Farm King 1600 Product manual

OPERATOR AND PARTS MANUAL
1600 High-Clearance Sprayer
04/2010
SXL-26030

1600 High-Clearance Sprayer
Introduction
TO THE OWNER
Thank you for purchasing a Farm King 1600 High-Clearance Sprayer.
Farm King Sprayers have been designed to provide many years of profitable and
dependable service. To assure maximum performance of your sprayer, it is mandatory
that you thoroughly study the operator’s manual and follow its recommendations.
Proper operation and maintenance are essential for safety, to maintain performance, and
to maximize the life of the sprayer.
It is the owner’s responsibility to:
• Operate and maintain this sprayer in a safe manner and in accordance with all
applicable local, state, and federal codes and/or laws; and in compliance with labeling
instructions furnished by the supplier of the chemical being used.
• Make sure each and every operator has read the operator’s manual and thoroughly
understands safe and correct operating procedures.
• Make sure unauthorized people do not operate or are not in the vicinity of the sprayer
while it is in operation.
• Maintain the sprayer in accordance with the maintenance schedule in this manual.
Furthermore, as additional technology becomes available, the owner is responsible
for improving the safety and reliability of the system.
• Fulfill all warranty obligations so as not to void the warranties. Verify the unit is
warranty registered prior to making any warranty claims. The warranty section at the
back of this manual outlines the warranty policy of Farm King.
Abuse or modifications to the sprayer that change the performance other than original
factory specifications void the warranty.
Farm King reserves the right to make product improvements to the equipment at any
time. It shall not be obligated to make such changes to machines already in service.
* The owner, manager and/or operator is responsible for safe, accurate operation and
maintenance of the Farm King 1600 High-Clearance Sprayer.
2

Table of Contents
Table of Contents
Safety Instructions - Section A .................................................................................................. 5
• Safety First .................................................................................................................... 6
• Safety Instruction for Operation .................................................................................. 7
• Decal Placement ......................................................................................................... 10
Operation Instructions - Section B ......................................................................................... 13
• Inspect Unit ................................................................................................................. 13
• System Overview ........................................................................................................ 14
• Hitch ............................................................................................................................. 15
• Liquid Tank & Cradle Frame ....................................................................................... 15
• Spray Boom & Nozzles............................................................................................... 15
• Liquid Pumping & Plumbing ..................................................................................... 16
- Centrifugal Pump ............................................................................................ 17
> Hydraulically Driven ......................................................................... 17
- Fill Solution Tank ............................................................................................. 18
> Fill Solution Tank, Utilizing Eductor (optional) ............................... 19
> Rinse Eductor While Filling .............................................................. 20
> Fill Solution Tank with Tank Agitation .............................................. 20
- Fill Clean Water Rinse Tank ............................................................................. 21
- Rinse Agitation System .................................................................................. 21
- Rinse Solution Tank ......................................................................................... 22
- Rinse Spray Boom Plumbing ......................................................................... 23
- Spraying .......................................................................................................... 24
> Spraying with Agitation ................................................................... 24
- Unload ............................................................................................................. 24
- Strainers .......................................................................................................... 25
• Hydraulics.................................................................................................................... 25
- Top Fold Spray Boom Folding Out ................................................................. 26
- Top Fold Spray Boom Folding In .................................................................... 27
• Solution Spray Control System ................................................................................. 28
• Light & Marking System ............................................................................................ 28
• Foam Marker ............................................................................................................... 28
Connection & Startup - Section C .......................................................................................... 29
• Connection .................................................................................................................. 30
- Hitch ................................................................................................................. 30
• Visual Inspection ......................................................................................................... 30
• Axles ............................................................................................................................ 31
- Adjustable Width Axles ................................................................................... 31
• Tire Weight Capacities ................................................................................................ 32
• Hydraulics.................................................................................................................... 33
- Tractor Hydraulic System Pressure ................................................................ 33
- Hydraulically Driven Centrifugal Pump ......................................................... 33
3

Table of Contents
Table of Contents
- Vertical Fold Boom Controller ........................................................................ 34
- Directional Stack Boom Box Mounting ......................................................... 35
• Spray Control System ................................................................................................ 36
• Light System ............................................................................................................... 37
• Foam Marker ............................................................................................................... 37
• Vertical Fold Boom Adjustment ................................................................................. 37
Storage - Section D .................................................................................................................. 39
• Winterization ............................................................................................................... 41
Maintenance, Service & Troubleshooting - Section E ........................................................... 43
• Liquid Tank, Frame and Plumbing ............................................................................. 44
• Hydraulics.................................................................................................................... 45
• Electrical & Control System ....................................................................................... 45
• Top Fold Spray Boom Lubrication ............................................................................. 46
• Wheel Lug Nut Torque ................................................................................................ 47
• Bolt Torque Data .......................................................................................................... 48
• Troubleshooting .......................................................................................................... 49
Parts & Schematics - Section F ............................................................................................... 51
Warranty - Section G .............................................................................................................. 103
4

Safety Instruction
Section A
5

Safety Instructions - Section A
Safety First
Accidents can be prevented by recognizing the causes or hazards before an accident occurs . . .
and doing something about them.
Regardless of the care used in the design and construction of this equipment, there are some
areas that cannot be completely safeguarded without interfering with the accessibility and
efficiency of operation.
In this manual and on labels used on the machine the words ”DANGER”, ”WARNING”, and
”CAUTION”, are used to indicate the following:
DANGER: Indicates an imminently hazardous
situation that, if not avoided, will result in
death or serious injury.
WARNING: Indicates a potentially hazardous situation
that, if not avoided, could result in death
or serious injury.
CAUTION: Indicates a potentially hazardous situation
that, if not avoided, may result in minor or
moderate injury.
In this manual the words ”IMPORTANT” and ”NOTE” are used to indicate the following:
IMPORTANT: Highlights information that must
be heeded.
NOTE: A reminder of other related information
that needs to be considered.
THIS MESSAGE ALERT SYMBOL IDENTIFIES IMPORTANT MESSAGES
IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, BE ALERT TO THE
POSSIBILITY OF PERSONAL INJURY AND CAREFULLY READ THE
MESSAGE THAT FOLLOWS.
THIS MESSAGE ALERT SYMBOL IDENTIFIES INFORMATION THAT
MUST BE HEEDED FOR PROPER OPERATION OF EQUIPMENT AND TO
PREVENT DAMAGE OR DETERIORATION OF THE EQUIPMENT.
6

Safety Instructions for Operation
1. DO NOT ALLOW ANYONE TO OPERATE THIS FARM KING SPRAYER UNTIL HE OR SHE HAS
READ THIS MANUAL AND IS COMPLETELY FAMILIAR WITH ALL SAFETY AND OPERATION
PROCEDURES.
Safety Instructions - Section A
DANGER Always wear protective clothing, goggles, respirator
and gloves when handling chemicals.
2. If any safety device on the sprayer itself is not functioning properly, DO NOT use the sprayer.
Remove it from service until it has been properly repaired by a qualified service technician.
3. Do not allow the following people to operate or repair this equipment.
• Children
• Irresponsible persons
• People under the influence of alcohol, medications or other drugs that can cause drowsiness
or impaired judgement.
• Persons unfamiliar with equipment or people who are careless or unfamiliar with safe
operating procedures.
WARNING
Observe the IMPORTANT SAFETY INSTRUCTIONS
listed below at all times! THE BEST KIND OF SAFETY IS
A CAREFUL OPERATOR.
CAUTION Always wear protective clothing, goggles, respirator
and gloves when handling chemicals.
WARNING
Observe all Federal and State EPA regulations and all
Local, State and Federal codes and / or laws regarding
licensing, handling, storage, transportation, application
and waste disposal of chemicals.
7

4. People who are allergic to any of the chemicals used must never be allowed in or near the
sprayer.
5. Always park the sprayer on a level surface, and lock the tractor brakes, or block the tires,
before making adjustments or repairs.
6. Before operating this equipment, thoroughly inspect the unit to ensure it is in good working
order.
7. Do not operate this unit if any defect or malfunction exists. Pay particular attention to safety
features such as safety chains.
8. Verify that the sprayer is securely hitched to the tractor and safety chains are in place.
9. Always position the spray boom in cradles prior to disconnecting the trailer hitch from the
tractor.
10. Stopping distance increases as the square of the speed. For example: It will take twice
as much distance to stop a unit traveling 15 mph as one going 10 mph; and four times
the distance at 20 mph (more than eight times the distance at 25 mph)! Road surface will
influence stopping distance. Dry pavement is usually considerably better than gravel road.
Materials (such as ice, snow, water, oil or mud) on the surface can greatly increase stopping
distance.
Road slope has a significant impact on stopping distance and can greatly magnify the other
factors mentioned above. Under some downhill conditions stopping can be very difficult or
impossible.
WARNING
Never disconnect the sprayer from the tractor hitch
while the spray boom wings are in the spray position.
This action will cause this sprayer to tip backwards with
a high probability of injury to the operator and damage
to the unit.
Safety Instructions - Section A
8

11. Do not replace components or parts with those other than genuine Farm King Factory Service
Parts. To do so may reduce the effectiveness of safety features or decrease the accuracy of
the unit.
12. Read the Operation Instructions section of this manual for further necessary information relat-
ing to the safe operation of the applicator.
WARNING
Certain chemicals can be very corrosive and may
oxidize steel over a period of time. This weakens steel
parts and can cause failure to perform as intended,
resulting in possible safety hazards. Periodically check
all safety shields and structural members for corrosion.
Replace or repair anything that could cause a potential
safety hazard.
Safety Instructions - Section A
9

DANGER
TO AVOID INJURY OR DEATH
KEEP EVERYONE CLEAR OF
MACHINE WHEN FOLDING
OR UNFOLDING WINGS
DO NOT open the lid of the
eductor while in operation as
splashing of chemical may occur.
CAUTION
DANGER
004776
To avoid injury or
death do not contact
electric lines when
moving or operating
this machine.
CAUTION
004775
ALWAYS WEAR
PROTECTIVE CLOTHING
GOGGLES, RESPIRATORS
AND GLOVES WHEN
HANDLING CHEMICALS
WARNING
004774
KEEP HANDS AND
BODY AWAY FROM
AREAS WHICH
EJECT FLUIDS UNDER
HIGH PRESSURE
004772
CAUTION
DO NOT RIDE
IN THIS
AREA 004773
CAUTION
SERVICE & PARTS
MANUAL MUST BE
READ & UNDERSTOOD
BEFORE OPERATING
UNIT. FAILURE TO DO
COULD RESULT IN
SERIOUS INJURY. 004772
CAUTION
USE CYLINDER LOCKUP WHEN
SERVICING OR STORING UNIT
CAUTION
AGRICULTURAL CHEMICALS
CAN BE DANGEROUS.
IMPROPER SELECTION OR
USE CAN INJURE PERSONS,
ANIMALS, PLANTS, SOILS
OR OTHER PROPERTY.
TO AVOID INJURY
1. SELECT THE RIGHT
CHEMICAL FOR THE JOB.
2. HANDLE AND APPLY IT
WITH CARE. FOLLOW
INSTRUCTIONS ISSUED
BY THE CHEMICAL
MANUFACTURER. 002438
Safety Decals on a Farm King
Model 1600 High-Clearance Sprayer
Safety Instructions - Section A
8
2
4
7
6
3
5
9
1
SX002438
SX004302
SX004772
SX004773 SX004774
SX004775
SX004776
SX006963
SX002439
10

Safety Decal Placement
Safety Instructions - Section A
11

NOTES:
Safety Instructions - Section A
12

Operation Instructions
Section B
13

IMPORTANT
Check machine thoroughly for screws, bolts, fittings,
etc., which may have come loose during transport or
operation.
CAUTION
Prior to loading with chemical, the operator needs to
test the sprayer with water only to ensure the system
is intact prior to putting chemical into the system. Test
to verify application at the desired rate and all compo-
nents work correctly.
Inspect Unit
System Overview
The Farm King Model 1600 High-Clearance Sprayer consists of the following subsystems:
• Hitch
• Liquid Tanks and Cradle Frame
• Spray Boom and Nozzles
• Liquid Pumping and Plumbing
• Solution Spray Control System
• Hydraulics
- Centrifugal Pump
- Spray Boom Folding
• Light and Marking System
• Foam Marker (optional)
Nozzles
Liquid Tank Spray Boom
*Spray Boom
Section Valves
Fresh Water
Safety Tank
Main
Strainer
Centrifugal
Pump
Valve Plate
Cradle
Frame
Foam Marker Tank
(Field installed option)
Clean Water
Rinse Tank
Operation Instructions - Section B
*Note: Spray boom section valves are on the center section of the boom.
14

Hitch
Verify hitch is correctly attached to the tractor.
See Section C for connection procedures.
Pintle/Clevis Style Hitch
IMPORTANT
1. Towing tractor must weigh 12,000 pounds to ensure
adequate stopping ability. Refer to your tractor
manufacturer rating capabilities.
2. Do not tow sprayer over 20 MPH.
Liquid Tank & Cradle Frame
A polyethylene tank is supported by a structural steel cradle skid and frame weld. The tank is
lowered into the cradle frame, requiring no additional strapping to hold in place.
WARNING
Never allow the clean water safety tank to become
contaminated with chemical. Use the clean water tank
for skin and eye rinse in case of accidental chemical
contact.
Spray Boom(s) and Nozzles (not included)
Spray boom sizes are 60' to 90' vertical fold. Hydraulic cylinders, powered via the tractor
hydraulics fold the Spray boom. The required size of the nozzles is dependent on the application
rate and the tractor rate of travel (i.e. speed). The spacing of the nozzles is dependent on the type
and size of nozzle utilized. See your Farm King Dealer for correct selection of nozzles and required
spacing.
Solution Quick Fill
Connection
Operation Instructions - Section B
Eductor System
(Field Installed Option)
15

Rinse Ball
Valve
Agitation
Valve
Spray Boom
Valve
Strainer
Flow Meter
Clean Water
Rinse Valve
Pressure
Gauge
Liquid Pump & Plumbing
The liquid system begins with a suction line supplying a centrifugal pump. This pump is powered
via tractor hydraulics and provides flow to the sprayer. The pump and plumbing have been
configured to provide for the following functions:
• Fill Solution Tank
• Fill Solution Tank, Utilizing Eductor (if equipped)
• Fill Solution Tank, With Tank Agitation
• Fill Clean Water Rinse Tank
• Rinse Agitation System
• Rinse Solution Tank
• Rinse Spray Boom Plumbing
• Spray
• Unload
Actual valve configuration will vary, depending on options purchased.
Operation Instructions - Section B
Front Panel Hydraulically Driven Centrifugal Pump
Under Tank View
Outlet
Vent Line
Inlet
(Suction Line)
Quick Fill Connections
Solution
Clean
Water
16

WARNING
004774
KEEP HANDS AND
BODY AWAY FROM
AREAS WHICH
EJECT FLUIDS UNDER
HIGH PRESSURE
Figure 1
Vent Line
Product Tank
Pump
Suction
Line Ideal
Suction
Line
Acceptable
Figure 2
Vent Line
Product Tank
Pump
Figure 3
Vent Line
Product Tank
Pump
Suction
Line Not
Acceptable Air Trap Point
IMPORTANT
The vent line is designed to prevent air lock by
bleeding off trapped air. This allows the pump to prime
and keeps some fresh solution circulating by the seal.
IMPORTANT
For proper venting, the vent line must continually rise
from the pump to the top of the tank. A small amount
of solution will move through this line back to the solu-
tion tank indicating a primed pump.
Centrifugal Pump
Pump operation is very important. The following must
be followed when operating a centrifugal pump. Proper
pump operation will make your system operate with
minimal maintenance and down time. Failure to follow the
manufacturer’s pump operation instructions will void the
pump warranty.
The pump must never be run in a non-flooded condition.
Operating the pump in a non-flooded condition will cause
extensive seal damage and possible pump damage. To
verify the pump is flooded, visually check pump vent
line for fluid. Fluid will appear in vent line when pump is
flooded.
A ”flooded” condition is when the centrifugal pump is
completely full of fluid and no pockets of air are present in
the pump. In order to get maximum pump efficiency the
mounting and plumbing must meet the guidelines stated
below.
1. The pump inlet must be mounted below the product
tank(s) sump to allow gravity to naturally fill the pump
with liquid. See Figures 1 - 3.
2. The suction line must have a continual rise from the
pump inlet to the tank sump.
3. The pump must have the vent line plumbed to it.
Hydraulically Driven Centrifugal Pump:
It is very important that the proper oil flow is supplied to
the hydraulic motor which powers the pump. Excessive flow
will over-speed the motor and cause motor damage. To reg-
ulate the correct oil flow to the pump motor see the pump
manufacturer’s manual.
Operation Instructions - Section B
17

IMPORTANT
Turn off a hydraulically driven centrifugal pump using
the ”float” position of the tractor’s hydraulic valve. This
allows the motor to stop slowly helping to protect the
motor and motor seals.
IMPORTANT
There are two basic rules to follow when operating a
hydraulically driven centrifugal pump:
1. Never run the pump in a ”non-flooded” condition.
2. Always have the correct oil flow to the pump motor.
Always read and follow the pump manufacturer’s opera-
tional instructions.
Fill Solution Tank
Load the solution tank without using the trailer sprayer
pump via the following steps.
1. Close all valves.
2. Remove solution quick fill cap and connect load hose.
3. Open solution quick fill valve and solution tank main
valve.
4. Open valve on loading reservoir (i.e. nurse tank).
5. Start the remote transfer pump.
6. Run remote transfer pump until the desired amount of
solution is transferred into the trailer sprayer.
7. Close valves on loading reservoir.
8. Close solution quick fill valve on trailer sprayer.
9. Remove load line and replace cap on trailer quick fill.
CAUTION
Small amounts of liquid will remain in the load hose.
Splashing of this liquid can cause a safety hazard to
you and to those in the vicinity of the trailer sprayer.
CAUTION
Overfilling may cause the tank lid to open causing
splashing of solution from the tank lid, which may be
hazardous to you and the environment.
Operation Instructions - Section B
Solution Quick
Fill Valve
(Closed Position)
Clean Water
Quick Fill Valve
(Closed Position)
Rinse Ball Valve
(Closed Position)
18

DO NOT open the lid of the
eductor while in operation as
splashing of chemical may occur.
CAUTION
CAUTION
AGRICULTURAL CHEMICALS
CAN BE DANGEROUS.
IMPROPER SELECTION OR
USE CAN INJURE PERSONS,
ANIMALS, PLANTS, SOILS
OR OTHER PROPERTY.
TO AVOID INJURY
1. SELECT THE RIGHT
CHEMICAL FOR THE JOB.
2. HANDLE AND APPLY IT
WITH CARE. FOLLOW
INSTRUCTIONS ISSUED
BY THE CHEMICAL
MANUFACTURER. 002438
Fill Solution Tank, Utilizing Optional Eductor
Load the solution tank using the optional eductor via
the following steps:
1. Close all valves.
2. Remove solution quick fill cap and connect load
hose.
3. Open solution quick fill valve and solution tank
main valve.
4. Open valve on loading reservoir (i.e. nurse tank)
5. Fill eductor with desired amount of chemical to be
pulled into the solution tank. CLOSE Eductor Lid.
6. Start the remote transfer pump.
7. Once there is a steady flow rate from the nurse
tank to the solution tank, open the eductor valve
and close the solution quick fill valve. Once there
is a steady flow rate again, open the eductor tank
valve for 15-30 seconds.
8. Close the eductor tank valve and verify the chemi-
cal has been completely removed from the educ-
tor tank. Repeat steps 7 and 8 if chemical remains
in the eductor tank.
9. Run remote transfer pump until the desired
amount of solution is transferred into the sprayer.
10. Close valves on the loading reservoir.
11. Close solution quick fill valve and the eductor
valve on the sprayer.
12. Remove load line and replace cap on sprayer
quick fill.
Operation Instructions - Section B
Solution Quick Fill Connection
Eductor Lid
Left Side View Eductor
(Optional)
Solution Quick Fill and Eductor
Plumbing (Optional)
Left Under Frame View
Eductor Inlet Valve
(Closed Position)
Solution Quick Fill
(Closed Position)
Eductor Outlet Valve
(Closed Position)
Eductor Tank Valve
(Closed Position)
19

IMPORTANT
Turn off a hydraulically driven centrifugal pump using
the ”float” position of the tractor’s hydraulic valve. This
allows the motor to stop slowly helping to protect the
motor and motor seals.
IMPORTANT
Only you, the operator, can determine the length of
time required to completely rinse all chemical residue
from the sprayer tanks and plumbing systems.
Rinse Eductor While Filling: Rinse the Eductor via the following:
1. Close and lock Cleanload lid by turning clock-
wise.
2. Release the safety locking band on the hopper
rinse ball valve and turn on for 20 seconds.
3. Close the rinse ball valve and return locking
band to locked position.
4. Open lid and inspect for chemical residue.
Repeat step 2 as necessary.
5. Close eductor tank valve.
6. Close eductor inlet valve and eductor outlet
valve.
7. Open solution quick fill valve to resume nor-
mal fill operation.
Fill Solution Tank, With Tank Agitation: Load the solution
tank using tank agitation via the following steps:
1. Close all valves.
2. Remove solution quick fill cap and connect load hose.
3. Open solution quick fill valve and the solution tank main
valve.
4. Open valve on loading reservoir (i.e. nurse tank).
5. Start the remote transfer pump.
6. Open the agitation valve.
7. Engage the liquid pump of the trailer sprayer.
8. Disengage the liquid pump of the trailer sprayer when
adequate agitation is achieved.
9. Run remote transfer pump until the desired amount of
solution is transferred into the trailer sprayer.
10. Close the agitation valve.
11. Close valves on loading reservoir.
12. Close the solution quick fill and the solution tank main
valves.
13. Remove load line and replace cap on sprayer quick fill.
Operation Instructions - Section B
Eductor Inlet Valve
(Closed Position)
Solution Quick Fill
(Closed Position)
Eductor Outlet Valve
(Closed Position)
Eductor Tank Valve
(Closed Position)
Valve Panel
(All valves in closed position)
Agitation
Valve
20