Page 11 - FreeStyler® Maintenance Manual

®
MAINTENANCE

Table of Contents

Chapter 1 Introduction ............................................................................................................... 1-1
Operational Warning.................................................................................................................................. 1-1
Important Safety Information ..................................................................................................................... 1-2
Safety Symbols and Signal Words ............................................................................................................ 1-2
IMPORTANT Safety Information – MUST READ ....................................................................................... 1-3
Document Overview .................................................................................................................................. 1-5
UL Information ........................................................................................................................................... 1-6
Warranty Information ................................................................................................................................. 1-7

Chapter 2 Preventative Maintenance ........................................................................................ 2-1
Support Equipment .................................................................................................................................... 2-1
Daily Inspection List ................................................................................................................................... 2-1
Monthly Inspection List .............................................................................................................................. 2-2
Periodic Inspection List .............................................................................................................................. 2-3
Maintenance Checklist............................................................................................................................... 2-5
Maintenance Management Report ............................................................................................................ 2-6
VPS® Photo-Eye ..................................................................................................................................... 2-15
General Input Locations .......................................................................................................................... 2-15
Main and Coalescent Filters .................................................................................................................... 2-17
Greasing the Bearings ............................................................................................................................. 2-18
Inspecting the Carriage Rollers ............................................................................................................... 2-19
Pumping Station Drive Belt Replacement and Tightening ....................................................................... 2-20
Pumping Station Float Valve ................................................................................................................... 2-23
Pumping Station Float Valve Seal Replacement Kit #105884 ................................................................. 2-24
Hydraulic Hose Information ..................................................................................................................... 2-33
Foaming Pod Connections ...................................................................................................................... 2-34
Chapter 3 General Repairs ......................................................................................................... 3-1
Torque Values ........................................................................................................................................... 3-1
Gearboxes ................................................................................................................................................. 3-2
Powder Coating Maintenance .................................................................................................................... 3-2
Powder Coating Repair .............................................................................................................................. 3-3
Pumping Station ........................................................................................................................................ 3-5
Repair Section Overview ........................................................................................................................... 3-7
Top View of the Carriage with all Wired Components ............................................................................... 3-7
View of Water/Chemical Valves ................................................................................................................ 3-9
Bearing Replacement .............................................................................................................................. 3-10
How to Disassemble the Top Wheel for Repairs ..................................................................................... 3-12
Top Wheel Troubleshooting .................................................................................................................... 3-15
Changing a Roller or Drive Shaft ............................................................................................................. 3-18
Replacing a Bent Shaft or Wheel Bearing ............................................................................................... 3-21
Replacing a Motor/Gearbox Assembly .................................................................................................... 3-23
Replacing an Arm Rotation Bearing ........................................................................................................ 3-27
Replacing a Pivot Shaft Assembly ........................................................................................................... 3-27
Inside the Pods ........................................................................................................................................ 3-30
Manifolds and Wiring ............................................................................................................................... 3-38
Spot Free (RO) ........................................................................................................................................ 3-38
Pulsatron™ Suction and Discharge Valve - Replacement Procedure ..................................................... 3-55
Metering Pumps ....................................................................................................................................... 3-56
Wheel Cleaning Pump ............................................................................................................................. 3-76
Water Softener ........................................................................................................................................ 3-90
Torque Plate and Electric Motor Replacement ...................................................................................... 3-110
Optional On-Board Dryer ....................................................................................................................... 3-114
Optional On-Board Dryer Motor Maintenance Supplied by Baldor® ...................................................... 3-119

1MANUL222 Belanger, Inc.® * PO BOX 5470 * Northville, MI 48167-5470 * Ph (248) 349-7010 * Fax (248) 380-9681