Sonny's Dual CounterWeight Top Brush User manual

Top Brush
Dual Counterweight (DCW)
Owner’s Manual
Sonny's Enterprises, Inc.
5605 Hiatus Road
Tamarac, Florida 33321
16v1

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*Table of Contents*
WARNING *SAFETY REQUIREMENTS* WARNING.......................................................... 3
*INTRODUCTION* ............................................................................................................... 5
Product Specifications ................................................................................................... 6
*INSTALLATION* ................................................................................................................ 8
Utilities Requirements .................................................................................................... 8
Dimensions NEED TO UPDATE ..................................................................................... 9
Equipment Installation.................................................................................................. 12
Installation Tools and Consumables........................................................................ 12
Brush Hub Installation............................................................................................... 15
Electric “Flender” Motor............................................................................................ 16
Adjustments and Testing ............................................................................................. 17
*GENERAL OPERATION*................................................................................................. 18
*PREVENTIVE MAINTENANCE*....................................................................................... 19
*WARRANTY*.................................................................................................................... 20
*CUSTOMER SERVICE* ................................................................................................... 21

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WARNING *SAFETY REQUIREMENTS* WARNING
1. All employees must be thoroughly trained in safe operation and standard maintenance
practices. All employees must review this entire manual monthly.
2. Do not enter the wash tunnel when the equipment is operating. Death or dismemberment
may occur.
3. 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 death or dismemberment.
4. 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.
5. 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.
6. Only those employees specifically instructed and trained by the location management
are permitted to enter the wash tunnel to perform inspections or maintenance. At least
two qualified maintenance people must be present when performing equipment repairs
or preventive maintenance.
7. 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.
8. When working on any equipment that is higher than your shoulders, always use a
fiberglass ladder that is in good condition.
9. Do not attempt to repair or adjust any pressurized liquid or pneumatic part, hose, pipe or
fitting while that equipment is in operation.
10.Electrical connections and repairs must be performed by a Licensed Electrician Only.
11.Emergency “STOP” buttons must be well marked and their location and proper use
reviewed with all personnel. Any activated “STOP” button must be reset only by the
person who activated it. Clear the wash tunnel of any people, ladders, hoses, tools and
other loose items before restarting the equipment. An audible device must sound to warn
people that the equipment is starting.
12.Do not operate any piece of equipment that requires safety covers with those covers
removed or improperly installed. Do not operate any piece of equipment if any component
of that piece is suspected to be defective or malfunctioning.

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13.Store all cleaning and 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.
14.All hydraulic and electric systems in the wash tunnel equipped with a torque relief or
overload should be checked and set at the minimum amount that will allow for proper
functionality under normal washing conditions.
15.No unauthorized people should ever be permitted in the wash tunnel or near the
equipment at any time.
* * *
! ! CAUTION ! !
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.

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*INTRODUCTION*
This Owner’s Manual contains information that is vital to the successful
installation, operation and maintenance of your SONNY’S vehicle
washing equipment.
Please read, and understand, the full contents of this manual before
installation and operation of the equipment. Keep this booklet in a
location where it may be used for ongoing reference.
Should you have any questions on the operation or servicing of this
equipment please contact
TECHNICAL SERVICES DEPT.
SONNY’S ENTERPRISES INC.
5605 Hiatus Road
TAMARAC, FLORIDA 33321
TELEPHONE: [phone] FAX: [phone]

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Product Specifications
Designed to occupy 108” of tunnel length and 152” width (attachments
available and add more length)
4” x 4” Aluminum alloy frame and legs for stability and durability
Heavy duty double roller pivot bearings increase durability and
smoothness of operation
Dual counterweights allows for smooth vehicle profiling
Simple linkage design is easy to maintain
Soap lubrication is required for operation
Requires VFD in order to change rotation to clean the rear of vehicles

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For Parts/Accessories Information Please Reference our Catalog or Website.

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*INSTALLATION*
Utilities Requirements
UTILITIES INTERCONNECTION AND THE MATERIALS REQUIRED FOR
INTERCONNECTION TO SONNY’S EQUIPMENT ARE THE RESPONSIBILITY OF
THE CUSTOMER!
PERFORM ALL TRADES WORK TO ALL APPLICABLE LOCAL AND
NATIONAL CODES!
Electrical
•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 and, 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 (see Figure #6 in Dimensions Section).
•The Customer’s Electrician is to provide materials and install 208VAC or 230VAC or
460VAC, 3-phase, 60Hz power to the electric motor 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 to provide and install a 1/2-inch compressed air line from
the Air Compressor to the Air Distribution Manifold for the Retract functions.
Chemical
•The installer is to run a ½ inch chemical line out to the brush to provide lubrication.
Technical Disclaimer
•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.

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Dimensions
Figure #1

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NOTE: 28” Brush is the maximum size that can be used. When using a 28” brush it will
require retracts to hold the brushes retracted until the Top Brush is on the hood of the
vehicle.
Figure #2

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Figure #3
CAUTION: Do not plumb any air to the back side of the cylinder, air is for retract only.
NOTE: Flow control adjustment required upon installation.
Meter-Out
Flow Control Valves

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Equipment Installation
Installation Tools and Consumables
Tools
Consumables
1. Safety Glasses
1. Anti-Seize Compound
2. ½ " Drive Ratchet Set
2. Marine Grease
3. Standard Combo Wrenches
4. 4’ Level
5. Electric Impact Wrench
6. 1” Hammer Drill
7. Tape Measure
8. Forklift - 2 Ton Load Capacity - (4,000 Lbs.)
Work Force
Time (assuming no problems)
Four (4) persons
5.00 – 6.00 hours
NOTE: Use Anti-Seize Compound on all the hardware: Bolts, U-Bolts, etc.
Forklift – 2 Ton Load Capacity
Roller Skids Are Recommended
1 Ton Min. Load Capacity

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Installation Steps
1. Determine where the Top Brush is to be installed (see Figures #1 & #2
in the Dimensions Section and the tunnel layout drawings for your
location).
2. Sweep any debris from where the Top
Brush will stand.
3. Insert aluminum couplers into the leg
posts. Holes must be in alignment. Place
the legs in the location where the top
brush will stand.
4. Place a small amount of Anti-Seize Compound on each bolt included in the kit.
5. Using the recommended forklift, place the assembled frame (with the brush toward
the end of the car wash) on top of the leg extensions, and make sure the frame is
sitting square on all leg posts.
6. With the hardware provided in the kit, join the leg posts,
cross beam and 3-way join plates, making sure to use anti-seize compound on bolts.

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7. Level and square the frame with the centerline of the
equipment (see Figure #1 in the Dimensions Section
and the tunnel layout drawings for your location).
8. Place and anchor the unit per the dimensions shown
in Figure #1. Be certain that the entrance and exit
cross beams are level (shim mounting feet, if
necessary) and that each of the 4 vertical legs are
plumb.
Note: Ensure the frame is correctly located before
installing any lag bolts. Before lagging the frame into position have a second person
double check all measurements against your tunnel equipment layout drawings to
ensure all measurements were performed correctly.
1. Run the air supply line hose from the air manifold to the retract cylinders for the
retract operation (see Figure #3 in the Dimensions Section).
2. Retract cylinder air regulators (Actuators) needs to be adjusted once the equipment
is in testing operation.
In order to adjust the retract function; slowly increase the pressure to the air
cylinders until the top brush retracts all the way to the bumpers (Recommended
pressure 40-60 PSI). Make sure flow control valves are fully closed, gradually
open up the flow control valves until the top brush is retracting in a smooth
motion.
3. Standard rotation of the brushes is against vehicle travel. As viewed from the driver
side the brush turns COUNTERCLOCKWISE. The brush requires a VFD to change
rotation to clean the back of vehicles.

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Brush Hub Installation
1. Remove and discard the retainer plate from one end of top
brush assembly. Insert the screws and lock washers to the
PS Spindle.
2. Hold the brush straight, insert the end of the brush to the
PS top brush arm spindle and tighten into place with the
screws. (Use anti-seize compound on screws).
CAUTION: Extra foam spacers are sent with the brush and may
need to be added. After the first week of operation, check the
brush for gaps in the foam. If any gaps are found, add spacers
to the end of the brush.
Failure to do so may result in damage to vehicles.
3. Remove and discard the retainer plate from the other end of
top brush assembly. Insert the screws and lock washers to
the DS Spindle.
4. Loosen PS bearing set screws to be able to slide the brush
hub on to the spindle.
Reuse Screws
Reuse Screws

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5. Slide the brush hub into the DS spindle and tighten the
screws.
6. Once the top brush assembly is securely tighten to both
spindles (DS & PS), go ahead and tighten the PS bearing set
screws. Check the DS bearing set screws to make sure they
are also tighten.
Electric “Flender” Motor
1. Loosen the DS and PS shaft bearing set screws to adjust the brush to the center of the
top brush arms. Once centered, tighten the shaft set screws.
DS Set Screws
PS Set Screws

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Adjustments and Testing
Adjust the Cleaning Pressure of the Washer
Ensure the air solenoid is manually put in the wash position so there is no air pressure applied
to the retract cylinder. Using a 3/4” wrench, loosen up the 4 bolts that secure the counterweight
assembly until lock washers have released pressure. (DO NOT unscrew the bolts more than 3
to 4 full turns.). Adjust the position of the counterweight so that when the counterweight is
released, the brush slowly moves downward. Using a 1/16” wrench, rotate the nut on the back
of the frame to adjust the counterweight. In order to get the brush to drop it may be necessary to
open the flow control valves on the air cylinder, see Figure 3.
After the initial adjustment has been made, manually activate and deactivate the air retract.
When deactivated the brush should fall smoothly to the down position. Final adjustment of the
counterweight can be accomplished while running test vehicles. Fine tuning of brush pressure
on vehicle should be made by moving the counterweight 1/8” – 1/4” at a time; this is equivalent
to 1-2 full rotations at the 1-1/16 nut.
Once adjusted properly, the cloth penetration should be about three to four inches across the
entire vehicle. If brush bounces too much the counterweight has been adjusted to far out.
Adjustment is easiest if made in small amounts, approximately 1/4” to 1/2” at a time.
The triangle weights on the brush control how heavy the brush is in the front to rear motion. If
the brush is applying to much pressure in the reverse direction more weight may be needed.
This adjustment is based on the type of vehicles being washed and the speed of the conveyor.
More triangles = Less pressure on the rear Less triangles = More pressure on the rear
Adjust the Rotation Speed of the Brush
The brush speed can be adjusted using a VFD and needs to be adjusted based on your chain
speed. If you purchased a VFD from Sonny’s, it will come programed to change directions with
an input provided by the car wash controller. The brush should change directions just after the
front windshield area.
Speed and Torque Adjustment (where applicable)
1. Electric
a. The speed can be adjusted on the Variable Frequency Drive (VFD).
b. To increase the speed, adjust the Hertz on the VFD to a higher number.
c. To decrease the speed, adjust the Hertz on the VFD to a lower number.
d. The Overload on the Motor Starter protector(s) must be set at the lowest level to allow
for operation. Adjust the amps in accordance with motor(s) name plate.

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*GENERAL OPERATION*
Top Brush Operation
Brush rotation starts and stops with a signal from the Customer supplied Controller
system. This Controller Start-Stop signal should also control soap solution delivery to the
spray bar on the brush.
BE CERTAIN THAT THE BRUSHES ROTATE AGAINST VEHICLE TRAVEL
With the brush rotating (against the direction of vehicle travel and at proper RPM) the
vehicle’s front hood contacts the brush and brush travels across the vehicle maintaining
steady contact while washing the hood, just after the front windshield the brush should
smoothly change directions to wash the roof and rear of the vehicle.
Proper cloth penetration on flat vehicle surfaces should be 3 to 4 inches. As the
brush rounds corners, such as on windshields, the cloth penetration may be greater,
but not deeper than half the distance to the aluminum brush core.
Retract Operation
When there is no vehicle approaching the brush the tunnel controller will retract the brush
from the wash position, toward the ceiling. This can also be set up in the controller to
retract for the beds of trucks to avoid problems.
It is recommended that the brush be retracted for:
1. Sun visors mounted over the windshield.
2. Any racks mounted on the roof.
3. Rear wipers on Acura Integra’s and Mazda RX-7’s unless they are taped down.
4. Open bed pickup trucks.

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*PREVENTIVE MAINTENANCE*
DAILY
1. Check all lines and fittings for leaks. Repair, or replace, as needed.
2. Check brush for proper operation, listening for any unusual noises from the equipment.
3. Inspect brush cloth for cuts, grease, or oil. Remove and repair, or replace, any cloth
panel if any of these conditions are found.
4. Check the brush retract and extend for proper operation, smoothness and correct
application pressure.
WEEKLY
1. Spray lubricant on the clevis pins on both ends of the retract cylinders.
2. Grease the brush shaft bearings. Do not allow grease to come in contact with brush cloth.
FOR THE FIRST MONTH OF OPERATION CHECK ALL HARDWARE AND FITTINGS FOR
TIGHTNESS EACH WEEK.
PERFORM THIS INSPECTION TO THE SCHEDULE SHOWN BELOW AFTER THE FIRST
MONTH OF OPERATION.
MONTHLY
1. Inspecting all hardware and fittings for tightness.
2. Grease all bearings. Do not allow grease to come in contact with brush cloth.
3. Inspect the bumper stops for wear to ensure the air cylinders have not reached the end of
their travel. If bumper stops are worn they can be flipped to extend life.
4. Thoroughly clean the equipment and framework.
SEMI-ANNUALLY
1. Carefully inspect brush equipment cloth for wear and damage. Replace as necessary.

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*WARRANTY*
SONNY’S ENTERPRISES, INC.
FACTORY LIMITED
LIFETIME WARRANTY
Equipment manufactured by SONNY’S ENTERPRISES, INC. is warranted to be free from defect in
material and workmanship. Welded metal framework and other non-moving, non-wearable
fabricated metal components manufactured by SONNY’S are warranted for the life of the equipment
to the original purchaser. Fabricated metal wearable surface and moving components manufactured
by SONNY’S are warranted for a period of one (1) year to the original purchaser of the equipment.
All components assembled to SONNY’S equipment that are manufactured by others are
warranted by the appropriate manufacturer and subject to that manufacturer’s limited warranty.
Contact SONNY’S for the specific information on other component manufacturer’s warranty terms. All
new cloth shipped with new SONNY’S equipment is warranted for a period of one (1) year or 80,000,
whichever occurs first.
This warranty is not assignable or transferable. The warranty period begins the first day
following installation or 30 days from the original invoice date, whichever occurs first. The Seller’s
liability shall be limited to repair or replacement of materials found to be defective within the warranty
period. In the event of repair or replacement this limited warranty is noncumulative. The Purchaser
must supply the Seller with immediate written notice when any defects are found. The Seller shall
have the option of requiring the return of defective material to establish the Purchaser’s claim. Neither
labor nor transportation charges are included in this warranty. Transportation damage claims are to
be submitted to the carrier of the damaged materials.
This warranty is based upon the Purchaser’s reasonable care and maintenance of the warranted
equipment. It does not apply to any equipment which has been subject to misuse, including neglect,
accident or exposure to harsh chemicals or chemicals that react violently with: water, organic acids
(e.g. acetic acid), inorganic acids (e.g. hydrofluoric acid), oxidizing agents (e.g. peroxides), and metals
(e.g. aluminum). Chemicals corrosive to: aluminum alloys, carbon steel, and other metals. Nor does it
apply to any equipment which has been repaired or altered by anyone not so authorized by SONNY’S.
Further, the equipment must be properly installed with proper accuracy of all specified plumbing,
electrical, and mechanical requirements. This warranty does not apply to normal wear and tear or
routine maintenance components.
EXCEPT AS EXPRESSLY STATED HEREIN, SONNY’S SHALL NOT BE LIABLE FOR DAMAGES OF ANY
KIND IN CONNECTION WITH THE PURCHASE, MAINTENANCE, OR USE OF THIS EQUIPMENT INCLUDING
LOSS OF PROFITS AND ALL CLAIMS FOR CONSEQUENTIAL DAMAGES. THE LIMITED WARRANTY
EXPRESSED HEREIN IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED. SONNY’S NEITHER
ASSUMES NOR AUTHORIZES ANY PERSON TO ASSUME FOR IT ANY OTHER OBLIGATION OR LIABILITY
IN CONNECTION HEREWITH.