Sonny's Compact top brush User manual

Installation Manual

Compact Top Brush™

* All parts and components MUST be installed by experienced and trained technicians.

For Equipment

Installation,

L Bracket

NOT Included

Order

Kit # 20019396

Work Force: 2 to 4 Technicians*

Installation: 4 to 6 Hours

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 1 of 58

Sonny’s and Sonny’s The CarWash Factory are Registered trademarks of Sonny’s Enterprises LLC

Make CarWashing Easy and Compact Top Brush are trademarks of Sonny’s Enterprises LLC

Products mentioned herein are for identification purposes only and may be registered trademarks of their respective companies. All

other brand names, trademarks or registered trademarks are the property of their respective owners.

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 2 of 58

TABLE OF CONTENTS

READ ALL INSTRUCTIONS PRIOR TO INSTALLATION

IMPORTANT SAFEGUARDS AND WARNINGS

3 - 5

INTRODUCTION

SAFETY WEAR REQUIRED FOR ALL PERSONNEL

TOOLS REQUIRED FOR INSTALLATION

INSTALLATION SUMMARY OVERVIEW

COMPACT TOP BRUSH FEATURES

CALLOUTS

EQUIPMENT SPECIFICATIONS

COMPACT TOP BRUSH DIMENSIONS

11 - 12

AIR CYLINDER POSITIONS

13 - 14

UTILITIES REQUIREMENTS

SUB-ASSEMBLIES REQUIRED FOR INSTALLATION

16 - 17

SHIPPING MANIFEST

UNPACK EQUIPMENT PALLET

EQUIPMENT INSTALLATION DIMENSIONS –MUST BE VERIFIED

20 - 21

INSTALLATION INSTRUCTIONS

22 - 43

COMPACT TOP BRUSH COMPLEMENTARY EQUIPMENT

ADJUSTMENTS AND TESTING

SPEED AND TORQUE ADJUSTMENTS

GENERAL OPERATION

MAINTENANCE

WEAR ITEMS AND REPLACEMENT PARTS

49 - 54

TECHNICAL SUPPORT

EMERGENCY CONTACTS

WARRANTY

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 3 of 58

•These instructions are a comprehensive step-by-step instruction guide on how to install the

Compact Top Brush and components. To review other manuals go online to SonnysDirect.com

under Support Tab.

•Make sure to read, understand and follow all these instructions.

•To address any questions relating to installation, ordering parts, operating the Compact Top Brush,

troubleshooting, maintenance, service or anything else, contact Sonny’s Technical Support Team

at 1-800-327-8723, Ext: 234.

•All deviations and alterations from these instructions MUST be reported to both your supervisor and

Sonny’s The CarWash Factory.

•WARNING: Do not perform any maintenance or work on equipment unless you first perform

Lock-Out Safety Precautions. All electrically powered equipment MUST have manually

operated disconnects capable of being locked in the “OFF” position. Equipment that has

been “locked out” for any reason must be restarted ONLY by the person who performed the

“lock out” operation. These procedures MUST be followed to avoid personal injury, death

and/or dismemberment.

•All parts and components MUST be installed by experienced and trained technicians.

•No unauthorized personnel should ever be permitted in the wash tunnel or near the equipment at

any time.

•Hardhat, safety glasses with side shields, closed steel toe shoes, anti-impact and cut resistant

gloves, dust mask, and earplugs if operating power tools, MUST be worn.

•When cutting or grinding any metal, safety glasses, earplugs, and dust mask MUST be worn.

•Do NOT leave a ladder or any other items such as wash down hoses or tools in the wash

tunnel while equipment is running. Vehicle damage and injury, including death, can occur.

•Do NOT wear loose fitting clothing or jewelry around moving equipment. Do not allow any

part of your body or other objects (including ladders, hoses, or tools) to come in contact

with moving equipment. Entanglement may result causing injury, death, or dismemberment.

•Always exercise caution when walking (never run) through the wash tunnel as there may be

slippery conditions. Be careful so you do not bump into or trip over equipment.

READ ALL INSTRUCTIONS PRIOR TO INSTALLATION

IMPORTANT SAFEGUARDS AND WARNINGS

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 4 of 58

•Electrical connections and repairs MUST ONLY be performed by a Licensed Electrician.

•Plumbing connections and repairs MUST ONLY be performed by a Licensed Plumber.

•When working on any equipment that is higher than your shoulders, always use a fiberglass ladder

that is in good condition.

•Use proper lifting technique. Team lifts are required for items over 50 lbs.

•Do NOT alter or modify parts in any way and do NOT interchange or substitute any components

without the authorization of your supervisor and Sonny’s The CarWash Factory.

•Do NOT install any parts or components into faulty materials.

•All damages and defects MUST be reported to both your supervisor and Sonny’s The CarWash

Factory.

•If there are any malfunctions with the Compact Top Brush; or if any questions arise regarding the

equipment operations, immediately contact your supervisor or Sonny’s The CarWash Factory.

•Only use approved hardware, parts, and components with the Compact Top Brush or any other

equipment.

•Protect your body parts against sharp corners and edges at all times.

•Keep loose articles of clothing and jewelry away from the removal, installation, or operation of all

equipment.

•The personnel installing the Compact Top Brush are responsible for making sure it works

according to the instructions in this manual.

•Always remove ladders, tools, parts, etc, from the wash tunnel when finished.

•All personnel MUST be trained in the safe operation of all equipment, wash tunnel operations,

safety regulations, emergency shutdown and maintenance practices to avoid any accidents.

•Only personnel specifically instructed and trained are permitted to enter the wash tunnel to perform

inspections or maintenance. At least two qualified maintenance personnel MUST be present when

performing equipment repairs or preventive maintenance.

•IMPORTANT: Call Technical Support to adjust wash cycle when new equipment is installed.

•WARNING: All hydraulic and electrical systems in the wash tunnel equipped with a torque relief or

overload should be checked and set to the minimum amount that will allow for proper functionality

under normal washing conditions.

IMPORTANT SAFEGUARDS AND WARNINGS

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 5 of 58

•WARNING: Possible wet floors and slippery conditions! To avoid an accident that might

result in personal injury, death or dismemberment, all personnel MUST proceed with

Caution.

•WARNING: Do NOT enter the wash tunnel when the equipment is operating. Personal injury,

death and/or dismemberment may occur.

•WARNING: Make sure the proper Chemistry (Brush Lubrication) is being used in the Car

Wash Tunnel to prevent vehicle and/or equipment damage.

•WARNING: If the Equipment Installation Dimensions at the time of installation are NOT

measured correctly, it may result in equipment damage and/or failure. Dimensions MUST be

verified if equipment is already installed. Contact Sonny’s Technical Support Team at 1-800-

327-8723, Ext: 234 for any Installation questions.

•WARNING: All connections and repairs MUST ONLY be performed by Licensed Professionals.

Perform all trade work in compliance with all applicable local and national codes.

•WARNING: Although building codes have been considered in developing all drawings, verification

of site-specific conditions and compliance with federal, state, and local building codes is the

exclusive responsibility of the customer and/or architect and engineer.

•WARNING: Do NOT attempt to repair or adjust any pressurized liquid or pneumatic part, hose,

pipe, or fitting while that equipment is in operation.

•WARNING: Do NOT operate any equipment that requires safety covers with those covers removed

or improperly installed. Do NOT operate any equipment if any component of that equipment is

suspected to be defective or malfunctioning.

•WARNING: Store all cleaning, washing solutions and oils in a well-ventilated area. Clean up

fluid spills immediately to prevent hazardous safety conditions. Be certain to follow all

safety procedures on SDS Sheets for each chemical product used.

•WARNING: When a piece of equipment must be in operation during inspection or

maintenance, one qualified technician must stay at the power disconnect switch while

another qualified technician performs the inspection or maintenance.

•WARNING: All Equipment MUST be given regular maintenance to prevent equipment

damage and/or failure that will VOID the warranty.

SAVE THESE INSTRUCTIONS

IMPORTANT SAFEGUARDS AND WARNINGS

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 6 of 58

INTRODUCTION

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 7 of 58

WARNING: Make sure to follow Local and State Safety Wear Required Regulations to

ensure the safety of all personnel. Failure to follow Safety Regulations may result in

personal injury, death and/or dismemberment.

Go online to SonnysDirect.com under Support Tab and look for:

Compact Top Brush™ Installation

Tools

Not Included

Impact Gun and Socket Set

Forklift

Standard Combo Wrenches

Ladder

1” Hammer Drill

Level

Nip Scissor

Allen Key Set

Tape Measure

Torque Wrench

Sledgehammer

C Clamp

Anti-Seize Compound Never•Seez®

Ratchet Strap with Clamps or S-Hooks

SAFETY WEAR REQUIRED FOR ALL PERSONNEL

TOOLS REQUIRED FOR INSTALLATION

INSTALLATION SUMMARY OVERVIEW

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 8 of 58

Sonny's Compact Top Brush is designed to fit in a smaller footprint and can also be

retrofitted to existing front to back 901 Mitter Foundation Frame. The simple mechanical operation

features a re-engineered pivot system that delivers a fluid motion over all horizontal surfaces for a

more consistent wash across a wider range of vehicles.

➢Gentle NeoGlide®Foam Hush Brush™does not absorb water and delivers a consistent

balanced wash, every time, regardless of volume, while reducing noise

➢Single Arm Cantilevered Design

➢High Strength Aluminum Alloy Top Brush Frame

➢304 Stainless Steel Main Support Weldment

➢304 Stainless Steel Counterweight Assembly is Powder Coated Safety Yellow

➢Brush tracks the contour of the vehicle using only a counterweight

➢Available as a Top Brush Spider, which allows for mounting of Entrance Wraps, Exit Wraps,

Tire Brush Attachments, Top Mount and Bottom Mount Side Brushes

➢Octagonal Sheetmetal Core Hub for light weight, smooth operation, and ease of NeoGlide®

replacement

➢Double Roller Pillow Block Bearings, 2” HD Pivot Shaft

➢Light Touch Shock for smooth operation and retract

➢2 Position Air Cylinder for optimal brush position control

COMPACT TOP BRUSH FEATURES

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 9 of 58

CALLOUTS

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 10 of 58

Footprint Length

98”

Footprint Width

144”

Height

140”

Vehicle Clearance

90”

RPM

75 - 85

Drive Electric

1 HP Transtecno

EQUIPMENT SPECIFICATIONS

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 11 of 58

COMPACT TOP BRUSH DIMENSIONS

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 12 of 58

Diameter

55”

Length

73” (Nominal)

BRUSH DIMENSIONS

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 13 of 58

Compact Top Brush - Pneumatic Diagram

Three Position Control

AIR CYLINDER POSITIONS

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 14 of 58

Compact Top Brush - Pneumatic Diagram

Two Position Control

PLUG

AIR CYLINDER POSITIONS

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 15 of 58

Utilities interconnection and the materials required for interconnection to

Sonny’s equipment are the responsibility of the customer.

All connections and repairs MUST ONLY be performed by Licensed Professionals.

Perform all trade work in compliance with all applicable local and national codes.

Water - The Customer’s Plumber is responsible for:

➢The Customer's Plumber is to provide and install a ½” city water line @60PSI (nominal) to

the solenoid valve on the chemical distribution system for the Washer.

Electric - The Customer’s Electrician is responsible for:

➢The Customer's Electrician is to provide and install single phase power from the (24 or 110

VAC as determined at time of order) from the Customer’s Controller system to the liquid

solenoid valve for the brush spray bars. If required, the motor starter coil for the hydraulic

power pack feeding the brush, and any pump motor for the chemical distribution system.

➢The Customer's Electrician is to provide and install single phase power from the remote

push-button station, through the tunnel equipment programmer; to the supplied air solenoid

valve, on the Air Distribution Manifold for retract of both washers upon selective signal.

➢The Customer’s Electrician is to provide materials and install 208VAC or 230VAC or

460VAC, 3-phase, 60Hz power to the electric motor on the hydraulic power pack; or VFD

panel from a properly sized three pole circuit breaker, and motor starter with three thermal

overloads when applicable.

Compressed Air - The Customer’s Plumber is responsible for:

➢The Customer's Plumber is to provide and install a ½” compressed air line from the Air

Compressor to the Air Distribution Manifold for the Retract functions.

Technical Disclaimer

though building codes have been considered in developing all drawings, verification of site-

specific conditions and compliance with federal, state, and local building codes is the exclusive

responsibility of the customer and/or architect and engineer.

UTILITIES REQUIREMENTS

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 16 of 58

The following sub-assemblies are included with shipment:

Compact Top

Brush Header

Cross Beam

(Only if NO Wrap

Header is

available)

Main Arm

Sub-Assembly

Hardware Kit # 10013864

4 Hex Bolts (5/8” – 11 X 3” Zc)

1 Hex Bolt (3/8" –16 X 4” SS)

10 Flat Washers (5/8” Zn)

4 Hex Nuts (5/8” – 11 Zc)

Brush

Sub-Assembly

Motor and

Gearbox

Sub-Assembly

SUB-ASSEMBLIES REQUIRED FOR INSTALLATION

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 17 of 58

The following sub-assemblies are included with shipment:

Counterweight

Sub-Assembly

Hardware Kit # 10013865

4 Hex Bolts (½” – 13 X 5½” SS)

8 Flat Washers (½” SS)

4 Hex Nuts (½”–13 SS)

11 Counterweight

Plates

(28 lbs. Each)

Main Support Frame

Hardware Kit # 10013866

8 Hex Bolts (½” –13 X 6” SS)

2 Hex Bolts (½” –13 X 5½” SS)

24 Flat Washers (½” SS)

10 Hex Nuts (½”X 13 SS)

Air Cylinder and

Shock Mount

Weldment

Hardware Kit # 10013867

4 Hex Bolts (½”–13 X 6” SS)

8 Flat Washers (½” SS)

4 Hex Nuts (½”–13 SS)

SUB-ASSEMBLIES REQUIRED FOR INSTALLATION

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 18 of 58

Brush Materials Drop Shipped

SHIPPING MANIFEST

Compact Top Brush™Installation Manual

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

This document is confidential and proprietary to SONNY’S and cannot be used, disclosed, or published without prior written consent.

Content, prices, and availability subject to change without notice.

Manual-I, Compact Top Brush –Part # 10013928-C

Page 19 of 58