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HTC DURATIQ T6 Workshop Manual

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Workshop manual
HTC DURATIQ T6, X6, T8, X8
English
950 - 001 -

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Summary of Contents for HTC DURATIQ T6

  • Page 1 Workshop manual HTC DURATIQ T6, X6, T8, X8 English 950 - 001 -...

  • Page 2: Table Of Contents

    Contents 1 Introduction 7 Repair and servicing 1.1 Document description..........3 7.1 Motor..............26 1.2 Target group............3 7.2 Tool holders ............30 1.3 Revisions..............3 7.3 Grinding head............30 1.4 Safety..............3 7.4 Radial shaft seal...........34 1.5 Servicing tools............3 7.5 Belt tensioner............35 7.6 Primary belt............

  • Page 3: Introduction

    WARNING: All personnel that repair or do servicing on the product must read and understand the safety instructions in this workshop manual. 1.5 Servicing tools The manual gives information about necessary servicing tools. Always use original tools from HTC. 950 - 001 - Introduction - 3...

  • Page 4: Safety

    2 Safety 2.1 Safety definitions 2.3 Special safety instructions Warnings, cautions and notes are used to point out The product has 2 emergency stop buttons. 1 specially important parts of the manual. emergency stop button is on the control panel and 1 is on the remote control.
  • Page 5 workplace and the persons at the workplace, equal voltage to the ground. Conductive mats and wristbands prevent electrostatic discharge when a charged part is touched. • It is recommended to use ESD shoes. 2.4.1 To prevent electrostatic discharge during servicing •...

  • Page 6: Servicing Data

    3 Servicing data 3.1 Symbols in the diagrams Tightening torque, Nm 6 - Servicing data 950 - 001 -...

  • Page 7: Tightening Torques Motor

    3.2 Tightening torques motor 950 - 001 - Servicing data - 7...

  • Page 8: Tightening Torques Grinding Head

    3.3 Tightening torques grinding head 8 - Servicing data 950 - 001 -...

  • Page 9: Tightening Torques Grinding Head

    3.4 Tightening torques grinding head T6:200 X6:230 T8:210 X8:210 950 - 001 - Servicing data - 9...

  • Page 10: Servicing Tools

    4 Servicing tools 4.1 Servicing tools overview Position Designation Used for Order No./Source ® Adhesive for threads – Loctite Grease To assemble the motor and grinding head. Molykote W2 Multi- purpose grease Circlip pliers General – Hex key, kit 2.5 - 10 mm General 525 45 52-01 Socket wrench...

  • Page 11: Servicing Tools Overview

    4.2 Servicing tools overview Position Designation Order No./Source Hub pulley tool 593 53 68-01 Press tool for the inner hub 593 54 09-01 Press tool for the outer center hub 595 75 94-01 Press tool for the radial seal 593 54 11-01 Press tool for the upper center hub 593 54 12-01 Press fixture for the center hub...

  • Page 12: Servicing Tools Overview

    4.3 Servicing tools overview Position Designation Order No./Source Press tool for the radial seal 593 54 21-01 Press tool for the center hub 593 54 40-01 Press tool for the center pulley 593 54 41-01 Press tool for the hub assembly 593 54 42-01 Support for the hub assembly tool 593 54 43-01...

  • Page 13: Servicing Tools Overview

    4.4 Servicing tools overview Position Designation Order No./Source Press tool for the hub assembly 593 54 30-01 Tilt support 593 58 41-01 Pin wrench 593 63 27-01 950 - 001 - Servicing tools - 13...

  • Page 14: Prepare And Do Servicing On The Product

    5 Prepare and do servicing on the product 5.1 To do a check of the firmware on the 3. Put the firmware for the main circuit board on USB 1 and put the control panel firmware on USB 2. machine 1.
  • Page 15 b) Move the fuse switches down. 4. The LED on the main circuit board starts to flash. 2. Put a USB memory stick into in to the USB 5. When the LED goes off, move the fuse switches connector on the main circuit board. down to stop the power.

  • Page 16: To Do An Update Of The Control Panel

    a) Move the fuse switches up. b) Push the stop button on the control panel. 2. Put the USB memory stick in to the USB connector on the control panel. b) Turn the battery switch counterclockwise. 3. Start the control panel. 5.4 To do an update of the control panel 1.

  • Page 17: To Do A Pairing Operation Between The Product And The Remote Control

    5.5 To do a pairing operation between the 4. The LED starts to flash. product and the remote control 1. Push the radio button on the control panel. 5. When the LED stop flash, remove the USB memory 2. Push the green button. stick.

  • Page 18: Function Overview

    6 Function overview 6.1 To clean and examine the product parts • Replace damaged or defective parts. • Clean and examine all parts fully. You find more • Always use original spare parts. instructions in the chapter for each part if special tools or procedures are necessary.

  • Page 19: Component Overview, Grinding Head

    6.3 Component overview, grinding head 1. Brush strip 5. Grinding head cover 2. Connection, vacuum hose 6. Tool plate 3. Connection, mist cooler system 4. Cable connection 6.4 Overview, control panel on the product 1. ON/OFF button for the product. 4.

  • Page 20: Overview Remote Control

    6. "OK" for approval of menu selections. To reset 14. Start and stop the dust extractor. distance gauge, press some seconds. 15. Clean the filter: Quickly press on the button to clean 7. Go back in the menu structure. 1 filter. Hold in the button to do a dust drain. 8.

  • Page 21: Overview Of The Receiver For The Remote Control

    7. Clean the filter: Quickly press on the button to to 17. Control for direction. D: forward, R: rearward, P: clean 1 filter. Hold in the button to do a dust drain. parking brake. 8. "EXTRA" : ON/OFF. 18. Control the left/right deviation of the product when it is in operation.

  • Page 22: Component Overview, Electrical Enclosure

    6.7 Component overview, electrical enclosure 1. Fan 24V DC 8. Fan package heatsink 2. Main circuit board 9. Heatsink 3. Power supply 10. Motor cable 4. MCB 11. Power cord 5. Switch 12. Plug M20 6. EMC filter 7. Frequency inverter 6.8 Overview, connection panel 22 - Function overview 950 - 001 -...

  • Page 23: Overview, Battery Charger

    1. Control panel. 7. Water supply valve. 2. Radio unit receiver. 8. Cooling fans. 3. CAN bus. 9. GPS. 4. Other equipment, 24 V. 10. Work lighting. 5. Other equipment 2. Used for future equipment. 6. Mist cooler system. 6.9 Overview, battery charger Symbol Signal Description...

  • Page 24: Display Overview

    6.10 Display overview 73 % 1001 H 24.0 V 1. The remote control is connected. 10. Time and date. 2. The front light is on. 11. Shows the quantity of power available. 3. The rear light is on. 12. Power meter. The power level indicator and the ring around it change color.

  • Page 25: Can Bus System

    6.11 CAN bus system 1. Connection panel 2. Remote control unit receiver 3. Powertrain 4. Remote control 5. Control panel on the product 950 - 001 - Function overview - 25...

  • Page 26: Repair And Servicing

    7 Repair and servicing 7.1 Motor 3. Pull the frame away from the motor and grinding head. 7.1.1 To remove the motor and the grinding head 1. Remove the weights from the frame. 2. Remove the screws and the top brackets. CAUTION: Do not pull the cable.
  • Page 27 5. Remove the cable from the motor connection box. 7.1.2 To remove the motor from the grinding head 1. Remove the screws. 6. Remove the frame from the motor and grinding 2. Remove the washers. head. 950 - 001 - Repair and servicing - 27...
  • Page 28 3. Remove the grinding head cover. 5. Remove the screws that hold the motor. 6. Remove the motor. 4. Remove the bottom brackets for the frame. 28 - Repair and servicing 950 - 001 -...
  • Page 29 7. Remove the motor plate and the grinding head cover 11. Put the removal tool into the center pulley. guide. 8. If the motor cannot be removed, use the removal tool. • 15 kW motors: 595 76 16-01 • 7.5 kW motors: 595 76 15-01 To open 9.

  • Page 30: Tool Holders

    7.2 Tool holders 7.3 Grinding head 7.2.1 To remove the tool holders 7.3.1 To open the grinding head 1. Remove the screws. 1. Loosen the belt tensioner screw. 2. Make sure that the line on the belt tensioner aligns with mark on the arrow. 2.
  • Page 31 3. Remove the 12 screws from the lid. 5. Tighten the removal tools for the grinding head. Refer to the picture and tighten in sequence from A to F. 6. Remove the lid from the housing. 4. Put removal tools for the grinding head in 3 of the holes.
  • Page 32 7. Remove the O-ring from the housing. 7.3.2 To close the grinding head 1. Install the new O-ring on the housing. 8. Discard the O-ring. 2. Make sure that the line on the belt tensioner aligns with the mark on the arrow. 32 - Repair and servicing 950 - 001 -...
  • Page 33 3. Put the lid on the housing. 5. Tighten the screws. Use a torque wrench. Refer to the picture and tighten in sequence from A to F. 4. Put the 12 screws in the 12 holes. 6. Use a torque wrench to adjust the belt tensioner. Hold the correct tension (B) and tighten the locknut (A).

  • Page 34: Radial Shaft Seal

    7.4 Radial shaft seal Note: Make sure that the flat side of the radial shaft seal points down in the lid. Refer to the picture. 7.4.1 To remove the radial shaft seals 1. Remove the radial shaft seals. Use a screwdriver. 2.

  • Page 35: Belt Tensioner

    7.5 Belt tensioner 7.5.2 To disassemble the belt tensioner 1. Remove the O-ring from the belt tensioner. 7.5.1 To remove the belt tensioner 1. Remove the belt tensioner from the housing. 2. Remove the idler shaft. 2. Remove the belt tensioner stop. 3.
  • Page 36 4. Remove the bearings from the idler pulley. Use a 3. Put the idler pulley into the belt tensioner. mandrel. 4. Put the idler shaft into the belt tensioner. 7.5.3 To assemble the belt tensioner 1. Push the bearings into the idler pulley. Use a force of 2000 kg.

  • Page 37: Primary Belt

    7.6 Primary belt 7.5.4 To install the belt tensioner 1. Install the belt tensioner in the housing. 7.6.1 To remove and install the primary belt 1. Remove the primary belt from the housing. 2. Install the belt tensioner stop. 2. Install in opposite sequence. Note: Make sure that the drive belt ribs align with the grooves on the pulley.

  • Page 38: Hub Assemblies

    7.7 Hub assemblies 3. Remove 1 hub assembly. If the hub assembly cannot be removed by hand, put an adapter on the hub shaft. 7.7.1 To remove the hub assembly 1. Remove the screws from the locking plates. Tool number: 593 58 39-01 4.
  • Page 39 7.7.2 To install the hub assemblies 4. Turn the secondary pulley to make it possible to install the other 2 hub assemblies. 1. Turn the secondary pulley to make it possible to install the hub assemblies. 5. Install 1 hub assembly. 2.
  • Page 40 7. Install the other hub assembly. 9. Install the washers. 8. Pull out the locking plates and install the screws. 7.7.3 To disassemble the hub assembly 1. Put the hub assembly in the hub pulley tool. 40 - Repair and servicing 950 - 001 -...
  • Page 41 Tool number: 593 53 68-01 4. Remove the pulley. 2. Install the bearing extractor bracket. Tool number: 593 54 52-01 3. Put the assembly in a press. Push in the bearing with the mandrel. 5. Put the shaft on the support. Tool number: 593 54 43-01 950 - 001 - Repair and servicing - 41...
  • Page 42 6. Remove the bearing with a press. 3. Put the hub assembly, the nut and the socket in the tool. 7.7.4 To assemble the hub assembly 1. Push the bearing onto the hub assembly. Use a force of 2000 kg. Use a press tool. Tool number: 593 54 17-01 4.

  • Page 43: Secondary Pulley

    7.8 Secondary pulley 5. Push the bearing with a support and a mandrel. 7.8.1 To remove the secondary pulley 1. Remove the screws for the secondary pulley. Tool number: 593 54 18-01 6. Install the washer and the nut. 2. Remove the secondary pulley. 950 - 001 - Repair and servicing - 43...
  • Page 44 7.8.2 To install the secondary pulley 7.8.3 To disassemble the secondary pulley 1. Install the secondary pulley. 1. Remove the bearing from the pulley center. Tool number: 593 54 30-01 2. Install the screws. 2. Remove the snap ring. 3. Push out the center pulley. Make sure that there is support below the area of the center hub.
  • Page 45 4. Push out the inner center hub. 7. Remove the bearing with a mandrel. 8. Remove the snap ring. 5. Remove the snap ring. 9. Remove the spacer. 6. Remove the bearing. 950 - 001 - Repair and servicing - 45...
  • Page 46 10. Remove the second bearing with a mandrel. 3. Install the spacer. 7.8.4 To assemble the secondary pulley 1. Push the bearing into the outer center hub with a force of 2000 kg. 4. Push the bearing with a force of 2000 kg. Tool number: 593 54 09-01 Tool number: 595 75 94-01 2.
  • Page 47 6. Put grease on the radial seal. 9. Push the inner and outer center hubs. Use the support cone and support. Tool numbers: 593 54 51-01, 593 54 13-01. Use Molykote W2 Multipurpose grease 10. Assemble the secondary pulley. 7. Push the bearing into the center hub. Tool number: 593 54 12-01.

  • Page 48: Idle Pulleys

    11. Install the secondary pulley on the center hub. 14. Install the snap ring. 12. Push the bearing onto the center pulley. 7.9 Idle pulleys 7.9.1 To disassemble the idle pulleys 1. Remove the idle pulley. Tool number: 593 54 12-01 13.
  • Page 49 3. Remove the bearings with a mandrel. Tool number: 593 54 19-01 2. Install the shaft and the snap ring. 7.9.2 To assemble the idle pulleys 1. Push the bearings with the mandrel. Use a force of 2000 kg. 950 - 001 - Repair and servicing - 49...

  • Page 50: S-Key

    7.10 S-key 5. Push in the new S-key and turn it clockwise. 7.10.1 To replace the S-key The S-key and the receiver card are purchased as a kit. The 2 units must be replaced at the same time. 1. Open the receiver for the remote control and replace the receiver card.

  • Page 51: Troubleshooting

    8 Troubleshooting 8.1 General Problem Cause Solution Display over- Error code is shown on the 1 of the alarm systems of the product is For more information refer to display. started. view on page 24 . The product has no connec- The CAN bus signal is broken.

  • Page 52: Error Codes

    8.5 Error codes The error messages and warnings are shown on the display on the product and/or the remote control. The display shows an error symbol and a description for the error. If the error message is yellow, you can continue to operate the product.
  • Page 53 Symbol Cause Solution A servicing of the product is necessary. Orange symbol: Servicing is necessary in the next 50 hours or 2 weeks. Red symbol: Servicing is not done in time. Speak to your servicing dealer. The water is low in the water tank. Fill water in the watertank.

  • Page 54: Diagrams

    9 Diagrams 9.1 Wiring diagram, electric box POWER SUPPLY 400/230 V Ground symbol GRN/YEL CONTACTOR 2.5mm EMC FILTER GRINDING MOTOR CIRCUIT BREAKER R− 2.5mm S− FREQUENCY INVERTER CIRCUIT BREAKER GROUND FAULT CIRCUIT INTERUPTER READ INSTRUCTIONS POWER −V −V +V +V SUPPLY 24VDC −...

  • Page 55: Wiring Diagram, Main Circuit Board

    9.2 Wiring diagram, main circuit board MAIN CIRCUIT BOARD CAN High CAN High CAN Low CAN Low 24VDC Out 1A (F1) 24VDC Out 1A (F1) 551007 /Cable HMI 24VDC E-Stop Sensor Out 24VDC E-Stop Sensor Out 24VDC E-Stop Sensor In 24VDC E-Stop Sensor In Not used COOLING FANS...
  • Page 56 2019-10-03...

This manual is also suitable for:

Duratiq x6Duratiq t8Duratiq x8

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