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INSTALLATION AND STARTUP

1-4

Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681

1MANUL220

Chapter 1 Introduction

IMPORTANT Safety Information

– MUST READ

Safety Warnings

DISCONNECT THE MAIN POWER SUPPLY AND

DISSIPATE ALL POTENTIALLY HAZARDOUS

ENERGY SOURCES PRIOR TO SERVICING OR

MAINTAINING EQUIPMENT

Belanger® recommends that all workers observe the OSHA (U.S. Department of

Labor Occupational Safety & Health Administration) Lockout / Tagout procedure
to dissipate all potentially hazardous energy sources (i.e. - electrical, mechanical,

hydraulic, pneumatic, chemical, thermal, etc.) prior to performing service or

maintenance on machinery and equipment.

Note:

Reference the OSHA standard for the Control of Hazardous Energy (Lockout/Tagout), Title 29

Code of Federal Regulations (CFR) Part 1910.147 and the example provided in 1910.147 Appendix
A for practices and procedures necessary to disable machinery or equipment, thereby preventing
the release of hazardous energy while employees perform servicing and maintenance activities. The
standard outlines measures for controlling hazardous energies – electrical, mechanical, hydraulic,
pneumatic, chemical, thermal, and other energy sources.

Note:

Reference the OSHA standard 29 CFR 1910.331 to 29 CFR 1910.335 for safe work practices to

protect employees working on electrical circuits and equipment. This section requires workers to
use safe work practices, including lockout and tagging procedures. These provisions apply when
employees are exposed to electrical hazards while working on, near, or with conductors or systems
that use electrical energy.

Note:

Both referenced OSHA standards can be found at the following website:

http://www.osha.gov/law-

. Browse to the General Industry tab under the Find an OSHA Standard heading, scroll

down to the link of interest and click on it.

Doing so will prevent unexpected energization, startup, or release of hazardous

energy while maintenance and servicing activities are being performed.

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Summary of Contents for FreeStyler

Page 1: ...FreeStyler Installation Startup FreeStyler Installation Startup 1MANUAL220 Rev14 ...

Page 2: ......

Page 3: ...s manual Do not make additional copies of this manual or electronically transmit it in any form whatsoever in whole or in part without the prior written permission of Belanger Inc The registered trademarks used in this document are the property of their respective owners The use of such trademarks is for reference purposes only and does not imply sponsorship or approval of Belanger Inc by these co...

Page 4: ......

Page 5: ...nt Updated images using AutoCad Inventor assemblies 3 8 Length Considerations Involving Treadle Movement was Length Considerations and the section was reformatted 3 9 3 10 Change titles to Square 6 Legged Frame Configuration 2 was Configuration 1 both images removed note to see next page Updated images using AutoCad Inventor assemblies Added center leg to the note explaining the 22 1 8 dimension C...

Page 6: ... position was between the end of the rail and the Head Beam and added Stop Clamp to image 4 15 Added note to image in Step 5 4 16 Configuring the Sonar Unit updated per current practices 4 19 Added Notes above instruction Changed dimension in Installing the Boom Mount step 3 from 110 7 8 to 112 7 8 and added the Notes below the image 4 20 Changed title from Standard Channel Boom Installation to In...

Page 7: ...e subheading Photo Eye Available Add on Options Removed the sentence The standard FreeStyler configuration has a set of Photo Eyes to install at the entrance of the bay Chap 6 Was Chapter 7 in Rev 13 Added images and updated per current practices Removed Vector reference in the Treadle Y Section step Chap 7 New Chapter added to manual Chemical Delivery and Pumping Station Chap 7 Removed informatio...

Page 8: ...rent practices 22 10 to 22 11 De Stroking Cylinder Arms was Entrance Arm Cylinders Exit Arm Cylinders Added instruction for Entrance Arm Cylinder Updated image in Exit Arm Cylinder 22 13 Added Clear FORCED ovals step in Top Wheel instruction 22 16 Added Installing the Triple Foam Pods 22 20 Added Nozzle part numbers and Tip information 22 21 Added images 22 24 to 22 25 Running Test Vehicles was Ve...

Page 9: ...op Clamp Placement 4 12 Carriage Placement 4 14 Sonar Placement 4 16 Adjusting the Sonar Unit 4 17 Adjusting the Multifunctional Sonar Units 4 18 Installing the Boom Mount 4 19 Installing the Optional Freestanding Boom Mount Leg 4 22 Determining Driver Side Passenger Side Equipment Room 4 25 Passenger Side Boom Install 4 26 Installing the Boom 4 31 Connecting the Standard Boom Channel 4 31 Routing...

Page 10: ... Dimensions 12 5 Undercarriage Assembly 12 6 Chapter 13 Water Softener Option 13 1 Water Softener 13 1 Getting Started 13 2 Water Softener Installation CP 213 13 3 Model 213S OD WA and WB Connections 13 6 CP 213s OD Scanned 13 9 Component Functionality Scanned 13 10 Water Softener Conversion Charts 13 12 Chapter 14 HydroBlade Assembly Option 14 1 HydroBlade Specifications 14 1 Complete Hose Circui...

Page 11: ...nel 20 7 E 1063 Operator Interface 20 8 Chapter 21 Pneumatic and Hydraulic Connections 21 1 Entrance Wheel Circuit Overview Driver Side Pod 21 1 Exit Wheel Circuit Overview Driver Side Pod 21 2 Top Wheel Circuit Overview Driver Side Pod 21 3 Driver Side Pod Air Solenoid Valves Overview 21 4 Drive Side Pod Air and Water Controls 21 5 Entrance Wheel Circuit Overview Passenger Side Pod 21 6 Exit Whee...

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Page 13: ... Chapter 1 Introduction Chapter 1 Introduction ...

Page 14: ......

Page 15: ...emicals in the wash process and the following list includes some but not all of the particularly corrosive chemicals that if used in conjunction with Equipment or Parts will void the warranty Hydrofluoric Acid Ammonium Bi fluoride Bromic Acid Muriatic Acid Sulfonic Acid Phosphoric Acid Hydrogen Cyanide Hydrochloric Acid Sodium Hydroxide and Chlorinated Solvents 5 Seller makes no warranty express o...

Page 16: ...f 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 ...

Page 17: ...jury or death Signal Words The signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards The precautions that follow must be followed to prevent death injury or damage to the equipment DANGER This signal word is used to alert you to a hazard or unsafe practice which WILL RESULT IN DEATH OR SERIOUS INJURY This alerts you to a hazard or unsafe pract...

Page 18: ...ssary to disable machinery or equipment thereby preventing the release of hazardous energy while employees perform servicing and maintenance activities The standard outlines measures for controlling hazardous energies electrical mechanical hydraulic pneumatic chemical thermal and other energy sources Note Reference the OSHA standard 29 CFR 1910 331 to 29 CFR 1910 335 for safe work practices to pro...

Page 19: ... 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 CONSULT A TRAINED ELECTRICIAN ONLY TRAINED OR AUTHORIZED INDIVIDUALS KNOWLEDGEABLE IN THE RELATED PROCEDURES SHOULD INSTALL INSPECT MAINTAIN OR SERVICE THIS EQUIPMENT BE AWARE OF HAZARDS ASSOCIATED WITH EQUIPMENT INSTALLED ON THE FLOO...

Page 20: ...s The Belanger system is not intended for use as source of preventing injury to persons nor is it intended for entrapment or obstruction protection as described in UL 325 This equipment is intended to enhance the system by signaling the doors desired position but be overridden by operator s safety features The operator that is in direct control of the door must independently provide entrapment pro...

Page 21: ... that your Belanger Representative has already visited the site taken measurements and quite possibly sent drawings showing equipment locations The installation manual also assumes that all these items have been thoroughly reviewed by the site General Contractor and Owner If that is not the case now is the time to do so For your convenience the Getting Started section reiterates some of the critic...

Page 22: ...oarse Threads Inch Torque Values FT LBS Torque Values FT LBS Torque Values FT LBS 10 24 NA 2 1 4 20 10 6 5 16 18 19 11 3 8 16 33 20 7 16 14 54 31 1 2 13 78 43 120 9 16 12 114 57 5 8 11 154 93 3 4 10 257 128 7 8 9 382 194 1 8 587 287 1 1 8 7 794 NA 1 1 4 7 1105 NA 1 3 8 6 1500 NA 1 1 2 6 1775 NA 1 5 8 5 5 2425 NA 1 3 4 5 3150 NA 1 7 8 5 4200 NA 2 4 5 4550 NA Bolt Torque Factors LUBRICANT OR PLATING...

Page 23: ...ation Sonar Unit Directional Sign Carriage Assembly Chapter 4 Chapter 4 Chapter 4 Photo Eye Floor Treadle Wheel Water Feed Metering Pump Chapter 5 Chapter 6 Chapter 7 Chapter 7 Triple Foam Manifold for Pulsatron Pump Universal Manifold Chapter 7 Chapter 7 MixStir Reclaim Water Adapter Kit Booster Pump Bug Spray Applicator Chapter 8 Chapter 9 Chapter 10 Chapter 11 ...

Page 24: ...n Undercarriage In Ground Rocker Spin Cleans Water Softener Chapter 12 Chapter 12 Chapter 13 HydroBlade Pump Platform 10 HP 25 HP Pump On Board Wheel Cleaner Chapter 14 Chapter 14 Chapter 15 On Board CTA Deluxe Wheel Cleaner CTA Chemical Tire Applicator Wash In Use Enter Wash Sign Combination Sign Chapter 16 Navigational Sign Chapter 15 Chapter 15 Chapter 16 Chapter 16 ...

Page 25: ... Control Center Chapter 17 Chapter 18 Chapter 20 Chapter 20 E 1063 Modem Air Cannon Dryer AirBlade Dryer Chapter 20 Chapter 20 Chapter 20 Chapter 20 Entrance Wheel Cylinder Assembly Exit Wheel Cylinder Assembly Chapter 21 and 22 Chapter 21 and 22 Top Wheel Cylinder Assembly Air Over Oil Regulator Assembly Chapter 21 and 22 Chapter 21 Chapter 21 4 Port Air Manifold 8 Port Air Manifold Regulator Ass...

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Page 27: ... Chapter 2 Recommended Installation Sequence Checklist Chapter 2 Recommended Installation Sequence Checklist ...

Page 28: ......

Page 29: ...ater Option Reclaim Water Option 9 1 k Booster Pump Booster Pump Assembly 10 1 l Wheel Cleaning and CTA Wheel Cleaning and CTA Options 15 1 m HydroBlade HydroBlade Assembly 14 1 n Bug Spray Optional Bug Spray Applicator 11 1 o Position Pumping Station HydroBlade Assembly 14 1 h Reclaim modifications to Pumping station if applicable Reclaim Water Option 9 2 MEET WITH ELECTRICIAN Trades 19 2 a Coord...

Page 30: ...nd Carriage Assembly Optional Signage 4 16 22 Electrical terminations made at ALL E Stops Not Supplied by Belanger NA INSTALL SOFT PLUMBING 23 Install soft plumbing to Pumping Station Optional HydroBlade Assembly 14 24 Install soft plumbing to Chemical Pumps Chemical Delivery MixStir Options 7 8 25 Install soft plumbing to Carriage Frame and Carriage Assembly 4 26 Install soft plumbing to RO Unit ...

Page 31: ... Chapter 3 Getting Started Chapter 3 Getting Started ...

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Page 33: ...t OPERATION Minimum operating bay height is 140 Maximum recommended vehicle height is 84 contact your Belanger Sales Representative for additional options if this is a restriction INSTALLATION Ideally for installation the bay should provide at least enough height clearance to raise the bottom of the head beams 133 off the floor with 2 forklifts See Building Height Considerations on page 3 14 of th...

Page 34: ... more clearance from a wall Consideration should be given to any approach turns that a driver may encounter while entering the bay that may be helped or hurt by the machine being offset Door width such as a 10 or 12 wide door would ease vehicle loading more than an 8 door if the FreeStyler was placed off the door centerline If there is no back room available then the equipment can be placed in the...

Page 35: ...7 0 The entrance rail travel stops can be adjusted in any increment up to 30 to fit into a bay length of 34 6 and can wash a 30 shorter vehicle such as a 19 3 F250 extended cab 6 bed truck If the entrance rail travel stops are adjusted 30 shorter the machine can still wash the longest vehicles without faulting The back end of these vehicles will not be cleaned or rinsed as well as they would be if...

Page 36: ... Wheels begin spinning in this position Machine Entrance Position Machine Exit Position 106 Machine Entrance Position Machine Exit Position This dimension taken from center of Boom Mount See top image for origin of where the 92 dimension is taken from The 106 dimension is taken from the exit edge of the leg 19 3 Vehicle Conditions Long Bay Software 34 6 Wheels begin spinning in this position The 1...

Page 37: ...e Entrance Position Machine Exit Position 106 Machine Entrance Position Machine Exit Position This dimension taken from center of Boom Mount See top image for origin of where the 92 dimension is taken from The 106 dimension is taken from the exit edge of the leg The 124 1 2 dimension taken from entrance side edge of exit leg See top image for origin of where the 124 1 2 dimension is taken from Pos...

Page 38: ...heels begin spinning in this position Machine Entrance Position Machine Exit Position 106 Machine Entrance Position Machine Exit Position This dimension taken from center of Boom Mount See top image for origin of where the 92 dimension is taken from The 106 dimension is taken from the exit edge of the leg 19 3 Vehicle Conditions Long Bay Software 34 6 Wheels begin spinning in this position The 124...

Page 39: ...Entrance Position Machine Exit Position 106 Machine Entrance Position Machine Exit Position This dimension taken from center of Boom Mount See top image for origin of where the 92 dimension is taken from The 106 dimension is taken from the exit edge of the leg The 124 1 2 dimension taken from entrance side edge of exit leg See top image for origin of where the 124 1 2 dimension is taken from Posit...

Page 40: ...tory wash results for both the front and rear of the vehicle The Treadle can be moved up to 24 total which would bring the vehicle 2 feet further forward This Treadle placement accommodates washing a 19 3 vehicle in a 30 0 building If the Treadle is moved up 24 the Triple Foam would not spray on the first few feet of the hood 6 Legged version of this configuration shown later in this section Note ...

Page 41: ...gth The 66 dimension is taken from the exit edge of the leg The 22 1 8 dimension is taken from center of Boom Mount to the entrance edge of the center leg Machine Entrance Position Machine Exit Position 19 3 Vehicle Conditions Small Bay Software 32 0 Wheels begin spinning in this position Machine Entrance Position Machine Exit Position The 52 dimension is taken from the exit edge of the leg 22 1 8...

Page 42: ...is taken from the exit edge of the leg The 22 1 8 dimension is taken from center of Boom Mount to the entrance edge of the center leg Machine Entrance Position Machine Exit Position 21 9 Vehicle Conditions Small Bay Software 34 6 Wheels begin spinning in this position Machine Entrance Position Machine Exit Position The 52 dimension is taken from the exit edge of the leg 22 1 8 The 22 1 8 dimension...

Page 43: ...h The 66 dimension is taken from the exit edge of the leg The 22 1 8 dimension is taken from center of Boom Mount to the entrance edge of the center leg Machine Entrance Position Machine Exit Position 19 3 Vehicle Conditions Small Bay Software 32 0 Wheels begin spinning in this position Machine Entrance Position Machine Exit Position The 52 dimension is taken from the exit edge of the leg 22 1 8 T...

Page 44: ... taken from the exit edge of the leg The 22 1 8 dimension is taken from center of Boom Mount to the entrance edge of the center leg Machine Entrance Position Machine Exit Position 21 9 Vehicle Conditions Small Bay Software 34 6 Wheels begin spinning in this position Machine Entrance Position Machine Exit Position The 52 dimension is taken from the exit edge of the leg 22 1 8 The 22 1 8 dimension i...

Page 45: ...d 5 towards the exit with satisfactory wash results for both the front and rear of the vehicle The Treadle can be moved up to 24 total which would bring the vehicle 2 feet further forward This Treadle placement accommodates washing a 19 3 vehicle in a 30 0 building If the Treadle is moved up 24 the Triple Foam would not spray on the first few feet of the hood Note Under this scenario a booster pum...

Page 46: ... to be lifted to 48 and clamped to the legs before flipping the forks See the image below The clearance from the entrance or exit door to where the carriage slides onto the rails may be too small for the carriage to fit Note It is important to note that EITHER the entrance OR exit end of the bay can be used to place the carriage on the rails The clearance required to lift the carriage onto the fra...

Page 47: ... raised up in between the rails Note Higher ceilings make service and repair easier Heaters lights and other items need to be placed clear of legs head beams and machine travel Vehicle Height Considerations The maximum vehicle height recommended is 84 7 0 tall Boom Mount Location Note The Boom Mount as it ships to the site is 72 long When the machine position has been determined and the final rail...

Page 48: ... NO I would like to align the center of the rails to the center of the doors YES NO If not shift the center of the rails towards the Driver side Passenger side How Far inches Summary of Length Considerations Record Here What is the maximum length vehicle you plan to wash 4 Legged Frame Treadle and vehicle should be set to factory spec of 9 behind entrance side of exit 4 x 6 leg YES NO 6 Legged Fra...

Page 49: ...installation Use the drawing diagram that best fits your site layout If your layout is not represented in these diagrams and or you do not have site specific drawings please contact your Belanger Representative or Belanger Technical Support at 248 349 7010 for assistance Door Width and Centerline of Building Although rare door widths less than 10 feet can affect equipment placement and overall sit...

Page 50: ...ted system is designed to be secured with 5 8 lag bolts Note Hydraulic hoses are rated by bend radius and PSI however this document uses PSI to rate hoses Other field supplied items that will be required depending on the level of your installation including water hose poly flow tubing hydraulic hose assemblies and other plumbing lines All these items are also typically available at an Industrial o...

Page 51: ... 107362 It will assist in routing the utilities from the bay to the equipment room Note See the chart that follows for a list of needed parts All these items below can be purchased through the Belanger Aftermarket group using the referenced part numbers Part Number Qty Description 6115 4 3 inch sq back plates for threaded rod 1FSTNR ST750 50 Kwick Bolt 5 8 x 6 stainless steel anchor 1STEEL TH415 2...

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Page 53: ... Chapter 4 Frame and Carriage Assembly Chapter 4 Frame and Carriage Assembly ...

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Page 55: ... 6 legged configurations Although the Aluminum Frame will be shown in most images both frames are installed using the same dimensions bracket orientations and bay placement The only assembly difference is the clamp styles and the way the clamps are secured to the legs The following images show the two clamp styles being secured to the two leg styles Aluminum Frame Oval Frame Note The forklift cons...

Page 56: ... FreeStyler uses a universal rail so both rails are identical 3 Place the two FreeStyler rails in the bay considering the notes in the above diagram If from the height considerations the carriage can be placed onto the rails with the rail spacing set to 92 1 4 then set rail spacing to that distance at this time If the rails need to be separated to 100 to lift the carriage up in between the rails s...

Page 57: ... on top of the head beam and start the bolts Tighten the passenger side bracket bolts down all the way at the location 46 1 8 from inside of the rail to the Head beam centerline Repeat the above steps on the exit end Head Beams and Clamps See assembled image below Check the rail spacing once more and tighten the driver s side head beam clamps down completely Note If the spacing needs to be spread ...

Page 58: ...ent to the forks before lifting 10 Take the two forklifts and place one under each head beam in the center and carefully lift the assembly 48 off the ground Locate the four legs and place them in the corner clamps with the base plates facing toward the outside of the building If the forks do not need to be flipped then move on to step 14 If the forks need to be flipped tighten the corner clamps on...

Page 59: ...legs 14 Raise the machine up and set the height from the bottom of the head beams to the ground to 133 at all four legs and tighten the clamps back onto the legs Clamps on forks in place CAUTION Use caution when lifting the frame with the flipped forks if the frame was to slide back and off the forks it could fall onto the forklift For this reason you must secure the head beam to each of the forks...

Page 60: ...frame is in the air 17 Using the supplied 5 8 lag bolts 1FSTNR ST750 secure the frame to the floor at all 4 corners Note If the rails are set at the 92 1 4 spacing the rail is completely erected except the rail travel stops Note If the spacing is 100 the driver side head beam clamps should be loosened to where the lock washers are not fully compressed and the rail travel stops need to be clamped o...

Page 61: ...will also reduce the time it takes to set the right amount of slack for the boom hoses at the machine side the center of the boom arms and at the boom wall mount weldment To prevent unwanted movement of the Carriage Assembly it is locked into place by a steel key located in the Carriage Gearbox The following will instruct you how to disengage the Gearbox allowing free movement during the installat...

Page 62: ...ed to replace it Note Moving the drive coupling away from the gearbox creates enough clearance to access the larger gearbox keys Note Each gearbox key has a 1 8 hole drilled into the end to allow a thin Phillips screwdriver or a thick piece of wire to remove the key See the image below 3 Slide the Gearbox Key from the main drive gearbox using the hole that is drilled at the end of the key as shown...

Page 63: ...olts see the image below The carriage will now roll freely up and down the rails Note DO NOT REPLACE THE LARGE KEY UNTIL RAIL PLACEMENT BOOM MOUNT BOOM PLACEMENT AND ELECTRONIC MOVEMENT AS DEFINED IN CHAPTER 22 OF THIS MANUAL ARE VERIFIED 5 If the carriage has been raised using the Jack Bolt s raise the bolt s and secure it into its raised position using the Jam Nut Assembly Overview Do not loosen...

Page 64: ...ed to be slightly moved to achieve the required 100 spacing one or both exit roller caps will have to be removed allowing the beam to be slightly repositioned under the roller Note There also may be a need to remove the roller end caps to place the carriage onto the rails if your site has limited ceiling clearance Follow the steps below to remove the caps 1 Remove the 5 roller nuts and the two pie...

Page 65: ...and Carriage Assembly Carriage Prep Adjusting the Rails 2 Replace the 5 roller nuts to secure the roller into position Note The carriage is now prepared for placement onto the rails 3 Once the carriage is positioned onto rails correctly replace the roller cap Note It may be necessary to use the Jack Bolt to safely reinstall the wheel caps ...

Page 66: ...to the edge of the rail The 7 16 through bolts will be tightened through the pre drilled holes in the rails If the machine is to be loaded from the exit end of the bay you must then determine where to position the Travel Stops Refer to the previous section under Length Considerations to refresh your memory on the Rail Travel Stop placement If no adjustment is needed for the Rail Travel Stop Clamp ...

Page 67: ...o stop 2 Check for binding and adjust the rail width as necessary to maintain clearance from the inner and outer lips of the carriage Rollers Note The clearance between each roller and the side of the rail at the center of each detail plate should be checked and verified to be around 1 16 3 Install End Limit Proximity Targets on the passenger side rails as shown below Note The entrance target inst...

Page 68: ... 2 If the rail spacing is Set to the 92 1 4 distance proceed to step 3 Set to the 100 distance proceed to step 4 3 92 1 4 Rail Spacing Pull the Carriage up to just in front of the rails Have someone on each side of the machine to check clearance and slowly drive the machine onto the rails 4 100 Rail Spacing From the predetermined end maneuver the Carriage into the bay on one of the forklifts and m...

Page 69: ...r side rollers until the roller lips are 1 8 from inside surface of the rail which ends up being approximately 92 1 4 between the rails 7 Lower the machine onto the rails slowly to make sure everything clears Adjust the L Bracket Clamps on the driver side as needed Note You may need to lift the machine back up to slide the rails inward Note When tightening the clamps the rails will close in toward...

Page 70: ...ee the image below 2 Use the supplied 2 1 2 bolt with a lock washer to start the Sonar Bracket through the hole closest to the entrance of the machine but do not fully tighten yet Start the 3 bolt through the bracket in the hole closest to the exit end of the machine 3 Snug both bolts down but do not over tighten because this will cause the bracket to bend Take the supplied 3 8 regular nut and tig...

Page 71: ...ions on this page will help you understand the proper way to adjust it 1 Loosen the setscrews to adjust the vertical positions at the sonar end Axis 1 as shown in the side view below 2 Loosen the setscrews to rotate the end horizontally Axis 1 as shown above and below The Image below shows a front view 3 Adjust the Sonar Unit until it is level with the floor front to rear of vehicle and tilted 1º ...

Page 72: ...Width digital MODE 7 Kondor Width frequency The frequency modes output changes in frequency corresponding to the measured distance from the face of the sonar Digital modes turn on the output when the floor is detected Changing the Parameters Holding the magnet to the sonar will cause it to cycle through the different modes Hold the magnet horizontally on the top of the wide ring and under the LED ...

Page 73: ...om Mount to the determined length 2 The following image shows the location to mark the wall for bay height placement of the Wall Mount For the bay height location measure up 112 7 8 from the ground and mark the wall This mark will be used to line up the bottom edge of the detail plate in Step 4 Measure this distance and subtract 3 1 2 Cut the Boom Mount at this length 5 1 2 Direction of Travel 112...

Page 74: ... the center of the Wall Mount in Step 4 For the bay depth location with a 6 Legged Frame measure 22 1 8 from the entrance side edge of the center leg toward the entrance of the bay and mark the wall for this dimension This mark will be used to line up the center of the Wall Mount in Step 4 Note All the above dimensions are applicable for either Driver side or Passenger side Boom orientation Wall M...

Page 75: ...Plate through the wall Then while placing one of the Mounting Plates on the opposite side of the wall in the equipment room secure the Wall Mount Assembly into position as shown in the images below 6 Square the Boom Mount base plate and drill the other two holes Complete the securing of the Boom Mount to the wall as shown in the images above 7 Take the Boom Mount Clamp and secure it 2 from the out...

Page 76: ...r the 6 Legged Frame configuration measure 22 1 8 from the entrance edge of the center leg toward the entrance of the bay and mark the ground The Freestanding Boom Mount Leg will be centered on this mark Then determine the distance that the leg should be from the equipment room wall Note The following instruction for installing the Freestanding Boom Mount in the bay applies to the FreeStyler eithe...

Page 77: ...om the inside surface of the Freestanding Boom Mount Leg to the outside surface of the rail and subtract 3 1 2 as shown below Cut the Boom Mount to the determined length 4 Then on the Freestanding Mount Leg measure up 112 7 8 from the floor and mark the bay height dimension for the Boom Mount Assembly This mark will be used to line up the bottom edge of the detail plate on the Boom Mount Assembly ...

Page 78: ...unt Assembly on the Freestanding Mount Leg as shown below 6 Secure the Boom Mount Assembly into position on the Freestanding Mount Leg using the supplied Clamp Mount Brackets and fasteners as shown in the above images 7 Take the Boom Mount Clamp and secure it 2 from the outer edge of the Boom Mount as shown below Boom Mount Assembly Freestanding Mount Leg Clamp Mount Brackets and Fasteners Boom Mo...

Page 79: ...e made based on the Equipment Room location the following symbol will appear Boom Install Orientation If your machine has a Driver side equipment room then move on to Installing the Boom Mount If the machine has a Passenger side equipment room then follow the steps below to reconfigure the machine for a Passenger side equipment room orientation On the machine there is a Bulkhead Mount Block shown ...

Page 80: ...ions below to reconfigure the Boom Hose Support if required 1 Remove the 3 3 8 16 x 4 3 4 socket head bolts that run through the black plastic halves and the 2 3 8 16 x 2 1 4 button head screws that attach the mount plate to the weldment 2 Flip the mount plate 180 and rotate the black plastic halves 180 3 Fasten the bolts back into place and tighten them down Step 1 Step 2 Step 3 Note Separating t...

Page 81: ...he four 5 16 18 fasteners flat washers Nylock nuts and the two clamps that are holding the manifold assembly to the carriage c channel as shown below 3 Move the manifold assembly to a workbench that has a vice on it so that you can rotate the fittings around to their appropriate orientation Once at the workbench loosen the brass swivel fittings that hold the Lexair Valves in place Remove the Lexai...

Page 82: ...e that the fittings are facing in the shown orientation 6 Take the manifold assembly back up to the carriage and tighten it into place on the Driver side of the carriage using the 5 16 18 fasteners washers Nylock nuts and the clamps as shown below Verify that the valve orientations match the image below The following 2 pages show the other components related to this Distribution Manifold that also...

Page 83: ...emove the manifold assembly as shown below 2 Change the orientation of the components pointed out below 3 Change the orientation of the components pointed out below Note If you have purchased the optional low pressure feed kit you may need to disconnect any airlines that are connected to it It is a good practice to label the airlines for ease of reinstallation 4 Secure the manifold assembly into p...

Page 84: ...r Side Boom Install Optional HydroBlade Wheel Cleaner Wheel Cleaner Center Feed Manifolds 1 Remove the clamps that are circled below to remove the manifold assembly as shown below 2 Change the orientation of the components pointed out below 3 Secure the manifold assembly into place and re connect the hoses to the previous fitting locations See image below Before After ...

Page 85: ...llowing instructions 1 Locate Machine Mount Boom Assembly as shown below Note The Boom Hose Support Posts are assembled at the factory for a driver side configuration If your Boom is configured for the passenger side rotate the posts to the holes labeled with the P passenger side circled on the right before running your utility lines 2 Locate the supplied 7 16 14 x 1 stainless steel fasteners 7 16...

Page 86: ...the Boom Linkage Wear Washer the supplied 1 2 x 5 8 stainless steel shoulder bolt and the 3 8 16 stainless steel Nylock nut Place the wear washer in between both linkage arms and tighten in place with the shoulder bolt and Nylock nut as shown below Note The Nylock nut should tighten to the shoulder bolt only and should not compress the Linkage Arms If the Linkage Arms do compress together remove t...

Page 87: ...llow the Electrical movement steps covered in Chapter 22 of this manual Note In the Boom Channels the hoses will require 52 of slack minimum as shown below 1 Move the carriage to the exit end hard stop to ensure the boom does not completely straighten 2 Move carriage to the entrance end hard stop to ensure that the boom does not completely straighten Note The machine MUST be in this location to be...

Page 88: ... on the machine is at the entrance end 4 First lay the 6 motor leads 5 field supplied 3 8 poly flow tubes and the single 1 2 main air poly flow tube into the bottom of the channel Lay the 3 umbilical cords on top of the previously laid items Lay the 3 water hoses on top of the Umbilical cords Place each group of lines on the outside of the bend radius as shown in step 3 Note When all utility hoses...

Page 89: ... See the image below Note In this orientation the lines are at the smallest required bend radius on the boom So they are also stretched to the longest length that will be needed to move the boom 6 Have a helper hold the lines with the correct bend radius on the machine head and tie the utilities to the machine mount boom arm tightly using the 4 sets of slots in the channel Tie the three 3 4 water ...

Page 90: ...rtically Preferred Method if it is possible a Run the lines from 1 to 2 feet above the mount bracket then down onto and along the mount bracket Note Vertical slack will help with the bend transition from exit to entrance of the bay A possible example of this loop set up is shown below Setting Up Slack Horizontally Alternate Method ONLY if Vertical method is not possible b Run the lines vertically ...

Page 91: ...acceptable Note In areas where the hoses may rub put some type of hose protector around the lines to protect them Optional Deluxe Boom Connecting the Boom There are two Boom Arm Assemblies that are mirror images of each other The location of the side detail plates will indicate which arm mounts to the wall and which arm mounts to the machine The detail plates mount to the Boom Bushings so they fac...

Page 92: ... Run two 50 inch lengths of liquid tight tubing on the wall side of the boom Run a 28 inch length of liquid tight tubing in the center of the boom on the inside Run a 33 1 2 length of liquid tight tubing in the center of the boom on the outside Run the remaining 2 lengths of 28 of liquid tight tubing on the machine side location Note It will be simpler to run the utility lines if the plastic tubin...

Page 93: ... at this time if the drive train has been disengaged If the drive train has not been disengaged follow the Electrical movement steps covered in Chapter 22 of this manual 1 Move the carriage to the exit end hard stop to ensure the boom does not completely straighten 2 Move carriage to the entrance end hard stop to ensure that the boom does not completely straighten Note The machine MUST be in this ...

Page 94: ... the order and location of the lines The lines will need to be routed in the following sequence a Through the 50 section of liquid tight tube b Through the machine mounted Boom Arm section atop the carriage c Through a center sections of liquid tight tube at the center of the boom d Through the Wall Mount Boom Arm e Finally through another 28 sections of liquid tight tube located atop the carriage...

Page 95: ...the cables thru each of the five stages listed above and to the equipment room 2 Take the three yellow junction box wires and run them from the machine back through each section of the outside pipe See the image below 3 Take the airlines and connect them in the equipment room Route them out to the machine through the outer tube that houses the yellow cables Connect each airline to the proper port ...

Page 96: ...p barb hose fitting Note The lines should be connected into the bulkhead on the machine in the same order Note Run these hoses in 3 sections to create a replaceable area in the center where most of the wear occurs Route the cables thru each of the five stages listed above and to the equipment room Installing the Wheel Cleaner Accessory Kit Overview If a HydroBlade and or a Wheel Stinger option hav...

Page 97: ...n in the pressure drop thru the line and improve the performance of the equipment The pipes should run to an area near the end of length for the high pressure lines to prevent any extra length of hose and make sure the hoses do not need to be trimmed and re crimped See the images below 2 Secure the above components to the wall side of the Deluxe Boom as shown below 3 Repeat the above process on th...

Page 98: ...ten it at 34 from the end as shown in the images below Note When routing hoses and lines at the Boom and through the Boom Utility Capture Assembly be sure to leave loops at the ends and slack in the middle to allow for hose bending and movement through the motion of the machine Note Check all hoses and lines to verify the proper amount of slack while running the first few test vehicles 34 34 Boom ...

Page 99: ...o the key 4 Line up the key slot in the gearbox with the key slot in the gearbox drive shaft 5 Slide the Gearbox Key back into the gearbox be sure to insert the key with the hole on the outside of the gearbox as shown below Note The gearbox may have to be moved or repositioned for ease of replacing sliding in the key Note You will know when the Gearbox Key is inserted all the way it will bottom ou...

Page 100: ...is 2 Position the Arm Mount onto the Cylinder Clevis as shown below Note Be sure to align the Cylinder Clevis on the tab of the Entrance Arm See the image below 3 Secure the cylinder using the removed fasteners Note Be sure the threads of the shoulder bolt are facing up and the white plastic washers are in place See the image below 4 When completed the assembly should appear as shown below 5 Repea...

Page 101: ...earings have two set screws each Slide one of the Bearing onto the shaft as shown Secure the Locking Collar to the shaft as shown Be sure the gaps on the Locking Collar are even Secure the Locking Collar into place as shown Locking Collar gaps are equal Be sure to add Anti Seize between the Bearing and the Shaft 1COLLR333 1BERNG848 Grease Fitting Facing Out for Easy Maintenance Note Use anti seize...

Page 102: ...n all the fasteners down completely as shown below 4 Slide the second bearing on to the bottom of the upper shaft with the flat side facing upward Note For ease of maintenance be sure that the grease fitting on the bearing faces outwards Secure the bearing to the arm with the four provided 9 16 12 x 1 1 2 bolts Tighten down completely Tighten the two set screws on the bearing completely Before Aft...

Page 103: ...o the shaft as shown later in this chapter in Mounting the Entrance and Exit Motors and Gearboxes Note NEVER FORCE THE GEABOX ON TO THE SHAFTS SAND OR DEBUR THEM IF NECESSARY APPLY ANTI SEIZE TO THE TOP OF THE SHAFT AND ON KEYSTOCK 7 Locate the 72 5 8 lower shaft and the clamp assembly Secure them into place as shown below 8 Repeat steps 1 to 7 for the Entrance Arm assembly on the opposite side 1S...

Page 104: ...ws as shown below Complete Assembly Place the Bearings as shown Slide the upper Bearing up and snug it under the Locking Collar Bearings have two set screws each Tighten the set screws on the upper bearings ONLY Grease Fittings Facing Out for Easy Maintenance 1BERNG848 Note Use anti seize on all bearings and on the top part of the shaft that slides into the gearbox Note Overtightening may strip th...

Page 105: ...utward for ease of maintenance 4 Locate 1STEEL KY150 and place it into the key slot See the image below Slide the correct motor onto the shaft as shown later in this chapter in Mounting the Entrance and Exit Motors and Gearboxes Note NEVER FORCE THE GEABOX ON TO THE SHAFTS SAND OR DEBUR THEM IF NECESSARY APPLY ANTI SEIZE TO THE TOP OF THE SHAFT AND ON KEYSTOCK Place the Hub and Shaft Assembly into...

Page 106: ...thville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL220 Chapter 4 Frame and Carriage Assembly Mounting the Exit Arm Accessories 5 Snap the plastic bearing cover into arm 6 Repeat steps 1 to 5 for the Exit Arm assembly on the opposite side Before After ...

Page 107: ...Note Be sure the Torque Plates are in the correct location and orientation as shown below Confirm the orientation of the Motor Gearbox Assemblies on all four arms When the arms are open the electrical boxes of the motors should face towards the wall of the bay Note that the Cord Grip for both the Gearbox and the Arm are always on the same side Electrical Box Electrical Box Electrical Box Electrica...

Page 108: ...ins through the stud holes Bend the cotter pins so they stay in place as shown below Note You may need to loosen the torque studs a couple of turns to get the flat washers and cotter pins in place Be sure to apply Loc Tite and re tighten them after the parts are in place 3 Repeat steps 1 and 2 for the other three Side Wheel Hub Assemblies 4 Install the optional motor covers using the supplied mach...

Page 109: ...ers two 1 4 20 x 1 2 SHCS and two 1 4 flat washers 2 Secure the sign to the Carriage as shown below using the tapped holes 3 Feed the two yellow electrical cables through the large center hole see the image above and connect them to the rear of the Navigational Sign See the image below Hole Pattern 1 4 20 x 1 2 SHCS Electrical Cable To STOP GO Terminal To BACKUP Terminal Tapped Hole 2 Large Center...

Page 110: ...el Cleaning Manifolds 4 Remove the four 1 2 13 x 2 fasteners and lock washers from the Upper Mount Plate 5 Position the Upper Mount Plate inside of the Utility Cabinet so the fasteners holes are aligned with the clearance holes found in the Utility Cabinets Base Plate 6 Insert the fasteners up through the Base Plate threading them into the Upper Mount Plate 7 Locate the 3 4 hydraulic line packaged...

Page 111: ...m to the field supplied line Note If the supplied 1 1 4 water hose is not long enough 33ft supplied by Belanger and it is necessary to purchase a longer hose from the field the specifications are as follows 500PSI 8 Bend Radius minimum Additional hose can be purchased by the foot from Belanger as part 1HOSE820 7 Cut 1 1 4 hose to the measured length DO NOT throw the remaining hose away 8 Attach an...

Page 112: ...There is a switch near the top of the tank that tells the solenoid water valve to fill the tank This switch is wired through an off delay timer that is mounted inside the motor starter box This switch is normally closed held open with a full water level Terminate this switch in the motor starter panel 102 and 103 3 The water solenoid will be terminated in the motor starter panel 18 and 142 4 32 am...

Page 113: ...lamp assemblies Secure one assembly 1 8 from the edge of the driver side Hub as shown below 2 Locate 90 ten inch Wash Clips and 15 eight inch Wash Clips 3 Slide the first row of 10 wide Neo Tex into every other slot as shown below and above to the right Secure one of the Neo Tex Clamp assemblies into place as shown below and snug it against the Wash Clips as shown below End View of Fill Pattern In...

Page 114: ...ll 1 row of 8 wide material Install one more row of 10 wide material Secure another Clamp Assembly snug against the Wash Clips as shown below 5 Install 1 row of 10 wide material Install another of the Clamp assemblies and snug it against the Wash Clips as shown below 6 Install the last row of 10 wide material Install the last Clamp assembly and snug it against the Wash Clips as shown below Install...

Page 115: ...ded to remove the hub safely You will need 10 feet of rope to tie the Top Wheel frame down and prevent it from rocking during the installation You will also need two work horses to set the hub on while loading the material Quick Fill Overview Parts Required Neo Tex Compression Cap Assembly One complete assembly includes the following Whisper Wheel Fill Pack 2 9329 Compression Cap 6 1FSTNR HH328 3 ...

Page 116: ...r Wheel Removing the Hub 1 Fix the Top Wheel in the down position by tying one of the side arms to the leg of the frame on the same side as shown below 2 Remove the two cotter pins that hold the motor in place as shown below 3 Disconnect the motor wires and remove the motor gearbox assembly away from the shaft as shown below Note Take care not to misplace the motor key and the two flat washers ...

Page 117: ...hapter 4 Frame and Carriage Assembly Loading Optional Top Wheel Whisper Wheel Removing the Hub 4 Loosen the setscrews on the bearings of both arms as shown below 5 Remove the Compression Cap fasteners and push it all the way toward the bearing on both arms as shown below 6 Loosen the Trans Torque on both arms as shown below ...

Page 118: ...Loading Optional Top Wheel Whisper Wheel Removing the Hub 7 Loosen the 3 button head screws and slide the shaft toward the center of the hub through the Trans Torque until it clears the bearing and the Compression Cap Repeat this procedure on the other side as shown below 8 Using an assistant remove the hub and set it on work horses as shown below Before After ...

Page 119: ...s Note There are 8 primary colored packs and 4 secondary colored packs 4 Reassemble the hub The table below lists the part numbers for the individual Fill Packs Black Blue Red Green Orange Yellow Nine Layer Fill Pack 108550 108551 108552 108554 108555 108553 Note If you are installing the Whisper Wheel option you will have to add the additional weight bar covered on the next page End View of Fill ...

Page 120: ...the steps and images below to understand installing and securing the weight bars 1 Locate the 2 supplied 42 1 4 x 3 1 2 x 5 8 Weight bars See the image below 2 Although there are four set screw locations only loosen the one s necessary to accommodate the length of bar being installed 3 Slide the Weight Bar into the rectangular tube 4 Tighten the set screws Set Screw 4 Insert Weight Bar Here 42 1 4...

Page 121: ...2 pieces of Neo Tex in this row Neo Tex Box 24 pieces 25 x 8 Load one pc of 1 4 Neo Tex per plastic clip 12 pieces of Neo Tex in this row Neo Tex Box 48 pieces 25 x 8 Load two pcs of 1 8 Neo Tex per plastic clip 24 pieces of Neo Tex in this row Neo Tex Box 24 pcs 41 x 8 Load one pc of 1 8 NeoTex when folded on plastic clip makes this a 20 2 ply Neo Tex pack 12 pcs of Neo Tex in this row Neo Tex Bo...

Page 122: ... Middle Hub Fill Pattern 6 diameter hub Fill slots as shown Overhead View of Lower Hub Fill Pattern 6 diameter hub Fill every slot as shown 16 pcs 33 x 10 x 1 8 thick folded in half 16 pcs 33 x 10 x 1 8 thick folded in half 24 pcs 18 x 10 with 2 taper cut 2 pcs per clip 24 pcs 20 x 10 with 2 taper cut 2 pcs per clip 24 pcs 22 x 10 with 2 taper cut 2 pcs per clip 24 pcs 24 x 10 with 2 taper cut 2 p...

Page 123: ... Chapter 5 Entrance and Exit Photo Eyes Chapter 5 Entrance and Exit Photo Eyes ...

Page 124: ......

Page 125: ...Note Read through this entire section to familiarize yourself with the Photo Eye requirements before installation Photo Eye Layout and Description This single set can handle up to 5 functions 3 Enter operations Door Operation and POS Communication Some of the typical items that are controlled by a single set of Photo Eyes are Rust Inhibitor Undercarriage Wash and machine activation If On Board Doo...

Page 126: ...s read and understand the Entrance Operations and Exit Operations sections from the FreeStyler Programming Manual The image below shows the zones that are assigned to a two Photo Eye set system The Entrance Zone is typically between the entrance Photo Eyes and just after the treadle Equipment in this zone typically turned on with the Photo Eye and then turned off by either the Photo Eye or the Tre...

Page 127: ...Identification Alignment 1 Point the Emitter directly at the Receiver 2 Point the Receiver directly at the Emitter 3 Finely adjust the position of the Receiver until Indicator 4 of the Signal Strength Light Bar is ON Working Temperature Range Non Heated 33 to 130 Fahrenheit Heated 10 to 90 Fahrenheit Note If Indicator 4 of the Signal Strength Light Bar CANNOT be obtained try re adjusting the Emitt...

Page 128: ...uency B In the case of Photo Eye Crosstalk both Emitter and Receiver must be wired for Frequency B View from Bay Entrance View from Overhead Wiring Wiring for the Vector QS30 Emitter Brown 340 24VDC Blue 338 0VDC Gray 340 24VDC White No Connection Receiver Brown 340 24VDC Blue 338 0VDC Gray 340 24VDC White FreeStyler Input X30 X35 Black No Connection If the Wall Mounted configuration is used mount...

Page 129: ...er of the main manifold of the undercarriage wash to the center of the leg of the photo eye Note You should have the receiver Photo Eye tall stand if floor mounted with its back to any direct sun light Direct sunlight may adversely affect the performance Overhead View The above image shows the correct clearance and offset angle required for both Photo Eye styles to operate properly Centerline of b...

Page 130: ...109356 FreeStyler VPS Virtual Positioning System Wall Mounted Aluminum 109357 FreeStyler VPS Virtual Positioning System Floor Mounted Aluminum 109358 FreeStyler VPS Virtual Positioning System Wall Mounted White 109359 FreeStyler VPS Virtual Positioning System Floor Mounted White Available Options Part Number Description PE 105858 Heating Kit 1 Set PE 105859 Heating Kit 2 Sets Equipment Included It...

Page 131: ...BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 5 7 Chapter 5 Entrance and Exit Photo Eyes VPS Virtual Positioning System Photo Eye Photo Eye Placement 4 Legged Frame 9 Driver Side Exit End Passenger Side Exit End 4 26 27 1 2 24 8 1 2 ...

Page 132: ...0 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL220 Chapter 5 Entrance and Exit Photo Eyes VPS Virtual Positioning System Photo Eye Photo Eye Placement 6 Legged Frame 27 1 2 27 1 2 24 9 26 Driver Side Exit End Passenger Side Exit End 21 ...

Page 133: ...e to the dryer system See the images below for more details 1 Locate the skid that the sign was shipped on Inspect for any damages at this time 2 Remove the sign from the skid 3 Jog the FreeStyler machine until it is at the exit positive stops at the end of the rails Turn the passenger side exit wheel arm on so that it is spinning and then fire the arm out 4 Position the sign on the passenger side...

Page 134: ...r Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL220 Chapter 5 Entrance and Exit Photo Eyes VPS Virtual Positioning System Photo Eye Signage VPS Virtual Positioning System Photo Eye Line of Sight Back Room ...

Page 135: ... Chapter 6 Treadle Assembly Chapter 6 Treadle Assembly ...

Page 136: ......

Page 137: ...lers 2 Remove the ends of the roller assemblies slide the Plastic Rollers on and reassemble Per each side there are 11 straight rollers and 1 tapered roller The tapered roller goes on the entrance side as shown above 3 Secure the two sections together by aligning the stainless steel Treadle Axles to the female holes in the Y Section vertical mounts as shown below CAUTION The bolts shown above MUST...

Page 138: ...nents and mark the floor at their locations See the image on the next page Note Be sure the Proximity Switches are tightened with pliers 1 4 turn Failure to do so may cause switches to fail due to moisture Note If you have the Dually option and you received a Cover Plate be sure to discard it as it is used only with the standard style Treadle Entrance Treadle Plate Exit Treadle Plate Entrance Trea...

Page 139: ...low complete rinsing of vehicles with long front ends Note Since the vehicle is 5 closer to the exit the Top Wheel will travel 5 further toward the exit This difference can prevent the entrance wheels from getting pinched between long vehicles and any other obstruction such as overhead door rails The 9 dimension is taken from the entrance edge of the exit leg to the exit edge of the Treadle Direct...

Page 140: ...long front ends Note Since the vehicle is 5 closer to the exit the Top Wheel will travel 5 further toward the exit This difference can prevent the entrance wheels from getting pinched between long vehicles and any other obstruction such as overhead door rails The 9 dimension is taken from the entrance edge of the exit leg to the exit edge of the Treadle Direction of Travel Centerline of doorway an...

Page 141: ... Box at least 6 feet from the floor to prevent unnecessary exposure to water and run conduit down the wall and over to the Treadle 2 Feed the open end of the supplied cables up through the conduit and terminate them in the Junction Box and to the SCC 3 Connect the two Euro Connectors to the Treadle Proximity Switches Note Take care NOT to reverse the entrance and exit connections 6 feet minimum Ju...

Page 142: ......

Page 143: ... Chapter 7 Chemical Delivery and Pumping Station Chapter 7 Chemical Delivery and Pumping Station ...

Page 144: ......

Page 145: ... from the equipment room and to the pods The lines from the Equipment Room run through the Boom tie wraps and into the manifold Be sure to loop the lines enough to allow proper rotation of the Boom and a sufficient bend radius on the lines Refer to the diagram below to identify the connection locations See Chapter 6 for Boom utility installation Triple Foam Manifold Triple Foam Out to Pods Typical...

Page 146: ...rsal Manifold Rinse Seal Wax Drying Agent ASCO Valve Main Water into Manifold from Boom Rinse Seal Wax Drying Agent Nozzles Under Pod on Opposite Side Seal Wax Chemical from Boom Drying Agent Chemical from Boom Rinse Seal Wax Drying Agent Nozzles Under Pod on Both Sides Optional RO Water Connection Both Sides See Images Below Optional RO Water In from Boom to the Manifold Rinse Seal Wax Drying Age...

Page 147: ...dard Water and Soap Circuit Connection Overview Center Pod Main Water into Universal Manifold from Boom Soap Pump Universal Manifold Water Feed Assembly Water and Soap Out to the Exit Wheels Soap Water Out to Machine Water and Soap Out to the Entrance Wheels Water Supply to Water Feed Assembly Entrance Wheel ASCO Valve Soap Water ASCO Valve Exit Wheel ASCO Valve Water and Soap Out to the Top Wheel...

Page 148: ...Block Overview The Electrical Distribution Block is where the connections are made to the Chemical Discharge from the MCC Either a single or dual plug can connect to this block Depending on your purchased options you may have either type in each location The electrical distribution block image below shows the destinations of dual plug feeds See the supplied prints and Electrical Drawings for more ...

Page 149: ... 48167 5470 Ph 248 349 7010 Fax 248 380 9681 7 5 Chapter 7 Chemical Delivery and Pumping Station ON OFF Controller Over Temp Thermostat Device Connections UPPER TERMINAL CONNECTIONS 5L1 5L2 5L3 035 BACK 227 FRONT X36 BACK 338 FRONT PROCESS CONTROL RB100 LIMIT CONTROL CB100L ...

Page 150: ... Fax 248 380 9681 1MANUL220 Chapter 7 Chemical Delivery and Pumping Station ON OFF Controller Over Temp Thermostat Device Connections LOWER TERMINAL CONNECTIONS AND TERMINAL BLOCK STRIP PROCESS CONTROL RB100 LIMIT CONTROL CB100L 547 TO TERMINAL BLOCK STRIP 547 TO CB100L 344 344 TO CB100L 547 344 ...

Page 151: ... Chapter 8 MixStir Options Chapter 8 MixStir Options Triple Foam and High Pressure Wax ...

Page 152: ......

Page 153: ... 2 main feed shown in the image below Note The typical pneumatic panel is NOT used for the MixStir Triple Foam option The MixStir Triple Foam option has its own pneumatic panels There is one pneumatic panel for each MixStir tank See the images below Application Connections from MixStir Triple Foam Pumping Panels Refer to the supplied MixStir manual to install and set up the rest of the equipment P...

Page 154: ...both arms simultaneously To set up the high pressure wax option 1 perform the following 1 For the high pressure style connect the wax solenoid cable located on the SDM to the SDM Electrical Distribution Block See the image below 2 At the HMI E 1063 Human Machine Interface program a Sealer Wax pass with a pump speed set between 31 100 For packages with low pressure wax see Application Configuration...

Page 155: ...ssure using both arms simultaneously The second pass involves medium pressure using both arms simultaneously The third pass involves high pressure using one arm at a time High pressure wax option 2 requires the Belanger MixStir tank to be installed MixStir Tank Assembly and Installation Locate the following parts MixStir Tank and mounting kit High Pressure Check Valve Plug 1 Secure the High Pressu...

Page 156: ... MixStir a mounting location should be selected that will minimize the length of utility lines 3 Secure the MixStir Tank to the wall in the appropriate location Note Make sure it is at least 6 feet from the floor and as close as possible to the Pumping Station Note Also be sure to leave room for inspection and repairs on all sides of the Pumping Station 4 Hang the MixStir Tank on the Mounting Plat...

Page 157: ...wn below If not secure a valve and barbed fitting into place See the images below 7 Run a 1 2 water line from the barbed fitting of the Solenoid valve to the barbed fitting on the High Pressure Check Valve Assembly See the images below 8 Position your field supplied chemical drum near the MixStir tank See the image below Note For best performance position the drum as close as possible to the tank ...

Page 158: ...ass with a pump speed of 25 to run a low pressure wax using the standard Pulsatron pump 13 For a medium pressure both arms program the wax pass with a pump speed of 31 100 Note This pass will use the MixStir high pressure wax option and come out of both arms 14 For a high pressure pass 1100 PSI one arm at a time or a low pressure pass see Application Configuration in your Programming Manual Note T...

Page 159: ...alled this Check Valve will prevent pressure from coming backward through the Asco Valve and overflowing the wax tank Float Check Valve Assembly Normally open no spring If the wax tank fails to fill the float ball will close the suction line and prevent the main pump from ingesting excessive air Float Main water feed Float Ball 1BALL PL150 Float Check Body 6880 Bulkhead Gasket 1GASKT650 1NUT JM500...

Page 160: ...INSTALLATION AND STARTUP 8 8 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL220 Chapter 8 MixStir Options Triple Foam and High Pressure Wax HydroMinder Scanned ...

Page 161: ...INSTALLATION AND STARTUP 1MANUL220 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 8 9 Chapter 8 MixStir Options Triple Foam and High Pressure Wax HydroMinder Scanned ...

Page 162: ...INSTALLATION AND STARTUP 8 10 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL220 Chapter 8 MixStir Options Triple Foam and High Pressure Wax HydroMinder Scanned ...

Page 163: ... Chapter 9 Reclaim Water Adapter Kit Option Chapter 9 Reclaim Water Adapter Kit Option ...

Page 164: ......

Page 165: ...rately Note The Reclaim Adapter can be installed ONLY in the larger Fresh Water Tank Locate the following parts 1VALVE WA298 Ball Check 1TEE PL978 Inlet TEE 1NIPPL PL825 2 1 1 2 CPVC Close Nipple 1 Remove the hose clamps and the barbed hose fittings from the bottom of the large water tank 2 Locate the ball check valve and inlet tee components and assemble them as shown below CAUTION Be sure the Fl...

Page 166: ...s line dumps water back into the large tank With the Reclaim Adapter the Relief Valve MUST be rotated 90 to prevent contaminated water from mixing with the fresh water of the large tank Run the bypass line to a drain Water MUST flow out of tank as indicated with the arrows in the images below It is simpler to make this modification if you remove the elbow tube assembly completely and replace it on...

Page 167: ... Chapter 10 Booster Pump Assembly Option Chapter 10 Booster Pump Assembly Option ...

Page 168: ......

Page 169: ...tor water pressure Is supplied with 3 brass ball valves These ball valves will allow you to switch over from the standard water feed to the booster pump at any time and vice versa for service Will supply a faster and more efficient rinse cycle which in turn will create a faster overall wash package Low noise level The pump is self priming The pump has a user friendly control panel The pressure tan...

Page 170: ... the Booster Pump and continue running the wash for example during maintenance procedures make sure that Ball Valves 1 and 2 are closed and 3 is open To Optional Wheel Cleaner Pumping Station To FreeStyler Main Water Feed To Optional Wheel Cleaner Pumping Station To FreeStyler Main Water Feed Applies additional pressure to the FreeStyler wash process only Applies additional pressure to the FreeSty...

Page 171: ...ll be cut If you need to go further than 6 0 it will be necessary to purchase additional hose Installation 1 Locate the main copper water line that feeds the fresh water to the 3 4 blue water hose running through the boom and to the FreeStyler utility plate This copper line will need to have a section cut out to install the Booster Pump Kit Note If the Wheel Cleaner option was selected the pump ca...

Page 172: ...ld supplied anchor bolts Note Be sure to tighten both anchors down completely 7 Locate the pump assembly and mount it to the bracket using the supplied 3 8 fasteners washers and nuts Note Be sure to tighten all four fasteners down completely 8 Locate the supplied 1 diameter 15 0 black water hose and make your two line connections as shown in the image in Step 2 Note Be sure to put the clamps on to...

Page 173: ...Replace the priming plug once this is complete See the image below 4 Open the return valve and the feed valve completely Keep the bypass valve closed See the image below 5 Turn on the electrical 110VAC to the pump 6 Run a wash cycle and verify that there is proper operation 7 Speed up the wash passes within the wash cycle until enough water is used to rinse your best triple foam package 8 Verify t...

Page 174: ......

Page 175: ... Chapter 11 Bug Spray Applicator Option Chapter 11 Bug Spray Applicator Option ...

Page 176: ......

Page 177: ...emical pump is the same type Pulsatron shown below as the ones used in the chemical delivery system for drying agent wax and triple foam Supply water is connected to the ball valve assembly and the chemical pump connected to the injector The discharge line from the ball valve then has a mix of water and bug spray chemical The discharge line is connected with a 3 4 water hose to the cross over tube...

Page 178: ...I 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL220 Chapter 11 Bug Spray Applicator Option Bug Spray Applicator Standard Treadle Circuit Overview Standard Treadle Installation Standard VPS Virtual Positioning System Circuit Overview Crossover Tube In line with tire ...

Page 179: ...ssembly needs to be mounted higher on the wall than the pump assembly Note The 3 8 poly flow line that will feed the chemical from the pump assembly to the Asco valve assembly is not provided Note The lines that are provided are the suction line with the foot valve and the priming line Both provided lines are 7 feet in length 2 Drop these two lines into the Bug Spray Applicator chemical drum Run t...

Page 180: ...le to the floor with the supplied floor lags and clamp it to the treadle plate with the supplied clamp Note Make sure the elbow is pointing toward the exit of the bay 4 Lag the Bug Spray Applicator manifold to the floor at the dimensions shown below Note The barbed hose fitting should point toward the entrance of the bay Bug Spray Applicator Nipple Treadle Elbow Hose Barb Driver Side Wall Straight...

Page 181: ...h of vehicle tires So it is important to protect the soft rubber feed hose A crossover tube made of hard piping is necessary See the image below OPTION 2 Mount the manifold and crossover feed in a trench cut into the floor This option will keep the bay floor clean and obstruction free It is still important to mount the hard pipe crossover tube in line with the tire so if the trench is not cleaned ...

Page 182: ...ay Note If the Asco valve and the Pulsatron pump are mounted onto the passenger s side of the bay then the hose will need to be plumbed up and over the top of the machine and to the other side of the bay to prevent premature hose wear from cars running over it repeatedly 7 Flush the lines for a couple of minutes Tighten the nozzles into the Bug Spray Applicator manifold Prime the chemical pump E 1...

Page 183: ... Chapter 12 Undercarriage Options Chapter 12 Undercarriage Options ...

Page 184: ......

Page 185: ...field 1 stainless steel water manifold with 3 4 NPT threads on each side 1 undercarriage water valve assembly 3 65 x 2 0 GPM nozzles 1 3 4 stainless barb hose fitting 1 3 4 stainless cap 1 3 4 stainless female elbow 2 3 4 ear clamps for the water line 4 Lag bolts to mount it to your floor Assembly Notes Be sure to tighten the 3 4 stainless elbow and 3 4 barbed hose fitting to the side of the manif...

Page 186: ...Mounting the In Ground Style Undercarriage in a Trench Be sure that there is adequate room for the fittings and pipe on each end You will also need to have the elbow angled up a little to allow room to clamp the hose Note Take care that the water hose does not stick up out of the trench to in a way that becomes a tripping hazard or a potential catch point Mounting the In Ground Style Undercarriage...

Page 187: ...e and is to be pointed towards the exit of the bay 2 Position the manifold with the center hole 5 towards the driver side of the doorway s centerline 3 Place the In Ground Undercarriage Weldment Assembly in the correct location as shown below and secure it to the floor using the supplied lag bolts Direction of Travel Centerline of Doorway 44 23 5 Photo Eye Between 2 and 20 Direction of Travel 2 Ph...

Page 188: ... as shown below 3 Mount the supplied Undercarriage Valve Assembly to the wall in the appropriate location 4 Run a field supplied 3 4 water hose from the Barbed Hose Fitting to the Plumbing Assembly See the image above 5 If you have the Rust Inhibitor option mount the supplied Chemical Pump Assembly see the image to the right to the wall in an appropriate location 6 Supply 110VAC feed to the Chemic...

Page 189: ...INSTALLATION AND STARTUP 1MANUL220 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 12 5 Chapter 12 Undercarriage Options Undercarriage Above Ground Dimensions 37 46 2 ...

Page 190: ...e available or system configuration Undercarriage Assembly 1 Position the Undercarriage Wash Rust Inhibitor in the desired location Traditionally it is placed just before the entrance leg to the first piece of equipment in a tunnel 2 Position it so that the right side of the Undercarriage Wash Rust Inhibitor is angled towards the bay entrance 3 Once it is in its permanent location lag it to the fl...

Page 191: ... Chapter 13 Water Softener Option Chapter 13 Water Softener Option ...

Page 192: ......

Page 193: ...ner See the image below If the On Board Wheel Cleaner Stinger option is purchased another 20GPM water softener is required In this scenario the 4 tank water softener model 213S OD WB is necessary to soften the water See the image below The water softening scenarios above do not include supplying the RO Spot Free Rinse A Pur Clean RO unit does not require softened water Model 213S OD WA 2 Tank Syst...

Page 194: ...ture can cause the unit to freeze Damage to the system will result It is recommended that a certified installer perform the installation Failure to install the system as instructed will void the warranty Proper ventilation must be provided when using PVC cleaner or glue Use a ladder for all work overhead that is beyond your natural reach If working continuously at a height of six feet or more the ...

Page 195: ...tion If sand silt or turbidity is present install a separate prefilter Use a ladder for all work over head that is beyond your natural reach If working continuously at a height of six feet or more the appropriate safety devices must be employed Identify state and local plumbing codes before continuing Verify that the installation complies with all applicable codes Install the system with by pass v...

Page 196: ...3S OD WA Non softened water in These lines are to be 1 1 4 or 1 1 2 All copper tubing Non softened water in This line MUST be 2 40PSI or less It can be 1 1 2 40PSI or greater The other lines are as follows WB 1 1 4 or 1 1 2 copper tubing Softened water out Five field supplied Shutoff Valves normally open close to bypass system One field supplied Shutoff Valve normally closed open to bypass system ...

Page 197: ...L CODES Before connecting the unit check for any obstructions or kinks Apply Teflon tape to the pipe threads on the side of the softener valve and install the two fittings supplied Connect the drain line to the valve If the drain lines for the CP 213 must travel more than 8 feet up and 30 feet over it is best to take the 5 8 drain line that fits the valve and attach it in a larger diameter line or...

Page 198: ... flat surface the height of the float cup can be measured with a ruler The height is measured from the base of the brine valve assembly to the top of the float cup See the image below Note that standard settings are defined by markings on the rod of the brine valve assembly The settings on the rod are listed in the tables at the end of this section Where the predefined settings are not adequate th...

Page 199: ...all the brine valve assembly in the brine drum Locate the brine valve in the brine well so that the bent tube is along the back of the brine well away from the brine drum wall The bent tube snaps into a notch and extends from the brine drum about 1 Note Do not drop the brine valve into the drum Note Dropping may lower the float cup resulting in an improper setting Plastic push on fitting typical o...

Page 200: ... the unit is full and pressurized With the unit in service and under pressure allow the brine drum to fill with water until the brine valve shuts off After the unit is fully pressurized purge the air from the lines by opening the soft water outlet When the installation is complete plumbing lines must be chlorinated for sanitation Common household bleach may be used The amount of bleach will vary b...

Page 201: ...INSTALLATION AND STARTUP 1MANUL220 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 13 9 Chapter 13 Water Softener Option CP 213s OD Scanned ...

Page 202: ...n the regeneration control valve opens and regeneration starts When open the regeneration control valve allows water to pass through a nozzle where it is directed to the regeneration turbine in the regeneration chamber As the regeneration turbine spins it drives the regeneration drive pawl which advances the control disc The control disc covers and uncovers holes in a ceramic disc beneath it to op...

Page 203: ... The brine valve is used to adjust the volume of brine to be produced for each cycle For a multiple system installation one standard brine tank is required for each control valve Central Brine System For larger multiple systems a Central Brining System alternative is available This will replace the need for multiple brine tanks when installing multiple units in parallel The Central Brining System ...

Page 204: ...78 0 00001578 25 4 2 54 0 0254 0 0000254 Feet 12 0 1 0 0 3333 0 0001894 304 8 30 48 0 3048 0 0003048 Yards 36 0 3 0 1 0 0 0005682 914 4 91 44 0 9144 0 0009144 Miles 63360 0 5280 0 1760 0 1 0 1609000 0 160900 0 1609 0 1 609 Millimeters 0 03937 0 003281 0 001094 0000006214 1 0 0 1 0 001 0 000001 Centimeters 0 3937 0 03281 0 01094 0 000006214 10 0 1 0 0 01 0 00001 Meters 39 37 3 281 1 094 0 0006214 1...

Page 205: ... Chapter 14 HydroBlade Assembly Option Chapter 14 HydroBlade Assembly Option ...

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Page 207: ...e with reclaim this pump is ideal for medium pressure high volume rinse Cat triplex plunger pump 25HP recommended for use when high pressure high volume rinse is desired Specifications 10HP Medium Pressure Pumping Station Pump Type Multistage Centrifugal Pump Motor Type 10HP 3 Phase 208 230 460 V Tank Capacity 30 Gallons Maximum Flow 40 GPM Maximum Pressure 260 PSI Inlet size Min 30 GPM 3 4 Barb h...

Page 208: ...31 5 Amps VAC 120 2 Amps constant from GFCI protected circuit side Specified output 120V signaled Water Requirements 1 30 GPM 40 PSI 25HP Pumping Station Electrical Requirements 25HP 3 phase 208 78 Amps 230 68 Amps 460 34 Amps VAC 120 2 Amps constant from GFCI protected circuit side Specified output 120V signaled Water Requirements 1 30 GPM 40 PSI Tools Required 3 4 wrench Two adjustable wrenches ...

Page 209: ...20 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 14 3 Chapter 14 HydroBlade Assembly Option Complete Hose Circuit Overview Complete Airline Circuit Overview Image below shows all available options ...

Page 210: ...their packaging 4 Remove the four 1 2 13 x 2 fasteners and lock washers from the Upper Mount Plate as shown below typical 5 Position the Upper Mount Plate inside of the side pod as shown above Note Notice the Upper Mount Plate mounts inside the side pod and the bolts tighten thru the bottom of the side pod plate Note Be sure to mount the driver side and passenger side in the correct location Passe...

Page 211: ...the image above are four 49 hydraulic hoses 2 for each manifold that will connect to the bulkheads that are tightened into the upper plate of the side spray manifolds See the image to the right High Pressure Hoses Installation 1 From the Upper Wheel Water Feed Manifold connect the two hoses to the entrance side bulkhead Run the other 2 hoses from the upper HydroBlade Water Feed Manifold to the exi...

Page 212: ... holes that are drilled on the angle Note At this point all the hose runs on the machine are complete See Nozzle Chart later in this chapter for more details Lexair Manifold Stauff Clamp Connect Hose Here Note The Lexair Manifold is located inside of the upper utility cabinet on a channel which is used to mount all the water valves and manifold blocks Note The Lexair Manifold is mounted on the sid...

Page 213: ...it Assembly the following are applications that you can use it for and benefit your carwash Rinse and or Sealer Wax Spot Free R O Low Pressure Feed Purge Air Note The fitting that is factory installed in the Universal Manifold is based on the options you have purchased Note See the images below for the fittings that correspond to the various options in the location circled in the image above Seale...

Page 214: ...ses shown below They each run between a side pod of the machine to the hose barbs located on the Brass Tee that is located in the Universal Manifold See the image below 4 Open the Passenger side pod cover and locate the brass cross assembly that is near the exit side of the machine See the image above in Step 3 5 Remove the other half of the 1 2 blue water hose that was removed in Step 3 It is loc...

Page 215: ...HydroBlade Low Pressure Feed Kit to the straight fitting that is in the tee on the Universal Manifold See the images below 9 Crimp both clamps once the hose has been cut to the proper length and secured into place Note Be sure that the hose is not positioned in a way that it will be cut or crimped by the machines operating motion 10 Remove the brass elbow from the brass tee on the Universal Manifo...

Page 216: ...ory Box locate the HydroBlade Low Pressure Feed Kit and install it as shown below Remove Brass Plug as shown above Install the HydroBlade Low Pressure Feed Kit as shown and place the previously removed Brass Plug in the end Note Located at the center of the carriage is the Universal Manifold The Asco Valve that controls the R O feed is in the center of this manifold circled in the image below 4 Re...

Page 217: ...ner most brass fitting in the HydroBlade Low Pressure Feed Kit to the straight fitting that is in the tee on bottom of the RO Asco valve in the Universal Manifold See the images below 9 Crimp both clamps once the hose has been cut to the proper length and secured into place Note Be sure that the hose is not positioned in a way that it will be cut or crimped by the machines operating motion 10 Remo...

Page 218: ...off all power supply to the FreeStyler to avoid any accidents 2 In the Accessory Box locate the HydroBlade Low Pressure Feed Kit and install it as shown below HydroBlade Low Pressure Feed Kit Remove the Brass Plug Install the Assembly into place 3 Locate the supplied MAC Valve assembly shown below 4 Cut the airline at 2 from the bulkhead and insert the MAC Valve Assembly as shown Cut the airline h...

Page 219: ...ly Installation 5 Install a section of 1 2 airline between the HydroBlade Low Pressure Feed Kit and the MAC valve See the images below 6 Run the electrical lead from the MAC valve to port 5 on the Electrical Junction Block Euroblock located in the C Channel in the Carriage as shown below Install Airline here Connect Electrical Feed as shown here HydroBlade Low Pressure Feed Kit MAC Valve ...

Page 220: ...l drain the spray tubes before you begin to run the 1st dryer pass If you did not have this option you would have to wait for the tubes to completely empty before making the 1st dryer pass so that the water is not draining on to the vehicle See the image below and to the right HydroBlade Rinse Quick Dump Assembly Installation 1 Locate the accessory box and verify that there are 2 Quick Dump Assemb...

Page 221: ...o its final location and lag it to the floor The utilities that are necessary depend on the pumping station purchased Follow the steps that apply to your site 10HP Pumping Station See the Nozzle Chart on the next page 25HP Pump 1 Run a field supplied 3 4 hose from the pumping station to the Lexair manifold inside the carriage Note The specifications of this line require a minimum rating of 1500 ps...

Page 222: ...er HydroBlade Lexair distribution manifold will be supplied with 1 1 4 yellow hydraulic hose Below are the Belanger part numbers along with the flow rate and pressure 10 HP Pump for Medium Pressure 40 GPM 250 PSI NZZL 105980 Nozzle kit for high pressure Wheel Cleaner NZZL 105985 Nozzle kit for high pressure HydroBlade Wheel Cleaner HydroBlade for 25 HP High Pressure If this configuration has been ...

Page 223: ...tinger HydroBlade for 10HP Medium Pressure Wheel Stinger HydroBlade Lexair Assembly 108479 10HP Wheel Cleaner Pumping Platform Assembly Nozzle kit Number NOZZL105980 for 10HP Medium Pressure Wheel Stinger Nozzle Kit and six Hockey Pucks Assemblies Nozzle kit Number NOZZL105983 for 10HP Medium Pressure HydroBlade 1NOZZL MG349 6 TIP MEG 4015 1NOZZL MG200 30 TIP MEG 0505 HP Puck Assembly 108502 6 ...

Page 224: ...l Stinger HydroBlade for 25HP High Pressure Wheel Stinger HydroBlade Lexair Assembly 108479 25HP Wheel Cleaner Pumping Platform Assembly Nozzle kit Number NOZZL105982 for 25HP High Pressure Wheel Stinger Nozzle Kit and six Hockey Pucks Assemblies Nozzle kit Number NOZZL105985 for 25HP High Pressure HydroBlade 1NOZZL MG758 6 TIP MEG 4008 1NOZZL MG100 30 TIP MEG 0502 HP Puck Assembly 108502 6 ...

Page 225: ... Chapter 15 Wheel Cleaning Chemical Tire Application Options Chapter 15 Wheel Cleaning Chemical Tire Application Options ...

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Page 227: ... side that are fully adjustable for pinpoint cleaning accuracy CTA delivery applicators Onboard photo eyes Sensors to notify the operators if a fault occurs Free Standing Items Pump platform with HydroMinder holding tank Bay entrance CTA applicators Sensors to notify the operators if a fault occurs Pump platform with HydroMinder holding tank How does it work Applies tire cleaning chemical through ...

Page 228: ...licator to the secondary applicator The center of the cross over tube should be positioned 3 1 4 inches from the center of the applicators and will act as a speed bump slowing or stopping the vehicle to allow the wheel of the vehicle to sit in the spray path to maximize coverage A Bell Hose style switch will be used to signal the input and turn on the applicators The center of the Bell Hose is to ...

Page 229: ...nd should be positioned on the equipment room side Note The Secondary Applicator will be mounted on the opposite side of the bay 2 From the center line of the equipment the applicators should be mounted 61 1 4 to the back of the base plate This should set the nozzles around 112 1 2 apart Note In a drive through configuration the applicators should not be mounted in the path of the vehicles Seconda...

Page 230: ... needs to be across half of the bay since only one tire is required to run over the hose to activate it 3 Once lagged to the floor secure the Bell Hose to the two Floor Mounts realizing it will need to be stretched and cut to fit Secure it into place using the supplied clamps The completed assembly should appear as shown below 4 The two floor mounts will be secured to the floor The one in the midd...

Page 231: ... pressure switch inlet port The hose compresses each time a vehicle runs over it The resulting displacement of air moves the diaphragm within the pressure switch enclosure See the images below 2 The pressure switch should be mounted to the wall so that a 1 4 poly flow tube can be connected to the hose port The switch should be mounted in a back room The 1 4 poly flow tube will push up into the ins...

Page 232: ...ow supplied on the inside cover of the pressure switch 4 Make all necessary wiring connections inside the Pressure Switch Enclosure using the cord in step 2 and the included connection wires shown below Refer to the wiring diagram inside the pressure switch enclosure shown above in step 3 and the included electrical schematic Note A tire sensing device is typically used to trigger input on the opt...

Page 233: ... run through the stainless steel tube between the applicators The center of the Cross Over Tube should be 3 1 4 from the center of each Applicator See the image below Note A 1 2 poly flow tube will deliver the chemical water mixture and a 1 4 poly flow tube will deliver the air from the Primary Applicator to the Secondary Applicator Note The cross over tube will act as a stop so that the wheel of ...

Page 234: ...will pull the mixture from the tank and supply the mixture to the applicators See the image below 2 Install 1 2 poly flow tubing into the inlet port on the air pump and run it into the tee on the bottom of the Hydro Minder holding tank See the image below for an overview 1 2 Poly Flow Tube to the Tee on the Back of the CTA 1 2 Poly Flow Tube from the Air Pump Inlet Behind the Factory Installed Red...

Page 235: ...3 4 Ball Valve Applicators 1 Run 1 2 poly flow tube from the outlet of the air pump to the 1 2 tee mounted into the back of the Primary Applicator See the image below 2 Run 1 4 poly flow tube from the foam air regulator outlet to the 1 4 tee mounted into the back of the Primary Applicator See the image below See Nozzle Chart at the end of this chapter for more details 1 2 Poly Flow Tube Air Pump O...

Page 236: ...etween the main supply line and the inlet on the Hydro Minder See the image below 2 Install a field supplied 1 4 ball valve to the field supplied main air line that will connect to the inlet of the electric valve on the delivery pumping panel This line will supply compressed air to the air pump and foam air regulator See the image below See Nozzle Chart at the end of this chapter for more details ...

Page 237: ... pressure 260 PSI Inlet size Min 30 GPM 3 4 Barb Hose Fitting Outlet size 1 1 4 Barb Hose Fitting Timer Settings 12 Off Delay 3 sec Range 3 sec Delay Utilities Electrical requirements 10 0 Hp 3 phase 208 32 Amps 230 31 5 Amps VAC 120 2 Amps constant from GFCI protected circuit side Specified Output 120V signaled Water Requirements 1 30 GPM 40 PSI Direction of Flow Schematics See Nozzle Chart at th...

Page 238: ...en Wrench Small Phillips Screwdriver Utility Knife 1 Locate the labeled parts below and install them on the Passenger side See the image below Note The Wheel Stinger mounts to the inside of the carriage and the fasteners come up through the bottom of the carriage Note The Hockey Pucks face toward the center of the machine 2 Repeat step 1 for the Driver side See the image above Four 1 2 13 x 2 Fast...

Page 239: ... 48167 5470 Ph 248 349 7010 Fax 248 380 9681 15 13 Chapter 15 Wheel Cleaning and CTA Options Wheel Stinger Installation General 3 The Wheel Stinger Manifold can be leveled in all directions by adjusting the setscrews located at the top of the manifold Four Leveling Setscrews ...

Page 240: ...r system 3 If the Tire Locator Assembly is part of your system attach the Emitter and Receiver Photo Eyes to the supplied brackets Be sure to run the 5m cord through the opening on top of the bracket as shown below Before After 4 If the Tire Locator is part of your system attach it to the Wheel Stinger Cover Support Mount Assembly using the supplied fasteners Be sure to run the 5m cord through the...

Page 241: ...riate washers and nuts attach the Wheel Stinger Cover Support Mount Assembly to the onboard Manifold Mount located near the bottom of the manifold 6 If On Board CTA is part of your system locate the CTA Chamber Assembly and the On Board CTA Bracket Secure them together using two of the 1 4 20 x 5 8 fasteners with the appropriate washers and nuts as shown below Before After Cover Support Mount Asse...

Page 242: ...ted about 14 from the bottom of the Wheel Stinger Manifold Weldment Note The On Board CTA Bracket should be positioned on the entrance side of the water manifold and with the bend oriented toward the center of the FreeStyler 8 Locate the supplied 1 4 poly tube natural and 1 2 polytube black Secure them to the fittings shown below Route the two hoses and the feed from the Photo Eye up the manifold ...

Page 243: ...he central carriage of the FreeStyler to the gray plastic junction box as shown below Note There are two cord grips in the junction box One has a single hole and the other has a multi hole Note The Photo Eyes are fed though the multi hole cord grip as shown below The location of the cord grips in relation to the junction box may vary during factory installation See Nozzle Chart at the end of this ...

Page 244: ...eel Stinger with On Board CTA Installation 10 Run the 1 2 and 1 4 Poly flow lines up into the central carriage of the FreeStyler as shown in example below Match and attach each line to its appropriate supplied 1 2 or 1 4 tee Note The Tees should be installed in the middle of the central carriage so that there is an even flow between the Primary and Secondary CTA applicators ...

Page 245: ...8 380 9681 15 19 Chapter 15 Wheel Cleaning and CTA Options Deluxe Wheel Stinger with On Board CTA Installation Utility Hook ups 1 Run a 1 2 and 1 4 poly flow line from your CTA pump station through the FreeStyler boom to its central Carriage Attach the poly flow lines to their appropriate tees as shown below ...

Page 246: ...receiver signal strength light bar indicates its highest amount of signal received the highest number lit d Tighten the emitter mounting hardware then repeat this step for the receiver Note Run your CTA pump station to test the onboard applicator system for leaks before installing the covers Hockey Puck Installation 1 Locate the 6 Hockey Puck assemblies and the 30 spray nozzles as shown in image t...

Page 247: ... should have their single vertical lines on the left of center See the image below 1 When all three Hockey Puck assemblies have been tightened completely the spray nozzle holes should be aligned as shown in the image above Verify the following The top and bottom Hockey Puck assemblies should have 3 nozzles to the right of the single line and 2 nozzles to the left of the single line The middle Hock...

Page 248: ...center locking 1 2 13 nut See image below for close up of both halves in place The final position of the nuts is just before the fastener threads would start emerging from the other side almost flush Before moving on to the other half of the Wheel Stinger Cover slide the crush proof tubing down over the top of the secured Wheel Stinger Cover so it will be out of the way as you work on the other si...

Page 249: ... Chapter 16 Signage Options Chapter 16 Signage Options ...

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Page 251: ...unted The optional Combination sign is customizable The Navigational sign and optional Combination sign are shipped with a stand to be floor mounted This section covers only the basic feeds to the available sign packages Some items may differ from your signs See your site specific prints for details Wait Go Sign 1 Supply 120VAC to the junction box mounted on the housing of the Wait Go Sign Refer t...

Page 252: ...nage Options Combination Sign 1 Supply 120VAC to the junction box mounted on the housing of the Combination Sign Refer to your electrical drawings Floor Mount The sign floor mount comes with a fully assembled stand The stand simply needs to be secured to the bottom of the sign enclosure and lagged to the floor in the desired bay location ...

Page 253: ... Chapter 17 Onboard Dryer Option Chapter 17 Onboard Dryer Option ...

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Page 255: ...is less equipment in the open viewing area Less ambient noise compared to a dryer that is either mounted outside or right at the exit doors The dryer can be run with the bay doors partially closed to overcome local noise restrictions Disadvantages Increased cycle time because of car exchange The Silencer option cannot be mounted on the car wash with the Onboard Dryer option General Information The...

Page 256: ...legs which are to be centered on the rails The Onboard dryer will come installed in the carriage Installing the Boom Mount If you purchased an optional Onboard dryer then your FreeStyler will come with a 6 Legged Frame Follow the instructions in Chapter 6 Carriage and Frame to install the Boom and Boom Mount Install the Boom Mount for the 6 Legged Frame in the location shown in the image below Not...

Page 257: ...e The Air Concentrator is operated by a 4 way pneumatic valve located inside of the driver side pod assembly on the 8 port pneumatic junction manifold When it is signaled to turn on the valve will fire and the deflector plates inside of each spiral blower housing will angle towards the sides of the vehicle creating a greater air flow down the sides of the vehicle See the image below Methods of Dry...

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Page 259: ... Chapter 18 Spot Free Rinse R O Option Chapter 18 Spot Free Rinse R O Option ...

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Page 261: ...at 916 978 9990 or 800 882 8854 General Requirements 1 Provide a covered and or heated enclosed area with at least 30 x 72 of floor space 2 Electrical see site specific drawings 3 Plumbing see site specific drawings 4 2 drain Utility Requirements Note See the site specific plumbing layout for more details Requirements Water 3 4 water line with Ball Valve 20 GPM 30 PSI for RO System Drain Electrica...

Page 262: ... valve set turn on tap water and flush the carbon tank to drain it until the water runs clear Re connect the hose from the carbon tank to the Water Inlet fitting on the inlet solenoid Drill a 2 1 2 hole centered 4 from the bottom of the storage tank and install a 1 1 4 tank adapter Be sure to vacuum out all plastic shavings from tank Install a float in the top of the tank by drilling a 1 3 4 hole ...

Page 263: ... end of the 1 2 tube attaches to the fitting behind the water quality light Connect the 1 1 4 hose from the tank adapter to the inlet of the re pressurization pump with the quick disconnect fitting Make sure the reverse osmosis control unit switch is off Now plug the reverse osmosis unit into the dedicated outlet RO Water Storage Tank RO Installation Final Check List 5 Is the RO unit plugged IN 6 ...

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Page 265: ... Chapter 19 Trades Chapter 19 Trades ...

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Page 267: ...te your project resource schedule Scope of Work It is good practice to provide your Electrician and Plumber a Scope of Work prior to beginning the installation and is often necessary when hiring skilled trade professionals If you do not have a scope of work outlined you can contact your Belanger Representative for a sample scope of work for electrical and plumbing system requirements Note We also ...

Page 268: ...ressure hose assemblies Discuss who is responsible for final terminations Penetrating the Wall for Boom Utilities This is where the electrical and plumbing utilities can be routed from the equipment room to feed the boom It is critical that this task is performed correctly There can be NO rubbing or chafing in this area The movement of the Boom is such that unless done properly there is a good cha...

Page 269: ...ional Thru Wall Kit The Wall Manifold requires a 1 hydraulic hose and runs from the Lexair Valve Assembly atop the Pumping Station to the inlet of the Wall Manifold Note All hoses shown below are field supplied The above image shows the hose connection from the Pumping Station Manifold to the Wall Manifold 3 4 Field Supplied Hydraulic Hose 1 Field Supplied Hydraulic Hose 3 4 Field Supplied Hydraul...

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Page 271: ... Chapter 20 Electrical Chapter 20 Electrical ...

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Page 273: ... take between three to five days to complete the work Please keep this in mind as you coordinate your project resource schedule Electrical Standards Overview This section will cover the required main electrical feeds needed for a standard installation Utility Requirements The following specifications are meant as a quick reference and guideline only Your site may vary depending on your setup confi...

Page 274: ...0 HydroBlade 10Hp Pump Station 3 4 40 260 25 Hp Pump Station 3 4 36 1000 Undercarriage Options SCC Controlled 3 4 12 40 Bug Spray Applicator SCC Controlled 3 4 12 40 Booster Pump Maximum Sold Separately SCC Controlled 1 12 43 Inlet 65 Boost 108 System On Board Dryer 64 208 3 56 230 3 28 460 3 Air Cannon Dryer See supplied Air Cannon Dryer manual AirBlade Dryer See supplied AirBlade Dryer manual Ai...

Page 275: ...ound bar ground terminals in the MCC or SCC as a path or connection point to the other electrical panel grounds Provide external systems with their own ground Motor Grounding It is highly recommended to use 4 core cable between the MCC and the motors with one of the cable s conductors being utilized as a ground These ground wires MUST NOT touch any other ground wires in the conduit or any of the j...

Page 276: ...0VAC and or 24VAC wiring with any 3 Phase through wire ties or by any other means Conduit runs and hubs that contain motor wires running from the MCC to the motor should only contain the wires running from the MCC to the motor These conduit runs and hubs should not contain wires from any other circuits especially 120VAC and 24VAC control wires unless conduit contains only the cables from FreeStyle...

Page 277: ...inside the MCC Enclosure Do not use the MCC or SCC panel as junction boxes Do not bring wires into these panels unless they are to be terminated in that panel Do not use SCC power or neutral wires as a method of powering items such as Point of Sales or back room outlets Do not use solid core wire for terminations within MCC and SCC panels Make sure appropriate size shielded wire is used between SC...

Page 278: ...s MUST be strictly observed Please read wiring notes within this chapter Notes are also referenced on sheet 11 of the Electrical Prints The above image shows the components located inside of the 208 VAC Machine Control Center Enclosure REFER TO YOUR SUPPLIED ELECTRICAL PRINTS AND SITE SPECIFIC DRAWINGS FOR INSTALLATION DETAILS Drive 2 Circuit Breaker Exit Wheels Motor Starters Drive 1 Carriage Dri...

Page 279: ...CC and the MCC This communication wire is used to communicate with the Variable Frequency Drives VFD s Any extra wires in CAT 5E wire must not be used for other circuits CAT 5E wires must be installed to match colors of wire indicated in electrical Prints The above image shows the components located inside of the System Control Center Enclosure REFER TO YOUR SUPPLIED ELECTRICAL PRINTS AND SITE SPE...

Page 280: ... e Rocker Spin Cleans or Side Blasters The Exit end of the wash is a safe zone although that location makes it difficult to manually load vehicles from the operator interface The best case scenario would be to mount it behind glass at the entrance of the bay NOTE TO ELECTRICIANS AND ARCHITECTS The communication cable for the E 1063 is a 6 condutor shielded cable Only connect shield to ground in th...

Page 281: ... you purchase a customer interface device that has credit card capability you will require a SECOND DEDICATED line for its use These two items will NOT work well on a single line Installation The installation contractor should provide a standard RJ 11 plug in jack next to the E 1063 from the same dedicated line serving the Modem for use in plugging in a telephone The above image shows the componen...

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Page 283: ... Chapter 21 Pneumatic and Hydraulic Connections Chapter 21 Pneumatic and Hydraulic Connections ...

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Page 285: ...ide Pod Note The Driver Side cylinder for the Entrance Wheel has 1 Reid switch Hydraulic Extend Hydraulic End of Cylinder 4 Stroke Pneumatic End of Cylinder 2 Stroke Needle Valve Pneumatic Extend Fitting Elbow Hydraulic Extend Fitting Air Solenoid for Driver Side Entrance Wheel Pneumatic Extend Pneumatic Retract Hydraulic Retract 8 Port Valve Manifold Pneumatic Retract Fitting Elbow Hydraulic Retr...

Page 286: ...21 Pneumatic and Hydraulic Connections Exit Wheel Circuit Overview Driver Side Pod Note The Driver Side cylinder for the Exit Wheel has 1 Reid switch Elbow Hydraulic Extend Fitting Air Solenoid for Exit Wheels Pneumatic Extend Pneumatic Retract Hydraulic Retract 8 Port Valve Manifold Hydraulic Extend Elbow Hydraulic Retract Fitting ...

Page 287: ...ulic Connections Top Wheel Circuit Overview Driver Side Pod Note The Driver Side cylinder for the Top Wheel has 1 Reid switch Note The Solenoid Applies Air to Retract the Cylinder and Raise the Top Wheel Note The Solenoid Exhausts Air to Drop the Top Wheel Elbow Pneumatic Retract Fitting Air Solenoid for Top Wheel Pneumatic Retract 8 Port Valve Manifold ...

Page 288: ...nce Wheel Driver Side Entrance Wheel Passenger Side High Low Pressure Entrance Hydraulics Exit Wheels Top Wheel Drive Forward Stop Light Back Up Light Connections to Euro Block in Driver Side Shuttle Valve High Low Pressure Entrance Wheel Driver Side Entrance Hydraulics Top Wheel Exit Wheels Entrance Wheel Passenger Side Soap Foam Optional Air Concentrator Optional Triple Foam Connections to Euro ...

Page 289: ...aulic Connections Drive Side Pod Air and Water Controls Optional Triple Foam Air Regulator and Gauge Soap Foam Air Regulator and Gauge Soap Foam Water Control Exit Wheel Air Regulator and Gauge Low Pressure Entrance Wheel Air Regulator and Gauge High Pressure Entrance Wheel Air Regulator and Gauge Typical Regulator and Gauge Connection Gauge Regulator ...

Page 290: ...nger Side Pod Note The Passenger Side cylinder for the Entrance Wheel has 2 Reid switches Hydraulic End of Cylinder 2 Stroke Elbow Hydraulic Extend Fitting Pneumatic Extend Pneumatic Retract Hydraulic Retract 8 Port Valve Manifold Pneumatic End of Cylinder 4 Stroke Elbow Pneumatic Extend Fitting Elbow Pneumatic Retract Fitting Elbow Hydraulic Retract Fitting Hydraulic Extend Air Solenoid for Entra...

Page 291: ...eumatic and Hydraulic Connections Exit Wheel Circuit Overview Passenger Side Pod Note The Passenger Side cylinder for the Exit Wheel has 1 Reid switch Elbow Hydraulic Extend Fitting Air Solenoid for Entrance Wheel Pneumatic Retract 8 Port Valve Manifold Pneumatic Extend Elbow Hydraulic Retract Fitting Hydraulic Retract Hydraulic Extend ...

Page 292: ...rriage Encoder B Carriage Encoder A Sonar Top Wheel Proximity Switch Enter Passenger Side Out Reed Switch Exit Passenger Side Out Reed Switch Enter Passenger Side In Reed Switch Exit Driver Side Out Reed Switch Enter Driver Side Out Reed Switch Tire Photo Eye 3 8 for Optional Drying Agent Feed 1 2 for Optional Triple Foam Feeds RED YELLOW BLUE EXTRA 3 4 for Optional RO Feed 3 4 for Fresh Water Fee...

Page 293: ... Chapter 22 Initial Startup Chapter 22 Initial Startup ...

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Page 295: ...tinent Startup Components SCC System Control Center MCC Motor Control Center E 1063 Dryer Panel On Board Wheel Cleaners R O Unit Regulator Assembly Foaming Pods Overview of SCC Components Main Terminal Strip PLC Circuit Breakers GFCI Output Board Modem Transformer More Details on Next Page 24VDC Power Supply Expansion Module MCR Motor Control Relay Ground Terminals ...

Page 296: ...r 22 Initial Startup Overview of SCC Components PLC Programmable Logic Computer Expansion Module Circuit Breakers Drive Communication Module Expansion Input 24VDC Output 3A 24VDC Power Supply Module 2A Modem Transformer Primary 1A PLC 0 5A Modem Transformer Secondary 1A Main 120 VAC Power Supply 20A Expansion Output Door Control ...

Page 297: ... Terminal Strip Overview of MCC Components GFCI Wash In Use MCR Motor Control Relay Door Control Top Wheel Motor Starter Drive 2 Circuit Breaker Exit Wheels Motor Starters Drive 1 Carriage Drive 2 Enter Wheels Distribution Block Enter Wheels Motor Protectors Exit Wheels Motor Protectors Top Wheel Motor Protector Drive 1 Circuit Breaker Main Disconnect Carriage Motor Terminal ...

Page 298: ...rfaces You should also familiarize yourself with the standard user screens MCC Note Verify that all communication wire between the MCC and SCC and Umbilical wires are CAT 5E Stranded DO NOT sue solid core wires 1 Check power at the following locations 208 230 V at MCC 120V at SCC Proper voltage at Dryer panel Proper voltage at optional wheel cleaner pump panel Note The procedure in step 1 should b...

Page 299: ...tion Module DIP Switches are in the OPEN position RD and SD lights are both blinking rapidly Set all Outputs to AUTO Close the door 2 Confirm that all doors are closed and turn on the power to each electrical panel at load center 3 Pull out the E Stop on the HMI E 1063 Human Machine Interface panel as well as any in bay E Stops Breakers up for ON Switches toward middle of Output Board for AUTO AUT...

Page 300: ...off at 75 psi and lower Adjust the pressure switch on the System Pneumatic Regulator Assembly to achieve this condition 7 Reset the air pressure to 105 psi 8 Turn off disconnect at each electrical panel and verify e stop trips MCC Dryer Optional Wheel Cleaner Pump Panel other E Stops etc 9 Flush freshwater line to FreeStyler Connect the line and turn it on 10 Perform the appropriate startup proced...

Page 301: ...s right to left swap the Encoder Prox wires at the proximity switches Encoder Proximity Switch Gap Slow Forward has been provided to check proper carriage Encoder operation Pressing the Slow Forward button first begins the Carriage moving slowly down the rails causing the gear in the Encoder to turn The ovals next to CARR ENCODER fill from left to right and clear from left to right If the oval fil...

Page 302: ...binding on the side of the rail Press the Carriage Home Button Verify that the carriage starts moving to the Exit of the bay Quickly move to the next step Press the Jog Button The carriage will move toward the Exit of the bay As the Carriage is moving view the Position numbers Verify that as they count down in inches to zero that the numbers prior to zero are single digit numbers Example 10 8 6 4 ...

Page 303: ...ltifunctional Sonar Unit see Sonar Setup in your HMI E 1063 Human Machine Interface Operation Manual under Sonar Screen Setup and Sonar Mode Change Verify the following inputs on the HMI E 1063 Human Machine Interface Low Air Oval filled Overload Trip Oval filled GFCI Oval filled E Stop Oval filled Low Water if option installed Oval filled Exit Passenger Side Out Exit Driver Side Out Enter Passeng...

Page 304: ...nger part 7310 See the images below for identification Entrance Arm Cylinder Using a wrench remove the cylinder rod so that the clevis stays attached Note DO NOT USE PLIERS VISE GRIPS OR ANY OTHER TOOL THAT WILL DAMAGE THE CYLINDER ROD THIS DAMAGE WILL CAUSE CYLIDER FAILURE Slide the Posi Stop into the Limit Stop Slide the Posi Stop and Limit Stop over the rod Thread the Limit Stop onto the cylind...

Page 305: ... stays attached Note DO NOT USE PLIERS VISE GRIPS OR ANY OTHER TOOL THAT WILL DAMAGE THE CYLINDER ROD THIS DAMAGE WILL CAUSE CYLIDER FAILURE Slide the Posi Stop into the Limit Stop Slide the Posi Stop and Limit Stop over the rod Thread the Lim it Stop onto the cylinder and tighten it down with light pressure Use a wrench to tighten the rod back onto the clevis Note Take care not to cross thread th...

Page 306: ...h Cylinder Passenger Side Entrance 1 Make sure the wheel to be reset is in the open position Depending on the wheel this position may be extended or retracted See the images below 2 Once the wheel is in the proper position loosen the Reed Switch clamp on the appropriate cylinder and slide it until the switch is illuminated 3 Using a marker mark the cylinder at the location where the light first co...

Page 307: ...ls Entrance and Exit Wheels Top View From the HMI E 1063 Human Machine Interface FORCE the Exit Wheels on EXIT ON and verify rotation as shown in the overhead image to the left Force EXIT BOTH and set air pressure to 65 psi Swap motor leads if necessary Turn off the Exit Wheels From the HMI E 1063 Human Machine Interface FORCE the Entrance Wheels on ENTER ON and ENTER RV Verify rotation as shown i...

Page 308: ...E A or B Adds 3 pounds each If the weight is too tight to just slide out then use a 3 8 16 x 1 3 4 bolt and a 3 8 nut to spread the arms C or D Adds 5 pounds each A plus B Adds 6 pounds total A plus C Adds 8 pounds total Note Both FreeStyler Top Wheel styles ship with no weight in location A and B See the image below This scenario provides the best initial weight adjustment Note As the cleaning ma...

Page 309: ...e The vise grips are used for hanging a 5 gallon pail Disconnect each chemical line one at a time from the injector at the water manifold Locate the supplied chemical priming gun and remove the black 1 4 line from the end of the gun Connect the 5 8 black line to the side of the priming gun for discharge into the 5 gallon pail Connect the priming gun to the line and draw the chemical to remove all ...

Page 310: ...s below Starting from the side of the manifold that has the push in fitting in the end connect the lines in order starting with green Verify that the color scheme is the same on both sides See the image below Triple Foam Airline Routing Triple Foam Chemical Routing Note The length of airline that runs to the driver side MUST equal the length run to the passenger side Then the stream to each side w...

Page 311: ...al Adjust the 3 Tri Foam gate valves inside the exit water manifold cover to achieve the desired wetness Note Yellow Tri Foam typically requires more chemical than the other colors Tilt the Tri Foam Pods to get the best spray pattern on average vehicles Turn soap back on and adjust the spray angle for the soap pods Clear all FORCED ovals Setting Cylinder Flow Controls 1 Set the cylinder flow contr...

Page 312: ...ols the flow controls alter the Top Wheel retract speed 3 From the HMI E 1063 Human Machine Interface activate the entrance arms by turning on the ENTER ON and ENTER BOTH Note Verify that the Entrance Wheels move in and that the water spray nozzles are flowing in the desired path Turn on ENTER D S and ENTER P S Verify the 2 stroke of each corresponding cylinder Note DO NOT CHANGE THE FLOW CONTROLS...

Page 313: ...yler should go to the HOME position at the exit end of the bay 6 Verify that no Faults have occurred at the Fault screen of the HMI E 1063 Human Machine Interface 7 Check for water leaks at each output Flush the lines and insert the nozzles per the diagram for those outputs See settings below 8 Install all nozzles according to the Nozzle Chart in this document Sealer Wax Triple Foam Chemicals Dryi...

Page 314: ...LSTC 2504 Upper Nozzle 1 5GPM 65 1NOZZL FJ696 TIP PLSTC 6515 Lower Nozzle 1 0GPM 25 1NOZZL FJ058 TIP PLSTC 2510 Upper Nozzle 0 5GPM 40 1NOZZL FJ232 TIP PLSTC 4005 Lower Nozzle 0 4GPM 15 1NOZZL FJ254 TIP PLSTC 1504 Upper Nozzle 1 5GPM 65 1NOZZL FJ696 TIP PLSTC 6515 Lower Nozzle 1 0GPM 25 1NOZZL FJ058 TIP PLSTC 2510 Two Nozzles 1 0GPM 40 1NOZZL FJ348 TIP PLSTC 4010 Exit Pod Nozzle Body Exit Wheel No...

Page 315: ...d is leveled using four 3 8 16 x 1 2 set screws located on the underside of the manifold flange mount plate See the images below Loosen the four bolts that hold the manifold to the solid link welded assembly Turn one or more of the set screws in or out to get the manifolds leveled Tighten the four bolts back down and check that the manifolds are leveled Fold the bellows back down and tighten the h...

Page 316: ...e entire system for leaks Set the control function to auto Note The following information was taken from documents provided by Grundfos the pump manufacturer Priming To prime the pump in a closed system or an open system where the water source is above the pump close the pump isolation valve s and open the priming plug on the pump head See Figures 5a 5b and 5d Gradually open the isolation valve in...

Page 317: ...lation will occur reducing the output pressure and flow Chemical Tire Applicator if applicable To startup the optional Chemical Tire Applicator CTA perform the following Contact your chemical supplier to get the correct dilution ratio for the specific chemical you will be using as well as the climate of your location Note Dilution is adjusted by changing the induction tip located on the HydroMinde...

Page 318: ...from the exit end of the bay observe the Top Wheel s Neo Tex fingers extending over the vehicle Confirm desired penetration while the wheel is moving from entrance to exit Observe Top Wheel movement from exit to entrance To achieve desired penetration add or remove Top Wheel Counterweights as shown on page 22 14 of this chapter While viewing from the exit end of the bay observe the Exit Wheels on ...

Page 319: ... the arm downward when it is in on a vehicle and increase penetration Note The bearing base may need to be tapped to slide inward Do not damage it Recheck both wheels for equal penetration using a test vehicle If the same wheel has less penetration repeat the process of loosening the bearings on the wheel with more penetration but lift the arm up before retightening the bearings Note When all pene...

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