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System 10000 MeteringSystem 10000 MeteringSystem 10000 MeteringSystem 10000 MeteringSystem 10000 Metering

SystemSystemSystemSystemSystemINSTRUCTION MANUAL

1204 Chestnut Avenue, Minneapolis, MN 55403TEL: (612) 332-5681 FAX: (612) 332-6937

TOLL-FREE FAX [U.S. only]: (800) 332-6812

MANUFACTURED FOR TERMINIX

The System 10000 is a fluid metering module that is installed in a pickup truck box, andis used to apply termite control fluids.

Maximum electrical input 16 VDC

Maximum fluid working pressure 150 psi

U.S. PATENT 6,568,559CANADA PATENT PENDING

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CAUTION: Misuse of the equipment can cause it torupture, malfunction, or start unexpectedly. Seriousinjury could result.

• This equipment is for use only by trained profession-als.

• Read all instructions, tags, and labels before operat-ing the equipment.

• ALWAYS use the equipment only for its intended pur-pose. If you are uncertain about usage, contact Wan-ner Engineering at 612-332-5681.

• NEVER alter or modify this equipment. Use only genu-ine Wanner replacement parts and accessories.

• ALWAYS check the equipment at the start of eachwork day. Repair or replace worn or damaged partsimmediately.

• NEVER exceed the maximum working pressure (150psi).

• ALWAYS route the hoses away from traffic areas,sharp edges, moving parts, and hot surfaces.

• NEVER expose the hoses to temperatures above 180o

F or below –40o F.

• ALWAYS use fluids or solvents that are compatiblewith the equipment wetted parts. Read all fluid andsolvent manufacturers’ warnings.

• ALWAYS wear hearing protection when operating thisequipment.

• ALWAYS comply with all applicable local, state, andnational fire, electrical, and other safety regulations.

Safety Precautions

TOXIC FLUID HAZARD!Hazardous fluids or toxic fumes can cause seriousinjury or death if splashed into the eyes or onto theskin, or if swallowed or inhaled.

Know the specific hazards of the fluid you are using.Read the fluid manufacturer’s warnings.

Store hazardous fluid in an approved container. Dis-pose of hazardous fluid according to local, state, andnational guidelines.

Wear appropriate protective clothing, gloves,eyewear, and respirator.

PRESSURIZED EQUIPMENT HAZARD!Spray from the gun, or leaks from the gun or rup-tured components, can splash fluid into the eyes oronto the skin and cause serious injury.

Turn off power and relieve the pressure wheneveryou are instructed to — in particular, when cleaning,checking, or servicing the equipment.

WARNING

CAUTIONIndicates a potential hazard that, if notavoided, could result in minor injury orproperty damage.

WARNINGIndicates a potential hazard that, if notavoided, could result in a low probabilityof death or serious injury.

WARNING

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ContentsPage

Service ..................................................................... 18

Servicing the Pumps ........................................... 18

Tools Needed for Troubleshooting ...................... 18

General Information ............................................ 18

Motor Drive Control ............................................ 18

System Interlocks ............................................... 20

Pressure, Flow Adjustments ............................... 20

Electrical Continuity Check ................................. 20

Radio Transmitter and Receiver (Fluid Counter) 21

Battery Recharging ............................................. 22

Troubleshooting ...................................................... 22

Pendant-Displayed Error Codes ......................... 22

“Power On” Indicator is Not Lit ........................... 24

Fluid Counter Stops “Beeping” ........................... 24

Troubleshooting Chart ........................................ 25

Problems with Pumps and Reel Assembly ......... 26

Nothing in the System Operates ......................... 27

Troubleshooting the Motor Drive Control ............ 27

Wiring Diagram........................................................ 28

Plumbing Schematic ............................................... 32

Specifications .......................................................... 34

Warranty ................................................................... 34

Replacement Parts .................................................. 35

102-067 Electrical Kit .......................................... 35

102-038 System ................................................. 36

102-119 20-Gallon Tank Subassembly ............... 37

102-121 250-Gallon Tank Subassembly ............. 38

102-045 Pumps Module ..................................... 39

102-046 Dispense Module .................................. 40

102-052 Fluid Control ......................................... 41

102-141 Topper Assembly .................................. 42

Page

How the System Works .......................................... 4

Operator Controls ................................................... 5

Computer Pendant ............................................. 5

Motor Drive Control ............................................ 6

Fluid Control Panel ............................................. 6

Standard Operation Mode ...................................... 7

Filling the System ............................................... 7

Checking the Fluid Counter ................................ 7

Circulating the Chemical ..................................... 7

Circulating the H2O ............................................. 8

Running a Job .................................................... 8

Reeling in the Hose ............................................ 9

Retrieving Previous Job Data ............................. 9

Checking the Strainers ....................................... 9

Door Latches ...................................................... 9

Operating in Cold Weather ................................. 9

Daily Checklist .................................................... 10

Weekly Checklist ................................................ 10

Secured Operation Mode........................................ 11

Accessing the Mode ........................................... 11

Exiting the Mode ................................................. 11

Synchronizing the Chemical ............................... 11

Synchronizing the H2O ....................................... 11

Reviewing Accumulated Data ............................. 12

Changing the Fluid Volume Per “Beep” .............. 12

Changing the Chemical Number ........................ 12

Changing the Ratio of H2O to Chemical ............. 13

Maintenance ............................................................ 13

Hoses and Fittings .............................................. 13

Pumps ................................................................ 13

Strainers ............................................................. 13

Annual Preventive Maintenance ............................ 14

Servicing the Strainers ....................................... 14

Servicing the Hose Reel ..................................... 14

Servicing the Pump Module ................................ 14

Servicing the Pressure Switches ........................ 15

Servicing the Topper Assembly ........................... 15

Servicing the Electrical System .......................... 15

Winterizing the System ....................................... 16

Lubricants and Cleaners ..................................... 17

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How the System Works

The System 10000 is a liquid-metering termite-control sys-tem that is sized to fit in an 8-ft pickup truck box. It uses achemical injection pump to force a proper amount of chemi-cal into a common line for each volume of water pumped.It also gives off an audible “beep” from the radio receiverfor each selected volume increment of mixed fluid.

The system consists of:

• Two tanks, two pumps, a plumbing system, and a hosereel module, all installed in a 1-ton pickup truck box

• A Motor Drive Control that is mounted behind the seatin the truck’s cab

• A computer Pendant that is semi-portable and is lo-cated in the cab

• A main power switch, located in the dashboard of thetruck

• A radio transmitter to provide volumetric signals, lo-cated in the cargo light cavity

• A battery-powered radio receiver (the “Fluid Counter”)to receive these signals, carried by the operator

• Wiring harnesses to connect the various components

• Storage space for all tools, equipment, and materials

• Safety equipment, located behind the seat in the cab

• A file organizer for the operator’s paperwork, in thecab

The tank module includes a 250-gallon water tank and a20-gallon chemical tank, with separate pumps to meterthe two liquids.

The entire system is powered from the truck’s 12 Volt DCbattery system. The switch on the dash, labeled “PumpPower,” is the main power switch and controls all power tothe entire system. The power first runs to the Motor DriveControl, which in turn supplies power to the computer Pen-dant and the radio transmitter. The Motor Drive Controlhas an interlock to allow operation only when the vehicleis in “Park.”

The system has a safeguard to prevent running the bat-tery too low. This safeguard automatically shuts the sys-tem down, to always allow the vehicle to be started by itsown battery. Once the safeguard is triggered, there aretwo alternatives to supply power to the system:

• The battery charger, which is permanently connectedto the vehicle’s battery, can be plugged into a 110Volt outlet to supply the power; or

• The vehicle can be started and run while using thesystem.

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COMPUTER PENDANTIMPORTANT: The Pendant is connected to the MotorDrive Control through a computer-style D-sub connec-tor. The system will not operate unless this connec-tion is properly made. Make sure the two lockingscrews on each end of the cable are tightened to en-sure proper operation.

CAUTION: When shipped, the Pendant is seton Chemical #1. You must set it to the correctchemical before using.

INDICATORS (LEDs)JOB. When lit, the display shows a job number.MIX. When lit, the display shows the total mix of H

2O and

chemical used, in gallons.

CHEM. When lit, the displays shows the amount of chemi-cal used thus far in the job, in gallons.

H2O. When lit, the display shows the amount of waterused thus far in the job, in gallons.

USING. When lit, the display shows which chemical isbeing used for the job. This is indicated by the chemical’snumber (e.g., “C_2”).

POWER ON. When lit, indicates that power is applied tothe Pendant.LOW BATTERY (red). Flashes when the truck batteryvoltage drops to 10.5 Volts or below. The truck has a built-in battery charger that can be plugged into house currentto recharge the vehicle’s battery. The system can con-tinue to be run while it recharges the vehicle’s battery.

H2O FLOW. When lit, the Pendant is receiving a signalfrom the H

2O pump. The light may be constantly on or it

may flash on and off, depending on how fast the H2O pump

is running.

CHEM FLOW. When flashing, the Pendant is detecting asignal from the chemical pump, indicating that the pump isrunning. Typically, there are short intervals when the pumpis off (i.e., the indicator is not flashing); these intervals varywith the H

2O-to-chemical ratio setting.

OPERATE SwitchApplies power to the system and supplies fluid to the ap-plication device. An indicator in the switch lights when theswitch is ON.

Operator Controls

AGITATE SwitchThis switch is not being used on the System 10000. It canbe left OFF.

SELECT ButtonUsed for scrolling through different Pendant displays, se-lecting new jobs, or continuing existing jobs.

UP ButtonUsed for scrolling between job numbers and chemical num-bers. Also used along with the DOWN button to accessvarious Pendant modes such as Circulate or Synchroni-zation.

DOWN ButtonUsed for scrolling between job numbers and chemical num-bers. Also used along with the UP button to access vari-ous Pendant modes such as Circulate or Synchronization.

COMPUTER PENDANT

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Operator ControlsMOTOR DRIVE CONTROLThe Motor Drive Control is located behind the seat in thevehicle’s cab.

• The normal operating position of the Power switch onthe Motor Drive Control is at Ignition. At that setting,12V DC power is applied to the system whenever thePump Power switch on the dash is ON.

• All power to the system is turned off if the Pump Powerswitch is set at OFF. To protect against inadvertentsystem operation, be sure the Pump Power switch isOFF whenever the truck is being used for other pur-poses or when servicing the system.

• If the switch is set at Internal Power, 12V DC power isalways applied to the system (no matter what the set-ting of the Pump Power switch, and as long as thevehicle is in Park or Neutral ).

MOTOR DRIVE CONTROL

FLUID CONTROL PANELNOTE: The chemical and H

2O ball valves are mechani-

cally tied together to prevent the possibility of running justone fluid on a job.

CHEMICAL Valve. Has two positions: RUN and CIR-CULATE & SYNC.

H2O Ball Valve. Has two positions: RUN and CIRCU-LATE & SYNC.To prevent leakage, make sure the valves are fully rotatedto the desired position.

Note that, by removing two of the panel’s four mountingscrews and loosening the other two, you can tilt the panelforward for easy maintenance.

FLUID CONTROL PANEL

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Standard Operation Mode

FILLING THE SYSTEMIMPORTANT: Avoid operating the pumps when the tanksare empty or nearly empty, as this will entrap air that istime-consuming to remove.

Filling the Chemical TankThis tank is for liquid chemical concentrates only! Keysare provided for the chemical tank cap. Remove the capand insert a low-profile wide-mouth funnel into the tank’sfill neck. Fill to the desired level. A level gauge on the tankindicates the volume of fluid in the tank.

Filling the H2O TankThis tank is for water only! A fill hose is provided forease of unattended filling. This fill hose is accessible fromthe small hose-reel door or from the tailgate area. A shutoffvalve on the end of the fill hose prevents leakage while thetank is not being filled. The ball valve must be open toallow the tank to be filled. A float valve automatically shutsoff further flow into the system once it has reached its filledcapacity. A clear site gauge on the tank indicates the vol-ume of fluid in the tank.

Recharging the Vehicle’s BatteryA battery charger is provided to allow operation withoutthe vehicle running. See page 4 for the location of theplug-in cord.

NOTE: The 250-gallon H2O tank is designed with various-

sized cavities that hold specific tools and supplies usedwhen doing a treating job.

CHECKING THE FLUIDCOUNTERTo check for the “beep” from the Fluid Counter:

1. Turn the Fluid Counter (radio receiver) to ON.

2. Turn the Pump Power switch to ON.3. Turn the Pendant’s OPERATE switch to ON.

4. Listen for a “beep” sound, and for the Pendant dis-play to momentarily show “bEEP”.

If you don’t hear the “beep,” refer to the Troubleshoot-ing section.

5. Turn the Fluid Counter to OFF.

CIRCULATING THE CHEMICALIMPORTANT: Circulate the chemical as explained be-low, until the pump runs and sounds smooth. Circu-late at the beginning of each workday and before start-ing each job.At the tanks:1. Turn the Fluid Control Panel lever to the “CIRCU-

LATE & SYNC” position.

2. Open the outlet ball valve at the bottom of the chemi-cal tank.

3. Open the chemical circulation ball valve, as shown:

On the dash:4. Turn the Pump Power switch to ON.

At the Pendant:5. Push the SELECT button until the CHEM indicator

lights.

6. Push the UP and DOWN buttons simultaneously un-til the Pendant display shows “Circ / C_n” (alternatingbetween the two).

7. Push the OPERATE switch to ON. The pump shouldnow run.

8. Allow the chemical to circulate until the pump soundslike it is running smoothly and there is no air in theplumbing lines.

• The Chemical pressure gauge should now showslight pulsation

• The H2O pressure gauge should read 0 psi

9. When finished circulating (that is, when the correctpressures are reached), push the Pendant OPERATEswitch to OFF.

10. Push the SELECTbutton once to exit the Circulationmode.

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Standard Operation ModeCIRCULATING THE H2OIMPORTANT: Circulate the H

2O as explained below,

until the pump runs and sounds smooth. Circulate atthe beginning of each workday and before startingeach job.At the tanks:1. Turn the Fluid Control Panel lever to the “CIRCU-

LATE & SYNC” position.

2. At the back of the truck, open the outlet ball valvenear the bottom of the H

2O tank. The ball valve is

open when the handle is in line with the hose.

3. Open the H2O circulation ball valve. The ball valve is

open when the handle is in line with the hose, asshown on the next page.

On the dash:4. Turn the Pump Power switch to ON.

At the Pendant:5. Push the SELECT button until the H2O indicator

lights.

6. Push the UP and DOWN buttons simultaneously un-til the Pendant display shows “Circ / H2O” (alternatingbetween the two).

7. Push the OPERATE switch to ON. The pump shouldnow run.

8. Allow the H2O to circulate until the pump sounds like

it is running smoothly and the H2O gauge is steady

between 25 and 60 psi.

RUNNING A JOBNOTE: Always circulate before running a job.

CAUTION: Make sure the treating gun or rod isoff or closed before starting a job.

To start a new job, or continue an existing job:At the tanks:1. Turn the Fluid Control Panel lever to the RUN posi-

tion.

At the dash:2. Turn the Pump Power switch to ON.

At the Pendant:3. The JOB indicator will be lit; if not, push the SELECT

button until it is.

4. Push the OPERATE switch to ON.

The display will show:

New_# [for example, “New_2” to indicate that thenext job number would be #2; the previous jobwould have been #1)

5. If you want to start this new job, push the SELECTbutton. Note that a new job means that all volumetotals are starting at zero.The display will now show:

Job_# (in this example, “Job_2”)

The pumps will momentarily run to build up pressurein the hose lines.

6. If a previous job is to be continued, use the DOWNbutton to go to that particular Job number (e.g.,“Cont_1”). Push the SELECT button to continue thatjob. A continued job will add to the volume totalswhich are already recorded.

If you want a different new job, use the UP button tochoose any new Job number. Push the SELECT but-ton to start the job.

7. Get the fluid counter, turn its Power switch to ON,and clip the counter on your shirt.

• The Chemical pressure gauge should now readbetween 35 and 115 psi; and

• The H2O pressure gauge should read between

45 and 115 psi

NOTE: You can push the SELECT button while a jobis running to display up-to-date job information whilethe system is pumping. Continue pushing it to cyclethrough the following displays:

• # (e.g., 0.2354), MIX indicator lights• # (e.g., 0.0304), CHEM indicator lights

• # (e.g., 0.2050), H2O indicator lights

• C_# (e.g., C_3), USING indicator lights

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CHECKING THE STRAINERSThe fluid strainer screens will eventually become pluggedenough to cause pump cavitation, which could result in er-rors in pressure and metering, and possible pump damage.

To prevent this, the strainers must be checked weekly.WARNING: To avoid siphoned spills, close theball valves before removing the strainers.

Each fluid system (20- and 250-gallon tanks) has an in-line strainer. Check each strainer. Clean or replace thescreens when necessary.

When you reassemble the strainer, be careful not to dam-age the gasket — or the system will suck air in with thefluid. Keep plenty of spare strainer gaskets on hand.

Refer to the Maintenance Section for cleaning and replace-ment procedures.

DOOR LATCHESAdjustable latches hold the doors closed. Adjust the nutsat both ends of the doors for optimum opening and clos-ing.

To lock the doors, use the key provided. Slam-lock mecha-nisms are used on the topper. If the door latches are inthe locked position when the door is closed, the door willstay locked; if they are unlocked when closed, the doorwill remain unlocked.

WARNING: Pinch hazard. Keep your handsclear when closing the door.

OPERATING IN COLD WEATHERCAUTION: Never allow the pumps, plumbinglines and fittings, or tanks to freeze. Seriousdamage will occur.

A 1500-Watt 120-Volt space heater is provided with thesystem, to minimize the possibility of freezing during shortdurations of freezing temperatures. Keep all doors closedwhile the heater is running, to optimize heating of the en-tire system.

CAUTION: Run the space-heater cord throughthe sides of the doors or the top of the tailgate,and allow extra cord length. Never run the cordon the side of the tailgate, or anywhere the cordcould get pinched or cut. This could cause anelectrical short or shock, and cause serious in-jury.

Standard Operation ModeAt the tanks:8. You can now operate the treating gun.

Both the Chem and H2O pressure gauges will vary in

pressure while you are treating, depending on the ma-terial (such as the soil type or density, wall or blockvoids) that the fluid is being pumped into.

When the Job is Completed1. When you are done with the job, push the OPERATE

switch to OFF.

2. Turn the fluid counter to OFF.

3. Record the job data.

4. Reel the hose in (see “Reeling in the Hose,” below).Discharge the pressure in the hose line through thetreating gun.

5. Push the Pump Power switch to OFF.

REELING IN THE HOSECAUTION: To prevent injury, hold the hose se-curely when operating the reel switch. Stayclear of moving parts. Hold the treating gunsecurely to prevent injury or damage. The reelretracts rapidly!

To reel in the hose, press and hold the REEL pushbuttonswitch (page 4) at the back of the topper. Hold back tightlyon the hose and guide it to ensure that it rewinds evenly.

NOTE: While the reel motor is running, an interlock shutsoff power to the two pump motors to prevent excess cur-rent draw. If the Pendant’s OPERATE switch is ON, thesystem may go into an error code of HP or CP; if this oc-curs, turn the OPERATE switch to OFF and finish reelingin the remaining length of hose. See the TroubleshootingSection for more information.

RETRIEVING PREVIOUS JOBDATA1. Make sure the OPERATE switch is at OFF before you

start.

2. When the JOB indicator lights, use the UP or DOWNbutton to select the Job number desired.

3. Push the SELECT button to scroll through the vari-ous Pendant displays for that particular job.

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Use the checklists below as reminders of the items to perform at the beginning of each work day and at the beginning ofeach work week. The procedures are described in more detail in other areas of this manual.

IMPORTANTSynchronize at the beginning of the day, and log the results!Synchronization is important to ensure quality:

• To know that the pumps and sensors are working correctly

• To know that the plumbing lines are clear, and that they are free ofleaks

This is the only way to assure metering accuracy during an incrementalamount of time.

WEEKLY CHECKLIST

WARNING: To avoid siphoned spills, close the tank outlet ball valves beforeremoving the strainers.

___ 1. Check for tank and plumbing leaks.___ 2. Clean or replace the Chemical screen.

DAILY CHECKLIST

WARNING: To avoid injury, check the system for damage before each use.WARNING: Fluid will flow in a sudden burst when the gun is first triggered.

___ 1. Check all hoses and fittings in the system for signs of wear, kinking, abrasion,and leakage. Replace or repair as necessary.

___ 2. Check the fluid levels in the Chemical and H2O tanks.___ 3. Check the fluid counter (radio receiver), then turn it off.___ 4. Circulate chemical. Check for leaks, and listen for a smoothly running pump.

Check the pressure gauge.IMPORTANT: Circulate the Chemical and H2O before every job.

___ 5. Circulate the H2O. Check for leaks, and for a smoothly running pump. Checkthe pressure gauge.

___ 6. Synchronize the chemical (see page 11), and log the results.___ 7. Synchronize the H2O (see page 11), and log the results.___ 8. Check the job information from the Pendant. Take information from the previous

day’s work.___ 9. Turn the Pump Power switch to OFF. Make sure the fluid counter is OFF.

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Secured Operation ModeACCESSING THE MODEA key is required for access to the Secured OperationMode. Insert the key into the side of the Pendant, and turnit clockwise. Then press and hold the SELECT and UPbuttons simultaneously until both the JOB and USING in-dicators light.

Once in the Secured Operation Mode, the JOB and US-ING indicators will be lit and the display will show the cur-rent chemical being used (e.g., C_3).

EXITING THE MODETurn the key counterclockwise and remove it. The Pen-dant is now in Standard Operation Mode.

SYNCHRONIZING THECHEMICALIMPORTANT: Always follow the chemical circulationprocedures before you synchronize. Always synchro-nize the chemical after you change to a different chemi-cal or after the pump is repaired or replaced.If there is air mixed in with the fluid while synchroniz-ing, the system will not be accurate. Circulate the fluiduntil the air gets worked out of the system, then syn-chronize again.1. Circulate chemical. Follow the procedure on page 7.

2. Access the Secured Operation Mode (see above).

At the tanks:3. Turn the Fluid Control Panel lever to the “CIRCU-

LATE & SYNC” position.4. Turn the chemical circulation ball valve to its closed

position.

5. Set the Chemical graduated beaker on the tailgate.Disconnect the chemical circulate hose at the quick-disconnect, and place the ball valve end of the hoseinto the Chemical graduated beaker.

6. Turn the Pump Power switch to ON.

At the Pendant:7. Push the SELECT and UP buttons simultaneously for

2.5 seconds.8. Push the SELECT button until only the CHEM and

USING indicators are lit.

9. Push the UP and DOWN buttons simultaneously un-til the Pendant display shows:

SYNC / C_n (alternating between the two)

10. Push the OPERATE switch to ON. The Chemicalpressure gauge should change to read 80 to 120 psi,and the H2O gauge should remain at 0 psi.

11. Open the Chemical ball valve and fill the graduatedbeaker with chemical to the 0.264 gallon (1000 mL)mark, then close the ball valve.

12. Empty the beaker back into the tank, and bring thefunnel to the branch.

13. Push the OPERATE switch to OFF.14. Use the Up or Down button to adjust the displayed

amount until it matches the amount of fluid in the bea-ker.

• If the display reads correctly, no adjustment is nec-essary. Press the SELECT button once to enterthe numbers and to exit the Synchronizationmode.

• If the amount displayed is 10% more or less thanthe amount of fluid in the beaker, repeat steps 1through 14 until it does match.

IMPORTANT: If your results are consistently offby more than 10% and you are not getting closerto the correct value, stop the procedure andsearch for the cause of the problem. Do not usethe system! Contact a Terminix Aardvark RepairPerson.

15. When the display matches the amount of fluid in thebeaker, push the SELECT button once to exit Syn-chronization mode.

16. Reconnect the chemical quick-disconnect hose to theconnector mounted on the chemical tank, then turnthe Circ Chemical ball valve to its opened position.

17. Turn the Pendant key counterclockwise to exit the Se-cured Operation Mode, then remove the key.

18. Log the Pendant-read vs. collected amounts in thelog book. This is your proof to agencies and au-thorities of your quality control.

SYNCHRONIZING THE H2OIMPORTANT: Always circulate the H

2O before you syn-

chronize it. Always synchronize the H2O after the pump

is repaired or replaced.If you notice that there is air mixed in with the fluidwhile synchronizing, the system will not be accurate.Circulate the fluid until the air gets worked out of thesystem, then synchronize again.1. Circulate H2O. Follow the procedure on page 7.

2. Access the Secured Operation Mode (see above).At the tanks:3. Turn the Fluid Control Panel lever to the “CIRCU-

LATE & SYNC” position.

4. Turn the H2O circulation ball valve to its closed posi-

tion.

5. Set the H2O graduated beaker on the tailgate. Dis-connect the H2O circulate hose at the quick-discon-

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nect, and place the ball valve end of the hose into theH

2O graduated beaker on the tailgate.

6. Turn the Pump Power switch to ON.

At the Pendant:7. Push the Select button until only the H2O and US-

ING indicators are lit.

8. Push the UP and DOWN buttons simultaneously un-til the Pendant display shows:

SYNC / H2O (alternating between the two)

9. Push the OPERATE switch to ON. The H2O pres-

sure gauge should change to read 80 to 120 psi, andthe Chemical gauge should remain at 0 psi.

10. Open the H2O ball valve and fill the graduated beaker

with H2O to the 1.0 gallon (3785 mL) mark, then close

the ball valve.

11. Push the OPERATE switch to OFF.

12. Use the UP or DOWN button to adjust the displayedamount until it matches the amount of fluid in the bea-ker.• If the display reads correctly, no adjustment is nec-

essary. Press the SELECT button once to enterthe numbers and to exit the Synchronizationmode.

• If the amount displayed is 10% more or less thanthe amount of fluid in the beaker, repeat steps 1through 12 until it does match.

IMPORTANT: If your results are consistently offby more than 10% and you are not getting closerto the correct value, stop the procedure andsearch for the cause of the problem. Do not usethe system! Contact a Terminix Aardvark RepairPerson.

13. When the display matches the amount of fluid in thebeaker, push the SELECT button once to exit Syn-chronization mode.

14. Reconnect the H2O quick-disconnect hose to the dis-connect mounted on the H2O tank, then turn the H2OCirc ball valve to its opened position.

15. Turn the Pendant key counterclockwise to exit the Se-cured Operation Mode, and remove the key.

16. Log the Pendant-read vs. collected amounts in thelog book. This is your proof to agencies and au-thorities of your quality control.

REVIEWING ACCUMULATEDDATATo review the accumulated totals (the accumulated totalsare from the last time the Chemical type was changed orthe ratio value was changed):

1. Access the Secured Operation Mode (see above).

2. Press the SELECT button until the MIX and USINGindicators are lit. The display shows (in gallons) thetotal mix of Chemical and H

2O used thus far— e.g.,

378.50.

3. Press the SELECT button until the CHEM and US-ING indicators are lit. The display shows the gallonsof chemical used thus far — e.g., 3.2517.

4. Press the SELECT button until the H2O and USINGindicators are lit. The display shows the gallons ofH

2O used thus far — e.g., 381.75.

CHANGING THE FLUID VOLUMEPER “BEEP”To change the amount of mixed fluid that is pumped foreach “beep” signal of the fluid counter:

1. Enter the Secured Operation Mode (see above).

2. Press the SELECT button until the JOB, MIX, andUSING indicators are all lit. The display will alternatebetween “bEEP” and the number of gallons of mixpumped for each “beep” — e.g., 0.10 / bEEP.

3. To change the setting, press the UP button to increaseor the DOWN button to decrease the volume of fluidper “beep.”

4. Press the SELECT button to accept the new setting.

5. Exit the Secured Operation Mode.

CHANGING THE CHEMICALNUMBER

NOTE: Changing the chemical number (which ischanging the chemical type) used will result in clear-ing the accumulated totals to all zeros.

1. Enter the Secured Operation Mode (see above). TheJOB and USING indicators will both be lit, and thedisplay will show the number of the chemical currentlybeing used — e.g., C_2.

2. Press the SELECT button until the CHEM and US-ING indicators are lit. The display will show the accu-mulated chemical information since the last clearingof the accumulated totals. Log this data.

3. Push the SELECT button until the JOB and USINGindicators are lit again.

4. Push the UP or DOWN button to change the chemi-cal number displayed.

5. Exit the Secured Operation Mode.

Secured Operation Mode

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CHANGING THE RATIO OF H2OTO CHEMICAL

NOTE: Changing the chemical ratio will result in clear-ing all the accumulated data, so log that informationbefore you begin.

To change the ratio of H2O to chemical in the mixed fluid:

1. Enter the Secured Operation Mode (see above).

2. Press the SELECT button until the CHEM, H2O, andUSING indicators are all lit. The display will alternatebetween showing the word “ratio” and the current

Secured Operation Modechemical ratio value — e.g., ratio / 116.4. This meansthere are 116.4 parts of H

2O to 1 part of Chemical.

IMPORTANT: Use the Terminix Chemical RatioChart. This is not the same as the active ingredi-ent percentage on the chemical labels!

3. Press the UP and DOWN buttons simultaneously untilthe display shows:

Clear / Sel (alternating between the two)

4. Continue to hold the UP and DOWN buttons, and alsopress the SELECT button. Then release all three but-tons. The display will alternate between Edit and theratio value — i.e., Edit / 116.4 in this example.

5. To modify the chemical ratio value, use the UP orDOWN button.

6. Press the SELECTbutton to accept the new ratio.

7. Exit the Secured Operation Mode.

Maintenance

WARNING: Relieve pressure before perform-ing any service: (1) Turn off Pendant switchesand Pump Power switch; (2) Pull gun triggeruntil both pressure gauges read zero.

HOSES AND FITTINGSAt the beginning of each workday, check all hoses andfittings in the system for signs of wear, kinking, abrasion,and leakage. Replace or repair as required.

PUMPSCheck the oil level in both pumps monthly. Change the oilas specified in the pump Service Manual.

CAUTION: Protect the pumps from freezing.Refer to “Winterizing the System,” page 16.

STRAINERSTo keep the pumps operating properly, check the strainerscreens at least once a week. If clogged, clean or re-place.

WARNING: To avoid spills and injuries: de-pressurize the system before disconnecting anyplumbing parts; turn off the ball valve at the tankoutlet before opening the strainer.

To service the screens in the fluid strainers:

IMPORTANT: Always keep spare gaskets on hand.1. Turn off the switches on the Pendant in the cab.

2. Place a drip tray below the strainer to catch spillage.

3. Unscrew the knurled strainer bow, and lower the bowl.

Clean or replace the screen. Check the strainer gas-ket for wear or nicks.

4. Reattach the strainer bowl:

a. Apply silicone grease to the gasket.b. Carefully insert the gasket up onto the ledge in

the strainer bowl.

Be careful not to damage the gasket — or thepump will suck air in with the fluid.

c. Insert the bowl (with the screen in place) into thecap, and tighten the bowl.

NOTE: The F-30 bowl should face upward, toact as an inlet dampener.

TOPPER LATCHESIf the topper won’t unlatch:

1. Cut the straight section from a wire clothes hanger,and bend a 1/2-in. loop on one end.

2. Open the tailgate. Reach in with the looped end ofthe hanger to grab and release the near latches. Liftthe rear of the door.

3. Slip the hanger under the door. Turn the loop upwardto snag and release the front latch.

14

Annual Preventive MaintenanceThis section outlines an overall preventive maintenanceprogram for the System 10000. Wanner Engineering rec-ommends completing these maintenance procedures atthe end of the operating season.

SERVICING THE STRAINERSClean or replace the strainers and screen elements. Re-fer to the procedures in the Maintenance Section.

IMPORTANT; During the remaining maintenance pro-cedures in this section, wipe up any spills as you go.NOTE: Throughout this preventive maintenance section,various types of lubricants and cleaners to be used areindicated in bold type. Refer to the chart on page 17 forexamples of high-quality lubricants and cleaners suitablefor maintaining the System 10000.

SERVICING THE HOSE REELNOTE: Instructions and parts lists for the hose reelare shown in the Hose Reel manufacturer’s instruc-tions, supplied with the system.

1. Adjust the chain so that it is snug, but not tight.

2. Spray the chain with high-pressure lubricant while youslowly turn the reel by hand.

3. Spray the motor shaft and sprockets with high-pres-sure lubricant.

4. Grease the swivel zerks with water-resistant lithiumgrease.

5. Pull the hose from the reel and operate the system.Check the hose for wear and for leaking connections.

6. Rewind the hose. Check and tighten all fasteners.

7. Clean up any spills.

SERVICING THE PUMP MODULE1. Remove the plastic belt guard, to expose the belt and

pulleys.2. Check the belt tension. Applying 2 to 3 lbs of force

halfway between the belt pulleys should deflect thebelt 1/8 inch. To adjust the tension, loosen the motorscrews and pry the motor and pump apart with anappropriate tool.

3. Adjust the sprocket alignment by loosening the setscrew. Using a straightedge, align the pulleys to within1/32 inch. Apply Loctite #242 to the set screw andretighten it.

4. Spray the motor and pump housings with long-termprotective coating.

5. Reinstall the belt guard. Check and tighten all fas-teners.

HOSE REEL ASSEMBLY

Step 4

Step 3

Steps 1, 2

PUMP MODULE

Step 7

Step 8

Step 3 Step 2

15

6. Clean up any spills.

7. Check the pumps for oil level, leaks, and contamina-tion. To add or change oil, refer to the Pump ServiceManual.

8. The F-30 pump should have the diaphragms and thecheck valves changed yearly. Refer to the PumpService Manual.

9. The D-10 pump should have the diaphragms andcheck valves checked yearly. Refer to the Pump Ser-vice Manual.

10. Operate the system and check the hoses and fittingsfor leakage.

11. Spray the pump shafts and pulleys with high-pres-sure lubricant.

SERVICING THE PRESSURESWITCHESRefer to the procedures in the switch manufacturer’s in-structions for adjusting or replacing the high and low pres-sure switches.The Fluid Control Panel can be tipped forward for accessto all pressure and flow switches. Remove the two rearscrews and loosen the two front screws to allow the panelto be tipped forward as shown:

Refer to the Wiring Diagram (pages 28 and 29) for wirelead numbers and connections.

Annual Preventive Maintenance

TOPPER ASSEMBLY

SERVICING THE TOPPERASSEMBLY1. Patch any cracks or holes with a moisture-resistant

filler, such as white silicone-rubber caulk.

2. Lubricate the key lock and internal latches with a pen-etrating lubricant, to free any corroded mechanisms.

3. Spray the latches, shock mounts, regulator adjust-ment screw, and door hinges with a high-pressurelubricant.

4. Spray all metal parts with a long-term protective coat-ing.

5. Wipe all fiberglass surfaces with a fiberglass surfacecleaner.

6. Close the doors. Check that all locks and latchesoperate properly.

7. Clean up any spills.

SERVICING THE ELECTRICALSYSTEM

NOTE: The Motor Drive Control is located in the cab,behind the seat.

1. Remove the cover of the Motor Drive Control. Cleanthe cover with an all-purpose surface cleaner.

2. Check the connection points for discoloration causedby excessive heat. If discolored, cut back enoughwire to get to unburned wire and remake the connec-tion; if this isn’t possible, contact Wanner CustomerService for exchange directions.IMPORTANT: To prevent future problems, periodi-cally retighten the terminal screws.

3. Reinstall the Motor Drive Control cover. Check thatthe system operates properly.

16

WINTERIZING THE SYSTEMIMPORTANT: Always perform all the above pre-ventive maintenance procedures before storingthe System 10000 at the end of the season.

1. Evacuate the tanks by pumping the fluids out throughthe circulate lines into appropriate containers.

NOTE: Park the vehicle with its front end uphill, toevacuate the most fluid and to minimize the amountof RV antifreeze needed.

2. Pour enough nontoxic (RV) antifreeze into the 250-gallon tank to allow circulating the fluids.

3. Pump a few gallons of the fluid from the 250-gallontank into the 20-gallon tank, and circulate.

4. Evacuate the fluid from the hose by starting a job onthe Pendant and pumping fluid from the tanks into a5-gallon bucket until the fluid is pumped out com-pletely.

5. Evacuate both the 20-gallon and 250-gallon tank bypumping the fluid into a collection tank.

NOTE: After extended storage, the system will haveto be run up to two hours before it will achieve fullperformance.

Annual Preventive Maintenance

17

Annual Preventive MaintenanceLUBRICANTS AND CLEANERSThroughout the Annual Preventive Maintenance Section,various types of lubricants and cleaners to be used areindicated in bold type. Refer to the chart below for ex-amples of high-quality lubricants and cleaners suitable formaintaining the System 10000.

epyTtnacirbuL stcudorPfoselpmaxE sesU;deriuqeRsetubirttA

erusserP-hgiHtnacirbuL

tnacirbuLerusserP-hgiH0002#peZ248ecroFSPL

stsiserdnasecafrusotserehdatahttnacirbulgnitsal-gnol,raelCro,noitarbiv,erusserpemertxerednutuo-ezeeuqsdnaffo-worht

03–foegnarerutarepmeT.tcapmidetaeper o 006otF o esU.Fno stekcorpsdna,tfahsrotom,niahcleer .

tnacirbuLgnitarteneP tnacirbuLgnitartenePCN54peZtnacirbuLnolfeTmungaMSPL

tahttnacirbuldetanirolhcnon,gnitsal-gnol,gnitartenepyldipaRnoesU.tsurdnanoisorrocdraterotgnitaocevitcetorpasevael llaleer,skcolrood,segnihsahcus,secafrusdnastrapgnivom

sgulplacirtceledna,smra .

evitcetorPmreT-gnoLgnitaoC

gnitaoCdalCnorIpeZtaoCdraHSPL

-flessitahtmlifevitcetorpekilxaw,tnerapsnartamrofotseirDrofnoitcetorpnoisorrocmret-gnolsedivorP.elbadlewdnagnilaeh.sroodtuodnasroodnihtob,secafruslatemsuorrefnondnasuorref

,fasro,leep,kcarctonlliW.erutsiomsecalpsiddnasetacirbuL04–foegnarerutarepmetasahdna o 005otF o ,norinoesU.F

ehtsahcus,secafrusdetniapdna,munimula,ssarb,reppoc,leetsdetniaprodetalprehtolladna,erawdrahrood,srotom

secafrus .

esaerGtnatsiseR-retaW tnatsiseR-retaWmuihtiLpeZesaerG

esoprupitluMxelpamrehTSPLesaerG

enelyhteylopdnaesaergmuihtilgninibmocesaergtnatsiser-retaWsaH.sevitiddaerusserp-emertxedna,srotibihninoitadixo,remylop

0foegnarerutarepmeta o 052otF o stsiserdnalatemotsgnilC.FesU.snoitidnocgnitarepotewerevesrednunoisorrocdnagnitsur

no sahcustcatnoclatemfosaerarehtodnasleviwsleeresohsehctalkcol .

esaerGcirtceleiD esaerGcirtceleiD777-001#rennaW)tnelaviuqeero(xetanyD,.E.G

evitisnesfotuoerutsiomspeekdnanoisorroctneverpspleH04–foegnarerutarepmetasaH.snoitcennoclacirtcele o otF

004 o ehtnoesU.F ehtneewtebsrotcennoclacirtcele,srotcennocdnaslanimretrotom,eludomehtdnarellortnoc

cte,slanimretyrettab .

epyTrenaelC stcudorPfoselpmaxE sesU;deriuqeRsetubirttA

tcatnoClacirtcelErenaelC

tcatnoClacirtcelEII-celEpeZrenaelC

renaelCtcatnoC0264SPL

.straplacirtcelenoisicerpmorftnildna,trid,lio,esaergsevomeR,efaS.eudiserfoeerfecafrussevaeldnaylkciuqsetaropavE

000,23fohtgnertscirtceleidhtiw,evisorrocnondna,elbammalfnonnoesU.stlov cte,sehctiwslacirtcele,stnenopmocrellortnoc .

renaelCecafruS-llA renaelCecafruS-llAlosoreA04peZrenaelCecafruSnaelC-VSPL

-woL.liosdna,skramregnif,sraemsecafrus,esaergsevlossiD.smelborpgnikaertsrehtaew-dlocsetanimilealumroferutarepmet

noesU ,ssalgrebifgnidulcni,00001metsySehtnosecafrusllaslaceddna,strapcitsalpdna,rebbur,leetssselniats .

epyTrelliF stcudorPfoselpmaxE sesU;deriuqeRsetubirttA

tnatsiseR-erutsioMrelliF

kluaC-tsaFpeZ)tnelaviuqero(.E.G

tahtdnuopmocgnilaesdnagnikluacrebburenocilisetihwA,cimarec,nialecrop,latem,sdoowylionon,ssalgotserehda

noesU.rebburdna,citsalp,secafrusdetniap tahtaerarehtoynatnalaesfoorp-erutsiomaseriuqer .

18

ServiceSERVICING THE PUMPSRefer to the Service Manuals for the individual pumps.

TOOLS NEEDEDFOR TROUBLESHOOTING

• Small flashlight

• Volt-Ohmmeter• 1/4” and 5/16” nut drivers

• Adjustable wrenches

• Wire cutter / stripper

• Crimping tool

• Screwdrivers (flat and Phillips)• Combination and socket wrench set

• Channel-lock pliers (large and small)

• Utility knife

• Allen wrench set (U.S. and metric)

GENERAL INFORMATIONIf you have a low-pressure condition, the first thing to do isto isolate the source of the problem — whether it is fromair leaks in the pump suction lines, leaky output lines, lowcontrol power, or the pump itself. If you know that theproblem is from air leaks in the suction lines, fix the leaksbefore proceeding.

If the H2O Pump Won’t PrimeIf you are unable to prime the H

2O pump, a major air leak

has probably caused a “bubble” to become entrenched inthe pump chamber. The pump must run at high speed to“drag” this air bubble out:

1. Run the H2O pump in circulate mode with the ball

valve wide open, for at least 10 minutes.

2. If this doesn’t clear up the problem, remove pumphose #2 where it goes into the check valve. Circu-late the H

2O, dumping it through hose #2 to the ground

or a bucket.

3. If the pump still doesn’t prime, remove pump inlet hose#1 and insert a water hose inside hose #1. Squeezethe hose closed and force-feed the fluid through theline toward the pump while the pump is running.

4. If the pump still doesn’t prime, refer to the Pump Ser-vice Manual for maintenance procedures.

MOTOR DRIVE CONTROLIMPORTANT: The Motor Drive Control (shown on page19) is not field-serviceable. It is designed for replace-ment only, after you use the diagnostic indicator lights

to determine the fault. Return the complete Motor DriveControl to Wanner Engineering for determination ofwarranty and for repair.IMPORTANT: Keep the terminal screws on the driveboard tight.

Operation Indicators (green)Each primary circuit in the system has associated greenindicator lights that are useful when troubleshooting.

NOTE: LB = logic board; DB = drive board.

H2O PUMP (Main)

LB-L3 lights when the H2O pump motor is sent a com-

mand to turn on.

DB-L5 lights when the pump motor actually turns on.LB-L4 lights whenever the H

2O system is in current-limit-

ing mode. This will always be true when you are not spray-ing. When in this mode, checking the current with a con-ventional ammeter will not give accurate readings. Checkthe current in this circuit only when L4 is dim or off.

CHEMICAL PUMP

LB-L5 lights when the dual-line motor is sent a commandto turn on.

DB-L3 lights when the dual-line pump motor actually turnson. Its brightness varies with the output drive voltage.

AGITATOR

An agitator is not used on this system.

REEL

LB-L1 lights when the reel motor is sent a command toturn on.

DB-L1 lights when the reel motor actually turns on.

Adjusters on PC BoardRefer to page 19 for location of the following adjusters.Consult the factory before you change the setting of anadjuster.

LOW-BATTERY ADJUSTER RSV1 (LO-BAT ADJ)

CAUTION: If the voltage is set too low, the bat-tery will drain too far and will not start the en-gine.

The Motor Drive Control is factory-set to shut off the sys-tem, and to turn on the LOW BATTERY indicator on thePendant, when the battery voltage drops to 10.5 Volts.

Potentiometer RSV1 changes the voltage point at whichthe system is shut off. Its setting should be changed onlyif the Motor Drive Control is shutting off the system at toohigh a voltage point.IMPORTANT: This is an Electronic Technician task.Turn the adjuster clockwise to select a lower voltagepoint at which the system shuts down.

19

Service

MOTOR DRIVE CONTROL

LogicBoard

DriveBoard

20

NOTE: The Pendant will not power up again until the bat-tery voltage rises to 13.5 Volts.

H2O CURRENT LIMIT ADJUSTER RSV3 (CURRENT LIMIT)

Potentiometer RSV3 is set at the factory and should notbe changed unless directed by a factory technician.IMPORTANT: This is an Electronic Technician task.Before adjusting, be sure there is no air in the system.With a Diagnostic Orifice Kit installed in-line with the H

2O

Circulate quick-disconnect (to provide a known load), cir-culate H

2O for a few minutes to warm up the motor and

pump. Set RSV3 to get a steady 70 psi on the H2O outlet

gauge. The pressure should be less than 120 psi whenthe H

2O Circulate valve is slowly closed. This pressure

should also exist for open spraying and corresponds to 30amps.

WARNING: To avoid injury from a burstinghose, never set the pressure higher than 120psi.

H2O MIX PULSE WIDTH ADJUSTER RSV4 (SPEED) (H2OPWM)

Potentiometer RSV4 is set at the factory and should notbe changed unless directed by a factory technician.

This potentiometer should be turned fully counterclockwise.It is a 25-turn pot with no stop: check gauge pressuresafter adjusting. Also, the shorting cap should be installedover the “MAIN FULL SPEED” position.

SYSTEM INTERLOCKSThe following interlocks are included to ensure that theMotor Drive Control doesn’t receive power when it is inap-propriate for the system to operate.

If desired, these interlocks can be bypassed by jumperingthe corresponding terminals on the Motor Drive Controlterminal strips, as instructed below.

IGNITION InterlockThis interlock applies +12 VDC to the terminal strip andallows the Motor Drive Control to operate only when thedash power switch is ON.To bypass the interlock, set the power switch to INT PWR.

TRANS InterlockThis interlock applies ground to the TRANS– terminal stripand allows the Motor Drive Control to operate only whenthe truck’s transmission is in park or neutral.

NOTE: Optionally, the system can be set up so this inter-lock allows the Motor Drive Control to operate only whenthe emergency brake is on.To bypass the interlock, install a jumper across terminalsTRANS + and TRANS –.

ServicePRESSURE, FLOWADJUSTMENTSTo check out the system and assure that it is operatingproperly, or if you suspect that a problem exists, make thefollowing tests and adjustments.

H2O Pump1. Adjust the Pendant to circulate H

2O (page 7).

2. Adjust the circulate H2O ball valve to cause pressure

to go above 80 psi. The gauge should then alternatebetween 80 and 90 psi.

3. Open the valve to make the pressure 70 psi. Thegauge should be steady. If not, go on to step 4.

4. Allow the H2O pump to run long enough to fully prime

and get rid of any air. Check for leaks and air bubblesin the suction lines, by shining a small flashlightthrough the translucent fittings while the pump is run-ning. If there are air leaks, you will see bubbles.

5. The H2O pump outlet pressure gauge (page 6) should

read 70 psi ±5, and the indicators LB-L4 and DB-L5should be on.

6. Shut off flow with the ball valve. The gauge shouldslowly alternate between 80 and 100 psi.

Chemical Pump1. Adjust the Pendant to circulate Chemical (page 7).2. Adjust the ball valve to cause the chemical to go above

90 psi. At this point, it should turn the fluid fully offand drop to 80 psi, at which time the fluid should turnback on.

3. Indicators LB-L5 and DB-L3 on the Motor Drive Con-trol should be on.

ELECTRICAL CONTINUITYCHECK1. Set the power switch on the Motor Drive Control to OFF.

2. Disconnect the harness wires from terminals TS1through TS8 of the main terminal strip on the MotorDrive Control.

3. Using a DC ohmmeter, check for the following mea-surements:

• All wires to truck ground: open

• Wire 1 to 4: less than 10 ohms• Wire 1 to 8: closed when reel switch is pushed;

open otherwise

• Wire 2 to 3: less than 10 ohms

• Wire 5 to 6: less than 10 ohms

4. If all measurements in step 3 are correct, the connec-tions are proper. Reattach the wires to terminals TS1through TS8 on the Motor Drive Control terminal strip.

21

Service

ELECTRICAL CONNECTIONSIn a corrosive fluids environment, electrical connections are the most likely suspect if a fault occurs. To minimizesuch problems, keep them tight and lubricated with dielectric grease. If any contacts are charred to such a degreeas to make the control unusable, contact Wanner Customer Service for exchange directions.

RADIO TRANSMITTER ANDRECEIVER (Fluid Counter)

ReplacementThe radio transmitter or the radio receiver can be replacedwith a new one without any changes to the system. Referto the “Replacement Parts” section of the manual.

Changing FrequenciesThe radio transmitter and receiver both have adjustablefrequencies. They must be set to the same frequency totransmit and receive a signal. The system is shipped fromthe factory as a matched pair. The procedure below de-scribes how to change the frequency of the two devices ifdesired. There is no need to change the frequency, evenwhen replacing one or both of the devices, as all systemsare set to the same frequency.

To change the radio receiver frequency:1. Remove the screws on the back of the radio receiver,

and take the rear cover off.2. Adjust the switch to the desired settings. Refer to the

illustration above.

3. Take the cargo light off the cab exterior, and removethe radio transmitter from it.

4. Remove the screws on the rear cover of the transmit-ter, and remove the cover.

5. Adjust the switch to the same settings as on the radioreceiver.

6. Test before reassembly.7. Reassemble in reverse order of the above.

BATTERY RECHARGINGThere are two common styles of batteries manufacturedfor vehicles today:

• “Flooded” Battery. This is the more common type. Ithas submerged lead plates filled with electrolytic fluid.

• “Valve-Regulated” Battery. This type is less com-mon. It has electrolytic gel inside, it weighs less, andwhen shaken it feels solid (without the liquid sound ofa flooded battery).

Battery Charger SettingAt the time this manual was published, all Ford F350 pickuptrucks had been shipped with the conventional lead-plate(flooded) battery.

IMPORTANT: When recharging the battery, the chargermust be set to the correct setting for the type of batterythat is being used.

If you have any question about what type of battery is in-stalled in your vehicle, call your local Ford dealer.

22

TroubleshootingWARNING: Toxic fluid hazard! Hazardous flu-ids or toxic fumes can cause serious injury ordeath if splashed into the eyes or onto the skin,or if swallowed or inhaled. Know the specifichazards of the fluid you are using. Read thefluid manufacturer’s warnings. Store hazard-ous fluid in an approved container. Dispose ofhazardous fluid according to local, state, andnational guidelines. Wear appropriate protec-tive clothing, gloves, eyewear, and respiratorwhenever handling hazardous fluids.

PENDANT-DISPLAYED ERRORCODESNOTE: Refer also to the troubleshooting chart on page25.

ErrCPError Code ErrCP means “the Pendant is not gettingChemical pump pulses when it should be.”

NOTE: Operating the hose reel (reeling in the hose) whilethe Pendant’s OPERATE switch is ON can cause an ErrCPcode. Make sure the OPERATE switch is OFF beforereeling in the hose.

• Check the chemical type that is being used. If theratio is 1:1, this will default to Error Code ErrCP.

• Make sure the system is synchronized within a 10%value (see the synchronization procedures on page 11).

CABLE OR WIRING FAILURE

Check for loose, shorted, or corroded wiring at:

• The connector labeled 045 on the Fluid Control Panel(wires to the motor encoder).

• The motor wire leads at the connectors labeled 2 and3 (black and red wires on the small pump motor).

• The following wires on the Motor Drive Control (101-787) terminal strip pins #2 and #3 (black and red wirerespectively), and Junction Connector Interface Board(101-789) (violet, yellow, and red/yellow wires).

CHEMICAL PUMP MOTOR ENCODER FAILURE

• While running chemical in circulate mode, watch forthe Pendant CHEM FLOW indicator to blink.

• Check that the motor and pump are actually running.

NOTE: The encoder is not field-repairable. This fail-ure will require the pump motor to be replaced, sincethe encoder is built into the motor.

CHEMICAL PUMP MOTOR FAILURE

• If the motor is not coming on at all, it may have failed.• Measure that 12 VDC is getting to the motor wires 2

and 3. If not, apply 12 VDC directly to these lead wires.

• If the motor still doesn’t run, replace the motor.

MOTOR DRIVE CONTROL FAILURE

• The Motor Drive Control indicator labeled L3 is lit ifpower is being sent to the motor. If the logic boardindicator L5 is not lit, the Pendant is not telling thecontrol to turn on. If the logic board indicator L5 is lit,but the drive board indicator L3 is not, the output isnot turning on.

• The Pendant POWER ON indicator must be lit.• With an ohmmeter, check cable number 101-750 and

101-792.

• Check for 12 to 16 VDC at terminal strip pins 2 and3.

• Replace the Motor Drive Control only if all the aboveitems have been verified. Wanner Engineering rec-ommends using a Pendant Bypass Kit to ensure thatthe Pendant is not the problem.

ErrHPError Code ErrHP means “the Pendant is not getting H

2O

pump pulses when it should be.”

NOTE: Operating the hose reel (reeling in the hose) whilethe Pendant’s OPERATE switch is ON can cause an ErrHPcode. Make sure the OPERATE switch is OFF beforereeling in the hose.

CABLE OR WIRING FAILURE

Check for loose, shorted, or corroded wiring at:

• The connector labeled 189 on the Fluid Control Panelthat goes to the motor sensor.

• The motor wire leads at the H2O pump motor labeled

5 and 6 (black and red wires on the large pump mo-tor)

• The Motor Drive Control (101-787) terminal strip pins#5 and #6, and the Junction Connector InterfaceBoard (101-789) tan, pink, and gray wires.

H2O PUMP MOTOR SENSOR FAILURE

• While running water in circulation mode, watch forthe Pendant H2O FLOW indicator to light, If it doesn’t:

– Check that the motor and pump are pumping fluid(see the circulation procedures on page 7).

– With power on, but motor power disabled by re-moving wire 6, remove the pulley guard and turn thepulley. Verify that the proximity sensor (102-189) in-dicator lights each time a pulley tooth passes. Ad-just the distance between the front of the sensor andthe pulley tooth. The distance between the two shouldbe .015 to .020 inches (use a feeler gauge). If theindicator still doesn’t light, replace the sensor andreconnect wire 6.

23

TroubleshootingH2O PUMP MOTOR FAILURE

• Check the belt between the motor and the pump, tosee if it has broken or is slipping.

• If you still do not hear the motor coming on at all,measure that 12 VDC is getting to motor wires 5 and6. If not, apply 12 VDC directly to these leads.

• If the motor still doesn’t run, replace the motor.

MOTOR DRIVE CONTROL FAILURE

• The Motor Drive Control indicator labeled L5 is lit ifpower is being sent to the motor. Also, the yellowindicator labeled MAIN CURRENT LIMIT may be flick-ering. If the logic board indicator L3 is not lit, thePendant is not telling the control to turn on. If thelogic board indicator L3 is lit, but not the drive boardindicator L5, the output is not turning on.

• The Pendant POWER ON indicator must be lit, andthe OPERATE switch must be ON and lit.

• With an ohmmeter, check cable number 101-750 and101-792.

• Check for 12 to 16 VDC at terminal strip pins #5 and#6.

• Replace the Motor Drive Control only if all the abovehave been verified. Wanner recommends using aPendant Bypass Kit to ensure that the Pendant is notthe problem.

ErrCFError Code ErrCF means “the Pendant is not getting thechemical pump flow signal when it should be.”

TANK OR SUPPLY PROBLEM

• Check that the chemical tank has at least 2 gallons init, and the outlet valve (at the bottom of the tank) isopen.

• Verify that the motor and pump are pumping fluid (seethe circulation procedures on page 7).

• Check that the filter isn’t plugged and that fluid is ac-tually flowing through, by using the synchronizationprocedure to collect fluid in the graduated beaker.

• If there is no fluid flow, the pump may need to bereprimed. While in circulation mode, open the bleedvalve (see below) on the front of the chemical pumpseveral turns until you notice air and fluid spitting out.

• Check for hose or tank leaks, or plumbing failures atthe chemical pump’s inlet and outlet lines.

CABLE OR WIRING FAILURE

Check for loose, shorted, or corroded wiring at:

• The connector labeled 188 on the Fluid Control Panelgoing to the flow sensor (102-059).

• The motor wire leads at the connector labeled 2 and3 (black and red wires on the small pump motor).

• The Motor Drive Control (101-787) terminal pins #2and #3, and check the Junction Connector InterfaceBoard (101-789) orange, blue, and brown wires (re-fer to the Wiring Diagram on pages 28 and 29).

CHEMICAL FLOW SENSOR (102-059) FAILURE

• While running in circulation mode, watch for the redLED at the bottom of the sensor to light each timethe fluid stops being pumped (whether in run or cir-culation mode). That is, a lit LED signifies there isno fluid flow; an LED not lit signifies there is fluidflow. If it doesn’t turn on and off while the pump isrunning, check the following items.

CHEMICAL PUMP MOTOR FAILURE

• Check that the motor and pump are pumping fluid(see the circulation procedures on page 7. If not,apply 12 VDC directly to lead wires 2 and 3 at themotor.

• If the motor runs, but the pump does not, the shaft orshaft key may be broken. If this is the case, the mo-tor will have to be replaced.

MOTOR DRIVE CONTROL FAILURE

• The Motor Drive Control indicator labeled L3 is lit ifpower is being sent to the motor. If the logic boardindicator L5 is not lit, the Pendant is not telling thecontrol to turn on. If the logic board indicator L5 is lit,but the drive board indicator L3 is not, the output isnot turning on.

• The Pendant POWER ON indicator must be lit.• With an ohmmeter, check cable number 101-750 and

101-792.

• Check for 12 to 16 VDC at terminal strip pins #2 and#3.

• Replace the Motor Drive Control only if all the aboveitems have been verified. Wanner recommends us-ing a Pendant Bypass Kit to ensure that the Pendantis not the problem.

ErrHFError Code ErrHF means “the Pendant is not getting theH

2O pump flow signal when it should be.”

TANK OR SUPPLY PROBLEM

• Check that the H2O tank has at least 50 gallons in it,

and the tank’s outlet ball valve is open.

24

LobatError Code Lobat means “the vehicle battery voltage istoo low.”

• Plug in the battery charger or start up the truck, tocharge the battery.

• If either of the above does not keep up, check for ashort or for excess current draw. Check also for a faultybattery charger or faulty vehicle charging system.

ErrSUError Code ErrSU means “the Pendant is completely mal-functioning.”

• Wiggle the Pendant cable connector to make sure itis fully seated and the connector screws are tight. Ifthis doesn’t solve the problem, replace the Pendant.

“POWER ON” LED IS NOT LITIf the POWER ON LED isn’t lit, the Pendant has lost power.

• Check or substitute the cable between the Pendantand the Junction Connector Interface Board.

• Check that the 3-amp fuse on the Motor Drive Con-trol (101-787) is not blown. The L6 LED will be lit if ithas blown.

• Check that the main 60-amp fuse under the hood isnot blown.

• Check for a Motor Drive Control failure. Look for anyindicators that should be lit.

• Check for Pendant failure by verifying if a substitutePendant works in place of the old one.

• If everything else checks out, check for a Motor DriveControl failure (see “ErrHP” above).

FLUID COUNTER STOPS“BEEPING”

• Make sure the fluid counter switch is ON before youtest it.

• Turn the Pendant OPERATE switch to ON, then toOFF, to test for a “beep” signal. The Pendant displaywill momentarily show “bEEP”.

• Check and replace the 9-Volt battery in the FluidCounter.

• Check the Radio Transmitter wires (red, green, andblack) going to the Junction Connector Interface Board.

• Check the wires going to the 9-Volt battery.• Check the wires going between the radio transmitter

and the antenna. Remove the cargo light for accessto the wires.

• If the above procedures don’t solve the problem, re-place the fluid counter. If that doesn’t solve the prob-lem, replace the radio transmitter.

• Check that the H2O gauge reads at least 20 psi, and

the pump is running smoothly in circulate mode (ifnot, then this error should appear). If necessary,use the H

2O circulate ball valve to control pressure

when circulating.

• Verify that the motor and pump are actually pumpingfluid (see the circulation procedures on page 7).

• Check that the filter isn’t plugged, and that fluid isactually flowing through, by using the synchroniza-tion procedure to collect fluid in the H

2O graduated

beaker.

• Check for a hose leak or plumbing failure in the H2Opump inlet and outlet lines.

CABLE OR WIRING FAILURE

Check for loose, shorted, or corroded wiring at:

• The connector labeled 185 on the Fluid Control Panelthat goes to the flow sensor (102-185).

• The motor wire leads labeled 5 and 6 (black and redwires on the large pump motor).

• The Motor Drive Control (101-787) terminal strip pins#5 and #6, and the Junction Connector InterfaceBoard (101-789) red and black wires.

H2O LOW-PRESSURE SENSOR (102-185) FAILURE

NOTE: Low flow is determined by sensing low pres-sure — 15 psi or below.

• Remove connector #185, and insert a jumper wire inthe end going to the cable. Run in circulate mode. Ifthe error disappears, the sensor is faulty — adjust orreplace it.

MOTOR DRIVE CONTROL FAILURE

• The Motor Drive Control indicator labeled L5 is lit ifpower is being sent to the motor. Also, the yellowindicator labeled MAIN CURRENT LIMIT may be flick-ering. If the logic board indicator L3 is not lit, thePendant is not telling the control to turn on. If thelogic board indicator L3 is lit, but not the drive boardindicator L5, the output is not turning on.

• The Pendant POWER ON indicator must be lit, andthe OPERATE switch must be ON and lit.

• With an ohmmeter, check cable number 101-750 and101-792.

• Check for 12 to 16 VDC at terminal strip pins #5 and#6.

• Replace the Motor Drive Control only if all the abovehave been verified. Wanner recommends using aPendant Bypass Kit to ensure that the Pendant isnot the problem.

Troubleshooting

25

PE

ND

AN

T D

ISP

LA

Y

OR

FA

ILU

RE

SY

MP

TO

M

MO

DE

H2O

In

let

or

Ou

tlet

Ho

se R

up

ture

H20 In

let

Ho

se w

ith

Air

Leakin

g in

H20 P

um

p is n

ot

Pri

med

H20 L

ow

-Pre

ssu

re S

wit

ch

Stu

ck O

PE

NO

ut

of

H20

H20 C

heck V

alv

e F

ailu

reH

20 E

nco

der

Sen

so

r F

ailu

reH

20 P

um

p S

top

sH

20 B

elt

Bre

aks

H20 M

oto

r F

ailu

reH

20 F

ilte

r h

as C

log

ged

Ch

em

ical L

ow

-Flo

w S

wit

ch

Stu

ck C

LO

SE

D

Ou

t o

f C

hem

ical

Ch

em

Ch

eck V

alv

e F

ailu

reC

HE

M E

nco

der

Sen

so

r F

ailu

reC

hem

Pu

mp

Sto

ps

Ch

em

Mo

tor

Failu

reC

hem

Filte

r h

as C

log

ged

Dri

ve C

on

tro

ller

Failu

reP

en

dan

t M

em

ory

Failu

re

Car

Batt

ery

Lo

w V

olt

ag

e -

11.0

Vo

lts

9V

Batt

ery

Failu

re

H20 H

igh

-Pre

ssu

re S

wit

ch

Stu

ck O

PE

NC

hem

Hig

h-P

ressu

re S

wit

ch

Stu

ck O

PE

N

Cab

le o

r W

irin

g F

ailu

reC

hem

ical In

let

Ho

se R

up

ture

sT

ruck F

use F

ailu

re

ErrCPRun X X X X X

Pulse Problem

Circ/Sync X X X X X

Run X X X X X X Pulse Problem

Circ/Sync X X X X X X

Run X X X X X Flow Problem

Circ/Sync X X X X X

Run X X X X Flow Problem

Circ/Sync X X X X

Run X Pendant Failure

Circ/Sync X

Run X Battery Problem

Circ/Sync X

Run X X Fluid Counter Problem

Circ/Sync ----* ----*

Run X X X***H20 Pump Problem

Circ/Sync X X X***

Run X X XPlumbing Problem

Circ/Sync ---- ---** X

Run X XH20 Relief Valve Problem

Circ/Sync X X

Run X***Chem Pump Problem

Circ/Sync X***

X X X

Power / Controller Problem

X XPower / Controller Problem

None of the System

Components Operates

X X

Power / Controller Problem

** Ball valve turned all the way off will break the pump & pressure gauge.

*** Failure symptoms will vary depending on the severity of the failure.

ErrCP

ErrHP

ErrSU

ErrHF

ErrCF

LowBat

Fluid Counter Receiver Stops

Beeping

Pulsating H20 Pressure Gauge

* The Fluid Counter Receiver will continuously beep if an error occurs during Circulation or Synchronization. If there is a failure in the wiring or the 9 Volt battery, the failure mode will not be identified by the Fluid Counter Receiver.

Overpressurized - Hose or Fitting

Breaks or Leaks

PENDANT DISPLAY IS

BLANK

Hose Reel Does Not Run

Pulsating Chem Pressure Gauge

H20 Relief Valve Stays Open

TROUBLESHOOTING CHART

Troubleshooting

26

PROBLEMS WITH PUMPS ANDREEL ASSEMBLY

H2O Pressure Gauge on Fluid Control Panelis Pulsating

NOTE: Refer to the plumbing schematic, pages 32and 33.

H2O PUMP IS NOT PRIMED

• If the pump is not fully primed, follow the circulationprocedures on page 7. Gradually close the CirculateH

2O ball valve to slowly increase pressure, until the

valve is fully closed. Then open the ball valve all theway. If the pump is still not primed, repeat the proce-dure several times as necessary.

NOTE: The pump is fully primed when it soundssmooth with no pulsations, and the pressure needleis steady.

• Check the H2O strainer to see if it is plugged.• Check for any obstructions at the inlet or outlet hoses.

Clean or remove any obstruction. Circulate the H2O

until the pump is fully primed.

H2O PUMP INLET PLUMBING LEAK

• Check all hoses and hose fittings. Replace any cutor worn hoses or fittings.

• Tighten any loose hose clamps, to ensure an airtight seal.

H2O TANK STRAINER CLOGGED

• Check the strainer screen, and clean or replace it.

H2O PRESSURE SWITCH NOT ADJUSTED

• Follow the circulation procedures on page 7, and closethe H

2O Circulation ball valve while still circulating.

The pump should turn off at 80 to 85 psi, although thepressure needle may drift a little higher. Wait a coupleminutes for the pressure needle to drop back down.See the pressure switch adjustments in the Mainte-nance Section. The H

2O pressure switch is set to

turn off at 85 psi and turn back on at 79 psi: if neces-sary, adjust to these values.

MOTOR DRIVE CONTROL CURRENT SETTING IS TOO HIGH

IMPORTANT: Only highly trained techniciansshould attempt this adjustment! (Also note thatthis is rarely the cause of the problem.)

• Excessive Motor Drive Control main current set RSV3can cause widely fluctuating pressure. Use a BypassOrifice Kit (and its instructions) to set a steady 75 psion the H2O pressure gauge.

H2O Pressure Gauge on Fluid Control PanelReads Too LowH2O PUMP FLUID SECTION NOT FULLY PRIMED

• If the pressure gauge is pulsating rapidly, circulateuntil it is steady.

AIR LEAK IN INLET PLUMBING

• Check for loose fittings or a damaged strainer gas-ket. The most common cause is air leaking through afaulty gasket.

MOTOR DRIVE CONTROL CURRENT SETTING IS TOO LOW

IMPORTANT: Only highly trained techniciansshould attempt this adjustment!

• Adjust the Motor Drive Control Main Current Set RSV3for a steady 70 psi on the H

2O pressure gauge, using

the Orifice Diagnostic Kit (and its instructions).

Low (or No) Chemical Pump PressureCHEMICAL PUMP FLUID SECTION NOT FULLY PRIMED

• Follow the circulation procedures on page 7. Circu-late chemical until the chemical pressure gaugeneedle has a slight bounce. The pump is fully primedwhen it sounds smooth with only slight pulsations(slight pulsation or bounce of the gauge needle isnormal, because the pump has one cylinder).

• Check all chemical pump hoses and fittings. Replaceany cut or worn hoses or fittings.

• Tighten any loose hose clamps to ensure an airtight seal.• Check the strainer screen, and clean or replace as

necessary.

• If the pump still doesn’t prime, loosen the bleed screw(see illustration on page 23) while the pump is run-ning in circulation mode. Allow the air to escape.When fluid starts to leak past the bleed screw, thepump chamber will be primed. Continue chemicalcirculation to ensure the pump is running smoothly.

CHEMICAL PUMP PRESSURE IS TOO HIGH

• Check the high-pressure switch wiring at the FluidControl Panel and at the Motor Drive Control.

• Check the chemical high-pressure switch:

– Attach an ohmmeter to the disconnected lead wires,and circulate the chemical.– Turn the chemical ball valve partially closed, untilthe pump periodically shuts off.

– The ohmmeter should read “open” below 90 psi and“closed” above 90 psi. If not, adjust or replace it.

NOTE: Do not exceed 120 psi while making this test.

Fluid is Leaking Out of the Chemical PumpWeep HoseCHEMICAL PUMP DIAPHRAGM FAILURE (if chemical is leak-ing out of the weep hose)

• The F-30 pump needs repair. Refer to the Pump Ser-vice Manual.

CHEMICAL PUMP O-RING FAILURE (if oil is leaking out ofthe weep hose)

• The F-30 pump needs repair. Refer to the Pump Ser-vice Manual.

Troubleshooting

27

TroubleshootingHose Reel Doesn’t RunCABLE OR WIRING FAILURE

• Check hose reel motor power wires #1 and #4 at themotor and the Motor Drive Control.

• Check hose reel switch wires #1 and #8 at the switch-box and at the Motor Drive Control.

NOTE: Substitute a jumper wire to act like the switchacross terminals #1 and #8 on the Motor Drive Con-trol.

MOTOR DRIVE CONTROL FAILURE

CAUTION: Make sure the hose and treating gunare secure before doing the following proce-dure.

• When the switch is pushed, or a jumper wire is used,both reel lights DB-L1 on the Motor Drive Control cir-cuit boards should light. If the one near terminal stripTS4 does not light, the board output has failed: re-place the Motor Drive Control.

• If the drive control light LB-L1 near the heat sink doesnot light, check the reel switch and its wiring.

HOSE REEL MOTOR FAILURE

• To verify that the hose reel motor has failed, connect12 VDC directly to the motor wire leads. If it doesn’toperate, the motor has failed. Refer to the Hose Reelinstructions for Part No. and source.

CHAIN BROKEN

• Refer to the Hose Reel instructions for Part No. andsource.

NOTHING IN THE SYSTEMOPERATES60-AMP MAIN SYSTEM FUSE BLOWN

• Check and replace the 60-amp fuse (under the hood).

3-AMP FUSE BLOWN

• Check and replace the 3-amp fuse going to the mainpower (“Pump Power”) switch.

CABLE OR WIRING FAILURE

• Check the main wire cables running to the 60-ampfuse. These wires run from the Motor Drive Controlthrough the cab floor, under the cab, and up to thefront of the truck’s main power fuse panel.

PUMP SYSTEM POWER SWITCH FAILURE

• Test the switch with an ohmmeter.

TROUBLESHOOTING THEMOTOR DRIVE CONTROL

IMPORTANT: Keep the terminal screws on the Mo-tor Drive Control tight.

NOTE: See also page 19.

60-AMP MAIN SYSTEM FUSE BLOWN

• A short exists! Check electrical continuity through thesystem (see “Electrical Continuity Check,” page 20).

• Check and replace the 60-amp fuse (under the hood).Operate the system, and watch the green indicatorson the Motor Drive Control.

A FUSE ON THE MOTOR DRIVE CONTROL IS BLOWN

• Check the red indicators to verify that a fuse hasblown. Replace the fuse.

• Check electrical continuity through the system. See“Electrical Continuity Check,” page 20.

• Operate the system, and watch the green indicatorson the Motor Drive Control.

• Follow the service procedures under “Motor DriveControl” on page 18.

• Install a clamp-on DC ammeter (e.g., an automotivebattery/starter meter), and check the current. Usethe “battery” section of the meter. Have the circula-tion fully turned on when making the following checks:

– The H2O current should be 30 amps DC ±5 on wires

#11 and #12 when the H2O pump only is on.

– The reel motor current should be 30 amps DC ±10on wires #11 and #12 when the reel only is running.

– The chemical motor current should be 7 amps DC±3 on wires #11 and #12 when the chemical pumponly is running at full speed in circulation mode.

• If the currents are not correct:– Check the voltages.

– Check all connections.

– Check or service the related motor and pump.

• If the pumps are not priming fully, or if air is in thelines, the currents will be low or erratic. To check forair in the lines, shine a flashlight through the plasticfittings at the tank selection valve outlets and watchfor air bubbles.

NOTE: Air in the system also shows up as vibrationof the pressure gauge needle.

28

Wiring Diagram

For a close-up of wiringto 102-052 Fluid Control,see page 30.

29

Wiring DiagramFor a close-up of wiring to 101-789 JunctionConnector Interface Board, see page 31.

30

Wiring DiagramClose-up of Wiring to102-052 Fluid Control

31

Wiring DiagramClose-up of Wiring to

101-789 Junction Connector Interface Board

32

Plumbing Schematic

33

Plumbing Schematic

34

Specifications

Power Requirements:Volts ..............................12 VDC min, 16 VDC maxAmps ........................... 60 DC max

Flow Rate:H

2O .............................. 3.0 GPM max

Chemical ...................... 0.3 GPM max

Working Pressure ............ 150 psi max

Working Temperature ...... 125o F max

Storage Temperature ....... 150o F maxWeight (dry), with tanks ... 1,000 lbs max

Weight (pump moduleand controls) .................... 350 lbs

Size (module) .................... 102 x 65 x 35 in.

Noise Level ....................... 82 decibels

Tank Capacities (actual):H2O tank ...................... 250 gallonsChemical tank .............. 20 gallons

Wetted Materials in System Components:AcetalBrassElgiloyEthylene propyleneFiberglassKydexNylonNeoprenePolyethylenePolypropylenePolyurethanePVCStainless steel 17-4Stainless steel 17-7Stainless steel 18-8Stainless steel 302Stainless steel 304Stainless steel 316Stainless steel 440CTeflonViton

Warranty

LIMITED WARRANTYWanner Engineering, Inc. extends to the original purchaser of equipment manufactured by it and bearing its name, alimited one-year warranty from the date of purchase against defects in material or workmanship, provided that theequipment is installed and operated in accordance with the recommendations and instructions of Wanner Engineering,Inc. Wanner Engineering, Inc. will repair or replace, at its option, defective parts without charge if such parts arereturned with transportation charges prepaid to Wanner Engineering, Inc., 1204 Chestnut Avenue, Minneapolis, Minne-sota 55403.

Wanner Engineering, Inc. does not warranty any parts that have been affected by freezing.

THIS WARRANTY DOES NOT COVER:

1. THE ELECTRIC MOTORS (IF ANY), WHICH ARE COVERED BY THE SEPARATE WARRANTIES OF THEMANUFACTURERS OF THESE COMPONENTS.

2. NORMAL WEAR AND/OR DAMAGE CAUSED BY OR RELATED TO ABRASION, CORROSION, ABUSE, NEG-LIGENCE, ACCIDENT, FAULTY INSTALLATION OR TAMPERING IN A MANNER WHICH IMPAIRS NORMAL OPERA-TION.

3. TRANSPORTATION COSTS.

THIS LIMITED WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES (EXPRESS OR IM-PLIED) INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PUR-POSE AND OF ANY NONCONTRACTUAL LIABILITIES INCLUDING PRODUCT LIABILITIES BASED ON NEGLI-GENCE OR STRICT LIABILITY. EVERY FORM OF LIABILITY FOR DIRECT, SPECIAL, INCIDENTAL OR CONSE-QUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED.

35

Replacement Parts

Where to Order PartsNOTE: Most parts listed on the following pages should beordered from Wanner Engineering:

• Contact Customer Service at Wanner Engineering, TEL.612-332-5681 OR FAX 612-332-6937.

Exception: Order parts for the topper (and its hardware),page 39, from Elmore Industries:

• Contact Elmore Industries at TEL. 1-507-943-3142 orFAX 507-943-3107.

IMPORTANTThe parts illustrations and listings on the followingpages cover most System 10000s as shipped from thefactory or with factory-authorized modifications.Questions? If you are in doubt about the correct PartNo. to order, contact Customer Service at Wanner En-gineering, TEL. 612-332-5681 or FAX 612-332-6937.

Serial No. You may be asked for the Serial No. ofyour unit. The Serial No. plate is located near the hosereel frame at the tailgate.

102-067 ELECTRICAL KIT

ITEM PART NO. DESCRIPTION QTY

1 101-750 CABLE, 9 PIN SUBMIN ........................ 1

2 101-787 CONTROL, MTR DRIVE, 8/10K ........... 1

3 101-788 CONTROL, PENDENT, 10K ................. 1

4 101-789 JUNCTION, INTERFACE .....................1

5 101-790 TRANSMITTER, RADIO.......................1

6 101-791 RECEIVER, RADIO ..............................1

7 101-792 CABLE, 25 PIN SUBMIN ...................... 1

10 102-137 DASH ON/OFF SWITCH ASSY ........... 1

11 145-031 HARNESS, POWER

(+FUSEHOLDER) ................................1

11.10 101-758 FUSEHOLDER .....................................1

11.11 102-183 FUSE, 50AMP, MAXI ............................1

12 100-772 WIRE TIES ......................................... 11

13 100-771 SCREW, SHMET ZP, .25.................... 10

15 100-777 GREASE, DIELECTRIC .......................1

Refer to Wiring Diagram, pages 28 and 29.

36

Replacement Parts102-038 SYSTEM

ITEM PART NO. DESCRIPTION QTY

1 102-046 MODULE, PUMP, METERING ............. 1

2 102-121 TANK, 250 GAL, COMPLETE ..............1

3 102-119 TANK, 20 GAL, COMPLETE ................1

7 102-141 TOPPER, FIBERGLAS.........................1

9 102-140 EXTENDER, TAILGATE .......................1

10 102-123 ORGANIZER, DR.SIDE........................ 1

11 102-124 ORGANIZER, PASS.SIDE ...................1

14 102-088 CHARGER, BATTERY .........................1

15 102-067 KIT, ELECTRICAL ................................1

16 102-136 KIT, INSTR MANUAL (complete) ..........1

16 102-156 MANUAL, SERVICE, D-10 ...................1

16 102-157 MANUAL, PARTS, D-10 .......................1

16 102-158 MANUAL, SERVICE, F-30 ...................1

16 102-159 MANUAL, PARTS, F-30 .......................1

18 102-128 GUIDE, HOSEREEL............................. 1

19 100-649 SCREW, TRUSS-HEAD, 1/4-20 ........... 4

21 102-162 LABEL, CIRC .......................................1

22 102-163 LABEL, RUN.........................................1

23 102-164 LABEL, RATIO...................................... 1

24 102-091 LABEL, LEVEL .....................................1

25 102-139 VELCRO, 1” X 1” ..................................1

NOTE: Refer to PlumbingSchematic, pages 32 and 33,for Item Nos.

37

Replacement Parts102-119 20-GALLON TANK SUBASSEMBLY

ITEM PART NO. DESCRIPTION QTY

1 102-072 BULKHEAD, 1/4FBE, BRS ...................1

2 102-102 O-RING, -210, VITON, 1/4 BULKHEAD.1

3 102-040 BULKHEAD, 3/8FBE, BRS ...................1

4 102-076 O-RING, -214, VITON,

3/8 BULKHEAD ....................................1

5 102-205 GROMMET, VITON ..............................1

6 102-093 GAGE, FLUID LEVEL...........................1

7 102-103 TUBE, .38OD .......................................1

8 102-094 ELB, .25MPTXHB ................................. 1

9 102-030 SOCKET, QD, .25MPT, .31 STUD ........ 1

10 102-203 ST EL, BRN, .38NPT MBE ...................1

11 102-053 VALVE, BALL, 2WAY, .38FBE, BRS .....1

12 100-833 BARB, .38MPTX.50HB .........................1

13 102-085 LOCKING GAS CAP ............................1

38

Replacement Parts102-121 250-GALLON TANK SUBASSEMBLY

ITEM PART NO. DESCRIPTION QTY

1 100-091 NIPPLE, .75X.50MBE, BRS ................. 1

2 102-091 LABEL, FLUID LEVEL .......................... 1

3 100-071 TUBING, CLEAR, .75ID .......................2

4 100-802 ELB, .75MNPT x .50IDT, NYL ..............1

5 100-050 ELB, .75MNPT x .75IDT, NYL ..............3

6 102-075 ELB, .75MXF, BRS ............................... 1

7 102-032 FILTER, .75FBE ...................................1

8 102-143 NIPPLE, .75MPT, BRS .........................1

9 102-044 VALVE, BALL, 2WAY, .75FPT, BRS...... 1

12 100-834 ELB, .38MPTX.50IDT, NYL .................. 1

14 100-038 CLAMP, HOSE .....................................3

15 102-070 NUT, SWIV, GARD HOSE .................... 1

16 102-064 ADAPTOR, GH SEAT X .50HB ............1

17 102-071 GASKET, SCREEN, GH SWIV ............. 1

18 102-074 VALVE, BALL, 2WAY, .75GHMXF ........ 1

21 102-090 FLOAT VALVE ASSY ............................1

22 100-050 ELB, .75MPTX.75IDT, NYL .................. 3

23 102-040 BULKHEAD, .38FPT, BRS ...................1

24 100-066 HOSE, BLACK, .50 ........................ 3 FT

25 100-124 CLAMP, HOSE .....................................4

26 100-048 BULKHEAD, 3/4FNPT .......................... 4

27 102-076 O-RING, -214, VITON,

3/8 BULKHEAD .................................... 1

28 SS757364000 COVER, 5”, BLK, NON-VENT ..............1

29 102-154 MUFFLER, EXH ...................................1

Strainer Assembly (102-032 Filter)50 102-144 GASKET, FILTER STRAINER, and

STRAINER, 40-MESH SCREEN ..........1

50

102-032 FILTER

39

Replacement Parts102-045 PUMPS MODULE

ITEM PART NO DESCRIPTION QTY

1 D10C6400002 D-10 PUMP ASSEMBLY ...................... 1

2 102-211 BRKT, D10; 8mm SENSOR MNTG ...... 1

3 100-908 MOTOR, 3/4 1800 RPM 12V PM-D10.. 1

4 100-909 PULLEY, D-10 ...................................... 1

5 100-910 PULLEY, 3/4HP ....................................1

6 100-911 BELT, D-10, cog ....................................1

8 100-503 BELT GUARD .......................................1

10 102-214 SCREW, FHSCS, .38-16X.87............... 4

11 100-944 WASHER, .375" SS Ext (PLATE

& MOTOR)............................................8

12 100-913 SCREW,3/8-16 X .75 LG SS HHS

(D-10 PUMP)) .......................................6

13 100-914 SCREW, 5/16-18X.75 SS HH

(MTR & MNTG PLT) ............................. 8

14 100-915 WASHER, .312 FLAT S.S..................... 4

17 F30C6400001 PUMP, F30 MECH, PLATE DIAPHR .... 1

18 102-208 MOTOR, MET, W/ENCODER, .05HP...1

19 100-916 SCREW, .250-20 X 3.00 LG SHCS ...... 3

20 100-064 WASHER, .250 SS FLAT...................... 3

23 100-930 SCREW, #10-32 X .62 LG SS HH .......4

24 100-544 O-RING, -225 .......................................1

25 D10-132-2200 BUSHING, BRS, 3/4X3/8 .....................1

26 D10-130-2200 BUSHING, BRS, 1"X3/4 .......................1

27 100-843 HOSE SAVER, .75MPT X .75IDT .........1

28 100-834 ELB, 3/8MPTX.50T ..............................1

29 D25-046-2111 O-RING, VITON, HOSESAVER

SWIVEL ................................................1

30 100-961 WASHER, EXT LOCK, .312 ................. 4

31 102-189 SENSOR, PROX, W/CONN ................. 1

— 100-975 SHAFT KEY, D10, .187 ........................ 2

— 100-976 SHAFT KEY, F30, .125 .........................1

For breakdown of D-10 Pump, refer

to Parts Manual 102-157 and

Service Manual 102-156.

For breakdown of F-30 Pump, refer

to Parts Manual 102-159 and

Service Manual 102-158.

40

Replacement Parts102-046 DISPENSE MODULE

51

100-010 FILTER

50

23

TEM PART NO. DESCRIPTION ................................................................... QTY

1 102-077 HEATER, ELECT, 120 VAC ..................................................... 1

4 102-096 HARNESS, CONTROL............................................................ 1

5 102-045 PUMPS, DUAL METERING, ASSY ......................................... 1

6 100-913 SCREW, .375-16 X0.75 LG. SS HH ...................................... 20

7 100-036 NUT, 3/8-16 SS NYLON LOCKING (REEL & PUMPS) ......... 20

8 100-037 WASHER, FLAT .................................................................... 20

9 102-209 REEL, HOSE, BARE, ELECT DRIVE (SEE REEL INSTR

SHEET FOR PARTS) .............................................................. 1

10 102-087 HOSE, 1/2", EVA ORA. .................................................. 300 FT

11 102-084 BARB, .50MPTX.50IDT, SST .................................................. 2

13 100-757 OPERATOR, REEL SWITCH .................................................. 1

16 100-695 NUT, HX NYLOK, .25-20, SS .................................................. 4

17 100-062 SCREW, HHCS, .25-20X.75, SS ............................................. 4

18 102-206 ELB, .50MX.50T, NYL.............................................................. 1

19 102-207 BUSHING, .50MX.38FPT, BRS ............................................... 1

20 100-010 FILTER, .50 FBE, NYL ............................................................ 1

22 102-052 FLUID CONTROL -SEE PAGE 42 .......................................... 1

23 100-124 CLAMP, HOSE, 13/16D .......................................................... 4

24 102-079 HOSE, BUNA RED, .50ID .................................................. 2 FT

26 102-201 NIPPLE, M GARD HOSE X .50IDT, BRS ................................ 1

27 100-070 HOSE, EPDM, .75ID .......................................................... 3 FT

28 100-038 CLAMP, HOSE, .75IDHOSE ................................................... 2

Strainer Assembly (100-010 Filter)50 100-139 GASKET, FILTER STRAINER ................................................. 1

51 100-121 STRAINER, 40-MESH SCREEN ............................................. 1

— 100-777 GREASE, SILICONE ..............................................................—

41

Replacement Parts102-052 FLUID CONTROL

ITEM PART NO. DESCRIPTION QTY

2 102-185 SWITCH, PRESSURE, 20 PSI ............. 1

3 100-066 HOSE, EPDM, BLK, .50ID............ 16 FT

5 102-078 VALVE, CHECK, .38FBE,BRS ............. 2

6 102-049 TEE, .38NPT, M.RUN, BRS..................1

7 102-048 MANIF, FLUID PANEL .......................... 2

8 102-047 VALVE, BALL, 3WAY, .38FX3............... 2

9 102-180 GAGE, FLUID .......................................2

10 102-059 SENSOR, FLOW, ASSY .......................1

11 102-173 VALVE, CHK, .38MPTX.50HB ..............2

12 102-203 ST EL, BRS, .38NPT MBE ...................1

13 100-834 ST EL, NYL, .38M X .50T .....................7

14 102-069 ST ELB, BRS, .25NPT.......................... 2

15 102-186 SWITCH, PRESSURE, 85 PSI ............. 1

16 102-187 SWITCH, PRESSURE, 90 PSI ............1

17 D25-038-2210 PLUG, BRS, .38NPT ............................1

18 102-202 BUSHING, BRS, .25X.125NPT ............2

19 100-648 TIEWRAP, NYLON ............................... 8

23 100-124 CLAMP, HOSE, .50IDT .......................16

24 102-079 HOSE, .50ID, BUNA, RED ................. 16

25 102-073 VALVE, BALL, 2WAY, .25FBE, BRS .....1

26 102-053 VALVE, BALL, 2WAY, .38FBE, BRS .....1

27 102-204 ST EL, NYL, .25MX.50IDT ...................1

28 102-086 PLUG, ORIF, .062", SST ...................... 1

29 102-017 PLUG, QD, .38MPT, .5 STUD ..............1

30 102-016 SOCKET, QD, .38MPT, .5 STUD ..........1

32 102-031 PLUG, QD, .25FPT, .31 STUD ............. 1

42

102-141 TOPPER ASSEMBLY

ITEM PART NO. DESCRIPTION QTY

1 SHELL, TOPPER ................................. 1

2 DOOR, DS ............................................1

3 DOOR. PS ............................................1

4 DOOR, RR............................................1

5 SEAL, EXTENSION, TAILGATE........... 1

6 LOCK COVER, CENTER .....................1

7 CABLE COVER, LEFT .........................2

8 CABLE COVER, RIGHT .......................2

9 PADDLE HANDLE, LEFT .....................1

10 PADDLE HANDLE, RIGHT...................1

11 ROTARY LATCH, LEFT........................ 2

12 ROTARY LATCH, RIGHT .....................2

13 CABLE ADAPTOR, LEFT .....................2

14 CABLE ADAPTOR, RIGHT .................. 2

15 CABLE ..................................................4

16 STRIKER “A” ........................................ 4

17 STRIKER “B” ........................................ 4

18 LOWER PROP MOUNT “D” ................. 3

19 LOWER PROP MOUND DS RR “C” .... 1

20 UPPER PROP MOUNT ........................ 4

21 PROP MOUNT STUD BALL ................. 4

22 PROP MOUNT ANGLE BALL ..............4

23 GAS PROP ...........................................4

24 REAR DOOR GASKET .................. 6 FT

25 MAIN DOOR GASKET .............. 20.5 FT

26 TAILGATE GASKET ....................... 6 FT

27 RR DOOR HINGES ..............................2

28 MAIN DOOR HINGES .......................... 6

29 RR DOOR LOCK ..................................1

30 CAM FOR REAR DOOR LOCK ........... 1

IMPORTANT!

Order all parts listed on this pagefrom Elmore Industries (see page 35),not from Wanner Engineering.

Order by Description, not by Part No.

Replacement Parts

43

44

©2004 Wanner Engineering, Inc. Printed in USA 10-04 Part No. 102-155 Rev. E