Parts & Maintenance Manual

Transcription

1 INCLUDES ITEMS Parts & Maintenance Manual Spraytek DS300 Sprayer Perkins Liquid Cooled Diesel Engine GB

2 1 Safety 1.1 Operating Safety Important Safety Notes Chemical Handling, Use and Storage Recommended Safety Equipment Work Area Safety Recommendations... 2 Standards and Publications 2.1 Standards and Publications Vehicle Identification Numbers 3.1 Vehicle Identification Number Engine Identification Numbers SDI Sprayer Tank Identification Numbers Specifications 4.1 Product Identification Engine vehicle Weights and Dimensions Accessories & Support Literature Adjustments 5.1 General Engine Access Front Cowl Access Access Panels Alternator Belt Sprayer Pump Belt Parking Brake Cable Torque Specification Maintenance.1 General Engine Engine Oil Engine Oil Change Power Steering Reservoir Cooling System Engine Overheat Procedure Air Filter Muffler and Exhaust Battery Jump Starting Table of Contents.12 Charging Battery Fuel Fuel System Tire Pressure Tire Removal and Installation Raising the vehicle Towing the Vehicle Hydraulic Brakes Differential Fluid Transmission Electrical System Dash Panel Headlight Replacement Tail Light Replacement Care and Cleaning Sprayer Cleaning Storage SDI Sprayer Maintenance 7.1 Spray System Components Control Valves System Dynamics Sprayer System Check Control Pressure Adjustment Boom Spray Tip Overlap Check Sprayer Tank additives calibration Measuring Ground Speed Nozzle Tip Size Determining Amount of Chemicals Required Adding water to tank Mixing Chemicals Troubleshooting 8.1 General Maintenance & Lubrication Charts 9.1 General Lubrication Chart Maintenance Charts Notes 11 Parts Catalog 11.1 Table Of Contents... 4 This manual is designed for the Maintenance and Adjustment of this equipment. Use the maintenance and adjustment instructions included in this manual and the operating instructions included in the Safety and Operation Manual to service the machine. The Safety and Operation Manual must be kept in the pouch on the back of the seat at all times for reference by the operator. Copyright 2005, Textron Inc. All rights reserved, including the right to reproduce this material or portions thereof in any form.

3 Suggested Stocking Guide To Keep your Equipment fully operational and productive, maintain a stock of the more commonly used maintenance items. We have included part numbers for additional support materials and training aids. A more complete listing of accessories and attachments can be found in the Specifications Section. Service Parts Qty. Part No. Description Qty. Part No. Description Engine Oil Filter Alternator-Power Steering Belt Engine Air Filter 0053 Sprayer Pump Belt Engine Fuel Filter 001 Safety and Operation Manual 002 Parts and Maintenance Manual To Order Parts 1. Write your full name and complete address on the order. 2. Explain where and how to make shipment. 3. Give product number, name and serial number that is stamped on the name plate or serial plate of your product. 4. Order by the quantity desired, the part number, paint code, and description of the part as given in the parts list. 5. Send or bring the order to an authorized Jacobsen Dealer.. Inspect all shipments on receipt. If any parts are damaged or missing, file a claim with the carrier before accepting. 7. Do not return material without a letter of explanation, listing the parts being returned. Transportation charges must be prepaid. Use of other than Jacobsen authorized parts will void the warranty. How To Use This Manual Abbreviations N/S - Not serviced seperately, can only be obtained by ordering main component or kit. AR -Variable quantity or measurement is required to obtain correct adjustment. Symbols such as, next to the item number, indicate that a note exists which contain additional information important in ordering that part. Indented Items Bulleted items indicate component parts that are included as part of an assembly or another component. These parts can be ordered separetely or as part of the main component. Item Part No. Qty Description Serial Numbers/Notes Mount, Valve Indicates a piece part Valve, Lift Includes Items 2 and Handle Serviced part included with Item 2 4 N/S 1 Seal Kit Non serviced part included with Item Screw, 1/4-20 x 2 Hex Head Indicates part painted Orange Screw, 1/4-20 x 2 Hex Head Indicates part painted Green 3

4 1 SAFETY 1 SAFETY 1.1 OPERATING SAFETY! WARNING EQUIPMENT OPERATED IMPROPERLY OR BY UNTRAINED PERSONNEL CAN BE DANGEROUS. Familiarize yourself with the location and proper use of all controls. Inexperienced operator s should receive instruction from someone familiar with the equipment before being allowed to operate the machine. 1. Safety is dependent upon the awareness, concern and prudence of those who operate or service the equipment. Never allow minors to operate any equipment. 2. It is your responsibility to read this manual and all publications associated with this equipment (Safety and operation manual, engine manual, accessories and attachments). If the operator can not read English it is the owner s responsibility to explain the material contained in this manual to them. 3. Learn the proper use of the machine, the location and purpose of all the controls and gauges before you operate the equipment. Working with unfamiliar equipment can lead to accidents. 4. Never allow anyone to operate or service the machine or its attachments without proper training and instructions; or while under the influence of alcohol or drugs. 5. Wear all the necessary protective clothing and personal safety devices to protect your head, eyes, ears hands and feet. Operate the machine only in daylight or in good artificial light.. Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by Jacobsen. 7. Stay alert for holes in the terrain and other hidden hazards. 8. Inspect the area where the equipment will be used. Pick up all the debris you can find before operating. Beware of overhead obstructions (low tree limbs, electrical wires, etc.) and also underground obstacles (sprinklers, pipes, tree roots, etc.) Enter a new area cautiously. Stay alert for hidden hazards. 12. Never disconnect or bypass any switch. 13. Do not change the engine governor setting or overspeed the engine 14. Carbon monoxide in the exhaust fumes can be fatal when inhaled. Never operate the engine without proper ventilation or in an enclosed area. 15. Fuel is highly flammable, handle with care. 1. Keep the engine clean. Allow the engine to cool before storing and always remove the ignition key. 17. Place transmission in neutral, depress clutch and engage parking brake before starting the engine (motor). Start the engine only when sitting in operator s seat, never while standing beside the unit. 18. Equipment must comply with the latest federal, state, and local requirements when driven or transported on public roads. Watch out for traffic when crossing or operating on or near roads. 19. Local regulations may restrict the age of the operator. 20. Operate the machine up and down the face of the slopes (vertically), not across the face (horizontally). 21. To prevent tipping or loss of control, do not start or stop suddenly on slopes. Reduce speed when making sharp turns. Use caution when changing directions. 22. Always use the seat belt when operating vehicles equipped with a ROPS. Never use a seat belt when operating vehicle without a ROPS. 23. Keep legs, arms and body inside the seating compartment while the vehicle is in motion. 9. Never allow anyone near the machine while in operation. The owner/operator can prevent and is responsible for injuries inflicted to themselves, to bystanders and damage to property. 10. Do not carry passengers. Keep bystanders and pets a safe distance away. 11. Never operate equipment that is not in perfect working order or is without decals, guards, shields or other protective devices securely fastened in place. 4

5 SAFETY IMPORTANT SAFETY NOTES! This safety alert symbol is used to alert you to potential hazards. DANGER - Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING - Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury. CAUTION - Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury and property damage. It may also be used to alert against unsafe practices. For pictoral clarity, some illustrations in this manual may show shields, guards or plates open or removed. Under no circumstances should this equipment be operated without these devices securely fastened in place By following all instructions in this manual, you will prolong the life of your machine and maintain its maximum efficiency. Adjustments and maintenance should always be performed by a qualified technician. If additional information or service is needed, contact your Authorized Jacobsen Dealer who is kept informed of the latest methods to service this equipment and can provide prompt and efficient service. Use of other than original or authorized Jacobsen parts and Accessories will void the warranty. 1.3 CHEMICAL HANDLING, USE AND STORAGE Chemicals are used in this sprayer and used in cleaning after use. A manufacturers MSDS (Material Safety Data Sheet) must be obtained from the chemical supplier for each chemical, and a copy kept near the area that the chemical is stored and used. Information listed on the MSDS are the chemical characteristics and hazards associated with its use. Special attention should be given to recommended safety equipment, first aid treatment for accidental inhalation, swallowing, absorption or injection and compatibility with other chemicals. All sprayer employees should know how to read a MSDS.! WARNING The Interlock system on this vehicle prevents the vehicle from starting unless the clutch pedal is depressed. NEVER operate vehicle unless the Interlock system is working.! WARNING 1. Before leaving the operator s position for any reason: a. Remove foot from accelerator pedal. b. Slow vehicle using service brake. c. Depress clutch and shift transmission to neutral. d. Engage parking brake. e. Stop engine and remove the ignition key. 2. Keep hands, feet, and clothing away from moving parts. Wait for all movement to stop before you clean, adjust or service the machine. 3. Keep the area of operation clear of all bystanders and pets. 4. Never carry passengers, unless a seat is provided for them. Use care when opening sprayer tank cover. Potentially dangerous chemical fumes may have accumulated inside tank. Chemicals and cleaning solutions may be flammable or produce flammable vapors. Do not smoke when working with chemicals. Never store chemicals near an open flame or spark which could ignite chemicals or chemical vapors. Never work with harmful chemicals alone. Always have a second person nearby in case of emergency. 5

6 1 SAFETY 1.4 RECOMMENDED SAFETY EQUIPMENT Special safety equipment is required to prevent accidental exposure to poisoning and should be worn at all times when working with chemicals. Contact your chemical supplier for proper material handling and compatibility. The following is strongly recommended, however other safety equipment may be required. Always refer to the chemical manufacturers MSDS (Material Safety Data Sheet), that is available for all chemicals for additional safety equipment that may be required. Mask / Respirator - Prevents inhalation of harmful fumes. Use an approved canister type with appropriate filter cartridges for chemical being used Spray Suit - Full coverage for arms, legs and body, free from rips or tears. PVC / Nylon Gloves - Protect hands and sleeve openings. Goggles - To cover eyes / glasses for better protection. Face Shield - To prevent accidental facial contact with chemicals. 1.5 WORK AREA SAFETY RECOMMENDATIONS Read this section carefully and thoroughly in order to become familiar with the proper safety techniques used when operating the sprayer. Be sure to obtain an operation demonstration from your Jacobsen dealer before attempting to operate this vehicle. The operator must be familiar with the function of all vehicle controls as well as the operating characteristics of the vehicle. This is best accomplished through careful application of proper operating procedures. The safety of the operator and bystanders depend on your good judgement in operating and maintaining this vehicle.! WARNING DO NOT operate this equipment until you have read the operators manual completely. Operators must be confident and sure of their skills before operating this unit. Only properly trained persons with proper safety equipment should be allowed to operate this vehicle. Use caution when operating on slopes, turning and braking. Avoid full throttle starts. The large liquid payload reacts differently during vehicle movement, than an equal sized dry load. This is heavy equipment that could cause serious injury or death to the operators and/or bystanders if used improperly or overturned. Never allow minors to operate the vehicle at any time. 1. It is recommended that all spray technicians obtain a CPA (Certified Pesticide Applicators) license or equivalent. Operators should request, read and follow all appropriate local, state and federal regulations pertaining to spraying equipment, chemical mixing and storage. Be informed, not a victim. 2. We recommend a run-off recovery or containment system for the mix and load area. if one is not available, be certain the run-off does not contaminate water supplies, public sewers or natural wet land areas. Check your local regulations for requirements in your area. 3. Do not allow non-sprayer personnel to enter the mix and load area. All mix and load operations should only be performed with proper safety equipment in place. Refer to the chemical manufacturers MSDS for required safety equipment, mixing and handling procedures. 4. Use an anti-backflow protection device on fill hoses and water source outlets, especially if using a public water system. An Air Gap Filler (anti-siphon) is available as an optional accessory for the Spraytek. 5. Never place fill hose into tank. This could contaminate the hose.. Keep hands, feet and other body parts away from moving components. Restrain loose clothing and use caution around moving parts. 7. Follow recommended safety and maintenance schedules for this equipment. Do not operate this equipment without safety devices in place or if the equipment is not working correctly. 8. Keeping proper records in regards to chemicals being used, batch size, time, date, areas treated, weather conditions and unusual occurrences can protect you and others should any problems occur after turf application has been made. 9. In case of an accident, injury or unprotected exposure, notify your supervisor immediately. If necessary, operator or supervisor should contact the poison control board, EPA, and / or local fire department to help with the situation.

7 STANDARDS AND PUBLICATIONS 2 2 PUBLICATIONS 2.1 STANDARDS AND PUBLICATIONS This product meets requirements of ANSI B5.8 and has been approved by the Factory Mutual Research Corporation to meet all Powered Industrial Truck portions (classification D or G) of the OSHA requirements (as stated in section ). Approved power trucks shall bear a label or some other identifying mark indicating approval by the testing laboratory. This product conforms to EC directives and amendment 89/392 & 91/38. Users, operators and service persons should be familiar with the following standards and publications: (The material may be obtained from the address shown) Factory Mutual Approval Standard: Class No s 7811 & 7813; Gasoline or Diesel Powered Trucks, Types G, GS, D or DS. Factory Mutual Research Corp Boston-Providence Highway Norwood, Massachusetts 0202 U.S.A. National Fire Protection Association: ANSI/NFPA #505; Powered Industrial Trucks Internal Combustion Engine Powered Industrial Trucks: ANSI/UL 558 American National Standards Institute, Inc Broadway New York, New York U.S.A. OR Underwriters Laboratories Inc. 333 Pfingsten Road Northbrook, Illinois 002 U.S.A. Flammable and Combustible Liquids Code: ANSI/NFPA 30 American National Standards Institute, Inc Broadway New York, New York U.S.A. OR National Fire Prevention Association Batterymarch Park Quincy, Massachusetts 0229 U.S.A. National Fire Prevention Association Batterymarch Park Quincy, Massachusetts 0229 U.S.A. Personal Burden Carriers: ANSI/ASME B5.8 American National Standards Institute, Inc Broadway New York, New York U.S.A. 7

8 3 VEHICLE IDENTIFICATION NUMBERS 3 IDENTIFICATION NUMBERS 3.1 VEHICLE IDENTIFICATION NUMBER The Vehicle Identification Number (VIN), consisting of the model number, date code and serial number are all printed on the Nameplate/Identification Decal attached to the cross member under the dash. The serial number is also stamped on the cross member. It is located to the left of the Nameplate/Identification Decal. NOTE: Reference to the Front, Rear, Left and Right sides of the vehicle are always determined by the operator s seated position. Record the Vehicle Identification information below for easy reference. Model Number: DS300 Date Code: Serial Number: GOLF, TURF & SPECIALTY PRODUCTS Augusta Georgia, USA MODEL DS300 DATE CODE M1903 LABEL # SERIAL # 75984G55 * * Lb/kg W Batt Nom Power Hp/kw This vehicle may be covered by one or more of the following U.S. patents: Figure 3A Always provide the Vehicle Identification Number of the unit when ordering replacement parts or requesting service information. Vehicle Identification Numbers must appear on all correspondence concerning this vehicle. 3.2 ENGINE IDENTIFICATION NUMBERS The Spraytek DS-300 is equipped with a Perkins 3 cylinder, diesel powered, liquid cooled, four cycle engine. The Engine Serial Number for the Perkins engine is stamped onto the engine block on the right side of the engine near the alternator. Record the Engine Serial Number below for easy reference. Engine Serial Number: Engine Serial No. Perkins Diesel Figure 3B 3.3 SDI SPRAYER TANK IDENTIFICATION NUMBERS The model number and serial number for the sprayer tank is stamped on a name plate located on the front of the sprayer frame, directly above the fuel tank. Record the Sprayer Identification information below for easy reference. Model Number: Serial Number: Sprayer Model and Serial No. 8 Figure 3C

9 SPECIFICATIONS 4 4 SPECIFICATIONS 4.1 PRODUCT IDENTIFICATION Spraytek DS 300 liquid cooled diesel engine, 4 speed manual transmission, 2 speed differential. Product EEC Sound Power Sound Pressure Level Operator Ear Vibration M/S 2 Arms Body db(a) 79.2 db(a) ENGINE Make...Perkins Model...403C.11 Horsepower hp (19.7 rpm Note: Actual sustained horsepower will likely be lower than listed in specifications due to operating limitations and environmental factors Displacement...9 cu. In. (1131 cc) Torque...49 ft. lbs. (7 200 rpm Fuel: Type...No. 2 Diesel Rating...Min. Cetane rating 45 Capacity...55 U.S. Gal. (24.5 liters) Governor...All Speed Mechanical Low Idle RPM High Idle RPM Lubrication: Capacity quarts (3.5 liters) Below 32 F (0 C)... SAE 10W F (0-25 C)... SAE 20W or 10W30 Above 77 F (25 C) SAE 30W or 10W30 API Classification... CH4 Air Filter... Dry type with evacuator valve. Alternator amp Cooling System... Liquid Cooled Capacity qt. (4.8 l) 50/50 water ethylene glycol mix 4.3 VEHICLE Tires: Front...20 x Multi Rib Rear...24 x Tire Pressure: Front...20 psi (138 kpa) Rear...Varies by load, See Section.15 Battery: Type...12 Volt Lead/Acid Group...24 Service Brake...4 Wheel hydraulic drum brakes Brake Fluid...DOT 3 Parking Brake...Integral to rear drum, hand lever actuated Gear Ratios: 4th Gear :1 3rd Gear :1 2nd Gear :1 1st Gear :1 Reverse :1 Differential :1 Steering... Front wheel power steering 9

10 4 SPECIFICATIONS 4.4 WEIGHTS AND DIMENSIONS Dimensions: Inches (mm) Length (3378) Height...49 (1245) Wheel Base (2240) Width with 15 Foot Boom...8 (1727) Width with 20 Foot Boom...77 (1955) Turning Radius (Outside) (14) Weights: Lbs. (kg) Working Weight with boom and manual control (823) 4.5 ACCESSORIES & SUPPORT LITERATURE Contact your area Jacobsen Dealer for a complete listing of accessories and attachments.! CAUTION Use of other than Jacobsen authorized parts and accessories may cause personal injury or damage to the equipment and will void the warranty SDIAccesories Air Blow Gun...JAC5098 Orange Touch-up Paint (12 oz. spray) Raven SCS330 Sprayer Control Raven SCS440 Console Transducer Speed Sensor Driveshaft Speed Sensor Radar Gun Speed Sensor Dash Handrail Mounting Bracket ft. 9-Nozzle Economy Boom ft. 18-Nozzle Economy Boom ft. 12-Nozzle Economy Boom ft. 9-Nozzle Deluxe Boom ft. 18-Nozzle Deluxe Boom ft. 12-Nozzle Deluxe Boom in. Ground Contour Wheel Kit in. Groung Contour Wheel Kit Electric Lift Actuator Kit ft. Shielded Boom Electric Lift Kit Storage Stand Gallon Tank Support Literature Safety & Operation Manual Parts & Maintenance Manual Service & Repair Manual Electric Hose Reel Kit... Contact SDI Manual Hose Reel Kit... Contact SDI SDI Phone (559) SDI-5555 Fax (559) SDI

11 ADJUSTMENTS 5 5 ADJUSTMENTS 5.1 GENERAL! WARNING To prevent injury, depress clutch pedal and shift transmission to neutral, engage parking brake, stop engine and remove key from ignition switch before making any adjustments or performing maintenance. Make sure the vehicle is parked on a solid and level surface. Never work on a vehicle that is supported only by the jack. Always use jack stands. If only the front or rear of the vehicle is raised, place chocks in front of and behind the wheels that are not raised. 1. Adjustments and maintenance should always be performed by a qualified technician. If proper adjustment cannot be made, contact an authorized Jacobsen Dealer. 2. Replace, do not adjust, worn or damaged components. 3. Long hair, jewelry or loose fitting clothing may get tangled in moving parts.! CAUTION Be careful to prevent entrapment of the hands and fingers between moving and fixed components of the machine. 4. Do not change governor settings or overspeed the engine. 5.2 ENGINE ACCESS Never remove or install the engine cover while the engine is running. The engine cover is a machinery guard and its removal exposes you to moving parts. Keep hands, hair and clothing away from flywheel, radiator cooling fan, alternator fan, engine belts, pulleys and air intake.! WARNING Keep clothing, hands and hair away from moving parts. These items could become entangled, causing serious personal injury. For servicing the engine and related components, the engine cover can be tilted forward or removed. To gain access to the engine, unlock key-lock if installed, push the engine cover latch towards the rear of the unit and tilt cover forward. When replacing the engine cover, make sure the retaining tabs located at the front corners of the engine cover are inserted into the slots in the floorboard. Tilt seat to the rear until the engine latch engages. Lock key-lock if equipped.! WARNING Failure to latch the seat properly can result in the engine cover tipping forward causing loss of control of the vehicle and possible personal injury. Engine Cover Latch Retaining Tab In Slot On Floor board Figure 5A Figure 5B 11

12 5 ADJUSTMENTS 5.3 FRONT COWL ACCESS The front cowl opens to gain access to two access panels, fuse panel, horn and master cylinder reservoir. To open the front cowl, locate the release lever at the upper left corner of front clip, near the left side headlight. Pull the lever toward the headlight to release the front cowl latch and at the same time pull up on the front cowl. Fully open the cowl and allow it to rest on the steering wheel or upper ROPS structure (if installed). The front cowl will not spring up when the release lever is pulled, it must be lifted manually. Front Cowl Release Lever Pull Lever To Release Cowl Latch Figure 5C 5.4 ACCESS PANELS There are two access panels located under the front cowl and one located in the middle of the floorboard. Remove panel (A) under cowl to access the shifter linkage and wiring for the instrument panel. Remove panel (B) under cowl to access the front suspension. Remove the center panel (C) in the middle of floorboard to access the throttle cable, accelerator pedal linkage, wire harness and rear hydraulic brake line. NOTE: It will be necessary to remove the accelerator pedal in order to completely remove the center floorboard panel. B A Figure 5D C Figure 5E 12

13 ADJUSTMENTS ALTERNATOR BELT Inspect and adjust new belt after first hours of operation. Adjust every 200 hours thereafter. Adjust alternator pulley so belt deflects 1/4 to 1/2 ( -12 mm) with a 20 lb. push at midpoint between water pump and alternator pulleys. If tension is incorrect, loosen alternator mounting bolts (D) and adjust alternator until proper belt tension is achieved. D Figure 5F 5. SPRAYER PUMP BELT Inspect and adjust new belt after first hours of operation. Adjust every 200 hours thereafter. Adjust sprayer pump so belt deflects 1/4 to 1/2 ( -12 mm) with a 20 lb. push at midpoint between pulleys. If tension is incorrect, loosen pump mounting bolts (E) and pry away from the engine until proper belt tension is achieved. E Figure 5G 5.7 PARKING BRAKE CABLE 1. Remove the engine cover. Put chocks in front of and behind at least two wheels at opposite corners of vehicle. 2. Engage parking brake. If handle is at an angle greater than 45 to the panel, adjustment is required. 3. Disengage parking brake. 4. Tighten adjustment nut (E) a couple of turns. 5. Engage parking brake. Repeat steps 3 and 4 until handle is at approximately a 45 angle when parking brake is engaged. E Figure 5H 13

14 5 ADJUSTMENTS 5.8 TORQUE SPECIFICATION CAUTION All torque values included in these charts are approximate and are for reference only. Use of these torque values is at your sole risk. Jacobsen is not responsible for any loss, claim, or damage arising from the use of these charts. Extreme caution should always be used when using any torque value. Jacobsen uses Grade 5 bolts as standard, unless otherwise noted. AMERICAN NATIONAL STANDARD FASTENERS SIZE UNITS AMERICAN NATIONAL STANDARD FASTENERS SIZE UNITS GRADE 5 GRADE 8 #-32 in-lbs (Nm) 20 (2.3) #8-32 in-lbs (Nm) 24 (2.7) 30 (3.4) #10-24 in-lbs (Nm) 35 (4.0) 45 (5.1) #10-32 in-lbs (Nm) 40 (4.5) 50 (5.7) #12-24 in-lbs (Nm) 50 (5.7) 5 (7.3) 1/4-20 in-lbs (Nm) 95 (10.7) 125 (14.1) 1/4-28 in-lbs (Nm) 95 (10.7) 150 (17.0) 5/1-18 in-lbs (Nm) 200 (22.) 270 (30.5) 5/1-24 in-lbs (Nm) 240 (27.1) 300 (33.9) 3/8-1 ft-lbs (Nm) 30 (40.7) 40 (54.2) 3/8-24 ft-lbs (Nm) 35 (47.5) 45 (1.0) GRADE 5 GRADE 8 7/1-14 ft-lbs (Nm) 50 (7.8) 5 (88.1) 7/1-20 ft-lbs (Nm) 55 (74.) 70 (94.9) 1/2-13 ft-lbs (Nm) 75 (101.7) 100 (135.) 1/2-20 ft-lbs (Nm) 85 (115.3) 110 (149.2) 9/1-12 ft-lbs (Nm) 105 (142.4) 135 (183.1) 9/1-18 ft-lbs (Nm) 115 (155.9) 150 (203.4) 5/8-11 ft-lbs (Nm) 150 (203.4) 195 (24.4) 5/8-18 ft-lbs (Nm) 10 (217.0) 210 (284.8) 3/4-10 ft-lbs (Nm) 170 (230.5) 220 (298.3) 3/4-1 ft-lbs (Nm) 175 (237.3) 225 (305.1) 7/8-14 ft-lbs (Nm) 300 (40.8) 400 (542.4) METRIC FASTENERS SIZE UNITS Non Critical Fasteners into Aluminum M4 Nm (in-lbs) 1.2 (11) 1.7 (15) 2.9 (2) 4.1 (3) 5.0 (44) 2.0 (18) M5 Nm (in-lbs) 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (8) 4.0 (35) M Nm (in-lbs) 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 1.5 (14).8 (0) M8 Nm (in-lbs) 10.5 (93) 13. (120) 24.4 (21) 33.9 (300) 40.7 (30) 17.0 (150) M10 Nm (ft-lbs) 21.7 (1) 27.1 (20) 47.5 (35).4 (49) 81.4 (0) 33.9 (25) M12 Nm (ft-lbs) 3. (27) 47.5 (35) 82.7 (1) 11. (8) (103) 1.0 (45) M14 Nm (ft-lbs) 58.3 (43) 7.4 (55) (97) (13) (12) 94.9 (70) 14

15 MAINTENANCE MAINTENANCE.1 GENERAL! WARNING Before you clean, adjust, or repair this equipment, depress clutch pedal and shift transmission to neutral, engage parking brake, stop engine and remove key from ignition switch to prevent injuries Make sure the vehicle is parked on a solid and level surface. Never work on a vehicle that is supported only by the jack. Always use jack stands. 1. Adjustment and maintenance should always be performed by a qualified technician. If proper adjustments cannot be made, contact an Authorized Jacobsen Dealer. 2. Inspect the equipment on a regular basis, establish a maintenance schedule and keep detailed records. a. Keep the equipment clean. b. Keep all moving parts properly adjusted and lubricated. c. Replace worn or damaged parts before operating the machine. d. Keep all fluids at their proper levels. e. Keep shields in place and all hardware securely fastened. f. Keep tires properly inflated. 3. Long hair, jewelry or loose fitting clothing may get tangled in moving parts. 4. Use the illustrations in the Parts Catalog as reference for the disassembly and reassembly of components. 5. Recycle or dispose of all hazardous materials (batteries, fuel, lubricants, anti-freeze, etc.) according to local, state or federal regulations..2 ENGINE IMPORTANT: A separate Engine Manual, prepared by the engine manufacturer, is supplied with this vehicle. Read the engine manual carefully until you are familiar with the operation and maintenance of the engine. Proper attention to the engine manufacturer s directions will assure maximum service life of the engine. To order replacement engine manuals contact the engine manufacturer. The proper break-in of a new engine can make a considerable difference to the performance and life of the engine. Note: The vehicle is designed to operate most efficiently at the preset governor setting. Do not change the engine governor settings or overspeed the engine. During the break-in period, Jacobsen recommends the following: 1. During the first 50 hours of operation, a new engine should be allowed to reach an operating temperature of at least 140 F (0 C) prior to operation at full load. 2. Check the engine oil level twice daily during the first 50 hours of operation. Higher than normal oil consumption is not uncommon during the initial break-in period. 3. Change engine oil and oil filter element after first 35 hours of operation. 4. Check and adjust sprayer pump and alternator belts. 5. Refer to Section 9.3 and Engine Manual for specific maintenance intervals.. If the injection pump, injectors or the fuel system require service, contact an authorized Jacobsen Dealer. Keep your engine clean. If dirt has accumulated on the engine, it should be washed with a non-flammable solvent or strong detergent. When washing becomes necessary, it can be carried out simultaneously when servicing the vehicle. In order to maintain reliable service from your engine, a regular check-up and maintenance scedule should be followed. Proper maintenance will prolong the engine s life and avoid premature overhaul. 15

16 MAINTENANCE.3 ENGINE OIL Check the engine oil at the start of each day, before starting the engine. To check the engine oil, remove the dipstick and wipe it with a clean rag. Reinsert the dipstick until it contacts the oil tube, remove the dipstick and read the oil level. The oil level should always be between the ADD and FULL mark on the dipstick. If oil level is below the add mark, remove filler cap and add oil to bring the level up between marks. Do Not Overfill. NOTE: If the engine has recently been running, allow time (with engine turned off) to let the oil settle to obtain a correct oil level reading. Use only engine oils with API classification CH4. Using oil other than the service class listed, or oil change intervals longer than recommended could reduce engine life. Damage to engine due to improper maintenance or use of incorrect oil quality and/or viscosity is not covered by the engine warranty. 1 Figure A.4 ENGINE OIL CHANGE Perform initial oil change after first 35 hours of operation and every 75 hours or two months thereafter. See Engine Manual. Significant oil loss can damage the engine. Considerable oil loss could be due to a loose or incorrectly installed drain plug, cracked gaskets, or even a loose oil filter. Drain plugs are located beneath the engine in the oil pan. Remove both plugs when changing the oil. Check drain plugs and oil for metal chips that could indicate engine damage. Replace drain plugs with damaged gasket surfaces immediately. After oil has completely drained, clean excess oil from oil pan and drain plugs. Install drain plugs and tighten securely. Refer to engine manual for proper torque. Always replace the engine oil filter when changing the engine oil. Apply a light coat of engine oil to the rubber gasket surface of new filter before installing. Fill Perkins engine with approximately 3.7 qts. (3.5 l) of clean engine oil. Check oil level and add additional oil if required. Refer to Section.3 for proper oil..5 POWER STEERING RESERVOIR! WARNING Before servicing or doing any maintenance work around the engine area, make sure the engine has had time to cool. Serious burns can result if the engine or surrounding surfaces are hot. The power steering reservoir is located on the right side of the engine, below the alternator. The level in the reservoir should be checked after the first 35 and 70 hours. After that level should be checked every 100 hours. When checking the fluid level before the engine has been warmed up, the level should be at the COLD mark on the ADD Above 77 F (25 C) 32 to 77 F (0 to 25 C) Below 32 (0 C) Engine Dipstick Oil Level Must Be Between Marks DO NOT OVERFILL SAE 30W or SAE10W30 SAE 20W or SAE 10W30 SAE10W FULL dipstick. After the engine has been warmed up and the fluid is warm, the level should be between the COLD and HOT marks. Use General Motors Power Steering Fluid as required to bring fluid up to proper level. ADD Power Steering Dipstick FULL COLD HOT Figure B

17 MAINTENANCE. COOLING SYSTEM This vehicle is equipped with a radiator, temperature controlled fan, temperature gauge and an overheat buzzer.! WARNING To prevent serious bodily injury from hot coolant or steam blow-out, never attempt to remove the radiator cap while the engine is running. Stop the engine and wait several hours until it is cool. Even then, use extreme care when removing the cap.! CAUTION Do not pour cold water into a hot radiator. Do not operate engine without a proper coolant mixture. Install cap and tighten securely.! WARNING The cooling fan is controlled by a temperature switch and may start at any time coolant temperature is above 150 F (5 C), even with the ignition switch in the OFF position. Do not attempt to service the cooling system without first disconnecting the negative battery cable or removing the fan fuse. NEVER add straight antifreeze to the radiator. Mix equal amounts of clean water with ethylene glycol based antifreeze in a separate container before adding it to the cooling system. Do not use a mixture of more than 50% antifreeze. Always recycle or dispose of used antifreeze in a responsible manner. Used antifreeze can be harmful to the environment. 1. Check coolant level daily. Radiator should be full and recovery bottle should be up to the cold mark. a. Tilt engine cover forward to gain access to the radiator. b. With the engine stopped and cool, remove radiator cap and check coolant level. The coolant level should be at or within 1/4 in. ( mm) of the filler port. Fill with a 50/50 antifreeze/water mixture if required. c. Visually check the reservoir tank. Coolant level should be at or above FULL line but less than 4 in. (102 mm). Add a 50/50 antifreeze/water mixture if required. 2. Drain and refill cooling system every 400 hours or 9 months, whichever comes first. Allow system to cool before draining. a. Remove the cooling fan fuse b. Remove the radiator cap. c. Open the engine block drain and the radiator drain. Remove lower radiator hose. Close both drains and install lower radiator hose once system has completely drained. d. Empty and clean the recovery bottle. e. Fill radiator to the bottom of the filler neck with 50/50 antifreeze/water mixture. f. Fill recovery bottle to full mark with 50/50 antifreeze/water mixture. 3. Keep radiator air passages clean. Use compressed air (30 psi maximum) to clean the fins. Water left between the fins will collect dirt and reduce the amount of air flow to properly cool the engine. 4. To provide proper air flow, do not obstruct the air intake screen on the right side of the vehicle. Keep screen clean. 5. Check and tighten the fan belt. Replace clamps and hoses every two years.. If you have to add coolant more than once a month, or add more than one quart at a time, have a authorized Jacobsen Dealer check the cooling system. 17

18 MAINTENANCE.7 ENGINE OVERHEAT PROCEDURE During vehicle operation, if the water temperature gauge shows 230 F (110 C) or above, and/or the overheat warning buzzer sounds, follow this procedure. 1. Stop the vehicle. DO NOT shut the engine off. Place vehicle in neutral and engage the parking brake. 2. Immediately disengage any accessories that are operating. 3. Slow the engine speed to a fast idle. 4. Remove any dirt, chaff, debris, etc. from the radiator intake screen located on the right side of the vehicle.! CAUTION Be careful when opening the engine access cover or cleaning the intake screen. Metal surfaces near the radiator and engine may be hot to the touch. Use a brush or gloves to clean screen. Temperature gauge needle should start to go down approximately 30 seconds after the screen is cleaned. If temperature does not go down, STOP the engine and check the following. 1. Check to see if cooling fan is operating. Fan should be turning with coolant above 180 F, even with ignition switch in OFF position. 2. Check engine oil level. 3. Check for a leak in the cooling system. Do not open radiator when hot. Check coolant levels after system completely cools. Failure to heed the overheat warning and properly maintain the cooling system will cause permanent engine damage..8 AIR FILTER Do not remove the element for inspection or cleaning. Unnecessary removal of the filter increases the risk of injecting dust and other impurities into the engine. When service is required, first clean the outside of the filter housing; then remove the old element as gently as possible and discard. 1. Carefully clean the inside of the filter housing without allowing dust into the air intake. 2. Inspect the new element. Do not use a damaged element and never use an incorrect element. 3. Assemble the new element and make sure it seats properly. 4. Reassemble cap making sure it seals completely around the filter housing. Dust evacuator (A) must be facing down. 5. Check all hoses and air ducts. Tighten hose clamps. A Figure C 18

19 MAINTENANCE.9 MUFFLER AND EXHAUST! WARNING Exhaust fumes contain carbon monoxide that is toxic and can be fatal when inhaled. NEVER operate an engine without proper ventilation. To protect from carbon monoxide poisoning, inspect the complete exhaust system regularly and always replace a defective muffler. If you notice a change in the color or sound of the exhaust, stop the engine immediately. Identify the problem and have the system repaired. Torque all exhaust manifold hardware evenly. Tighten or replace exhaust clamps..10 BATTERY Make absolutely certain the ignition switch is Off and the key has been removed before servicing the battery.! CAUTION Always use insulated tools, wear protective glasses or goggles and protective clothing when working with batteries. You must read and obey all battery manufacturer s instructions. Tighten cables securely to battery terminals and apply a light coat of silicone dielectric grease to terminals and cable ends to prevent corrosion. Keep vent caps and terminal covers in place. Keep the top of the battery clean and free of corrosion by washing with a solution of baking soda and water. Rinse with clean water. Verify battery polarity before connecting or disconnecting the battery cables. 1. When installing the battery, always assemble the RED, positive (+) battery cable first and the ground, BLACK, negative (-) cable last. 2. When removing the battery, always remove the ground, BLACK, negative (-) cable first and the RED, positive (+) cable last. 3. Make sure battery is properly installed and secured to the battery tray..11 JUMP STARTING Before attempting to jump start the vehicle, check the condition of the discharged battery. Engage parking brake of both vehicles, shift transmission to neutral and turn off all electrical loads! WARNING Batteries generate explosive hydrogen gas. To reduce the chance of an explosion, avoid creating sparks near battery. Always connect the negative jumper cable to the frame of the vehicle with the discharged battery, away from the battery.! WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash your hands after handling. 3. Connect the BLACK jumper cable from the negative (-) terminal on the good battery to the frame of the vehicle with the discharged battery. After cables have been connected, start the engine on the vehicle with the good battery then start the vehicle. When connecting jumper cables: 1. Stop the engine on the vehicle with a good battery. 2. Connect RED jumper cable to the positive (+) terminal on the good battery and to the positive (+) terminal on the discharged battery. 19

20 MAINTENANCE.12 CHARGING BATTERY! WARNING Charge battery in a well ventilated area. Batteries generate explosive gases. To prevent an explosion, keep any device that may create sparks or flames away from the battery. To prevent injury, stand away from battery when the charger is turned on. A damaged battery could explode. 1. Refer to Section.10. Read the Battery and Charger s manual for specific instructions. 2. Whenever possible, remove the battery from the vehicle before charging. If battery is not sealed, check that the electrolyte covers the plates in all the cells. Battery cables must be disconnected before using a fast charger or damage to the alternator may result. 3. Make sure the charger is Off. Then connect the charger to the battery terminals as specified in the charger s manual. 4. Always turn the charger Off before disconnecting charger from the battery terminals..13 FUEL Handle fuel with care - it is flammable and highly explosive under certain conditions. Use an approved container, the spout must fit inside the fuel filler neck. Avoid using cans and funnels to transfer fuel.! WARNING Remove the fuel cap slowly. Fuel may be under pressure. Spray could cause serious injury. Never remove the fuel cap from the fuel tank, or add fuel, when the engine is running or while the engine is hot. Do not smoke when handling fuel. Never fill or drain the fuel tank indoors. Do not spill fuel and clean spilled fuel immediately. Never handle or store fuel containers near an open flame or any device that may create sparks and ignite the fuel or fuel vapors. Be sure to reinstall and tighten fuel cap securely. 1. Fill the fuel tank to within 1 in. (25 mm) of the bottom of the filler neck. 2. Store fuel according to local, state or federal ordinances and recommendations from your fuel supplier. 3. Never overfill or allow the tank to become empty. Check fuel level in the tank by turning the ignition switch to the ON position and reading the level indicated by the fuel gauge. 4. Check fuel lines and clamps every 50 hours. Replace fuel lines and clamps at the first sign of damage. 5. The fuel tank capacity is.5 gal. (24.5 l). Fill tank using the following fuel recommendations: a. Use clean, fresh, #2 Diesel fuel when operating temperature is above 20 F (-7 C). Minimum Cetane rating 45. b. Use clean, fresh, #1 Diesel fuel when operating temperature is below 20 F (-7 C). If #1D fuel is not available, a winterized blend of #1D and #2D may be available. This blended fuel is usually called #2D and may be used in colder climates. Do not use #2D unless you are sure it has been winterized. Cold temperatures may cause it to thicken, which will keep your vehicle from running. c. DO NOT use Aviation Fuel JP4. Refer to Engine Manual for additional information. 20

21 MAINTENANCE.14 FUEL SYSTEM Then Perkins diesel engine in the Spraytek is self priming. It is not required to purge air from the system. Refer to Section 9.3 for specific maintenance intervals. Before replacing any filter, thoroughly clean the filter housing and the area around the filter. Dirt must not be allowed to enter into fuel system..15 TIRE PRESSURE Keep tires properly inflated to prolong tire life. Check inflation pressure while the tires are cool. Inspect tread wear. Lower pressure will help avoid leaving tire marks in soft turf. Higher pressures may be required for heavier loads. Rear tire pressure must be set at 28 psi (193 kpa) when operating with a full 300 gallon load. Never exceed the maximum pressure indicated on the tire. Check the pressure with an accurate, low pressure tire gauge. Due to the low volume of air needed, overinflation may be reached in a matter of two to three seconds. Keep tires inflated to: Front - 20 psi - (138 kpa) Rear - Varies, determined by load. (See Chart) Figure D.1 TIRE REMOVAL AND INSTALLATION Removal: 1. Park the vehicle on a flat and level surface. Apply parking brake, shut off engine and shift transmission to 1st gear. 2. Refer to Section.17 for proper lifting procedures. Always use jack stands, never rely only on a jack for support. Raise the vehicle only enough to remove the tire. Never place feet hands or any part of your body under the vehicle when raising it. 3. Remove the wheel retaining nuts and remove wheel and tire assembly from the hub. 4. Perform required service on tire. Rear Tire Pressure psi (kpa) Installation: 28 (193) 23 (159) 18 (124) 13 (90) 8 (55) 0! Load (Gallons) CAUTION Unless you have the proper training, tools and experience, DO NOT attempt to mount a tire on a rim. Improper mounting can produce an explosion which may result in serious injury. 1. Remove dirt, grease and oil from stud thread. Do not lubricate threads. 2. Position wheel on hub and inspect to insure full contact between mounting surface of wheel and hub or brake drum. Make sure valve stem is located towards the outside. Finger tighten all hardware then torque hardware in criss-cross order; always tighten nuts in the top position. 3. Check and retorque daily until torque is maintained, ft.lbs. ( Nm) 21

22 MAINTENANCE.17 RAISING THE VEHICLE! WARNING Make sure the vehicle is parked on a solid and level surface. Never work on a vehicle that is supported only by the jack. Always use jack stands. Block Tire Here Whenever possible empty the sprayer tank before raising the vehicle. Liquid moving inside the tank can cause an unbalanced load that could tip the vehicle. Never raise the vehicle with the engine running or with a person sitting in the operator s seat. - Jacki ng Location Always block the tire diagonally opposite the tire being raised. Never place hands, feet or any part of your body under the vehicle when raising it with a hoist or is not properly supported by jack stands. If Using Jack Here A scissors type jack or a floor jack with a 1-1/2 ton (minimum) capacity that can be lowered to 3-3/8 (8 mm) height is required. Refer to figure for jacking locations. Shift the transmission into 1st gear and apply the parking brake. Chock or block the tire diagonally opposite the side being raised. Raise the vehicle only enough to perform maintenance required. Jack the vehicle to the appropriate height and place jack stands or equivalent support beneath the frame near the jack. Lower the jack and allow the vehicle to rest on jack stands. When using a hoist to raise the vehicle, use the same procedure for supporting the frame and blocking the tires as you would when using a jack. To prevent damage to the vehicle or attached accessory, never use a hoist to raise only one corner of the vehicle. Always raise BOTH front or rear corners equally. Figure E 22

23 MAINTENANCE.18 TOWING THE VEHICLE! WARNING To prevent injury or vehicle damage, the following guidelines should always be followed. Never accelerate or stop suddenly when towing a vehicle. Never change the direction of the vehicle abruptly or make sharp turns on an incline when towing a vehicle. Never tow the vehicle faster than 5 m.p.h. (8 km/h). Towing at excessive speed could cause either vehicle to lose proper steering control Adjust your speed for weather and surface conditions when towing (rain, snow, ice, hills, etc.). If for any reason the vehicle needs to be towed, follow the procedures below. 1. If towing the vehicle with a tow-rope or chain, an operator is required to steer the vehicle and to control the brakes. 2. Attach a tow-roper only to the front vertical frame member on either side of the vehicle. 3. Shift transmission Neutral and release parking brake. 4. Slowly drive towing vehicle forward until tow-line is pulled tight. 5. While towing, try to keep the tow light taught at all times. Be careful going down inclines and turning corners. Tow Line Attachment A Front Bumper Accessory (Part No ) is available for use with the Spraytek. If a Front Bumper is mounted to your vehicle, make sure to follow the instructions included with the bumper for proper connection of the chain or tow rope Figure F 23

24 MAINTENANCE.19 HYDRAULIC BRAKES! WARNING Improper maintenance of the brake system may result in loss of vehicle control by the operator. Losing control of the vehicle due to brake loss may cause injury to the operator or bystanders and vehicle damage This vehicle is equipped with four wheel hydraulic brakes controlled by the brake pedal and a hand operated parking brake lever. Keep your brake system clean and properly maintained. Do not operate the Spraytek if the brakes do not stop vehicle properly. The brake fluid master cylinder reservoir is located under the front cowl. The fluid level in the master cylinder reservoir must be kept between the MIN (minimum) and MAX (maximum) marks. Add DOT 3 type brake fluid as required. If the brake fluid indicator light comes on and remains on, check the fluid level in the reservoir. Bleeding Hydraulic Brakes: If the brakes do not hold properly, if they feel spongy or if the brake fluid reservoir is allowed to run-dry, it may be required to bleed the system in order to remove air from the brake lines. 1. Bleed the brakes in the following order, Left Rear, Right Rear, Right Front and Left Front. 2. Attach a hose to the bleeder screw and place the other end of the hose in a container to catch fluid run-off when bleeding the system. 3. Bleed brake. a. Loosen the bleeder screw. b. Have an assistant push down on the brake pedal and hold the pedal down. c. Tighten the bleeder screw. d. Have assistant release pedal. NOTE: Do Not release brake pedal until the bleeder screw is tightened or air will be sucked back into the brake lines 5. Most communities have a disposal system for DOT 3 brake fluid. Please dispose of fluids properly. Brake Fluid Reservoir Brake Fluid Lever Indic ator Light Fluid Level Figure G Figure H Figure I e. Repeat steps a through d as required until all air bubbles are purged from the system and a steady flow of fluid comes from the brake line. f. Periodically check fluid level in reservoir. Do not allow the reservoir to fully empty or bleeding procedure will need to be repeated. 4. Repeat Step 3 for each brake. 24 Bleeder Screw Figure J

25 MAINTENANCE.20 DIFFERENTIAL FLUID The differential fluid should be checked every 100 hours or 3 months. Fluid should be changed after the first 100 hours and every 00 hours (or yearly) thereafter. Differential Fluid Capacity pints (2.5 l) Fluid Type...SAE EP Gear Lube To check differential fluid level, remove the filler plug from the front of the differential. Fluid should be level with the bottom of filler hole. If fluid is low, add gear lube until fluid begins to leak from hole. Apply pipe thread sealant and install filler plug. To change differential fluid, remove drain plug from rear of differential. Allow fluid to drain into a suitable container. Dispose of used fluid properly according to local and state regulations. Apply pipe thread sealer to drain plug and install. Fill differential with gear lube until fluid begins to leak from hole. Apply pipe thread sealant and install filler plug. Level Check And Fill Plug Figure K Drain Plug Figure L.21 TRANSMISSION The transmission fluid should be checked every 100 hours or 3 months. Fluid should be changed every 00 hours (or yearly). Differential Fluid Capacity qts (1.3 l) Fluid Type...SAE EP Gear Lube To check transmission fluid level, remove the filler plug from the front of the transmission. Fluid should be level with the bottom of filler hole. If fluid is low, add gear lube until fluid begins to leak from hole. Apply pipe thread sealant and install filler plug. To change fluid, remove drain plug from rear of transmission. Allow fluid to drain into a suitable container. Dispose of used fluid properly according to local and state regulations. Apply pipe thread sealer to drain plug and install. Fill transmission with gear lube until fluid begins to leak from hole. Apply pipe thread sealant and install filler plug. Level Check And Filler Plug Transmi ssi on Drain Plug Figure M 25

26 MAINTENANCE.22 ELECTRICAL SYSTEM! CAUTION Always turn the ignition switch off and remove the negative battery cable (Black) before inspecting or working on the electrical system. 5. Do not wash or pressure spray around electrical connections and components.. Circuits are protected by fuses located under the front cowl and a fuse located near the cooling fan. General precautions that can be taken to reduce electrical problems are listed below. 1. Make certain all terminals and connections are clean and properly secured. 2. Check the Interlock system, and fuses regularly. If the Interlock does not function properly and the problem cannot be corrected, contact an authorized Jacobsen Dealer. 3. Keep the wire harness and all individual wires away from moving parts to prevent damage. 4. Check the battery and battery charging circuit. Power Port 15 A Brake Light, 5th Wheel Brake Flashers & Horn Headlights 10 A 10 A 15 A 20 A Dash Panel, Fuel Pump & Ignition 10 A Accessary 10 A Heater Accessary 10 A Wiper, Dome Light & Back-Up Alarm Figure N.23 DASH PANEL The dash panel contains gauges and instrument lights to display unit functions. Maintenance of the panel is limited to replacing bulbs and setting the DIP switches. Remove the four screws securing the instrument panel to the dash. Pull panel out, tilt panel forward and disconnect electrical connector for easier access to rear of panel. Light Bulb Replacement: 1. Determine which bulb needs to be replaced. 2. Rotate bulb holder 1/4 turn counter-clockwise and pull up and away from dash panel. 3. Replace old bulb with a new bulb of equal type. 2 Location... Replacement Bulb A Voltmeter...C58 B Temperature Gauge...C58 C Fuel Gage...C58 D Hour Meter...C58 E Tachometer...C11 F Left Turn Signal...C11 G Oil Pressure...C11 H Glow Plug...C11 J Brake Fluid...C11 K Right Turn...C11 L Parking Brake...C11 M High Beam...C58 N Alternator / Battery...C11 4. Place bulb and holder back into panel. Turn holder 1/4 turn clockwise to secure into panel. Ensure base of holder is properly seated in panel. Tachometer DIP Switch Setting: The dash panel uses a DIP Switch sequence code to identify the number of input pulses per engine revolution and engine type to correctly display the engine RPM on the tachometer. If you are replacing the dash panel or if the tachometer is not operating correctly, check to be sure the sequence code is set correctly. The Spraytek with a Perkins Diesel engine uses the following sequence code for 8.5 pulses / revolution. Sequence Code: Using a small blade screwdriver or similar tool, push the switch levers either up or down to match the sequence code for this unit. K L M Dipswitch Setting C E D 1 0 B A F G H J Figure O

27 MAINTENANCE.24 HEADLIGHT REPLACEMENT The headlight should be replaced as soon as it stops functioning or is damaged. The headlight is a sealed unit and can only be replaced as a complete unit. Description...Bulb Type Jacobsen Part No. Headlight...H Disconnect the negative battery cable. 2. Remove the four screws securing the headlight bezel to the front cowl. 3. Pull headlight and bezel forward, out of the front clip opening. 4. Disconnect the electrical connector from the rear of the headlight, 5. Remove the headlight from the bezel. Properly dispose of old bulb.. Install new headlight in reverse order of removal. Figure P.25 TAIL LIGHT REPLACEMENT The tail light should be repaired as soon as it stops functioning or is damaged. The tail light bulb, and lens are replaceable components. Damage to the body of the tail light requires a complete replacement. Description...Bulb Type Jacobsen Part No. Tail light bulb Remove the two screws securing lens. Remove lens and gasket. 2. Push bulb in, turn 1/4 turn and remove bulb. Dispose of old bulb properly. 3. Install new bulb in reverse order of removal. Ensure lens gasket is properly positioned. 4. To remove complete tail light assembly, remove two nuts and shake proof washer securing tail light to frame. Disconnect harness and remove tail light from frame. Figure Q.2 CARE AND CLEANING Wash the vehicle after each use. Keep the equipment clean. Note: Do not wash any portion of the equipment while it is hot. Do not use high pressure spray or steam. Use cold water and automotive cleaners. 1. Use compressed air to clean engine and radiator fins. A special blow gun is available through Jacobsen Dealer. 2. Use only fresh water for cleaning your equipment. Note: Use of salt water or affluent water has been known to encourage rust and corrosion of metal parts resulting in premature deterioration or failure. Damage of this nature is not covered by the factory warranty. Headlight Bezel Remove The Four (4) Screws For Headlight Removal Remove The Two (2) Screws For Bulb Or Lens Replacemen t 3. Do not spray water directly at the dash panel, ignition switch, controls or any other electrical components, or at bearing housings and seals. 4. Clean all plastic or rubber trim with a mild soap solution or use commercially available vinyl/rubber cleaners. Repair damaged metal surfaces and use Jacobsen touch-up paint. Wax the equipment for maximum paint protection.! CAUTION Clean grass and debris from drives, muffler and engine to prevent fires. 27

28 MAINTENANCE.27 SPRAYER CLEANING! WARNING Sprayer cleaning solutions are chemicals and should be given the same attention as chemicals used during sprayer operation. Special safety equipment may be required to prevent accidental exposure to poisoning and should be worn at all times when working with chemicals. Contact your chemical supplier for proper material handling. Always refer to the chemical manufacturers MSDS (Material Safety Data Sheet), that is available for all chemicals. Special attention should be given to required safety equipment, first aid treatment for accidental inhalation, swallowing, absorption or injection and compatibility with other chemicals. Never work with harmful chemicals alone. Always have a second person nearby in case of emergency. Some chemicals and cleaning solutions may be flammable or produce flammable vapors. Do not smoke when handling or mixing chemicals. Never store chemicals near an open flame or spark which could ignite chemical or chemical vapors. After use, clean the sprayer thoroughly with a cleaning solution. During cleaning, always follow these guidelines. 1. Use care when opening sprayer tank cover. Potentially dangerous chemical fumes may have accumulated inside tank. 2. Type of cleaning solution required is determined by chemical used in sprayer. Refer to the chemical label for cleaning solution compatibility and specific cleaning instructions. 3. Sprayer cleaning should only be performed in an area with run-off recovery or containment. If one is not available, be certain the run-off does not contaminate water supplies, public sewers or natural wet land areas. Check your local regulations for requirements in your area. 4. Remove the nozzles from spray booms. Clean nozzle tips and screens in a strong detergent solution or kerosene using a soft bristled toothbrush. 5. Flush the sprayer system with clean water.. Add a mixture of 2 pounds (0.91 kg) of cleaning solution for each 30 to 40 gallons (114 to 152 l) of water. This should be sufficient for removing most pesticides. 7. Close hose reel and/or boom supply valves. Operate pump to allow cleaning solution to circulate through the system and agitate in the tank thoroughly. Open supply valves and allow detergent solution to flow through remainder of the system for several minutes. 8. Flush the system twice with clean water. 9. During the cleaning, examine the hoses, clamps, connections, no-drip valves, nozzle tips and screens. Replace any components if damaged, leaking or not functioning properly. Special Cleaning Requirements: 1. Some pesticide combinations (especially if oil is used) may produce a putty like paste inside the tank. a. Flushing out residue of such chemicals after each load will help prevent accumulation. b. If water alone does not remove the build up, add a solution equal to 1 gallon (3.8 l) or solvent (Stoddard solvent, kerosene or diesel fuel) per 25 gallons (95 l) or water. Allow the paste to dissolve then agitate and flush the system. 2. If phenoxy herbicides, such as 2,4-D, have been used in the system: a. Rinse the tank with clean water. b. Mix one of the following chemicals with 25 gallons (95 l) of clean water. 1 Quart (0.95 l) household ammonia 1 Pound (0.45 kg) of washing soda (sal soda) 2 Pounds (0.91 kg) of trisodium phosphate c. Rinse inside of tank with solution. Allow mixture to agitate in tank and let a small amount flow through the nozzles. d. Keep remainder of mixture in the system overnight and pump it out in the morning. e. Rinse and flush the system with clean water. 28

29 MAINTENANCE.28 STORAGE General 1. Wash the vehicle thoroughly and lubricate. Repair and paint damaged or exposed metal. 2. Inspect the vehicle, tighten all hardware, replace worn or damaged components. 3. Drain and refill radiator. 4. Clean the tires thoroughly and store the vehicle so the load is off the tires. If vehicle is not on jack stands, check tires at regular intervals and reinflate as necessary. 5. Keep the machine and all its accessories clean, dry and protected from the elements during storage. Never store equipment near an open flame or spark which could ignite fuel or fuel vapors. Battery 1. Remove, clean and store battery in upright position on a non-conductive surface (wood) in a cool, dry place. To prevent accelerated discharge, do not store battery on concrete or steel surface. 2. Check and recharge battery every 0 to 90 days while in storage. 3. To reduce the self discharge rate, room temperature should not be above 80 F (27 C) or fall below 20 F (- 7 C) to prevent electrolyte from freezing. Engine (General) 1. While the engine is warm, remove the drain plug, drain the oil from the crankcase and change oil filter. Install drain plug and refill with fresh oil. Let engine cool before storing. 2. Clean exterior of engine. Paint exposed metal, or apply a light coat of rust preventative oil. Add a fuel conditioner or biocide to prevent gelling or bacterial growth in fuel. See your local fuel supplier. If storing indoors, drain fuel from tank. Close fuel shut off valve. Sprayer System 1. Clean inside of tank after use. [Section.27] 2. Remove no-drip valves, nozzle tips and strainers. a. Clean removed parts and dry thoroughly. b. Store metal nozzle tips in a can of light oil such as kerosene or diesel fuel. c. Store plastic or nylon nozzle tips in a safe dry place. d. Make sure nozzle tips are stored in a manner that the orifices cannot be damaged by contacting other parts. 3. Drain or remove all water from tank, hoses, and pump. To make sure hoses are completely drained, purge them with compressed air. 4. Put 50/50 water-antifreeze mix with rust inhibitor in the pump and other metal sprayer parts. This will protect against corrosion as well as freezing if water was not completely removed. 5. Tape or cover all openings such as nozzle openings, so dirt, insects or other foreign material cannot get into the system.. Remove hoses from booms and store inside a building a. Clean all dirt and debris from hoses before storing. b. Coil the hoses around a basket or other large round object to prevent sharp bends c. DO NOT hang hoses over a beam, nail or similar object. This can cause a permanent crease that reduces flow through the hose 7. Repair and paint damaged or exposed metal on sprayer frame, booms or other sprayer attachments. After Storage 1. Check and reinstall battery 2. Check or service fuel filter and air cleaner. 3. Check the radiator coolant level. 4. Check oil level in the engine crankcase. 5. Fill the fuel tank with fresh fuel. Open fuel shut off valve and bleed the fuel system.. Remove antifreeze mixture from sprayer pump. 7. Assembly boom hoses, no-drip valves, nozzle tips and strainers. 8. Make certain that the tires are properly inflated. 9. Start and operate the engine at 1/2 throttle. Allow enough time for the engine to become properly warmed and lubricated.! WARNING Never operate the engine without proper ventilation; exhaust fumes can be fatal when inhaled. 29

30 7 SDI SPRAYER MAINTENANCE 7 SDI SPRAYER MAINTENANCE 7.1 SYSTEM COMPONENTS The basic sprayer system components are listed below. 1. Spray Tank - containment for fluid and product mix chamber. Tank is constructed of fiberglass and resin compound with a 300 gallon ( L) capacity. 2. Anti-Vortex Plate - located in sump (lowest part of tank interior), facilitates complete liquid draining without causing pump cavitation (suction loss) or prime break. This plate attaches to the suction flange. 3. Suction Flange - external hose barb assembly on tank sump area, connects tank to main suction hose. 4. Suction Ball Valve - brass ball-valve which allows fluid to be shut off during suction screen cleaning or pump maintenance. Must be open during normal operating conditions. 5. Suction Strainer - filters out particulate matter and debris from supply tank. Extends pump life and eliminates foreign objects which may disrupt normal boom or spray-gun operations.. Centrifugal Pump - the center of the impeller has an eye which allows liquid to pass through curved guide vanes to expel water in an outward direction (centrifugal force) towards the exit port on the pumps outerhousing (volute). 7. Agitation Control Gate Valve - controls amount of tank agitation by amount of liquid passing through the Venturi nozzle multiplier orifice. It is recommended this valve remain fully open at all times, even if there is alow tank liquid level. 8. Jet Agitation Nozzle Assembly - a eight-head Venturi nozzle assembly in the lower sump area provides liquid agitation formixing loaded chemicals with carrier (water). 9. Hose Reel (Not Shown)- this accessory is a hose holding spool which allows hook-up of a hand-held spray gun orwalking type spray boom. It holds supply/spray hose for repeated use while keeping hose and supplies organized. 10. Boom Controls (Not Shown)- supplies liquid to boom control valves (manual) or motorized valve assemblies for dispersal through the spray dispersal bar (boom). 11. Boom Tubes (Not Shown)- SST pipe with nozzle bodies attached evenly distributes spray liquid to turf area (ground) with an over-lapping pattern. Nozzle bodies are diaphragm check (drip free) and supply liquid to the nozzle tips when liquid pressure exceeds 10 psi (9 kpa). When the boom shuts off the diaphragms keep the tips from dripping and also allows a quick air-free (hiss free) resumption of the spray pattern. Centrifugal Pump Jet Agitation Nozzle Assembly Agitation Control Gate Valve Open valve to use boom. Close valve to use hose. Anti-Vortex Plate Suction Flange Suction Strainer (Filter) Front Of Vehic le Turn valve to use hos e or boom Suction Ball Valve Close valve to service pump and/or filter. You can service the pump and/or filter with liquid in the tank, as long as the 30

31 SDI SPRAYER MAINTENANCE CONTROL VALVES The control valves for determining which accessory to use are located on the left side of the vehicle directly behind the operators seat. The agitator control handle controls an eight jet nozzle assembly in the lower tank sump area. This handle controls the amount of liquid passing through the nozzles allowing complete agitation for mixing loaded chemicals with carrier (water). It is recommended to leave this valve fully open at all times even with low tank liquid level. The hose reel and boom valve allows isolated use of either the hose reel or the boom. The hose reel position allows hook-up to a hand-held spray gun or walking type spray boom. The boom position allows use of all spray boom accessories. The boom control valve needs to be open if the hose reel & boom selector valve is in the boom position, if the selector valve is in the hose reel position, this control valve needs to be in the closed position. The suction valve needs to be in the open position for normal operation. If the pump and/or the filter need servicing or repair, this valve can be turned to the closed position (with liquid in the tank) allowing these items to be worked on. Agitator Control Handle Hose Reel and Boom Selector Valve Suction Valve Boom Control Valve Figure 7A Figure 7B 7.3 SYSTEM DYNAMICS The sprayer pump is belt driven off the engine. Electrical power for the sprayer is supplied by the vehicle battery. The sprayer to truck mounting style makes the two systems act as one complete machine.! WARNING DO NOT operate sprayer pump with out liquid present in the system. Mechanical seals must be constantly lubricated with cool circulating liquid (spray mix). Running the system dry will heat up the ceramic seat and the addition of a cool liquid to a hot/dry seal will cause the ceramic to crack. Centrifugal Pump Lubrication - lubrication for the impeller inside the pump housing (volute) is your spray liquid. This liquid lubricates the mechanical seal (made of ceramic and graphite rings) that are around the impeller shaft. The pump rotation creates heat, so the liquid is also needed for cooling. The centrifugal pump is lubricated by the spray material therefore, the use of certain materials may affect maintenance or operation techniques. Venturi-Jet Agitator Nozzles - installed with ceramic metered orifices (ceramic is a longer lasting material in comparison to plastic). Long lasting ceramic orifices provide stable agitation flow rates for trouble-free fluid mixing. Suction Strainer - provides liquid filtering of particulate matter in spray material. Screen mesh sizes available are: 20, 50, 80 and 40 (standard) in SST material. The suction strainer (filter) should be cleaned daily or more often as the need arises. Remember to close the suction ball-valve (if liquid is in the tank) before removing the strainer. Non-Corrosive Plumbing - all sprayer plumbing is SST, nylon or PVC, or polypropylene for all liquid handling parts. 31

32 7 SDI SPRAYER MAINTENANCE 7.4 SPRAYER SYSTEM CHECK Before operating the Spraytek, the following components should be checked to ensure proper operation of sprayer. 1. Sprayer Tank and Tank Frame Inspect frame for broken welds and cracks. Make sure all mounting hardware is properly tightened. Inspect sprayer tank for cracks or leaks Inspect the lid and gasket for warpage or leaks. Clean any dirt or other debris from lid threads and gasket. Apply a light lubricant to gasket (such as silicon spray). Check lid check vent. Remove any residue from ball and seat. Check hinge pin. Remove lid and strainer basket. Visually inspect the interior of the tank for flaking or residue build up. Check anti-vortex plate in sump area for debris. Blocked suction can cause damage to the pump. Check jet agitator venturi nozzle position. Aim as necessary for proper agitation. Check ceramic orifices in agitator nozzles for cracks or blockage. Improperly functioning orifices can lead to reduced agitation and possible mixing problems. 2. Sprayer Pump Inspect suction and pressure hose for cracks or any damage that could cause a leak. Check pump for seal leakage at rear weep holes around rear shaft bearing. Check plastic vent tube from top of pump for kinks or dried powder products. Inspect and clean suction strainer screen. Inspect bowl and gasket. Improper gasket seating can result in poor pump performance. If necessary, replace gasket before operating unit. During bowl replacement, install bowl and tighten hand tight. DO Not use tools to tighten bowl. Between loads, wipe bowl with rag to maintain clarity. Check to be sure suction ball valve is open and free from damage. Make sure agitation valve is fully open. Due to the unique design of the tank sump and anti-vortex area, turning the agitation down or off with low fluid level in tank is not required Spray Boom Inspect support frame and mounting hardware for loose, damaged or missing components. Repair or replace if required before operating Spraytek. Adjust return spring tension for stiffer or looser action. With vehicle tires properly inflated for load and tank full of water, make sure boom is level and adjusted to the proper height (See Boom Accessory instructions for adjustments). Grease boom hinges (Breakaway booms) and remove any debris which may have accumulated on and around the pivot plate area. Inspect boom end caps for cracks or leaks. Repair as required. Between spray loads, check and clean all boom nozzle assemblies. Inspect check valve diaphragms for tears or warpage. Check and clean tips with a soft nylon brush (DO NOT use metal or hard brushes, tip damage will occur). Clean strainer screens and tip gaskets. Replace worn or damaged items as needed. Proper tip maintenance will result in optimum performance and pattern development. 4. Boom Control Systems The Spraytek will have one of the following three boom control systems. Identify which system is used on your machine. Motorized Boom Controls: Check battery connections for proper pole hook-up (+ / -). Make sure all wires connected to the clips and their fasteners are tight. Check control box mount and console wing nuts for tightness. Clean dirty console with a damp cloth (mild soap), Do Not use solvents to clean the console! Check all toggle switches for play and replace as needed. If switches are rubber booted, check boots for cracks or tears and replace as necessary. (Continued on next page) Check control console pressure gauge bezel (clear plastic ring which holds gauge into console). The raised tabs should be in the and 12 o'clock positions. Check back side of console and make sure power & control cables are locked into the pin connectors. Replace the rubber boot if it shows signs of excessive wear or cracking.

33 SDI SPRAYER MAINTENANCE 7 Check fuse and rubber boot. Check plastic pressure gauge tube for kinks, breaks or blockage, repair as needed. To clear a blocked tube (packed with dry powder): a. Put some clean water in the spray tank, 2 to 5 gallons (7. to 18.9 L) is sufficient. Turn sprayer on and set rpm's to 3000 on truck. b. On the back-side of the console is a metal tube receiver with an 1/8" tube engaged. Push the tube and top of the metal coupler in with your thumb and index finger, while holding the metal ring in, pull the tube out with your other hand. Point end of tube away from unit and your face and allow debris to clear from tube. c. If unsuccessful, remove other end of tube from Boom Valve inlet. Use a rubber tipped air nozzle to force high pressure air through the tube. If still unsuccessful, replace the tube with a new piece and start flushing the new tube after each spray application. Move back to the boom area at the rear of the sprayer. Inspect the connector plugs on the motorized valve harness, they should be tight against the valve body tighten if necessary (there should be no prongs showing from the valve). Check valve mating joints (seams) for leakage. if a leak is detected, tighten the nuts on the 4 guide rod bolts (there are o-rings in each joint area, Do Not tighten too tight. If the leak persists, separate the valve bodies and replace the o-rings with new ones. Make sure the U-clips on the boom feed barbs and metered by-pass valve are pushed in and secured (leakage can result if U-clips are not in place). Follow the boom hoses from each motorized valve to the corresponding boom section, make sure the brass compression clamp (pipe saddle feeder) with the nylon fitting is snug against the SST tube and the pipe saddle is parallel to the ground (improper saddle alignment can cause reduced flow during large tip use, adjust as necessary). Move to the control console, Listen carefully as you perform the next series of checks. Push up on the pressure-adjust toggle switch, the Servo motor on the yellow striped valve should run. Reverse toggle switch position, verify motor works in both directions. Push the master power toggle to the "ON" position, check the switches one-at-a-time for boom 1, then boom 2, then boom 3, checking switches in both directions. Verify each blue striped valve works in both directions. Raven SCS330 and SCS440 Control System Procedures are similar to the motorized valve control, refer to the manual supplied with the Raven SCS330 Accessory for test procedures. Wipe any debris from the console using a damp rag and mild soap. Verify your pre-set calibration numbers, do they match your records sheet in the Raven Manual? Modify any numbers that do not match. Verify tip size in the boom is correct based on your desired spray speed, tip spacing, and target output. Make sure all harness connectors on the back of the box, at the flow meter and at the flow regulator servo valve are secure. Inspect drive-line speed sensor assembly, Remove any debris, especially metal shavings, from the red & black magnet assemblies on the drive-line (the metal particles can affect the pick-up sensors ability to read the signal, resulting with inaccurate speed readings and/or bad calibration settings by the computer). Place control box power switch to the "manual" position. Push the master power toggle to the "ON" position, check the switches one-at-a-time for boom 1, then boom 2, then boom 3, checking switches in both directions. Verify each blue striped valve works in both directions. If the Raven system is equipped with the RADAR speed sensor, refer to the Raven Manual for check-list and test procedures. 5. Optional accessories that may be installed. Proceed with the check list for each accessory that has been installed on the Spraytek. Refer to the accessory manuals for adjustment and set-up procedures. 33

34 7 SDI SPRAYER MAINTENANCE Electric Boom Lift Check both actuator mounting bolts for tightness and for wing down position parallel to ground position, adjust according to set-up instructions. Check control harness fuse (30 amp rating). Check control console toggle switch for play and proper operation. Check harness connectors at control box and at each actuator. Hose Reel Check supply hose, from pressure side of pump to the swivel inlet on reel drum, for cracks, kinks or leaks. Lubricate the reel swivel at the grease zerk (if equipped). Check reel to tank hardware for tightness and evidence of leaks. Gasket sealer and fender washers should be used if not present (refer to the mounting instructions that come with the accessory). If electric rewind option is used, check battery and harness connections (40 amp circuit breaker should also be installed). Foam Marker Inspect solution tank for leaks and cracks. Check cap assembly for cracks and leaks. Check fuse in control harness (10 amp rating) Be sure to use only SDI Foam Concentrate with the foam marker accessory. Use of other brands will cause adverse performance. Activate power switch to the left then to the right positions and verify corresponding solenoid operation (you will hear a click) the compressor will start and if there is fluid in the container, liquid should flow to the feed tube on corresponding solenoid and foam generator cone junction tube. If solenoid clicks but foam liquid doesn't move through foam generator cone feed tubes, check each feed line check valve located just before each solenoid inlet. Clean as needed. Check supply fasteners on boom tubes for proper tightness and position. They should be positioned so they do not interfere with the tips or nozzle check valves. The loom (black ribbed cover) should run along the top of the boom tube and fastened with nylon cable ties. Check foam generator cone position. It should be at the end of the boom wing and clear the spray pattern distribution area. Keep cones out of spray by tilting up (required for rainbow style tips). 7.5 CONTROL PRESSURE ADJUSTMENT Proper spray pressure adjustment is important to obtain the proper nozzle output based on standards given in the boom calibration formulas. The pressure control adjustment procedure varies depending on type of control system used. Use the following recommendations and follow more in depth procedures outlined in control system manuals. Motorized Valve Control System: Motorized valves are adjusted using the pressure adjustment toggle switch, which controls the motorized pressure regulator. Raven SCS330 and SCS 440 Control System: Raven computer equipped sprayers can operate in manual mode and follow the same guidelines as the Motorized Valve Control adjustment (no metered by-pass to adjust when the Raven system is used). Raven should be in manual mode to adjust system pressure. NOTE: The Raven System works on flow, not pressure. To check system pressure, an optional gauge should be installed on the boom or on the tip assembly. 34

35 SDI SPRAYER MAINTENANCE 7 7. BOOM SPRAY TIP OVERLAP CHECK To verify the boom is properly set-up and the tip and nozzle height is correct, a water only pass over a dry concrete or asphalt parking area can reveal much information about your systems set-up. With only water in the tank, operate the machine as you normally would when spraying turf. With the spray boom fully on, apply a pattern to the dry surface. After the first pass, watch the spray dry and look for uneven areas or extra wet or extra dry zones. Uniform and even drying indicates the system is applying a uniform pattern. Uneven drying or wet stripes can identify overlap problems (check each nozzle with a calibration catch container to acquire data for proper setup of system. The illustrations below show examples of what to look for when adjusting boom height (proper tip height and overlap are found in the set-up instructions that come with the accessory). If the TeeJet tips are set for a 30% overlap on a 20" (508 mm) spacing, the proper tip to target height would be 18" (457.2 mm). Tip to target, proper height Tips set at correct height to achieve proper overlap will create an even spray pattern. Tip to target, boom too high Wet stripes between nozzle tips can indicate the boom is too high. Tip to target, boom too low Stripes under nozzle tips can indicate the boom is too low. 35

36 7 SDI SPRAYER MAINTENANCE 7.7 SPRAYER TANK ADDITIVES Dye Markers - Avoid heavy, thick dye markers and only add dyes into a full mixing tank, Do not add to an empty tank. Due to pigment granules and/or by-products, the use of dyes can lead to mechanical seal problems. Because of the high speed of the impeller seal and the heat that is generated, the pigments can scale up the ceramic seal surface. This will cause the seals to leak (pump appears broken). Frequent rinsing between smaller tank loads (batches) can reduce the leakage at the seals. Also, using less dye than recommended, but enough to still see a color (marker) change, can result in better performance. Spray Liquid Viscosity - the addition of certain WP (Wettable Powders), WDG (Water Dispersers Granular) or EC (Emulsified Concentrate) chemicals, etc. may cause the viscosity (thickness) of the water to increase. This can sometimes affect the calibration of the spray nozzle out-put at pre-calibration water numbers. Consult Chemical Supplier for recommended modifications to your system. 7.8 CALIBRATION Practice with water - after you have followed all recommendations, it is advisable to familiarize yourself with the operation of the dedicated sprayer and sprayer package. Practicing with plain water before the addition of expensive and potentially destructive chemical formulas (when mis-applied), can be smart and cost effective. To spray and spray accurately, you must have a set standards to spray by. The easiest method of calibration is to use as many fixed constants that can be controlled, and then modify the tip size & out-put pressure to lock in your desired application rate. When using the following formulas, the application rate can be maintained by fixing the constants for each category. To properly calibrate the sprayer, the following information is required. Desired Application Rate - GPA (Gallons Per Acre) or G/1000 ft 2 (Gallons per 1000 square feet) Nozzle Spacing - Distance in inches between spray tips Desired Ground Speed - A fixed, ground speed is recommended to maintain accurate calibration Tip Style - Type of pattern for particle distribution of applicable chemical to be applied, i.e. (FL, XR, TT). Tip Size - Determines volume per minute, per nozzle and desired droplet (micron) size of spray carrier particles. The following Formulas and conversion factors will help you obtain the necessary information. Abbreviations: km - kilometer m - meter G - Gallon l - Liter GPA - Gallons per Acre GPM - Gallons per Minute MPH - Miles per hour PSI - Pounds per square inch W - Nozzle spacing in inches Conversion Factors: One Acre = 43,50 ft 2 = ft 2 = hectares One Hectare = Acres One GPA = 2.9 Fluid Ounces/1000 ft 2 = 9.35 l/hectares One G/1000 ft 2 = 43.5 GPA One Gallon = 4 Quarts = 8 Pints = 128 fluid ounces One Gallon = 3.79 l = 0.83 Imperial Gallons One Mile = 5,280 ft = 1.1 km = 110 m One PSI = 0.09 bar =.89 kilopascal Fomulas: GPM (per nozzle) = (GPA x MPH x W) / 5,940 GPM (per nozzle) = (G/1000 ft 2 x MPH x W) / 13 GPA = (5,490 x GPM (per nozzle)) / (mph x W) G/1000 ft 2 = (13 x GPM (per nozzle)) / (mph x W) 3

37 SDI SPRAYER MAINTENANCE MEASURING GROUND SPEED KPH KPH MPH MPH RPM The Spraytek offers four forward speeds, plus a high-low differential range. This gives you the option of eight (8) possible speeds. All spraying operations should be performed with the differential set in the low speed. The spray pump is designed to run with an engine speed of 3,000 to 3,200 rpm. The ground control decal indicates the speed the vehicle should travel at different engine rpm settings. It is recommended you establish ground speed based on the following information: Measure a test course in the area to be sprayed or in an area with similar surface conditions (terrain) of the area to be sprayed. A minimum length of 100 ft. (30.5 M) to test speeds up to 5 mph (8 km/h) is recommended. A minimum length of 200 ft (1 M) to test speeds from 5 mph (8 km/h) up to 10 mph (1 km/h) is recommended. To help ensure accuracy, conduct the speed check with the sprayer tank half-full and select the throttle setting and forward gear that will be used when spraying. Figure 7C Determine the time required to travel the test course and run the course several times using the average time of all runs. Use the following equation or the table shown to determine ground speed. speed (MPH) = (Distance ft x 0) / (Time (Seconds) x 88 Speed in MPH (km/h) 100 ft (30.5 m) Time in Seconds 200 ft (1 m) 300 ft (91.4 m) 0.5 (0.8) (1.) (2.4) (3.2) (4.0) (4.8) (5.) (.4) (7.2) (8.0) NOZZLE TIP SIZE Tip size selected for use in your sprayer will depend on the desired GPM rate per nozzle, ground speed, nozzle spacing and spray pressure. The following chart will help in determining tip size, etc. when using the formulas mentioned on the previous page. The chart was taken from Page 10 of TeeJet Catalog 49A. For a complete listing of tip options and charts, call SDI or your local dealer for a new TeeJet Catalog. An example of using the chart and formula: Fixed Constants: G/1000 ft 2 =1 MPH = 2.9 W = 20 inch Nozzle Spacing GPM (per nozzle) = (G/1000 ft 2 x MPH x W) / 13 GPM (per nozzle) = (1 x 2.9 x 20) / 13 = 29 / 13 GPM (per nozzle) = 0.42 If we take the answer (0.213) and look at the chart on the next page, we see a brown XR tip at 30 psi (20 kpa) or a gray XR tip at a 20 psi (138 kpa) will apply the proper amount based on Rate/Speed & Spacing constants used in the formula. 37

38 7 SDI SPRAYER MAINTENANCE 38 Tip Color Tip No. (Strainer Screen) Liquid Pressure in PSI Capacity 1 Nozzle in GPM Capacity 1 Nozzle in oz/min 20 Nozzle Spacing Gallons Per Acres Gallons Per 1000 Square Feet 80 Series 110 Series 2 mph 3 mph 4 mph 5 mph 2 mph 3 mph 4 mph 5 mph Orange XR8001 (100 Mesh) XR11001 (100 Mesh) Green XR80015 (100 Mesh) XR (100 Mesh) Yellow XR8002 (50 Mesh) XR11002 (50 Mesh) Purple XR (50 Mesh) Blue XR8003 (50 Mesh) XR11003 (50 Mesh) Red XR8004 (50 Mesh) XR11004 (50 Mesh) Brown XR8005 (50 Mesh) XR11005 (50 Mesh) Grey XR800 (50 Mesh) XR1100 (50 Mesh) White XR8008 (50 Mesh) XR11008 (50 Mesh)

39 SDI SPRAYER MAINTENANCE DETERMINING AMOUNT OF CHEMICALS REQUIRED To determine the amount of chemicals to add to the spray tank, you need to know: The recommended application rate of the chemical. This information is given on the chemical label. The rate will be listed as pounds per acre (or pounds of active ingredient) for wettable powders and pints, quarts, or gallons per acre for liquids. The capacity of the tank. The Spraytek is equipped with a 300 gallon spray tank. The calibrated output of the sprayer. Example 1, Dry Formulation: A carbaryl recommendation calls for 2 pounds of active ingredient (a.i.) per acre. You have purchased Sevin (80- percent wettable powder). Your sprayer has a 300 gallon tank and is calibrated to apply 20 gallons per acre. How much Sevin should be added to the spray tank? 1. Determine the number of acres you can spray with each tankful Tank Capacity / Spray Rate = 300 / 20 = 15 Acres 2. Determine the pounds of pesticide product needed per acre. Because only 80% of thesevin in the bag is an active ingredient, you will have to add more than two pounds of the product to each "acre's worth" of water in your tank. Divide the percentage of active ingredient (80%) into the total (100%). 100 / 80 = 1.25 Multiply the result times the application rate. 2 lb/acre x 1.25 = 2.5 lb. Sevin per acre 3. Determine the amount of pesticide to add to each tankful. With each tankful you will cover 15 acres (Step 1), and you want 2.5 lbs. of product per acre (Step 2). 15 acres x 2.5 lb. sevin per acre = 37.5 lb. To apply the recommended application rate, you will need to add 37.5 lb. of Sevin for each full 300 gallon tankful. Example 2, Liquid Formulation: A trichlorfon recommendation calls for 1 pound of active ingredient (a.i.) per acre. You have purchased Dylox 4E (4 pounds per gallon formulation). Your sprayer has a 300 gallon tank and is calibrated at 15 gallons per acre. How much Dylox should you add to the spray tank? 1. Determine the number of acres you can spray with each tankful Tank Capacity / Spray Rate = 300 / 15 = 20 Acres 2. Determine the amount of product needed per acre. Divide the percentage of active ingredient (1 lb) into the concentration of the formula (4 lb / Gallon). 1 lb / 4 lb per gallon = 0.25 Gallon per acre 3. Determine the amount of pesticide to add to each tankful. With each tankful you will cover 20 acres (Step 1), and you want 0.25 Gallons of product per acre (Step 2). 20 acres x 0.25 Gallon Dylox per acre = 5 Gallons To apply the recommended application rate, you will need to add 5 Gallons of Dylox for each full 300 gallon tankful. Adjuvants: The chemical manufacturer may recommend that you add a small amount of an adjuvant (spreader-sticker, surfactant, etc.) in addition to the regular chemical. This recommendation is often given as "percent concentration." If you use an adjuvant at a 1/2% concentration by volume, how much should you add to a 300 gallon tank. Convert percentage into decimal form 1/2% = Multiply tank capacity by decimal amount of adjuvant 300 Gallons x = 1.5 Gallons adjuvant 39

40 7 SDI SPRAYER MAINTENANCE 7.12 ADDING WATER TO TANK. 1. Park Vehicle on level ground, turn off engine, place gear selector into neutral and apply the park brake.! CAUTION Use care when opening sprayer tank lid. Potentially dangerous chemical fumes may have accumulated inside tank. b. All nozzles should come on and develop a full pattern. Check boom, hoses and nozzles for leaks and faulty patterns. Repair and/or clean any items which may require attention. c. If all systems are operating properly, you may proceed to the loading and mixing area. 2. Remove the lid from the top of the spray tank by turning counter-clockwise (if unit is equipped with an anti-siphon device for back-flow protection, rotate and lock the goose neck filler into position). 3. Keep the strainer basket in place, attach the feeder hose to the goose neck filler or place hose end into tank opening to begin filling. Slowly, turn the water source on gradually bringing it up to full stream (avoid splashing). The basket strainer should always be left in place when adding any material to the tank. 4. Determine amount of spray mix to be used for your application. If the required amount is less than full tank capacity, fill to desired level. If the required amount is a full load, only fill tank to 3/4 full (this will leave room for adding the chemicals which will be mixed, the balance of the fill water will be added later). 5. If the pump suction strainer (filter) is not installed, do so at this time and open the suction gate-valve to the pump.. Start the engine and using the governor hand control, set the engine rpm's to 3,000 rpm's. 7. Flip the pump switch to the ON" position. Look into the open lid (remove basket temporarily to look inside the tank). You should be able to see the water moving around from the force of the agitation jets etc. (the agitation handle should be in the fully open position). 8. If there is no water movement from the jets or from the sump area, stop the engine and check the trouble-shooting guidelines for possible causes. 9. Once the system is operational, a quick test should be performed before adding any product to the tank. a. Lower the boom wings to their operating position. Turn on the Master Boom Control and adjust pressure to 40 PSI (27 kpa) on the controller gauge. Strainer Basket Suction Strainer (Filter) Agitation Jets Handle Tank Lid (Shown Removed) Liquid Level Sight Tube Suction Gate-Valve Figure 7D Figure 7E Figure 7F 40