gp-pom001108 - general sprayer operations

8/20/2019 Gp-pom001108 - General Sprayer Operations

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General Sprayer Operation

Part No: GP-POM001108


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GP-POM001108-Rev 1

Contents

Foreword

Important Information Section 1

Pre-Operation Section 2

Sprayer Operation Section 3

Lubrication & Maintenance Section 4

Trouble Shooting Section 5


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GP-POM001108-Rev 1

Foreword

About This Manual

This manual provides assembly, setting up,operating and maintenance instructions foryour Croplands sprayer.

Please pass on this manual with thesprayer at the time of resale for usage bythe new owner.

Before Operating

Your Sprayer1 Before attempting to use your

sprayer, make sure youread the Operator’s Manual andproperly understand:

• All Safety Issues.

• Assembly & Installation

instructions. • Calibration of the sprayer.

• Sprayer Operation.

• Sprayer Maintenance.

2 Read and follow instructions onchemical manufacturers' labels.

3 Always wear applicable protectiveclothing.

Read and understand this Operators’ Manual beforeoperating the sprayer.

Terminology

These terms/symbols used throughoutthis manual:

• NOTE - to convey usefuloperating information.

• CAUTION - to highlight potentialinjury or machinerydamage.

• WARNING - to stress potentialdangers and theimportance ofpersonal safety.

Indicates the strong possiblility of severe

personal injury or damage to machinery ifinstructions are not followed.

WARNING

Highlights hazards, unsafe/unwise practices

which could cause injury, damage to property,machinery or loss of crop yield if instructionsare not followed.

CAUTION

Refers to important and useful information whichshould not be overlooked.

NOTE


4/51GP-POM001108-Rev 1 1.11.1

Section 1Important Information

Introduction 1.2

Your Sprayer's Specifications 1.3

Shipping Information & Product ID 1.4

Warranty Policy 1.5Pre-Delivery Check List 1.7

Warranty Registration 1.9


5/511.2 GP-POM001108-Rev 1

Important Information

Congratulations on the purchase of yournew Croplands sprayer.

Croplands have been in the business ofbuilding and selling spraying equipmentsince 1972. For over 30 years we havebeen supplying sprayers to farmers,contractors, growers and all our customersinvolved in growing crops and in the control

of pests and diseases.

Croplands is a wholly owned subsidiaryof Nufarm Ltd, the largest supplier of cropprotection chemicals in Australasia, andone of the fastest growing global suppliersworld-wide.

At Croplands, we pride ourselves onour commitment to supplying machinerythat is at the forefront of the industry’sneeds. We believe we can back up ourproducts and through constant researchand development, bring to you the bestequipment you can find.

We welcome any feedback from you aboutour equipment.

Introduction

On this page you will find our contactdetails, and locations where our staff canbe reached during business hours.

After hours, you can e-mail us and expecta reply the following morning.

Please read this manual in its entiretybefore you operate your sprayer.

We trust you will get years of good usefrom your Croplands Sprayer.

Yours sincerely

Brendan Deck

General Manager

Contact details:

AUSTRALIA

Croplands Equipment Pty Ltd

ACN 006 450 184

PO Box 2441, Dry Creek

50 Cavan Road, Dry Creek

S.A. 5094Australia

FreePhone: 1800 999 162

FreeFax: 1800 623 778

e-mail: [email protected]

website: www.croplands.com.au

NEW ZEALAND

Croplands Equipment Ltd

PO Box 14-004

11 – 13 Cairns St

Rongotai

WellingtonNew Zealand

FreePhone: 0800 10 68 98

FreeFax: 0800 11 77 11

e-mail: [email protected]

website: www.croplands.com.au

Brendan Deck, General Manager of Croplands


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Important InformationShipping Information & Product ID

Product

IdentificationAlways use the serial number of the sprayerwhen requesting service information orwhen ordering parts.

Early or later models (identification made

by serial number) may use differentparts, or it may be necessary to use adifferent procedure for specific serviceoperations.

It is recommened that all serial numbersbe recorded.

Horticultural Serial Number Plate AR Pump Serial Number Plate

(C)(B)

Serial Number Plate

On Broadacre units, the Serial NumberPlate is located on the main frame at thefront of the frame near the drawbar (A) orlink pins.

On Horticultural units, the Serial NumberPlate is located on the left hand side of the

chassis (B) near the tie down point.This plate shows name of manufacturer,serial number, product code and date ofmanufacture.

Pump Serial Number Plate

The Pump Serial Number Plate is locatedon the pump (C).

This plate shows name of manufacturer,serial number, type of pump, year ofmanufacture, maximum flow rate andmaximum working pressure of the pump.

Foam Marker SerialNumber Plate (if fitted)

The serial number provides importantinformation about your RHS Foam Markerand may be required to obtain the correctreplacement part(s).

The Serial Number Plate for the marker

is located on the bottom right side of theenclosure.

Controller Serial NumberPlate (if fitted)

The Controller Serial Number is usuallylocated on the back of the console.

RHS Foam Marker Serial Number Plate (if fitted).

Maximum Towing Speed

Do not exceed 30 km/h when towing on roads.

WARNING

It is recommended to record all serial numbers

on the Your Sprayer's Specifications page 1.3 ofthis manual.

NOTE

Broadacre Serial Number Plate

(A)

Serial Number on MT3405 Console


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1.6 GP-POM001108-Rev 1

Important Information


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1.8 GP-POM001108-Rev 1


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1.10 GP-POM001108-Rev 1


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GP-POM001108-Rev 1 2.1

Section 2Pre-Operation

Safety 2.2

Hook-up 2.10

Pre-Operation Check 2.14


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S ti 2 S f t


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2.5GP-POM001108-Rev 1

Section 2 Safety

Please order replacements if requiredDecals -

P O tiS f t


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2.6 GP-POM001108-Rev 1

Pre-OperationSafety

Please order replacements if requiredDecals -


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Section 2 Hook-up


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2.11GP-POM001108-Rev 1

Section 2 Hook-up

2 Linkage HitchingMost Croplands linkage sprayers areequipped to fit tractors with Category I, IIor III linkages.

Models 500 & 700 litre have Cat II for thelower linkage arms, and Cat I for the toplink with sleeve if your tractor has Cat II.

The 1000 litre linkage sprayer has a clevis-type Cat III hitch for the lower arms andCat II for the top link.

The 1200 litre has Cat III pins on thelower linkage & Cat II on the upper linkagepoint.

Your Croplands Sprayer must be connectedto a suitable tractor, making sure thedrawbar hitch and PTO shaft are fittedaccording to the instructions that follow:

1 Remove the PTO shaft from thesprayer by depressing the locking pin.

2 Lower the tractor linkage and attachit to the sprayer’s lower hitch pins of

the appropriate category, thenconnect the upper linkage arm usingthe tractor’s linkage pin.

3 Secure all linkage pins with the lynchpins.

4 Raise the tractor linkage to thedesired spraying height and level thesprayer by adjusting the length of thetop linkage arm.

5 Clean and grease the splines on thetractor and sprayer PTO stub shaftsand install the PTO shaft makingsure that the spring loaded locking

pins engage in the interferencegrooves of both stub shafts.

6 Ensure that the PTO shaft guardsand safety chains are attached to thesprayer and tractor.

PTO Shaft Length1 Set the linkage height so that the

ends of the two shafts are at theirclosest distance.

2 Install the PTO shaft making surethat there is at least 25mm oftelescopic travel remaining betweenthe male and female sections.

3 Raise and lower the sprayer to checkthat the telescopic tubes of the PTOoverlap by approximately 1/3rd oftheir length, and not less than150mm, in all operating positions.

If the PTO shaft must be shortened, cutequal amounts from both male and femaleshafts and safety covers.

Carefully remove all burrs, swath them cleanand re-lubricate before reassembling.

Upon delivery of a new PTO driven sprayer, it isthe selling dealer’s responsibility to install and

set the PTO driveshaft to the correct length, aspart of the installation service. The following/ above information is provided for reference.

NOTE

Remove the PTO shaft from the sprayer.

Raise and lower the sprayerto check that the telescopic

tubes of the PTO overlap byapproximately 1/3rd of their

length, and not lessthan 150mm,

in all operating positions.

Pre-OperationHook-up


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2.12 GP-POM001108-Rev 1

Pre OperationHook up

Important Factors whenFitting the PTO Shaft

The following three factors must be

correct to avoid pump damage andmaximise PTO operating life:

1 When travelling straight ahead, thepoint at which the sprayer drawbarpin is joined to the tractor should beas close as possible to centrebetween the universal joints of aStandard PTO shaft, as illustrated.

The tractor is then able to makemaximum turns with minimalbending of the universals.

Minimum shaft contact length of 300mm (12") (Do not cut shaft too short)

Make sure shaft ends do not butt up.(Do not cut shafts too long)

Tractor hitch Sprayer hitch

Make sure shaft ends do not butt up.(Do not cut shafts too long)

On Standard PTO shafts, the drawbar pin connecting the tractor & sprayer should be centred between the twouniversal joints of the PTO shaft.

Standard PTO

2 When the tractor is towing thesprayer straight ahead, the twotelescopic sections of the powertake-off shaft are at maximum

extension.

When turning or crossing aninversion, the telescopic shaftsections close up.

3 The height difference between thetractor PTO spline and the PTOspline of the machine should not bemore than 100mm.

This ensures PTO joint angles areapprox equal and do not exceedlimits. If greater than 100mm, a wideangle (constant velocity) PTO shouldbe used.

Standard PTO Operating Limits

Heed the Operating Limitsof the Standard PTO Shaft

The standard sprayer is fitted with a

STANDARD PTO shaft.

The maximum intermittent turningangles of the Standard PTO shaft is onlyrecommended where should not exceed45° turning angle of the PTO.

Standard PTO Operating Limits

Ensure that the drive shaft is the correct length toavoid any "butt up" damage to the pump.

CAUTION

IMPORTANT: Do not allow more than 10%difference in the two halves of drawbar length. If

more than 10% difference occurs, a wide angleshaft must be used.

NOTE

Pump warranty is not valid for damage causedby incorrect PTO shaft mounting.

CAUTION

Maximum PTO speed for Croplands diaphragmpumps is 540 RPM.

WARNING

Section 2 Hook-up


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2.13GP-POM001108-Rev 1

Section 2 Hook up

Standard hose connectors for boom lift and fold.

Boom

fold/unfoldhoses

Boom lift hoses

3 Connect Hydraulic Hoses to the

TractorBoom Fold and Lift

If a standard hydraulic boom is fitted, the boom will providesimultaneous unfolding of boom sections and hydraulic liftadjustment of boom height.

Prior to connecting your boom hydraulic hoses, remove theboom lock-plate (see below). This plate is in place for transportto your dealer from the Croplands' factory.

Connect the boom hydraulic hoses to thetractor, namely:

a) Boom fold hoses.

b) Boom parallelogram lift hoses.

c) If fitted, connect the hoses for the

wing lift (optional) - see following

pages.

d) If fitted, connect the hoses for the

hydraulic pump drive (optional) -

see following pages.

Boom fold hose connection.

Connect hydraulic hoses to the tractor.

If Quantum Mist Fans Are Fitted

Once the hitch & PTO adjustments are complete, it is importantto correctly set up the hydraulic supply for the tractor.

Your dealer will carry out this step to ensure no damage orwarranty issues will result from incorrect set up. A small chargemay be incurred for this procedure.

A ¾” return fitting is supplied with your Quantum Mist. This is the

DIRECT BACK-TO-TANK fitting required to ensure there is noback-pressure on the oil return from the Quantum Mist sprayer.

On all models, it is important that these steps are done - to makeit easy for you to use your sprayer, and to protect the sprayer’shydraulic system:

1 Ask you dealer to fi t the ¾” female return coupler directback-to-tank.

2 Decide on the best supply remote on your tractor to use foroil supply for the fan system

3 Plug the ½” oil supply line coupling to your selected remoteand ensure the hydraulic line does not foul your PTO or anyworking parts at the rear of the tractor. Allow sufficient slackin the hydraulic line for turning.

4 Hook up the ¾” return line to the tractor. As with thepressure line, ensure there is sufficient slack & no

interference with tractor working parts.

¾” return fitting.

Remove theboom lock-plate

(shown right)

Pre-OperationPre-Operation Check


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2.14 GP-POM001108-Rev 1

Pre OperationPre Operation Check

Check foam marker operates correctly.Check pump oil level.Read Operators’ Manuals before operating machine.

Pre-Operation Checklist1 Before attempting to use this machine,

Read Operator’s Manuals thoroughly.

2 Read and follow instructions onchemical manufacturers labels.

3 Always wear applicable protectiveclothing.

4 Check that all maintenanceprocedures have been followed.

5 Check all plumbing and fittings toensure they are tight, not damaged orleaking.

6 Check PTO shaft or hydraulic pumpdrive is correctly set up.

7 Grease the PTO shaft if necessary.

8 Check diaphragm pump oil level.(Not applicable if fitted with Hyprocentrifigal pump).

9 Check air pressure in the diaphragmpump air chamber is 70 - 100 kPa(10-15 psi). As a general guidelineit should be 10% - 20% of operatingpressure. (Not applicable if fitted with

Hypro centrifigal pump)

10 Check that the suction and pressurefilters are clean.

Clean the suction and pressure filtersout after initial use, and nozzles ifnecessary.

Check suction filter is clean.

11 Check that the foam marker operatescorrectly if applicable.

12 Check overall spraying functionsusing our chosen controller.

IMPORTANT: Clean the suction filter out afterinitial use.

Whilst all precautions are taken during assembly,it is possible to get filings in the tank and lines.

These will accumulate in the suction filter duringfirst use.

NOTE

Check pump air chamber pressure.

Check the pressure filters are clean.

Section 3Sprayer Operation


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GP-POM001108-Rev 1 3.1

p y p

Filling 3.2

Filters 3.4

Calculation Formula 3.5

Spraying Pointers 3.6

Quantum Pointers 3.8

Cleaning 3.9

Sprayer OperationFilling


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3.2 GP-POM001108-Rev 1

p y p

Open spray tank lid for top-filling.

Top/bottom filling inlet. Open flush tank lid for top-filling.

g

Filling the TanksYour Sprayer has up to four tanks whichwill all require filling. Each tank can be filledvia its top lid. The spray tank and flushingtank can filled via a top/bottom-filling inletif this option is fitted.

1 Spray Tank

Use clean, fresh water (preferablyrainwater), free of suspended organicmatter or clay. Some chemicals aredeactivated when they contact thesematerials.

Always calculate the correct water quantityrequired, and when filling, allow sufficientwater quantity for adding and mixingchemicals. If necessary top up the tank torequired quantity after adding chemicals.

Main Tank Top-Fillinga) Open the spray tank lid and ensure

the basket filter is in place.

b) Fill the spray tank with the requiredamount of water.

c) Close the spray tank lid.

Top/Bottom-Fill (Optional)(Main & Flushing Tanks)

The bottom-fill facility requires a pressured

water source and is used to fill both thespray tank and flushing tank. Follow thesteps outlined:

a) Connect the filling hose to the bottomfill inlet connector.

b) Select either the main tank or theflushing tank with the 3-way valve.

c) Fill the main or flushing tank with therequired amount of water.

c) Disconnect filling hose and replacethe bottom fill inlet cap.

2 Flush Tank - Top Filling

Use clean, fresh water (preferablyrainwater) in the flush tank. Always fill the

flushing tank before spraying.To top-fill the flush tank:

a) Position the machine and open theflush tank lid.

b) Fill the flush tank.

c) Close the flush tank lid.

Section 3 Filling


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3.3GP-POM001108-Rev 1

Open foam marker lid for filling.Optional RHS 20 l/min foam marker.Optional Arag foam marker tank.

Fresh water tank for personal safety.

Always add foam concentrate after filling tank

with water to minimise foaming when filling.

NOTE

g

3 Foam Marker Tanks(Optional)

If your sprayer is fitted with the optional

Arag or RHS foam marker, fill with cleanfresh water (preferably rainwater).

Use the tank lid for top-filling and addingfoam concentrate.

To fill the foam marker tank:

a) Unscrew the tank lid.

b) Fill the tank with the required amount

of water

c) Replace the lid after filling.

4 Fresh Water Tank (Optional)

A 30 litre fresh water tank. Always fillthe optional fresh water tank before

spraying.To fill the fresh water tank:

a) Unscrew the tank lid.

b) Fill the tank using only rainwater.

c) Replace the lid after filling.

Sprayer OperationFilters


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Filter MaintenanceClean filters ensure that no solids enterthe spraying system to block or damagepump or nozzles.

All filters should be cleaned regularly orafter each spraying period.

Remove outer screw and bowl of suction filter. Remove & clean the filter element & components. Reassemble & tighten outer screw of suction filter..

Nozzle FiltersNozzle filters should be cleaned regularlyto avoid nozzle blockages.

If leaking occurs from the nozzle cap,check caps are correctly fitted with seals&/or the condition of the seals. Replace ifnecessary.

Foam Marker FilterThe foam marker filter should be cleanedregularly or after each tank of foam hasbeen emptied.

The foam marker is protected by:• A 50 mesh filter under the cabinet, &• A 100 mesh filter located in the line

before the liquid orifice.

Regularly check and clean nozzle filters.

Suction FilterThe suction filter should be cleanedregularly, or after each spray tank hasbeen emptied.

To clean the suction filter:

1 Completely stop all sprayerfunctions.

2 Turn the Suction Line valve to “Off”position to shut Off liquid from thespray tank.

3 Remove the outer filter screw andbowl, and then remove the filter andthoroughly clean it beforere-assembling the filter.

4 Return the Suction Line valve to“Spray” position.

Pressure Filters (if fitted)The pressure filters should be cleanedregularly, or after each spray tank hasbeen emptied.

To clean the pressure line filter:

1 Completely stop all sprayerfunctions.

2 Open the valve at the bottom of thefilter to ensure all pressure isremoved from the filter.

3 Remove the outer filter bowl, andthen remove the filter and thoroughlyclean it before re-assembling thefilter.

Be careful not to damage or deform the mesh orO-ring while cleaning and refitting the filters.

NOTE

Always wear protectivegloves when cleaning filters

containing toxic chemicals.

WARNING In some circumstances you may find the nozzlefilters are best not used.

If your nozzle filters continuously block, checkthat your main pressure filter is not torn or thatthe product you are using is not the cause.

NOTE

Remove foam marker filter bowl & 50 mesh screen.

Section 3 Calculation Formula


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Area Covered (ha) =

Tank Volume (litres) ÷ SprayApplication Rate (l/ha)

eg.

1500 ÷ 400

= 3.75 hectares

Calculate Water &Chemical QuantitiesBefore spraying it is necessary to calculatethe exact quantities of water and chemicalneeded to spray the required area.

a) For chemical rates expressed inlitres or kg per hectare (land area),

use the formula:

Chemicals required (litres)

=

Tank Volume (l) x Recommended

Chemical Rate (l/ha) ÷ SprayApplication Rate (l/ha)

eg.1500 x 5 ÷ 400

= 18.75 litres.

b) For volume of mixture required tospray the selected area, use thefollowing formula:

Tank Volume Required (litres)

=

Area (ha) x Spray Application Rate (l/ha)

eg.

18.75 x 400

= 1500 litres

Accuately calculate the amount of chemical required. 25 litre measuring bucket.

Important: Be sure to mix only enough spraymixture to cover the area required. Avoid wastageand problems of needless chemical disposal.

NOTE

c) For chemical rates expressed inlitres or kg per 100 litres of water(water volume), use the formula:

Chemicals Required (litres)

=

Tank Volume (litres) x Recommended

Chemical Rate (l/100 litres) ÷100

eg.

1500 x 3.0 ÷100

= 45 litres.

Sprayer OperationSpraying pointers


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When to Spray

Spraying results are best when the windspeed and the temperature are low but therelative humidity is reasonably high.

An ideal time is at sun up or nearing the

end of the day when these conditions aremore likely to occur.

For more information, contact Croplandsabout our SprayWise® program.

Also, the use of the WINDMATE™ Windmeter would be of excellent value toanyone doing regular spraying.

Field Patterns (Broadacre)

For the best coverage, spray two swathwidths around the outer perimeter ofthe field as shown in the diagram. This

establishes a good headland and will giveyou adequate room to turn around.

Turn the booms off when you comeback on to the headland to prevent overspraying and wastage.

Using a guidance system such as GPS orfoam markers can prevent overlaps andensure you get better coverage.

Ground SpeedModern tractors should have sufficientspeed accuracy for sprayers of this size.

To check the speed, fill the tanks andopen the boom to simulate usual sprayingconditions.

Measure out 100 metres and count the

time it takes to travel the distance. Usethe formula

Speed =

360 ÷ time in seconds to cover 100m

Spray QualitySpray quality is becoming extremelyimportant for the correct application ofchemicals. Refer to your advisor, local DPIor check the Croplands Buyers Guide formore information.

Many chemical labels now specify thespray quality required for the product

being used.

Loosely, spray quality falls into a dropletrange of:

• Extremely Coarse

• Very Coarse

• Coarse

• Medium

• Fine • Very fine

Most spray applications will fall into theMedium to Very Coarse range, dependingon the application.

Talk to a qualified Agronomist or Advisorif uncertain.

WINDMATE ™

Section 3 Spraying pointers


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Nozzle Spacing & Height(Broadacre)

Nozzles overlap should be 50% at the pointof contact with the spraying surface.

Croplands booms operate with a nozzlespacing of 500mm with nozzles slightlyoffset to avoid interference.

Nozzles can be supplied with 80° and 110°angled patterns.

The recognized height to achieve therequired 50% overlap is 600mm for 80°and 400mm for 110° nozzles but a 50- 80mm variation is acceptable without anoticeable effect.

Nozzle Pattern &Uniformity (Broadacre)

Your nozzle spray patterns, overlap anduniformity need to be monitored and canbe tested in the following manner.

Keep a spare new nozzle to with whichyou can compare the other nozzles onyour unit.

Place the new nozzle at a central point onthe boom and fill the tank with fresh, cleanwater and switch the boom on.

Examine the spray patterns against adark background and replace any thatshow signs of damage or sufficient wear

as shown below.

Application Rates &Variables

Your sprayer’s application rate is affectedby the speed of travel, the size of thenozzle and your operating pressure.

These are part of the spraying variables.These variables need to be correct toensure optimum performances from yourCroplands sprayer.

Proper calibration considers all spraying variables.

Sprayer OperationQuantum Pointers


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Operating PointersWhile spraying, continually ensure that:

1 Engine and PTO speed are correct.

2 Correct operating pressure is beingmaintained.

3 Ground speed is correct and

constant.4 Quantum Mist spray heads are

operating correctly and aimed towardthe target foliage.

Position the SprayHeadsThe Quantum Mist spray heads canbe adjusted individually for width &direction.

Each head should be individually adjusted

to maximise coverage and penetration intothe target foliage.

Adjust mount for tilt (upwards or downwards) in relationto canopy.

Adjust mount for forward/rearward fan adjustment.

a) Individual Fan Width &Height Adjustment

To individually adjust each Quantum Mistspray head width and height:

1 Loosen the clamp bolts.

2 Adjust the mast or wing uprights andfan head assemblies up or down & inor out.

3 Retighten the clamp bolts afteradjustments have been made.

4 Repeat steps 1 - 3 as necessary foreach fan head assembly.

Spin mount to move fan closer to canopy, and to allowtilt adjustment.

Refer to the Independent Quantum Mist Report

to learn about suitable spray head settings foryou canopy.

NOTE

b) Directional AdjustmentTo adjust individual Quantum Mist fanhead direction:

1 Loosen the cradle-to-upright boltsand adjust the head up or down tosuit.

2 Retighten the cradle-to-upright bolts.

3 Loosen the cradle-to-motor bolts andadjust the head fore or aft to suit.

4 Retighten the cradle-to-motor bolts.

5 Repeat steps 1 - 4 as necessary foreach fan head.


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Sprayer Operation


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3.10 GP-POM001108-Rev 1

Section 4Lubrication & Maintenance


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GP-POM001108-Rev 1 4.1

Greasing & Service Procedures 4.2Grease Point Diagrams 4.3

Pumps 4.4

Diaphragms, Straps & Foam Markers 4.6

Lubrication & MaintenanceGreasing & Service Procedures


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4.2 GP-POM001108-Rev 1

Greasing & ServiceProcedures1 Clean suction line filter with each

tank load.

2 Clean pressure line filter.

3 Check nozzle filters.

4 Check tyre pressure and check wheelnuts, if applicable.

5 Check flush tank straps and tighten ifnecessary.

6 Clean Rapid-check flowmeter, if fitted.

10 Check pump air chamber pressureon a regular basis. As a generalguideline it should be 10%-20% ofoperating pressure (70-100 kPa [10-15 psi]).

11 To ensure trouble free spraying,flush the sprayer with fresh waterthoroughly each day, and beforechanging chemicals.

Dispose of tank wash accordingto chemical manufacturersinstructions.

12 Grease all boom joints, heightadjuster points and other greasepoints.

13 Grease the jack, if fitted.

7 Grease tractor to sprayer PTOuniversal joints every 8 hours.

Grease lightly until grease becomesfirm in seals. Over greasing will breakseals and allow dust and moisture topenetrate - increasing wear.

8 Grease PTO inner tubes every 8hours.

To lubricate the inner tube, slide PTOshaft apart, clean the telescopictubes, grease and reassemble.

9 Grease the PTO covers every 20hours.

Every 200 Hours

1 Lubricate quick release lock pins onPTO shaft.

2 Re-pack wheel bearings with grease.

3 Inspect the bushes & pins on thetandem axle (if fitted).

4 Change air filter for foam marker.

5 Fully flush foam marker.

6 Grease all tank lid seals with vaseline.

Ensure the sliding inner tubes of the PTO are

greased every 8 hours (working around the clock

equals 3 times/day), especially when doing a lotof tight turning

NOTE

Check the tank straps. Clean the Rapid Check Flowmeter (if fitted).

Grease the jack (if fitted).

Repack the wheel bearings at 200 hours.

Section 4 Grease Point Diagrams


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4.3GP-POM001108-Rev 1

Boom Grease PointsPTO Grease Points


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Lubrication & MaintenanceDiaphragms, Straps & Foam Markers


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4.6 GP-POM001108-Rev 1

Non-DripDiaphragms (if fitted) Non-drip diaphragms should be cleanedregularly to prevent dripping fromnozzles.

To clean the non-drip diaphragms:

1 Completely stop all sprayer functions.

2 Unscrew and remove the diaphragmcap.

3 Remove and clean any sediment Offthe diaphragm membrane.

Replace the diaphragm membrane ifdamaged.

4 Refit the diaphragm.5 Refit the diaphragm cap and carefully

tighten.

Remove & clean non-drip diaphragms regularly.

Tank StrapsAny tank straps of the flush tank should bekept tight so that the tank does not slide.

Tank clamps should be checked two orthree times a day when the sprayer is newand the tank and frame are bedding-in.

Thereafter the tank clamps should be

checked regularly.

Regularly check that tank straps are tight.

Do not over tighten the diaphragm cap. Overtightening the cap may impede flow through thediaphragm.

NOTE

Foam MarkerMaintenance

Arag Double Sided FoamMarkers (Option)

Pressure relief valve

The pressure relief valve on the tank capneeds no maintenance.

Operating the pressure discharge ringunder the tank cap prevents incrustationsforming on the pressure relief valve at thesame time checks its efficiency.

Machine Down for Up to 7 DaysFor periods of inactivity of at most 7 days,carry out the following operations:

• Slacken the band “B” and removethe diffusor “A”.

• Remove the grid “C” turning itanticlockwise.

• Take the sponge “D” out of thefoam nozzle.

• Carefully wash the foam diffusersand sponge with water.

• Reassemble the parts, taking carewhen inserting the spongethat must go freely into its seatwithout crushing that would alter

the operation of the foam marker.

• Repeat the above operations forthe other foam nozzle as well.

Weekly Cleaning (Figure 11).

Section 5Trouble Shooting


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GP-POM001108-Rev 1 5.1

Diaphragm Pump Problems 5.2General Sprayer Problems 5.4

Hydraulic Pump Drive Problems 5.5

Foam Marker Problems 5.6

Trouble ShootingDiaphragm Pump Problems


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5.2 GP-POM001108-Rev 1

PROBLEM

A Pump does not draw or deliver liquid.

Pressure gauge fluctuates badly.

B Liquid flow is irregular (Also check items under A)

C Pump delivers insufficient pressure

D Output drops & pump is noisy.

PROBABLE CAUSE

1 One or more valves are not seating properly.

2 The pump is sucking in air through suction line.

3 Air has not been entirely evacuated from thepump.

4 Blocked suction filter.

5 Damaged or worn suction valves.

1 The air in the air chamber of the pump isincorrectly set.

2 Diaphragm split.

3 Damaged or worn valves.

4 Foreign matter holding valves open.

1 Regulating valve:

• Sticking open

• Not set for pressure.

• Damaged or worn seat or spring.

2 Cylinder diaphragm ruptured.

3 Pump valves blocked, worn or damaged.

4 Spray nozzles worn, missing or exceedpump capacity.

1 Oil level is too low.

REMEDY

1 Clean valve seating.

2 Examine the suction hose and ensure it isfirmly secured.

3 Rotate the pump with outlet hose and tapsopen.

4 Clean suction filter.

5 Replace suction valves.

1 Check pressure in air chamber of pump. Setat 210-280Kpa (30-40 psi), or 10% of you averagespraying pressure.

2 Replace diaphragm.

3 Replace valves.

4 Clean valves.

1 Fix the regulator:

• Unstick the valves.

• Set the pressure.

• Replace the spring.

2 Replace diaphragms.

3 Unblock valves and or replace.

4 Replace spray nozzles with appropriate size.

1 Top up with oil to correct level (1/2 way up thesump sight glass).

Section 5 Diaphragm Pump Problems


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5.3GP-POM001108-Rev 1

PROBLEM

E Oil being discharged through deliveryline or discoloured oil in sight glass of

pump.

F Suction hose vibration.

G Pump valves hammering.

H No water flow on suction hose.

I Pressure gauge pointer swings violently.

J Control valve leaking from spindle.

K Pressure gauge showing correctworking pressure no pressure atnozzle.

PROBABLE CAUSE

1 One or more diaphragms split or ruptured.

SUCTION SIDE OF PUMP

1 Air getting into suction.

1 Suction tap partly turned off.

2 Suction strainer(s) blocked.

1 Obstruction in tank or suction line.

DISCHARGE SIDE OF PUMP

1 Pressure control valve spindle doesn’t moveeasily.

1 Split diaphragm or O-rings.

1 Burst discharge line.

2 Blocked pressure filter where fitted.

3 O-ring(s) jamming flow in discharge line.

4 Ants, wasps build nests in discharge line ornozzles.

REMEDY

1 Immediately drain oil from pump and flush toremove all spray residues from sump. Remove

pump heads & fit new diaphragms.

Fill to correct level with motor oil 20W/30.

1 Seal all joints securely with tape or sealant. Firm up clamps.

1 Turn tap fully on.

2 Clean filters.

1 Clean foreign material from tank & suction line.

1 Lubricate with light oil or C.R.C.

1 Remove 4 body set screws, replacediaphragm and O-rings.

1 Replace discharge line.

2 Clean pressure filter.

3 Clean discharge line of foreign materials.

4 Clean nozzles of foreign materials with toothbrush

Trouble ShootingGeneral Sprayer Problems


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5.4 GP-POM001108-Rev 1

PROBLEM

1 No spray when turned on.

2 Sprays for short time only.

3 Spray is uneven around the boom.

4 Pressure going up - output going down.

5 Pressure falling.

6 Spray pattern narrow.

7 Foam in the tank.

8 Spray pattern streaky.

REMEDY

1 Dismantle, clean & re-assemble.

2 Change pump.

1 Clean air vent.

2 Dismantle, clean & re-assemble the filter. If filterproblem persists, clean out the tank & start again.

1 Remove, clean & check. Check output & for streaks.

2 Check nozzle output, replace worn nozzles.3 Remove a nozzle in each boom section & check

that flow rate is the same. If different, check forblockages.

1 Dismantle, clean & refit. Check pressure returnsto normal. Check all filters and spray mixture.

1 Dismantle & clean the filter.

2 Check nozzle output, replace worn nozzles.

3 Check with new pressure gauge.

4 Repair or replace the pump.

1 Check that the correct nozzles are being used.

2 Check that the tank is not empty. If not, there isan air leak between the pump & tank or in thepump. Check plumbing & repair.

1 Check that the return line is at the bottom of thetank. Partly close agitation and valve

1 Remove & clean. If it continues, the nozzle is

damaged. Replace with same size tip, check flowrate of replacement nozzle.

PROBABLE CAUSE

1 Filter on the inlet side of the pump blocked.

2 Faulty pump.

1 Air inlet to tank blocked.

2 Filter on suction side of pump blocking orblocked.

1 Some nozzle filters or tips are blocked.

2 Nozzle tips worn.3 Different pressure along the boom.

1 Nozzle filters blocking.

1 Filter on suction side blocked.

2 Nozzle tips worn.

3 Pressure gauge faulty.

4 Pump worn.

1 Pressure too low.

2 Pressure too low & spluttering.

1 Too much agitation.

1 Nozzle partly blocked.

Section 5 Hydraulic Pump Drive Problems

PROBLEM PROBABLE CAUSE REMEDY


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5.5GP-POM001108-Rev 1

PROBLEM

A A Low discharge

B Hydraulic system overheating

PROBABLE CAUSE

1 Pump not primed.

2 Air leaks in suction line.

3 Blocked or clogged line filter.

4 Impeller plugged.

5 Undersized or collapsed suction hose.

6 Improperly sized hydraulic motor.

7 Bypass adjustment screw not properly set.

8 Eye of impeller rubbing on volute.

1 Improper hydraulic motor size.

2 Bypass adjustment screw set to bypass toomuch oil.

3 Improper metering orifice installed in pressureport.

4 Insufficient hydraulic hose size.

REMEDY

1 Remove top most vent plug from face of pumpand run pump to expel trapped air.

2 Check and reseal inlet fittings.

3 Inspect filter & clear any debris from screen.

4 Inspect and clear obstruction.

5 Suction line should be the same diameter asinlet port of pump or larger.

6 Refer to pump selection guide to determineproper size.

7 Adjust bypass screw on the side of thehydraulic motor.

8 Remove volute (front cover) and inspect theimpeller. If wear is detected, sand the impellereye O.D. with emery cloth.

1 Refer to pump selection guide to determineproper size for your system.

2 Close adjustment screw on side of hydraulicmotor to lessen the amount of bypassing oil.

3 Install proper size orifice. Refer to HyproManual.

4 Check hydraulic hose size. Hose should be atleast ½”. For large open-centre systems ¾”.

Trouble ShootingFoam Marker Problems - RHS Marker

PROBLEM PROBABLE CAUSE REMEDY


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5.6 GP-POM001108-Rev 1

PROBLEM

A Marker doesn’t run at all

B Air pump runs – nothing coming out –

no pressure showing on gauge

C Nothing coming out – high pressureshowing

PROBABLE CAUSE

1 Harness plug not plugged in or

2 Circuit breaker popped or fuse blown.

1 Liquid pump shut Off or not primed.

(Hint: When working on liquid pump, it is helpful tounplug the air pump so you can hear the liquid pumprunning. Remove the two black wires form the air pumpand clamp them together).

2 Electronic speed control failed causing liquid pumpnot to run.

(Hint: When working on liquid pump, it is helpful tounplug the air pump so you can hear the liquid pump

running)

3 Liquid pump valves or diaphragm have failed.

4 Liquid pump motor failed.

1 Liquid orifice plugged.

REMEDY

1 Check all wiring plugs and connections.

2 Check breaker/fuse and reset/replace if necessary.

1 Turn liquid control knob clockwise as far as it willgo. This will run the pump at full speed to aid inpriming. Allow a minute or two to prime.

If it still won’t prime, find the liquid orifice assemblynear the discharge of the pump & uncouple brieflyto allow air pressure to be relieved.

If it still doesn’t prime, either the tank strainer/outlet is completely plugged or the pump needsservice or replacement.

2 Check this component by feeling and listening tothe motor while you turn the knob up & down. Ifit speeds up & slows down, the control & pumpmotor are OK. If not,unplug the liquid pump fromthe speed control. Using jumper wires, apply 12Volts DC directly to the liquid pump. It should runfull speed indicating the pump is OK & the SpeedControl is not working.Check polarity of wires to power supply. speedcontrol will not operate in reverse polarity. If you’reabsolutely sure it is correct, replace the electronicspeed control.

3 If the liquid pump appears to run normally asdescribed above, but can’t prime or pump the

liquid, it may need a new diaphragm, or valvecartridge. We suggest replacing both.

4 If you’ve determined in the above step the liquidpump did not work when 12 Volts was applied,replace pump motor or whole pump.

1 Find liquid orifice assembly near outlet of liquidpump. Unplug orifice and clean orifice strainer.

Section 5 Foam Marker Problems - RHS Marker

PROBABLE CAUSEPROBLEM REMEDY


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5.7GP-POM001108-Rev 1

PROBABLE CAUSE

1 Air On/Off solenoid valve doesn't operate.

2 Pressure regulator incorrectly adjusted.

3 Pressure regulator damaged.

4 Air discharge plugged.

1 Concentrate weak or water too hard.

2 Liquid pressure too high.

3 Air supply not operating or plugged.

1 Foam quality poor or weak air supply.

1 Left-Right hoses hooked up backwards.

1 No power to valve.

2 Valve failure.

1 Valve Failure

PROBLEM

D Discharges almost all water -Air Flow Restricted

E Discharge foamy but very watery

F Not enough foam

G Foam goes to wrong side

H Foam won't switch sides

I Foam comes out both sides at the same time

REMEDY

1 Check for 12V to solenoid. If not, check forelectrical issues. If so, replace air ON/Off solenoid

valve.2 Set pressure regulator to 28 psi.

3 Replace pressure regulator.

4 Inspect air check valve located near solenoiddischarge for proper operation.

1 Strengthen concentrate mixture or add water

conditioner. If this doesn’t work, try a different watersupply.

2 Reduce liquid pressure to under 40 psi.

3 See air pump remedies above. Service air cleaner.

1 Measure the output by catching in a bucket. Ifoutput exceeds 20 litres/min, the marker is working

at full capacity. If not, make sure foam quality isgood as described above. Also, low output canbe related to poor air supply performance. Seedescription above.

1 Reverse hoses on Directo-Valve.

1 Check electrical connection to the valve

2 Replace valve.

1 Replace valve.

Trouble Shooting

Foam Marker Problems - Arag Marker

1 No current reaches the control unitThe electric compressor will not work the pilot 1 Check the fuse


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5.8 GP-POM001108-Rev 1

1 No current reaches the control unit.

1 Electrical connection between control unit and

electric compressor broken.

1 The tank will not pressurize.

2 Break in the pneumo/hydraulic circuit.

1 Sponge dirty or hardened .

2 Water-foaming agent mix old.

3 Flow-rate adjustment wrong.

4 Constrictions in pipes.

1 Solenoid valve jammed.

1 Constrictions in the pipes.

2 Solenoid valve jammed.

1 Incorrect fitting seal.

The electric compressor will not work, the pilotlights fail to come on

The electric compressor will not work, the pilot

lights come on

No foam comes out of dark the foam nozzles

Foam formation is not good

Foam continues to be formed in the foam nozzlenot selected

Air bleeds from the safety valve on the cap

Air or liquid leaks from the fittings

For problems not specified, call your Dealer.

1 Check the fuse.2 Check the electrical connections of the control box.

1 Check the connections between the control box and

the electric compressor.

1a Close the tank cap properly.

1b Check the tightness of the pipes connecting thecompressor with the cap.

2a Check there are no cracks in the dark the blue pipeinside the tank (from the filter to the plug) and onthe outer pipes.

2b Clean the bottom filter of liquid.

2c Check for any constrictions along the pipes.

1 Clean or replace the sponge inside the foam nozzle.

2 Redo the water-foaming agent mix.

3 Use the flow-rate regulator on the tank cap to obtaina sufficiently dense foam.

4 Check the pipes towards the foam.

1 Disconnect the pipes going from the compressorunit to the foam node, then blow with compressedair into the unions of the solenoid valves towards.

1 Check the pipes towards the foam nozzles.

2 Clean the relevant solenoid valve of liquid byblowing compressed air through the union leadingto the foam nozzle.

1 At the quick connections or threaded fittings,uncouple the pipe and shorten it by approximately10 rpm to eliminate the defects of deformation atthe seal.

gp-pom001108 - general sprayer operations

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