Rapid Spray FIRE MARSHAL Service manual

FIRE MARSHAL
OPERATORS HANDBOOK
Fire
Fighting
FIRE MARSHAL
FIRE MARSHAL PLUS
L / L

Compact Fire Fighters by Rapid Spray
Rapid Spray Fire Marshal Operators Handbook
CONTENTS
01 Introduction & Models
02 Warnings
03 Product Risk Assessment
04 Troubleshooting
05 Operation
05 Before Beginning Operation
05 Operation
06 Honda GX35 Engine
12 Kawashima Fire Pump
15 Cleaning & Maintenance
17 Fire Marshal Breakdowns & Spare Parts
18 Marshal Tank
19 Poly Fire Fighting Hose Reel
20 Warranty
23 Warranty Registration

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INTRODUCTION
Thank you for your purchase of a Rapid Spray Fire Marshal. The Fire Marshal 250 and
Fire Marshal 325 is an Australian Made compact fire fighter great for back burning, tree
watering, and stock water supply - all from the back of your UTV.
DISCLAIMER: In line with our policy of continuous improvement, the weights, dimensions and design may change slightly from what is shown in this
operators handbook.
*WARNING: Always obey vehicle and UTV/ATV manufacturer instructions regarding loading and operation. Please check weight restrictions. Serious
death or injury can occur from improper usage. Rapid Spray accepts no liability for the unsafe operation of this unit.
MODELS
Please note your unit may not have all the parts or accessories listed in this handbook.
This handbook covers the following models (including any custom variations):
Example Codes:
SF0200ALZ
SF0325LZ
Example Codes:
SF0200ALZH4
SF0325LZH4
FIRE MARSHAL FIRE MARSHAL PLUS

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WARNINGS
1. When mounting to any vehicle, ensure that you have read the Vehicle Owner’s Manual and
that you comply with all the weight restrictions as specified by the vehicle manufacturer,
as overloading can cause injury or death. Remember that one litre of water weighs one
kilogram. Ensure equipment is secure during transport.
2. To ensure your own safety and that of your employees or colleagues (if applicable) you must
comply with all relevant environmental, work place health and safety legislation and codes
of practice. In particular be aware of Rural Fire Service guidelines for safety when fighting
fires or backburning.
3. You must be in good mental health to operate this unit and not be under the influence of
alcohol or any drugs that could impair your vision, physical strength, dexterity, judgment or
other mental capacity.
4. Improper or careless use of this unit can cause serious injury. Minors should never be
allowed to use this unit. This unit should not be used when bystanders or animals are in the
area. This unit should never be used while children are in the area.
5. Before using, check the electrical and fuel systems for damage and deterioration. Replace
parts as necessary. Do not modify the equipment or use any attachments other than those
specified by the manufacturer.
6. Select and wear appropriate Personal Protective Equipment (PPE) in accordance with the
label of the product you intend on using and your own safe work practices.
7. Never leave the sprayer unattended without turning o the engine and relieving the line
pressure.
8. All operators must be trained in safe use of this unit.
9. Carry out maintenance as per the recommendations. Ensure that the unit is cool and
securely stabilised on a level surface before commencing maintenance.
Read all warnings below and obey any instruction stickers or warnings on the unit.
Failure to do so may result in serious bodily harm or death.

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PRODUCT RISK ASSESSMENT
TASK HAZARDS RISK CONTROL MEASURES
Partially fill the tank
with water, start the
motor and test the
fire fighting unit.
Manual handling;
slips, trips or falls;
petrol fumes; fingers
jammed
Medium Concentrate on tasks, follow safe manual
handling techniques: don’t li on your
own if > 20kg, bend knees, keep back
straight; keep fingers clear; keep unit at
least 8m away from overhead power-lines;
fire extinguisher nearby; follow warning
stickers on tanks; wear PPE for petrol and
fumes (mask and gloves)
Check weather and
ground conditions
and select the
appropriate PPE to
suit the chemicals to
be used.
Manual handling;
slips, trips or falls.
Low Put on PPE as per the chemical
requirements in the Material Safety Data
Sheet (MSDS) - coveralls, gloves and
respirator; follow safe manual handling
techniques: don’t li on your own if > 20kg,
bend knees and keep back straight
Mix chemicals (if
applicable) and fill
fire fighting unit
As above; spray dri,
chemical spillage,
emission of vapours
or flammability:
weather; untrained
visitors.
Medium As above; user trained in the state’s
chemical mixing and administration
course e.g. Chem Cert; follow the relevant
Environment Protection Authority
requirements, fire extinguisher present;
keep visitors away from the job unless
wearing full PPE
Use fire fighter unit As above; loss of
load; heat and cold;
noise; exceed load;
limit of vehicle; hose
entanglement;
exhaust fumes;
terrain and slopes;
run over by unit
High As above; wear clothes to suit heat and
cold; wear hearing protection if pump
noise > 85 dBa; follow manufacturer’s safe
operation instructions for the vehicle and
spray unit; don’t overload - water weighs
1kg per 1L; secure load to vehicle; hose tidy
Clean up,
maintenance and
storage
As above Low As above; continue to wear PPE for clean-
up, store unit in a dry, well ventilated area
Pump / Motor See pump / motor Operators Handbook

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TROUBLESHOOTING
CONDITION CAUSE REMEDY
Pump will not
prime / draw
water
1. Insuicient motor RPM
2. Air leak on suction plumbing
3. Blocked/ restricted intake
hose
4. Filter cap disengaged
5. Filter gasket damaged /
missing
1. Increase motor RPM until pump primes
2. Tighten/ replace fittings and hose
clamps. Verify suction hoses are in good
condition.
3. Remove blockage from suction line,
ensure line is not kinked.
4. Lock filter cap into position.
5. Replace filter gasket.
Pumps runs but
will not develop
pressure
1. Residue on pump valves
2. Worn regulator
1. Remove and clean pump valves
2. Install regulator service kit
Pressure drops
/ fluctuates
during standard
operation
1. Restriction on suction line
2. Pump sucking air
3. Plugged filter
4. Damaged regulator
1. Inspect tank and suction lines and
remove restriction
2. Tighten fittings
3. Remove and clean filter mesh and
housing
4. Remove regulator stem and inspect for
broken parts / pieces
Pressure gauge
not registering
1. Plugged with debris 1. Unthread, check and clean pressure
gauge
Oil in pump
or gearbox
appears white
and murky aer
operation
1. Water or chemical has
contaminated oil.
1. Check pump valves, seals and pump oil
breather cap. Replace / fix if needed.
2. Replace oil if needed.
Hand gun loses
pressure
1. Debris in hose or nozzle
2. Pump losing prime
3. Pump pressure dropping /
fluctuating
1. Unthread nozzle tip and clean
2. See ‘Remedy’ for ‘Pump will not prime’
3. See ‘Remedy’ for ‘Pressure drops /
fluctuates during standard operation’
Pump / Motor See pump / motor Operator’s Handbook

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OPERATION
BEFORE BEGINNING OPERATION
1. Check all hoses, connections and hose clamps to ensure that the unit has been
delivered to you without transportation loss or damage.
2. Before attempting any fire fighting with your new unit, operate it to familiarise yourself
with its features and capabilities and to ensure that your unit has arrived in a safe
working condition. Please contact your dealer immediately should anything appear to
have been damaged.
3. Load the unit onto the back of a vehicle and fasten the unit securely to the vehicle by
strapping or bolting it down. Ensure that the straps do not interfere with any hoses or
connections. Do not place the straps over the pump or engine. Keep hoses and straps
away from hot engine, exhaust and exhaust fumes.
4. Familiarise yourself with the MOTOR and PUMP instruction / operators handbook
(supplied with the unit) and ensure you follow all warnings and instructions contained
within.
WARNING! Motor is shipped without oil or fuel. Before operation, fill the motor with the
correct oil and fuel as advised in the MOTOR instruction / operators handbook.
OPERATION
1. Fill tank from appropriate water source. Open ball valve on suction hose at bottom
of tank. Start motor and allow to warm up. Bypass valve is fitted to top of pump and
should be adjusted to allow bypass for warm up period.
2. Unlock hose reel to allow hose to be pulled out. When using fire fighter adjust nozzle to
desired spray pattern.
3. Increase engine speed and adjust bypass to achieve desired flow rates. When job is
finished turn engine o, rewind hose onto reel and lock reel to prevent unwinding.
Close ball valve on suction hose.
4. Please note this unit is designed for fire fighting and washdown or tree watering use
and not for chemical spraying. Please consult the manufacturer for further information.
WARNING! Be sure the pump is filled with water before starting the engine as advised in the
PUMP instruction / operators handbook.

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You will also see other important messages that are preceded by the word NOTICE.
This word means:
Your safety and the safety of others are very important. We have provided important
safety messages in this manual and on the engine. Please read these messages carefully.
A safety message allerts you to potential hazards that could hurt you or others. Each
safety messages is preceded by a safety alert symbol and one of these three words:
DANGER, WARNING or CAUTION.
This signal words mean:
HONDA GX35 ENGINE
Please read the Honda®Owners Manual for full safety, operation, parts and
maintenance instructions. Always follow manufacturers directions.
SAFETY INFORMATION
• Understand the operation of all controls and learn how to stop the engine quickly
in case of emergency. Make sure the operator receives adequate instruction before
operating the equipment.
• Do not allow children to operate the engine. Keep children and pets away from the
area of operation.
• Your engine’s exhaust contains poisonous carbon monoxide. Do not run the engine
without adequate ventilation, and never run the engine indoors.
• The engine and exhaust become very hot during the operation. Keep the engine
atleast 1 meter (3 feet) away from buildings and other equipment during operation.
Keep flammable materials away, and do not place anything on the engine while it is
running.
SAFETY MESSAGES
DANGER
WARNING
CAUTION
You WILL be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow
instructions.
You CAN be HURT if you don’t follow instructions.
NOTICE
Your engine, other property, or the environment can be damaged if
you don’t follow instructions.

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HONDA GX35 ENGINE CONT.
COMPONENT & CONTROL LOCATIONS
WARNING LABEL
AIR CLEANER
PRIMING PUMP
FUEL FILLER CUP
FUEL TANK
TANK GUARD
(Applicable type)
RECOIL STARTER
STARTER GRIP
MUFFLER
(Inside the
top cover)
TOP COVER
SPARK PLUG
(Inside the
top cover)
OIL FILLER CAP/
DIPSTICK
ENGINE CONTROLS:
CHOKE LEVER
THROTTLE
LEVER THROTTLE
LEVER
ENGINE
SWITCH
GX/GX: Applicable Types
Centrifugal Clutch
The centrifugal clutch automatically engages and transmits power when engine speed
is increased above approximately GX35: 4,200 min-1(rpm). At idle speed, the clutch is
disengaged.
NOTICE: Do not run the engine without mounting it on equipment that includes the
centrifugal clutch drum and housing, or centrifugal force will cause the clutch shoes to
contact and damage the engine case.
FEATURES

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BEFORE OPERATION CHECKS
Is your engine ready to go?
For your safety, to ensure compliance with environmental regulations, and to maximize
the service life of your equipment, it is very important to take a few moments before you
operate the engine to check its condition. Be sure to take care of any problem you find, or
have your servicing dealer correct it, before you operate the engine.
HONDA GX35 ENGINE CONT.
WARNING
Improperly maintaining this engine, or failure to correct a problem before
operation can cause a malfunction in which you can be seriously hurt or killed.
Always perform a pre-operation inspection before each operation
and correct any problem.
Before beginning your pre-operation checks, be sure the engine is level and the engine
switch is in the OFF position.
Always check the following items before you start the engine:
Check the General Condition of the Engine
1. Look around and underneath the engine for signs of oil or gasoline leaks.
2. Remove any excessive dirt or debris, especially around the muler and recoil starter.
3. Look for signs of damage.
4. Check that all shields and covers are in place, and all nuts, bolts and screws are
tightened.
Check the Engine
1. Check the fuel level. Starting with a full tank will help eliminate or reduce operating
interruptions for refuelling.
2. Check the engine oil level. Running the engine with a low oil level can cause engine
damage.
3. Check the air filter elements. A dirty air filter element will restrict air flow to the
carburetor, reducing engine performance.
4. Check the equipment powered by this engine.
Review the instructions provided with the equipment powered by this engine for any
precautions and procedures that should be followed before engine startup.

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HONDA GX35 ENGINE CONT.
SAFE OPERATING PRECAUTIONS
Before operating the engine for the first time, please review the SAFETY INFORMATION
section and the BEFORE OPERATIONS CHECKS on previous cards.
For your safety, do not operate the engine in an enclosed area such as a garage. Your
engine’s exhaust contains poisonous carbon monoxide gas that can collect rapidly in an
enclosed area and cause illness or death.
Review the instructions provided with the equipment powered by this engine for any
safety precautions that should be observed with engine startup, shutdown or operation.
STARTING THE ENGINE
Refer to the instructions provided with the equipment for throttle lever and engine switch.
1. To start a cold engine, move the choke lever [1] to the CLOSED [A] position.
To restart a warm engine, leave the choke lever in the OPEN [B] position.
2. Press priming pump [2] several times until
the priming pump is filled with fuel. Even if
the priming pump is pressed too many times,
the extra fuel will return to the fuel tank. If
the priming pump is not pressed enough, the
engine may not start.
WARNING
Exhaust contains poisonous carbon monoxide gas that can build up to dangerous levels in closed
areas. Breathing carbon monoxide can cause unconsciousness or death.
Never run the engine in a closed or even partly closed area where people may be present.

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Hot Restart: If the engine is operated at higher ambient temperatures, then turned o
and allowed to sit for a short time, it may not restart on the first pull.
If necessary, use the following procedure:
STARTING THE ENGINE cont.
HONDA GX35 ENGINE CONT.
4. Pull the start grip [4] lightly until you feel resistance, then pull briskly in the direction
of the arrow [5]. Return the starter grip gently.
Notice: Do not allow the starter grip to snap back against the engine. Return it gently to
prevent damage to the starter.
5. If the choke lever was moved to the CLOSED [A] position to start the engine, gradually
move it to the OPEN [B] position as the engine warms up.
3. Turn the engine switch [3] to the ON (|) [A] position.

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IMPORTANT SAFETY PRECAUTION
Turn the engine switch to OFF position before performing the following procedure.
This will prevent the engine from starting and running at maximum speed when the
throttle is in the MAX speed position. If the engine starts with the throttle in th MAX speed
position, the equipment can move forward rapidly or the trimmer attachment can spin at
maximum speed. This mas result in personal injury.
1. Turn the engine siwtch to OFF [O] [B] position.
2. Move the choke lever to the OPEN position
3. Hold the throttle level [6] on the equipement in the MAX [B] position.
4. Pull the starter grip 3 to 5 times.
Follow the STARTING THE ENGINE procedure and start the engine with the choke lever in
the OPEN position.
HONDA GX35 ENGINE CONT.
STOPPING THE ENGINE
To stop the engine in an emergency, simply turn the engine switch to the OFF (O) position.
Under normal conditions, use the following procedure.
1. Move the throttle lever to the MIN ( ) [A] position.
2. Turn the engine switch to the OFF (O) position.
SETTING THE ENGINE SPEED
Position the throttle lever for desired engine speed.
STARTING THE ENGINE cont.

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KAWASHIMA FIRE PUMP
Please read the Pump Owners Manual for full safety, operation, parts and
maintenance instructions. Always follow manufacturers directions.
SAFETY INFORMATION
• Do not start the engine if the pump has no water.
• Place the pump on a firm and level surface to prevent the pump from overturning.
• Never pump flammable or corrosive liquids such as gasoline or acid.
• To avoid pump corrosion, never pump sea water, chemical medicinal liquids or
caustic liquids - such as used oil, wine or polluted water.
• To prevent fire hazards and to provide adequate ventilation, keep the pump at least 1
meter (3 feet) away from building wall and other equipment during operation.
• Do not place flammable objects close to the pump.
• Children and pets must be kept away from the area of operation to reduce a
possibility of burns from the hot engine components.
WATER HOSE INSTALLATION
1. Install the hose joints on the pump.
2. Connect the hoses on the joints with clamp.
NOTE. When installing the joint to the pump, be sure the gasket is in place. Ensure that the
hoses are securely installed or air lead will occur and water will not be drawn up.
CLAMP
CLAMP

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KAWASHIMA FIRE PUMP CONT.
WATER HOSE INSTALLATION CONT.
3. Connect the strainer on the inlet hose end.
WARNING! Be sure the strainer is installed or
pump damage will occur.
NOTE. Discharge port angle can be changed
to 3 dierent directions. Adjust to your
operating condition.
4. Submerge the suction hose strainer in the water
5. Remove self-suction plug and top up the pump with water. Make sure the water is at
pump casing upper level. Add water as necessary
UPPER LEVEL
WARNING! Be sure that the pump is filled up with water before starting the engine, else
mechanical seal damage will occur.

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KAWASHIMA FIRE PUMP CONT.
OPERATION - THROTTLE LEVER
Pump output is controlled by adjusting the throttle lever. At maximum throttle position,
the pump will deliver the highest output volume. Moving the throttle level toward the idle
position will decrease the output volume of the pump.
OPERATION - STOPPING ENGINE
1. Lower the throttle level fuly and cool the engine down for 1-2 minutes at low speed.
2. Press the stop button to stop the engine running.
T
H
L
T - Throttle Level
H - MAXIMUM
L - IDLE
STOP BUTTON
STOP BUTTON
NOTE. Stop the engine immediately in the event of an emergency.

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CLEANING & MAINTENANCE
Maintenance to pump and engine should be carried out regularly. Refer to pump and engine
handbooks for Maintenance Schedule.
PUMP MAINTENANCE
Check pump Operators Handbook for maintenance schedule and further instructions.
• Check to make sure that all screws are tightened and that no parts are missing.
• Check to make sure there are no loose connections on hoses, nozzle, or valves.
• Thoroughly clean the nozzle.
INSPECT THE ENGINE - All repairs to be carried out by certified Honda dealer.
Check engine Honda Owners Manual for maintenance schedule and further
instructions.
• Check to make sure there are no loose or missing screws in any part of the engine.
• Clean the air filter regularly - particularly if working in a dusty environment.
• Clean and adjust the spark plug as necessary.
• Clean the cooling fan, air intake opening and parts around the muler.
• Check the engine oil and change it as necessary.
• Inspect the fuel line filter, check for fuel leaks.
LONG TERM CLEANING & STORAGE
• When storing the unit, ensure that it is clean and dry and kept in a ventilated place where
it will not be subject to freezing temperatures. Frozen water may crack metal components
and void warranty.
• Completely drain any fuel from the tank and water from the pump. (Check pump
instruction manual)
• Wipe o water on the pump using dry cloth. Cover the pump and store indoors in a
storage area with low-humidity.
• If operating in areas where freezing occurs we recommend leaving anti-freeze in the
pump, regulator/bypass valve and handgun/nozzle while not being used to prevent
possibility of frost damage.

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CLEANING & MAINTENANCE cont.
ITEM FREQUENCY TASK
PUMP & GEARBOX Daily Perform visual inspection of pump: ensure screws
are tight and no parts are missing.
Daily Check oil level in sight gauge - top up if
necessary (see pump Operators Manual for oil
specifications).
As needed Replace pump and gearbox oil (see pump
Operators Manual for oil specifications.
ENGINE Daily Perform visual inspection of engine: ensure
screws are tight and no parts are missing.
Daily Check oil level on dip tube - top up if
necessary (see engine Operators Manual for oil
specifications).
Daily Inspect the fuel line and filter, check for leaks or
contamination.
Weekly Clean air filter in accordance with engine
manufacturers instructions (see engine tab).
As needed Replace engine oil (see engine tab for frequency
and oil specifications).
HOSE REEL Daily Check hose and fittings for leaks or excessive
movement. Replace damaged fittings and
clamps.
Every 6 months Swap hose reel end for end to spread wear and
increase hose lifespan.
GENERAL
FITTINGS
Daily Clean suction filter in warm soapy water using
filter brush.
Daily Check hose and fittings for leaks or excessive
movement. Replace damaged fittings and
clamps.
Daily
MAINTENANCE SCHEDULE
Maintenance of your fire fighting unit should be carried out regularly. See below table for
suggested guidelines in ensuring your unit stays at optimum performance.

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FIRE MARSHAL BREAKDOWN & PARTS
Please consult with your local Rapid Spray dealership or contact the Rapid Spray
service team on 1800 011 000 before replacing / altering parts.
Any unauthorized alteration, modification, attachments or repair to equipment may void
the warranty as oered on Rapid Spray product or other componentry.
Please read the Honda Engine Operators / Instruction Manual and Warranty Policy. All
repairs should be carried out by a licensed Honda dealer or maintenance shop, or by
any engine repair establishment or individual using parts that are “certified” to EPA
standards.
Attempting to repair your Honda engine may void the warranty if engine not correctly
repaired / altered.
Remember than an authorised Honda servicing dealer knows your engine best and is fully
equipped to maintain and repair it. To ensure the best quality and reliability, use only new
Honda Genuine parts or their equivalents for repair and replacement.

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MARSHAL TANK PARTS BREAKDOWN
1
# Part No. Qty Description
1 AMPTC00200ATT / 400BTT 1 200 / 400L Marshal Tank
2, 3, 4 ARLP250VSR 1 255mm Screw Lid
5 AMAXPM010BK 1 10L Rinse Tank (only Marshal Plus units)
6,7 CFNB20M 1 3/4 poly Drain Bun & Seal
8 CFVTB20M 1 3/4 20mm Bibcock (only Marshal Plus units)
250L MARSHAL TANK
910 (L) x 730 (W) x 620 (H)
325L MARSHAL TANK
1040 (L) x 880 (W) x 750 (H)
2
3
4
6
7
7
5