FMR Recycling sprayer STANDARD OPERATING PROCEDURE
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Introduction FMR Group Ltd has developed a range of Standard Operating Procedures (SOP) for all FMR and ERO machines. SOPs make use of pictures and concise wording to clearly demonstrate key functions and maintenance requirements of FMR and ERO viticulture equipment. SOPs do not replace technical manuals, company specific SOPs, risk assessments and training systems. SOPs are handy tools in your personal preparation and understanding of the machinery you will operate. They have been created for your safety and to assist you in your job. If you require specific instruction, your first action must be to contact your immediate supervisor who will ensure you and your colleagues are safe and clear instruction is given.
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Introduction FMR Recycling Sprayer SOPs:
Models SP1500R, SP2300R, SP2300RT and SP3000RT all operations are the same. In design some areas differ.
Purpose:
To instruct and assist in the safe and effective operation of a FMR Recycling Sprayer
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Safety equipment signs Symbol
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Mandatory requirements
Symbol
Mandatory requirements
Eye protection must be worn
Protective clothing must be worn
Safety helmet must be worn
Face shield must be worn
Foot protection must be worn
Safety gloves must be worn
High visibility clothing must be worn
Please wash hands before returning to work
Safety information Before operating the FMR Recycling Sprayer read the following safety instructions. Failure to comply with these warnings may result in serious injury or death. •• Under no circumstances is anyone allowed to ride on the sprayer •• Wear ear protection when operating the sprayer in a non-sound proof cabin •• Do not operate the sprayer while wearing loose fitting clothing, untied long hair, jewellery or anything that could become entangled in rotating components or that could limit your vision •• Never allow an untrained person to operate the sprayer •• This sprayer is designed and manufactured solely for the purpose of applying agricultural chemicals to crops. Under no circumstances should it be used for any other purpose •• Before using the sprayer carefully read and ensure you understand the contents of this manual and any other information supplied with the sprayer •• Before operating the sprayer read all the safety warnings which are carried on various parts of the machine •• Only operate the sprayer on a tractor fitted with a roll-over protective structure (ROPS), or a cab incorporating a ROPS, complying with AS1636 or equivalent NZ standards •• Ensure the PTO power output and towing capacity of the tractor match the power requirement and loaded mass of the sprayer •• Refer to the tractor operator’s manual for safe working loads and relevant tractor safety instructions 5
Safety information •• •• •• •• •• •• •• •• •• •• •• 6
Exercise extreme care when operating in hilly or uneven terrain to ensure proper stability Refer also to the tractor manufacturer’s operating and safety instructions Do not operate the sprayer without all the tractor and sprayer safety shields in place Apply the parking brake, switch off the tractor engine and remove the key before performing any service work on the sprayer. Ensure the sprayer and boom arms are properly supported and restrained before performing any maintenance work Do not support the sprayer by the jockey wheel when the tank is full or partly full of liquid Do not stand near or perform adjustments on the boom arms, air tubes or nozzles without first stopping the tractor engine and removing the key to ensure the arms cannot move due to inadvertent operation of the hydraulic controls Relieve all hydraulic pressure before disconnecting hoses. Oil escaping under pressure can penetrate the skin, causing serious injury. Seek medical advice immediately if injured by escaping oil Before use of any chemicals refer to the chemical manufacturer’s label and safety instructions for safe handling procedures, correct method of use and required protective clothing and equipment. Always use the recommended personal protective clothing and equipment Always wear gloves when carrying out any adjustments to the sprayer or boom Ensure that all operators and associated personnel are familiar with the legal regulations and codes of practice that apply to the safe use, storage and disposal of spray chemicals Do not enter the sprayer tank under any circumstances
BASIC INFORMATION
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Basics / Checklist Daily responsibilities for Operators Note: Only trained and experienced staff to operate the FMR Recycling Sprayer. Start of Shift •• Check all hardware is tight, especially wheel bolts •• Inspect for any hydraulic or spray fluid leaks •• Check tyres: inflation regularly (35 psi on single axle and 50-60 on tandem axle), cracks and other damage •• Check and grease wheel hubs •• Check oil in pump: level and colour (if oil looks milky contact service agent immediately!) End of Shift (see also ‘Cleaning machine‘) •• Clean all filters •• Flush sprayer system with fresh water from flush tank (Never leave chemicals in tank!) •• Wash sprayer •• Grease Weber fan units after washing machine: 2-3 pumps per nipple
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Basics / Front view Front view
H
E
B G
C
I
D K F
J
1.
Recycling unit
2.
Composite tank
3.
Hydraulic drive system
4.
Fully galvanized boom
5.
Fully galvanized chassis
6.
Individually adjustable shield system
7.
Breakaways
8.
Calibrated level sight glass
9.
Tank drain
10. Access step 9
Basics / Nose cone C
B
E
D
Nose cone
F
H
G
J
N M
L I
1.
Left and right section valves
2.
Pressure sensor
3.
Flow meter
4.
Pressure regulator
5.
Pressure relief
6.
Master valve
7.
Pressure filter
8.
Suction filter
9.
Fresh water tap
10. Pump 11. Front agitator tap
K 10
12. Rear agitator tap 13. Optional tap
Basics / Shroud unit Recycling Filter
C
D
B
E
F
1.
Weber cross flow tangential fan delivery system
2.
Hydraulic drive motor
3.
Double roll-over nozzle bodies (7 or optional 10)
4.
Grease nipple
5.
Recycling Filter
6.
Drain tap
G 11
Basics / Recycling Filter
C B Recycling Filter
D
E F
12
1.
Filter Screen
2.
Filter Screen O-ring
3.
Filter Bowl
4.
Filter Bowl O-ring
5.
Filter Bowl Nut
Basics / Recycling Pump Recycling Pump
Remove 4x wing screws turning left Then remove fibre glass cover
1.
Oil reservoir
2.
Drive motor
3.
Delivery hose to filters
4.
Suction manifolds
5.
Recycling pump speed control
(Adjust knob to increase pump speed.)
Q
B C F E D 13
Basics / R-Series Options
Electro-hydraulic width control of recycling unit
Hydraulic height adjustable kit
3 point pivoting hitch
Individual width adjustment of recycling units to position them at the optimum proximity to canopy for coverage and drift control.
Left & right outer recycling units can be individually raised or lowered independently to allow for terracing, contouring and terrain undulations in the row.
Sprayer wheels can track exactly in the wheel track of the tractor for easier exit of rows and tighter turning in limited headland space.
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CONNECTING TO TRACTOR
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Connecting to tractor / Road travel Road travel 1.
Ensure sprayer complies with regulations on lighting and signs
local
Road lights available optional. 16
2.
Only travel when main tank is empty
Open drain valve and empty tank. Close valve.
Main tank is empty.
Connecting to tractor / Road travel 3.
Remove Jack stand from sprayer
4. Turn Power and Master switches on Controller Off
Turn Master switch off. Jack stand.
Jack stand removed.
Turn Power switch off.
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Connecting to tractor / Connecting drawbar Drawbar 1. 2. 3.
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Ensure draw bar pin is fitted securely and safety pin is secured Drawbar of sprayer can be fitted either way up to suit the height of tractor Length of sprayer drawbar can be adjusted to alter how the sprayer tracks when turning
Connecting to tractor / Connecting 3 point hitch B
B
C
D
E
F
3 point pivoting hitch 1. 2. 3. 4. 5.
Connect sprayer to tractor with 3 point linkage Ensure all pins and lynch pins are fitted securely Set linkage at correct height so sprayer is sitting level, adjust top link so hitch frame is vertical Lock stabiliser arms so there is no side to side movement in the linkage Lift stands to the highest position possible
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Connecting to tractor / Connecting Hydraulics Connecting Hydraulics to tractor Connect main dump hose first Connect pressure line to spool valve of tractor, ensure tractor spool has a positive detent 3. Case drain line, can be connected in two ways: a) for tractors that have a return access with more than 40 PSI, the case drain line needs to be plumbed directly to the tank b) for tractors that have a return access with less than 40 PSI, the case drain line can be fed into the main return line
C
1. 2.
B
Main dump hose 20
C
Pressure line
D
Case drain line
B
D
SET-UP CONTROLLER
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Controller / Overview Function keys 1. Function keys
B
Keys to select data or modify parameters 2. Decrease (data browsing) 3. Increase (data browsing) 4. Data reset 5. Data confirmation 6. ON/OFF or Quit data modification 7. Output Manual / Automatic Operating switches for control unit valves 8. Main control on/off 9. Open/ closed Section 10. Increase/ Decrease of output Switches to use the hydraulic functions 11. Left arm open/close 12. Right arm open/close 13. Fans on/off 14. Hydraulic width adjust switches 22
C D E F G H I
L M
J
N
K
O
Controller / Connecting B
E
Main loom plug
F
C
Hyd control power plug
F
C Main power plug
B E
D
D Hyd control loom plug
SD card Insert card with cut edge A facing downward; push card until it engages into place and close the slot with cover. To remove card, press and immediately release the card into the slot and slide it out.
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Controller / Turn on & Main screen Turn on Controller
B C J F 24
D
E
K G H
I
1.
Controller is turned off
2.
Switch on Controller by pressing
Main Screen 1. 2. 3. 4. 5.
Target rate Row spacing Main switch on/off Time Current fluid pressure
6. 7. 8. 9.
Fan speed (RPM) Tank level Flow rate (LPM) Current application rate (LPH) 10. Speed
Controller / Job selecting B
C
Select
Select
D
Use press
and
to select job and 25
Controller / Job programming B
C
Select
and
Select
D
Use and setup menu’ 26
to select ‘Jobs
Controller / Job programming E
F
Use press
and
to select job and
G
Use and to select target rate and row width
G
Change target rate
Change row width 27
Controller / Accessing job data B
C
Select
Select
D
E
Use press 28
and
to select job and
To save data to SD card, use and and press
SET-UP MACHINE
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Set-up / Fan adjustments Fan adjustment
500mm
Adjustment of fan angle
Set fan up so there is a 500 mm gap between fan and edge of canopy. It can be decreased in thick sprawl canopies.
Adjusting Breakaway tension Usual setting is a 2mm gap between nut and end cup.
Loosen top and bottom bolt, turn fan to desired angle and re-tighten bolts. Normal adjustment for fans is 15-20ยบ forwards for the inside fans and 10-15ยบ backwards for the outside fans. 30
For less tension, adjust nut towards end cup.
Set-up / First start-up Before you start •• •• •• •• •• ••
Use only fresh water to familiarize with the operation of the sprayer Check all systems are correctly functioning without leaking Fill tank (see next pages) Engage hydraulic spool leaver on tractor Allow pump to run for 1-2 minutes to fully prime Observe pressure readout on controller to make sure pump is operating correctly
Once you‘ve started •• •• •• ••
Once running correctly increase tractor revs to desired operating level Make sure all bystanders are clear Unfold boom arms using hydraulic control switches Use test run to familiarize with all functions of the controller (see section ‚Set-up Controller‘)
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Set-up / Filling main tank Filling through main lid
B
C
D
E
Q Open lid by rotating it anti clockwise
P Check strainer basket is clean
Basket can be removed for filling if water source is clean
Close lid by rotating clockwise
Filled by using a cam lock fitting 1. 2. 3. 4. 5. 6. 32
Connect fill hose to cam lock Open ball valve Encase fill pump Shut off pump once tank is full Close ball valve Remove fill hover from cam lock
Set-up / Adding chemicals Before applying chemicals with this sprayer read the label of the chemical manufracturer or supplier for the recommended personal protective equipment and use it as recommended. Protect yourself •• Always wear gloves, eye protection and all recommended protective clothing when mixing and filling sprayer with chemicals •• Take care to avoid spillage of chemicals and solution •• Always wash your hands after filling Adding the chemical •• •• •• ••
Before adding chemicals, fill tank with 500-600lt of water Ensure all boom sections are closed so all pump output is passed through to the agitation system Chemicals can be added to the water in the tank or through basket strainer under main tank lid If adding chemicals through the main lid, always stand on the side rail of sprayer, not on the tank or wheel 33
Set-up / Boom and Fan heads Folding sprayer boom Fans must be running for hydraulic functions to operate. Once hyd flow is running: •• Move left switch for left boom •• Move right switch for right boom •• Open boom L •• Close boom M Adjusting fan heads •• Each head is attached to the boom arm with a bracket, using 8 M12 bolts •• To adjust head position, slacken the 8 bolts and move to desired position, then re-tighten bolts •• When tightening top and bottom row of bolts on brackets, ensure the two nuts on inside of steel plates are wound out to keep plates parallel to eachother 34
Set-up / Nozzles Nozzle configuration
Nozzles can be angled and shut off to target the desired area of the canopy •• For full canopy spray all nozzles can be used to create an even curtain of spray •• For bunch line spray you can use only 2-3 nozzles angled together to target that exact piece of canopy
Nozzle turned off Nozzle turned on
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Set-up / Nozzles Changing nozzle sizes
UP
Sprayer is supplied with two complete sets of nozzles, one high flow and one lower flow. These can be varied to regulate the application rate and pressure.
STRAIGHT
Changing angle adjustment To concentrate application toward a particular zone such as bunch line change angle adjustment individually. -> move nozzle body up and down Larger nozzles can be run in a certain zone: to create a percentage split of chemical application, e.g. 60% bunch and 40% canopy. 36
DOWN
Set-up / Calibrating the sprayer Output per Nozzle (l/min) = Application rate (1/ha) * Speed (km/h) * Spray width (m) 600 * Number of Nozzles operating Application Rate (1/ha) •• Depending on chemicals and stage of crop •• See information from your chemical supplier
Spraying width (m) •• Distance between rows multiplied by number of rows being sprayed
Speed (km/h) •• Average travel speed that is expected during spraying
Number of Nozzles operating •• Total number of nozzles being used while spraying
Calibrating example: •• Application rate = 300 •• Spray speed = 7.5km/h •• Spray width = 2 rows * 2.7m row space = 5.4 •• Number of nozzles used = 18 Output per nozzle = 300 * 7.5 * 5.4 = 1.266 600 * 18 37
Set-up / Calibrating the sprayer Nozzle size and spraying pressure •• •• •• ••
Controller will automatically select and regulate the pressure to maintain the application rate Pressure between 5 and 10 bar is required for efficient nozzle operation Operating at lower pressure caused deposition to be too coarse and too high pressure can increase drift When using IDK Nozzles (Air injected) for flowering and bunch closure sprays, ensure pressure is between 7 and 10 bar
Nozzle configuration 1. 2.
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Select nozzle from output chart (previous page) that will give required application rate at most suitable pressure Fit selected nozzles that are to be used in operation (see nozzle configuration next page)
Set-up / Nozzle configuration
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Set-up / Starting the sprayer Starting and Operating in normal operation 1.
Switch ‚on‘ controller , set to ‚auto‘ ‚close all boom sections‘
2.
Start tractor, engage hydraulic spool lever and increase tractor to operation RPM
3.
Select required row spacing and application rate on controller (see section ‚Set-up Controller‘)
4.
Switch on ‚master switch‘ and ‚open‘ and ‚close‘ left and right sections to check all functions
5.
When spraying, use ‚master switch‘ maintain the required boom configuration
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and
to
CLEANING MACHINE
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Cleaning machine / Draining & Flushing Routines at the end of each day 1.
Open drain valve and empty remaining chemical in tank. Close valve again.
2.
Turn over ball valve in suction line to flush sprayer with fresh water.
3.
Start sprayer running and flush sprayer with fresh water by using the manual mode. Continue for 1-2 minutes.
4.
Turn off sections on controller and open taps at bottom of sprayer line on heads. Open sections again for 15-30 seconds.
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Cleaning machine / Draining & Flushing 5.
Shut down sprayer and open tank drain again to drain tank completely.
6.
Remove and clean all filters (see next page).
7.
Wash sprayer with high volume hose or water blaster, ensure fans are kept clean and free from build up.
8.
Grease 3 grease nipples on each fan unit (2-3 pumps per nipple); after wash down is completed, run fans briefly afterwards before disconnecting sprayer from tractor.
If sprayer is stored in environment below 0c ensure all fluid is purged from the system! 43
Cleaning machine / Filter Pressure Filter
B
Filter is ‚self-cleaning‘ but should still be removed and cleaned once per tank load.
P
Self-cleaning bypass flow can be regulated by adjusting the red screw valve on end of filter bowl (usual setting is one and half turns out). Suction Filter
C
P
Should be cleaned after each tank of chemical is emptied and at the end of each day. •• make sure, sprayer and tractor are turned off •• push the red centre of filter in, turn it clockwise and remove it •• unscrew filter nut to remove element Recycling Filter
D 44
Should be cleaned after each tank of chemical is emptied and at the end of each day. •• make sure, sprayer and tractor are turned off •• unscrew filter nut to remove element
NOTES
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Notes
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Notes
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AUSTRALIA: 1800 269 773 OR VISIT WWW.FMRGROUP.NET.AU NEW ZEALAND: 0800 367 583 OR VISIT WWW.FMRGROUP.CO.NZ
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