Dupont Corteva APPLI-PRO EZ User manual

1
Operation & Installation
Manual
EZ-OPR
6/18
EZ
Super Low Volume
Application System

2

3
Appli-Pro EZ Table of Contents
Page
Introduction
4
Tools
4
Safety
5
Safety Sign Location
5
Components
6
Installation of Applicator
7-13
Mounting of Pump Housing
7-8
Recommended Spray Nozzle Positions
8-12
Plumbing Installation
12
Harness and Control Installation
13
End-of-Row Installation
13-15
Preparing the Applicator for Operation
16
Operation of Controls
17
Message Light
17
Calibration
18
Calibration Reminders
19
Maintenance
19-20
Winter Storage
20
Troubleshooting
21
Parts Breakdown
22-26
20 Liter Tank
22
EZ Components
23
Control Box
24
Parts Bag
25
Tank Assembly
26

4
Introduction
The Appli-Pro EZ Application System was built for Pioneer Hi-Bred International, Inc. by a
leading agricultural manufacturer. The EZ is an integrated system, designed and calibrated
specifically for Pioneer® brand products. This manual will take you through the steps of operation
of the applicator and also point out all safety precautions that need to be made while using the
applicator.
Read this manual carefully to learn how to install and operate the equipment correctly. Failure to
do this can result in personal injury or equipment malfunction. If you are unsure about operating
the system after consulting this manual, contact your local authorized dealership for additional
assistance. If you are in need of parts for the system please see the parts breakdown in the back
of this manual and contact your local authorized dealer to order the parts.
This unique system was developed to offer you the following advantages:
• Appli-Pro EZ treats up to 250 or 500 tons with 20 liter tank
• Simple design with reliable components
• Well suited for small operations
• Tank size: 20 Liter
Tools
• 7/16” Wrench and Sockets
• 1/2” Wrench and Sockets
• 9/16” Wrench and Sockets
• Hose Cutter
• Side Cutter
• Flat Screw Driver
• Drill and Bits

5
Safety
Carefully read all the safety signs in this manual and on the applicator before use. Keep signs
clean and in good working order. Replace missing or damaged safety signs. Replacement signs
are available from your local authorized dealer. See your installation manual for under the
replacement parts section for the correct part numbers.
Keep your applicator in proper working condition. Unauthorized modifications to the applicator
may impair the function and/or safety of the machine.
Carefully read and understand all of the applicator safety signs before installing or servicing the
applicator. Always use the supplied safety equipment on the forage harvester to service the
applicator.
Safety Sign Locations
Safety Signs
Number 1
Spraying hazard. Disconnect power before
servicing the applicator
Part no. DCL-8003
Number 2
Read and understand the operator’s manual
before using or working around the equipment.
Part no. DCL-8000
1
2
2

6
Components:
Control unit
Pump housing
Power harness
Tip
20 l Tank
Flow Gauge
3 Way Valve
Harness
Inside view

7
Installation of Applicator:
Position on chopper
1. It is recommended for chopper forage harvesters to mount the EZ on the right fender of
the harvester. Note: Make sure you can see the flow gauge from the operator’s platform
and opening of pump housing should be guaranteed.
2. After finding a sturdy mounting location for the EZ on the fender, use the mounting
bracket as a template and drill (4) 7/16” diameter holes to mount the EZ.
NOTE: ENSURE THE FRAME IS MOUNTED WITH AT LEAST 11 7/32” (285mm) BETWEEN
THE SIDES.
3. Secure the mounting bracket with four 3/8” or 10mm bolts, nuts, flat, and lock washers
(not included).
Two holes drilled on each side
side.

8
Installation of Applicator:
Position on loading wagon/baler
1. It is recommended for loading wagons and balers to mount the EZ on the front side of the
harvester or on the drawbar. Note: Make sure you can see the flow gauge from the operator’s
platform and opening of pump housing should be guaranteed.
2. After finding a sturdy mounting location, use the mounting bracket as a template and drill (4)
7/16” diameter holes to mount the EZ.
Recommended Spray Nozzle Positions on Chopper
Claas Jaguar SPFH
1. Locate the air intake on the back -
side of the blower (right).
2. Loosen one bolt near intake hole.
Connect strap to that bolt. Make
sure spray tip is centered in
opening.
3. Install spray tip, strainer, and
tubing to nozzle strap.

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Claas Jaguar: 820 – 900
1. Install spray tip, strainer and tubing to
nozzle strap.
2. Loose screw from blower and fix nozzle
holder inside that hole, ensure central tip
position inside the blower.
John Deere SPFH (7000 Series)
1. Locate the accelerator.
2. Install spray tip, strainer and tubing to
nozzle strap.
3. Without removing the nuts, place nozzle
strap over existing bolts and nuts (right).
Fasten in place with additional nuts and
lock-washers.
Claas:
Düse am Ansaugloch positioniert

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John Deere SPFH (8000 Series)
1. Locate the blower.
2. Install spray tip, strainer and tubing to
nozzle strap.
3. Without removing the nuts, place nozzle
strap over existing bolts and nuts (right).
Fasten in place with additional nuts and
lock-washers.
Krone
1. Locate the right accelerator.
2. Install spray tip, strainer and tubing to
nozzle strap.
3. Loose one screw from accelerator and
place nozzle strap over existing bolts and
nuts (right). Fasten in place with additional
nuts and lock-washers. Ensure central tip
position inside the blower.
New Holland FX
1. Front Mount installation of nozzle.
50 – 60 cm above the feed rollers.
2. Install spray tip, strainer and tubing to
nozzle strap.
3. Bolt the nozzle strap to the feed roll frame
with the supplied hardware. Position the
nozzle so it sprays directly in front of the
feed rolls.

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New Holland FR
1. Locate the blower.
2. Install spray tip, strainer and tubing to
nozzle strap.
3. Drill a hole to position the nozzle. Locate
the nozzle inside the accelerator, fix outside
and ensure central tip position.
.
Chopper Systems not listed
For best results on brands/models not mentioned, position nozzle to apply product prior to crop
entering knives and blower.
Recommended Spray Nozzle Positions on loading wagons/balers
For best results on loading wagons and balers, position nozzle to apply product prior to crop
entering knives and rollings, best 50-60 cm above pick-up/swath)
Option 1: inside (advantage under windy conditions - less drift)
1. Install spray tip, strainer and tubing to nozzle strap.
2. Bolt the nozzle strap to the feed roll frame with the supplied hardware. Position the nozzle so
it sprays directly in front of the feed rolls (50-60 cm above pick-up.) - see picture.

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Option 2: under the drawbar
1. Install spray tip, strainer and tubing to nozzle strap.
2. Bolt the nozzle strap to the feed roll frame with the supplied hardware. Position the nozzle so
it sprays directly in front of the feed rolls (50-60 cm above pick-up.) - see picture.
Installation of Plumbing
Care should be taken when routing the tubing on the machine. Considerations as you select a
route for your tube: 1) be sure to avoid interference with moving parts or hot hydraulic lines that
could damage the tubing, 2) route tubing in a way to prevent low spots (traps) in the line, 3) for
best results the finished run should have a continual “down-flow” from the tank to the nozzle
without any looping or coiling of additional tube. Cut tube to the length that you will need.
1. Locate the 20ft length of 1/4” EVA tubing.
2. Remove the compression nut on the end of the spray nozzle assembly.
3. Place the compression nut over one end of the tubing so 1/4” of it extends through the nut.
4. Begin to thread the compression nut back onto the spray nozzle assembly. Before the nut is
tight, push the tubing in as far as possible. Tighten the nut the rest of the way.
5. Cut to length and locate female coupler from the parts bag. Secure coupler to tubing with a
hose clamp. Place rubber o-ring into coupler. Attach the coupler to the EZ.
6. Secure tubing to machine with supplied jiffy clips.
Nozzle position
under the drawbar

13
Installation of Harness and Controls
Power / Communication Cable
1. Power harness with orange and black eyeloops is needed.
2. Attach the plug on the harness to the side plug of the EZ cabinet.
3. Run eyeloops down to the 12 volt battery. Check voltage with volt meter before attaching to
machines batteries. Some machines have two battery compartments. One is 24 volts and
the other is 12 volts. DO NOT HOOK TO 24 VOLTS OR IT WILL DAMAGE THE
ELECTRONICS OF BOTH THE EZ AS WELL AS THE HARVESTER.
4. Connect the orange eyeloop to the positive pole and the black eyeloop to the minus pole.
5. Run the other end of the harness into the cab and connect to the 4-pin connector on the
controller.
Installation of End-of-Row
1. The EZ is designed to operate using the harvester’s end-of-row capabilities for automatic
on/off operation.
2. Connect 12V+ from your end-of-row switch to the green pigtail where the wiring harness
connects to the controller with a quick disconnect.
3. The EZ will not start application until the machine is running with its head down, and the
feed rolls are engaged.
A. John Deere 7000 Series (Not Used with Green Star)
1. The self-propelled forage harvester should have been ordered with code 6024 or you will
need to order bundle B713547.
2. Locate harness (AZ100126) that came with the Forage Harvester. It has a green wire (065),
black wire (310) and red wire (122).
3. Connect green wire of harness to the green wire on tower end of Intell harness (006-
4524M).
4. Red wire is not used. Terminate it so it doesn’t spark. This wire will supply 12 VDC all the
time.
5. Plug harness (AZ100126) into socket located underneath headlights on the right fender.
To nozzle strap
assembly.

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6. To operate unit using the machines input,
press the Liquid Injection Pump Switch
ONCE (located on right hand arm rest
control panel). All of the following has to
be present before the power is supplied to
the sprayer:
• The road safety switch is in field
operating mode.
• The forage harvester is traveling
forward.
• The ground speed is greater than 1.25
mph.
• The feed rolls are turning in forward
direction.
7. To allow EZ to run all of the time, press the Liquid Injection Pump Switch TWICE.
Note: When the Liquid Injection Pump Switch is in standby mode, the tank indicator icon on
the corner post will flash. When the pump is running, the icon will display solid. Also
there is a light next to the switch that will light up when the switch is activated.
For more information refer to the 7000 Series Operators Manual.
B. John Deere 6000 Series
1. The following John Deere parts are
necessary:
• AL57901 Rocker switch
• Z52626 Lens insert
• RE11344 Plug
2. The switch is to be located in position 8 (shown below). Knock out the panel plug in position
8. Connect the switch to the connector labeled 534, (if the 534 label is not found, look for
the connector having a brown wire #231). Snap the rocker switch into the panel with tank
symbol forward and refer to the operator’s manual for the switch operating information. The
switch has three positions:
3. Connect the green wire on the tower end of the Intell harness (006-4524M) to the center pole
of the plug (RE11344 not included). Connect the plug to the socket behind the cab.
(REAR) ON (CENTER) OFF (FRONT) ON WHEN FEED ROLLS ENGAGE

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C. Claas 830 - 990
1. The following Claas parts are required for
the end of row function:
• 2337950 Plug
• 1787620 Plug pins
2. For Claas choppers (830 - 990), connect the
green wire on the tower end of the Intell
harness (006-4524M) to the “T” shaped plug
hanging above blower next to the automatic
oilier. The plug will have a brown and white
wire leading into it. Connect the end of row
wire to the white wire on the plug. The
chopper will turn on the box when the feed
rolls are engaged, head down, and the
machine is moving forward.
D. New Holland FX Series
1. The following New Holland part is required to utilize
the end of row feature:
• 86508819 Plug
Connect a wire to the green wire on the tower end of
the harness (006-4524M) and attach the other end to
the center pole of the 86508819 plug with enough wire
to reach out of the cab to the socket under the main
fuse box behind the cab.
E. New Holland FR Series
1. Depending on the year of the machine the plug will be found at the back of the machine on
the right side above the rear axle (2009 & up) or behind the cab (2008 and older). The
harness can also be traced to the cab and connected closer to the control box.
2. Connect a wire to the green wire on the tower end of the harness
(006-4524M) to the white wire on the plug.
FR Series 2008 and older
FR Series 2009 and up

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Preparing the Applicator for Operation
Connect the power harness
Attach one end of wire harness (006-4597H) to the side of the applicator. Connect other end to
the control box. The power harness (006-4597P) that supplies power from the tractor battery to
the applicator will be connected to the control box in the cab. Connect the two units together for
operation. Always disconnect before servicing the applicator or forage harvester.
Fill the tank
Read the label of the product being filled into the tank to determine what individual protective
measures need to be taken. Clean the tank lid area and unscrew the lid. Transfer product from
the container into the tank.
Water is recommended for first time and annual start up procedures.
Attention: Please keep care what kind of application base rate you will work with
(recommendation chopper: 40 ml/t and loading wagon/baler: 80 ml/t - see application rate table).

17
Operation of the Controls
Understanding and using the control
The model 457 EZ control is pictured below. The toggle switch (A) is used to supply and cut off
power to the pump and compressor. With the switch in the up position (shown) the power is on.
Flip switch to down position to turn power off. The dial (B) is used to adjust the pump speed to
increase or decrease flow of product to the tip when power is applied. Use the numbers on the
dial only as reference. The flow gauge on the side of the applicator will be used to determine the
exact flow. The message light (C) will always be illuminated when the power is on. If the light
ever blinks during operation please reference the manual section “Message light”.
Message Light
The LED above the speed dial will be steady on when the applicator is running under normal
situations. If the light blinks on and off use the below information for the message.
Slow steady on and off blink: The system is attached to the machine end of row. This
message means that the pump is paused. The light will come on constant once the forage
harvester is back in the windrow.
Two quick blinks: The pump motor or pump harness is shorted.
Three quick blinks: Pump motor is over the current limit (10 amps).
Four quick blinks: Power is under current from a bad connection.
The control box must have the on/off switch toggled to clear the message after the fault
has been fixed to clear.

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Calibration for Forage Harvesters, Baggers and Silo Blowers
There are two steps that you need to know when calibrating your applicator: determining your
ton/hour and using the flow gauge to set the correct pump output.
Step 1
Time how long it takes to process a load. Determine how many tons are in a load by weighing it
and use the chart below to determine the tons you are processing per hour.
Load size Minutes to Process a Load
In Tons
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
4
80
60
48
40
34
32
26
24
22
20
18
17
16
15
14
13
13
12
6
120
90
72
60
51
48
39
36
33
30
27
26
24
23
21
20
19
18
8
160
120
96
80
68
64
52
48
44
40
36
34
32
30
28
26
25
24
10
200
150
120
100
85
80
65
60
55
50
45
43
40
38
35
33
32
30
12
240
180
144
120
102
96
78
72
66
60
54
51
48
45
42
40
38
36
14
280
210
168
140
119
112
91
84
77
70
63
60
56
53
49
46
44
42
16
320
240
192
160
136
128
104
96
88
80
72
68
64
60
56
53
50
48
18
360
270
216
180
153
144
117
108
99
90
81
77
72
68
63
59
57
54
20
400
300
240
200
170
160
130
120
110
100
90
85
80
75
70
66
63
60
Chart based on continuous feeding of machine
Example: It takes you 10 minutes to fill a wagon. You weigh the wagon and determine you are
making a 10 ton load. Looking at the rate chart above, you see that you are chopping at 60
ton/hour.
Step 2
Use the chart on the right for the required
flow gauge reading to ensure the correct
application harvesting rate.

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Calibration Reminders
*Watch the flow gauge, as the setting will vary with tractor’s electrical output, temperature and
other factors.
*Check your application rate by measuring product used against actual tons processed.
REMEMBER, ONLY YOU CAN CONTROL HOW MUCH PRODUCT IS APPLIED AND THAT
WILL DETERMINE IF YOUR CROP WILL KEEP!
Maintenance
• If you are unsure how to perform any of the maintenance steps have your local
authorized dealer perform the tasks.
Maintenance Schedule
Daily
10 hrs
400 hrs
Weekly
Monthly
Season
Flush system with water
X
X
Tip & tip screen cleaning
X
X
Tank lid cleaning
X
X
Dielectric grease connections
X
X
Rebuild pump
X
X
Battery connections
X
X
Visually inspect hoses
X
X
Tip & tip screen cleaning: Before cleaning the tips and screens all personal protective
equipment must be worn. Refer to product label for equipment needed.
Remove the tip, and screen. Some models may require a wrench to remove. Clean off any debris
and soak tip and screen in warm water with a mild soap if necessary. Once the tips and screens
are cleaned reinstall by following the directions in reverse.
Tank lid cleaning: Before cleaning the tank lid all personal protective equipment must be worn.
Refer to product label for equipment needed.
The tank lid is located on the top of the tank. If tank lid cannot be removed from ground level, use
a safe and secure platform to access the tank. Unscrew the tank lid and bring down ground level.
Use compressed air clean out the tank screen (D). If the screen cannot be thoroughly cleaned
with compressed air, replace fitting (005-9022B3). Once the screen is cleaned reinstall the cover.
Dielectric grease connections: Disconnect all harnesses on the applicator, clean the
connections, and repack with dielectric grease.
D

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Rebuild pump:
• Squeeze tube – Replace squeeze tube at the beginning of each season (002-9011→ 30
Inches).
o To replace the squeeze tube; the four front screws need to be removed from the pump.
Remove the old tube and place one side of the tube through the top hole leaving an 8-
inch section out of the tube. Use the supplied key to gently roll the tube into the pump
and though the opposite top opening. Reinstall the four screws and install on the
motor.
• Tip – Replace tip and screens at the beginning of each season.
• Check calibration.
Battery connections: Follow the batteries safety warnings and clean the battery connections. If
the connections cannot be cleaned, replace harness.
Miscellaneous Maintenance:
1. Depending on the product being used, the system may need to be flushed with water at a
regular interval.
a. The 3-way valve on the side of the machine will switch the system to drawing
water out of the fresh water for a system flush at the end of each use.
2. Although the pump can run dry, extended operation of a dry pump will increase wear.
Watch the inoculant level in the tank.
Figure 1. Valve set to draw from tank. Figure 2. Valve set to flush
Winter Storage
1. Thoroughly flush the system with water.
2. Drain all lines on the outlet side.
3. Never use oils or alcohol based anti-freeze in the system.
4. Remove control box from tractor and store in a warm, dry place.