CHAPIN 97500 (01) PDF MANUAL

Tools required:

1- 9/16″ End Wrench

1- Thread Sealant

Assembly Instructions:

1. Install the gauge in the fitting as illustrated using a good grade thread sealant to prevent leaks. DO NOT OVER TIGHTEN.

2. Insert the lead wire assembly into the plug at the rear of the pump.

3. Join the red wire of the lead wire to a +12V source on the garden tractor. The black wire should be grounded or connected to the negative battery post.

The pumping system draws solution from the tank, through the strainer and to the pump. The pump forces the solution under pressure to the spray wand.

The pump has a pressure switch which will shut the pump off when it reaches 60 PSI.

Pressure may be regulated by opening or closing the bypass valve located on the top of the tank. The more it is opened, the lower the pressure will be.

Regularly inspect the suction supply screen on the inside of the tank. Flush with water to clear any accumulated debris.

A lever turns the Spray Boom on and off (if equipped).

Another lever adjusts the system pressure by relieving liquid back to the tank. Adjusting this lever will increase or decrease pressure to the Spray Wand or the Spray Boom.

Pressure should be adjusted by regulating the by-pass valve (slightly opening or closing).

40 PSI – This can be accomplished by turning on the pump and adjusting the bypass valve until the gauge reads 40 PSI (or slightly higher). The pump will run continuously. Ensure that the boom and/or handgun is not spraying while you set the pressure. The pressure will drop slightly when the boom and/or handgun is operated.

Please refer to the operation instructions for boom operating pressures; varying boom pressures can be achieved by regulating or adjusting the by-pass valve. Typically the spray wand will be operated between 20 and 40 PSI.

The PowerFLO Series 7800 pump is controlled by a built-in pressure sensing demand switch. Should the pressure switch OFF setting vary with use and time to an unsuitable value, it may be adjusted for optimum performance. Turn the setscrew clockwise to increase the OFF pressure setting and counter-clockwise to decrease. The screw should not be adjusted more than one half turn without consulting the Factory. Excessive adjustment of the pressure switch could cause low system pressure, rapid cycling ON/OFF operation, and reduced pump and motor life. Damage may occur.

After use fill the sprayer part way with water. Start the sprayer and allow clear water to be pumped through the plumbing system and out through the spray wand.

Refill the tank about half full with plain water and use a chemical neutralizer and repeat cleaning instructions. Flush the entire sprayer with the neutralizing agent. Follow the chemical manufacturer’s disposal instructions of all wash or rinsing water.

Drain all water and chemical out of sprayer, paying special attention to pump and valves. These items are especially prone to damage from chemicals and freezing weather.

The sprayer should be winterized before storage by pumping a solution of RV antifreeze through the entire plumbing. Proper care and maintenance will prolong the life of the sprayer.

WARNING: Some chemicals will damage the pump valves if allowed to soak untreated for a long period of time. Always flush the pump with water after use. Do not allow chemicals to sit in pump for extended times of idleness. Follow chemical manufacturers instructions on disposal of all waste water from the sprayer.

1. The pump is equipped with a pressure sensing demand switch that controls the maximum operating pressure.

2. In addition, never subject the pump to pressures above 125 PSI (8.5 bars).

3. As long as there is inlet water pressure, the pump will not stop forward flow of water even if the motor is turned off. Be sure the system has positive means of shutting off water supply.

4. Do not operate pump in an explosive environment. Arcing from the motor brushes, switch or excessive heat from an improperly cycled motor may cause an explosion.

5. Do not locate the pump motor near low temperature plastics or combustible material. The surface temperature of the motor may exceed 250°F (120°C).

6. Do not pump gasoline or other flammable liquids. Pump head materials are designed for use with water only. Do not use with petroleum products.

7. Do not assume fluid compatibility. If the fluid is improperly matched to the pumps’ elastomers, a leak may occur.

8. To prevent electrical shock, disconnect power before initiating any work. In the case of pump failure, the motor housing and/or pump fluid may carry high voltage to components normally considered safe. Therefore, always consider electrical shock hazard when working with and handling electrical equipment. If uncertain, consult an electrician. Electrical wiring should only be done by a qualified electrician per local and state electrical codes.

Every Year: Check system against operating standards.

Every 2-3 Years: We recommend replacing the diaphragm and checking against operating standards.

Check the following:

• Correct voltage (±10%) and electrical connections

• Fuse or breaker

• Pressure switch operation and correct voltage at switch

• Rectifier or motor for open or grounded circuit

• Locked drive assembly

• All electrical connections. Ensure switch is in the on position. Check in-line fuse and/or fuse in car adapter end. Ensure correct voltage +/- 10%. 12-13 volt.

If there is no discharge with the motor running, check for:

• Debris in strainer

• Restriction (kinks) in inlet/outlet tubes

• Debris or swelling in inlet/outlet valves

If the output line is closed and there are no leaks, check for:

• Air trapped in outlet line or pump head

• Correct voltage to pump

• Debris in pump inlet/outlet valves

• Loose drive assembly or pump head screws

• Pressure switch operations/adjustments

Check for:

• Loose screws at switch or pump head

• Switch diaphragm ruptured or pinched

• Punctured diaphragm if fluid is present

Check for a clogged suction hose and/or suction strainer. Often you will need to clean the suction strainer. Check for proper voltage.

This is a demand pump and only runs with flow; spray wand, by-pass, spray tips or leak in system.

Low flow may cause the pump to surge (or cycle). This could happen when the spray wand is adjusted for a small or fine spray pattern. To overcome, slightly open the by-pass valve.

Ensure the by-pass is completely closed and your system has no leaks. Check by-pass hose to ensure no fluid is passing through the valve while in the closed position. If so replace valve.

Pump 7802 2.0 GPM comes preset from the factory to shut off at 60 PSI. Should this vary please see, “Adjusting the Pressure Switch” in the operation manual. Turn on pump and hold spray wand open, slowing adjust until the pump shuts off at 60 PSI.

1) Excessive voltage 2) Improper adjustment of the pressure switch 3) Damaged wiring harness.

Yes, there is a fuse for the sprayer. It can be an in-line fuse, a fuse located in the car adapter housing or both.

A 7.5 amp fuse should be used as a replacement.

To remove or replace the fuse, unscrew the in-line fuse connector, or unscrew the car adapter housing.

Yes, however your wand comes with a #18 tip which is standard. Brass tips generally produce better spray patterns than plastic.

35 feet max.

When you return your pump for repair, you must always do the following:

1. Flush chemical residue from the pump (best done in the field).

2. Tag pump with type of chemicals having been sprayed.

3. Include complete description of operation problem, such as how pump was used, symptoms of malfunction, etc. Since pumps can contain residues of toxic chemicals these steps are necessary to protect all the people who handle return shipments, and to help pinpoint the reason for the breakdown.

To Order Replacement Parts: 1-800-950-4458