Castle 7700 User manual

INSTALLATION INSTRUCTIONS

61301603904 Rev. A

®

Castle

7700

FLOOR LOADING

CART WASHER

INSTALLATION
INSTRUCTIONS

®

Castle

7700 FLOOR LOADING
CART WASHER

Getinge/Castle, Inc.

1777 East Henrietta Road
Rochester, New Yor k 14623- 31 33
Phone: [phone] USA
Facsimile: [phone]

INSTALLATION INSTRUCTIONS 61301603904

Rev A (10/30/01)

Related Publication:

Operator Manual X970015, Rev. B (11/24/97)

DESCRIPTION OF SYMBOLS AND NOTES IN MANUAL

The following symbols with related notes appear in this manual.

“Warning” notes alert the user to the possibility of personal injury.

WARNING

“Caution” notes alert the user to the possibility of damage to the equipment.

CAUTION

“Notes” alert the user to pertinent facts and conditions.

NOTE

NOTE

Castle

Copyright ©2001 by Getinge/Castle, Inc.

®

is a registered trademark.

This manual contains proprietary information of Getinge/Castle, Inc. It shall
not be reproduced in whole or in part without the written permission of
Getinge/Castle, Inc.

ii

Section 1 Installation Requirements

GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . 1–1

MODEL IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . 1–2

UTILITIES AND SPECIFICATIONS. . . . . . . . . . . . . . . . . . 1–3

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Hot Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Cold Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Steam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Condensate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

Overall Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

INSTALLATION ADVISORY . . . . . . . . . . . . . . . . . . . . . . . 1–4

WASHER OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4

Floor Mount vs. Pit Mount . . . . . . . . . . . . . . . . . . . . . . 1–4

Left Side vs. Right Side Controls. . . . . . . . . . . . . . . . . 1–4

Barrier Flanges and Service Enclosure . . . . . . . . . . . . 1–4

Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4

Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4

Seismic Anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4

SHIPPING CONFIGURATION. . . . . . . . . . . . . . . . . . . . . . 1–5

TOOLS AND MATERIALS REQUIRED. . . . . . . . . . . . . . . 1–6

Table of Contents

Section 2 Installation

ASSEMBLE THE WASHER STRUCTURE . . . . . . . . . . . . 2–1

Install the Base/Sump Assembly . . . . . . . . . . . . . . . . . 2–1

Assemble the Washer Panels . . . . . . . . . . . . . . . . . . . 2–5

Channel Fillers and Threshold Assemblies . . . . . . . . 2–11

Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12

Trim Panels (Non-Service Side) . . . . . . . . . . . . . . . . 2–14

INSTALL COMPONENTS ON TOP OF THE WASHER . 2–15

Dryer and Condenser Assemblies. . . . . . . . . . . . . . . 2–15

Power Floor Tilt Pulley System . . . . . . . . . . . . . . . . . 2–20

Transformer and Emergency Stop Switch

Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22

Rear Emergency Stop Switch . . . . . . . . . . . . . . . . . . 2–23

Plumbing Mounting Brackets. . . . . . . . . . . . . . . . . . . 2–24

61301603904 iii

INSTALL COMPONENTS ON THE OUTSIDE

OF THE WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25

Spray Manifold Drive Motor. . . . . . . . . . . . . . . . . . . . 2–26

Exhaust Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27

Washer Light Assembly. . . . . . . . . . . . . . . . . . . . . . . 2–28

Front Dryer Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29

Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31

Junction Box Assembly. . . . . . . . . . . . . . . . . . . . . . . 2–32

Front Emergency Stop Switch. . . . . . . . . . . . . . . . . . 2–33

Detergent and Rinse Aid Dispensers . . . . . . . . . . . . 2–34

Unload End Indicator Panel Box . . . . . . . . . . . . . . . . 2–35

Door Proximity Switches . . . . . . . . . . . . . . . . . . . . . . 2–36

Sump Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–37

Wash Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–38

Booster Heater Assembly . . . . . . . . . . . . . . . . . . . . . 2–39

PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–40

Stainless Steel Plumbing. . . . . . . . . . . . . . . . . . . . . . 2–40

Black Iron (Steam) Plumbing. . . . . . . . . . . . . . . . . . . 2–41

Hot Water (Copper) Plumbing. . . . . . . . . . . . . . . . . . 2–41

Cold Water (Copper) Plumbing . . . . . . . . . . . . . . . . . 2–41

ELECTRICAL WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42

INSTALL COMPONENTS ON THE INSIDE

OF THE WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–45

Rear Dryer Ducts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–45

Drive Chain Tension Idlers and Idler Bearings . . . . . 2–47

Chain Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . 2–49

Spray Manifold Supports and Manifold Assembly. . . 2–51

Manifold Cover and Spray Guard, Manifold Guard

Tubes, Wash Cart Tubes . . . . . . . . . . . . . . . . . . 2–54

Emergency Stop Switch Cables . . . . . . . . . . . . . . . . 2–57

FINAL INSTALLATION TASKS . . . . . . . . . . . . . . . . . . . . 2–59

Final Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2–60

Dispenser Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–61

Sanitary Barrier Flanges . . . . . . . . . . . . . . . . . . . . . . 2–62

Pit Covers (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 2–63

Service Area Enclosure (Option). . . . . . . . . . . . . . . . 2–64

Base Shrouds (Floor Mounted Option) . . . . . . . . . . . 2–65

Ramps (Floor Mounted Option). . . . . . . . . . . . . . . . . 2–66

Exhaust Connection . . . . . . . . . . . . . . . . . . . . . . . . . 2–66

Plumbing System Connections . . . . . . . . . . . . . . . . . 2–66

Electrical Supply Connection. . . . . . . . . . . . . . . . . . . 2–67

Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–67

iv

General Description

HW-006

Section 1 Installation Requirements

The Castle 7700 Floor Loading Cart Washer is a fully automatic, floor
loading, hydro-spray cart washer with dual side-by-side wash compartments
that is used to clean case carts, stands, utensils, containers, tote boxes, and
similar bulk items.

Processing cycles are set up using a programmable controller equipped
with a touch screen interface (touch control panel). Four cycle definitions
are possible. The operator needs only to select and start a cycle.

A standard cycle consists of the following sequential phases: wash, rinse 1,
rinse 2, drying, and exhaust. The length of a cycle’s phase can be adjusted
at the touch control panel.

The washer can be installed in a pit or at floor level. When installed in a pit,
the floor of the washer’s chamber is level with the room floor, which allows
the direct loading and unloading of carts. When the washer is installed at
floor level, the floor is higher than the room floor. Ramps are then provided
as standard equipment to facilitate loading and unloading.

The washer is designed for pass-through operation. Items to be cleaned are
placed in the washer’s compartment through one of the load end doors.
After cleaning, the items are removed from the opposite end of the washer
through the unload end doors.

The washer is generally installed in a facility’s decontamination room with
the unload end doors opening out into a clean-preparation area. The unit is
110" (2794 mm) wide and 108" (2743 mm) high. The washer is currently
available in two compartment lengths: 98" (2489 mm) and 106" (2692 mm).

Figure 1–1. 7700 Floor Loading Cart Washer

61301603904 1–1

Installation Requirements

Model Identification

The rating plate for a 7700 washer is affixed to the inside of the control box
door.

Record the model type and serial number (S/N) from the rating plate.
TYPE: _________________________________
SERIAL NO: ____________________________
Include the model type and serial number when communicating with

Getinge/Castle.
Figure 1–2. Rating Plate Location

1–2

Utilities and Specifications

7700 Floor Loading Cart Washer

Electrical

Hot Water

Cold Water

Steam

208 V, 60 Hz, 3 phase, 50 A, 5-wire with neutral and ground
240 V, 60 Hz, 3 phase, 50 A, 4-wire with ground
380 V, 50 Hz, 3 phase, 50 A, 4-wire with ground
415 V, 50 Hz, 3 phase, 30 A, 4-wire with ground
480 V, 60 Hz, 3 phase, 25 A, 4-wire with ground
600 V, 60 Hz, 3 phase, 25 A, 4-wire with ground

1" IPS (25.4 mm)
40–60 PSI (276–414 kPa)
780 gal/hr (2953 l/hr) demand rate
180 gal/cycle (681 l/cycl e) cons ump tion
120° F min. (49° C)

3/4" IPS (19 mm)
40–60 PSI (276–414 kPa)
600 gal/hr (2271 l/hr) demand rate
100 gal/cycle (379 l/cycle) consumption, vented unit
220 gal/cycle (833 l/cycle) consumption, non-vented unit

1-1/2" IPS
40–50 PSI (276–345 kPa)
1200 lb/hr demand rate
88 lb/cycle consumption

Condensate
Drain

Exhaust

Weight
Overall Size

3/4" IPS (19 mm)

3" IPS (76. 1 mm) minimum
280 gal/cycle (1060 l/cycle), vented unit
400 gal/cycle (1514 l/cycle), non-vented unit

12" square flanged (304.8 mm)

3

/hr (22.7 m3/hr)

800 ft
1/4" static pressure

1800–2200 lb (811–991 kg) approximate

108" high x 110" wide x 106" long (2743 mm x 1321 mm x 1829 mm)
108" high x 110" wide x 98" long (2743 mm x 1321 mm x 2489 mm)

61301603904 1–3

Installation Requirements

Installation Advisor y

A 7700 washer is assembled at the factory, tested, then disassembled for
shipment. Extensive on-site reassembly is required. The installation
instructions in this manual are intended as the primary reference for
accomplishing this reassembly. Every effort has been made to make this
information as accurate as possible. No two washers are exactly alike,
however.

Each washer is uniquely configured to meet the demands of its operational
site. These demands most often necessitate variances in the location of a
washer’s e xterior components. These variances, in turn, impact the
configuration of related plumbing and electrical wiring assemblies.

For this reason, some instructions or illustrations carried here may not
reflect the actual location or configuration of selected component
assemblies for a specific site. Where applicable, installers should refer to
specifications contained in the product information documents, such as
Rough-In and Assembly drawings, that have been forwarded to local
Getinge/Castle product support personnel.

Wa sher Options

Floor Mount vs. Pit Mount

Left Side vs. Right Side
Controls

Barrier Flanges and Service
Enclosure

Electrical Service

Printer

There are a number of options that may be included with your washer.
These options affect the procedures that apply to your specific installation.

A floor mounted washer will require the installation of ramps to provide
access to the washer. The two options may have different plumbing
specifications.

The location of controls on your washer will also determine the location of
the service area, as well as the barriers flanges and service enclosure that
may be provided with your washer.

Your installation may have barrier walls at the load or unload end of the
washer, or both, as well as have a service enclosure. These structures will
be designed specifically for your site.

The electrical service at your facility determines the specific high voltage
devices (motors, pumps, etc.), transformer, and control box provided with
your washer.

If your washer has the printer option, the printer will already be mounted on
the control box.

Seismic Anchoring

1–4

Washers with the seismic anchoring option have base/sump assemblies
that are mounted differently.

Shipping Configuration

7700 Floor Loading Cart Washer

A disassembled 7700 washer is shipped on 4 to 8 pallets of various lengths.
The maximum size of any one pallet may be as large as 10' x 5'
(approximate). For stability during transit, selected pallets are often pegged
(with nails) to the floor of the truck.

Moving the disassembled washer from the truck to the installation site
requires the use of any available combination of the following:

• fork lift

• pallet jack

• dollies

• Johnson bars

A sufficient supply of commonly used fasteners (#10-32 and 1/4-20, for
example) is bagged for shipment. Speciality hardware and fasteners (door
latches and hinges, for example) are labeled and bagged separately for
shipment.

Many disassembled items, such as plumbing and panel sections, are
marked with handwritten numbers with black grease pen to identify their
location, orientation, or connection points. Take care not to inadvertently
smudge or erase these identifying marks.

61301603904 1–5

Installation Requirements

Tools and Materials Required

The following tables list the specific tools and materials required at the
installation site. Items marked with an asterisk * are supplied by Getinge/
Castle.

Table 1–1. Tools Required

Tool Quantity

Common hand tools Assorted
Bar clamp 2
C-clamp 2
Johnson bar 1
Pry/pinch bar 2
Caulking gun 1
1/4-20 tap, short 1
1/4-20 tap, long 1
10-32 tap, short 1
10-32 tap, long 1
#7 drill bit 2
#21 drill bit 2
Torpedo level 1
4’ level 1
Scratch awl 2

Table 1–2. Materials Required

Material Quantity

* Silicone adhesive 8 tubes
* Silicone primer 1 pt
* Thinner 1 pt
* Polish 1 container
* Stainless steel nuts, bolts,

washers, lock washers

Assorted

1–6

* Wire nuts, ti e wraps Assorted
* 3" x 6" stainless steel shims:

• 12 ga

• 14 ga

• 16 ga

• 18 ga

12
12
12
12

7700 Floor Loading Cart Washer

Material Quantity

1" x 4" x 6" wood block 2
2" x 4" x 52" wood block 4

The following items are recommended for use if a floor mounted washer is
to be assembled out-of-position, then moved to its intended operational site:

* 4’ x 8’ x 1/8" Masonite, smooth 2 to 3
Pipe, rigid 3/4" x 60" L 4

The Masonite protects the floor during assembly . The pipe is used to roll the
washer into position after assembly.

61301603904 1–7

Installation Requirements

1–8

Assemble the Washer Structure

This section contains procedures for assembling the basic structure of the
washer compartment. Refer to the following sections.

•“Install the Base/Sump Assembly” on page 2-1

•“Assemble the Washer Panels ” on page 2-5

•“Channel Fillers and Threshold Assemblies” on page 2-11

•“Door Assembly” on page 2-12

•“Trim Panels (Non-Service Side)” on page 2-14

Section 2 Installation

Install the Base/Sump
Assembly

NOTE

WARNING

General Instruction

The base/sump assembly is shipped in two halves that you must assemble
on the site. If the load or unload ends of the base are not marked, check the
configuration of the base’s sump against the rough-in drawing to determine
the correct orientation.

Some installation sites may have an existing wall in close proximity to the
non-service side of the washer that could interfere with the assembly of the
washer's side panels. If this situation exists, you will have to seat the base
temporarily out-of-position until the side, top, and non-service side trim
panels are assembled. You can then maneuver the unit to its operating
position, where you can level and anchor it, if required.

Installation

Silicone primer (orange) is extremely flammable, harmful if
swallowed or inhaled, and harmful to eyes or skin. Wear
protective clothing, gloves, and eye wear when using this
product. Keep it away from heat, sparks, and flames. Store
upright in a cool place (less than 30°C (85°F). Keep the
container closed when not in use. Use only in a well-ventilated
area. Avoid breathing vapors.

Silicone Primer stains/discolors clothing, stainless steel surfaces, flooring,

CAUTION

etc. Avoid accidental spills. Avoid spreading this substance onto exterior
surfaces of the washer.

61301603904 2–1

Installation

1/4-20 FASTENERS
(12 PLACES UNDERNEATH)

REAR BASE HALF

FRONT BASE HALF

1/4-20 FASTENERS
(2 PLACES EACH END)

1. Clean all mating surf aces w here the tw o ha lv es of the base

meet with thinner, treat with silicone prime r , and then apply

a generous amount of silicone sealant.

2. Move the two halves of the washer base together and

attach the halves together:

a. Underneath the sump , secure the a ngle brac kets o f the

frame halves together with 1/4-20 fasteners (16 each
3/4" hex head bo lts, loc k w ashers, and n uts), as sho wn
in Figure 2–1.
The frame halves are secured with two sets of
fasteners a t each end a nd tw e lv e sets alon g the len gth
of the washer (nine on top and three on the bottom.

Figure 2–1. Base Frame Halves

2–2

b. At each end, secure the front and rear sump halves

together with 1/4- 20 f asten ers (tw o each 3/4" hex head
cap screws, lock washers, and nu ts) as shown in
Figure 2–2.

7700 Floor Loading Cart Washer

1/4-20 FASTENERS
(2 PLACES EACH END)

Figure 2–2. Sump Halves

3. Move the base assembly into its final operating position.

CAUTION

4. Check the base for level.
Use the 4' level to check from all sides of the base and in
all directions. Adjust the level if necessary using the
stainless steel shims that are provided.

Failure to critically level the base will result in the misalignment of mounting
holes and will make assembly of the washer panels difficult.

If seismic anchoring is required, a 3" flange (with anchor bolt holes) is
welded to the bottom frame of the base for this purpose.

5. Drill holes for the anchors through the holes in the base
flanges.

Table 2–1. Drilling Specifications

Drill Bit Size
Embedment
Torque 50 ft.-lb.

1/2

"

1 1/4" to 3 1/2

"

61301603904 2–3

6. Secure the base to the floor using the 1/2 x 4-1/2" stud
anchor bolts provided.

Installation

FLOOR LIFT

TRACK/FRAME

ASSEMBLY

WELDMENTS

7. Lay the two track/frame assemblies into the base so that
the floor lift weldments are to wa rd the center of the w asher ,
as shown in Figure 2–3. Track/Frame Assemblies

Figure 2–3. Track/Frame Assemblies

8. Place the debris screens over the opening to the sump.

NOTE

9. Lay the six floor grates in the tracks into the track/frame
assemblies.

It is recommended that you place a layer of protective material, such as
cardboard or masonite, on the floor grates on each side of the washer
chamber to protect the floor grates during the rest of the installation.

2–4

7700 Floor Loading Cart Washer

Assemble the Washer Panels

Objective

Assemble the door, side, and top panels. Install the required number of
interior side panel seam cover strips and the center mounting bracket.

There are six side panels and three top panels. Each of the end (door)
panels in turn consists of five panels: three vertical panels and two
horizontal panels (one over each door) that connect to the vertical panels.

Door panels and side panels are marked to indicate their location. Top
panels are not marked (check this). The unload end top panel has two
rectangular cutouts for the condenser mountings, a cutout for one of the rear
dryer ducts, and numerous threaded holes on its exterior surface for
mounting the dryer assemblies. The load end top panel one cutout for the
second rear dryer duct and has fewer mounting holes (for a transformer and
plumbing mounting plates). the middle panel has mounting brackets for the
floor tilt actuators. The width of a top panel is the width of the washer (92").

The side panels have 7/16" diameter holes that carry 3/8" thru bolts (five on
each side of the washer) to hold the panels together. The top panels have
holes to carry five thru bolts.

There is no established order to follow for panel assembly. You can start
from the load or the unload end. You can assemble all the vertical panels
first, followed by the top panels; or you can add individual top panels as you
erect the vertical panels. The method illustrated below starts from the load
end and progressively adds top panels as the vertical panels are erected.

NOTE

WARNING

You must clean all mating surfaces with thinner, then treat with silicone
primer, and then apply a generous amount of silicone sealant.

Installation

Refer to Figure 2–4. Washer Panel Assembly for help to identify the washer
panels.

You must clean all mating surfaces with thinner, then treat with silicone
primer, and then apply a generous amount of silicone sealant.

Silicone primer (orange) is extremely flammable, harmful if
swallowed or in haled, and harmful to eyes or skin. Wear
protective clothing, gloves, and eye wear when using this
product. Keep it away from heat, sparks, and flames. Store
upright in a cool place (less than 30°C (85°F). Keep the
container closed when not in use. Use only in a well-ventilated
area. Avoid breathing vapors.

61301603904 2–5

Installation

CAUTION

Silicone Primer stains/discolors clothing, stainless steel surfaces, flooring,
etc. Avoid accidental spills. Avoid spreading this substance onto exterior
surfaces of the washer.

Figure 2–4. Washer Panel Assembly

1. Clean all mating surfaces (where a wall panel is attached
to the base or another panel) with thinner, treat with silic­one primer, and apply a generous bead of silicone seala nt.

2. Attach the load end door panels to the base. There are
three vertical panels. The service side panel is narrow and
has three mounting holes at the top to attach to the
horizontal panels, the middle panel is narrow and has six
mounting holes at the top, and the non-service side panel
is wide.

a. Position a vertic al panel.
b. Secure the bottom of the p anel to the base wit h 1/4-2 0

fasteners (1/2" hex head bolts, flat washers, and lock

washers).
c. Repeat steps a and b for the other vertical panels.
d. Secure each horizontal panel between two ver tical

panels with 1/4-20 fasteners (six each 3/4" hex head

bolts and lock washers).

2–6

7700 Floor Loading Cart Washer

PIPE CLAMP

3. Attach the load end sid e panels to the bas e and to the l oad
end door.

a. Position one of the load end side panels.
b. Partially insert five 3/8" diameter thru rods through the

7/16" diameter holes to stabilize and align the side
panel with the door panel.

c. Use pipe clamps to draw the panels tight as shown in

Figure 2–5.

Figure 2–5. Installin g Washer Panels

d. Secure the bottoms o f the side p anel to the ba se frame

with 1/4-20 fasteners (1/2" hex head bolts and lock
washers).

e. Repeat steps a through d for the other load end side

panel.

4. Attach the middle side panels to the base and to the load
end panels.

a. Remove the pipe clamps.
b. Position one of the middle side panels.
c. Extend the five thru bolts to stabilize and align the

panels with the load end side panel.
d. Attach the pipe clamps to draw these pan els tight.
e. Secure the bottoms of the middle Side panel to the

base frame with 1/ 4-20 fasteners (1/2" hex head bolts

and lock washers).
f. Repeat steps a through d for the other middle side

panel.
g. To ensure side panel alignment, attach C-clamps and

2x4" wooden blocks across the top edge of the

adjoining panels at the vertical seam.

61301603904 2–7

Installation

5. Attach the load end top panel to the door panel and to the
load end side panels.

a. Position the load end top panel.
b. Secure the top panel to the door and load end side

panels with 1/4- 20 fast eners (1-3/4" hex hea d bolts, fl at
washers, and lock washers).

c. Partially i nsert the five remaining 3/8" diameter thru

bolts through the 7/16" diameter holes in the panel.

6. Attach the unload end side panels to the base and to the
middle (or load end) side panels.

a. Remove the pipe clamps.
b. Position one of the unload end side panels.
c. Extend the five thru bolts to stabilize and align this

panels with the previously erected panels.
d. Attach the pipe clamps to draw these panels tight.
e. Secure the bottom of the unload end side panel to the

base frame with 1/ 4-20 fasteners (1/2" hex head bolts

and lock washers).
f. Repeat steps a throug h d f or th e other u nload end si de

panel.
g. Move the C-clamp and 2" x 4" wooden block

assemblies to the vertical seams created by the

installation of t hese panels.

7. Attach the middle top panel to the load end top panel and
to the middle side panels.

a. Position the middle top panel.
b. Extend the two thru bolts.
c. Secure this panel to the mid dle side panel s with 1/4-20

fasteners ( 1-3/4" hex head bolts, flat wash ers, and lo ck
washers).

2–8

7700 Floor Loading Cart Washer

CENTER
MOUNTING
BRACKET

1/4-20
FASTENERS
(6 PLACES)

8. Attach the unload end door panels to the base and to the
unload end side panels.

a. Remove the pipe clamps.
b. Position a vertical panel.
c. Secure the bottom legs of the panel to the base frame

with 1/4-20 fasteners (1/2" hex head bolts, flat

washers, and lock washers).
d. Repeat st eps a and b for the other vertical panels.
e. Secure each horizontal panel between two ver tical

panels with 1/4-20 fasteners (six each 3/4" hex head

bolts and lock washers).
f. Extend the ten side thru bolts.
g. Attach the pipe clamps to draw the door panels tight.
h. Secure the thru bolts at both ends of the washer with

3/8" acorn nuts and flat washers.

9. Attach the unload end top panel to the unload end side
panels and to the unload end door panel.

a. Remove the C-clamp assemblies.
b. Position the unload end top panel.
c. Extend the five thru bolts.
d. Secure this panel to the unload end door panels and

side panels with 1/4-20 fasteners (1-3/4" hex head
bolts, flat washers, and lock washers).

e. Secure the thru bolts at both ends of the washer with

3/8" acorn nuts and flat washers.

10. Inside the washer, attach the four panel seam cover strips
over the vertical seams between adjoining side panels
using #10-32 fasteners (six each screws and lock washers
per cover strip).

Figure 2–6. Center Mounting Plate

61301603904 2–9

Installation

11. Attach the center mounting plate inside the washer, from
the load end to the unload end, as shown in Figure 2–6.

a. Align the holes in the mounting plate with the threaded

holes along the center of the washer.

b. Secure the mounting plate to the washer with six 1/4-

20 fasten ers ( 3/ 4" hex head cap screws, lock washers ,
and flat washers).
The mounting plate is attached to the top panels in four
places and once in each center end panel.

2–10

7700 Floor Loading Cart Washer

CHANNEL FILLERS

THRESHOLD ASSEM BLI ES

(2 PLACES AT EACH END)

(2 PLACES AT EACH END)

Channel Fillers and
Threshold Assemblies

Objective

Install two channel fillers on the floor just inside each end of the washer.
Install two threshold assemblies just outside each end of the washer.

Installation

Refer to Figure 2–7. Channel Fillers and Threshold Assemblies.
Figure 2–7. Channel Fillers and Threshold Assemblies

1. Position the four channel fillers (two on each end of the
washer) in the floor and secure each with two #10 -32 x 3/8"
phillips head screws.

2. Install the four threshold assemblies in the floor.

NOTE

There are two sizes: the longer threshold is installed on the rear (non­service side) of the washer, one on each end. The shorter threshold is
installed on the front (service side) of each end.

a. Position one threshold assembly in its appropriate

location with the gasket facing toward the inside of the
washer.

b. Secure the assembly to the washer base with two #10-

32 x 3/8" phillips head screws.

61301603904 2–11

Installation

HINGE MOUNT

DOOR HINGE

(3 PER DOOR)

DOOR LATCH
RETAINERS
(2 PER DOOR)

DOOR HANDLE

DOOR LATCH
(2 PER DOOR)

(3 PER DOOR)

Door Assembly

Objective

Attach hardware to the doors and related door panels. Install two doors
each on both the load and unload ends of the washer. Plumb and square all
four doors.

Installation

Refer to Figure 2–53. Door Assembly.
Figure 2–8. Door Ass embly

2–12

WARNING

NOTE

A washer door is heavy and awkward to handle. Take care to
avoid crushing or strain injuries.

The washer may be shipped with all of the hardware (hinges, latches, striker
plates, etc.) already mounted on both the doors and the door panels. If so,
start with step 3 below.

7700 Floor Loading Cart Washer

1. Attach the following items to each door panel:
a. Attach three hinge m oun ts u s ing ni ne 1/ 4- 20 fasteners

(1" phillips head screws).

b. Attach two door latch retain er s, two door latch shims,

and two spacers using four 5/16-18 fasteners (2" hex
head cap screws and lock washers).

2. Attach the following items to each door:
a. Attach two door latches using four 5/16-18 fasteners

(1" hex head cap screws and lock washers).

b. Attach three hinges using twelve 1/4-20 fasteners

(1" phillips head screws).

c. Attach the door handle using four 5/16-18 fasteners

(1" hex head cap screws and lock washers).

3. Check the door opening for plumb and square. If
necessary, us e the shims that are provided.

NOTE

4. Mount the door on the washer.
a. Raise and maneuver the door until its hinge posts are

in vertical alignment over the three hinge mounts
attached to the door panel.

b. When aligned, lower the door and properly seat al l

three posts in their respective mounts.

Repeat steps 1 through 4 for the other door assemblies.

After the plumb and square of all doors is checked and corrected, it may be
easier to lift the doors off their hinges and set them aside until the washer
installation is complete.

61301603904 2–13

Installation

Trim Panels (Non-Service
Side)

Objective

The narrow width of the trim panels and the presence of a restrictive wall
may require that you assemble the washer out-of-position up to this point.
After you attach the panels, you can move the washer to its exact
operational position, where you can level the washer, and seismically
anchor it if required.

Installation

1. Attach any required trim panels to the non-service side of
the washer using #10-32 fasteners (3/8" pan head screws
and lock washe rs).

2. If necessary, move the washer to its final position. Level
and, if required, anchor the washer.

2–14

Install Components on Top of the Washer

There are a number of components that are installed on the top panels of
the washer. Although there is no specific order in which the components
should be installed, the list below presents the items in a recommended
order. Refer to the following sections.

•“Dryer and Condenser Assemblies” on page 2-15

•“Power Floor Tilt Pulley System” on page 2-20

•“Transformer and Emergency Stop Switch Junction Box” on page 2-22

•“Rear Emergency Stop Switch” on page 2-23

•“Plumbing Mounting Brackets” on page 2-24

Before installing any components on top of the washer, you must ensure

CAUTION

that the door openings are plumb and square. Failure to do so can result in
doors that do not open and close correctly, as well as water leaks.

7700 Floor Loading Cart Washer

Dryer and Condenser
Assemblies

Objective

Assemble the two dryer/blower assemblies, the two condenser duct
assemblies, and the rear top dryer duct.

Generally, the dryer assemblies are mounted on top of the washer. When
sufficient space is not available, these assemblies are redesigned for
installation in the unit’s service area. These configurations vary and are not
accurately represented in these Installation Instructions. To install the dryer
assemblies in the washer's service area, refer to the Rough-In Drawing for
guidance.

61301603904 2–15

Installation

FRONT

HEATING COIL

FRONT

UNLOAD END

FRONT SIDE

CONDENSER
CUTOUT

#10-32

FASTENERS

(8 PLACES)

DRYER/BLOWER

ASSEMBLY

Installation

1. Install the front dryer/blower assembly and the condenser
on the washer.

Figure 2–9. Front Dryer/Blower Assembly

a. Position the front dryer/blower assembly on top of the

unload end top panel with the steam heating coils
aligned with the front (service side) of the washer, as
shown in Figure 2–9.

NOTE

The front (service side) dryer is normally located at the unload end of the
washer and oriented so that the heating coil faces the side of the washer.

b. Align the holes in the assembly’s mounting frame with

the matching #10-32 threaded holes in the panel.

c. Apply sealant to the screw threads and secure the

frame to the panel with #10-32 fasteners (eight each
3/4" slotted pan head screws, lock washers, and flat
washers).

d. Apply silicone sealant to the edge of the front

condenser cut out in the top panel.

2–16

7700 Floor Loading Cart Washer

FRONT

FRONT

DUCT ASSEMBLY

UNLOAD END

FRONT SIDE

CONDENSER
DRAIN ELBOW

#10-32

FASTENERS

DRYER/BLOWER
ASSEMBLY

CONDENSER

(8 PLACES)

Figure 2–10. Front Condenser Assembly

e. Place the front condenser duct assembly on the unload

end top panel. Position the assembly with the intake
flange over the cutout in the top panel and the
condenser vent pointed over the unload end doors, as
shown in Figure 2–10.

f. Align the holes in the assembly’s flange to the

matching #10-32 threaded holes around the outside of
the opening in the panel.

g. Secure the condenser’s flange to the top panel with

#10-32 (eight each 3/4" phillip s head screws, lock
washers, and flat washers).

h. Attach the 9" vent hose to the condenser and to the

dryer with hose clamps.

61301603904 2–17

Installation

HEATING COIL

REAR

LOAD END

REAR SIDE

TOP DRYER DUCT

#10-32
FASTENERS
(8 PLACES)

#10-32
FASTENERS
(15 PLACES)

#10-32
FASTENERS
(9 PLACES)

DRYER/BLOWER
ASSEMBLY

2. Install the rear dryer/blower assembly, condenser, and top
dryer duct on the washer.

Figure 2–11. Rear Dryer/Blower Assembly

a. Position the rear dryer/blower assembly on top of the

middle top panel with the steam heating coil facing
toward the two cutouts for the rear dryer duct, as
shown in Figure 2–11.

b. Align the holes in the assembly’s mounting frame with

the matching #10-32 threaded holes in the panel.

c. Apply sealant to the screw threads and secure the

frame to the panel with #10-32 fasteners (eight each
3/4" slotted pan head screws, lock washers, and flat
washers).

d. Apply silicone sealant to the edge of the front

condenser cut out in the top panel.

e. Apply silicone sealant to the mating flange surrounding

the rear dryer’s heating coil and to the mating surfaces
surrounding the tw o 18" x 7-1 /2" re ctangu lar cuto uts in

the top pane ls.
f. Position the rear dryer duct on top of the washer.
g. Secure the duct to the heating coil flange with #10-32

fasteners (fifteen each 1/2" phillips head screws, lock

washers, and flat washers).
h. Secure the duct to the top panel with nine #10-32

fasteners per cutout (nine each 1/2" phillips head

screws, lock washers, and flat washers).

2–18

i. Inside the washer compartment, apply additional

sealant to the interior joints formed between the duct

and the panel.

7700 Floor Loading Cart Washer

REAR

REAR CONDENSER

DUCT ASSEMBLY

UNLOAD END

REAR SIDE

CONDENSER
DRAIN

#10-32 FASTENERS (8 PLACES)

DRYER/BLOWER
ASSEMBLY

FITTING

Figure 2–12. Rear Condenser Assembly

j. Place the front condenser duct assembly on the unlo ad

end top panel. Position the assembly with the intake
flange over the cutout in the top panel and the
condenser vent pointed over the unload end doors, as
shown in Figure 2–12.

k. Align the holes in the assembly’s flange to the

matching #10-32 threaded holes around the outside of
the opening in the panel.

l. Secure the condenser’s flange to the top panel with

#10-32 (eight each 3/4" phillip s head screws, lock
washers, and flat washers).

m. Attach the 9" vent hose to the condenser and to the

dryer with hose clamps.

3. Connect the dr ain output from each of the con de nse rs and
the elbow fitti ng located bene ath each blo wer to dr ain using
3/4" diameter flexible tubing, hose clamps, and tee
connectors. Refer to Figure 2–13.

Figure 2–13. Condenser and Dryer Drain Tubing

FRONT

CONDENSER

REAR

CONDENSER

REAR

BLOWER

TEE

CONNECTORS

61301603904 2–19

FRONT

BLOWER

TO

DRAIN

Installation

ACTUATOR

1/4-20 FASTENERS
(6 PLACES)

RETRACT LIMIT SWITCH

EXTEND LIMIT SWITCH

Power Floor Tilt Pulley
System

Objective

Install the power floor tilt pulley system. The top panels have 1/4-20
threaded holes to mount the system’s five components. The actuator
assembly is installed on the top middle panel, with the actuator mounted on
the front (service) side and the pulleys in the middle. The pulley cables run
the length of the washer from the middle to ends of the washer above the
load and unload end doors.

Installation

Figure 2–14. Power Floor Tilt Actuator Assembly

1. Install the following components on the service side of the
washer’s top panels:

a. Align the actuator assembly with the holes in the top

panel and secure with six 1/4-20 fasteners. Refer to
Figure 2–14. Power Floor Tilt Actuator Assembly.

b. Secure the two lo ad end pulle y mou nts to the middle o f

the load end top panel with 1/4-20 fasteners (two each
1/2" hex he ad scre ws, loc k w ashers , and f lat w ashers).
Refer to Figure 2–15. Power Floor Tilt Pulley Mounts.

c. Secure the two unload end pulle y mounts to the middle

of the unload end top panel with 1/4-20 fasteners (two
each 1/2" hex head screws, lock washers, and flat
washers).

2–20

7700 Floor Loading Cart Washer

1/4-20 FASTENERS
(2 PLACES EACH)

PULLEY MOUNTS

FLOOR LIFT
WELDMENTS

CABLE
FASTENERS

Figure 2–15. Power Floor Tilt Pulley Mounts

2. Route the four pulley cables from the actuator, through the
pulley mounts, and then down through the four gasketed
cable holes in the paneling to the compartment floor.

NOTE

You may have to enlarge a gasket hole with a drill if the cable does not fit
through the hole.

3. Slide the black cable sleeves over the section of cable
inside the washer.

4. Using a cable fastener, secure each of the four pulley
cables to its corresponding floor lift weldment. Ref er to
Figure 2–16. Attaching Cables to Floor Lift Weldments.

Figure 2–16. Attaching Cables to Floor Lift Weldments

61301603904 2–21

5. Using #6-32 fasteners, attach the two limit switches to the
actuator's mounting plate.

Installation

EMERGENCY STOP SWITCH

JUNCTION BOX

TRANSFORMER

LOAD END

FRONT SIDE

Transformer and Emergency
Stop Switch Junction Box

Objective

Install the transformer and the junction box for the emergency stop switches
to the top of the washer. The specific transformer used with your washer
depends on the house-supplied voltage.

Figure 2–17. Transformer and Emergency Stop Junction Box Locations

Installation

Refer to Figure 2–17. Transformer and Emergency Stop Junction Box
Locations.

1. Install the transformer.
Transformers are siz ed d ifferently but are general ly loca ted

on the service side of the load end top panel and
positioned so that the output power cable is facing the
service side fo the washer.

1. Align the transfor mer’s mounting holes to the threaded
holes in the panel.

a. Secure the transformer to the panel with four 1/4-20

fasteners.

2. Install the emergency stop switch junction box.
a. Remove the face plate of the box.
b. Align the mounting holes in the back of the bo x with the

two #10-32 threaded holes on the top panel near the

transf ormer you installed above.
c. Use #10-32 fasteners to secure the box to the washer.
d. Install the face plate.

2–22

7700 Floor Loading Cart Washer

REAR EMERGENCY

1/4-20 FASTENER

MOUNTING
BRACKET

(4 PLACES)

REAR SIDE

LOAD END

STOP SWITCH

Rear Emergency Stop Switch

Objective

Attach the rear emergency stop switch to the top of the washer. The switch
is mounted on the rear (non-service side) of the washer at the load end.

Installation

Refer to Figure 2–18. Rear Emergency Stop Switch.
Figure 2–18. Rear Emergency Stop Switch

1. Mount the emergency stop switch to the mounting bracket
using 1/4-20 fa steners (two each hex head cap screws,
lock washers, and flat washers).

2. Align the two holes in the mounting bracket with the holes
on the load end top panel.

3. Secure the bracket and switch to the washer with 1/4-20
fasteners (two each hex head cap screws, lock washers,
and flat washers).

61301603904 2–23

Installation

Plumbing Mounting Brackets

Objective

Attach four mounting brackets to the top of the washer to support the piping
for the rear side of the washer.

Installation

1. Determine the correct location for each bracket. The
brackets are marked with index markers that match
numbers on the top panel.

2. Align the holes in one mounting bracket with the two holes
in the top of the washer.

3. Secure the bracket with 1/4-20 fasteners (two each hex
head cap screws, lock washers, and flat washers).

4. Repeat st eps 2 and 3 for the other brackets.

2–24

Install Components on the Outside of the Washer

This section provides instructions for installing equipment on the outside of
the washer. The procedures are presented in a recommended order (some
larger components are easier to install if they are done earlier, f or example).
Refer to the following sections.

•“Spray Manifold Drive Motor” on page 2-26

•“Exhaust Elbow” on page 2-27

•“Washer Light Assembly” on page 2-28

•“Front Dryer Ducts” on page 2-29

•“Control Box” on page 2-31

•“Junction Box Assembly” on page 2-32

•“Front Emergency Stop Switch” on page 2-33

•“Detergent and Rinse Aid Dispensers” on page 2-34

•“Unload End Indicator Panel Box” on page 2-35

•“Door Proximity Switches” on page 2-36

•“Sump Drain Valve” on page 2-37

•“Wash Pump” on page 2-38

•“Booster Heater Assembly” on page 2-39

7700 Floor Loading Cart Washer

61301603904 2–25

Installation

FLANGE BEARING

3/8-16 FASTENERS
(4 PLACES)

LOAD END

MOUNTING

BRACKET

HOLES

(6 PLACES)

1/4-20 FASTENERS

(6 PLACES)

Spray Manifold Drive Motor

Objective

Assemble the spray manifold’s flange bearing and the spray manifold drive
motor.

Installation

Figure 2–19. Manifold Drive Flange Bearing

1. Use 3/8"-16 fa sten ers (four each 1" hex head cap screws
and lock washers) to loosely secure the flange bearing in
position at the upper corner of the load end side panel, as
shown in Figure 2–19.

2–26

NOTE

You will tighten the bearing after you assemble the drive shaft and couple it
to the drive motor (refer to “Chain Drive Assembly” on page 2-49).

Figure 2–20. Spray Manifold Drive Motor

2. As shown in Figure 2–20, position the spray drive manifold
motor and bracket over the six threaded holes located in
the panel directly below the flange bearing and use 1/4-20
fasteners (six each 3/4" hex head cap screws, lock
washers, and flat washers) to secure the mounting fixture
to the panel.

7700 Floor Loading Cart Washer

1/4-20 FASTENERS
(8 PLACES)

Exhaust Elbow

Objective

Install the exhaust elbow on the side of the washer.

Installation

Refer to Figure 2–21. Exhaust Elbo w.
Figure 2–21. Exhaust Elbow

1. Apply silicone sealant to the mating surface surrounding
the 12" cutout next to the spray manifold drive motor.

2. Position the exhaust elbow against the cutout and secure
with 1/4-20 faste ne rs (e ight each hex head cap scre ws,
lock washers, and flat washers).

3. Inside the washer comp artment, apply additional sealant to
the interior joint formed between the elbow and the side
panel.

61301603904 2–27

Installation

#10-32 FASTENERS
(4 PLACES)

#10-32 FASTENERS
(8 PLACES)

Washer Light Assembly

Objective

Install the interior light in the cutout located on the front (service side) wall.

Installation

1. Remov e and retai n the eight fasteners securing the interior
lens and gasket to the light assembly. Set the lens and
gasket aside.

2. Apply silicone sealant around the edge of the light
assembly.

3. Align the holes in the light assembly with the holes
surrounding the cutout in the front panel.

4. Secure the light assembly to the front panel with four #10­32 fasteners (phillips head screws and flat washers) as
shown in Figure 2–22.

Figure 2–22. Washer Light Assembly (Outside)

2–28

5. On the inside of the washer, place the gasket and cover
over the light assembly and secure with eight #10-32
fasteners (phillips head screws, lock washers, and flat
washers) as shown in Figure 2–23.

Figure 2–23. Washer Light Assembly (Inside)

7700 Floor Loading Cart Washer

HORIZONTAL SECTION OF
FRONT DRYER DUCT

Front Dryer Ducts

Objective

Mount the front dryer ducts.
The front (service side) dryer duct connects the dryer’s heating coil to two

13-1/4" x 18" cutouts in the side panels. Generally, the duct work consist of
a vertical and a horizontal section. However, other configurations are
possible if the dryer is mounted against the side of the unit. The rear (non­service side) dryer duct connects to two cutouts on the top panel of the
washer, which in turn, connect to the two rear dryer ducts on the inside of
the washer.

Installation

1. Install the lower (horizontal) section of the front (service
side) dryer duct. Refer to Figure 2–24. Horizontal Section
of Front Dryer Duct.

Figure 2–24. Horizontal Section of Front Dryer Duct

a. Apply silicone sealant to the mating surfaces

surrounding the 18" x 13-1/4" rectangular cutouts in
the front (service side) side panels.

b. Secure the horizont al secti on o f the duct to the cutout s

with ten #10-32 fasteners (1/2" phillips head screw,
lock washer, and flat washer) per cutout.

c. Inside the washer compartment, apply additional

sealant to the interior joints formed between the duct
and the panel.

61301603904 2–29

Installation

VERTICAL SECTION OF

FRONT DRYER DUCT

HORIZONTAL

HEATING COIL

#10-32 FASTENERS
(9 PLACES)

#10-32 FASTENERS
(10 PLA CES)

SECTION

2. Install the upper (vertical) section of the front dryer duct.
Refer to Figure 2–24. Horizontal Section of Front Dryer
Duct.

Figure 2–25. Vertical Section of the Front Dryer Duct

NOTE

a. Apply silicone sealant to the mating flange surrounding

the dryer’s heating coil and to the mating surface

between the vertical and horizontal ducts.
b. Position the vertical duct on the horizontal duct.
c. Secure the upper end to the heating coil flange with

#10-32 fasteners (fifteen each 1/2" phillips head

screws, lock washers, and flat washers).
d. Secure the lower end to the horizontal duct with #10-

32 fasteners (nine 1/2" phillips head screws, lock

washers, and flat washers).

One or more standoffs may have been welded to the dockworker to support
a plumbing assembly. Clamps are provided to secure plumbing to standoffs.

2–30

7700 Floor Loading Cart Washer

1/4-20 FASTENERS

CONTROL BOX

(4 PLACES)

EXHAUST ELBOW

LOWER DRYER
DUCT

Control Box

Objective

Attach the control box to the load end side panel.

Installation

Refer to Figure 2–26. Control Box.
Figure 2–26. Control Box

1. Remove the pins from the door hinges and set the door
aside.

2. Position the control box on the load end side panel and
align the mounting tabs on the top and bottom of the box
with the four threaded holes in the panel.

3. Use 1/4-20 fasteners (4 each 3/4" hex head cap screws,
flat washers, and lock washers) to s ecure the control bo x to
the panel.

4. Install the door on the control box.

61301603904 2–31

Installation

#10-32 FASTENERS
(4 PLACES)

LOWER DRYER DUCT

EXHAUST ELBOW

Juncti on B ox Assembly

Objective

Install the junction box assembly to the side of the washer.

Installation

Refer to Figure 2–27. Junction Box Assembly.
Figure 2–27. Junction Box Assembly

1. Position the junction box and align its mounting holes with
those on the front panel of the exhaust elbow and on the
top of the lower dryer duct.

2. Secure the junction box to the exhaust elbow and to the
dryer duct using #10- 3 2 fasteners (four each 3 /8" pa n h ea d
screws and lock washers).

2–32

7700 Floor Loading Cart Washer

FRONT EMERGE NC Y

1/4-20 FASTENERS

MOUNTING

(4 PLACES)

BRACKET

STOP SWITCH

LOAD END

Front Emergency Stop Switch

Objective

Attach the front emergency stop switch to the side panel of the washer. The
switch is mounted at the load end of the washer, over the detergent
dispenser.

Installation

Refer to Figure 2–28. Front Emergency Stop Switch.
Figure 2–28. Front Emergency Stop Switch

1. Mount the emergency stop switch to the mounting bracket
using two 1/4-20 fasteners (hex head cap screws, lock
washers, and flat washers).

2. Align the two holes in the mounting bracket with the holes
on the load end side panel.

3. Secure the bracket and switch to the washer with two 1/4­20 fasteners (hex head cap screws, lock washers, and flat
washers).

61301603904 2–33

Installation

RINSE AID
DISPENSER

DETERGENT

DISPENSER

LOAD END

Detergent and Rinse Aid
Dispensers

Objective

Mount the detergent dispenser on the unload end side panel, below the
lower dryer duct.

Installation

Refer to Figure 2–29. Detergent and Rinse Aid Dispensers.
Figure 2–29. Detergent and Rinse Aid Dispensers

1. Remove the cover of detergent dispenser.

2. Align the mounting holes in the back plate with the left set
of threaded holes in the panel.

3. Use two #10-32 fasteners to secure the dispenser in place.

4. Replace the c over.

5. Repeat steps 1 through 4 to install the ri nse aid dispen ser
to the right of the detergent dispenser.

2–34

7700 Floor Loading Cart Washer

Unload End Indicator Panel
Box

Objective

Mount the indicator panel box on the unload end of the washer.

Installation

Refer to Figure 2–30. Unload End Indicator Panel Box.
Figure 2–30. Unload End Ind icator Panel Box

1. Remove the face plate of the box.

2. Align the mounting ho les in the bac k of the b ox wi th the two
#10-32 threaded holes at the edge of the unload end
barrier panel.

3. Use #10-32 fasteners to secure the box to the panel.

4. Install the face plate.

61301603904 2–35

Installation

PROXIMITY SWITCH
ASSEMBLY

Door Proximity Switches

Objective

Install a proximity switch assembly on both the load and the unload end door
panels.

Installation

Refer to Figure 2–31. Door Proximity Switches.
Figure 2–31. Door Proximity Switches

1. Orient the two ends of the switch assembly as shown in
Figure 2–31 and align with the threaded mounting holes in
the panel.

2. Use three #10-32 fasteners (phillips head screw and lock
washer) to secure the top of the assembly to the middle
panel above and between the doors.

3. Use four #10-32 fasteners (phillips head screw and lock
washer) to secure the bo ttom of the assembly to the middle
panel between the door latches.

4. Route the as sembly’s cables to the junction box on the
service side of the washer:
The load end cables, P3 and P5, connect to the junction
box at J3 and J5, respectively. The unload end cables, P4
and P6, connect to the junction box at J4 and J6,
respectively.

5. Repeat st eps 1 through 4 for the other door assembly.

2–36

7700 Floor Loading Cart Washer

SUMP

DRAIN VALVE

CONNECTION

SUMP OV ERFLOW

CONNECTION

TO DRAIN

Sump Drain Valve

Objective

Install the motorized sump drain valve assembly.

Installation

Refer to Figure 2–32. Sump Drain Valve.
Figure 2–32. Sump Drain Valve

1. As shown in Figure 2–32, use a hose clamp to attach one
flexible hose on the drain valve assembly to the 2" outlet on
the sump.

2. Use a hose clamp to atta ch the hose from the d rain v alve to
a stainless steel tee.

3. Connect t he tee to the sump overflow elbow and route the
the other end to drain.

61301603904 2–37

Installation

FASTENERS

(4 PLACES)

LEVELING FOOT

3" INTAKE PIPE

3" FLANGE

2" FLANGE

W a sh Pum p

Objective

Install the wash pump on the service side of the washer and connect the
intake to the sump.

Installation

Refer to Figure 2–33. Wash Pump.
Figure 2–33. Wash Pump

1. Align the wash pump mounting bracket with the two holes
in the angle bracket on the base frame and secure the
bracke t to the frame with 1/4-20 fasteners (two each 1/2"
hex head cap screws, lock washers, and flat washers).

2. Check the mount in g bracket for level. If nece ssary, use the
leveling foot to adjust the level.

Figure 2–34.

3. Secure the 2" flange and gasket to the discharge of the
pump with four each hex head screws, flat washers, lock
washers, and nuts.

4. Secure the 3" flange and gasket to the intake of the pump
with four each hex head screws, flat washers, lock
washers, and nuts.

5. Connect the 3" pipe section between the pump’s i ntake and
the 3" fitting on the sump.

2–38

7700 Floor Loading Cart Washer

1/4-20 FASTENERS

(4 PLACES)

WASH PUMP

MOUNTING

BRACKET

MOUNTING

BRACKET

BOOSTER
HEATER

1/4-20 FASTENERS
(4 PLACES)

Booster Heater Assembly

Objective

Install the booster heater assembly on the side of the base assembly at the
unload end of the washer.

Installation

Refer to Figure 2–35. Booster Heater Assembly Mounting Bracket.
Figure 2–35. Booster Heater Assembly Mounting Bracket

1. Align the holes in the mounting bracket with holes in the
base assembly at the unload end of the washer.

2. Secure the mounting bracket to the washer base.

Figure 2–36. Booster Heater Assembly

3. Position the booster heater assembly on the mounting
bracket and align with the holes in the bracket.

4. Secure th e assembly to the mounting bracket with 1/4-20
fasteners (four each 3/4" hex head cap screws, flat
washers, and lock washers).

61301603904 2–39

Installation

Plumbing

The washer plumbing is designed with a large number of quick-disconnect
joints that enable service personnel to isolate problems and to replace
components easily. When a washer is disassembled at the factory for
shipment to a customer, plumbing sections are removed for efficient packing
and quick assembly at the installation site. All plumbing sections are tagged
at both ends to indicate what the section is connected to. The sections
provide only general descriptions of the completed plumbing. For details of
the plumbing for your site, refer to the drawings provided with your washer
and to the information tagged to each plumbing section.

Stainless Steel Plumbing

Objective

Install the washer’s stainless steel tubing.

Installation

Refer to Figure 2–37. Typical Stainless Steel Plumbing Connector.
Figure 2–37. T ypical Stainless Steel Plumbing Connector

The stainless steel plumbing for the washer consists of the following
sections:

• The sump to the intake of the wash pump.

• The discharge of the wash pump to two 2-1/2" sanitary fittings on the

front wall, and over the top of the washer to a 2-1/2" sanitary fitting on the
rear of the load end top panel.

• The inside front wall to the two front manifold hoses.

• The inside rear wall to the rear manifold hoses.

2–40

7700 Floor Loading Cart Washer

Black Iron (Steam) Plumbing

Hot Water (Copper)
Plumbing

Cold Water (Copper)
Plumbing

Objective

Install the steam supply line and the condensate return line.

Installation

The black iron steam plumbing for the washer consists of the following
sections:

• The utility connection to the booster heater, to the sump, and over the top

of the washer to the two dryer heaters.

• Condensate from the dryer heaters, the booster heater, and the

circulation tank.

Objective

Install the hot water supply line.

Installation

The copper plumbing for hot water consists of the following sections:

• The utility connection to the intake of the booster heater.

• The discharge of the booster heater to the sump.

Objective

Install the cold water supply line.

Installation

The copper plumbing for cold water consists of the following sections:

• The utility connection up over the top of the washer to the two

condensers.

• The discharge of the condensers to the sump.

61301603904 2–41

Installation

Electrical Wiring

Objective

Make all required electrical wire connections between the electrical
components and the control box and junction boxes.

Installation

1. Route all component electrical cables, including
thermocouple cables, from the control box or junction box
to the appropriate elect rical component.

Refer to Table 2–2 and Table 2–3 for the routings.

2. Connect the cables to the corresponding electrical
component.

Most cables have keyed connectors that plug in and are secured with
threaded fittings. Cables that must be wired to the component are noted in
Table 2–2 and Table 2–3.

NOTE

Attach all solenoid coil housings to their related solenoid valve bodies, as
shown in Figure 2–38.

Figure 2–38. Solenoid Valve Assembly

The actual configuration for your washer may vary from that listed here.

2–42

7700 Floor Loading Cart Washer

Table 2–2. Junction Box Cable Connections

Jack Cable P/N Cable Label Destination

J2 61301603973 P1 – P2 Control Box Jack J1
J3 Y960788 P3 – 1PS Load End Left Proximity

Switch 1PS

J4 Y960788 P4 – 2PS Unload End Left Proximity

Switch 2PS

J5 Y960788 P5 – 3PS Load End Right Proximity

Switch 3PS

J6 Y960788 P6 – 4PS Unload End Right Proximity

Switch 4PS
J7 61301603975 P7 – 1LS Retract Limit Switch 1LS
J8 61301603975 P8 – 2LS Extend Limit Switch 2LS
J9 61301603976 P9 –2MV Sump D rain Valve 2MV

J10 61301603988 P10 – 7MTR Exhaust Elbow Damper 7MTR
J11 61301603978 P11 – 6MTR Front Condenser Damper

6MTR

J12 61301603978 P12 – 8MTR Rear Condenser Damper

8MTR

J13 Y960456 P13 – 3SOL Sump Hot Water Fill Solenoid

Valve 3SOL

J14 Y960456 P14 – 4SOL Sump Steam Solenoid Valve

4SOL

J15 Y960456 P15 – 5SOL Booster Heater Steam Sole-

noid Valve 5SOL

J16 Y960456 P16 – 1SOL Front Dryer Steam Solenoid

Valve 1SOL

J17 Y960456 P17 – 8SOL Rear Dryer Steam Solenoid

Valve 8SOL

J18 Y960456 P18 – 2SOL Front Condenser Cold Water

Solenoid Valve 2SOL

J19 Y960456 P19 –9SOL Rear Condenser Cold Water

Solenoid Valve 9SOL

J20 P20 – 6SOL Exhaust Duct 6SOL (Non-

Vented Washers Only)

J21 Not used.
J22 61301603980 P22 – P22A Unload End Indicator Box
J23 61301603981 P23 – 9MTR Detergent Pump 9MTR
J24 61301603981 P24 – 10MTR Rinse Aid Pump 10MTR
J25 61301603982 P25 – 1E/2E Sump High and Low Water

Level Probes

J26 61301603983 P26 – 1ACT Floor Tilt Actuator 1ACT
J27 61301603984 P27 – 1DS Washer Compartment Light

1DS

J28 Not used.
J29 Not used.
J30 Not used.

61301603904 2–43

Installation

Table 2–3. Control Box Cable Connections

Jack Cable P/N Cable Label Destination

J1 61301603973 P1 – P2 Junction Box Jack J2
J31 61301603985 P31 – 1TC Sump Thermocouple 1TC
J32 61301603985 P32 – 2TC Front Dryer Thermocouple

2TC

J33 61301603985 P33 – 3TC Rear Dryer Thermocouple

3TC

J34 61301603985 P34 – 4TC Booster Heater Water Ther-

mocouple 4TC
J35 Not used.
J36 P36 – 1MTR Wash Pump 1 MTR
J37 P37 – 2MTR Front Dryer Blower 2MTR
J38 P38 – 3MTR Rear Dryer Blower 3MTR
J39 P39 – 4MTR Manifold Drive Motor 4 MTR
J40 P40 – TTransformer T
J50 61301604279 P50 – 3E High and Low Sump Level
J51 P51 – 5MTR Exhaust Vent Damper Motor

5MTR (Non-Vented Only)
J53 P53 – 3S Emergency Stop Switch Junc-

tion Box

2–44

Install Components on the Inside of the Washer

REAR DRYER
DUCTS

MOUNTING PLATE

This section provides instructions for installing equipment on the inside of
the washer. The procedures are presented in a recommended order. Refer
to the following sections.

•“Rear Dryer Ducts” on page 2-45

•“Drive Chain Tension Idlers and Idler Bearings” on page 2-47

•“Chain Drive Assembly” on page 2-49

•“Spray Manifold Supports and Manifold Assembly” on page 2-51

•“Manifold Cover and Spray Guard, Manifold Guard Tubes, Wash Cart
Tubes” on page 2-54

•“Emergency Stop Switch Cables” on page 2-57

7700 Floor Loading Cart Washer

Rear Dryer Ducts

Objective

Attach the two rear interior ducts to the rear wall of the washer and to the
cutouts in the ceiling. Attach the mounting plate between the dryer ducts.

Installation

Figure 2–39. Interior Dryer Ducts

1. Inside the washer, apply silicone sealant to the two 18" x 7-

1/2" rectangular cutouts in the top of the washer
compartment.

61301603904 2–45

Installation

2. Position one of the dryer ducts on the wall and align the
mounting holes with those in the compartment wall and
ceiling.

3. Secure the duct to the wall with eight #10-32 fasteners
(1/2" phillips head screws, lock washers, and flat washers).

4. Secure the duct to the ce iling cutouts with nine #10-32
fasteners per cutout (1/2" phillips head screws, lock
washers, and flat washers).

5. Repeat steps 2 through 4 for the o ther duct.

6. Install the mounting plate between the two dryer ducts.
Secure to the dryer ducts and to the top panel with seven
#10-32 fasteners.

2–46

7700 Floor Loading Cart Washer

FRONT
TENSION
IDLER

REAR
TENSION
IDLER

MIDDLE
TENSION
IDLERS

CENTER

MOUNTING

BRACKET

MOUNTING

BRACKET

DRYER DUCT

Drive Chain Tension Idlers
and Idler Bearings

Objective

Install the following components inside the washer compartment:

• Four drive chain tension idlers

• Two idler bearings

Installation

Refer to Figure 2–40. Drive Chain Idler and Idler Bearing.
Figure 2–40. Drive Chain Idler and Idler Bearing

1. Mount the f our driv e cha in tension i dlers , one on eith er side
of the compartment and two in the middle, as shown in
Figure 2–41.

Figure 2–41. Tension Idlers

61301603904 2–47

Installation

1/4-20
FASTENERS
(3 PLACES)

The front driv e chain ten sion idle r is attache d to the wash er
panel, the rear idler is attached to the mounting bracke t
between the two dryer ducts, and the midd le idlers are
attached to either side of the center mounting bracket.
Secure each with four 1/4-20 fasteners (3/4" hex head cap
screw and lock washer).

2. Mount the two idler bearings for the manifold drive shaft at
the load end of the rear side panel and of the front side of
the center mounting bracket, as shown in Figure 2–42.
Secure each with three 1/4-20 fasteners (1" hex head cap
screw, lock nut, lock washer, and flat washer).

Figure 2–42. Idler Bearing

2–48

7700 Floor Loading Cart Washer

#10-32

FASTENERS

FRONT DRIVE

SHAFT SEAL

LOAD END

(4 PLACES)

Chain Drive Assembly

Objective

Install the drive shaft, drive chains, and push rod that comprise the chain
drive assembly.

Installation

Refer to Figure 2–43. Chain Driv e Assem bly.
Figure 2–43. Chain Drive Assembly

1. Insert the drive shaft key into the keyway in the spray
manif old drive motor that you installed previously.

Figure 2–44. Drive Shaft Seal

2. Mount the front drive shaft seal to the inside of the upper
corner of the load end side panel, opposite the flange
bearing that you installed previously.

a. Position the seal so its rubber side is against the panel.
b. Secure in place with #10-32 fasteners (3/8" pan head

screw and lock washer).

61301603904 2–49

Installation

3. Insert, but do not fasten, the motor and idler ends of each
shaft assembly into the shaft coupling.

4. Hang the two push rod/chain ass emblies from the shaft
assembly.

5. Fit the idler end into the idler bearing that you installed
previously.

6. Extend the moto r e nd through the seal a nd fl an ge bearing,
and then engage the key (installed in step 1) with the
shaft’s keyway.

7. Rotate the idler end of the shaft until its sprocke t key is in
alignment with the sprocket key at the shaft's motor end.

8. Secure the shaft ends to the sha ft coupling with two #10-32
bolts and jam nuts.

9. Use #10-32 f asteners (f our ea ch 1/4" pan head scre ws and
lock washers) to attach the drive coupling guard to the
motor’s mounting fixture.

NOTE

You can wait until the operation of the motor has been checked by Product
Support personnel before installing the drive coupling guard.

10. Insert the ends of the push rod chain assembly into the
push rod sleeve.

11. Fit the chains onto their related sproc kets at the drive shaft
and at the drive chain tension idlers that you installed
previously.
Make sure the ends of the push rod ar e seated on
matching sprocket teeth.

12. Adjust the chain tensi on so there is no more tha n 1" of pla y
in either line.
You can loosen a tension idler’s 3/8-16 bolt to permit
move m ent of it s sprocket. Turning the 1/4-20 adjustment
bolt repositions the sprocket, thereby increasing or
decreasing chain tension.

13. Repeat steps 2 through 11 for the rear c hain drive
assembly.

2–50

7700 Floor Loading Cart Washer

CAPTIVE

BRACKET

MOUNTING
ANGLE

MANIFOLD
SUPPORT

Spra y Manifold Supp orts and
Manifold Assembly

Objective

Install the three spray manifold supports, one on either side of the washer
compartment and one in the middle, and then install the two spray manifold
assemblies.

Installation

Refer to Figure 2–45. Spray Manifold Support.
Figure 2–45. Spray Manifold Support

1. Seat the ends of the outside ( front and rear ) spra y manif old
supports in the uppermost captive brac k ets that are welde d
to the inside of the end panels.

2. Apply silicone sea lant to f our #10- 32 fa steners, t hen secure
the mounting angle of the front support to the front side
panel.

3. Use four #1 0- 32 fasteners to secure the mounting angle of
the rear support to the mounting plate between the two
dryer ducts.

4. Attach 1/4-20 fasteners to the captive brackets to ensure
the ends of the spray manifold suppor ts remain in place.

61301603904 2–51

Installation

5/16-18

FASTENERS

STRINGER

(PLACES)

MANIFOLD

MANIFOLD

Figure 2–46. Spray Manifold Assembly

5. Attach two hose connectors to the inlet ports in the front
side panel. Repe at for the rear panel. When tight, all
connectors should point toward the unload end of the unit
at an angle of approximately 45 degrees.

6. Set the two spray manifolds on the two outside manifold
supports.

7. Seat the ends of the middle spray manifold support in the
uppermost captive br ack ets that ar e welded to the in side of
the end panels.

8. Attach 1/4-20 fasteners to the captive brackets to ensure
the ends of the spray manifold suppor ts remain in place.

Figure 2–47. Manifold Stringers

2–52

7700 Floor Loading Cart Washer

9. Connect the manif olds at th e top with tw o stringer s in each
compartment. Orient the stringers so that their push pins
are directed toward the load end. Use 5/16-18 fastener s to
secure the stringers to the manifolds.

10. Use 5/16-18 fasteners to connect the manifolds at the
bottom (one on e ach side and one in th e middle ) with three
connector bars. Use two sets of fasteners at each end of
each connector bar.

11. Install the hoses between the manifold and the panel hose
connectors. Secure each end of each hose with two hose
clamps. Position the hoses so they rest against the panels
and not obstruct manifold movement.

61301603904 2–53

Installation

Manifold Cover and Spray
Guard, Manifold Guard
Tubes, Wash Cart Tubes

Objective

Install the following components inside the washer:

• Two manifold covers

• Manifold spray guard

• Four manifold guard tubes

• Three wash cart guide tubes

Installation

Refer to Figure 2–48. Manifold Cover and Spray Guard, Manifold Guard
Tubes, Wash Cart Guide Tubes.

Figure 2–48. Manifold Cover and Spray Guard, Manifold Guard Tubes,

Wash Cart Guide Tubes

2–54

7700 Floor Loading Cart Washer

SPRAY GUARD

#10-32

FASTENERS

(6 PLACES)

1. Position a manifold cover on top of each side of the spray
manifolds. Secure the cover in place at the load and unload
ends with eight #10-32 fasteners (two at each end of each
cover).

Figure 2–49. Manifold Spray Guard

2. On the front side of the w ash er, position the manifold spr ay
guard against the inside of the spray manifolds so that the
cutouts fit over the manifold nozzles. Secure the guard in
place at the load and unload ends with six #10-32
fasteners.

NOTE

3. Attach the ten manif old gu ard tubes to the brac k ets w elded
to the load and unload end door panels. For each wash
compartment, attach three tubes to the outer side and two
tubes on the side at the middle of the washer.

a. Place a 1/4-20 bolt through the manifold guard tube

brackets on each end of the washer at the appropriate
level and secure with a locknut.

b. Insert each end of the manifold guard tube so that it

rests on the bolt inside the bracket.

There are two manifold guard tubes that each have three eyebolts to
accommodate the emergency stop cables. These tubes should be installed
as the middle of the three tubes that are installed on the outer sides of the
washer. These tubes are also secured to the bracket through holes in the
tube, rather than by resting on the bolt.

61301603904 2–55

Installation

4. Install the six wash cart guide tubes, three on each outer
side of the washer.

a. Position three wash cart guid e tubes on the outside

edge of the front wash compartment.

b. Butt the edges of the tube’s mounting brac kets against

the floor frame over the sump.

c. Using the brackets as templates, drill and tap four 1/4-

20 holes into the grate. Make sure the holes are
located against the inside of the bracket slots so the
tube can to be adjusted back toward the center line of
the floor.

d. Repeat steps a through c f or three remaining w ash cart

guide tubes on the outside edge of t he re ar w ash
compartment.

e. Secure all six tubes to the floor with 1/4-20 fasteners.

2–56

7700 Floor Loading Cart Washer

EMERGENCY
STOP CABLE

CABLE CONNECTOR

LOAD END

EYE BOLT

EMERGENCY

STOP CABLE

FRONT
WELDMENTS

TO FRONT

EMERGENCY STOP

SWITCH

Emergency Stop Switch
Cables

Objective

Install the emergency stop cables. One cable runs along each side of the
washer. The front cable passes through the side panel and connects to the
emergency stop switch on the service side of the washer. The rear cable
passes through the top panel and connects to the switch mounted on top of
the washer.

Installation

1. Install the emergency stop cable on the front side of the
washer and connect to the switch on the outside of the
washer.

a. Refer to Figu re 2–50. At the unloa d end of the wa she r,

attach one en d of the cable to the guide rail bracket.
Loop the cable through the next hole in the bracket
above the guide rail and secure with a cable fastener.

Figure 2–50. Emergency Cable Connection

b. As shown in Figure 2–51, feed the cable through the

three ey ebolt s on the gui de rail to the load e nd, aroun d
the two we ldments o n the fron t side panel , and throu gh
the opening in the front side panel.

Figure 2–51. Front Emergency Stop Cable

61301603904 2–57

Installation

LOAD END

EYE BOLT

EMERGENCY
STOP CABLE

REAR
WELDMENT

TO REAR
EMERGENCY
STOP SWITCH

c. Secure the end of the cable to the emergency stop

switch assembly with a cable fastener as shown in
Figure 2–28.

2. Install the emergency stop cable on the rear side of the
washer and connect to the switch on the top of the washer.

a. Refer to Figu re 2–50. At the unload end of the washer,

attach one en d of the cable to the guide rail bracket.
Loop the cable through the next hole in the bracket
above the guide rail and secure with a cable fastener.

b. As shown in Figure 2–52, feed the cable through the

three ey ebolt s on the gui de rail to the load e nd, aroun d
the weldment on the end panel, and up through the
opening in the rear side top panel.

Figure 2–52. Rear Emergency Stop Cable

2–58

c. Secure the end of the cable to the emergency stop

switch assembly with a cable fastener as shown in
Figure 2–18.

Final Installation Tasks

7700 Floor Loading Cart Washer

This section provides instructions for completing the installation of the
washer. Refer to the following sections.

•“Final Door Assembly” on page 2-60

•“Dispenser Tubing” on page 2-61

•“Sanitary Barrier Flanges” on page 2-62

•“Pit Covers (Option)” on page 2-63

•“Service Area En cl osur e (Opti on) ” on page 2-64

•“Base Shrouds (Floor Mounted Option)” on page 2-65

•“Ramps (Floor Mounted Option)” on page 2-66

•“Exhaust Connection” on page 2-66

•“Plumbing System Connect ion s” on page 2-66

•“Electrical Supply Connection” on page 2-67

•“Concluding Tasks” on page 2-67

61301603904 2–59

Installation

Final Door Assembl y

Objective

Hang the load and unload doors back on their hinges.

Installation

Refer to Figure 2–53. Door Assembly.
Figure 2–53. Door Assem bly

2–60

WARNING

A washer door is heavy and awkward to handle. Take care to
avoid crushing or strain injuries.

1. Raise and maneuver the door until its hinge posts are in
vertical alignment over the three hinge mounts attached to
the door panel.

2. When aligned, lower the door and properly seat all three
posts in their respective mounts.

Repeat steps 1 and 2 for the other door assemblies.

7700 Floor Loading Cart Washer

TO DETERGENT

TO RINSE AID

SUPPLY

TO SUMP

SUPPLY

TO SUMP

RINSE AID
FITTING

DETERGENT

FITTING

FITTING

FITTING

Dispenser Tubing

Objective

Connect the detergent and rinse aid dispenser pump tubing. Refer to Figure
2–54. Detergent and Rinse Aid Pumps.

Installation

Figure 2–54. Detergent and Rinse Aid Pumps

1. Connect one end of the supply tubing to the left side of the
detergent pump. Place the other end in the detergent
supply container.

2. Connect one end of the disch arge tubing to the right side of
the detergent pump. Connect the other end to the plastic
compression fitting on the side of the sump.

3. Connect one end of the supply tubing to the left side of the
rinse aid pump. Place the other end in the rinse aid supply
container.

4. Connect one end of the disch arge tubing to the right side of
the rinse aid pump. Connect the other end to the plastic
compression fitting on the side of the sump.

61301603904 2–61

Installation

Sanitary Barrier Flanges

NOTE

Objective

Attach the sanitary barrier flanges to the load and unload ends of the
washer.

The following instructions apply to units with structural walls situated at both
the load and unload ends. Units with only one wall (generally at the unload
end) receive a service area enclosure and an unload end top barrier flange.
For the latter configuration, refer to “Service Area Enclosure (O ption)” on
page 2-64.

The method and materials for securing the sanitary barrier flanges to a
structural wall are to be provided by the customer.

Installation

1. Using #10-32 fasteners, attach the two shor t attachment
angles to the load end side panel and the single long
attachment angle to the unload end side panel. Position the
proximity switch and indicator panel cables so they route
through the cutouts provided in the angles.

2. Secure the load and unload end side barrier flanges to the
attachment angles with #10-32 fasteners.
The interior edge of a flange seats between an angle and
the side panel.

3. Attach the top barrier flanges.
a. Remove and retain the acorn nut fasteners from the

two top thru bolts.
b. Attach the load and unload end top barrier flanges.
c. Use the acorn nuts along with #10-32 fasteners to

secure the flanges to the top panels and to the side

barrier flanges.

4. Attach the intake frame assembly to the unload end top
barrier flange.

2–62

7700 Floor Loading Cart Washer

Pit Covers (Option)

Objective

Install the pit covers, if that option has been provided, at the load and unload
Ends of a pit mounted washer.

An additional pit cover may be provided for installation along the non-service
side of the washer if that side is exposed.

1. Place the pit covers in position against the washer.

2. Using the mounting holes in the cover flanges as a
template, drill and tap #10-32 holes into washer base.

3. Secure the pit covers to the washer base with #10-32
fasteners.

61301603904 2–63

Installation

Service Area Enclosur e
(Option)

Objective

Assemble the servi c e area encl os ure.
The service area enclosure is usually installed on units that do not have a

structural wall at either the load or unload end.

Installation

1. Attach the two short attachment angles to the load end
side panel and the single long attachment angle to the
unload end side panel with #10-32 fasteners. Position the
proximity switch and indicator panel cables so they route
through the cutouts provided in the angles.

2. Use four 1/4-2 0 fasteners to attach the mounting base
frame to the base frame of the washer.

3. Secure th e load and unload e nd side panels to t he
attachment angles. The interior edge of a panel seats
between an angle and the washer’s sid e panel. Use #10-3 2
fasteners to secure the base of the each panel to the
mounting base frame.

4. Position the access panel divider in the middle of the
mounting base frame. The upper end of the divider has two
#10-32 threaded holes and the lower end has two 1/4"
diameter hol es. Secure the bottom of the divider to the
frame with two #10-32 fasteners.

2–64

NOTE

Longer units may have two dividers.

5. Secure the top panel to the load and unload end side
panels. Use #10-32 fasteners to secure it to the top of the
access panel divider.

6. Install the service access panels.
a. Fit the holes in the bottom of a panel to the panel

mounting studs on the mounting base frame.

b. Turn the latches 90 degrees to secure the service

access panel in place.

7. Attach the load and unload end top barrier flanges.

7700 Floor Loading Cart Washer

Base Shrouds (Floor
Mounted Option)

Objective

Install the base shrouds at the load and unload ends of a floor mounted
washer.

Installation

Refer to Figure 2–55. Base Shroud.
Figure 2–55. Base Shroud

1. Align the holes in the base shroud with #10-32 threaded
holes in the base frame.

2. Secure in place with #10-32 fasteners.

Repeat steps 1 and 2 for the other base shrouds.

61301603904 2–65

Installation

Ramps (Floor Mounted
Option)

Exhaust Connection

Objective

Install the ramps at the load and unload ends of a floor mounted washer.

Installation

Refer to Figure 2–56. Ramp.
Figure 2–56. Ramp

Insert the 1" support flange of the ramp behind the front edge of the drip
trough that extends from the door threshold. No fasteners are required.

This procedure applies only to vented washers.

Plumbing System
Connections

Install a dedicated, corrosion-proof, watertight duct (800 CFM, negative 1/4"
static pressure) from the 12-inch diameter exhaust elbow (Figure 2–21 on
page 2–27) to the building’s exhaust system. The duct assembly should be
sloped toward the washer.

All service connections must conform to local codes. The supply line
connections are labeled for identification. Refer to “Utilities and
Specifications” on page 1-3 for pipe sizes, pressures, and requirements at
site of installation.

1. Connect the 1-inch hot water supply line to the 1-inch
servic e connection.

2. Connect the 3/4-inch col d water supply line to the 3/4-inch
servic e connection.

3. Connect the 1-1/2 inch steam supply line to the 1-1/2 inch
servic e connection.

4. Connect the 3/4-inch steam return or drain line to the 3/4 ­inch condensate line connection.

5. Connect a 3-inch drain line to the 3-inch drain fitting.

2–66

Electrical Supply Connection

7700 Floor Loading Cart Washer

NOTE

A fused disconnect (supplied by customer) must be installed in the electrical
supply line . It s hou ld be si tua ted clos e to th e uni t f o r eas y acce ss b y se rvice
personnel.

1. Route the e lectrical supply line through the top of the
control box to the power distribution block.

2. Connect the electrical supply line. Refer to “Utilities and
Specifications” on page 1-3.

Concluding Tasks 1. Apply silicone sealant to all pe rmanent exterior seams.

2. Remove the protective film from all exterior surfaces of the
washer.

3. Clean and polish the exterior surfaces of the washer.

NOTE

At this point, installation is complete. You should contact Getinge/Castle
personnel so that mechanical adjustments and electrical performance tests
can be accomplished before you operate the equipment. Failure to have the
specified Product Support personnel inspect and test this equipment before
operation voids the warranty.

61301603904 2–67

Installation

2–68

Index

A

Actuator Assembly 2–20

B

Barrier Flanges 2–62
Base Shrouds
Base/Sump
Black Iron (Steam) Plumbing
Booster Heater Assembly

2–1

2–65

2–39

2–41

C

Cables, Emergency Stop Switch 2–57

2–11

2–10

2–49

2–15

1–3

1–3

2–41

2–41

2–41

2–44

2–19

Center Mounting Plate
Chain Drive Assembly
Channel Fillers
Cold Water (Copper) Plumbing
Cold Water Specifications
Condensate Specifica tions
Condenser and Dryer Drain Tubing
Condenser Assemblies
Control Box
Control Box Cable Connections
Copper (Cold Water) Plumbing
Copper (Hot Water) Plumbing

2–31

D

Detergent and Rinse Aid Dispensers 2–34
Dispenser Tubing
Door Assembly
Door Latch Retainers
Door Proximity Switches
Drain Specifications
Drain Valve, Sump

2–61

2–12, 2–60

2–13

1–3

2–37

2–36

Drive Chain Tension Idlers
Dryer and Condenser Drain Tubing
Dryer Assemblies
Dryer Ducts, Front
Dryer Ducts, Rear

2–15

2–29

2–45

2–47

E

Electrical Specificat io ns 1–3
Electrical Supply Connec tio n
Electrical Wiring
Emergency Stop Switch Cables
Emergency Stop Switch Junction Box
Emergency Stop Switch, Front
Emergency Stop Switch, Rear
Exhaust Elbow
Exhaust Specifications

2–42

2–27

1–3

2–67

2–23

2–57

2–33

F

Final Door Assembly 2–60
Floor Grates
Floor Mount Option
Floor Tilt Pulley System
Front Dryer Ducts
Front Emergency Stop Switch

2–4

2–29

1–4

2–20

2–33

G

General Description 1–1
Guard Tubes

2–54

H

Hinge Mounts 2–13
Hot Water (Copper) Plumbing
Hot Water Specifications

1–3

2–41

2–19

2–22

61301603904 I–1

Index

I

Idler Bearings 2–47
Installation Advisory
Installation Procedures

Base Shrouds 2–65
Base/Sump Assembly
Black Iron (Steam) Plumbing
Booster Heater Assembly
Chain Drive Assembly
Cold Water (Copper) Plumbing
Components on Inside of Washer
Components on Outside of Washer
Components on Top of Washer
Concluding Tasks
Control Box
Detergent and Rinse Aid Dispensers
Dispenser Tubing
Door Assembly
Door Proximity Switches
Drive Chain Tension Idlers and Idler Bearings
Dryer and Condenser Assemblies
Electrical Supply Connectio n
Electrical Wiring
Emergency Stop Switch Cables
Emergency Stop Switch Junction Box
Exhaust Elbow
Final Door Assembly
Final Installation Tasks
Front Dryer Ducts
Front Emergency Stop Switch
Hot Water (Copper) Plumbing
Junction Box
Light Assembly
Manifold Cover and Spray Gu ard, Manifold Guard Tubes,

Pit Covers
Plumbing
Plumbing Mounting Brac kets
Plumbing System Connections
Power Floor Tilt Pulley System
Ramps
Rear Dryer Ducts
Rear Emergency Stop Switch
Sanitary Barrier Flanges
Service Area Enclosure
Spray Manifold Drive Motor
Spray Manifold Supports and Manifold Assembly
Stainless Steel Plumbing
Sump Drain Valve
Trim Panels
Unload End Indicator Panel Box
Wash Pump
Washer Panels
Washer Structure

2–66

1–4

2–1

2–49

2–67

2–31

2–61

2–12

2–42

2–27

2–60

2–59

2–29

2–32

2–28

Wash Cart Tubes

2–63

2–40

2–45

2–64

2–37

2–14

2–38

2–5

2–1

2–39

2–36

2–54

2–62

2–40

2–41

2–67

2–33

2–41

2–24

2–23

2–26

2–41

2–45

2–15

2–15

2–57

2–66
2–20

2–35

2–25

2–34

2–22

2–47

2–51

J

Junction Box 2–32
Junction Box Cable Connections

L

Light Assembly 2–28

M

Manifold Assembly 2–51
Manifold Cover
Manifold Drive Motor
Manifold Guard Tubes
Manifold Spray Guard
Manifold Supports
Materials and Tools Required
Model Identification
Mounting Brackets, Plumbing

2–54

2–51

1–2

2–26

2–54

2–54

1–6

2–24

O

Options 1–4

P

Panels 2–5
Pit Covers
Pit Mount Option
Plumbing

Plumbing Mounting Brackets
Plumbing System Connections
Power Floor Tilt Pulley System
Printer Option
Proximity Switches, Door
Pulley Mounts
Pump, Wash
Push Rod/Chain Assemblies

2–63

1–4

2–40
Black Iron (Steam)
Cold Water
Hot Water
Stainless Steel

1–4

2–20

2–38

2–41

2–41

2–40

2–41

2–36

2–24

2–50

2–66
2–20

2–43

I–2

R

Ramps 2–66
Rating Plate
Rear Dryer Ducts
Rear Emergency Stop Switch
Rinse Aid and Detergent Dispensers

1–2

2–45

2–23

S

Sanitary Barrier Flanges 2–62

2–54

1–3

2–41

2–3

1–3

2–64

1–5

1–4

2–51

2–51

2–40

2–26

2–39

Seismic Anchoring
Service Area Enclosure
Service Enclosure Option
Shipping Configuration
Size Specification
Spray Guard
Spray Manifold Assembly
Spray Manifold Drive Motor
Spray Manifold Supports
Stainless Steel Plumbing
Steam Booster Heater Assembly
Steam Plumbing
Steam Specifications

2–34

7700 Floor Loading Cart Washer

Sump

2–1

Sump Drain Valve

2–37

T

Tension Idlers 2–47
Threshold Assemblies
Tools and Materials Required
Trim Panels
Tubing, Condenser and Dryer Drain
Tubing, Dispenser

2–14

2–61

2–11

1–6

U

Unload End Indicator Pa nel Box 2–35
Utilities and Specifications

1–3

W

Wash Cart Tubes 2–54
Wash Pump
Washer Options
Washer Panels
Washer Structure
Weight Specification
Wiring, Electrical

2–38

2–5

1–4

2–1

2–42

1–3

2–19

61301603904 I–3

Index

I–4