Table Of Contents

Introduction

Cleaning Section Outline

Cleaning Levels

Safety Requirements

Detergent Safety & Spill Response

Pre-job Assessment & Success Criteria

Potential Replacement Parts

Level 1 – Nozzle Inspection & Cleaning

Standard Nozzles

High-Pressure Nozzles

Nozzle Inspection & Cleaning Video (Including HPP)

Level 2 – Manifold, Rainbar, & Foamer Cleaning

Procedure

Manifold, Rainbar, & Foamer Cleaning Video

Level 3 – Poly & Stainless Line Clearing

Procedure

Poly & Stainless Line Clearing Video

Final Testing & Verification

Verification Criteria & Escalation Guidance

Detergent / Arch Reference

Nozzle / Injector Compatibility Checks

Water Quality, pH, and Wash-Quality Checks

Quick Symptom-To-Check Guide

Detergent Preventive Maintenance

Preventive Maintenance Procedures

Tommy Line Cleaner Detergent Utilization

Procedure

Volumetric Testing Tool Utilization

50 mL Volumetric Tool Key

Volumetric Testing Procedure

Reading, Calculation, & Documentation Requirements

Documentation Requirements & Post-Service Checklist

SOP DOCUMENT OVERVIEW

Purpose

The goal of this SOP is to provide Tommy’s Express locations with a single standard procedure for diagnosing, cleaning, restoring, and verifying arch components when coverage, foam quality, or spray performance is weak or inconsistent.

Use This SOP When

• Detergent foam coverage is uneven, watery, or subpar across the vehicle.

• Detergent is not pulled into the injector during operation.

• Nozzles or manifold holes are clogged and/or spraying irregularly.

• Foamers, ports, or tubing are suspected to be restricted.

Standard Detergent Flow

Cleaning Section Outline

Each cleaning procedure is organized into three progressive levels to standardize troubleshooting and ensure issues are addressed efficiently without unnecessary disassembly. Each level builds on the previous, moving from easily accessible components to deep cleaning manifolds.

This structure helps Team Members:

1. Follow a consistent, step-by-step approach.
2. Isolate the source of restriction or performance loss.
3. Avoid skipping critical checks or over-servicing components.
4. Escalate only when required based on system condition.

Cleaning Level

Level 1 – Surface Cleaning
Level 1 is intended for fast, non-invasive correction of minor issues. This includes isolated clogged nozzles, slight spray pattern inconsistencies, or light debris affecting coverage. It should always be the first step before moving into more involved cleaning.

The goal is to restore a full, even spray pattern with minimal downtime. If proper coverage is not achieved after this step, Level 2 is required.

Level 2 – Component Cleaning
Level 2 is used when problems are more widespread or persistent. This includes multiple clogged ports, poor foam quality, heavy buildup in the manifold or rainbar, or recurring issues after Level 1 cleaning.

The goal is to restore consistent flow and proper detergent performance across the entire component. If flow issues or inconsistencies remain after reassembly and testing, the problem is likely deeper in the system and requires escalation to Level 3.

Level 3 – Line Clearing
Level 3 is reserved for situations where Levels 1 and 2 do not resolve the issue and a restriction within the supply lines is suspected. This typically presents as continued low flow, uneven distribution, or intermittent detergent delivery despite clean components.

The goal is to restore full, unrestricted flow throughout the system. Because this is the most invasive level, it should only be performed after confirming that the previous levels were completed correctly.

Safety Requirements

1. Ensure the wash is not running during deep cleaning.
2. Wear required PPE before handling nozzles, manifold components, tubing, detergent, or cleaning chemicals.
3. Confirm the discharge path is controlled before any manual test or line-clearing step.
4. Keep all Team Members clear of nozzles, open tubing ends, and manifold discharge points during testing.

Expanded Detergent Safety 
& Spill Response

Tunnel Detergent PPE

• Wear chemical-resistant gloves such as nitrile or neoprene when handling detergents or working inside the tunnel.

• Use safety goggles or a face shield anywhere splashing or overspray is possible.

• Use non-slip, detergent-resistant footwear in wet tunnel areas.

• If inhalation risk is present in an enclosed area, follow the SDS and site safety guidance for appropriate respiratory protection.

Spill Cleanup and Emergency Response

• Immediately contain spills with absorbent materials or spill-kit supplies from the detergent storage area.

• For spill cleanup, wear detergent-resistant gloves, goggles, a face shield, detergent-resistant footwear, and a full-body protective suit as needed for exposure level.

• Ventilate enclosed spaces during spill cleanup, dispose of contaminated material according to the SDS, and report/document the incident with a supervisor.

• Know the nearest eye wash station before beginning work. If detergent gets into the eyes, hold eyelids open and flush with water for at least 15 minutes, then seek medical attention immediately.
 

Pre-job Assessment

1. Identify the affected arch function.
2. Observe the issue: weak coverage, uneven pattern, dead holes in the manifold, poor foaming, or visible leaks.
3. Determine whether the issue appears isolated to one or two nozzles, a manifold section, the foamer assembly, or a major restriction within the tubing/polyline.
4. Begin with Level 1 unless the condition clearly requires Level 2.

Success Criteria

• No leaks are visible during function test

• Spray pattern and foam output are restored

• Coverage is even and consistent

Potential Replacement Parts

Level 1 – Nozzle Inspection & Cleaning

Required PPE, Tools, and Materials

PPE

• Safety glasses

• Gloves

• Hearing protection as required by site conditions

Tools and Cleaning Materials

• 9/16 in. wrench

• Adjustable wrench

• Pliers

• Various Replacement Nozzles

• Thread tape

• Small welding tip cleaner

• Ladder

Standard Nozzles

1. Ensure the wash is not running.
2. Remove the clogged nozzle from the arch.
3. Rinse the nozzle with water.
4. Remove debris with a small welding tip cleaner.
5. Do not blow on the nozzle.
6. Apply thread tape to the nozzle threads, exposing the last few threads.
7. Reinstall the cleaned nozzle in the correct location.
8. Test the function manually.
9. Inspect for leaks and check spray pattern.

High-Pressure Nozzles

1. Ensure the wash is not running.
2. Remove the nozzle from the high-pressure blaster manifold.
3. Remove the dome screen and rinse thoroughly in the sink; replace if damaged.
4. Secure the nozzle halfway in a vise.
5. Use pliers to remove the stainless-steel cap.
6. Use two adjustable pliers or wrenches to loosen the thin retaining nut on the back of the nozzle.
7. Remove the remaining cap half.
8. Split the inner body and expose the internal components.
9. Clean and rinse each internal component individually.
10. Reassemble in reverse order.
11. Apply thread tape to the nozzle threads, reinstall the nozzle, and test for leaks.

Nozzle Inspection & Cleaning Video (Including HPP)

Helpful Documents

2025 Metering Tip Detergent Standard

2025 Versadial Detergent Standard

Level 2 – Manifold, Rainbar, & Foamer Cleaning

Required PPE, Tools, and Materials

PPE

• Safety glasses

• Gloves

• Hearing protection as required by site conditions

Tools and Cleaning Materials

• C-Sprayer (P-M2086)

• Foam Generator (P-CHE-2132)

• Foam Generator Insert (P-CHE-2140)

• Bay Wash Gun

• Ladder

Procedure

1. Remove all foamers from the manifold.
2. Remove the foam inserts.
3. Clean the inserts or replace them depending on wear and age.
4. Clean the foam generators, with the insert removed, with a Scotch-Brite pad and Tommy Brite or Dawn dish soap.
5. Rinse the generators thoroughly in the sink.
6. Remove the black 9-hole foaming head.
7. Spray out both sprayers with the bay wash gun.
8. Flush the wax manifold starting at one end.
9. Repeat the flush from the opposite end.
10. Spray each hole from underneath the manifold.
11. Reinstall all foamers, fittings, and nozzles on the manifold.
12. Manually fire the affected function.
13. Check for correct coverage.
14. If coverage is still inconsistent, repeat cleaning once more before escalating to Level 3.

Manifold, Rainbar, & Foamer Cleaning Video

Helpful Videos

Video: Foam Generator Clean Out

Video: Replace Foot Valve, Weights, and Draw line (Detergents)

Level 3 – Poly & Stainless Line Clearing

Use this procedure only if, after cleaning the nozzle, manifold, and foamer, the output has not been restored to proper levels.

Required PPE, Tools, and Materials

PPE

• Safety glasses

• Gloves

• Hearing protection as required by site conditions

Tools and Cleaning Materials

• Foam Ear Plugs

• Ladder

• 1/2“ Black Nylon Tubing (P-WAT-3121)

Procedure

1. At the arch, disconnect the 1/2” polyline from the manifold that connects to the stainless-steel tubing.
2. At the POD, disconnect the 1/2” polyline from the injector.
3. Inspect the inner diameter of both polylines for buildup. If buildup is present, replace the 1/2" polylines.
4. Insert one foam earplug into the disconnected 1/2" polyline at the injector. 
5. Reconnect the 1/2" polyline to the bottom of the injector

1. Manually activate the function until the ear plug exits the line.
2. Repeat steps 1 – 6 until the lines are clear of debris and buildup or detergent flow is restored. Always confirm that the ear plug has left the stainless tubing before reconnecting the 1/2” polyline to the manifold.

Manually test the function and inspect for:

• Leaks
• Improved Detergent Draw
• Even Foam Coverage

Poly & Stainless Line Clearing Video

Final Testing & Verification

1. Confirm all nozzles, foamers, and lines are reinstalled securely.
2. Confirm thread tape has been applied where required, plastic-on-metal, metal-on-metal.
3. Manually fire only the affected function.
4. Watch for leaks at fittings, uneven output, clogged manifold holes, weak spray, or inconsistent foam.
5. Verify improved performance before returning the function to normal operation.

Verification Criteria

• No leaks are visible during function test

• Spray pattern is restored

• Foam density is consistent where applicable

• Coverage is even across the intended application area

• No obvious striping, gaps, or dead spots remain

• Flow is improved compared to the original condition
 

Escalation Guidance

1. Recheck nozzle condition and placement.
2. Recheck manifold holes and foamer assembly.
3. Inspect injectors and metering tips.
4. Inspect Versadial.
5. Inspect Hydra-Flex performance.
6. Inspect or replace foot valves as needed.
7. Verify air pressure settings.
8. Escalate to Equipment Support if the restriction/Issue cannot be isolated.

Detergent System Standards & Verification

The 2025 TX Detergent Handbook provides critical reference standards for the detergent side of the system, including:

• Proper detergent application behavior and expected performance
• Correct nozzle and injector configurations for each function
• Pod operation, versadial performance, and detergent delivery consistency
• Water quality, pH balance, and system conditions that affect wash results

These checks should be verified before repeating cleaning procedures, replacing components, or escalating further. Many performance issues originate from incorrect setup, detergent imbalance, or system conditions rather than physical blockage.

Using this reference ensures that troubleshooting efforts are focused, accurate, and aligned with Tommy’s Express standards, preventing unnecessary disassembly, repeated line-clearing, and misdiagnosis.

Detergent / Arch Reference

Nozzle / Injector Compatibility Checks

• Using incorrect nozzles can create back pressure, poor wash quality, and loss of detergent suction.

• Before sending an ear plug through the tubing, confirm that the total sum of nozzle flow rates on the affected function exceeds the injector size for that function.

• If the injector capacity is larger than the total nozzle capacity, loss of suction and back pressure can appear even when the line is not physically restricted.

* Tire Gloss should only be applied through a Metering Tip-compatible injector. If the function has the wrong injector or nozzle setup, correct the standard before escalating to more aggressive cleaning.

Water Quality, pH, and Wash-Quality Checks

After the hardware path is cleaned, use these handbook checks to confirm the chemistry side of the system is also in standard.

• Hard water above roughly 2–3 GPG (Grains of Hardness Per Gallon) reduces detergency, clogs foamers and applicators, and can leave hard-water spotting or white residue on equipment. True soft water is typically at or below 1 GPG.

• Pure Finish water should have a low TDS reading. If vehicles continue to spot after the final rinse, inspect RO performance and confirm outgoing Pure Finish water quality.

• Reclaim water is intended for pre-blaster, UnderFlush, dual-blaster, and belt-flush applications. Do not use reclaim water for detergent functions or final rinses.

• pH strip targets: Center Detox PreWash should typically read alkaline at 10–13, Combo 1 Leg 2 should typically read acidic at 5–6, and the vehicle should be neutral at 7 as it exits Spot Free Rinse.

• Water should bead as the vehicle enters the blower room. Flat water usually points to Rain Away draw issues, chemistry imbalance, overapplication of high-pH product, or suction problems at the injector / Versadial for Tommy Guard® or Rain Away.

Quick Symptom-To-Check Guide

Detergent Preventive Maintenance

Use the following preventive-maintenance checks to keep the manifolds, tubing, and pod components from repeatedly plugging or losing suction.

Procedures

• Nightly Hot-Water Flush: Flush Tommy’s Express #8 (Tire Gloss), #5 (Ceramic Body Wax), and #6 (Tommy Guard) with hot water every night before closing. Disconnect the draw line from the injector, run the function in manual for about 2–3 minutes, then return the function to auto and reconnect the line.

   

• If a POD function stays on after the output shuts off on the iPad, inspect the Hydra Cannon / Hydra Flex valve. A sticking plunger or failed spring may require service or replacement (Hydra Cannon part no. P-HFI-265).

   

• If a detergent tote becomes contaminated, fully drain and rinse the tote before refilling with the correct product.

   

• Routinely inspect spray applicators and nozzles for clogs or damage. If damaged, replace with the same tip and verify the correct standard for that function.

   

Tommy Line Cleaner Detergent Utilization

This procedure is a last resort cleaning method and should only be performed after Cleaning Levels 1–3 have been completed and detergent flow has not been restored.

Tommy Line Cleaner is intended for as-needed use only for severe buildup that cannot be removed through the line-clearing procedure and should not be used as part of routine maintenance.

Use only where products are prone to buildup if not properly flushed, including:

• Tire Shine / Tire Gloss (#8)
• Ceramic Body Wax (#5)
• Tommy Guard (#6)
• Drying Agent (#7)

Procedure

1. Only perform this procedure after Cleaning Levels 1–3 have been completed and detergent flow has not been restored.
2. Disconnect the detergent draw line from the injector and position the line so discharge is directed away from team members and equipment.
3. Run clean water through the line for 2–3 minutes to remove residual product.
4. Connect Tommy Line Cleaner to the injector and apply at a dilution ratio of 1:4 to 1:20, depending on the severity of the clog.
5. Allow the diluted solution to remain in the line for 5–15 minutes to break down internal buildup.
6. Disconnect the line cleaner and flush the line with clean water for a minimum of 10 minutes, or until discharge is clear and unrestricted.
7. Thoroughly rinse the surrounding arch and components using a fire hose to remove any chemical residue.
8. Send a foam ear plug through the line and run the function until the plug exits the discharge to verify the line is fully cleared.
9. If flow is not restored, inspect for mechanical restrictions or replace the affected tubing or components.

Volumetric Testing Tool Utilization

The volumetric tool is a diagnostic and verification tool that measures the volume of detergent consumed during a single wash. The result is recorded as mL per car and used to confirm whether the affected function is drawing detergent at the expected rate.

When to Use

• Detergent coverage remains weak after Cleaning Levels 1 - 3 have been completed.
• The function appears to have poor suction, inconsistent draw, or possible injector/Versadial performance issues.
• Detergent usage needs to be verified against the expected standard for the site or function.
• Gather data on the weekly price per car.

Required PPE, Tools, and Materials

 PPE

• Safety glasses

• Chemical-resistant gloves

• Hearing protection as required by site conditions

Tools and cleaning materials

• 50 mL Volumetric Tool (P-WAT-3746)

• Detergent draw line, foot valve, & weight

• Paper towel / absorbent material

• Documentation method for start and end readings

Volumetric Testing Procedure

Follow this procedure to measure detergent usage for one test wash. Readings must be taken carefully because air bubbles, incorrect valve position, or a tilted tool body will cause inaccurate results.

1. Disconnect the detergent line currently connected to the injector that you wish to be tested.
2. Then, connect that line to the hose barb on the detergent inlet valve on the left side of the volumetric tool.
3. Connect the detergent outlet line from the graduated body to the versadial/injector being tested.
4. Open the incoming detergent valve on the left side of the tool, while keeping the air break valve on the right side of the tool closed.
5. Lower and rotate the tool so it is upside down, with the carabiner toward the ground.
6. Turn on the detergent function to pull air out of the tool and replace it with detergent. Detergent should pull through the inlet tube, fill the main tool body, and eventually return to the injector.
7. When the tool body is full and detergent has made it back to the injector, turn the function off.
8. If the tool does not fill with detergent, check for a volumetric tool air leak, a failed injector/no vacuum condition, or a clogged detergent inlet tube.
9. If needed, remove the injector tip or temporarily adjust the VersaDial up to fill the tool faster, then return the function to the correct setup before testing.
10. Close the incoming detergent valve on the left side of the tool.
11. Remove air bubbles from the detergent outlet tube and main tool body by gently shaking and adjusting the tool so bubbles float out. Do not begin the test with visible air bubbles in the outlet tube or main body.
12. Turn the tool upright so the detergent outlet is toward the ground and the carabiner is toward the ceiling.
13. Open the air break valve on the right side of the tool.
14. Verify the tool body is vertical, then record the starting detergent level before the test wash.
15. Wash one car using the function being tested.
16. Record the new detergent level after the test wash.
17. Calculate detergent usage by subtracting the ending level from the starting level.

Reading and Calculation

Record the result as “mL per car” for the tested function. Compare the result against the site standard, Metering Tip / Versadial setup, or Equipment Support guidance.
 

Price per car = Average mL per car ÷ 3,785 × Cost per gallon

Volumetric Documentation Requirements

After testing, document:

• Date & time.
• Detergent function tested.
• Starting mL reading and ending mL reading.
• Calculated mL used per car.
• injector / Metering Tip / Versadial setup checked.
• whether vacuum gauge testing was performed and the result.
• corrective action taken or recommended next step.

Volumetric Reference Document

The reference document used for this chapter can be found here: Volumetric Tool Manual

Documentation Requirements

Once the work is complete, the Team Member should document the following details: the date and time of service, the arch/function that was serviced, the issues observed, the level of cleaning performed, any parts replaced, whether leaks were detected, whether coverage has improved, any chemistry or pod checks completed, and whether further escalation is necessary.

Post-Service Checklist