Greenleaf Workhorse PSE ATV 1502 Parts list manual

— GENERAL INFORMATION — WARRANTY / PARTS / SERVICE
WARNING: Some chemicals will damage the pump valves if allowed to soak untreated for a long period of time.
Always flush the pump with water after use. Do not allow chemicals to sit in pump for extended times of idleness.
Follow chemical manufacturers instructions on disposal of all waste water from the sprayer.
— ASSEMBLY INSTRUCTIONS
Tools required:
2 — 7/16” End Wrenches
1 — 9/16“ End Wrench
1 — Thread Sealant
1 — Blade Screwdriver
1 — 3/16” Allen Wrench
DELUXE ATV 2 NOZZLE SPRAYER
MODEL # ATV 1502 and ATV 2502
Workhorse products are warranted for one year from the date of
purchase against manufacture or workmanship defects for personal
or homeowner usage with proof of purchase. Workhorse products
are warranted for 90 days for commercial users. Any unauthorized
modification of a Workhorse brand sprayer will void warranty.
Your authorized dealer is the best source of replacement parts and
service. To obtain prompt, efficient service, always remember to
give the following information: 1) Correct part description and part
number. 2) Model number and serial number of your sprayer.
Part description and part numbers can be obtained from the
illustrated parts list section of this manual.
Whenever you need parts or repair service, contact your distributor
/ dealer first. For warranty work always take your original sales slip,
or other evidence of purchase date, to your distributor / dealer.
The purpose of this manual is to assist you in assembling, operating
and maintaining your lawn and garden sprayer.
Please read it carefully as it furnishes information which will help you
achieve years of dependable trouble-free operation.
• Polyethylene Tank
• 2 Nozzle Boom Assembly
• 12 Volt Diaphragm Pump
• 2.2 G.P.M.
• Quick Attach Mounting System
• 80 inch coverage with Check Valve and Filter
• Lever Handgun
• 15 Ft. of 3/8” Hose (Handgun)
• Pressure Gauge
• Adjustable Pressure Range (0-60 PSI Max.)
Assembly / Operation Instructions / Parts
ATV 1502
ATV 2502
PRECISION SPRAY EQUIPMENT, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.grnleafinc.com 800-654-9808
a division of Green Leaf, Inc ®
PRECISION SPRAY EQUIPMENT
PSE
®
WORKHORSE
WORKHORSE
S P R A Y E R S
by PSE®, a Division of Green Leaf, Inc®by PSE®, a Division of Green Leaf, Inc®
®

— OPERATION
— CALIBRATION
— AFTER SPRAYING
— WINTER STORAGE
— TIP CHARTS
— SPEED CHART
Chemical labels may show application rates in gallons per acre,
gallons per 1000 square feet or gallons per 100 square feet. You
will note that the tip chart shows all three of these rating systems.
Once you know how much you are going to spray then determine
(from the tip chart) the spraying pressure (PSI), and the spraying
speed (MPH).
Conditions of weather and terrain must be considered when
setting the sprayer. Do not spray on windy days. Protective
clothing must be worn in some cases. Be sure to read the
chemical label carefully.
For the best spray pattern coverage, the nozzles may be rotated
rearward 15°.
To determine the ground speed of your sprayer, measure and mark
driving distances of 100, 200, or 300 feet. Our speed chart indicates
the number of seconds needed to travel these distances. Set your
throttle, and with a rolling start, drive the measured distance of your
choice. Adjust your throttle until you can match the number of driving
seconds needed. Mark the throttle setting and note the gear range
so you can use them while spraying.
Add water and chemicals in the proper amounts in the spray tank and
drive to your starting point. When you are ready to spray, turn your
boom control valve to the “ON” position. Once the pump is turned
on, the unit will begin spraying. The system pressure will decrease
slightly when you see solution flowing from the spray nozzles. This is
normal, the pressure will return as before when you turn the control
valve to the “OFF” position.
You will find optimal spraying in the 20 to 30 PSI range.
After use, fill the sprayer part way with water. Start the sprayer and allow
clear water to be pumped through the plumbing system and out
through the spray nozzles.
Refill the tank about half full with plain water and use a chemical
neutralizer such as Nutra-Sol® or equivalent and repeat cleaning
instructions. Flush the entire sprayer with the neutralizing agent.
Follow the chemical manufacturer’s disposal instructions of all wash
or rinsing water.
Remove tips and screens from the boom. Wash tips thoroughly with
water or cleaning solution (appropriate for chemical used). Blow out
orifice, clean and dry. If orifice remains clogged clean it with a fine
bristle (not wire) brush, or with a toothpick. Do not damage the orifice.
Water rinse and dry tips before storing.
Drain all water and chemical out of sprayer, paying special
attention to pump and valves. These items are especially prone
to damage from chemicals and freezing weather.
The sprayer should be winterized before storage by pumping a
solution of RV antifreeze through the entire plumbing.
Proper care and maintenance will prolong the life of the sprayer.
The pumping system draws solution from the tank, through the
strainer and to the pump. The pump forces the solution under
pressure to the boom nozzles and spray wand.
The pump has a pressure switch which will shut the pump off
when it reaches 60 PSI.
Pressure may be regulated by opening or closing the valve
located on the top of the tank. See “Valve Operation” illustrated in
this manual.
The nozzles on the boom will spray an 80 inch wide swath.
Check the nozzle spray pattern by spraying water on a con-
crete surface.
Regularly inspect the suction supply screen on the inside
of the tank. Flush with water to clear any accumulated debris.
PRECISION SPRAY EQUIPMENT, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.grnleafinc.com 800-654-9808
a division of Green Leaf, Inc ®
PRECISION SPRAY EQUIPMENT
PSE
®
Speed in MPH Time Required in Seconds to Travel a distance of:
(Miles Per Hour) 200 ft. 300 ft.100 ft.
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
68.0
34.0
23.0
17.0
14.0
11.0
9.7
8.5
7.6
6.8
136
68
45
34
27
23
19
17
15
14
205
102
68
51
41
34
29
26
23
20
Tip Spray Pressure Capacity
Tip Spray Pressure Capacity
Tip Spray Pressure Capacity
GALLONS PER ACRE - BASED ON WATER
No. Height (PSI) (GPM)
No. Height (PSI) (GPM)
No. Height (PSI) (GPM)
1 MPH 2 MPH 3 MPH 4 MPH 5 MPH 7.5 MPH 10 MPH
1 MPH
2 MPH 3 MPH 4 MPH 5 MPH 7.5 MPH 10 MPH
1 MPH
2 MPH 3 MPH 4 MPH 5 MPH 7.5 MPH 10 MPH
GALLONS PER 1000 SQ. FT. - BASED ON WATER
GALLONS PER 100 SQ. FT. - BASED ON WATER
3 18"
3 18"
3 18"
10.0
20.0
30.0
40.0
0.30
0.42
0.52
0.60
10.0
20.0
30.0
40.0
0.30
0.42
0.52
0.60
10.0
20.0
30.0
40.0
0.30
0.42
0.52
0.60
1.01
1.40
1.74
2.06
.100
.140
.174
.206
0.50
0.72
0.87
1.00
.050
.072
.087
.100
.340
.480
.596
.688
.034
.048
.059
.068
.254
.360
.440
.500
.025
.036
.044
.050
.204
.290
.350
.408
.020
.029
.035
.040
.135
.190
.236
.270
.013
.019
.0236
.027
44.0
63.0
76.0
90.0
22.0
31.5
38.0
45.0
14.9
20.9
26.0
30.0
11.1
15.7
19.3
22.0
08.9
12.6
15.4
17.8
05.9
08.4
10.3
11.8
.103
.140
.176
.200
.010
.014
.017
.020
4.50
6.30
7.70
8.90
WARNING:
This product can expose you to
chemicals including DEHP, known
to the State of California to cause birth
defects or other reproductive harm.

Instruction #1— GENERAL ASSEMBLY
PRECISION SPRAY EQUIPMENT, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.grnleafinc.com 800-654-9808
a division of Green Leaf, Inc ®
PRECISION SPRAY EQUIPMENT
PSE
®
PARTS LIST
DESCRIPTION
PART NUMBER
QTY
ITEM
25 Gallon Tank600132
11
Tank Lid600133
1
2
Tank Lid Tether600134
1
3
ATV Boom Mount
6001892
4
ATV Helix Lever
60019025
5/16-18 Flat Head Screws600188
46
Spray Wand Clip
60015127
#10-24 x 3/8" Screw
60015228
Drain Cap Assembly
60029819
Deluxe Wand and 15ft Hose
600156110
Lead Wire Assy. w/ Switch (96")
600153111
15 Gallon Tank
600239112
Assembly Instructions
1.0--Install ATV Boom Mounts & ATV Helix Levers
in two places on bottom of tank as illustrated
using 5/16" Flat Head Screws. Note the
the orientation of all parts as their orientation
is essentail for proper assembly.
1.1--Install Drain Cap Assembly
1.2--Insert Lead Wire Assembly into plug at rear
of the pump.
1.3--Join the red wire of the two wire cabel to a +12v
source such as a switch, ammeter, or positive
battery post. The black wire should be grounded
or connected to the negative battery post
66
4
5
66
4
5
10
7
8
11
1
2 3
9
12

— SPRAY BOOM ASSEMBLY
PRECISION SPRAY EQUIPMENT®, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.workhorsesprayers.com 888-433-6631
a division of Green Leaf, Inc
®
PRECISION SPRAY EQUIPMENT
PSE
®
PARTS LIST
DESCRIPTIONPART NUMBERQTYITEM
Spray Boom Assembly63002221
Boom Insert
600256
1
2
ATV Angle Bracket60019123
φ1/4" U-Bolt w/ Nuts
60016924
B 11-34 R60011325
NTL38 P Fitting60011226
N1116 P Nut6001162
7
Check Valve / Strainer60011728
FT Spray Tip60011829
8027 P Nut600119210
Boom Hose Assembly
600115111
5/8" Hose Clamp
600120412
2.0--Insert ATV Angle Brackets into ATV Mounts as Ilustrated
2.1--Attach Spray Boom Assembly to ATV Angle Brackets using
U-Bolts with nuts at desired height.
2.2--Install Boom Clamps onto each end of the Spray Boom Assembly
and tighten screws. (screws should be on top of the Spray Boom)
2.3--Install Hose Clamps over each end of the Boom Hose assembly
as illustrated and press hose ends onto NTL38P Fittings. Then
tighten down Hose Clamps to secure the fittings to the Hose
Assembly.
2.4--Insert the NTL38P Fittings through the the holes on the Boom
Clamps that were previously installed on the Spray Boom.
Secure in place with N1116 P Nuts.
2.5--Insert Check Valves/Strainers into the NTL38P Fittings.
2.6--Insert Spray Tips into 8027 P Nuts and then screw nuts onto
fittings. (assure that tips are oriented downward to achieve the
correct spray pattern.
1
11
12 6
5
10
9
8
7
44
44
4
4
1
11
3
3
1
2

— Pump & Valve Assembly
PRECISION SPRAY EQUIPMENT®, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.workhorsesprayers.com 888-433-6631
a division of Green Leaf, Inc ®
PRECISION SPRAY EQUIPMENT
PSE
®
PARTS LIST
DESCRIPTIONPART NUMBERQTYITEM
2.2 GPM Pump*640451
11
4.0 GPM Pump*63020111
5.0 GPM Pump*630031
11
Manifold Body
60028912
Elbow (2.2 pumps)
60029113
Elbow (4.0 & 5.0 pumps)600292
1
3
Gauge 0-100 PSI60012914
Inline Valve6002162
5
QD EL 1260028716
5/8" Hose Clamp
60012027
1/2" Hose Clamp600288
1
8
10-24 x 1.25 Screw60013049
Relief Hose Assembly600213
1
10
Suction Hose Assembly
600315311
Cap Assembly (not shown)600298
1
12
Wand Hose Assembly
Relief Hose Assembly
Boom Hose Assembly
if equipped
The Lever adjusts the system pressure by
relieving liquid back to the tank. Adjusting
this lever will increase or decrease pressure
to both the spray wand and the spray boom.
The lever turns the spray
boom on and off
Install Wand Hose Assembly onto
Swivel Barb Assembly, by placing a
Hose Clamp over the open end of the
hose on the Wand Hose Assembly.
Then pressing the open end of the
hose onto the Swivel Barb Assembly
like shown. Secure in place by
tightening the Hose Clamp as shown.
7
Wand Hose Assembly
Boom Hose Assembly
1
1
4
3
2
0
5
6
8
1
9
7
1
*Pump included depends upon model purchased.

PowerFLO™7800 Series
12 Volt DC Motor-Driven Diaphragm Pumps
Specifications —
Motor:
Type: 12 VDC, permanent magnet, totally enclosed, non-ventilated
Leads: 18 AWG, 12” long
Duty Cycle: See Heat Rise graph
Temperature Limits: Motor is not equipped with thermal
protection. For user safety, optimal performance, and
maximum motor life, the motor surface temperature should
not exceed 150°F (66°C) (see Heat Rise graph above right).
Pump:
Type: 3 chamber positive displacement diaphragm pump, self
priming, capable of being run dry, demand or bypass model.
Certifications: NSF Standard 58
Liquid Temperature: 140°F (60°C) Max.
Priming Capabilities: 14 feet (4 m)
Max Pressure: 60 PSI
Inlet/Outlet Ports: 7802: Quick Attach
Materials of Construction:
Housing: Polypropylene Diaphragm: Santoprene
Valves: Viton Fasteners: Stainless steel
Weight: 6 lbs (2.7 kg)
Installation and Operation Precautions —
1. The pump is equipped with a pressure sensing demand switch that
controls the maximum operating pressure.
2. In addition, never subject the pump to pressures above 125 PSI
(8.5 bars).
3. As long as there is inlet water pressure, the pump will not stop
forward flow of water even if the motor is turned off. Be sure the
system has positive means of shutting off water supply.
4. Do not operate pump in an explosive environment. Arcing from the
motor brushes, switch or excessive heat from an improperly cycled
motor may cause an explosion.
5. Do not locate the pump motor near low temperature plastics or
combustible material. The surface temperature of the motor may
exceed 250°F (120°C).
6. Do not pump gasoline or other flammable liquids. Pump head
materials are designed for use with water only. Do not use with
petroleum products.
7. Do not assume fluid compatibility. If the fluid is improperly
matched to the pumps’ elastomers, a leak may occur.
8. To prevent electrical shock, disconnect power before initiating any
work. In the case of pump failure, the motor housing and/or pump
fluid may carry high voltage to components normally considered
safe. Therefore, always consider electrical shock hazard when
working with and handling electrical equipment. If uncertain,
consult an electrician. Electrical wiring should only be done by a
qualified electrician per local and state electrical codes.
Pressure Sensing Demand Switch —
The PowerFLO Series 7800 pump is controlled by a built-in pressure
sensing demand switch. When a faucet or valve is opened down stream of
the pump, line pressure drops thus starting the pump automatically.
Conversely, when the valve shuts, the line pressure increases turning the
pump off automatically. The pressure switch actuates in response to the
pump outlet pressure at a predetermined and preset pressure. The pump
label indicates the predetermined ON and OFF pressures. Typically, the OFF
pressure is accurately set at the Factory and the ON pressure is within an
allowable range below that value. In response to the characteristics of the
system in which the pump is installed, the flexibility and length of the
tubing, the faucet or valves and the duration that they are open; these
pressure settings may vary. Therefore, variation in pressure setting is
expected with use and over time.
Adjusting the Pressure Switch:
Should the pressure switch OFF setting vary with use and time to an
unsuitable value, it may be adjusted for optimum performance. Turn the
setscrew clockwise to increase the OFF pressure setting and counter
clockwise to decrease. The screw should not be adjusted more than one
half turn without consulting the Factory. Excessive adjustment of the
pressure switch could cause low system pressure, rapid cycling ON/OFF
operation, and reduced pump and motor life. Damage may occur. The
Warranty does not cover improper adjustment of the pressure switch.
Servicing —
Every Year: Check system against operating standards.
Every 2-3 Years: We recommend replacing the diaphragm and
checking against operating standards.
* Important return safety instructions:
When you return your pump for warranty or repair, you must always do the
following:
1. Flush chemical residue from the pump (best done in the field).
2. Tag pump with type of chemicals having been sprayed.
3. Include complete description of operation problem, such as how pump
was used, symptoms of malfunction, etc. Since pumps can contain
residues of toxic chemicals these steps are necessary to protect all the
people who handle return shipments, and to help pinpoint the reason for
the breakdown.
Model: 7802: 2.2 GPM
PRECISION SPRAY EQUIPMENT, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.grnleafinc.com 800-654-9808
a division of Green Leaf, Inc ®
PRECISION SPRAY EQUIPMENT
PSE
®

Troubleshooting Guide —
Problem/Causes and Remedies:
Pump will not Start
Check:
• Correct voltage (±10%) and electrical connections
• Fuse or breaker
• Pressure switch operation and correct voltage at switch
• Rectifier or motor for open or grounded circuit
• Locked drive assembly
Pump will not Prime (No discharge with motor running)
Check:
• Debris in strainer
• Restriction (kinks) in inlet/outlet tubes
• Debris or swelling in inlet/outlet valves
Pump will not Shut Off (Output line closed and no leaks)
Check:
• Air trapped in outlet line or pump head
• Correct voltage to pump
• Debris in pump inlet/outlet valves
• Loose drive assembly or pump head screws
• Pressure switch operations/adjustments
Leaks from Pump Head or Switch
Check:
• Loose screws at switch or pump head
• Switch diaphragm ruptured or pinched
• Punctured diaphragm if fluid is present
Spray & Pump FAQs —
--Why does the pump not run all the time?
This is a demand pump and only runs with flow; spray wand, by-pass, spray tips or leak in system
--Why does the pump surge while using the spray wand?
Low flow may cause the pump to surge (or cycle). This could happen when the spray wand is adjusted for a small or fine spray
pattern. To overcome, slightly open the by-pass valve.
--How do I adjust the pressure?
Pressure should be adjusted by regulating the by-pass valve (slightly opening or closing).
--What is the optimal operating pressure?
40 PSI - This can be accomplished by turning on the pump and adjusting the bypass valve until the gauge reads 40 PSI (or slightly
higher). The pump will run continuously. Ensure that the boom and/or handgun is not spraying while you set the pressure. The
pressure will drop slightly when the boom and/or handgun is operated.
--What pressure should the pressure gauge read?
Please refer to the operation instructions for boom operating pressures, varying boom pressures can be achieved by regulating or
adjusting the by-pass valve. Typically the spray wand will be operated between 20 and 40 PSI.
--What is the recommended PSI to inflate the tires?
30 PSI Max
--My pump quit and will not restart - what should I check?
Check all electrical connections. Ensure switch is in the on position. Check in-line fuse and/or fuse in car adapter end. Ensure
correct voltage +/- 10%. 12-13 volt
--Low flow or no flow at all - what should I check?
Check for a clogged suction hose and/or suction strainer. Often you will need to clean the suction strainer. Check for proper voltage.
--Is there a fuse for the sprayer?
Yes, either an in-line fuse, a fuse located in the car adapter housing or both.
--What size fuse should I use as a replacement?
7.5 amp
--What is the range of the spray wand?
35 feet max
--How should I clean the tank after use?
Tank should be cleaned with Nutrasol® or similar tank cleaning agent, and then rinsed with water.
--Is there an adjustment screw on the pump to adjust pressure?
Yes, please refer to the operation instructions, "Adjusting the Pressure Switch".
--How do I remove / replace fuse?
Unscrew in-line fuse connector, or unscrew the car adapter housing.
--Can the spray tip on the wand be replaced with a different type of tip?
Yes, however your wand comes with a #18 tip which is standard. Brass tips generally produce better spray patterns than plastic.
--Each time I turn on the pump my fuse blows.
1) Excessive voltage 2) Improper adjustment of the pressure switch 3) Damaged wiring harness.
--What is the warranty (time duration) on pump, tank, trailer pieces, and accessories?
1 year as stated in operation instructions.
--Pressure gauge reads 85 -90 psi before shutting off - should pump shut off at 60 psi?
Pump 7802 2.2 GPM comes preset from the factory to shut off at 60 PSI. Should this vary please see, "Adjusting the Pressure
Switch" in the operation manual. Turn on pump and hold spray wand open, slowing adjust until the pump shuts off at 60 PSI.
--Pump continues to run and surge when not spraying.
Ensure the by-pass is completely closed and your system has no leaks. Check by-pass hose to ensure no fluid is passing through the
valve while in the closed position. If so replace valve.
WARNING - Ensure the wiring harness does not become pinched or damaged in any way. This may damage the pump or cause the wiring harness to overheat,
resulting in a melt down or fire.
PRECISION SPRAY EQUIPMENT, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.grnleafinc.com 800-654-9808
a division of Green Leaf, Inc ®
PRECISION SPRAY EQUIPMENT
PSE
®
12/16