HTC 500 Service Manual
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HTC 500 Service Manual

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Service Manual

HTC 500, 650 & 800
v.3
HTC Sweden AB
www.htc-sweden.com

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Summary of Contents for HTC 500

  • Page 1: Service Manual

    Service Manual HTC 500, 650 & 800 HTC Sweden AB www.htc-sweden.com...

  • Page 3: Introduction

    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.

  • Page 4: Table Of Contents

    CONTENTS Introduction ........................... 3 Technical data HTC 500, HTC 650 and HTC 800 ..............5 Exploded diagram, HTC 500 ....................6 Exploded diagram, HTC 500 ....................7 Parts list, HTC 500 ....................... 8 Exploded diagram, HTC 650 ....................11 Exploded diagram grinding holder, HTC 650 ..............12 Parts list, HTC 650 ......................

  • Page 5: Technical Data Htc 500, Htc 650 And Htc 800

    Technical data HTC 500, HTC 650 and HTC 800 HTC 500 Model: HTC 502E HTC 504E HTC 504S Motor output 2.2 kW 4.0 kW 4.0 kW Current: 10 Amp 16 Amp 16 Amp Voltage: 220 V 3x380 V 3x380 V...

  • Page 6: Exploded Diagram, Htc 500

    Exploded diagram, HTC 500...

  • Page 7: Exploded Diagram, Htc 500

    Exploded diagram, HTC 500...

  • Page 8: Parts List, Htc 500

    310009 WATER VALVE TO GRINDER 110007 SCREW M6S M5X20 GALV 310010 WHEEL FITTING KIT 110008 WHEEL HTC 650 WKCP 2803 6553 110350 also 110381, wheel HTC 500 MOTOR 4 different models SCREW M6S M12X25 GALV 310011 WASHER BRB M12 GALV 310003 SCREW MC6S M6X10 8.8 GALV...
  • Page 9 SCREW MFT-TT M6X16 8.8 GALV 310014 UPPER COVER HTC 500 110022 FIXING BOSS, NON-ZINC 110023 SCREW MFT-TT M6X25 8.8 GALV 310025 BEARING CUP, TOP CENTRE HTC 500 110024 BALL BEARING 6012-2RS C3 110026 BEARING CUP, BOTTOM CENTRE 500 110027 CIRCLIP SGA 60 310018...
  • Page 10 HUB COVER HTC 500 110049 SCREW MFT-TT M6X25 8.8 GALV 310025 CYLINDER PIN CP 6X20 H8 310046 CIRCLIP SGA 60 310018 SGRINDING HOLDER UPPER HTC 500 110050 HOLDER, POLYCORD, OUTER 110051 SCREW MC6S M6X16 8.8 GALV 310082 PAD, POLYCORD GREEN 168MM 110370...

  • Page 11: Exploded Diagram, Htc 650

    Exploded diagram, HTC 650...

  • Page 12: Exploded Diagram Grinding Holder, Htc 650

    Exploded diagram grinding holder, HTC 650...

  • Page 13: Parts List, Htc 650

    SCREW M6S M12X65 GALV 310034 NUT NYLOCK M12 GALV DIN985 310004 CHASSIS HTC 650 BOTTOM 110643 WHEEL FITTING KIT 110008 WHEEL HTC 650 WKCP 2803 6553 110350 WATER VALVE TO GRINDER 110007 SCREW M6S M5X20 GALV 310010 WATER TANK HTC 650/800 110069 MOTOR 7.5 DPIG 132M-4 200/346...

  • Page 14: Parts List, Htc 650

    BALL BEARING 6207 2RS C3 110078 TENSIONING WHEEL HTC 650 110079 BELT, INNER S-250 HTC 650 110080 BELT, INNER S-250 HTC 650 SOFT START 110376 BALL BEARING 6207 2RS C3 110078 CIRCLIP SGA 35 310038 SCREW MFT-TT M6X16 8.8 GALV...

  • Page 15: Parts List, Htc 650

    Parts list, HTC 650 Pos. Description Part No. Remarks -------- BALL BEARING 6207 2RS C3 110078 BEARING CUP PULLEY UPPER HTC 650 110086 CIRCLIP SGA 40 310043 SHAFT, PULLEY 110093 WEDGE RK 12X8X40 310044 WEDGE RK 12X8X30 310045 PULLEY HTC 650 50X180...

  • Page 16: Exploded Diagram Htc 800 (Models Built Before Year 2000)

    Exploded diagram HTC 800 (models built before year 2000)
  • Page 17 Exploded diagram HTC 800 (models built before year 2000)

  • Page 18: Parts List Htc 800 (Models Built Before Year 2000)

    Parts list HTC 800 (models built before year 2000) Pos. Description Art.No: Remarks CHASSIS HTC 650/800 HANDLE 110057 CONSOLE CONTROL PANEL 110058 SCREW RXS B10X16 GALV 310029 SCREW MC6S M6X12 8.8 GALV 310030 WASHER BRB M6 GALV 310012 WIRING HOLDER (CLIP) JR12...
  • Page 19 Parts list HTC 800 (models built before year 2000) Pos. Description Art.No: Remarks SCREW M6S M12X45 GALV 310037 BELT RING HTC 800 110105 BELT, UPPER S-140 HTC 800 110106 SCREW MFT-TT M6X16 8.8 GALV 310014 SCREW M6S M10X25 GALV 310114...
  • Page 20 Parts list HTC 800 (models built before year 2000) Pos. Description Art.No: Remarks WEDGE RK 12X8X40 310044 WEDGE RK 12X8X30 310045 PULLEY HTC 650 50X180 110118 CIRCLIP SGA 40 310043 BEARING CUP PULLEY LOWER HTC650 110094 CIRCLIP SGA 60 310018...

  • Page 21: Exploded Diagram - Htc 800 E

    Exploded diagram - HTC 800 E...
  • Page 22 Exploded diagram - HTC 800 E...
  • Page 23 Exploded diagram - HTC 800 E...
  • Page 24 Exploded diagram grinding holder, HTC 800...

  • Page 25: Parts List - Htc 800 E

    Parts list - HTC 800 E Pos. Description Part No. Remarks CHASSIS HTC 650/800 HANDLE 110057 SHRINK TUBING TO HTC HANDLE 110308 COVER PLUG TO HTC HANDLE 110357 CONSOLE CONTROL PANEL 110058 SCREW RXS B10X16 GALV 310029 CONTROL PANEL, COMPLETE...
  • Page 26 Parts list - HTC 800 E Pos. Description Part No. Remarks SCREW not available CONNECTOR, MALE, MOTOR as specified ELECTRICAL CABLE, MOTOR as specified CONTROL PANEL CABLE as specified CONTROL PANEL CABLE as specified WATER TANK HTC 650/800 110069 NUT 1253-3/8 (T-HOSE CONNECTOR)
  • Page 27 Parts list - HTC 800 E Pos. Description Part No. Remarks SCREW MFT-TT M6X16 8.8 GALV 310014 BEARING CUP MOTOR PLATE HTC 800 110151 BALL BEARING 6314-2RS C3 110174 UPPER COVER HTC 800 (NEW) 110325 SCREW MC6S M8X16 GALV 8.8...
  • Page 28 Parts list - HTC 800 E Pos. Description Part No. Remarks 104A CYLINDER PIN CP 6X20 H8 310046 104B GRINDING HOLDER UPPER HTC 650/800 110098 104C HOLDER, POLYCORD, OUTER 110099 104D SCREW MC6S M6X16 8.8 GALV 310082 PAD, POLYCORD BLACK 184MM...

  • Page 29: Exploded Diagram - Htc 800 Hd

    Exploded diagram - HTC 800 HD...
  • Page 30 Exploded diagram - HTC 800 HD...
  • Page 31 Exploded diagram - HTC 800 HD...
  • Page 32 Exploded diagram grinding holder, HTC 800 HD...

  • Page 33: Parts List - Htc 800 Hd

    Parts list - HTC 800 HD Pos. Description Art.No: CHASSIS HTC 650/800 HANDLE 110057 SHRINK TUBING TO HTC HANDLE 110308 COVER PLUG TO HTC HANDLE 110357 CONSOLE CONTROL PANEL 110058 SCREW RXS B10X16 GALV 310029 CONTROL PANEL, COMPLETE 110122 EMERGENCY STOP, COMPLETE XB4...
  • Page 34 Parts list - HTC 800 HD Pos. Description Art.No: SCREW not available CONNECTOR, MALE, MOTOR as specified ELECTRICAL CABLE, MOTOR as specified CONTROL PANEL CABLE as specified CONTROL PANEL CABLE as specified WATER TANK HTC 650/800 110069 NUT 1253-3/8 (T-HOSE CONNECTOR)
  • Page 35 Parts list - HTC 800 HD Pos. Description Art.No: WASHER BRB M12 GALV 310003 NUT NYLOCK M12 GALV DIN985 310004 BELT RING HTC 800 NEW 110143 BELT, UPPER, HTC 800 NEW MODEL 110126 SCREW MFT-TT M6X16 8.8 GALV 310014 BEARING CUP MOTOR PLATE HTC 800...
  • Page 36 Parts list - HTC 800 HD Pos. Description Art.No: TERMINATION PLUG BRASS M25 M25 110138 SCREW MC6S M6X12 8.8 GALV 310030 GRINDING HOLDER, COMPLETE, HTC 800 110603 GRINDING HOLDER, COMPLETE, HTC 800EZ 111244 108A CYLINDER PIN CP 6X20 H8 310046...

  • Page 37: Changing The Inner Belt, Htc 500/650/800

    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).
  • Page 38 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.
  • Page 39 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.
  • Page 40 Fig. 12 37. 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. 13 Fig.

  • Page 41: Changing The Upper Belt, Htc 500

    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.

  • Page 42: Changing The Upper Belt, Htc 650/800

    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.

  • Page 43: Overhauling The Grinding Holders

    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.
  • Page 44 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. Inner polycord holder Upper grinding holder Inner grinding holder, polycord and upper grinding holder Lower grinding...

  • Page 45: Maintenance

    Scrape and vacuum the parts that are enclosed by the cover. Check the upper belt. Change as needed. • Check the seals of 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). •...

  • Page 46: Troubleshooting

    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. •...

  • Page 47: Electronic Error Codes - Hitachi

    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...

  • Page 48: Checking The Latest Error Code - Hitachi

    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 ma- chine.

  • Page 49: Special Tools

    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 •...
  • Page 52 HTC SWEDEN AB Box 69 614 22 Söderköping, Sweden Tel: +46 (0) 121-294 00 Fax: +46 (0) 121-152 12 www.htc-sweden.com...

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