The Zap - Pack Trouble Shooting

Battery and Electrical

Battery draining prematurely:
Ensure the unit is fully charged before use. The charger supplied is an intelligent charger and will not overcharge the battery.

Sudden loss of flow:
Check battery level, all electrical connections, hose fittings, and confirm there is adequate product in the tank.

Pump Performance

Pump pulsing or losing pressure:
This typically indicates the tank has run empty and air has entered the system.

Priming:
The Zap-Pack pump is self-priming. No manual priming is required.

Pump running but no delivery:
Confirm the tank contains liquid. Inspect all fittings from tank to nozzle to ensure they are properly seated.

Weak flow despite full battery:
Check all fittings, verify nozzle size, and ensure the switches are set correctly (Variable OFF; Speed ON).

Pump running briefly after trigger release:
This is normal behaviour as the pressure switch resets.

Blockages & Nozzles

Suspected pump blockage:
Drain the tank and inspect the inline gauge filter.

Distinguishing pump faults from lance/nozzle faults:
Most issues originate from loose or incorrectly fitted connectors rather than the pump itself. Inspect all fittings first.

Fitting tightness:
Fittings must be hand-tight only.

Recommended nozzles:
Use Benz 6.5 or 10 tips for optimum performance.

Incorrect nozzle use:
May result in poor spray patterns, reduced flow, or excessive pump cycling.

Blocked nozzle:
Remove the nozzle and clear using a suitable fine metal object.

Chemical Use & Ratios

Crystallisation risk:
Lightning Cleanze can crystallise if left in the pump, emphasising the importance of rinsing after use. Bio Cleanze does not crystallise.

Incorrect ratios:
A common mistake is confusing the dilution rates of Lightning Cleanze and Bio Cleanze. Always refer to the product guidance.

Over-strength Lightning Cleanze:
May lead to crystallisation and premature pump failure.

Under-strength Bio Cleanze:
Will produce inconsistent or slow results.

Leaving chemicals in the tank:
Lightning Cleanze must not be left in the system. Bio Cleanze presents no issue, though rinsing remains good practice.

Capabilities

Lightning Cleanze compatibility:
The Zap-Pack can apply Lightning Cleanze at dilutions down to 4:1.

Bio Cleanze compatibility:
Capable of applying Bio Cleanze at dilutions down to 25:1.

Acid compatibility:
Suitable for light acids only.

Maximum application height:
Approximately 10 metres through a pole from ground level.

Maintenance & Storage

Pump longevity:
With correct rinsing, the pump will give long service.

Routine maintenance:
Rinse the unit thoroughly after each use.

Warranty conditions:
Failure to rinse the system after Lightning Cleanze use is the most common cause of warranty invalidation.

Winter storage:
Store the battery at approximately three-quarters charge in a cool, dry location.

If the unit stops mid-operation:
Check battery level, product level in tank, and all fittings in that order.

Common user error:
Filling from the top instead of the bottom, causing foaming and unnecessary downtime.

Release pressure when in storage. If using non drip couplings, release pressure when in storage.

The product must not be left or stored in areas where standing water is present.

Warranty

The Zap-Pack is covered by a 6-month warranty, subject to Benz Softwash terms and conditions.

Terms and conditions

The Zap-Pack has been designed and is warranted for use with Benz Softwash Lightning Cleanze & Bio Cleanze when used at the recommended dilution rates and in accordance with our operating instructions.
To maintain warranty coverage, the system must be thoroughly rinsed with clean water after each use. Failure to adequately flush the system may result in damage that is not covered under warranty.
This warranty does not cover damage caused by sodium hypochlorite at concentrations stronger than those recommended by Benz Softwash, nor does it cover damage resulting from the use of incompatible chemicals, misuse, neglect, or improper maintenance.