Operator s Manual. Manufacturing, Inc. Tractor Mount Sprayer TM500 & TM700

Transcription

1 Operator s Manual TM500 & TM700 Tractor Mount Sprayer Manufacturing, Inc.! Read the operator s manual entirely. When you see this symbol, the subsequent instructions and warnings are serious - follow without exception. Your life and the lives of others depend on it! Cover illustration may show optional equipment not supplied with standard unit. Copyright 1997 Printed 5/13/ M

2 Table of Contents Important Safety Information Wear Protective Equipment Handle Chemicals Properly Safety Decals Introduction Intended Usage Models Covered Using This Manual Definitions Owner Assistance Preparation and Setup Tractor Requirements Before You Start Case/IH Tractor Mount Assembly Instructions John Deere Tractor Mount Assembly Instructions John Deere Tractor Mount Assembly Instructions Plumbing & Controls Instructions Agitation & Gauge Plumbing Boom & Attachment Plumbing Instructions Tractor / PTO Pump Hook-Up Tractor / Hydraulic Pump Hook-Up Quad-Jet Agitators {S.S. Tanks Only} Control Box Assembly {Manual Control Systems Only} Control Box Wiring Assembly Instructions {Manual Control System Only} Operating Instructions Basic Sprayer Operating Procedures Plumbing Operations {Manual Control System Only} Operating Pump Filling Tank Procedures Using Handwash Tank Operating Whirlfilter To clean-out the solution To clean out the tank-fill Transporting General Notes For Field Operation Adjustments Sprayer Pre-Calibrations Calibration Procedures Basic Sprayer Calibration Miles Per Hour Calibration Worn Nozzles & Flow Table Information TeeJet Worn Nozzles & Flow Table MeterCone Worn Nozzles & Flow Table Spraying Solutions Other Than Water Useful Formulas Check Valve Restriction Data Miscellaneous Conversion Factors General Field Adjustments Boom Height Nozzle Solenoid Throttling Valve {Manual Control System Only} Adjustments {Manual Control System Only} Troubleshooting Maintenance and Lubrication Maintenance Equipment Cleanup General Information Pump Maintenance & Repair Lubrication Storage Specifications and Capacities Appendix Torque Values Chart Warranty Copyright 1997 All rights Reserved Great Plains Manufacturing, Inc. provides this publication as is without warranty of any kind, either expressed or implied. While every precaution has been taken in the preparation of this manual, Great Plains Manufacturing, Inc. assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. Great Plains Manufacturing, Inc. reserves the right to revise and improve its products as it sees fit. This publication describes the state of this product at the time of its publication, and may not reflect the product in the future. Great Plains Manufacturing, Incorporated Trademarks The following are trademarks of Great Plains Mfg., Inc.: Application Systems, Ausherman, Land Pride, Great Plains All other brands and product names are trademarks or registered trademarks of their respective holders. Printed in the United States of America. 5/13/ M

3 Important Safety Information 1 Important Safety Information Look for Safety Symbol The SAFETY ALERT SYMBOL indicates there is a potential hazard to personal safety involved and extra safety precaution must be taken. When you see this symbol, be alert and carefully read the message that follows it. In addition to design and configuration of equipment, hazard control and accident prevention are dependent upon the awareness, concern, prudence and proper training of personnel involved in the operation, transport, maintenance and storage of equipment.! Be Aware of Signal Words Signal words designate a degree or level of hazard seriousness. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is limited to the most extreme situations, typically for machine components that, for functional purposes, cannot be guarded. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practices. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.! DANGER! WARNING! CAUTION 5/13/ M

4 2 Tractor Mount Sprayer Be Familiar with Safety Decals Read and understand Safety Decals, page 8, thoroughly. Read all instructions noted on the decals. Keep Riders Off Machinery Riders obstruct the operator s view. Riders could be struck by foreign objects or thrown from the machine. Never allow children to operate equipment. Keep all bystanders away from machine during operation. Shutdown and Storage Fold the Tractor Mount Sprayer Boom, put tractor in park, turn off engine, and remove the key. Secure Tractor Mount Sprayer using blocks and supports provided. Detach and store Tractor Mount Sprayer in an area where children normally do not play. OFF Use Safety Lights and Devices Slow-moving tractors and towed implements can create a hazard when driven on public roads. They are difficult to see, especially at night. Use flashing warning lights and turn signals whenever driving on public roads. Use lights and devices provided with implement. Use A Safety Chain Use a safety chain to help control drawn machinery should it separate from tractor drawbar. Use a chain with a strength rating equal to or greater than the gross weight of towed machinery. Attach chain to tractor drawbar support or other specified anchor location. Allow only enough slack in chain to permit turning. Replace chain if any links or end fittings are broken, stretched or damaged. Do not use safety chain for towing M 5/13/2003

5 Important Safety Information 3 Transport Machinery Safely Maximum transport speed for implement is 20 mph. Some rough terrains require a slower speed. Sudden braking can cause a towed load to swerve and upset. Do not exceed 20 mph. Never travel at a speed which does not allow adequate control of steering and stopping. Reduce speed if towed load is not equipped with brakes. Comply with state and local laws. Do not tow an implement that, when fully loaded, weighs more than 1.5 times the weight of towing vehicle. Carry reflectors or flags to mark Tractor Mount Sprayer in case of breakdown on the road. Keep clear of overhead power lines and other obstructions when transporting. Refer to transport dimensions under Specifications and Capacities, page 57. Do not fold or unfold the Tractor Mount Sprayer Boom while the tractor is moving. Avoid High Fluids Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic lines. Use a piece of paper or cardboard, NOT BODY PARTS, to check for suspected leaks. Wear protective gloves and safety glasses or goggles when working with hydraulic systems. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. 5/13/ M

6 4 Tractor Mount Sprayer Practice Safe Maintenance Understand procedure before doing work. Use proper tools and equipment. Refer to this manual for additional information. Work in a clean, dry area. Fold the Tractor Mount Sprayer, put tractor in park, turn off engine, and remove key before performing maintenance. Make sure all moving parts have stopped and all system pressure is relieved. Allow Tractor Mount Sprayer to cool completely. Disconnect battery ground cable (-) before servicing or adjusting electrical systems or before welding on Tractor Mount Sprayer. Inspect all parts. Make sure parts are in good condition and installed properly. Remove buildup of grease, oil or debris. Remove all tools and unused parts from Tractor Mount Sprayer before operation. OFF Prepare for Emergencies Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctor, ambulance, hospital and fire department near phone. 911 Tire Safety Tire changing can be dangerous and should be performed by trained personnel using correct tools and equipment. When inflating tires, use a clip-on chuck and extension hose long enough for you to stand to one side not in front of or over tire assembly. Use a safety cage if available. When removing and installing wheels, use wheel-handling equipment adequate for weight involved M 5/13/2003

7 Important Safety Information 5 Wear Protective Equipment Great Plains advises all users of chemical pesticides or herbicides to use the following personal safety equipment. Waterproof, wide-brimmed hat. Waterproof apron. Face shield, goggles or full face respirator. Goggles with side shields or a full face respirator is required if handling or applying dusts, wettable powders, or granules or if being exposed to spray mist. Cartridge-type respirator approved for pesticide vapors unless label specifies another type of respirator. Waterproof, unlined gloves. Neoprene gloves are recommended. Cloth coveralls/outer clothing changed daily; waterproof items if there is a chance of becoming wet with spray. Waterproof boots or foot coverings. Do not wear contaminated clothing. Wash protective clothing and equipment with soap and water after each use. Personal clothing must be laundered separately from household articles. Clothing contaminated with certain pesticides must be destroyed according to state and local regulations. Read chemical label for specific instructions. Wear clothing and equipment appropriate for the job. Avoid loose-fitting clothing. Prolonged exposure to loud noise can cause hearing impairment or loss. Wear suitable hearing protection such as earmuffs or earplugs. Avoid wearing radio headphones while operating machinery. Operating equipment safely requires the full attention of the operator. 5/13/ M

8 6 Tractor Mount Sprayer Handle Chemicals Properly Read and follow chemical manufacturer s instructions. Wear protective clothing. Handle all chemicals with care. Agricultural chemicals can be dangerous. Improper use can seriously injure persons, animals, plants, soil and property. Inhaling smoke from any type of chemical fire is a serious health hazard. Store or dispose of unused chemicals as specified by the chemical manufacturer. Before adding chemical to the tank, make sure tank is at least half full. Do not pour concentrate into an empty tank. Never leave fill hose attached to the sprayer after filling tank. Chemicals in tank can siphon out of tank and contaminate freshwater source. Always keep hand-wash tank filled with clean water and have soap available in case of an emergency. Immediately and thoroughly flush any area of the body that is contaminated by chemicals. Do not touch sprayer components with mouth or lips. If chemical is swallowed, carefully follow the chemical manufacturer s recommendations and consult with a doctor. If persons are exposed to a chemical in a way that could affect their health, consult a doctor immediately with the chemical label or container in hand. Any delay could cause serious illness or death. Dispose of empty chemical containers properly. By law rinsing of the used chemical container must be repeated three times. Puncture the container to prevent future use. An alternative is to jet-rinse or pressure rinse the container. Wash hands and face before eating after working with chemicals. Shower as soon as spraying is completed for the day. Spray only with acceptable wind conditions. Wind speed must be below 5 mph. Make sure wind drift of chemicals will not affect any surrounding land, people or animals. Never wash out the sprayer tank within 100 feet of any freshwater source or in a car wash. Rinse out the tank. Spray rinse water on last field sprayed M 5/13/2003

9 Important Safety Information 7 Safety At All Times Thoroughly read and understand the instructions in this manual before operation. Read all instructions noted on the safety decals. Be familiar with all Tractor Mount Sprayer functions. Operate machinery from the driver s seat only. Do not leave Tractor Mount Sprayer unattended with tractor engine running. Do not dismount a moving tractor. Dismounting a moving tractor could cause serious injury or death. Do not stand between the tractor and Sprayer Boom during hitching. Keep hands, feet and clothing away from power-driven parts. Wear snug-fitting clothing to avoid entanglement with moving parts. Watch out for wires, trees, etc., when folding and raising Sprayer Boom. Make sure all persons are clear of working area. Do not turn tractor too tightly, causing Sprayer Boom to ride up on wheels. This could cause personal injury or equipment damage. Use only water without pesticides added to calibrate the sprayer. Do not exceed the calibrated sprayer speed and pressure when operating. When using a PTO pump, be sure that PTO shield is in place on the tractor, PTO coupler bolts are torqued to the correct specification, and torque bar is properly chained to tractor drawbar. Spray with the boom in the unfolded position only. The boom has many pinch points during field operation and folding. Keep all bystanders away. 5/13/ M

10 8 Tractor Mount Sprayer Safety Decals Your implement comes equipped with all safety decals in place. They were designed to help you safely operate your implement. Read and follow decal directions. Keep all safety decals clean and legible. Replace all damaged or missing decals. Order new decals from your Great Plains dealer. Refer to this section for proper decal placement. When ordering new parts or components, also request corresponding safety decals. To install new decals: 1. Clean the area where the decal is to be placed. 2. Peel backing from decal. Press firmly on surface, being careful not to cause air bubbles under decal C Caution! General Sprayer Safety Information C Danger! Power line hazard C Caution! Use proper personal safety equipment. Also, refer to previous page M 5/13/2003

11 Important Safety Information C Caution! Do Not run pump dry C Notice! Gauge protector C Notice! Control box power leads. 5/13/ M

12 10 Tractor Mount Sprayer Introduction Great Plains welcomes you to its growing family of new product owners. This Tractor Mount Sprayer has been designed with care and built by skilled workers using quality materials. Proper setup, maintenance and safe operating practices will help you get years of satisfactory use from the machine. Intended Usage Use this Tractor Mount Sprayer as part of a pressurized sprayer system to apply liquid pesticides, herbicides or fertilizers to production-agriculture crops only. Do not modify sprayer for use with attachments other than those approved by Great Plains. Models Covered TM500 & TM700 Tractor Mount Sprayer Using This Manual This manual will familiarize you with safety, assembly, operation, adjustments, troubleshooting and maintenance. Read this manual and follow the recommendations to help ensure safe and efficient operation. The information in this manual is current at printing. Some parts may change to assure top performance. Definitions The following terms are used throughout this manual. Right-hand and left-hand as used in this manual are determined by facing the direction the machine will travel while in use unless otherwise stated. Owner Assistance If you need customer service or repair parts, contact a Great Plains dealer. They have trained personnel, repair parts and equipment specially designed for Tractor Mount Sprayer products. Your machine s parts were specially designed and should only be replaced with Tractor Mount Sprayer parts. Always use the serial and model number when ordering parts from your Great Plains dealer. Record your sprayer model and serial number here for quick reference: Model Number: Serial Number: Your Great Plains dealer wants you to be satisfied with your new machine. If you do not understand any part of this manual or are not satisfied with the service received, please take the following actions. 1. Discuss the matter with your dealership service manager. Make sure they are aware of any problems so they can assist you. 2. If you are still unsatisfied, seek out the owner or general manager of the dealership. 3. For further assistance write to: Product Support Great Plains Mfg. Inc., Service Department PO Box 5060 Salina, KS IMPORTANT: A crucial point of information related to the preceding topic. For safe and correct operation, read and follow the directions provided before continuing. NOTE: Useful information related to the preceding topic M 5/13/2003

13 Preparation and Setup 11 Preparation and Setup Tractor Requirements To operate your Great Plains Sprayer, a tractor using a 12 volt electrical system must be used. The tractor will need two hydraulic outlets (one pair) if the sprayer is equipped with a hydraulic pump. Before You Start Read and understand the owners manual for your sprayer. A basic understanding of how the sprayer works will aid in the assembly, setup and operation of your sprayer. Before attempting to assemble the sprayer, use the following as a checklist. Having all the needed parts and equipment readily at hand will speed up your assembly task and will make the job as safe as possible. 1. Check for all sprayer components and hardware. 2. If a bolt, pin or other component has been removed, or if you are unsure about where it is used, refer to the parts manual to identify it. Case/IH Tractor Mount Assembly Instructions Refer to Figure 2 on page 12 To assemble the side-mount tanks, you will need to remove the steps, the front fenders (if equipped) and possibly other components to fit the tanks onto the tractor. 1. Assemble the right (1) and left (2) side plates onto the front of the tractor frame using the twelve 5/8" x 5" long bolts, flat washers and flange nuts. 2. Remove the two front bolts from the tractor drawbar support (3). 3. Assemble the rear bracket support (4) with the two longer M16.2.0x75 metric bolts (5) and 5/8" flat washers included. 4. Bolt together the right (1) and left (2) side plates to the rear bracket support (4) with the six 5/8" x 2" long bolts, flat washers and flange nuts. 5. Assemble the two tank rails (6) onto the right (1) and left (2) side plates with the backup plates (7), 5/8" x 6" long bolts, flat washers, and flange nuts. There are three locations to bolt these rails. Make sure that when you fasten the rails on that you bolt them in the same perspective hole locations or else the tanks won t fit on the rails. 6. Position the notched tank on the left rails and the full tank on the right rails with the tank caps toward the outside.! WARNING Lifting Hazard -Use a crane or hoist to lift and position the tanks. -The tanks can fall causing potential injury if not handled correctly. Move the tanks so that there is sufficient clearance between the tanks and the tractor. Refer to Figure 1 7. Assemble the angles (8) onto the outer holes in the tank saddles using the 3/4" x 1 3/4" long bolts, and flange nuts. There are four angles on each saddle that support the four corners of the saddle. 8. Hook the four angle brackets (9) onto the rails for each tank and bolt them to the angles (8) using the 1/2" x 1 3/4" long bolts, and flange nuts. Release the overhead support of the tanks after they are securely fastened. 9. Check and make sure all nuts are torqued to the correct specs listed in the Torque Values Table on page Proceed with the Plumbing & Controls Instructions on page Figure 1 Angles on Saddle 5/13/ M

14 12 Tractor Mount Sprayer Figure 2 Case/IH Tractor Mount Assembly Instructions M 5/13/2003

15 Preparation and Setup 13 John Deere Tractor Mount Assembly Instructions Refer to Figure 3 To assemble the side-mount tanks, you will need to remove the steps, the front fenders (if equipped) and possibly other components to fit the tanks onto the tractor. 1. Assemble the left (1) and right (2) side plates onto the front of the tractor frame using the eight 5/8" x 2" long carriage bolts, flat washers and flange nuts. 2. Mount the spreader bar (3) onto the left and right side plates with the u-bolts, 5/8" flange nuts, and washers but do not tighten the nuts completely. 3. Determine where the left (4) right (5) side rails will be positioned so that when the tanks are mounted, there will be sufficient clearance between the tires and the tanks. You will have to slide the spreader bar (3) to position where the rails will be. 4. Fasten the left (4) and right (5) side rails to the spreader bar (3) with four 5/8" x 2" long carriage bolts, flat washers, and flange nuts on each rail. Support the rear of the rails by assembling a few of the bolts in step After determining where the left and right rails (4 & 5) will be positioned, use the optimum holes in the rear portion of the rails (4 & 5) with the two spacer blocks (6), four backup angles (7), eight 5/8" x 11 1/2" long bolts (8), and the eight 5/8" flange nuts and washers. 6. Tighten all the hardware on all the components assembled to the correct torque specifications listed on page Assemble the four tank rails (9) using the 5/8" x 2" long bolts, flat washers and flange nuts. 8. Position the notched tank on the left rails and the full tank on the right rails with the tank caps toward the outside.! WARNING Lifting Hazard -Use a crane or hoist to lift and position the tanks. -The tanks can fall causing potential injury if not handled correctly. Move the tanks so that there is sufficient clearance between the tanks and the tractor. 9. Assemble the angles (10) onto the outer holes in the tank saddles (refer to Figure 1 on page 11) using the 3/4" x 1 3/4" long bolts, and flange nuts. There are four angles on each saddle that support the four corners of the saddle. 10. Hook the four angle brackets (11) onto the rails for each tank and bolt them to the angles (10) using the 1/2" x 1 3/4" long bolts, and flange nuts. Release the overhead support of the tanks after they are securely fastened. 11. Check and make sure all nuts are torqued to the correct specs listed in the Torque Values Table on page Proceed with the Plumbing & Controls Instructions on page 15. Figure 3 John Deere Tractor Mount Assembly Instructions /13/ M

16 14 Tractor Mount Sprayer John Deere Tractor Mount Assembly Instructions Refer to Figure 4 To assemble the side-mount tanks, you will need to remove the steps, the front fenders (if equipped) and possibly other components to fit the tanks onto the tractor. 1. Assemble the left (1) and right (2) side plates onto the front of the tractor frame using the eight 5/8" x 2" long carriage bolts, flat washers and flange nuts. 2. Mount the spreader bar (3) onto the left and right side plates with the u-bolts, 5/8" flange nuts, and washers but do not tighten the nuts completely. 3. Determine where the left (4) right (5) side rails will be positioned so that when the tanks are mounted, there will be sufficient clearance between the tires and the tanks. You will have to slide the spreader bar (3) to position where the rails will be. 4. Fasten the left (4) and right (5) side rails to the spreader bar (3) with four 5/8" x 2" long carriage bolts, flat washers, and flange nuts on each rail. Support the rear of the rails by assembling a few of the bolts in step After determining where the left and right rails (4 & 5) will be positioned, use the optimum holes in the rear portion of the rails (4 & 5) with the two spacer blocks (6), four backup angles (7), and the eight 5/8" x 10" long bolts (8), flange nuts and washers. 6. Tighten all the hardware on all the components assembled to the correct torque specifications listed on page Assemble the front two tank rails (9) using the eight 5/8" x 2" long bolts, flat washers and flange nuts. 8. Assemble the rear to tank rails (10) using the four 5/8" x 5" bolts, four 5/8" x 2" long bolts and the eight 5/8" flange nuts and flat washers. 9. Position the notched tank on the left rails and the full tank on the right rails with the tank caps toward the outside.! WARNING Lifting Hazard -Use a crane or hoist to lift and position the tanks. -The tanks can fall causing potential injury if not handled correctly. Move the tanks so that there is sufficient clearance between the tanks and the tractor. 10. Assemble the angles (11) onto the outer holes in the tank saddles (refer to Figure 1 on page 11) using the 3/4 x 1 3/4" long bolts, and flange nuts. There are four angles on each saddle that support the four corners of the saddle. 11. Hook the four angle brackets (12) onto the rails for each tank and bolt them to the angles (11) using the 1/2" x 1 3/4" long bolts, and flange nuts. Release the overhead support of the tanks after they are securely fastened. 12. Check and make sure all nuts are torqued to the correct specs listed in the Torque Values Table on page Proceed with the Plumbing & Controls Instructions on page 15. Figure 4 John Deere Tractor Mount Assembly Instructions M 5/13/2003

17 Preparation and Setup 15 Plumbing & Controls Instructions Refer to Figure 5 1. Measure the distance A to determine where the tank union tee should be placed. 2. The length B and length C should be as follows: Length B 75% of Length A Length C 25% of Length A! CAUTION Chemical Hazard Make sure the tank union tee is assembled according to instructions. Failure to place the tee in the correct position may cause water overflow out of a tank when filling the tanks. Chemical residue previously in the tank could be exposed to the environment if the fill-water is spilled. Refer to Figure 6 on page Assemble the 1 1/2" hose barb tank union tee (1) with the correct length of 1 1/2" ID hose according to the measurements you determined in step 2. It is recommended to use petroleum jelly or some type of lubricant in the inside diameter of the hose before it is assembled on the hose barbs. It will make the assembly much easier. Tighten the #28 hose clamps after the hose is assembled. 4. Mount the quick-fill bracket (2) on the front of your tractor so that the fill-coupler is easily accessed. You may be able to place the quick-fill bracket in-between two tractor weights. 5. Cut a short section of 1 1/2" hose (3) and assemble a second 1 1/2" hose barb tee (4) on the section of hose. Fasten the hose with the #28 hose clamps when finished. 6. Measure out and cut a section of 1 1/2" ID hose from the tee (4) to the hose barb (5). Secure the #28 hose clamps when finished. Use plastic cable-ties 6) to secure the hose to the tractor. Make sure the hose does not droop below the tractor where it could get caught. 7. Attach another short section of 1 1/2" ID hose (7) in between tee (4) and the tee assembly (8). Tighten the #28 hose clamps. 8. Follow the Tractor/PTO Pump Hook-Up on page 20 {if equipped} and mount the pump onto the tractor. 9. Measure and assemble a section of 1 1/2" ID hose from the tee assembly (8) to the pump with a 1 1/2" hose barb elbow (9) just below the pump. The section of hose in-between the hose barb elbow (9) and the pump should be less than a foot long. Tighten the #28 hose clamps. 10. Use cable ties (6) to secure the hose under the tractor Figure 5 Tank Union Tee 5/13/ M

18 16 Tractor Mount Sprayer Figure 6 Plumbing Assembly Instructions M 5/13/2003

19 Preparation and Setup 17 Refer to Figure Cut a 1" ID hose (10) that leads from the pump to the solution Whirlfilter hose barb. You will need to place 1" elbow hose-barbs (11) as shown to orient the hose up the side of the tank. Measure out and cut a length of hose guard material (14) along the area between the tractor and the tank, and route hose from pump to Whirlfilter hose barb through the hose guard material. Pump suction and pressure line should also be routed through the hose guard material where sharp corners exist under the tractor transmission area. Tighten the #16 hose clamps. 12. Use cable ties (6) to secure the hose under the tractor Figure 7 Head Assembly 5/13/ M

20 18 Tractor Mount Sprayer Refer to Figure Cut a 1" ID hose (12) that leads from the tee assembly (8) to the bypass elbow. A 1" hose-barb elbow will need to be in place at the bottom and top of the tank as shown. An additional 1" elbow (13) will need to be assembled so that the hose can be connected without kinking. Also route this hose through hose guard material between tractor and tank. Tighten the #16 hose clamps on all hose ends after assembling the hose. 14. Use cable ties (6) to secure the two hoses Figure 8 Solenoid Valve Assembly M 5/13/2003

21 Preparation and Setup 19 Agitation & Gauge Plumbing Refer to Figure 9 1. Assemble a section of 1" hose (1) on to the agitation hose barb (2). Route the hose along the other two hoses assembled in Figure 6 on page Place the 1" hose barb elbow (3) so that the vertical section of the 1" hose guard material {Figure 6 (14)} that secures the other two hoses {Figure 6 (10) & (12)} assembled vertically along the side of the tank. 3. Secure the hose to the hose barbs with the number 16 hose clamps. After all the hoses are routed through the hose guard material {Figure 6 (14)}, fold the ends of the hose guard material back underneath and tie with cable ties {Figure 6 (6)}. 4. Attach the tee assembly (4) to the vertical 1" hose. 5. Measure and cut two pieces of hose 3/4" (5) so that they are assembled from the tee assembly (4) to the agitation elbow (6) on both tanks. Secure the number 12 hose clamps on the 3/4" hose. 6. Cut a section of 3/8" hose (7) to a length that is satisfactory for where you will place the gauge on the tractor. Route the hose from the 3/8" hose barb on the solenoids to the 3/8" hose barb on the gauge assembly as shown. Secure the hose with the number 5 hose clamps Figure 9 Agitation Assembly 5/13/ M

22 20 Tractor Mount Sprayer Boom & Attachment Plumbing Instructions Refer to Figure 8 on page If the 3-point boom is being mounted on a tractor with Great Plains side-mount tanks remove the cap plugs on the solenoid hose barbs and route the left boom feed-line hose from the corresponding female fluid connector to the right solenoid (right being as you sit in the tractor) marked with red tape. Connect the center boom feed-line hose from the corresponding female fluid connector to the middle solenoid marked with yellow tape. Now aconite the right feed-line hose from the corresponding female fluid connector to the left solenoid marked with green tape. Take care when routing the boom hoses to the tractor to ensure there will be no kinking, drooping, hanging bellow the tractor, or rubbing on the tractor frame when in operation. Route boom hoses through the remaining hose guard material along the front side of the left-hand tank. 2. If the Great Plains side-mount tanks are being mounted with another implement, route and connect the hoses to the solenoid valve as described in (1) above. Tractor / PTO Pump Hook-Up 1. With the tractor not running, position the PTO pump on the tractor s PTO shaft with the coupler bolt loose on the splined end. 2. Push the coupler of the pump on to align with notch in the tractor PTO shaft and install bolt. 3. Make sure there is adequate hose length to reach the pump. 4. If you have a 540 RPM pump or a 1000 RPM 1 3/8 inch spline pump, torque the 1/2 inch Grade 8 coupler bolts to 105 ft-lbs. If you have a 1000 RPM 1 3/4 inch spline PTO pump, torque the 5/8 inch Grade 8 coupler bolt to 210 ft-lbs and the other 1/2 inch Grade 8 coupler bolt to 105 ft-lbs. 5. Rotate the PTO shaft by hand to make sure the bolts clear the PTO shielding. 6. Attach the torque bar chain to the drawbar securely. 7. Hook the tarp strap in such a way that the slack in the chain is taken up slowly when the PTO is engaged so the torque bar does not bang. 8. Tie up any loose hoses with cable ties to prevent hose damage. Tractor / Hydraulic Pump Hook-Up 1. Your tractor should be equipped with at least two remote outlets (one pair). 2. If your tractor has an open-center hydraulic system, remove the orifice restrictor in the pressure line. If your open-center hydraulic system produces more than 15 GPM, it is not recommended to hook this hydraulic pump up to your tractor. Without a flow divider of adequate capacity the pump will spin too fast. If your open-center hydraulic system is 15 GPM or less, it is recommended to install a hydraulic flow divider so that you can adjust the speed of the pump. A Gresen model number CFDA or similar flow divider will work. The maximum flow for the hydraulic motor is 6 GPM. 3. For the hydraulic motor to turn in the right direction, the pressure hose must be connected to the "A" port of the motor and the return line connected to the "B" port. Install hydraulic hose clamp label provided {refer to hydraulic pump section in parts manual} approximately18 inches from tractor quick couplers so that the hydraulic cylinder retract symbol and arrow aligns with the pressure hose going to motor port "A". If your tractor is a John Deere, leave the restrictor in the pressure side of the hydraulic pump. If your tractor has a closed center hydraulic system and is not a John Deere, remove the restrictor. 4. If your tractor has a closed-center system, or a flow divider has been installed in your tractor s open-center system, set the hydraulic flow control valve at a minimum flow for the pair of outlets that operates the pump. 5. With water in the sprayer tank, and water in the pump, place the hydraulic lever in the float position and start the tractor. 6. Place a stop in the neutral position of your tractor hydraulics so that the lever can only be moved to the float and down positions. Refer to your tractor operator s manual or tractor dealer on information for the neutral stop. IMPORTANT: DO NOT move the hydraulic lever into the neutral position while the hydraulic pump is running. To do so may cause damage to the hydraulic pump. 7. To set the hydraulic flow control on the tractor, first engage the pump by placing the hydraulic lever in the down position. Once the system builds pressure, close the agitation valve, shut off the boom section switches and close throttling valves {if applicable} M 5/13/2003

23 Preparation and Setup 21 Sprayers with Raven Automatic Monitors do not have throttling valves. The pump is now at dead head pressure. Adjust the hydraulic flow control valve so that the spray pressure reaches 80 maximum on the nozzle pressure gauge. If so equipped, reset the solenoid throttling valves as described in the "Solenoid Throttling Valve" on page 51. Quad-Jet Agitators {Stainless Steel Tanks Only} Refer to Figure 10 The Quad-Jet agitator is the agitator in the stainless steel tank. Each agitator has four holes that shoot jets of water out at a high velocity. The agitator head is oriented at 45 degrees, with reference to the tank ends, so that the water jets are aimed at the corners of the tank. To ensure proper agitation, make sure that the agitator head is always kept in the orientation as shown Figure 10 Tank Top View Quad-Jet Agitator Head Orientation 5/13/ M

24 22 Tractor Mount Sprayer Control Box Assembly {Manual Control Systems Only} Refer to Figure Remove the solenoid cover to gain access to the solenoid terminals. 2. Mount the control box on your tractor. Connect the red wire (1) to the positive terminal of the 12 volt battery and the white wire (2) to the negative terminal. You will need to pull the red and white wires out of the black harness (3) until there is enough wire to reach the battery. Note: You may want to attach the battery leads (4) to the battery terminals and the control box power leads so that the control box can be disconnected easily. After the power leads (1) & (2) are hooked to the battery, you should be able to turn on the master switch and see the red power light come on. Turn the master switch OFF BEFORE proceeding to the next step. 3. Attach the electric solenoid cord (5) to the solenoids as shown. The green wire attaches to the front solenoid {front being toward the hitch}. The yellow wire attaches to the middle solenoid and the brown wire attaches to the rear solenoid. Connect the other wire {white} to all three solenoids. 4. Hook up the electric solenoid cord (5) to the solenoid plug (6). You may need to use the extension cord included to reach the solenoid valves more easily. Turn the master switch on and flip the boom section switches to see if the solenoids are operating properly. The left boom switch should operate the front solenoid, the center boom switch should operate the middle solenoid, and the right boom switch should operate the rear solenoid. If the switches don t correspond with the correct solenoids, check your electric cord assembly in step 3, or the wiring of the control box under "Control Box Wiring Assembly Instructions" on page Attach the electric ball valve cord (7) to the terminals (8) on the electric ball valve. 6. Hook up the electric ball valve cord (7) to the ball valve plug (9). You may need to use the extension cord included to reach the ball valve. Turn the master boom switch and flip the pressure adjust switch. The ball valve should operate when the switch is flipped. 7. Reassemble the solenoid cover over the top of the solenoids Figure 11 Control Box Assembly M 5/13/2003

25 Preparation and Setup 23 Control Box Wiring Assembly Instructions {Manual Control System Only} Refer to 12 The electrical assembly schematic is shown for the control box in a view that is looking into the back of the box with the cover off. There are four separate wiring harnesses that enter into the control box along with the positive and negative power leads. In this control box, the red wires are always positive and the white wires are always negative. Other colored wires could be positive or negative. Make sure that all wires are attached as shown in the schematic. There are two wire nuts that attach several wires at once and are displayed by the large asterisk (*) signs in the drawing. Attach the wires as shown in the drawing for any electrical repair work. This will also serve as a guide for replacing the electrical wiring. Refer to "Sprayer Control Box Assembly" in the parts manual. IMPORTANT: Disconnect battery leads before working on any electrical components in this control box. Failure to do so may result in damage to the electrical components Figure 12 Control Box Wiring Assembly 5/13/ M

26 24 Tractor Mount Sprayer Operating Instructions Basic Sprayer Operating Procedures 1. Make sure to read the label on the chemical compound that is to be applied. It is the law. 2. Consider how the chemical will be stored and how you will dispose of the chemical, according to the chemical label. 3. When calibrating, filling the tank, or working around chemicals, wear protective clothing that covers the body. Refer to "Personal Safety Equipment" on page 5. Have soap and clean water available to wash any exposed areas. Never open a container with your bare hands. 4. When filling the sprayer, it is better to mix the chemical in the field where it is to be applied. Position the sprayer 100 feet from any well or other water source BEFORE mixing chemical. 5. By law, you must repeat the rinsing of the chemical container 3 times. The container should then be punctured to prevent future use. An alternative is to jet-rinse or pressure rinse the container. 6. Check the condition of hoses and connections frequently. Release system pressure BEFORE working on the sprayer by shutting off the pump and flipping the individual boom section switches on the control box. ALWAYS wear rubber gloves when making repairs or adjustments. 7. If equipped with level-float boom, remove the level float pin and place in the storage position after unfolding the boom. Refer to your Great Plains Boom Manual for more information. Note: If possible, do not operate your Great Plains Sprayer Boom without first unlocking the level-float pin. The boom will float over the contours of the ground more effectively and minimize stress on the boom. 8. Apply spray when the wind is 5 m.p.h. or less. Minimize drift by using nozzle tips with the largest practical openings and by operating the sprayer boom at the lowest practical height and lowest practical pressure. 9. Drive at the same speed you used in your calibration. Refer to "Sprayer Calibrations" on page 28. Keep your sprayer calibrated. 10. If possible work crosswise to the wind, starting from the downwind side of the field. Do this so you won t ever be heading directly into chemical fumes. 11. Take note of adjoining crops, houses, gardens, people, etc. 12. When you are finished spraying, empty the tank and flush the sprayer with water, including the pump, the nozzles and the bypass line from the solenoids. Properly store the chemical emptied from the tank or dispose of it by the recommendations on its label. 13. When turning at the end of a field, make sure you are correct on the rows so that the boom will not overlap on crop previously sprayed. Plumbing Operations {Manual Control System Only} The basic plumbing diagrams are shown for the tractor mount plumbing. A basic knowledge of how the sprayer is plumbed will help you to understand how to operate you Great Plains Sprayer. Throughout this manual, the components on this diagram will be described with the terminology labeling these components. For further details about the plumbing components, refer to the parts manual. Fluid is drawn out of the sump in the tank and passes through the pump. From the pump it passes through the solution Whirlfilter and filters out or grinds up all undissolved chemical and solid particles. The fluid then passes through the agitation ball valve or proceeds through the electric pressure adjustment ball valve. If the fluid passes through the electric ball valve, it proceeds to the 3-way solenoid valves. If a solenoid valve is on, the fluid passes to its perspective boom section and is sprayed out the individual nozzles. If that solenoid is off, the fluid bypasses back into the pump inlet. You can monitor the nozzle pressure gauge and adjust the pressure to the booms by adjusting the pressure switch on the control box. The pressure switch rotates the electric ball valve. To decrease the sensitivity of the pressure adjustment switch the manual pressure adjustment valve must be set. To set this valve, run the pump at the same rpm you would when spraying. Open the electric ball valve completely and adjust the manual pressure adjustment valve down so that the nozzle pressure gauge reads 10 to 20 psi greater than the pressure you will spray at. This will decrease the amount of flow to the electric ball valve and reduce its sensitivity. Note: When pressure is increased at a later date, the manual pressure adjustment valve will need to be opened M 5/13/2003

27 Operating Instructions 25 The agitation can be set by adjusting the agitation pressure valve while the pump is at operating speed. Adjust the valve until you get the desired agitation pressure you would like on the agitation pressure gauge. There are tank shut off valves everywhere there is an outlet from the tank so that if there is a leak, the source can be shut off and the chemical spill reduced. These valves need to be wide open when the sprayer is in use. IMPORTANT: Do not move the hydraulic lever to the neutral position while the hydraulic pump is running. To do so may cause damage to the hydraulic pump. Filling Tank Procedures! CAUTION When filling the sprayer tank, use a check valve or anti-siphon device to prevent the solution in the tank from infiltrating into the fresh water source and contaminating it. Your Great Plains Sprayer fills the tank from the bottom of the tank and uses a standard 2 inch Cam-Lock coupler to connect to the freshwater hose. An 1 1/2 inch camlock coupler is also available as an accessory. Refer to "Quick Fill Assembly" in the parts manual. 1. To fill the tank, hook up the freshwater hose to the quick-fill camlock coupler with the quick-fill ball valve in the closed position. 2. Turn the water on and open the quick-fill ball valve for the freshwater to enter the tank. When using a positive displacement pump to fill the tank, open the quick fill ball valve first and then pump water into the tank Plumbing Diagrams Stainless Steel Tank {Manual Control System Only} Operating Pump To operate the PTO pumps, engage the PTO shaft slowly at the tractor s idle throttle position. Slowly accelerate to the desired PTO RPM (On a 540 RPM pump it is recommended to operate the pump at 540 RPM and on a 1000 RPM pump it is recommended to operate the pump at 1000 RPM). Disengage the PTO at any RPM to stop the pump.! WARNING Never operate the PTO pump without the tractor PTO shield in place, and the pump torque bar firmly chained in place. To operate the hydraulic pump, first make sure that the hydraulic hoses are routed correctly so that the pump turns in the correct direction. See the Tractor/Hydraulic Pump Hook-Up on page 20, for more details. To run the pump, push the hydraulic lever in the down position. When you want to stop the pump, push the hydraulic lever in the float position.! CAUTION Do not add the chemical until you are at the field, just prior to spraying. When you add the chemical, follow the manufacturer s instructions for mixing the spray solution in order to achieve the desired application rate.! CAUTION Read the manufacturer s label carefully before handling chemicals. 3. Before you add the chemical to the tank, make sure the tank is at least one half full. The concentrate should not be poured into an empty tank. 4. Keep the spray solution away from all skin. Wear protective clothing and goggles. If the solutions comes in contact with the body, wash off the contaminated area with soap and water. 5. Keep chemical containers low when pouring. 6. Let the wind blow fumes and dust away from you while pouring the chemical. 7. DO NOT smoke while handling chemicals. 5/13/ M

28 26 Tractor Mount Sprayer Using Handwash Tank In the event when an accident occurs and chemical is spilled on your skin or in your eyes, use the Handwash Tank to flush away the chemical. 1. Open the tank valve and use the hose to direct the clean water on all contaminated areas. Wash all areas of skin that has been contaminated with soap and water. To flush your eyes, point the hose and water stream upward while you lower your eye into the stream of flowing water. 2. Close the tank valve and refill the handwash tank with fresh water when you are finished. 3. Periodically refill the handwash tank with fresh water. ALWAYS keep the handwash tank clean. Operating Whirlfilter There are two Whirlfilters on your Great Plains Sprayer. One filters the water entering the tank and the other filters the chemical solution being sprayed. Transporting 1. Park your sprayer in an open area where you will not hit power lines, buildings, etc. when the boom is folded. 2. Secure the level-float pin in the lock position, if using a level float boom. 3. NEVER allow riders when transporting the sprayer. 4. When transporting your sprayer, be sure to watch the height clearances of your folded boom to prevent damage to the boom and possible injury.! DANGER Contact with electrical power lines can cause death by electrocution. 5. DO NOT exceed 20 mph transporting your sprayer. 6. DO NOT transport sprayer while filled with chemical mixture. To clean-out the solution Whirlfilter, proceed with the following: 1. Fill the sprayer tank with water and turn the pump on. 2. With the pump running, slowly open the clean-out valve and allow the grit to flow out into a bucket. Clean out the solution Whirlfilter only when the sprayer tank is filled with water and no chemical has been added. 3. Close the clean-out valve and turn off the pump. 4. Dispose of the grit and water in the same manner described on the manufacturer s label of the latest chemical used in the sprayer. To clean out the tank-fill Whirlfilter, proceed with the following: 1. Start with an empty sprayer tank. 2. Position a bucket under the plug in the sump of the Whirlfilter and allow the grit to fall out. 3. Screw the plug back in using pipe thread sealant to seal the plug. 4. Dispose of the grit and water in the same manner described on the manufacturer s label of the latest chemical used in the sprayer M 5/13/2003