Gearmore GDL200 Guide

SPRAYERS
ASSEMBLY, OPERATION &
PARTS MANUAL FOR
5-IN-1 SPRAYER MODELS:
GDL200, GDL400 & GDL600
AIR BLAST SPRAYER MODELS:
APL200, APL400 & APL600
March 2007 Rev.
FORM: GDL5in1sprayer.QXD

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
How To Operate Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Suction Filter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Rate Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Tank Assembly 50 Gallon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12
Tank Assembly 100 & 150 Gallon . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-15
Run of Fluids 50 Gallon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-18
Run of Fluids 100 & 150 Gallon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-21
Electric Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-23
Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-26
Optional Volute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27-29
Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-31
Sprayer Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-34
Nozzle Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Tommy Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36-37
Pump Assembly for GDL200 & APL200 . . . . . . . . . . . . . . . . . . . . . . .38-40
GS40 Valve Assembly for GDL200 & APL200 . . . . . . . . . . . . . . . . . . .41-42
Pump Assembly for GDL400, 600, APL400 & 600 . . . . . . . . . . . . . . .43-45
GS40 Valve Assembly for GDL400, 600, APL400 & 600 . . . . . . . . . .46-47
Hose Reel Assembly 112-4-75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48-49
Hose Reel Assembly 1125-4-325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-51
Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
TABLE OF CONTENTS
Date of Purchase:__________________________
Model Number:____________________________
Serial Number:____________________________

INTRODUCTION
Page 1
We welcome you as an owner of the Gearmore 3-point hitch sprayer. Before you read on to the
operation and maintenance of the sprayer, please read the following general information.
1. POWER SOURCE: The sprayer is designed to mount to any 540 RPM tractor with a
3-point hitch. The horsepower required will vary depending on the pressure setting of
the control valve.
2. PUMP: The pump on the sprayer is a diaphragm pump. Pistons power the diaphragms
that pump the liquid. The unit has protection against corrosion, as the valves are stainless
steel.
3. TANK: The tank comes with a jet agitation system. It also has a sump, so the tank can be
completely drained.
4. STRAINERS: The sprayer is equipped with three strainers. A large filter screen is located
under the tank cover. A main strainer located by the side of the pump and a strainer screen
in every nozzle assembly. All strainers are easily accessible for cleaning.
5. TRANSMISSION (Optional on GDL units): If your sprayer has an air blast fan, then
it will have a special single speed transmission with neutral. Speed one and neutral are
indicated by the decal on the machine. Neutral is for when you want to use your sprayer
for handgun spraying and thus, the fan will not be turning.
6. BLOWER (Optional on GDL units): Air is supplied by an 8 blade propeller. The fan is
made of a special high strength plastic alloy and precision balanced for smoother operation.
The whole fan assembly is protected by heavy wire mesh screening. However, special care
should be taken when working around the blower.
7. NOZZLES (Optional on GDL units): The air blast fan assembly is equipped with
special ceramic nozzle tips that can be changed for different gallonage requirements. The
nozzles can be shut off individually by turning 90 degrees.

1. Connect sprayer to tractor 3-point hitch.
2. Connect up the P.T.O. driveshaft, after you have checked to make sure the driveshaft is not
too long.
3. Check strainer screen, to make sure it is clean.
4. Check strainer shut-off valve, making sure the handle is in the open position.
5. Select transmission speed, if your sprayer is equipped with the air blast fan assembly.
6. Refer to calibration page to calibrate the sprayer. Set regulator pressure as required.
Important - The pressure regulator adjusting knob must be unscrewed (turned to left)
as far out as possible before operating sprayer. Then gradually screw in (turn to right)
to desired pressure. Failure to operate in this manner could cause a sudden surge, which
could damage the sprayer. By sliding the control handle left towards the pressure gauge,
you can turn the valve one-half a turn to put the valve in bypass position. This would be
used for mixing chemicals, etc. It takes the pressure off the pump and sends the liquid
back to the tank. Turn the valve in the opposite direction for spraying. By sliding the handle
away from the pressure gauge, you can adjust the pressure setting by turning the valve.
7. Engage tractor P.T.O. and run for a couple of minutes to make sure the jet agitator has
mixed the chemicals thoroughly. Last, turn the control valve handles to the position required.
Either right hand, left hand or both sides spraying.
Remember, it is always best to make a practice run with water to be sure you have the
correct rates and coverage.
TO OPERATE SPRAYER
Page 2

1. DRIVESHAFT -The driveshaft comes not greased, so must be done before sprayer is put
into use. After that, grease every 50 hours. It is also necessary, from time to time, to
untelescope the driveshaft to clean and re-grease tubings.
2. TRANSMISSION - Observe the sight gauge, and install 90 weight transmission oil when
necessary.
3. PUMP - The clear oil reservoir should be filled to the indicator mark. If oil is low, add
engine oil, non-foaming, non-detergent 30 weight oil. The pump oil must be changed
after the first 100 running hours and then at the end of every working season. (See pump
page for more details.)
GENERAL MAINTENANCE
Carefully follow all instructions as stated in this operators manual. This includes lubrication,
maintenance and operation of the sprayer. The sprayer was designed and built for years of
reliable service if properly cared for. However, an air blast sprayer is a high R.P.M. machine,
thus, daily attention is required.
1. Check all bolts for tightness.
2. Check sprayer for leaks.
LUBRICATION
Page 3

1. Wash and flush out sprayer after completion of each phase of your spraying program.
2. Flush out sprayer when changing chemicals, if there is a possibility of incompatibility.
3. Clean sprayer very thoroughly before storing at the end of the spraying season. If you
are in a cold climate, final rinse should be with a sufficiently concentrated anti-freeze to
prevent freeze-up in areas that were not thoroughly drained.
4. Check sprayer over for needed repairs before time to spray again.
5. Preparing the sprayer for use in the Spring means completion of all needed repairs,
installation of all drain plugs and checking sprayer for leaks with a tank of water.
SAFETY TIPS
Sprayer should be operated only by qualified persons.
Always fill sprayer slowly to avoid spillage.
When starting sprayer, maintain a safe distance from moving parts.
Never run P.T.O. at speeds in excess of 540 R.P.M.
Do not make adjustments when sprayer is running, unless specifically
recommended.
Never leave sprayer unattended while it is running.
Keep hands, feet and clothing away from all moving parts.
Handle chemicals carefully; follow the manufacturer's directions for mixing and
applying chemicals.
CLEANING & STORAGE
Page 4

1. Remove the plunger valve (ref. A) from filter assembly (ref. B).
2. Unscrew large ring nut on filter assembly, removing nut and cover.
3. Remove and clean strainer on cartridge, replace if necessary.
SUCTION FILTER SERVICING
Page 5

Use of pressure relief device, on the discharge side of pump, is required to prevent damage from
pressure build-up, if the discharge is closed or blocked, while the power source is still running.
Do not operate pump above recommended R.P.M.
Do not pump at pressure higher than the maximum recommended for the pump (see specifications).
Operate pump between 45oand 145oF liquid temperatures.
Make certain that the power source conforms to the requirements of your equipment.
Provide adequate protection in guarding around the moving parts, such as the shaft and pulleys.
Disconnect power before servicing.
Release all pressure within the system before servicing any component.
Drain all liquids from the system before servicing.
Secure the discharge lines before starting the pump. An unsecured discharge line may whip, causing
personal injury and/or property damage.
Check hoses for weak or worn condition before each use. Make certain that all connections are
tight and secure.
Periodically inspect the pump and the system components. Perform routine maintenance as
required (see maintenance section).
Do not operate a gasoline engine in an enclosed area. Be sure the area is well ventilated.
Use only pipe, hose and fittings rated for maximum rated pressure of pump or pressure at
which pressure relief valve is set. Check with local supplier for proper pressure rating. (Do not
use used pipe!)
Do not use these pumps for pumping water or other liquids for human or animal consumption.
GENERAL SAFETY INFORMATION
Page 6
WARNING - Do not pump flammable or explosive fluids such as
gasoline, fuel oil, kerosene, etc. Do not use in explosive atmos-
pheres. The pump should be used only with liquids compatible with
the pump component materials. Failure to follow this warning may
result in personal injury and / or property damage and will void the
product warranty.

The pump is serviced, tested and ready for use. Nevertheless, before starting the sprayer,
we advise checking the oil level.
The oil level should be filled to the mark on the plastic tube.
When adding oil, remove cap and fill to level mark with SAE 30 weight engine oil.
CHANGING THE OIL
1. Remove the pump and drain the oil by turning the pump upside down. To do
this remove the filler cap and turn the P.T.O. shaft by hand.
2. Fill the crankcase with mineral (flushing) oil to wash all internal parts. Then
drain pump again.
3. Add new oil and at the same time turn the P.T.O. shaft by hand. When the
correct oil level has been reached, continue to turn the shaft until all the air
bubbles in the oil have disappeared.
DIAPHRAGM AND VALVE REPLACEMENT
I. Valve & O-ring Replacement
1. Occasionally debris can cause the valves to not seat properly or damage
the o-rings. To check for this problem, follow these steps:
a. Remove the check valve manifold. (See parts list for your model.)
b. With manifold removed, valves can readily be removed and checked
for debris or wear.
To replace valves or o-rings, refer to parts list for appropriate kits.
II. Diaphragm Replacement
1. Drain the oil from the pump. Rotate the shaft to remove excess oil.
2. Remove the pump heads.
3. Use a box wrench to remove the diaphragm retaining bolt, support
washer and diaphragm.
(To replace diaphragms order appropriate repair kit. See parts list.)
4. Turn the crankshaft to bring the piston to its downstroke and seat the new
diaphragm into the sleeve groove. Install retaining washer and tighten bolt.
5. Refill crankcase with 30 weight oil. Rotate the shaft to distribute oil and fill
to proper level.
Page 7
PUMP MAINTENANCE

The pump does not One or more valves are Examine the valve seatings and
draw water. seating improperly. clean them.
Suction line is plugged Examine suction line. Clean
or collapsed. Clogged strainer.
strainer.
Pressure gauge fluctuates The pump is sucking in Examine the suction hose and
excessively. air through the suction make sure it is firmly secured.
union or air has not been Run the pump with the outlet
entirely evacuated from hose open to evacuate air from
the pump. the pump.
The liquid flow is One or more valves are Examine the valve seatings and
irregular. seating improperly. clean them.
Output drops and the Oil level is too low. Add oil to correct level (halfway
pump is noisy. up the sight tube).
Oil comes out of the One or more diaphragms Drain the pump of oil.
discharge port. split. Dismantle the heads and fit
new diaphragms. Fill to correct
oil level with motor oil (30W).
Water is pumped at The sealing valve on the Replace washer and, if necessary,
little or no pressure. pressure control valve the valve seat.
is worn.
TROUBLESHOOTING
Page 8
PROBLEM: CAUSE: REMEDY:

These must be known:
1. Tree spacing in feet (swath width)
2. Tractor speed in feet per minute
3. Gallons per acre desired
Note:(a.) 1 acre = 43,560 sq. ft.
(b.) 1 MPH = 88 ft./min.
Tree spacing _____ ft. x tractor speed _____ ft./min. x application rate _____ gal./acre ÷43,560 =
G.P.M. Divide G.P.M. by number of sprayer nozzles to determine G.P.M. per nozzle. Now choose
correct nozzle disc and pressure setting from charts. Charts give G.P.M. per nozzle disc.
CALIBRATION FORM
Tree spacing ______________________________ ft.
Tractor speed _____________________________ ft./min.
Application rate ___________________________ gal./acre
Tree spacing _____ ft. x tractor speed _____ ft./min. x application rate _____ gal./acre ÷43,560 =
G.P.M.
Next: G.P.M. _____ ÷number of nozzles _____ = _____ G.P.M. per nozzle
Refer to chart for: Nozzle disc # __________ Swirl plate __________
Pressure setting __________ P.S.I.
RATE CHART FOR SINGLE NOZZLES, WITH SMALL PINK DISC
Page 9
FORMULA & RATE CHART
For Calibrating Gearmore Air Blast Sprayers
CSID
EZIS
LRIWS
ETALP
).I.S.P(ERUSSERP
0557001521051571002052003053004
8.0eloh261.81.02.22.42.62.82.03.43.63.83.
0.10.152.03.63.04.44.84.15.85.46.96.27.
2.10.104.94
.75.36.96.47.87.78.79.40.111.1
5.12.155.46.47.18.09.69.20.121.122.113.173.1
8.15.167.49.90.112.123.193.174.116.147.178.199.1
0.28.129.51.173.
105.156.137.159.111.273.245.236.2
2.20.220.172.135.176.128.169.111.253.275.277.249.2
5.22.275.118.150.262.254.236.218.230.392.335.327.3
DISC
SIZE
SWIRL
PLATE
PRESSURE (P.S.I.)

Page 10
TANK ASSEMBLY 50 GALLON

REF # QTY. PART NO. DESCRIPTION
1 1 0600187 Lid
2 1 0600189 Tank, Handwash
3 1 0600190 Drain Valve
4 1 0600187 Lid
5 1 0600182 Tank, Flush
6 2 0100107 Plate
7 1 0101477 Bracket
8 1 0101478 Bracket
9 4 1800036 Bolt M10 x 25
10 6 1800130 Washer D.10
11 2 1300036 Fitting Assembly
12 1 0600191 Gasket
13 4 2100135 Bushing 28.4 x 22.4
14 1 1400009 Nut, Ring
15 2 2100009 Lift Pin Assembly
16 4 2900001 Protector D.22
17 1 1800177 Nut M5
18 1 1800113 Washer 6.4 x 12.5
19 1 1400007 Chain
20 1 1800003 Bolt M5 x 12
21 2 1800186 Nut M.10
22 1 0101454 Frame
23 3 1400001 Nut
24 1 0600014 Gasket
25 1 1400130 Elbow
26 1 2100001 Hair Pin
27 1 0100203 Pin D.18
28 1 1800350 Clamp D2.9 x 9
29 1 1700015 Gasket
30 1 1400212 Drain Valve
31 3 1700001 Gasket 33 x 21 x 2
32 1 1400002 Nipple
33 1 1700021 Gasket 19 x 4
34 1 1400124 Plug
35 1 0600184 Tank 50 Gallon
36 2 0101476 T Handle
37 1 1400204 Nozzle D.1.5
38 1 1400130 Elbow
39 1 0600051 Clamp
Continued....
TANK ASSEMBLY 50 GALLON
Page 11

REF # QTY. PART NO. DESCRIPTION
40 As Req'd 12X17 Hose 12 x 17 Per Foot
41 1 1400192 Fitting
42 1 1500007 Clamp
43 As Req'd 19X26 Hose 19 x 26 Per Foot
44 1 1700006 O-Ring 36 x 26 x 5
45 1 0600192 Strap
46 1 1400074 Agitator
47 1 2100143 Hook
48 1 0600193 Knob
49 1 1400075 Elbow
50 1 1700010 Gasket 18 x 12 x 2
51 As Req'd 10X19 Hose 10 x 19 Per Foot
52 1 1500003 Clamp
53 1 1400062 Elbow D.20
54 1 0600007 Lid, Vent
55 1 00.723.010 Lid
56 1 00.646.000 Strainer Basket
TANK ASSEMBLY 50 GALLON
Page 12

TANK ASSEMBLY 100 & 150 GALLON
Page 13

REF # QTY. PART NO. DESCRIPTION
1 1 0600187 Lid
2 1 0600189 Tank, Handwash
3 1 0600190 Valve, Drain
4 1 0600187 Lid
5 1 0600167 Tank, Flush
6 1 0101488 Support
7 6 1800130 Washer M.10
8 4 1800036 Bolt M10 x 25
9 2 0100107 Plate, Threaded
10 1 0101487 Support
11 1 2100001 Hair Pin
12 1 0100203 Pin D.18
13 4 2100135 Bushing 28.4 x 22.4 L=45
14 1 0600191 Gasket
15 2 2100007 Lift Pin Assembly
16 4 2900001 Garment, Rubber D.22
17 1 1400009 Ring Nut
18 1 0600014 Gasket
19 1 1400212 Drain Plug Assembly
20 1 1700015 Gasket 57.5 x 40 x 3
21 2 1800186 Nut M10
22 1 0101450 Frame
23 3 1400001 Ring Nut
24 1 2600009 Gasket
25 2 1400130 Elbow
26 2 0600051 Clamp
27 1 0600185 Tank 100 Gallon
27 1 0600186 Tank 150 Gallon
28 2 0101476 T Handle
29 1 1400124 Plug
30 As Req'd 19X26 Hose 19 x 26 Per Foot
31 1 1500007 Clamp
32 1 1400192 Nipple D.20
33 1 0600023 Strainer Basket
34 1 0600006 Lid 17 7/8" O.D.
35 1 0600007 Vent Lid
36 1 1800177 Nut M5
37 1 1800113 Washer 6.4 x 12.5
Continued....
TANK ASSEMBLY 100 & 150 GALLON
Page 14

REF # QTY. PART NO. DESCRIPTION
38 1 1400007 Chain D3.5 L=300
39 1 1800003 Bolt M5 x 12
40 1 1400062 Elbow D.20
41 3 1700001 Gasket
42 1 1500003 Clamp
43 1 1700021 Gasket
44 1 1400075 Elbow
45 1 1700006 Gasket
46 1 0600193 Knob
47 1 1700010 Gasket
48 1 1400204 Nozzle D1.5
49 1 0600192 Strap
50 1 1600690 Hose 10 x 19
51 1 1400074 Agitator Body
52 1 1400002 Nipple
53 As Req'd 12X17 Hose 12 x 17 Per Foot
TANK ASSEMBLY 100 & 150 GALLON
Page 15

RUN OF FLUIDS 50 GALLON
Page 16

REF # QTY. PART NO. DESCRIPTION
1 1 1400075 Elbow
2 1 1700006 O-Ring 36 x 26 x 5
3 1 1400204 Nozzle D.1.5
4 1 1400074 Body
5 5 1700010 Gasket
6 1 1600690 Hose 10 x 19 L=1250
7 1 320406 Support Bracket
8 2 1800021 Bolt M8 x 20
9 2 1800180 Nut M8
10 5 1800120 Washer D.8
11 1 0100236 Bracket
12 1 1800131 Washer M10 x 30 x 2.5
13 1 1800063 Bolt M10 x 20
14 1 0100235 Support
15 1 1400200 Agitator Assembly
16 2 1800181 Nut M8
17 1 GS40I Control Valve Assembly
18 2 130491 Ball Valve R.H.
19 1 621370 Adaptor 20 mm
20 2 1600277 Hose 10 x 19
21 As Req'd 19X26 Hose 19 x 26 Per Foot
22 2 1500003 Clamp
23 1 550460 Elbow D.18
24 1 OR1554262 O-Ring 15.54 x 2.62
25 1 550450 Ring Nut
26 3 1800024 Bolt M8 x3 5
27 1 550545 Gauge
28 2 390180 O-Ring 18.72 x 2.62
29 1 450145 Flange
30 1 580060 Ring Nut
31 1 1600003 Hose 10 x 19
32 1 130492 Ball Valve L.H.
33 1 1300035 Tee
34 1 390290 O-Ring 29 x 3
35 1 580040 Elbow D.30
36 1 7104056FFT077 Driveline
37 1 680350 Bolt M8 x 35
38 1 961340 Washer D.8.5
39 8 1800036 Bolt M10 x 25
Continued....
RUN OF FLUIDS 50 GALLON
Page 17

REF # QTY. PART NO. DESCRIPTION
40 8 1800130 Washer M10
41 4 0100107 Plate
42 2 0101456 Support Mount
44 1 1400026 Ring Nut
45 2 1700011 Gasket 40 x 26 x 2
46 1 1400193 Hose Barb D.25
47 6 1500004 Clamp
48 As Req'd 25X37 Hose 25 x 37 Per Foot
49 1 1400197 Filter Assembly
50 1 1400007 Chain, Plastic L=300
51 1 1400205 Plug
52 1 1400206 Ring Nut
53 1 1400207 Cover
54 1 1400209 O-Ring 5.34 x 91.44 x 102.1
55 1 1400208 Strainer
56 2 1700052 O-Ring 71.1 x 2.6
57 1 1400210 Body
58 1 1300034 Nipple
59 1 0600188 Gasket
60 1 1800027 Bolt M8 x 40
61 1 1040760 Flange
62 3 1800447 Bolt M8 x 16
63 1 0101475 Bracket
64 1 1400362 Ball Valve
65 3 1400057 Elbow D.25
66 3 1700012 O-Ring 31.89 x 26.65 x 2.62
67 3 1400013 Ring Nut
68 2 1400149 Nipple 1 1/4"
69 3 1700009 O-Ring 48.15 x 37.47 x 5.34
70 1 1300001 Elbow, Brass
71 1 1400009 Ring Nut
72 As Req'd 30X42 Hose 30 x 42 Per Foot
73 1 1400042 Elbow D.25
74 1 0600187 Lid
75 1 0600182 Tank
76 1 1500008 Clamp
77 1 1400141 Elbow D.25
78 1 AR403 Pump Assembly
RUN OF FLUIDS 50 GALLON
Page 18