 - SS316
0.011
11 1
Nut M6
0934A406 1.4401 - SS316
0.002
10 1
Drive crank complete 36.3
2197.081_B
Gepassiveerd
0.074
9 2
filling ring
2100.400
1.4401 - SS316
0.001
8 1
Lagerbus 255BS 255 WD 35mm
2197.157
Brass
0.214
7 4
Nut M20x1
2100.350
1.4401 - SS316
0.003
6 5
Lock washer 6mm
2100.413
1.4401 - SS316
0.001
5 1
Hexagon bolt
0933A406025
1.4401 - SS316
0.009
4 3
Hexagon bolt
0933A406016
1.4401 - SS316
0.007
3 1
Block plug
2178.003 - C180906 ABS PC
0.010
2 1
Motor 12Volt 55Nm
2100.1255RHD-A
3.2315 - EN-AW 6082
1.830
1 1
Housing 255BS
2197.035
1.0037 (S235JR) passivated
1.415

Exalto type 255BSS - 17
7.2 Parts list
Pos. QT Y. Description Part nr/Note
1 1 Wiper housing for 255BS 2197.035
2 1 Exalto Motor 12V 55Nm RHD 2100.1255RHD-A
1 Exalto Motor 24V 55Nm RHD 2100.2455RHD_A
3 1 Plug for 223BD/223BS 2178.003 - C180906
4 3 Hexagon head bolt s.s. M6x16 (A4) 0933A406016
5 1 Hexagon head bolt s.s. M6x25 (A4) 0933A406025
6 5 Lock washer 6mm 2100.413
7 4 Nut M20x1 2100.350
8 1 Bearing house 255BS bh = 35mm 2197.157
1 Bearing house 255BS bh = 65mm 2.197.187
9 2 Plain washer s.s. M12x1,0 2100.400
10 1 Drive crank L=36,3mm for 255BS 2197.081_B
11 1 Nut s.s. M6 A4 din934 0934A406
12 2 Nut s.s. M10 A4 din934 0934A410
13 1 circlip 12mm 0471A2012
14 1 Connecting rod Ø10 L=175 2100,939
15 1 Spindle with lever and pin bh = 35mm 2197.103_A
1 Spindle with lever and pin bh = 65mm 2197.104_A
16 2 Rubber ring Ø36.5×21×2mm 2197.095
17 1 Ring-DIN125A-A4-M20 0125A420
18 1 Ring-DIN125A-A4-M8 0125A408
19 1 Ring-DIN125A-A4-M10 0125A410
20 1 Weathercap M20 2100.361
21 1 Self-locking nut M8 0985A408
22 2 Hexagon head bolt s.s. M10x35 (A4) 0933A410035
23 1 Lock ring M10x21mm 2100.412L

- Exalto type 255BSS
18
7.3 Motor Wiring Schematic - Connection data
7.4 Wiring diagrams for switches and control systems.
Exalto wiper motors can be connected through a wide variety of simple switches to
complex controllers. Below you will nd some connection wiring diagram examples
of Exalto switches and controllers. Please refer for detailed instructions to the specic
switch or controller manual.

Exalto type 255BSS - 19
Switch 2134 & 2135:

- Exalto type 255BSS
20
Carling switching VEB1:
(Exalto number 70906425.SET) as per following details which is wiper switch specic.
For a standard 3 stage switch of Carling or alternative this scheme below has to be
used. This scheme can also be used for the case of digital switching modules with
only simple output channels.