Model XKE - London Foggers
Contents
1. 01 2013 WWW LONDONFOGGERS COM EMAIL SALESSUPPORT LONDONFOGGERS COM LARGE AREA ULV GENERATOR OPERATING INSTRUCTIONS AND ILLUSTRATED PARTS For machines serial numbers above 1950 905 Brimhall Ave PO Box 406 Long Lake Minnesota 55356 PHONE 800 448 8525 FAX 952 473 5302 INDEX Forward Specifications Safety Precautions Assembly Installation Service Before Start UP Pre Start Check List Start Up Operation Setting Flow Rate Calibration Spraying Flushing Service Schedule Maintenance Air Pressure Air Pump Belts Engine Oil Nozzle Flushing Air Pump Oil Formulation Filter Engine Air Cleaner Battery O 11 11 12 12 13 14 16 17 19 20 21 39 18 21 22 24 25 25 INDEX continued Maintenance continued Pulsation Damper 28 High Pressure Switch NA Trouble shooting 30 Preparation for storage winterization 33 Schematic Fluid System 34 Wiring Diagram Machine 35 Machine Exploded View 35 36 37 Illustrated Parts 38 39 Warranty 40 FORWARD The application of insecticides is the predominant methods by which we can limit the size of insect populations Due to economic as well as environmental reasons it is desirable to treat a given area with the least amount of insecticide that can be made to be effective The most efficient method is to break up 1 2 ounces of liguid into aerosols and distribute these fine droplets over the affected acre of land The fin2. All tanks corrosion resistant high density polyethylene formulation and flushing tanks only Formulation 15 U S Gallons 56 7 Liters Flushing Optional 1 5 U S Gallons 5 6 Liters Optional Gasoline 3 0 U S Gallons 11 3 Liters o to 20 Microns MMD Mass Median Diameter depending on flow rate and viscosity 280 Pounds 127 Kilograms 38 Inches 106 cm 33 Inches 86 cm 31 inches 76 cm SAFETY PRECAUTIONS WARNING READ AND UNDERSTAND THESE SAFETY PRECAUTIONS BEFORE OPERATING MACHINE 1 ENGINE AND FUEL This machine uses gasoline as the fuel for the internal combustion engine and all precautions commonly applying to this volatile fuel should be observed Exercise extreme caution to avoid spilling of gasoline If spillage occurs wipe it off and allow evaporation time before starting the engine DO NOT attempt to put fuel in the tank while the machine is still running Avoid smoking or open flames in area when handling gasoline Never run the unit indoors unless exhaust is vented outside These fumes contain carbon monoxide which is colorless and odorless and can be fatal NOTE DO NOT OPERATE ENGINE WITHOUT MUFFLER DO NOT TOUCH HOT MUFFLER CYLINDERS OR FINS AS CONTACT MAY CAUSE BURNS Except for adjustment DO NOT OPERATE THE ENGINE IF AIR CLEANER OR COVER DIRECTLY OVER THE CARBUETOR AIR INTAKE 15 REMOVED DO NOT RUN THE UNIT IF THE BELT GUARD IS REMOVED DO NOT TAMPER WITH THE GOVERNOR SPRINGS GOVER
3. Service Breaker Points ll Clean Engine CoolingFins LL X Check Set Engine Timing il Check Valve Clearances ll 121 UN Bee Mi xg NI gt lt Check Set Governor Over Pressure Cut Off Switch 17 VIII MAINTENANCE AIR PRESSURES A Low Air Pressure 1 Air pressure to air tip 75 85 psi as measured by air pressure gauge on machine gauge panel 2 Engine should run at 2700 rpm and air pump at 925 rpm A loose or slipping belt can cause loss of air pump rpm Malfunctioning engine or governor out of adjustment can cause improper engine rpm 3 Air leaks can cause reduced pressure even though engine and air pump are operating OK Air leak at or around air fluid nozzle tip or junction with the nozzle body can cause reduced pressure Be sure that Teflon gasket part 6 306 which seals the mating surfaces between the air fluid nozzle and nozzle body is in good condition and properly installed Be sure that air fluid nozzle is properly tensioned against the Teflon gasket Air leaks at any of the air line joints can also cause reduced pressure Low pressure as indicated at remote control panel can cause poor atomization resulting in too large fluid droplets NOTE If nozzle air pressure is below normal on Daily Check up check for air leaks at all joints Air leaks can be detected by holding the hand or fingers close to the various joints and feeling if air under pressure is blown against
4. HE SOLUTION DO NOT SPRAY NEAR AN OPEN FLAME OR HOT MATERIALS DO NOT LEAVE THE MACHINE UNATTENDED 1 CALIBRATION SETTING THE FLOW RATE CAUTION Before calibration be sure the machine fluid lines are free from any air bubbles On initial start up it may be helpful to temporarily move the pump pointer to a high scale reading to get the system primed and the lines purged of any air bubbles 13 OPERATION continued 2 SPRAYING CAUTION Before dispensing insecticide be certain that no one is present in the area of the nozzle or aerosol dispersion area A To dispense insecticide with the ULV machine running move the flow control on off nozzle switch cab control to the ON position The green indicator light should come on B The air pressure gauge on the cab control panel should read between 75 and 85 pound per square inch pressure If this pressure is not present shut off the flow control switch and see Air Pressure Instructions DO NOT dispense insecticide until the air pressure problem is corrected OPERATION continued The fluid pump system is calibrated to the graduated scale on the pump at the London Fog factory If any major deviation in the flow rate occurs first check the other components in the system such as strainers fittings etc Check for air bubbles in the suction side of the lines as well as the pressure side Check for fluid leaks in the pressure side of the lines Minor deviations not creat
5. NOR LINKS OR OTHER PARTS WHICH MAY INCREASE OR DECREASE THE GOVERNED ENGINE SPEED 2 ENGINE SPEED RPM should be checking periodically to ensure that it is operating correctly as the engine affects the air pressure and formulation flow which affects droplet size The correct engine speed should be 2700 RPM plus or minus 150 RPM 3 MACHINE DAMAGE Never operate a machine after it has been damaged A damaged machine can be very hazardous 4 WIND Spraying during windy conditions is not usually practical because the formulation will drift out of the intended area However under NO circumstances should spraying into the wind be attempted This may cause hazardous accumulations of formulation on the machine or carrying vehicle Safety Precautions Continued 5 SAFETY EQUIPMENT In addition to any safety equipment that may be required by the type of formulation which is being used the following items should be with each vehicle which carries this machine during fogging operations Fire Extinguisher Chemical type rated for fuel fires First Aid Kit Eye Wash solution Safety Glasses Container of Oil Dry Compound Gloves rated for high temperature Respirator adequate for formulation being used 6 CHILDREN Many spraying operations are preformed in residential areas commonly at dusk This presents the operator with the problem of children who are attracted to the noise and or the mist being created The Possib
6. UprightTall 1 37 6 300 Nozzle Exploded Views Item gt N i 5 5 5 2 5 17 18 19 Dart Description Ouantity Seperator Assembly Complete Seperator Assy to Stand Pipe Nipple 1 2 NPT mmm 6 640 Compressor Stand Pipe Double Thick Pipe Nipple 3 4 NPT 1 6 310 streetElbowBras Td 6 309 Nozzle Ball Joint Brass Heavy Duty Top and Bottom 1 6 308 Male Elbow 64 Degree 1 6 604 Stainless Steel Nipple SolenoidXKE A 6 600 Spray Flush Solenoid Viton Seals Complete Assy __ 1 6 639 Reducer Elbow for Standpipe Ae 1 6 301 Nozzle Assy Aluminum Body to Nozzle Tip Complete 1 6603 SolenoidPipePlug 1 6 307 AluminumNozzleBodyXKE A 6 306 TeflonGasket o o 1 6304 FluidNozle 1 63093 Aircap Le 1 630 NNozleRing 1 6 627 GasketVitonSeperatorassy 1 6 629 FilterElement LA 38 6 500 XKE Pump Box Exploded View Item Part 1 6 500 1 1 502 2 1 550 3 1 503 4 1 504 5 1 505 7 1 510 8 1 511 9 1 512 10 1 513 11 6 504 12 1 515 1 516 1 517 1 518 1 520 1 521 1 522 1 551 1 552 Description Pump Box Complete Pump Box Only Black Pump F M I 3 8 in Ceramic Piston Resistor 18 20 XKE 9 10 Incl Heat Sheild Pulse Dampener w Bracket and Hose Fittings Rubber Vibration Mounting Foot Panel Electrical Assembly Complete Toggle Swit
7. ack starter motor white red xke standard engine wiring d m battery 6 28 12 amp plug female male pins 34 XKE 8 5 HP Kohler Pump Box Wire Harness 8 8 12 pump box wiring xke standard 8 95 kohler command pro C pump motor 5 amp fuse PL red pl to back oF D I yellow engine harness KEE black control male amp plug engine male amp with female pins with female 35 XKE 8 5 HP Kohler Pump Box Wire Harness 8 28 12 brown 8 95 kohler command pro option gps xke standard cab control with gps option light back view cab control wire and switches P4 black 45 Orange D I brown wam i Y w option gps Sje s uje 36 6 1000 XKE Exploded View Item n a 10 11 12 13 14 15 16 17 Hart Description Ouantity 6 401 XKE Frame Assy Complete 6 100 Engine Kohler Complete Wired 2 6 411 Belt Guard Assembly 1 6 775 Battery Box 15 Gallon Formulation Tank 1 6650 FilterAssembly A _620 Compressorxke 6300 Nozzle assembly 1 6 625 seperator Assy Attached to Nozzle 1 6 626 SeperatorFilterOnly amp A 6500 PumpBoxAsembly 1 6681 GaugePanelony LL 6 675 PressureGaugeAssyComplete 1 6412 TankTrayXKEpre 2013 1 6413 Tank TrayUprightshot 4 A 6414 TankTray
8. always be checked while engine is level With threaded plug type dipstick remove and wipe oil off reinsert but do not turn plug in To check oil level shoulder plug on top of the hole After checking again turn plug all the way into crankcase CAUTION DO NOT operate engine with oil level below L mark or over mark Also read Oil Change under maintenance instructions OIL TYPE Use oil meeting the requirements of SAE service class SC SD SE and SF Select oil viscosity based on the air temperature at the time of operation as shown 5 Clean Air Fluid nozzles Air Temperature Oil Viscosity Above 32 F 0 C SAE 30 Below 32 F 0 C SAE 5W 20 or SAE 5W 30 Use straight weight oils as specified Do not use multi viscosity oils above 32 F as considerable increases in oil consumption and combustion deposits will result See instructions under Air Pressure paragraph 1 6 FLUSHING Flush out he chemical system with soap and water or other suitable flushing fluid after each use Always flush thoroughly prior to down time or storage oee Operation Section for flushing instructions MAINTENANCE continued f Change Oil Pump Oil Change the air pump crankcase oil Use Amsoil Synthetic Reciprocating Compressor Oil or Anderoil 500 Reciprocating Compressor Lubricant or SAE 30 Non Detergent Oil DIPSTICK DRAIN COMPRESSOR 8 Change Engine Oll Change engine crankcas
9. anking cycles of several seconds prolonged cranking can damage the starter motor if cranked more than 15 seconds per minute CAUTION On each start up be sure the formulation pump does not run dry If there is no formulation in the lines immediately turn on the spray nozzle so that formulation is drawn through the system The spray must be turned off as soon as formulation reached the nozzle 12 VI OPERATION Read this complete OPERATION section and the section on SAFETY PRECAUTIONS before starting the macnine For first time operation the sections on INSTALLATION SERCIVE BEFORE STARTUP and PRESTART CHECKLIST must be performed before proceeding with operation When operating this machine for the first time move to an uncongested and well ventilated work area in an open area away from flammable materials WARNING READ THIS SECTION ON SAFETY PRECAUTIONS BEFORE PREPARING TO DISPENSE FORMULATION READ AND THOROUGHLY UNDERSTAND ALL INFORMATION CAUTIONS AND WARNINGS ON THE FORMULATION LABEL WHICH MAY AFFECT PERSONAL SAFETY KNOW ANY DANGERS OF THE SOLUTION USED AND KNOW WHAT TO DO IN CASE OF AN ACCIDENT INVOLVING THE SOLUTION ALWAYS USE THE APPROPRIATE SAFETY EQUIPMENT AND DRESS ACCORDING TO THE CHEMICAL FORMULATION WHICH IS BEING USED DO NOT USE ANY SUBSTANCES FROM UNMARKED CONTAINERS OR FROM CONTAINERS WITH OBVIOUSLY ALTERED LABELS READ AND FOLLOW THE INSTRUCTIONS ON THE CHEMICAL SOLUTION LABEL FOR ULV SPRAYING OF T
10. art Engine misses or runs erratically NO POSSIBLE CAUSE CORRECTIVE ACTION SE a Battery cable a Clean tighten cable connections loose dirty or connections Replace damaged a damaged cable battery c Starter solenoid c Replace solenoid amp defective or loose tighten connections connections d Defective starter d Check starter button switch on engine and or starter switch on remote control box e Starter defective e Replace starter f Air pump locked up f Inspect air pump for rotation a START STOP switch a Place switch in start on engine in stop position position replace faulty or faulty switch b Machine ON OFF switch located on remote b Place switch in start position replace faulty control box in OFF Switch position or faulty fuel tank and refuel filter plugs defective engine service center wiring defective terminals replace defective wiring disconnected wire disconnected wire c Contaminated fuel c Replace fuel d Clogged fuel filter d Clean or replace e Carburetor mounting e Tighten bolts gasket leaks replace gasket if necessary f Cylinder head gasket f Tighten cylinder head 1 LUlegke Engine knocks or develops a Crankcase oil low a Fill oil to proper level noise after oil fill if noise continues consult nearest engine service center b Muffler clogged b Cleanorreplace ____ engine se
11. ch Pressure Switch Pump Fitting Jaco 1 4 x 3 8 male Pump Fitting Jaco 1 4 x 1 4 90 deg male Amp Plug Square Receptacle Automotive style Fuse Holder Male Female 5 AMP SloBlo Fuse 3 8 O D TUBING price by Foot Hobbs Meter Optional Pump Box Lid Decal London Foggers Pump Head FMI Pump Lip Seal Kit including 2 gland washers 1 lip seal F N P FB P d F k 39 LONDON FOGGERS ONE YEAR LIMITED WARRANTY LONDON FOG INC SUBJECT TO THE PROVISIONS BELOW WARRANT EACH NEW PRODUCT MANUFACTURED BY THE COMPANY TO BE FREE FROM DEFECTS IN MATERIAL AND OR WORKMANSHIP IN NORMAL SERVICE FOR THE PERIOD OF ONE 1 YEAR COMMENCING WITH DELIVERY OF THE MACHINE TO THE ORIGINAL USER The obligation under this warranty is expressly limited to the replacement or repair at the Company s option at the plant of LONDON FOG INC Long Lake Minnesota or at a service facility designated by the company of such part or parts as inspection shall disclose to have been defective This warranty does not apply to defects caused by damage or unreasonable use including failure to provide reasonable and necessary maintenance while in the possession of the user LONDON FOG INC SHALL NOT BE LIABLE FOR COLLATERAL INDIRECT INCIDENTAL OR CONSEQUTIAL DAMAGES OF ANY KIND including but not limited to consequential labor costs or transportation charges in connection with the replacement or repair of defective parts or machi
12. ck of the fluid nozzle Blow through the three holes with compressed air it available All nozzle assembly parts should be soaked in acetone if necessary to soften gum varnish or other deposits Use care not to over tighten the fluid nozzle against its Teflon gasket so as to avoid extruding or damaging this gasket Replace Teflon gasket if worn or damaged in any Way Unduly high pressure can be caused by air pump turning in excess of 900 rpm which is unlikely 19 MAINTENANCE continued AIR PUMP Check oil level daily Oil level must never be higher than the upper mark on the dip rod or lower than the lower mark Use Amsoil Synthetic Reciprocating Compressor Oil Anderoil 500 Synthetic Reciprocating Compressor Lubricant or SAE 30 nonOdetergent petroleum based oil NOTE The synthetic type oil is recommended due to the lower maintenance requirements for the air pump and other components 20 MAINTENANCE continued 3 BELTS Check drive belts which should be in perfect alignment and neither excessively tight nor loose enough to slip ALIGNMENT E i o Ail lE INCORRECT INCORRECT CORRECT An alignment gage can be made from a piece of scrap metal or wood and be used to line up the pulleys 21 MAINTENANCE continued 4 Check engine oil Before checking oil level clean area around dipstick and oil fill areas to prevent dirt from entering into engine Oil should
13. e oil after each 25 hours of operation Use detergent oil API service classification SC 22 MAINTENANCE continued 9 Clean Formulation Filter There is a fine mesh filter screen located in the large cylindrical white nylon housing This screen can be removed for inspection and or cleaning by manually unscrewing the cap When reassembling be sure that the sealing gasket is properly positioned so as to avoid damage caused by pinching Tighten housing only hand tight during replacement do not use tools If the screen should become clogged maximum formulation flow rate will not be attained Form Filter Schematic shown upside down as position does not matter mea FILTER SCREEN FILTER BODY 10 Check Air Pump filters The air intake filters in the air pump should be cleaned or replaced every 100 hours or sooner if dirty 23 24 11 Clean or replace Engine Air Cleaner Element This engine is equipped with a dry type air cleaner element Inspect air cleaner element every 50 operating hours and replace when dirty or damaged Check more frequently under extremely dirty dusty conditions 12 Check Battery 1 Test battery with a volt ohm meter Connect the positive meter lead to the positive battery pole Connect the negative meter lead to the negative battery pole and set the meter on volts If the meter reads 11 5 to 12 volts the battery is OK If the meter reads less than 11 5 volts chec
14. e particles stay suspended for longer periods of time due to their size and are distributed more evenly remaining effective longer The term U L V is an abbreviation for the terms Ultra Low Volume Ultra Low Volume is the designation of the technique of treating areas with relatively small amounts of chemicals in the aerosol state These chemicals are usually in a more concentrated state than chemicals used in other methods of application For best results London Fog ULV Aerosol Generator should be operated and maintained in compliance with formulation label instructions DESCRIPTION This machine is intended to be vehicle or trailer mounted and is designed to be operated by the driver of the vehicle with the in cab remote control box AIR PUMP FORMULATION PUMP NOZZLE SYSTEM TANKS PARTICLE SIZE WEIGHT EMPTY LENGIH WIDTH HEIGHT SPECIFICATIONS Vehicle or trailer mountable Non Thermal U L V Ultra Low Volume cold fog aerosol generator Kohler Command one cylinder 4 cycle gasoline 8 5 HP 12 Volt Fuel Consumption regular or no lead automotive 0 5 gal hr electric start with alternator Positive displacement 4 cylinders all cast iron belt driven 900 R P M Positive displacement piston pump with adjustable output from 0 to 18 oz min 0 to 295 7 ml min 360 horizontal adjustment azimuth and 30 60 vertical adjustment elevation
15. ed by equipment malfunctions should they occur may be recalibrated by measuring the flow and adjusting the pump metering pointer until the desired flow is obtained To measure the flow disconnect the fluid line from the aerosol nozzle Place the disconnected line into an empty container Start the pump With the cab panel flow control switch turned on fluid will be pumped through the disconnected line into the container Move the disconnected line from the container to a measuring beaker for a measured amount of time preferably using a stop watch Compare the measured amount to the flow desired or to the pump scale Adjust or lock the pump pointer as may be required Be sure to replace all lines and fittings after calibrating The following are trough estimates of flow rates using very light mineral oil Always calibrate to establish correct flow rates for the chemical or insecticide to be used Flow Rate ml minute Flow Rate oz minute p Scale Setting 14 20 15 OPERATION continued FINISHED OPERATION When the spraying operation is complete the unit must be flushed in accordance with FLUSHING SYSTEM section of this manual 4 FLUSHING A Before Storage When flushing for storage drain the formulation tank and place flushing fluid in the main formulation tank Run the generator with the nozzle solenoid valve in both the ON and OFF positions to clean all lines Drain any remaining flushing solution fr
16. k the specific gravity of the electrolyte MAINTENANCE continued 2 Charge the battery a Ifthe battery does not hold a charge replace the battery b Ifthe battery holds a charge return the battery to the machine 13 Check Gap Spark Plug Check spark plug visually Replace if necessary Consult engine manual 25 MAINTENANCE continued 17 Check Valve Tapped Clearances Refer to Engine Service Manual or Authorized Service Dealer 18 Check All Fittings Check all hoses and fittings fror cracks leaks and or loosness Tighten plastic fittings hand tight only 19 Check Engine Flywheel Screen Make sure the air intake screen Is clean and unobstructed If debris builds up on screen during engine operation STOP engine immediately and clean off An obstructed screen can cause engine overheating 20 Check Set RPM NOTE The belts should be connected to the pulleys while checking the engine speed A Check the engine operating speed with a hand held tachometer The engine should run at 2700 rpm If the speed is not 2700 rpm adjust the throttle Adjust the engine speed to 2700 rpm Move the throttle lever up to decrease rpm or down to increase engine speed 26 22 MAINTENANCE continued Check Pulsation Damper The piston type metering pump tends to deliver a slightly pulsating flow of insecticide For best aerosol particle size a more even non pulsating flow is desirable A small ai
17. le hazard lies in the toxic effect of some formulations the severity of which depends upon the chemical used mist density and the length of time of direct exposure IT IS THE OPERATOR S RESPONSIBILITY TO DISCOURAGE ANY ONE FROM PLAYING IN THE MIST OR BEING NEAR THE MOVING VEHICLE 7 FORMULATIONS Ensure that formulations are applied only in strict compliance with the formulation label as well as local state and federal regulations and that these formulations are dispersed only by trained personnel of public health organizations mosquito abatement districts pest control operators or other qualified personnel a Always comply with any requirements for protective clothing goggles gloves facial masks or respirators required on formulation label b Do not exceed the dosage set fourth on the registration label of the insecticide to be used c Always store formulation in its original labeled container IN NO WAY IS IT TO BE CONSTRUED THAT THE CHEMICAL AND OR DOSAGES ARE THE RECOMMENDATION OF LONDON FOG INC LONDON FOG INC SHALL IN NO EVENT BE LIABLE FOR CONSEQUENTIAL DAMAGE OR CONTINGENT LIABILITIES ARISING OUT OF THE FAILURE OF ANY AEROSOL GENERATOR OR PART TO OPERATE PROPERLY Il ASSEMBLY INSTALLATION INSTRUCTIONS 1 Uncrate the unit and remove all packing materials NOTE It is a good idea to retain the original machine shipping carton as well as its inner packing and blocking material for any future storage and or shi
18. nes The user assumes all liability for any damage of any kind which may result from its use or misuse by any employees agents persons or third parties unknown to Company or User All warranties express or implied including any warranty created or established by statutory law or operation of law are deemed null and void in the event that a product has been physically modified in any manner by the use or any person or party other than the company The company makes no warranty with respect to engines air pumps blowers and products distributed by Company Those parts and products are subject to the warranties of their respective manufacturers THE WARRANTY EXPRESSED IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED STATUTORY OR OTHERWISE INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE NO WARRANTIES ARE EXPRESSED OR IMPLIED WHICH EXTEND BEYOND THE DESCRIPTION CONTAINED IN THIS WRITTEN WARRANTY AND NO ONE IS AUTHORIZED TO MODIFY THIS WRITTEN WARRANTY 40
19. ol Amsoil Synthetic Reciprocating Compressor non detergent type oil for the first 50 hours of operation Oil level should never be higher than the upper mark on the dipstick nor lower than the lower mark After the 50 hour break in period the compressor oil should be changed to a synthe tic oil such as Anderol 500 or Amsoil Synthetic Reciprocating Compressor oil available locally or from London Fog Inc part number 6 205 NOTE The synthetic type oil is recommended due to the lower maintenance reguirements for the air pump and other components DO NOT mix oils Drive Belts Check drive belts which should be in perfect alignment and tight ALIGNMENT MO gt k 1 d 3 INCORRECT INCORRECT CORRECT IV PRE START CHECKLIST 1 Verify that the remote control is within easy reach of the operator 2 Verify that the nozzle is in the correct position as reguired for the spraying operation to be accomplished and that the ball joint which allows this positioning is tight Verify that the air pump has sufficient fuel and is properly lubricated 4 Verify that the air pump has been serviced 5 Inspect all hoses for abnormal conditions 6 Verify that no foreign objects or tools have been left in or about the machine Verify that sufficient amount of formulation is in the tank and that the tank filling plug is tight and that the air vent hole located on the under
20. olenoid Should be 12 volts If not check for voltage at control panel gasket pinched e Move flow lever to to wrong side correct position g Pump defective g Visually check pump for rotation and piston movement 31 X PREPARATION FOR STORAGE WINTERIZATION Flush out chemical system thoroughly If the engine is to be out of service for approximately two months or more use the following procedure A Drain oil from crankcase while engine is still warm from operation Refill engine to F mark on dipstick with proper viscosity oil B Drain fuel tank and carburetor or run engine until tank is empty C Remove spark plug and add a tablespoon of engine oil into the spark plug hole Install plug but do not connect the plug lead Crank engine slowly 2 to 3 revolutions D Clean exterior surfaces of engine Spread a light film of oil over any exposed metal surfaces of engine to prevent rust Store a clean dry place 5 FLUID SYSTEMS DIAGRAM Magnum Engine SPRAY NOZZLE 3 WAY ELECTRIC SOLENOID VALVE PULSATION DAMPER FORMULATION PUMP FILTER FORMULATION TANK XKE 8 5 HP Kohler Engine Wire Harness kill relay start relay aF bolt orn block 85 stock grouncd Sue behind ign key switch to kohler stock nozzle wires white Hi rare to be added to back of red engine amp redu NN white trace blue starter pS red sol reu PO bl
21. om the formulation tank Repeat as necessary After each use without Built In Flusher accessory 1 With the aerosol generator running turn ON the spray nozzle 2 At the formulation filter large white nylon assembly disconnect the larger 3 8 fluid line which runs from the filter to the Posi Drive pump Place this line in a container of flushing solution Run the unit until the flushing fluid has cleaned the lines pump and nozzle NOTE More rapid flushing may be accomplished by moving the pump pointer to a high flow rate setting CAUTION When flushing the generator the spray switch MUST be turned ON at the cab control so that the machine is discharging aerosol 3 Reconnect the fluid line to the formulation filter Tighten very finger tight Do not use wrenches After each use with Built In Flusher Use same method as B above except in step 2 just turn the flush valve to the FLUSH position Eliminate step 3 above VII SERVICE SCHEDULE INTERVAL HOURS ITEM TO BE SERVICED DAILY GE ______ S Nozzle X ll Calibration X J J Check Air Pump Oil EL J j S o Check Air Pump Betz EL li Check Engine Oil AL j o Clean Nozze ll X Flush J X J J o Change Air Pump Oil XX Change EngineCl _ o X Replace Engine Air Cleaner Element Check Battery _ r ____ _ X Check Battery ll Check Gap Spark Plug ll Decarbonize Engne ll
22. or ASSEMBLY INSTALLATION INSTRUCTIONS continued Remove battery from its mounting and place on a stable workbench Charge 12 volt battery at 30 40 amps until the acid temperature is above 80 degrees F 26 degrees C and the hydrometer reading is 1 250 or higher Connect Positive cable leading from the starter switch which is located on the engine switch panel to the positive post on the battery and tighten bolt Connect the negative cable to the negative post on the battery and tighten bolt a When installing battery connect the negative cable last to prevent sparking and shorting b When disconnecting is required remove negative connection first C Reversed polarity can cause damage to the starting and charging systems NOTE After battery has been initially services only water should be added to restore the liquid level in each cell Further addition of acid will cause battery failure Loosen the ball swivel joint and orient the nozzle as required by the formulation label Usual set up is towards the rear and 45 up Retighten the ball joint 1 SERVICE BEFORE START UP Engine Service engine with gasoline and oil as per the accompanying Engine Operating and Maintenance Instructions Engine may come serviced with oil from factory Air Pump Compressor Before starting the machine remove the dipstick eck oil level Fill as necessary with synthetic compressor oil such as Ander
23. pment which may be required 2 Place the Remote Control Unit where it will not be damaged while machine is being prepared 3 Lift the machine onto the vehicle with the discharge end of the machine towards the rear of the vehicle 4 f permanent vehicle installation is desired the remote control cable can be passed through a small hole in the vehicle cab and then reconnected Make sure the small hole provides proper protection against wiring damage and is re sealed to prevent exhaust gases from entering inside of the vehicle 5 Using the most convenient routing run control harness to the connecting support bracket located on the engine gas tank bracket Orient the electrical plug on the harness so that the electrical pin location match the mating pin receptacles in the socket and push the plug firmly into the socket 6 Securely bolt the machine to the vehicle 7 Correct battery type is any GM 12V car battery with the most cold cranking AMPS as possible Please do not use a lawn mower tractor battery WARNING DANGER POISON BATTERIES PRODUCE EXPLOSIVE GASES KEEP SPARKS FLAME CIGARETTES AWAY VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE BATTERIES CONTAIN SULFURIC ACID WHICH CAUSES SEVERE BURNS IF ACID CONTACTS EYES SKIN OR CLOTHING FLUSH WELL WITH WATER FOR CONTACT WITH EYES GET IMMEDIATE MEDICAL ATTENTION KEEP BATTERY AND ACID AWAY FROM PERSONS WHO MAY NOT BE AWARE OF DANGERS INVOLVED 2 ch 500
24. r chamber type pulsation damper is located in the metering pump pressure outlet line between the pump and the aerosol discharge nozzle It is a white nylon assembly with an air dome that can be unscrewed by hand for inspection It has a gasket which seals the joint between the air dome and the lower section The air dome should be checked periodically to make sure that it has not become filled with insecticide If the dome has no air in it it will not function as a pulsation damper Be careful to position the gasket ring carefully so as to avoid pinching when replacing the dome 27 MAINTENANCE continued Some problems that may cause the pump fuse to blow and turn the pump off are A E F Kinked or plugged fluid lines Defective or plugged solenoid valve Plugged orifice in fluid nozzle Nozzle body plugged in fluid carrying portion Teflon nozzle gasket leaking air into fluid carrying portion of nozzle Clogged Formulation Filter Element On occasions where the blockage or problem keeps the fluid line pressure right at the cutoff point pump surging will occur indicating that the cutoff switch is continually turning the pump off and on as the pressure slightly increases and decreases Whenever this or complete pump cutoff occurs be sure to find and remedy the cause before trying to continue operation IX TROUBLE SHOOTING SYMPTOMS Starter fails to crank engine Engine hard to start or fails to st
25. rvice center smoothly of adjustment carburetor level C NU NN shroud Exhaust restricted c Replace muffler lean o a replace Le BET adjust valve improper head engine service center BE A rings engine service center eee lead E leaks replace gasket power parily closed b Air dirty c Carburetor defective c Clean adjust or replace Kee d Exhaust restricted d Replace muffler switch _ water or gum amp check fuel filter e Air pump locked up e Inspect air pump for rotation f Fuel pump defective f Clean or replace g Faulty wiring g Tighten loose terminal replace defective wiring Air pump will not operate a Defective or loose belts a Check belts and belt 29 while engine is running Air pump makes excessive noise Output light not lit when output switch is in ON position Posi Drive Pump runs but no output 30 tension b Gears in blower b Consult factory damaged a Machine not turned a Turn on ignition ON switch b Defective switch b Replace switch owitch may be temporarily shorted across terminals for test c Lamp defective c Replace bublb a Leak in suction line a Check lines tighten b Out of formulation b Check that both formulation tank and flush tank have solution in them c Output solenoid not c Check voltage at opening connector which goes to s
26. side of the tank handle is not obstructed 8 Verify that the battery is mounted securely and cable connections are proper and tight 9 Verify that all safety equipment is in place and is in proper working order CAUTION 11 Before proceeding with any spraying operation the operator should be thoroughly familiar with starting and stopping the machine and with all the operating controls If you are operating the machine for the first time exercise the machine through its full operational sequences from a position of full visibility of the machine before operating the machine fully remote This is also a good idea for experienced operators who may be operating a new machine or who may be reactivating a machine after repairs or a period of inactivity Refer to the operation section for starting and stopping instructions START UP NOTE On machines equipped with remote start the engine maybe started from either the engine or the remote control box When cold choking may be required on the initial start up Verify that the spray On Off switch on the remote control box is in the OFF position Place the Ignition On Off switch on the remote control box into the ON position and the ignition key on the engine to the ON position The engine may now be started from either the remote control box with the START switch of from the engine by turning the key to the START POSITION NOTE The best starter life is provided by using short cr
27. the hand or fingers Low nozzle air pressure may also be caused by failure to close the pulsation chamber drain valve after use for draining High Air Pressure If air pressure exceeds normal setting and the engine rpm has not increased above normal a partial blockage may have occurred in the air cap of the aerosol nozzle assembly To clean air cap and fluid nozzle when necessary use acetone as a solvent for gum or varnish and wipe all surfaces clean with a rag Carefully clean the orifices in the air cap with toothpicks and acetone Blow through these orifices with compressed air if available While air cap is removed wipe clean all exposed surfaces of the fluid nozzle 18 MAINTENANCE continued Be sure that any deposit or build up is wiped clean from the projecting snout of the fluid nozzle where it projects through the center orifice of the air cap TEFLON NOZZLE GASKET Bop ZE a Nezz LE La AIR CAP SOLENOID VALNE While air cap is removed also inspect the three holes in the fluid nozzle for deposits or internal build up Cleaning of these holes and removal of the fluid nozzle is seldom reguired due to the large area in relation to the air flow area through the air cap To clean the holes in the fluid nozzle remove nozzle and clean the three holes with a toothpick and acetone Also clean all exposed surfaces with a rag and acetone At the same time clean the circular air groove in the ba
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