Belanger FreeStyler Owner's Manual
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Belanger FreeStyler Owner's Manual

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FreeStyler® Installation & Startup
FreeStyler® Installation & Startup
1MANUAL220 Rev14

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Summary of Contents for Belanger FreeStyler

  • Page 1 FreeStyler® Installation & Startup FreeStyler® Installation & Startup 1MANUAL220 Rev14...
  • Page 3 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 ®...
  • Page 5 System Control Center (SCC) Panel Layout moved to Chapter 5 – Electrical. Added 3-17 Skilled Trades, Equipment Locations and Establishing an Origin in the Bay Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 6 Quantity of Boom Clamp hardware is 4 each, was 2 each. Quantity of 2 added to 4-42 PVC Snap Clamp 4-44 Added Freestanding Mount images 4-45 Updated Drive Shaft Re-engagement process Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 7 Removed reference to Blow Off in General Information and removed Onboard Dryer 17-1 Blowoff section that was in Chapter 8 of rev 13. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 8 In text box, specified the Prox Gaps as 1/4" per Engineering 22-20 Changed 1NOZZL-FJ154 to 1NOZZL-FJ254 for the Exit Wheels Lower Nozzle Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 9: Table Of Contents

    Wiring ..................................5-4 Miscellaneous ................................. 5-5 VPS Virtual Positioning System® Photo-Eye ......................5-6 VPS Virtual Positioning System® Photo-Eye Signage ..................... 5-9 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 10 Wheel Stingers® and Freestanding CTA - Utility Connections ................15-9 MixStir® Holding Tank and Delivery Pumping Panel .................... 15-10 On-Board Wheel Cleaner Specifications ......................15-11 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 11 Leveling the Optional On-Board Wheel Cleaner ....................22-21 Wheel Cleaner Pump Startup ..........................22-22 Chemical Tire Applicator (if applicable) ....................... 22-23 Running Test Vehicles ............................22-24 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 13: Chapter 1 Introduction

    ® Chapter 1 Introduction Chapter 1 Introduction...

  • Page 15: Belanger Incorporated® Limited Warranty

    PURPOSE CONTAINED IN THE UNIFORM COMMERCIAL CODE – SALES ARE EXPRESSLY DISCLAIMED. Copyright ©2021 by Belanger, Inc. All rights reserved. No part of this work may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, or by any information storage or retrieval system, except as may be expressly permitted by the 1976 Copyright Act.

  • Page 16: Operational Warning

    Belanger, Inc®., does not endorse or condone the use of chemicals that are potentially dangerous to human health, the environment or property. Belanger® recognizes that it is the right and sole decision of the end user operators of our equipment as to the type and dilution ratio of the chemicals used in their facilities. We strongly recommend that the end user does not select products containing any of the chemicals listed above as an ingredient in the wash solutions.

  • Page 17: Important Safety Information - Must Read

    Read, understand and follow this manual and any other labels or related materials supplied with this equipment. If you do not understand the procedure, call a Belanger, Inc®. representative at 248-349-7010. It is imperative to your safety and the safety of others to understand the procedures before beginning work.
  • Page 18 Doing so will prevent unexpected energization, startup, or release of hazardous energy while maintenance and servicing activities are being performed. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 19 BE SURE TO SAVE THESE INSTRUCTIONS. It is imperative to your safety and the safety of others to always follow safe work procedures. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 20: Ul Information

    2 feet of a solid object, etc. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 21: Scope Of This Manual

    Address safety issues. Installation Manual This is the manual that covers the installation portion of a FreeStyler® system. In this manual there is very little content as to operation, maintenance, troubleshooting and so on. For those items please reference the FreeStyler®...

  • Page 22: Torque Values

    Reduce torque 25% Zinc plating Reduce torque 15% Information provided by raskcycle.com Torque values should be reduced if using lubricants such as anti-seize. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 23: Component Identification

    Chapter 7 Chapter 7 Booster Pump Bug Spray Applicator MixStir® Reclaim Water Adapter Chapter 8 Chapter 9 Chapter 10 Chapter 11 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 24 Wash In Use/Enter Combination Sign Wheel Cleaner Applicator) Wash Sign Chapter 16 Navigational Sign Chapter 16 Chapter 15 Chapter 15 Chapter 16 1-10 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 25 Chapter 21 and 22 Chapter 21 Chapter 21 4-Port Air Manifold 8-Port Air Manifold Regulator Assembly Chapter 21 Chapter 21 Chapter 22 1-11 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 27: Chapter 2 Recommended Installation Sequence Checklist

    ® Chapter 2 Recommended Installation Sequence Checklist Chapter 2 Recommended Installation Sequence Checklist...

  • Page 29: Become Familiar With Site

    Frame and Carriage Assembly & Optional 4 & 16 Signage 10.d Undercarriage Wash Undercarriage 10.e Install Treadle and Bug Spray Option (if applicable) Treadle Assembly Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 30: Main Installation Checklist

    Dryer Adjustments Optional Onboard Dryer & Initial Startup 17 & 22 Run Test Vehicles with customer Initial Startup Customer Training on Operation Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 31: Chapter 3 Getting Started

    ® Chapter 3 Getting Started Chapter 3 Getting Started...

  • Page 33: Installation Overview

    The working envelopes Floor Mounted frames along with all other components are covered on the 11 x 17 support pages supplied at the end of this manual. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 34 OVERALL BAY CONSIDERATIONS • The FreeStyler® fits best in a building 16’ - 6” wide, with a back room and the doors on center of the walls and frame. • At 16’-0” wide with no obstructions and 8’-0” either side of center, the wheels can travel their full stroke and wash the widest vehicles, such as a dually truck, but the upper Neo-Tex™...
  • Page 35 • The FreeStyler® fits best in a building that is at least 37’-0” long, with a back room and the doors on center of the walls and frame. The FreeStyler® operating bay length can be reduced using either of two methods or both.
  • Page 36 Positive Stop Clamps the 92” dimension is taken from Moved In 30” 6-Legged version of this configuration shown later in this section Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 37 Positive Stop Clamps the 92” dimension is taken from Moved In 30” 6-Legged version of this configuration shown later in this section Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 38 Positive Stop Clamps the 92” dimension is taken from Moved In 30” 6-Legged version of this configuration shown later in this section Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 39 Positive Stop Clamps the 92” dimension is taken from Moved In 30” 6-Legged version of this configuration shown later in this section Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 40 Contact your Belanger Sales Representative before attempting the 24” Treadle forward Note: technique. 6-Legged version of this configuration shown later in this section Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 41 19’ – 3” Vehicle Conditions: Small Bay Software (32’-0”) Wheels begin spinning in this position See Second Configuration on the Next Page Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 42 See top image for diameter of 21’ – 9” Vehicle Conditions: wheels when spinning Small Bay Software (34’-6”) Wheels begin spinning in this position 3-10 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 43 19’ – 3” Vehicle Conditions: Small Bay Software (32’-0”) Wheels begin spinning in this position See Second Configuration on the Next Page 3-11 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 44 See top image for diameter of wheels when spinning 21’ – 9” Vehicle Conditions: Small Bay Software (34’-6”) Wheels begin spinning in this position 3-12 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 45 The 24” treadle forward technique is not recommended even though it has been done Note: previously in the field. Contact your Belanger Sales Representative before attempting the 24” Treadle forward Note: technique. 3-13 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 46 Mast Width bottom of the Rail is approximately 1/8”. Keep this in mind when sliding the machine onto the Rails 3-14 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 47 Placement of these items is determined from the machine centerline and the exit legs and can only be determined after the length and width considerations above have been finalized. 3-15 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 48: Freestyler® Position Considerations

    192” in the area of the head beams, they must be cut to a length 2” shorter than P + D. 3-16 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 49: Skilled Trades

    Undercarriage Wash, Photo-Eyes, Support Legs, manifold travel, signage, drip space, and doors. Reference clearance requirements on the Support Documents included at the end of this manual for further details. 3-17 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 50: Fastening Needs And Other Required Materials

    Navigational (In-Bay) Sign – Optional 3/8” anchors (4) holes to mount frame Combination (In-Bay) Sign - Optional 3/8” anchors (4) holes to mount frame 3-18 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 51: Freestyler® Utility Recommendations Floor Mounted

    1/4" gray poly x 100-foot bag 1AIRLN413 1/4" orange poly x 100-foot bag 1TIE800 Cable Tie heavy duty bag of 100 3-19 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 53: Chapter 4 Frame And Carriage Assembly

    ® Chapter 4 Frame and Carriage Assembly Chapter 4 Frame and Carriage Assembly...

  • Page 55: Frame Overview

    The following images show the two clamp styles being secured to the two leg styles. Aluminum Frame Oval Frame Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 56: Floor Mounted Frame

    Note: The 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.
  • Page 57 8) Once the driver side head beam clamp assemblies are completely tight, loosen the bolts until the lock washers are no longer compressed. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 58 Raise frame 48” and secure legs to frame with bases facing outward 11) Lower the forks and back away from the head beams and flip the forks (if necessary). Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 59 Clamps on forks in place 133” Measurement taken from the underside of the Head beam to the floor. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 60 Note: Leveling is CRITICAL for proper machine operation! Note: After this point, the forklifts are no longer necessary and leveling also becomes far more difficult without the forklifts. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 61: Carriage Prep

    1) Locate the drive shaft coupling closest to the gearbox shown below.  Using a 9/16” open end wrench or ratchet with socket, loosen the coupling bolts. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 62 Note: Keep in mind that the keys will need to be reinstalled upon completion of the installation process. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 63 Do not loosen wheel bearing attachment fastener (1/2” hex flange bolt) when preparing the carriage for placement. DO NOT loosen this center bolt Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 64 Follow the steps below to remove the caps. 1) Remove the 5 roller nuts and the two-piece roller cap. 4-10 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 65 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. 4-11 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 66: Rail Travel Stop-Clamp Placement

     Use the 7/16 x 4-1/2” bolts and lock nuts to secure the clamp into place on the rail. 15/32” Fixture 3-1/2” Through-Holes 4-12 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 67 The entrance target installs on the Rail Travel Stop Clamps. Note: The exit target installs onto the rails. Exit Entrance Direction of Travel 4-13 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 68: Carriage Placement

    There is 1/8’’ of clearance between the pods and the rails, keep this in mind when loading Note: the carriage onto the rails. Entrance Exit 4-14 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 69  Apply a small amount of Red Loc-Tite™ to all 4 of them.  Install the Safety Bracket Weldments to the driver side and passenger side of the Carriage as shown below. 4-15 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 70: Sonar Placement

    See following pages for adjustment and configuration of the Multifunction Sonar. See Configuring the Sonar Unit later in this chapter. 4-16 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 71: Adjusting The Sonar Unit

    (left to right). CAUTION CONFIRM THAT THE SONAR UNIT CLEARS THE MAIN CROSSBEAM PRIOR TO RUNNING THE MACHINE 4-17 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 72: Adjusting The Multifunctional Sonar Units

    Configuring the Sonar Unit This Multifunction Sonar has multiple modes for utilizing the same sonar unit on various pieces of Belanger® equipment. The modes are switched by holding a magnet up to the designated location of the sonar unit until it switches into the corresponding mode. The LED on the sonar will flash a pulse pattern count that corresponds to the MODE number that it’s in.

  • Page 73: Installing The Boom Mount

    All of the above dimensions are applicable for either Driver side or Passenger side Boom orientation. Note: The Wall Mount bay height is the same for the 4-Legged Frame and 6-Legged Frame configurations. 4-19 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 74 6-Legged Frame of Travel Note: All the above dimensions are applicable for either Driver side or Passenger side Boom orientation. 4-20 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 75 The outer edge of the rail to the edge of the Boom Mount Clamp should measure 2”. If the Note: distance is not 2” adjust the Clamp as necessary. 4-21 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 76: Installing The Optional Freestanding Boom Mount Leg

    From entrance side of From center of the center 4 x 6 frame leg 22-1/8” Freestanding Mount Leg Direction 6-Legged Frame of Travel 4-22 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 77 Assembly Freestanding Mount Leg Note: The 112-7/8” measurement is taken from the bottom of the detail plate. 112-7/8” to floor 4-23 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 78 From the outer edge of the rail to the edge of the Boom Mount Clamp should measure 2”. Note: If the distance is not 2”, adjust the Clamp as necessary. 4-24 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 79: Determining Driver Side / Passenger Side Equipment Room

    If your site has a passenger side equipment room/boom location, then the utilities will need to be relocated to the other side of the FreeStyler® carriage. You will also need to turn the hydraulic fittings on the optional HydroBlade® center feed manifold and the optional Wheel Cleaner center feed manifold so that they will face toward the Driver side.

  • Page 80: Passenger Side Boom Install

    Half (2) Mount Plate Weldment Note: Separating the black plastic halves also makes it easier to maintain any lines or wires. 4-26 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 81 Note: Make sure that all the other fittings stay tight! Main Feed Connection Before After 4-27 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 82 The following 2 pages show the other components related to this Distribution Manifold that also need to have their orientation changes. 4-28 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 83 4) Secure the manifold assembly into place and re-connect the hoses to the previous fitting locations. See image below. 4-29 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 84 After 3) Secure the manifold assembly into place and re-connect the hoses to the previous fitting locations. See image below. 4-30 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 85: Installing The Boom

    If the Boom Wall or Freestanding Mount Leg is on the Driver side, the Boom Arm will connect to the Carriage Assembly on the Passenger side. Boom Mount Plate Boom Arm Mount Plate (Driver or Passenger Side) 4-31 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 86 It should have no more than 3/8” of thread length and 5/8” of shoulder length. See the images below. 3/8” 5/8” Boom Linkage Wear Washer (Gray 1/2 x 5/8” Shoulder Bolt Plastic) 4-32 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 87: Routing Boom Utilities

    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 begin routing the utilities. 4-33 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 88 When all utility hoses and tubes are in place, there should be sufficient slack to avoid any binding of the hoses. 4-34 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 89 8) Slide the Parallel Mount Assembly to the position that captures the lines best and tighten the clamp into place. 4-35 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 90 Note: A possible example of this loop setup is shown on the next page. 4-36 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 91: Optional Deluxe Boom

    See image below for an overview of the Boom placement. Boom Arm Detail Plates 4-37 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 92 Note: Use the procedure that begins on the next page to route utilities properly through the boom. 4-38 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 93 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 begin routing the utilities. 4-39 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 94 Note: Also leave a little slack in the center area of the boom to allow the hoses to bend properly. 4-40 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 95 3/8” Sealer Wax 3/8” Soap 1/2” Main Chemical Feed Chemical Air Feed (Optional) Feed 3/4” Fresh Water Feed “Inside” Pipe “Outside” Pipe 4-41 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 96 • 1/4-20 x 3” socket head fasteners Quantity 2 • 1/4” flat washers • 1/4” lock nuts Boom Tube Clamps (2 halves) PVC Snap Clamp 4-42 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 97 • 1/4-20 x 4” socket head fasteners • 1/4” flat washers • 1/4” lock nuts Nuts and washers go behind the Detail Plates of the Boom 4-43 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 98 Note: Check all hoses and lines to verify the proper amount of slack while running the first few test vehicles. 4-44 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 99: Re-Engaging The Drive Shaft

    7) 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. 4-45 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 100: Mounting The Cylinders To The Entrance Arms

    4) When completed, the assembly should appear as shown below. 5) Repeat Steps 1 to 4 for the entrance arm cylinder in the other side pod. 4-46 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 101: Mounting The Entrance Arm Accessories

    Bearing and the Shaft. Complete Assembly Note: For ease of maintenance, be sure that the grease fitting on the bearing faces outward. 4-47 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 102  Tighten the two set screws on the bearing completely. Grease Fittings Facing Out for Easy Maintenance Before After 4-48 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 103 Center Fastener through Lower Shaft 8) Repeat steps 1 to 7 for the Entrance Arm assembly on the opposite side. 4-49 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 104: Mounting The Exit Arm Accessories

    Use anti-seize on all bearings and on the top part of the shaft that slides into the gearbox. Note: Overtightening may strip the threads on the locking-collar. 4-50 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 105 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. 1STEEL-KY150 1STEEL-KY150 in place 1STEEL-KY150 4-51 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 106 5) Snap the plastic bearing cover into arm. Before After 6) Repeat steps 1 to 5 for the Exit Arm assembly on the opposite side. 4-52 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 107: Mounting The Entrance And Exit Motors And Gearboxes

    Electrical Box Note that the Cord Grip for both the Gearbox and the Arm are always on the same side 4-53 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 108 3) Repeat steps 1 and 2 for the other three Side Wheel Hub Assemblies. 4) Install the optional motor covers using the supplied machine screws as shown below. Optional Motor Cover Machine Screw 4-54 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 109: Mounting The Navigational Sign

    Navigational Sign. See the image below. STOP/GO Terminal Electrical Cable To BACKUP Terminal 4-55 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 110: Optional On-Board Wheel Cleaner

    8) Position the 3/4” hydraulic line and secure it to the 3/4” JIC bulkhead found on the Upper Mount Plate, as shown above in the image in step 4. 4-56 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 111 1-1/2" (38.1 mm) 2" (50.8 mm) 40 GPM 1.15/.079 0.51/.035 PSI per 10 foot of pipe/BAR per 3 meters of pipe 4-57 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 112 This timer is set up as an “Off-Delay”. It controls the water level in the tank incrementing Note: the large dial on the timer will increase the amount of water in the tank. 4-58 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 113: Loading Standard Top Wheel Neo-Tex

     Secure one of the Neo-Tex™ Clamp assemblies into place as shown below and snug it against the Wash Clips, as shown below. Install row of Neo-Tex™ Install Neo-Tex™ Clamp Driver Side 4-59 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 114 6) Install the last row of 10” wide material.  Install the last Clamp assembly and snug it against the Wash Clips as shown below. 4-60 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 115: Loading Optional Top Wheel Whisper Wheel

    • 6 - 1WASHR-LC291 (3/8” lock washers) • 6 – 1WASHR-FL498 (3/8” flat washers) 42-1/4” Weight • 2 – 9141 (Weight) 4-61 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 116 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. 4-62 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 117 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. 4-63 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 118  Repeat this procedure on the other side as shown below. Before After 8) Using an assistant, remove the hub and set it on work horses as shown below. 4-64 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 119 If you are installing the Whisper Wheel® option, you will have to add the “additional weight Note: bar” covered on the next page. 4-65 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 120 3) Slide the Weight Bar into the rectangular tube. Insert Weight Bar Here Insert Weight Bar Here 4) Tighten the set screws. 4-66 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 121: Loading Entrance Wheel Neo-Tex

    Neo-Tex™ Box: (48 pcs) ”x 10” Neo-Tex™ Packs 2-Ply piece- folded on plastic clip 24 pcs of Neo-Tex™ in this row (1/8” thick) 4-67 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 122: Loading Exit Wheel Neo-Tex

    10” x 1/8” thick, folded in half Lower Completed Fill 16 pcs. - 33” x 10” x 1/8” thick, folded in half 4-68 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 123: Chapter 5 Entrance And Exit Photo-Eyes

    ® Chapter 5 Entrance and Exit Photo-Eyes Chapter 5 Entrance and Exit Photo-Eyes...

  • Page 125: Photo Eye Placement

    6” Off-Set Entrance Exit Door Door Tracks Tracks Direction of Travel Photo-Eyes with 6” Off-Set Image Shown with Wall Mounted Photo-Eyes Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 126 END OF CYCLE and then turned off when past the Photo-Eyes. Many other on/off options are available. The actual installation of the Photo-Eyes is covered later in this document. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 127: General

    If an optional Photo-Eye Heat Kit has been installed, turn the power to the heat OFF before the temperature exceeds 90º Fahrenheit. Turn the power back ON before the temperature falls below 33º Fahrenheit. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 128: Wiring

    Reference Sheet 4 of the Electrical Schematics. White FreeStyler® Input X30 – X35 Actual input wire numbers can vary by site. Black No Connection Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 129: Miscellaneous

    If possible, leave access around the backside of the Photo Eyes so that you do not have to walk in front of them and risk activating the system. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 130: Vps Virtual Positioning System® Photo-Eye

    Part Number Description PE 105858 Heating Kit (1 Set) PE 105859 Heating Kit (2 Sets) Equipment Included Item Receiver Assembly Emitter Assembly Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 131 VPS Virtual Positioning System® Photo-Eye Photo-Eye Placement - 4-Legged Frame Driver Side, Exit End 26” 9” 4” Passenger Side, Exit End 8-1/2” 24” 27-1/2” Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 132 VPS Virtual Positioning System® Photo-Eye Photo-Eye Placement - 6-Legged Frame Driver Side, Exit End 21” 26” 9” Passenger Side, Exit End 27-1/2” 24” 27-1/2” Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 133: Vps Virtual Positioning System® Photo-Eye Signage

    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.
  • Page 134 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 5-10 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 135: Chapter 6 Treadle Assembly

    ® Chapter 6 Treadle Assembly Chapter 6 Treadle Assembly...
  • Page 137 The bolts shown above MUST be installed with the nuts on the exit side! Vehicle Travel Treadle Axle (2) “Y” Section Mount (2) Nuts MUST face exit side of Treadle Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 138 Using a plumb line, mark the floor across the bay in line with entrance edge of the exit 4” x 6” leg. See the image on the next page. Snap a line across the bay. Using the centerline of the FreeStyler®, place the components 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).

  • Page 139: Positioning: 4-Legged Frame

    This difference can prevent the entrance wheels from getting pinched between long vehicles and any other obstruction such as overhead door rails. Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 140: Positioning: 6-Legged Frame

    This difference can prevent the entrance wheels from getting pinched between long vehicles and any other obstruction such as overhead door rails. Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 141: Connections

    Take care NOT to reverse the entrance and exit connections. Euro-Connector (typical) Side View of Treadle (Floor Level) Conduit to Junction Proximity Switch (typical) Floor Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 143: Chapter 7 Chemical Delivery And Pumping Station

    ® Chapter 7 Chemical Delivery and Pumping Station Chapter 7 Chemical Delivery and Pumping Station...

  • Page 145: Triple Foam Connections- Optional

    Triple Foam Injector Valve Water In from Typical (3) Chemical / Water In from the Pump Universal Manifold Typical (3) Typical (3) Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 146: Rinse Seal Wax And Drying Agent Connections- Optional

    Universal Manifold Rinse Seal Wax & Drying Agent Water Flow Lower (Purple) Line RO Water Flow Outer (Red) Line RO ASCO Valve Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 147: Water And Soap To Various Brushes Connections - Standard

    Soap / Water ASCO™ Valve Soap / Water Out to Machine Entrance Wheel ASCO™ Valve Water and Soap Out to the Entrance Wheels Soap Pump Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 148: Electrical Distribution Block Connections

    Electrical Distribution Block Center Pod Soap Water Triple Foam Water Top Wheel Water Exit Wheel Water RO Water Entrance Wheel Water Rinse / Wax Water Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 149: On/Off Controller & Over Temp Thermostat Device Connections

    ON/OFF Controller & Over Temp Thermostat Device Connections UPPER TERMINAL CONNECTIONS BACK FRONT BACK FRONT PROCESS LIMIT CONTROL CONTROL RB100 CB100L Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 150 LOWER TERMINAL CONNECTIONS AND TERMINAL BLOCK STRIP LIMIT CONTROL CB100L PROCESS CONTROL RB100 547 TO CB100L 547 TO TERMINAL BLOCK STRIP 344 TO CB100L Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 151 ® Chapter 8 MixStir Options Chapter 8 MixStir® Options Triple Foam and High Pressure Wax...

  • Page 153: Chapter 8 Mixstir® Options Triple Foam And High-Pressure Wax

    Refer to the supplied MixStir® manual to install and set up the rest of the equipment. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 154: High Pressure Wax Option Overview

    Distribution Pressure (dual) Block plug. The optional High Pressure SDM Electrical (single) plug may Distribution Block go here in its place Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 155: High Pressure Wax Option #2

    Secure the High-Pressure Check Valve assembly and the supplied plug to the bottom of the MixStir® tank. See the image below. Plug Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 156 On the rear of the tank assembly there is an overflow fitting that requires a 1/2” hose to be run down to a drain or splash-safe location. Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 157 For best performance, position the drum as close as possible to the tank. Note: That orientation will reduce chemical travel distance. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 158 In the high-pressure wax #2 configuration, the Drying Agent uses the MixStir® and the Sealer Wax uses an additional Pulsatron™ pump. Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 159: Parts Identification

    Asco™ Valve and overflowing from ingesting excessive air the wax tank Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 160: Hydrominder (Scanned)

    INSTALLATION AND STARTUP Chapter 8 MixStir® Options Triple Foam and High-Pressure Wax HydroMinder (Scanned) Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 161 INSTALLATION AND STARTUP Chapter 8 MixStir® Options Triple Foam and High-Pressure Wax HydroMinder (Scanned) Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 162 INSTALLATION AND STARTUP Chapter 8 MixStir® Options Triple Foam and High-Pressure Wax HydroMinder (Scanned) 8-10 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 163: Chapter 9 Reclaim Water Adapter Kit Option

    ® Chapter 9 Reclaim Water Adapter Kit Option Chapter 9 Reclaim Water Adapter Kit Option...

  • Page 165: Assembling Reclaim Adapter Components

    Locate the ball check valve and inlet tee components and assemble them as shown below. Before After • CAUTION Be sure the “Flow Arrow” on the side of the inlet tee faces down. Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 166 120VAC Valve that will be controlled by one of the system’s Output Boards. See the Operation Manual: Source Select for setup information. Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 167: Chapter 10 Booster Pump Assembly Option

    ® Chapter 10 Booster Pump Assembly Option Chapter 10 Booster Pump Assembly Option...
  • Page 169 The Booster Pump Kit was designed for the FreeStyler® product line. It is a highly efficient pump that can add 65 psi of water pressure to the Freestyler® system. The pump itself consists of a control panel, pressure tank, and an internal flow and pressure switch. Here are some of the features that the Booster Pump Kit has to offer: •...
  • Page 170 To bypass 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. 10-2 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 171 When you make your cut to the copper pipe, try to keep the cuts as straight as possible. This precision will allow the pipe to seat into the male copper fittings properly. 10-3 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 172 Run this wire to the closest electrical junction box and connect to the 120VAC circuit that will run the pump. Supplied Cord Grip 10-4 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 173 “city water output” to only turn on and off when necessary. Return Pressure Gauge Return Ball Valve Feed Pressure Gauge Bypass Ball Valve Booster Pump Feed Ball Valve 10-5 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 175: Chapter 11 Bug Spray Applicator Option

    ® Chapter 11 Bug Spray Applicator Option Chapter 11 Bug Spray Applicator Option...
  • Page 177 Bug Spray Applicator Nipple Assembly Bug Spray Applicator Manifold Assembly 11-1 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 178 Standard Treadle Circuit Overview Standard Treadle Installation Standard VPS Virtual Positioning System® Circuit Overview Crossover Tube (In line with tire) 11-2 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 179  Run the field supplied poly flow line from the top of the Pulsatron™ pump to the chemical injector on the Asco™ valve assembly. If you have a VPS System, move directly to step 5. 11-3 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 180 NOT IN THE PATH OF THE EXIT SIDE WHEELS BEFORE SECURING IT TO THE FLOOR Hose Barb Entrance of Bay Bug Spray Applicator Manifold Floor Lag (4) 11-4 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 181 Hard piping “crossover” tube in the tire path to prevent premature wear of a rubber Centerline hose. of Head beam 11-5 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 182 Rename the OUTPUT that is used and change the “tag” on the Output Board. See the image below. Rename the ENTRANCE OPERATION that is used (typically this is 2 or 3). See the image below. 11-6 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 183: Chapter 12 Undercarriage Options

    ® Chapter 12 Undercarriage Options Chapter 12 Undercarriage Options...

  • Page 185: Undercarriage Overview

    3/4” stainless cap to the opposite end. • Apply liquid Teflon to all stainless fittings before tightening. FreeStyler® Undercarriage (In-Ground) Tunnel Style Undercarriage (Above-Ground) 12-1 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 186: Undercarriage In-Ground Placement

    The mounting tabs will have to be bent to the floor so the undercarriage manifold can be lagged. See the image below. Direction of Travel 12-2 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 187 Photo Eye 2” Direction of Travel Photo Eye Between 2” and 20” 12-3 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 188 Chemical Injector as shown in the example below. 6) Supply 110VAC feed to the Chemical Pump. Chemical Pump Assembly (Rust Inhibitor) 12-4 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 189: Undercarriage Above-Ground Dimensions

    INSTALLATION AND STARTUP Chapter 12 Undercarriage Options Undercarriage Above-Ground Dimensions 37” 46” 2” 12-5 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 190: Undercarriage Assembly

    Once it is in its permanent location, lag it to the floor. Plumb water feed from Undercarriage Wash valve assembly. 12-6 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 191: Chapter 13 Water Softener Option

    ® Chapter 13 Water Softener Option Chapter 13 Water Softener Option...

  • Page 193: Water Softener

    The FreeStyler® can operate using a 20GPM water softener and typically requires 12GPM or less. A base FreeStyler® can operate using the 213S OD / WA model (2 tanks). A booster pump is recommended to increase water pressure and make up for the pressure loss through the water softener. See the image below.

  • Page 194: Getting Started

    13-2 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 195: Water Softener Installation Cp 213

    Locate the enclosed kit containing: four O-rings, two pipes with O-rings, and a silicone packet. Apply a liberal amount of silicone to  the four O-rings and the O-rings on the two pipes. Install the four O-rings on the inlet/outlet adapters. 13-3 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 196 These lines are to be 1-1/4” or 1-1/2”. All copper tubing. Softened water One field supplied Shutoff Valve (normally closed, open to bypass system) 13-4 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 197 ➢ The float cup height determines how much softened water flows back into the brine drum to prepare for the next regeneration. 13-5 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 198: Model 213S Od / Wa And Wb Connections

    15lbs @ the 1.25 tab is Adjuster 10-1/2” next for the Tube Adjuster Tube Base of Brine Valve 13-6 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 199 Dropping may lower the float cup, resulting in an improper setting. 1/2” barbed overflow fitting (typical on all storage tanks) Plastic push-on fitting (typical on all storage tanks) 13-7 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 200 (Change to white disc) Disc Selection (Compensated Hardness*) Setting Capacity Efficiency Dosing Meter Disc 15.0 lbs. 60,000 gpg 4,000 grains/lb. 6.0 lbs./ft Hardness 13-8 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 201: Cp 213S Od (Scanned)

    INSTALLATION AND STARTUP Chapter 13 Water Softener Option CP 213s OD (Scanned) 13-9 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 202: Component Functionality (Scanned)

    Remote Adapter This tank adapter is used to provide a quick connection, via the interconnecting piping, to the control valve. 13-10 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 203 Central Brining System. Depending on the CP unit selected, the Venturi Throat and Brine Flow Control may need to be changed. 13-11 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 204: Water Softener Conversion Charts

    7.481 6.229 1728.0 28.32 0.02832 Liters 1.057 0.2642 0.22 61.02 0.03531 0.001 Cubic Meters 1057.0 264.2 220.0 61023.0 35.31 1000.0 13-12 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 205: Chapter 14 Hydroblade® Assembly Option

    ® ® Chapter 14 HydroBlade Assembly Option Chapter 14 HydroBlade® Assembly Option...

  • Page 207: Hydroblade® Specifications

    Chapter 14 HydroBlade® Assembly Option HydroBlade® Specifications Overview There are 2 Pump Station options for the FreeStyler® HydroBlade® Option. In addition, there is a separate nozzle kit for each Pump Station. These Pump Stations are offered as follows, • Grundfos™ Centrifugal pump 10HP pumping station recommended for use with reclaim, this pump is ideal for medium pressure high volume rinse •...
  • Page 208 3/4” wrench Two adjustable wrenches 1/16’’ Allen wrench Safety glasses See Nozzle Chart later in this chapter for more details. 14-2 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 209: Complete Hose Circuit Overview

    INSTALLATION AND STARTUP Chapter 14 HydroBlade® Assembly Option Complete Hose Circuit Overview Complete Airline Circuit Overview Image below shows all available options. 14-3 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 210: Side Manifold Installation

    Note: Be sure to mount the driver side and passenger side in the correct location. Upper Mount Plate 14-4 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 211  When completed it should look like the image below. Upper HydroBlade® Water Feed Manifold Upper Wheel Water Feed Manifold 14-5 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 212 At this point all the hose runs on the machine are complete. See Nozzle Chart later in this chapter for more details. 14-6 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 213: Hydroblade® Optional Assemblies - Overview

    See the images below for the fittings that correspond to the various options in the location circled in the image above. Sealer Wax and R.O. R.O. Sealer Wax 14-7 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 214: Hydroblade® Rinse / Sealer Wax Assembly

     Shut the pod cover door when complete. Repeat Steps 4 and 5 for the Driver side of the machine. Remove water hose from the Elbows 14-8 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 215  Run a test wash to verify that there are no leaks and that all connections are tight. See Nozzle Chart later in this chapter for more details. 14-9 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 216: Hydroblade® R.o. / Low Pressure Feed Assembly

    Open the Passenger side pod cover and locate the brass cross assembly that is towards the entrance side of the machine. See the image above in Step 4. 14-10 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 217  Run a test wash to verify that there are no leaks and that all connections are tight. See Nozzle Chart later in this chapter for more details. 14-11 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 218: Hydroblade® Purge Air Assembly - Circuit Overview

    Cut the airline at 2” from the bulkhead and insert the MAC Valve Assembly as shown. Insert MAC Cut the airline Valve Assembly here at 2” from the bulkhead Bulkhead 14-12 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 219 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. Connect Electrical Feed as shown here 14-13 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 220: Hydroblade® Rinse Quick-Dump Assembly - Overview

    1-3/8” Hole to Remove 1/4" Plug Quick-Dump Assembly in Place 14-14 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 221: Setting Up The Pumping Station And Running The Utilities

     Run the line through the smallest window on the utility hose support.  Tighten the line onto the Lexair™ manifold. Note: See Routing Boom Utilities in Chapter 6 for further details. 14-15 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 222: Nozzle Kits / Nozzle Chart

    Wheel Stinger / HydroBlade® for 10 HP Medium-Pressure. If this configuration has been purchased, your Wheel Cleaner/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: •...
  • Page 223 Hockey Pucks Assemblies 1NOZZL-MG200 (30) TIP: MEG 0505 Wheel Stinger® / 10HP Wheel Cleaner HydroBlade® Lexair™ Pumping Platform Assembly: 108479 Assembly 14-17 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 224 Hockey Pucks Assemblies 1NOZZL-MG100 (30) TIP: MEG 0502 Wheel Stinger / HydroBlade® Lexair™ Assembly: 108479 25HP Wheel Cleaner Pumping Platform Assembly 14-18 Belanger, Inc. ®* PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 225 ® Chapter 15 Wheel Cleaning & Chemical Tire Application Options Chapter 15 Wheel Cleaning & Chemical Tire Application Options...

  • Page 227: Chapter 15 Wheel Cleaning And Cta Options

    Provides effective cleaning results tire debris and providing effective cleaning results on all on all types of vehicle tires. types of vehicle tires. 15-1 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 228: Wheel Stingers® And Freestanding Cta

    This image assumes a Driver 3-1/4” Side Equipment Room Secondary Applicator 6” Crossover Tube 3-1/4” Driver Side Bell Hose Direction of Travel Passenger Side 15-2 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 229 Center-Line 61-1/4” 61-1/4” Note: In a drive-through configuration the applicators should not be mounted in the path of the vehicles. 15-3 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 230 The floor mount in the middle of the tunnel will have a plug installed in the end. The floor mount on the wall side will have a 1/4” push-in tube fitting installed. Note: 15-4 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 231 The other end of the tube is to be connected to the air fitting on the Bell Hose mount. See the image above. 15-5 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 232 See the wheel sensor timer prints when a bell hose is used with a wheel sensor timer instead. 15-6 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 233 3-1/4” Mounting the MixStir® Tank See the MixStir® Manual that ships with every MixStir® for details. 15-7 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 234 Pump Inlet (Behind the Factory Installed Red 3/8” Hose) to the Tee on the Bottom of the Hydro- Minder™ Tank 15-8 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 235 Flow Tube Primary Applicator 1/4" Tee Foam Air Regulator See Nozzle Chart at the end of this chapter for more details. 15-9 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 236 Tee on the Bottom of the Hydro- Minder™ Tank See Nozzle Chart at the end of this chapter for more details. 15-10 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 237 Motor and Pump 3/4” Hydraulic Hose Tank Gauge Check Valve See Nozzle Chart at the end of this chapter for more details. 15-11 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 238: Wheel Stinger Installation (General)

    The “Hockey Pucks” face toward the center of the machine. Note: 2) Repeat step 1 for the Driver side. See the image above. 15-12 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 239 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 15-13 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 240: Deluxe Wheel Stinger® With On-Board Cta Installation

    Stinger Cover Support Mount as shown below. Before After Cover Support Mount Assembly Supplied Fasteners (2) and Washers (2) (Size 8-32) Tire Locator Assembly 15-14 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 241 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 Bracket Chamber 15-15 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 242  Route the two hoses and the feed from the Photo Eye up the manifold using the supplied wire-ties to secure them to the manifold. 15-16 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 243 INSTALLATION AND STARTUP Chapter 15 Wheel Cleaning and CTA Options Deluxe Wheel Stinger® with On-Board CTA Installation 9) Run the Photo Eyes electrical lines up into the central carriage of the FreeStyler® to the gray plastic junction box as shown below. Note: There are two cord grips in the junction box.
  • Page 244 Chapter 15 Wheel Cleaning and CTA Options Deluxe Wheel 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.
  • Page 245 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. 15-19 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 246: Hockey Puck Installation

    Do not tighten them completely.  Repeat Step 2 for the Passenger side spray pipe weldment.  See the image below. 15-20 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 247 Make sure not to get any liquid Teflon™ inside of the nozzle as this may cause it to plug the hole up. 15-21 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 248: Cover Assembly

    Be sure to position the tie wrapped utility lines to emerge from the utility path at the top of Wheel Stinger® Cover as you mate the two together. 15-22 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 249: Chapter 16 Signage Options

    ® Chapter 16 Signage Options Chapter 16 Signage Options...

  • Page 251: Wait/Go Sign

    1) Supply 120VAC to the junction box mounted on the housing of the Navigational Sign. Refer to your electrical drawings. 16-1 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 252: Combination Sign

    16-2 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 253 ® Chapter 17 Onboard Dryer Option Chapter 17 Onboard Dryer Option...

  • Page 255: Chapter 17 Onboard Dryer Options

    • The plastic spiral blower housings are only offered in a gray color. • The Air Concentrator is optional. If it is ordered it will be mounted to the FreeStyler® before shipment. • Onboard Dryers are offered in various voltages.
  • Page 256 Frame Installation 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 frame. The only addition will be another head beam and two center mount legs which are to be centered on the rails.
  • Page 257 First pass without Air Concentrator puts maximum drying on the center of the vehicle. Second pass with Air Concentrator on to dry the vehicle sides • One pass with Air Concentrator oscillating throughout the entire pass 17-3 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 259: Chapter 18 Spot Free Rinse (Ro) Option

    ® Chapter 18 Spot Free Rinse (R.O.) Option Chapter 18 Spot Free Rinse (R.O.) Option...

  • Page 261: General Requirements

    RO unit. Front View 72” 64” 100-Gallon Tank Note: See the site-specific plumbing layout for more details. 18-1 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 262: Connections For Model 3000 Gpd, Stand Mounted System

    In from Membrane Re-circulation Valve Tap Pressure Out to Pre-Filter Housing To Pressure Switch Inlet Solenoid In from Carbon Tank 18-2 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 263 8) Is the float plugged into the controller? See Initial Startup (Chapter 22), before turning this unit on! Note: Refer to the electrical schematics for connections. Note: 18-3 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 265: Chapter 19 Trades

    ® Chapter 19 Trades Chapter 19 Trades...

  • Page 267: Required Man Hours

    This section is intended to help you get the most from Electrical and Plumbing contractors that you may have involved in the project. The following concepts are especially helpful if this is the first FreeStyler® installation that they have performed.

  • Page 268: Plumbing Coordination Meeting

    PVC can also be used if supported properly. • 3/4” stainless tubing or piping is preferred for the plumbing lines. 19-2 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 269: Boom Feeds

    The above image shows the hose connection from the Pumping Station Manifold to the Wall Manifold Note: See Wall Manifold section for details and images of proper connection. 19-3 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 271: Chapter 20 Electrical

    ® Chapter 20 Electrical Chapter 20 Electrical...

  • Page 273: General

    ❖ Values listed below are only valid for 208V systems. Contact the factory if you are operating with a voltage other than 208/230V. The FreeStyler® carwash should have a 2” water meter at 60PSI or 1-1/2” meter at 60PSI to supply the entire system.
  • Page 274 See Local electrical codes for service factor amps. Size load center and wires accordingly. Note: See the Conduit Electrical information page of the system print set for full details. 20-2 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 275: Best Practice Methods

    Amps, a larger wire provides a better ground which prevents intermittent problems due to electrical noise generated when using Variable Frequency Drives (VFD’s). 20-3 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 276 Please contact Belanger® Technical Support for further assistance at 248-349-7010. 20-4 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 277 Doing so will ensure all connections are good. REFER TO THE ELECTRICAL PRINTS FOR INSTALLATION DETAILS. 20-5 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 278: Machine Control Center (Mcc) Panel

    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 20-6 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 279: System Control Center (Scc) Panel

    The above image shows the components located inside of the System Control Center Enclosure REFER TO YOUR SUPPLIED ELECTRICAL PRINTS, AND SITE- SPECIFIC DRAWINGS FOR INSTALLATION DETAILS 20-7 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 280: E-1063 Operator Interface

    The above image reflects the E-1063 HMI (Human Machine Interface) Home Screen REFER TO YOUR SUPPLIED ELECTRICAL PRINTS, AND SITE- SPECIFIC DRAWINGS FOR INSTALLATION DETAILS 20-8 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 281 RS232 Connection DIP Switches Not Used Phone Line The above image shows the components located inside of the FreeStyler® E-1063 HMI (Human Machine Interface) Enclosure REFER TO YOUR SUPPLIED ELECTRICAL PRINTS, AND SITE SPECIFIC DRAWINGS FOR INSTALLATION DETAI 20-9 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681...

  • Page 283: Chapter 21 Pneumatic And Hydraulic Connections

    ® Chapter 21 Pneumatic and Hydraulic Connections Chapter 21 Pneumatic and Hydraulic Connections...

  • Page 285: Entrance Wheel Circuit Overview - Driver Side Pod

    Hydraulic Retract Fitting Air Solenoid for Driver Side Pneumatic Entrance Wheel Retract Pneumatic Extend Hydraulic Retract 8 Port Valve Manifold Hydraulic Extend 21-1 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 286: Exit Wheel Circuit Overview - Driver Side Pod

    Elbow Fitting Hydraulic Extend Hydraulic Retract Fitting 8 Port Valve Manifold Air Solenoid for Exit Wheels Hydraulic Extend Pneumatic Extend 21-2 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 287: Top Wheel Circuit Overview - Driver Side Pod

    The Solenoid Applies Air to Retract the Cylinder and Raise the Top Wheel. Note: The Solenoid Exhausts Air to Drop the Top Wheel. 21-3 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 288: Driver Side Pod Air Solenoid Valves Overview

    4 Port Valve Manifold 8 Port Valve Manifold Connections to See the Euro Block in Image Above Driver Side Pod 21-4 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 289: Drive Side Pod Air And Water Controls

    Entrance Wheel Air Regulator and Gauge Water Control Regulator and Gauge Regulator and Gauge Regulator Gauge Typical Regulator and Gauge Connection 21-5 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 290: Entrance Wheel Circuit Overview - Passenger Side Pod

    2” Stroke Elbow Elbow Pneumatic Extend Fitting Hydraulic Retract Fitting Pneumatic End Elbow of Cylinder Hydraulic Extend Fitting 4” Stroke 21-6 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 291: Exit Wheel Circuit Overview - Passenger Side Pod

    Air Solenoid for Entrance Wheel Pneumatic Retract Pneumatic Extend Hydraulic Hydraulic Retract Extend Elbow Elbow Hydraulic Extend Fitting Hydraulic Retract Fitting 21-7 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 292: Connections To Euro Block - Passenger Side Pod

    3/8" for Soap Chemical Feed 3/4" for Fresh Water Feed 1/2" for 3/8" for Optional Main Air Feed Sealer Wax Chemical Feed 21-8 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 293: Chapter 22 Initial Startup

    ® Chapter 22 Initial Startup Chapter 22 Initial Startup...

  • Page 295: Overview Of Pertinent Startup Components

    Supply Expansion Module Modem Transformer Main Terminal Strip Output Board (Motor Control Relay) Ground Terminals More Details on Next Page 22-1 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 296 24VDC Power Supply Module: 2A 24VDC Output: 3A Main 120 VAC Power Supply: 20A PLC: 0.5A Modem Transformer (Secondary): 1A Modem Transformer (Primary): 1A 22-2 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 297: Overview Of Mcc Components

    Drive 2: Enter Carriage Wheels Top Wheel Carriage Motor Motor Terminal Protector Enter Wheels Motor Protectors Exit Wheels Motor Protectors 22-3 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 298: Startup Procedure

    Confirm that the power to the MCC is off at load center (building electrical Panel)  Turn on all breakers  Close the door  Turn ON the main disconnect. 22-4 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 299: Scc And Other Components

    Confirm that all doors are closed and turn on the power to each electrical panel at load center. Pull out the E-Stop on the HMI (E-1063 Human Machine Interface) panel, as well as any in-bay E-Stops. 22-5 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 300 Be aware that when wheel movement is triggered manually, the water will come on. If you do not wish to get wet, turn off the water main before moving the wheels. 22-6 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 301: Check Inputs And Motion

    Encoder Proximity Switch (2) A=.053 B=.051 Encoder Proximity Switch Encoder Proximity Switch Gap A = 0.053” Gap B = 0.051” 22-7 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 302 If you see a countdown that jumps in large increments, for example: 30”, 20”, 0”, this is an Note: indication that the encoder proximity switches are not counting properly. 22-8 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 303 This is the default status with 2 Photo-Eyes except CARR ENCODER and TIRE PHOTO 22-9 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 304: De-Stroking Cylinder Arms

     Adjust the Reed Switch accordingly. See Resetting the Cylinder Reed Switches later in this section.  Repeat the process on the other arm if necessary, to clear any obstructions. Reed Switches 7300 7310 22-10 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 305  Adjust the Reed Switch accordingly. See Resetting the Cylinder Reed Switches later in this section.  Repeat the process on the other arm if necessary, to clear obstructions. Reed Switch 7310 7340 22-11 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 306: Re-Setting The Cylinder Reed Switches

     Continue to slide the Reed Switch in the same direction until the light turns back off and mark the cylinder at that location too. Secure the clamp centered between the two marks on the cylinder. 22-12 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 307: Confirming Wheel Rotation

    60 psi. • Hit the DISABLE FORCE and clear all ovals. This switches the machine back to high-pressure. 22-13 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 308: Top Wheel Counterweight Setup

    See the next page for the instruction on checking he chemical outputs and removing the air from the chemical lines. 22-14 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 309  Adjust water and air to achieve desired consistency.  Turn off SOAP CHEM, and SOAP WTR/AIR.  Clear all FORCED ovals. 22-15 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 310: Installing The Triple Foam Pods

    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 will be equalized, creating even coverage during operation. 22-16 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 311: Foaming Components Setup

    Never lower the top wheel when the entrance water manifold cover is open. 2) Close the entrance and exit water covers and both pod covers. 22-17 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 312: Check The Remaining Outputs

     Force on ENTER DOOR and EXIT DOOR. Verify proper operation (if applicable).  Force on DRYER and check rotation according to the Dryer manual (if applicable). 22-18 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 313 Check the Remaining Outputs 4) Close both side pods covers and the manifold covers. 5) Press Fault Reset and the FreeStyler® 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).

  • Page 314: Nozzle Chart

    0.4GPM @ 15° 1.0GPM @ 25° 1NOZZL-FJ254, 1NOZZL-FJ058, 1NOZZL-FJ254, 1NOZZL-FJ058, TIP: PLSTC, 2504 TIP: PLSTC 2510 TIP: PLSTC 1504 TIP: PLSTC 2510 22-20 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 315: Leveling The Optional On-Board Wheel Cleaner

    Manifold to the Solid Link (4) Solid Link 3/8-16 x 1/2” Setscrew (4) Solid Link Manifold Flange Mount Plate Manifold Manifold 22-21 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 316: Wheel Cleaner Pump Startup

    The bypass valve connects the suction and discharge sides of the pump, thus making the filling procedure easier. When the operation is stable, the bypass valve must be closed. 22-22 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 317: Chemical Tire Applicator (If Applicable)

     Run a few test vehicles of various sizes and adjust the nozzles on the CTA applicators to maximize coverage on both wide and narrow vehicles. 22-23 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

  • Page 318: Running Test Vehicles

    When both driver side and passenger side have equal penetration, adjust the air pressure to achieve your final desired penetration of the Neo-Tex™. Note: See the instruction on the next page for equalizing the wheel penetration. 22-24 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...
  • Page 319 The Entrance, Driver Side Wheel should come in slower than the Passenger side Entrance wheel for best cleaning and the “wig-wag” (side-to-side motion) of the Entrance Wheels. 22-25 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220...

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