Owner's Manual Plastic Lifter/Wrapper Model PR200 PaulB LLC 0 Wood Corner Rd Lititz PA 13 www.cropcareequipment.com (1) 38-30 A Paul B Zimmerman Inc. Company Form OM0013B Rev. Date /10
CropCare would like to thank you for choosing to purchase one of our plastic wrappers. We appreciate your business and want to fill all of your sprayer and equipment needs. We also desire to provide you with the technical support and needed parts that will allow you to continue operating without disruption. For parts and service please contact your local CropCare dealer. Table Of Contents Before You Begin...3 Safety Precautions... General Guidelines Before Operation During Operation Following Operation Operating Instructions... Setting the Width Setting the Depth Preparing for Wrapping Using the Control Levers Plastic Wrapping 8 Removing the Plastic 8 Maintenance Instructions...9 Routine Maintenance 9 Adjusting the Reels 9 Hose Maintenance 9 Breakdowns & Parts Lists...10 PR200 Breakdown 10 PR200 Parts List 10 Hydraulic Hose Kit Layout & Breakdown 12 Gauge Wheel Breakdown & Parts List 13 Side Coulter Breakdown & Parts List 1 Center Coulter Breakdown & Parts List 1 Reel Breakdown & Parts List 1 CropCare Limited Warranty...1 Contact Us...18 Ordering Parts 18 Before You Begin Please read and understand this manual and its instructions and warnings completely before operating the picking assistant. Be aware of all safety guidelines, warnings, and cautions. Familiarize yourself and other operators with the plastic wrapper s components and how all parts are operated. Always remember that good safety practices are the most important part of operating a piece of equipment. 3
Safety Precautions General Guidelines Every year many unnecessary accidents occur due to improper equipment handling and a disregard for safety precautions. You, the operator, can avoid accidents by observing the precautions in this section. The operators of the tractor and the plastic wrapper should be responsible adults. Do not allow persons to operate this machine until they have displayed a thorough understanding of the safety precautions and operational use! Figure 1: Moving parts warning decal (DE2) Never attempt to operate this machine while under the influence of alcohol or drugs. The best defense against accidents is a careful and responsible operator. Be aware of the location of all safety warning decals (Figures 1-2). When transporting the plastic wrapper on public roads, always follow state and local regulations regarding safety and transportation requirements. Use the necessary lights and slow moving vehicle (SMV) emblems. If there is any portion of this manual that you do not fully understand, please contact an authorized CropCare dealer. Figure 2: Owner s Manual Decal (DE39) Before Operation Carefully study and understand this owner s manual. Give the plastic wrapper a visual inspection for any worn parts, loose bolts, or other visible problems, and make any needed repairs. See the maintenance section (page). Have all operators practice operating the plastic wrapper until all operators are completely capable of safe operation. Do not wear loose-fitting clothing which may catch in moving parts. Ensure that the plastic wrapper does not exceed the tractor s load rating. The plastic wrapper, when empty, weighs approximately 1000 lbs. Never check for hydraulic hose leaks with your hands! If oil penetrate s the skin and enters the bloodstream, it could result in serious injury or death. If there is any visible damage to the hoses, replace them immediately. Make sure that the operating area is clear of any people or obstructions before using the plastic wrapper. Do not allow people near the plastic wrapper at any time during operation! Never allow personell to ride on the operator s platform while the wrapper is in the raised position for transport!
Satey Precautions During Operation Always be aware of bystanders, particularly children! Never allow anyone, other than the operator, near the plastic wrapper when it is in operation or when the tractor is running. No passengers are allowed on or in the picking assistant at any time. Be aware of the spinning reel which holds the plastic! Never allow anyone to adjust, clean, or be near the reels while the tractor is running! Keep all body parts, clothing, and tools (including the reel release bar) away from the reels during operation. Failure to follow these safety warnings could result in serious injury or death. Always turn the tractor off before removing plastic from the reels! Excersise caution when using the reel release bar due to the fact that the reel is under much tension. Never attempt to operate the plastic wrapper alone! One person must operate the tractor while another person operates the plastic wrapper. The plastic wrapper operator needs to follow special safety precautions. Never jump off of the plastic wrapper during operation! Always keep both hands on the grab rails. This practice will ensure stability in the case of sudden movements casued by uneven terrain. The operator of the tractor shouldn t routinely turn around to check the plastic wrapper. The tractor operator s main focus should be on driving. The plastic wrapper operator should signal verbally if the tractor operator should stop or adjust the speed. Never obstruct the movement of the control levers! The levers must be able to return to the neutral position when released. Never operate the tractor at speeds over mph. Practice special caution when operating the plastic wrapper on uneven surfaces and on inclines. Do not attempt to operate the plastic wrapper on terrain that will, or could possibly, endanger the tractor or plastic wrapper operator! Be aware of dangerous terrain such as holes, slopes, drop-offs, banks, rocks, and hidden hazards. Remember that accidents can even happen to seasoned operators. Always take the necessary time and follow all safety instructions. Never leave running equipment unattended. Never allow personell to ride on the operator s platform while the wrapper is in the raised position for transport! Following Operation Following operation, stop the tractor unit, set the brakes, shut off the engine, and remove the ignition key. Before unhooking the plastic wrapper, lower the drop leg to provide stability. Park the plastic wrapper on a hard, level surface. Park the plastic wrapper indoors if at all possible. Store the plastic wrapper away from any human or livestock activty. Do not allow children to play on or around the plastic wrapper.
Operating Instructions Before operating the plastic wrapper, it is important to read the entire owner s manual and know all of the safety precautions. Always take the necessary time and be alert when operating the plastic wrapper. The simple actions will allow for continuous operation without accident or interruption. Note: Remember to raise the drop leg (a), as shown (Figure 3), before operation! Setting the Width a Before setting the width, ensure that the plastic wrapper and all hydraulic hoses are properly connected. Adjust the coil spring shanks so that the edge of the plastic (d) is 1-2 from the inner side (c) of each coil spring shank as shown (Figure ). If the wrapper is equipped with side coulters, position them so that the coulter is centered with the coil spring shanks, as shown (Figure ). b a c d Setting the Depth Figure 3: Drop leg Figure : Setting the width The coil spring shanks, gauge wheels, and side coulters (if equipped) will need to be adjusted to the correct depth. The depth adjustment will vary with the type of plastic rows (raised bed, flat bed) and with the amount of soil your plastic layer uses for coverage. Raised Bed The center coulter (a) should run about 2-3 into the soil. It is important to note that the center coulter has only two settings and the higher setting is used for raised beds (Figure ). The gauge wheels (c), coil spring shanks (d), and the side coulters (b) (if equipped) will need to be adjusted lower for the raised bed (Figure ). Adjust the gauge wheels (c) to achieve the desired depth of the center coulter (a) and adjust the coil spring shanks (d) and the side coulters (b) to proper depth (Figure ). The wings on the coil spring shanks should be set 1 below the plastic with the shank about 2 off of the outside edge of the plastic. The depth of the soil covering the plastic will vary with different plastic layers. Adjust the side coulters so that they run at approximately the same depth as the shovel on the spring shank, and they are centered with the spring shank as shown (Figure ). c d b Figure : Setting the depth a b d c
Operating Instructions Flat Bed Set the center coulter (a) to the lowest setting. The center coulter and side coulters (b) (if equipped) should run about 2-3 into the soil (Figure, page ). The coil spring shanks (c) and side coulters (b) should be set at the same depth (Figure, page ). Adjust the gauge wheels (d) to achieve the desired depth of about 2-3 for the center coulter (a), then adjust the coil spring shanks (c) and the side coulters (b) to the proper depth (Figure, page ). The wings of the coil spring shanks should be set 1 below the plastic with the shank 1-2 off of the outside edge of the plastic. The depth of the soil covering the plastic will vary with different plastic layers. Adjust the side coulters so that they run at approximately the same depth as the shovel on the spring shank, and they are centered with the spring shank as shown (Figure, page ). Preparing for Wrapping It is very important for the tracotr driver to start straight on the row. b With the plastic wrapper set to the correct depth, drive 1 to 20 feet on the row to split and lift the plastic. Lift the end of the plastic and thread the it through the plastic guide (a) and wrap it around the reel (b) as shown (Figure ). a Wrap the plastic around the reel and tie it to itself. (DO NOT tie the plastic directly to the reel as this will make removing the plastic difficult). Repeat the process for the other reel. Figure : Preparing for wrapping Using the Control Levers WARNING: Never operate the plastic reels while not standing on the operator s platform, or while a person is close to the reels The wrapper operator should stand on the wrapper platform and firmly grip the handrails at all times during operation. Be sure that the wrapper operator is familiar with the control levers before begining operation. The control levers control the speed at which the reels rotate. Pushing the levers forward will cause the reels to speed up, while pulling the levers back will cause the reels to slow down. The reels will stop when the levers are released. Before moving, push the levers forward to wrap up any excess plastic. When the tractor is in motion, the job of the wrapper operator is to control the speed of the reels. The reel speed must be adjusted to match the speed of travel. The plastic should be lifted approximately -0 behind the coil shank. When the reels are spinning at the proper speed, the plastic should not touch the plastic guide. Note: Running the reel too slowly for an extended period of time will cause the plastic to wrap unevenly on the reel or fall off of the reel.
Operating Instructions Plastic Wrapping While wrapping, the tractor driver should drive at a speed that is comfortable for the plastic wrapper operator. A comfortable speed may vary with the conditions, but generally 3- mph is recommended for safe and efficient operation. For plastic with heavy trash cover it may be necessary to slow down to give the trash time to fall away from the plastic. Operating the wrapper too slowy increases the chance of tearing the plastic. DO NOT operate the wrapper at speeds over mph! The tractor driver s primary focus should always be on driving and the tracotr straight on the rows. Removing the Plastic When the reel is at, or near, capacity, it is time to remove the plastic from the reels. Turn the tractor off! With the tractor off, insert the reel release bar (a) into the reel and pull towards the front of the wrapper, as shown (Figure ), to release and collapse the reel. Note: If it requires too much force to collapse the reel, the reel stops may need to be adjusted (see Adjusting the Reel, page 9). With the reels collapsed, the plastic should slide easily off of the reel. Before beginning wrapping again, push the reel towards the front of the wrapper to ensure that it is firmly in the wrapping postion so that the reel does not collapse during operation. Figure : Removing the plastic a Routine Maintenance It is very important to perform routine maintenance on your plastic wrapper before and after each use. Good maintenance practices will help to guard against any unnecessary machine breakdowns or accidents. 1. It is recommended to perform a visual and physical inspection for any worn parts, loose bolts, or other visible problems. Make all necessary repairs before operating. Contact an authorized CropCare dealer for instructions on ordering parts and technical help. 2. It is important to regularly grease any parts with grease zerks. 8
Maintenance Instructions Routine Maintenance... continued 3. The grease zerks on the center coulter (a), and side coulters (b) (if equipped) should be greased before every use (Figure 8).. The two shaft bearings (a) on each reel should be greased every 0 hours, or one season, of operation (Figure 9). a Adjusting the Reels 1. Over time, as the plastic wrapping reels wear, it may be necessary to adjust the stop bolts (a) on the reel bars (Figure 10). b Figure 8: Side and center grease zerks b 2. When the stop bolts are adjusted properly the links (b) on the outer reel tubes should be tilted forward slightly and it should only take minimal force to release the reel (Figure 10). a 3. If the links are tilted forward too far it will take excessive force to release the reel, which could result in damage to the reel. If the links are not tilted front enough, the reel may collapse on its own during operation. Figure 9: Shaft bearing grease zerks. Adjust the nuts on the link stop bolts (a) to change the tilt of the links (b) (Figure 10).. The ends of the collapsable tubes (c) should extend 3-1/8 beyond the end of the center tube as shown (Figure 10). a c b 3-1/8 Hose Maintenance 1. It is important to give the hydraulic hoses on the plastic wrapper a thorough inspection before every use. Check the hoses for leaks and hose hose damage such as metal fibers showing. 2. NEVER check for hydraulic hose leaks with your hands! Figure 10: Adjusting the reel stop bolts 3. If oil penetrates the skin and enters the bloodstream, the results can be fatal!. If there is any visible damage to the hoses, replace them immediately. 9
Breakdowns & Parts Lists PR200 Breakdown 13 18 12 2 10 19 21 9 3 2 23 1 9 30 22 23 2 1 28 8 1 8 1 1 23 23 0 3 1 3 2 3 31 0 31 2 3 8 2 28 2 2 38 33 1 31 1 29 0 39 3 31 2 29 33 32 9 3 32 3 11 28 2 1 2 20 20 31 2 3 3 3 0 PR200 Parts List 0 Ref # Qty. Part Number Description 1 2 00213 Lift arm pin, cat. 1 or 2, forged w/ nut and lock washer 2 1 0118 Pin - 3/8" x 3 1/2" 3 3 0203 Linch pin, /1" 1 03011 Top link pin, cat. 2, /1" usable 10-08-08 Hydraulic adapter, 1/2" mpt x 1/2" fpt swivel 2 103-08-08-08 Hydraulic tee, 1/2" fpt swivel 1 PR223 * Hydraulic hose kit, PR200 8 1 0-08-08 Hydraulic nipple, 1/2" mpt x 1/2" mpt 9 UCP208-2 Bearing, pillow block, 1 1/2" 10 2 0313P Shaft collar, /1" 10
Breakdowns & Parts Lists PR200 Parts List... continued Ref # Qty. Part Number Description 11 ER2082 Locking collar, 1 1/2" 12 900-08-08 Hydraulic adapter, 1/2" orb x 1/2" fpt swivel 13 2 901-08-08 Hydraulic 90 ell, 1/2" orb x 1/2" fpt swivel 1 2 ADM100-RP Hydraulic motor, 1" shaft, 1/2" npt port 1 1 ATR08 Hydraulic check valve, 1/2" fpt 1 CB12*11G Carriage bolt, 1/2-13 x 1 1/" grade 1 2 CB12*212G Carriage bolt, 1/2-13 x 2 1/2" grade 18 CB1*212G Carriage bolt, 1/-20 x 2 1/2" grade 19 2 CB1*8 Carriage bolt, /1-18 x 8" 20 DE2 Decal "DANGER MOVING PARTS" 21 1 DE39 Read owner's manual warning decal 22 2 DE Decal "CROP CARE" 3.9" x 19.3" 23 FN12 Flange nut, 1/2-13 2 FN1 Flange nut, 1/-20 2 2 FN8 Flange nut, /8-11 2 8 FW12 Flat washer, 1/2" 2 GF101 Grease fitting 1/-28 straight 28 8 HC12*2 Hex head bolt, 1/2-13 x 2" grade 29 8 HC38*1 Hex head bolt, 3/8-1 x 1" grade 30 2 HC8* Hex bolt, /8-11 x ", grade 31 22 JNC12 Jam nut, 1/2-13 32 8 LW12 Lock washer, 1/2" 33 8 LW38 Lock washer, 3/8" 3 8 NC12 Hex nut, 1/2-13 3 Plow Bolt PB1*2 3 2 PR2013 ** Side coulter assembly w/ toolbar clamp 3 2 PR201 Tool bar clamp, for 1" coil shank 38 2 PR201 Tool bar clamp, gauge wheel 39 2 PR201 Reel release bar, 1" square x 18" 0 1 PR2018 Offset shovel, right side 1 1 PR2019 Offset shovel, left side 2 2 PR201 *** Wrapper reel, complete 3 1 PR202 Wrapper tool bar 1 PR203 Wrapper operator s platform 1 PR20 Wrapper platform tube, 3" x " 1 PR20 **** Center coulter assembly 2 PR20 Reel motor plate 8 1 PR20 Rear leg stand 9 1 PR208 Wrapper platform tube clamping plate 0 2 PR210 ***** Gauge post and wheel with tire 1 1 PR220 Plastic guide left 2 1 PR221 Plastic guide right 3 2 PR222 Reel mounting post 2 PR231 Coil spring shank w/ plate, 1" square 2 RDRS-108-1 Flow control, 0-1 gpm, with relief # 8 2 PR21 Tool bar clamp, side coulter 2 S1C-100-100-BLA 1" single split coupler, 1/" keyway 8 2 S1- Hydraulic tip male 1/2" fpt 9 2 SC-8 Extension spring, SS /1" x 2 /8" 0 10 SHS12*112 Square head set screw, 1/2-13 x 1 1/2" 1 SHS12*11 Square head set screw, 1/2-13 x 1 1/" 2 10 SHS12*2 Square head set screw, 1/2-13 x 2" 3 1 SP00 Stainless serial number plate 2 TK12*11H Tek screw, 12-2 x 1 1/", hex head * Hose kit breakdown is listed on page 11 ** Side coulter breakdown is listed on page 1 *** Reel breakdown is listed on page 1 **** Center coulter breakdown is listed on page 1 ***** Gauge wheel breakdown is listed on page 13 11
Breakdowns & Parts Lists Hydraulic Hose Kit Layout & Breakdown Hyd. Tee (103-08-08-08) 38 28 9 Hyd. Tee (103-08-08-08) 130 130 3 13 112 Hyd. tip, male (S1-) Check valve (ATR08) Hose Kit Parts List: Hydraulic Hose part #: 109-08 Hose End part #: HY08-08MP Hose lengths are overall lengths (includes hose ends) 12
Breakdowns & Parts Lists Gauge Wheel Breakdown & Parts List 2 1 3 Ref # Qty. Part Number Description 1 1 10 Hub cap, 1.988" O.D. x 1.21" I.D. 2 00820 Wheel bolt, 1/2-20 x 1" 3 1 CNF1 Castle nut,1-12, fine thread 1 CT18*1 Cotter pin, 3/32" x 1 1/2" 1 MW1TR Air tire, lug rim 1 MWHC Hub, " bolt center, 1" taper bearing (complete) - 1 L3 * Bearing cone (not shown) - 1 L10 * Bearing cup (not shown) - 1 12192TB * Seal (not shown) 1 PR209-P Gauge wheel tube and spindle * Included in MWHC 13
Breakdowns & Parts Lists Side Coulter Breakdown & Parts List 11 8 10 1 3 12 9 3 2 Ref # Qty. Part Number Description 1 CB12*1G Carriage bolt, 1/2-13 x 1" grade 2 1 F11MLWR Fluted coulter blade, 1" 3 2 FB120-8 Bushing, 1" ID x 1 1/" OD, 1" long flanged FN12 Flange nut, 1/2-13 1 FN3 Flange nut, 3/-10 1 FW3 Flat washer, 3/" 1 GF101 Grease fitting 1/-28 straight 8 1 HC3* Hex bolt, 3/-1 x " grade 9 1 PR200B Coulter blade hub 10 1 PR2013A Side coulter tube 11 1 PR21 Tool bar clamp, 2" side coulter 12 1 PR232 Coulter hub bushing 1
Breakdowns & Parts Lists Center Coulter Breakdown & Parts List 11 1 10 12 1 1 1 3 13 1 1 12 8 9 8 2 9 Ref # Qty. Part Number Description 1 1 1298 Spring 3" x 10" 2 CB12*1G Carriage bolt, 1/2-13 x 1" grade 3 1 F11MLWR Fluted coulter blade, 1" FB120-8 Bushing, 1" ID x 1 1/" OD, 1" long flanged FN12 Flange nut, 1/2-13 2 FN3 Flange nut, 3/-10 2 GF101 Grease fitting 1/-28 straight 8 2 HC12*12 Hex head bolt, 1/2-13 x 1/2" grade 9 2 HC3*12 Hex bolt, 3/-1 x 1/2" 10 1 N22132 Eyebolt, 1/2" x 8" 11 2 NC12 Hex nut, 1/2-13 12 2 PR200A Center coulter side plate 13 1 PR200B Coulter blade hub 1 2 PR200E Center coulter spring bushing 1 1 PR20C Center coulter mounting bracket 1 2 PR232 Coulter hub bushing 1
Breakdowns & Parts Lists Reel Breakdown & Parts List 9 10 2 3 2 1 1 11 1 11 12 11 8 12 8 9 11 12 12 1 Ref # Qty. Part Number Description 1 CB38*1G Carriage bolt, 3/8-1 x 1" grade 2 FN38 Flange nut, 3/8-1 3 HC38*13 Hex head bolt, 3/8-1 x 1 3/" grade 8 LW12 Lock washer, 1/2" 8 NC12 Hex nut, 1/2-13 8 NC38 Hex nut, 3/8-1 1 PR201A Reel center tube, 1-1/2" shaft 8 2 PR201B Reel outer tube 9 2 PR201C Reel outer tube 10 1 PR201D Reel guard, 2" diameter 11 8 PR201E Hex head bolt, 1/2-13 x " grade 12 S-2 Spring, /8" x 3-1/2"
CropCare Limited Warranty Picking Assistant: Model PR200 Warranty Coverage CropCare hereby provides a Limited Two (2) Year Warranty on Plastic Wrappers, manufactured by CropCare. Plastic Wrappers manufactured by CropCare are warrantied against any manufacturer s defects in any of the Plasitc Wrapper s components in the 2 months following the original date of purchase. Defective components will be repaired or replaced at the discretion of the manufacturer. It is the responsibility of the purchaser to return warranted components to the manufacturer. This warranty is limited to the repair or replacement of Plastic Wrapper components only. CropCare is not to be held liable for incidental or consequential damages of any kind. This warranty covers the purchaser of this Plastic Wrapper and any other owners who own it during the two year warranty period. To retain the warranty, the Plastic Wrapper must be operated and maintained as ascribed by its owner s manual. For warranty service, please have a copy of the purchase invoice available. Warranty Is Void if: 1. The Plastic Wrapper has been subjected to, in the opinion of CropCare, negligent handling, misuse, an accident or if the instructions in the owner's manual were not completely followed. 2. The Plastic Wrapper s components have been altered in any manner or repairs have taken place with unapproved parts. Getting Service All Plastic Wrapper warranty claims must be made through an authorized CropCare dealer. All warranty claims must be submitted with an invoice or a proof of purchase that denotes the purchase date and place of purchase. If you have any questions or comments concerning this warranty, please contact an authorized CropCare dealer. 1
Contact Us We desire to give you continuing service in the best manner possible. This includes listening to your comments, suggestions, and problems. We will do our best to answer all questions thoroughly and in a timely manner. We have trained customer service specialists who are more than willing to listen to any questions or problems and help you to find a feasible solution. Ordering Parts We have a fully-stocked parts department that will be able to meet all of your parts needs. Our trained customer service specialists will ensure that all purchases are processed smoothly and shipped in a timely manner. We regularly ship our parts and products on the same business day and we are willing to work with you to find the best shipping solution. We also offer priority shipping to reduce your downtime and keep your CropCare equipment on the job. Note: When ordering parts, please provide our sales staff with the correct part number and description listed on the parts list. To directly reach our parts department, please call (1) 38-3 ext 2000. PaulB LLC A Paul B Zimmerman Inc. Company 0 Woodcorner Road Lititz PA 13 Parts Dept. (1) 38-3 ext 2000 Corporate Office (1) 38-30 Fax (1) 38-801 www.cropcareequipment.com 18