Belanger Wave Across User manual

Wave Across™
1MANUL850
REV 14
Belanger, Inc.
P.O. Box 5470
Northville, MI 48167-5470
Customer Service Phone [phone]
Fax [phone]
www.belangerinc.com

Belanger Equipment Owners Manual
Wave Across
Copyright 2010
Belanger, Inc®
This manual and the accompanying equipment are protected by United States and International copyright and patent laws.
You may make one copy of this manual. Do not make additional copies of this manual or electronically transmit it in any form
whatsoever, in whole or in part, without the prior written permission of Belanger, Inc.®

WAVE ACROSS
1MANUL850 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]
Table of Contents
Belanger Incorporated Limited Warranty........................................................ 2
Operational Warning......................................................................................... 3
Introduction....................................................................................................... 4
Important Safety Information...................................................................................................................................4
Safety Symbols and Signal Words..........................................................................................................................4
IMPORTANT Safety Information – MUST READ....................................................................................................5
Safety Warnings......................................................................................................................................................5
Available Styles.......................................................................................................................................................6
Before You Get Started...........................................................................................................................................7
Specifications.................................................................................................... 8
Requirements..........................................................................................................................................................8
Output......................................................................................................................................................................8
Dimensions..............................................................................................................................................................9
Installation....................................................................................................... 10
Frame Assembly...................................................................................................................................................10
Tunnel Placement.................................................................................................................................................11
Utilities...................................................................................................................................................................12
Cloth......................................................................................................................................................................14
Maintenance .................................................................................................... 19
Routine Procedures............................................................................................................................................... 19
Special Attention Items.......................................................................................................................................... 20
Exploded Parts View.............................................................................................................................................21
Upper Frame Assembly.........................................................................................................................................................21
Water Manifolds.....................................................................................................................................................................21
Rack Assembly......................................................................................................................................................................22
Drive Arm Assemblies...........................................................................................................................................................22
Drive Rack Assembly (1 of 2 identical assemblies)...............................................................................................................23
Follower Rack Assembly (1 of 2 identical assemblies) .........................................................................................................23
Stud/Retainer Assembly........................................................................................................................................................24
Stud Retainer with Castle Nut Assembly...............................................................................................................................24
Rack Bushing Assembly........................................................................................................................................................24
Motor/Gearbox Assembly......................................................................................................................................................25
Misc. Components.................................................................................................................................................................26
Drive Arm / Rack Connector Bushing Replacement .............................................................................................27

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2Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]MANUL850
Belanger Incorporated Limited Warranty
LIMITED WARRANTY: Equipment: Seller warrants to the original purchaser that the goods sold hereunder, which are
fabricated by Seller, shall be free from defects in workmanship and material under normal use and service for a period of 1
year plus 30 days from the date of invoice - CAT®Pumps will be warranted for 2 years from the date of invoice. All
warranties, express, implied, or statutory, pertaining to Seller’s machinery, parts, and equipment are fully set forth
herein. This limited warranty applies to the original purchaser only and is not transferable. No addition to or
modification of any of the provisions of this stated Limited Warranty shall be binding upon the Seller, unless made
in writing and signed by a duly authorized employee of Seller. This warranty is subject to the following limitations:
(1) This warranty shall be void if the factory specifications for operation and maintenance, found in original
equipment manuals, and component manuals, are not followed, or if other than factory authorized erection,
alterations or modifications are made to any parts or equipment; (2) Defective parts are warranted to the Purchaser
for repair or replacement through an authorized distributor or value added reseller (VAR) of Seller, or direct with
Seller for a period of 13 months from the date of invoice. Parts warranty excludes all claims for failure resulting
from normal wear and tear to the depreciable parts, improper installation, omission of factory specified preventative
maintenance, misuse, abuse, negligence, third party damages, or acts of God. Purchaser agrees to submit to and
assist Seller or its authorized distributor or value added reseller (VAR) in conducting in-warranty inspections of the
machinery and equipment including inspection of any part claimed to be defective by the Purchaser; (3) Labor to
repair or replace parts is warranted to Purchaser during normal business hours through an authorized distributor or
value added reseller (VAR) of Seller, or direct with Seller, for 120 days from date of invoice. Labor warranty
excludes all claims for failure resulting from normal wear and tear to the depreciable parts, improper installation,
and omission of factory specified preventative maintenance, misuse, abuse, negligence, third party damages, or
acts of God. Seller reserves the sole right to make determinations on the above stated limitation. All labor and
service provided beyond the labor warranty period shall be subject to labor charges at the rates established by the
local authorized distributor or value added reseller (VAR) or direct with Seller; (4) This warranty shall be void for all
equipment failures and premature component wear caused by the use of corrosive chemicals in the wash process.
The following list includes some, but not all, of the particularly corrosive chemicals that if used in conjunction with
Belanger equipment will void the warranty: Hydrofluoric Acid, Ammonium Bi-flouride, Bromic Acid, Muriatic Acid,
Sulfonic Acid, Phosphoric Acid, Hydrogen Cyanide, Hydrochloric Acid, Sodium Hydroxide and Chlorinated
Solvents. (5) Seller makes no warranty, express or implied, with respect to the design or operation of any entire
system, in which Seller’s goods sold hereunder are mere components. (6) In no event shall Seller be liable for any
incidental, special, consequential or exemplary damages resulting from the furnishing, performance or use of any
goods or services sold pursuant hereto, whether due to a breach of contract, breach of warranty, the negligence of
Seller or to otherwise; not for loss of business; inconvenience, or property damage of any kind; not for any
damages of whatever nature resulting in any way from the purchaser’s selection and use of any chemicals not
manufactured exclusively by seller but used with the purchased goods; or for any service not expressly provided
herein related to or arising from the equipment or goods sold. This limitation of liability extends to purchaser’s use
of any engineering recommendations, sales representations, technical assistance, advice or data supplied by seller
to purchaser in connection with the goods or services supplied, other than that information contained in Belanger
manuals.
Parts: Seller warrants to the original purchaser that the Replacement Parts sold hereunder, shall be free from
defects in workmanship and material under normal use and service for a period of 30 days from the date of invoice.
This limited warranty applies to the original purchaser only and is not transferable. (1) This warranty shall be void if
the factory specifications for operation and maintenance are not followed; (2) Parts warranty excludes all claims for
failure resulting from normal wear and tear to the depreciable parts, improper installation, omission of factory
specified preventative maintenance, misuse, abuse, negligence, third party damages, or acts of God. (3) This
warranty shall be void for all replacements parts failures and premature component wear caused by the use of
corrosive chemicals in the wash process. The following list includes some, but not all, of the particularly corrosive
chemicals that if used in conjunction with Belanger replacement parts will void the warranty: Hydrofluoric Acid,
Ammonium Bi-flouride, Bromic Acid, Muriatic Acid, Sulfonic Acid, Phosphoric Acid, Hydrogen Cyanide,
Hydrochloric Acid, Sodium Hydroxide and Chlorinated Solvents.
THIS LIMITED WARRANTY FOR EQUIPMENT AND REPLACEMENT PARTS IS EXPRESSLY IN LIEU
OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, WHETHER STATUTORY OR OTHERWISE,
INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE.
Copyright © 2000 by Belanger, Inc. All rights reserved. No part of this work may be reproduced or transmitted in any form or by
any means, electronic or mechanical, including photocopying and recording, or by any information storage or retrieval system,
except as may be expressly permitted by the 1976 Copyright Act. Revised as of 8-15-01. Belanger reserves the right to change or
modify the Belanger Inc. Limited Warranty without notice.

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1MANUL850 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]
Operational Warning
Formulations containing the chemicals listed below are particularly dangerous and should not
be used even at low concentrations:
•Hydrofluoric Acid
•Ammonium Bi-flouride
•Bromic Acid
•Muriatic Acid
•Sulfonic Acid
•Phosphoric Acid
•Hydrogen Cyanide
•Hydrochloric Acid
•Chlorinated Solvents
Belanger, Inc., does not endorse or condone the use of chemicals that are potentially
dangerous to human health, the environment or property. Belanger recognizes that it is the
right and sole decision of the end user operators of our equipment as to the type and dilution
ratio of the chemicals used in their facilities. We strongly recommend that the end user does
not select products containing any of the chemicals listed above as an ingredient in the wash
solutions. The chemicals listed above are potentially dangerous to human health, and have a
detrimental, deteriorating effect on the equipment and the facility. Be advised that a portion of,
or all of your warranty will be voided if you determine to use any of the chemicals listed above
as an ingredient in the wash solutions in conjunction with your Belanger automatic car wash
equipment:
Limitation (4), of Paragraph (8), Limited Warranty, of the Belanger Terms and Conditions of
Sales describes the potential limitation of warranty due to your chemical selection:
(4) This warranty shall be void for all equipment failures and premature component wear
caused by the use of corrosive chemicals in the wash process. The following list includes
some, but not all, of the particularly corrosive chemicals that if used in conjunction with
Belanger equipment will void the warranty: Hydrofluoric Acid, Ammonium Bi-flouride,
Bromic Acid, Muriatic Acid, Sulfonic Acid, Phosphoric Acid, Hydrogen Cyanide, Hydrochloric
Acid, and Chlorinated Solvents. The Purchaser also agrees to accept the responsibility and
liability for the selection and use of any chemicals listed above;
However, should the end user decide to use formulations containing any of the above
ingredients, the end user should institute a comprehensive training program and implement
detailed operational parameters within their organization for the proper handling and treatment
of such products to minimize the potential dangers involved. Consult your chemical supplier for
assistance in establishing operational guidelines in the use of their products. MSDS (Material
Safety Data Sheet) should be obtained from the chemical supplier before using any chemical
formulation.
CAUTION
During the installation process the installer is responsible for re-tightening ALL
lugs, set screws and terminals located in the electrical panels. Components may
vibrate loose during shipping.

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4Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]MANUL850
Introduction
Important Safety Information
This section introduces the hazard and safety precautions associated with installing, maintaining or servicing this product.
Before performing any task on this product, read this safety information and the applicable sections in this manual, where
additional hazards and safety precautions for your task may be found. Electrical shock could occur and cause death or
serious injury if these safe service procedures are not followed.
Safety Symbols and Signal Words
Alert Symbol
This safety alert symbol is used in this manual and on warning labels to alert you to precautions which
must be followed to prevent potential personal safety hazards. Obey safety directives that follow this
symbol to avoid possible injury or death.
Signal Words
The signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards. The
precautions that follow must be followed to prevent death, injury or damage to the equipment.
DANGER
This signal word is used to alert you to a hazard or unsafe practice which WILL RESULT IN
DEATH OR SERIOUS INJURY
This alerts you to a hazard or unsafe practice which COULD RESULT IN DEATH OR
SERIOUS INJURY
CAUTION
This signal word designates a hazard or unsafe practice, which MAY RESULT IN MINOR
INJURY
CAUTION
When used by it self, CAUTION designates a hazard or unsafe practice which MAY RESULT
IN PROPERTY OR EQUIPMENT DAMAGE
Before You Begin
Only trained or authorized individuals knowledgeable in the related procedures should install, inspect, maintain or
service this equipment.
Read the Manual
Read, understand and follow this manual and any other labels or related materials supplied with this equipment. If
you do not understand the procedure, call a Belanger, Inc. representative at 248-349-7010. It is imperative to your
safety and the safety of others to understand the procedures before beginning work.

WAVE ACROSS
1MANUL850 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]
Introduction
IMPORTANT Safety Information – MUST READ
Safety Warnings
DANGER
DISCONNECT MAIN POWER SUPPLY PRIOR TO
SERVICING OR MAINTAINING EQUIPMENT
Belanger recommends that all workers observe the OSHA (U.S. Department of
Labor Occupational Safety & Health Administration) Lockout / Tagout procedure
prior to performing service or maintenance on machinery and equipment. Doing
so will prevent unexpected energization, startup, or release of hazardous energy
while maintenance and servicing activities are being performed.
BE SURE TO OBSERVE OPERATING ENVELOPE.
EQUIPMENT MAY START UNEXPECTICALLY. OVERHEAD,
ROTATING AND/OR MOVING COMPONENTS COULD
RESULT IN SERIOUS INJURY OR DEATH.
BE AWARE OF FOREIGN OBJECTS IN THE AREA
SURROUNDING A ROTATING PIECE OF EQUIPMENT.
OBJECTS MAY BECOME TANGLED WITH EQUIPMENT AND
COULD RESULT IN SERIOUS INJURY OR DEATH.
CAUTION
BE AWARE OF HAZARDS ASSOCIATED WITH
EQUIPMENT INSTALLED ON THE FLOOR
THAT MAY BE A TRIP HAZARD.
It is imperative to your safety and the safety of others to always follow
safe work procedures.

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6Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]MANUL850
Introduction
Congratulations on your purchase of the Belanger, Inc. Wave Across®. The Belanger, Inc. Wave Across®is designed to
operate in only 84” (213.4 cm) of tunnel space. If followed by a rinse arch, an envelope of 116” (294.6 cm) is required.
Available Styles
Part Number Description
WAVE A CROSS-386 Wave Across Wave Mitter, 380V, 60Hz
WAVE A CROSS-50 Wave Across Wave Mitter, 380V, 50Hz
WAVE A CROSS-60 Wave Across Wave Mitter, Standard Voltage
WAVE A CROSS-75 Wave Across Wave Mitter, 575V, 60Hz
The replacement cloth is available in the standard colors: Black, Blue, Green and Red.
The plastic pieces that hold the mitter cloth (“Mitter Waves”) come in Black, Blue, Green, Red and Yellow.
The cloth pieces or the “Mitter Waves” (plastic fins) can be purchased in complete sets or individually.
Contact your local distributor for details.
The purpose of this manual is to familiarize you with the way that the Wave Across®is installed.
The “Installation” section will be used in conjunction with the location diagram, and the Wave Across®drawings. All of
these combined are your guides to installation.
The “Maintenance” section will be used to make sure you can keep your car wash component looking and
functioning like new.
Whether you have already operated a car wash or you are new to our industry, you know the importance of the
appearance of a car wash and its equipment to the customer. Keeping the equipment clean will not only make the
equipment easier to maintain, it will act as an example to your customer to keep their equipment (their vehicle) clean
as well. Replacing the cloth in your tunnel as necessary will also help the image of your wash and keep the customer
coming back.
Read through the entire manual to familiarize yourself with the Wave Across®before installation. When installation is
completed, you will want to keep this manual as a guide to proper maintenance.

WAVE ACROSS
1MANUL850 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]
Introduction
Before You Get Started
Tools needed for installation:
Fork lift (with side shift if available) Lifting straps
Hammer drill with 5/8” bit 50 foot extension cord
Tape measure (25 foot or greater) Safety glasses
Pry bar Work gloves
Level Miscellaneous hand tools
Ladder Tin snips
Equipment included: Qty
Head assembly 1
Support legs 3
Accessory box 1
Cloth 1 complete set
Note: Uncrate and inspect shipment for damage, and to verify that all pieces are there. If there
is any damaged equipment, file a claim with the trucking company immediately. Receiving
party is responsible for filing claim with trucking company. Notify your local distributor
or Belanger, Inc. immediately if shipment is determined damaged or incomplete.

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8Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]MANUL850
Specifications
Requirements
Physical
Tunnel space required 84” minimum
Unit height 126”
Unit width 146”
Utility
Electrical 208/230 – 480 VAC
Water (2) 3/4” pipe @ 6 GPM @ 40 PSI
Output
Physical
Vehicle clearance, height 90”
Vehicle clearance, width 127”
DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE SERVICING ANY
EQUIPMENT.
CAUTION
Always wear safety glasses when performing maintenance on any equipment.
CAUTION
It is recommended that a licensed electrician is contracted to perform all electrical installations.
CAUTION
A compressed Air System should be set correctly to support 90 PSI necessary to operate
equipment, but should never be set to deliver more than 120 PSI air pressure to the Belanger
specified equipment.
Note: YOUR HYDRAULIC SYSTEM MUST BE CAPABLE OF ADJUSTMENT TO 76 RPM
AT 900 PSI WHILE LOADED AGAINST VEHICLE. PLEASE VERIFY YOUR
SYSTEMS CAPABILITY TO MEET THESE SETTING WHILE RUNNING A
VEHICLE PRIOR TO INSTALLING PIECE OF EQUIPMENT!

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1MANUL850 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]
Specifications
Dimensions
Operating envelope when followed by rinse
Standard envelope
The 126” dimension is taken from the floor to the top of the gearbox
126”
116”
84”
146”

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10 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]MANUL850
Installation
Frame Assembly
1) Place the head assembly in its approximate tunnel location. Using a forklift, strap the head
assembly securely to the forks and raise above the height of the support legs.
Note: Be sure to clamp or strap equipment securely to the forks of the forklift before lifting
equipment. Do not stand under load while fork lift is in operation
2) Locate the leg assemblies and secure them to the head assembly using the supplied bolts,
washer and nuts.

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1MANUL850 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]
Installation
Tunnel Placement
When placing a piece of equipment, tunnel depth will vary from site to site. Be sure to allow an adequate operating
envelope. The Wave Across®can be installed facing either direction as there is no entrance or exit side.
1) Position the assembled unit in its permanent tunnel location.
2) While placing a level on the vertical surface of one of the legs, place shims under the base
plate as needed to make the assembly level in both directions. Repeat this leveling process
on the other leg.
Note: Shims not supplied by Belanger, Inc.
3) Once the assembly is positioned correctly and level, lag it to the floor using the supplied lag
bolts.
The 45” dimension is taken from the inside edge of the inside conveyor guide rail to the outside edge of the equipment leg.
Although the main water feed is shown on the driver side, it can be installed on eitherside.
45” Center
Line
DIRECTION
of
TRAVEL

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12 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]MANUL850
Installation
Utilities
Locate the following items:
(2) Copper manifolds, one with a vertical water feed and one without
(1) Section of water hose
(3) Barbed hose fittings
(3) Hose clamps
Water Manifolds Assembly
CAUTION
It is recommended that a licensed plumber is contracted to perform all water installations.
1) Determine the side in which you would like to supply the unit with water.
2) Secure the manifolds to the clamps on the underside of the crossbeam as shown.
Overhead View
3) Locate the barbed hose fittings. Secure one to opening on the underside of each manifold. This is
how one manifold will be fed from the other.
4) Secure the other fitting to the end of the vertical manifold. This is the main water feed.
Note: Fittings require a water sealant. We recommend using Teflon®tape, pipe dope or an
equivalent.
5) Locate the hose clamps and slide two of them onto the supplied 3/4” water hose. Use the water
hose to connect the two manifolds together and slide the hose clamps into position.
6) Slide the third hose clamp onto the hose being used as a main water feed and secure the main
water feed hose to the vertical manifold. Slide the hose clamps into position.
Clamp (typical)Crossbeam
Barbed
hose fitting
(typical)
Teflon®tape
(typical)
Hose Clamp
(typical)
Water feed

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1MANUL850 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]
Installation
Utilities
Electrical
CAUTION
It is recommended that a licensed electrician is contracted to perform all electrical
installations.
1) Supply 3-phase power to the motor on top of the frame assembly.
Overhead View
Gearbox
Motor
Main electrical
feed

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14 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]MANUL850
Installation
Cloth
This section will explain the cloth installation procedure.
Note: Do not install any cloth until all equipment has been installed, turned on and checked for
hydraulic, pneumatic and water leaks.
Locate the following hand tools:
1-1/8” wrench 9/16” socket
5/16” hex wrench Work gloves
3/16” hex wrench Safety glasses
Ladder
Parts Identification Entrance View
Upper drive arm
Lower drive arm
Drive rack Passenger side
follower rack
Center
follower rack
1-1/8” bolt,
(remove for cloth installation, typical)
Retainer pin
(typical)
Pitman
arm

WAVE ACROSS
1MANUL850 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]
Installation
Cloth
Helpful Hint
Collar Placement
Placement typical on all six bearings (Overhead view of Head Frame)
DO NOT LOOSEN ANY OF THE SIX
COLLARS DURING CLOTH
INSTALLATION OR REPLACEMENT!
If circumstances require doing, so see
dimensions below
Overhead View
Collar Assembly
Collars are to be butted up
against the side-plates Collars are to be butted up against the side-plates

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16 Belanger, Inc. * 1001 Doheny Ct. * Northville, MI 48167 * Ph [phone] * Fax [phone]MANUL850
Installation
Cloth
In order to install the cloth, some disassembly is necessary. Pay attention to how the machine is taken apart.
1) Loosen the upper locking collar on the drive rack with a 3/16” hex wrench and slide it over against
the flat washer.
2) Loosen lower locking collar of the drive rack using a 5/16” hex wrench.
3) Slide lower locking collar out away from rack and butt it against the plastic end cap.
Side View
Lower locking
collar (typical)
1-1/8” bolt,
(remove for cloth installation, typical)
Cloth
(typical)
Plastic end cap
(typical)
Upper drive arm
Upper locking collar 1-1/8” bolt,
(remove for cloth installation, typical)
Shaft
bearing
(typical)