Belanger Top Winder Owner'S Manual Download Page 18

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TopWinder

Belanger, Inc. ®* 1001 Doheny Ct. * Northville, MI 48167 * Ph (248) 349-7010 * Fax (248) 380-9681

1MANUL755

Installation

Frame Assembly

Attaching the Crossbeam

1) Locate the Crossbeam. See the image below.

2) Secure the Cross Beam to the arms, as shown below, using 1/2-13 x 1-

1/4” bolts and 1/2”

lock washers.

Before completely tightening the Cross Beam, be sure to take a measurement at both
ends of the arms to make sure the frame is square. Once square, tighten all bolts.

3) The Crossbeam Assembly comes with the Filler Strip installed. Check to make sure the

Filler Strips are secure and are the proper length.

Cross Beam

ORIENTATION NOTE:

When completely assembled the Spray Nozzles in the Crossbeam will face the Hub.

Secure the Crossbeam to the Arms

Mount to Drive Side

Arm Assembly

Mount to

Passenger Side

Arm Assembly

Spray Nozzle

Openings

Driver Side Arm

Assembly

Passenger Side

Arm Assembly

Spray Nozzle

Openings

Summary of Contents for Top Winder

Page 1: ...TopWinder Top Winder 1MANUAL755 Rev01 ...

Page 2: ......

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

Page 4: ......

Page 5: ...eature per Project 10010 15 Updated Step 2 to include Keep in mind the required operating space for other tunnel components Updated Step 3 to include at the dimension specified in the image on the previous page 23 Added Note at top of Air Panel and Air Cushioning Installation page about retracting top wheel per Project 10010 72 Changed Shock Assembly part number from 1SHOCK800 to 112532 per Projec...

Page 6: ......

Page 7: ...tallation 18 Wiring for the Auto Retract 19 Photo Eye Retract Cylinder 20 Installing the Air Cushion Regulator 20 Filler Strip Installation for Leg Assemblies 21 Air Panel Air Cushion Installation 23 Counterweight Installation 24 Installing the Drive Shaft and Hub Assembly 27 Loading the ShineMitt onto the Hub Assembly 32 Connecting the Motor and Slip Ring to the Drive Shaft 35 Electric Motor Inst...

Page 8: ...10955 Zone 2 72 Driver Side Arm Assembly Aluminum 110941 Silver PC 110955 Zone 3 72 Driver Side Arm Assembly Aluminum 110941 Silver PC 110955 Zone 4 73 Passenger Side Arm Assembly Aluminum 110948 Silver PC 110957 74 Passenger Side Arm Assembly Aluminum 110948 Silver PC 110957 Zone 1 74 Passenger Side Arm Assembly Aluminum 110948 Silver PC 110957 Zone 2 75 Passenger Side Arm Assembly Aluminum 11094...

Page 9: ...rocess 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 or implied with respec...

Page 10: ... Warranty of the Belanger Terms and Conditions of Sales describes the potential limitation of warranty due to your chemical selection 4 This warranty shall be void for all equipment failures and premature component wear caused by the use of corrosive chemicals in the wash process The following list includes some but not all of the particularly corrosive chemicals that if used in conjunction with B...

Page 11: ...ords used in this manual and on warning labels tell you the seriousness of particular safety hazards The precautions that follow must be followed to prevent death injury or damage to the equipment This signal word is used to alert you to a hazard or unsafe practice which WILL RESULT IN DEATH OR SERIOUS INJURY This alerts you to a hazard or unsafe practice which COULD RESULT IN DEATH OR SERIOUS INJ...

Page 12: ...inery 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 workin...

Page 13: ...he cleaning wheel A Belanger supplied air panel that utilizes a 3 way solenoid and an adjustable regulator feeds air to the retract cylinder The TopWinder is available with two different electrical motors For 208 230 460 VAC there is a 60Hz 1HP STDV motor or for 575 VAC there is a 60Hz 1HP 575V motor The TopWinder also includes a plastic motor gearbox cover for protection from water and other cont...

Page 14: ...ger Side Arm Assembly 110948 110957 1 Crossover Beam Assembly 110931 110952 1 Filler Strip 1PLSTC EX062 70 FT Hub Assembly 111359 1 HUB LED Assembly 110944 1 ShineMitt 111060 112 Retract Assembly with Photo Eye Set 110805 107193 only compatible with Centra Controller 1 Slip Ring Assembly 111362 1 Motor Gearbox Assembly 110935 110937 1 Motor Gearbox Cover Assembly 110720 1 Accessory Box 110939 1109...

Page 15: ...EFORE SERVICING ANY EQUIPMENT CAUTION Always wear safety glasses when performing maintenance on any equipment CAUTION It is recommended that a licensed electrician is contracted to perform all electrical installations YOUR HYDRAULIC SYSTEM MUST BE CAPABLE OF ADJUSTMENT TO 116 RPM AT 900 PSI 62 1 BAR WHILE LOADED AGAINST VEHICLE PLEASE VERIFY YOUR SYSTEMS CAPABILITY TO MEET THESE SETTING WHILE RUNN...

Page 16: ...TopWinder 8 Belanger Inc 1001 Doheny Ct Northville MI 48167 Ph 248 349 7010 Fax 248 380 9681 1MANUL755 Specifications General Dimensions 150 7 8 133 When in Retract Position 150 7 8 118 1 2 ...

Page 17: ...d to each side of the Mount Plate refer to the image below 2 The Arm Assemblies come with the Filler Strips already installed Check to make sure the Filler Strips are secure and are the proper length 3 The driver side Arm Assembly will also have two conduit fittings attached and the wires for the Motor Gearbox and LED will be extending out of the fittings Driver Side Arm Assembly Passenger Side Ar...

Page 18: ...o take a measurement at both ends of the arms to make sure the frame is square Once square tighten all bolts 3 The Crossbeam Assembly comes with the Filler Strip installed Check to make sure the Filler Strips are secure and are the proper length Cross Beam ORIENTATION NOTE When completely assembled the Spray Nozzles in the Crossbeam will face the Hub Secure the Crossbeam to the Arms Mount to Drive...

Page 19: ...er side leg 1 Cut the tie wrap from the shocks mounted to the driver side and passenger side arms to access and remove the 5 8 x 3 1 4 Shoulder Bolts Then remove the shock assemblies See the image below Shock Mount on both Legs Posi Stop on both Legs Non Driven Pivot Bearing Mount on both Legs Passenger Side Leg Driver Side Leg 5 8 x 3 1 4 Shoulder Bolt Cylinder Pivot Mount on passenger side ONLY ...

Page 20: ...n against the Posi Stop on each Leg Assembly You may need someone to rotate the end of the legs to get the bolts into place Shock Mounts located here typical Passenger Side Arm Assembly Posi Stop Driver Side Arm Assembly Secure both legs to the arms Driver Side Leg Asy Arm Asy Four 4 Bolts 7 16 14 x 1 Passenger Side Arm Asy Four 4 Bolts 7 16 14 x 1 Leg Asy You may have to pivot the legs to access ...

Page 21: ...with a Belanger 13 or 14 1 2 wide Conveyor that has either a single or double guide rail Identifying the conveyor is crucial for properly positioning the TopWinder assembly during installation The Belanger conveyor options are shown in the images below Single Guide Rail Conveyor Assemblies 13 14 1 2 Wide Double Guide Rail Conveyor Assemblies 13 14 1 2 Wide 13 14 1 2 13 14 1 2 Guide Rail ...

Page 22: ... installed at the site be sure to add 3 4 to the dimension to position the outside edge of the driver side leg base plate as shown in the image below Note Note The image below is shown with the Over Under Conveyor option Your system may have the standard Guide Rails Placement is the same for both 13 Conveyor 47 1 2 14 1 2 Conveyor 48 1 4 from the inside edge of the inside guide rail to the outside...

Page 23: ...nd under load while forklift is in operation 2 Slowly raise the skid until the Legs are hanging in a vertical position and move the unit into its tunnel location Keep in mind the required operating space for other tunnel components 3 Anchor the driver side leg to the floor at the dimension specified in the image on the previous page 4 Check that the frame is square by verifying the same distance b...

Page 24: ...ion Shock Assembly 1 Secure the Shock Assemblies into the Clevis on the Leg Assemblies using the supplied 5 8 Shoulder Bolts 2 Using the supplied 5 8 Shoulder Bolts secure the unattached end of each Shock to the Clevis on the Arm Assemblies as shown below Secure Shock Assembly onto Leg Secure Shock Assembly onto Arm ...

Page 25: ...eg Assemblies with the Photo Eyes on the entrance side of the TopWinder as shown below The Photo Eyes are recommended to be installed at the height shown below Note When installing the Auto Retract take care not to scratch the powder coating on the frame After mounting and wiring the Photo Eyes to the Leg Assemblies you will need to cut the Filler Strips to fit around the Photo Eyes Driver Side Ph...

Page 26: ...2 13 x 2 Fastener and 1 2 Lock Washer Auto Retract Sensitivity Reducer 2 Secure the Photo Eye mount assemblies to the driver side and passenger side Leg Assemblies using the mounting wedge plates and socket head fasteners as shown below Note Verify that the Photo Eye Mount Assemblies are set at the appropriate height Note The Socket Head Fasteners pass through the Clamps and the Wedge Plates Socke...

Page 27: ...X10 Lower Receiver Brown 340 24VDC Blue 338 DC COM Black Signal X11 Upper and Lower Emitter Gray 340 24VDC Black 338 DC COM Cap Photo Eye and Sensitivity Reducer End Cap End Cap Sensitivity Reducer Sensitivity Reducer Wire the Pneumatic Retract Cylinder to NAMED 6 Output Y20 or NAMED 7 Output Y21 DO NOT run any of these wires through the crossbeam Once wired confirm that both Auto Retract Upper an...

Page 28: ...g the Air Cushion Regulator 1 Locate the Air Cushion Regulator in the Accessory Box 2 Secure the Air Cushion Regulator to the passenger side Leg Assembly using the mounting wedge plate and socket head fasteners as shown below Note The large Socket Head Fastener passes through the Mounting Plate and Wedge Plate Secure cylinder here using the supplied white plastic washers on both sides 1 4 Washer 5...

Page 29: ...on Filler Strip Installation for Leg Assemblies 1 Locate the Filler Strip for the Leg Assemblies 2 For the Driver Side Leg Assembly trim the Filler Strip to the lengths called out in the image below and secure them in place 3 4 1 3 4 7 7 16 56 15 16 7 7 8 4 5 16 27 11 16 3 1 2 36 3 8 7 7 8 Driver Side Leg Assembly ...

Page 30: ...ger Side Leg Assembly trim the Filler Strip to the lengths called out in the image below and secure them in place 4 The Filler Strips will need to be trimmed again if the wiring for the Photo Eyes or the airlines for the Cylinder or Air Cushion are routed behind the Filler Strips 3 4 1 3 4 7 7 16 48 3 4 7 7 8 22 3 4 12 1 4 3 1 2 36 3 8 7 7 8 6 11 16 Passenger Side Leg Assembly ...

Page 31: ...w airline from the other side of the Shuttle Valve on the Cylinder to the Retract Regulator on the Air Panel 1 4 Field Supplied Airline Retract Regulator Air Cushion Valve Air Panel Assembly Air Cushion Regulator Cylinder 3 8 Airline for Cylinder Retract 3 8 Airline to Air Cushion Regulator Passenger Side Leg Assembly Air Cushion Valve Retract Regulator 3 8 Airline from Air Cushion Regulator Shutt...

Page 32: ...tration some counterweight should be added then proceed to use the Air Cushion as normal Counterweight Installation Things to Know The Counterweights are added to the end of the Arm Assemblies to off set the weight of the ShineMitt cleaning material and the Motor Gearbox Assembly Since the Motor Gearbox Assembly is typically on the driver side there will be more weights added to that side to preve...

Page 33: ...ion has been determined place the rear cover on the back of the arm as shown below making sure all holes are aligned 4 Place all required weight s onto the arm keeping all holes lined up Note You may need a screwdriver to help position holes and keep them aligned 5 Tightly secure all weights in place using the correct 1 2 13 bolts flat washers and lock washers 6 Once the weights have been secured ...

Page 34: ...e weight cover 10 Drill a 1 4 hole from the bottom of the cover at 1 1 2 inward from the edge as shown below Note This hole will allow water to drain out of the cover 11 In a situation where the Counterweights are not needed place the Rear Cover on the back of the arm and tighten it down with the provided 1 2 13 x 1 bolts and the flat washers Front View Drill Here Bottom View 1 1 2 Front View Plas...

Page 35: ... Shaft and Jam Nut from the Drive Shaft Assembly as shown below 3 Orient the Drive Shaft and Hub Assembly with the Key Slot toward the driver side Arm Assembly Driver Side Drive Shaft Hub Assembly Passenger Side Drive Shaft Hub Assembly Key Slot Driver Side Arm Assembly Jam Nut Slip Ring Retainer Disk Key Slot Drive Shaft Slip Ring Shaft Remove the Retainer Disk Slip Ring Shaft and Jam Nut Step 2 ...

Page 36: ...ss to the mounting bolts Then remove the Outside Mount Inside Mount Bearing Assembly and the End Cap Refer to the image below 6 Loosen the set screws slightly on all the Shaft Bearings on both Arm Assemblies Passenger Side Arm Assembly Driver Side Arm Assembly Inside Mount Bearing Assembly End Cap Outside Mount Inside Mount Bearing Assembly End Cap Outside Mount Shaft Bearing Shaft Bearing Slightl...

Page 37: ...ng the outermost mounting bolt Refer to the image below for proper installation of the parts 9 Lift and slide the Drive Shaft and Hub Assembly into the end of the Arm Assemblies as shown below Grease Fitting on Bearing must face out Passenger Side of Drive Shaft Slide on the Inside Mount Bearing Assembly Step 7 Passenger Side Driver Side Slide Drive Shaft and Hub Assembly into the end of the Arm A...

Page 38: ...n reattach the Shaft Bearing to the Outside Mount Refer to the image below for proper installation of the parts 12 Reattach the End Cap to the Driver Side Arm Assembly 13 On the driver side make sure the Locking Collar Groove on the Drive Shaft is past the bearing and is completely visible Drive Shaft Passenger Side Driver Side Secure the Mounts to the Passenger Side Arm Assembly Step 10a Reattach...

Page 39: ...Drive Shaft position it in the groove and tighten see below 16 Make sure the Locking Collar is resting on the top of the Shaft Bearing and then tighten the set screws on all the Shaft Bearings Locking Collar Slide the Locking Collar over the Drive Shaft position it in groove and tighten Step 15 Tighten set screws on all Shaft Bearings Step 16 Orient the Locking Collar it is to be installed with th...

Page 40: ...mbly and disconnect the four 4 LED Wires from the Wire Harness connectors 4 Pull the Wire Harness Wires out of the End Plate holes and slide the End Plate toward the Arm Assembly 5 Locate the ShineMitt there should be a total of 112 pieces Clip ShineMitt 19 45 Degree Short Lead Hub Cap End Plate Hub Assembly Driver Side Arm Assembly Clamp 4 Remove the plastic Clamps from the End Plate Step 2 Remov...

Page 41: ...the Drive Shaft toward the Hub Assembly thread the four Wire Harness Plugs through the holes in the End Plate 8 Insert the LED Wires into the circular slots on the outer edge of the End Plate shown below Side View of ShineMitt Hub Fill Pattern 7 1 4 diameter hub Fill every slot as shown Make sure that the fill is facing in the correct direction as shown in the image to the left Side View from Driv...

Page 42: ...ate Fasteners and reassemble the End Plate back onto the Hub Assembly 12 Secure the LED Wires to the End Plate with the plastic Clamps refer to image above on right 13 Apply Anti Seize to the Hub Cap Fasteners and reassemble the Hub Cap back onto the Hub Assembly Align tabs on connectors and press together gently Wrap connection with electrical tape Step 9 Apply Red Loctite 271 to the End Plate Fa...

Page 43: ...Key and Key Slot Insert the Key into the slot in the Drive Shaft 4 Slide the Motor Gearbox and Cover Assembly over the Drive Shaft and Torque Studs shown below 5 Secure the Motor Assembly to the Torque Studs using the Flat Washers and Cotter Pins as shown above DRIVE KEY FLAT WASHER 2 COTTER PIN 2 See Flat Washers and Cotter Pins Installed on Right Apply Anti Seize to the Key and the Key Slot then...

Page 44: ...with tie straps refer to the image below 8 Route the Slip Ring Plug Wire through the center of the Retainer Disk and Slip Ring shown above and below 9 Slide the Slip Ring Shaft over the Slip Ring Plug Wire shown in image above Slide the Slip Ring Shaft over the Slip Ring Plug Step 9 Secure Slip Ring Wire to Retainer Disk with tie straps Step 7b Route the Slip Ring Wire through the center of the Di...

Page 45: ...ently refer to images above Wrap the connection with electrical tape 12 Thread the Slip Ring Shaft onto the Drive Shaft then slide the Slip Ring down onto the Slip Ring Shaft 13 Secure the Slip Ring to the Torque Mount on the Motor see images below Thread the Slip Ring Shaft onto the Drive Shaft Step 12a Slide the Slip Ring onto the Slip Ring Shaft Step 12b LED Cable Receptor Slip Ring Plug Align ...

Page 46: ... Ring 15 Attach the Wire Retainer Disk to the top of the Slip Ring Shaft using the two 8 32 X 1 2 screws 16 Route the 24VDC LED Power Supply Cable and Motor Wires coming out of the Arm Assembly through the Conduit supplied and into the bottom of the Motor Cover Secure the Slip Ring to the Slip Ring Shaft using the four 4 setscrews on the Inside Shaft Collar Step 14 Attach the Retainer Disk to the ...

Page 47: ...Slip Ring Receptor Align the tabs on the LED Main Power Cable Plug with the Slip Ring Receptor and press the connectors together gently 18 Wrap the wire connection with electrical tape and tuck inside the Motor Cover Step 17a Apply dielectric grease to the Receptor Align tabs on connectors and press together gently Wrap connection with electrical tape Step 17b Wrap connection with electrical tape ...

Page 48: ...ve 3 On the other end the LED Cable has already been connected to the Slip Ring in the previous section The Motor Gearbox cable will need to be connected to the Motor remove the cover on the Motor Electrical Box route the Motor Cable through the Motor Cord Grip and secure to the four 4 wire leads See the image below CAUTION It is recommended that a licensed electrician is contracted to perform all...

Page 49: ...4 water line to the Main Feed Fitting coming out of the Crossbeam as shown below 2 Using field supplied tie straps tie the water feed the Motor Gearbox and LED electrical lines together as shown below Doing so will prevent the utilities from being damaged during the pivoting motion of the Top Wheel 3 4 Main Water Feed LED Main Lead 3 4 Main Water Feed Motor Gearbox Main Lead ...

Page 50: ... weight using the supplied fish scale See the images below Hook the scale to the passenger side arm and raise the arm perpendicular to the legs Power up the wheel to verify the actual weight of penetration that the wheel is applying to the vehicle surface 1 Adding weights will decrease wheel weight thus creating less wheel penetration 2 Removing weights will increase wheel weight creating more whe...

Page 51: ...ate the four 4 Nozzles and Nozzle Fittings in the Accessory Box and assemble them together Install the Nozzle Assemblies into the Manifold 3 Adjust each of the Nozzle Assemblies so that they are at about a 5 degree angle from the centerline of the Crossbeam Manifold Assembly as shown in the image below 4 Run a test vehicle 5 Check the system for any air leaks 6 Adjust the Entrance and Exit Posi St...

Page 52: ...ff Check all water hose connections for leaks Weekly Verify that Hub Caps on the Hub Assembly are tight to the media and secured in place Go through the Hub Assembly and make sure that all fasteners that hold the Hub Skins in place are tight Check counterweight on the TopWinder cleaning wheel to confirm the desired balance Adjust as necessary Check penetration weight of the TopWinder cleaning whee...

Page 53: ...debris DO NOT use a power washer or high pressure water as this can wear and cause harm to the powder coated surface 2 Using a mild detergent and warm water clean the powder coat surface with a soft cloth sponge or a soft natural bristle brush DO NOT use water heated to a temperature above 140 F as this can wear and cause harm to the powder coated surface 3 Rinse the sponge or soft brush as needed...

Page 54: ...rface by washing it with a detergent and a non scratch scrub sponge Use a solution of warm water and non abrasive pH neutral pH 5 8 detergent to clean material prior to painting Thoroughly rinse and dry the surface If solvents are needed to remove marks a soft cloth dampened with Isopropyl Alcohol may be used Solvents containing esters ketones or chlorinated solvents must not be used without consu...

Page 55: ...ch end of the stroke Patience On a warm day if each coat has been allowed to dry before the next application it should be possible to rub the paint down after about 30 minutes If it starts to drag and ball the paint leave it to dry further It will now have to be rubbed right back to a smooth surface again which may take another hour More patience is required The thinner the coats of paint the fast...

Page 56: ...connectors 4 Pull the Wire Harness Wires out of the End Plate holes and slide the End Plate toward the Arm Assembly 5 Locate the Hub LED light that needs to be replaced Remove the LED from the Hub Channel 6 Install the new Hub LED light assembly into the channel shown below LED Assembly Hub Channel Hub Cap End Plate Hub Assembly ShineMitt omitted for clarity of images Driver Side Arm Assembly Clam...

Page 57: ...9 Apply dielectric grease to the receptor on the new LED light Align the indicators on the LED Receptor and the Wire Harness Plug and press them together gently so the pins do not get bent 10 Wrap the new LED light connection with electrical tape to protect it from the car wash elements Apply dielectric grease to the new LED Light Receptor Step 9a Thread the four Wire Harness Plugs through the hol...

Page 58: ... Anti Seize to the Hub Cap Fasteners 13 Secure the LED Wires to the End Plate with the plastic Clamps 14 Apply Anti Seize to the Hub Cap Fasteners and reassemble the Hub Cap back onto the Hub Assembly Apply Anti Seize to the fasteners and reattach the Hub Cap to the Hub Assembly Step 14 Secure the LED Wires to the End Plate with the Clamps Step 13 Apply Red Loctite 271 to the End Plate Fasteners S...

Page 59: ...wing the Lock out procedure stated above for the main panel prior to servicing the equipment 2 Remove the plastic Cover from the Cover Base by removing the 2 Phillips head screws See the image below Note Removing the Cover will allow access to the Motor Gearbox mounted on the Torque Studs 3 Check the voltage at the Junction Box with a multi meter to ensure all power has been properly removed from ...

Page 60: ...astic fitting at the bottom of the Junction Box Note The plastic fitting at the bottom of the Junction Box will need to be loosened or removed to pull the wiring down through the base of the Cover if equipped Note The Terminal Block may need to be removed from the side of the Motor for additional access Use a Phillips screwdriver 7 Disconnect the LED wire lead from the Slip Ring 8 Remove the Retai...

Page 61: ...move the Slip Ring from the Motor Assembly by removing the Shoulder Bolt from the Torque Mount and sliding the Slip Ring off the Slip Ring Shaft 11 Unthread the Slip Ring Shaft from the Drive Shaft Loosen the four 4 setscrews that secure the Slip Ring to the Slip Ring Shaft Step 9 Shoulder Bolt 5 16 X 3 4 Nut 1 4 20 Torque Mount Unthread the Slip Ring Shaft from the Drive Shaft Step 11 Remove shou...

Page 62: ...removed 15 Pull the Motor Gearbox and Cover Assembly straight off the Torque Studs and Drive Shaft 16 Move the Motor Gearbox Assembly to a work surface and turn it over to expose the bottom Cover and the Cover Mounting Plate if so equipped Note You will need a work surface such as a table or a bench available to allow for disassembly of the Gearbox Torque Plate LED Cable Receptor Slip Ring Plug Di...

Page 63: ...n the Cover Mount Plate See the images below Note Once the Cover Mount and Cover are removed you will be able to access the bottom of the Gearbox Torque Plate Assembly 18 To separate the Mounting Ring and expose the mounting holes on the Gearbox use a 5 mm hex head socket to remove the eight fasteners and Torque Plate See the images below Mount Plate Fasteners 1 4 20 X3 4 1 4 Locking Washer Torque...

Page 64: ...FSTNR FH075 Carefully apply some of the supplied 271 Red Loctite on each fastener as they are installed Note Loctite should be applied lengthwise to the bottom half of the fasteners with a bead as wide as the 3 16 nozzle tip 4 Turn the fastener a 1 4 turn and reapply the Loctite in the same fashion 5 Insert the flat head fasteners into the threaded mounting holes and tighten until the fastener hea...

Page 65: ... line it up with the Key in the Drive Shaft Once the Key and Keyway are aligned slide the Gearbox onto the Torque Bolts to its resting position 3 To secure the Gearbox locate and install the Washers and new zinc Cotter Pins 4 Apply Anti Seize to the threads on the Drive Shaft Thread the Jam Nut onto the end of the Drive Shaft Apply Anti Seize then thread the Jam Nut onto the Drive Shaft Step 4 See...

Page 66: ...Plug with the LED Cable Receptor and press the connectors together gently refer to images above Wrap the connection with electrical tape 8 Thread the Slip Ring Shaft onto the Drive Shaft then slide the Slip Ring down onto the Slip Ring Shaft Slide the Slip Ring Shaft over the Slip Ring Plug Step 5 Slip Ring Shaft Slip Ring Plug Thread the Slip Ring Shaft onto the Drive Shaft Step 8a Slide the Slip...

Page 67: ...mages below 10 Secure the Slip Ring to the Slip Ring Shaft by tightening the four 4 fasteners located on the Inside Shaft Collar of the Slip Ring 11 Secure the Wire Retainer Disk to the top of the Slip Ring Shaft using the two 8 32 X 1 2 screws Secure the Slip Ring to the Slip Ring Shaft using the four 4 setscrews on the Inside Shaft Collar Step 10 Torque Mount Shoulder Bolt 5 16 X 3 4 Nut 1 4 20 ...

Page 68: ...or Cover 13 Apply dielectric grease to the Slip Ring Receptor Align the tabs on the LED Power Cable Plug with the Slip Ring Receptor and press the connectors together gently 14 Wrap the wire connection with electrical tape and tuck inside the Motor Cover Driver Side Arm Motor Wires 24VDC LED Power Supply Cable Motor Cover Step 13a Apply dielectric grease to the Receptor Align tabs on connectors an...

Page 69: ...ously tagged motor leads to maintain the proper wiring positions Note If there are insulated ring terminals on the Terminal Block we recommend replacing them with non insulated ring terminals which can be purchased at a local hardware or 1ELECT FS855 can purchased through our Aftermarket Sales Department Note The non insulated ring terminals provide more room within the Junction Box to secure wiri...

Page 70: ...Counterweights and Cover Passenger Side Arm Asy Driver Side Arm Asy Manifold Main Feed Air Cushion Regulator Asy Drive Shaft Retract Cushion Cylinder Asy Passenger Side Leg Asy Motor Gearbox and Cover See Enlarged View Photo Eye Set Electrical Box Spray Nozzles See Enlarged View Below Hub Assembly with LED Lights Cable from Slip Ring for LED Lights Wire Harness for LED Lights Four 4 Plugs connect ...

Page 71: ...bly Aluminum 110779 Silver PC 110799 Overview ASSEMBLED EXPLODED ZONE 1 SEE EXPLODED VIEW BELOW ZONE 2 SEE EXPLODED VIEW BELOW ZONE 3 SEE EXPLODED VIEW BELOW ZONE 5 SEE EXPLODED VIEW BELOW ZONE 7 SEE EXPLODED VIEW BELOW ZONE 6 SEE EXPLODED VIEW BELOW ZONE 4 SEE EXPLODED VIEW BELOW ITEMS SHOWN IN ZONES 6 AND 7 ARE NOT INCLUDED IN ASSEMBLY 110779 110799 ...

Page 72: ...R HH585 3 1WASHR LC498 3 Aluminum 9838 Black PC 7951 1FSTNR HH585 3 PASS THRU HOLES IN 110774 110887 AND ARE SECURED BY THREADS IN 9838 7951 1FSTNR HH451 4 1WASHR LC420 4 1FSTNR HH354 2 1WASHR LC291 2 1FSTNR HH354 2 PASS THRU HOLES IN 110774 110887 AND ARE SECURED BY THREADS IN 9885 9886 1FSTNR SB563 ZONE 1 IS IDENTICAL FOR THE DRIVER SIDE AND PASSENGER SIDE LEG ASSEMBLIES ZONE 3 IS IDENTICAL FOR ...

Page 73: ... 9884 DS Aluminum 110798 Black PC 108680 PS Aluminum 110802 Black PC 108679 1WASHR LC498 2 1FSTNR HH666 2 PASS THRU HOLES IN 110797 108564 AND 110774 110887 THEN ARE SECURED BY THREADS IN THE OTHER SIDE OF 110797 108564 1FSTNR150 6 1FSTNR HH666 2 1WASHR LC498 6 1FSTNR HH522 6 ZONE 4 IS IDENTICAL FOR THE DRIVER SIDE AND PASSENGER SIDE LEG ASSEMBLIES EXCEPT FOR THE NOTED BRACKET PART NUMBER Aluminum...

Page 74: ...REPLACEMENT FILLER STRIPS MUST BE CUT TO SIZE PART NUMBER FOR FULL 120 FILLER STRIPS IS SHOWN IN THE CHART BELOW APPROXIMATE CUT LENGTHS NEEDED ARE SHOWN ON THE LEFT 9715 1ELECT FS750 2 1WASHR500 2 1ELECT FS176 2 NO FILLER STRIPS ARE INCLUDED IN ANY OF THE LEG ASSEMBLIES DS 110779 110799 OR PS 110801 110914 DRIVER SIDE ONLY 4 5 16 7 7 16 69 1 16 7 7 8 7 7 8 56 15 16 Aluminum 110797 Silver PC 10856...

Page 75: ...R SIDE LEG ASSEMBLY ASSEMBLED EXPLODED ZONE 1 SEE EXPLODED VIEW ABOVE IN DRIVER SIDE LEG ASSEMBLY ZONE 7 SEE EXPLODED VIEW ON THE FOLLOWING PAGES ZONE 3 SEE EXPLODED VIEW ABOVE IN DRIVER SIDE LEG ASSEMBLY ZONE 4 SEE EXPLODED VIEW ABOVE IN DRIVER SIDE LEG ASSEMBLY ZONE 6 SEE EXPLODED VIEW ON THE FOLLOWING PAGES ITEMS SHOWN IN ZONES 6 AND 7 ARE NOT INCLUDED IN ASSEMBLY 110801 110914 ZONE 5 SEE EXPLO...

Page 76: ...D ARE SECURED BY THREADS IN 9840 9385 1WASHR FL332 1NUT LC210 1WASHR FL332 2 1CLAMP294 2 1FSTNR SH384 2 1WASHR FL415 1CYLND968 1NUT JM250 1WASHR PL500 2 Aluminum 995 Black PC 9901 Aluminum 110796 Silver PC 108693 Aluminum 9840 Black PC 9385 1FSTNR SB125 1BSHNG364 2 1VALVE PN405 1FSTNR HH354 2 1WASHR LC291 2 1ELBOW PL535 2 1VALVE PN767 1ELBOW ST154 1FSTNR SB125 1NUT LC210 Cylinder Assembly Aluminum...

Page 77: ...0 Filler Strip Silver 1PLSTC EX062 REPLACEMENT FILLER STRIPS MUST BE CUT TO SIZE PART NUMBER FOR FULL 120 FILLER STRIPS IS SHOWN IN THE CHART BELOW APPROXIMATE CUT LENGTHS NEEDED ARE SHOWN ON THE LEFT THE FILLER STRIPS ARE NOT INCLUDED IN EITHER THE 110801 OR 110914 PASSENGER SIDE LEG ASSEMBLIES 3 4 48 3 4 7 7 8 79 3 8 Aluminum 110797 Silver PC 108564 Aluminum 110796 Silver PC 108693 7 7 16 1 3 4 ...

Page 78: ... PC 110955 Overview ASSEMBLED EXPLODED ZONE 2 SEE EXPLODED VIEW BELOW ZONE 3 SEE EXPLODED VIEW BELOW REPLACEMENT FILLER STRIPS MUST BE CUT TO SIZE PART NUMBER FOR FULL 120 FILLER STRIPS AND LENGTHS TO CUT STRIPS ARE SHOWN IN DRIVER SIDE ARM ASSEMBLY ZONE 4 ZONE 1 SEE EXPLODED VIEW BELOW ZONE 1 SEE EXPLODED VIEW BELOW ZONE 2 SEE EXPLODED VIEW BELOW ZONE 4 SEE EXPLODED VIEW BELOW ...

Page 79: ...IPS ARE INCLUDED IN ARM ASSEMBLIES APPROXIMATE CUT LENGTHS NEEDED ARE SHOWN IN ZONE 4 ON THE FOLLOWING PAGE 1ELECT CB874 16GA Cable 4 Conductor Length 156 1FSTNR SH177 2 7926 2 Aluminum 9941 Silver PC 9952 Aluminum 9831 Silver PC 9303 Aluminum 9942 Black PC 9953 1WASHR LC581 4 1FSTNR HH684 2 1WASHR LC581 4 Aluminum 1BERNG848 2 Silver PC 1BERNG849 2 1WASHR LC498 2 1FSTNR HH630 2 9821 4 9644 9729 1W...

Page 80: ... IN 9937 9950 1WASHR LC498 NO FILLER STRIPS ARE INCLUDED IN THE ARM ASSEMBLIES APPROXIMATE CUT LENGTHS NEEDED ARE SHOWN IN ZONE 4 ON THE FOLLOWING PAGE 1FSTNR HH585 1FSTNR HH630 3 1WASHR LC498 3 1WASHR LC291 5 Shock Asy 112532 6101 1FSTNR SB563 Aluminum 9887 Silver PC 9888 Aluminum 9729 Silver PC 9841 OUTSIDE FILLER STRIP 9644 BEHIND FILLER STRIP Aluminum 9937 Silver PC 9950 1FSTNR HH288 5 1WASHR ...

Page 81: ...I 48167 Ph 248 349 7010 Fax 248 380 9681 73 Maintenance Exploded Parts Driver Side Arm Assembly Aluminum 110941 Silver PC 110955 Zone 4 Full Length 70 Filler Strip Silver 1PLSTC EX062 28 Aluminum 110941 Silver PC 110955 35 5 8 11 11 16 3 3 4 14 1 8 8 1 8 15 1 4 ...

Page 82: ...D VIEW BELOW ZONE 2 SEE EXPLODED VIEW BELOW REPLACEMENT FILLER STRIPS MUST BE CUT TO SIZE PART NUMBER FOR THE FULL 120 FILLER STRIP AND THE CUT LENGTHS FOR THE PASSENGER SIDE ARM ASSEMBLY ARE SHOWN IN ZONE 4 ASSEMBLED ZONE 4 SEE EXPLODED VIEW BELOW ZONE 2 SEE EXPLODED VIEW BELOW 1FSTNR SH177 2 7926 2 Aluminum 9942 Silver PC 9953 Aluminum 9831 Silver PC 9303 Aluminum 9944 Black PC 9954 1FSTNR HH684...

Page 83: ...1FSTNR HH354 2 1FSTNR SB563 1WASHR LC498 3 1WASHR LC498 1FSTNR HH585 PASSES THRU A HOLE IN 110942 110956 AND IS SECURED BY THREADS IN 9887 9888 Aluminum 9938 Silver PC 9951 Aluminum 9887 Silver PC 9888 1WASHR LC291 2 1WASHR FL498 4 6101 Aluminum 9937 Silver PC 9950 Aluminum 9837 Black PC 9384 1WASHR LC291 4 1FSTNR HH288 4 Aluminum 110942 Silver PC 110956 NO FILLER STRIPS ARE INCLUDED IN ARM ASSEMB...

Page 84: ...8167 Ph 248 349 7010 Fax 248 380 9681 1MANUL755 Maintenance Exploded Parts Passenger Side Arm Assembly Aluminum 110948 Silver PC 110957 Zone 4 Full Length 70 Filler Strip Silver 1PLSTC EX062 28 Aluminum 110948 Silver PC 110957 35 5 8 20 1 8 24 7 16 2 1 16 14 ...

Page 85: ...UDED with the Cross Tube Assembly they are located in the Accessory Box Complete Cross Tube Assembly Aluminum 110931 PC Silver 110952 1FSTNR HH495 8 1WASHR LC456 8 Aluminum 110951 PC Silver 110953 1FSTNR SH177 2 7926 2 Aluminum 9831 PC Silver 9303 1NOZZL FJ638 4 1PLUG BR200 1FSTNR BH505 3 1FTTNG AJ250 4 1MCONC SS015 4 7926 2 1ELBOW BR381 1FTTNG BH286 1VALVE WA231 Aluminum 9932 PC Silver 9949 1FSTN...

Page 86: ...Belanger Inc 1001 Doheny Ct Northville MI 48167 Ph 248 349 7010 Fax 248 380 9681 1MANUL755 Maintenance Exploded Parts Crossbeam Assembly Filler Strips Full Length 70 Filler Strip Silver 1PLSTC EX062 119 1 2 128 1 4 ...

Page 87: ...9 Maintenance Exploded Parts Counterweight Components Front 1PLSTC CR470 2 includes both pieces 6833 50 6834 25 6834 25 8282 5 1CLIP PL250 6 Back 1PLSTC CR470 2 includes both pieces 1FSTNR HH666 4 1FSTNR HH522 2 1WASHR FL706 6 1WASHR LC456 6 8282 5 8283 10 8283 10 6833 50 6833 50 6833 50 6833 50 6833 50 ...

Page 88: ...Assembly Overview 111359 Hub Shaft Assembly 111359 Zone 1 ZONE 1 SEE EXPLODED VIEW BELOW ZONE 3 SEE EXPLODED VIEW BELOW ON FOLLOWING PAGES ZONE 2 SEE EXPLODED VIEW ON FOLLOWING PAGE 10342 6144 4 1FSTNR BH505 4 9724 9723 1FSTNR PH108 2 1WASHR LC291 2 1FSTNR HH288 2 10341 9945 Cable 111363 See image on page 84 10172 1CLAMP330 4 1FSTNR BH155 4 ...

Page 89: ...ploded Parts Hub Shaft Assembly 111359 Zone 2 1FSTNR HH198 2 1WASHR FL415 2 111356 2 1WASHR LC270 2 1NUT RG402 2 End Spider Assemblies 111357 2 10170 2 1FSTNR HH183 24 1WASHR LC271 24 1WASHR FL333 24 1FSTNR HH198 2 1FSTNR HH346 1WASHR FL415 2 111355 2 1NUT LC214 1WASHR LC270 2 1NUT RG402 2 Middle Spider Assembly 111358 ...

Page 90: ...Belanger Inc 1001 Doheny Ct Northville MI 48167 Ph 248 349 7010 Fax 248 380 9681 1MANUL755 Maintenance Exploded Parts Hub Shaft Assembly 111359 Zone 3 6144 4 1FSTNR BH505 4 1FSTNR HH288 2 10341 10342 1WASHR LC291 2 ...

Page 91: ...arbox 110935 STDV or 110967 575V 1HP STDV 112273 1HP 575V 112274 110935 110967 See Exploded View Below 7912 108661 1FSTNR FH075 8 9721 1ELECT FS855 4 110720 See Exploded View on Following Page 110720 See Exploded View on Following Page 1STEEL KY150 9945 1COLLR333 1WASHR FL747 1RETNR129 See View on Following Page 111362 See Exploded View on Following Pages 111363 Slip Ring to Wire Harness Cable See...

Page 92: ...earbox Cover 110720 Motor Drive Assembly 60 Hz Retainer Clips Washers 1WASHR FL747 2 1RENTR129 2 111362 See Exploded View on Following Page Slip Ring Shaft Jam Nut and Wire Retainer Disc are included in the Hub Shaft Assembly 111359 See Part Numbers Below and Installed on Left 1FSTNR HH045 3 1FSTNR SM502 2 7918 1WASHR LC125 3 1PLSTC CV080 1PLSTC CV075 1DECAL SL010 ...

Page 93: ...x 248 380 9681 85 Maintenance Exploded Parts Motor Drive Assembly 60 Hz Slip Ring 111362 Motor Drive Assembly 60 Hz Conduit Power Cables 111361 1FSTNR SB093 1GRMIT100 1NUT RG335 1ELECT FS231 1ELECT FS230 Length 5FT 110886 24VDC LED Power Supply Cable 1ELECT CB874 Motor Power Supply Cable ...

Page 94: ... Wire Harness Cable 111363 LED Assembly 110944 Hub Assembly with LED Lights 111363 Cable from Slip Ring for LED Lights 110718 Wire Harness Four 4 Plugs connect to LEDs 110945 Slip Ring Cable connects to Wire Harness Receptor 110945 4 110718 111363 18 Gage 4 Conductor Cable Length 4FT Plug connects to Wire Harness Receptor connects to Slip Ring ...

Page 95: ...itt Fill Replacement Side View of ShineMitt Hub Fill Pattern 7 1 4 diameter hub Fill every slot as shown Make sure that the fill is facing in the correct direction as shown in the image to the left Side View from Driver Side of the Tunnel Hub 111359 Diameter 7 1 4 Height 84 1 16 14 Rows of ShineMitt Fill 111060 with a quantity of 8 per Row 19 45 DEG Short Lead ...

Page 96: ...r Inc 1001 Doheny Ct Northville MI 48167 Ph 248 349 7010 Fax 248 380 9681 1MANUL755 Tops Maintenance Replacement Parts ShineMitt 19 inch 45 Degree Short Lead 111060 Qty 112 10010 9985 21 1PLSTC CL010 2 10011 2 7 Short Lead ...

Page 97: ...rts Air Cushion Regulator Assembly Aluminum 110906 Silver PC 110907 1RGLTR750 1GUAGE500 1ELBOW PL535 2 1NUT PL550 1REDUC ST111 7971 1FSTNR SH177 2 1WASHR LC115 2 1FSTNR SH738 Aluminum 9898 Black PC 9899 Aluminum 9889 Black PC 9890 1AIRLN635 2 3 8 Natural Plastic Airline Length 110 FT Complete Assembly On Passenger Side Leg Only ...

Page 98: ...f the aluminum tube When replacing a Photo Eye be sure to position the clear LED indicators toward the closest end to make verification of operation easier Complete Assembly Driver Side Aluminum 110806 Silver PC 108960 Passenger Side Aluminum 110807 Sliver PC 108961 1CAP138 2 7707 Passenger Side Only 1ELECT SN654 DRIVER SIDE 2 1ELECT SN620 PASSENGER SIDE 2 NOTE LED INDICATORS ARE TO FACE UP 1FSTNR...

Page 99: ... 91 Maintenance Exploded Parts Retract Air Panel 102913 102913 Air Panel Assembly Complete 1VALVE EL370 2 1ELBOW PL535 2 1RGLTR175 1VALVE PN405 2 1GAUGE500 1AIRLN165 1MADAP BR600 1FSTNR SH177 6 1ELBOW PL666 1AIRLN275 2529 1WASHR LC115 6 1MADAP BR600 1TEE PL706 2501 2 1WASHR LC115 4 1FSTNR SH059 4 3699 ...

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