Hydrospray Rainmaker Problem

Hey, new to the forum... thanks for having me!

Over 25 years experience in car washing. But I cannot figure this one out...

I have a Hydrospray Rainmaker at one of my locations... what started out as a rare occurrence of it getting stuck, has turned into a big problem happening several times daily and leaving me no choice but to shut down the wash at night and several times during the day Customers are getting upset.

The carriage will stop when the tower crests the right rear corner of a vehicle during a wash. If you can catch it right there and grab the arm and rattle it, it sometimes will take off and finish the wash. Both pancake prox switches are seen when the tower is at that point. When I go inside and hit the buttons to return the tower to the home position, it sometimes takes a little bit to respond. Not sure if that is related... maybe?

I have talked to Hydro Spray, and 2 other techs. Today, I purchased the 18-wire conductor main loom to see if that solves my issue, as suggested by Hydro Spray. And I am also replacing the cable from the center pod to the tower. I am only doing this because I am scratching my head as to what else it could possibly be.

Any suggestions?? I am going crazy over here with this thing.

When that happens have you checked the outputs? Is the contactor for the trolley pulled in like it is trying to run the trolley motor? If so, it could be losing a leg at the commutator. The rings and brushes can eventually wear and cause intermittent loss to one or more circuits.