DuraScrubber. Wheel Washer 1MANUL080 REV 04. For Electric and Hydraulic Drive

Transcription

1 DuraScrubber Wheel Washer Belanger, Inc. P.O. Box 5470 Northville, MI Customer Service Phone (248) Fax (248) For Electric and Hydraulic Drive 1MANUL080 REV 04

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3 Belanger Equipment Owners Manual DuraScrubber Wheel Washer Copyright 2013 Belanger, Inc This manual and the accompanying equipment are protected by United States trademark, copyright, and patent laws. You may make one copy of this manual. Do not make additional copies of this manual or electronically transmit it in any form whatsoever, in whole or in part, without the prior written permission of Belanger, Inc. The registered trademarks used in this document are the property of their respective owners. The use of such trademarks is for reference purposes only and does not imply sponsorship or approval of Belanger, Inc. by these companies or any companies affiliated with their respective owners.

4 CURRENT REVISION LOG Rev Release Date Page Description 04 TBD Cover Updated component images to reflect current design 6 to 7 Updated Safety Warnings to include reference to OSHA specifications 8 Updated component images to reflect current design 10 Added optional water utility requirement 17 Updated component images to reflect current design 18 Added optional water utility requirement 22 Updated component images, removed bullet points about pulley alignment and added note on motor orientation to reflect current design 27 Under Daily, added check for unusual vibration Under Monthly, added second note, check wiring connections and check chain tension Under Yearly, added all checks 28 Removed sections titled Broken Belt or Tension Failure, Belt Delaminating or Tooth Shear, Belt Edge Wear & Premature Belt Tooth Wear (See p 26 of Rev 03) Added sections titled Excessive Noise, Wear on Roller Link Plates, Chain Clings to Sprocket Teeth & Chain Climbs the Sprocket Teeth Removed section titled Belt Tensioning and Tightening (See p 27 to to of Rev 03) 31 Added section titled ChainReplacement and Adjustment 32 to to 35 In section titled To Remove the Existing Brush removed reference to pulley in step 1, updated step 9 to reflect current design In the section titled To Install the New Brush updated references to other sections of the manual per rev 04 updates & removed step 4 Removed sections titled Pulley Removal and Installation (see p 30 of rev 03) & Pulley and Taper Lock Bushing Installaion (see p 31 of Rev 03) Added section titled Sprocket and Taper Lock Bushing Installation 36 Updated references to other sections of the manual pre Rev 04 updates 37 to 39 Updated Powder Coat Maintenance section In Hydraulic Motor Mounting Components (Both Sides) added Exit 44 Spindle, 1PLSTC-CV045 was DS, now PS and 1PLSTC-CV047 was PS, now DS 45 Updated exploded view of electric drive to reflect current design

5 Table of Contents Belanger Incorporated Limited Warranty... 3 Operational Warning... 4 Important Safety Information... 5 Safety Symbols and Signal Words... 5 IMPORTANT Safety Information MUST READ... 6 Introduction... 8 Before You Get Started... 9 Requirements Cross beam Fixture Installation Tunnel Placement Overview Tunnel Placement Assembly Utilities Overview Understanding Brush Rotation Utility Connections: Hydraulic Utility Connections: Electric Pneumatic (Air) Circuit Overview Water Connections for Spray Manifolds Operation Overview of Controls Adjustments Options / Effects MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

6 Table of Contents Maintenance Daily Monthly Yearly Trouble Shooting Chain Replacement and Adjustment Brush Replacement Sprocket and Taper Lock Bushing Installation Sprocket / Pulley Alignment Powder Coating Maintenance Cleaning Procedure Powder Coating Repair Replacement Parts Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

7 Belanger Incorporated Limited Warranty LIMITED WARRANTY: Equipment: Seller warrants to the original purchaser that the goods sold hereunder, which are fabricated by Seller, shall be free from defects in workmanship and material under normal use and service for a period of 1 year plus 30 days from the date of invoice - CAT Pumps will be warranted for 2 years from the date of invoice. All warranties, express, implied, or statutory, pertaining to Seller s machinery, parts, and equipment are fully set forth herein. This limited warranty applies to the original purchaser only and is not transferable. No addition to or modification of any of the provisions of this stated Limited Warranty shall be binding upon the Seller, unless made in writing and signed by a duly authorized employee of Seller. This warranty is subject to the following limitations: (1) This warranty shall be void if the factory specifications for operation and maintenance, found in original equipment manuals, and component manuals, are not followed, or if other than factory authorized erection, alterations or modifications are made to any parts or equipment; (2) Defective parts are warranted to the Purchaser for repair or replacement through an authorized distributor of Seller or direct with Seller for a period of 13 months from the date of invoice. Parts warranty excludes all claims for failure resulting from normal wear and tear to the depreciable parts, improper installation, omission of factory specified preventative maintenance, misuse, abuse, negligence, third party damages, or acts of God. Purchaser agrees to submit to and assist Seller or its authorized distributor in conducting in-warranty inspections of the machinery and equipment including inspection of any part claimed to be defective by the Purchaser; (3) Labor to repair or replace parts is warranted to Purchaser during normal business hours through an authorized distributor of Seller or direct with Seller, for 120 days from date of invoice. Labor warranty excludes all claims for failure resulting from normal wear and tear to the depreciable parts, improper installation, and omission of factory specified preventative maintenance, misuse, abuse, negligence, third party damages, or acts of God. Seller reserves the sole right to make determinations on the above stated limitation. All labor and service provided beyond the labor warranty period shall be subject to labor charges at the rates established by the local authorized distributor or direct with Seller; (4) This warranty shall be void for all equipment failures and premature component wear caused by the use of corrosive chemicals in the wash process. The following list includes some, but not all, of the particularly corrosive chemicals that if used in conjunction with Belanger equipment will void the warranty: Hydrofluoric Acid, Ammonium Bi-flouride, Bromic Acid, Muriatic Acid, Sulfonic Acid, Phosphoric Acid, Hydrogen Cyanide, Hydrochloric Acid, Sodium Hydroxide and Chlorinated Solvents. (5) Seller makes no warranty, express or implied, with respect to the design or operation of any entire system, in which Seller s goods sold hereunder are mere components. (6) In no event shall Seller be liable for any incidental, special, consequential or exemplary damages resulting from the furnishing, performance or use of any goods or services sold pursuant hereto, whether due to a breach of contract, breach of warranty, the negligence of Seller or to otherwise; not for loss of business; inconvenience, or property damage of any kind; not for any damages of whatever nature resulting in any way from the purchaser s selection and use of any chemicals not manufactured exclusively by seller but used with the purchased goods; or for any service not expressly provided herein related to or arising from the equipment or goods sold. This limitation of liability extends to purchaser s use of any engineering recommendations, sales representations, technical assistance, advice or data supplied by seller to purchaser in connection with the goods or services supplied, other than that information contained in Belanger manuals. Parts: Seller warrants to the original purchaser that the Replacement Parts sold hereunder, shall be free from defects in workmanship and material under normal use and service for a period of 30 days from the date of invoice. This limited warranty applies to the original purchaser only and is not transferable. (1) This warranty shall be void if the factory specifications for operation and maintenance are not followed; (2) Parts warranty excludes all claims for failure resulting from normal wear and tear to the depreciable parts, improper installation, omission of factory specified preventative maintenance, misuse, abuse, negligence, third party damages, or acts of God. (3) This warranty shall be void for all replacements parts failures and premature component wear caused by the use of corrosive chemicals in the wash process. The following list includes some, but not all, of the particularly corrosive chemicals that if used in conjunction with Belanger replacement parts will void the warranty: Hydrofluoric Acid, Ammonium Bi-flouride, Bromic Acid, Muriatic Acid, Sulfonic Acid, Phosphoric Acid, Hydrogen Cyanide, Hydrochloric Acid, Sodium Hydroxide and Chlorinated Solvents. THIS LIMITED WARRANTY FOR EQUIPMENT AND REPLACEMENT PARTS IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, WHETHER STATUTORY OR OTHERWISE, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Copyright 2000 by Belanger, Inc. All rights reserved. No part of this work may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, or by any information storage or retrieval system, except as may be expressly permitted by the 1976 Copyright Act. Revised as of Belanger reserves the right to change or modify the Belanger Inc. Limited Warranty without notice. 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

8 Operational Warning Formulations containing the chemicals listed below are particularly dangerous and should not be used even at low concentrations: Hydrofluoric Acid Ammonium Bi-flouride Bromic Acid Muriatic Acid Sulfonic Acid Phosphoric Acid Hydrogen Cyanide Hydrochloric Acid Chlorinated Solvents Belanger, Inc., does not endorse or condone the use of chemicals that are potentially dangerous to human health, the environment or property. Belanger recognizes that it is the right and sole decision of the end user operators of our equipment as to the type and dilution ratio of the chemicals used in their facilities. We strongly recommend that the end user does not select products containing any of the chemicals listed above as an ingredient in the wash solutions. The chemicals listed above are potentially dangerous to human health, and have a detrimental, deteriorating effect on the equipment and the facility. Be advised that a portion of, or all of your warranty will be voided if you determine to use any of the chemicals listed above as an ingredient in the wash solutions in conjunction with your Belanger automatic car wash equipment: Limitation (4), of Paragraph (8), Limited Warranty, of the Belanger Terms and Conditions of Sales describes the potential limitation of warranty due to your chemical selection: (4) This warranty shall be void for all equipment failures and premature component wear caused by the use of corrosive chemicals in the wash process. The following list includes some, but not all, of the particularly corrosive chemicals that if used in conjunction with Belanger equipment will void the warranty: Hydrofluoric Acid, Ammonium Bi-flouride, Bromic Acid, Muriatic Acid, Sulfonic Acid, Phosphoric Acid, Hydrogen Cyanide, Hydrochloric Acid, and Chlorinated Solvents. The Purchaser also agrees to accept the responsibility and liability for the selection and use of any chemicals listed above; However, should the end user decide to use formulations containing any of the above ingredients, the end user should institute a comprehensive training program and implement detailed operational parameters within their organization for the proper handling and treatment of such products to minimize the potential dangers involved. Consult your chemical supplier for assistance in establishing operational guidelines in the use of their products. MSDS (Material Safety Data Sheet) should be obtained from the chemical supplier before using any chemical formulation. CAUTION During the installation process the installer is responsible for re-tightening ALL lugs, set screws and terminals located in the electrical panels. Components may vibrate loose during shipping. 4 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

9 Important Safety Information This section introduces the hazard and safety precautions associated with installing, maintaining or servicing this product. Before performing any task on this product, read this safety information and the applicable sections in this manual, where additional hazards and safety precautions for your task may be found. Electrical shock could occur and cause death or serious injury if these safe service procedures are not followed. Safety Symbols and Signal Words Alert Symbol This safety alert symbol is used in this manual and on warning labels to alert you to precautions, which must be followed to prevent potential personal safety hazards. Obey safety directives that follow this symbol to avoid possible injury or death. Signal Words The signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards. The precautions that follow must be followed to prevent death, injury or damage to the equipment. DANGER This signal word is used to alert you to a hazard or unsafe practice which WILL RESULT IN DEATH OR SERIOUS INJURY This alerts you to a hazard or unsafe practice which COULD RESULT IN DEATH OR SERIOUS INJURY CAUTION This signal word designates a hazard or unsafe practice which MAY RESULT IN MINOR INJURY CAUTION When used by itself, CAUTION designates a hazard or unsafe practice which MAY RESULT IN PROPERTY OR EQUIPMENT DAMAGE Before You Begin Only trained or authorized individuals knowledgeable in the related procedures should install, inspect, maintain or service this equipment. Read the Manual Read, understand and follow this manual and any other labels or related materials supplied with this equipment. If you do not understand the procedure, call a Belanger, Inc. representative at It is imperative to your safety and the safety of others to understand the procedures before beginning work. 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

10 Important Safety Information IMPORTANT Safety Information MUST READ Safety Warnings DISCONNECT THE MAIN POWER SUPPLY AND DISSIPATE ALL POTENTIALLY HAZARDOUS ENERGY SOURCES PRIOR TO SERVICING OR MAINTAINING EQUIPMENT Belanger recommends that all workers observe the OSHA (U.S. Department of Labor Occupational Safety & Health Administration) Lockout / Tagout procedure to dissipate all potentially hazardous energy sources (i.e. - electrical, mechanical, hydraulic, pneumatic, chemical, thermal, etc.) prior to performing service or maintenance on machinery and equipment. Note: Reference the OSHA standard for the Control of Hazardous Energy (Lockout/Tagout), Title 29 Code of Federal Regulations (CFR) Part and the example provided in Appendix A for practices and procedures necessary to disable machinery or equipment, thereby preventing the release of hazardous energy while employees perform servicing and maintenance activities. The standard outlines measures for controlling hazardous energies electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and other energy sources. Note: Reference the OSHA standard 29 CFR to 29 CFR for safe work practices to protect employees working on electrical circuits and equipment. This section requires workers to use safe work practices, including lockout and tagging procedures. These provisions apply when employees are exposed to electrical hazards while working on, near, or with conductors or systems that use electrical energy. Note: Both referenced OSHA standards can be found at the following website: Browse to the General Industry tab under the Find an OSHA Standard heading, scroll down to the link of interest and click on it. Doing so will prevent unexpected energization, startup, or release of hazardous energy while maintenance and servicing activities are being performed. 6 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

11 Important Safety Information Safety Warnings BE SURE TO OBSERVE OPERATING ENVELOPE. EQUIPMENT MAY START UNEXPECTICALLY. OVERHEAD, ROTATING AND/OR MOVING COMPONENTS COULD RESULT IN SERIOUS INJURY OR DEATH. BE AWARE OF FOREIGN OBJECTS IN THE AREA SURROUNDING A ROTATING PIECE OF EQUIPMENT. OBJECTS MAY BECOME TANGLED WITH EQUIPMENT AND COULD RESULT IN SERIOUS INJURY OR DEATH. CAUTION BE AWARE OF HAZARDS ASSOCIATED WITH EQUIPMENT INSTALLED ON THE FLOOR THAT MAY BE A TRIP HAZARD. It is imperative to your safety and the safety of others to always follow safe work procedures. 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

12 Introduction This document covers both the Electric and Hydraulic Drive DuraScrubber. The installation for both systems is the same except utility connections which will be covered separately. Most images will show the Hydraulic Drive system. The DuraScrubber Wheel Washer is designed to scrub and brush off heavy residue, grime and break dust by utilizing an alternating diameter nylon brush. The firmness of the seven inch diameter sections break-up most of the heavy residue, while the sweeping twelve inch diameter sections have the softness and reach to get into the wheels and brush off grime and break dust. At a length of 96- inches, the DuraScrubber brush provides an effective balance between firm bristled grime removal and soft bristle cleaning on the vehicle wheels for one full rotation. The framework is constructed of durable double wall aluminum, and the shaft is supported by oversized pivot bearings and brush spindle bearings to withstand the substantial abuse of a car wash. A slotted mounting method allows the height of the arms on the base stanchions to be fine adjusted, to position the brush and optimize cleaning on all types of tires. Although the arms are adjusted individually, they should be level throughout the movement of the brush. A lead-in guide section was incorporated into the design of the DuraScrubber to self-adjust the driver-side and passenger-side brush to run parallel with all size vehicles. The contour design and self-locking edge of the lead-in plastic guide rail provides both durability and a safe method in aligning the brush with the vehicle tire. Available in either a hydraulic motor or 1hp electric motor application, the DuraScrubber operates at 120 RPM. A floating mounting method is used for the hydraulic motor; whereas the electric motor is mounted parallel and drives the brush by utilizing a chain and sprocket. The hydraulic motor is protected by a yellow polyethylene cover that also provides a contact point for the tire, to prevent unwanted wheel damage. In a hydraulic application the machine speed is adjusted by the flow control valve on the systems main hydraulic power unit. Both the driver-side and passenger-side brushes scrub the tires in a downward motion, as not to sling the dirt back onto the vehicle, and directing the dirt into the conveyor pit. The DuraScrubber also includes a standard retract feature that allows the operator to draw in the machine for certain vehicles. CAUTION THE BELANGER, INC. DURASCRUBBER WILL NOT WORK WITH THE TOP TRAK CONVEYOR Hydraulic Drive Electric Drive 8 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

13 Introduction Before You Get Started Tools Needed for Installation: Miscellaneous Hand Tools Level Tape Measure (25 Foot or Greater) Hammer Drill With 5/8 Bit Safety Glasses Equipment Include Square Extension Cords Pry Bar Tin Snips Work Gloves Qty. Note: Uncrate and inspect shipment for damage, and to verify that all pieces are there. If there is any damaged equipment, file a claim with the trucking company immediately. Receiving party is responsible for filing claim with trucking company. Notify your local distributor or Belanger, Inc. immediately if shipment is determined damaged or incomplete. DISCONNECT AND LOCKOUT ELECTRICAL POWER AND DISSIPATE ANY POTENTIALLY HAZARDOUS ENERGY SOURCES BEFORE SERVICING ANY EQUIPMENT! CAUTION Always wear safety glasses when performing maintenance on any equipment. CAUTION It is recommended that a licensed electrician is contracted to perform all electrical installations. CAUTION A compressed Air System should be set correctly to support 90 PSI necessary to operate equipment, but should never be set to deliver more than 120 PSI air pressure to the Belanger specified equipment. 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

14 Specifications Requirements Physical Tunnel space: Driver-side 144 *may vary slightly from site to site Tunnel space: Passenger-side 165 Utilities Hydraulic Drive Option Electrical requirement Hydraulic Lines Pneumatic requirement Water requirement (optional) (1) one 110 VAC output from Controller to air panel PSI; 1/2 supply and return lines 1/4 90 PSI minimum 120 PSI maximum 1/2" water line, connected to another component Electric Drive Option Electrical requirement 3-phase motor Pneumatic requirement Water requirement (optional) (1) one 110 VAC output from Controller to air panel 208V, 60Hz, 3.30 amp 230V, 60Hz, 3.30 amp 460V, 60Hz, 2.00 amp 1/4 90 PSI minimum 120 PSI maximum 1/2" water line, connected to another component Cross beam Fixture All Belanger Tire Applicators require our shipping crossbeam to properly position and space the legs. In order to save distributors and customers money we have made the purchase of the shipping crossbeams an option. This allows the installer to use the same crossbeam for multiple installations. If your unit did not come with the shipping crossbeam, it is assumed that you have one in stock. Locate it and install it as shown below.. 10 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

15 Installation Tunnel Placement Overview Note: Brushes should face each other with arms angled toward the tunnel s exit end. The driver side DuraScrubber will act as part of the conveyor guide rail. Note: The dimensions shown below can vary depending on the surrounding equipment locations. It is important that the DuraScrubber is moved through its full range of motion to ensure conveyor clearance before lagging the DuraScrubber to the floor. 1/2" Operating Envelope Hydraulic Motor Cover Plate (typical) 172 Note: This dimension is approximate. Adjust so that when the DuraScrubber arm is fully retracted, the hydraulic motor cover plate is flush with the outside guide rail. 1 to 27 actual distance may vary according to other equipment 55-1/ /2 Leg of existing piece of equipment Note: The DuraScrubber is shown fully extended. The 55-1/4" dimension is taken from the outer leg to the driver side edge of the inside guide rail. 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

16 Installation Tunnel Placement 1) Uncrate the DuraScrubber. Note: DO NOT remove the optional steel shipping crossbeams from the assemblies until stated. Note: If you are using steel shipping crossbeams from stock, install them at this time, as shown previously. 2) Assuming that there is already a conveyor in place, select the desired location for the Dura- Scrubber to be installed using the diagram shown in the overview below. Note: The scrubbing brushes should face each other with arms angled toward the tunnel s exit end. Note: The dimensions shown below can vary depending on surrounding equipment locations. It is important that the DuraScrubber is moved through its full range of motion to ensure conveyor clearance before lagging to the floor. Guide Rail Section Removal 1) Using a torch cut away 158 of the outside section of the existing conveyor guide rail at the appropriate location to accommodate the driver side DuraScrubber. As stated before, the size of the cut-away may vary from site to site. Step 1 Remove 158 of the guide rail at the predetermined DuraScrubber location Step 2 Cut the entrance side of the remaining guide rail at a 45 angle to make for a smooth lead-in Electric: 152 Hydraulic: 158 Step 3 File, grind or sand the angled edge round and smooth The two dimensions shown in the above image are suggested lengths of guide rail to remove. The Lead-In location is the same on hydraulic and electric drive systems. It is the Lead-Off which will vary due to vehicle clearances. 12 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

17 Installation Assembly 1) Locate the following assemblies and fasteners. Driver Side Lead-In Passenger Side Lead-In Fasteners (4 each per side) 1/2-13 x 1-1/4 2) Secure the driver side Lead-In assembly to the tapped holes of the driver side frame as shown below. 3) Repeat the process on the passenger side. 4) Locate the following parts and fasteners. Lead-Outs (2) Fasteners (2 each per side) 1/2-13 x 1-1/4 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

18 Installation Assembly 5) Secure the passenger side Lead-Out to the tapped holes of the passenger side frame as shown below. 6) Repeat the process on the driver side. 7) Locate the Posi-Stop assembly and install it as shown below. After the installation is complete, it will need to be adjusted. 8) Position the driver side assembly so that the back of the upright stand is set a 55-1/4 from the inside edge of the inside guide rail as shown below. 55-1/4 Ground level, entrance view 14 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

19 Installation Assembly 9) When the driver side assembly is positioned in its desired location, drill and install one 5/8 lag bolt into the middle of the slotted hole on the base plate as shown below. Center lag bolt here 10) Move the brush back and forth through its full range of motion to insure proper clearance. As you move the brush you will see if you have removed enough of the guide rail. It may be necessary to remove more. 11) The brush should be set 9 inches off of the conveyor top surface (as shown below) and the lead-in guide rail will be at 5-1/2 inches off the conveyor. The arms and main beam should be set level throughout the movement. 9 Center of the Brush Ground level, entrance view 12) There are leveling bolts that will thread into the taped holes in the base plate to help with the leveling as shown below. 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

20 Installation Assembly 13) Once the driver side DuraScrubber is placed and leveled, lag it down through the other holes in the base plates and tighten all lag bolts. 14) Locate the Passenger side DuraScrubber. Note: DO NOT remove the optional steel shipping crossbeams from the assemblies until stated. Note: If you are using steel shipping crossbeams from stock, install them at this time, as shown previously. 15) Position it across the bay from the Driver side brush. The back of the Passenger side upright should be 161-1/2 inches from the back of the Driver side upright as shown below /2 Ground level, entrance view 16) Install one lag bolt into the middle of the slotted hole in the base plate. Install the leveling bolts into the base plate and set the passenger side as you did on the Driver side. The Passenger side will be set 9 inches from the center of the brush to the passenger floor 60 inches over from the center of the conveyor bed Center of the Brush Ground level, entrance view This will set the lead-in guide rail 5-1/2 inches of the floor. 17) Once the passenger side is set and level install the lag bolts into the other holes in the base plate and tighten down the lag bolts. 18) Remove both steel shipping crossbeams from the assembly. Note: DO NOT dispose of the steel shipping crossbeams. Keep them for future installations. 19) Locate the height adjusting bolts at the rear of the support legs. 16 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

21 Installation Assembly Height Adjustment With the adjustments of the arms on base stanchions the height of the brush can be fine adjusted to match your site. If you adjust the arm height on the passenger side the cylinder may have to be adjusted to make it level. This is done by moving the rod end clevis on the exit arm. Side View (Electric Drive Shown) Front View 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

22 Installation Utilities Overview Hydraulic Drive Run hydraulic feeds to the hydraulic manifolds atop the legs. Electrical requirement (1) one 110 VAC output from Controller to air panel Hydraulic Lines Pneumatic requirement Water requirement (optional) Electric Drive Supply both motors with 3-phase power. Electrical requirement 3-phase motor Pneumatic requirement Water requirement (optional) PSI; 1/2 supply and return lines 1/4 90 PSI minimum 120 PSI maximum 1/2" water line, connected to another component (1) one 110 VAC output from Controller to air panel 208V, 60Hz, 3.30 amp 230V, 60Hz, 3.30 amp 460V, 60Hz, 2.00 amp 1/4 90 PSI minimum 120 PSI maximum 1/2" water line, connected to another component Understanding Brush Rotation Ground Level, Entrance View Note: Optimal brush rotation: 120 RPM. Hydraulic drive units will require adjustment Clockwise Floor Level (Looking Toward the Exit) Counter Clockwise CAUTION It is imperative that no foreign materials are in the supply lines before final connections are made. To be sure of this, the lines should be blown out prior to final hookup. All utilities MUST be installed in accordance with all local and national codes 18 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

23 Installation Utility Connections: Hydraulic Hydraulic Circuit (Typical) Hydraulic Return Hydraulic Feed Hydraulic Drive Brush Rotation The following will explain the factors that determine rotation of the brushes. Failure to understand this factor can result in equipment or vehicle damage. Feed for counterclockwise rotation Feed for clockwise rotation Out Out IN IN 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

24 Installation Utility Connections: Hydraulic 1) Locate the two manifold weldments and fittings. Assemble them as shown below. NOTE: Apply plumbing thread sealant to the fittings before installing them. Before After 2) Locate the appropriate fasteners and secure the manifold weldments to the legs that are closest to the motors as shown below. 20 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

25 Installation Utility Connections: Hydraulic 3) Locate the two sets of hydraulic hoses. The driver side hoses are 70 long and the passenger side hoses are 76 long. 4) Secure them into place on both legs as shown below. Be sure to feed the hoses between the looped clamps. 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

26 Installation Utility Connections: Electric Electric Circuit (Typical) Electrical Feed Electrical Feed Direction of Rotation Junction Box Direction of Rotation Direction of Travel Junction Box Electric Drive Note: Be sure the rotation matches the image shown previously. If the rotation is incorrect, reverse the leads on the motor(s). Note: The junction box on both motors must face the ground. This orientation will help avoid water entering the motor. 22 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

27 Installation Pneumatic (Air) Circuit Overview Note: The EXTEND and RETRACT labels below indicate the position of the arms. Extended means the arms are IN towards the tires, whereas Retracted means back and away from the tires. Extend Retract Extend Regulated air supply to driver side cylinder (extend), 1/4 airline Retract Regulated air supply to driver and passenger side cylinders (retract), 1/4 Regulated air supply to passenger side cylinder (extend), 1/4 airline Manual Over-ride Wheel retract regulator Retract Rate Flow Control Main air supply 90-PSI minimum 120-PSI maximum 110VAC In Extend Rate Flow Control 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

28 Installation Water Connections for Spray Manifolds The Spray Manifold ships with the main water feeds on the exit end of the machine. If you would like the feeds at the entrance, remove the 4 Stauff Clamps (2 per side) and turn the manifold assembly around. Be sure to replace the Stauff Clamps. From the water feeds of existing components, insert the supplied Tee s in the lines and run feeds to the plastic elbows on the manifolds as shown in the following images. Overview Supplied Tee Water feed to and from other components Water feed to and from other components Supplied Tee Attach the feed line to the desired piece of existing equipment using the supplied plastic barbed hose tees and clamps as shown below. Keep in mind that the manifold will only spray when the supplying piece of equipment is on. Before After 24 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

29 Installation Water Connections for Spray Manifolds Spray Directional Adjustment You can have the water applied to either the brush or directly onto the vehicle. To change this, loosen the clamp bolts slightly so the manifold can be rotated to adjust the spray pattern aimed slightly down from 90 to apply liquid to the brush or slightly above 90 to apply liquid to the vehicle. Tighten clamps and repeat the process on the other side. 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

30 Operation Overview of Controls There are five control valves which affect the operational performance for the DSC assembly. They are as follows: Driver side extend pressure Passenger side extend pressure Driver/Passenger retract pressure Extend exhaust flow control Retract exhaust flow control See the Installation section for a depiction of the labeled control panel. Adjustments Options / Effects The adjustable controls may uniquely affect your site. The effect depends on your operational model (i.e. retract between uses, line speed, allowed extend time). 1) Passenger Side Regulator: This control is active in dictating how much penetration pressure may be seen from the passenger side brush. Increasing the pressure will cause the brush to bury itself deeper into the side of the car. If your operational plan calls for the brush to be activated prior to a selected car then the pressure increase will also cause the extend feature of the Passenger side DuraScrubber to react more quickly. Decreasing the pressure will allow the brush to greater resist the penetrating force into the side of the car. If your operational plan calls for the brush to be activated prior to a selected car then the pressure decrease will also cause the extend feature of the Passenger side DuraScrubber to react more slowly. 2) Driver Side Regulator: This control is active in dictating how much penetration pressure may be seen from the driver side brush. Increasing the pressure will cause the brush to bury itself deeper into the side of the car. If your operational plan calls for the brush to be activated prior to a selected car then the pressure increase will also cause the extend feature of the Driver side DuraScrubber to react more quickly. Decreasing the pressure will allow the brush to greater resist the penetrating force into the side of the car. If your operational plan calls for the brush to be activated prior to a selected car then the pressure decrease will also cause the extend feature of the Driver side DuraScrubber to react more slowly. 3) Retract Regulator: This control is active in dictating the retract motion of both passenger and driver side brush. Increasing the pressure will cause the brush on both Driver and Passenger side to react and move more swiftly to the retract position. Decreasing the pressure will cause the brush on both Driver and Passenger side to react and move less swiftly to the retract position. 26 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

31 Operation Adjustments Options / Effects 4) Retract Rate Flow Control: This helps control the rate at which the air is released from the extend side of the cylinders Turning the needle clockwise or further engaging it will restrict the flow of air trying to escape the extend side of the cylinders. Effectively slowing down the rate of retract at a designated pressure. Turning the needle counter-clockwise or less engagement will allow a greater flow of air to escape the extend side of the cylinders. Effectively increasing the rate of retract at a designated pressure. 5) Extend Rate Flow Control: This helps control the rate at which the air is released from the retract side of the cylinders. Turning the needle clockwise or further engaging it will restrict the flow of air trying to escape the retract side of the cylinders. Effectively slowing down the rate of extend at a designated pressure. Turning the needle counter-clockwise or less engagement will allow a greater flow of air to escape the retract side of the cylinders. Effectively increasing the rate of extend at a designated pressure. Maintenance Daily Inspect the DuraScrubber brush for missing bristles, loose bolts or bent shaft that may cause wobbling, and worn bearings. Run scrubber to check for any unusual noise or vibration. Monthly Inspect the DuraScrubber brush for damage prior to greasing. Note: Before GREASING and after GREASING wipe off all bearing seal surfaces and Zerks. Grease should only be applied until water is pushed out and bearings seals start to swell. Grease arm pivot bearings (8 per side). Note: Before working on a drive, DISCONNECT POWER to the drive. Open the motor junction box and inspect the wiring and connections. Clean any corrosion and repair or rewire any connections that show signs of arcing, shorting or separation. Recommended every (3) months, check chain tension and correct if necessary. Yearly Check for wear on side plates; replace as necessary Check for chain elongation; replace as necessary Check for cleanliness of components; remove any accumulation of dirt or foreign materials Check for wear on sprockets; replace as necessary 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

32 Maintenance Trouble Shooting Problem Cause Solution DuraScrubber brush stalls when scrubbing tires Inadequate pressure supply from hydraulic unit Adjust the pressure settings so that the hydraulic unit provides adequate pressure to turn the brush. Inadequate flow rate Check pressure on regulator from air control panel. If the regulated pressure is too high, it may cause brush to stall. Release pressure by turning knob counter clockwise until stalling halts. Be sure that there is still enough pressure to allow the main beam to pivot smoothly. DuraScrubber brush not spinning Mechanical failure may be possible Check to see if bearings are seized up. If so, see replacement parts. If using flow control, make sure it is open. If unsure, whether it is working properly, remove and try without flow control Check hydraulic unit. Check that the DuraScrubber shaft keyway and coupler are intact. DuraScrubber will not retract Faulty electrical signal Check electrical signal Faulty MAC valve Check for power to the coil. If YES, manually shift the valve. If the air changes and the machine doesn t retract check the cylinder Excessive vibration Floor lags may be loose Make sure that DuraScrubber is tightly lagged to floor Bearing may need replacing Brush may be bent Check for play in DuraScrubber shaft bearings, if sloppiness is evident, bearings will have to be replaced. See replacement parts Excessive noise Obstruction Inspect and remove obstruction; replace chain if necessary Excessive chain slack Adjust chain tension Excessive chain wear Replace chain Excessive sprocket wear Inspect chain for damage and replace sprockets Sprocket misalignment Inspect chain and sprockets for damage and realign sprockets and shafts Wear on roller link plates and on one side of the sprocket tooth surface Sprocket misalignment Inspect chain and sprockets for damage and realign sprockets and shafts Chain clings to sprocket teeth Excessive sprocket wear Inspect chain for damage and replace sprockets Sprocket misalignment Inspect chain and sprockets for damage and realign sprockets and shafts Chain climbs the sprocket teeth Excessive chain slack Adjust chain tension Excessive chain wear Replace chain Excessive sprocket wear Inspect chain for damage and replace sprockets Extreme overload Inspect drive. Replace chain and eliminate the cause of overload 28 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

33 Maintenance Chain Replacement and Adjustment Note: Over tensioning the chains will shorten the life of the chains and the bearings. 1) Turn off the systems main disconnect and lock it out. 2) Remove the Chain Guard Covers as shown below. Remove these fasteners and washers Remove these fasteners and washers Remove this cover Remove this cover 3) Loosen and remove the three bolts on the Belt Tension Plate as shown below. Chain Links Removed For Clarity-To See Connection to Belt Tension Plate Belt Tension Plate Loosen this fastener and washers Remove these fasteners and washers 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

34 Maintenance Chain Replacement and Adjustment 4) Move the motor inward to provide slack in the chain. 5) Verify the junction box orientation on both drives and adjust as necessary. Note: The junction box on both motors must face the ground. This orientation will help avoid water entering the drive. 6) Retighten the fasteners that were loosened to hold the motor location. 7) Remove the brush shaft end cover mounting and the drive chain as shown below. 8) Verify sprocket alignment. Follow the steps in Sprocket Alignment. If adjustment is required, adjust the sprocket on the brush shaft end. 9) Locate the 39 length of chain then remove the Master link and retainer as shown below. Drive chain Brush shaft end cover mounting and fasteners. Remove these parts. Brush shaft end sprocket Chain Master link and retainer Chain Master link side plate Chain retainer 30 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

35 Maintenance Chain Replacement and Adjustment 10) Wrap the chain around the sprockets and reinstall the Master link making sure the Master link side plate and retainer are secured in position. 11) Lower the motor into its rest position by loosening the bolt in the slot of the tension plate. Moving the motor into the rest position will create tension in the chain. 12) Adjust chain tension so that the upper portion is taught and the lower section has a total slack of approximately 5/8 to 3/4 at the midpoint, as shown below. 5/8 to 3/4 acceptable slack 13) Retighten the remaining two sets of fasteners on the tension plate. 14) Once the chain has been installed or adjusted on both the driver and passenger sides, verify that all objects are clear of the machines in order to start it properly. 15) Provide power to the machine and watch the chain to verify that it is tracking straight. 16) Turn off the systems main disconnect and lock it out. 17) Recheck the lower section of the chain for a total slack of approximately 5/8 to 3/4 at the midpoint. See the image above in step ) Replace the brush shaft sprocket end cover mounting, and the chain guard covers. 19) Turn on the main power. 20) Test run vehicles through the system. 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

36 Maintenance Brush Replacement To Remove the Existing Brush 1) Remove the Hydraulic or Electric Motor components as required. 2) Remove the fasteners securing the shaft bearings to the main beam. 3) Lift the brush assembly (Brush, spindles, and bearings) off of the main beam. 4) Evaluate the bearings and spindles to determine if replacements should be made. If not then you may skip the next step. 5) Unlock the set screws and slide the bearing off. 6) Remove the fasteners from each spindle and set them aside. 7) Take out the old brush and replace it with the new piece. Note: When securing the spindles to the brush it is very important to make sure that the spindles seat and sit straight into place as shown below. The protrusion of the short spindles should rest in the recess of the brush shaft Protrusion on the short spindles Recessed area in the brush shaft Overhead View 8) Place the spindles in their seat at the end of the brush and one drop of Loctite 271 on each fastener. 32 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

37 Maintenance Brush Replacement 9) Finger tighten the fasteners. To properly tighten and seat the spindles start at one of the finger tightened fasteners and follow a star pattern in tightening them down. This is to seat the spindle squarely and assure a true brush rotation during operation. Complete the tightening pattern several times ) Slide the bearing back on to the spindles and push them as close to the brush as they will go. (Do NOT tighten the set screws yet) Electric Drive Spindle: Push the bearing all the way to its seat and tighten the setscrews. To Install the New Brush 1) Lift the brush assembly back onto the main beam. 2) Place the bearing fasteners back in position. After each is set tighten them all. Note: The spindles have to seat into the bushing to assure the brush rotation is true or that the spindles run concentric to each other (having a common center). Before installing the drive, rotate the new brush by hand and inspect that the spindles are turning concentrically. Hydraulic Drive: After locking the hydraulic motor to the hydraulic driven spindle, you may tighten the set screws on the shaft bearings. Electric Drive: See the section titled Sprocket and Taper Lock Bushing Replacement/ Chain Replacement and Adjustment. 3) Finish by placing the final motor cover components back in position and securing them. 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

38 Maintenance Sprocket and Taper Lock Bushing Installation 1) Turn off the system s main disconnect and lock it out. 2) Remove the Chain Guard Covers as shown in Chain Replacement and Adjustment. 3) Loosen and remove the three bolts on the Belt Tension Plate as shown in Chain Replacement and Adjustment. 4) Move the motor inward to provide slack in the chain. 5) Retighten the fasteners that were loosened to hold the motor location. 6) Remove the brush shaft end cover mounting and the drive chain as shown in Chain Replacement and Adjustment. 7) Remove the sprocket fasteners and taper lock bushing, key and set screw from each sprocket as shown below. Taper Lock Bushing Bushing Set Screw Sprocket fasteners Motor drive shaft reference Bushing Key Sprocket Note: The sprocket fasteners are used to unlock the sprocket from the taper lock bushing. 8) To unlock the bushing, place the removed sprocket fasteners into the other three threaded holes (jack screw holes). Tighten all fasteners alternatively and progressively. Keep turning the sprocket fasteners in small equal amounts until the tapered surfaces disengage. 9) Loosen the taper lock bushing set screw, which is located over the key. 10) Slide the taper lock bushing off of the motor drive shaft. 11) Inspect the shaft to verify it is clear of all foreign substances such as dirt, metal chips, lubricants, etc. 12) Locate a new key stock and install it into the keyway of the motor drive shaft. 13) Using your finger or a screwdriver, slide the taper lock bushing onto the shaft over the key. 34 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

39 Maintenance Sprocket and Taper Lock Bushing Installation 14) To align the taper lock bushing and the key, verify that the back surface of the taper lock bushing is flush with the key. Note: The distance between the motor/gearbox adjustment plate and the back side of the taper lock bushing should be approximately 1/2 as shown below. NOTE The distance between the back side of the taper lock bushing and the main beam on the brush end shaft should be approximately 1, as shown below. 1 1/8 to 1/4 1/2 Main beam on brush shaft end Motor drive shaft reference Face of sprocket Flange of taper lock bushing Back side of taper lock bushing Motor/Gearbox adjustment plate 15) Tighten the set screw to secure the key stock. 16) Slide the sprocket on the motor drive shaft and set it over the taper lock bushing. 17) Tighten the sprocket fasteners alternately and progressively until the tapers are seated. Note: The distance between the face of the sprocket and flange of the bushing should be between 1/8 and 1/4, as shown above. DO NOT OVER TIGHTEN. 18) Verify the sprocket alignment as shown in Sprocket Alignment. 19) Reinstall the drive chain as shown in Chain Replacement and Adjustment. 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

40 Maintenance Sprocket / Pulley Alignment Sprocket Alignment and parallelism of the shafts is very important. Place a straightedge against the outside edges of the sprockets and move sprockets until the straightedge touches the two outside and two inside edges of the sprockets or is as close as possible. The straightedge should cross the sprockets as near the shafts as possible. If the pulleys are out of alignment they must be corrected to assure proper operation of the drive train. 1) Using a straight edge, measure the difference needed to move the sprocket into alignment. 2) Follow steps 1-8 of Sprocket and Taper Lock Bushing Installation to prepare the brush shaft end sprocket for adjustment. 3) Move the Taper Lock Bushing the difference needed which was measured in step 1. 4) Follow steps 9-19 in Sprocket and Taper Lock Bushing Installation to secure the sprocket. 5) Check the alignment of the sprockets. Repeat steps as needed. 36 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

41 Maintenance Powder Coating Maintenance Just as washing your car is important for removing dirt and grime, your powder coated equipment needs to be given a regular wash to keep it looking good. In conjunction with a regular maintenance program, your powder coated equipment requires special care to maintain its durable finish, and is a smart way to protect your investment. The effects of atmospheric pollution, general dirt, grime and airborne salt deposits can all accumulate over time and should be removed at regular intervals. As a general rule powder coat cleaning should take place every six months. In areas where pollutants are more prevalent, cleaning programs should be carried out on a more frequent basis i.e. every three months. Cleaning Procedure Cleaning should start at the time the product is installed, ensuring that construction materials such as concrete, plaster and paint splashes are removed before they have a chance to dry. Failure to remove these materials at an early stage will require the use of aggressive cleaning materials and techniques with potential damage to the powder coated surface. The best method of cleaning is by regular washing of the coating using a solution of warm water and non-abrasive, ph neutral (ph 5-8) detergent solution. 1. Spray the powder coated surface with a garden hose to rinse off any loose dirt or debris. DO NOT use a power washer or high-pressure water as this can wear and cause harm to the powder coated surface. 2. Using a mild detergent and warm water clean the powder coat surface with a soft cloth, sponge, or a soft natural bristle brush. DO NOT use water heated to a temperature above 140 F, as this can wear and cause harm to the powder coated surface. 3. Rinse the sponge or soft brush as needed to prevent any abrasive debris from collecting on the cleaning surface. 4. Thoroughly rinse the powder coat surface with a garden hose after cleaning it to rinse off and remove all detergent residues. Tips & Warnings Over-cleaning or excessive rubbing can do more harm than good To prevent marring, make sure cleaning sponge, cloth, etc., are grit-free Abrasive materials such as steel wool, abrasive brushes, etc., can wear and harm finishes Do not scour painted surfaces Do not under any circumstances use strong solvents such as thinners, aggressive alkaline, acid or abrasive cleaners Do not use a power washer, high-pressure, or water heated above a temperature of 140 F, as these can wear and cause harm to the powder coated surface Always use a test surface first Use nothing stronger than white spirits to assist with stubborn stains. Cleaning with white spirits should be carried out in shade and during cooler temperatures using a soft cloth and gentle wiping only. It is also recommended that a small non-visible area be tested initially to ensure that no color change or damage will occur If you have any questions or concerns regarding how to clean powder coat equipment please call Belanger Technical Support / Aftermarket Group for additional assistance. 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

42 Maintenance Powder Coating Repair Repair, fading, blemishes and light scratches, to powder coating. Repair faded powder coating Faded powder coating means, the surface of the coating has oxidized. This is usually only the surface (2-3 microns). By rubbing with cutting compound the oxidized surface will be removed and new paint exposed with its original color. However, if the original coating was a matte finish it will now have been polished to a gloss. Repair light scratches and blemishes to powder coating. Scratches may be deeper than 2-3 microns. Use cutting compound to remove the powder coating down to the level at the bottom of the scratch. A fine rubbing down paper may speed up the process (800 to 400 grit, no coarser), but the job will need to be finished with cutting compound to remove the fine scratches left by the rubbing down paper. Repair Powder Aerosol Cleaning prior to painting. The original paint needs to be clean prior to touch up, or touching in repainting. Indoor components may have been polished with polishes containing Silicone. Silicone will repel any further painting and must be removed from the local area. Clean the surface by washing it with a detergent and a non scratch scrub sponge. Use a solution of warm water and non-abrasive, ph neutral (ph 5-8) detergent to clean material prior to painting. Thoroughly rinse and dry the surface. If solvents are needed to remove marks, a soft cloth dampened with Isopropyl Alcohol may be used. Solvents containing esters, ketones, or chlorinated solvents must not be used without consulting the paint manufacturer, as these are too aggressive and will melt the paint. A small discrete area should be tested first. Repair Powder The surface contaminants may need to be removed by abrading with fine rubbing down paper 400 grit. If the component has been damaged, causing chipping or cutting to the paint, the loose flakes should be removed. Ugly steps where the paint has been chipped need to be feathered. Coarse rubbing down paper 80 grit will do this faster, but it will leave noticeable scratches. Finer paper will produce better results, 250 grit paper is a good compromise, (this will wear smooth quickly, so replace it frequently). Primer preparation When the original paint edges have been rubbed down smooth and a step is not noticeable, remove the dust, apply a light coat of paint/primer, and allow it to dry. This will show how well the area has been prepared. Continue rubbing down and applying light coats, until the edges of the damaged paint have disappeared. Applied properly, at this stage all physical signs of repair can be lost. 38 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

43 Maintenance Powder Coating Repair Application technique for aerosol Apply three very light coats and allow each to dry. When the surface has been covered with the new paint, heavier coats may be applied. Do not rush, as this will produce runs; allow two minutes between each coat. The aerosol should never be nearer than 6 inches (150mm). Continue to move when spraying and keep the same distance from the work piece. Smooth strokes from side to side, covering the local area of damage. Start to move the aerosol before releasing the paint, and before the end of the stroke, stop releasing the paint. This should avoid ridges of paint at each end of the stroke. Patience On a warm day, if each coat has been allowed to dry before the next application, it should be possible to rub the paint down after about 30 minutes. If it starts to drag and ball the paint, leave it to dry further. It will now have to be rubbed right back to a smooth surface again, which may take another hour. More patience is required. (The thinner the coats of paint, the faster they will dry.) Types of paint The paint must have an aggressive solvent that will melt its way into the powder coating. An indication of suitability is the amount of time it takes to dry. Household polyurethane, which takes 24 hours to harden, is not suitable. This will sit on the powder, instead of melting its way into it. The result is that it will peel off. It is always a good practice to mechanically abrade a key by using rubbing down paper, or at least use a non scratch scrub sponge. A small discrete area should be tested first. 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

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45 Maintenance Replacement Parts Complete Assemblies Aluminum: Green: Driver Side Lead-In Assembly: FSTNR-BH510 (5) 1FSTNR-HH504 (8) Aluminum: Green: WASHR-LC498 (8) NUT-CL375 (5) Passenger Side Lead-In Assembly: Parts not labeled in the image below are the same as the image above Aluminum: Green: Entrance Side Bearing Components (Both Sides) 1FSTNR-HH558 (3) FSTNR-HH270 (4) 1WASHR-IT375 (4) WASHR-LC498 (3) 1NUT-RG603 (3) 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

46 Maintenance Replacement Parts Passenger Side Main Beam and Brush Components Hydraulic Main Beam Aluminum: Green: BRUSH510 Electric Main Beam Aluminum: Green: ZONE 1 ZONE (2): Hydraulic ONLY ZONE 1 ZONE 2: Hydraulic ONLY 1CLAMP462 (2) 1WASHR-FL332 (2) 483 1SPRNG332 1WASHR-LC125 (2) 1WASHR-LC291 (2) 1FSTNR-HH270 (2) 1FSTNR-HH023 (2) Hydraulic Manifold Assembly 1MCONC-ST250 (4) 1FSTNR-HH504 (4) 1WASHR-LC498 (4) Green: Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

47 Maintenance Replacement Parts Passenger Side Entrance Stand and Arm Assembly 1WASHR-LC415 (4) 1FSTNR-HH486 (2) 1FSTNR-HH586 Aluminum: 2203 Green: PLUG-PL500 (4) 1BERNG627 (4) 1FSTNR-HH811 (2) 1FSTNR-HH449 (4) 1WASHR-LC415 (4) 1FSTNR-HH468 (2) Aluminum: Green: NUT-LC220 (2) Aluminum: Green: SHOCK875 Passenger Side Exit Stand and Arm Assembly 1WASHR-LC415 (4) 1FSTNR-HH486 (2) Aluminum: 2203 Green: BERNG627 (4) 1FSTNR-HH586 Aluminum: Green: Aluminum: 2229 Green: 8093 Aluminum: 2202 Green: WASHR-LC291 (2) 1NUT-RG469 (2) 1WASHR-LC415 (4) 1FSTNR-HH449 (4) 1FSTNR-HH468 (2) Aluminum: Green: See Below 1FSTNR-HH360 (2) 483 1SPRNG332 1WASHR-LC291 (2) 1FSTNR-HH270 (2) Passenger Side Cylinder Assembly 1FSTNR-HH864 1ELBOW-PL666 (2) 1CYLND751 1NUT-JM250 1FSTNR-SB125 1NUT-LC808 1WASHR-PL500 (2) Aluminum: 995 Green: NUT-LC210 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

48 Maintenance Replacement Parts Hydraulic Motor Mounting Components (Both Sides) 1WASHR-IT375 (4) EXIT SPINDLE FSTNR-HH270 (4) FSTNR-HH558 (3) 1FSTNR-HH680 (2) 1COLLR333 Passenger Side Aluminum: Green: Driver Side Aluminum: Green: FSTNR-HH288 (4) 1WASHR-LC291 (4) 1WASHR-LC498 (2) 1NUT-RG603 (2) 1WASHR-LC498 (4) WASHR-LC581 (2) Hydraulic Motor Components (Both Sides) WASHR-LC498 1FSTNR-BH420 (2) Passenger Side Aluminum: Green: Driver Side Aluminum: Green: FSTNR-HH488 1FSTNR-HH504 (2) 1WASHR-LC498 (2) 1WASHR-FL706 (2) 1MOTOR-HY568 1WASHR-FL332 (2) Driver Side: 1PLSTC-CV047 Passenger Side: 1PLSTC-CV045 1MCONC-ST375 (2) Passenger Side: 8098 Driver Side: 8099 Driver Side Main Beam and Brush Components Hydraulic Main Beam Aluminum: Green: Electric Main Beam Aluminum: Green: Hydraulic ONLY 1WASHR-LC125 (2) 1WASHR-FL332 (2) 1CLAMP462 (2) 1FSTNR-HH023 (2) (2): Hydraulic ONLY 1BRUSH Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

49 Maintenance Replacement Parts Electric Drive Components (Both Sides) 1GEABX-AS985 1FSTNR-HH162 1WASHR-LC270 1WASHR-FL935 1FSTNR-HH558 1STEEL-KY Aluminum: 8286 Green: WASHR-LC498 1FSTNR-FH836 1WASHR-FL706 (3) 1WASHR-LC498 (3) 1FSTNR-HH552 (3) 1BSHNG485 KEY (2) 1BSHNG485 TAPER LOCK (2) 9361 (2) 1BSHNG485 SET SCREW (2) 1BSHNG485 LOCK WASHER (6) 1BSHNG485 HEX HEAD (6) 1FSTNR-HH504 (2) Passenger Side Aluminum: 8292 Green: 8296 Driver Side Aluminum: 8291 Green: WASHR-FL415 (4) 1WASHR-LC270 (4) 1FSTNR-HH155 (4) 1CHAIN805 & 1CHAIN800 PIN LINK RETAINER Passenger Side: Driver Side: WASHR-LC498 (2) WASHR-IT375 (4) 1FSTNR-HH270 (4) 1FSTNR-HH558 1WASHR-LC FSTNR-HH504 (2) 1WASHR-LC498 (2) 1WASHR-FL706 (2) NUT-RG603 (2) 1FSTNR-BH370 (2) 1WASHR-LC498 (2) WASHR-LC498 1WASHR-LC125 (2) 1WASHR-FL332 (2) Passenger Side: 1PLSTC-CV046 Driver Side: 1PLSTC-CV048 1FSTNR-HH558 (2) Aluminum: 8286 Green: FSTNR-HH504 Aluminum: Green: WASHR-LC581 (2) 1FSTNR-HH680 (2) 1BSHNG485 TAPER LOCK 1BSHNG485 SET SCREW 1BSHNG485 KEY BSHNG485 LOCK WASHER (3) 1BSHNG485 HEX HEAD (3) 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

50 Maintenance Replacement Parts Driver Side Entrance Section 1FSTNR-HH811 (2) 1SHOCK875 Aluminum: Green: PLUG-PL500 Aluminum: 2330 (2) Green: 8094 (2) 1FSTNR-HH586 1WASHR-LC415 (4) 1FSTNR-HH485 (2) Aluminum: 2203 Green: FSTNR-HH486 (2) Aluminum: Green: NUT-LC220 (2) 1WASHR-LC415 (4) 1WASHR-LC291 (2) 483 1FSTNR-HH449 (4) 1SPRNG332 1BERNG626 (4) 1FSTNR-HH270 (2) Driver Side Exit Section Parts not labeled in the image below are the same as the image above. Aluminum: Green: FSTNR-HH864 See Next Page Aluminum: Green: Aluminum: Green: NUT-LC808 1CYLND720 1NUT-JM250 1ELBOW-PL666 (2) 1FSTNR-SB125 1WASHR-PL504 (2) 1NUT-LC Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

51 Maintenance Replacement Parts Posi-Stop Assembly 1SPRNG332 1NUT-RG938 1SLEEVE Air Panel: MADAP-BR600 (4) 2529: Bracket (3) 1FSTNR-SH177 (6) 1WASHR-LC115 (6) 1TEE-PL706 1DECAL-MF040 1AIRLN440 (8 ) 1AIRLN440 (8 ) 1DECAL-MF451 1VALVE-EL710 1DECAL-MF042 1AIRLN440 (8 ) 1GAUGE500 (3) 1ELBOW-PL666 (3) 1RGLTR175 (3) 1DECAL-MF409 1REDUC-ST111 (2) 1VALVE-PN531 (2) 1MANUL080 Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

52 Maintenance Replacement Parts Spray Manifold Assembly 1VALVE-WA256 (2) 1REDUC-PL406 (2) 1ELBOW-BH902 (2) 1CLAMP (4) Aluminum: 8922 (4) Powder Coated: 8923 (4) (2) 1NOZZL-FJ870 (8) 1FSTNR-SH413 (8) 1PLUG-PL660 (2) 1FSTNR-HH458 (8) 1PLUG-PL660 1ELBOW-BH902 1REDUC-PL406 1VALVE-WA256 1CLAMP478 (3/4 ) 1CLAMP467 (1/2 ) 1TEE-PL Belanger, Inc. *PO BOX 5470 *Northville, MI * Ph (248) * Fax (248) MANUL080

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54 DuraScrubber Wheel Washer 1MANUL080 Belanger, Inc. * P.O. Box 5470 * Northville, MI Customer Service Phone (248) * Fax (248)