Work Order # 230V SoftGloss Service [Sg4s03]

Transcription

1 230V SOFTGLOSS SERVICE MANUAL Work Order # 230V SoftGloss Service [Sg4s03] SERIAL # For Model: RYKO Solutions, Inc S.E. 37 th Street Grimes, IA

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3 THIS MANUAL IS ASSIGNED TO: MACHINE SERIAL NUMBER: INSTALLATION DATE: ELECTRICAL POWER: 208V/230V, THREE PHASE 460V, THREE PHASE ACTIVATOR: Standard Air Switch * Code-A-Wash System Option Coin Box / Accumulator Auto Cashier Applicable to all Code-A-Wash systems including present (Code-A-Wash IV), past, and future versions. OTHER ACCESSORIES: FOR SUPPLIES, PARTS OR SERVICE CONTACT: Name Company Address Phone ( ) Page i SoftGloss Service Manual Work Order # 230V SoftGloss Service [Sg4s03]

4 THIS MANUAL CONTAINS INSTRUCTIONS FOR MAINTAINING AND OPERATING A RYKO SOFTGLOSS VEHICLE WASH SYSTEM. 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 SOLUTIONS, INC. 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, IF 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! SERVICING OF THIS EQUIPMENT REQUIRES PERSONNEL TO WORK WITH AND NEAR HIGH VOLTAGE WIRING AND TO WORK ABOVE FLOOR LEVEL. EXTREME CARE MUST BE EXERCISED FOR PERSONAL SAFETY. FOLLOW LOCAL CODES AND SAFETY REGULATIONS. IMPORTANT: ALL PERSONNEL WHO WORK DIRECTLY OR INDIRECTLY WITH THE MACHINE AND ANY ASSOCIATED EQUIPMENT SHOULD READ THIS MANUAL BEFORE OPERATING, MAINTAINING OR SERVICING THIS EQUIPMENT. PAY PARTICULAR ATTENTION TO THE SECTION ENTITLED "FOR YOUR SAFETY" AND TO ALL "CAUTION", "WARNING" AND "IMPORTANT" NOTES THROUGHOUT THE MANUAL. RYKO RECOMMENDS THAT A QUALIFIED RYKO TECHNICIAN PERFORM ALL INSTALLATION AND SERVICE MAINTENANCE FOR THIS EQUIPMENT. INSTALLATION OR SERVICE MAINTENANCE OF THIS EQUIPMENT BY ANY PARTIES NOT VERSED IN ITS INSTALLATION, MAINTENANCE AND OPERATION COULD VOID THE WARRANTY. Page ii SoftGloss Service Manual Work Order # 230V SoftGloss Service [Sg4s03]

5 CONTENTS GENERAL INFORMATION... 1 FOR YOUR SAFETY... 1 "CAUTION" AND "WARNING" DECALS... 3 CONTROL PANEL DOOR ACCESS AND PROTECTION... 3 RECYCLING / DISPOSAL INFORMATION... 3 BASIC REQUIREMENTS AND SPECIFICATIONS... 4 ELECTRICAL REQUIREMENTS... 4 AIR REQUIREMENTS... 5 WATER REQUIREMENTS... 5 PHYSICAL SPECIFICATIONS... 6 ACCEPTABLE VEHICLE DIMENSIONS... 6 MISCELLANEOUS... 6 RECOMMENDED BAY DIMENSIONS... 7 ELECTRICAL TESTING LABORATORIES (ETL) LISTING... 8 TERMS / DEFINITIONS... 9 TERMS AND DEFINITIONS... 9 CONTROL PANEL SWITCHES OPERATION STARTUP / SHUT DOWN, AND EMERGENCY STOP PROCEDURES STARTUP AND SHUT DOWN PROCEDURES EMERGENCY STOP PROCEDURE WASH SEQUENCES INFORMATION MACHINE PROGRAM DESCRIPTION OF OPERATION MACHINE SETUP INFORMATION OPERATOR'S CHOICE PROGRAMMING COLD WEATHER OPERATION OPTIONAL REMOTE ARMING DEVICES WATER SYSTEM ADDITIVE SYSTEM (WITH BLUE WHITE PUMPS) POLYTUBE CONNECTIONS ADDITIVE PUMP PRIMING AND DIAL SETTING RYKO ADDITIVE SETTING CHARTS ADDITIVE SYSTEM OPERATION FOAM BATH, TRIFOAM DETERGENT, TRIFOAM WAX, AND HOT WAX TEST ADJUSTMENTS - AIR AND WATER (FOAM BATH, TRIFOAM DETERGENT, & TRIFOAM WAX) TRIFOAM DETERGENT OPTION MAINTENANCE FOAMBRITE LUBRICATION GUIDELINES ADDITIVE SYSTEM (NON-RYKO CHEMICAL PUMPS) ADJUSTMENTS - AIR AND WATER (FOAM BATH AND TRIFOAM DETERGENT) ADDITIVE SYSTEM OPERATION FOAM BATH TEST, TRIFOAM DETERGENT TEST, AND HOT WAX TEST TRIFOAM DETERGENT OPTION MAINTENANCE PROGRAMMABLE LOGIC CONTROLLER OPERATION COMMUNICATIONS INTERFACE BOX AND 2 DIGIT CODE DISPLAY AIR PRESSURE SOLENOIDS INFORMATION AIR REGULATORS AND AIR USE ASSOCIATED AIR REGULATOR EQUIPMENT MOVING THE MACHINE MANUALLY (MANUAL SWITCH BOX) MOVING THE MACHINE MANUALLY (LCD DISPLAY) Page iii SoftGloss Service Manual Work Order # 230V SoftGloss Service [Sg4s03]

6 VARIABLE FREQUENCY DRIVE UNIT INFORMATION DIRECTION SIGNAL SPEED SIGNAL CONTACTOR ON SIGNAL OSCILLATING PRE-WASH OPTION SPECIFICATIONS AND REQUIREMENTS REPLACEMENT NOZZLES RECLAIM SYSTEM OPTION CUSTOM MESSAGE DISPLAY SIGNS SHORT BAY OPERATION WHEEL SCRUB OPTION BASIC OPERATION WHEEL DETECTION ONBOARD HIGH PRESSURE OPTION PUMP LUBRICATION ONBOARD TIRE CHEMICAL OPTION MAINTENANCE MAINTENANCE SCHEDULE COMMUNICATION INTERFACE BOX MOTORS - GENERAL INFORMATION MOTOR CIRCUIT PROTECTORS SPEED REDUCERS AMP SENSORS PROXIMITY SWITCH ADJUSTMENT END STOP PROXIMITY SWITCH TRIP PLATE INSTALLATION ADJUSTMENT AND TESTING END STOP PROXIMITY SWITCHES AND TRIP PLATE ADJUSTMENT & TESTING SIDE ARM PROXIMITY SWITCHES SIDE ARM PROXIMITY SWITCH ADJUSTMENT PROCEDURES TOP ARM PROXIMITY SWITCH END STOP PROXIMITY SWITCHES WHEEL SCRUB, AND WIPER PROXIMITY SWITCHES LEVELING ARMS TOP BRUSH INTERRUPT AND PROXIMITY SWITCH ADJUSTMENT TOP BRUSH INTERRUPT (TBI) OPERATION PROXIMITY SWITCH ADJUSTMENT TOP BRUSH COUNTERWEIGHT ADJUSTMENT DRY FOAMBRITE BRUSHES LUBRICATION LUBRICATION - GREASE ZERKS AND BEARINGS PANELS AND COVERS - CLEANING AND WAXING RECOMMENDED CLEANING AGENTS RECOMMENDED WAXING AGENTS CLEANING AND WAXING AGENTS NOT RECOMMENDED SOFTGLOSS WITH FOAMBRITE OPERATION / ADJUSTMENTS ULTRASONIC PROFILING TOP BRUSH SIDE BRUSHES CURRENT SENSING PREWASH PROGRAM OPERATION FOAMBRITE BRUSH CLEANING BRUSH REPLACEMENT Page iv SoftGloss Service Manual Work Order # 230V SoftGloss Service [Sg4s03]

7 TOP BRUSH TALL REAR SIDE ARM BRUSHES WIPER DRIVE BELT ADJUSTMENT PUMP TROUBLESHOOTING PROCEDURES MULTI-STAGE CENTRIFUGAL PUMPS SINGLE STAGE PUMPS WARRANTY INFORMATION WARRANTY PARTS RETURN SITE INFORMATION LOG DRAWINGS Pneumatic/Hydraulic Schematic, Rocker Panel Blaster, Reclaim Pneumatic/Hydraulic Schematic, SoftGloss & Rocker Panel Blaster, Fresh Water Pneumatic/Hydraulic Schematic, SoftGloss, Bug Buster Pneumatic/Hydraulic Schematic, SoftGloss Pneumatic/Hydraulic Schematic, SoftGloss, Onboard, Tire Chemical Pneumatic/Hydraulic Schematic, SoftGloss, Onboard, High Pressure Pneumatic/Hydraulic Schematic, SoftGloss Pneumatic/Hydraulic Schematic, SoftGloss, Electrical Schematic, Tire Chemical Sprayer OffBoard Boost Pump Electrical Schematic SoftGloss Phase Generator OnBoard Dry, Hot Wax Electrical Schematic Short Bay Operation Guide Electrical Schematic/SoftGloss,FX3U Pre-Wash Hydraulic Schematic Instructions / FoamBrite Brush Arm Proximity Switch Adjustment Instructions Electrical Schematic, Lighted 3 Message Sign Electrical Schematic, Lighted 8 Segment Sign Electrical Schematic, Lighted 3 Message Sign, No Escrow Electrical Schematic, Rocker Panel Blaster Electrical Schematic, Window Rinse Control Electrical Schematic/Pivoting Wheel Blaster Instr/PLC Interface Display, Touch Screen Electrical Schematic,/Onboard High Pressure Pump Control Electrical Schematic/Onboard Tire Chemical Control MANUALS AVAILABLE FOR THIS PRODUCT: Pre-Installation Installation Service Owner's Page v SoftGloss Service Manual Work Order # 230V SoftGloss Service [Sg4s03]

8 GENERAL INFORMATION FOR YOUR SAFETY Operators should insist that the following safety instructions, as well as all other instructions listed throughout this manual, be read and adhered to by all personnel maintaining or operating this equipment. 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 installation. Also, be sure all personnel 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 Comminication Interface. 208/230V operated machines may have 2 electrical power supplies. 460V operated machines will have 2 electrical power supplies. The power disconnect switch may not completely de-energize high voltage power to the machine. Therefore, 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 via the Communication Interface. 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. Page 1 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

9 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 AND THROUGH 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 as directed by labels on containers of chemicals and solvents. 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, include the following instructions: Close Windows And Remain In Vehicle While Machine Is Operating Or In Motion. Do Not Use If Vehicle Has Body Damage, Loose Chrome, Or Non-Standard Accessories (e.g., Loose Bug Deflector Shield, Exterior Windshield Visor). Do Not Use If Vehicle Has Large or Wide Tires That Extend Beyond The Body Of The Vehicle. 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. Page 2 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

10 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. "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. 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 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. RECYCLING / DISPOSAL INFORMATION When dismantling this equipment or replacing various parts, it is important to recycle or dispose of materials and parts properly in accordance with local ordinances and state and federal regulations. To assist you, RYKO has identified and labeled mercury switches used on reclaim tanks, bay plate treadle switches and arm assemblies with the following label. CONTROL SWITCH WITHIN CONTAINS MERCURY DON'T PUT SWITCH IN TRASH RECYCLE OR DISPOSE AS HAZARDOUS WASTE PART NO Page 3 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

11 BASIC REQUIREMENTS AND SPECIFICATIONS For proper operation customer-provided utilities should meet the minimum utility requirements that follow. 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. Onboard High Pump 60 Amps at 208/230V. Pressure Control 15 Amps at 120V. NOTE: If an Onboard High Pressure Pump is installed with this machine,additional separate 3 phase and 1 phase services are required. Page 4 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

12 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 apply to both the Standard and Fast programs. SoftGloss 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. (Note: 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, SINCE THE PRE-WASH IS A SEPARATE PASS WHICH USES 35 GPM. IMPORTANT: THERE SHOULD BE NO RESTRICTIONS IN THE AIR OR WATER LINES. Page 5 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

13 PHYSICAL SPECIFICATIONS Length: 11' 4" Width: 13' 1-1/8" with brushes idle 15 2" 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. IMPORTANT: WEIGHTS LISTED ARE APPROXIMATE, AND INCLUDE SOME SKIDDING WEIGHT. ACCEPTABLE VEHICLE DIMENSIONS RYKO SoftGloss systems WILL accommodate vehicles within the dimensions below. SoftGloss systems WILL NOT accommodate vehicles beyond these dimensions. Length: 19' 0" Width (body): 99" Width (tire to tire): 80" Height: 84" MISCELLANEOUS 1. As a precautionary measure be sure to check all bolts for tightness. Check gear boxes for proper oil levels as described in the Maintenance Schedule in this manual. 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 key drive switch. This switch is a part of the Communication Interface Box. CAUTION! THE MANUAL DRIVE KEY SWITCH MUST BE USED ONLY WHEN THE MACHINE IS IN THE "AT REST" POSITION. Page 6 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

14 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 15' 2" (4622 mm) 16' 4" (4979 mm) With Aluminum ThrustPro Dryer 15' 2" (4622 mm) 16' 4" (4979 mm) With Aluminum SlimLine Dryer 15' 2" (4622 mm) 16' 4" (4979 mm) With Stainless Steel Overhead Dryer 15' 2" (4622 mm) 16' 4" (4979 mm) Adjustable up to 18' 4" (5588 mm) With Stainless Steel SlimLine Dryer 15' 2" (4622 mm) 16' 4" (4979 mm) Adjustable up to 18' 4" (5588 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. Height: 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) With Stainless Steel Overhead Dryer and Stainless Steel Fascia With Stainless Steel Overhead Dryer and Plastic Fascia * 42' 8" (13,005 mm) * 55' 8" (16,965 mm) * 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) For All SoftGloss 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. Page 7 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

15 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. Listing details are available at ELECTRICALTESTING LABORATORIES (ETL) CONTROL NUMBER 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. Page 8 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

16 TERMS / DEFINITIONS TERMS AND DEFINITIONS ARMED The rollover has been prepared for activation by its arming device and is ready to cycle when the activation device provides input information to the Programmable Logic Controller (PLC). ARMING DEVICE This device is installed at the entrance of the bay and is used by the customer to purchase a wash. Arming devices available include; the Code-A-Wash System, the Auto Cashier, the standard coin box and the Multi-Upgrade coin box. ACTIVATION DEVICES These devices cause the machine to begin actual operation by providing inputs to the Programmable Logic Controller (PLC). Activation devices include: bay plates or switches, air switches, loop activation devices or push buttons. AT REST This machine is in the 'At Rest' position after completing a wash cycle. All motors are off. The Programmable Logic Controller resets, operational control circuits are deactivated, and the PLC is ready to be "Armed". BAY SWITCH The bay switch is installed between the tracks. When the front tires of the vehicle make contact with the bay switches, a relay is energized causing the wash cycle to begin. LEFT AND RIGHT SIDE The left side refers to the side of the bay or machine to the driver's left upon entering the bay. The right side refers to the side of the bay or machine to the driver's right upon entering the bay. FRONT AND REAR OF MACHINE The front of the machine is considered the side of the machine that is viewed from the exit end of the bay. The rear of the machine is the side of the machine the customer would see on entering the bay. FORWARD AND REVERSE (DIRECTION) Machine movement toward the exit end of the bay is considered forward. Reverse refers to machine movement toward the entrance end of the bay. PASS A pass refers to the passing of the machine over the vehicle once in either the forward or reverse direction during operation. Each time the machine travels from front to rear or from rear to front of the vehicle is a pass. WASH CYCLE The wash cycle is the specific wash that a customer will receive via the wash selections available at a given wash location. ELECTRICAL CONTROL PANEL Located on the right interior side of the machine, the Electrical Control Panel houses low and high voltage components and circuitry. Page 9 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

17 WARNING! THE HIGH VOLTAGE DISCONNECT SWITCH WILL NOT SHUT OFF THE 120VAC SINGLE PHASE POWER IN THE HIGH VOLTAGE PANEL. PROGRAMMABLE LOGIC CONTROLLER (PLC) The Programmable Logic Controller is a compact, self-contained, computerized controller that is located in the Electrical Control Panel. It provides fast, reliable transmitting and monitoring of required signals, while eliminating the wiring and maintenance needs required by conventional relays. For further descriptive information pertaining to the operation of the PLC refer to Programmable Logic Controller Operation. EMERGENCY STOP STATION SWITCH This normally closed switch, if activated during a wash, shuts off all 24VAC power to the low voltage components in the Electrical Control Panel, thus causing the machine to cease operation. The Emergency Stop switch does not remove high voltage from the machine. This switch is a part of the Communication Interface Box that is normally installed in the bay. This box also houses the touch screen LCD display which contains the Manual Drive and Operation Mode (Car Wash Open/Car Wash Closed) functions. Singular style Emergency Stop Stations (optional) are also available. CONTROL POWER Control power is 24VAC power from the transformer. It is always present unless the Emergency Stop Station switch is activated. DISCONNECT SWITCH The disconnect switch is located in the control panel. It works in conjunction with the ON/OFF Activation Device that is located on the control panel door. The door can only be opened when the ON/OFF Activation Device is placed to the OFF position. When placed in the OFF position, all high voltage power to the panel is disconnected through the disconnect switch. The door must be closed and the ON/OFF Activation Device turned ON before the machine will be able to resume operation. WARNING! THE HIGH VOLTAGE DISCONNECT SWITCH WILL NOT SHUT OFF THE 120VAC SINGLE PHASE POWER IN THE HIGH VOLTAGE PANEL. PNEUMATICS Pneumatics consist of regulators, valves and solenoids that are located on the right side of the machine. Air pressure adjustments are made at this location. WASH BAY TERMINAL BOX Mounted on either side wall, all power feeds through this box to the machine. CIRCUIT PROTECTORS Circuit Protectors are thermal devices that are assigned to each motor to protect it from overload failure. See Motor Circuit Protector Protection. CONTACTORS The machine's contactors are energized by 24VAC power controlled by the PLC. When these contactors are energized, high voltage power to various machine motors or heating elements. These motors and heating elements include; the right and left gantry drive motors, the top brush motor, the right and left front brush motors, the right and left rear brush motors, the wheel scrub motors - 2 (optional), the dryer fan - 2 (optional), the wiper - 1 (optional), and the hot wax heater element. Page 10 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

18 WARNING! RYKO SAFETY SERVICE REQUIREMENT. SERVICE PERSONNEL MUST PERFORM LOCKOUT / TAGOUT SAFETY PROCEDURES PER OSHA REGULATIONS, 29 CRF AND THROUGH MACHINE PROGRAM The machine has one program that enables numerous wash combinations. A service technician enters machine setup information appropriate for each individual wash location. OPERATOR S INTERFACE BOX If ordered as an option, an Operator s Interface Box houses the Emergency Stop switch and the drive switches for the SoftGloss carwash machine. The manual drive switches are inside the box, where the Emergency Stop switch is on the outside of the box. COMMUNICATIONS INTERFACE BOX If ordered as an option, the Communications Interface Box, which is normally installed in the bay, houses an Emergency Stop switch and a touch screen LCD display. Additional detailed descriptions for the Emergency Stop switch and the touch screen LCD display are provided elsewhere in this manual. Manually moving the machine, opening or closing the wash, answering set-up questions & adjustable timers, testing of various wash functions and Wash Counts are also attainable from this box. PROXIMITY SWITCHES A proximity switch is an electrical device that detects a target plate when a specific condition in the machine s operation has been met. When the target plate is detected, the proximity switch then signals the PLC that the condition has been met. For locations and operation of proximity switches that exist on the machine, refer to Proximity Switches. VARIABLE FREQUENCY DRIVE (VFD) UNIT(S) The Variable Frequency Drive unit(s) controls the operation of the wiper and the drive motors on the machine. For additional information, see Variable Frequency Drive Unit. ULTRASONIC SENSOR Used to "read" or detect the profile of vehicles, this device "sees" the drop from the roof to the hood of vehicles and the drop from the vehicle roof to the trunk of a sedan style vehicle or the bed of a pickup. When these distance "drops" are seen, the clutch disengages. This device also reads or detects the presence of pickup truck beds to activate the top brush interrupt. CURRENT RELAY A current relay is an electromechanical device that is capable of sensing electrical current through a piece of wire. When a specific current value is reached a signal is sent to notify the PLC. For a machine with FoamBrite brush option, the second phase of the top brush, both front and rear brush motors wires are monitored by three current relays through three stepdown transformers, These current relays will signal the PLC to take precautionary action when any of these brush motors is overloading. This can minimize unnecessary circuit protector trip. Note: Current sensors should be set according to setting labels. Changing the setting values without consulting with authorized RYKO personnel is not recommended. If top brush current sensor trips unnecessarily during normal operations, check the exhaust port flow control valve on the top brush air cylinder and readjust as described in Dry FoamBrite Brushes at Top Brush Proximity Switch / Counterweight Adjustment in this manual. Recommended adjustment: To adjust the top brush air cylinder exhaust port, open the exhaust port flow control valve half a turn at a time until the current sensor stops tripping on the windshield of a tall vehicle. Page 11 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

19 CONTROL PANEL SWITCHES Control Panel Switches are located in the Control Panel next to the Variable Frequency Drive Controller. A description and operation of each switch follows. PLC Power Switch Settings for this switch are ON and OFF. When a cassette must be exchanged or an irrecoverable error has occurred this switch would be placed to the OFF position. Wheel Scrub Switch Settings for this switch are ENABLE and DISABLE. This switch is normally set at the ENABLE position. It is only placed to the DISABLE position if, for any reason, a malfunction occurs to the wheel scrub that does not hinder other wash operations of the machine or if the owner/operator desires not to operate the wheel scrub. Wiper Switch Settings for this switch are ENABLE and DISABLE. This switch is normally set at the ENABLE position. Set at DISABLE only if a malfunction occurs to the wiper that does not hinder of the machine's other wash operations or if the owner/operator does not desire to operate the wiper. Circuit Protectors To the right of the switches described above are four (4) circuit protectors, CB0 (24 VAC), CB1 (24 VAC), CB2 (24 VAC), CB3 (24 VAC). To reset a circuit protector, press in on the button of the circuit protector that has tripped. Other parts/components that are located in the control panel consist of the Programmable Logic Controller (PLC), the Variable Frequency Drive Controller (VFD), Disconnect Switch, and various circuit protectors and contactors. Descriptions of these items are provided in Terms and Definitions. Page 12 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

20 OPERATION STARTUP / SHUT DOWN, AND EMERGENCY STOP PROCEDURES The following information discusses use of the emergency stop switch and the startup and shut down of the wash system. Also discussed are tasks that the owner/operator/attendant should attend to previous to opening or before closing. STARTUP AND SHUT DOWN PROCEDURES Startup and shut down of the vehicle wash system, at such times as opening and closing, is made via the Communications Interface Box. Although this box (normally installed in the bay), houses only a Touch Screen Display and an Emergency Stop Switch, a wash OPEN/CLOSED button from the Touch Screen display provides the Communication Interface Box the ability to open or close the car wash. To shut the system down, touch the OPEN button on the screen. This button will change to read CLOSED, and the system is shut down. To start the system, touch the CLOSED button. This button will change to read OPEN, and the system is ready to wash. For more details, refer to the Touch Screen operation document. IMPORTANT: UNLESS AN EMERGENCY SITUATION ARISES, THE SOFTGLOSS SHOULD ONLY BE STARTED AND STOPPED VIA THE CAR WASH OPEN/CLOSE TOUCH SCREEN SWITCH. Other considerations to shutdown and startup of the machine at opening and closing include: Before startup perform all daily, weekly, and monthly, etc. maintenance directives according to the Maintenance Schedule in this manual. Verify that all exit and entrance doors to the bay are secured when closing and unlocked when opening. During cold weather verify that all heaters (including heaters built in with equipment; pump stand, hot water heater, etc.) in the bay, and the equipment room, are functioning properly. EMERGENCY STOP PROCEDURE (TO BE USED IN EMERGENCY ONLY) The Emergency Stop Switch is part of the Communication Interface Box. Optional single style Emergency Stop Stations for installation in the bay or other desired locations are also available. Should an emergency situation occur that requires immediate shut down of the machine, it is important to know the simple operation of this switch. To shut the machine down in the event of emergency, press in the large button type Emergency Stop Switch. This will also prevent any coin box activity from reactivating the machine. To return the equipment to normal operation, pull out on the switch. As a safety consideration, RYKO recommends installation of at least one additional single type Emergency Stop Switch at the opposite end of the bay from where the Communication Interface Box is installed. This recommendation is not, however, an installation requirement. WARNING! THE HIGH VOLTAGE DISCONNECT SWITCH WILL NOT SHUT OFF THE 120VAC SINGLE PHASE POWER IN THE HIGH VOLTAGE PANEL. Page 13 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

21 WASH SEQUENCES INFORMATION The wash sequences desired and available with this machine will depend on the program Standard or Fast, and the options that are installed. Normally these wash combinations are determined by the owner/operator previous to installation. They can, however, be altered to meet changing marketing situations. While wash sequences may indicate wash combinations of the same likeness, a) the time it takes to complete a wash cycle, b) the sequence of travel (forward, reverse), and c) the locations on the track where the machine begins various wash applications, sequences may differ with each program as well as the wash combination offered. The Description of Operation that follows gives an overall general description of a wash with a machine that has all wash options (UnderCar, On-Board Dry, Foam Bath Application, etc.) installed. For information pertaining to setting up the machine for specific sequences see Machine Setup information and the product section of the Technical Manual. MACHINE PROGRAM As stated in Terms and Definitions, this machine has one program that enables numerous wash combinations depending on machine setup entry. Additional information as it pertains to the possible wash cycles and travel sequences is available on the FST System. Refer to the program number under Info Reference > Program Reference > Equipment > SoftGloss. DESCRIPTION OF OPERATION Activation of a wash and various wash sequences are initiated by one of three types of arming devices as listed in Terms and Definitions, Activation Devices. Due to the variances in operation and programs, the information that follows gives a general description only of wash options that are normally featured with a wash cycle. The wash sequence will depend on the program and options installed and may differ from the following description. Operation begins when: Step 1: Activation 1. The customer activates the automatic attendant to arm the machine for the selected wash. 2. The automatic attendant activates the PLC. When this occurs a green light on each of the front brush arms of the machine illuminates. This indicates to the driver to drive into the bay. 3. As the vehicle enters the bay, its front tires make contact with and close the bay switches. The green lights turn off and the red lights, also located on each front arm, illuminate informing the customer to stop. Step 2: Oscillating Pre-Wash If the OscillatingPre-Wash is part of the selected wash, the oscillating manifold of the Pre-Wash sprays the rocker panel of the vehicle. The manifold oscillates as the gantry drives to the rear of the vehicle and then back to the "home" position. Page 14 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

22 Step 3: Foam Bath or TriFoam Detergent (if present) Application 1. If the Foam Bath and/or the TriFoam Detergent option is part of the selected wash, concentrated detergent is sprayed over the surface of the vehicle. The direction of the machine movement during foam application varies depending on program setups and the wash combination selected. The ultrasonics will "read" or detect the profile of the vehicle during this pass. Step 4: Wash Cycle 1. The wash cycle begins with water and detergent mixture spraying from all main spray nozzles on the machine. This reverse pass must be to the rear of the vehicle to allow the ultrasonics to "read" the profile of the vehicle unless the "read" pass is accomplished during the Foam Bath cycle. 2. The four (4) side brushes begin to spin. The drives start in a forward direction, and the machine will move to the front of the vehicle. As previously stated, route of travel will vary depending on the program installed as well as the wash combination selected. 3. When the machine reaches the front of the vehicle, the front side brushes wrap around and clean the grill and head lights. To assure a thorough cleaning, High Air-In is activated for this washing process. The machine moves forward. At a preset point, the lead brushes make contact with the proximity switch. The proximity switch causes the machine to stop its forward or reverse movement. The side brushes move to an out position and stop spinning. At this time the machine reverses directions and makes another wash pass over the vehicle. This depends on programming and the wash combination selected. At the end of the reverse wash pass the rear side brushes wrap around and clean the back bumper and tail lights when the machine is at the rear of the vehicle. After a delay wavering at the rear of the vehicle, the machine continues reverse movement to enable the top brush to clean the vehicle s rear window and deck. When the proximity switch contact is made at the rear of the vehicle the machine stops and the brushes stop spinning. IMPORTANT: MACHINE PROGRAMMING PROVIDES FOR THE WHEELS TO BE SCRUBBED DURING THE MACHINE'S FIRST FORWARD TO REAR WASH PASS. 4. If foam and detergent are applied in combination at the same time, the machine's travel sequence varies depending on programming and the wash combination selected. 5. Water / detergent mixture that is spraying from the machine's nozzles will change to conform with the wash requirements the customer has purchased. Step 5: Wheel Scrub 1. If the Wheel Scrub is installed and featured with the wash cycle selected by the customer, the front wheels will be scrubbed during the wash passes. The vehicle's rear wheels are detected by the frontside photoeyes and scrubbed during the rear to front (forward) wash pass. The vehicle's front wheels are detected by the rear-side photoeyes and scrubbed during the front to rear (reverse) wash pass. Located on the lower inside portion on each side of the machine s frame is 1 circular brush. When the wheels of a vehicle are detected by photo-electric eyes, these wheel brushes are activated and extend to provide a thorough cleaning and scrubbing of both the front and rear wheels. The wheel scrub brushes operate in accordance to the description that follows. Page 15 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

23 The scrub brushes provide a double scrubbing sequence to the wheels. During this wash, the wheel scrub brushes come in on the front wheels during the machine's reverse movement, spin in one direction, retract, reverse their spin direction, then re-extend to give the wheels a second scrubbing. After the brushes retract the second time, the machine continues washing the vehicle until the rear wheels are detected. The wheel scrub repeats the same wash sequence on these wheels as it made on the front wheels. If installed, refer to the literature included in shipment of this option for maintenance and operation procedures. After the wheels of the vehicle have been cleaned and the pass over the vehicle is completed, water and detergent mixture from the main spray nozzles stops. Depending on program and wash combination selected, the machine is positioned at either the rear or the front of the vehicle ready to proceed with the next wash occurrence, Rinse, Hot Wax, or Cold Wax application. Step 6: Rinse Application 1. The next function that occurs after the wash cycle is the application of a rinse over the vehicle. Note: Except for a few programmed wash combinations that give a hot wax application rather than a rinse, all other programmed wash combinations deliver a water or a Rinse-Off rinse of the vehicle after a wash cycle. When this occurs, water or Rinse-Off will spray from the nozzles on the manifold as the machine makes a pass over the vehicle. In most programmed wash combinations, the rinse cycle will begin at the front of the vehicle and move to the rear of the vehicle. At the rear position, the machine stops, and rinse water from the nozzles discontinues spraying. If programming calls for a second rinse of the vehicle, rinse water or rinse-off continues to spray and the machine continues operation by reversing its direction toward the front of the vehicle and making a second rinse pass. Note: The majority of programs and wash combinations call for the machine to apply a rinse after a wash cycle. Whether this rinse pass consists of one or two passes over the vehicle depends on programming and wash combinations. Whether the rinse consists of one or two passes, at such time the rinse cycle is complete the rinse water from the nozzles discontinues spraying, arms are in the out position, and the wash is either complete or the next wash function commences according to programming. Page 16 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

24 Step 7: Cold Wax, Hot Wax, TriFoam Wax, or Clear Coat Application 1. Should the wash combination not call for a dry cycle, application of either a rinse or Cold Wax or a combination of both is made over the vehicle. Depending on the program, application may be made from front to rear or rear to front. In some situations, application may consist of more than one pass over the vehicle. 2. If the wash cycle includes a dry cycle, Wax Luster (Hot Wax) and/or Clear Coat sealant is then sprayed on the vehicle. It should be remembered that in many instances Clear Coat sealant is sold as a car care enhancement option and is applied instead of the Hot Wax. Go to Step 9. Step 8: Completion of Wash Cycle 1. If the vehicle is not to receive an onboard dry the wash ends. At this time the green (GO) lights on the side arms come on indicating that the customer should drive out. The machine is in the "At Rest" position at the exit end of the bay and the wash cycle is complete. If an On-Board Dry of the vehicle is to be made after the wash, continue to Step 9: Dry Cycle. Step 9: Dry Cycle 1. If an on-board dry cycle is to be received after the wash cycle, the green (GO) light does not come on when the wash cycle is complete. Operation of the machine continues from a point where the machine goes to a "Rest" position at the end of a wash cycle. 2. All brushes will be idle and in a retracted position. 3. While still in the raised position, the top brush spins to clear excess water. The wiper located on the top assembly clears water from the drip pan to prevent it from dripping on the vehicle. 4. Before the machine begins to move, the fans start and the oscillating louvers on both fans begin moving to dry the vehicle. The PLC signals the electric (wiper) motor to turn on. This electric motor then enables the wiper drive tape so the wiper moves from one side of the machine to the other at the beginning of each dry pass. 5. When the dry cycle is complete, the machine is in the "At Rest" position with fans and oscillators shut off. The dry cycle, like with the wash cycle, may be a single pass or double pass dry depending on machine setups. MACHINE SETUP INFORMATION This machine may be programmed to enable different wash functions and wash sequences to occur with respect to; a) the options that may be installed with the machine, b) the number of passes the machine makes over the vehicle during a wash cycle, and c) the speeds at which wash and dry cycles are made. Specific PLC machine setup programming by a RYKO Service Technician is required to attain the owner/operator setups desired. Consult ithe Setups and Tmers document listed for the program number on the FST System under Info Reference > Program Reference > Equipment > SoftGloss. OPERATOR'S CHOICE PROGRAMMING Operator's Choice Programming allows the operator to perform the machine setups for the wash operation. It also provides Variable Wash Speed programming that automatically changes wash operation speeds according to customer traffic or allows the operator to initiate changes to the machine's operation speed from the office or kiosk using a key on the Code-A-Wash IV console. Operator's Choice Programming is completed on the Code-A-Wash IV in the Manager's Mode. For details, refer to the Operator's Choice Programming Instruction document on the FST System. Look under the appropriate program at Info Reference > Program Reference > Equipment > SoftGloss. Page 17 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

25 COLD WEATHER OPERATION This machine may be operated during the colder months of the year. Such operation, however, is subject to the owner/operator's discretion. During freezing weather ice build up on limit switches, brushes, and floors, if left unattended, can cause damage to the machine or vehicles. Ice build up must be removed. If a wash bay is equipped with any of the optional RYKO Automatic Door Openers that allow one bay door to be open at a time, the machine will be protected for operation at a lower temperature than if both doors remain open. An optional Frost Protection feature is available to remove water from the system between wash cycles and further protect the machine during freezing weather. This option is highly recommended for machines operating in climates with inclement winter weather. OPTIONAL REMOTE ARMING DEVICES RYKOwash Vehicle Wash Systems are controlled automatically with one of three optional remote automatic attendant arming devices. These devices include the; RYKO Code-A-Wash IV, the Auto Cashier, or the RYKO Accumulator (Coin Box). All RYKO automatic attendants will activate the machine whenever; 1) the control power is on, 2) a vehicle is on the bay switches, and 3) the Emergency Stop switch is not activated. Once a vehicle is on the bay switches, blocking coils in the Coin Box prevent another activation of the machine until the vehicle being washed has finished its cycle. The Code-A-Wash IV can accept the input of the next customer before the current customer has finished the wash cycle. Instructions for operation of these automatic attendants are included with shipment of the option. IMPORTANT! IF THE ARMING DEVICE USED IS AN AUTO CASHIER, THE VEND DURATION TIME MUST BE SET TO 9.9 SECONDS (MAXIMUM). THIS IS DONE TO ENSURE THAT IF A CUSTOMER LEAVES THE WASH BEFORE THE WASH CYCLE IS COMPLETE, ESCROWED CODES ARE NOT LOST. REFER TO THE AUTO CASHIER MANUAL INCLUDED WITH THE AUTO CASHIER FOR INSTRUCTIONS ON HOW TO ADJUST THE VEND DURATION TIME. Comment [RM1]: Added this note on 4/17/96 per CAR #4499/4/10/96 Roger Topper WATER SYSTEM Water is the basic ingredient in all vehicle wash systems. Various additives and techniques are used to increase the cleaning action of water, such as liquid soap for better particle dissolution, and the agitation by brushes. However, to insure a quality wash, the correct supply and usage of water is a primary factor. Water system operation guidelines for the machine follow. As stated in Basic Requirements and Specifications, the machine's water needs (without UnderCar Wash option) may be provided by city water or any other source capable of supplying 30 GPM at 40 PSI (minimum) to 150 PSI (maximum). IMPORTANT: THE UNDERCAR WASH OPTION REQUIRES 30 GPM IN ADDITION TO THE FLOW REQUIREMENTS LISTED ABOVE. IMPORTANT: THERE SHOULD BE NO RESTRICTIONS IN THE AIR OR WATER LINES. Page 18 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

26 The water flows from its source through a flexible rubber "umbilical" hose and into the machine. The water system sprays from the top and sides of the gantry and from the side arms through nozzles placed to provide maximum saturation. The front side arm nozzles may be adjusted to owner/operator preference. Loosen the three mounting bolts, then swivel the nozzle, and retighten the bolts with the nozzle in the desired position. Nozzles should be adjusted to provide good water coverage of the vehicle. The Pre-Wash Option includes an accessory pump (not installed on the gantry) which boosts the inlet wash water pressure an additional 80 PSI. Either reclaim or fresh water may be used. The pressurized Pre-Wash water routes to the Pre-Wash manifolds through a flexible, rubber "umbilical" hose. Note: Due to the sequence of operation the Pre-Wash requires no additional water service. ADDITIVE SYSTEM (WITH BLUE WHITE PUMPS) USING APPROPRIATE ADDITIVES WITH THIS WASH EQUIPMENT Alkaline or acid presoak type detergents that are normally used with touch free wash systems are not appropriate for use with RYKO friction wash equipment. These detergents are more suited for use with high volume spray wash equipment and do not provide adequate lubrication on friction wash brushes. On filament machines and on FoamBrite machines these detergents can increase the likelihood of damage to the vehicle. Presoak detergents require sufficient water volume to rinse off completely. Unlike RYKO's spray wash equipment, RYKO's friction wash machines are not designed to rinse vehicles with the volume of water that would be necessary to completely remove a presoak type detergent. The residual presoak remaining on surfaces or glass could damage the vehicle. Presoak detergents do not foam as well as friction wash detergents. Though foam does not indicate the detergent's ability to clean, customers perceive that more foam equals better cleaning. RYKO has prepared and tested additives for effective and safe use with this equipment. Before using an additive supplied by others, consult the Material Safety Data Sheet information pertaining to the product and discuss the advisability with your local RYKO service representative. The additive solutions used in the machine are very important. RYKO cleaning aids have been specially formulated for use with RYKO equipment and are recommended for best operation. RYKO Cleaning Aids are available in 5, 15, and 55 gallon containers. Mixing RYKO Cleaning Aids is not required. Simply connect the detergent lines and prime the lines initially. RYKO Mountain Pine Foaming Detergent solution aids water in softening and loosening road film, grime, and dirt that have accumulated on the vehicle. It also helps remove foreign particles to provide a better cleaning job. In addition, this pine scented detergent acts as a lubricant between the brushes and the vehicle surface to protect delicate paint finishes. Proper detergent concentration also increases brush life and reduces bristle tangling. If Cold or Hot Wax options are not used, application of Rinse-Off is necessary to sheet the water that minimizes spotting when the vehicle will not be blown dry. RYKO Mountain Pine Foaming Detergent is quick cleaning non-streaking, biodegradable, fast rinsing, and highly lubricative. Detergent costs per vehicle are minimal. For non-scented detergent, order RYKO High Foam detergent. Page 19 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

27 RYKO offers ultra-concentrated high foam detergent in three colors for use with the TriFoam Detergent option. It performs the same functions as the Mountain Pine Foaming Detergent. RYKO Rinse-Off is used when the vehicle does not receive an automatic dry. RYKO Citrus Shine Wax is necessary during the wax cycle to bead the water so it is easily blown from the vehicle surface by the dryer fans, providing optimum drying results. This RYKO Citrus Shine Wax is citrus scented and on its application to the vehicle's surface provides a lemon aroma that lingers on the vehicle's surface for a short period of time after application. For non-scented wax order RYKO Wax Luster. RYKO Red, Yellow and Blue Foam Wax Concentrate provides the same benefits as RYKO Wax Luster R. Its application is visually highlighted using colorful wax and optional flashing spotlights during the TriFoam Wax cycle. RYKO Clear Coat is a polymer (silicone) base type product that offers longer lasting qualities than hot wax, without the required heating. In many installations, this additive option is sold as an option and applied after a wax application. RYKO Tire Cleaner is used for cleaning the tires via the Wheel Scrubber application and/or the Tire Chemical Spray option. RYKO Rust Inhibitor is used during the application of the UnderCar Wash cycle. POLYTUBE CONNECTIONS The polytubes must match correctly to ensure the correct coloration of the TriFoam options. The Air Tubing and Detergent or Wax tubings are identified by color and should be connected as described in the charts below. Detergent Air Tubing Yellow Blue Red Wax Air Tubing Orange Green Purple Detergent Tubing (Clear) # 1 TriFoam Detergent (Yellow) # 2 TriFoam Detergent (Blue) # 3 TriFoam Detergent (Red) Wax Tubing (Clear) # 1 TriFoam Wax (Yellow) # 2 TriFoam Wax (Blue) # 3 TriFoam Wax (Red) Page 20 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

28 ADDITIVE PUMP PRIMING AND DIAL SETTING Before priming any additive pumps, connect the pump inlet and outlet to the appropriate lines. CAUTION! ONLY HAND TIGHTEN THE PUMP FITTINGS. 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 RYKO additive (Foaming Detergent, Rinse-Off, Wax, 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 manual switch and set the dial adjustment on each pump to 100%. 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. After the additive system is completely primed, set the dials for the appropriate recommended additive disbursement, per the Additive Pump Setting Chart that follows. Should the pump setting for the specific additive be set for a higher or lower volume than that which is recommended, problems could occur. A setting that allows too little additive to be disbursed may not provide proper cleaning. 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. This allows air to enter the additive line. If this symptom occurs, verify and correct. RYKO ADDITIVE SETTING CHARTS The information that follows gives recommended dial settings to allow the proper volume of additive for each wash. These settings are provided as a starting point and guide. Fine tuning may be necessary to meet location requirements. Additives Dial Setting Foam Bath or Detergent 3 to 5 (30% to 50%) TriFoam Detergent 6 (60%) Rinse-Off 1 to 3 (10% to 30%) Wax or Clear Coat 6 (60%) TriFoam Wax 6 (60%) Tire Cleaner 9 to Maximum (90% to 100%) Rust Inhibitor 3 to 5 (30% to 50%) Page 21 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

29 TRIFOAM DETERGENT & TRIFOAM WAX AIR & WATER SETTINGS Additive Air Water Control Valve TriFoam Detergent 12 PSI 2-1/2 turns open TriFoam Wax 12 PSI 2-1/2 turns open Note::Adjust air and water from initial settings to desired foam appearance. ADDITIVE SYSTEM OPERATION The detergent, wax/rinse-off system is designed to automatically dispense additives mixed with water over the surface of the vehicle being washed. This is accomplished when the called out additive is released into the water line and then disbursed on the vehicle's surface from nozzles that are located on the water manifold. Note: Pre-Wash water does not use any additives. The detergent used for washing the vehicle is added to the water system of the machine from a 120VAC pump that pumps an accurate amount of additive on each vehicle. Back flow to the detergent tank drum is prevented by a check valve that is installed in the line. The amount of detergent injected in the line is controlled by the stroke of the detergent pump that has been adjusted for a determined flow rate. When the dial is set for the desired setting, this valve restricts the stroke of the pump. The longer the stroke, the more detergent solution is released into the water system. If the vehicle is not to receive an automatic dry, the Rinse-Off additive is necessary to sheet the water in order to minimize spotting. One rinse pump (optional) will need to be installed to enable application of the RInse-Off additive. This pump allows an accurate amount of Rinse-Off to be disbursed into the water line which in turn applies this mixture over the vehicle surface at the appropriate time called out during the wash cycle. As with the detergent additive, back flow to the rinse-off tank drum is prevented by a check valve in the line. The wax pump is only installed with machines that have the cold or hot wax options. Wax is needed ONLY if a Dry cycle is used. If wax is applied and not blown off, spotting could occur. If a dry is performed without wax application, water will not bead up and the water may not be sufficiently removed. Unless hot wax is present, the wax is pumped directly into the water system located on the gantry of the machine. There is a check valve at this location to prevent back flow of the wax. Should hot wax be present, wax is pumped to the wax routing solenoid where it is distributed to the hot or cold wax system. If featured, the Foam Bath option is capable of dispersing a foamy shampoo over the vehicle previous to the start of the wash cycle. This occurs when detergent is dispensed to the foam bath manifold, rather than into the water line. This foam bath foaming assembly is located on each side of the frame underneath the access panel doors. It operates by mixing air (coming from the foamer solenoid in the pneumatic panel and activated by the PLC), with detergent and water in the Foam Bath foamer assembly. The air and detergent are forced through a fine mesh to create a foam. Adjustment is possible with the flow valve in the air line (located on the pneumatic panel on the machine's right side) and the flow valve in the water line (located in the Remote Chemical Pump Assembly above the chemical pumps). The Foam Bath System gets its pressure from the air manifold and is controlled by the foam bath regulator. This assures identical additive usage from cycle to cycle. Page 22 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

30 When installed on the SoftGloss, the TriFoam Detergent option allows the simultaneous application of colorful streams of foamy ultra-concentrated detergent over the surface of the vehicle preceding the wash cycle. A chemical/water mixture feeds the TriFoam Detergent manifolds on each side of the machine gantry. The manifolds deliver two of the three colored detergent streams and the standard detergent foam bath nozzles on each side provide the third color. The effect is visually striking while providing a high quality vehicle wash. Clogging of the additive system is prevented by a screen filter in the main additive line. FOAM BATH, TRIFOAM DETERGENT, TRIFOAM WAX, AND HOT WAX TEST Access the site menu screen on the Communication Interface touch screen display. Select TEST ITEMS on the screen to display all the available test functions. Press the circle on the right of an appropriate chemical application to activate its test function for adjusting water, air and chemicals, or the hot wax system to test the Hot Wax Heater. Other test functions that can be performed via this Test Functions screen includes the Pre-Wash Oscillate Test and Fan Nozzle Oscillate Test. For operation procedures of the TEST buttons refer to Communications Interface Box information given in this manual. ADJUSTMENTS - AIR AND WATER (FOAM BATH, TRIFOAM DETERGENT, & TRIFOAM WAX) AIR WATER Adjustments to air flow for the Foam Bath is made using the flow control valves located on the pneumatic panel on the right side of the machine inside the access door on the end cover. The Foam Bath solenoid valve (located on the pneumatic manifold) and its flow control valve control the detergent used for Foam Bath. The TriFoam Detergent solenoid valve and its flow control valve are located on a separate offboard pump assembly and control the air for the TriFoam Detergent manifolds (three colors). The TriFoam Wax solenoid valve and its flow control valve are located on a separate offboard pump assembly and control the air for the TriFoam Wax manifolds (three colors). To increase the air to the foaming assemblies, turn the valve knob counterclockwise. To decrease the air to the foaming assemblies, turn the valve knob clockwise. The addition of air to the foaming assemblies will produce a creamier foam. Adjustments to water flow for the Foam Bath is made using the flow control valve located on the basic offboard chemical pump assembly. The TriFoam Detergent water flow control valve located in a separate offboard pump assembly controls the TriFoam Detergents dispersed from the TriFoam manifolds on the machine. The TriFoam Wax water flow control valve located in a separate offboard pump assembly controls the TriFoam Wax dispersed from the TriFoam manifolds on the machine. Additional flow control valves used to fine tune the flow previous to each foaming assembly are located near the front arms. On any of the flow controls, turn the valve knob counterclockwise to increase, or clockwise to decrease, the water flow. The addition of water to the foaming assemblies will increase the spray distance, but will decrease the foam. Note: If foam is building up at the foaming manifolds and is not coming out as a stream, there is too much air and/or not enough water. Page 23 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

31 TRIFOAM DETERGENT OPTION MAINTENANCE Regular maintenance is important to the operation of the TriFoam Detergent option equipment. The nozzles holes in the foamer manifolds are 5/64" diameter. In the event holes in the TriFoam manifolds should become clogged, the foam will not dispense in a stream but create a large ball of foam at the foamer manifold. If this occurs, the nozzle hole must be cleared. If one stream is dispensing at an undesirable angle there may be a burr in the inner ID of the pipe. In this case it may be necessary to bore out the hole with a 5/64" drill bit. Take care not to enlarge the hole as this could affect the disbursement of the TriFoam Detergent and possibly the additive, air, and water adjustments. FOAMBRITE LUBRICATION GUIDELINES FoamBrite brushes require adequate lubrication to provide the optimum wash. The following important lubrication and detergent guidelines are specific to FoamBrite brushes. 1. Detergents purchased from suppliers other than RYKO should not be more than 85% volatile (or less than 15% solids). This should be stated on the product MSDS. If not, this information can be requested from the detergent supplier. Refer also to Concentrated Detergents below. 2. Detergent should be set at a feed rate that is equal to or higher than RYKO's High Foam Detergent recommended settings (see Additive Setting Chart). Set at a higher setting for more viscous detergents. Note: Only if detergent meets criteria in guidelines 1, 3, 4, & 5 should the feed rate be lowered to a level below that of RYKO High Foam Detergent. When set at this new feed rate, these criteria should still be met. 3. Most vehicles should wash without the FoamBrite brushes 'squeaking' if the detergent is adjusted correctly. Squeaking caused by the friction of the FoamBrite brushes against a vehicle during a wash cycle may indicate that lubrication is inadequate. To resolve this problem, either increase the detergent feed rate or change detergents. 4. The detergent should rapidly dissolve in water with little or no agitation. After adding the detergent to water the solution should be homogenous or uniform in consistency and appearance. 5. The detergent must not be a presoak which is typically used in touch-free machines. Detergent labeled as 'dual purpose' for use in both friction and touchless machines should not be used. Note: It is possible that detergents meeting all the above criteria still might not deliver adequate lubrication when used on machines equipped with FoamBrite brushes. CONCENTRATED DETERGENTS Some manufacturers supply detergent in a concentrated form that must be diluted before use. To ensure that the detergent is diluted properly for each batch and has solids of at least 15%, refer to the formula below to determine how much water and concentrated detergent is needed. Formula: Formula Key: (0.15*G)/S = V d G - V d = V w G Total gallons of finished product desired (water + concentrated detergent combined) Note: Differences in specific gravity of detergent and water are ignored in formula. This will account for no more than a 5% error. S Total solids of concentrated detergent before diluted (e.g., 45% is expressed as 0.45) V d Volume of detergent needed Volume of water needed V w Page 24 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

32 In other words, 0.15 (Desired solids percentage) (multiplied by) X G (Total gallons of finished product desired) A Then A (See above) (divided by) S (Total solids of concentrated detergent before diluted) V d (Volume of detergent needed) Then G (Total gallons of finished product desired) (Minus) - V d (Volume of detergent needed) V w (Volume of water needed) Example: A concentrated detergent with a solids of 40% needs to be diluted to make 55 gallons total of finished product. Therefore, G = 55 gallons and S = Find V d and V w to make a 55 gallon batch of finished product at 15% solids. (0.15*55)/(0.40) = V d or 20.6 gallons of concentrated detergent needed for a 55 gallon batch. 55 minus 20.6 = V w or 34.4 gallons of water needed for a 55 gallon batch ADDITIVE SYSTEM (NON-RYKO CHEMICAL PUMPS) USING APPROPRIATE ADDITIVES WITH THIS WASH EQUIPMENT Alkaline or acid presoak type detergents that are normally used with touch free wash systems are not appropriate for use with RYKO friction wash equipment. These detergents are more suited for use with high volume spray wash equipment and do not provide adequate lubrication on friction wash brushes. On filament machines and on FoamBrite machines these detergents can increase the likelihood of damage to the vehicle. Presoak detergents require sufficient water volume to rinse off completely. Unlike RYKO's spray wash equipment, RYKO's friction wash machines are not designed to rinse vehicles with the volume of water that would be necessary to completely remove a presoak type detergent. The residual presoak remaining on surfaces or glass could damage the vehicle. Presoak detergents do not foam as well as friction wash detergents. Though foam does not indicate the detergent's ability to clean, customers perceive that more foam equals better cleaning. RYKO has prepared and tested additives for effective and safe use with this equipment. Before using an additive supplied by others, consult the Material Safety Data Sheet information pertaining to the product and discuss the advisability with your local RYKO service representative. The information below pertains to machines with the TriFoam Detergent Option, only. Page 25 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

33 When installed on the SoftGloss, the TriFoam Detergent option allows the simultaneous application of colorful streams of foamy ultra-concentrated detergent over the surface of the vehicle preceding the wash cycle. The manifolds deliver red and blue streams of detergent and the standard detergent foam bath nozzles on each side provide streams of white or yellow. The effect is visually striking while providing a high quality vehicle wash. ADJUSTMENTS - AIR AND WATER (FOAM BATH AND TRIFOAM DETERGENT) AIR Adjustments to air flow for both the Foam Bath (yellow or white color only) and TriFoam Detergent (red and blue colors only) are made using the respective flow control valves located on the pneumatic panel on the right side of the machine inside the access door on the end cover. The Foam Bath solenoid valve (located on the pneumatic manifold) and its flow control valve control the Yellow (or White) detergent used for TriFoam Detergent and also for the standard Foam Bath. The TriFoam Detergent solenoid valve (plumbed into the top of the pneumatic manifold) and its flow control valve control the air for the blue and red detergents of TriFoam Detergent. To increase the air to the foaming assemblies, turn the valve knob counterclockwise. To decrease the air to the foaming assemblies, turn the valve knob clockwise. The addition of air to the foaming assemblies will produce a creamier foam. WATER Adjustments to water flow for both the Foam Bath (yellow or white color only) and TriFoam Detergent (red and blue colors only) are made using the respective flow control valves located on the offboard chemical pump assembly above the chemical pumps. The Foam Bath water flow control valve controls the Yellow (or White) detergent used for TriFoam Detergent and also for the standard Foam Bath. The TriFoam Detergent water flow control valve is the basic control for the blue and red TriFoam detergents. There are also flow control valves used to fine tune the flow previous to each foaming assembly located by the front arms. On any of the flow controls, turn the valve knob counterclockwise to increase, or clockwise to decrease, the water flow. The addition of water to the foaming assemblies will increase the spray distance, but will decrease the foam. Note: If foam is building up at the foaming manifolds and is not coming out as a stream, there is too much air and/or not enough water. Page 26 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

34 RYKO ADDITIVES The additive solutions used in the machine are very important. RYKO cleaning aids have been specially formulated for use with RYKO equipment and are recommended for best operation. RYKO Cleaning Aids are available in 5, 15, and 55 gallon containers. Mixing RYKO Cleaning Aids is not required. Simply connect the detergent lines and prime the lines initially. Also available when using RYKO additives is a Keep Full Service additive supply system. This system allows easy monitoring and replenishment of additive supply. Discuss this system with your RYKO service representative. RYKO Mountain Pine Foaming Detergent RYKO Citrus Shine Wax RYKO Clear Coat TriFoam Detergents Aids water in softening and loosening road film, grime, and dirt that have accumulated on the vehicle. It also helps remove foreign particles to provide a better cleaning job. This pine scented detergent also acts as a lubricant between the brushes and the vehicle surface to protect paint finishes. Proper detergent concentration also increases brush life and reduces bristle tangling. If Cold or Hot Wax options are not used, application of Rinse-Off is necessary to sheet the water that minimizes spotting when the vehicle will not be blown dry. RYKO Mountain Pine Foaming Detergent is quick cleaning nonstreaking, biodegradable, fast rinsing, and highly lubricative. Detergent costs per vehicle are minimal. For non-scented detergent, order RYKO High Foam detergent. Necessary during the wax cycle to bead the water so it is easily blown from the vehicle surface by the dryer fans, providing optimum drying results. This RYKO Citrus Shine Wax is citrus scented and on its application to the vehicle's surface provides a lemon aroma that lingers on the vehicle's surface for a short period of time after application. For non-scented wax order RYKO Wax Luster. Polymer (silicone) base type product that offers longer lasting qualities than hot wax, without the required heating. In many installations, this additive option is sold as an option and applied after a wax application. RYKO offers ultra-concentrated high foam detergent in multiple colors for use with the TriFoam Detergent option. See the TriFoam Detergent Ordering information below. Page 27 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

35 TriFoam Detergent Ordering Information Detergent RYKO Part No. Detergent RYKO Part No. 5 Gallons Blue Foaming Yellow Foaming Gallons Blue Foaming Yellow Foaming Gallons Blue Foaming Yellow Foaming Detergent RYKO Part No. Detergent RYKO Part No. 5 Gallons Red Foaming High Foaming Gallons Red Foaming High Foaming Gallons Red Foaming High Foaming Note: Verify part numbers with a RYKO service representative or RYKO Parts Department representative when ordering. FOAMBRITE LUBRICATION GUIDELINES FoamBrite brushes require adequate lubrication to provide the optimum wash. The following important lubrication and detergent guidelines are specific to FoamBrite brushes. 1. Detergents purchased from suppliers other than RYKO should not be more than 85% volatile (or less than 15% solids). This should be stated on the product MSDS. If not, this information can be requested from the detergent supplier. Refer also to Concentrated Detergents below. 2. Detergent should be set at a feed rate that is equal to or higher than RYKO's High Foam Detergent recommended settings (see RYKO Additive Setting Chart). Set at a higher setting for more viscous detergents. Note: Only if detergent meets criteria in guidelines 1, 3, 4, & 5 should the feed rate be lowered to a level below that of RYKO High Foam Detergent. When set at this new feed rate, these criteria should still be met. 3. Most vehicles should wash without the FoamBrite brushes 'squeaking' if the detergent is adjusted correctly. Squeaking caused by the friction of the FoamBrite brushes against a vehicle during a wash cycle may indicate that lubrication is inadequate. To resolve this problem, either increase the detergent feed rate or change detergents. 4. The detergent should rapidly dissolve in water with little or no agitation. After adding the detergent to water the solution should be homogenous or uniform in consistency and appearance. 5. The detergent must not be a presoak which is typically used in touch-free machines. Detergent labeled as 'dual purpose' for use in both friction and touchless machines should not be used. Note: It is possible that detergents meeting all the above criteria still might not deliver adequate lubrication when used on machines equipped with FoamBrite brushes. Page 28 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

36 CONCENTRATED DETERGENTS Some manufacturers supply detergent in a concentrated form that must be diluted before use. To ensure that the detergent is diluted properly for each batch and has solids of at least 15%, refer to the formula below to determine how much water and concentrated detergent is needed. Formula: Formula Key: (0.15*G)/S = V d G - V d = V w G Total gallons of finished product desired (water + concentrated detergent combined) Note: Differences in specific gravity of detergent and water are ignored in formula. This will account for no more than a 5% error. S Total solids of concentrated detergent before diluted (e.g., 45% is expressed as 0.45) V d Volume of detergent needed Volume of water needed In other words, V w 0.15 (Desired solids percentage) (multiplied by) X G (Total gallons of finished product desired) A Then A (See above) (divided by) S (Total solids of concentrated detergent before diluted) V d (Volume of detergent needed) Then G (Total gallons of finished product desired) (Minus) - V d (Volume of detergent needed) V w (Volume of water needed) Example: A concentrated detergent with a solids of 40% needs to be diluted to make 55 gallons total of finished product. Therefore, G = 55 gallons and S = Find V d and V w to make a 55 gallon batch of finished product at 15% solids. (0.15*55)/(0.40) = V d or 20.6 gallons of concentrated detergent needed for a 55 gallon batch. 55 minus 20.6 = V w or 34.4 gallons of water needed for a 55 gallon batch ADDITIVE SYSTEM OPERATION The detergent, wax/rinse-off system is designed to automatically dispense additives mixed with water over the surface of the vehicle being washed. This is accomplished when the called out additive is released into the water line and then disbursed on the vehicle's surface from nozzles that are located on the water manifold. If featured, the Foam Bath option is capable of dispersing a foamy shampoo over the vehicle previous to the start of the wash cycle. This occurs when detergent is dispensed to the foam bath mixing assembly, rather than into the water line. This foam bath foaming assembly is located on each side of the frame underneath the access panel doors. It operates by mixing air (coming from the foamer solenoid in the pneumatic panel and activated by the PLC), with detergent and water in the Foam Bath foamer assembly. The air and detergent are forced through a fine mesh to create a foam. Adjustment is possible with the flow valve in the air line (located on the pneumatic panel on the machine's right side) and the flow valve in the water line (located in the Remote Chemical Pump Assembly above the chemical pumps). Page 29 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

37 The Foam Bath System gets its pressure from the air manifold and is controlled by the foam bath regulator. This assures identical additive usage from cycle to cycle. Clogging of the additive system is prevented by a screen filter in the main additive line. Wax is needed ONLY if a Dry cycle is used. If wax is applied and not blown off, spotting could occur. If a dry is performed without wax application, water will not bead up and the water may not be sufficiently removed. Unless hot wax is present, the wax is pumped directly into the water system located on the gantry of the machine. There is a check valve at this location to prevent back flow of the wax. Should hot wax be present, wax is pumped to the wax routing solenoid where it is distributed to the hot or cold wax system. FOAM BATH TEST, TRIFOAM DETERGENT TEST, AND HOT WAX TEST Access the site menu screen on the Communication Interface touch screen display. Select TEST ITEMS on the screen to display all the available test functions. Press the circle on the right of an appropriate chemical application to activate its test function for adjusting water, air and chemicals, or the hot wax system to test the Hot Wax Heater. Other test functions that can be performed via this Test Functions screen includes the Pre-Wash Oscillate Test and Fan Nozzle Oscillate Test. For operation procedures of the TEST buttons refer to Communications Interface Box information in this manual. TRIFOAM DETERGENT OPTION MAINTENANCE Regular maintenance is important to the operation of the TriFoam Detergent option equipment. The nozzles holes in the foamer manifolds are 5/64" diameter. In the event holes in the TriFoam red and blue foamer manifolds should become clogged, the foam will not dispense in a stream but create a large ball of foam at the foamer manifold. If this occurs, the nozzle hole must be cleared. If one stream is dispensing at an undesirable angle there may be a burr in the inner ID of the pipe. In this case it may be necessary to bore out the hole with a 5/64" drill bit. Take care not to enlarge the hole as this could affect the disbursement of the TriFoam Detergent and possibly the additive, air, and water adjustments. Page 30 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

38 PROGRAMMABLE LOGIC CONTROLLER OPERATION PROGRAMMABLE LOGIC CONTROLLER OPERATION Located in the machine's electrical control panel, the Programmable Logic Controller (PLC) consists of one computer base unit and I/O expansion blocks. The number of expansion blocks installed depends on the options that are installed on or with the machine. Additional products, such as expansion units and / or special adapters may be added in the interest of product improvement, or due to special design requirements, only. The base unit of the PLC is the main control center. It houses the programmed memory module which determines the sequence of wash operations by monitoring external signals from sources such as push buttons, sensors, and switches. On monitoring these signals (Inputs), the base unit transmits signals to the output sections which perform the required external operational functions. External functions are mechanical operations of the machine such as relays, motor contactors, valves, or indicator lights. The I/O Expansion Blocks add more channels and the capability of receiving more input signals. They also will transmit more signals. Located on the front cover of the CPU are four (4) Status Indicator lights (LED's). When lit, each LED indicates specific information pertaining to the operation of the unit. Note also that a POWER LED also exists on each Expansion Block. Items as they pertain to these Indicator lights, include: POWER (POWER INDICATOR LIGHT): When this LED is lit, it shows that power is being supplied to the unit. RUN: When this LED is lit, it indicates that the machine is in the operating RUN mode necessary for the PLC to run the program. BATT. V: (BATTERY VOLTAGE INDICATOR LIGHT): This LED will light if the battery voltage drops. PROG-E/CPU-E (ERROR INDICATOR LIGHT): This LED serves as an ERROR Indication light in one of two ways. 1. This LED may flash if a PROGRAM error has occurred; or battery voltage is abnormally low. 2. This LED may light continuously, if a CPU error occurs. Other LED's on the Basic Unit and the Expansion Blocks significant to operation monitor the inputs and indicate the outputs of the program. Each LED is identified by a number directly beside it. LED's on the basic unit of the machine are in two separate areas with I/O numbers 0 through 77. During a wash cycle these LED's monitor the inputs and indicate the outputs of the program. This monitoring process determines the sequence of operation for the machine. This sequence is determined by the program in the Central Processing Unit. Expansion Blocks allow the addition of inputs and outputs. The first Expansion Block used in the setup of the PLC system is attached directly to the end of the base unit via a connection cable. Additional Expansion Blocks required thereafter are attached to one another, also via a connection cable. Expansion Blocks also have LED's which monitor input and output activities. Unlike the base unit which monitors both inputs and outputs, Expansion Blocks will normally monitor either inputs or outputs exclusively. Page 31 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

39 PLC usage with the machine also provides basic diagnostics. Basic diagnostics allows site personnel to monitor things on the machine that do not require additional hardware for the machine to operate. This also includes internal Diagnostic History that can be accessed with the display on the Communication Interface Box by a service technician. The internal history will contain the 20 most recent events that have occurred during the machine's operation. This information includes: 1. The "sequence" in the wash cycle that an "event" occurred in. An example of an event might be the tripping of a brush circuit protector which needs to be reset. 2. What the "event" actually was that occurred. 3. The wash count in progress when the event occurred. 4. If expanded diagnostic option has been ordered, the date and time the event occurred. Monitoring the "event" in question is possible via the display on the Communication Interface Box that is located in the bay. In the occurrence of an "event", a 2 digit code will appear on the display. The Electrical Schematic drawing for the machine given in this manual shows the external devices generating inputs to the CPU or Expansion Unit. It also shows which external devices are controlled by the output channels. Should a problem occur with the machine, refer to the Electrical Schematic drawing to perform simple troubleshooting techniques. OPERATOR S INTERFACE BOX If ordered as an option, an Operator s Interface Box houses the Emergency Stop switch and the drive switches for the SoftGloss carwash machine. The manual drive switches are inside the box, where the Emergency Stop switch is on the outside of the box. COMMUNICATIONS INTERFACE BOX AND 2 DIGIT CODE DISPLAY If ordered as an option, the Communications Interface Box houses a Touch Screen LCD display. This display enables the owner/operator and service personnel to visually obtain a 2 digit code which reflects a specific wash function as it occurs. Refer to the 2 Digit Diagnostic Code Information provided in the Drawings section of the Owner's Manual. This display also contains the Manual Drive (see Moving the Machine Manually) and Operation Mode (see Start-up and Shut-down Information) functions which allows the owner/operator and Service personnel to move the machine and OPEN/CLOSE the wash. Besides the Touch Screen LCD Display, the Communications Interface Box also houses the Emergency Stop Station switch (see Terms and Definitions). AIR PRESSURE Air is pumped from an air compressor or other source through the air line and into a flexible umbilical hose. The air umbilical enters the machine at the same place on the machine as the water and electrical umbilicals. From here the air flows into a moisture trap near the air manifold and then through the air regulator and into the air manifold. This is a complete unit located in a compartment on the right side of the machine. The pneumatic manifold consists of standard (with machine) and optional electrically operated solenoids air pressure regulators with gauges. The gauges give the pressure readings of their respective regulators as well as the pressure which passes through the solenoids. For recommended regulator settings refer to the Pneumatic/Hydraulic Schematic drawing/s given in this manual. IMPORTANT: PRESSURE SETTINGS GIVEN IN THIS MANUAL ARE SUBJECT TO CHANGE. Page 32 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

40 SOLENOIDS INFORMATION Refer to the Pneumatic Panel Assembly drawing in this manual for the locations of the solenoids, and to the Pneumatic & Hydraulic Schematic. Note: Remember that installation of additional solenoids will depend on the options installed on the machine. AIR REGULATORS AND AIR USE Refer to the Pneumatic & Hydraulic Schematic drawing in this manual for the recommended regulator pressure settings. Refer to the Pneumatic Panel Assembly drawing for the location of each regulator. IMPORTANT: WHEN ADJUSTING REGULATORS, USE THE MINIMUM AIR PRESSURE NEEDED TO ACHIEVE THE DESIRED BRUSH CONTACT. DO NOT EXCEED THE MAXIMUM SETTING. REAR RETURN (REGULATOR 4) AND FRONT RETURN (REGULATOR 5) AIR REGULATORS Return Air passes through the Rear Return air solenoid and/or the Front Return air solenoid into the respective brush arm cylinder and retracts it. Rear Return air and/or Front Return air is used to retract the side brushes. REAR TRAIL IN (REGULATOR 6) REGULATOR IMPORTANT: AIR PRESSURE SET TOO HIGH MAY CAUSE THE ARMS TO BOUNCE. Depending on the direction the machine is moving, trailing air passes through the Rear Trail In solenoid. Rear Trail In air extends the respective cylinders which pushes the right and left trailing brushes against the vehicle being washed. REAR AIR (REGULATOR 7) AND FRONT AIR (REGULATOR 9) REGULATORS Depending on the direction the machine is moving, air passes through the Rear arms solenoid or the Front arms solenoid. Air extends the cylinders on the front or rear brushes, which pushes both leading front or rear arms toward the vehicle as it is being washed. Note: Depending on whether filament brushes or cloth pads are installed, pressure settings for the Rear Air - Regulator 7 will differ. FRONT HIGH AIR (REGULATOR 8) REGULATOR Extra High Air is used during the wash at the front of the vehicle to clean the front part (grill, head lights, bumper, etc.) of the vehicle. TOP BRUSH (REGULATOR 10) REGULATOR CAUTION! DO NOT EXCEED 120 PSI AIR PRESSURE. IMPORTANT: FOR PROPER OPERATION, THE TOP BRUSH AIR PRESSURE REGULATOR SHOULD NORMALLY BE SET AT 110 PSI (RANGE IS 100 TO 120 PSI). THE TOP BRUSH SHOULD GENTLY RISE TO ITS MAXIMUM UP POSITION. TO PREVENT THE TOP BRUSH FROM RISING TOO RAPIDLY AND BOUNCING AGAINST THE TOP BUMPER, ADJUST THE NEEDLE VALVE ON THE OUTLET OF THE TOP BRUSH CYLINDER. PERFORM THIS TEST WITH WET BRUSHES. Page 33 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

41 Top Brush air passes through the Top Brush solenoid and a Flow Control Valve (see Flow Control Valve description that follows). Top Brush air pushes the Top brush up. FOAM BATH (REGULATOR 1 - OPTIONAL) REGULATOR The Foam Bath regulator provides air to the foam bath solenoid and the Flow Control Valve to enable air to the foam bath manifold. IMPORTANT: PRESSURE SETTING HIGHER THAN 60 PSI SHOULD BE AVOIDED. WHEEL SCRUB RIGHT (REGULATOR 2 - OPTIONAL) REGULATOR AND WHEEL SCRUB LEFT (REGULATOR 3 - OPTIONAL) REGULATOR Air passes through the energized appropriate Wheel Scrub Right Extend solenoid and the Wheel Scrub Left solenoid to the respective wheel scrub cylinder. The cylinders extend to extend the Wheel Scrub Brushes. IMPORTANT: PRESSURE SETTING HIGHER THAN 50 PSI SHOULD BE AVOIDED. ASSOCIATED AIR REGULATOR EQUIPMENT TOP BRUSH FLOW CONTROL VALVE The speed with which the top brush drops can be controlled by adjusting a flow control valve in the air line from the top brush cylinder. This valve is located in the pneumatic panel on the top brush air solenoid. Turning the knob clockwise restricts air flow and slows the top brush descent. Rotating the knob counterclockwise allows the brush to drop more rapidly. The flow control valve does not affect the speed with which the top brush rises. AIR LINE FILTER All air to the machine passes through a filter before entering the air manifold. This filter is located in the pneumatic compartment area on the right side of the machine. Its function is to trap moisture and foreign particles before they reach the air manifold. The filter is easily accessible and has an automatic drain valve on the bottom side of the bowl for self draining. AIR MANIFOLD DRAIN VALVE Occasionally check the filter with the automatic drain to be certain it is draining moisture. AIR CYLINDERS There are five identical air cylinders, one for each side arm and one for the top brush arm. To move the side arms, air from one Air-In solenoid flows into the front of the air cylinder pushing the rod in and the side arm in. When air from the Return Air solenoid is applied to the rear of the cylinder the rod is pushed out of the cylinder and the side arm is pulled out. Air for the top brush is forced into the lower end of the cylinder from the top brush solenoid to move the top brush arm, pushing the rod out and forcing the top brush arm down. When this pressure is released by the solenoid, the top brush counterweight raises the top brush arm. The rate at which the top brush arm descends is controlled by the adjustable Flow Control Valve. If the Wheel Scrub option is installed there will be 4 additional cylinders. These cylinders allow extension and retraction of the Wheel Scrubber. If the Dryer option is installed there will be 2 additional cylinders. These cylinders allow oscillation of the Dry fans. Page 34 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

42 MOVING THE MACHINE MANUALLY (MANUAL SWITCH BOX) If the manual switch box is installed as an option, the manual drive switches are inside the enclosure. Open the enclosure and, using the switches, drive the machine manually, forward or reverse as desired. Make sure that the machine is placed at the front home position so that the machine can operate normally. CAUTION! MANUAL DRIVE SHOULD BE USED ONLY WHEN THE MACHINE IS IN ITS "AT REST" POSITION (ALL MOTORS ARE TURNED OFF). If manual drive forward or reverse button is used during a wash, the PLC will automatically reset to the "At Rest" condition. The machine cannot be armed while the manual drive toward or reverse button is in use. If the machine is armed, but the vehicle is not on the bay switch, the machine will reset to an unarmed "At Rest" condition. MOVING THE MACHINE MANUALLY (LCD DISPLAY) 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. CAUTION! MANUAL DRIVE SHOULD BE USED ONLY WHEN THE MACHINE IS IN ITS "AT REST" POSITION (ALL MOTORS ARE TURNED OFF). If manual drive forward or reverse button is used during a wash, the PLC will automatically reset to the "At Rest" condition. The machine cannot be armed while the manual drive toward or reverse button is in use. If the machine is armed, but the vehicle is not on the bay switch, the machine will reset to an unarmed "At Rest" condition. Page 35 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

43 VARIABLE FREQUENCY DRIVE UNIT INFORMATION As stated in Terms and Definitions the Variable Frequency Drive (VFD) unit(s) controls operation of the drive motors and the wiper motor. In addition, the motor control circuitry for each drive motor and the wiper motor is connected in parallel to the output of the appropriate VFD. If an error in the control of all three motors (1 wiper, 2 drive) occurs, the problem lies with the VFD or its input control circuitry. If only one or two motors are effected, the problem lies with the motor circuit protector or wiring. In order for the motors to operate properly, three signals are required from the CPU. These signals consist of the Direction Signal, the Speed Signal, and the Contactor On Signal. DIRECTION SIGNAL These signals from the CPU are received by the VFD. They are connected to the VFD at terminals 5 and 6. These direction signals correspond to the manual drive switch and will move the machine in a forward or reverse direction. Note: All inputs use terminals 3 and 7 on the VFD as input common. These two terminals are connected together internally. SPEED SIGNAL There are three (3) Speed Signals supplied to the VFD from the CPU. These signals are: a) SW1 - It is connected to terminal 1 on the VFD. b) SW2 - It is connected to terminal 2 on the VFD. c) SW3 - It is connected to terminal 4 on the VFD. Depending on setup programming pertaining to speeds for various wash and dry sequences, there are seven (7) drive speeds that a single or combination of inputs of the 3 speeds listed above may provide. Page 36 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

44 CONTACTOR ON SIGNAL This signal goes to the appropriate motor contactor from the CPU. It only selects the appropriate motor and has nothing to do with the operation of the VFD. OSCILLATING PRE-WASH OPTION The Oscillating Pre-Wash option enhances overall wash quality by removing excessive dirt or mud adhering to the sides of the vehicle. The Pre-Wash operates before detergent is applied or brushes make contact with the vehicle. In this way the detergent makes better contact with the vehicle surface and the life of brush material is extended. The Pre-Wash is provided at the beginning of the wash cycle and is comprised of one pass to the rear of the vehicle and a return pass to the vehicle front. Fresh or reclaim water is sprayed at the vehicle sides via eighteen (18) nozzles, nine on each side of the machine. The nozzle manifolds oscillate up and down to apply spray from more than one angle. This loosens dirt more effectively and provides more complete coverage of the vehicle rocker panels. SPECIFICATIONS AND REQUIREMENTS ELECTRIC Pump Motor 208/230 V, 3 Phase, 60 HZ, 15 Amp or 460V, 3 Phase, 60 HZ, 15 Amp AND Left and Right Oscillate Motors 120 VAC, 1 Phase, 60 HZ, 15 Amp MOTORS A small geared motor on each side of the machine provides the power required to oscillate the nozzle manifolds. See the specifications above. WATER The Pre-Wash option does not require additional water service. Water usage rate is 35 GPM. REPLACEMENT NOZZLES In the event nozzles require replacement, order the following: RYKO Part No. Description /8 MPT x 0 Deg x 1.0 GPM, PL RECLAIM SYSTEM OPTION The purpose of the Reclaim System Option is to provide a quality vehicle wash which requires a lower consumption of fresh water. This optional system filters and holds in storage previously used vehicle wash or rinse water which can then be reused during specified segments of a future vehicle wash. Details regarding the reclaim system's specifications, components, operation, service and maintenance are available in the Environmentalist II-B (EV II-B) manuals which were shipped with the EV II-B. Page 37 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

45 CUSTOM MESSAGE DISPLAY SIGNS Custom Message Display (CMD) Signs are a both a necessity and an enhancing option when used with the SoftGloss. These programmable message signs are valuable instruction, information and sales tools. Programming on these signs allows the operator to create unique and eye-catching displays to instruct or inform customers. The onboard Fascia Sign and the Freestanding Instruction Sign CMDs are both optional with the SoftGloss. FREESTANDING INSTRUCTION SIGN (16 Characters in 2 lines) The freestanding CMD Instruction Sign is an optional unit mounted either on the wall or on a pedestal and installed in the bay separate from the SoftGloss. This display provides a 16 character message screen in a 2 lined format. Eight characters are displayed on each line. Refer to the Custom Message Display (CMD) Instruction Sign Programming document in the Drawings section of this manual (See the Table of Contents). SHORT BAY OPERATION Installation of the SoftGloss in a non-standard (short) bay requires special hardware and changes the operation of the rear arms. For programming and operation information, refer to the Short Bay Operation Guide in the Drawings section of this manual. WHEEL SCRUB OPTION If the Wheel Scrub option is installed with the SoftGloss and selected in the wash package purchased by the customer, it is featured during the wash cycle and provides a "double scrub" action to each wheel. BASIC OPERATION Located on the lower inside of each side of the SoftGloss frame is one circular brush. When the wheels of a vehicle are detected and activated during a wash pass, the wheel scrub brushes spin and extend to provide a thorough scrubbing of the wheels. The brushes then retract, reverse spin direction, and reextend to give the wheels a second scrubbing. When finished scrubbing, the brushes retract until the next wheels are detected. WHEEL DETECTION Photoelectric eyes are installed low on the right and left sides of the SoftGloss frame to the front and rear of the wheel scrub brushes. These photoeyes detect the vehicle's wheels during a wash cycle. Wheel scrub operations are activated when the photoeyes have been blocked and then unblocked by the vehicle's tires as the SoftGloss travels over the vehicle. The rollover halts travel when detection occurs so that wheel scrub operations may be performed. When wheel scrub operation is completed, the gantry's travel resumes. The vehicle's rear wheels are detected by the front-side photoeyes and scrubbed during the rear to front (forward) wash pass. The vehicle's front wheels are detected by the rear-side photoeyes and scrubbed during the front to rear (reverse) wash pass. During operation, the Programmable Logic Controller (PLC) receives signals sent from the sensors working as part of the wheel scrub option and transmits appropriate commands in response to the signals it receives. The photoeyes that detect the tires are part of this communication system and ensure that that the brushes are centered over the tires. A proximity switch on each wheel scrub brush notifies the PLC when the wheel scrub brushes have retracted from their extended position. Upon receiving this Page 38 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

46 signal, the gantry may safely resume travel. In the event signals indicate wheel scrub operation faults, the PLC will generate diagnostic codes and, if appropriate, may terminate the wash cycle so as to prevent the possibility of damage to the vehicle and/or equipment. ONBOARD HIGH PRESSURE OPTION The Onboard High Pressure option sprays high pressure water onto the vehicle from the gantry of the machine to remove heavy sediment prior to the friction wash passes. Fresh or reclaim (10 micron or less) water is supplied to the high pressure pump stand, and is sprayed through the vertical side manifolds and rotary sprayer assemblies on the machine. The Onboard High Pressure is comprised of one pass to the rear of the vehicle and a return pass to the vehicle front. The machine can be set up to slow and jog front-to-back at the wheels during the entranceto-home pass. The Onboard High Pressure pass can be set up to occur at the beginning of a wash, and/or be set up to occur after the Onboard Tire Chemical/Presoak pass. PUMP LUBRICATION DO NOT RUN PUMP WITHOUT OIL IN CRANKCASE. Change initial fill after 50 hours of running. The communication interface touch screen will pop up a window notifying you when 50 hours of use have been completed. Refer to the PLC interface touch screen instructions on how to reset the hours and stop change oil window from popping up. Once oil has been changed and hours have been reset change oil every 500 hours. ONBOARD TIRE CHEMICAL OPTION The Onboard Tire Chemcial option applies foamed Tire Chemical to the wheels and rocker panel of a vehicle, through the gantry of the macine prior to the friction wash passes. The Onboard Tire Chemical is comprised of a chemical pass to the rear of the vehicle and a return pass with adjustable dwell time. During the tire chemical application, the machine will slow at the tires to supply a larger amount of chemical on the tires and rims as the gantry moves towards the rear of the vehicle. The Onboard High Pressure pass can be set up to occur in place of, or simulaneous to presoak. Page 39 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

47 MAINTENANCE WARNING! WHEN SERVICE OR SERVICE MAINTENANCE IS REQUIRED FOR THE MACHINE AND/OR ANY ASSOCIATED EQUIPMENT, 1) DISABLE THE MACHINE TO PREVENT MOVEMENT, AND 2) CLOSE THE BAY AND THE BAY CONTROLS TO TRAFFIC. MAINTENANCE SCHEDULE Daily Servicing 1. IMPORTANT! Clean photo-electric lenses. 2. Check the air line moisture trap. 3. Inspect bay for cleanliness. 4. Check Control Panel to confirm doors are padlocked. 5. Check additive tank levels, fill or replace if necessary. 6. Visually inspect the machine and all associated equipment for damage. 7. Check brush fingers for tangles. 8. Ensure that the entrance and exit doors are functioning properly. 9. Check the bay and equipment room for leaks (water, air additives, etc.) Weekly Servicing or Each 1,000 Wash Cycles 1. Lubricate grease points on all bearings. 2. Rinse, wash, rinse the machine. Use of a mild liquid detergent for washing is recommended. Cleaning the surface weekly helps to eliminate excessive lime and dirt build up and extends surface appearance. 3. Lubricate all pneumatic air cylinder swivel joints; replace worn pins if necessary. 4. Check the condition of bay switch and associated wiring. Pick up and remove all debris to insure free movement of the bay plate treadle. 5. Insure all lights are functional in Stop & Go sign. Clean lenses if necessary. Insure instructions and decals are legible. Replace if necessary. 6. Check remote activation device, (if present) for correct operation. Check coin/token chute slides for cleanliness and obstructions. 7. Check pressures on all regulators. 8. Verify settings on additive pumps are set for correct increments. Monthly Servicing or Each 5,000 Wash Cycles 1. Check tightness of brush assembly holding screws on hubs. 2. Tighten all cover screws. 3. Grease all bearings, note worn bearings, tighten all set screws and collars. 4. Check gear box alignment and Lovejoy coupler assemblies for excessive wear. 5. Check wheels and track for extreme or improper wear. 6. Check clevis pins for wear. 7. Check all brush and bearing bolts for tightness. 8. Check rubber bumpers and stops for tightness. If loose, tighten. 9. Check all air, water, and power lines for abrasions, cracks, or over-tight ties. 10. Check air lines, regulators, and solenoids for leaks. Check air cylinder for proper operation. 11. Check foamer for proper operation. Clean additive system filters. 12. Check for loose or burned wires in Control Panel. Page 40 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

48 13. Check Pre-Wash pump mechanisms for proper operation. 14. Check clutch and ultrasonic for proper operation. 15. Check brushes for wear and build up of dirt or oil. 16. Run the machine through several cycles and check general operation. 17. Inspect bay for cleanliness. Each 50,000 Wash Cycles 1. Check all Caution decals for wear. Replace if illegible. (Decal replacement is important to machine maintenance and good safety procedure practices.) 2. Check oil levels on all gear boxes. COMMUNICATION INTERFACE BOX Refer and adhere to the applicable procedure of the two that follow when cleaning the touch screen. 1) The touch screen comes with three clear plastic covers that can be removed when they become dirty. These covers use static cling to stick to the touch screen and can be removed by peeling off the top cover from the next one down. 2) To clean the touch screen in the absence of the plastic covers: A) For light build-up of dirt and grime: a. Dust and clean the screen with a soft, clean, damp cloth. Wipe the surface gently when performing this procedure. DO NOT use cloths containing grit or abrasive particles, or kitchen scouring type compounds to clean or dust the touch screen. b. In addition, a mild detergent can be used on the screen with a damp cloth. B) For build-up of hard water deposits: c. A mild acid, such as vinegar can be used on the screen with a damp cloth for wiping the acid away. DO NOT use chemicals such as thinners, organic solvents and strong acids, since they may cause the protective sheet to be deformed or the dissolvable paint on the surface to peel off. In addition, do not use spray solvents since they may cause the electrical failure of the touch screen. Additional static cling plastic covers can be purchased through RYKO Parts department. Page 41 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

49 MOTORS - GENERAL INFORMATION CAUTION! BE SURE TO DISCONNECT ALL SUPPLIES BEFORE SERVICING. Three phase motors run on 208V/230V or 460V 60 HZ power. Note: 460V motors are wired differently than the 208V/230V motors. IMPORTANT: SET MOTOR CIRCUIT PROTECTORS AT FULL LOAD AMPERAGE (FLA) RATING. REFER TO THE MACHINE'S NAMEPLATE ON EACH OF THESE PUMPS FOR HORSE POWER (HP), AMPERAGE, RPM AND MAXIMUM LOAD SPECIFICATIONS MOTOR CIRCUIT PROTECTORS Each of the motors on the machine is protected from the strains of overloading by circuit protectors. These circuit protectors are located in the Control Panel. They "sense" the amperage being drawn by each motor. When a motor is overloaded, the circuit protector for that motor will activate. When activated, the circuit protector will break the common power line to the contactor coils and cause the contactors to break immediately. Power will not be able to feed the motors and they will shut down. The circuit protector will also close a circuit that signals the PLC and interrupts all control power to the Control Panel. This double safety system insures that a malfunctioning motor will shut the machine down. The machine will remain inoperative until the responsible circuit protector is manually reset. The circuit protectors may be reset by turning the control to the OFF position and then turning it back to ON. A tripped circuit protector may require up to five minutes cooling time before it can be safely reset. Each circuit protector has an adjustment for its capacity. The circuit protectors have been preset at the factory as improper adjustment could reduce the effectiveness of the overloads. A label on the inside of the control panel lists the correct settings for specific motor brands. IMPORTANT: ADJUSTMENTS SHOULD BE MADE ONLY BY YOUR AUTHORIZED RYKO SERVICE REPRESENTATIVE. A tripped circuit protector may or may not indicate a serious problem. Occasionally, an unusual circumstance may cause a motor to overload. If a circuit protector trips, note which motor is involved and make a quick inspection of that motor and its related mechanics. If nothing appears to be wrong, reset the circuit protector and return the machine to service. Attention! Should the motor circuit protectors require servicing, refer to circuit protector overload settings on the label inside the control panel door. Page 42 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

50 SPEED REDUCERS This machine uses right angle, worm gear in-line speed reducers to receive the output from the motors, reduce the RPM, and then transmit the reduced RPM to the brushes or drive wheels. Exception to use of this type of reducer are the Wheel Scrub brushes that use enclosed Helical gear reducers that are greased and sealed, thus eliminating any lubricant servicing. All speed reducers require periodic maintenance to assure proper operation and a long, dependable life. Unless performing maintenance that requires disassembling the gearbox, no oil change is necessary. It is, however, important that a proper oil level be maintained. To check the oil, remove the non-vent level plug on the side of the speed reducer. An acceptable oil level tolerance would range from oil running out of the speed reducer as the plug is loosened to as much as one-quarter (1/4) inch below the level plug. If the oil level is lower than the tolerance level stated, add the amount of oil needed to meet the maintenance requirement. Note: Check the oil level on each speed reducer every three (3) months. This machine may be equipped with two types of reducers. Each type of reducer uses different gear lubricants that are not compatible with each other. It is important to identify the correct reducer type and use the appropriate gear reducer lubricant. If the reducer has a dull, rough housing and has a label specifying the use of Mobil Glygoyle 460 oil, use synthetic gear lubricant, part number available in 1 quart containers. If the reducer has a smooth, shiny housing and doesn t have a label specifying oil, use Ryko synthetic gear lubricant, part number available in 1 gallon containers. DO NOT dilute the gear lubricant with kerosene or other additives. DILUTING GEAR LUBRICANT WITH ADDITIVE(S) WILL VOID THE GEAR BOX WARRANTY. AMP SENSORS The SoftGloss is equipped with an Amp Sensing for the front, rear and top arms. The Amp Sensors read the current draw to the motors. The rear arms, front arms and the top brush each have one Amp Sensor. If the current draw is excessive for those arms, the Amp Sensors signal the PLC which shuts off the arm's brushes for the duration of the immediate cycle in operation (i.e. bumper dwell, reverse pass). The other brushes are not affected. The brushes will resume spinning at the start of the next immediate cycle. Example: As the rear brushes dwell on the rear of a van with a ladder, the amp sensor will detect a large current draw as the brush speed is impeded by the ladder. The PLC will detect this current draw and shut off the rear brush spin. The brushes will remain off until the rear brush dwell cycle has ended. The brushes will resume spinning for the next cycle which is the Wash Forward (if double pass is present). Page 43 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

51 PROXIMITY SWITCH ADJUSTMENT 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. 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 he bay. 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. 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 & TESTING 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 will need 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 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. SIDE ARM PROXIMITY SWITCHES Each side arm of the machine has a proximity switch mounted on the main frame where it will be activated as the arm swings in. These four proximity switches serve as locating devices that informs the programmable controller of the machine's position during a wash cycle. Activation of the proximity switches provides signals to the PLC and starts and runs the side brushes, and drive motors, reverses their rotational direction, and reverses machine motion. One proximity switch (one per each side arm brush), is positioned so it will activate as the side arm brushes wrap around the front or the rear of the vehicle. If one of the switches becomes inoperative, the machine will still function normally using the remaining proximity switch on the opposite side of the frame. Page 44 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

52 The proximity switch system is further aided by the 2 Digit Code Display which points out malfunctioning switches. Also, see Bypass Toggle Switches. CAUTION! DO NOT ATTEMPT TO OPERATE THE MACHINE WITH MORE THAN ONE FRONT OR REAR LIMIT SWITCH TURNED OFF. THE MACHINE WILL NOT BE ABLE TO PROPERLY LOCATE THE ENDS OF THE VEHICLE. SIDE ARM PROXIMITY SWITCH ADJUSTMENT PROCEDURES The front arm, rear arm and top brush prox switches are non-adjustable from side to side. A space of 1/8" +/- 1/32 (3 mm +/- 1 mm) should exist between the proximity switch face and the aluminum side arm channel that serves as the proximity switch target. Any deviation from the 1/8" +/- 1/32" distance stated could cause the machine to not properly locate the ends of the vehicle being washed. IMPORTANT: SWITCH. IMPROPER ADJUSTMENT WILL PREVENT THE ARM FROM ACTIVATING THE PROXIMITY Should the proximity switch require adjustment, loosen the two jam nuts that secure the proximity switch to the proximity switch bracket. When loose, raise or lower the proximity switch to the 1/8" +/- 1/32" space requirement. When adjusted, retighten the two jam nuts and the mounting bolts. After front and rear arm proximity switch space is adjusted as required, the distance at which the proximity switch shuts off must also meet specific dimensions. These dimensions are shown on the Arm Proximity Switch Adjustment Instructions drawing in the Drawings section of this manual. Note: Since the front and rear arm proximity brackets are non-adjustable from side to side, to meet the dimension required it may be necessary to use channel lock type pliers to tweak the bracket to one side or the other until the dimension is achieved. Refer also to Leveling Arms in this manual for additional information which will ensure proper operation and a quality wash. TOP ARM PROXIMITY SWITCH To adjust the Top Arm proximity switch, refer to adjustment instructions on the FoamBrite Option drawing. END STOP PROXIMITY SWITCHES These switches are located on the right, bottom side of the machine on the outside of the tracks. The entrance end stop proximity switch is located beneath the right side drive motor. The exit end stop proximity switch is located near the right front idler wheel. As the machine reaches the end of the track, the end stop proximity switch senses a metal trip plate attached to the track riser. There is a trip plate bolted to the outside exit end and outside entrance end of the tracks. When a proximity switch senses a trip plate, it signals the PLC. The PLC then removes power to the drive contactor and shuts off the motors. Should the machine travel to the end of the tracks, the end stop proximity switch will stop the machine before it hits the end stop bumpers. This feature prevents damage to the machine, vehicles or bay. When adjusting these switches, leave a minimum of 1/2" (13 mm) between the side of the switch and all track mounting bolts they pass over. The face of these switches should be adjusted to within 1/8 +/- 1/32 (3 mm +/- 1 mm) of the trip plate target. Page 45 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

53 WHEEL SCRUB, AND WIPER PROXIMITY SWITCHES Space requirements for Wheel Scrub (2) and Wiper (2) Proximity Switches call for the same 1/8 +/- 1/32 space requirement between the proximity switch face and the assigned target as for the side arms, and end stop proximity switches. LEVELING ARMS Level and balanced arms are essential to proper operation of brush rollover machines. Level arms can be defined as arms that do not significantly swing in or out when the air is released from them. It is especially important that the arms perform alike. They should act in a similar fashion when the pressure is removed. If that is so, they should also perform alike when the air cylinders are pressurized. When balanced, the arms brush shafts are aligned with the gearbox output shafts via the couplings so that both shafts are concentric and parallel. Note: The track level from side to side will have a great affect on this adjustment and should be considered when leveling arms. To determine if the machine's arms are level follow the procedure below. Check either front or rear arms together. 1. Relieve the air to the machine. 2. Rotate the arms inward against the instop bumpers to ensure that pressurized air is out of the cylinder. 3. Rotate the arms slightly outward until there is an approximate 1" gap between the bumper and the arm. 4. Release the arms. If level, the arms will not swing out or in more than six (6) inches as measured at the brush shaft. 5. Rotate the arms to the outmost position. 6. Repeat steps 3 and 4 for the outstop bumpers. Note: Machine operation and wash quality will be affected if one arm swings in slightly and the other swings outward slightly. It would be preferable, if perfect level is not attainable, to have a VERY SLIGHT swing toward the center of the bay. IF THE ARM SWINGS OUT 1. Swing the arm in until there is about two inches between the arm and the instop bumper. 2. Place a floor jack under the brush shaft and raise it until the weight is just removed from the arm. 3. Loosen the four (4) bearing bolts for the pivot bearings on the machine. Page 46 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

54 4. Lower the arm with the jack three or four inches. NOTE: The distance the arm is lowered is relative to the amount of swing being corrected. The intent is to allow the weight of the arm to assist in repositioning the bearings. It may be necessary to lower the jack completely. 5. Retighten the bolts and test the level of the arm. IF THE ARM SWINGS IN Follow the procedure above, but, after the bolts are loose, raise instead of lowering the jack. TOP BRUSH INTERRUPT AND PROXIMITY SWITCH ADJUSTMENT TOP BRUSH INTERRUPT (TBI) OPERATION The top brush interrupt (TBI) prevents the top brush from descending into pickup beds where it could come into contact with any accumulated debris and possibly damage the vehicle or the machine. The SoftGloss utilizes the ultrasonics to perform the top brush interrupt. The ultrasonics "reads" the profile of the vehicle to determine what type of vehicle is present. The proximity switch on the top of the arm is still present, but is used as a safety feature to determine the position of the arm at various times during the wash cycle. If the vehicle is identified as a sedan or tall vehicle, the TBI logic is bypassed and the top brush does not interrupt. If the vehicle is identified as a pickup, the following occurs: When the top brush drops at the front of the pickup, the machine begins to drive to the rear of the pickup. As the ultrasonic passes over the pickup cab, it looks for a drop in height of 14" or greater from the cab height that was determined during the vehicle profile pass. Once the point of this drop is located, an adjustable timer begins to determine when to shut off and raise the top brush. Note: It may be necessary to adjust this timer to ensure optimum operation. PROXIMITY SWITCH ADJUSTMENT 1. The proximity switch is located on the right side of the Top Brush Arm Support. A metal bracket that attaches to the top brush support weldment on the overhead beam serves as the mounting bracket for the proximity switch. 2. Use the manual drive forward or reverse button from the Communication Interface box and move the machine to a position on the tracks so the right idler wheel is approximately 13 feet from the front end of the track. 3. With the top brush in a lowered position, adjust the proximity switch to a distance of 1/16" to 1/8" (1,58 mm-3,17 mm) from the arm channel. Next, adjust the proximity switch bracket up and down so that the proximity signal indicator light (on the back of the proximity switch) goes off just when the top brush shaft centerline is 76 (1930 mm) off the floor. Page 47 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

55 TOP BRUSH COUNTERWEIGHT ADJUSTMENT 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. It is necessary to weigh the top brush (when dry) and then adjust the top brush counter balance as described in Dry FoamBrite Brushes. DRY FOAMBRITE BRUSHES Follow the steps below to weigh and adjust the top washer with dry FoamBrite brushes only. 1. The top brush should be completely assembled (brushes, motor, reducer, cover, etc.) 2. Remove the air from the top brush pneumatic cylinder. On the pneumatic manifold: 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 the flow control on the exhaust port of the 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 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. Take another weight measurement by lowering the top brush through the horizontal position from the fully raised position. IMPORTANT: For top arms with 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. 7. Average the "raising" and "lowering" weights [(Weight UP + Weight DOWN) divided by 2]. This eliminates the UHMW bearing friction that may be added or subtracted from the actual weight [(Weight + Friction + Weight - Friction) divided by 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 top brush weight to 15 (6,8 kg) to 18 (8,2 kg) pounds and verify that this weight obtains a crush of 6 to 10 inches (15,2 cm to 25,4 cm) by washing at least 20 various vehicles. Adjust the top brush drop using the top brush flow control valve on the pneumatic manifold. With top FoamBrite brushes dry, fully open the top brush flow control valve. Using the handheld programmable panel (HPP), force the top brush spin and top brush drop several times while adjusting the 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 the HPP to force the top brush to spin for 10 minutes to dry. Page 48 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

56 9. With the top arm counterweight and the top arm drop adjusted as described above, adjust the flow control valve on the exhaust port of the top arm pneumatic cylinder inward only until the top arm rises without slamming against the top arm return bumper stops. The amount of crush should be the ultimate determining factor when setting the counterweight. Note: Crush measurements refer to the length of the brush material that is bent and folded over when making contact with the vehicle surface. LUBRICATION All machines with moving parts require regular lubrication, and RYKO machines are no exception. With a routine maintenance schedule, parts are checked visually and physically to insure proper working condition. Lubrication of areas such as bearings where "metal rides on metal" helps to minimize the heat and recoverable loss caused by friction. Proper lubrication should be a first consideration of a regular maintenance program. IMPORTANT: LACK OF LUBRICATION WILL VOID THE WARRANTY. Every machine leaving the factory has been thoroughly checked and lubricated and should need no further service for one week from the date of installation. LUBRICATION - GREASE ZERKS AND BEARINGS Careful examination of the machine reveals 32 grease zerks (30 without on-board dry option). These zerks (also referred to as nipples) should be lubricated regularly with a good No. 2 grade lithium-based lubricant, (see Maintenance Schedule). The zerks and lubrication schedule for each are: WHEELS AND AXLES - EIGHT (8) GREASE ZERKS Eight (8) zerks are associated with the wheels and axles. All wheel axles are connected to the frame via two 2-bolt bearings, one (1) each to the inside and outside of the wheel assembly. Grease these eight (8) bearings weekly. TOP BRUSH BEARINGS - TWO (2) GREASE ZERKS Four (4) grease zerks and bearings are associated with the top brush assembly. One 2-bolt bearing is at each end of the brush shaft, bolted to the top brush frame. Grease these two (2) bearings weekly. SIDE ARMS - SIXTEEN (16) GREASE ZERKS There are sixteen (16) zerks and bearings associated with the side arms, four (4) on each arm. Each side arm is connected to the frame by a vertical shaft supported by two 2-bolt bearings. One (1) bearing is mounted under the upper side arm shelf, and the other is on the lower shelf. Both are positioned with the bearing zerk on the outward end of the shelf where it is easily accessible. Grease these eight (8) zerks weekly. Page 49 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

57 At the brush end of each side arm are two (2) bearings holding the brush shaft at the top and bottom of the side arm. The lower bearing is just above the side brush and the upper bearing is inside the motor cover and can be lubricated through an access hole. Bearings on units with tall rear arms are located directly above the cover. There is no bottom to this cover so access to bearings for lubrication purposes is simple. Grease these bearings weekly. Note: At the top of each side brush is a disk of black carpet material. It has been placed at this location to catch grease and reduce fouling of the brushes. These disks should be replaced if they become excessively greasy. Pump only enough grease into a zerk and bearing to force the new grease out around the bearing until it is visible. This bead of new grease should be only about 1/16 inch in diameter. Be sure the zerk is wiped clean before new grease is inserted and wiped again afterward to remove excess grease. This practice prevents grease dropping onto a bristle or being picked up from the bay floor by the side brushes and transferred to the vehicle. Although some manufacturers recommend that bearings be lubricated while they are in motion, that procedure is not safe or practical for this equipment. CAUTION! DO NOT ATTEMPT TO LUBRICATE ANY PORTION OF THE MACHINE DURING A WASH CYCLE. PANELS AND COVERS - CLEANING AND WAXING Refer and adhere to the procedures that follow when cleaning and waxing panels and covers of the machine. Dust and clean the panels/covers with a soft, clean, damp cloth or chamois. Wipe the surface gently when performing this procedure. DO NOT use cloths containing grit or abrasive particles, or kitchen scouring type compounds to clean (wash, wax, polish, etc.) or dust the machine covers or panels. For light build-up of dirt and grime, use pure liquid soap and lukewarm water. For heavy build-up of dirt, grime, or lime, wash down with lukewarm water and, while still wet, follow with full strength RYKO General Purpose Cleaner. See Recommended Cleaning Agents. NEVER use boiling water, strong solvents or other materials (see Cleaning and Waxing Agents Not Recommended), to clean the covers or panels, as they will soften the plastics. When washing is complete, rinse the surface with lukewarm water. Use a clean, damp cloth or chamois and dry the panels/covers after rinsing. When performing this procedure, blot dry the surface. Do Not Wipe The Surface. To obtain the best protection and highest degree of polish, wax the panel / cover surfaces sparingly. See Recommended Waxing Agents. Use a soft, clean cloth and apply wax sparingly in a thin, even film over the entire surface of each panel or cover. If required, let the wax dry before polishing the cover or panel surface. Refer to directions on the wax container to determine how long wax should remain on the surface before polishing. Page 50 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

58 Use a clean, cotton flannel or jersey cloth and polish the waxed surfaces lightly. After polishing, use a damp, clean cloth and gently wipe the surfaces. This helps to ground any electrostatic charges that may attract dust particles. NEVER subject covers or panels to hard, direct blows. Light scratches and abrasions might be removed by waxing with Simonize paste wax. Deeper scratches or abrasions might be removed by lightly buffing the cover/panel with a fine grade of rubbing compound. RECOMMENDED CLEANING AGENTS For light build-up: RYKO Detergent, Fantastic, Mr. Clean, 409, Joy, Cascade. All cleaning agents must be in liquid form. For heavy build-up: RYKO Cleaner/General Purpose (Part No ). RECOMMENDED WAXING AGENTS Simonize, Aero Wax, and Glo-Coat. CLEANING AND WAXING AGENTS NOT RECOMMENDED Wisk, Liquid All, Dynamo, Cold Power Liquid, Endust, Lestoil, Pine-Sol, Gain, Halogenated Hydrocarbons, Ketones, Cellosolve Acetate, Aromatic Hydrocarbons (Amsoc G, Solvesso 100, Solvesso 150), Tetrahydrofuran, Butyl Cellosolve, Methanol, Ethanol, Isopropanol (90% & 70% Commercial), Gasoline, Brake Fluid, Kerosene, Isopar K, Hexane, Spot Cleaner (Trichlorethane, Trichlorethylene, Perchlorethylene), Abrasives (cleaners, example "Comet"), Plasti Shine, Carnu, Turtle Wax, Body Sheen, Johnson's Pride, Dupont No. 7 (rubbing compound), and Lighter Fluid. SOFTGLOSS WITH FOAMBRITE OPERATION / ADJUSTMENTS The following information pertains only to SoftGloss machines with FoamBrite. ULTRASONIC PROFILING The ultrasonic sensor is located on the entrance side of the machine directly under the boom. Its purpose is to define the vehicle's dimensions for the wash equipment in a process referred to as mapping. MAPPING During mapping, the ultrasonic sensor takes readings of the vehicle during the first pass over the vehicle that is not a pre-wash pass. a) The hood value, when read, is assigned the value X. b) 28" after the tire photoeye detects the front tire, sort the last five (5) ultrasonic readings on the roof and store the longest reading. This value is Y. Note: This process is done to so that a light bar such as is found on a police cruiser is ignored. c) After value Y is determined, locate the rear tire. If there are six consecutive readings of 18" or greater than Y when the rear tire is detected, the vehicle is mapped as a pickup. Page 51 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

59 d) If the vehicle is not a pickup, determine if the vehicle has a flat roof as follows: Subtract value Y from the ultrasonic reading when the rear tire is detected. If the difference is less than 7" or if the value of Y is less than Adjustable Roof Height, the vehicle is mapped as a station wagon, van or a pickup with a topper. e) If the vehicle is neither a pickup or a flat roof vehicle, the system defaults to a sedan. Internal memory locations indicate what type of vehicle is being washed. M450 = Tall Vehicle M451 = Sedan M452 = Pickup Note: During the profile pass the program constantly looks for the tallest point of the vehicle. If the machine detects the rear end stop BEFORE the rear tire is detected, the program uses this information to determine the type of vehicle based on data collected during the profile pass. The vehicle in this situation may not be identified correctly because the rear tire wash not detected. "ADJUSTABLE ROOF HEIGHT" Adjustable Roof Height is used in the event the rear window of a van or sport utility vehicle is steeply sloped enough to cause the ultrasonic to read it as a rear wiper or rear bumper. Also, it may be necessary to adjust from the default value if the slope of the bay floor is irregular and causes the vehicle to appear lower in the bay. Refer to "Recommended Set-up Settings for SoftGloss" documentation for detailed setting instructions. IMPORTANT: WHEN THE MACHINE IS 'AT REST', WITH NO VEHICLES IN THE WASH, AN ULTRASONIC VALUE OF LESS THAN 95 INCHES IN D29 INDICATES A PROBLEM. TOP BRUSH ROTATION: 70 RPM UHMW BEARINGS The UHMW bearings are used to reduce top brush bounce during operation. These bearings create a drag on the top brush pivot shaft and may interfere somewhat when weighing the top brush. It is necessary to weigh the brush in a continuing motion to obtain an accurate reading. See Top Brush Counterweight Adjustment in this manual for weighing procedures. TOP BRUSH PROX This prox is provided as a safety feature. Page 52 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

60 BRUSH SEGMENTS The FoamBrite top brush is comprised of eleven 12" x 60" segments. The measurement of the top brush segments end to end is 68-3/4 inches + 0 inches, - 1-1/6 inches. The folds on five of the segments point in one direction. The folds on the remaining six segments point in the opposite direction. Orientation of the segments during assembly is critical to operation. The segments must be tightly compressed so that there is no gap between them. SIDE BRUSHES FRONT Standard Front Arm Option: Each front side brush is comprised of five segments each measuring 24" x 48". The segments are arranged with the folds pointing upward. Tall Front Arm Option: Each tall front arm side brush is comprised of five 24" x 48" segments and two 12" x 52" segments. The segments are arranged with the folds pointing upward. REAR The upper section of each rear brush is comprised of two different segment types. Assembled at the top of the section are four 12" x 60" segments. At the bottom of the upper section are two 12" x 52" segments. The lower section of each rear brush is comprised of two 24" x 48" segments. CURRENT SENSING The current sensors are located in the main electrical control panel on the right side. Their purpose is to detect overcurrents during machine operation. CURRENT SENSORS The three current sensors (relays) below are present on machines with the FoamBrite option. Below are the required settings. Sensors Settings Top Brush K96 Threshold 25 Front Brushes K97 Hysteresis Minimum or 5 Rear Brushes K98 Time Delay 2 seconds CURRENT TRANSFORMERS The three current transformers below are present on machines with the FoamBrite option. These transformers may be either gray or brown. Also below is wiring information. Transformers Wiring Top Brush T3 T3 L2 of the top brush motor is looped four times through T3. Front Brushes T4 T4 L2 of both front brush motors goes through T4. Rear Brushes T5 T5 L2 of both rear brush motors goes through T5. Page 53 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

61 MACHINE RESPONSE If an overcurrent is detected by the arm current sensors during certain phases of the wash cycle, the brushes will stop spinning and retract to the out position. When the next wash step begins, the brushes will restart. If a top brush overcurrent is detected, the top brush will stop spinning and raise. The machine will drive forward for 4 seconds. The wash will continue without the top brush until the rear arm proxes are detected. At that time the brush will spin and drop. If the overcurrent occurs again, the top brush will raise for the remainder of the wash reverse pass. If the machine is armed for a 2 pass top brush, the top brush lowers a second time at the front on the second reverse pass. PREWASH There are two prewash oscillating nozzle manifolds, one on either side of the machine on the entrance side next to the wheel scrub units. Each oscillating nozzle manifold is operated by a small oscillate motor. The manifold delivers at 80 PSI above the incoming city water pressure. A 2 HP centrifugal Grundfos CR2 pump supplies the water which is then applied on the vehicle from five O o nozzles. PROGRAM OPERATION The program separates all vehicles into one of three categories: Sedans, Trucks, or Tall Vehicles. The machine's operation alters according to how the vehicle in the wash is categorized. VEHICLE TYPE Sedan OPERATION The machine washes from front to rear while mapping the vehicle (see Mapping). At the rear of the vehicle the rear arms come in with the clutch off and the top freewheeling. When reaching the rear windshield area the clutch turns on and remains on until the machine is at the front windshield. The clutch then turns off. When the reverse drive begins, the clutch turns on again and remains on until the rear windshield area is reached. Truck The machine washes from front to rear while mapping the vehicle (see Mapping). At the rear of the vehicle, the rear arms come in with the clutch on. The clutch remains on until the machine is at the front windshield area. The clutch then turns off. When the reverse drive begins, the clutch turns on and remains on for the entire reverse pass. Since mapping has determined a pickup is in the wash, the top brush will raise just before the pickup bed, depending on the vehicle and the value placed in location D429. Tall Vehicle The machine washes from front to rear while mapping the vehicle (see Mapping). At the rear of the vehicle the rear arms come in with the clutch on. The clutch remains on until the machine reaches the front windshield area. The clutch then turns off. When the reverse drive begins the clutch turns on. The clutch remains on for the entire reverse pass. At the rear of the vehicle the arms remain in and the machine drives forward to wash the rear window. When a rear arm prox is activated, the high pressure is released and the machine dwells at the rear. After the dwell time the machine finishes washing in reverse to complete the wash. Page 54 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

62 FOAMBRITE BRUSH CLEANING As stated in the Maintenance Schedule, brushes should be checked monthly for dirt and / or oil build up that may be caused by several operation conditions. A high quality wax is necessary to avoid build-up or growths on the FoamBrite. Should brushes appear dirty or oily, clean according to the steps below. Do not use water hotter than 120 o F. Do not use cleaning chemicals with a ph of 10 or higher. Do not use cleaning chemicals with a ph of 4 or lower. 1. The brushes should be wet prior to the cleaning process. If the brushes are dry, run the wash on the service vehicle for several washes to wet the brushes. 2. Drop the top brush. 3. Apply 8-10 oz. of a mild liquid dish washing cleaning agent to the top brush and work it in thoroughly by hand. Dishwashing detergents prove to work well as cleaning agents. 4. Run the top brush on the hood of the service vehicle for 5 minutes without water to further work cleaning agent into the brush. 5. While top brush is spinning, turn on the machine's water supply, or apply water (warm water works best if available) from a garden hose until brushes are well lathered. Turn the water supply off and allow top brush to spin for approximately 5 minutes. 6. Raise the top brush. 7. Reduce front and rear side arm return air pressures to zero (0). 8. Pull front arms, rear arms, or all arms in until they contact the in-stop bumpers and tie them as close together as possible with a rope or similar holding device so the fingers overlap as much as possible. 9. Apply 8-10 oz. of a mild liquid dish washing cleaning agent to each brush and work it in thoroughly by hand. Dishwashing detergents prove to work well as cleaning agents. 10. Energize the brush motors for approximately 5 minutes (in each direction for rear brushes) without water to further work cleaning agent into the brushes. 11. While brushes are spinning, turn on the machine's water supply, or apply water (warm water works best if available) from a garden hose until brushes are well lathered. Turn the water supply off and allow brushes to spin (each direction for rear brushes) for approximately 5 minutes. 12. If time allows let all the brushes stand idle for approximately one hour to let soap work. 13. Reset the side arm return air pressures properly. 14. After the brushes have been idle, rinse out the soap. This can be done by washing the service vehicle several times. Page 55 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

63 BRUSH REPLACEMENT Depending on the volume of vehicles washed at a given wash location, machine brushes will eventually wear and require replacement. When replacement becomes necessary, the RYKO Solutions, Inc. Standard Equipment Limited Warranty does offer certain benefits for replacement of the side brushes, only. Refer to the Proration Schedule - Side Brush Replacement provided in the Warranty Information section of the Owner's Manual. Also see the Brush Parts drawing in this manual. This drawing illustrates and provides instructions for the installation of brushes to the top brush and side brush hubs. TOP BRUSH There are eleven (11) complete brush sections which make up the Top Brush assembly. Each is identical. The orientation of each, however, depends on its location. See the FoamBrite Brush Parts Option drawing for clarification. Note that the folds of the brush material are to the outer sides of the brush assembly. IMPORTANT: UNDER NORMAL OPERATION, TOP BRUSH WEAR IS NOT AS EXTREME AS WEAR TO THE SIDE BRUSHES. TALL REAR SIDE ARM BRUSHES This brush assembly consists of eleven (11) brush sections that, when assembled onto tubes, consist of a top section and a bottom section. See Brush Parts drawing and refer to the Rear Arm and Shaft Assembly drawing. Note that the folds of the brush material are on the top side of the brush. When replacing the brush sections, refer to the FoamBrite Brush Parts drawing for details on the assembly procedure. Note the need to drill assembly holes through the brush section hubs to hold the brush sections in place on both the top and bottom half of the Tall Rear Arm brushes. The upper half of the Tall Rear Side Arms are on a separate core which does not always spin when the bottom half of the rear brush is spinning. However, the bottom brush section on the upper half of the rear brush extends down over the flange weldment of the lower half of the brush. Refer to the Brush Parts drawing. Ensure the above mentioned brush section cannot engage the keystocks of the brush core pipe of the lower half of the Tall Rear Arms. WIPER DRIVE BELT ADJUSTMENT Weekly, check the wiper drive belt for tension. If the belt is loose or extremely tight, this belt will need to be adjusted. Failure to check and adjust the belt if required, could result in a broken belt. Refer to procedures that follow for the wiper drive belt adjustment. The proper belt tension should be just tight enough so the belt wraps around the drive sprocket and the teeth engage, but do not slip, on the belt. Normally after 100 hours of operation the belt will stretch and will need to be checked and tightened (usually one hole). Once the first belt stretch occurs, the belt should not continue to stretch. The belt should not be so loose as to snap or flex enough to slap the aluminum structure running along the side of the belt. Page 56 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

64 PUMP TROUBLESHOOTING PROCEDURES MULTI-STAGE CENTRIFUGAL PUMPS Refer to the correction procedure appropriate for equipment conditions. Problem: The Pump Does Not Run Motor is defective - Pump is bound - Troubleshooting Procedure Turn off the power and disconnect the wiring. Measure the lead to lead resistances with an ohmmeter (RX-1). Measure lead to ground values with an ohmmeter (RX-100K). Record the measured values. If an open or grounded winding is found, remove the motor and repair or replace. Turn off the power and manually rotate the pump shaft. If the shaft does not rotate easily, check the coupling setting and adjust as necessary. If shaft rotation is still tight, remove the pump and inspect. Disassemble and repair. Problem: The Pump Runs At Reduced Capacity Or Does Not Deliver Water. Troubleshooting Procedure Wrong rotation - Check wiring for proper connection. Correct wiring. Strainers, check or foot valves are clogged - Pump has leaks - Suction and/or discharge piping leaks - Remove the strainer, screen ore valve and inspect. Clean and replace. Reprime pump. Replace seals or gaskets. Air in the suction pipe. Suction pipe, valves and fittings must be airtight. Repair any leaks and retighten all loose fittings. Check the tank for proper water level. Pump impeller or guide is clogged - Disassemble and inspect pump passageways for debris. Remove any foreign materials. Page 57 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

65 Problem: Fuses Blow Or Circuit Breakers Or Overload Relays Trip Troubleshooting Procedure Low voltage - Check voltage at the starter panel and motor. If voltage varies more than +/- 10%, contact the power company. Check the wire sizing. Motor overloads are set too low - Cycle the pump and measure the amperage. Increase the heater size or adjust the trip setting to a maximum of the motor nameplate (full load) current. Three-phase current is imbalanced - Check the current draw on each lead to the motor (must be within +/- 5%). If not within range, check the motor and wiring. Rotating all leads may eliminate this problem. Motor is shorted or grounded - Wiring or connections are faulty - Pump is bound - Bad overload - Too much water flow - Turn off the power and disconnect the wiring. Measure the lead to lead resistances with an ohmmeter (RX-1). Measure lead to ground values with an ohmmeter (RX-100K). Record the measured values. If an open or grounded winding is found, remove the motor and repair or replace. Check for proper wiring and loose terminals. Tighten loose terminals. Replace damaged wire. Turn off the power and manually rotate the pump shaft. If the shaft does not rotate easily, check the coupling setting and adjust as necessary. If shaft rotation is still tight, remove the pump and inspect. Disassemble and repair. Measure the amp draw versus the setting. Check for leaks or wrong nozzles which would cause the pump to pump more water than the motor can handle. Page 58 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

66 SINGLE STAGE PUMPS Refer to the correction procedure appropriate for equipment conditions. Problem: Failure to Pump Pump not properly primed - Speed too slow - Motor rotation is wrong - Troubleshooting Procedure Be sure that the pump case and suction line are full of water. Check the voltage at the motor terminals and at the meter when the pump is operating. Check for loose connections. Verify that the pump is wired correctly. Problem: Reduced Capacity and/or Head Clogged impeller - Air pockets or leaks in suction - Excessively worn impeller - Motor rotation is wrong - Troubleshooting Procedure Remove and clean. Check the line under pressure to find the leak in the line. Order replacement impeller. Make sure pump is wired correctly. Problem: Pump Loses Prime Air leaks in suction line - Troubleshooting Procedure Check suction piping. Check line under pressure to locate the leak. Problem: Motor Will Not Start or Makes Noises Troubleshooting Procedure No electric current to motor - Check the power supply and for loose or incorrect connections. Motor hums but will not start - Bent shaft or damaged bearings - Turn off power. Check the rotating element to see if it turns freely. Replace with new pump. Page 59 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

67 WARRANTY INFORMATION WARRANTY PARTS RETURN All RYKO machines and accessories are built for longevity and reliability. Engineering designs are thoroughly tested and only the highest quality parts and components are used in the manufacture of RYKO equipment. Occasionally, however, a part or component may be defective. If a part on your machine equipment should fail under the conditions set forth in the RYKO Rollover Limited Warranty, it should be returned. If your equipment was installed by a RYKO distributor, return the part freight prepaid to your authorized distributor. If you are located in the factory-direct sales and service area, return the part prepaid to RYKO. Be sure to contact the distributor or factory before returning any part to insure correct procedure is followed to receive a replacement part. A RYKO Return Material Tag must be completely filled out and attached to each part returned. Several of these tags are included with this manual, and additional tags are available upon request. Effective June 1994 Page 60 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

68 SITE INFORMATION LOG The Site Information Log is intended as a record of changes from the standard electrical schematic or when mechanical changes are made to equipment which significantly modify the performance of the car wash machine. DATE = Date of change. MACHINE AFFECTED = Product Name CHANGE MADE = How machine operation was changed. CHANGE REQUESTED BY = Owner, Technician or RYKO Customer Service / Engineering. CAR ID# = If CAR submitted. TECHNICIAN INITIALS = Initials of Technician making change DATE MACHINE AFFECTED CHANGE MADE CHANGE REQUESTED BY CAR ID# TECHNICIAN INITIALS Page 61 RYKO SoftGloss Maxx Service Manual Work Order # 230V SOFTGLOSS SERVICE [SG4S03]

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86 Service Manual For Work Order Page SA-18 SHORT BAY OPERATION GUIDE SOFTGLOSS XS (8K and 16K Modules),SOFTGLOSS MAXX, VOYAGER II, PREMIER PLUS The program requires special hardware that changes the operation of the rear arms. An additional proximity switch and two targets are used to keep the rear arms closed at the rear of the vehicle and to monitor the prox to ensure it is working properly. This occurs at different times during the wash and allows washing longer vehicles in a non-standard (short) bay. PROFILE PASS During the profile pass (with or without foam bath), the program monitors the short bay prox input. If the short bay prox is detected before the adjustable timers time out, the machine stops and the wash forward cycle starts from that point. This is the location that the machine can safely travel reverse with the rear arms open without hitting the inside obstruction. SoftGloss MAXX or SoftGloss XS with 16K program module: If Tri-Foam detergent option is available and machine is armed for a Tri-Foam application, the machine will stop when the short bay prox is detected, shut off the Tri-Foam outputs and fold in the rear arms. When the rear arm prox inputs are detected, the Tri-Foam outputs will turn on and the machine will continue reverse, with the rear arms folded in, until the adjustable timer times out or the rear endstop is detected. At that point the wash forward cycle starts. WASH REVERSE CYCLE During the wash reverse cycle, the program monitors the rear arm prox switches. If neither of the proxes is detected and the short bay prox is detected at the rear of the vehicle, the machine will stop and reset the rear arms as a safety measure. This is the location that the machine can safely open the rear arms without hitting the inside obstruction. The program will then continue the wash cycle in the forward direction from this point. If, while washing reverse, one of the rear arm proxes is detected before the short bay prox is detected, the program will continue washing reverse with the rear arms closed. The short bay prox is used at this point to monitor the machine position with the rear arms closed Page 1 of 3 Rev. G ECO: Aprv: RB Date: 01/20/11

87 REAR ARM RESET CALCULATION As the machine rinses or dries FORWARD, the rear arms remain closed until the machine drives forward enough to clear the inside obstruction. This distance is calculated based on machine speed while the short bay prox is on and the machine is washing reverse. RESET DURING PRESOAK OR ONBOARD TIRE CHEMICAL After the Short Bay Prox turns on at the rear of the vehicle, the rear arms will fold in. The machine travels the same speed in both, reverse and forward, directions at the rear. The Trunk Wash Speed adjustment controls this. The PRESOAK/TIRE CHEMICAL OFFSET VALUE determines when the rear arms will open again. Once the rear arms open, the speed will change to 90 Hertz. NOTE: If TRUNK WASH SPEED is changed, it is important to change PRESOAK/TIRE CHEMICAL OFFSET VALUE; if TRUNK WASH SPEED is decreased then increase PRESOAK/TIRE CHEMICAL OFFSET VALUE and vise versa. SoftGloss Maxx: Presoak and Tire Chemical utilize the Foam Bath speed(d986). Presoak, if armed by itself, will drive in reverse at the selected speed and stop when the Short Bay Proximity switch turns on. Tire Chemical will drive in reverse at the selected speed and slow down to 10 hertz after detecting the tires. If the Short Bay proximity switch turns on while spraying the tires, the machine will stop sooner than it would in a Presoak cycle, due to the speed of the machine. This will result in the arms folding in sooner (closer to the vehicle) and retracting later. Keep this in mind when setting the PRESOAK/TIRE CHEMICAL OFFSET VALUE. RESET DURING RINSE After the Short Bay Prox turns on at the rear of the vehicle, the rear arms will fold in. The machine travels the same speed in both, reverse and forward, directions at the rear. The Trunk Wash Speed adjustment controls this. The RINSE OFFSET VALUE determines when the rear arms will open again. Once the rear arms open, the speed will change to RINSE SPEED. NOTE: If TRUNK WASH SPEED is changed, it is important to change RINSE OFFSET VALUE; if TRUNK WASH SPEED is decreased then increase RINSE OFFSET VALUE and vise versa. SoftGloss Maxx or SoftGloss XS with 16K program module: Setup question ArmsInW/RNS? has been added to allow the rear arms to fold in during the rinse reverse pass. This will allow the machine to drive further back and cover more area at the rear of vehicles but the wash time will be increased. When the rear arms fold in, the speed changes to the TRUNK WASH SPEED so that the RINSE OFFSET VALUE can be used to determine when the arms will open during the next forward pass Page 2 of 3 Rev. G ECO:

88 RESET DURING DRY The dry cycle has adjustable speeds in both the forward and reverse direction. The machine speed must be the same in both the reverse and forward directions to determine when to open the rear arms, therefore it is important that both are set the same and it is recommended to set them at 3 or less. If they are not equal, the possibility exists that: 1. The arms will open before clearing the inside obstruction or 2. The arms will not open soon enough and hit the rear of the vehicle. Because the dry speed is adjustable, DRY OFFSET VALUE determines when the rear arms will open. Once the arms open, the dry will continue at the same speed. NOTE 1: If Dry Reverse and Dry Forward speeds are changed, it is important to change DRY OFFSET VALUE; if Dry speeds are decreased then increase DRY OFFSET VALUE and vise versa. NOTE 2: During the DRY REVERSE CYCLE, the program monitors the short bay prox. When the prox is detected at the rear of the vehicle, the machine stops and closes the rear arms. If BOTH rear arm proxes are detected within 10 seconds, the dry continues in the reverse direction. If the proxes are not detected within 10 seconds, the rear arms are reset and the machine dries forward from that point. MACHINE SAFETY Another feature with this program is that BOTH the short bay prox and the front end stop prox MUST be detected before the machine can be armed. If a 2 digit code 33 is displayed, it means that one of these proxes is not being detected and therefore the machine is not at the home position. The short bay prox is also monitored during the wash to ensure that it is working correctly. This is accomplished by the offset of the front end stop prox target and the added target for the short bay prox. As the machine drives in the reverse direction, the short bay prox MUST go off before the front end stop prox. If the short bay prox is on at the front of the vehicle when the front end stop prox goes off, the machine will shut down. The program detects this as a prox always on condition. 2 digit code 14 will be displayed to help diagnose this problem. NOTE: Refer to SETUP AND ADJUSTABLE TIMER INSTRUCTIONS for SETUP and TIMER information used with these programs Page 3 of 3 Rev. G ECO:

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99 Service Manual For Work Order Page SA-31 INSTRUCTIONS/ARM PROXIMITY SWITCH ADJUSTMENT 1. MUST FIRST ADJUST FRONT AND REAR BRUSH ARM PROXIMITY SWITCHES SO SWITCH FACE WILL BE 5/32 +1/32,-1/16 FROM THE ARM TUBE SURFACE 2. THE FRONT AND REAR BRUSH ARM PROXIMITY SWITCHES MUST BE ADJUSTED TO THE DIMENSIONS SHOWN ON THIS DRAWING. THESE DIMENSIONS ARE THE DISTANCE AT WHICH THE PROXIMITY SWITCH GOES BACK OFF, AS THE ARMS ARE MOVED IN. THIS NEEDS TO BE CHECKED AND ADJUSTED AS NEEDED. INSTR/ARM PROX SW ADJUSTMENT PAGE 1 OF 1 Rev. - ECO Aprv: GDL Date: 3/14/00

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106 Service Manual For Work Order Page SA-38 Operating Instructions for the Touch Screen PLC Interface Display Table of Contents Main Screen... 2 Information Menu Screen... 3 Major History Screen... 3 Diagnostic History Screen... 4 PLC Program Information Screen... 4 Display Program Information Screen... 5 Site Menu Screen... 6 Manual Drive Screen... 6 Wash Counts Screen... 7 Back Up/Non-Network Arming Wash Packages Screen... 7 Operator Adjustable Wash Timers Screen... 8 Test Functions Screen... 9 Operator Adjustable Setup Question Screen... 9 Clock Setting Screen Technician Menu Screen Technician Set-up Question Screen Technician Adj. Wash Timers Screen Monitor Mode Screen SAMPLE SCREEN SHOTS CHANGING SCREENS ENTERING MONITOR DEVICES TEST OPERATION TEST OPERATION KEY WINDOW SCREENS TEST OPERATION MENU SCREEN QUICK TEST DELETING DEVICES Manual Drive with Monitor NOTE: This document pertains to the program The information within this document is generic in nature and will show screen shots of the Radius for reference only. The intention of this document is to provide direction for navigational purposes for all machine that use the PLC User Interface, Touchscreen. CAUTION: THE HPP MUST NOT BE USED WITH A FX3U PLC Rev. B ECO Page 1 of 28 Aprv. GDL Date: 5/8/08

107 Main Screen When powered up, the display will show copyright information for the manufacturer of the display. After 5 seconds, the display will change to the Main Screen. The top two lines of the Main Screen display the current date and time. This is the date and time stored in the Real Time Clock in the PLC. This date and time are used to tag history events as described later. At the bottom of the screen is displayed a two-digit diagnostic code and a short description of the code displayed. In the middle of the display are prompts that indicate which function keys are to be used to access other screens: Touch the Information Screen box to access the Information Screen. Touch the Site Screen box to access the Site Screen. Touch the Technician Screen box to access the Technician Screen. Touch the OPEN to toggle between Wash Open and Wash Closed modes. If the display is left on any other screen for 15 minutes with no key presses, the display will go into a Screen Saver mode (display will go dark) and return to the Main Screen. This will also reset all entered passwords. If the PLC transitions from Run to Stop and then back to Run, the passwords will also reset and return to the Main Screen. When accessing the Site Menu screen or Technician Menu screen, a key window will appear and the display will prompt you for a password. Enter the appropriate password and touch ENTER. After successfully entering a correct password, the screen will change to acknowledge the success or error of the password. Touch OK and then close the key window by touching the X in upper right hand corner of the window Rev B ECO Page 2 of 28

108 Information Menu Screen This screen allows access to diagnostic and copyright information: Back will return to the Main Screen. Major History will access the Major History Screen. Diagnostic History will access the Diagnostic History Screen. PLC Program Information will access copyright information for the program in the Programmable Controller that controls the machine. Display Program Information will access copyright information for the program in the display. Major History Screen The Major History Screen will display the last 10 major diagnostic events. These events are displayed in the following format: SSSS DDDD CCCC ## mm/dd hh:mm Ten events will be displayed on the screen. The following information is displayed: SSSS: Sequence code for the event. DDDD: Diagnostic code for the event. CCCC: Wash count when the diagnostic event occurred. ## Diagnostic event number 01 through 10. mm/dd: Month and date that the event occurred. hh:mm Time of day that the event occurred using 24 hour time. Refer to the sequence code document for this machine and the 4-digit code document to translate these codes. Pressing Back will return you to the Information Screen Rev B ECO Page 3 of 28

109 Diagnostic History Screen The Diagnostic History Screen will display the last 20 diagnostic events. The events are displayed in the following format: SSSS DDDD CCCC ## mm/dd hh:mm Ten events will be displayed on each screen. The following information is displayed: SSSS: Sequence code for the event. DDDD: Diagnostic code for the event. CCCC: Wash count when the diagnostic event occurred. ## Diagnostic event number 01 through 20. mm/dd: Month and date that the event occurred. hh:mm Time of day that the event occurred using 24 hour time. Refer to the sequence code document for this machine and the 4-digit code document to translate these codes. Pressing Back will return you to the Information Screen. PLC Program Information Screen This screen displays the following information: PLC program name. PLC program part number and revision level. PLC program copyright date and other copyright information. Release date of this revision to the PLC program. Serial Number of the machine. All the Support Document s for the Display. Pressing Back will return you to the Information Screen Rev B ECO Page 4 of 28

110 Display Program Information Screen This screen displays the following information: Display program name. Display program part number and revision level. Display program copyright date and other copyright information. Release date of this revision to the Display program. All the Support Document s for the Display. Pressing Back will return you to the Information Screen Rev B ECO Page 5 of 28

111 Site Menu Screen This screen cannot be accessed unless the Site password or the Technician password has been entered. The site password is This screen allows access to Site accessible items: Back will return to the Main Screen. The Manual Drive Screen. The Wash Counts Screen. Back Up/NonNetwork Arming Wash Packages Screen. Operator Adjustable Wash Timers Screen Test Items Screen. Operator Adjustable Set-up Questions Screen. Clock Settings Screen. Manual Drive Screen The Manual Drive Screen will allow the machine to be driven manually. Back will return to the Site Menu Screen. Press and hold the ROTATE FORWARD button to cause the arm to rotate forward. Press and hold the ROTATE REVERSE button to cause the arm to rotate reverse. Press and hold the GANTRY FORWARD button to cause the gantry to drive forward. Press and hold the GANTRY REVERSE button to cause the gantry to drive reverse. Press and hold the TROLLEY LEFT button to cause the trolley to drive to the left. Press and hold the TROLLEY RIGHT button to cause the trolley to drive to the right. Note that the buttons that cause movement are momentary switches. Movement will only occur while the button is pressed Rev B ECO Page 6 of 28

112 Wash Counts Screen Back will return to the Site Menu screen. The Next button will access the second screen of Wash Counts. Back Up/Non-Network Arming Wash Packages Screen If your machine is Network armed the screen will display the Network Back-Up Wash screen. Press the circle next to the arming option to toggle each wash arming selection on or off for the wash package being set up. If the circle is dark, it is not on and if it is white, it is on. There are 8 screens associated with Back-Up Arming. Press Next to access the successive screen of wash options for the Back-Up wash package. These wash options are in the same order as shown in the Network Interface Bits document ( ). When the last screen is displayed, the Next button will return to the Site Screen. If your machine is Non-Network Armed, the screen will display Wash #1 thru Wash #6, A la Carte #1 and A la Carte #2 (washes are activated via plc inputs). Press the circle next to the arming option to toggle each wash arming selection on or off for the wash package being set up. If the circle is dark, it is not on and if it s white, it s on. Press Next to access the second screen of wash options for the current wash package. There are 6 wash packages available. When the second screen of the 6th wash package is displayed the Next button will return to the Site Screen. To access earlier wash packages, press the Back button on the display unit Rev B ECO Page 7 of 28

113 Operator Adjustable Wash Timers Screen Only adjustable wash timers that are designated by the PLC program, to be accessible by Site personnel, will be displayed. These timers start at D920 and run through D999. For further explanation of Operator Adjustable Wash Timers refer to applicable Machine Setup and Timer document and the Operators Choice Programming Instructions. There are 5 screens associated with the Operator Adjustable Wash Timers within the Site Screen. Below are examples of some of the screens. Press the number next to the adjustable timer to change the value. Select the new value on the key window and press ENTER. The key window will disappear and the adjustable timer will display the new value. Press Next to access the successive screen of Operator Adjustable Wash Timers. There are 5 Operator Adjustable Wash Timer screens available. When the last screen is displayed the Next button will return to the Site Screen. The Back button on the display unit will return to the previous screen Rev B ECO Page 8 of 28

114 Test Functions Screen Back will return to the Site Menu Screen. Press the circle as indicated on the display to toggle each test function on or off. If the circle is dark, it is not on and if it is white, it is on. For further explanation of the Test Functions refer to applicable Test Function Instructions document. Operator Adjustable Setup Question Screen Only setups that are designated by the PLC program to be accessible by Site personnel will be displayed. For further explanation of Operator Adjustable Setup Questions refer to applicable Machine Setup and Timer document and the Operators Choice Programming Instructions. Press the circle as indicated on the display to toggle each setup question on or off. If the circle is dark, it is not on and if it is white, it is on. When the last screen of the Operator Adjustable Setup Questions is displayed, the Next button will return to the Site Menu Screen. To access the previous page of setup questions, press the Back button on the display unit Rev B ECO Page 9 of 28

115 Clock Setting Screen Pressing Clock Settings on the Site Menu Screen will access the Clock Setting Screen. This screen can be used to set the clock in the PLC to the current time. The date is displayed on the first line as MM/DD/YYYY. The time is displayed on the second line as HH:MM:SS. The time is in 24 hour format. To change the date or time, press the desired date or time. A Key window will appear Once the date and time have been updated, press the Enter key and then the OK button. Close the Clock window (touch the X in the upper right hand corner to return to the Site screen Rev B ECO Page 10 of 28

116 Technician Menu Screen This screen cannot be accessed unless the Technician password has been entered. The Technician password is This screen allows access to Technician accessible items: Back will return to the Main Screen. Technician Adjustable Set-up Question Screen. Technician Adjustable Wash Timers Screen. Monitor Mode Screen. Manual Drive With Monitor Screen. Ability to toggle the PLC between RUN and STOP modes Rev B ECO Page 11 of 28

117 Technician Set-up Question Screen All setup questions are accessible through this screen. For a further explanation of Setup Questions refer to applicable Machine Setup and Timer document. Press the circle as indicated on the display to toggle each setup question on or off. If the circle is dark, it is not on and if it is white, it is on. When the last screen of the Technician Adjustable Setup Questions is displayed, the Next button will access the Operator Adjustable Set-up Questions Screen. To access the previous page of setup questions, press the Back button on the display unit Rev B ECO Page 12 of 28

118 Technician Adj. Wash Timers Screen Only adjustable wash timers that are designated by the PLC program, to be accessible by Site personnel, will be displayed. These timers start at D570, D571, D575 and D850 through D999. For further explanation of Adjustable Wash Timers refer to applicable Machine Setup and Timer document. There are 5 screens associated with the Technician Adjustable Wash Timers within the Technician Screen. Below are examples of some of the screens. Press the number next to the adjustable timer to change the value. A key window will be displayed on the screen. Select the new value on the key window and press ENTER. The key window will disappear and the adjustable timer will display the new value. Press Next to access the successive screen of Technician Adjustable Wash Timers. There are 5 Technician Adjustable Wash Timer screens available. When the last screen is displayed the Next button will display the Operator Adjustable Wash Timers. If the Back button is pressed when in the Operator Adjustable Wash Timers screen, the display will return to the Site screen Rev B ECO Page 13 of 28

119 Monitor Mode Screen CAUTION: THE HPP MUST NOT BE USED WITH A FX3U PLC. The monitor mode function is capable of monitoring and changing devices within a PLC. It is intended to troubleshoot the controller system and to assist with maintenance operations. The Monitor Mode replaces the functionality of the HPP. The main screen of the Monitor Mode will be displayed as shown above. There are 5 parts to this screen DEV MON Performs device monitoring in the Device Monitoring window. Individual D registers (16 bit), Double D registers (32 bit), M Bits, PLC inputs (X), PLC outputs (Y), S bits and R registers can all be monitored through this screen. Timers and Counters cannot be monitored with this function. (See Fig. 1) BAT MON Performs Batch monitoring of the devices described in DEV MON, with the addition of Timers and Counters. This feature will display 16 consecutive devices. Timers and Counters will only display their current value. (See Fig.2) TC MON Performs monitoring of Timers and Counters only. This feature will display 8 consecutive T/C, their current value and the status of the coil (ON/OFF). (See Fig. 3) BM MON This feature will not be given an explanation. Ryko does not utilize this function. END Ends the Monitor Mode function and returns to the Technician Screen unless the screen goes into a sleep mode and then it will return to the Main Screen Rev B ECO Page 14 of 28

120 SAMPLE SCREEN SHOTS Device Monitor Batch Monitor The Device Monitor function monitors up to 8 controller devices entered by the user in a single window. Fig. 1 The Batch Monitor function monitors up to 16 controller devices from the device number specified by the user in a single window. Fig. 2 TC Monitor The TC monitor function monitors the present value, set value, contact point, and coil of up to 8 controller timers (T)/ counters (C) from the device number specified by the user in a single window. Fig Rev B ECO Page 15 of 28