CONQUEST
Transcription
CONQUEST
AB20053, Rev 2 10-03 DOING OUR BEST TO PROVIDE YOU THE BEST CONQUEST 1100 GALLON OWNER/OPERATORS MANUAL READ complete manual CAREFULLY BEFORE attempting operation. ASSEMBLY CALIBRATION OPERATION REPLACEMENT PARTS DEMCO Dethmers Mfg. Co. 4010 320th St. P.O. Box 189 Boyden, IA 51234 PH: (712) 725-2311 Toll Free: 1-800-543-3626 FAX: 1-800-845-6420 www.demco-products.com Page 1 Page 2 Table of Contents General information ............................................................................................................... 4 Bolt Torque ............................................................................................................................ 5 Safety Sign Locations ........................................................................................................ 6-7 Valve Set-up ...................................................................................................................... 8-10 Axle and Hitch Assembly .................................................................................................... 11 Rinse Tank Assembly .......................................................................................................... 12 Lids, Platform and Ladder Assembly ................................................................................... 13 Tank and Wheel Assembly ................................................................................................... 14 Foam Tank, Foam Marker, Owner’s Manual Cannister, and Hand Rail Assembly ............... 15 Main Parts Breakdown ....................................................................................................... 16-17 ACE/Hypro Belt Driven Pump Mounting Assembly ........................................................... 18-19 Plumbing Breakdown ......................................................................................................... 20-22 Inductor Assembly Breakdown ............................................................................................ 23 TeeJet® Sprayer Control System Wiring .............................................................................. 24 Raven Sprayer Control System Wiring ................................................................................. 25 Monitor ................................................................................................................................. 26 Sprayer Checklist ................................................................................................................ 27 Page 3 Thank you for purchasing a Demco sprayer. We feel you have made a wise choice and hope you are completely satisfied with your new sprayer. If you have any questions regarding the applications of certain solutions or chemicals, contact your chemical supplier and follow chemical manufacturer recommendations as well as all licensing and use restrictions or regulations. WARNING: TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE, OBSERVE FOLLOWING INSTRUCTIONS: Chemicals are dangerous. Know exactly what you're going to do and what is going to happen before attempting to work with these products. Improper selection or use can injure people, animals, plants and soil. Always wear protective clothing such as coveralls, goggles and gloves when working with chemicals or sprayer. Be sure to dispose of all unused chemicals or solutions in a proper and ecologically sound manner. GENERAL INFORMATION 1. Unless otherwise specified, high-strength (grade5) (3 radial-line head markings) hex head bolts are used throughout assembly of this sprayer. 3. When placing a parts order, refer to this manual for proper part numbers and place order by PART NO. and DESCRIPTION. 2. Whenever terms "LEFT" and "RIGHT" are used in this manual it means from a position behind sprayer and facing forward. TeeJet is a registered trademark of Spraying Systems Company Page 4 BOLT TORQUE TORQUE DATA FOR STANDARD NUTS, BOLTS, AND CAPSCREWS. Tighten all bolts to torques specified in chart unless otherwise noted. Check tightness of bolts periodically, using bolt chart as guide. Replace hardware with same grade bolt. NOTE: Unless otherwise specified, high-strength Grade 5 hex bolts are used throughout assembly of equipment. Bolt Torque for Standard bolts * Torque Specifications A 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 GRADE 2 lb-ft (N.m) GRADE 5 lb-ft (N.m) GRADE 8 lb-ft (N.m) 6 10 20 30 45 70 95 165 170 225 9 18 30 50 75 115 150 290 420 630 12 25 45 80 115 165 225 400 650 970 (8) (13) (27) (40) (60) (95) (130) (225) (230) (300) (12) (25) (40) (70) (100) (155) (200) (390) (570) (850) (16) (35) (60) (110) (155) (220) (300) (540) (880) (1310) Bolt Torque for Metric bolts * A Torque figures indicated are valid for non-greased or non-oiled threads and heads unless otherwise specfied. Therefore, do not grease or oil bolts or capscrews unless otherwise specified in this manual. When using locking elements, increase torque values by 5%. * GRADE or CLASS value for bolts and capscrews are identified by their head markings. 6 7 8 10 12 14 16 18 20 22 24 CLASS 8.8 lb-ft (N.m) CLASS 9.8 lb-ft (N.m) CLASS 10.9 lb-ft (N.m) 9 15 23 45 78 125 194 268 378 516 654 10 18 25 50 88 140 216 ----- 13 21 31 61 106 170 263 364 515 702 890 GRADE-2 CLASS 8.8 8.8 Page 5 (13) (21) (31) (61) (106) (169) (263) (363) (513) (699) (886) GRADE-5 CLASS 9.8 9.8 (14) (24) (34) (68) (118) (189) (293) ----- GRADE-8 CLASS 10.9 10.9 (17) (29) (42) (83) (144) (230) (357) (493) (689) (952) (1206) SAFETY SIGN LOCATIONS Types of safety sign and locations on equipment are shown in illustration below. Good safety requires that you familiarize yourself with various safety signs, type of warning, and area or particular function related to that area, that requires your SAFETY AWARENESS. BYPASS VALVE JACK STORAGE WARNING ON Failure to follow this warning could result in serious injury or death from pinching. 12/98 AB21034 1 14 OFF 01/99 Keep all persons and objects clear while any part of this machine is in motion. AB21029 REV 1 AB21019 15 AGITATION VALVE INCREASE AGITATION 2 15 NO AGITATION 01/99 AB21028 40 50 60 30 80 10 90 3 3 2 100 0 01/99 AB21032 PRESSURE VALVE TANK FLUSH WARNING 14 70 20 10 4 9 6 13 13 11 1 12 Keep off ladder while machine is being moved or in operation AB21018 REV 1 5 12 8 SPRAY BOOM Improper use may cause serious injury or death FRESH WATER ONLY 12/98 AB21024 4 OFF 01/99 7 AB21031 QUICK REFILL INLET 11 REV 1 THROTTLING VALVE AB21021 INCREASE PRESSURE 5 SPRAYING OPERATION SET VALVES AS SHOWN OFF REV 1 AGITATION VALVE AB21030 WARNING CLEAN WATER TANK OFF SPRAY BOOM OFF OFF Throttling and agitation valves will have various settings depending on individual operator agitation and boom pressure requirements. 9 • Stay clear of hydraulic oil under pressure. 7 • Relieve pressure before removing hose, valves or servicing the hydraulic system. REV 1 AB21035 is loaded. REV 1 SPRAY BOOM OFF OFF SPRAYER TANK CLEAN WATER TANK OFF MAIN VALVE STEP 1: Engage pump and flush will begin in large spray tank. CLEAN WATER TANK STEP 2: Switch pressure valve from tank flush to spray boom. Switch MAIN VALVE from CLEAN WATER TANK to SPRAYER TANK and dispense rinse water through boom while driving across field. Engage pump and drive across field until clean water flows from nozzles. SPRAYER TANK STEP 3: For thorough clean out do this procedure until all parts are clean. REV 1 AB21025 SPRAYER TANK •Do not operate or work on this machine with out reading and understanding the operator’s manual. •If manual is lost, contact your nearest dealer for a new manual. •Avoid unsafe operation or maintenance. To prevent serious injury or death Do not use jack when equipment TANK FLUSH THROTTLING VALVE INCREASE PRESSURE MAIN VALVE MAIN VALVE CLEAN WATER TANK • Refer to chemical supplier and manufacturer recommendations as well as all licensing restrictions or regulations. • Always wear recommended protective clothing when working with chemicals or sprayer. • Be sure to dispose of all unused chemicals or solutions in proper and ecologically sound manner. Improper use can injure people, animals, plants and soil. WA R N I N G To avoid injury or property damage OFF OFF PRESSURE VALVE To prevent serious injury or death AB21020 CAUTION ON WARNING SPRAYER TANK REV 1 THROTTLING VALVE INCREASE SPRAY BOOM PRESSURE TANK FLUSH BYPASS VALVE INCREASE AGITATION NO AGITATION PRESSURE VALVE INCREASE PRESSURE To prevent serious injury or death 6 SYSTEM RINSE SET VALVES AS SHOWN AGITATION VALVE ON AGITATION THROTTLING VALVE PRESSURE VALVE TANK FLUSH MAIN VALVE BYPASS VALVE INCREASE AGITATION NO NO AGITATION 10 AGITATION VALVE ON INCREASE AGITATION 8 BOOM RINSE SET VALVES AS SHOWN BYPASS VALVE AB21026 WARNING DANGER To prevent serious injury or death Contact with electric lines will result in Serious injury or death. • Read operators manual before using machine. • Keep all shields in place. • Disengage power take off and shut off engine before servicing, cleaning or clearing a clogged machine. • Keep hands, feet and clothing away from all moving parts. • Do not stand or climb on machine when operating. • No riders shall be allowed on this equipment at any time. WARNING To prevent serious injury or death • Do not ride or stand on sprayer while any part of sprayer is moving. • No riders shall be allowed on sprayer at any time. Use care when moving or operating this machine near electric lines. Electrocution can occur without direct contact. REV 1 Page 6 AB21036 WARNING To prevent serious injury or death • Be sure cylinder and attaching hoses are fully charged with oil before operating boom. Failure to do so may allow boom to fall rapidly when lowering from folded position. • Stay clear of boom during raising, lowering, and folding. AB21011 16 (Not shown on frame) WA R N I N G To prevent serious injury or death from pinching. • Keep all persons and objects clear while any part of this machine is in motion. • Be aware of PINCH POINT symbols on boom, and all related parts. PINCH POINTS REV 1 AB21023 17 (Not shown on frame) WA R N I N G To prevent serious injury or death • Stay clear of hydraulic oil under pressure. 03/99 AB21027 PINCH POINTS • Relieve pressure before removing hose, valves or servicing the hydraulic system. REV 1 AG21052 19 (Not shown on frame) 18 (Not shown on frame) * Not sold separately, only available in decal kit #AB21037 ** Not sold separately, only available in decal kit #AB21038 ***Not sold separately, only available in decal kit #AB21039 REF. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART NO. *AB21029 *AB21028 *AB21032 *AB21031 *AB21030 *AB21020 **AB21026 **AB21035 **AB21036 *AB21025 *AB21021 *AB21024 **AB21018 *AB21034 ***AB21019 ***AB21011 ***AB21023 ***AB21027 ***AG21052 QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 4 8 DESCRIPTION 5 x 5 Decal for Bypass Valve 5 x 5 Decal for Agitation Valve 8 x 7 1/2 Decal for Boom Pressure Gauge 6 x 6 Decal for Pressure Valve 6 x 6 Decal for Throttling Valve 9 1/4 x 7 3/4 Decal for Main Valve 6 x 2 1/2 CAUTION for Jack 11 7/8 x 3 7/8 Three Panel WARNING 6 7/8 x 5 3/4 Two Panel WARNING One Panel DANGER 18 3/4 x 7 Valve Panel Operation Instruction Decal 18 1/2 x 5 1/2 Quick Refill Inlet, Outlet, and Meter Decal 5 x 1 1/2 Fresh Water Only Decal 3 7/8 x 3 7/8 WARNING Decal For Ladder 5 x 1 1/2 Decal for Showing Jack Storage 5 7/8 x 5 7/8 WARNING Decal for Pinching Hazard 6 3/8 x 2 3/8 WARNING Decal for Boom 6 x 12 Decal for Pinch Points 2 x 2 Decal for Pinch Points 5-3/4 x 2-1/4 Warning Decal for Hydraulic cylinders for boom Page 7 SPRAYING OPERATION SET VALVES AS SHOWN BYPASS VALVE AGITATION VALVE ON INCREASE AGITATION NO AGITATION OFF THROTTLING VALVE PRESSURE VALVE INCREASE PRESSURE SPRAY BOOM TANK FLUSH OFF OFF MAIN VALVE CLEAN WATER TANK Throttling and agitation valves will have various settings depending on individual operator agitation and boom pressure requirements. Page 8 SPRAYER TANK BOOM RINSE SET VALVES AS SHOWN AGITATION VALVE BYPASS VALVE ON INCREASE AGITATION NO AGITATION THROTTLING VALVE TANK FLUSH INCREASE PRESSURE SPRAY BOOM OFF OFF MAIN VALVE CLEAN WATER TANK Engage pump and drive across field until clean water flows from nozzles. Page 9 SPRAYER TANK SYSTEM RINSE SET VALVES AS SHOWN AGITATION VALVE BYPASS VALVE ON INCREASE AGITATION NO AGITATION OFF THROTTLING VALVE PRESSURE VALVE TANK FLUSH SPRAY BOOM INCREASE PRESSURE OFF OFF MAIN VALVE STEP 1: Engage pump and flush will begin in large spray tank. STEP 2: Switch pressure valve from tank flush to spray boom. Switch MAIN VALVE from CLEAN WATER TANK to SPRAYER TANK and dispense rinse water through boom while driving across field. STEP 3: For thorough clean out do this procedure until all parts are clean. Page 10 CLEAN WATER TANK SPRAYER TANK Axle and Hitch Assembly 5 5 6 1 5 10 11 2 8 10 3 11 4 9 7 4 3 3 6 16 19 14 15 4 18 17 19 13 12 5 Axle and Hitch Assembly jam nuts (#11). 1. Begin by resting frame (#1) on a solid object so frame is off the ground 36 to 40. 5. Secure jack (#12) on sprayer tongue with ball lock pin (#13). 2. Fasten undercarriage(#2) to frame using six 3/4 x 2 bolts (#3), 3/4 flatwashers (#4) and 3/4 nylon lock nuts(#5). 6. Fasten hitch (#15) to hitch ring (#14) using one 3/4 x 5 bolt (#16) and one 3/4 nylon lock nut (#5). 3. Slide axle (#6) into carriage to desired wheel spacing(60120 or optional 90-144). Note: If a 80 or 90 boom is ordered, Demco recommends 88-144 wheel spacing. 7. Attach hitch to tongue using three 3/4 x 6-3/8 pins (#17), six 1/2 machine washers (#19), and six 1/8 x 1-1/2 cotter pins (#18). Boom warrenty is void on units with wheel spacing less than 88. NOTE: Use bolt torque chart on page 5 for torque settings. 4. Secure axle using two axle mounting brackets (#7), four 5/8 x 2 bolts (#8) and four 5/8 nylon lock nuts (#9). Tighten the six 5/8 set screws (#10) and 5/8 Page 11 Rinse Tank Assembly 1 2 6 3 6 6 5 4 5 4 5 4 5 4 Rinse Tank Assembly 1. Begin by bolting side covers (#2 & #3) to side of frame, using ten 1/2 x 1-1/4 bolts (#4), 1/2 flatwashers (#5), and 1/2 nylon locknuts (#6). 2. Lower rinse tank (#1) into frame. Tank should butt up against angle crossmember. NOTE: Use bolt torque chart on page 5 for torque settings. Page 12 Lids,Platform and Ladder Assembly 10 7 3 5 4 19 26 15 13 14 4 16 25 27 17 9 8 19 18 23 21 6 24 19 12 5 11 18 22 20 2 1 18 Platform, Ladder and Lid Assembly 1. Bolt tool box holder (#1) to side of frame, using two 5/16 x 1 bolt (#2) and 5/16 nylon insert locknuts. using ten 3/8 x 1-1/4 bolts (#4), twelve 3/8 flatwashers, (#5) and ten 3/8 nylon insert locknuts (#6). 2. Bolt platform (#7) to side cover, opposite of ladder side, using two 1/2 x 1-1/4 bolts (#8), two 1/2 flatwashers (#9), and two 1/2 nylon locknuts (#10). 5. Attach pump cover (#20), using four 3/8 hand knob clamps (#19), four 3/8 flatwashers (shown on page 24), and 3/8 spring nuts (#18). 3. On ladder side of platform, insert ball (#15) and spring (#14) into roller bushing (#13). Hold bushing against ladder side rail and slide ladder into platform ladder pocket (#7). Bolt platform to side cover using two 1/2 x 1 bolts, two 1/2” lock washers (#11), 1/2 flatwashers(#12), and bushings(#13). DO NOT tighten nuts and bolts at this time. 6. Attach both left (#21) and right (#22) male hinge to side covers, using two 5/16 x 1 slotted truss bolts (#23) and nylon lock nuts(#24). Slide female hinges (#25) over male hinges and attach valve cover to female hinges, using four 1/4 x 3/4 slotted truss bolts (#26) and 1/4 nylon locknuts (#27). Then use two 3/8 hand knob clamps (#19) and 3/8 spring nuts (#18). 4. Bolt rinse tank cover (#3) to side covers and platform, Page 13 NOTE: Use bolt torque chart on page 5 for torque settings. Tank, Hose Holder, and Wheel Assembly 5 6 2 11 10 9 2 8 1 7 4 3 16 15 12 14 13 Tank, Hose Holder, and Wheel Assembly 1. Set 1100 gallon tank (#1) onto frame. bracket (#8), using four 1/4 x 3/4 bolts (#11), 1/4 lockwashers (#10), and 1/4 flatwashers (#9). 2. Bolt four tank tie down post (#2) to frame, using four 1/2 x 2 full thread bolts (#3), four 1/2” lock washers, and 1/2 flatwashers (#4). Do not tighten. 5. Attach hydraulic hose holder (#12) with two 3/8 x 3/4 bolts (#13) and 3/8 lockwashers (#14). 3. Tighten the two tie down cables (#5) to posts (#2) with four 3/8 nylon insert locknuts (#6). Tighten the four 1/2x 2 full thread bolts (#3). 6. Attach wheels (#15) to hubs with twenty 3/4 flanged nuts (#16). 4. Insert five gallon eye wash tank (#7) onto 1100 gallon tank (#1). Tie down five gallon tank with eye wash NOTE: Use bolt torque chart on page 5 for torque settings. Page 14 Foam Tank, Foam Marker, Owner’s Manual Cannister, and Hand Rail Assembly 11 10 2 17 18 12 13 1 2 3 4 3 6 14 Figure A 15 9 8 7 8 3 4 16 5 9 7 NOTE: Use bolt torque chart on page 5 for torque settings. Foam Tank and Hand Rail Assembly 1. Bolt foam tank bracket (#1) to rinse tank cover, with eight 5/16 x 1 bolts (#2), sixteen 5/16 flatwashers (#3), and eight 5/16 nylon insert locknuts (#4). 4. Bolt the foam marker (#13) to the tank cover using four 5/16 x 1 Bolts (#14), four 5/16 flatwashers(#15) and nylon locknuts(#16). 2. Lower foam tank (#10) into Bracket. Secure the tank 5. Attach the owner’s manual bracket(#17) to the strap using three nylon straps (#11), six strap anchors (#12), on foam tank as shown. Then attach the owner’s three 5/16 x 1 bolts (#2), and three 5/16 full thread manual cannister (#18) to the bracket. bolts (back side of tank). Thread strap to anchor as shown in figure A. 6. Remove the lid of the foam marker generator unit 3. Attach left and right hand rails (#5 & #6) to side cov(#13). Attach the base to the top plate as shown ers, using four 1/4 x 1-1/2 u-bolt (#7), eight 1/4 above using four 5/16 x 1 bolts (#14) , four 5/16 flatwashers, eight 1/4 nylon insert locknuts (#8), flatwashers (#15), and four 5/16 nylon insert lock two 3/8 x 1-1/4 bolts (#9), and two 3/8 nylon innuts (#16). Reattach the lid of the generator. sert locknuts. Page 15 PARTS BREAKDOWN 32 65 50 67 Back of Tank 66 45 66 32 70 49 64 32 51 52 53 51 52 53 48 71 68 44 46 68 45 49 32 69 45 50 49 49 55 63 54 68 58 45 29 57 57 56 68 46 31 32 33 29 56 31 28 59 25 47 39 29 3 37 29 3 35 36 34 37 20 3 22 18 40 17 31 9 21 40 31 26 25 39 23 25 25 25 62 30 1 5 2 8 27 30 25 42 43 41 4 18 7 11 10 3 Page 16 24 24 24 14 14 17 12 24 45 13 16 13 12 15 13 12 44 19 PARTS LIST REF. NO. PART NO. QTY. REF. NO. DESCRIPTION 1. 07887-30 1 Hitch Ring 2. 07888-30 1 Hitch Clevis 3. 02961 7 3/4 Nylon Lock Nut 4. 02389 1 3/4 x 5 Gr. 5 Bolt 5. 00116 6 5/32 x 1-1/2 Cotter Pins 6. 01159-95 3 3/4 x 6-3/8 hitch Pins 7. 09219-30 1 7000 Lb. Jack 8. 05328 1 Ball Lock Pin 9. 09595-30 1 Undercarriage for Frame 10. 01263 4 5/16 x 3/4 Gr. 5 Bolt 11. 00036 4 5/16 Lock washer 12. 01235 6 3/4 x 2 Gr. 5 Bolt 13. 00492 6 3/4 Flat Washer 14. 00290 4 5/8 x 2 Gr. 5 Bolt 15. 02587 4 5/8 Nylon Lock Nut 16. 09596-30 2 Axle Insert Mt. 17. 00489 6 5/8 Jam Nut (right hand) 18. 09946 6 5/8 x 2 Sq. HD Set Screw 19. 09599-30 2 Axle Insert (60-120 Spacing) 10 Bolt 09953-30 2 Axle Insert (90-144 Spacing) 10 Bolt 10698-30 2 Axle Insert (60-120 Spacing) 8 Bolt 10699-30 2 Axle Insert (94-144 Spacing) 8 Bolt 20. * 09730(-10)(-20) 1 Frame 21. P75C 1 Rinse Tank with Spinwell Fitting 22. * 09586(-10)(-20) 1 Right Side Platform Support 23. * 09407(-10)(-20) 1 Left Side Platform Support 24. 00967 13 1/2 x 1-1/4 Gr. 5 Bolt 25. 00085 18 1/2 Flat washer 26. 02178 13 1/2 Nylon Lock Nut --. 10031 1 Tool Box 28. * 09587(-10)(-20) 1 Top Cover for Rinse Tank 29. 00523 15 3/8 x 1-1/4 Gr. 5 Bolt 30. 02384 6 1/2 Machine Washers 31. 00059 21 3/8 Flat washer Please order replacement parts by PART NO. and DESCRIPTION. 60 61 * (-10) Red (-20) Green 82 10 11 80 81 79 78 77 76 73 Items #72, #73, and 72 74 #74 are not included in hub assembly 5474 75 PART NO. QTY. 32. 02592 15 33. 09738-30 1 34. 09934-95 2 35. 09921 2 36. 09922 2 37. 09731-30 1 38. * 09682(-10)(-20) 1 39. * 09732(-10)(-20) 1 40. 09944 8 41. 09945 8 42. 04795 2 43. 00084 6 44. 09428-30 1 45. 02990 13 46. 02802 22 47. 02995 4 48. 09176-30 1 49. 09749-30 4 50. 09819 2 51. 01076 4 52. 00057 4 53. 00214 16 54. 1 55. P1100DA 1 56. 00955 4 57. 02772 12 58. 09833-30 1 59. 09927-30 1 60. 07435 20 61. 09605-15 2 T46L 61. 07481-15 1 T13.6L 62. 05669-30 1 63. *09942(-10)(-20) 1 64. P60 1 65. 09823 3 66. 05785-95 6 67. 04352 3 68. 00004 26 10137-95 2 10167-95 1 10168-95 1 01906 4 00671 2 69. 10241 1 70. 10242 1 71. 5513 1 72. 05088 1 73. 07354 1 74. 07353 1 DESCRIPTION 3/8 Nylon Lock Nut Platform Roller 5/8 SS Ball Bearing SS Spring Ladder Top Lid for Valves Front Pump Lid 3/8 Hand Knob Clamp 3/8 Spring Nut 1/2 x 1 Gr. 5 Bolt 1/2 Lock Washer Tool Box Mounting Bracket 5/16 x 1 Gr. 5 Bolt 5/16 Nylon Lock Nut 1/2 x 2 Full Thread Bolt Eye Wash Tank Bracket Tank Hold Down 1/4 Tie Down Cable 1/4 x 3/4 Gr. 5 Bolt 1/4 Lock Washer 1/4 Flat Washer Eye Wash Tank 1100 Gal. Tank 1/4 x 1 x 2 U Bolt 1/4 Nylon Lock Nut Left Side Hand Rail Right Side Hand Rail Lug Nut Wheel, 46” x 10A, 10 Bolt 320/90R46 radial tires Wheel, 38” x 12, 8 Bolt Tire, 38” x 13.6 Bias Hydraulic hose holder Foam Marker Tank Bracket 60 Gallon Foam Marker Tank Nylon Strap, 1-3/4 x 56 Strap Anchor 5/16 x 4 Full Thread Bolt 5/16 Flat Washer FemaleHinge (see page 13) Left Male Hinge (see page 13) Right Male Hinge (see page 13) 1/4 x 3/4 Slotted Truss Bolt (see p.13) 5/16 x 1 Slotted Truss Bolt (see p. 13) Operators Manual Cannister Operators Manual Cannister Mount Foam Marker Generator 7/32 x 2 Lg. Cotter Pin 1-1/16 I.D. x 2 1/8 O.D. Flat washer 1-1/4 Castle Nut - 5691 2 8 Bolt Hub Assembly 75. 76. 77. 78. 79. -80. 81. 82. 5474 04305 07362 07358 07360 07861 07359 07357 07361 2 4 1 1 1 1 1 1 1 1 10 Bolt Hub Assembly 5/16 x 1/2 Gr. 5 Bolt Hub Cap Outer Cone Bearing (460) Outer Cup (453A) 10 bolt Hub (W871) w/ Stud Bolts Replacement Stud Inner Cup (39520) Inner Cone Bearing (39585) Oil Seal (CR30087) * Numbers ending with (-10)(-20). This two digit number is a color code, shown in box above. For proper color for your needs use this code. Page 17 BELT DRIVEN PUMP MOUNT PARTS BREAKDOWN VIEW B VIEW A 24 Center to Center 6-1/4 inside edge to inside edge Make sure that zerk of u-joint is facing pump for easier service. NOTE: Bracket #15 is used ONLY with ACE pumps. 15 9 12 ACE PUMP 18 17 25 9 3 HYPRO PUMP 21 13 14 2 20 10 23 6 19 26 1 11 30 4 23 9 16 12 8 28 13 7 24 26 5 12 27 8 10 22 29 27 Page 18 23 REF NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. PART NO. 09957-30 09962-30 09961-30 03625 10395-35 09959 09960-95 09956-30 00914 00004 02148-30 02178 02592 04932-30 07206-30 00059 00084 00085 00095 00182 00183-95 00662 00685 00789 00967 01989 04053 05669-30 ----02802 BELT DRIVEN PUMP INSTALLATION QTY. 1 1 1 1 1 1 1 2 8 3 1 8 8 1 1 4 2 2 2 1 1 1 8 1 2 2 8 1 1 8 DESCRIPTION Shaft Guard Pump mtg backing plate Pump mounting bracket Pillow block bearing 900 grease zerk U-Joint Shaft 27 F/PTO Guard Mount 3/8 x 1-1/2 Gr5 Hex Bolt 5/16 Flatwasher Panel Mount 1/2 Nylon Insert Locknut 3/8 Nylon Insert Locknut PTO Shaft Holder Extra Bracket for ACE Pumps 3/8 Flatwasher 1/2 Spring Lockwasher 1/2 Flatwasher 3/8 x 3/4 Sq. Hd Set Screw 7 Ga Hairpin Removable Pin 5/16 x 1-3/4 Roll Pin 5/16 x 1-1/4 Gr5 Hex Bolt 3/8 x 3/8 Socket Head Set Screw 1/2 x 1-1/4 Gr5 Hex Bolt 1/4 x 1/4 x 1 Key 1/2 x 5-1/2 Gr5 Hex Bolt Hose Holder Constant Velocity PTO Shaft 5/16 Nylon Insert Locknut Please order replacement parts by PART NO. and DESCRIPTION. NOTE: When assembling or replacing #4- 03625- Pillow bearing it will be necessary to remove a straight grease zerk and replace it with #5-10395- 900 grease zerk. 1. Start by removing the plastic shield from the pump if not already removed. Mount the pump to the pump mount ing bracket (#3) using two 1/2 x 1-1/4 bolts (#25), 1/2 lockwashers (#17), and 1/2 flatwashers(#18). Now put the shield back onto the pump using the supplied nuts and bolts that came with the pump. 2. Now mount the assembled pump and mounting bracket to the tongue using the pump mounting backup plate (#2) as shown on page 26. Use four 3/8 x 1-1/2 bolts (#9), and four 3/8 nylon insert locknuts (#13). These brackets should be placed as far back as possible; so that it just misses the top plate of the main frame as shown in VIEW A on page 18. Tighten these nuts and bolts at this time. 3. Now attach the guard mounts (#8) to the tongue using eight 1/2 x 5-1/2 bolts (#27) and eight 1/2 nylon insert locknuts (#12). Leave these loose at this time to allow for adjusting according to the PTO shaft. 4. Next assemble the pillow block bearing (#4), the U-joint (#6), and the PTO shaft (#7). Note: The ends of the PTO shaft are different. One end has a hole drilled into it. This is for the constant velocity PTO shaft. The other end is referred to as the U-joint end. Start by mounting the pillow block bearing (#4) to the front guard mount (#8) using two 3/8 x 1-1/2 bolts (#9), two 3/8 flatwashers(#16), and two 3/8 nylon insert locknuts (#13). Leave these bolts loose at this time. Now insert the PTO shaft (#7) into the U-Joint (#6) so the the shaft is flush with the inside of the of the U-Joint. Make sure that the grease zerk in the U-Joint is facing the pump to make doing maintainence easier as shown in VIEW B on page 18. Insert one 1/4 x 1/ 4 x 1 key stock (#26) into the key way and then tighten the set screws on the U-Joint. Now insert the shaft and the U-joint into the pillow block bearing making sure that the 90° grease zerk (#5) on the pillow block bearing is facing towards the front of the sprayer and the U-Joint is towards the pump. 5. Now tighten the nuts and bolts on the guard mounts (#8) spacing them according to VIEW A on page 18. Next tighten the pillow block bearing making sure that the bearing is lined up with the PTO shaft. HYDRAULIC PUMP INSTALLATION 1. The hydraulic pump is mounted by using two 3/8 x 1 bolts and two 3/8 nylon lock nuts to the two holes in the Tongue as shown below. When mounting the pump, make sure that the hydraulic ports are facing foward. 6. Attach the constant velocity PTO shaft to the end of the PTO shaft by first inserting one 1/4 x 1/4 x 1 keystock(#26) into the keyway, then driving in the 5/16 x 1-3/4 roll pin (#22), and then tightening the 3/8 x 3/8 set screw (#24). After the PTO shaft is attached, lay it off to the side of the hitch. 7. Next attach the PTO shaft guard (#1) to the PTO guard mounts using eight 5/16 x 1-1/4 bolts (#23), eight 5/16 nylon insert locknuts (#13), and three 5/16 flatwashers (#16). Do NOT tighten the front nuts and bolts at this time. Attach the panel mount (#11) to the front of the guard using the two existing 5/16 bolts, nuts and two of the 5/16 flatwashers as shown on page 18. Insert the PTO shaft holder (#14) into the panel mount and secure into place with two 3/8 x 3/4 sq. hd. set screws (#19). Place the constant velocity PTO shaft into the storage position in the holder (#14) and secure using the removable pin (#21) and hair pin (#20). Page 19 8. Attach the hose holder (#28) to the PTO shaft guard using the two existing 5/16 bolts, nuts and one of the 5/16 flatwashers mentioned in step #7. Tighten the front 5/16 nuts and bolts at this time. 32 48 48 46 49 71 71 71 67 67 20 19 74 66 MAIN TANK 66 75 70 18 62 19 73 RINSE TANK 64 64 68 29 BLEEDER LINE 23 23 53 57 22 #60 AND #61 ARE BEHIND THIS PANEL 46 62 62 4 27 31 23 53 3 PUMP 55 2 PUMP BOOM BALL VALVES 33 62 1 FLUSH LINE 24 56 62 72 21 24 30 AGITATION LINE 25 26 69 63 MAIN VALVE 53 62 68 73 5 70 See page 26 34 FRONT CONTROL PANEL 35 45 BYPASS LINE STRAINER 62 58 53 36 44 36 37 PRESSURE VALVE 36 39 52 40 41 AGITATION VALVE 38 50 46 45 BYPASS VALVE 62 51 38 53 REGULATING VALVE THROTTLING VALVE See page 26 62 42 45 44 ALL FLANGED CONNECTIONS HAVE GASKET AND CLAMP DEPENDING ON SIZE: 62 43 1”- M100G & 09938 2”- 112G & 09939 2” FULL PORT- 200G & 09940 5 SECTION SHOWN 3 SECTION HAS 3 Y-STRAINERS FLOW METER See page 26 GAUGE AGITATION VALVE BYPASS VALVE PRESSURE VALVE THROTTLING VALVE Page 20 BOOM LINE REAR OF THE SPRAYER 47 46 PLUMBING PARTS BREAKDOWN TRAILER PLUMBING BREAKDOWN REF. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 30. 31. 32. 33. 33. 34. 35. --. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. PART NO. QTY. M100G 112G 200G 09938 09939 09940 B6H B12H B20H B24H B32H 120RB 340RB 1010RB 1140RB S112 S2020 03900 A3812 BEL3412 FEL220 MV220CF FEL220 200HB A200 BTT200 FV220SLCF FEL220 150HB BEL200 EL114 112 BA112 200 A200 A1814 EL1414 FA200 125MPT FA200 150MPT FA200 FLST150 LST1550 FEL200 125HB BA112 114 FV200BLCF FT200 FF200 FEL200 100HB FEL200 FRB200 100 MV100CF FEL100 100HB BA1010 BTT100 BEL1010 BM1000 FT100 200 FA200 125HB FA100 100MPT LS075 80 10024 5 13 6 5 13 6 6 24 10 16 2 ------1 2 1 1 1 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 2 1 1 1 1 1 2 3 4 1 2 1 1 1 1 3/5 1 TRAILER PLUMBONG CON’T DESCRIPTION 1 Gasket 1 1/2 Gasket 2 Gasket 1 Clamp for FLG fittings 2 Clamp for FLG fittings 2 Clamp, Full Port f/ FLG fittings 3/8 Gear Clamp 3/4 Gear Clamp 1 Gear Clamp 1 1/4 Gear Clamp 1 1/2 Gear Clamp 1/2 Spiral Ag Hose 3/4 Spiral Ag Hose 1 Spiral Ag Hose 1 1/4 Spiral Ag Hose 1 1/2 Wire Braided Suction Hose 2 Wire Braided Suction Hose 3/8 MPT Valve 1/2 MPT x 3/8 HB Straight 3/4 MPT x 1/2 HB Elbow 2 FLG x 2 FLG Elbow 2 Full Port FLG Valve 2 FLG x 2 HB Elbow 2 MPT x 2 HB Straight 2 FPT(3x) Tee 2 Full Port FLG Valve (side load) 2 FLG x 1 1/2 HB Elbow 2 MPT x 2 HB ELbow 1 1/4 MPT x 1 1/2 HB Elbow 1 1/2 MPT x 1 1/2 HB Straight 2” MPT x 2 HB Straight 1/8 MPT x 1/4 HB Straight 1/2 MPT x 1/4 HB Elbow 2 FLG x 1 1/4 MPT Straight 2 FLG x 1 1/2 MPT Straight 2 FLG x 2 FLG Straight 1 1/2 FLG x 1/1/2 FLG Strainer Screen Filter for FLST150 2 FLG x 1 1/4 HB Straight 1 1/2 MPT x 1 1/4 HB Elbow 2 FLG Valve (bottom load) 2 FLG (3x) Tee 2 FLG Plug 2 FLG x 1 HB Elbow 2 FLG x 2 FLG Elbow 2” FLG x 1 FLG Reducer 1 FLG Valve 1 FLG x 1 HB Elbow 1 MPT x 1 HB Straight 1 FPT (3x) Tee 1 MPT x 1 HB Elbow 1 MPT Nipple 1 FLG x 2 FLG (2x) Tee 2 FLG x 1 1/4 HB Straight 1 FLG x 1 MPT Straight Y-shaped Line Strainer Rubber Grommet for Gauge REF. NO. 55. 56. 57. 58. 59. 60. 61. 62. -- PART NO. QTY. 104GBF BRB200 100 EL3838 BEL114 B44H FC1400 A1438 BA3434 BA3434 1 1 1 1 6 1 1 10 6 DESCRIPTION Liquid filled Pressure Gauge 2” MPT x 1” MPT Reducer 3/8” x 3/8” HB Elbow 1-1/4” MPT x 1-1/4” HB Elbow 2” Gear Clamp 1/4” FPT Coupling (For Gauuge) 1/4” MPT x 3/8” HB (For Gauge) (5 Section) 3/4” MPT x 3/4” HB (3 Section) 3/4” MPT x 3/4” HB TANK PLUMBING BREAKDOWN REF. NO. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. - PART NO. QTY. VC200 09941 1010RB BA1010 11067 BRB1034 BTT100 FC1000 P100DA FTF220BD PP180 03813 B16H G140 02989 1 2 -2 2 2 1 2 3 1 -2 2 -1 DESCRIPTION Antivortex Vent Cap Agitator Jet 1 Spiral Ag Hose 1 MPT x 1 HB Straight 1 Nipple 1 MPT x 3/4 MPT Reducer 1 FPT (3x) Tee 1 FPT Coupling 1 Tank Fitting 2 Full Port Tank Ftg. Bottom Drain 1 Schedule 80 Pipe, Polyprop. 1 Spray Ball 3/4 Gear Clamp 1/4 EVA Tubing Rinse Tank Valve Please order replacement parts by PART NO. and DESCRIPTION. Page 21 OPTIONAL “DRYMATE” QUICK REFILL PLUMBING BREAKDOWN (9428082) REF. NO. OPTIONAL “DRYMATE” QUICK REFILL PLUMBING BREAKDOWN 79. 09940 80. 200G 81. A200 82. B32H 83. DM200A 84. DM200D 85. FEL220 200HB 86. S2020 TANK 85 To Pump 86 81 83 84 PART NO. QTY. 3 3 2 5 1 1 1 -- DESCRIPTION 2 Clamp, Full Port for FLG fittings 2 Gasket 2 MPT x 2 HB Straight 1 1/2 Gear Clamp 2 Drymate Valve (male) 2 Drymate Valve (female) 2 FLG x 2 HB Elbow 2 Wire Braided Suction Hose 81 OPTIONAL QUICK REFILL PLUMBING BREAKDOWN (9428081) REF. NO. 90. 09940 91. 200G 92. 4011 2 93. B44H 94. 633C2020 95. 633F2020 96. FEL220 200HB 97. S2020 98. 634B2020 99. A200 OPTIONAL QUICK REFILL PLUMBING TANK 96 To Pump 98 95 97 94 92 PART NO. QTY. 3 3 1 5 1 1 1 -1 1 DESCRIPTION 2 Clamp, Full Port for FLG fittings 2 Gasket 2 Valve 1 1/2 Gear Clamp 2 Hose Shank for Quick Couplers 2 MPT Adapter for Quick Couplers 2 FLG x 2 HB Elbow 2 Wire Braided Suction Hose 2 Cap for Quick Coupler 2 MPT x 2 HB Straight 99 VALVE BRACKET BREAKDOWN REF. NO. PART NO. QTY. 103. 104. 105. 106. 107. 108. 109. 110. 111. 112. 10049-95 09805-30 09806-95 09807-95 00214 01906 02772 09804-30 00523 02592 1 1 2 1 9 8 9 1 2 8 DESCRIPTION Eye Wash Hose Holder 2 Full Port Valve Bracket 2 Valve Bracket 1 Valve Bracket 1/4 Flatwasher 1/4-20UNC x 3/4 Slotted Hd. Bolt 1/4-20UNC Nylon Insert Locknut Quick Refill Brkt. OPTION ONLY 3/8-18UNC x 1 1/4 Bolt 3/8-18UNC Nylon Locknut Page 22 INDUCTOR PARTS BREAKDOWN (9428079) 2 5 3 5 6 7 6 7 1 4 10 To Pu mp m Fro 18 nk Ta 9 8 10 17 11 16 15 12 8 14 13 15 13 INDUCTOR PARTS LIST REF. PART NO. NO. QTY. 1. 10047-30 2 2. 00523 4 3. 02592 4 4. 10048-30 1 5. 01263 6 6. 00036 6 7. BEL1010 1 8. 09318 1 09319 1 9. A200 1 10. B44H 2 11. BEL200 1 12. 1010RB 13. A3410 2 14. UV075FP 1 15. B16H 4 16. BA114 1 1 17. BRB200 114 1 18. BTT200 1 12 15 7 15 DESCRIPTION Mounting Bracket 3/8"- 16 UNC x 1-1/4" Bolt 3/8"- 16 UNC Nylon Locknut Tank Mounting Plate 5/16"- 18 UNC x 3/4" Bolt 5/16" Lockwasher 1" MPT x 1 HB elbow fitting 5 Gallon Cone Tank with Lid 5 Gallon Cone Lid 2 MPT x 2 HB 2 SS Hose Gear Clamp 2 MPT X 2 HB GFP Elbow 1 Rubber Hose 3/4 MPT x 1 HB 3/4 Single Union Ball Valve 3/4 SS Hose Gear Clamp 1-1/4 MPT x 1 HB 2 MPT x 1-1/4 FPT Reducer 2 FPT Tee Please order replacement parts by PART NO. and DESCRIPTION. Page 23 TEEJET® CONTROL SYSTEM WIRING CONTROL MONITOR WIRES REF. NO. 1. 2. 3. HITCH-TOVALVE CABLE (#2) BACK OF THE CONSOLE PART NO. QTY. *09460 *10798 *10799 1 1 1 DESCRIPTION Power Cord Hitch to Ball Valves Wire Harness Console to Hitch Wire Harness * Included In kit #9428065 (3 Section) and #9425067 (5 Section) Please order replacement parts by PART NO. and DESCRIPTION. TO OPTIONAL RADAR 3 FROM CONSOLE CABLE (#3) NEGATIVE 1 WIRE ENDS MUST BE ATTACHED TO THE BATTERY POSITIVE TO POWER CABLE (#1) TO WHEEL PROXIMITY SENSOR FROM CONSOLE CABLE (#3) 2 TO FLOW METER TO REGULATOR VALVE TO BOOM BALL VALVES Page 24 RAVEN CONTROL SYSTEM WIRING CONTROL MONITOR WIRES REF. NO. 1. -2. ---. 3. PART NO. QTY. *10312 **10808 *10313 **10807 10046 ***10309 1 1 1 DESCRIPTION 10 Console Control Cable (440 only) 10 Console Control Cable (450 only) 12 Flow Control Cable (440 only) 12 Flow Control Cable (450 Only) Speed Sensor Extension (optional) 24 Speed Sensor Cable Please order replacement parts by PART NO. and DESCRIPTION. * Included In kit #9428043 (3 Section) ** Included In kit #9428045 (5 Section) *** Included In both kits CONSOLE TO SPEED SENSOR TO FLOW METER 3 SIGNAL WIRES ED R BLACK BROWN WH ITE BLUE BLK/WHT TO BOOM BALL VALVES BRN/WHT USED ONLY IF THERE IS A 6TH BOOM SECTION 1 2 Page 25 BLU/WHT TO REGULATOR VALVE MONITORS CONTROL MONITOR SYSTEMS REF. NO. 1. --. 2. 3. 4. 5. -6. -7. 8. 9. PART NO. QTY. *10802 *10801L 09458 09691 09459 10933 AB460 10907 10826 10310 10308 10311 1 1 1 1 1 1 1 DESCRIPTION TeeJet® 844-E (One wire connection to the console) TeeJet® 844 (Three wire connections to the console) Flow Meter Proximity Wheel Sensor 1 Regulating Ball Valve Replacement 460 Ball Valve Repair Kit for 460 Ball Valve Raven 440 Control (3 Section) Raven 450 Control (5 Section) (Shown) Flow Meter Proximity Wheel Sensor 1 Regulating Butterfly Valve * This console can be used for either 3 or 5 section booms Please order replacement parts by PART NO. and DESCRIPTION. 5 (SHOWN HERE IN A BANK OF FIVE) 7 6 9 8 5 (SHOWN HERE IN A BANK OF THREE) 4 1 2 OLD STYLE OF MONITOR SHOWN. NEW STYLE HAS ONE PORT IN THE SIDE. 3 Page 26 SPRAYER CHECKLIST: Downtime caused by field breakdowns is costly and time consuming. Many breakdowns can be eliminated by periodic equipment maintenance. By spending time reviewing this checklist before seasonal spraying application time and following proper after-season care, you can save time and money later. WARNING: To Prevent Serious Injury Or Death • Keep hands, feet, and loose clothing away from rotating parts. • Wear protective clothing recommended by your chemical and fertilizer manufacturer when working with chemicals. Check Before Going To The Field : After Season Care: 1. NOTE: It is important to wear proper safety equipment when cleaning the sprayer. See your chemical or fertilizer package for this information. NOZZLES Check tip for excessive wear by checking for grooves in or near tip opening. Check nozzle spacing by starting at center and working outwards. Check boom for proper height. 2. HOSES Check all hoses for worn or soft spots. Be sure all hose clamps are tightened and hoses are not kinked or pinched. Check for leakage in any lines. 3. TANK Remove and clean agitator orifices. Check orifices for excessive wear by checking for grooves in or near orifice opening. Inspect fitting and grommets to insure they are in good condition. 1. After spraying chemicals, run water mixed with cleaners through tank, pump and all hose hookups. If wettable powder dries out in the system, it is very difficult to put back into suspension and can cause malfunction, damage or injury. 2. When cleaned, tank should have all openings closed or covered to keep dirt from entering. 3. Pump should be flushed with soluble oil and pump ports plugged to keep out moisture and air. 4. CONTROLS Check for leakage, plugging, or wear on all valves, fittings, etc. Clean off any build up of foreign material. Disassemble tips and rinse with water or cleaning solution. (Appropriate for chemical sprayed). 5. Clean tip opening with a wooden toothpick. Never use wire or hard object that could distort opening. 5. PUMP Check to be sure pump turns freely. 6. Dispose of all unused chemicals or solutions in a proper and ecologically sound manner. 6. FRAME Be sure all bolts are tightened. 7. Water rinse and dry tips before storing. 7. REPLACEMENT PARTS Replace all worn or damaged parts. 8. TANK TIE DOWN CABLES Be sure tie down cables are tight. 4. NOTE: DETHMERS MANUFACTURING COMPANY does not and will not make any recommendations concerning application of various chemicals or solutions. These recommendations relate to either amount or procedure of materials applied. If you have any questions regarding application of certain chemicals or solutions, contact your chemical supplier and follow chemical manufacturer recommendations. Page 27 DETHMERS MFG. COMPANY P.O. BOX 189 4010 320th St., BOYDEN, IA. 51234 PH: (712) 725-2311 FAX: (712) 725-2380 TOLL FREE: 1-800-54DEMCO (1-800-543-3626) www.demco-products.com Page 28