Top Wheel Mix & Match Belanger, Inc. P.O. Box 5470 Northville, MI 48167-5470 Customer Service Phone (248) 374-4700 Fax (248) 380-9681 www.belangerinc.com 1MANUL749 REV 09
Belanger Equipment Owners Manual Top Wheel Mix and Match Copyright 2011 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.
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 Safety Warnings... 6 Introduction... 7 Before You Get Started... 8 Specifications... 9 Requirements... 9 Output... 9 General Dimensions... 10 Installation... 11 Hub Assembly... 11 Neo-Tex Hub Assembly... 12 Whisper Wheel Hub Overview... 15 Parts Required and Relevant Note... 15 Whisper Wheel Hub Assembly... 16 Frame Assembly... 17 Securing Drive Shaft Assembly to the Driver Side Arm (Electric Drive)... 17 Securing Drive Shaft and Hydraulic Motor Assembly to the Driver Side Arm... 19 Securing the Arms to the Hub... 21 Installing the Crossbeam... 22 Attaching the Legs... 23 Tunnel Placement Overview... 24 Erecting the Frame... 25 Motor/Gearbox Installation: Electric Drive Neo-Tex/ Whisper Media... 26 Motor/Gearbox Installation: Electric Drive Brush Wheel... 28 Posi-Stops Installation... 29 Shock Assembly... 30 Auto Retract Option Installation (if applicable)... 31 Overview... 31 Parts Identification... 32 Air Panel Installation and Photo-Eye Utility Connection (if applicable)... 34 Counter Weight Installation... 35 Counter Weight Configuration... 35 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1
Table of Contents End Caps... 38 Utility Connections... 39 Water Feeds... 39 Electric Drive Motor Feed... 40 Hydraulic Drive Motor Feed... 41 Startup...43 Verify Rotation and Speed... 43 Verify Wheel Penetration... 43 Adjusting Internal Counter Weights... 44 Verify Retract Pressure (if applicable)... 44 General Startup... 44 Maintenance...45 Routine Procedures... 45 Daily... 45 Weekly... 45 Monthly... 45 General Repairs... 46 Bearing / Shaft Replacement... 46 Torque Plate and Electric Motor Replacement... 48 Replacing Torque Plate Fasteners... 50 Neo-Tex Fill Replacement... 52 Whisper Wheel Fill Replacement... 56 Exploded Parts... 59 Neo-Tex Media Hub Assembly... 59 Nylon Brush Hub Assembly... 60 Leg Assemblies... 60 Passenger Side Arm Assembly... 61 Weight Cover... 61 Driver Side Arm Assembly... 62 Shock and Mount Assembly... 62 Drive Assembly (Hydraulic)... 63 Electric Drive Assembly (2HP; Brush Application)... 63 Electric Drive Assembly (1HP; Neotex / Whisper Wheel)... 64 Cross Beam Assembly: 102909 Complete... 65 Spray Nozzle Assembly Complete... 65 Posi-Stop Parts... 66 Retract Cylinder... 66 Auto Retract Photo Eye Tree... 67 Retract Air Panel... 68 2 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
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 or value added reseller (VAR) 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 or value added reseller (VAR) 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 or value added reseller (VAR) 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 value added reseller (VAR) 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 8-15-01. Belanger reserves the right to change or modify the Belanger Inc. Limited Warranty without notice. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 3
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. 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. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
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. 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 This signal word designates a hazard or unsafe practice, which MAY RESULT IN MINOR INJURY When used by it self, 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 248-349-7010. It is imperative to your safety and the safety of others to understand the procedures before beginning work. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 5
Important Safety Information IMPORTANT Safety Information MUST READ Safety Warnings DISCONNECT MAIN POWER SUPPLY 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 prior to performing service or maintenance on machinery and equipment. Doing so will prevent unexpected energization, startup, or release of hazardous energy while maintenance and servicing activities are being performed. 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. 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. 6 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Introduction Congratulations on your purchase of the Belanger, Inc. Top Wheel. The Top Wheel is designed to operate in only 114 of tunnel space. This manual covers Hydraulic and Electric drive units. The purpose of this manual is to familiarize you with the way that the Top Wheel is installed. The Installation section will be used in conjunction with the location diagram, and the Top Wheel drawings. All of these combined are your guides to installation. The Maintenance section will be used to make sure you can keep your car wash component looking and functioning like new. Whether you have already operated a car wash or you are new to our industry, you know the importance of the appearance of a car wash and its equipment to the customer. Keeping the equipment clean will not only make the equipment easier to maintain, it will act as an example to your customer to keep their equipment (their vehicle) clean as well. Replacing the cleaning material in your tunnel as necessary will also help the image of your wash and keep the customer coming back. Read through the entire manual to familiarize you with the Top Wheel before installation. When installation is completed, you will want to keep this manual as a guide to proper maintenance. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 7
Introduction Before You Get Started Tools needed for installation: Forklift Hammer drill with 5/8 (15.8 mm) bit Torque wrench with 1/2" drive Tape measure (25 foot [8 m] or greater) Miscellaneous hand tools Level Equipment included: Clamps Tin snips 1-1/8 socket with 1/2 drive Safety glasses Work gloves 50 foot extension cord Qty Driver side leg weldment 1 Passenger side leg weldment 1 Driver side arm assembly 1 Passenger side arm assembly 1 Crossover beam assembly 1 Neo-Tex or brush wheel Depending on selection Neo-Tex, skins and wash clips Neo-Tex machines ONLY Accessory box 1 Electric or Hydraulic drive assembly Depending on selection Retract assembly option 1 if purchased Styles Available: Base top wheel Wheel option Drive Option Retract option Standard parts Neo-Tex, Whisper Wheel or Brush Hydraulic or Electric Uses air cylinder and panel to retract 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. 8 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Specifications Requirements Physical Tunnel space required 114 Unit height 140 Unit width 146 Utility Electrical Hydraulic Pneumatic Water 3 phase, 1HP motor standard 3 phase, 2HP motor for Brush Application 110V for Retract Option 6 GPM @ 900 PSI.3 CFM @ 90 PSI minimum 120 PSI maximum (1) 3/4 hose @ 4 GPM @ 40 PSI Output Physical Vehicle clearance, height 90 DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE SERVICING ANY EQUIPMENT! Always wear safety glasses when performing maintenance on any equipment It is recommended that a licensed electrician is contracted to perform all electrical installations. YOUR HYDRAULIC SYSTEM MUST BE CAPABLE OF ADJUSTMENT TO 116 RPM AT 900 PSI (62.1 BAR) WHILE LOADED AGAINST VEHICLE. PLEASE VERIFY YOUR SYSTEMS CAPABILITY TO MEET THESE SETTING WHILE RUNNING A VEHICLE PRIOR TO INSTALLING PIECE OF EQUIPMENT 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. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 9
Specifications General Dimensions 114 146 140 When in Retract Position 146 10 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Hub Assembly The type of cleaning material you have ordered will determine the first steps to assembly. Below are the instructions for the various types. Follow the one that pertains to your system and then move on to the next section. Do not discard shipping frame as it will be used to assist in installation of machine. Neo-Tex Media Hub Overview Parts Required Locking Collar Clamp Assembly Clamp Assembly includes the following: 2-1FSTNR-HH081 (1/4-20 x 1-1/2 bolts) 4-1WASHR-FL330 (1/4 flat washers) 2-1NUT-LC201 (1/4 Nylock nuts) 1PLSTC-CL050 (10 Wash Clip) The images below show some of the details that are important for proper Neo-Tex installation. When installed properly, one side of cleaning material is 6 longer than the other side Load Neo-Tex in every other slot of the hub Note: Always keep the long side of the Neo-Tex on the same side to assist in wheel balance. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 11
Installation Hub Assembly Neo-Tex Hub Assembly 1) Locate the 2 wooden risers from the shipping pallet and place the hub on the risers with the 5-hole pattern on the driver side and secure the locking collar to the hub as shown below. 5-Hole Pattern 13-1/2 13-1/2 This measurement is taken from the outside of the collar to the outer edge of the 4-Hole Hub Driver Side Position 1 4-Hole Pattern Passenger Side 2) Slide the first row of 10 wide Neo-Tex cleaning material into every other slot. Secure one of the locking collars into place, snug it against the wash clips as shown below. Note: Slide in the Neo-Tex pieces using every other slot on the hub; spin the hub as needed until there are 15 pieces around the hub. Driver Side Install Row 1 Install Clamp 12 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Hub Assembly Neo-Tex Hub Assembly 3) Install the second row of 10 wide Neo-Tex cleaning material into every other slot, followed by placing another locking collar into place, snug it against the wash clips as shown below. Install Row 2 Install Clamp 4) Install the next five rows of 10 wide Neo-Tex cleaning material, followed by placing another locking collar after the fourth row. Snug the locking collar against the wash clips as shown in the following images. Install Row 3 Install Row 4 Install Row 5 Install Row 6 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 13
Installation Hub Assembly Neo-Tex Hub Assembly Install Row 7 Install fourth locking collar 5) Load the last row of 10 wide Neo-Tex cleaning material, then secure the last locking collar into place, snug against the wash clips as show below. 6) Locate the supplied Hub Guard and fasteners. Secure them to both ends of the Hub Assembly as shown below. Hub Guard and Fasteners Before After 14 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Hub Assembly Whisper Wheel Hub Overview Driver Side Passenger Side Parts Required and Relevant Note 14 Whisper Wheel Packs Locking Collar Clamp Assembly Clamp Assembly includes the following: Whisper Wheel Fill Pack End View of Fill Pattern. 2-1FSTNR-HH081 (1/4-20 x 1-1/2 bolts) 4-1WASHR-FL330 (1/4 flat washers) 2-1NUT-LC201 (1/4 Nylock nuts) Notice the tabs on the Fill Packs go into the blotspaces of the hub. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 15
Installation Hub Assembly Whisper Wheel Hub Assembly 1) Locate the 2 wooden risers from the shipping pallet and place the hub on the risers with the 5-hole pattern on the driver side. Secure the Locking Collar to the hub in the position as shown below. 13-1/2 2) Slide the 14 Whisper Wheel media packs onto the hub one at a time until all are in place. First Fill Pack Complete Fill 3) Once all 14 Whisper Wheel media packs are loaded on the hub secure the second locking collar onto the passenger end of the hub, and tighten it snug to the Whisper Wheel media packs to hold material in place as shown below. Slide final collar tight to Whisper Wheel Pack 4) Locate the supplied Hub Guard and fasteners. Secure them to both ends of the Hub Assembly as shown below. Hub Guard and Fasteners (typical) Before After 16 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Frame Assembly Securing Drive Shaft Assembly to the Driver Side Arm (Electric Drive) The driver side Arm requires the installation of a shaft assembly prior to securing it to the frame assembly. 1) Locate the driver side Arm (shown below). It is identified by the Motor Drive Mount Plate pointed out in the image below. Motor Drive Mount Plate 2) From the accessory box, locate the 1/2-13 x 3-1/2 bolt. 3) Rotate the bearing so the opening is aligned with the lower bearing mount bolt. Align this slot and bolt together 4) Remove the existing 1 long bolt and the lock washer. Replace it with the 3-1/2 bolt from the accessory box. This will prevent the bearing from spinning during the torque process. Remove the 1 bolt and the lock washer Insert the 3-1/2 bolt 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 17
Installation Frame Assembly Securing Drive Shaft Assembly to the Driver Side Arm (Electric Drive) 5) From the accessory box, locate the 1/2 thick spacer and the shaft. Also retrieve the 3/4-16 x 1-1/2 bolt, 3/4 flat washer and the 3/4 lock washer. Secure the parts into place as shown below. Apply Red Loctite 271 on the 3/4-16 x 1-1/2 bolt. Electric Drive Shaft 3/4 flat washer 3/4 lock washer Drive Shaft for 1HP Motor used for Neo-Tex and Whisper Wheel 1/2 thick spacer 3/4-16 x 1-1/2 bolt (Apply Red Loctite 271 ) Electric Drive Shaft 3/4 flat washer 3/4 lock washer 1/2 thick spacer Drive Shaft for 2HP Motor used for Brush Style Wheel 6) Using a torque wrench, tighten the 3/4-16 x 1-1/2 bolt to 120 ft/lb. 3/4-16 x 1-1/2 bolt (Apply Red Loctite 271 ) Drive Shaft for Whisper Wheel Shown 7) Remove the 3-1/2 bolt and replace the original 1 bolt and tighten it into place. Remove 3-1/2 bolt Reinstall 1 bolt and the lock washer 18 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Frame Assembly Securing Drive Shaft and Hydraulic Motor Assembly to the Driver Side Arm The hydraulic drive shaft is shipped secured to the motor/torque plate assembly. The instructions below show how to install the shaft and hydraulic motor assembly. 1) From the accessory box, locate the 1/2-13 x 3-1/2 bolt. 2) Rotate the bearing so the opening is aligned with the lower bearing mount bolt. Align this slot and bolt together 3) Remove the existing 1 long bolt and the lock washer. Replace it with the 3-1/2 bolt from the accessory box. This will prevent the bearing from spinning during the torque process. Remove the 1 bolt and the lock washer Insert the 3-1/2 bolt 4) From the accessory box, locate the Hydraulic Motor/Shaft Assembly, the 1/2 thick spacer, 3/4-16 x 1-1/2 bolt, ¾ flat washer and the 3/4 lock washer. Secure the parts into place as shown below. Be sure to apply Red Loctite 271 to the threads of the 3/4-16 x 1-1/2 bolt. 1/2 thick spacer 3/4 flat washer 3/4 lock washer Motor/Torque Plate and Shaft Assembly 3/4-16 x 1-1/2 bolt (Apply Red Loctite 271) 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 19
Installation Frame Assembly Securing Drive Shaft and Hydraulic Motor Assembly to the Driver Side Arm 5) Using a torque wrench, tighten the 3/4-16 x 1-1/2 bolt to 120 ft/lb. 6) Remove the 3-1/2 bolt and replace the original 1 bolt and tighten it into place. Remove the 3-1/2 bolt Reinstall the 1 bolt and lock washer 7) Tighten the four nuts of the torque plate securely to the arm. Be sure the torque plate grommets are not bottomed out on the arm or the four bolts. The torque plate should kind-of float. The images below display tips on how to gauge the proper positions of the bolts. Bolts should be flush on the inside of the beams (typical) 2 from inside edge of bolt to outside edge of mounting plate 20 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Frame Assembly Securing the Arms to the Hub The images below show how to install the arms onto the hubs. You may need someone to rotate the end of the arms to get the bolts into place. The driver side requires five 1/2-13 x 1 bolts, and the passenger side requires four 7/16-14 x 1-1/4 bolts. Be sure to use lock washers on all bolts. Secure the arms to the hub Driver Side Passenger Side You may have to pivot the arms to access the bolt holes Direction of Travel 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 21
Installation Frame Assembly Installing the Crossbeam Locate the Crossbeam. Secure the Cross Beam to the arms making sure the spray nozzles are facing the hub as shown below. Use 1/2-13 x 1-1/4 bolts with 1/2 flat washers and 1/2 lock washers. Before completely tightening the Cross Beam, be sure to take a measurement at both ends of the arms to make sure the frame is square. Once square, tighten all bolts. Cross Beam NOTE: Spray Nozzles are to face the hub Secure the Crossbeam to the Legs 22 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Frame Assembly Attaching the Legs See the image below to help determine the passenger side leg from the driver side leg. Driver Side Leg has this Posi-Stop Mount 1) Cut the tie-wrap from the shock mounted to the driver side arm and remove the 5/8 x 3 bolt and nut to allow removal of the Shock Assembly from the driver side Arm Assembly. 2) Once the two legs have been identified, secure the leg to the arms in the orientation shown below. Shock located here Direction of Travel You may need someone to rotate the end of the legs to get the bolts into place. Four 7/16-14 x 1 bolts are required on each leg. Use lock washers on all bolts. You may have to pivot the legs to access the bolt holes Secure the driver side legs to the arms Secure the passenger side legs to the arms 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 23
Installation Frame Assembly Tunnel Placement Overview As stated earlier, tunnel depth placement will vary from site to site. The images below show the correct side-to-side placement. Note: The image below is shown with the Over-Under Conveyor option. Your system may have the standard Guide Rails. Placement is the same for both. 45 Direction of Travel Floor Note: The 45 dimension is taken from the outside driver side leg base plate, to the inside guide rail. 24 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Frame Assembly Erecting the Frame 1) Locate the shipping skid that the unit arrived on and slide it under the hub assembly. Clamp the Top Wheel to the skid. Be sure to clamp equipment securely to the forks of the forklift. Do not stand under load while forklift is in operation. 2) Slowly raise the skid until the legs are hanging in a vertical position and move the unit into its tunnel location. 3) Anchor driver side leg to the floor keeping in mind the required operation space for other tunnel components. 4) Measure distance between the upper and lower legs. Make sure the frame is square and lag the passenger side leg to the floor. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 25
Installation Frame Assembly Motor/Gearbox Installation: Electric Drive Neo-Tex/ Whisper Media 1) If you have the Plastic Motor Cover option, locate and assemble the cover mount plate, the 1/4-20 x 3/4 bolts and the 1/4 lock washers. Secure the Motor Cover into place as shown below. 2) Secure the Motor/Gearbox assembly into place in the order shown below. Steel Key Motor Cover Option 9/16 Lock Washers Torque Plate Studs 9/16 Flat Washers Retainer Pins 3) When assembled it should appear as one of the images below. Standard Retainer Pins Motor Cover Option 26 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Frame Assembly Motor/Gearbox Installation: Electric Drive Neo-Tex/ Whisper Media 4) After the motor has been wired, secure the lid onto the plastic motor cover using the supplied self-tapping screws as shown below. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 27
Installation Frame Assembly Motor/Gearbox Installation: Electric Drive Brush Wheel 1) Locate the electric motor 1/4 x 1/4 steel key. Apply Never Seize to the drive shaft keyway and slide the key into the slot on the driver side arm as far as it will go in as shown below. Before After 2) Carefully secure the motor assembly to the mount in the proper orientation as shown below. 3) The electric drive gearbox will be secured to the outer holes of the mounting plate using 3/8-16 x 1-1/4 bolts with lock washers. Before After 4) Tighten the setscrews of the gearbox using a 5/32 Allen wrench. Setscrews located here 28 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Frame Assembly Posi-Stops Installation 1) Locate the Posi-Stop mounting parts shown below. 2) Slide the spacer over the longer mount (below, right) and secure the two 3 Rubber Stop Spacers to the posts as shown below. 3 Rubber-Stop Spacer Posi-Stop Down Mount Posi-Stop Up Mount 2-1/4 x 1-1/4 Spacer Up Mount with 2-1/4 x 1-1/4 Spacer Down Posi-Stop Mount with 3 Rubber-Stop Spacer Posi-Stop Up Mount with 3 Rubber-Stop Spacer 3) Secure the Posi-Stop mount assemblies into place on both legs as shown below. Mount Posi- Stops on driver side leg here Up Stop Block Down Taller mount is to be installed on the entrance 3 Rubber Stop Spacer Direction of Travel Direction of Travel 4) Locate the two Posi-Stops and the four white plastic sleeves shown below. Pinch the sleeve together and slide it into the rubber stop. Slide the rubber stops onto the mounts. Rubber Stop Plastic Sleeve Stop Block Down Rubber Stop 5) Screw the Down Rubber Stop until the wheels center height is at 53 and verify that the shock does not make contact with the Stop Block. Note: Make sure that both arms make contact with the rubber stops. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 29
Installation Frame Assembly Shock Assembly 1) Secure the Shock Assembly back onto the driver side Arm Assembly. 2) Secure the unattached end of the shock to the clevis as shown below. 30 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Auto Retract Option Installation (if applicable) This option includes a set of Photo Eyes Trees that mount on the legs of the Top Wheel to detect the presence of a pickup truck. Note: The Auto Retract MUST be mounted with the Photo Eyes on the entrance side of the Top Wheel legs as shown below. Overview Driver Side Photo Eye Emitter Tree Passenger Side Receiver Tree 1) Locate the Photo-Eye Tree Mount Assemblies, the mounts and the appropriate hardware. 2) Secure the Photo-Eye Mount onto the leg as shown below. Both upper Photo Eyes to be set at 60 from floor Both lower Photo Eyes to be set at 40 from floor 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 31
Installation Auto Retract Option Installation (if applicable) Parts Identification 1) Locate the 2 Photo-Eye Trees. 2) Install the 2 End Caps to each of the Photo-Eye Tree Mounts (one on the top and one on the bottom of each) it they are no already in place; End Cap 3) Screw the Sensitivity Reducer onto the upper Receiver on the passenger side as shown below. Photo Eye and Sensitivity Reducer 32 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Auto Retract Option Installation (if applicable) Wiring for Optional Auto Retract The information below covers the electrical connections required for proper operation of the Top Wheel Optional Auto-Retract. Upper Receiver Brown + Blue - Black (Signal) Lower Receiver Brown + Blue - Black (Signal) Upper and Lower Emitter Brown + Blue - 340 (24VDC) 338 (DC COM) X10 340 (24VDC) 338 (DC COM) X11 340 (24VDC) 338 (DC COM) Wire the Pneumatic Retract Cylinder to NAMED 6 Output Y20 or NAMED 7 Output Y21 DO NOT run any of these wires through the crossbeam Once wired, confirm that both Auto- Retract Upper and Lower inputs are ON by verifying that the LED s of the Output Board are ON Block each Receiver and confirm that the correct Input turns OFF. Blocking Emitter may not turn off Input If the upper Auto-Retract Input does not com ON, adjustment may be required. Do so by loosening the Photo Eye tube on the passenger side and rotate until Input is ON and remains ON 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 33
Installation Auto Retract Option Installation (if applicable) Secure the Retract Cylinder into place on the passenger side arm and leg as shown below using 1/4-20 shoulder bolts with 1/4-20 Nylock nuts and washers. Secure cylinder here using the supplied white plastic washers on both sides Secure cylinder here using the supplied 5/16 and 1/4 flat washers Air Panel Installation and Photo-Eye Utility Connection (if applicable) 1) Locate the Air panel and secure it to the wall, preferably in the equipment room. 2) Run 3/8 poly-flow airline from the regulator of the air panel to the fitting on the Retract Cylinder as shown below. 34 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Counter Weight Installation Things to Know The counter weights are used to off-set the weight of the cleaning material and the motor/gearbox assembly. Since the motor/gearbox assembly is typically on the driver side, there will be more weights added to that side to prevent torque motion during operation or when making contact with the positive stops. The fewer counter weights used, the more weight (penetration) will be applied to the vehicle surface during operation. Below are examples of typical configurations. Counter Weight Configuration Use the following charts to determine the proper counter weight configuration to suite your washing preference. Electric Drive with Brush Driver Side Passenge r Side Electric Drive with Neo-Tex Driver Side Passenge r Side Hydraulic Drive with Brush Driver Side Passenge r Side 50# 3 2 3 1 3 1 25# 1 1 0 1 0 1 10# 0 0 0 0 0 0 Bolt Length 6 5 5 3-1/2 5 3-1/2 Hydraulic Drive with Neo-Tex Hydraulic Drive with Whisper Wheel Electric Drive with Whisper Wheel Driver Side Passenger Side Driver Side Passenger Side Driver Side Passenger Side 50# 3 0 2 1 3 1 25# 0 0 1 0 1 1 10# 0 0 0 1 0 1 Bolt Length 6 5 5 3-1/2 5 3-1/2 Be aware of the pivoting arms. Either block and clamp the pivoting section in place or have someone assist in keeping it in place until the weights have been bolted down! 1) Locate the 2 piece weight covers and the 6 plastic clips. 2) Use the Counter Weight Configuration Chart to determine the amount of weight required to balance your Top Wheel, and the bolts required to hold the weights in place. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 35
Installation Counter Weight Installation Counter Weight Configuration 3) Once the required weight configuration has been determined place the Rear Cover on the back of the arm as shown below, making sure all holes are lined up and place all required weight(s) onto the arm keeping all holes lined up. Note: You may need a screwdriver to help position holes and keep them lined up. Weights (typical) Front Cover Rear Cover 4) Tightly secure all weights in place using the correct 1/2-13 bolts, flat washers, and lock washers. 5) Once the weights have been secured into position, place the Front Cover over the weight(s). 6) Drill one 1/4 hole thru the top of the Front and Rear Covers at 5/8 from the edge as shown below. Drill two more 1/4 holes 120 degrees in each direction from the top hole. 5/8 Overhead View 36 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Counter Weights and Covers 7) Insert the 3 black plastic clips into the holes to secure the 2-piece weight cover. Plastic Clip (typical) Front View 8) Finally drill a 1/4 hole from the bottom of the cover at 1-1/2 inward from the edge as shown below. This will allow water to drain out of the cover. Front View Bottom View 1-1/2 Drill Here 9) In a situation where there is an arm that requires no Counter Weights, place the Rear Cover on the back of the arm and tighten down with the provided 1/2-13 x 1 bolts and the flat washers. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 37
Installation End Caps 1) Assuming the system has been flushed and the correct configuration for the weights have been figured out, look in the Accessory Box and locate the 2 black plastic End Caps and the tube of Loctite glue. 2) Take one of the Caps and notch off one side. This will be placed on the driver side Arm to allow room for the weld. 3) Locate the supplied glue and apply to the inside of Caps on all 4 sides and then secure one Cap to the end of each of the Arms. 4) Drill a 1/4 hole at the upper and lower end of each End Cap. The upper hole is to allow for the scale to get the weights right and the lower hole is to let any water drain from the frame. Passenger Side (Before) Passenger Side (After) Driver Side (Before) Driver Side (After) Install Cap Here Install Cap Here 38 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Utility Connections Water Feeds 1) Install and tighten the supplied plastic elbow for the water feed to the water manifold. The elbow MUST face in the direction shown in the image below which is in the opposite direction of the spray nozzles. 2) Install 3/4 water hose to spray manifold located in the cross beam using the supplied Hose Clamp as shown below. Hose Clamp 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 39
Installation Utility Connections Electric Drive Motor Feed Note: The image below shows the standard 1HP electric motor/gearbox assembly. The same routing applies to all electric drive assemblies. 1) Route electrical feeds to the motor as shown below and follow wiring directions on motor to make proper connections. Tie-wrap cable and hose together Water Feed Electrical Feed Image above shown with stauff clamps in place It is recommended that a licensed electrician is contracted to perform all electrical installations. 2) Locate the green plastic stauff clamps and secure them to the side of the driver side arm as shown below using 1/4-20 x 1-1/4 socket head fasteners. The mounting plates are designed to accommodate both electric and hydraulic drive. For electric drive be sure to insert the socket head fasteners into the top and third holes as shown below. Use these holes for electric drive Clamp Mounts 40 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Installation Utility Connections Hydraulic Drive Motor Feed 1) Locate the two 1/2 MJIC Straight Fittings and two 1/2 MJIC Elbows from the Accessory Box. Apply liquid Teflon to all threads of the fittings and secure into place as shown below. Before After 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 41
Installation Utility Connections Hydraulic Drive Motor Feed 1) Route hydraulic feeds from the motor to the distribution block as shown below. They are then to be fed to the Hydraulic Power Unit. See the arrows in the image below for proper motor and wheel rotation. Tie-wrap cable and hose together Water Feed Distribution Block Feed Hydraulic Feeds Return Image above shown with stauff clamps in place 2) Locate the green plastic stauff clamps and secure them to the side of the driver side arm, stacked two high as shown below using 1/4-20 x 2-3/4 socket head fasteners. The mounting plates are designed to accommodate both electric and hydraulic drive. For hydraulic drive be sure to insert the socket head fasteners into the second and bottom holes as shown below. Use these holes for electric drive Clamp Mounts 42 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Startup Verify Rotation and Speed There are numerous ways to check rotation speed of a wheel. One way that we recommend is to tie a white thin object, such as a tie-wrap, around the hub. Power up the wheel up and count the rotation of the tie-wrap. Optimal Rotation Speeds Hydraulic Drive with Neo-Tex or Whisper Wheel 112-120 RPM Adjust using the hydraulic flow control Hydraulic Drive with Brush 95-100 RPM Adjust using the hydraulic flow control Electric Drive with Neo-Tex or Whisper Wheel 116 RPM Verify proper gearbox Electric Drive with Brush 116 RPM Verify proper gearbox Verify Wheel Penetration Be sure the wheel is spinning at the proper speed and in the proper direction. Always check wheel penetration while the wheel is spinning. The initial wheel weight can be checked using the supplied fish-scale. Hook the scale to the passenger-side arm, and raise arm perpendicular to the legs. Power up the wheel to verify the actual weight of penetration the wheel is applying to the vehicle surface. Notice the scale is hooked to passenger side arm while arms are perpendicular to legs. Direction of travel The wheel weight can be adjusted three ways Sliding the internal arm weights shown below Removing one of the sliding weights from the passenger side arm Adding weights; which will decrease wheel weight thus creating less wheel penetration Removing weights; which will increase wheel weight creating more wheel penetration BE AWARE OF THE AREA SURROUNDING A ROTATING PIECE OF EQUIPMENT. OBJECTS MAY BECOME TANGLED WITH EQUIPMENT AND COULD RESULT IN SERIOUS INJURY OR DEATH. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 43
Startup Adjusting Internal Counter Weights Sliding the weights inward (towards the legs) will increase wheel weight thus creating more wheel penetration. Sliding the weights out will decrease wheel weight creating less wheel penetration. Inner weight slides back and forth Loosen these bolts to slide the internal weight back and forth Verify Retract Pressure (if applicable) With the wheel spinning, adjust the air pressure on the regulator located on the Photo-Eye Retract Air Panel. This will adjust the speed in which how fast or slow wheel will raise off the vehicle surface. General Startup Flush water through the manifold to remove any debris Install the nozzles on manifold Run a test vehicle 44 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Maintenance Routine Procedures Daily Start with a Test Wash to insure proper operation of all equipment. Check overall performance for any abnormalities. Inspect for clogged nozzles. This can best be done while running the Test Wash. Nozzles can be cleaned by removing the nozzle bodies and tapping or inserting a thin wire into the nozzle opening. Make sure cleaning material is not tangled. Check for water and/or chemical leaks after equipment is turned off. Weekly Check weights on the wheel to confirm the desired balance. Adjust as necessary. Go through the Hub Assembly and make sure that all fasteners that hold the Hub Adaptors, are in place and tight. Hose down the component and surrounding area. This will remove the majority of the dirt and other debris that builds up during a week. Monthly Wash component down with a good degrimer such as laundry detergent and hot water. Check wash material for wear. Replace if necessary. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 45
Maintenance General Repairs Bearing / Shaft Replacement The best method to capture a bearing is by properly tightening it in position. When tightening a bearing assembly an adequate amount of torque needs to be applied to ensure that the bearing is securely captured. When replacing or performing maintenance that requires disassembling the Top Wheel Drive Bearing follow the instruction below to ensure the bearing is securely captured. Due to the amount of force applied when tightening to 120 ft/lb we recommend replacing the 3/4-16 x 1-1/2 bolt whenever the drive bearing assembly requires maintenance or is disassembled. Drive Bearing Replacement 1) Install new bearing, using two of the three 1/2-13 X 1 bolts to secure the bearing to the driver-side arm. 2) Temporarily install a 1/2-13 x 3-1/2 bolt to prevent the bearing from spinning during the torque process. Insert 3-1/2 bolt 3) Secure the parts into place as shown below. Apply Red Loctite 271 on the threads of the 3/4-16 x 1-1/2 bolt. Drive Shaft 1/2 thick spacer 3/4 flat washer 3/4 lock washer 3/4-16 x 1-1/2 bolt (Apply red Loctite 271 ) 46 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Maintenance General Repairs Drive Bearing Replacement 4) Using a torque wrench, tighten the 3/4-16 x 1-1/2 bolt to 120 ft/lb. 5) Remove the 3-1/2 bolt and replace the original 1 bolt and tighten it into place. Remove the 3-1/2 bolt Replace with 1 bolt and lock washer Follow this same assembly process when replacing or performing maintenance to the drive shaft 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 47
Maintenance General Repairs Torque Plate and Electric Motor Replacement DANGER DISCONNECT MAIN POWER SUPPLY PRIOR TO SERVICING OR MAINTAINING EQUIPMENT Remove Motor Gearbox assembly 1) To ensure safety we recommend following the OSHA Lockout / Tagout procedure prior to performing service or maintenance on machinery and equipment. If the assembly does not have a cover proceed to step 3 2) Remove both Phillip head screws, to allow plastic cover to be removed from cover base. Remove Phillip Head Screws 3) Verify power has been removed from circuit by checking voltage at the junction box with a multi-meter to confirm no power is being supplied to the equipment. 4) Remove the junction box cover to gain access to motor wiring. 5) Remove the nuts to release wiring from the terminal block. 6) Verify wiring has been tagged for proper terminal connections if not previously identified at original installation. 7) Disconnect wiring leads, and remove electric feed Wires are located behind the terminal strip and will need to be pulled through the cord grip fitting on the bottom of the junction box. The cord grip will need to be loosened, or removed so that the wiring can be pulled down through the cover base if equipped. 48 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Maintenance General Repairs Torque Plate and Electric Motor Replacement Remove Motor Gearbox assembly 8) Remove torque stud retainer pins and washers. This will allow the motor gearbox assembly to be removed by pulling the assembly straight up and off of the torque studs and off the wheel shaft. Move the motor gearbox assembly to a work surface and turn it over to expose the bottom of the cover and the cover mounting plate if so equipped. You will need a work surface such as a table or a bench available to allow for disassembly of the gearbox torque plate. If the assembly does not have a cover proceed to step 10 9) The cover base can be removed by removing the three fasteners on the cover mount plate. Once the cover mount and cover are removed it will allow access to the bottom of the gearbox torque plate assembly. 10) Using a 5 mm Allen wrench; remove the four fasteners to separate the torque plate and mounting ring from the gearbox to expose the mounting holes on the gearbox. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 49
Maintenance General Repairs Torque Plate and Electric Motor Replacement Replacing Torque Plate Fasteners 1) Using the Loctite cleaner, clean the bottom of the gearbox along with the threaded holes. Allow time to air dry, in a warm environment. Make sure the gearbox mounting holes are clean and thoroughly dry; if not repeat the process. Once the mounting holes are cleaned and dry the gearbox can be reassembled. 2) Assemble the torque ring and torque plate back onto the gearbox as shown. Note: Confirm the position of the torque plate to ensure proper orientation on the gearbox. 3) Before installing the M8 flat head fasteners used to secure the torque plate onto the bottom of the gearbox you will need to prepare the fasteners with Red Loctite 271. The following steps will guide you through how to properly prepare the fasteners: a. Carefully apply a bead of Red Loctite 271 lengthwise to the bottom half of the fastener. The bead should be as wide as the Loctite nozzle tip (approximately 3/16 ). b. Turn the fastener a 1/4 turn, then reapply the Loctite in the same fashion. c. Repeat steps on remaining fasteners. 4) Insert the fasteners into the threaded mounting holes and tighten until the fasteners touch the chamfered hole within the torque plate. Before tightening fasteners to the proper torque, once again verify that the torque plate orientation is correct on the gearbox. 5) Using a torque wrench with a 5 mm hex-bit socket, torque all four fasteners to 25 ft-lbs. 6) Allow this assembly to cure at least 24 hours in a warm (70 degree) environment. Doing so ensures the fasteners will set properly. Loctite requires at least 24 hours to set properly. Reinstall Motor Gearbox assembly If the assembly does not have a cover proceed to step 2 1) Secure the plastic cover to the gearbox, by reinstalling the cover mount and tightening the fasteners into position as show below. 2) Slide the gearbox assembly back onto the drive shaft, by aligning the gearbox keyway with the key in drive shaft. 3) Once the key and keyway are aligned, lower the gearbox onto the torque bolts to its resting position. 50 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Maintenance General Repairs Torque Plate and Electric Motor Replacement Reinstall Motor Gearbox assembly 4) Secure gearbox in position using washers and retainer pins. 5) Feed the wiring through cover base, then through cord grip on the motor junction box. Make sure to tighten cord grip properly to prevent any water intrusion. 6) Fasten the terminal block back into position using the Phillips screws. Be careful not to crimp or crush any of the existing wiring. 7) Connect the wiring leads to the proper terminal, using previously tagged motor leads to maintain proper wiring positions. 8) Replace junction box cap. Be careful not to crimp or crush any of the existing wiring. 9) Once the motor gearbox unit is properly secured into position, power can be turned back ON. 10) Verify wheel rotation prior to running any test vehicle through the system. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 51
Maintenance Neo-Tex Fill Replacement Neo-Tex Hub Overview Parts Required Neo-Tex Clamp Assembly Clamp Assembly includes the following: 2-1FSTNR-HH081 (1/4-20 x 1-1/2 bolts) 4-1WASHR-FL330 (1/4 flat washers) 2-1NUT-LC201 (1/4 Nylock nuts) 1PLSTC-CL050 (10 Wash Clip) The images below show some of the details that are important for proper Neo-Tex installation. When installed properly, one side of cleaning material is 6 longer than the other side Load Neo-Tex in every other slot of the hub Note: Always keep the long side of the Neo-Tex on the same side to assist in wheel balance. Top Wheel Neo-Tex Cleaning Media Part Numbers Black Blue Red Green Orange Yellow 41 x 10 x 1/8 thick 6342 6343 6345 6344 7414 6405 52 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Maintenance Neo-Tex Fill Replacement 1) Place the hub on riser type platform with the 5-hole pattern on the driver side and secure the locking collar to the hub as shown below. 13-1/2 13-1/2 This measurement is taken from the outside of the collar to the outer edge of the 4-Hole Hub 5-Hole Pattern 13-1/2 Driver Side Position 1 4-Hole Pattern Passenger Side 2) Slide the first row of 10 wide Neo-Tex into every other slot as shown below. Secure one of the locking collars into place as shown below and snug it against the Wash Clips. Note: Slide in the Neo-Tex pieces using every other slot on the hub; spin the hub as needed until there are 15 pieces around the hub. Driver Side Install Row 1 Install Clamp 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 53
Maintenance Neo-Tex Fill Replacement 3) Install the second row of 10 wide Neo-Tex cleaning media into every other slot, followed by placing another locking collar into place, snug against the wash clips as shown below. Install Row 2 Install Clamp 4) Install the next five rows of 10 wide Neo-Tex cleaning media into every other slot, followed by placing another locking collar into place, snug against the wash clips as shown below Install Row 3 Install Row 4 Install Row 5 Install Row 6 54 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Maintenance Neo-Tex Fill Replacement Install Row 7 Install fourth locking collar 7) Load the last row of 10 wide Neo-Tex cleaning material, then secure the last locking collar into place, snug against the wash clips as shown below. 8) Attach the Hub Guard and fasteners to both ends of the hub as shown below. Hub Guard and Fasteners Before After 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 55
Maintenance Whisper Wheel Fill Replacement Whisper Wheel Hub Overview Driver Side Passenger Side 14 Whisper Wheel Packs Whisper Wheel Fill Pack Part Numbers The table below lists the part numbers for the individual Fill Packs Whisper Wheel Fill Pack Black Blue Red Green Orange Yellow 108550 108551 108552 108554 108555 108553 End View of Fill Pattern. Notice the tabs on the Fill Packs go into the slotted-spaces of the hub Parts Required Locking Collar Clamp Assembly Clamp Assembly includes the following: 2-1FSTNR-HH081 (1/4-20 x 1-1/2 bolts) 4-1WASHR-FL332 (1/4 flat washers) 2-1NUT-LC210 (1/4 Nylock nuts) 56 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Maintenance Replacing Whisper Wheel Cleaning Material 1) Secure Locking Collar 13-1/2 from the driver side edge of hub as shown below. 13-1/2 Note: 5-hole pattern is on the driver side. 4-hole pattern is on the passenger side. 2) Slide the 14 Fill Packs onto the hub one at a time until all are in place. First Fill Pack Complete Fill 3) Once all 14 Packs have been loaded onto the hub, secure the second Locking Collar onto the passenger side end of the hub and tighten it snug to the Whisper Wheel to hold the material in place as shown below. Slide final collar tight to Whisper Wheel Pack 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 57
Maintenance Replacing Whisper Wheel Cleaning Material 4) Attach the Hub Guard and fasteners to both ends of the hub as shown below. Hub Guard and Fasteners (typical) Before After 58 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Maintenance Exploded Parts Neo-Tex Media Hub Assembly 7546: Drive Adaptor (5-Bolt Hub) 7587 (2) 7545 108286: Hub Assembled 7547: Drive Adaptor (4-Bolt Hub) 6100: Driver Side 5-Bolt Bearing 7144: Hub Assembly Complete 108286: Top Wheel Solid Neo-Tex Assembly 6839: Hub Clamps (5 sets) 6101: Passenger Side 4-Bolt Bearing 1WASHR-FL332: 4 pieces 1FSTNR-HH081: 2 pieces 1FSTNR-BH510 (4) 6839 1FSTNR-HH491: 5 pieces 1WASHR-LC456: 5 pieces 1FSTNR-HH453: 4 pieces 1WASHR-LC420: 4 pieces 6839 7141 1NUT-LC210: 2 pieces 6839 Complete 7587 Complete 6100 5-Bolt 6101 4-Bolt 7546: Drive Adaptor (5-Bolt Hub) 7547: Idler Adaptor (4-Bolt Hub) 7545 Uses: 1FSTNR-BH510 (4) Uses: 1FSTNR-BH510 (4) Uses: 1FSTNR-BH510 (6) 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 59
Maintenance Exploded Parts Nylon Brush Hub Assembly 6100: Driver Side 5-Bolt Bearing 1BRUSH845 6101: Passenger Side 4-Bolt Bearing Leg Assemblies See previous page for fastener information on the bearings 102912: Passenger Side Leg Assembly 102901: Driver Side Leg Weldment 102902: Passenger Side Leg Weldment 1BSHNG364 (2) 60 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Maintenance Exploded Parts Passenger Side Arm Assembly 6101: 4-Bolt Bearing 1FSTNR-HH288: 4 pieces 1WASHR-FL498: 4 pieces 1WASHR-LC291: 4 pieces Passenger Side Arm Assembled: 102907 1WASHR-FL706: 2 pieces 1WASHR-LC456: 2 pieces 6833: 50 pound weight 6834: 25 pound weight 102905 1WASHR-LC415: 2 pieces 1FSTNR-HH594: 3-1/2 1FSTNR-HH630: 5 1FSTNR-HH666: 6 1BSHNG364 6832: Adjustable Weight 1WASHR-FL585: 2 pieces 1FSTNR-HH449: 2 pieces 6101: 4-Bolt Bearing 1FSTNR-HH288: 4 pieces 1WASHR-FL498: 4 pieces 1WASHR-LC291: 4 pieces Weight Cover 1PLSTC-CR470 (includes both pieces) 1CLIP-PL250 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 61
Maintenance Exploded Parts Driver Side Arm Assembly Driver Side Arm Assembled: 102908 1WASHR-LC456: 2 pieces 1WASHR-FL706: 2 pieces 6834: 25 pound weight 6833: 50 pound weight 1FSTNR-HH594: 3-1/2 1FSTNR-HH630: 5 1FSTNR-HH666: 6 6100: 3-Bolt Bearing 1FSTNR-HH491: 3 pieces 102904 6832: Adjustable Weight 1WASHR-FL585: 2 pieces Assembly Shown Below 6101: 4-Bolt Bearing 1FSTNR-HH288: 4 pieces 1WASHR-FL498: 4 pieces 1WASHR-LC291: 4 pieces 1WASHR-LC415: 2 pieces 1FSTNR-HH449: 2 pieces Shock and Mount Assembly 1WASHR-FL830 1FSTNR-HH288: 4 pieces 1WASHR-LC291: 4 pieces 6845: Sleeve 1NUT-LC220 1SHOCK875 6838 1NUT-LC220 1FSTNR-HH918 1WASHR-FL830 Hydraulic Hose Fittings 1FSTNR-HH811 100092 1FSTNR-HH811 1ELBOW-ST539 1MCONC-ST250 62 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Maintenance Exploded Parts Drive Assembly (Hydraulic) Note: See General Maintenance procedure when replacing shaft components. 1FSTNR-HH817 6841: 1/2 Spacer 1SHAFT840 1COLLAR333 1NUT-RG670 (4) 101567 1FSTNR-HH734 (4) 1254 1WASHR-FL810 1WASHR-LC830 1MOTOR-HY711 1WASHR-LC291 (4) 1FSTNR-HH270 (4) Hydraulic Drive Assembly Complete 102914 All parts from Hydraulic Motor to 1SHAFT840 Electric Drive Assembly (2HP; Brush Application) 1FSTNR-HH817 1FSTNR-HH288 (4) 1GASKT825 1MOTOR-EL621 1WASHR-LC830 1WASHR-LC291 (4) 1WASHR-FL810 Key included with Gearbox 1GEABX295 6841: 1/2 Spacer 1WASHR-ST375 (4) 1SHAFT830 1FSTNR-HH261 (4) Standard Electric Drive Assembly Complete 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 63
Maintenance Exploded Parts Electric Drive Assembly (1HP; Neotex / Whisper Wheel) Note: See General Maintenance procedure when replacing shaft components. 1WASHR-LC830 1WASHR-FL810 1WASHR-LC125 (3) 1GEABX-AS985 1FSTNR-PH040 (2) 108661 6841: 1/2 Spacer 1SHAFT835 1FSTNR-HH045 (3) 1FSTNR-HH817 Key included with Gearbox See Chart 7918 1WASHR-LC581 (2) 8556 (2) 1FSTNR-FH025 (4) 1MOTOR-EL621 7912 1RETNR129 (2) 1WASHR-FL747 (2) 1PLSTC-CV075 Motorvario Electric Drive Assembly Complete Black: PLSTC-CV080 Blue: PLSTC-CV082 Green: PLSTC-CV088 Gray: PLSTC-CV092 Orange: PLSTC-CV086 Red: PLSTC-CV084 Yellow: PLSTC-CV090 1RETNR129 1FSTNR-PH040 64 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Maintenance Exploded Parts Cross Beam Assembly: 102909 Complete 1FSTNR-HH504 (4 per side) 769 (Plug) 102903: Cross Beam Weldment 1WASHR-LC498 (2) 1FSTNR-HH504 (2) 1WASHR-LC498 (4 per side) 1CLAMP269 6279 1ELBOW-PL915 1CLAMP478 102906: Water Manifold Weldment Spray Nozzle Assembly Complete 1NOZZL-FJ116: Nozzle Tip 1NOZZL972: Cap and Gasket 1NOZZL993: Nozzle Body 1MCONC-SS025: Extension 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 65
Maintenance Exploded Parts Posi-Stop Parts 2078 6820 6819 6814 1SPRNG332 1SLEEV666 Retract Cylinder 105835: Cylinder Assembly Complete 1MADAP-BR605 1NUT-LC210 1NUT-LC210 1WASHR-FL332 1VALVE-PN405 1CYLND968 1NUT-JM250 995 1WASHR-PL500: 2 pieces 1FSTNR-SB125 1WASHR-FL415 1FSTNR-SB125 Clamps used to secure Cylinder Hose to Leg Assembly 1CLAMP294: 2 pieces 1FSTNR-SH384: 2 pieces 1WASHR-FL332: 2 pieces 66 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Maintenance Exploded Parts Auto Retract Photo Eye Tree 1ELECT-SN654: Driver Side (2) 1ELECT-SN653: Passenger Side (2) NOTE: LED Indicators are to face UP 1CAP152 1FSTNR-HH648 (2) 1WASHR-LC498 (2) 6804 6757 6805 102977: Driver Side Complete Assembly 1WASHR-LC125 (2) 1FSTNR-SH457 (2) NOTE: LED Indicators are to face DOWN 1ELECT-EN500 102975 1ELECT-FS180 (2) 1ELECT-FS183 (2) 1ELECT-FS182 (2) 1FSTNR-SH148 (4) Auto-Retract Photo Eye (includes 1 thick plastic nut and 1NUT-PL600 which is thin) The Photo-Eyes include two plastic nuts (only one is used). The nut used for mounting the Photo-Eye (inside of the tube) is 1NUT-PL600 and must be ordered separately. The thin nut goes on the inside of the aluminum tube. When replacing a Photo-Eye be sure to position the clear LED indicators toward the closest end to make verification of operation easier. 1MANUL749 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 67
Maintenance Exploded Parts Retract Air Panel 102913: Air Panel Assembly Complete 1FSTNR-SH177: 2 pieces 1WASHR-LC115: 2 pieces 1WASHR-LC115: 2 pieces 1WASHR-LC115: 2 pieces 1MADAP-BR600: 2 pieces 1FSTNR-SH177: 2 pieces 2501 1ELBOW-PL666 2529 1VALVE-EL370 1FSTNR-SH059: 2 pieces 3699 1AIRLN165 1RGLTR175 1GAUGE500 1ELBOW-PL535 68 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL749
Top Wheel Mix and Match 1MANUL749 Belanger, Inc. * P.O. Box 5470 * Northville, MI 48167-5470 Customer Service Phone (248) 374-4700 * Fax (248) 380-9681