Belanger FreeStyler User manual

FreeStyler® Installation & Startup

1MANUAL220 Rev14

Belanger® Equipment Owner’s Manual

FreeStyler®Friction Rollover: Installation and Initial Startup

Belanger, Inc®

This manual and the accompanying equipment are protected by United States trademark, copyright, and patent laws. You may

make one copy of this manual. Do not make additional copies of this manual or electronically transmit it in any form whatsoever,

in whole or in part, without the prior written permission of Belanger, Inc.®

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

affiliated with their respective owners.

INSTALLATION AND STARTUP

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

Rev

Release

Date

Page

Description

L. Dietze

Prior to

9/7/21

1-3

Added IMPORTANT note and removed Before You Begin

1-4

Updated Danger Note and added reference to OSHA specifications

1-5

Added Warning note about Trained Electrician and Important note

1-7

Scope of this Manual was Greetings, Installation Manual was Owners Manual,

Ensure A Safe Work Environment was A Final Word on Safety (all sections updated

per current practices)

1-8

Added SAE Grade 8 torque value

1-9 to 1-12

Updated Component Idenification

2-1 to 2-2

Added Chapter references to Checklist. Removed Rocker Blaster from Item 10.d

3-1

Added Working Envelope: Overview, Utility Requirements moved to Chapter 5 –

Electrical

Changed height clearance from 131” to 133”

Changed page reference for Building Height Considerations from page 3-11 to page

3-14

3-2

Width Consideration section reformatted and added intro paragraph

3-3

Length Consideratins section reformatted

3-4 & 3-5

Changed titles to Square 4 Legged Frame:

Configuration #1 & #2 changed the dimension 130-1/2 and the note “The 130-1/2”

dimension taken from exit side edge of the leg“ to 124-1/2 and “The 124-1/2”

dimension is taken from entrance side edge of exit leg.”

Updated images using AutoCad Inventor assemblies.

Changed note: Positive Stop Clamps at Pre-Drilled Position to Position of the

Positive Stop Clamps will be determined by the bay length

3-6 & 3-7

Added pages to show Length Considerations for Oval 4 Legged Frame with optional

Freestanding Boom Mount. Updated images using AutoCad Inventor assemblies.

3-8

Length Considerations Involving Treadle Movement was Length Considerations and

the section was reformatted

3-9 & 3-10

Change titles to Square 6 Legged Frame:

Configuration 2 was Configuration 1 (both images), removed note to see next page

Updated images using AutoCad Inventor assemblies

Added “center leg” to the note explaining the 22-1/8 dimension

Changed note: Positive Stop Clamps at Pre-Drilled Position to Position of Positive

Stop Clamps will be determined by the bay length

3-11 & 3-12

Added pages to show Length Considerations for Oval 6 Legged Frame with optional

Freestanding Boom Mount. Updated images using AutoCad Inventor assemblies.

3-13

Length Considerations Involving Treadle Movement was Length Considerations and

the section was reformatted

3-14

Under Building Height Considerations, Ideal Height Scenario changed 131” to 133”

in two places

Changed both of the 131” dimensions in the image to 133”

3-15

Under Boom Mount Location added Freestanding Mount to Note.

3-16

Dimension P was D and dimension D was E

In sentence below charts changed “length considerations” to “width and length

consideration charts”

3-17

Under Equipment Locations removed the information for the Reservoir and Wall

Manifold.

3-17

Under Equipment Locations, Back Room Equipment removed the words “to the Wall

Manifold” from the following statement: Short runs from the Pumping Station and

Solution Delivery Modules to the Wall Manifold optimize performance.

Changed Injection Chemical System (ICS) to SDM Solution Delivery Pumps

3-17

In Establishing an Origin in the Bay removed Rocker Blasters/Roocker Spin Cleans.

3-17

System Control Center (SCC) Panel Layout moved to Chapter 5 –Electrical. Added

Skilled Trades, Equipment Locations and Establishing an Origin in the Bay

INSTALLATION AND STARTUP

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

Rev

Release

Date

Page

Description

3-18

Under Base FreeStyler® removed Carriage and Boom Assembly, Pump Station –

Optional and Pneumatic Manifold –Optional along with the specifications of the

poly-flow tubing and hydraulic hose assembly information for each of these.

3-17 to 3-18

Machine Control Center (MCC) Panel Layout and E-1063 Operator Interface moved

to Chapter 5 –Electrical. Added Fastening Needs and Other Required Materials

3-18

Under Fastening Needs and Other Required Materials removed Rocker Spin Clean

–Optional and Rocker (side) Blasters –Optional.

3-19

Added FreeStyler® Utility Recommendations Floor Mounted

3-20

Removed “and Rocker Spin Clean” after the word Undercarriage in the second

bullet point

4-1

Chapter 4 –Added reference to Chapter 17 for Onborad Drying Applications. Frame

Overview was Floor Mounted Frame and bay was tunnel in second intro paragraph

Changed the word Rectangular to Square (2 places)

4-2

Chapter 3 was previous section in Step 1

4-5 & 4-6

In Floor Mounted Frame step 14, step 18 and the image on page 4-5 changed the

dimension from the floor to the underside of the headbeam from 131” to 133”.

4-7 to 4-11

Carriage Prep updated per current practices, updated Drive Shaft Disengagement

4-12

Step 1 was 10. Updated Stop Clamp images per current design.

Step 1 was changed from “which position of the travel stops” to “where to position

the Travel Stops”.

4-13

Step 2 was 11. Step 3 was 12. Updated Stop Clamp images per current design.

4-14

In Step 1, center position was between the Rail Travel Stop and the Head Beam. In

Step 4, center position was between the end of the rail and the Head Beam and

added Stop Clamp to image.

4-15

Added note to image in Step 5.

4-16

Configuring the Sonar Unit updated per current practices.

4-19

Added Notes above instruction.

Changed dimension in Installing the Boom Mount step 3 from 110-7/8” to 112-7/8”

and added the Notes below the image.

4-20

Changed title from Standard “Channel” Boom Installation to Installing the Boom

Mount

Added “frame” to the note From entrance side of exit 4 x 6 frame leg

Added “frame” to the note From entrance side of center 4x6 frame leg

Changed dimension 23-1/16” to 22-1/8”

Copied 6-Legged Boom Mount information to Chapter 17.

4-19 to 4-21

Changed the order of the steps for Installing the Boom Mount and added more detail

instructions to steps 2-5.

4-22 to 4-24

Added Installing the Optional Freestanding Boom Mount Leg section.

4-31

Added or Freestanding Mount Leg to both of the Notes in step 2

4-32

Added or Freestanding Mount Leg to the bullet item in step 3

4-34

Added or Freestanding Mount Leg to both images before step 3

Added or freestanding to step 3

4-35

Step 5 was 6. Step 6 was 5.

Added or freestanding to Step 5

4-36

In section Setting Up Slack Vertically (step a) changed wall mount bracket to mount

bracket (two places). Added Note: The mount bracket is either attached to the wall

or the freestanding mount leg.

Added or Raceway to Boom Channel note in image

Removed Wall in Mount Bracket note in image

4-37

Removed Wall in Mount Bracket note in image

In the Notes: above Step 10 removed “wall” before mount bracket and “all” before be

4-38

Added or Freestanding Mount to the notes in the images

Added or Freestanding to the Notes in the box below the images

4-42

Quantity of Boom Clamp hardware is 4 each, was 2 each. Quantity of 2 added to

PVC Snap Clamp

4-44

Added Freestanding Mount images

4-45

Updated Drive Shaft Re-engagement process

INSTALLATION AND STARTUP

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

Rev

Release

Date

Page

Description

4-53

Added callout for Cord Grip location

Added the following note: The images in this section show the motors mounted with

the optional motor covers.

4-54

In step 4 changed “both” to “the”

Added Optional Motor Cover to image

4-56

Added to Step 8, as shown above in the image in step 4

4-59 to 4-60

No Content Change –Loading Top Wheel Neo-Tex™ is the Standard offering, so it

was relocated to before optional Loading Top Wheel Whisper Wheel®

4-61 to 4-66

Loading Top Wheel Whisper Wheel® updated per current practices

4-61

Quick Fill image was 11 fill packs with clamp assemblies, now is 12 fill packs with 2

compression cap assemblies. In parts Required: Compression Cap was Clamp,

Hardware updated accordingly and

42-1/4” Weight was 48” weight.

4-62

Updated images per current practices.

4-62 to 4-64

Updated procedure for disassembly of Compression Cap and new style material hub

and updated images per current practices.

4-65

Updated Installing the Cleaning Material images and procedure per current

practices. In Step 1 Compression Cap was Clamp. In Steps 2 and 3, 12 was 11 and

8 was 7 in the note.

4-66

Updated Installing the Weight Bars images and procedure per current practices. In

step 1 42-1/4” was 48” and 5/8” was 3/4".

4-67

Updated image of Entrance Wheel with Neo-Tex™added more fill information

4-68

Removed page for Loading Entrance Wheel Neo-Tex™with Nylon Brush

Chap 5

New information added to update to current practices

5-1

Changed subheading from Photo-Eye Available Styles to Photo-Eye Available Style

Options

Added “Add-on” to the subheading: Photo Eye Available Add-on Options

Removed the sentence: The standard FreeStyler® configuration has a set of Photo-

Eyes to install at the entrance of the bay.

Chap 6

Was Chapter 7 in Rev 13. Added images and updated per current practices.

Removed “Vector” reference in the Treadle/Y-Section step

Chap 7

New Chapter added to manual - Chemical Delivery and Pumping Station

Chap 7

Removed information for the Optional Super Heat Water Heater Installation,

Connections and Wiring Schematic

Chap 8

New Chapter added to manual - MixStir® Options

Chap 9

New Chapter added to manual - Reclaim Water Adapter Kit Option

Chap 10

New Chapter added to manual - Booster Pump Assembly Option, existing

information was in Chapter 9 of Rev 13, new information updated to current

practices

Chap 11

New Chapter added to manual - Bug Spray Applicator Option, existing information

was in Chapter 9 of Rev 13, new information updated to current practices

Chap 12

Was Chapter 6 of Rev 13, new information updated to current practices

Chap 12

Removed installation information on the Rocker Blaster and Rocker Spin Clean.

Chap 13

New Chapter added to manual - Water Softener Option, existing information was in

Chapter 9 of Rev 13, new information updated to current practices

Added Water Softener Conversion Charts

Chap 14

New Chapter added to manual - HydroBlade® Assembly Option, existing

information was in Chapter 9 of Rev 13, new information updated to current

practices

Chap 15

New Chapter added to manual - Wheel Cleaning and Chemical Tire Application

Options, existing information was in Chapter 9 of Rev 13, new information updated

to current practices

Chap 16

New Chapter added to manual –Signage Options

Chap 17

Was Chapter 8 in Rev 13. Added images and updated per current practices

17-1

Removed reference to Blow Off in General Information and removed Onboard Dryer

Blowoff section that was in Chapter 8 of rev 13.

INSTALLATION AND STARTUP

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

Rev

Release

Date

Page

Description

17-2

Relocated Frame Installation and Installing the Boom Mount sections from Chapter

4 (Frame and Carriage) in rev 13.

Re-wrote the last two sentences in Overview: Frame Installation was: The only

addition will be an additional head beam and center mount leg. These items are

centered on the rails and installed in the carriage and centered on the rails. See

page 17-2 for the changed version.

Changed dimension in image from 23-1/16” to 22-1/8”

Added Frame to note in image

Add “or Freestanding” to note in image

Chap 18

New Chapter added to manual - Spot Free Rinse (R.O.) Option, existing information

was in Chapter 9 of Rev 13, new information updated to current practices

Chap 19

New Chapter added to manual - Trades per current practices

Chap 20

New Chapter added to manual - Electrical per current practices

Chap 21

New Chapter added to manual –Pneumatic and Hydraulic Connections

Chap 22

Was Chapter 10 in rev 13

22-4

Updated MCC Startup per current practices

22-5 to 22-6

SCC and Other Components was SCC. Section updated per current practices.

22-7 to 22-9

Check Inputs and Motion was SCC. Section updated per current practices.

22-10 to 22-

De-Stroking Cylinder Arms was Entrance Arm Cylinders, Exit Arm Cylinders. Added

instruction for Entrance Arm Cylinder. Updated image in Exit Arm Cylinder.

22-13

Added “Clear FORCED ovals” step in Top Wheel instruction

22-16

Added Installing the Triple Foam Pods

22-20

Added Nozzle part numbers and Tip information

22-21

Added images

22-24 to 22-

Running Test Vehicles was Vehicle Testing. Section was reorganized and added

Equalizing the Entrance or Exit Wheel Penetration section title.

Randy

Morton

9/7/21

3-14, 4-1, 4-

7, 4-10 & 4-

Added the following Note: The forklift considerations for the carriage are as follows:

load weight of the carriage is 2,250 lbs., load is 136” wide, load center is 40”, and the

load needs to be lifted 72” high.

4-49 and

4-50

Added anti-seize not in the note box (felt like it needed more attention brought to it)

8-7

Changed VCT-HPW-001 to 106999

12-4

Removed image showing placement of Pump below Injector it did not accurately

support note, Note is sufficient.

14-16

Changed NZZL-105982 to NZZL-105980

14-17

Changed 1NOZZL-HP125 to 1NOZZL-MG200

Changed TIP: MEG2025 to MEG0505

14-18

Changed 1NOZZL-HP120 to 1NOZZL-MG100

Changed TIP: MEG2025 to MEG0502

20-2

Added Hydro Blade Water GPM and PSI to Chart for the 10HP & 25 HP Pump

Stations

20-6

Corrected the word “Topwheel”

22-8

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

INSTALLATION AND STARTUP 
1MANUL220 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 
 
Table of Contents 
Chapter 1 Introduction............................................................................................................... 1-1 
Belanger Incorporated® Limited Warranty...............................................................................................................1-1 
Operational Warning...............................................................................................................................................1-2 
IMPORTANT Safety Information –MUST READ.....................................................................................................1-3 
UL Information ........................................................................................................................................................1-6 
Scope of This Manual .............................................................................................................................................1-7 
Torque Values.........................................................................................................................................................1-8 
Component Identification.........................................................................................................................................1-9 
Chapter 2 Recommended Installation Sequence Checklist................................................... 2-1 
Become Familiar with Site.......................................................................................................................................2-1 
Main Installation Checklist.......................................................................................................................................2-1 
Optional Items to be Installed Anytime ....................................................................................................................2-2 
When Installation is Finalized..................................................................................................................................2-2 
Chapter 3 Getting Started.......................................................................................................... 3-1 
Installation Overview............................................................................................................................................... 3-1 
FreeStyler® Position Considerations.....................................................................................................................3-16 
Skilled Trades....................................................................................................................................................... 3-17 
Equipment Locations............................................................................................................................................. 3-17 
Establishing an Origin in the Bay...........................................................................................................................3-17 
Fastening Needs and Other Required Materials.................................................................................................... 3-18 
Fastening Needs and Other Required Materials.................................................................................................... 3-18 
FreeStyler® Utility Recommendations Floor Mounted ........................................................................................... 3-19 
Chapter 4 Frame and Carriage Assembly................................................................................ 4-1 
Frame Overview......................................................................................................................................................4-1 
Floor Mounted Frame.............................................................................................................................................. 4-2 
Carriage Prep..........................................................................................................................................................4-7 
Rail Travel Stop-Clamp Placement........................................................................................................................4-12 
Carriage Placement .............................................................................................................................................. 4-14 
Sonar Placement ..................................................................................................................................................4-16 
Adjusting the Sonar Unit........................................................................................................................................4-17 
Adjusting the Multifunctional Sonar Units .............................................................................................................. 4-18 
Installing the Boom Mount..................................................................................................................................... 4-19 
Installing the Optional Freestanding Boom Mount Leg ..........................................................................................4-22 
Determining Driver Side / Passenger Side Equipment Room ................................................................................ 4-25 
Passenger Side Boom Install ................................................................................................................................ 4-26 
Installing the Boom................................................................................................................................................4-31 
Connecting the Standard Boom Channel ..............................................................................................................4-31 
Routing Boom Utilities........................................................................................................................................... 4-33 
Optional Deluxe Boom.......................................................................................................................................... 4-37 
Re-engaging the Drive Shaft................................................................................................................................. 4-45 
Mounting the Cylinders to the Entrance Arms........................................................................................................4-46 
Mounting the Entrance Arm Accessories...............................................................................................................4-47 
Mounting the Exit Arm Accessories....................................................................................................................... 4-50 
Mounting the Entrance and Exit Motors and Gearboxes........................................................................................4-53 
Mounting the Navigational Sign............................................................................................................................. 4-55 
Optional On-Board Wheel Cleaner........................................................................................................................4-56 
Loading Standard Top Wheel Neo-Tex™..............................................................................................................4-59 
Loading Optional Top Wheel Whisper Wheel®...................................................................................................... 4-61 
Loading Entrance Wheel Neo-Tex™ .....................................................................................................................4-67 
Loading Exit Wheel Neo-Tex™ .............................................................................................................................4-68 
Chapter 5 Entrance and Exit Photo-Eyes................................................................................. 5-1 
Photo Eye Placement.............................................................................................................................................. 5-1 
Photo-Eye Available Style Options.......................................................................................................................... 5-1 
Photo-Eye Available Add-on Options ......................................................................................................................5-1 
Photo-Eye Layout and Description..........................................................................................................................5-1 
General...................................................................................................................................................................5-3 
Wiring .....................................................................................................................................................................5-4 
Miscellaneous.........................................................................................................................................................5-5 
VPS Virtual Positioning System® Photo-Eye...........................................................................................................5-6 
VPS Virtual Positioning System® Photo-Eye Signage.............................................................................................5-9 
 

INSTALLATION AND STARTUP 
 Belanger, Inc.® * PO BOX 5470. * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681 1MANUL220 
 
Table of Contents 
Chapter 6 Treadle Assembly......................................................................................................6-1 
Treadle Assembly....................................................................................................................................................6-1 
Positioning: 4-Legged Frame...................................................................................................................................6-3 
Positioning: 6-Legged Frame...................................................................................................................................6-4 
Connections.............................................................................................................................................................6-5 
Chapter 7 Chemical Delivery and Pumping Station ................................................................7-1 
Triple Foam Connections- Optional..........................................................................................................................7-1 
Rinse Seal Wax and Drying Agent Connections- Optional .......................................................................................7-2 
RO Water Connections –Optional...........................................................................................................................7-2 
Water and Soap to Various Brushes Connections - Standard..................................................................................7-3 
Electrical Distribution Block Connections.................................................................................................................7-4 
ON/OFF Controller & Over Temp Thermostat Device Connections..........................................................................7-5 
Chapter 8 MixStir® Options Triple Foam and High-Pressure Wax........................................8-1 
MixStir® Triple Foam Option Overview....................................................................................................................8-1 
High Pressure Wax Option Overview.......................................................................................................................8-2 
High Pressure Wax Option #1..................................................................................................................................8-2 
High Pressure Wax Option #2..................................................................................................................................8-3 
Parts Identification...................................................................................................................................................8-7 
HydroMinder (Scanned)...........................................................................................................................................8-8 
Chapter 9 Reclaim Water Adapter Kit Option...........................................................................9-1 
Assembling Reclaim Adapter Components..............................................................................................................9-1 
Chapter 10 Booster Pump Assembly Option .........................................................................10-1 
Booster Pump........................................................................................................................................................10-1 
Chapter 11 Bug Spray Applicator Option...............................................................................11-1 
Bug Spray Applicator Option..................................................................................................................................11-1 
Chapter 12 Undercarriage Options .........................................................................................12-1 
Undercarriage Overview........................................................................................................................................12-1 
Undercarriage In-Ground Placement .....................................................................................................................12-2 
Undercarriage Above-Ground Dimensions.............................................................................................................12-5 
Undercarriage Assembly........................................................................................................................................12-6 
Chapter 13 Water Softener Option ..........................................................................................13-1 
Water Softener ......................................................................................................................................................13-1 
Getting Started ......................................................................................................................................................13-2 
Water Softener Installation CP 213........................................................................................................................13-3 
Model 213S OD / WA and WB Connections...........................................................................................................13-6 
CP 213s OD (Scanned).........................................................................................................................................13-9 
Component Functionality (Scanned)....................................................................................................................13-10 
Water Softener Conversion Charts ......................................................................................................................13-12 
Chapter 14 HydroBlade® Assembly Option...........................................................................14-1 
HydroBlade® Specifications...................................................................................................................................14-1 
Complete Hose Circuit Overview ...........................................................................................................................14-3 
Side Manifold Installation.......................................................................................................................................14-4 
HydroBlade® Optional Assemblies –Overview......................................................................................................14-7 
HydroBlade® Rinse / Sealer Wax Assembly..........................................................................................................14-8 
HydroBlade® R.O. / Low Pressure Feed Assembly .............................................................................................14-10 
HydroBlade® Purge Air Assembly –Circuit Overview..........................................................................................14-12 
HydroBlade® Purge Air Assembly –Installation...................................................................................................14-12 
HydroBlade® Rinse Quick-Dump Assembly –Overview......................................................................................14-14 
HydroBlade® Rinse Quick-Dump Assembly –Installation....................................................................................14-14 
Setting up the Pumping Station and Running the Utilities.....................................................................................14-15 
Nozzle Kits / Nozzle Chart...................................................................................................................................14-16 
Chapter 15 Wheel Cleaning and CTA Options .......................................................................15-1 
Wheel Cleaning and Chemical Tire Application (CTA) Options ..............................................................................15-1 
Wheel Stingers® and Freestanding CTA ...............................................................................................................15-2 
Wheel Stingers® and Freestanding CTA –Installation of a Bell-Hose....................................................................15-4 
Wheel Stingers® and Freestanding CTA - Installation of Cross-Over.....................................................................15-7 
Mounting the MixStir® Tank...................................................................................................................................15-7 
Wheel Stingers® and Freestanding CTA - Connecting the MixStir®......................................................................15-8 
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 