IMPORTANT READ THIS INSTRUCTION MANUAL CAREFULLY BEFORE ATTEMPTING TO OPERATE THE UNIT.

Transcription

1 CONGRATULATIONS SprayMAX would like to thank you for investing in a retractable hose reel spraying system. Our units are manufactured to the highest standard of quality to give our customers the best product and service possible. This manual should be considered a permanent part of your SprayMAX Unit and should remain with it at all times. This manual covers the Operation and Maintenance of your system. IMPORTANT READ THIS INSTRUCTION MANUAL CAREFULLY BEFORE ATTEMPTING TO OPERATE THE UNIT. No part of this manual may be reproduced without written permission. All information in this manual is based on the latest product information available at the time of printing. This unit is designed to rewind the hose and should not be used to support the weight of the operator or pull other equipment when retracting. When you write to SprayMAX about any problem, please give us this information: >Model and Serial Number >Who the unit was purchased from >Date of purchase >Your name, address and telephone number >A detailed description of the problem WARNING Improperly maintaining this unit, or failing to correct a problem before operating, could cause a malfunction in which you could be seriously injured. Always perform a pre-operation inspection before each operation and correct any problems. 1

2 Unpacking and Set up 3 Model MAX-Reel Powered 4 Model MAX Reel Remote Control 5 Model MAX-12 Single Reel Diagram 6 Model MAX-100 Single Reel Diagram 7 Model MAX-160 Single/Twin Reel Diagram 8 Basic Operation and Hints MHz Radio Diagram MHz Radio Tuning 12 Maintenance 13 Trouble Shooting Guide (Always refer to this before calling) 14 Warranty Policy 15 Warranty Registration Form 16 2

3 Unpacking When unpacking your new SprayMAX unit check thoroughly for any transport damage, and that all parts, accessories and extras are included. 1. Instruction Manuals 3. Aerial (If applicable) 2. Accessories as ordered 4. Transmitter (If applicable) WARNING: READ THIS MANUAL CAREFULLY AND IN ITS ENTIRETY BEFORE USING THIS UNIT. Set Up Mount machine securely by bolting through all mounting lugs located on the base frame of the unit, using M10 High Tensile Bolts. Ensure a minimum of 50mm or 2 inches clearance from all sides to prevent damage. CAUTION: (If applicable); Fit aerial to mounting base tightening only finger tight and then just a nip more. If aerial is over tightened a break in the coaxial cable may result in which remote control range will diminish to only 20 meters or 60 feet. If not purchased with a Spray Gun, connect the spray hand piece of your choice. WARNING: All models - For hard wiring to a vehicle battery: Leads must be at least or 3/8 starter cable or larger and a fusible link (80 amp) must be connected in the main power lead at the battery end, to prevent fire in the case of an accidental short circuit. A two pin plug can be fitted between the unit and the vehicle battery for ease of removal. For best results use a fully charged heavy duty battery, 70AH or larger. DO NOT ATTACH ANY POSITIVE EARTH MACHINERY 3

4 Model Max-Reel Powered 3/8 ID Nylon Supa Slip Hose Part # Volt Motor Part Number Push Button Switch Part #

5 Model Max-Reel Remote Control 915 MHz Radio Receiver # Radio Box Transmitter # MHz Antenna (Shown shorter that actual length) Part Number /8 ID Nylon Supa Slip Hose Part # Volt power in Junction Box QC Part Number Volt Motor Part Number Aerial Base Part #

6 Model Max-12 Single Reel MAX-REEL M30 Lance Part # Push Button Switch Part # Flojet 12 Volt Pump Part #

7 Model Max-100 Single Reel MAX-REEL M30 Lance Part # Pressure Gauge 25 Bar Part # Push Button Switch Part # NPR Controller Part # Honda GX100 3hp Motor Manual Start Part # RT4 Twin Diaphragm Pump Part #

8 Model Max-160 Single/Twin Reel MAX-REEL 12 Volt Motor Part # Pressure Gauge 40 Bar Part # Push Button Switch Part # Karin Controller Part # Gearbox Part # Honda GX hp Motor Manual Start Part # PA430 Pump Part # way Brass Ball Valve Part #

9 915 MHz Radio Receiver Box and Transmitter Switch Always in 1 Position Radio Receiver Board Part Number Aerial Base Part Number Radio Relay 70 Amp Part Number Radio Receiver Dip-switch Code which must match Radio Transmitter 9

10 Pre-Operation Check 1. Spray Gun connected 2. Unleaded Fuel in Motor (MAX-100/MAX-160) 3. Oil Level in Motor (MAX-100/MAX-160) refer to Engine Manual 4. Oil Level in Pump (MAX-100/MAX-160) refer to Pump Manual 5. Oil level in Gearbox (MAX-100/MAX-160) 6. Pressure Lever in By-Pass Position (MAX-100/MAX-160) 7. Safety Guards and Shields are in place 8. All Nuts, Bolts, and Screws are tight 9. Unit is in an open area (MAX-100/MAX-160) Exhaust Gas is poisonous! 10. All Maintenance has been completed 11. Start Engine or Electric Motor/Pump 12. Adjust Revs to approximately ¾ range (MAX-100/MAX-160) CAUTION: Children and pets must be kept away from the area of operation. CAUTION: Know how to stop the engine quickly. CAUTION: Make sure fuel cap is closed securely Safety First IMPORTANT: Heed all these WARNINGS as failure to do so may result in serious and/or permanent bodily harm. 1. DO NOT let any person near the unit while it is operating. 2. DO NOT start the unit until you have read this manual carefully. 3. DO NOT start motor with the pressure lever in the press position. 4. DO NOT pull the hose out too fast as the reel may run on, causing the hose to become tangled. 5. DO NOT alter the equipment in any manner. If repairs are necessary, use only genuine factory repair parts or WARRANTY may be void. 6. DO NOT leave the unit running unattended at any time. 7. DO NOT operate the unit if there are any leaks from hoses, fittings, ETC. Fluids which are under high pressure can penetrate the skin. 8. DO NOT operate near powerlines, as contact could result in electrocution. 9. DO NOT refuel the engine until it has been stopped and cooled. If any fuel has been spilled, make sure that the area is cleaned & dry before starting the engine. 10

11 Basic Operation Powered Reel Ensure all set-up instructions are complete. When you are ready to operate the reel connect the unit to a 12 Volt power source. The reel will free-wheel out to the desired distance. CAUTION: Do not pull hose out too fast, as the reel may run on, causing the hose to become entangled. When you are ready to retract the hose, press the push button on the unit. Keep tension on the hose when rewinding to enable the hose to slip into the low spot on the reel drum. Basic Operation Remote Control Reel When you are ready to operate the reel ensure to carry the transmitter with the operator. The reel will free-wheel out to the desired distance. CAUTION: Do not pull hose out too fast, as the reel may run on, causing the hose to become entangled. When you are ready, press and hold the transmitter button to retract the hose back to the unit. Always ensure the hose is in front of the operator. To operate the transmitter for retraction, the operator must be at least 2-3 meters away from the unit. Use the manual button on the radio receiver box to retract any slack hose within 2 meters of the unit. CAUTION: Be ready to release the radio transmitter button when approaching the reel, as injury may result. This unit has been designed to operate in a continuous start/stop mode without damage to the unit. Keep tension on the hose when rewinding to enable the hose to slip into the low spot on the reel drum. Hints If the hose becomes entangled or caught, release the retraction button immediately or damage to the motor could result. Keep the unit under cover when not in use. A low power or voltage battery will cause weak or intermittent operation of the units motor. This can cause damage to the radio relay. Always insure that the 9 volt battery in the transmitter is replaced every 3 months and that the 12 volt power supply is charged on a regular basis and putting out optimal Voltage. 11

12 Basic Operation MAX-12, MAX-100, MAX-160 Ensure all set-up instructions are complete. MAX Ensure pre-operation check is complete. 2. Fill tank to desired level. CAUTION: Never fill tank with the lid closed. 3. Connect to a 12 Volt Power Source (see page 3) 4. Allow the pump to prime and remove any air from the plumbing lines 5. Press the Push Button on the reel to retract the hose 6. (If Remote Control) - When ready press the button on the transmitter to retract the hose back onto the unit reel. CAUTION: Be ready to release the transmitter button when approaching the reel as personal injury or damage to the unit may result. MAX-100, MAX Ensure pre-operation check is complete. 2. Fill tank to desired level. CAUTION: Never fill tank with the lid closed. 3. Ensure the pump is in the By-pass Position before starting the engine. CAUTION: Always start with the pressure at 0 Bar, never with the pump in pressure as this cause stress to the internal components of the pump. 4. Turn fuel valve to the on position and run engine for at least 30 seconds until all air has been removed from the plumbing lines to prime the pump. 4. With the pump primed turn pressure controller lever to the press position. 5. Adjust working pressure with the pressure knob. (Clockwise for more pressure counter-clockwise for less). 6. Open the 2 way ball valve to reel/s. 7. To stop the pump Reset the pressure controller lever into the By-Pass position. 8. Adjust the working pressure knob back down to zero 13. Turn fuel valve to the off position. For winter storage, if freezing conditions are expected, empty pump completely and flush with a mixture of water and antifreeze to prevent unrepairable damage to your unit. 12

13 Tuning 915 MHz Transmitter to Receiver* Your 12 volt reel is delivered pre tuned from the factory. If at some point you need a new radio transmitter or receiver board you will need to follow these instructions to re tune you system: Have a look at the photo on page 6 of your manual at the 915 MHz radio receiver module and radio transmitter. You will see in the photo description that there is a set of dip-switch codes, one set on each of the receiver and transmitter. These switches can be moved to either the up or down position. Make sure that both the radio receiver dip-switch code and the radio transmitter dip-switch code exactly match. Always keep No 1 in the ON position. This will enable the remote control to operate properly. When changing the 9 Volt battery in your radio transmitter make sure not to bump any of the dip-switch codes. This would render your remote control feature unusable until the dip-switch code was put back into its original position. If two or more 915 MHz systems are in use in the near vicinity make sure that the dip-switch codes from one system to the other are different. If they are too close in dip-switch combination radio interference or cancellation can occur from one unit to another. *NOTE: The working range of SprayMAX Radio Transmitters is affected by the many factors that typically affect all 915 MHz Transmissions. These include operating in the vicinity of high tension power lines, buildings and other obstructions, other radio transmitters, and certain other atmospheric conditions. A range of 100 meters or more can be achieved under ideal conditions. 13

14 Maintenance Daily Check the battery condition, water level and voltage (12 volt). Make sure all safety guards and decals are in place. Inspect all nuts and bolts for missing or loose items and check all hoses and hose fittings for damage or leaks. Insure the aerial is a little more that finger tight to the base and in good condition. 20 Hrs Remove the belt drive guard and check the belt tension. Grease the reel swivel if needed. Do not over grease as damage will occur to the swivel. 200 Hrs Replace the 9 volt transmitter battery. Grease all bearings if needed and do not over grease. The motor brushes must be checked by an auto electrician. Maintenance Notes 14

15 Troubleshooting Problem Probable Cause Remedy Reel does not retract and manual button does not work. -On/off switch not on or faulty -Discharged 12volt battery -Loose Connection on 12 volt battery -Blown fuse -Switch on or replace. -Re-charge battery. -Fix loose connection. -Replace fuse with 10 amp. (If Remote control Retractable) Reel does not retract and manual button works. -Discharged 9 volt transmitter battery -Faulty radio receiver board, pre regulator board, or transmitter -Replace 9 volt battery -Return radio receiver to factory with transmitter for testing and repair (CALL FIRST FOR PROCEDURE) (If Remote control Retractable) Reel only retracts at close distance. -Dip-switch (915 MHz) or digital code (433MHz) not synchronised -Discharged 9 volt transmitter battery. -Aerial broken or loose on base. -Coax cable broken inside the aerial base. -Discharged 12 volt battery. -Faulty receiver board or transmitter. -Aerial braid not connected to negative supply. -Re-match dips-witch code (915 MHz) or retune (433 MHz) -Replace 9 volt battery. -Tighten or replace. -Repair or replace coax cable and aerial base. -Recharge or replace. -Return radio receiver to factory with transmitter for testing and repair. (CALL FIRST FOR PROCEDURE) -Reconnect 15

16 Problem Pump does not deliver pressure (If good flow is being achieved from bypass back to the tank) Pump does not deliver pressure (If irregular flow is being achieved from by-pass back to the tank) Pump delivers insufficient Pressure (If hoses are jumping) Pump delivers insufficient Pressure (If hoses are not Probable Cause -Pressure Controller regulator not set for pressure -Damaged or worn seat or spring in pressure regulator -Sticking pressure regulator slide -Spray nozzle worn, missing or exceeding pump capacity -One or more of the pump valves not seated correctly -Sucking air through the suction line, suction fittings or filter -Air has not been entirely evacuated from the pump -Blocked suction filter or ball valve closed -Ruptured Spray Hoses or Fittings -One or more of the pump valves not seated correctly -Sucking air through the suction line, suction fittings or filter -Air has not been entirely evacuated from the pump -Diaphragm split (Oil will be milky in colour) -Oil level is low -Damaged or worn seat or spring in pressure Remedy -Set lever to Press and adjust the knob -Replace with Pressure Controller repair kit or new spring -Remove slide and lubricate with marine grease -Replace spray nozzle with correct size -Clean or replace valves -Examine & repair -Run pump in the Bypass mode until all air is evacuated -Clean filter or open ball valve -Repair or replace -Clean or replace valves -Examine & repair -Run pump in the Bypass mode until all air is evacuated -STOP PUMP, replace all diaphragms -Top up with AE30 or 10W30 -Replace with Pressure Controller repair kit or

17 jumping) Pump is noisy Oil is changing colour to white or oil in the spray hose T400 Gun leaks regulator -Sticking pressure regulator slide -Spray nozzle worn, missing or exceeding pump capacity -Leaking hoses or fittings -Oil level is low -Sucking air or air in the pump -Blocked Filter -1 or more diaphragms are split -Worn seat or seal in handle new spring -Remove slide and lubricate with marine grease -Replace spray nozzle with correct size -Repair or replace -Top up with AE30 or 10W30 -Examine or repair -Clean Filter -STOP PUMP, replace all diaphragms -Replace with T400 repair kit Troubleshooting Notes 17

18 Machine Specifications Model MAX-12 MAX-100 MAX-160 MAX-160 Single Single Single Twin Reels Horsepower N/A 3hp 5.5hp 5.5hp Motor Electric Honda Honda Honda Pump Flojet 2130 RT4 PA430 PA430 Series Litre per Minute (LPM) (MAX) PSI (MAX)

19 SprayMAX Warranty Policy Warranty Policy SprayMAX warrants to its authorised Dealer/Service Agent, who in turn, warrants to the original purchaser (Owner) that each new SprayMAX sprayer, hose reel, part or accessory will be free from proven defects in material and workmanship for twelve (12) months to the first Owner according to the conditions outlined, unless a specific warranty period applies to a component listed in appendix A. This warranty does not cover damages resulting from shipping and handling, abuse, accidents, alterations, normal wear or failure to maintain or use the SprayMAX product with due care. During the warranty period, SprayMAX or its authorised Dealer/Service Agent shall repair or replace, at SprayMAX option, without charge for parts and standard labour any part of the SprayMAX product which fails because of defects in material or workmanship. The Owner must provide SprayMAX or the authorised Dealer/Service Agent with prompt written notice of the defect (within 14 days of its occurrence), and allow reasonable time for replacement or repair. SprayMAX (at its option) may request failed parts to be returned prepaid to the authorised servicing Dealer/Service Agent or SprayMAX Factory. Any travel time of a service technician and/or transportation of the SprayMAX product to the authorised servicing Dealer/Service Agent or SprayMAX Factory for warranty work are the responsibility of the Owner. SprayMAX assumes no responsibility for improper choice of models or where products are used in excess of rated capacities and design functions, or under abnormal conditions. We make available a free technical service to help with any product selection, application or situation. This warranty is in lieu of all other warranties (except those of title), expressed or implied, and there are no warranties of merchantability or fitness for a particular purpose. In no event shall SprayMAX or the authorised Dealer/Service Agent be liable for downtime expenses, loss of chemicals, loss of machine use or other incidental, consequential or special damages 19

20 Conditions of Warranty 1. The warranty is not transferable. 2. The Warranty Registration Form must be returned to SprayMAX by the Owner Operator within 14 days of taking delivery of the unit. Only when warranty registration is completed and returned, can SprayMAX fulfil all warranty obligations. 3. Components and conditions not covered by warranty are: Abuse: Failure resulting from neglect, such as improper operation, lack of required maintenance or continued use of a sprayer after the discovery of a defect which results in greater damage to the unit. Environmental Conditions and Application: Deteriorated or failed components such as but not limited to: radio receiver modules, diaphragms, O-rings, hoses, seals, electrical wiring and connections damaged by corrosive chemicals, dirt and sand, excessive heat or moisture. Owners should ensure the type and strength of chemicals used in the SprayMAX sprayer, hose reel, part or accessory are compatible with the design of the unit. Normal Wear: Normal wear and consumable items such as but not limited to: oils and lubricants, diaphragms, o-rings, seals, gaskets, filter elements, flow meters, clutches, drive belts, pivot pins, paint, batteries, radio transmitters, radio relays, push buttons, switches, hose rollers, aerials, spray guns and nozzles are considered to be normal wear items and are not warranted. Maintenance: Component failure caused by not performing scheduled maintenance service such as: oils, grease, failure to clean tanks, pumps, filters, spray lines, nozzles or any other components. Not tightening or replacing loose or missing bolts, nuts, fittings, shields and covers. Damage: Damage or machine failure caused by carelessness or accidental damage, improper operation, inappropriate transportation or storage of the unit or attachment. Power Source: Failures due to faulty or inadequate electrical sources of power. Owners who use their own 12 volt power source must make sure that it is suitable for operating the spraying equipment. Alterations: Any unauthorised alteration, modification, attachments or unauthorised repairs to the SprayMAX unit. Written approval must be obtained from SprayMAX for any such items to maintain warranty. Removal & Installation: The time taken to remove and re-install a warranted part or component into other brands of equipment will not be covered by the SprayMAX warranty. Only parts and labour directly attributable to the repair of the SprayMAX unit is covered. 20

21 Clean-up Time: SprayMAX does not pay for cleaning the unit, parts, accessories or work area before or after the warranty repair. Clean-up time is affected primarily by the application or conditions in which the unit is operated and maintained. Since clean-up time can be so variable, cleaning time is considered a customer expense. Transportation Costs: Warranty does not cover transportation or insurance costs for sprayers or other equipment needing repair or replacement of warranted components. Nor does it cover any freight or insurance costs in obtaining new parts or returning old parts to SprayMAX for inspection purposes. Travel Time: Travel time required for warranty repairs is the responsibility of the owner. Diagnostic Time: Warranty does not cover time required to diagnose a warranty problem. Diagnostic time is affected greatly by the training and expertise of the technician employed to do the job. With proper training of external service personnel, diagnostic time should be at a minimum. Since SprayMAX is not in control of this factor, we do not cover diagnostic time. Non-Genuine Parts: Use of parts other than SprayMAX parts for repair of warranted items will automatically negate any warranty. Warranted components must be replaced with genuine SprayMAX parts. Unauthorised Repairs: Repairs by an unauthorised agent will automatically forfeit any warranty. Warranty repairs must be carried out by SprayMAX or an authorised SprayMAX Dealer/Service Agent only. The judgement of SprayMAX in all cases of claims under this warranty shall be final and conclusive and the purchaser agrees to accept its decisions on all questions as to defect, repair and to the exchange of any part or parts. Appendix A: 1. Bertolini Pumps Warranty period is 6 months 2. Honda Motors Refer to your Honda Manual. (Warranty period is up to 3 years) 3. Radio Receiver Warranty period is 5 years on all non moving parts. 21

22 WARRANTY REGISTRATION FORM THIS FORM MUST BE COMPLETED AND RETURNED TO: SPRAYMAX WARRANTY DIVISION 37 PRODUCTION AVENUE WARANA QLD 4575 WITHIN 14 DAYS OF TAKING DELIVERY OF THE UNIT ONY WHEN THIS REGISTRATION FORM IS COMPLETED AND RETURNED, CAN SPRAYMAX FULFIL ALL WARRANTY OBLIGATIONS PRODUCT INFORMATION SPRAYMAX MODEL/TYPE.. SERIAL NUMBER.. DEALER NAME.. PURCHASE DATE. ENGINE SERIAL NUMBER... PUMP SERIAL NUMBER... PURCHASER DETAILS COMPANY NAME... TITLE (MR/MRS/MS).SURNAME.. GIVEN NAME. POSTAL ADDRESS.. TOWN... STATE....POSTCODE... TELEPHONE...FAX..

23 22 SprayMAX Warranty Division 37 Production Avenue Warana QLD 4575 Australia Fold here and seal at top for retuning by Post