All Styles Belanger, Inc. P.O. Box 5470 Northville, MI 48167-5470 Customer Service Phone (248) 374-4700 Fax (248) 380-9681 www.belangerinc.com 1MANUL247 REV 25
Belanger, Inc. Gyro Wrap All Styles
Table of Contents Belanger Incorporated Limited Warranty... 3 Operational Warning... 4 Introduction... 5 Important Safety Information... 5 Safety Symbols and Signal Words... 5 IMPORTANT Safety Information MUST READ... 6 Safety Warnings... 6 Before You Get Started... 8 Specifications... 9 Requirements... 9 Output... 9 General Dimensions (Left-Hand Drive)... 10 General Dimensions (Right-Hand Drive)... 11 Electric Drive Considerations... 11 Wash Module... 12 Motor Assembly Component Orientation... 13 Installation... 14 Gyro Head Overview Parts Identification... 14 Gyro Head Orientation... 15 Tunnel Placement... 16 Attaching the Booms... 21 Shaft Insertion: Electric Drive... 23 Shaft Insertion and Motor/Gearbox Installation... 23 Shaft Insertion: Hydraulic Drive... 25 Positive Stops... 28 Utilities... 29 Waves and Fins Cleaning Material... 37 Neo-Tex Cleaning Material... 43 Startup... 47 Confirming Proper Installation... 47 Initial... 47 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1
Table of Contents Maintenance...49 Routine Procedures...49 Trouble Shooting...50 Exploded Parts View...51 Gyro Head Assembly: Hydraulic...51 Gyro Head Assembly: Electric (Upper Section)...53 Gyro Head Assembly: Electric (Lower Section)...54 Air Cylinder Assembly...55 Air-Over-Oil Assembly...55 Posi-Stop Assembly...56 Gyro Wrap Air Panel...56 Aluminum Hub Assembly (Overview)...57 Aluminum Hub Assembly (Upper Section): 106782...58 Aluminum Hub Assembly (Lower Section): 106026...59 Wave Hub Assembly (Overview)...60 Wave Hub Assembly (Upper Section)...61 Wave Hub Assembly (Middle Section)...62 Wave Hub Assembly (Lower Section)...63 Wave Hub Assembly (Plastic Waves)...64 Misc. Wave Hub Components...65 Wave Cleaning Material: Cloth Fill:...66 Wave Cleaning Material: Neotex Fill:...66 Aluminum Hub Neotex Fill...67 2 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
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. 1MANUL247 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 1MANUL247
Introduction 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. 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 5
Introduction 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 1MANUL247
Introduction Congratulations on your purchase of the Belanger, Inc. Gyro Wrap. The Belanger, Inc. Gyro Wrap is designed to operate in only 126 (320 cm) of tunnel space. This document now covers both left and right hand drive configurations. It is written as a left-hand drive document although basic layout and assembly instructions may cover both. Detailed Right Hand Drive information can be found under the headings Right-Hand Drive. This document also covers both Hydraulic and Electric drive. See the appropriate sections for more details. There are 2 types of cleaning materials available. The traditional cloth (felt) and the NEW Neo-Tex foam material. Both are covered in this document. The replacement cloth pieces (Fins) are available in the standard colors: Blue and Red. The replacement Neo-Tex is available only in Blue and Red. The Waves (plastic pieces that hold the cleaning material) are available only in Black. The Waves and/or Fins can be purchased in complete sets or individually. Contact your local distributor for details. The purpose of this manual is to familiarize you with the way that the Gyro Wrap is installed. The Installation section will be used in conjunction with the location diagram, and the Gyro Wrap 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 Gyro Wrap before installation. When installation is completed, you will want to keep this manual as a guide to proper maintenance. It is imperative that wheels are spinning during any period that the conveyor is activated 1MANUL247 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 Tape measure (25 foot [8 m] or greater) Miscellaneous hand tools Level Equipment included: Clamps Tin snips Safety glasses Work gloves 50 foot extension cord Qty Head frame assembly 1 Support legs 2 Gyro-Wrap boom assemblies 2 Gyro-Wrap shafts 2 Side Wheel waves 2 sets (cloth machines ONLY) Hitch Hiker waves 2 sets (cloth machines ONLY) Neo-Tex, skins and wash clips Neo-Tex machines ONLY Accessory box 1 Side Wheel cleaning material 1 set (per wheel) Hitch Hiker cleaning material 1 set (per wheel) Air Panel 1 Styles Available: GYRO-WRAP-RDCL GYRO-WRAP-BLCL GYRO-WRAP-RDNX GYRO-WRAP-BLNX GYRO-RDCL-60 GYRO-BLCL-60 Gyro Wrap with Red Cloth Gyro Wrap with Blue Cloth Gyro Wrap with Red Neo-Tex Gyro Wrap with Blue Neo-Tex Gyro Wrap with Red Cloth-60hZ Gyro Wrap with Blue Cloth-60hZ 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. Belanger, Inc. 1995 This manual and the accompanying equipment are protected by United States and International 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. 8 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Specifications Requirements Physical Tunnel space required 134 Unit height 118 Unit width 146 Utility Electrical Hydraulic Pneumatic Water 3 phase, 2HP motors (optional) 4 GPM @ 900 PSI.3 CFM @ 90 PSI minimum 120 PSI maximum (2) 3/4 pipe @ 8 GPM @ 40 PSI Output Physical Vehicle clearance, height 90 Utility Pneumatic.3 CFM @ 90 PSI 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 76 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. 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 9
Specifications General Dimensions (Left-Hand Drive) 146 134 146" dimension is taken from the outer legs on both sides 118 45 10 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Specifications General Dimensions (Right-Hand Drive) 146 134 146" dimension is taken from the outer legs on both sides 118 45 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 11
Electric Drive Considerations Note: If your system is a Hydraulic Drive, skip this Electric Drive section and move on. Wash Module Before moving on to the next steps, understand that it is very important that the motor assemblies at the end of the booms are correctly oriented. Although they are pre-assembled at the factory, inspect and confirm placement and orientation. The following section will assist you in assuring that this is done. The following components MUST be confirmed for positioning and orientation: Spin Stops (both styles) Gearboxes (electric drive) Motors (both styles) Motor Junction Boxes (electric drive) IF ANY OF THE ITEMS LISTED ABOVE ARE INSTALLED INCORRECTLY, SERIOUS DAMAGE CAN OCCUR TO THE MACHINE AND THE POTENTIAL FOR SERIOUS INJURY IS PRESENT. CAREFULLY CHECK ALL LISTED COMPONENTS! 12 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Electric Drive Considerations Motor Assembly Component Orientation Parts Identification (Electric Drive) Motor/Gearbox Motor Junction Box and Electrical Feed Spin Stop Gyro Head Mounting Plate Sticker located here indicates Driver Side or Passenger Side Parts identification for electric drive Gyro Head Note: Above image shows driver side motor and mounting assembly. Gyro Head Overview Confirm that the following items have the correct orientation: Motor and Spin Stops: Inspect and compare positioning of your spin stops Gearboxes: The gearboxes have a specific orientation, which is determined by the offset of the hole on top. Junction Boxes: The junction box cable opening MUST point downward Overhead View Driver side Passenger side DIRECTION of TRAVEL There are Stauff clamp tabs on both sides of the arms allowing the Motor/Gearboxes Assemblies to be identical. The goal is to run the electrical feeds on the inside of the arms and not cross over the gussets. This tab configuration also allows for a right hand drive system whereas the arms will be switched. 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 13
Installation Gyro Head Overview Parts Identification Motor Torque Plate Spin Stop Spin Stop Gyro Head Mounting Plate Sticker indicating driver side or passenger side Parts identification for hydraulic drive Gyro Head 14 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Gyro Head Orientation Confirm that the following items have the correct orientation: Spin Stops: Inspect and compare positioning of your spin stops Hydraulic Lines: Make sure they travel along the inside of the booms Note: There are driver side / passenger side labels sandwiched between the Booms and Gyro- Head Mounting Plates. They are not visible unless the Heads are disassembled. Left-Hand Drive Overhead View FIGURE 1a Driver Side Label DIRECTION of TRAVEL Passenger Side Label Driver Side (Short Boom) Passenger Side (Long Boom) Overview of the correct orientation for Gyro Head components Right-Hand Drive (European Typical) Overhead View FIGURE 1b Driver Side Label DIRECTION of TRAVEL Passenger Side Label Passenger Side (Long Boom) Driver Side (Short Boom) Overview of the correct orientation for Gyro Head components 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 15
Installation Tunnel Placement When placing a piece of equipment, tunnel depth will vary from site to site. Be sure to allow an adequate operating envelope as shown on the previous pages for Right-Hand and Left-Hand Drive systems. 1) Using a forklift, clamp the head frame assembly securely to the forks and place the unit in the appropriate tunnel location (FIG 2a and 3a or FIG 2b and 3b). Raise the head frame assembly above the height of the support legs. Note: Boom cylinder mount should be toward the exit of the tunnel (see Tunnel Placement, next page to identify parts). 2) Secure legs to the head frame assembly using the supplied bolts, washers and nuts. Be sure to clamp equipment securely to the forks of the forklift. Do not stand under load while forklift is in operation Side View Head assembly Support leg 3) Position the assembled unit in its permanent location from the inside surface of the inside Guide Rail to the outside of the driver side leg (FIG 2a and 3a or FIG 2b and 3b). 4) Placing a level on one of the vertical posts, place shims under the support leg as needed to make vertical post plumb. Repeat leveling process on the other support leg. Note: Shims not supplied by Belanger, Inc. 5) Once the unit is level, lag it to the floor using the supplied lag bolts. 16 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Tunnel Placement Standard, Standalone (Left-Hand Drive) FIGURE 2a 120 Cylinder Mount (typical) 14 45 DIRECTION of TRAVEL Overhead view of standard, standalone tunnel placement 45" dimension is taken from the outer leg to the driver side edge of the inside guide rail Note: Unit shown with booms and cleaning material installed to indicate operating envelope required to function properly. 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 17
Installation Tunnel Placement Standard, Standalone (Right-Hand Drive) FIGURE 2b 120 14 45 DIRECTION of TRAVEL Overhead view of standard, standalone tunnel placement 45" dimension is taken from the outer leg to the driver side edge of the inside guide rail Note: Unit shown with booms and cleaning material installed to indicate operating envelope required to function properly. 18 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Tunnel Placement Staggered with a set of Wave Low Side Washers (Left-Hand Drive) Equipment Envelope 151 FIGURE 3a 50 144 80 45 146 DIRECTION of TRAVEL Staggered with Wave Low Side Washer 146 dimension is taken from the outer legs on both sides Note: Unit shown with booms and cleaning material installed to indicate operating envelope required to function properly. 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 19
Installation Tunnel Placement Staggered with a set of Wave Low Side Washers (Right-Hand Drive) Equipment Envelope 151 FIGURE 3b 50 144 80 45 146 DIRECTION of TRAVEL Staggered with Wave Low Side Washer 146 dimension is taken from the outer legs on both sides Note: Unit shown with booms and cleaning material installed to indicate operating envelope required to function properly. 20 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Attaching the Booms Determine the driver side boom from the passenger side boom. The shorter boom is ALWAYS driver side. For European systems using a Right-Hand Drive Conveyor, the Gyro Heads will have to be swapped as shown on page 14, figure 1b. The hydraulic hoses will also have to be moved to the opposite sides of the Boom (also shown on page 14). 1) Position the forks of the forklift under the driver side (shorter) boom and CAREFULLY lift it to the mounting bearing of the head frame assembly. 2) Remove the lock washers, flat washers, bolts and bearings from the Gyro Wrap head assembly. There are four bolts each on four bearings. Boom mounting bearings (4 per bearing) 3) Place the bearings on the shaft end of the boom, making sure the grease fittings are facing outward for easy access. Before After Boom mounting bearings Boom mounting shaft Side view (cross section) of head frame assembly 4) Move the boom into position and secure the bearings as shown above. 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 21
Installation Attaching the Booms continued Both booms when loaded with cleaning material should slope down-hill 1/4 per foot. For example, if you used 4 foot level on the passenger side boom, the level would have a 1 slope (as shown below). 4 foot level 1 The slope can be accomplished when the installation is complete by shimming the legs. 5) Secure the cylinder to the clevis mount of the boom. 6) Repeat steps 1 through 4 on the passenger side. 22 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Shaft Insertion: Electric Drive Note: We have found it easier to install the shafts before mounting the heads onto the booms. The shaft is held in place using a steel key, four setscrews and a split-locking collar. There are 3 grooves in the shaft. Two grooves to accommodate the setscrews and one for the locking collar. There are also two setscrews in the two bearings that are shown in a close-up image on the next page. See the image below to understand how the complete assembly goes together, and then follow the instructions on the upcoming pages. 1) Slide the shaft up through both bearings until the groove for the locking collar has cleared the upper bearing. Note: You may need to loosen the bearing fasteners to install the shaft. After the shaft is installed, re-tighten the fasteners. 2) Place the key locking collar and secure it into place. 3) Allow the shaft to slide down until the locking collar rests on the upper bearing. 4) Tighten all the setscrews on both bearings. 5) Place the key into the shaft slot. Apply Anti-Seize to the shaft, the key and the key slot. 6) Slide the complete Motor housing Assembly into place over the shaft studs as shown below. Steel Key Locking Collar Bearing Shaft Insertion and Motor/Gearbox Installation 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 23
Installation Installing Shaft Components Key (apply Anti-Seize to the key and the key slot) 7) Locate the 2 flat washer and 2 cotter pins and install them as shown below. Bend the ends of the cotter pin to lock it into place. Cotter Pin (typical) Flat Washer 24 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Shaft Insertion: Hydraulic Drive The shaft is held in place using a steel key, two setscrews in each of the two bearings and a split-locking collar. There is a groove in the shaft to accommodate the locking collar. The setscrews in the bearings are shown in a close-up image on the next page. See the image below to understand how the complete assembly goes together then follow the instructions on the next page. Steel Key Shaft Groove Bearing Locking Collar 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 25
Installation Shaft Insertion 1) Locate the two side-wheel shafts. 2) Loosen the four mounting bolts on the upper and lower shaft bearings of the head assembly to allow freedom of alignment. 3) Loosen both setscrews in each of the shaft bearings. Close-up view of head assembly Shaft bearing Bearing mounting bolt (typical) Bearing set screw (typical) Shaft bearing 4) Locate the accessory box and separate its contents. 5) Slide the shaft up through both bearings until the shaft of the hydraulic motor is inside of the sidewheel shaft. 6) Secure the supplied split-locking collar into position. This will hold the shaft in place. Shaft slot (keyway) Wheel shaft Woodruff key Split locking collar Shaft bearing 7) Tighten all bearing bolts and the setscrews. 26 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Shaft Insertion 8) Repeat the above steps on the other side. Do not install any cleaning material until all equipment has been installed, turned on and checked for hydraulic, pneumatic and water leaks. Note: If you have purchased the motor cover for electric drive units, see next page. 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 27
Installation Positive Stops Overview Positive stops dictate the range of motion for the booms. If set incorrectly, damage may occur to the equipment and/or vehicles. After the initial setup, they may need to be adjusted for optimum performance. Positive stop adjustment bolt Placement Positive stop adjustment bolt 1) Locate and install the upper and lower driver side positive stop assemblies. 2) Repeat this procedure on the passenger side. 28 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Utilities General The control relay function on the CCU to the MAC 4-Way Valve should be wired normally open. When there is no vehicle at the Gyro-Wrap, the solenoid valve is off (open), and line pressure is fed to the back of the boom cylinders thus retracting both booms. Before a vehicle reaches the Gyro-Wrap, the control relay should energize the solenoid valve, sending 20 PSI of regulated air to the front of the cylinders, bringing in both booms to the vehicle. Note: 20 PSI is a good starting point with a wheel speed of 72 to 80 RPM. Air pressure can be adjusted for more or less penetration. 1) Flow controls on each cylinder needs to be adjusted to control speed at which booms move in and out. View from entrance end Regulated air feeding front side of the passenger side boom cylinder, typically a blue 1/4 airline Regulated air supply feeding front side of the driver side boom cylinder, typically a red 1/4 airline The rear reservoirs (exit side) are line pressure air feeds from a TEE, typically gray 1/4 The rear reservoirs (exit side) are line pressure air feeds from a TEE, typically gray 1/4 2) Secure all hoses to the frame using the supplied hose clamps. Passenger Side Hose Clamps Driver Side Hose Clamp 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. 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 29
Installation Utilities Water The following section will explain the installation of the water connections. The copper tubing atop the head frame assembly can be turned 180 degrees to accommodate whichever side of the building your main water supply is located. 1) Connect a 3/4 water supply feed to the copper manifold located atop the head frame assembly. Main Water Feed 2) Cut blue hose to the appropriate length for the water feed to the nozzles. 3) Mount them into position. Feed to water nozzle (typical on both ends of manifold) Connection to water nozzle (typical on both driver side and passenger side booms) Boom 30 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Utilities Pneumatics The following section will explain the connection of the pneumatic lines to the oil reservoir. Note: Early models of the Pro Class 80 and 100 systems use pneumatic valves and regulators on the CCU. Refer to their system manual for connections. The air panel can be mounted in the tunnel or the back room. The preferred location is the back room. Pneumatic (Air) Panel 1) Locate supplied air panel and supply controlled 110VAC from relay of CCU to the MAC Valve. 2) Supply 120PSI maximum pneumatic line pressure from CCU or other clean, dry air supply to the main air in feed. Regulated air supply to oil reservoirs feeding boom cylinder (extend), typically a red 1/4 airline (Driver side) Line pressure air supply to oil reservoir feeding rear side of each boom cylinder, typically a gray 1/4 airline Manual Over-ride 110VAC Main air supply 90-PSI minimum 120-PSI maximum Regulated air supply to oil reservoirs feeding boom cylinder (extend), typically a blue 1/4 airline (Passenger side) Note: Airline installed at the factory is subject to color changes; therefore the colors stated in this manual are the colors used at the time this document was produced. Typical Pneumatic Cylinder Boom Extend Boom Retract Counter-clockwise slows Extend Adjustment Counter-clockwise slows Retract 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 31
Installation Utilities Wheel Rotation for Hydraulic Drive The following will explain the factors that determine wheel rotation. Failure to understand this factor can result in equipment or vehicle damage. Feed for counterclockwise rotation Feed for clockwise rotation Out Out IN IN Rotation Direction Hydraulic Driver side: counter clockwise Passenger side: clockwise It is recommended that licensed technicians are contracted to perform all utility installations. 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 32 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Utilities Hydraulic Drive Overview This section will explain the installation of the hydraulic connections. The stainless steel tubing atop the head frame assembly can be turned 180 degrees to accommodate whichever side of the building your hydraulic unit is located. 1) Cut black hydraulic hose to the appropriate length to run from the stainless steel tubing to the hydraulic hoses on the CCU or power unit. 2) Secure them into position. Note: Hydraulic hose not supplied by Belanger, Inc. Hose can be purchased as an optional item. Left-Hand Drive Overhead view of section of head frame assembly Wheel Rotation Wheel Rotation Return from driver side motor and back to hydraulic supply tank Feed to driver side motor DIRECTION of TRAVEL Feed to passenger side motor Return from passenger side motor Feed from hydraulic supply tank Right-Hand Drive Above image shows typical driver side hydraulic installation. Overhead view of section of head frame assembly Wheel Rotation Wheel Rotation Return from passenger side motor Feed to passenger side motor DIRECTION of TRAVEL Feed to driver side motor Return from driver side motor and back to hydraulic supply tank Feed from hydraulic supply tank Above image shows typical driver side hydraulic installation. 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 33
Installation Utilities Hydraulic General Close-up view of hydraulic fittings located atop the head frame assembly Hydraulic feeds or return, whichever accommodates building facilities best (typical on both ends of both stainless steel tubes) 34 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Utilities Electric Drive Overview This section will assist you in making the necessary connections top the 3 phase motors atop the side wheels. There are factory-mounted junction boxes mounted on the upper leg assemblies. It is recommended that licensed technicians are contracted to perform all utility installations. Electric Drive Connections 1) Supply 3 phase power and ground to the junction box mounted on top of the Gyro Wrap frame. 2) The electric motor should be mounted so that the feeds are facing inward as shown below. Motor wire feed-tabs are available on the opposite side of the arms for Right-hand-Drive installations. This allows the leads to be reversed and the motors to be wired correctly. Note: Be sure to leave enough slack on the electrical feeds to allow the heads full movement. Overhead View Electric Motor DIRECTION of TRAVEL Motor main electrical feed Junction box Rotation Direction Electric CAUTION Be sure to match the wheel rotation shown above. If the rotation is opposite as show below, reverse 3 phase connection. 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 35
Installation Utilities Left-Hand Drive Note: Be sure to match the wheel rotation shown below. If the rotation is opposite as show below, reverse the hydraulic feed lines to the motor. Overhead view Right-Hand Drive Note: Be sure to match the wheel rotation shown below. If the rotation is opposite as show below, reverse the hydraulic feed lines to the motor. Overhead view 36 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Waves and Fins Cleaning Material Note: If your system has Neo-Tex cleaning material, skip this section and move on to section 11. This section is intended to assist in assembling the hubs and installing the cleaning material. Note: Do not install any cleaning material until all equipment has been installed, turned on and checked for hydraulic, pneumatic and water leaks. Tools Needed for Installation: 3/4 wrench 13/16 socket (2) 9/16 wrenches 3/4 socket 1/2 impact wrench or ratchet Ladder Miscellaneous hand tools Tape measure (25 foot or greater) Work gloves Safety glasses 5/32 Allen wrench DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE SERVICING ANY EQUIPMENT! Always wear safety glasses when performing maintenance on any equipment 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 37
Installation Waves and Fins Cleaning Material Shaft Brackets 1) Locate the Side Wheel Wave boxes and open them upside down to expose the drive plate assemblies. Drive Plate Drive Plate Assembly 2) Remove the drive plates and secure them to the wheel shafts at 10-1/2 above the floor by tightening the shaft brackets into place. Shaft Bracket 10-1/2 Floor 38 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Waves and Fins Cleaning Material Lower Side Wheels The cleaning material fills for the lower side wheels are the same as the Belanger, Inc. Wave Low Side Washer. This section will assist in the installation of the lower side wheel cleaning material. Do not install any cloth until all equipment has been installed, turned on and checked for hydraulic, pneumatic and water leaks. 1) Install bottom drive wave and seat counter-bore over the drive plate. Counter Bore 2) Locate the 24 Fins. Place 4 pieces over pins on bottom drive Wave. One piece of wash material should straddle the opening on each Wave. 3) Install next Wave with slot opposite the opening on the previous one. 4) Repeat steps 2 and 3 until 9 waves have been stacked on top of the bottom Wave (total of 10 rows of cleaning material). 5) Press down on the top Wave stack to seat the cleaning material and verify the bottom Wave is on the drive plate. 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 39
Installation Waves and Fins Cleaning Material Hitch Hiker Hubs The Hitch Hiker is a clutched wheel that periodically spins independently from the lower side wheel. This section will assist in the installation of the Hitch Hiker hubs. 1) Install the top Wave cap and the cloverleaf assembly. 2) Secure with (4) 9/16-12 x 6-1/2 bolts and tighten until cloverleaf bottoms out on the shaft clamp. Cloverleaf Assembly Cloverleaf Close-up Cloth bolts Neo-Tex bolts 9/16-12 x 6-1/2 9/16-12 x 8 3) Locate the Neolite discs and the plastic filler inserts and fasten them together. Plastic Disc Plastic Filler Insert 4) Place it on top of the hub assembly and press it down until the insert is flush with the surface of the lower side-wheel top cap. Plastic Filler Insert 40 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Waves and Fins Cleaning Material Hitch Hiker Hubs 5) Remove the Hitch Hiker Waves from their packages (below, left). Remove the top retainer plate and remove the plastic Waves from the Hitch Hiker frame assembly (below, center). Upper Retainer Plate Frame Assembly 6) Turn the frame assembly upside down and remove the front half of the plastic bushing on both ends (the side that covers the slotted opening is the front) as shown below, left. Turn frame back over and place it on top of the white plastic disc. While holding the frame assembly up, replace lower front side bushing and tighten from the bottom (below, right). Frame Assembly turned upside-down Lower Retainer Plate 7) Locate the skirts and place one of them on top of the hub assembly. Place a second skirt on top of the opposite wheel. 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 41
Installation Waves and Fins Cleaning Material Hitch Hiker Note: Hitch Hiker Fins come in 28 for the lower portion of the Hitch Hiker and 30 for the upper portion of the Hitch Hiker. 1) Locate the bottom plastic Wave and place it on the frame assembly with the opening opposing the opening on the lower retainer plate (below, left). 2) Locate the 28 Hitch Hiker Fins. Place one on each of the pegs with the fold following the rotation of the wheel (below, right). Rotation Closed (folded) Edge 3) Place the next Wave on the frame making sure that the openings are opposing each other. 4) Continue to install the Fins and the Waves until 5 rows of wash material have been completed. 5) Locate the 30 Hitch Hiker Fins. Place one on each of the pegs with the fold following the rotation of the wheel. 6) Place the next Wave on the frame making sure that the openings are opposing each other. 7) Continue to install the Fins and the Waves until the last 5 rows of wash material have been completed. 8) Once all on the wash material has been installed, locate the top retainer and the two plastic bushings that were removed earlier (below, left). Secure them to the shaft above the Hitch Hiker. 9) Slide it down onto the Hitch Hiker and replace the previously removed bolts (below, right). 10) Locate the split locking collars and install one of them 1/4 above the top of the Hitch Hiker hub to prevent the hub from climbing up the shaft. 42 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Neo-Tex Cleaning Material The aluminum hub configuration requires the installation of the lower hub first followed by the installation of the upper hub. Once the two hubs are installed, you may then install the Wash Clips and Neo-Tex. Lower Hub Note: Electric Drive ONLY: There are an extra set of holes located on the lower portion of the skins. The upper holes will be used to secure the Spider halves into place. 1) Mount the 12 diameter x 28-1/4 tall hub so that the top is 36 from the Conveyor surface on the driver side by securing the Spider Clamps to the shaft and securing the Skins to the Spiders as shown below. Be sure that the open ends of the C channels are facing upward. Spider assembly flush to top of hub Open end of C Channel 36 Skin (typical) Spider (typical) Floor 2) On the passenger side, mount the 12 diameter x 28-1/4 tall hub at 36 from the floor while the hub is 60 from the inside Guide Rail. 60 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 43
Installation Neo-Tex Cleaning Material Lower Hub 3) Locate the 33 x 10 Neo-Tex pieces. Fold them in half and slide one in every other slot of the aluminum hub with the Wash Clip, making sure they are pushed all the way to the bottom of the hub. Wash Clip Cloth Insert Wash Clips into cloth holes Fold cloth in half to slid into hubs 4) Following the same procedure, install 24 pieces of the 33 x 8 Neo-Tex in the center follow by 24 pieces of the 33 x 10 on top. When folded in half, this piece is 16 x 10 When folded in half, this piece is 16 x 8 When folded in half, this piece is 16 x 10. 44 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Installation Neo-Tex Cleaning Material Upper Hub 1) Mount the two 6 diameter x 42-1/2 tall hubs so that they set on top of the lower hubs by securing the Spider Clamps to the shafts and securing the Skins to the Spiders as shown. Be sure that the open ends of the C channels are facing upward (FIGURE 1). 2) Locate the 41 x 8 Neo-Tex pieces that are 1/4 thick (thicker Neo-Tex material). Fold them in half and place one in the first, middle and last slot of each skin of the hub, making sure they are pushed all the way to the bottom (FIGURE 2). 3) Locate the 25 x 8 Neo-Tex pieces that are 1/8 thick (thinner Neo-Tex material). Load two pieces onto each 8 clip to provide the fill for this row. Place 12 of these assemblies into the previous slots filled to continue stacking the upper hub. 4) Locate the 25 x 8 Neo-Tex pieces that are 1/4 thick (thicker Neo-Tex material). Load one piece onto each 8 clip to provide the fill for this row. Place 12 of these assemblies into the previous slots filled to continue stacking the upper hub. 5) Locate the 28 x 8 Neo-Tex pieces that are 1/4" thick (thicker Neo-Tex material). Load one piece onto each 8 clip to provide the fill for this row. Place 12 of these assemblies into the previous slots filled to continue stacking the upper hub. 6) Locate the 32 x 10 Neo-Tex pieces that are 1/4" thick (thicker Neo-Tex material) Load one piece onto each 10 clip to provide the fill for this row. Place 12 of these assemblies into the previous slots filled to continue stacking the upper hub. First, middle and last slot of a skin FIGURE 2 Upper Hub (Top view) FIGURE 1 Top Row 32 x 10 Insert into one 10 clip. FIGURE 3 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 45
Installation Neo-Tex Cleaning Material Upper Hub 32 x 10 NeoTex Box: (24 pieces # 7003) 32 x 10 Load one piece of 1/4 NeoTex onto each plastic clip 12 pieces of NeoTex in this row 28 x 8 NeoTex Box: (24 pieces # 6798) 28 x 8 Load one piece of 1/4 NeoTex onto each plastic clip 12 pieces of Neo-Tex in this row 25 x 8 NeoTex Box: (24 pieces # 6797) 25 x 8 Load one piece of 1/4 NeoTex onto each plastic clip 12 pieces of Neo-Tex in this row 25 x 8 NeoTex Box: (48 pieces # 6341) 25 x 8 Load two pieces of 1/8 NeoTex per plastic clip 24 pieces of Neo-Tex in this row 20 x 8 NeoTex Box: (24 pieces # 6228) 41 x 8 Load one piece of 1/8 Neotex when folded on plastic clip makes this a 20 (2 ply) NeoTex pack 12 pieces of NeoTex in this row 46 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Startup Confirming Proper Installation It is very important that the following components are installed correctly in order for the system to function properly. Verify using a level that your booms slope downhill toward the tunnel exit approximately 1/4 per foot. Loosen bearings and adjust if necessary. Verify your wheels are spinning at the RPM as follows when measured on the shaft, and adjust if necessary: 72-80 RPM for Waves and Fins 88-92 for Neo-Tex Note: Do not measure using the top hitch-hiker cleaning material, as this may not spin at the same speed) Verify that the cleaning material is installed correctly Verify that clean hydraulic oil is in the reservoirs when booms are extended and retracted. Fill or replace if necessary. Initial Settings 1) Close both flow controls on the boom extend cylinders (turn clockwise). Verify that both boom cannot be moved inward or outward. If they can then bleed air out of the oil in the cylinders. 2) Open both flow controls (turn counter clockwise completely) on each boom at this time. 3) Check Gyro Head spin stops for proper orientation. Correct if necessary. 4) Verify that hydraulic hoses to the motors are not pinched or stretched while moving the Gyro Heads completely around. Allow a little extra cable or hose in case of severe movement. (i.e. drive through) 5) Verify that your shafts are not bent, the gyro sphere has not been cracked or damaged, that all bearings on the head are tight, and that the wheels come in completely before a vehicle gets to them. Correct as necessary. 6) Set your fixed stops for proper travel when the wheels are extended and retracted. Spread extended stops farther apart in areas with front license plates. 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 47
Startup Initial Flow Controls Pressure settings on each boom will effect how fast the booms move in and out, and must be set before setting the flow controls. At this point both flow controls on each boom extend cylinder should be open completely (turn counterclockwise). 1) Set initial boom extend pressure per the chart below. Driver side: 20 Passenger side: 40 2) Run a test vehicle and adjust the pressure on each side for proper penetration while on the side of a large car or van. See sketch below. Decrease air pressure if more mirror clearance is required 3) Run a test vehicle and close the front flow control (rod end side of the cylinder) as necessary to keep the wheel from leaving the vehicle front fender. Higher line speeds require this flow control to be open more, so the wheels can get out of the way of the vehicle. 4) Opening the flow control too much can cause the wheel to leave the front of the vehicle and bounce back into the side. 5) Close the rear flow control (entrance side of the extend cylinder) to slow the inbound motion of the wheels. How much this gets closed depends on your air pressure and conveyor speed. At the rear corner of the vehicle the wheel should walk around the back a little faster than the boom can come in. This can help keep the boom from shooting over the vehicle when passing wheel wells and provide better cleaning of the vehicle back. The boom pivot points are inside of the vehicle sides, and allows the wheels to chase the back of the vehicle somewhat. Start with flow controls on the rod end side of the cylinder at 3 turns out from closed, and the entrance side flow controls 4 turns out from closed (see Hydraulic Installation page). 48 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Maintenance Routine Procedures Daily Start every washday with a Test Wash to insure proper operation of all equipment. Inspect the component for clogged nozzles. This can best be done while running the Test Wash in the morning. Nozzles can be cleaned by removing the nozzle bodies and tapping or inserting a thin wire into the nozzle opening. Dump any water that has settled in the air compressor or install a timed pump valve (not supplied). Check operation to insure uniform foam is being applied where applicable. This is best be checked while running the Test Wash in the morning. Check for oil leaks Check the chemical injection pump(s) to insure that the pump is properly primed if applicable. This is done by checking the chemical inside of the clear supply tubing. There should be no bubbles or breaks in the fluid (if applicable). Check overall performance for any abnormalities on the first few vehicles washed each day. Hose down the component and surrounding area at the end of each washday. This will remove the majority of the dirt and other debris that builds up during a washday. Check for water and chemical leaks after equipment is turned off. Weekly Check all mixing tanks periodically for sludge build-up on bottom. If too much sediment is evident, drain tank and clean (if applicable). Grease all bearings. Monthly Wash component down with a good degrimer such as Tide laundry detergent and hot water. Quarterly Scrub down aluminum portions of the component with a fine steel wool such as S.O.S. pads and wash with good degrimer such as Tide laundry detergent and hot water (whenever using steel wool on aluminum, always follow the grain to prevent scratching the finish). 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 49
Trouble Shooting Problem Wobbling Boom or Shaft Solution Check for missing pieces or damaged cleaning material Check Bearings for wear Check for bent shaft Check shock for leaking oil, loose bolts or worn out rubber mount grommet Brush is turning too slow Confirm flow control setting is all the way open Confirm hydraulic unit has 1000 1100 PSI Replace motor on hydraulic unit Electric drive: Wheel Speed Check motor starter Check gearbox Check motor 50 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Maintenance Exploded Parts View Gyro Head Assembly: Hydraulic 1FSTNR-HH741 (4) 1GRMIT222 (4) 101562 1WASHR-LC292 (4) 1FSTNR-HH261 (4) 1NUT-RG670 (4) 1BERNG809 1FSTNR-HH540 (4) 1WASHR-LC456 (4) 3211 1NUT-LC514 (4) 102032: Complete Assembly 3621 (4) 1BERNG809 1FSTNR-HH680 (4) 1WASHR-LC581 (4) 1MOTOR-HY710 1MCONC-ST375 (2) 3628 Pivot Stops shown on next page 1FSTNR-FH842 (4) 1254 1COLLR333 3625 1FSTNR-SH958 (4) 1FSTNR-SH472 (8) 3687 3626 3627 1WASHR-LC456 (4) 1FSTNR-HH558 (4) 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 51
Maintenance Exploded Parts View Gyro Head Assembly: Hydraulic 1WASHR-LC125 (8) 1FSTNR-HH023 (8) 3629 (2) 3622 (4) 52 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Maintenance Exploded Parts View Gyro Head Assembly: Electric (Upper Section) See Chart 1FSTNR-SM500 1COLLR333 1GEABX-AS986: Std. Voltage 1GEABX-AS988: 575 Volts (Gearboxes Include Steel Key) 108661 7912 1PLSTC-CV075 1FSTNR-FH025 (4) See Chart Black: PLSTC-CV080 Blue: PLSTC-CV082 Green: PLSTC-CV088 Gray: PLSTC-CV092 Orange: PLSTC-CV086 Red: PLSTC-CV084 Yellow: PLSTC-CV090 1FSTNR-SM500 (2) 7918 1WASHR-LC125 (3) 1FSTNR-HH045 (3) 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 53
Maintenance Exploded Parts View Gyro Head Assembly: Electric (Lower Section) 1COLLR333 1RETNR129 (2) 1WASHR-FL747 (2) 7735 (2) 1GRMIT222 (2) 1FSTNR-HH680 (2) 1WASHR-LC581 (2) 1BERNG810 1MOTOR-EL621 1FSTNR-HH540 (4) 1WASHR-LC456 (4) 7913 3211 3621 (4) 1FSTNR-HH680 (4) 108661 1WASHR-LC581 (4) 1BERNG810 1STEEL-KY150 3628 1FSTNR-FH842 (4) 7736 3625 Pivot Stops shown earlier in this section 1FSTNR-SH472 (8) 1WASHR-LC456 (4) 3627 1FSTNR-HH558 (4) 54 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Maintenance Exploded Parts View Air Cylinder Assembly 1WASHR-FL415 1FSTNR-SB125 1ELBOW-ST462 1ELBOW-ST462 102037: Complete Assembly (1 Set) 1VALVE-HY395 1NIPPL-ST444 1VALVE-HY395 1NIPPL-ST444 1FSTNR-SB125 1CYLND250 1WASHR-PL500 1NUT-LC210 1034 Air-Over-Oil Assembly 1NUT-RG603 1NUT-LC210 1WASHR-FL332 1ELBOW-PL666 Complete Assembly 1RSRVR835 1TEE-PL664 1ELBOW-ST539 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 55
Maintenance Exploded Parts View Posi-Stop Assembly 2080 Complete Assembly 1SPRNG332 1NUT-RG938 1SLEEV666 2078 Gyro Wrap Air Panel Complete Assembly 1MADAP-BR600 1ELBOW-PL666 1AIRLN495 (Red, 4-1/2 ) 1MADAP-BR600 3699 1TEE-PL706 1WASHR-LC115 (2 per bracket) 1FSTNR-SH177 (2 per bracket) 2529: Bracket (2) 1FSTNR-HH081 (2) 1ELBOW-PL666 1RGLTR175 (2) 1GAUGE500 (2) 1AIRLN440 (Purple, 8 ) 1MADAP-BR600 1WASHR-LC125 (2) 56 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Maintenance Exploded Parts View Aluminum Hub Assembly (Overview) 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 57
Maintenance Exploded Parts View Aluminum Hub Assembly (Upper Section): 106782 1FSTNR-HH045 (2 per Spider Half) 1WASHR-LC125 (2 per Spider Half) 1WASHR-FL332 (2 per Spider Half) 101141: 6 x 1-1/2 Bore Spider Assembly (2 per wheel) 1FSTNR-HH180 (1 per Spider Half) 1WASHR-LC270 (1 per Spider Half) 101141: Complete Assembly 1141: CW6 x 1-1/2 Spider Half 102491: 6 x 42-1/4 Skin Assembly (4 per wheel) Complete Assembly 58 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Maintenance Exploded Parts View Aluminum Hub Assembly (Lower Section): 106026 1WASHR-LC498 (1 per Spider Half) 1FSTNR-HH504 (1 per Spider Half) 1132: 1-1/2 x 1-1/2 Spider Half 101132: Complete Assembly 1FSTNR-HH270 (2 per Spider Half) 1WASHR-LC291 (2 per Spider Half) 1WASHR-FL498 (2 per Spider Half) 101132: 12 x 1-1/2 Bore Spider Assembly (2 per wheel) 101118: 12 x 28-1/4 Skin Assembly (4 per wheel) Complete Assembly 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 59
Maintenance Exploded Parts View Wave Hub Assembly (Overview) 60 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Maintenance Exploded Parts View Wave Hub Assembly (Upper Section) 1FSTNR-HH392 (4) 1WASHR-LC291 (4) 1FSTNR-FH313 (4) 3753: Upper Plate 3693: Plastic Bushing (2) 1WASHR-FL332 (4) 1NUT-LC210 (4) Complete Assembly 3754: Tie Bar Spacer (4) 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 61
Maintenance Exploded Parts View Wave Hub Assembly (Middle Section) 102099: Tie Bar (4) 3766: Cloth Skirt 3766: Cloth Skirt 1WASHR-FL332 (4) 1NUT-LC210 (4) 3693: Plastic Bushing (2) 102129: Plate with Neolite Complete Assembly 1FSTNR-FH313 (4) 1FSTNR-FH750 (4) 62 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Maintenance Exploded Parts View Wave Hub Assembly (Lower Section) 3900 1FSTNR-FH313 (2) 3722 1WASHR-FL332 1FSTNR-HH745 (4) 1NUT-LC210 (2) 101908: Top Clamp 1PLSTC-SW200: Top Cap 1NUT-RG436 (2) 3648: Clamp Half 1WASHR-FL498 (2) 1FSTNR-HH441 (2) 1WASHR-LC291 (2) 1WASHR-LC456 (4) Complete Assembly 1FSTNR-HH562 (4) 3708: Clamp 1NUT-LC219 (4) 101907: Drive Plate Weldment 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 63
Maintenance Exploded Parts View Wave Hub Assembly (Plastic Waves) 1PLSTC-SW600 (9) Hitch Hiker Hub Assembly 105509: Complete assembly includes all fasteners 1PLSTC-SW800: Bottom Cap 1PLSTC-SW200: Top Cap 1PLSTC-SW100 (9) Lower Hub Assembly 105464: Complete assembly includes all fasteners Complete Assembly 1PLSTC-SW300: Bottom Cap 64 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Maintenance Exploded Parts View Misc. Wave Hub Components 102118 102129 3693 101908 102024: Drive Plate Assembly 101907: Drive Plate Weldment 1PLSTC-CL025: 8 Clip 1PLSTC-CL050: 10 Clip 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 65
Maintenance Exploded Parts View Wave Cleaning Material: Cloth Fill: Upper Hub: Top 5 Rows 105515: 30 HH Cloth, Blue (40 pieces), 1 set per wheel 105517: 30 HH Cloth, Red (40 pieces), 1 set per wheel Upper Hub: Bottom 5 Rows (includes cloth skirt) 105506: 28 HH Cloth, Blue (40 pieces), 1 set per wheel 105508: 28 HH Cloth, Red (40 pieces), 1 set per wheel Lower Hub: All Rows 105477: 24 HH Cloth, Blue (20 pieces), 2 sets per wheel 105479: 24 HH Cloth, Red (20 pieces), 2 sets per wheel Wave Cleaning Material: Neotex Fill: Upper Hub: Complete Hub = 10 Rows Each Assembly Number Fills 5 Rows On One Hub BLUE 105623 30 x 80 pcs of 6209 Top 5 Rows BLUE 105619 28 x 80 pcs of 6205 Bottom 5 Rows RED 105625 30 x 80 pcs of 6211 Top 5 Rows RED 105621 28 x 80 pcs of 6207 Bottom 5 Rows BLACK 105622 30 x 80 pcs of 6208 - Top 5 Rows BLACK 105618 28 x 80 pcs of 6204 - Bottom 5 Rows GREEN 105624 30 x 80 pcs of 6210 - Top 5 Rows GREEN 105620 28 x 80 pcs of 6206 - Bottom 5 Rows YELLOW 105745 30 x 80 pcs of 6381 -Top 5 Rows YELLOW 105742 28 x 80 pcs of 6378 - Bottom 5 Rows Lower Hub: Complete Hub = 10 Rows Each Assembly Number Fills 5 Rows On One Hub BLUE 105615 24 x 20 pcs of 6201 Fills 5 Rows RED 105617 24 x 20 pcs of 6203 Fills 5 Rows BLACK 105614 24 x 20 pcs of 6200 Fills 5 Rows GREEN 105616 24 x 20 pcs of 6206 Fills 5 Rows YELLOW 105727 24 x 20 pcs of 6372 Fills 5 Rows 66 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL247
Maintenance Aluminum Hub Neotex Fill NeoTex Red Fill kit #105836 NeoTex Blue Fill kit #105837 Upper fill can ONLY be ordered as a complete wheel or individual pieces Top three sections are 1/4 thick These two sections are 1/8 thick On the bottom row, place the 20 additional clips in the remaining slots of the bottom row to prevent to brush packs above from sliding down. 32 x 10 NeoTex Box: (24 pieces # 7003) 32 x 10 Load one piece of 1/4 NeoTex onto each plastic clip 12 pieces of NeoTex in this row 28 x 8 NeoTex Box: (24 pieces # 6798) 28 x 8 Load one piece of 1/4 NeoTex onto each plastic clip 12 pieces of Neo-Tex in this row 25 x 8 NeoTex Box: (24 pieces # 6797) 25 x 8 Load one piece of 1/4 NeoTex onto each plastic clip 12 pieces of Neo-Tex in this row 25 x 8 NeoTex Box: (48 pieces # 6341) 25 x 8 Load two pieces of 1/8 NeoTex per plastic clip 24 pieces of Neo-Tex in this row 20 x 8 NeoTex Box: (24 pieces # 6228) 41 x 8 Load one piece of 1/8 Neotex when folded on plastic clip makes this a 20 (2 ply) NeoTex pack 12 pieces of NeoTex in this row 16 x 10 NeoTex Box: (48 pieces) 33 x 10 NeoTex Packs 2-Ply piece when folded onto plastic clip 24 pieces of NeoTex in this row (1/8 thick) 16 x 10 NeoTex Box: (48 pieces) 33 x 10 Neo-Tex Packs 2-Ply piece when folded onto plastic clip 24 pieces of Neo-Tex in this row (1/8 thick) Single Piece Part Numbers RED: 6798 BLUE: 6801 Single Piece Part Numbers RED: 6797 BLUE: 6800 Single Piece Part Numbers RED: 6341 BLUE: 6339 Single Piece Part Numbers RED: 6230 BLUE: 6228 Single Piece Part Numbers RED: 7003 BLUE: 6985 24 Piece Set Part Numbers RED: 102477 BLUE: 102475 24 Piece Set Part 16 x 8 Numbers NeoTex Box: (48 pieces) 33 x 8 Neo-Tex Packs RED: 105849 BLUE: 105848 2-Ply piece when folded onto plastic clip 24 pieces of Neo-Tex in this row (1/8 thick) 24 Piece Set Part Numbers RED: 102477 BLUE: 102475 The fill for the upper section is available in two colors: Red Blue 42 Single Piece Part Numbers RED: 6226 BLUE: 6224 1PLSTCL050: 10 Plastic Wash Clip, Requires 12 Clips (1 piece of NeoTex per clip) Single Piece Part Numbers RED: 6218 BLUE: 6216 1PLSTCL050: 10 Plastic Wash Clip, Requires 12 Clips (1 piece of NeoTex per clip) Single Piece Part Numbers RED: 6226 BLUE: 6224 1PLSTCL050: 10 Plastic Wash Clip, Requires 12 Clips (1 piece of NeoTex per clip) 28 1MANUL247 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 67
Gyro Wrap 1MANUL247 Belanger, Inc. * P.O. Box 5470 * Northville, MI 48167-5470 Customer Service Phone (248) 347-4700 * Fax (248) 380-9681