SONNY'S The CarWash Factory

Introduction

This manual is a comprehensive step-by-step user instruction guide for the Top Brush and its components. For additional manuals, please visit SonnysDirect.com under the Support Tab. It is crucial to read, understand, and follow all instructions provided herein.

For any questions regarding ordering parts, operating the Top Brush, installation, troubleshooting, maintenance, or service, please contact Sonny's Technical Support Team at 1-800-327-8723, Ext: 234. Any deviations or alterations from these instructions must be reported to Sonny's The CarWash Factory®. Keep this manual in an accessible location for ongoing reference.

Trademarks: Sonny's and Sonny's The CarWash Factory are registered trademarks of Sonny's Enterprises LLC. Make CarWashing Easy and OneWash are trademarks of Sonny's Enterprises LLC. 'Designed here. Built here. Backed here.' is a trademark of Sonny's Enterprises LLC. Other product names and trademarks mentioned are for identification purposes only and are the property of their respective owners.

Important Safeguards and Warnings

WARNING: Do not perform any maintenance or work on equipment unless Lock-Out Safety Precautions are first performed. All electrically powered equipment must have manually operated disconnects capable of being locked in the "OFF" position. Equipment locked out must be restarted only by the person who performed the lockout. These procedures are mandatory to prevent personal injury, death, and/or dismemberment.

• All parts and components must be installed by experienced and trained technicians.
• No unauthorized personnel should be permitted in the wash tunnel or near the equipment at any time.
• Required Personal Protective Equipment (PPE): Hardhat, safety glasses with side shields, closed steel toe shoes, anti-impact and cut-resistant gloves, dust mask, and earplugs if operating power tools.
• When cutting or grinding metal, safety glasses, earplugs, and a dust mask must be worn.
• Do not leave ladders, wash-down hoses, or tools in the wash tunnel while equipment is running, as this can cause vehicle damage and injury, including death.
• Do not wear loose-fitting clothing or jewelry around moving equipment. Keep all body parts and objects away from moving equipment to prevent entanglement, which can cause injury, death, or dismemberment.
• Exercise caution when walking through the wash tunnel; floors may be slippery. Avoid bumping into or tripping over equipment.
• Electrical connections and repairs must only be performed by a Licensed Electrician.
• Plumbing connections and repairs must only be performed by a Licensed Plumber.
• When working at heights above shoulders, use a fiberglass ladder in good condition.
• Use proper lifting techniques; team lifts are required for items over 50 lbs.
• Do not alter, modify, interchange, or substitute any components without authorization from your supervisor and Sonny's The CarWash Factory.
• Do not install parts or components into faulty materials.
• Report all damages and defects to your supervisor and Sonny's The CarWash Factory.
• If malfunctions occur or questions arise, immediately contact your supervisor or Sonny's The CarWash Factory.
• Use only approved hardware, parts, and components.
• Protect body parts from sharp corners and edges at all times.
• Keep loose articles of clothing and jewelry away from equipment during removal, installation, or operation.
• Personnel installing the Top Brush are responsible for ensuring it operates according to this manual.
• Always remove ladders, tools, and parts from the wash tunnel after use.
• All personnel must be trained in safe operation, wash tunnel procedures, safety regulations, and emergency shutdown/maintenance practices.
• Only instructed and trained personnel may enter the wash tunnel for inspections or maintenance. At least two qualified maintenance personnel must be present for repairs or preventive maintenance.
• IMPORTANT: Contact Technical Support to adjust the wash cycle when new equipment is installed.
• WARNING: Hydraulic and electrical systems with torque relief or overload should be checked and set to the minimum amount for proper functionality under normal washing conditions.
• WARNING: Possible wet floors and slippery conditions. Proceed with caution to avoid accidents.
• WARNING: Do not enter the wash tunnel while equipment is operating to prevent injury or death.
• WARNING: Ensure proper Chemistry (Brush Lubrication) is used in the Car Wash Tunnel to prevent vehicle and equipment damage.
• WARNING: If Equipment Installation Dimensions are not measured correctly, it may result in damage or failure. Verify dimensions if equipment is already installed. Contact Sonny's Technical Support Team at 1-800-327-8723, Ext: 234 for installation questions.
• WARNING: All connections and repairs must only be performed by Licensed Professionals, complying with all applicable local and national codes.
• WARNING: Building code verification is the customer's responsibility.
• WARNING: Do not attempt to repair or adjust pressurized liquid or pneumatic parts while equipment is in operation.
• WARNING: Do not operate equipment with safety covers removed or improperly installed, or if any component is suspected to be defective or malfunctioning.
• WARNING: Store cleaning solutions and oils in a well-ventilated area. Clean up spills immediately. Follow SDS Sheets for chemical products.
• WARNING: When equipment must be in operation during inspection or maintenance, one qualified technician must monitor the power disconnect switch while another performs the work.
• All equipment must receive regular maintenance to prevent damage or failure that would void the warranty.

SAVE THESE INSTRUCTIONS

Equipment Specifications

• Designed to occupy 120" of tunnel length and 144" width.
• 4" x 4" aluminum frame and legs for stability and durability.
• Pivot bearing is solid UHMW with a grease fitting for smooth operation.
• Double Roller bearings on shaft.
• Hydraulic brush drive motors use 6 GPM @ 800 PSI.
• Pivot shaft constructed of 1½" stainless steel.
• Hub does not absorb water with NEOGLIDE material.
• Optional Whisper Brush available to reduce noise.
• Chemical delivery system sold separately.
• Brush tracks vehicle contour using a counterweight system.
• Requires a ½" city water connection.

Diagram Description (Figure #1): This diagram illustrates the overall dimensions of the Top Brush unit, showing the driver side and passenger side clearances, total width (144"), and height (90"). It indicates key measurements like 45" from the driver side leg to the center, 99" from the center to the passenger side leg, and a total width of 144".

Diagram Description (Figure #2): This diagram labels the various components of the Top Brush assembly, including the Counter Weight Cap, Weight QTY (10), Counter Weight Base, Cross Beam, Cylinder Gusset QTY (2), Brush Assy, Air Cylinder Assy. (10" Stroke QTY (2)), and Lateral Frame QTY (2).

Top Brush Complementary Equipment

SONNY'S Hush Series Top Brush

Problem: Need to remove heavy dirt or bugs from vehicle top surfaces and eliminate windshield "eyebrow" in a limited tunnel distance.

Solution: The Hush Brush features a simple, proven design with a unique counterweight balancing system that applies equal wash penetration on all horizontal surfaces. The NEOGLIDE foam wash material and hub do not absorb water, maintaining constant pressure. The Hush Brush reduces interior noise without sacrificing wash quality, brush longevity, or safety.

Features:

• Gentle Hush Brush with NEOGLIDE foam material.
• Operator-friendly stainless steel counterweight adjustments.
• Cleans contoured hoods and eliminates windshield "eyebrows".
• Perfect balance.
• Sturdy frame & standard components for easy maintenance.
• Durable QuadX Aluminum frame construction.
• Optional Foundation Frame available to mount additional wash components.

Visual Description: The page shows images of the Top Brush, including the electric and hydraulic versions. It highlights features like the NEOGLIDE foam material, counterweight balance, detergent application system, and optional powder coating. It also shows different brush wrap options (Reverse Wraps, Poodle Brush).

Utilities Requirements

Utilities interconnection and materials are the customer's responsibility. All connections and repairs must be performed by Licensed Professionals in compliance with applicable codes.

Water:

Customer's Plumber must provide and install a ½" city water line at 60 PSI (nominal) to the solenoid valve on the chemical distribution system.

Electric:

Customer's Electrician must provide and install single-phase power (24 or 110 VAC) from the Controller System to the liquid solenoid valve for brush spray bars. If required, install motor starter coil for the hydraulic power pack and any pump motor for the chemical distribution system.

Provide and install single-phase power from the remote push-button station through the tunnel equipment programmer to the air solenoid valve on the Air Distribution Manifold for retract functions.

Provide materials and install 208VAC, 230VAC, or 460VAC, 3-phase, 60Hz power to the electric motor on the hydraulic power pack or VFD panel, using a properly sized three-pole circuit breaker and motor starter with thermal overloads.

Compressed Air:

Customer's Plumber must provide and install a ½" compressed air line from the Air Compressor to the Air Distribution Manifold for retract functions.

Technical Disclaimer: Verification of site-specific conditions and compliance with federal, state, and local building codes is the exclusive responsibility of the customer, architect, and engineer.

Top Brush Dimensions

Diagram Description (Figure #1): This diagram shows the overall dimensions of the Top Brush unit, indicating a total width of 144 inches. It details measurements from the driver's side and passenger's side legs to the center, with specific distances provided (e.g., 45" from driver side, 99" to passenger side). The height is indicated as 90 inches.

Diagram Description (Figure #2): This diagram labels the components of the Top Brush assembly, including the counterweight system (cap, base, weights), cross beam, air cylinder assembly, lateral frame, and brush assembly.

Air Cylinder Position

Diagram Description (Figure #3): This is a pneumatic diagram for the Top Brush air cylinder, illustrating the air cylinder, air regulator, compressed air supply, and the flow of air through ports (EXH, IN, PLUG) and valves (3(N.O), 2(N.C)).

WARNING: Make sure to follow Local and State Safety Wear Required Regulations to ensure the safety of all personnel. Failure to follow Safety Regulations may result in personal injury, death and/or dismemberment.

Equipment Installation Dimensions

Note: L Bracket is not included; order Kit # 20019396.

Installation Steps:

1. Attach L Bracket to the Conveyor Passenger's Side using a C Clamp (not included). Ensure the L Bracket is against the Banana Peel before clamping (A).
2. Measure the overall width of the Equipment Arch from the outside of the Leg to the outside of the Leg (B3).
3. Refer to Drawing (C) on the following page for the Equipment Width being installed.
4. Measure from the installed L Bracket to the outside of the Arch Leg Driver's Side (B1).
5. Position the Arch according to the measurement on Drawing (C) selected (B1).
6. Anchor the Leg in its location.
7. Measure from the installed L Bracket to the outside of the Arch Leg Passenger's Side (B2).
8. Position the Passenger's Side Leg according to the measurement on Drawing (C) selected (B2).
9. Anchor the Leg in its location.
10. Once all equipment is installed, remove the C Clamp and L Bracket.

IMPORTANT: Keep C Clamp and L Bracket for the next installation.

WARNING: If Equipment Installation Dimensions are not measured correctly during installation, it may result in equipment damage and/or failure. Dimensions must be verified if equipment is already installed. Contact Sonny's Technical Support Team at 1-800-327-8723, Ext: 234 for any installation questions.

Diagram Description (Page 14): This page details the installation process with diagrams showing how to attach the L Bracket and measure the overall width and leg positions. It references drawings on the next page.

Diagram Description (Page 15): This page continues the installation dimensions, showing the "OUT to OUT Arch Width" and "TYPICAL EQUIPMENT INSTALLATION DETAIL" with measurements, referencing Drawing (C).

Installation Instructions

Tools Required:

• Safety Glasses
• ½" Drive Ratchet Set
• Standard Combo Wrenches
• 4' Level
• Electric Impact Wrench
• 1" Hammer Drill
• Tape Measure
• Sledgehammer

Consumables:

• Anti-Seize Compound
• Marine Grease

Work Force:

2 Experienced & Trained Technicians

Time Required:

2-4 Hours (No Setbacks)

1. Determine the installation location for the Top Brush, referencing Figure #1 and Equipment Installation Dimensions.
2. Sweep the installation area clear of debris.
3. Check all hardware and apply a small amount of Anti-Seize Compound to each bolt.
4. Place the assembled frame side legs, cross beams, and gussets in the permanent location, with the brush counterweight facing the car wash entrance.
5. Join the legs, cross beams, and gussets to the frame using the provided interconnection hardware, tightening "finger tight".
6. Place and anchor the unit according to the dimensions shown in Figure #1. Ensure entrance and exit cross beams are level (shim mounting feet if necessary) and all 4 vertical legs are plumb.
7. Level and square the frame with the equipment centerline, referencing Figure #1 and Equipment Installation Dimensions.
8. IMPORTANT: Ensure the frame is correctly located before installing lag bolts. Have a second person double-check all measurements against the Equipment Installation Dimensions.
9. Place an anchor bolt in each corner and tighten all hardware.
10. Check each leg for plum and the frame for level, then install the remaining anchor bolts in each leg.
11. Install the brush and counterweight assembly onto the frame.
12. Install the air retract cylinder and run airlines to the manifold for retract operation.
13. NOTE: Air is used only to hold the brush in the retracted position; no air is used during the wash process.
14. Connect chemical lines from the Chemical Distribution Manifold to the frame's chemical line for application nozzles.
15. Connect a ½" PRESSURE line from the Hydraulic Power Pack to the BLACK high-pressure hose fitting on the frame.
16. Connect a ½" RETURN line from the Hydraulic Power Pack to the ORANGE/RED high-pressure hose fitting on the frame.
17. Brush rotation is against vehicle travel. When viewed from the driver's side, the brush turns COUNTERCLOCKWISE.
18. Install the brush onto the frame.

Brush Hub Installation

Diagram Description (Page 18, Image A): Shows the DS Bolts being inserted through lock washers and into the DS Spindle after removing the Retainer Plate from one end of the Top Brush Assembly.

Diagram Description (Page 18, Image B): Shows the Brush held straight, with its end inserted into the DS Top Brush Arm spindle, and the DS Bolts being tightened.

1. Remove and discard the Retainer Plate from one end of the Top Brush Assembly. Insert the Bolts through Lock Washers and the DS Spindle.
2. Hold the Brush straight, insert the end of the Brush to the DS Top Brush Arm spindle and tighten Bolts into place.

Diagram Description (Page 19, Image C): Shows the PS Bolts being inserted through lock washers and into the PS Spindle after removing the Retainer Plate from the other end of the Top Brush Assembly.

Diagram Description (Page 19, Image D): Shows PS Bearing Set Screws being loosened to allow the Brush to slide.

3. Remove and discard the Retainer Plate from the other end of Top Brush Assembly. Insert the Bolts through lock washers and the PS Spindle.
4. Loosen PS Bearing Set Screws to be able to slide the Brush.

Diagram Description (Page 20, Image E): Shows the Brush sliding into the PS Spindle and the Set Screws being tightened.

Diagram Description (Page 20, Image F): Shows the DS Bearing Set Screws being tightened after the Top Brush Assembly is secured to both spindles (DS & PS), ensuring the PS Bearing Set Screws are also tightened.

5. Slide the Brush into the PS Spindle and tighten the Set Screws.
6. Once the Top Brush Assembly is securely tightened to both spindles (DS & PS), tighten the DS Bearing Set Screws. Check the PS Bearing Set Screws to make sure they are also tightened.

Electric Flender Motor

Diagram Description (Page 21, Image G): Shows the Electric Flender Motor assembly connected to the Top Brush system.

Electric Winsmith Motor with Gearbox

Diagram Description (Page 22, Image H): Shows close-ups of the motor and gearbox assembly, highlighting areas for adjustment.

1. To adjust the Brush to the center of the Top Brush Arms, loosen the DS and PS Shaft Bearing Set Screws, and then loosen the inner Shaft Collar Set Screws.
2. Once the Brush is centered, tighten the inner Shaft Collar Set Screws, and then tighten the DS and PS Shaft Bearing Set Screws.

Hydraulic Motor

Diagram Description (Page 23, Image J): Shows close-ups of the hydraulic motor assembly and adjustment points.

1. To adjust the Brush to the center of the Top Brush Arms, loosen the DS and PS Shaft Bearing Set Screws.
2. Loosen the inner Shaft Key Set Screw, and then loosen the Collar Bolts.
3. Once the Brush is centered, verify, and center the Shaft Key to the middle of the Collar.
4. Tighten the inner Shaft Collar Set Screws, and outside Collar Bolts.
5. Tighten the DS and PS Shaft Bearing Set Screws.

Adjustments and Testing

Adjust the Cleaning Pressure of the Washer:

Ensure the air solenoid is in the wash position (no air pressure to the retract cylinder). Adjust the counterweight so the brush moves downward slowly when released. After initial adjustment, manually activate and deactivate the air retract. The brush should fall smoothly when deactivated. Final adjustment can be made during test vehicle runs. Proper cloth penetration should be 3 to 4 inches on flat surfaces. If the brush bounces excessively, the counterweight is adjusted too far out. Make adjustments in small increments (approx. ¼" to ½").

Adjust the Rotation Speed of the Brush:

Brush speed is adjusted via the flow control valve on the hydraulic power pack. Recommended speeds are 85-95 RPM with conveyor speeds of 100-150 CPH. If conveyor speed is reduced to 60-90 CPH, reduce brush speed to 75-85 RPM.

Adjust for Smooth Retract Operation:

Adjust the air pressure regulator to approximately 30 PSI in the retract position. The tunnel controller should be set to put the brush into the wash position before the vehicle arrives. This involves deactivating retracts before the vehicle reaches the brush and setting a "look ahead" function for vehicle proximity.

Speed and Torque Adjustment (where applicable):

Hydraulic:

• Speed is adjusted via the flow control on the power pack. Move the handle towards '10' to increase speed, towards '1' to decrease speed.
• Torque must be set prior to operation between 600 and 900 PSI. Refer to the Hydraulic Power Pack Manual for details.

Electric:

• Speed is adjusted via the Variable Frequency Drive (VFD). Adjust Hertz on the VFD to a higher number to increase speed, or a lower number to decrease speed.
• Motor Starter protector overload must be set to the lowest level for operation. Adjust amps according to the motor nameplate.

General Operation

Top Brush Operation:

Brush rotation starts and stops via a signal from the customer-supplied controller to the hydraulic power pack. This signal should also control soap solution delivery to the spray bar.

IMPORTANT: MAKE SURE THE BRUSHES ROTATE AGAINST VEHICLE TRAVEL.

With the brush rotating against vehicle travel at the proper RPM, the vehicle's front hood contacts the brush, and the brush moves across the vehicle, maintaining steady contact to clean the hood, roof, and trunk.

IMPORTANT: Proper cloth penetration on flat vehicle surfaces should be 3 to 4 inches. On corners like windshields, penetration may be greater, but not deeper than half the distance to the aluminum brush core.

Retract Operation:

When no vehicle is approaching, the tunnel controller retracts the brush from the wash position towards the ceiling. This can also be configured to retract for truck beds to avoid issues.

It is recommended that the Brush be retracted for:

• Sun visors mounted over the windshield.
• Any racks mounted on the roof.
• Rear wipers on certain vehicles (e.g., Acura Integra, Mazda RX-7) unless taped down.
• Open bed pickup trucks.

Parts List

Diagram Description (Page 26): This page lists parts for the Hydraulic Motor, 4-Bolt Bearing, 2-Bolt Bearing, Hydraulic Shaft & Split Collar, Torque Channel, Nozzle Components, Top Brush Cloth Hub & Spider Assembly, and 6in Hub Disk & Split Collar. Each item includes an item number, description, and quantity needed.

Diagram Description (Page 27): This page continues the parts list, detailing components for the Cylinder, Winsmith Gearbox & Sterling Motor, E5 Couplers, Brush & Winsmith Gearbox Shafts, Counter Balance Adjuster & Weight Bar, and Rubber Bumper Stops. It also includes part numbers, descriptions, and prices where applicable.

Maintenance

IMPORTANT: FOR THE FIRST MONTH OF OPERATION, CHECK ALL HARDWARE AND FITTINGS FOR TIGHTNESS EACH WEEK!

WARNING: Ensure proper Chemistry (Brush Lubrication) is used in the Car Wash Tunnel to prevent vehicle and equipment damage.

Daily:

• Check all hydraulic, air, and chemical lines/fittings for leaks. Repair or replace as needed.
• Check brush operation, listening for unusual noises.
• Inspect brush cloth for cuts, grease, or oil. Remove, repair, or replace any affected cloth panels.
• Check retract and extend operation for smoothness and correct pressure.
• Check for proper chemical solution delivery.

Weekly:

• Spray lubricant on clevis pins at both ends of retract cylinders.
• Grease brush shaft bearings, avoiding contact with brush cloth.
• Drain water from FRL and check lubricant level in FRL.

Monthly:

• Inspect all hardware and fittings for tightness.
• Grease UHMW pivot bearings, avoiding contact with brush cloth.
• Inspect bumper stops for wear to ensure air cylinders have not reached their travel limits. Worn stops can be flipped to extend life.
• Inspect soap solution spray nozzles for wear; replace as necessary.
• Thoroughly clean the equipment and framework.

Semi-Annually:

• Carefully inspect brush equipment cloth for wear and damage; replace as necessary.
• If fluid in reservoirs is contaminated, drain, purge, and refill.

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Customer Service & Technical Support

Need more help?

For questions regarding installation, operational issues, settings, or servicing, please contact Sonny's Tech Support at extension 234 or email Sonnys-Support@SonnysDirect.com.

To order replacement parts, contact Customer Service at ext. 200, email CustomerService@SonnysDirect.com, or visit www.SonnysDirect.com.

Contact Information:

• Toll Free Main Line: 800-327-8723 (Office: Monday – Friday 8:00 AM – 5:30 PM ET)
• Fax Number: 800-495-4049
• Local Number: 954-720-4100
• Customer Service: Option 3 (Monday – Friday 8 AM – 8 PM ET)
• Parts: Option 3
• Equipment Sales: Option 4
• Technical Support: Option 5

SONNY'S ENTERPRISES INC.
5605 Hiatus Road
TAMARAC, FLORIDA 33321

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Warranty

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SONNY'S ENTERPRISES LLC FACTORY LIMITED LIFETIME WARRANTY

Equipment manufactured by SONNY'S ENTERPRISES LLC is warranted to be free from defects in material and workmanship. Welded metal framework and other non-moving, non-wearable fabricated metal components are warranted for the life of the equipment to the original purchaser. Fabricated metal wearable surfaces and moving components are warranted for one (1) year to the original purchaser.

Components manufactured by others are warranted by their respective manufacturers. Contact Sonny's for specific warranty terms.

New cloth shipped with equipment is warranted for one (1) year or 80,000 washes, whichever occurs first.

This warranty is not assignable or transferable. The warranty period begins on the first day following installation or 30 days from the original invoice date, whichever occurs first. Seller's liability is limited to repair or replacement of defective materials within the warranty period. Purchaser must provide immediate written notice of any defects. Seller may require return of defective material. Labor and transportation charges are not included. Transportation damage claims must be submitted to the carrier.

This warranty is based on reasonable care and maintenance. It does not apply to misuse, neglect, accident, exposure to harsh chemicals (organic acids, inorganic acids, oxidizing agents, peroxides), aluminum, carbon steel, or other metals. It also does not apply to equipment repaired or altered by unauthorized personnel, or equipment not properly installed with accurate plumbing, electrical, and mechanical requirements. Normal wear and tear or routine maintenance are not covered.

Limitation of Liability: SONNY'S SHALL NOT BE LIABLE FOR DAMAGES OF ANY KIND IN CONNECTION WITH THE PURCHASE, MAINTENANCE, OR USE OF THIS EQUIPMENT, INCLUDING LOSS OF PROFITS AND CONSEQUENTIAL DAMAGES. THE LIMITED WARRANTY EXPRESSED HEREIN IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED. SONNY'S NEITHER ASSUMES NOR AUTHORIZES ANY PERSON TO ASSUME FOR IT ANY OTHER OBLIGATION OR LIABILITY.

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If a vital Sonny's manufactured component fails or is believed to be failing, a replacement will be shipped. The faulty component can be returned in the received crate for diagnostics and repair. If under warranty, the repair is FREE.

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