HTC 650 Service Manual
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HTC 650 Service Manual

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Service Manual

HTC 650, 800 & 950
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HTC Sweden AB
www.htc-sweden.com

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Summary of Contents for HTC 650

  • Page 1: Service Manual

    Service Manual HTC 650, 800 & 950 X models HTC Sweden AB www.htc-sweden.com...

  • Page 3: Introduction

    Introduction Contact HTC or your nearest retailer if you have any questions or quiries. Make sure to have the serial number of your machine available when you call, since all machines are registered and this helps us provide you with the best possible service. The serial number is located on the right-hand side of the chassis (seen from behind) and on the right-hand fixing lug.

  • Page 4: Table Of Contents

    Maintenance HTC 650, HTC 800 and HTC 950 RX ..............54 Troubleshooting HTC 650 and HTC 800 ..................55 Electronic error codes HTC 650 and HTC 800 - Hitachi ............. 56 Checking the latest error code - Hitachi ..................57 Troubleshooting HTC 950 RX .......................

  • Page 5: Technical Data Htc 650, Htc 800 And Htc 950

    Technical data HTC 650, HTC 800 and HTC 950 650 HDX 0 kg Weight: 190 kg Weight chassis: 650 mm HTC 650 Grinding diameter: 250 kg Weight grinding head: 270 kg Grinding pressure weights forward: 200 kg Grinding pressure weights back:...

  • Page 6: Exploded Diagram, Htc 650 Chassis

    Spacer screw HTC 650 10255 Screw MC6S M6X16 8.8 galvanised 10082 Screw MC6S M85 8.8 galvanised 10189 10 Wear protection upper HTC 650 1110 11 Screw thermoplastic PT WN 152 TX 1018 12 Washer BRB M6 galvanised 10012 1 Washer BRB M8 galvanised...
  • Page 7 Parts list, HTC 650 chassis cont. No. Description Art. No. 1 Screw MC6S M8x16 8.8 galvanised 8.8 10080 15 Screw MFT M6x16 galvanised 8.8 10251 16 Wear protection, weight stop 11181 17 Drive mechanism, HTC 650 11111 18 Washer BRB M2 galvanised...

  • Page 8: Exploded Diagram, Htc 650 Mist Cooler System

    Exploded diagram, HTC 650 Mist Cooler System Parts list HTC 650 Mist Cooler System No. Description Art. No. Screw MC6S M5x12 1010 Hose connection 2601-12-1/ 110205 Elbow piece MF -2020-1/ 11016 Water valve 110007 Hose large reinforced PVC 0.7m 11010...
  • Page 9 Parts list HTC 650 Mist Cooler System cont. No. Description Art. No. 17 Nut nylock M6 galvanised DIN985 10072 18 Pump EH-C15VC-PR2-IPVC 1119 19 Screw MC6S MC6S M6x16 8.8 galvanised 10082 20 Rubber hose 1.5 m 11199 21 Cable clips 8 mm with M8 hole...

  • Page 10: Exploded Diagram, Htc 650 Handle

    Exploded diagram, HTC 650 handle Parts list, HTC 650, handle No. Description Art. No. Screw MC6S M6X16 8.8 galvanised 10082 Washer BRB M6 10012 Packing control panel 111166 Console instrument panel HTC 800 111289 Handle HTC 950 1110 Nut M6M M5 galvanised...
  • Page 11 Parts list, HTC 650, handle cont. No. Description Art. No. 15 Handle ball HTC 950 11108 16 Pin HTC 950 111028 17 Screw MC6S M6X16 8.8 galvanised 10082 18 Washer BRB M6 10012 19 Sprint chassis HTC 950 11102 20 Spring HTC 950...

  • Page 12: Exploded Diagram, Htc 650 Drive Mechanism

    Exploded diagram, HTC 650 drive mechanism Parts list, HTC 650 drive mechanism No. Description Art. No. Screw MC6S M12x25 galvanised 8.8 10175 Washer BRB M12 galvanised 10057 Pulling anchorage HTC 650 11189 Drive mechanism, HTC 650 11111 Wheel HTC 650...

  • Page 13: Exploded Diagram, Htc 650 Grinding Head

    Fixing lug 11177 Motor plate HTC 650 (-0) 111072 Belt ring part 1 HTC 650 (-0) 1118 10 Belt ring part 2 HTC 650 (-0) 1119 11 Screw MFT 6x16 1001 12 Screw MC6S M8x20 8.8 galvanised 10161 1 Hub Motor plate HTC 650 (-0)
  • Page 14 Parts list, HTC 650, grinding head cont. No. Description Art. No. Qty 1 Nilos ring 6017 JV 110950 15 Bearing cup 110917 16 Ball bearing 6017-2RS1 C 110951 17 Screw MC6S M8x120 galvanised 12.9 1025 18 Circlip SGA 85 10166...

  • Page 15: Exploded Diagram, Htc 650 Grinding Holder

    Exploded diagram, HTC 650 grinding holder Parts list, HTC 650 grinding holder (1x4) No. Description Art. No. Grinding holder, upper HTC 950 11098 Polycord holder, outer HTC 9500 110958 .1 Pad, polycord black 18 mm 11071 .2 Pad, polycord, green 18 mm...

  • Page 16: Exploded Diagram, Htc 800 Chassis

    11155 Hose large reinforced PVC 11110 Water valve to grinder 110007 Handle complete HTC 800 CE 1117 Power unit 11kW HTC 800 EX 11106 Chassis HTC 800 HDX 11122 Screw MC6S M85 8.8 galvanised 10189 Screw MC6S M6X16 8.8 galvanised...
  • Page 17 10189 Wear protection lower HTC 950 11100 Screw thermoplastic PT WN 152 TX 1018 Washer BRB M6 galvanised 10012 Shaft for chassis grinding holder HTC 950 11118 Bushing BM25 1111 Locking pin LSR 25 102 Screw M6S M12x5 galvanised 1007...

  • Page 18: Exploded Diagram, Htc 800 Mist Cooler System

    Exploded diagram, HTC 800 Mist Cooler System Parts list HTC 800 Mist Cooler System No. Description Art. No. Screw MC6S M5x12 1010 Hose connection 2601-12-1/ 110205 Elbow piece MF -2020-1/ 11016 Water valve 110007 Hose large reinforced PVC 0.7m 11010...
  • Page 19 Parts list HTC 800 Mist Cooler System cont. No. Description Art. No. 17 Nut nylock M6 galvanised DIN985 10072 18 Pump EH-C15VC-PR2-IPVC 1119 19 Screw MC6S MC6S M6x16 8.8 galvanised 10082 20 Rubber hose 1.5 m 11199 21 Cable clips 8 mm with M8 hole...

  • Page 20: Exploded Diagram, Htc 800 Handle

    Washer BRB 5,x10x1 1019 Connecting plate elec. HTC 950 111010 Screw MC6S M6X16 8.8 galvanised 10082 10 Control casing lower HTC 950 1110 11 Washer BRB M6 10012 12 Screw MC6S M6X16 8.8 galvanised 10082 1 Wall inlet 2A 6-15V 5P RED...
  • Page 21 Parts list, HTC 800, handle cont. No. Description Art. No. 1 Screw MC6S M5x20 galvanised 10185 15 Handle ball HTC 950 11108 16 Pin HTC 950 111028 17 Screw MC6S M6X16 8.8 galvanised 10082 18 Washer BRB M6 10012 19 Sprint chassis HTC 950...

  • Page 22: Exploded Diagram, Htc 800 Drive Mechanism

    Exploded diagram, HTC 800 drive mechanism Parts list, HTC 800 drive mechanism No. Description Art. No. Screw MF6S M10x0 galvanised 10.9 1016 Drive mechanism, HTC 800 1117 End, drive mechanism, HTC 800 1118 Washer BRB M12 galvanised 10057 Screw M6S M12x5 galvanised...

  • Page 23: Exploded Diagram, Htc 800 Grinding Head

    Exploded diagram, HTC 800 grinding head Parts list HTC 800 grinding head No. Description Art. No. Qty Screw M6S M16X0 galvanised 10170 Washer BRB M16 galvanised 1002 Motor 15 kW 1109 Motor 11 kW 80-20 160M- 1100 Screw MF6S 10x16 galvanised...
  • Page 24 Parts list, HTC 800, grinding head cont. No. Description Art. No. Qty 19 Screw M6S M10x0 galvanised 10066 20 Washer TBRSB M10 galvanised 1002 21 Screw MC6S M6X20 12.9 10027 22 Gamma ring 9RB 25x2x0 11099 2 Screw MC6S M5x8 galvanised...

  • Page 25: Exploded Diagram, Htc 800 Grinding Holder

    Exploded diagram, HTC 800 grinding holder Parts list, grinding holder (1x4) No. Description Art. No. Grinding holder, upper HTC 950 11098 Polycord holder, outer HTC 9500 110958 .1 Pad, polycord black 18 mm 11071 .2 Pad, polycord, green 18 mm...

  • Page 26: Exploded Diagram, Htc 950 Chassis

    Barrel nipple /8 111129 Handle complete see page 1 Screw MC6S M5x12 galvanised 1010 10 Washer BRB 5,x10x1 1019 11 Connection, extractor HTC 950 111016 12 Power unit 15kW X00 HTC 950 110986 1 Screw MC6S M8x5 8.8 galvanised 10189...
  • Page 27 1 Circlip SGA 25 10021 2 Screw MC6S M8x16 galvanised 10080  Hose large reinforced PVC HTC 950 11110  Grinding head HTC 950 RX™ Page 5 5 Machine cover HTC 950 11100 6 Velcro male width 8mm 11026 7 Washer BRB M8...

  • Page 28: Exploded Diagram, Htc 950 Mist Cooler System

    Exploded diagram, HTC 950 Mist Cooler System Parts list HTC 950 Mist Cooler System No. Description Art. No. Screw MC6S M5x12 1010 Fixing plate ball valve, Left HTC 800 10977 Hose connection 2601-12-1/ 110205 Elbow piece MF 2020-1/ 11016 Water valve to grinder...
  • Page 29 Parts list HTC 950 Mist Cooler System cont. No. Description Art. No. 18 Nut nylock M6 galvanised DIN985 10072 19 Fixing plate, pump 1115 20 Hose large reinforced PVC 1.1 m 11010 21 Nut Nylock M8 galvanised DIN985 10067 22 Washer BRB M8 galvanised...

  • Page 30: Exploded Diagram, Htc 950 Handle

    Washer BRB 5,x10x1 1019 Connecting plate elec. HTC 950 111010 Screw MC6S M6X16 8.8 galvanised 10082 10 Control casing lower HTC 950 1110 11 Washer BRB M6 10012 12 Screw MC6S M6X16 8.8 galvanised 10082 1 Wall inlet 2A 6-15V 5P RED...
  • Page 31 Parts list, HTC 950, handle cont. No. Description Art. No. 1 Screw MC6S M5x20 galvanised 10185 15 Handle ball HTC 950 11108 16 Pin HTC 950 111028 17 Screw MC6S M6X16 8.8 galvanised 10082 18 Washer BRB M6 10012 19 Sprint chassis HTC 950...

  • Page 32: Exploded Diagram, Htc 950 Drive Mechanism

    Exploded diagram, HTC 950 drive mechanism Parts list, HTC 950 drive mechanism No. Description Art. No. Drive mechanism, middle HTC 950 110999 Screw MF6S M10x20 10078 End drive mechanism, left HTC 950 111000 End drive mechanism, right HTC 950 111001 Washer BRB M12 1x2x2.5...

  • Page 33: Exploded Diagram, Htc 950 Grinding Head

    Exploded diagram, HTC 950 grinding head Parts list HTC 950 grinding head No. Description Art. No. Qty Screw M6S M16X0 galvanised 10170 Washer BRB 17x0x 10171 Screw MC6S M8x20 8.8 galvanised 10161 Fixing lug HTC 950 110912 Screw M6S M8x16 galvanised...
  • Page 34 Parts list, HTC 950, grinding head cont. No. Description Art. No. Qty Hub Motor plate HTC 950 1109 Screw MFT-TT M6X16 8.8 galvanised 1001 Belt ring HTC 950 11092 Motor plate HTC 950 110926 Screw MF6S M10x20 10078 Motor 15kW HTC 950...

  • Page 35: Exploded Diagram, Htc 950 Grinding Holder

    Exploded diagram, HTC 950 grinding holder Parts list, HTC 950 grinding holder (1x4) No. Description Art. No. Grinding holder, upper HTC 950 11098 Polycord holder, outer HTC 9500 110958 .1 Pad, polycord black 18 mm 11071 .2 Pad, polycord, green 18 mm...

  • Page 36: Changing The Inner Belt, Htc 650, 800 And 950

    Changing the inner belt, HTC 650, 800 and 950 Separate the grinding head from the chassis and unscrew the motor connector. Remove the plastic cover Remove the upper belt. Scrape and vacuum the parts that are en- closed by the cover.
  • Page 37 Changing the inner belt, HTC 650, 800 and 950, continued Remove the motor bolts. Lift out the motor. Use a hoist. Use the spe- cial tool with art. No. 11079 for dismantling the motor. See the section about special tools on page 62.
  • Page 38 Changing the inner belt, HTC 650, 800 and 950, continued Remove the shaft pivots (They are threaded inwards with M10) and check the wear. Lift the motor plate with the upper cover. Clean the cover and check the central bear- ings.
  • Page 39 Changing the inner belt, HTC 650, 800 and 950, continued Check the bearings on the hub packet. Change if necessary. (Be careful to place them correctly in relation to the shafts that drive the upper belt). Remove the spacer before the new hub packet is mounted.
  • Page 40 Changing the inner belt, HTC 650, 800 and 950, continued Mount the grinding holders. Put Loctite flange sealant 5970 on the edging strip. Mount the upper cover with motor plate. Use Loctite 270 on all screws. Spread the sealant.
  • Page 41 Changing the inner belt, HTC 650, 800 and 950, continued Mount the shaft pivots with new seals, mounting grease on the shaft and Loc- tite 270 on the screws. Lock the upper belt on the shaft. Use special tool with art. no. 11077. See the section about special tools on page 62.
  • Page 42 Changing the inner belt, HTC 650, 800 and 950, continued Use mounting grease. Mount the motor. If needed, use the special tools for inserting the motor axel, page 62. Use the tool with art. no. 11078 for mounting the motor.
  • Page 43 Changing the inner belt, HTC 650, 800 and 950, continued Refit the cover. Refit the motor cable. Refit the chassis onto the head.

  • Page 44: Changing The Upper Belt, Htc 650, 800 And 950

    Changing the upper belt, HTC 650, 800 and 950 On machines with four-piece belt rings: Remove the grinding head from the chassis and lift off the plastic cover. It is not necessary to remove the motor to change the upper belt.
  • Page 45 Changing the upper belt, HTC 650, 800 and 950, continued. On machines with four-piece belt rings: Correct position. Rescrew the short pieces again. Use new screws and Loctite 270. Fasten the plastic cover and mount together the head and the chassis.
  • Page 46 Changing the upper belt, HTC 800 and 950, continued. On machines with whole belt rings: Separate the grinding head from the chassis and unscrew the motor connector. Remove the plastic cover Remove the upper belt. Scrape and vacuum the parts that are enclosed by the cover.
  • Page 47 Changing the upper belt, HTC 800 and 950, continued. On machines with whole belt rings: It is not necessary to remove the motor. Lock the upper belt on the shaft. Force it down around the motor plate.
  • Page 48 Changing the upper belt, HTC 800 and 950, continued. On machines with whole belt rings: Refit the cover. Refit the motor cable. Refit the chassis onto the head.

  • Page 49: Changing The Motor, Htc 650, 800 And 950

    Changing the motor, HTC 650, 800 and 950 Separate the grinding head from the chassis and unscrew the motor connector. Remove the plastic cover Scrape and vacuum the parts that are en- closed by the cover. Remove the motor bolts.
  • Page 50 Changing the motor, HTC 650, 800 and 950, continued. Lift out the motor. Use a hoist. Use the spe- cial tool with art. No. 11079 for dismantling the motor. See the section about special tools on page 62. Use mounting grease.
  • Page 51 Changing the motor, HTC 650, 800 and 950, continued. Pull down the motor using the special tool. Refit the cover. Refit the motor cable. Refit the chassis onto the head.

  • Page 52: 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 53: Parts List, Grinding Holder (1X4)

    Parts list, grinding holder (1x4) No. Description Art. No. Grinding holder, upper HTC 950 11098 Polycord holder, outer HTC 9500 110958 .1 Pad, polycord black 18 mm 11071 .2 Pad, polycord, green 18 mm 11069 Polycord holder, inner HTC 950 110957 Screw MFT-TT M6X16 8.8 galvanised...

  • Page 54: Maintenance Htc 650, Htc 800 And Htc 950 Rx

    Maintenance HTC 650, HTC 800 and HTC 950 RX Daily: • Clean the machine if it has been used for wet grinding or mist spray. • Check wear on the tools – abnormal or uneven wear can indicate damage to the grinding holder.

  • Page 55: Troubleshooting Htc 650 And Htc 800

    Troubleshooting HTC 650 and HTC 800 Machine does not start: • Emergency stop? • Cable OK? • Full voltage in all phases? • Error message on the display? • Motor cable OK? • Speed setting? Not on the highest. The machine shuts down often: •...

  • Page 56: Electronic Error Codes Htc 650 And Htc 800 - Hitachi

    Electronic error codes HTC 650 and HTC 800 - 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 5.

  • Page 57: Checking The Latest Error Code - Hitachi

    Error Explanation Description of possible fault code Processor interference The processor experiences interference, gen- erates errors and needs to be reset. Comes from interference from the mains or other disruptive equipment. Try resetting the elec- tronics by keeping the RESET button pressed for two seconds.

  • Page 58: Troubleshooting Htc 950 Rx

    Troubleshooting HTC 950 RX The grinder does not go into standby mode when the key is turned. Check that the grinder has the correct feed, that all fuses are intact and that the earth fault breaker has not tripped. Try putting the grinder in standby mode without connecting it to the mains.

  • Page 59: Electronic Error Codes - Htc 950 Rx

    Electronic error codes - HTC 950 RX The HTC 950 RX™ is fitted with an advanced frequency converter. The converter can provide an error code for certain errors that assists when fault tracing. Always state the error code if possible when contacting support. For resetting see page 7.
  • Page 60 Electronic error codes - HTC 950 RX continued. Error code Cause Action OLF = Overload motor Reduce the speed of the grinder. Tripped motor protection. Arises follow- The grinder runs too robustly. It takes ing long-term overload of the motor.

  • Page 61: Resetting The Converter Htc 950 Rx

    Things to remember. The grinder will not start if the front/back position is engaged when the power supply is applied Check the latest error code HTC 950 RX Keep ESC pressed in until  dashes appear ----. When rdy (ready) appears, press ENTER.

  • Page 62: Special Tools

    Special tools Special tools may be required to perform some repairs. • Extractor for dismantling ball bearings • Hydraulic press for mounting Belt tensioning tool. Art.No. 111514 Special tool for fixing the upper belt. Art.No. 11077 Special tool for insertion and extraction of the motor.
  • Page 64 HTC SWEDEN AB Box 69 61 22 Söderköping, Sweden Tel: +6 (0) 121-29 00 Fax: +6 (0) 121-152 12 www.htc-sweden.com...

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