HTC Floor Systems 500, 650, 800 Service Manual
Service Manual
GB
HTC 500, 650 & 800
HTC Sweden AB
www.htc-sweden.com
v.3
Introduction
Contact HTC or your nearest reseller if you have questions or comments. 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 righthand side of the chassis (seen from behind) and on the right-hand fixing lug. It is also found on
the machine sign located on the electrical housing
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.
Best wishes!
HTC Sweden AB
3
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 .............................................................................................................13
Parts list, HTC 650 .............................................................................................................14
Parts list, HTC 650 .............................................................................................................15
Exploded diagram HTC 800 (models built before year 2000) ............................................. 16
Parts list HTC 800 (models built before year 2000) ............................................................ 18
Exploded diagram - HTC 800 E ..........................................................................................21
Parts list - HTC 800 E ......................................................................................................... 25
Exploded diagram - HTC 800 HD ....................................................................................... 29
Parts list - HTC 800 HD ...................................................................................................... 33
Changing the inner belt, HTC 500/650/800 ........................................................................ 37
Changing the upper belt, HTC 500 ..................................................................................... 41
Changing the upper belt, HTC 650/800 .............................................................................. 42
Overhauling the grinding holders ........................................................................................43
Maintenance ....................................................................................................................... 45
Troubleshooting .................................................................................................................. 46
Electronic error codes - Hitachi ..........................................................................................47
Checking the latest error code - Hitachi .............................................................................48
Special tools ....................................................................................................................... 49
4
Technical data HTC 500, HTC 650 and HTC 800
HTC 500
HTC 650
Model: HTC 502E HTC 504E HTC 504S
Motor output
Current:
Voltage:
Weight:
Grinder diameter:
Grinding pressure:
Revolutions per
minute:
Water tank
(volume):
Grinding wheels:
Model: HTC 650E HTC 650S
Motor output:
Current:
Voltage:
Weight:
Grinder diameter:
Grinding pressure:
Revolutions per
minute:
Water tank
(volume):
Grinding wheels:
2.2 kW 4.0 kW 4.0 kW
10 Amp 16 Amp 16 Amp
220 V 3x380 V 3x380 V
120 kg 140 kg 120 kg
500 mm 500 mm 500 mm
100 kg 120 kg 100 kg
300-1300 rpm 300-1300 rpm 750 rpm
17 l 17 l 17 l
3x220 mm 3x220 mm 3x220 mm
7.5 kW 5.5 kW
16 Amp 16 Amp
3x380 V 3x380 V
240 kg 220 kg
650 mm 650 mm
210 kg 190 kg
300-1300 rpm 750 rpm
40 l 40 l
3x220 mm 3x220 mm
HTC 800
Model: HTC 800HD HTC 800E
Motor output:
Current:
Voltage:
Weight:
Grinder diameter:
Grinding pressure:
Revolutions per
minute:
Water tank
(volume):
Grinding wheels:
11 kW 7.5 kW
25 Amp 16 Amp
3x380 V 3x380 V
315-370 kg 280 kg
800 mm 800 mm
280-335 kg 240 kg
300-1300 rpm 300-1300 rpm
40 l 40 l
3x270 mm 3x270 mm
5
Exploded diagram, HTC 500
6
Exploded diagram, HTC 500
7
Parts list, HTC 500
The grinding machine’s design may vary based on the year’s model. Machines produced between 1992 and 1995, for example, have a drive system that is simple to upgrade.
Do not forget to quote the serial number when ordering spare parts. The serial number is located
on the right-hand side of the chassis (seen from behind) and on the right-hand fixing lug. It can
also be found on the nameplate.
Shown below is a parts list corresponding to the exploded diagram on the previous pages.
Pos. Description Part No. Remarks
1 CHASSIS HTC 500 HANDLE 110616
2 CHASSIS HTC 500 POST 110618
3 SCREW M6S M8X25 GALV 310001
4 SCREW M6S M12X85 GALV 310002
5 WASHER BRB M12 GALV 310003
6 WASHER BRB M12 GALV 310003
7 NUT NYLOCK M12 GALV DIN985 310004
8 SPRINT CHASSIS HTC 500 110001
9 SCREW MC6S M8X10 8.8 GALV 310006
10 WATER TANK HTC 500 110002
11 COVER, WATER TANK Discontinued New tank without cover
12 FREQUENCY CONVERTER 11 different models According to specification
12a PROTECTIVE CAGE 110385
13 SCREW M6S M10X35 GALV 310007
14 CHASSIS HTC 500 BOTTOM 110617
15 WASHER TBRB M10 GALV 310008
16 NUT NYLOCK M10 GALV DIN985 310009
17 WATER VALVE TO GRINDER 110007
18 SCREW M6S M5X20 GALV 310010
19 WHEEL FITTING KIT 110008
20 WHEEL HTC 650 WKCP 2803 6553 110350 also 110381, wheel HTC 500
21 MOTOR 4 different models
22 SCREW M6S M12X25 GALV 310011
23 WASHER BRB M12 GALV 310003
24 SCREW MC6S M6X10 8.8 GALV 310005
25 WASHER BRB M6 GALV 310012
26 COVER HTC 500 COMPLETE 110142
27 FIXING LUG 110013
28 WASHER BRB M12 GALV 310003
29 SCREW M6S M10X35 GALV 310007
30 SPLIT PLATE 110014
31 SCREW MF6S M6X20 10.9 GALV 310013
32 BELT RING Discontinued The motor plate and the belt ring
are one piece
33 BELT, UPPER S-140 HTC 500 110016
34 SCREW MFT-TT M6X16 8.8 GALV 310014
8
Parts list, HTC 500
Pos. Description Part No. Remarks
35 MOTOR PLATE HTC 500 110017
36 SCREW M6S M8X25 GALV 310001
37 WASHER TBRSB M8 GALV 310015
38 CIRCLIP SGA 20 310016
39 SHAFT BELT TENSIONER 110018
40 BALL BEARING 6005-2RS C3 110019
41 TENSIONING WHEEL HTC 500 110020
42 BELT, INNER S-250 HTC 500 110021
43 BALL BEARING 6005-2RS C3 110019
44 CIRCLIP SGA 20 310016
45 SCREW MFT-TT M6X16 8.8 GALV 310014
46 UPPER COVER HTC 500 110022
47 FIXING BOSS, NON-ZINC 110023
48 SCREW MFT-TT M6X25 8.8 GALV 310025
49 BEARING CUP, TOP CENTRE HTC 500 110024
50 BALL BEARING 6012-2RS C3 110026
51 BEARING CUP, BOTTOM CENTRE 500 110027
52 CIRCLIP SGA 60 310018
53 CENTRE HUB 110030
54 BALL BEARING 6205 2RS C3 110031
55 BEARING CUP PULLEY UPPER HTC
500
56 FIXING BOSS, NON-ZINC 110023
57 SCREW MFT-TT M6X16 8.8 GALV 310014
58 SCREW MFT-TT M6X16 8.8 GALV 310014
59 SPACER 6205 110033
60 SCREW MC6S M10X60 12,9 310019
61 COVER, CENTRE HUB HTC 500 110034
62 SCREW MFT-TT M6X25 8.8 GALV 310025
63 SCREW M6S M8X25 GALV 310001
64 WASHER TBRSB M8 GALV 310015
65 SHAFT BELT TENSIONER 110018
66 SCREW MFT-TT M6X25 8.8 GALV 310025
67 CIRCLIP SGA 20 Discontinued Gamma ring is used instead
68 GAMMA RING RB 20X35X4 110564
69 SHAFT COVER 110036
70 SPACER 6205 110033
71 BALL BEARING 6205 2RS C3 110031
72 BEARING CUP PULLEY UPPER HTC
500
73 CIRCLIP SGA 25 310021
74 --------
75 --------
76 --------
110032
110032
9
Parts list, HTC 500
Pos. Description Part No. Remarks
77 SHAFT, PULLEY 110039
78 WEDGE RK 8X7X25 H9 310023
79 WEDGE RK 8X7X25 H9 310023
80 PULLEY HTC 500 32X150 110040
81 --------
82 --------
83 --------
84 CIRCLIP SGA 25 310021
85 BEARING CUP PULLEY LOWER HTC500 110041
86 CIRCLIP SGA 50 310024
87 BALL BEARING 6010 2RS C3 110044
88 PULLEY HUB HTC 500 110045
89 EDGING STRIP HTC 500 110046
90 LOWER COVER HTC 500 110047
91 SPACER 6010 110048
92 HUB COVER HTC 500 110049
93 SCREW MFT-TT M6X25 8.8 GALV 310025
94 CYLINDER PIN CP 6X20 H8 310046
95 CIRCLIP SGA 60 310018
96 SGRINDING HOLDER UPPER HTC 500 110050
97 HOLDER, POLYCORD, OUTER 110051
98 SCREW MC6S M6X16 8.8 GALV 310082
99 PAD, POLYCORD GREEN 168MM 110370 2 per grinding holder
100 HOLDER, POLYCORD INNER 110386
101 SCREW MFT-TT M6X16 8.8 GALV 310014
102 SPRING 110052
103 GRINDING HOLDER, LOWER, HTC 500 110053
104 SCREW 310027
105 CROSS-PIECE PART 3 110054
106 CROSS-PIECE PART 1 M6 110055
107 SCREW MC6S M6X20 12.9 310027
108 CROSS-PIECE PART 2 110056
109 SCREW MF6S M5X8 GALV 310028
10
Exploded diagram, HTC 650
11
Exploded diagram grinding holder, HTC 650
12
Parts list, HTC 650
Pos. Description Part No. Remarks
1 CHASSIS HTC 650/800 HANDLE 110057
2 CONSOLE CONTROL PANEL 110058
3 SCREW RXS B10X16 GALV 310029
4 SCREW MC6S M6X12 8.8 GALV 310030
5 WASHER BRB M6 GALV 310012
6 WIRING HOLDER (CLIP) JR12 110059
7 WASHER BRB M6 GALV 310012
8 SCREW MC6S M6X12 8.8 GALV 310030
9 WIRING HOLDER (CLIP) JR12 110059
10 WASHER BRB M6 GALV 310012
11 SCREW MC6S M6X12 8.8 GALV 310030
12 CHASSIS HTC 650/800 POST 110060
13 SCREW M6S M16X120 GALV 310031
14 WASHER BRB M16 GALV 310032
15 SPRINT CHASSIS HTC 650/800 110061
16 WASHER BRB M16 GALV 310032
17 NUT NYLOCK M16 GALV DIN985 310033
18 SCREW MF6S M8X25 GALV 310071
19 TANK BRACKET 110062
20 WASHER BRB M6 GALV 310012
21 SCREW MC6S M6X12 8.8 GALV 310030
22 FREQUENCY CONVERTER 7.5 kw According to
specification
22 SOFT START 5.5 kw According to
specification
22a PROTECTIVE CAGE FREQUENCY CONVERTER 110158
22a PROTECTIVE CAGE SOFT START 110003
23 SCREW M6S M12X65 GALV 310034
24 NUT NYLOCK M12 GALV DIN985 310004
25 CHASSIS HTC 650 BOTTOM 110643
26 WHEEL FITTING KIT 110008
27 WHEEL HTC 650 WKCP 2803 6553 110350
28 WATER VALVE TO GRINDER 110007
29 SCREW M6S M5X20 GALV 310010
30 WATER TANK HTC 650/800 110069
31 MOTOR 7.5 DPIG 132M-4 200/346 110226
31 MOTOR 5.5KW DPIG132S-4,400/690 110368
31 MOTOR 5.5KW DPIG132S-4 200/400 110312
32 SCREW M6S M12X25 GALV 310011
33 WASHER BRB M12 GALV 310003
34 SCREW MC6S M6X25 12.9 GALV 310035
35 WASHER BRB M6 GALV 310012
36 COVER HTC 650 COMPLETE 110121
37 FIXING LUG 110072
13
Parts list, HTC 650
Pos. Description Part No. Remarks
38 MOTOR PLATE HTC 650 110073
39 SCREW MC6S M8X25 12.9 310036
40 WASHER BRB M12 GALV 310003
41 SCREW M6S M12X45 GALV 310037
42 BELT RING HTC 650 110074
43 BELT, UPPER S-140 HTC 650 110075
44 SCREW MFT-TT M6X16 8.8 GALV 310014
45 SCREW M6S M10X25 GALV 310114
46 WASHER TBRSB M10 GALV 310042
47 CIRCLIP SGA 35 310038
48 SHAFT BELT TENSIONER 110077
49 BALL BEARING 6207 2RS C3 110078
50 TENSIONING WHEEL HTC 650 110079
51 BELT, INNER S-250 HTC 650 110080
51 BELT, INNER S-250 HTC 650 SOFT START 110376
52 BALL BEARING 6207 2RS C3 110078
53 CIRCLIP SGA 35 310038
54 SCREW MFT-TT M6X16 8.8 GALV 310014
55 FIXING BOSS, NON-GALV 110023
56 UPPER COVER HTC 650 110081
57 SCREW MFT M6X30 8.8 GALV 310017
58 BEARING CUP TOP, CENTRE HTC650 110082
59 BALL BEARING 6214-2RS1 110083
60 BEARING CUP, BOTTOM CENTRE 650 110084
61 CIRCLIP SGA 70 310040
62 CENTRE HUB 110085
62 CENTRE HUB SOFT START 110159
63 BALL BEARING 6207 2RS C3 110078
64 BEARING CUP PULLEY UPPER HTC 650 110086
65 EDGING STRIP HTC 650 110087
66 SPACER 6207 110088
67 SCREW MC6S M12X60 12,9 310041
68 COVER, CENTRE HUB HTC 650/800 110089
69 SCREW MFT-TT M6X25 8.8 GALV 310025
70 FIXING BOSS, NON-ZINC 110023
71 SCREW MFT-TT M6X16 8.8 GALV 310014
72 SCREW M6S M10X25 GALV 310114
73 WASHER TBRSB M10 GALV 310042
74 COUNTERWEIGHT HTC 650/800 110090
75 SCREW MFT-TT M6X25 8.8 GALV 310025
76 CIRCLIPSGA 25 310021
77 --------
78 SHAFT COVER 110092
14
Parts list, HTC 650
Pos. Description Part No. Remarks
79 --------
80 BALL BEARING 6207 2RS C3 110078
81 BEARING CUP PULLEY UPPER HTC 650 110086
82 CIRCLIP SGA 40 310043
83 SHAFT, PULLEY 110093
84 WEDGE RK 12X8X40 310044
85 WEDGE RK 12X8X30 310045
86 PULLEY HTC 650 50X180 110118
87 CIRCLIP SGA 40 310043
88 BEARING CUP PULLEY LOWER HTC650 110094
89 CIRCLIP SGA 60 310018
90 BALL BEARING 6012 2RS C3 110026
91 PULLEY HUB HTC 650 110095
92 LOWER COVER HTC 650 110096
93 SCREW MFT-TT M6X16 8.8 GALV 310014
94 HUB COVER (PROCESSING) HTC 650(/800) 110097
95 SCREW MFT M6X30 8.8 GALV 310017
96 CIRCLIP SGA 70 310040
97 GRINDING HOLDER UPPER HTC 650/800 110098
98 CYLINDER PIN CP 6X20 H8 310046
99 HOLDER, POLYCORD, OUTER 110099
100 SCREW MC6S M6X16 8.8 GALV 310082
101a PAD, POLYCORD BLACK 184MM 110371
101b PAD, POLYCORD GREEN 184MM 110369
101c PAD, POLYCORD GREEN 184MM 110369
102 HOLDER, POLYCORD INNER 110397
103 SCREW MFTS M6X16 8.8 GALV 310251
104 SPRING 111183
105 GRINDING HOLDER, LOWER, HTC 650 110101
106 SCREW MC6S M6X20 12.9 310027
107 CROSS-PIECE PART 3 110054
108 CROSS-PIECE PART 1 M8 110257
109 SCREW MFT M8X16 8.8 GALV 310070
110 CROSS-PIECE PART 2 110056
111 SCREW MF6S M5X8 GALV 310028
15
Exploded diagram HTC 800 (models built before year 2000)
16
Loading...