Work Order #

Transcription

1 The Finest Vehicle Wash Systems SOFTGLOSS XS SERVICE MANUAL Work Order # SERIAL # For Models: RYKO Manufacturing Co N. W. 54 th Avenue Grimes, IA

2 :

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 XS Service Manual Work Order #

4 THIS MANUAL CONTAINS INSTRUCTIONS FOR MAINTAINING AND OPERATING A RYKO SOFTGLOSS XS 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 MANUFACTURING COULD NOT POSSIBLY KNOW, EVALUATE, AND ADVISE THE SERVICE TRADE OF ALL CONCEIVABLE WAYS THAT SERVICE MAY BE PERFORMED, OR OF THE POSSIBLE HAZARDS OF EACH. ACCORDINGLY, 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 XS Service Manual Work Order #

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 & PULSAFEEDER PUMPS) ADJUSTMENTS - AIR AND WATER (FOAM BATH AND TRIFOAM DETERGENT) ADDITIVE INFORMATION ADDITIVE SYSTEM OPERATION FOAM BATH TEST, TRIFOAM DETERGENT TEST, AND HOT WAX TEST TRIFOAM DETERGENT OPTION MAINTENANCE PULSAFEEDER ADDITIVE PUMPS PULSAFEEDER PUMP REQUIREMENTS AND SPECIFICATIONS PULSAFEEDER PUMP OPERATION AND CONTROLS PULSAFEEDER PUMP PRIMING PULSAFEEDER PUMP FLOW ADJUSTMENT PULSAFEEDER PUMP MAINTENANCE AND REPAIR PULSAFEEDER PUMP DIAPHRAGM PULSAFEEDER PUMP TROUBLESHOOTING Page iii SoftGloss XS Service Manual Work Order #

6 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 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 MAINTENANCE MAINTENANCE SCHEDULE 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 XS WITH FOAMBRITE OPERATION / ADJUSTMENTS ULTRASONIC PROFILING TALL ARM CLUTCHES TOP BRUSH SIDE BRUSHES CURRENT SENSING PREWASH Page iv SoftGloss XS Service Manual Work Order #

7 PROGRAM OPERATION FOAMBRITE BRUSH CLEANING BRUSH REPLACEMENT TOP BRUSH TALL REAR SIDE ARM BRUSHES PICTOGRAM SIGN OPTION PICTOGRAM SIGN MAINTENANCE PICTOGRAM SIGN REPLACEMENT WIPER DRIVE BELT ADJUSTMENT PUMP TROUBLESHOOTING PROCEDURES MULTI-STAGE CENTRIFUGAL PUMPS SINGLE STAGE PUMPS REAR BRUSH SHAFT CLUTCH REMOVAL WARRANTY INFORMATION WARRANTY PARTS RETURN SITE INFORMATION LOG DRAWINGS Pneumatic/Hydraulic Schematic, SoftGloss & Rocker Panel Brush, Reclaim Pneumatic/Hydraulic Schematic, Rocker Panel Brush, Reclaim Pneumatic/Hydraulic Schematic, SoftGloss & Rocker Panel Brush Pneumatic/Hydraulic Schematic, SoftGloss XS Pneumatic/Hydraulic Schematic, SoftGloss XS, Single Chemical OffBoard Boost Pump Electrical Schematic Keep Full Service Installation Keep Full Service with Float Switch Overload Settings Label SoftGloss XS Phase Generator OnBoard Dry, Hot Wax Electrical Schematic Short Bay Operation Guide Electrical Schematic Pre-Wash Hydraulic Schematic Brush Assembly Instructions, FoamBrite Arm Proximity Switch Adjustment Instructions CMD (Customer Message Display) Instruction Sign Programming 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 MANUALS AVAILABLE FOR THIS PRODUCT: Pre-Installation Installation Service Owner's Page v SoftGloss XS Service Manual Work Order #

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, remove the key from the manual drive switch. Only authorized personnel should have access to this key. 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 switch. a) If no "clicking" of contactors, go to Step 3. b) If "clicking" of contactors is heard, locate the second source for power and shut power off. Page 1 RYKO SoftGloss XS Service Manual Work Order #

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 XS Service Manual Work Order #

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 XS 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 XS Service Manual Work Order #

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. 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. Page 4 RYKO SoftGloss XS Service Manual Work Order #

12 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 XS 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 XS Service Manual Work Order #

13 PHYSICAL SPECIFICATIONS Length: 11' 4" Width: 12' 9-1/8" with brushes idle 14 10" with brushes spinning Height: 10' 4-1/2" Machine with Boom Mounted 8' 9 1/2" Machine Only 11' 1-1/2" with Top Brush spinning Height dimensions listed, represent the machine when positioned on the tracks. Weight 3255 pounds (machine only) 3755 pounds (with OnBoard Dry) 3500 pounds (with Wheel Scrub) 4000 pounds (with OnBoard Dry and Wheel Scrub) IMPORTANT: WEIGHTS LISTED ARE DRY WEIGHTS AND WITHOUT SHIPPING SKIDS AND SHIPPING PACKAGING. NOTE: SHIPPING SKIDS AND SHIPPING PACKAGING ADD ABOUT 450 POUNDS. Note: The Dry option, as it pertains to specification or dimensions, is in reference to a machine with onboard dryer fans. If the dry option is a free standing system (ThrustPro or SlimLine), specifications will differ. IMPORTANT: WEIGHTS LISTED ARE APPROXIMATE, AND INCLUDE SOME SKIDDING WEIGHT. ACCEPTABLE VEHICLE DIMENSIONS RYKO SoftGloss XS systems WILL accommodate vehicles within the dimensions below. SoftGloss XS systems WILL NOT accommodate vehicles beyond these dimensions. Length: 19' 0" Width (body): 95" 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 XS Service Manual Work Order #

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 13' 6" (4115 mm) 16' 0" (4875 mm) With Aluminum ThrustPro Dryer 13' 6" (4115 mm) 16' 0" (4875 mm) With Aluminum SlimLine Dryer 13' 6" (4115 mm) 16' 0" (4875 mm) With Stainless Steel Overhead Dryer 13' 6" (4115 mm) 16' 0" (4875 mm) Adjustable up to 18' 0" (5485 mm) With Stainless Steel SlimLine Dryer 13' 6" (4115 mm) 16' 0" (4875 mm) Adjustable up to 18' 0" (5485 mm) Length: With or Without Onboard Dry 32' 9" (9980 mm) 34' 3" (10,440 mm) Required length when using Auto Door Kit with Photo Eyes. 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 XS 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 XS Service Manual Work Order #

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 XS Service Manual Work Order #

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 Accumulator, 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 XS Service Manual Work Order #

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 manual drive key switch, the 2 Digit Code Display LED, and the Operation Mode (Car Wash Open/Car Wash Closed) switch. 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 XS Service Manual Work Order #

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. COMMUNICATIONS INTERFACE BOX The Communications Interface Box, which is normally installed in the bay, houses the manual drive switch, the Operation Mode (Car Wash Open/Car Wash Closed) switch, and the Emergency Stop switch and the 2 Digit LED display. Additional detailed descriptions for each of these switches and the 2 Digit LED are provided elsewhere in this manual. 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. CLUTCH A pneumatic operated clutch has been installed on the upper portion of the rear arms. The clutch engages (spins) the upper section of the arms for tall vehicles (e.g., vans, sport utility vehicles) pickup trucks and the passenger portion of sedan style cars. The clutch disengages at the hoods of all vehicles. 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 XS Service Manual Work Order #

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 Switch Settings for this switch are RUN and STOP. At such time a program change with the Hand Held Programmer is required or anytime an output is forced on, this switch must be placed to the STOP position. 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 XS Service Manual Work Order #

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. This box (normally installed in the bay), houses a 2 Digit Code Display, a Manual Drive Key Switch, an Emergency Stop Switch, and the Operation Mode (Car Wash Open/Car Wash Closed Switch). To shut the system down, place the Operation Mode (Car Wash Open/Car Wash Closed) switch to the CLOSED position. To start the system, place the Operation Mode (Car Wash Open/Car Wash Closed) switch to the OPEN position. IMPORTANT: UNLESS AN EMERGENCY SITUATION ARISES, THE SOFTGLOSS XS SHOULD ONLY BE STARTED AND STOPPED VIA THE CAR WASH OPEN/CLOSE 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 XS Service Manual Work Order #

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 XS. 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 Page 14 RYKO SoftGloss XS Service Manual Work Order #

22 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. 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: UnderCar Wash 1. The UnderCar Wash option sprays water on the bottom of the vehicle for a period of 5 seconds (approximate) before the machine begins its wash cycle. Water continues to spray from nozzles on the two manifold for 15 seconds (approximate) after the machine begins operation. Total running time of the UnderCar Wash option is 20 seconds. The UnderCar Wash operates during the Pre- Wash if present. If the Pre-Wash is not present but the Foam Bath is, then the UnderCar Wash operates during the Foam Bath. If neither the Pre-Wash or Foam Bath are present, the UnderCar Wash operates during the start of the wash cycle. If this option is installed, refer to the owner s manual included with shipment of this product for maintenance and operation procedures. Step 5: 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. Page 15 RYKO SoftGloss XS Service Manual Work Order #

23 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 6: 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. 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 7: 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 XS Service Manual Work Order #

24 Page 17 RYKO SoftGloss XS Service Manual Work Order #

25 Step 8: 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 9: 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 10: 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 XS. 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 Page 18 RYKO SoftGloss XS Service Manual Work Order #

26 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 XS. Page 19 RYKO SoftGloss XS Service Manual Work Order #

27 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. 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 20 RYKO SoftGloss XS Service Manual Work Order #

28 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 21 RYKO SoftGloss XS Service Manual Work Order #

29 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 22 RYKO SoftGloss XS Service Manual Work Order #

30 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 23 RYKO SoftGloss XS Service Manual Work Order #

31 Page 24 RYKO SoftGloss XS Service Manual Work Order #

32 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 25 RYKO SoftGloss XS Service Manual Work Order #

33 When installed on the SoftGloss XS, 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 Located in the Communications Interface Box is a TEST button. This button when pressed, enables activation of the Foam Bath system (or the TriFoam Detergent or TriFoam Wax if present) to allow adjustment of water, air and detergent or the hot wax system to test the Hot Wax heater. Other test functions that can be performed via this TEST button include; the Pre-Wash Oscillate Test, Fan Nozzle Oscillate Test, and UnderCar Wash Manifolds 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 26 RYKO SoftGloss XS Service Manual Work Order #

34 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 Vd Vw Total solids of concentrated detergent before diluted (e.g., 45% is expressed as 0.45) Volume of detergent needed Volume of water needed Page 27 RYKO SoftGloss XS Service Manual Work Order #

35 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 Vd and Vw to make a 55 gallon batch of finished product at 15% solids. (0.15*55)/(0.40) = Vd or 20.6 gallons of concentrated detergent needed for a 55 gallon batch. 55 minus 20.6 = Vw or 34.4 gallons of water needed for a 55 gallon batch ADDITIVE SYSTEM (NON-RYKO CHEMICAL & PULSAFEEDER 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 Page 28 RYKO SoftGloss XS Service Manual Work Order #

36 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. Page 29 RYKO SoftGloss XS Service Manual Work Order #

37 The information below pertains to machines with the TriFoam Detergent Option, only. When installed on the SoftGloss XS, 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. Pulsafeeder pumps feed additive to the TriFoam Detergent manifolds on each side of the machine gantry. 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. ADDITIVE INFORMATION The information that follows gives the recommended dial settings on the additive pumps to allow the proper volume of additive for each wash operation. These settings are provided as a starting point and guide. Fine tuning may be necessary to meet location requirements. Note: For additive pump priming procedures refer to Pulsafeeder Additive Pumps in this manual. Additive Setting Chart (For Model using Formula Finish Additives only) Additives Stroke Rate Stroke Length (Frequency) Detergent 90% 40% TriFoam Detergent 90% 40% Wax 100% 90% Page 30 RYKO SoftGloss XS Service Manual Work Order #

38 RYKO ADDITIVES RYKO Additive Setting Chart (using RYKO Additives only) Additives Stroke Rate (Frequency) Stroke Length Detergent (High Foam or Mountain Pine) 90% 70% Detergent (Yellow Concentrate) 90% 40% TriFoam Detergent 90% 40% Wax 100% 100% 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 31 RYKO SoftGloss XS Service Manual Work Order #

39 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 32 RYKO SoftGloss XS Service Manual Work Order #

40 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. In other words, S Vd Vw 0.15 (Desired solids percentage) (multiplied by) X G (Total gallons of finished product desired) A Total solids of concentrated detergent before diluted (e.g., 45% is expressed as 0.45) Volume of detergent needed Volume of water needed 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 Vd and Vw to make a 55 gallon batch of finished product at 15% solids. (0.15*55)/(0.40) = Vd or 20.6 gallons of concentrated detergent needed for a 55 gallon batch. 55 minus 20.6 = Vw 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. All detergents used for washing the vehicle are pumped from their supply containers by a Pulsafeeder additive pump to manifolds on the machine in amounts calculated to perform a quality wash. Back flow to the detergent supply container is prevented by a check valve that is installed in the line. The amount of detergent injected in the line is controlled by the length and frequency of the detergent pump's strokes. Both the stroke length and frequency rate are adjusted to allow the required flow rate. (For additional details refer to Pulsafeeder Additive Pumps in this manual. 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. Page 33 RYKO SoftGloss XS Service Manual Work Order #

41 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. 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 Located in the Communications Interface Box is a TEST button. This button when pressed, enables activation of the Foam Bath and TriFoam Detergent (if present) system to allow adjustment of water, air and detergent or the hot wax system to test the Hot Wax heater. Other test functions that can be performed via this TEST button include; the Pre-Wash Oscillate Test, Fan Nozzle Oscillate Test, and UnderCar Wash Manifolds Oscillate Test. For operation procedures of the TEST buttons refer to Communications Interface Box information in this manual. Page 34 RYKO SoftGloss XS Service Manual Work Order #

42 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. PULSAFEEDER ADDITIVE PUMPS The Pulsafeeder pumps deliver the additives from their supply containers to the manifolds and nozzles which dispense additives during the SoftGloss XS operation. PULSAFEEDER PUMP REQUIREMENTS AND SPECIFICATIONS The Pulsafeeder pump requires the following electrical and air service for proper operation. ELECTRIC INJECTION PRESSURE OUTPUT 115V AC, 60 HZ, 1 Phase or 115V AC, 50HZ, 1 Phase.4 Amps Maximum: 100 PSI (7 bars) 22 GPD 3.47 LPH (83.28 LPD) 57.8 ml/min. WARNING! DO NOT USE THIS PUMP TO DISPENSE FLAMMABLE LIQUIDS. PULSAFEEDER PUMP OPERATION AND CONTROLS PULSAFEEDER PUMP OPERATION The Pulsafeeder pumps dispense the additives by an electromagnetic drive mechanism (solenoid) that is connected to a diaphragm. When an 'ON' signal pulse is input (received) from the PLC of the machine, the pump operates one stroke and the fluid is discharged. These input signals are from relay contacts inside the pump control box. After receiving the input signal the pump generates the power necessary to actuate the solenoid. The external signal input is debounced by the pump circuit. Note: The pump may be operated continuously at a rate of 125 strokes per minute by repeated 'ON' and 'OFF' input signals. PULSAFEEDER CONTROLS The pumps are marked with universally accepted symbols. The following illustrations are provided for your convenience. Page 35 RYKO SoftGloss XS Service Manual Work Order #

43 CONTROLLING PROCEDURE For optimum pump performance it is necessary to determine the settings for pump stroke length and frequency according to the pump and the characteristics of the fluid to be pumped. Follow the procedure below to ensure proper settings. Note: The closer to 100% the stroke length is set, the better the pump will perform. 1. Set the stroke length to 100%. Then, as a starting point, adjust the stroke frequency rate. 2. Measure the flow. 3. If the measured flow is less than required, increase the stroke frequency and remeasure. 4. When the measured flow is acceptable, readjust the stroke length for fine capacity control. 5. Measure the capacity once more to verify that the required flow is delivered. EXAMPLE (This information only applies if pumping into 100 PSIG of back pressure) Important: With the Stroke Length and the Stroke Rate both set to 100% (maximum) this pump provides a Maximum Output Capacity of 22 GPD (Gallons Per Day) or 57.8 ml/min (Rated Pressure). Step 1: Determine a Desired Flow Rate (Using a Desired Flow of 9 GPD or 23.6 ml/min in this example) Step 2: Determine an Output Capacity 0.50 (Set the Stroke Rate to 50 %) x 22 GPD or 57.8 ml/min. (Pump's Maximum Output Capacity) 11 GPD or 28.9 ml/min* (Output Capacity) Step 3: Determine Stroke Length Setting Desired Flow Example: 9 GPD or 23.6 ml/min divided by Output Capacity 11 GPD or 28.9 ml/min x 100 x 100 Stroke LengthSetting 80% (approximate) Analysis: To obtain the desired flow, set the stroke length at 80% and stroke rate at 50% ( 0.80 (Stroke Length Setting) x 0.50 (Stroke Rate Setting) x 22 (Maximum Pump Capacity) = approximately 9 GPD or 23.6 ml/min. (Desired Flow Rate) PULSAFEEDER PUMP PRIMING The Pulsafeeder pumps may be primed using a hand pump or using the self priming process described below. CAUTION: WEAR PROTECTIVE GEAR (I.E. CLOTHING, GLOVES, GLASSES, ETC.) WHEN WORKING ON OR WITH THE PULSAFEEDER PUMPS. 1. Turn on power to the pump. 2. Set the stroke rate knob to 100%. 3. Set the stroke length knob to 100%. 4. Using a bleed valve, bypass the discharge line temporarily during the pump priming (until the head has been filled with fluid). Note: All air must be purged from the pump head before the pump will pump against pressure. Air Bleed: a) Turn the bleed valve adjustment screw counterclockwise while the pump is running. b) With the valve open, run until fluid flows from the bypass tubing in a steady stream (without air bubbles). c) Turn the bleed valve adjustment screw clockwise to close. Page 36 RYKO SoftGloss XS Service Manual Work Order #

44 5. After a few minutes, additive should reach the pump head. If not, remove the discharge fitting and moisten the ball and check valve seats with a few drops of the additive. 6. If the pump still fails to prime, refer to Pulsafeeder Pump Troubleshooting. 7. When the pump has primed and is pumping additive through the head, turn off the power. Reconnect the discharge line (if removed). If any additive has spilled on the pump housing or head, clean immediately. 8. Turn on power again and adjust the pump flow rate as desired for operation. 9. Always check pump calibration after start-up. Calibrate during normal operation conditions for best results. PULSAFEEDER PUMP FLOW ADJUSTMENT Additive flow can be adjusted using the Capacity Control Knobs on the Pulsafeeder pumps. Refer to the information below. CAPACITY CONTROL KNOBS The Stroke Frequency Knob allows settings ranging between 10% (12 spm) and 100% (125 spm). Note: The Stroke Frequency knob may be set during pump operation. Capacity: 12 to 125 spm (strokes per min.) Recommended Setting: Refer to the appropriate Additive Setting Chart for the additive used with the machine. The Stroke Length may be controlled to between 10% and 100% diaphragm displacement for normal use. Important: Do Not turn this knob while the pump is stopped. Capacity: 0% to 100% diaphragm displacement. Recommended Setting: Refer to the appropriate Additive Setting Chart for the additive used with the machine. Note: The closer the stroke length is to 100% the better the pump will perform. Do Not use a stroke length below 20%. Page 37 RYKO SoftGloss XS Service Manual Work Order #