Berthoud BOXER II 3000 A User manual

1
BOXER II - 3000/4000 A Front boom
D.P. TRONIC regulation
(Electronic proportion flow control)
82.428-E ENGLISH
to be read attentively
and kept for further reference
03/2005
Safety, checking,sprayers maintenance : see manual N° 82.471
Nozal nozzles : see manual N° 82.467 AXIALE boom : see manual N° 82.438
DPTronic regulation : see manual N° 82.465 EKTAR boom : see manual N° 82.461
82.471
82.467
82.465
82.438
82.461

2

3
See pages
- GENERAL (see manual N° 82471)
. Technical characteristics of the Boxer 3000/4000A ................................ 7
. Warning................................................................................................... 8
. Descriptive plate ...................................................................................... 9
. Table of weights....................................................................................... 9
. Dimensions.............................................................................................. 10
. Position of safety stickers........................................................................ 11
- STARTING-UP THE SPRAYER (see manual N° 82471)
. Rinsing the equipment before first use .................................................... 14
- CHOICE OF NOZZLES AND TABLES OF FLOW RATES
(see manual N° 82471)
. Presentation of thecontrol box................................................................. 16
- MAIN SPRAYER FUNCTIONS WITH THE DELTAPUMP
. Filling ...................................................................................................... 18/19
. Transferring ............................................................................................. 18/19
. Rinsing the main tank with mains water .................................................. 18/19
. Rinsing the main tank with the rinse tank................................................ 18/19
. Rinsing the spraying circuit with the rinse tank ....................................... 18/19
. Rinsing the spraying circuit with the main tank ....................................... 18/19
- OTHER SPRAYER FUNCTIONS
. Incorporation hopper ............................................................................... 22/23
. Spraying function (agitation).................................................................... 24/25
. Electric gauge ......................................................................................... 26/27
. Handwash tank ........................................................................................ 26/27
. Rinse tank................................................................................................ 26
. Height of the boom .................................................................................. 28
. Agitation................................................................................................... 28
. Foaming into the tank .............................................................................. 28
. Last filling operation................................................................................. 28
. Draining the tank ..................................................................................... 28/29
- BOOM FOLDING/UNFOLDING FUNCTION
(see boom manuals N°82438 and N° 82461)
- MAINTENANCE OF SPRAYING EQUIPMENT (see manual N° 82471)
. Practical recommendations for maintening your sprayer......................... 32
. Checks before spray season ................................................................... 32
. Maintenance after operation .................................................................... 33
. Winter storage ......................................................................................... 33
. Nozzles or filters dirty .............................................................................. 34
. Delivery filter ............................................................................................ 34/35
. Servicing the boom .................................................................................. 36
. Servicing the pump .................................................................................. 36
CONTENTS
- MAINTENANCE DIAGRAMS
. Hydraulic circuits ..................................................................................... 40
. Wiring diagrams ...................................................................................... 41/44
. Notes on parameters ............................................................................... 45
. Notes on treatments ................................................................................ 46

4

5
GENERAL
AND
SAFETY
warning.
Acceptable use of the sprayer.
General safety instructions.
Maintenance.
Counterindications.
Meaning of the safety stickers.
See manual «Safety, Control, Maintenance» N° 82471

6

7
SELF PROPELLED SPRAYER
- Self propelled base with IVECO Diesel engine liquid
cooled. 6 cylinders, 163 HP, 5.9 liters.
(optionengineIVECO6 cylinders, 200 HP,5.9liters).
- Welded frame in square profile.
- GRP tank with flotting gauge, capacity 3000/4000
liters + 5% with baffle and separate 400-liter rinsing
tank.
- Diesel tank 210 Iiters. Oil tank 105 liters.
- Ground clearance 1.15 m (option 1.30 m).
- Fixed track width 1.80 m to 2.70 m.
(in option: Variable wheel track by sliding axles
1.80 m to 2.25 m or 2 m to 2.40 m).
- Wheelbase 3.65 m.
- 4 wheel drive by hydrostatic drive POCLAIN with
brakes et variable delivery pump REXROTH and
hydro-mecanic locking system.
- 4wheelsteeringwithhydrostaticsteeringbyOrbitrol
DANFOSS.
- Wheels 270/95 R 48 adjustable rims
(options: 300/95 R 46 - 460/85 R 38 - 480/70 R 38 -
520/70 R 38 - 520/85 R 38 - 580/70 R 38).
- Speed road: 27.5 km/h. Speed field: 13.7 km/h.
- Hydraulic brakes on the rear wheels.
- Multicontrol joystick for forwad speed, spraying,
boom height and angle control (option for variable
geometry).
- Protected under frame.
- Panoramic pressurized/heated cab, FM/tape radio,
tinted windows, UTAC-approved windshield. Two
activated carbon filters.
- Lighting in compliance with the Highway Safety
Code.
- Gyrolight.
- Pneumatic seat.
- Sound alarm for rear movement.
- Double external control of engine speed. Double
external control of PTO.
- Two front and rear work lamps.
Options on Self propelled sprayer:
Air compressor equipment with air blow gun.
SPRAYING EQUIPMENT for
SELF-PROPELLED BOXER 3000/4000 A
Dual-turbine, rotary DELTA pump for double output,
enabling:
- Filling, agitation, rinse, transfert and spraying.
- Double filtering system:
- filling filter (sieve 8/10° mesh),
- delivery filter (1/4 turn filter, 4/10° mesh).
- Chemical hopper fitted on parallelogram.
- Nivelec gauge.
- Berlogic: Display of valve handle positions of the
various functions.
- Electronic regulation D.P.TRONIC with saved
memory.
- In cab, unic control box with:
- Control display.
- Simple cumuls management and cumuls
management on 10 fields.
- Spraying remote control by:
- 4 motorised valves with stainless steel ball
(AXIALE 24/28 and variable geometry),
- 5 motorised valves with stainless steel ball
(AXIALE 30 variable geometry, EKTAR 30,
EKTAR 32),
- 6motorisedvalves(EKTAR36andEKTAR38),
- 7 motorised valves (EKTAR 42),
- 8 motorised valves (EKTAR 40).
AXIALE Booms:
- Axiale 24, Axiale 24 variable geometry, Axiale 28,
Axiale 28 variable geometry, Axiale 30 variable
geometry, fitted on the front.
- Axiale suspension on pivot with springs and
oscillation shock absorbers.
- Independent folding of outer arms. Angle corrector.
7 rams on Axiale 24 and Axiale 28.
- Independent folding of outer arms. Angle corrector.
Variable geometry. 9 rams onAxiale 24/28 variable
geometry, Axiale 30 variable geometry.
- QUADRIX nozzle holder.
- 2 sets of nozzles KWIX Alumine AFX 110° Yellow
and Blue,
2 sets of liquid fertilizer nozzles KWIX Trifilet Red
and Brown.
EKTAR Booms:
- EKTAR 30, EKTAR 32, EKTAR 36, EKTAR 38,
EKTAR 40, EKTAR 42, fitted on the front.
- Pendulum suspension.
- Independent folding of outer arms. Angle corrector.
Variable geometry. 11 rams and 9 electro-hydraulic
spool valves.
- QUADRIX nozzle holder.
- Nozzles KWIX AlumineAFX 110°.
Options on spraying equipment
of BOXER 3000/4000 A:
- 6, 7, 8, 9 or 10 motorised valves with stainless
steel ball.
- Pneumatically-controlled anti-drip system.
- GESTRONIC control box, management of 99 fields,
filling programming an end of operation alarm or
auto-stop.
TECHNICAL CHARACTERISTICS

8
are therefore essential operations, and you have
every reason to carefully read the details in this
booklet.
"This sprayer has been manufactered using
materials which withstand most plant protection
chemicals currently available on the market.
Nevertheless, BERTHOUD cannot assume
responsibility for any damage resulting from an
incompatibilitty of the crop protection chemicals
or product mixtures with the plastic materials:
(polyethylene, polyvinyl chloride, polypropylene,
Vitton, nitrile polyamide)."
WARNING
Successful treatment depends on correct
operation of your sprayer.
Correct operation depends on accurate
calibration of the equipment, and this requires
careful checking.
When this checking has been undertaken, the
sprayer must be starting-up correctly, this also
being necessary for correct spraying and
operation.
Finally, to be certain that your sprayer can give
you the performance you expect, for a long time,
make sure that you undertake the maintenance
operations required.
CHECKING, STARTING-UP,
OPERATION, MAINTENANCE
PRECAUTIONS WHEN WELDING
When performing welding operations on your
self-propelled sprayer unit, DISCONNECT
the batteries + and – terminals.
It is imperative that the spraying pump be
started with the motor at idle speed.
Because of our policy of constant product improvement,
we reserve the right to modify product specifications or design without prior notice.

9
The "Kerb weight" and "Gross vehicule weight"
boxes use the datas in the table below.
DESCRIPTIVE PLATE
- The location of the descriptive plate on your machine is indicated on the view 3/4, see page 11.
- The box "Type" is made up of letters and figures.
- Example : BOX E 30 SX 28
Year and month of manufacture
The box "N° of series" is made up of 6 figures.
Example : 97 1042 = order number.
28 = width 28 meters (or 24, 30, 32, 36, 38, 40, 42 meters).
SX = AXIALE boom (or EK = EKTAR boom).
30 = Tank capacity 3000 liters (or 40 = 4000 liters ).
E = D.P. TRONIC regulation.
BOX = Self-propelled BOXER.
TABLE OF WEIGHTS
1, rue de l’industrie
69220 BELLEVIE SUR SAONE - FRANCE
EQUIPM ENT BOOM > AXIALE
24 GV AXIALE 28 GV AXIALE 30 GV EKTAR 30 GV EKTAR 32 GV EKTAR 36 GV EKTAR 38 GV EKTAR 40 GV EKTAR 42 GV
KERB
WEIGHT
GROSS
MACHINE
WEIGHT 12400 kg 12400 kg 12400 kg 12400 kg 12400 kg 12400 kg 12400 kg 12400 kg 12400 kg
KERB
WEIGHT 7250 kg 7580 kg 7591 kg 7640 kg 7650 kg
GROSS
MACHINE
WEIGHT 13440 kg 13440 kg 13440 kg 13440 kg 13440 kg 13440 kg 13440 kg 13440 kg 13440 kg
BOXER II
3000 A
4 wheel drive
BOXER II
3000 A
4 wheel drive

10
DIMENSIONS
A
1.80to2.70m
B
C
D
E
GFH
BOOMSSPRAYERS DIMENSIONS (in meters)
ABCDEFGH
2.60
2.60
2.95
2.95
2.95
2.99
2.99
2.99
2.99
2.60
2.60
2.95
2.95
2.95
2.99
2.99
2.99
2.99
11.13
7.28
11.13
3.90
4.31
3.90
1.615
1.52
1.615
5.43
1.55
5.43
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
3.65
3.65
3.65
3.65
3.65
3.65
3.65
3.65
3.65
3.65
3.65
3.65
3.65
3.65
3.65
3.65
3.65
3.65
2.00
2.00
2.00
2.00
2.08
2.00
2.00
2.00
2.00
BOXER 2
3000 A
4 wheel drive
AXIALE 24
AXIALE 28
AXIALE 30
EKTAR 30
EKTAR 32
EKTAR 36
EKTAR 38
EKTAR 40
EKTAR 42
AXIALE 24
AXIALE 28
AXIALE 30
EKTAR 30
EKTAR 32
EKTAR 36
EKTAR 38
EKTAR 40
EKTAR 42
BOXER 2
4000 A
4 wheel drive

11
POSITION OF SAFETY STICKERS
It is very important to keep the safety stickers in location and in good condition as they draw your
attention to possible dangers and refer to the operator's manual.
See the following pages and check their location on the sprayer.
417.465 417.576
Onthehandwashtank
Inthecab
417.586 417.572
417.575
418.630
Onthehopper
1, rue de l’industrie
69220 BELLEVIE SUR SAONE - FRANCE

12

13
STARTING-UP
THE SPRAYER
Checking forward speed.
Checking sprayer wheel circumference.
Checking flow/hectare.
see manual «Safety, Checking, sprayer maintenance» N° 82471

14
RINSING THE SPRAYER BEFORE FIRST USE
Before using your sprayer for the first time with phytosanitary product (weedkillers,
insecticide or other product), rinse the machine completely.
- Remove the nozzles if they are fitted.
- Undo the end plugs on the pipes.
- Fill 1/5th of the volume of the tank with water.
- Spray (Refer to the pump OPERATION chapter).
- Remove and clean the filter.
- Retighten the pipe end nuts.
- Fit the nozzles.
- Any foreign particles which may be in the spraying circuit will thus be eliminated and there will be no risk of
them blocking the holes in the nozzles.

15
CHOICE OF NOZZLES
AND
TABLES OF FLOW RATES
see manual N° 82467
«NOZAL nozzles»
D.P. TRONIC REGULATION
voir notice N° 82465
«D.P.Tronic regulation»

16
I0
PRESENTATION OF THE CONTROL BOX
NOTE
- Fuse: The control box (2) is protected by 3 fuses: diam. 5 x 20 mm:
- 5 Amps for the D.P. TRONIC electronic board (3),
- 10 Amps for the boom control board (4),
- 10 Amps for the boom spraying sections board (5).
Display
Electronic regulation
switches
(see manual 82465)
Control box power
switch
Manual spraying
regulator valve
switch control
7
1
Control switches for
boom
(seemanual:
AXIALE boom N° 82438
EKTAR boom N° 82461)
Plugs
2
4
3
5
6
Manual/automatic mode
switch for regulator valve
Control switch for spraying
(see pages 34 to 39)

17
MAIN SPRAYER FUNCTIONS
WITH
THE DELTA PUMP
ALL THE VALVE OPERATIONS MUST BE DONE WITH THE ENGINE STOPPED.
POWER UP THE CONTROL BOX.

18
FUNCTIONS PUMP (figure 6)
FILLING 1
- Check that the draining orifice is closed (figure 15, page 29).
- Fill the centrifugal pump priming tank with water. To do this, draw the hexagon socket head screw (1) located
on the upper part of the pump body (figure 5).
- Filling without incorporation hopper using:
- Connect the filling pipe (T1) on the quick-fitting union (4).
- Turn all the valve handles to position .
- Put the pipe (T1) into the liquid to be suck.
- Trip the switch which enables the spraying pump to be engaged.
- Engine speed should kept high enough to permit the filling operation (approximately 2,500 rpm).
When the filling operation is finished, turn valve handle (4) to horizontal position, disconnect the filling
pipe (T1), replace the plug on the quick-fitting union.
- Filling with incorporation hopper using: (see page 22)
TRANSFERRING 6
- To transfer the liquid contained into the tank to another one, proceed as follows:
- Connect the transferring pipe (T2) to the quick-fitting union (7).
- Turn all the valve handles to position .
- Trip the switch which enables the spraying pump to be engaged.
- Engine speed should kept high enough to permit the filling operation (approximately 2,500 rpm).
RINSING THE MAIN TANK WITH MAINS WATER 7
- Pump stopped:
- Connect the mains water hose (T3) to the quick connector (6).
- Turn all the valve handles to position .
- Open the water supply.
- Drain the tank (figure 15, page 29).
RINSING THE MAIN TANK WITH THE RINSE TANK 8
- Pump stopped:
- Turn all the valve handles to position . NOTE: For valve No. (2) place the handle in the "dashed"
position during 2 minutes, then turn the handle to the normal position .
- Power up the control box, (reference 1, figure 11, page 25).
- Stop spraying: switches (2) and (4) (figure 11, page 25).
- Trip the switch which enables the spraying pump to be engaged.
- Engine speed should be held at 1,400 rpm for proper rinsing.
- Drain the tank (figure 15, page 29).
RINSING THE SPRAYING CIRCUIT WITH THE RINSE TANK 9
- Pump stopped:
- Turn all the valve handles to position .
- Power up the control box, (reference 1, figure 11, page 25).
- Open spraying: switches (2) and (3) (figure 11, page 25).
- Trip the switch which enables the spraying pump to be engaged.
- Engine speed should be held at 1,400 rpm to obtain proper rinsing pressure.
This operation is not enough when changing chemical products.
RINSING THE SPRAYING CIRCUIT WITH THE MAIN TANK
- When changing chemical product.
- Put 300 liters of clear water with a cleaning product (All Clear type) in the main tank.
- Turn all the valve handles to position (pump startup) during 1 minute.
- Then, turn all the valve handles to position (hopper) except valve (6) which is to be placed in position
during 1 minute.
- Finish by turning all the valve handles to position (spraying).
- In the 3 cases:
- Power up the control box (reference 1, figure 11, page 25).
- Program the control box on CONSTANT PRESSURE (3 bar) (see manual N° 82465).
- Open spraying: switches (2) and (3) (figure 11, page 25).
- Trip the switch which enables the spraying pump to be engaged.
- Engine speed should be held at 2,500 rpm to obtain proper rinsing pressure.
1
6
7
888
9
11
84
2

19
RIN‚AGECUVE
AVECEAUDU
RESEAU
RIN‚AGECUVE
AVECCUVEDE
RIN‚AGE
RIN‚AGE
CIRCUITDE
PULVERISATION
NETTOYAGE
FILTREDE
REFOULEMENT
DEMARRAGE
POMPE
REMPLISSAGE
10
9
8
7
6
1
2
3
4
5
11
TREMIE
ASPIRATION
CUVE
TREMIE
ASPIRATION
EXTERIEUR
PULVERISATION
AVEC
BRASSAGE
PULVERISATION
SANS
BRASSAGE
P.D.F.ARRETEE
P.D.F.3000tours/min
P.D.F.3000tours/min
P.D.F.ARRETEE
TRANSFERT
45
11
9
6
7810
910
45
11
245
11
6
4
12
83
1235
78911 6
13
8
245
11 6
123456
91011
2345
78910
7
6
1
11
13
7
78910
89
236
7
1
8
10
10
76
4
1
2
7
3
5
5
1
6
○○○○○○○○○○
T1T3T2

20