softgloss maxx installation manual work order #...

RYKO Manufacturing Co. 11600 N. W. 54th

Avenue Grimes, IA 50111 515-986-3700

SOFTGLOSS MAXX

INSTALLATION MANUAL

Work Order # 7984380

For Model: 99069060

Page i

RYKO SoftGloss Maxx Installation Manual


THIS MANUAL CONTAINS INSTRUCTIONS FOR INSTALLING A RYKO SOFTGLOSS MAXX VEHICLE WASH

SYSTEM IN A NEW OR EXISTING BAY.

ATTENTION! SAFE WORKING CONDITIONS AND PRINCIPLES MUST BE CONSIDERED PREVIOUS TO

UNLOADING THE MACHINE AND CARRIED OUT DURING ALL PHASES OF ITS ASSEMBLY AND

INSTALLATION. READ AND ADHERE TO ALL CAUTION, WARNING AND SAFETY NOTES AND PROCEDURES

GIVEN IN THIS MANUAL. RYKO MANUFACTURING COULD NOT POSSIBLY KNOW, EVALUATE, AND ADVISE

THE SERVICE TRADE OF ALL CONCEIVABLE WAYS THAT SERVICE MAY BE PERFORMED, OR OF THE

POSSIBLE HAZARDS OF EACH. ACCORDINGLY, WHEN USING A SERVICE PROCEDURE THAT IS NOT

RECOMMENDED IN THIS PUBLICATION BE CERTAIN THAT NEITHER PERSONAL NOR VEHICLE SAFETY, IS

JEOPARDIZED BY THE SERVICE METHODS SELECTED.

CAUTION! INSTALLATION OF THIS EQUIPMENT REQUIRES PERSONNEL TO

CONNECT HIGH VOLTAGE WIRING AND TO WORK ABOVE FLOOR LEVEL.

EXTREME CARE MUST BE EXERCISED FOR PERSONAL SAFETY. FOLLOW

LOCAL CODES AND SAFETY REGULATIONS.

RYKO RECOMMENDS THAT A QUALIFIED RYKO TECHNICIAN PERFORM ALL INSTALLATION AND SERVICE

MAINTENANCE OF THIS EQUIPMENT. INSTALLATION OR SERVICE MAINTENANCE OF THIS EQUIPMENT BY

ANY PARTIES NOT VERSED IN ITS INSTALLATION, MAINTENANCE AND OPERATION COULD VOID THE

WARRANTY.

STUDY SPECIFICATIONS AND REQUIREMENTS FOR INSTALLATION OF THE MACHINE AND ANY

ASSOCIATED EQUIPMENT CAREFULLY BEFORE PROCEEDING WITH ANY INSTALLATION.

Page ii



CONTENTS

GENERAL INFORMATION ..................................................................................................................... 1 FOR YOUR SAFETY ............................................................................................................................... 1

CONTROL PANEL DOOR ACCESS AND PROTECTION ............................................................................................................. 3 “CAUTION” AND “WARNING” DECALS ....................................................................................................................... 3

BASIC REQUIREMENTS AND SPECIFICATIONS ................................................................................. 3 ELECTRICAL REQUIREMENTS ................................................................................................................................. 3 AIR REQUIREMENTS ................................................................................................................................................ 5 WATER REQUIREMENTS ......................................................................................................................................... 5 PHYSICAL SPECIFICATIONS .................................................................................................................................... 5 ACCEPTABLE VEHICLE DIMENSIONS..................................................................................................................... 5 RECOMMENDED BAY DIMENSIONS ..................................................................................................................................... 6 MISCELLANEOUS ..................................................................................................................................................... 7 ELECTRICAL TESTING LABORATORIES (ETL) LISTING ................................................................................................. 7

INSTALLATION ...................................................................................................................................... 8 TRACK INSTALLATION .......................................................................................................................... 8 MACHINE, EQUIPMENT, AND PARTS INSTALLATION ......................................................................... 9 END STOP PROXIMITY SWITCH TRIP PLATE INSTALLATION, ADJUSTMENT AND TESTING ........ 11

END STOP PROXIMITY SWITCHES AND TRIP PLATE ADJUSTMENT ...................................................................................... 11 AND TESTING PROCEDURES .......................................................................................................................................... 11

ELECTRIC, WATER, AND AIR CONNECTIONS................................................................................... 12 WIRING OPTION OUTPUTS TO THE PLC ........................................................................................... 12 PHOTOELECTRIC INSTALLATION -- WHEEL SCRUB ........................................................................ 12 RYKO ADDITIVE SYSTEM (WITH BLUE WHITE PUMPS) ................................................................... 13

ADDITIVE PUMP PRIMING ................................................................................................................................................ 13 ADDITIVE SYSTEM INSTALLATION (NON-RYKO CHEMICAL WITH PULSAFEEDER PUMPS) ......... 14

ADDITIVE SYSTEM CONNECTIONS .......................................................................................................................... 14 ADDITIONAL ADDITIVE SYSTEM INFORMATION.......................................................................................................... 14

PRODUCT, ACCESSORY AND OPTION INSTALLATION .................................................................... 14 FIXED UNDERCAR WASH ................................................................................................................... 14 DOOR KIT WITH LOOP DETECTION INSTALLATION ......................................................................... 16

LOOP DETECTION ADJUSTMENTS (DELUXE MODEL) ........................................................................................................ 17 MODE (FREQUENCY) SWITCH........................................................................................................................................ 17 AUTOMATIC REVERSE SAFETY SWITCH ............................................................................................................. 17

DOOR KIT WITH PHOTOELECTRIC INSTALLATION .......................................................................... 17 COVER OPTION INSTALLATION ......................................................................................................... 18 MANUAL DRIVE KEY SWITCH OPERATION ....................................................................................... 18 TOP BRUSH PROXIMITY SWITCH / COUNTERWEIGHT ADJUSTMENT ............................................ 18 U.S. / METRIC CONVERSION INFORMATION .................................................................................... 20 INSTALLATION TOOL CHECK LIST..................................................................................................... 22

DRAWINGS:

Hose Connection Boom Assembly Installation ........................................................................ 12189-007

Maximum Operating Space .................................................................................................... 12515-015

Photoeye Door Kit Bay Instructions ......................................................................................... 12846-007

Loop Door Kit Bay Instructions ............................................................................................... 12846-008

ThrustPro Dryer Installation without PLC, 46' Bay & Less ....................................................... 12981-011

Field Wiring, Stop & Go Light Assembly .................................................................................. 13421-003

OnBoard Dry Phase Generator Kit ........................................................................................... 13563-011

Rainmaker III Installation, with Repressurization, 1 Tank ......................................................... 14149-015

Photoelectric Installation ......................................................................................................... 16573-003

Top Brush Cover Kit Installation .............................................................................................. 16964-509

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Standard Bay Installation, Fixed UnderCar .............................................................................. 16974-003

Standard Bay Installation, Fixed UnderCar, Trench .................................................................. 16974-007

Backlight Box Instl/SoftGloss Maxx ........................................................................................... 17612-502

Field Wiring Manual Activation Packages ................................................................................. 18043-013

Loop Assembly Installation ..................................................................................................... 18551-000

Frost Alarm Installation, SoftGloss MAXX ............................................................................... 19100-503

Boost Pump System Installation, SoftGloss MAXX ................................................................. 19160-507

Field Wiring, Wash Bay Terminal Box ..................................................................................... 19915-036

Rust Inhibitor Installation ........................................................................................................ 19935-500

Cover Option Installation, No Wheel Scrub with Wheel Blaster ................................................ 19983-500

Cover Option Installation, Wheel Scrub with Wheel Blaster ..................................................... 19983-501

Cover Option Installation, Packaged ....................................................................................... 19983-514

Cover Option Installation, Dry ................................................................................................. 19983-520

Cover Option Installation, Dry, with TriFoam Detergent ............................................................ 19983-523

Cover Option Installation, Ultrasonic Bracket Assembly ........................................................... 23329-500

Cover Option Installation, No Dry ............................................................................................ 19983-540

Cover Option Installation, No Dry, with TriFoam Detergent ....................................................... 19983-543

Cover Option Installation, Tall Front Arm ................................................................................. 19983-552

Cover Option Installation, Wheel Scrub .................................................................................. 19983-560

Cover Option Installation, No Wheel Scrub ............................................................................. 19983-580

Chemical Float Switches Field Wiring ..................................................................................... 20034-000

Machine with Existing EV II Field Wiring ................................................................................. 20224-000

Panel/Elec, SG MAXX, FX3U ................................................................................................... 20242-007

Heat Shield Kit Installation ...................................................................................................... 20354-500

Tire Chemical Sprayer Installation ............................................................................................ 20411-500

Wash Bay Terminal Box Installation ........................................................................................ 20500-000

OffBoard Auxiliary Heater Kit Installation ................................................................................. 20525-500

Wiring Diagram/ONBD Chm Flt SW ......................................................................................... 20542-000

Communication Interface Box Field Wiring,Touch Screen ........................................................ 20816-001

CMD Sign Installation ............................................................................................................... 20817-000

Track, Rail and Bay Switch Installation .................................................................................... 20925-003

Frost Protection, R.O., WW Auxiliary Solenoid Installation ...................................................... 20978-505

Field Wiring/ Expanded Diagnostics, Chm, Jump ..................................................................... 21001-002

Frost Protection Solenoid Accessory Installation ..................................................................... 21085-500

OffBoard Chemical Monitor Expanded Diagnostics Installation ................................................ 21158-003

Installation Start-Up Test Procedure, Fixed UnderCar Wash ............................................. 21179-006

Installation Start-Up Test Procedure, Raimaker III, Voyager II, SoftGloss MAXX .............. 21179-160

Installation Start-Up Test Procedure, Offboard Auxiliary Boost Pump .............................. 21179-191

Installation Start-Up Test Procedure, Oscillating Rocker Panel Blaster, SoftGloss MAXX 21179-213

Installation Start-Up Test Procedure .................................................................................... 21179-255

Typ Bay Instl/Foam Tire Ch,SG ................................................................................................ 21209-101

Field Installation with EVII-A .................................................................................................... 21454-000

Installation Instructions, Pre-Wash ......................................................................................... 22264-002

FoamBrite Brush Assembly Instructions ................................................................................ 22518-001

Installation Instructions, Short Bay Option ............................................................................... 22738-501

Lighted Menu Sign Installation ................................................................................................ 25009-001

Lighted Menu Sign Installation, Tall ......................................................................................... 25009-003

Sign Installation, Lighted, 3 Message with Floodlight ............................................................... 25130-000

Sign Installation, Lighted 8 Segment Sign ............................................................................... 25130-001

Installation Instructions/Arch,Affinity ......................................................................................... 27657-000

Pivoting Wheel Blaster Installation, Entrance, SoftGloss MAXX ................................................ 27701-000



GENERAL INFORMATION

FOR YOUR SAFETY

All personnel installing, maintaining or operating this equipment should read and observe the following

safety information. They should also read and be familiar with safety directives provided regarding

specific procedures throughout this manual.

When installing RYKO equipment, the installation must comply with local, state, and national

building codes. If in question, consult local building code authorities for additional information.

The bay should be kept clean at all times. Proper bay cleaning will reduce the possibility of slipping

or similar accident in the car wash bay. Cleaning is the responsibility of the car wash operator.

No one should climb or stand on this equipment for any reason.

In an emergency, it is important to know how to stop this equipment quickly. An emergency stop

can be made by pressing the Emergency Stop Switch. The Emergency Stop Switch is installed

in a convenient location (normally on the wall), that is compatible to the wash operation and that will

allow immediate access by the car wash owner/operator should a need to stop the machine be

required. Review and learn procedures for use of this switch with your RYKO service technician at

the time of installation. Also, be sure all personnel that are involved with operation of the machine are

trained to know when and how to use this switch.

All personnel should read; be familiar with; and observe the "CAUTION" AND "WARNING" decals

and labels placed on the equipment and its various parts. See “CAUTION” AND “WARNING”

illustrations given in this manual.

All persons should stay clear of the equipment when it is operating or in motion.

All shields, guards, nuts, bolts, and screws should be kept in place and securely tightened.

A padlock and key are provided for the specific purpose of locking each control panel. Be sure to

lock the electrical panel with the padlock provided, except when servicing. Only authorized personnel

should have access to the key.

To prevent undesired movement of the machine on the track, always logoff the Communication

Interface after accessing the site or technician screen. Only authorized personnel should have

access to the passwords for the Communication Interface box.

208/230V operated machines may have 2 electrical power supplies. 460V operated machines have

2 electrical power supplies. The power disconnect switch may not completely de-energize high

voltage power to the machine. Disconnect all power supplies before servicing. To verify that high

voltage has been disconnected, check the voltage with a volt meter on each circuit. If a volt meter is

not available:

1. Turn off high voltage at remote electrical panel.

2. Operate the manual drive switch.

a) If no "clicking" of contactors, go to Step 3.

b) If "clicking" of contactors is heard, locate the second source for power and shut power off.



3. Pull the top brush down. If

a) the proximity switch indicator light does not light, the power is off.

b) the proximity switch indicator light is on, locate the second source for power and shut off the

power.

SERVICE PERSONNEL ARE TO PERFORM LOCKOUT AND TAGOUT SAFETY REQUIREMENT

PER OSHA REGULATIONS 29 CFR 1910.147 and 1910.331 through 1910-335.

Use a safe, sturdy ladder of sufficient height to access any part of the machine that cannot be

conveniently reached from the ground.

Never place hands in any moving portion of the equipment.

Never walk under the top brushes or blowers while the equipment is operational.

Always keep eyes away from blower nozzles during dry cycle and "run-down" of fan.

Use appropriate protective gear when handling chemicals and solvents. Refer to directions on

chemical and solvent container labels.

Always handle and dispose of empty chemical containers properly. Refer to the label on each

container for chemical handling and disposal guidelines.

When substances or combustible materials (such a gas, gas fumes, oil, etc.) come in contact with

electrical equipment, fire prevention measures and appropriate safety precautions must be taken.

When installing or operating any RYKO equipment, adhere to all fire and safety rules/regulations

according to local, state, and national authorities.

For customer safety and to help prevent damage to vehicles and/or the machine, the RYKO warning

sign should be installed at the wash bay entrance. If the RYKO sign is to be replaced by a customer

designed warning sign, the following instructions should be included:

Close Windows And Remain In Vehicle While Equipment Is Operating Or In Motion.

Do Not Use If Vehicle Has Body Damage, Loose Chrome, Or Non-Standard Accessories (e.g., Loose Bug

Deflector Shields, Exterior Windshield Visors).

If Vehicle Has Large or Wide Tires That Extend Beyond The Body Of The Vehicle, Do Not Use.

Do Not Wash Vehicles With Exposed Propane Or Compressed Gas Tanks Or Loose Items In Pickup Beds.

Retract Or Lower All Antennae Or Aerials.

Leave Wipers Off.

Fold In Pickup And Van Mirrors.

Confirm That All Latching Parts (Doors, Hoods, Trunk Lids, Tailgates, Etc.) Are Secured.

Drive In Slowly Until STOP/GO Device Indicates STOP Condition.

Place Gear Selector In Park Or Engage Parking Brake.



Drive Out Slowly When STOP/GO Device Indicates GO Condition.

Due To A Wide Variety And Conditions Of Vehicles, Operator Is Not Responsible For Damage Or Injury.

CONTROL PANEL DOOR ACCESS AND PROTECTION The plastic control panel doors on the inside of the machine gantry are secured by a double protection

system to prevent the doors from opening accidentally during SoftGloss MAXX operation. A rubber draw

latch stretches over the door opening and fastens the doors shut. This large black latch provides easy

visual evidence that the doors are secured.

A plastic half clamp, attached to the Dry/No Dry cover above the control panel doors provides a

secondary safety device by blocking access to the control panel. A label affixed to the clamp instructs the

operator to "PUSH UP" while holding the clamp. Pushing up gently on the clamp raises both the Dry/No

Dry cover and the clamp enough to allow the control panel doors to open.

“CAUTION” AND “WARNING” DECALS “CAUTION” and “WARNING” decals are attached in or on this and associated equipment in various

locations. All personnel should read; be familiar with; and observe these “CAUTION” AND “WARNING”

labels. Replace the decals if they become damaged or illegible.

BASIC REQUIREMENTS AND SPECIFICATIONS

For proper operation customer-provided utilities should meet the minimum utility requirements

that follow.

Note: Metric conversion information is provided in this manual for your convenience. Refer to the Table of

Contents.

ELECTRICAL REQUIREMENTS 208/230V AC, 60 HZ, 3 Phase, and

120V AC, 60 HZ, 1 Phase, OR

460V AC, 60 HZ, 3 Phase, and

120V AC, 60 HZ, 1 Phase



AMPERAGE ELECTRICAL REQUIREMENTS

The following amperage requirements are recommended for electrical service that will be installed with

time-delay protective fuse. For electrical service with an inversed time breaker consult with a RYKO

Customer Service Representative for additional information.

ONBOARD

Electrical Requirements: Basic: 35 Amps at 208/230 V.

3 Phase Service 15 Amps at 460V.

With Hot Wax: 45 Amps at 208 V. 40 Amps at 230 V. 20 Amps at 460 V.

With OnBoard Dryers: 100 Amps at 208 V. 90 Amps at 230 V. 45 Amps at 460 V.

Separate Power Supply:

Single Phase Service

Additional Requirements (Required on all machines)

15 Amps at 120 V.

OFFBOARD

Electrical Requirements: Off-Board Boost Pump: 15 Amps at 208/230 V.

(Additional requirements for offboard optional equipment)

NOTE: If an Off-Board auxiliary boost pump is installed with this

machine an additional, separate 3 phase service is required.

Pre-Wash Pump 15 Amps at 208/230V. 15 Amps at 460V.

Oscillate Motors 15 Amps at 120V.

NOTE: If a Pre-Wash with pump is installed with this machine

additional and separate 3 phase and 1 phase services are required.

To determine the appropriate electrical service requirements for the machine, choose the highest

amperage requirement at the appropriate voltage level that includes the options installed. For example, a

208V machine with a Hot Wax option but without an onboard dryer requires 45 amps. However, a 208V

machine without the Hot Wax option but with an onboard dryer requires 100 amps.

NOTE: 100 AMPS is only required if the On-Board Dry option (machine mounted fans) is installed. If

the Free-Standing Dryer option is installed, additional electrical requirements will be necessary. To

determine the amperage requirement for a free-standing dryer, refer to the Installation Manual for the

freestanding dryer.

Note: Always refer to the drawings and manuals which are shipped with an option for detailed information.

PHASE GENERATOR

At a site where only single phase service is available, a phase generator may be installed to convert

single phase service to three phase service to meet machine requirements.

Electrical Requirements: Machine with On-Board Dryer (with or without Reclaim):

175 Amps at 230 V, single phase



AIR REQUIREMENTS The air requirements that follow are applicable to both the Standard program and the Fast program.

SOFTGLOSS MAXX BASIC WASH UNIT ONLY

Minimum 3/8" ID line at 100 PSI at 3 CFM flow.

Maximum pressure of 125 PSI at 3 CFM flow.

(Minimum and maximum listed also apply to all options below.) With Foam Bath 4 CFM With UnderCar Wash 4 CFM With Foam Bath and UnderCar Wash 4 CFM With TriFoam Wax or TriFoam Detergent 4 CFM With Dry Option and Frost Protection 5 CFM

WATER REQUIREMENTS Minimum 1" service at 40 PSI with 35 GPM flow rate.

Maximum 1" service at 150 PSI with 40 GPM flow rate.

IMPORTANT: THE UNDERCAR WASH OPTION REQUIRES 27 GPM IN ADDITION TO THE FLOW

REQUIREMENTS LISTED ABOVE.

IMPORTANT: THE PRE-WASH OPTION DOES NOT REQUIRE ADDITIONAL GPM, BUT DOES INCREASE

WATER USAGE. THE PRE-WASH IS A SEPARATE PASS WHICH USES 35 GPM.

IMPORTANT: THERE SHOULD BE NO RESTRICTIONS IN THE AIR OR WATER LINES.

PHYSICAL SPECIFICATIONS Standard RYKOwash SoftGloss MAXX machines have the following specifications:

Length: 11' 4"

Width: 12' 9-1/8" with brushes idle 14’ 10" with brushes spinning

Height: 10' 4-1/2" Machine with Boom Mounted 8' 9 1/2" Machine Only 11' 1-1/2" with Top Brush spinning Height dimensions listed, represent the machine when positioned on the tracks.

Weight 3255 pounds (machine only)

3755 pounds (with OnBoard Dry)

3500 pounds (with Wheel Scrub)

4000 pounds (with OnBoard Dry and Wheel Scrub)

IMPORTANT: WEIGHTS LISTED ARE DRY WEIGHTS AND WITHOUT SHIPPING SKIDS AND SHIPPING

PACKAGING. NOTE: SHIPPING SKIDS AND SHIPPING PACKAGING ADD ABOUT 450 POUNDS.

Note: The Dry option, as it pertains to specification or dimensions, is in reference to a machine with onboard dryer

fans. If the dry option is a free standing system (ThrustPro or SlimLine), specifications will differ.

ACCEPTABLE VEHICLE DIMENSIONS RYKO SoftGloss MAXX systems WILL accommodate vehicles within these dimensions only.

Length: 19' 0"

Width (body): 95"

Width (tire to tire): 80"

Height: 84"



RECOMMENDED BAY DIMENSIONS

IMPORTANT: MACHINE OPERATIONS DESCRIBED IN THIS MANUAL PERTAIN TO EQUIPMENT INSTALLED

IN BAYS CONSTRUCTED TO RECOMMENDED DIMENSIONS. OPERATIONS MAY ALTER SLIGHTLY WHEN

EQUIPMENT IS INSTALLED IN BAYS CONSTRUCTED TO LESS THAN RECOMMENDED DIMENSIONS.

MINIMUM RECOMMENDED

Width: With or Without Onboard Dry 13' 6" (4115 mm) 16' 0" (4875 mm)

With Aluminum ThrustPro Dryer 13' 6" (4115 mm) 16' 0" (4875 mm)

With Aluminum SlimLine Dryer 13' 6" (4115 mm) 16' 0" (4875 mm)

With Stainless Steel Overhead Dryer

13' 6" (4115 mm) 16' 0" (4875 mm)

Adjustable up to

18' 0" (5485 mm)

With Stainless Steel SlimLine Dryer

13' 6" (4115 mm) 16' 0" (4875 mm)

Adjustable up to

18' 0" (5485 mm)

Length: With or Without Onboard Dry 32' 9" (9980 mm) 34' 3" (10,440 mm)

Required length when

using Auto Door Kit with

Photo Eyes.

34' 9" (10,950 mm)

With Optional 2' 0"

(610 mm) Track

Extensions

36' 3" (10,975 mm)

Required length with

Optional 2' 0" (610 mm)

Track Extensions

With Aluminum ThrustPro Dryer * 42' 6" (12,955 mm) * 50' 6" (15,930 mm)


and Stainless Steel Fascia

* 42' 8" (13,005 mm) * 55' 8" (16,965 mm)


and Plastic Fascia

* 42' 4" (12,905 mm) * 55' 4" (16,865 mm)

With Aluminum SlimLine Dryer * 34' 1" (10,390 mm) * 47' 1" (14,350 mm)

With Stainless Steel SlimLine Dryer * 37' 1" (11,305 mm) * 50' 1" (15,265 mm)

Height: For All SoftGloss MAXX and Select-A-

Wash Applications

11' 4" (3455 mm) 12' 0" (3660 mm)

* For Wash Bays With 2' 0" (610 mm Optional Track Extensions Add 2' 0" (610 mm) to this

length.



MISCELLANEOUS 1. Check all bolts for tightness and gear boxes for proper oil levels.

2. Two hasps are located on the side of the control panel door to allow the operator to lock the door. A

padlock and keys (2) are located in the shipping kit for this purpose. This feature helps to prevent

unauthorized personnel from gaining access to the control panel. These keys should be kept in the

possession of authorized personnel.

3. The machine may be moved manually to any location on the tracks by using the manual drive forward

or reverse button from the Communication Interface box.

CAUTION! ONLY USE THE MANUAL DRIVE WHEN THE MACHINE IS IN THE

"AT REST" POSITION.

ELECTRICAL TESTING LABORATORIES (ETL) LISTING A label on electrical industrial control panels indicates compliance with Underwriters Laboratories (UL)

standards and listing with Electrical Testing Laboratories.

ELECTRICALTESTING LABORATORIES (ETL)

CONTROL NUMBER 3036523

Listing details are available at www.etlsemko.com

CAUTION: WHEN REPLACING PARTS OR COMPONENTS IN THE ELECTRICAL

INDUSTRIAL CONTROL PANEL, USE IDENTICAL OR SIMILARLY RATED PARTS OR

COMPONENTS. REPLACEMENT OF ORGINAL EQUIPMENT WITH PARTS OR

COMPONENTS NOT IDENTICAL OR SIMILARLY RATED MAY VOID THE E.T.L.

LISTING AND COULD POTENTIALLY CAUSE ELECTRICAL SAFETY HAZARD.



INSTALLATION

TRACK INSTALLATION

OSHA INSTALLATION REQUIREMENT: IMPORTANT! The Occupational Safety and Health Administration

(OSHA) has issued regulations, 29 CFR 1910.147, requiring the use of locks and/or tags prior to performing service or maintenance on equipment and machinery. A lockout is a device that provides positive means for rendering a switch, valve, raised load, coiled spring or any energy source, (air, water, or electric) inoperative. Lockout is a necessary step for ensuring worker safety prior to performing maintenance or service. For this reason lockouts and/or tags must be used per OSHA regulations, 29 CRF 1910.147. If in doubt on these required regulations, contact a local RYKO representative for assistance,

previous to proceeding with installation.

For proper placement and installation of the machine tracks (pipe and risers) refer and adhere to the

Steps that follow and to the Track, Guide Rail and Bay Switch Installation drawing.

1. Each set of tracks consists of two (2) long track pipes and risers and two (2) short track pipes and

risers.

2. Installation of the tracks must be level from one end of the bay to the other.

3. Install one long and one short track riser to form one side of the tracks. Repeat this same assembly

for the other side of the bay. On completion of installation the tracks must be 11' apart from center to

center.

IMPORTANT: THE TRACK RISER MUST BE PARALLEL AND LEVEL. IT MAY BE NECESSARY TO PLACE

SHIMS UNDER THE TRACK FEET TO LEVEL THE TRACK RISERS.

4. After the track risers are installed lay one long and one short section of track pipe in each riser.

IMPORTANT: DO NOT INSTALL THE TRACK PIPE SO THAT A SPLICE BETWEEN THE TRACK PIPES IS

LOCATED OVER A SPLICE OF THE TRACK RISERS. IF THIS OCCURS, SWITCH THE POSITIONS OF THE

LONG AND SHORT TRACK PIPES.

5. With the track pipe laying in the angle of the riser, slip the section of pipe with the deburred end over

the extended splice in the other section of track pipe. Next, tap on the end of the track pipe with a

hammer until the deburred end of the pipe butts up snug with the splice end.

6. Drill through the track pipe end using the collar as a drill guide.

7. Install a bolt (provided) through the collar hole of each riser clamp and through the existing hole in

the track pipe. Thread the nut and tighten. Repeat this procedure at the other end of the track.

IMPORTANT: WHEN SECURING EACH END OF THE TRACK PIPE IN THE RISER CLAMP, IT IS VERY

IMPORTANT NOT TO TIGHTEN THE NUT ON THE BOLT TOO TIGHTLY. TIGHTEN JUST ENOUGH SO A

COUPLE OF SCREW THREADS EXTEND PAST THE NYLON LOCK NUT.

8. If there is play in the splice joint, remove the bolt and nut from one collar end and pull the track apart.

Apply a bead of silicone rubber sealant around the splice end of the track pipe (12' 6"). Silicone

sealant is RYKO Part No. 10455-202.



9. Tap the track back together and wipe excess silicone off the pipe. Install the bolt back in the collar

and secure with nut.

10. Place the machine track stops on the outside of the track as directed on the Track, Guide Rail and

Bay Switch Installation drawing.

INSTALLATION OF THE MACHINE IN A BAY WITH LESS THAN OPTIMUM DIMENSIONS MAY REQUIRE

SPECIAL CONSIDERATION AND ALLOWANCES. CONTACT A LOCAL RYKO REPRESENTATIVE FOR

INFORMATION CONCERNING BAYS OF MINIMUM DIMENSIONS.

MACHINE, EQUIPMENT, AND PARTS INSTALLATION

The instructions that follow give procedures for placing the machine on the tracks and installing other

equipment and/or parts necessary for its operation.

For proper placement and installation of the bay plates and switch assembly, tire stop, and guide rails,

refer to the Steps that follow, and to the Track, Guide Rail and Bay Switch Installation drawing.

Safety Note! Use a sturdy ladder of sufficient height when installing, servicing, maintaining, or inspecting areas of

the machine that cannot be reached from the floor. Never climb on equipment, stand on covers, arms or any other part of any RYKO equipment.

CAUTION! WHEN LIFTING OR PLACING THE MACHINE ON THE TRACKS, AVOID OVERHEAD

OBSTRUCTIONS AND CENTER PITS WHICH COULD INTERFERE WITH INSTALLATION.

IMPORTANT: DO NOT INSTALL GUIDE RAILS PRIOR TO PLACING THE MACHINE ON THE TRACKS.

INSTALLING GUIDE RAILS PRIOR TO PLACING THE MACHINE ON THE TRACKS MAY NOT ALLOW

SUFFICIENT ROOM FOR INSTALLATION.

1. Install the bay plates in the bay according to the Track, Guide Rail and Bay Switch Installation

drawing.

2. Place the machine on the tracks. Machine dollies are recommended for this phase of installation.

Should machine dollies be unavailable, 1" pipes placed under the skids may be used to move the

machine.

3. After the machine has been placed on the tracks, remove the iron frame used in shipment. Once the

iron frame is removed, install the track stays, but do not tighten at this time.

CAUTION! DO NOT OPEN THE SIDE BRUSH ARMS OR PHYSICALLY MOVE THE

MACHINE UNTIL THE TRACK STAYS ARE FITTED AND INSTALLED.

With the machine installed, place the guide rails in the bay according to information given on the

Track, Guide Rail and Bay Switch Installation drawing. Do not fasten guide rails at this time.

4. Install the machine boom and umbilical cable (electric, water, air and chemical line) according to

Installation drawings.

5. Position and install the Backup Air Switch Hose 4" behind (exit end) the tire stop.



6. Once the machine and all associated equipment have been installed, cables and hoses for electric,

water, and air can be connected to their designated locations. See Electric, Water and Air

Connections in this manual.



END STOP PROXIMITY SWITCH TRIP PLATE INSTALLATION,

ADJUSTMENT AND TESTING

To install the end stop proximity switch trip plate and bumper mounts, refer to the following instructions

and to the Track, Guide Rail and Bay Switch Installation drawings.

The trip plates are bolted at each outside end portion of the right track. This would be the track on the

right side of the bay when viewed from the Entrance End of the bay. Refer to the Track, Guide Rail and

Bay Switch Installation drawing for installation locations of these trip plates. These trip plates work in

conjunction with the proximity switches in stopping the machine.

Also, a total of four (4) bumper mounts must be installed on the tracks. Position and install one bumper

mount at the end of each track. Fastening material is provided. See drawing No. 19515-000 for the

installation location of these mounts. The bumper mounts must be installed to keep the machine from

running off the tracks or hitting the entrance or exit door tracks.

END STOP PROXIMITY SWITCHES AND TRIP PLATE ADJUSTMENT

AND TESTING PROCEDURES When installation of the trip plates and bumper mounts, including the electrical, air and water

connections is complete, install, adjust and test the end stop proximity switch according to Steps that

follow.

1. There are two (2) end stop proximity switches that are standard equipment with each machine.

These proximity switches come assembled on a bracket that is attached on the bottom outside

channel of the machine (Electrical Control Panel side). This bracket needs to be installed on the

machine and adjusted. Adjustment is required to enable reading the trip plates (targets).

2. The bracket that the proximity switch is assembled to is secured to the machine with bolts and nuts

(provided). The proximity switches are threaded to allow easy adjustment. Once the bracket has

been secured to the machine, adjust the proximity switches so that the face of each switch is 3/16 of

an inch away from the trip plate as illustrated below.

3. On completing installation and adjustment of the switches, drive the machine back and forth on the

track a few times to insure the dimensions are maintained at all times. The end stop proximity

switches should cause the drives to shut off before the unit touches the end stop rubber bumpers.

When the drives shut off, the machine will coast slightly and make contact with the end stop bumpers

before coming to a rest position. Readjust the switches if required.

IMPORTANT: REFER TO THE SERVICE MANUAL FOR ADJUSTMENT PROCEDURES OF OTHER PROXIMITY

SWITCHES ON THE MACHINE.



ELECTRIC, WATER, AND AIR CONNECTIONS

Make all required electric, water and air connections according to drawings given in this manual and/or

drawings and information sent with any optional products. Follow directions and read all NOTES on

these drawings to complete installation properly.

IMPORTANT: SERVICE PERSONNEL ARE REQUIRED TO PERFORM LOCKOUT AND TAG SAFETY

PROCEDURES PER OSHA REGULATIONS 29 CFR 1910.147 AND 1910.331 THROUGH 1910.335.

Electrical connections will vary depending on the activation device and options that are installed.

Required electrical connections include connections of the main power cable, control cables, valves, and

the activation device that is used with the machine.

For wiring optional equipment refer to the information given in this manual and/or information included

with shipment of the options. Also see Wiring Option Outputs to Programmable Logic Controller (PLC) in

this manual.

WIRING OPTION OUTPUTS TO THE PLC

For wiring option outputs to the Programmable Logic Controller (PLC) refer to Electrical drawings given in

this manual and/or the service manual.

When the machine is manufactured, it is wired for one (1) of the automatic attendant options (Network

Arming or alternate arming).

It is recommended that all drawings or information pertaining to wiring optional outputs to the PLC be

reviewed in order to be familiar with all factory wired options.

PHOTOELECTRIC INSTALLATION -- WHEEL SCRUB

It is important that both the entrance and exit end photoelectrics are installed correctly in order to provide

proper wheel scrub operation. To install and adjust the photoelectric eyes, refer and adhere to all steps

and illustrations of the Photoelectric Installation drawing.

Each set of photoelectrics consists of two (2) main components, an Emitter Module and a Receiver

Module. These modules work together to detect the vehicles' wheels and allow wheel scrub operation to

occur at the appropriate times. This is possible when the emitter projects a beam of light to the receiver

that is installed directly across the gantry of the machine.

IMPORTANT: REFER AND ADHERE TO THE PHOTOELECTRIC INSTALLATION DRAWING. NOTE 11 ON THIS

DRAWING PERTAINS TO REVERSE MOUNTING OF THE PHOTOELECTRIC MODULES. NOTE THAT

ALTERNATE (REVERSE) MOUNTING IS REQUIRED MOUNTING ON ALL MACHINES WITH THE ONE DRIVE

OPTION INSTALLED.



RYKO ADDITIVE SYSTEM (WITH BLUE WHITE PUMPS)

RYKO Cleaning Aids are recommended for use with the RYKO

SoftGloss MAXX. These products are available in Keep Full

Service 15 gallon containers, 55 gallon drums, and 5 gallon

container. The Blue White Pump is illustrated at right.

For additional information on these detergents including

settings, refer to the machine service manual.

ADDITIVE PUMP PRIMING Before priming the additive pumps, connect the pump inlet and

outlet to the appropriate lines.

CAUTION! ONLY HAND TIGHTEN THE PUMP

FITTING. NEVER USE PLIERS OR WRENCHES

FOR TIGHTENING: BREAKAGE OF FITTINGS OR

CRACKS IN THE PUMP HEAD COULD RESULT,

WHICH COULD VOID THE WARRANTY

Make sure the correct additive (Detergent, Wax, Rinse-Off, Etc.) is in the appropriate container and that it

is filled above the foot valve in the additive supply container.

Turn the pumps “ON” with the priming switch and set the dial adjustment to MAX. Only adjust the dial

when the pump is operating.

Provided there is some liquid in the pump head and the discharge pressure is not excessive, the pumps

should self prime. If the pump fails to prime, check to make sure there is liquid in the pump head and

that the inlet and outlet lines are free of obstructions. If necessary, liquid can be added to the pump head

by removing the pump fitting. The pumps should now be primed.

Note: As these pumps are low volume, it is possible that it could take 30 minutes to fill the lines.

After the additive system is completely primed, set the pump dials for the appropriate recommended

additive disbursement. Refer to the Service Manual for recommended additive settings. Setting

any additive pump settings for a higher or lower volume than is recommended in the Service Manual,

could cause wash or dry quality problems. A setting that disburses too little additive may not allow for

proper cleaning. A setting that disburses too much additive could be detrimental in allowing for a proper

dry.

Note: Pump settings are recommended based on results from testing RYKO Cleaning Aids and pumps under a

variety of washing situations/conditions, including the use of soft water. These settings may need to be altered in order to meet the specific needs of a wash location. This would especially hold true if soft water is not used.

If the pump does not deliver, or only delivers a limited portion of the additive on the initial start-up of the

unit, the problem may be that an inlet and/or outlet valve is not seating properly. If this symptom occurs,

verify and correct.



ADDITIVE SYSTEM INSTALLATION (NON-RYKO CHEMICAL WITH

PULSAFEEDER PUMPS)

ADDITIVE SYSTEM CONNECTIONS Install the Pulsafeeder chemical pumps and connect all

additives according to the detailed instructions provided on the

OffBoard Chemical Pump Installation, TriFoam Detergent,

Wax, Clear Coat drawing and the SoftGloss MAXX Pneumatic

Hydraulic Schematic drawing. The Pulsafeeder Pump is

illustrated at right.

IMPORTANT: FOR UNINTERRUPTED ADDITIVE FLOW, THE

ADDITIVE STRAINER/FOOT VALVE MUST BE SUBMERGED

BELOW THE ADDITIVE LEVEL.

ADDITIONAL ADDITIVE SYSTEM INFORMATION For information pertaining to additive pump priming, and

additive system operation including setttings, adjustments,

maintenance and repair, refer to the SoftGloss MAXX Service

Manual.

PRODUCT, ACCESSORY AND OPTION INSTALLATION

It is important that all products, accessories, and options (Loop Detection, Door Kit with Photoelectric,

UnderCar Wash, EV II-B, etc.) are installed correctly in order to provide proper operation. If procedures

for the installation of a product, accessory or option are not provided in this manual, refer to the

information included with shipment of the product, accessory or option for installation procedures.

FIXED UNDERCAR WASH

Before operation, machine setup and timer adjustments are entered according to the program installed.

Timer information determines the duration of the Fixed UnderCar operation. The timer information

entered may be decided by the equipment operator. Timer settings allow a minimum of 10 seconds to a

maximum of 40 seconds operation.

The Fixed Undercar Wash begins operation when the car wash is armed at the coin box. When the

arming signal is sent, the undercar nozzles in the manifold assembly affixed to the wash bay floor begin

to spray cold water. These nozzles project a spray of water on the underside of the vehicle as it drives

forward into the bay. The spray continues until the preprogrammed time expires.



DOOR KIT WITH LOOP DETECTION INSTALLATION

If ordered as the detection device, it is important that the Loop Detection system is installed correctly in

order for the doors to operate properly. Refer to the Door Kit with Loop Detect Bay Installation drawing in

this manual and to the directions below.

RYKO Install Note: If installing a Loop Detector in a bay where a freestanding dryer is installed, contact RYKO

Customer Service for assistance.

IMPORTANT: THE LOOP INSTALLATION AREA SHOULD BE DRY AT THE TIME OF INSTALLATION TO ALLOW

MAXIMUM ADHESIVE CONTACT AND PERFORMANCE.

1. The detection loop should be installed 3' from the exit door. Keep the loop at least three (3) feet away

from steel inspection covers, grid, or metal doors. Also, avoid underground heating cables and/or

pipes as significant loss of electrical sensitivity may occur.

2. Begin the detector loop installation by cutting slots in the pavement. For proper installation of wire,

these slots should measure no less then 1/4" wide and 1 1/2" in depth, (refer to drawings). If

reinforcement has been used in the concrete, cuts should be more than 2" from any reinforcement

material to avoid loss of electrical sensitivity.

3. Place wire in the slots in the concrete as instructed on the Loop Door Kit Bay Instructions.

4. Use 14AWG stranded wire to construct the loop detector, (either Type UL XHHW or THHN should be

used) to allow for flexibility.

5. The loop slot and incoming conduit must not contain any wire other than that used for loop detection.

6. The loop must have five continuous revolutions of wire around the perimeter.

7. The lead-in wire from the structure and the loop wire should be a continuous unbroken length of wire.

Refer to the exception stated in Step 8 below.

8. The lead-in wire coming from the structure must be twisted no less then four twists per foot. If, for any

reason, it is impractical to twist wire, use a separate lead-in wire (a shielded twisted pair may be used)

and connect to loop.

9. Should a separate lead-in wire to the loop be necessary, it must be soldered and waterproofed to the

same effectiveness as the original insulation.

10. Lead-in wire distance should be no more than 20 to 30 feet from the structure to the loop location.

11. Taking Steps 1 through 10 into consideration, insert wire in slots.

12. After wire is inserted in slots, the slot must be filled with RYKO Caulk Backer, (Part No. 15417-000).

These are 3/8" x 20' foam rubber strips that serve as insulation to prevent corrosion. Ensure that all

areas of wire placed in slots are covered.



13. After caulk backer strips are inserted in slots, the slot must be thoroughly filled with 3M detector loop

sealant (RYKO Part No. 15380-001 - Detector Loop Sealant, 32 oz.). Visually check for gaps or

cracks which would allow water or other foreign materials access to the wire. Correct if necessary.

14. On completing loop installation, check the resistance to earth with a "Megger". Broken insulation can

cause the detector to go off tone from time to time.

Note: A "Megger" tester is normally available through most electronic distributors. The "Megger" tester allows the

user to put out high voltage current to measure resistance of wire to ground. A low reading indicates if problems exist in the loop detection line, such as a broken line.

LOOP DETECTION ADJUSTMENTS (DELUXE MODEL) The loop detector consists of a series of wires implanted in the pavement outside of the exit door. When

the vehicle leaves the detection loop, signals are relayed to the Programmable Logic Controller (PLC)

which in turn sends a signal to close the door.

Located in the wash bay terminal box is a single channel vehicle detector. This detector allows the

operator to adjust the loop detection system for frequency or sensitivity.

MODE (FREQUENCY) SWITCH The Mode Switch should be set to the FM position. The remaining two mode settings, FH and FL, are

used if second or third loop detection systems are installed next to one another.

AUTOMATIC REVERSE SAFETY SWITCH Due to malfunctions which could occur during operation of door equipment or the possibility of

obstructions in the door pathway, installation of an automatic reverse safety switch to the door control

system is recommended. This switch should be installed to the door control circuitry, (preferably at time

of door installation) to prevent possible accidental property damage or personal injury.

Automatic reverse safety switches are available through most garage door distributors.

DOOR KIT WITH PHOTOELECTRIC INSTALLATION

If ordered as the detection device, it is important that the Photoelectrics are installed correctly in order to

provide proper operation of the doors. Refer to the Door Kit with Photoelectric Bay Installation drawing in

this manual and to the directions below.

Installation Requirements and Instructions 1. All conduits should be watertight 1/2" (13mm) rigid and threaded.

2. Mount the photoelectric emitter and receiver as close to the bay exit as possible, but do not allow

stationary objects within the bay to interfere with the light beam. Check the Preinstallation or Track,

Rail and Bay Switch Installation drawing to determine the proper distance between the end of the

track pipe and the inside bay wall so that the front brushes do not block the photoeye beam (Note:

FoamBrite brushes require a greater distance than filament brushes). Mount the photoeye receiver

with a maximum of 1/2" protruding through the mounting plate.

3. Shielded wires must be insulated from touching any other exposed metal.

4. Typical wiring of the door kit will work with most door opener brands. Consult with Customer Service

if difficulty arises.



5. Drill a 1/4" (6 mm) diameter drain hole in the bottom of all junction boxes and terminal boxes that are

located in the wash bay.

6. Connect the photoelectric wires to the relay bases. Refer to the shielded cable information below.

a) Remove 3" of the outer jacket on the cable, being careful not to cut any strands of the shielded

braid underneath.

b) Push back the braided shield to loosen it. Using a paper clip or a pointed hard tool, carefully pick

the center conductor out from between the braids at the edge of the remaining outer jacket where

the 3" of outer jacket was removed. Then twist the braid until it becomes a second stranded

conductor.

COVER OPTION INSTALLATION

Refer to the appropriate Cover Option Installation drawing in this manual when installing the covers on

the SoftGloss MAXX

MANUAL DRIVE KEY SWITCH OPERATION

The machine may be moved manually to any location on the tracks using the manual drive forward and

reverse buttons from the touch screen LCD display on the Communication Interface Box. Refer to the

Touch Screen Operation document for help on accessing the Site Menu screen or the Technician Menu

screen, and help on the touch screen menus. When the manual drive forward button is pressed on the

screen, the machine’s drive contactor is activated, and the machine drives forward toward the exit end of

the bay. When the manual drive reverse button is pressed, the machine drives in reverse toward the

entrance end of the bay. Brushes will not spin during either the forward or reverse drives when using the

manual drive buttons.

The two keys sent with each machine are included with shipment of the Emergency Stop Control Box. It

is important that these keys remain in the possession of authorized personnel only.

CAUTION! ONLY USE THE MANUAL DRIVE WHEN THE MACHINE IS IN AN "AT

REST" POSITION (ALL MOTORS ARE TURNED OFF).

TOP BRUSH PROXIMITY SWITCH / COUNTERWEIGHT ADJUSTMENT

The top brush interrupt prevents the top brush from descending into pickup beds where it could come in

contact with any accumulated debris and possibly damage the vehicle or machine. Adjustment of the

counterweight affects the correct operation of the top brush and the top brush interrupt.

For Top Brush Proximity Switch and Counterweight adjustment procedures refer to the Service manual.

IMPORTANT: DEPENDING ON THE MACHINE SHIPMENT METHOD AND IN ORDER TO MINIMIZE SHIPPING

SPACE, SOME MACHINES MAY REQUIRE COMPRESSION OF THE COUNTERWEIGHTS DURING SHIPMENT.

IF THIS IS REQUIRED, THE COUNTERWEIGHT IS MARKED AT THE TESTED POSITION ON THE TOP SIDE OF

THE TOP BRUSH CHANNEL. THE COUNTERWEIGHT CAN THEN BE ADJUSTED BACK TO THIS MARKED

POSITION DURING MACHINE INSTALLATION. THIS PROCEDURE APPLIES TO BOTH FILAMENT AND CLOTH

MACHINES.



U.S. / METRIC CONVERSION INFORMATION

The information below provides common conversions used when metric measure is required for installation rather than U.S. measure.

LENGTH WEIGHT

1 inch = 2.54 centimeters = 25.4 millimeters 1 pound = 0.4536 kilograms (kg)

1 foot = .30481 meters =4.4482 Newton's (FORCE)

1 mile = 1.609 kilometers = 1609 meters 1 kilogram = 2.2046 pounds

1 centimeter = 0.3937 inches (cm) = 35.274 ounces

1 millimeter = 0.03937 inches (mm) TEMPERATURE

1 meter = 100 centimeters (m) C =.556 (F - 32)

= 1000 millimeters F = 1.8 (C + 32)

= 39.37 inches MOMENT

= 3.2808 feet 1 foot pound = 1.356 Newton Meters

1 kilometer = 0.6214 miles (km) = 1.356 Joules

VOLUME PRESSURE

1 ounce = 29.57 milliliters (ml) 1 pound / square inch = 0.06895 bars

1 quart = 0.9464 liters (also liters) = 6.895 KPA (Kilo

Pascals)

1 gallon = 3.785 liters = 6895 Newton/sq

m

1 cubic inch = 16.39 cubic centimeters 1 KPA = 0.145 PSI

1 cubic foot = 28.32 liters 1 bar = 14.504

pounds/square

inch

1 milliliter = 1 cubic centimeter = .03382 ounces = 1.019

kilograms/square

centimeter

1 cubic foot = 7.5 gallons = 750.067 mm Hg

at 0 Deg. C

1 liter = .001 cubic meter = 100 KN/M2

= 1000 cubic centimeters (Note: 1 bar is approximately 1 atmosphere

of pressure.

= 61.023 cubic inches

= 1.057 quarts ELECTRICAL POWER

= 0.2642 gallons Horse Power (HP) = 745.7 W

1 cubic meter = 35.313 cubic feet

= 264.134 US gallons

FLOW

1 gallon/minute = 3.785 liters/minute

= 0.06308 liters/second

1 gallon/hour = 63.08 milliliters/minute

1 cubic foot/minute = 28.32 liters/minute

1 cubic foot/minute = 0.472 liters/second

1 ounce (US fluid) /second = 0.02957 liters/second

= 29.57 cc/sec

= 29.57 milliliters/sec

1 liter/minute = 0.2642 gallons/minute

1 liter/second = 15.852 gallons/minute

= 2.1186 cubic feet/minute

1 cubic centimeter/second = 0.03382 oz/sec



WIRE SIZES

Wire size is expressed in square millimeters rather than AWG number. Below is an approximate Cross

Reference AWG to mm sq.

AWG mm sq. AWG mm sq.

30 0,05 16 1,5

28 0,08 14 2,5

26 0,14 12 4

24 0,25 10 6

22 0,34 8 10

21 0,38 6 16

20 0,50 4 25

18 0,75 2 35

17 1,0 1 50

CONDUIT SIZES

Inch Size Metric Steel Metric PVC

1/2" 16 mm 16 mm

5/8' 16 mm 16 mm

3/4" 20 mm 20 mm

1" 25 mm 25 mm

1 1/4" 32 mm 32 mm

1 1/2" 38 mm

2" 50 mm



INSTALLATION TOOL CHECK LIST

The Installation Tool Check List that follows consists of recommended tools, equipment, and supplies

that should be readily available when installing a RYKO machine and/or truck wash system. Having

these tools available when beginning the installation will help to eliminate costly delays.

There must be a sufficient amount of shims and/or spacers available to insure the track is level on

completion of its installation. If in question on shims/spacers needed, contact your local Technical

Support Representative for assistance.

These Shims/Spacers are similar in shape and size as the feet on the track risers, with two (2) holes for

anchoring.

Shims/Spacers can be ordered from RYKO by using part number 10709-000 - Plate /Mounting Feet.

Recommended tools, equipment, and supplies for RYKO installations.

QUANTITY DESCRIPTION

1 ____ Roto Hammer (heavy duty)

1 ____ 1/2” X 16” Roto Hammer Bit

1 ____ 3/4” X 16” Roto Hammer Bit

1 ____ Hydraulic Jack (2 ton)

1 ____ Heavy Duty Extension Cord (100’)

1 ____ All Purpose Drill

1 ____ 1/4” X 6” Masonry Drill Bit

1 ____ Set Drill Index, 1/16” thru 1/2” (by 64th’s)

1 ____ 8 ft. Step Ladder

1 ____ Hacksaw / with Extra Blades

1 ____ 3 lb. Hammer

1 ____ 7” Side Cutter / with Insulated Handle

1 ____ 30 ft. Tape Measure

1 ____ Adjustable Wrench (12”)

1 ____ Utility Knife / with Extra Blades

1 ____ Channel Lock Pliers

1 ____ 18" Pipe Wrench

1 ____ 12” Pipe Wrench

1 ____ Phillips Screwdriver Set

1 ____ Flat Screwdriver Set

1 ____ 1/8” Wide Flat Screwdriver (for terminal connections)

1 ____ Needle Nose Pliers

1 ____ Set 1/4” thru 1” End Wrenches

1 ____ 3/8” Socket Set with Extensions

1 ____ 1/2” Socket Set with Extensions

1 ____ Chalk Line with chalk

1 ____ Wire Stripper

1 ____ 2 ft. Level

1 ____ Set Assorted Allen Wrenches



QUANTITY DESCRIPTION 1 ____ Coarse Rattail File

1 ____ Coarse Flat File

1 ____ 8” Vise Grip Pliers

1 ____ Pry Bar (6 ft.)

1 ____ Fork Lift (5,000-6,000 pound) or boom Truck - 20’ lift minimum.

Used for unloading the machine from the trailer and for raising

and placing it on the tracks after it is assembled.

1 ____ Fork Lift (4,000 pound) for unloading the machine from the trailer

and for placing it on the tracks.

1 ____ 4’ X 10’ X 16’ Man Lift for hanging Cable Carrier

2 ____ Heavy, Durable, Strapping, Rope or Chain. Sufficient length 8’ to

10’. Used to stabilize the machine during various phases of

installation.

1 ____ Transit or Laser for leveling track.

2 ____ 20 ft. Extension or Step Ladder.

____ Blocking (4” X 6” recommended), or machine to lay on during

assembly and when raising. (shipping blocks are normally used

for this purpose.)

4 ____ 1/2” X 2 1/4” Compression Anchors (part #10429-201)

100 ____ 1/2” X 2 3/4” Compression Anchors (part #10429-202)

Installation Manual For Work Order 7984380 Page IA-1

INSTALLATION START-UP TEST PROCEDURE NO. 21179-006

Page 1 of 1

REV. - ECO 0196-35

APRV RDC DATE 1/15/96

INSTALLATION START-UP TEST PROCEDURE CHECKLIST FOR USE WITH

FIXED UNDERCAR WASH MODELS 9901601X.

CAUTION! INSTALLATION OF THIS EQUIPMENT MAY REQUIRE PERSONNEL TO



LOCAL CODES, SAFETY REGULATIONS, AND OTHER SAFETY REQUIREMENTS

AS LISTED IN THE INSTALLATION MANUAL.

EQUIPMENT REQUIRED: VOLTMETER

CHECK √ OPERATION TO PERFORM

1. Verify equipment arrived at installation site in proper condition.

2. Verify that the equipment has been installed per the appropriate

installation drawings and instructions.

3. Verify that the voltage supplied to the equipment is correct per the

appropriate installation drawings and instructions within 10% as read on

the voltmeter.

4. Verify that water and air supplied to the equipment appears to be of

sufficient pressure and volume to operate the fixed undercar wash.

5. Arm the wash for undercar wash, then have a vehicle drive over the

undercar wash manifold. The manifold should begin operating when the

vehicle is over the manifold and should turn off shortly after the vehicle

passes over the manifold.

6. During the undercar wash cycle, verify that there appears to be sufficient

flow and pressure to apply water to the underside of a vehicle.

(opt)

7. If rust inhibitor is present, verify that rust inhibitor is drawn into the

undercar water line during an undercar cycle.

(opt)

8. If frost protect is present on an Undercar Wash with a separate control

box, verify that the undercar manifolds are evacuated with air at the end of

each undercar cycle.

The Installation Start-up Test Procedure for the Fixed Undercar Wash is now complete.



PAGE 1 OF 1

REV. - ECO 0600-059

APRV: GDL DATE: 6/16/00


RAINMAKER III RKIT/VOYAGER II, SOFTGLOSS XS (22932-001).






CAUTION! MOVING EQUIPMENT. STAY CLEAR WHILE TESTING WASH CYCLES.

MAKE SURE ALL DOORS OF A TEST VEHICLE ARE CLOSED PRIOR TO

INITIATING A WASH CYCLE. DO NOT ENTER OR EXIT A TEST VEHICLE FOR ANY

REASON WHILE THE TEST VEHICLE IS BEING WASHED.

EQUIPMENT REQUIRED:

Hand Held Programmer for PLC.





3. Answer machine setup question for the R.O. option with hand held

programmer for the PLC. Adjust R.O. drive delay timer for this option if

necessary.

4. Arm the machine for a wash that includes reverse osmosis. Observe the

wash to ensure that reverse osmosis water is supplied. Also, ensure there

are no plumbing leaks.

The Installation Start-up Test Procedure for the Rainmaker III Retrokit is now complete.



PAGE 1 OF 1

REV. - ECO 0602-030

APRV: SGT DATE: 6/13/02


SOFTGLOSS XS OFFBOARD AUXILIARY BOOST PUMP.








INITIATING A WASH CYCLE. DO NOT ENTER OR EXIT A TEST VEHICLE FOR ANY

REASON WHILE THE TEST VEHICLE IS BEING WASHED.

EQUIPMENT REQUIRED:

VOLTMETER

CHECK v OPERATION TO PERFORM





appropriate installation drawings and instructions within +/- 10% as read

on the voltmeter.

4. Verify that water supplied to the equipment is correct per the appropriate


5. Verify the boost pump motor is rotating in the correct direction.

6. Arm the car wash machine and ensure that water is delivered to the car

wash by this auxiliary boost pump. Ensure that the float valve opens when

the water level falls below it and is able to supply enough water to keep up

with the pump.

7. Start the Rainmaker and ensure the reject water is routed to the tank.

(For reclaim sites, use any overflow R.O. reject water to fill the pits.)

The Installation Start-up Test Procedure for the Offboard Auxiliary Boost Pump is now complete.


INSTALLATION START-UP TEST PROCEDURE NO. 21179-255 Page 1 of 4

REV. - ECO 0508-051 APRV: BH DATE: 5/15/08


SOFTGLOSS MAXX.








INITIATING A WASH CYCLE. DO NOT ENTER OR EXIT A TEST VEHICLE FOR

ANY REASON WHILE THE TEST VEHICLE IS BEING WASHED.

EQUIPMENT REQUIRED: VOLTMETER




installation drawings and instructions. Pay particular attention to the arm leveling information in the text of the service manual. Also check to see if front and rear brush arm proximity switches meet dimensions as shown on “Instructions/arm proximity switch adjustment” located in the service manual.


appropriate installation drawings and instructions within 10% as read on the voltmeter.

4. Verify that air and water supplied to the equipment is correct per the

appropriate installation drawings and instructions.

5. Check that the Emergency stop switch input on the PLC turns on and off

when the switch is activated.

6. Activate all manual drive switches and verify that the gantry, top brush and

side brush motors respond appropriately and in the correct directions as indicated on the switch label.

7. Verify the weight of the top brush as detailed in the Service Manual.


INSTALLATION START-UP TEST PROCEDURE NO. 21179-255 PAGE 2 OF 4

REV. - ECO 0508-051

(opt) 8. If this machine includes a reclaim system, verify that wash water is being

supplied to the machine. If that reclaim system also includes a fresh water supply, verify that fresh water is supplied to the machine as well.

9. Activate the wash water valve to verify the spray nozzles are not clogged

and there appears to be sufficient flow and pressure to wash a vehicle.

(opt) 10. If an onboard auxiliary water boost pump is installed on the machine,

activate the auxiliary water boost pump and verify that water discharges from the rinse manifold nozzles on the gantry and appears to be of sufficient flow and pressure to rinse a vehicle.

(opt) 11. If an offboard boost pump has been installed, activate the offboard boost

pump, wash water valve and auxiliary water valve outputs. Verify that water discharges from the wash manifold and auxiliary water manifold nozzles on the gantry and appears to be of sufficient flow and pressure to wash and rinse a vehicle.

12. Position the gantry in the “home” position and check that the Custom

Message Display (CMD-optional) and/or the activation device (i.e.: coinbox) indicate that the machine is ready for activation by code or currency.

13. Using the touch screen display on the Communication Interface box,

monitor PLC register D29 to insure that Ultrasonic Sensor is reading correctly. D29 should read +/-1" of measurement from the face of the Ultrasonic Sensor to the bay floor.

(opt) 14. If this machine has been installed with the Frost Protect accessories,

jumper a piece of wire across the thermostat terminals and verify that all the chemical and chemical pump heaters are on. Also verify that machine blows out all the water hoses after each wash.

15. Verify that current relays are adjusted to the factory default settings as

shown on the labels next to them.

16. Arm and operate the system for as many washes as necessary to check

the following operations of the equipment:

(opt) a) Verify that foam bath discharges from the foamer manifolds on the

gantry and there appears to be sufficient flow and pressure to completely cover a vehicle.

(opt) b) If this machine has TriFoam chemicals, make sure that the TriFoam

armings are answered per the machine setup guide. Verify adequate coverage and stripe pattern, and check for air and chemical leakage. Also, check the operation of the Trifoam Spot lights.

(opt) c) If this machine has a backlight sign, verify that the sign is illuminated.

(opt) d) Verify that the operations of the red and green lights on the fascia

correspond to the operations of the red and green lights on the arms.


REV. - ECO 0508-051

(opt) e) If the wheel scrub option is installed, verify that the wheel scrub

brushes extend fully and rotate for a few second in either direction at the wheels. Also verify that there is enough pressure on the wheel scrub brushes to wash the wheel of the vehicle.

(opt) f) If on board dry is installed, verify that the fan nozzles oscillate fully

and opposite of each other and that there appears to be sufficient airflow to dry off a vehicle.

(opt) g) If a stand-alone dryer is installed, verify that it runs at the appropriate

time when dry is armed.

(opt) h) If oscillating undercar is installed, verify that the undercar manifolds

oscillate fully from side to side and there appears to be sufficient flow and pressure to apply water to the underside of a vehicle.

(opt) i) If a fixed undercar is installed, verify that it activates as a car drives

into the bay and that there appears to be sufficient flow and pressure to apply water to the underside of a vehicle.

(opt) j) If rust inhibitor is installed, verify that the rust inhibitor pump operates

at the proper time upon undercar operation.

(opt) k) If an Oscillating Rocker Panel Blaster, an Offboard Pre-Wash, or an

entrance Pivoting Wheel Blaster is installed, verify that it activates as a car drives into the Bay. Also, verify that the Spray manifolds oscillate fully and that there appears to be sufficient flow and pressure at the nozzles.

(opt) l) If the cold wax option is installed, verify that a wax/water solution

discharges from the rinse manifold nozzles and appears to be of sufficient flow and pressure to completely wax the vehicle.

(opt) m) If the hot wax option is installed, verify that a wax/water solution

discharges from the hot wax manifold nozzles and appears to be of sufficient flow and pressure to completely wax the vehicle.

(opt) n) If the rinse off, clear coat and super polish is installed, verify that a

water/chemical solution discharges from the rinse manifold nozzles and appears to be of sufficient flow and pressure to completely cover the vehicle.

(opt) o) If the tire chemical option is installed, verify that a water/chemical

solution discharges from the tire chemical spray manifold on the floor and appears to have sufficient flow and pressure to cover the tires of a vehicle as it drives into the bay. Also, verify that it shuts off as the rear tires pass the tire chemical air switch.

(opt) p) Verify that the CMD, if installed, flashes the stop and go light and

displays the corresponding message for the wash cycle performed.

q) Verify that the front arm traffic lights operate to indicate when the

vehicle is to enter, stop, backup, and exit.


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r) While driving into the bay to wash a car, drive over the bay switch to

activate the back-up air switch. Check the CMD displays “BACK UP SLOWLY” or the back-up light illuminates.

(opt) s) If Rear Arm Soft Oscillate option is installed, verify that the setup

questions are answered to include this option. Also verify that one of the rear arming move away from the machine at the rear of the vehicle, and then repeat with the other arm when washing the back of the tall vehicle.

(opt) t) If a Reverse Osmosis spot free rinse system is installed, check that

water discharges from the rinse manifold or the Free-standing Rinse Arch during the spot free rinse cycle.

(opt) u) If a lighted 3 message sign is installed, verify that the proper

message lights up to instruct the driver into the car wash bay.

(opt) v) If a lighted 8 segment sign is installed, verify that the message which

is lighted corresponds to the wash cycle being performed.

(opt) 17. If an automatic door option is installed, verify that the doors open and close

when cars need to enter for a wash or exit from the wash.

18. Verify that the rear arm clutches and top brush interrupt are performing

properly among cars, pickup trucks and tall vehicles.

(opt) 19. If pre-wash option is installed, verify that the pre-wash water nozzles

oscillate on both sides of this machine, pre-wash pump comes on during the pre-wash cycle, and the pre-wash pump is rotating in the correct direction.

(opt) 20. If the IFSF option is installed at this site, verify the LED on the PC-Lon

Works module is on and that an IFSF error code does not occur.

(opt) 21. If Short Bay Option is installed, verify that it is working properly by manually

driving the machine up and down the track. The PLC input X63 will come on when the Short Bay proximity switch (on left side of machine) detects the newly installed short bay target plates. Refer to the SHORT BAY OPERATION area of the Service Manual for operation details.

(opt) 22. If Bay Switch Buzzer option is installed, verify that the Buzzer sounds when

a vehicle gets on the bay plates after the machine is armed.

The Installation Start-up Test Procedure for the SoftGloss MAXX Brush Wash is now complete.

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FoamBrite

Brush Instructions For Rollovers Notes: 1) It may be necessary to spray a minimal amount of lubricant on the aluminum tubes to assist in sliding

the brush-sections on. 2) As received from the manufacturer, the FoamBrite brush-sections (Ryko P/N 21815-XXX) have all of

the FoamBrite material wrapped in plastic film on one side of the brush-section. When the plastic film is removed, the FoamBrite material has a slight “memory” and tends to maintain it’s packaged shape, leaving a type of “flat-spot” on the brush. If, when assembled, all of the flat-spots line-up on the tube, the arm will be imbalanced. To prevent this, when assembling the individual FoamBrite sections onto the aluminum tubes, rotate the angular position of the FoamBrite tails as shown in the Brush-Section View. Assemble any non-pair brush-sections (due to odd number of brushes) closest to the gearbox (See Brush-Section View).

Top Arm Brush Assembly 1) On the 66-3/4” aluminum tube, assemble the brushes as follows:

A) When assembled, the four outside brush-sections on both ends of the top brush must not have any surface “void” (imperfection in the white plastic material) wider than 1/4” and longer than 1/2” (See Top Washer View).

B) Arrange the brush-sections on the aluminum tube so that the folded edge of the brush material points in the direction of the arrows (See Top Washer View).

C) On the side with the six (6) brush-sections that point in the same direction, extend the first brush segment beyond the end of the aluminum tube (See Detail D).

D) Ensure that all eleven (11) brush sections are compressed together with no material caught between them.

2) Select an appropriate location on the end brush-section to drill two (2) holes 180

o opposite of each

other. An appropriate location would: A) Be no less than 1-3/4”(45mm) in from the outside edge of the flange shaft, on each end. B) Allow the 1/4”(7mm) washer to rest flat on the outside of the brush-section without interfering

with the brush material and be in a non-recessed area. C) Not allow the 1/4”(7mm) nylon nut on the inside of the tube to interfere with any of the four

aluminum bosses (See Detail A). D) Not interfere with any of the four keystocks on the aluminum tube (See Detail A).

3) Once a spot is located, drill a .3906”(10mm) diameter hole as marked through the brush-section and

aluminum tube (See Detail A). Drill the second hole as opposite as possible (180o45

o) from the first

hole in an appropriate location (See A-D above). 4) Slide the 1/4”(7mm) washer and 3/8” (10mm) OD aluminum sleeve onto the 1/4(7mm)-20x2(50mm)

screws (See Detail A). 5) Insert the screw assemblies into the 3/8”(10mm) holes and secure from the inside with 1/4”(7mm)

washers and 1/4"(7mm) nylon nuts.

Top Arm Counterweight Adjustment Follow the steps below to weigh and adjust the top washer with dry FoamBrite brushes only. 1) Verify that the top arm is completely assembled (brushes, motor, reducer, cover, etc.). 2) Remove the air from the top brush pneumatic cylinder. On the pneumatic manifold:


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A) Turn the inlet air valve to the OFF position. B) Turn the exhaust port valve to the OPEN position to release air from the entire pneumatic

system. C) Turn flow control on exhaust port of top arm pneumatic cylinder fully open.

3) With the top brush lowered, fasten a scale to the middle of the top shaft. 4) SLOWLY and STEADILY raise the top brush by the scale to a horizontal position. 5) While the top brush is in the horizontal position, take the weight measurement. IMPORTANT: For top

arms with the UHMW bearings, do not allow the tension in the scale to go slack, even slightly. Tension should not be eased on the scale when reaching the horizontal position for taking measurement. This prevents the weight from being “held up” by friction between the top arm bearing races and the UHMW bearings.

6) Repeat steps 4 and 5 except take the measurement while lowering the top brush through the

horizontal position.

7) Take the average of the “raising” and “lowering” weights (Weight Up + Weight Down)/2. This method eliminates any friction the UHMW adds to or subtracts from the actual weight (Weight+Friction + Weight-Friction)/2=Weight.

8) For top arms with 25:1 (69 RPM @ 60 Hz) or 20:1 (71 RPM @ 50 Hz) reducers, measure and, if necessary, adjust the weight of the top brush to 15 (6,8 kg) to 18 (8,2 kg) pounds and verify that this weight obtains a crush of 6 inches to 10 inches (15,2 cm to 25,4 cm) by washing at least 20 various vehicles. Top arm drop can be adjusted by the top brush flow control valve on the pneumatic manifold. With top FOAMBRITE brushes dry, fully open the top brush flow control valve on the pneumatic manifold. Using the handheld, force the top brush spinning and the top brush drop, doing this several times, while adjusting top brush flow control valve inward until the top brush, while spinning, drops in 25 seconds +/- 5 seconds. (Note: If top FOAMBRITE brushes are wet, use handheld and force top brush to spin for 10 minutes to dry).

9) For top arms with 12.5:1 (113 RPM @ 50 Hz) reducers, measure and, if necessary, adjust the weight of the top brush to 19 (8,6 kg) to 24 (10,9 kg) pounds and verify that this weight obtains a crush of 3 inches to 7 inches (7,6 cm to 17,8 cm) by washing at least 20 various vehicles. Top arm drop can be adjusted by the top brush flow control valve on the pneumatic manifold. With top FOAMBRITE brushes dry, fully open the top brush flow control valve on the pneumatic manifold. Using the handheld, force the top brush spinning and the top brush drop, doing this several times, while adjusting top brush flow control valve inward until the top brush, while spinning, drops in 25 seconds +/- 5 seconds. (Note: If top FOAMBRITE brushes are wet, use handheld and force top brush to spin for 10 minutes to dry).

10) With top arm counterweight and top arm drop adjusted as stated above, the flow control on the

exhaust port of top arm pneumatic cylinder needs to be adjusted inward until top arm rises without slamming against the top arm return bumper stops.

The amount of crush should be the ultimate determining factor in setting the counterweight. Note: Crush measurements refer to the length of brush material that is bent and folded-over when making contact with the vehicle surface.

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Front Arms, and Rear Arms without Clutches Brush Assembly 1) Slide the first brush-section onto the aluminum tube and position the top of it as follows:

A) With arm assemblies that contain steel flange shafts, position the brush even with the TOP of the steel flange shaft (See Front Washer w/Flange Shaft View and Detail C.)

B) With front arm assemblies that have gearboxes that come with the flange attached to the output-shaft (flanged gearbox), position the brush even with the BOTTOM of the output-shaft flange (See Front Washer w/Flanged Gearbox View, Normal Option, and Detail E).

C) For locations with Tall Front Arm assemblies that have bottom brush section higher from the floor than normal due to extreme bay slope or track spaced higher than normal, an option is available: see Tall Front Washer with Flange Gearbox View, Modified for Field Locations and DETAIL F.

NOTE: When lowering brushes (3” (76MM) maximum) be sure to allow for any bay obstruction such as tracks and guide rails. To keep tall front arms operation as normal as possible after lowering the brushes. The brush drop distance should be the same for both the right and left arm.

2) Slide the remaining brush-sections onto the tube, making sure that the top brush-section remains in

position (See Detail C and Detail E). 3) Select an appropriate location on the bottom brush-section of both front and rear washers to drill two

(2) 180o opposite each other. An appropriate location would:

A) Be within 2”(50mm) of the bottom of the bottom brush-section. Allow the 1/4”(7mm) washer to rest flat on the outside of the brush-section without interfering with

the brush material and be in a non-recessed area. B) Not allow the 1/4”(7mm) nylon nut on the inside of the aluminum tube to interfere with any of

the four aluminum bosses (See Detail A). C) Not interfere with any of the four keystocks on the aluminum tube (See Detail A).

4) Once a spot is located, drill a .3906”(10mm) diameter hole as marked through the brush-section and

aluminum tube (See Detail A). Drill the second hole as opposite as possible (180o45

o) from the first

hole in an appropriate location (See A-C above). 5) Slide the 1/4”(7mm) washer and 3/8”(10mm) OD aluminum sleeve onto the 1/4(7mm)-20x2(50mm)

screws (See Detail A). 6) Insert the screw assemblies into the 3/8”(10mm) holes and secure from the inside with 1/4”(7mm)

washers and 1/4"(7mm) nylon nuts.

Rear Arms with Clutches and Plastic Rings Brush Assembly The rear arms are divided into a separately rotating top and bottom section. The bottom end of top section and the top end of the bottom section are held apart to clear the plastic rings that separate the top and bottom section. The top end of the top section is held in place to clear the clutch from the top section. This is done by using six (6) 1/4(7mm)-20x2(50mm) screws, 1/4"(7mm) washers, 3/8”(10mm) OD aluminum sleeves, and 1/4(7mm)-20 rivet nuts. The bottom section at the bottom end is held on the same as the front arm. Make sure the folded edge of the brush material points toward the top (See Rear Washer With Clutch View).

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The suggested assembly process is:

1) Before installing any brushes, the first top brush section must have one .3906”(10mm) hole drilled 1” +0 –1/8” (25mm +0 –3mm) from the top side of the brush section core between any two molded square keyways in the brush section cores (be sure the folded edge of the brush material points

toward the top). Install one 3/8” (10mm) outside diameter aluminum sleeve into the .3906”(10mm) hole, (do not push aluminum sleeve to far into the inside diameter of the brush section core as to interfere with sliding onto aluminum tube), See Detail G. With aluminum sleeve installed slide the first brush section onto the aluminum tube and position it near the bottom of the clutch. Make sure the folded edge of the brush material points toward the top (see rear washer with clutch view and Detail G). With this first brush section in place per detail G add two (2) holes 180

o opposite of each other.

An appropriate location would:

A) Be down 3 1/8”1/4”[80mm6mm] from the top side of the first brush section (see Detail G). B) Allow the 1/4”(7mm) washer to rest flat on the outside of the brush-section without interfering

with the brush material and be in a non-recessed area. C) Not allow the 1/4(7mm)-20 rivet nut attached to the aluminum tube to interfere with any of the

four aluminum bosses (See Detail B). D) Not interfere with any of the four keystocks on the aluminum tube (See Detail B).

2) Once a spot is located, drill a 0.3906” (10mm)+.006/-0(+0.1524/-0) hole through the brush-section

and aluminum tube (See Detail B). Drill the second hole as opposite as possible (180o45

o) from the

first hole in an appropriate location (See A-D above). 3) Slide the first brush-section down out of the way and insert the rivet nuts into the drilled holes (use a

hand tool only for the rivet nut insertion).

4) For machines with brushes and cores that are direct-shipped or for the Premier Plus FoamBrite w/Clutches Retrokit:

5) Slide five more brush-sections on the aluminum tube, making sure the folded edges of the brush

material point up and that the space between the clutch and top brush-section is maintained. (See Rear Washer With Clutch View).

6) Attach the 30 7/8”(784mm) bottom aluminum section to the rear arm steel flange using the existing

hardware and retaining compound (Loctite 680 or equivalent). 7) Select an appropriate location on the sixth brush-section (from the top) to drill two (2) holes 180

o

opposite of each other. An appropriate location would: A) Be down no more than 33”(840mm) from the bottom of the clutch (not the flange part of the clutch). B) Allow the 1/4”(7mm) washer to rest flat on the outside of the brush-section without interfering



8) Once a spot is located, drill a 0.3906”(10mm)+.006/-.000(+0,1524/-0) hole through the brush-section

and aluminum tube (See Detail B). Drill the second hole as opposite as possible (180o45

o) from the

first hole in an appropriate location (See A-D above).

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9) Slide the sixth brush-section down out of the way and insert the rivet nuts into the drilled holes (use a hand tool only for the rivet nut insertion).

10) Slide the sixth brush-section back into position and insert the 1/4(7mm)-20x2(50mm) screws, using the 1/4”(7mm) washers and 3/8”(10mm) OD aluminum sleeves (See Detail B).

11) Place the plastic ring on top of the 24x48” seventh brush section and slide the section onto the rear arm. Adjust the distance between the ring and brushes so that they cannot become dislodged from between the two brush sections (gap to large) and so the ring does not engage the top and bottom brush sections (gap to small). This gap should be between 1/8” and 3/16”. (See Rear Washer With Clutch View).

12) Select an appropriate location on the seventh brush-section (from the top) to drill two (2) holes 180o

opposite of each other. An appropriate location would:

A) Be down 3 1/8” 1/4” (80mm6mm) from the top side of the seventh brush section.. B) Allow the 1/4”(7mm) washer to rest flat on the outside of the brush-section without interfering



13) Before adding the two (2) holes 180 opposite of each other to the seventh brush section the gap between brush section six and brush section seven as mentioned in step 13 MUST be maintained. Once a spot is located, drill a 0.3906”(10mm) +.006”1-.000(+0.1524/-0) hole through the brush-

section and aluminum tube (See Detail B). Drill the second hole as opposite as possible (18045) from the first hole in an appropriate location (See A-D above).

14) Slide the seventh brush-section down out of the way and insert the rivet nuts into the drilled holes

(use a hand tool only for the rivet nut insertion). 15) Slide the seventh brush-section back into position and insert the 1/4(7mm)-20x2(50mm) screws,

using the 1/4”(7mm) washers and 3/8”(10mm) OD aluminum sleeves (See Detail B). 16) Slide the remaining brush-sections on.

17) Select an appropriate location on the bottom brush-section to drill two (2) holes 180

o opposite of each

other. An appropriate location would: A) Be within 3”(76mm) of the bottom of the bottom brush-section. B) Allow the 1/4”(7mm) washer to rest flat on the outside of the brush-section without interfering

with the brush material and be in a non-recessed area. C) Not allow the 1/4”(7mm) nylon nut attached on the inside of the aluminum tube to interfere

with any of the four aluminum bosses (See Detail A). D) Not interfere with any of the four keystocks on the aluminum tube (See Detail A).

18) Once a spot is located, drill a 0.3906”(10mm)+.006”/-.000”(+0.1524/-1) hole through the brush-section

and aluminum tube (See Detail A). Drill the second hole as opposite as possible (180o45

o) from the

first hole in an appropriate location (See A-D above).

19) Slide the 1/4”(7mm) washer and 3/8”(10mm) OD aluminum sleeve onto the 1/4(7mm)-20x2(50mm) screws (See Detail A).

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20) Insert the screw assemblies into the 3/8”(10mm) holes and secure from the inside with 1/4”(7mm) washers and 1/4"(7mm) nylon nuts.

Installation Manual For Work Order 7984380 - NOTES Page IA-109

softgloss maxx installation manual work order #...

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