Low Side Washer Belanger, Inc. P.O. Box 5470 Northville, MI 48167-5470 Customer Service Phone (248) 349-7010 Fax (248) 380-9681 www.belangerinc.com 1MANUL858 REV 18
Belanger Equipment Owners Manual Low Side Washer Copyright 2010 Belanger, Inc 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.
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 (Left-Hand Drive)... 10 General Dimensions (Right-Hand Drive)... 11 Installation... 12 Tunnel Placement... 12 Assembly... 19 Utilities... 20 Hubs, Side Wheels and Cleaning Material... 24 Waves and Fins Cleaning Material... 25 C-Channel Cleaning Material... 28 Welted Cloth Cleaning Material... 30 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1
Table of Contents Maintenance...31 Routine Procedures...31 Trouble Shooting...32 Torque Plate and Electric Motor Replacement...33 Remove Motor Gearbox assembly...33 Replacing Torque Plate Fasteners...35 Reinstall Motor Gearbox assembly...35 Exploded Parts View...37 Leg and Arm Weldments...37 Leg Clamp and Shock Assembly...37 Arm Mounting Components...38 Hydraulic Drive Fittings and Fasteners...38 Hydraulic Motor and Shaft Assembly...39 Electric Motor and Shaft Assembly...40 Electric Motor and Gearbox Assembly...41 Water Manifolds...41 Aluminum Hub Assembly (Overview)...42 Aluminum Hub Assembly: 106026...43 Wave Hub Assembly (Overview)...44 Wave Hub Assembly (Parts)...45 Wave Hub Assembly (Plastic Waves)...46 Misc. Wave Hub Components...47 Cleaning Material...48 Waves and Fins Cleaning Material...48 Neo-Tex Cleaning Material...48 Welted Cleaning Material...48 2 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
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. 1MANUL858 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 1MANUL858
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. 1MANUL858 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 1MANUL858
Introduction Congratulations on your purchase of the Belanger, Inc. Low Side Washer. The Belanger, Inc. Low Side Washer is designed to operate in only 66 (167.6 cm) of tunnel space. This document now covers both left and right hand drive configurations. It is written as a left-hand drive system although basic layout and assembly instructions may cover both. Detailed Right Hand Drive information can be found under the headings Right-Hand Drive. 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 is available in the standard colors: Blue and Red. The replacement Neo-Tex is available in Blue and Red. The Waves (plastic pieces that hold the wash material) are available only in Black. The wash material pieces or the Waves (plastic 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 Low Side Washer is installed. The Installation section will be used in conjunction with the location diagram, and the Low Side Washer 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 wash 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 yourself with the Low Side Washer 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 1MANUL858 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: Fork lift (optional) Hammer drill with 5/8 bit Tape measure (25 foot or greater) Miscellaneous hand tools Level Equipment included: 50 foot extension cord Tin snips Safety glasses Work gloves 13/16 socket for wash material installation Qty Side frame assemblies 2 Side wheel waves 2 boxes Drive plate assembly (located inside of the Side Wheel Wave boxes) 2 Accessory box 1 Wash material 1 set (per wheel) 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 1MANUL858
Specifications Requirements Physical Tunnel space required 68 Utility Electrical Hydraulic Pneumatic Water 110VAC 4 GPM @ 900 PSI.3 CFM @ 90-PSI minimum 120-PSI minimum (2) 3/4 pipe @ 6 GPM @ 40 PSI Output Utility Pneumatic.3 CFM @ 90 PSI Note: Schedule 40 pickled black pipe or hydraulic stainless steel tubing @ 1/2 diameter is recommended on all hydraulic installations. 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. 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. Note: YOUR HYDRAULIC SYSTEM MUST BE CAPABLE OF ADJUSTMENT TO 76 RPM AT 900 PSI WHILE LOADED AGAINST VEHICLE. PLEASE VERIFY YOUR SYSTEMS CAPABILITY TO MEET THESE SETTING WHILE RUNNING A VEHICLE PRIOR TO INSTALLING PIECE OF EQUIPMENT! 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 9
Specifications General Dimensions (Left-Hand Drive) 68 50 149 Top View Side View 50 Front View 10 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Specifications General Dimensions (Right-Hand Drive) 68 50 149 Top View 50 Side View Front View 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 11
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 There are three traditional installation configurations for the Low Side Washer. Standard, stand alone Staggered with a set of Wave Wraps Staggered with a set of Gyro Wraps Shown in figures 1a, 1b and 1c are the floor dimensions for each configuration. 1) Position the side wheel stand assemblies in the appropriate tunnel location (FIG 1a, FIG 1b or FIG 1c). 2) Placing a level on the vertical post, place shims under the base plate as needed to make vertical post plumb. Note: Shims not supplied by Belanger, Inc. 3) Repeat leveling process on opposite side. 4) Once stands are level, lag them to the floor using the supplied lag bolts. 12 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Installation Tunnel Placement Standard, Standalone (Left-Hand Drive) FIGURE 1a 68 50 99 The 50 dimension and the 99 dimension are measured from the inside edge of the inside conveyor guide rail to the outside edge of the side-wheel leg. Wheels shown with wash material installed to indicate operating envelope required to function properly 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 13
Installation Tunnel Placement Standard, Standalone (Right-Hand Drive) FIGURE 1b 68 99 50 The 50 dimension and the 99 dimension are measured from the inside edge of the inside conveyor guide rail to the outside edge of the side-wheel leg. Wheels shown with wash material installed to indicate operating envelope required to function properly 14 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Installation Tunnel Placement Low Side Washer with Wave Wraps (Left-Hand Drive) FIGURE 2a 76" 99 110" 50 60" 128" 204" Note: The 50 /60 dimension and the 99 /110 dimension are measured from the inside edge of the inside conveyor guide rail to the outside edge of the side-wheel leg. Note: Wheels shown with wash material installed to indicate operating envelope required to function properly. 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 15
Installation Tunnel Placement Low Side Washer with Wave Wraps (Right-Hand Drive) FIGURE 2b 204" 128" 50 60" 110" 99 76" Note: The 50 /60 dimension and the 99 /110 dimension are measured from the inside edge of the inside conveyor guide rail to the outside edge of the side-wheel leg. Note: Wheels shown with wash material installed to indicate operating envelope required to function properly. 16 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Installation Tunnel Placement Low Side Washer with Gyro Wraps (Left-Hand Drive) FIGURE 3a 146" 80" 144" Top View 50 45" Front View The 45 /50 dimension is measured from the inside edge of the inside conveyor guide rail to the outside edge of the side-wheel leg. Wheels shown with wash material installed to indicate operating envelope required to function properly. 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 17
Installation Tunnel Placement Low Side Washer with Gyro Wraps (Right-Hand Drive) 144" 80" FIGURE 3b 146" Top View 50 45" Front View The 45 /50 dimension is measured from the inside edge of the inside conveyor guide rail to the outside edge of the side-wheel leg. Wheels shown with wash 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 1MANUL858
Installation Assembly 1) By loosening the bolts on the side-wheel arm bracket, set height of the side-wheel arm to 42 above the height of the conveyor surface plate on the driver side and 42 from the floor on the passenger side. Side-wheel arm bracket (typical) 42 42 View from entrance. 2) Attach the shock absorber to the clevis mounts on both the driver side and the passenger side. Note: Unit may ship with either end of the shock absorber not secured. Whichever end is loose, secure it as shown above. 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 19
Installation Utilities Water 1) Connect the water supply to the main water feeds on the manifolds of both units. Main Water Feed 20 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Installation Utilities Wheel Rotation The following will explain the factors that determine wheel rotation. Failure to understand these factors can result in equipment or vehicle damage. Feed for counterclockwise rotation Feed for clockwise rotation Passenger Side Driver Side Out Out IN IN Rotation Direction: See Confirming Wheel Rotation page. 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. 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 21
Installation Utilities Hydraulics 1) Connect the hydraulic supply to the main hydraulic feeds and returns on the manifolds of both units. Hydraulic Feed Return 2) The Low Side Washer comes pre-plumbed hydraulically. If you need for some reason to plumb the hydraulic lines, run the feed and return hydraulic hoses through the two hydraulic hose clamps of each unit and to the hydraulic motors of the units. 22 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Installation Utilities Confirming Wheel Rotation (Left-Hand Drive) Overhead View Driver side DIRECTION of TRAVEL Passenger side Note: Wheels shown with wash material installed to illustrate proper wheel rotation. Confirming Wheel Rotation (Right-Hand Drive) Overhead View Passenger side DIRECTION of TRAVEL Driver side Note: Wheels shown with wash material installed to illustrate proper wheel rotation. 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 23
Installation Hubs, Side Wheels and Cleaning Material This section is intended to assist in assembling the hubs and installing the wash material. Note: Do not install any wash 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 24 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
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 assembly Drive plate 2) Remove the drive plates and secure them to the wheel shafts at 10-1/2 (26.7 cm) above the floor or the Conveyors top surface by tightening the shaft brackets into place. Driver Side Shaft Bracket Passenger Side To Conveyor Surface 10-1/2 10-1/2 Floor To Floor Note: Certain machine configurations require the driver side wheel to use 22 Fins. Otherwise, all Fins will be 24. If you have received 22 Fins with your order, load wash material accordingly. 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 25
Installation Waves and Fins Cleaning Material Lower Side Wheels The wash material fills for the lower side-wheels are the same as the Belanger, Inc. Low Side Washer. This section will assist in the installation of the lower side-wheel wash material. CAUTION Certain machine configurations require the driver side wheel to use 22 Fins. Otherwise, all Fins will be 24. If you have received 22 Fins with your order, load wash material accordingly. Do not install any cleaning material 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 wash material). 5) Press down on the top Wave stack to seat the wash material and verify the bottom Wave is on the drive plate. 26 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Installation Waves and Fins Cleaning Material Lower Side Wheels 6) Install remaining waves from the bottom up. Once all waves are in place, install the remaining wash material pieces. Lift and insert waves 7) Once all of the wash material has been installed, place the two top Wave cap sections atop the wheel. Use the provided washers with the supplied fastening bolts and secure into place. Cloth bolts Neo-Tex bolts 9/16-12 x 6-1/2 9/16-12 x 8 Top wave cap section 8) Adjust wheel speed between 110 to 120 RPM while under vehicle load at 900 to 1100 PSI. 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 27
Installation C-Channel Cleaning Material 1) Remove the plastic shaft cover shown below (if applicable). Plastic Shaft Cover 2) 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 Skin (typical) Spider (typical) 36 Floor 3) 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 28 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Installation Neo-Tex Cleaning Material 1) Locate the 33 x 10 Neo-Tex pieces. Fold them in half and slide one into 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 slide into hubs 2) Following the same procedure, install 24 pieces of the 33 x 8 Neo-Tex in the center followed 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. 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 29
Installation Welted Cloth Cleaning Material 1) Locate the 18 x 10 welted cloth pieces and slide one into every slot of the aluminum hub with the, making sure they are pushed all the way to the bottom of the hub. 2) Following the same procedure, install 44 pieces of the 18 x 8 welted cloth pieces in the center followed by 44 pieces of the 18 x 10 on top. This piece is 18 x 10 2 angle cut This piece is 16 x 10 NO angle cut This piece is 20 x 8 4 angle cut. 30 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
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 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). 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 31
Maintenance 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: Wheels not turning Check motor starter Check gearbox Check motor 32 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Maintenance Torque Plate and Electric Motor Replacement The wiring to each motor will have to be removed in order to gain access to the bottom of the gearbox. There you can inspect and change the flat head bolts used to mount the torque plate. Remove Motor Gearbox assembly 1) Turn off the power and place the disconnects in the OFF position. To ensure safety we recommend following the Lock out procedure stated above for the the main panel prior to servicing the equipment. If the assembly does not have a cover, proceed to step 3 2) Remove plastic cover from the cover base by removing the (2) Phillips head screws mounted in to the cover base. This will allow access to the motor gearbox that is mounted on the torque studs. 3) To ensure all power has been properly removed from the circuit, check 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 the wiring on the side of the motor. 5) Confirm that the wiring has been be tagged for terminal location if not previously identified upon installation. Remove the nuts to release wiring from the terminal block. Wires are located behind the terminal strip and will need to be pulled back out through the plastic fitting at the bottom of the junction box. This fitting will need to be loosened, or removed so that the wiring can be pulled down through the cover base if equipped. Also, the terminal block may need to be removed from the side of the motor for additional access using a Phillips screwdriver. 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 33
Maintenance Torque Plate and Electric Motor Replacement Remove Motor Gearbox assembly 6) Remove the torque stud retainer pins and washers from above the gearbox torque plate mounting holes. This will now allow the motor gearbox 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 8 7) The cover base can be removed by removing the three fasteners on the cover mount plate. Once the cover mount and cover are removed, this will allow access to the bottom of the gearbox / torque plate assembly. 8) Using a 5 mm hex head socket; remove the four fasteners and torque plate and separate mounting ring to expose the mounting holes on the gearbox. 9) Remove the torque stud retainer pins and washers from above the gearbox torque plate mounting holes. This will now allow the motor gearbox to be removed by pulling the assembly straight up and off of the torque studs and off the wheel shaft. 34 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Maintenance 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 dry at this point. If not, repeat the process. Once the mounting holes are cleaned and dry the gearbox can be reassembled. 2) Place the torque plate and the torque ring back onto the gearbox at the same position as when it was removed. Note: Confirm the position of the torque plate to verify correct orientation on the gearbox. 3) Locate the supplied M8 flat head fasteners (1FSTNR-FH075). Carefully apply some of the supplied 271 Red Loctite on each fastener as they are installed. Loctite should be applied lengthwise to the bottom half of the fasteners with a bead as wide as the 3/16 nozzle tip. 4) Turn the fastener a 1/4 turn and reapply the Loctite in the same fashion. 5) Insert the flat head fasteners into the threaded mounting holes and tighten until the fasteners touch the chamfered hole within the torque plate. 6) Repeat steps 3 and 5 on the remaining fasteners. Before tightening fasteners to the proper torque, this is once again an opportunity to verify that the torque plate orientation is correct on the gearbox. 7) Using a torque wrench along with a 5 mm hex key socket, torque all four fasteners to 25 ftlbs. 8) Allow this assembly to cure at least 24 hours in a warm (70 degree) environment, as the Loctite takes at least this time to cure properly. Doing so will ensure the fasteners will set appropriately. 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 plate and tightening the fasteners into position as show below. 2) Place the gearbox assembly back onto the wheel shaft using the keyway of the motor to line it up with the key in the wheel shaft. Once the key and keyway are aligned, lower the gearbox onto the torque bolts to its resting position. 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 35
Maintenance Torque Plate and Electric Motor Replacement Reinstall Motor Gearbox assembly 3) Locate and secure washers and the newly supplied zinc cotter pins into place. This will secure the gearbox into position. 4) Feed the wiring up through the cover and through the plastic fitting on the motor junction box. Make sure to tighten the fitting properly to prevent any water intrusion. 5) Once the wire is feed back into the junction box, secure the terminal block back into position using the Phillips screw. Be careful not to crimp or crush any of the existing wiring. Reconnect the wiring leads to the previously tagged motor leads to maintain the proper wiring positions. 6) Replace the junction box cap while being careful not to crimp or crush any of the existing wiring. 7) Once the motor gearbox unit is properly secured into position, power can be turned back ON. 8) Verify wheel rotation prior to running any test vehicle through the system. 36 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Maintenance Exploded Parts View Leg and Arm Weldments 104491: LSW Arm Weldment (passenger side) 102043: LSW Stand 104490: LSW Arm Weldment (driver side) Leg Clamp and Shock Assembly 1PLUG-PL500 (4) 102041: LSW Pivot Clamp 1WASHR-LC498 (4) 1FSTNR-HH811 101576: Shock and Spring Assembly 1FSTNR-HH811 102042: LSW Utility Clamp 1NUT-LC220 1FSTNR-HH594 (4) 102040: LSW Shock Clevis Weldment 1NUT-LC220 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 37
Maintenance Exploded Parts View Arm Mounting Components 6565: LSW Pivot Bolt 1FSTNR-HH486 (2) 1BERNG540: 2 Bolt Bearing (2) 1024: Sleeve 1WASHR-IT500 (2) 1NUT- LC924: 1-8 Nut 1NUT-RG536 (2) Hydraulic Drive Fittings and Fasteners 1WASHR-LC456 (4) 1ELBOW-ST539 (4) 1FTTNG-BH286 (2) 1ELBOW-ST385 (2) 1FSTNR-HH491 (4) 38 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Maintenance Exploded Parts View Hydraulic Motor and Shaft Assembly 1MOTOR-HY568 1MCONC-ST375 (2) 1254 1FSTNR_HH739 (2) 101064 1NUT-RG670 (4) 1COLLR333 1BERNG847 1WASHR-LC291 (4) 1FSTNR-HH270 (4) 1FSTNR-HH684 (2) 328 1FSTNR-SM500 (4) 1BERNG847 3688 1PLSTC-SW500: Plastic Sleeve 1WASHR-FL747 (4) 1FSTNR-HH729 (4) 329: Hydraulic Side Wheel Shaft Complete Assembly 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 39
Maintenance Exploded Parts View Electric Motor and Shaft Assembly 1RETNR129 (2) 1WASHR-FL747 (2) 7203 (2) 1COLLR333 1FSTNR-HH720 (2) Details on the Motor/Gearbox Assembly shown on next page 1BERNG848 1STEEL-KY150 1FSTNR-SM500 1COLLR333 1CLAMP257 & 1FSTNR-SH400 (2): (Used to secure electrical feed line to legs, 4 sets for driver side and 5 sets for passenger side) 7738 1FSTNR-SM500 (4) 328 1BERNG848 3688 1WASHR-FL747 (4) 1FSTNR-HH729 (4) 1PLSTC-SW500: Plastic Sleeve Complete Assembly See Next Page for More Details on This Assembly 40 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Maintenance Exploded Parts View Electric Motor and Gearbox Assembly 1PLSTC-CV040 1GEABX-AS986: Std. Voltage 1GEABX-AS988: 575 Volts 7912 1PLSTC-CV075 Black: PLSTC-CV080 Blue: PLSTC-CV082 Green: PLSTC-CV088 Gray: PLSTC-CV092 Orange: PLSTC-CV086 Red: PLSTC-CV084 Yellow: PLSTC-CV090 1WASHR-LC270 (3) SEE CHART 108060 1FSTNR-fH075 (4) 1FSTNR-SM500 (4) 7918 1FSTNR-HH154 (3) Water Manifolds 1FTTNG-BH269 103196 (complete assembly) 1NOZZL972 Cap and Gasket 1NOZZL993 Nozzle 1NOZZL-FJ696 (2 per side) 1NOZZL-FJ696 Nozzle Tip 1CLAMP385 Used to secure manifold to leg 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 41
Maintenance Exploded Parts View Aluminum Hub Assembly (Overview) 42 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Maintenance Exploded Parts View Aluminum Hub Assembly: 106026 1FSTNR-HH504 (2 per Spider Half) 1WASHR-LC498 (2 per Spider Half) 1132: 1-1/2 x 1-1/2 Spider Half 101132: Complete Assembly 1PLSTC-CL025: 8 Clip 1FSTNR-HH270 (8 per Skin) 1WASHR-LC291 (8 per Skin) 1WASHR-FL489 (8 per Skin) 101132: 6 x 1-1/2 Bore Spider Assembly (2 per wheel) 1PLSTC-CL050: 10 Clip 101118: 6 x 42-1/4 Skin Assembly (4 per wheel) 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 43
Maintenance Exploded Parts View Wave Hub Assembly (Overview) 102126: Hub Assembly Complete (includes all fasteners) 44 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Maintenance Exploded Parts View Wave Hub Assembly (Parts) 1FSTNR-HH744 (4) 1WASHR-FL747 (4) 1PLSTC-SW400: Top Cap Half (2) 1PLSTC-SW400: Top Cap Half (2) 1NUT-RG436 (2) 3648: Clamp Half 1WASHR-FL498 (2) 1FSTNR-HH441 (2) 1WASHR-LC291 (2) 1WASHR-LC456 (4) 1NUT-LC219 (4) 1FSTNR-HH562 (4) 3708: Clamp 101907: Drive Plate Weldment 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 45
Maintenance Exploded Parts View Wave Hub Assembly (Plastic Waves) 1PLSTC-SW400: Top Cap Half (2) 1PLSTC-SW100 (9) Lower Hub Assembly 1PLSTC-SW300: Bottom Cap 46 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Maintenance Exploded Parts View Misc. Wave Hub Components 102024: Drive Plate Assembly 101907: Drive Plate Weldment 101064 1MANUL858 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 47
Maintenance Cleaning Material Waves and Fins Cleaning Material Part Number Description 105476 Fin 20 piece set, 24 1/2 of 1 wheel Black 105477 Fin 20 piece set, 24 1/2 of 1 wheel Blue 105479 Fin 20 piece set, 24 1/2 of 1 wheel Red Neo-Tex Cleaning Material Part Number Description Blue: Full Row 102459 33 x 8 Neo-Tex, box / 48pcs, Blue 102475 33 x 10 Neo-Tex, box / 48pcs, Blue Red: Full Row 102460 33 x 8 Neo-Tex, box / 48pcs, Red 102477 33 x 10 Neo-Tex, box / 48pcs, Red Blue: Individual Pieces 6216 33 x 8 Neo-Tex, 1 piece, Blue 6224 33 x 10 Neo-Tex, 1 piece, Blue Blue: Individual Pieces 6218 33 x 8 Neo-Tex, 1 piece, Red Welted Cleaning Material Part Number Description Black: Box of Free-Standing Cloth Passenger side or driver side equaling one complete wheel with 44 slots 3BOX XLFPS132BLK Welted Cloth, 3 boxes / 132pcs, Blue Blue: Box of Free-Standing Cloth Passenger side or driver side equaling one complete wheel with 44 slots 3BOX XLFPS132BLU Welted Cloth, 3 boxes / 132pcs, Blue Red: Box of Free-Standing Cloth Passenger side or driver side equaling one complete wheel with 44 slots 3BOX XLFPS132RED Welted Cloth, 3 boxes / 132pcs, Blue 1PLSTC-CL025: 8 Clip 1PLSTC-CL050: 10 Clip 48 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL858
Low Side Washer 1MANUL858 Belanger, Inc. * P.O. Box 5470 * Northville, MI 48167-5470 Customer Service Phone (248) 374-4700 * Fax (248) 380-9681