Pioneer APPLI-PRO DASIC User manual

Operations and Instruction Manual
Revised November 2011

TABLE OF CONTENTS
Topic
Page
TOOLS NEEDED for INSTALLATION and SERVICE…………………………..
3
HARDWARE NEEDED for INSTALLATION…………………………………..….
3
ASSEMBLY of APPLICATOR………………………………………………….…..
4-6
MOUNTING TANK ASSEMBLY to MACHINE or TRACTOR……………..……
6
ASSEMBLY of NOZZLE BAR……………………………………………………...
6-7
INSTALLATION of NOZZLE BAR
SMALL BALER……………………………………………………………..
8
LOADING WAGON…………………………………………………………
8
CHOPPER…………………………………………………..……………….
8
INSTALLATION of the CONTROL BOX………………………………………….
9
INSTALLATION of the CABLES…………………………………………………..
9
OPERATION…………………………………………………………………………..
9
CALIBRATION
SMALL SQUARE BALER…………………………………………………
10
ROUND and LARGE SQUARE BALER………………………………….
11
FORAGE HARVESTER, BAGGER, or SILO BLOWER……………….
12
ADDITIONAL RATE CHARTS………………………………………………………
13
CALIBRATION REMINDERS……………………………………………………….
14
ROUTINE SERVICE and MAINTENANCE………………………………………...
14
WINTER STORAGE…………………………………………………………………..
14
TROUBLE SHOOTING……………………………………………………………….
15
PARTS BREAKDOWN
12 GALLON BASE UNIT……………………………………………………
16
25 GALLON BASE UNIT……………………………………………………
17
55 GALLON BASE UNIT………………...………………………………….
18
CONTROL BOX……………………………………………..……………….
19
PUMP and DISCHARGE ASSEMBLIES…………………………………
20
NOZZLE BAR……………………………..………………………………….
21
HARDWARE………………………………………………………………….
22

3
INTRODUCTION
The Appli-Pro Basic Application System was built for Pioneer Hi-Bred International, Inc. by a
leading agricultural manufacturer. The Basic is an integrated system, designed and calibrated
specifically for Pioneer® brand products. This unique system was developed to offer you the following
advantages:
 Appli-Pro Basic 12G treats up to 200 tons with 12 gallons of water
 Appli-Pro Basic 25G treats up to 200 tons with 25 gallons of water
 Appli-Pro Basic 55G treats up to 440 tons with 55 gallons of water
 Simple design with reliable components
 The system has a strainer in the feed line and all nozzles have stainless steel insert tips
 Well suited for small operations
 Offered in two tank sizes: 25 or 55 gallon
TOOLS NEEDED FOR INSTALLATION AND SERVICE
 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
HARDWARE NEEDED FOR INSTALLATION AND NOT INCLUDED
 Some hardware is included, but you may need additional hardware depending on the machine
that you are mounting it to

4
ASSEMBLY OF APPLICATOR
Step 1
Thread the intake assembly into side tank fitting, and make sure filter is pointed towards the front of
the tank as well.
Step 2
Locate free end of hose that is installed to the pump’s intake. Attach it to the elbow (003-EL1438)
next to filter on side of tank. Tighten hose clamps.
Step 3
The gauge will need to be mounted in a location that is easily viewable from the operator’s station.
Below are two options that the operator can use to mount the gauge that best suits their application
system.
Option A – Pump mounted gauge
Attach gauge (002-2207P) to fitting (003-TT12) on discharge assembly and tighten. Gauge should be
facing directly away from tank.
Attach free
hose end to
elbow
Thread in
gauge here
Intake
assembly
on side of
tank

5
Option B – Remote mounted gauge
1. Remove gauge tee from pump assembly and remove fitting (003-M1212) from tee.
Step 1
2. Thread straight fitting (003-A3812) into both the removed tee and the one still on the pump
assembly.
Step 2
Step 2
3. Attach gauge holder (001-4717B) to the tee assembly by threading gauge into it. Additional ½“ flat
washers may be needed as spacers to ensure a tight fit.
Step 3
Step 3
Remove this section
003-A3812
003-A3812

6
4. Drill holes and mount the gauge holder in a location that can be seen from the operator’s station.
5. Cut a length of hose (002-9003AS) that will reach from the pump discharge to the remote mounted
gauge. Attach one end to the pump discharge and the other to the intake barb fitting on the gauge
assembly. Secure both ends with hose clamps.
Step 5
Step 5
MOUNTING TANK ASSEMBLY TO MACHINE OR TRACTOR
Note: modification or fabrication may be needed for your specific machine.
MOUNTING to the BALER, FORAGE HARVESTER, or other MACHINE
- Locate a large enough flat area in-which the tank can be bolted to the machine. If there is not
enough space you will have to fabricate one. Please keep in mind the weight of the full tank.
- Position so you can see the pressure gauge and be able to operate both the mixing valve and
shut off valve.
-
MOUNTING to the TRACTOR
- This is highly recommended if you have the 55 gal system. You will need to fabricate some
brackets to do this.

7
ASSEMBLY OF NOZZLE BAR
The Appli-Pro Basic system comes with the ability to use one, two, or three nozzles at a time. Set up
your nozzle bar as follows-
1. Loosen the screw on ½” Bar Clamp (004-1209). Do not fully remove screw.
2. Slide top half of bar clamp off.
3. Hold bottom half of bar clamp to bottom side and center of nozzle bar (001-4707C).
4. Slide two-way nozzle body into square slot of bar clamp.
Step 1-2
Step 3-4
5. Slide square slot of top bar clamp into nozzle body and screw, then tighten screw.
6. Repeat for remaining nozzle bodies one on each side of center. Leave screw loose unit
aligned.
Step 5-6
7. Measure the width of the area that you want to spray. Divide it by five. Place the two outside
nozzles in from the outside edge by using this measurement.
Example: The width of your round baler pickup head is 60 inches. Divide this by 5 and you will get 12
inches. Place the two outside nozzles 12 inches from the outside edge of the pickup head. Cut hose
to length between nozzle bodies and secure them to nozzle bodies with hose clamps.
Note: Hose can be left a little long for additional adjustment at a later date.

8
INSTALLATION OF NOZZLE BAR – BALER
Recommendation: use 1-2 nozzles, depending on swath width.
Determine a location to mount the nozzle pipe on the front hood and above the pickup head of the
baler. Make sure not to interfere with any moving pieces of the baler. Note: Additional modification
and fabrication maybe needed for your specific machine.
The nozzle pipe can be mounted vertically or horizontally depending on your baler. Make sure the
pipe is 18” above the hay as it would be entering into the baler. This will allow for a proper spray
pattern.
Connect one end of hose to pump discharge or remote mounted gauge assembly. Connect other end
to first tee fitting on nozzle bar. Secure both ends with hose clamps.
INSTALLATION OF NOZZLE BAR – LOADING WAGONS
Recommendation: use 1-3 nozzles, depending on swath/pick up width.
Determine a location to mount the nozzle pipe over the pick up/feed intake. Make sure not to interfere
with any moving pieces of the machine. Note: Modification or fabrication maybe needed for your
specific machine.
The nozzle pipe can be mounted vertically or horizontally depending on your machine. Make sure the
pipe is ~50 cm above the crop as it would be entering into the machine. This will allow for a proper
spray pattern.
Connect one end of hose to pump discharge or remote mounted gauge assembly. Connect other end
to first tee fitting on nozzle bar. Secure both ends with hose clamps.
INSTALLATION OF NOZZLE BAR – CHOPPER
Recommendation: use 1 nozzle.
Determine a location to mount the nozzle pipe directly into the blowing or suction system.

9
INSTALLATION OF THE CONTROL BOX
LOCATION of CONTROL BOX
Locate the control where it can be easily reached from the tractor’s seat.
WIRING
Route the wire to the starter solenoid on all 12v tractors. Connect the green lead marked+
to the hot terminal on the starter. Connect the black lead to a good ground. DO NOT
REVERSE THE LEADS. CONNECTION OF THE GROUND-LEAD TO A HOT
TERMINAL ON THE TRACTOR WILL TRIP THE CIRCUIT BREAKER. Be sure to use a
voltmeter to verify that you do have 12 volts running to the box.
Note: For tractors with 24v starters (most John Deere 3020 and 4020 diesels,) connect the
power leads to the tractor’s right hand battery. Do not connect the leads to the starter.
Connect the lead marked + to the positive battery terminal and the lead marked- to the
negative on the battery. Wiring connections to the battery normally results in corrosion;
terminal coating is recommended.
CAUTION: Do not run a pump or use an electronic control box directly off a battery charger. For
stationary use, the applicator can be connected to a new battery and the battery connected to a
charger.
INSTALLATION OF THE CABLES
Attach one end of wire harness (006-4575AS) to the pump. Connect other end to the control box.
OPERATION
The Appli-Pro Basic applicator is very simple to operate. After installing the applicator, fill the tank
with 5 gallons of water. With control box connected to the applicator and the power cord hooked to
the 12-volt battery we can start the test. First flip on the toggle switch. You might hear the buzzing of
the motor. Turn the dial on the control box until the gauge starts to climb. By turning the dial
clockwise the pressure will go up. By turning the dial counter clockwise the pressure will decrease.
With the applicator spraying at about 30 PSI, look for leaks at all the hose connections and fittings.
Using water in this step instead of inoculant will save you from wasting inoculant and making a mess
if leaks are found. When you are comfortable with the operation of the controls you can set the
applicator to the amount of inoculant you would like it to put on.
Message Light
The LED under 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 hay indicators (474A) or a foot switch.
This message means that the pump is paused. The light will come on constant once the baler 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.

10
CALIBRATION FOR SMALL SQUARE BALERS
There are two steps that you need to know when calibrating your applicator: determining your
ton/hour and using the correct tip(s) and PSI.
Step 1
Bale for three minutes and count the number of bales made in those three minutes. Weigh several
bales to determine the average weight. Using the conventional bale rate chart below, determine the
tons you are baling per hour.
Example: You baled 17 bales in three minutes. After weighing some of the bales you found the
average bale weight to be 55 lbs. Using the chart above, cross reference 17 bales and 55lbs and you
will find the rate to be 9.3 ton/hour.
Step 2
Look in the chart below for your determined ton/hour. The left column will tell you how many and of
what size tip to use, and the top row will tell you what PSI to run depending on the tip.
Treatable Tons Per Hour at 64 OZ per Ton (1/2 gal per Ton)
Qty - Tip Size
15 PSI
20 PSI
25 PSI
30 PSI
1 - XR11001VS
7.5
8.4
9.4
10.3
2 - XR11001VS
15.0
16.9
18.8
20.6
3 - XR11001VS
22.5
25.3
28.1
30.9
1 - XR11002VS
15.0
16.9
18.8
20.6
2 - XR11002VS
30.0
33.8
37.5
41.3
3 - XR11002VS
45.0
50.6
56.3
61.9
1 - XR11005VS
29.1
32.8
36.6
40.3
25 Gallons Treat 50 Ton
55 Gallons Treat 110 Ton
Additional rate charts found on page 15
Example: You are baling at 9.3 ton/hour. According to the 64oz per ton rate, you would use one
XR11001VS tip at 25 PSI.

11
CALIBRATION FOR ROUND AND LARGE SQUARE BALERS
There are two steps that you need to know when calibrating your applicator: determining your
ton/hour and using the correct tip(s) and PSI.
Step 1
Make three bales and record average time it takes to make a bale. Estimate the weight of the bale
and use the chart below to determine your ton/hour.
Example: You made 3 round bales and it took you an average of 2 minutes a piece to bale each of
them. Your baler’s operator manual tells you that an average bale made by your machine weighs
1200lb. (Remember if the hay is dry it will weigh less and if the hay is wet it will weigh more.) Using
the chart above, cross-reference 2 minutes with 1200lb. and you will come up with 18 ton per hour.
Step 2
Look in the chart below for your determined ton/hour. The left column will tell you how many and of
what size tip to use, and the top row will tell you what PSI to run depending on the tip.
Treatable Tons Per Hour at 32 OZ per Ton (1/4 gal per Ton)
Qty - Tip Size
15 PSI
20 PSI
25 PSI
30 PSI
1 - XR11001VS
15.0
16.9
18.8
20.6
2 - XR11001VS
30.0
33.8
37.5
41.3
3 - XR11001VS
45.0
50.6
56.3
61.9
1 - XR11002VS
30.0
33.8
37.5
41.3
2 - XR11002VS
60.0
67.5
75.0
82.5
3 - XR11002VS
90.0
101.3
112.5
123.8
1 - XR11005VS
58.1
65.6
73.1
80.6
25 Gallons Treat 100 Ton
55 Gallons Treat 220 Ton
Additional rate charts found on page 15
Example: You are baling at 18 ton/hour. According to the 32oz per ton rate, you would use one
XR11001VS tip at 25 PSI.

12
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 correct tip(s) and PSI.
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
Look in the chart below for your determined ton/hour. The left column will tell you how many and of
what size tip to use, and the top row will tell you what PSI to run depending on the tip.
Treatable Tons Per Hour at 16 OZ per Ton (1/8 gal per Ton)
Qty - Tip Size
15 PSI
20 PSI
25 PSI
30 PSI
1 - XR11001VS
30.0
33.8
37.5
41.3
2 - XR11001VS
60.0
67.5
75.0
82.5
3 - XR11001VS
90.0
101.3
112.5
123.8
1 - XR11002VS
60.0
67.5
75.0
82.5
2 - XR11002VS
120.0
135.0
150.0
165.0
3 - XR11002VS
180.0
202.5
225.0
247.5
1 - XR11005VS
116.3
131.3
146.3
161.3
25 Gallons Treat 200 Ton
55 Gallons Treat 440 Ton
Additional rate charts found on page 15
Example: You are chopping at 60 ton/hour. According to the 16oz per ton rate, you would use two
XR11001VS tips at 15 PSI.

13
ADDITIONAL RATE CHARTS
Treatable Tons Per Hour at 16 OZ per Ton. (1/8 gal per Ton)
Qty - Tip Size
15 PSI
20 PSI
25 PSI
30 PSI
1 - XR11001VS
30.0
33.8
37.5
41.3
2 - XR11001VS
60.0
67.5
75.0
82.5
3 - XR11001VS
90.0
101.3
112.5
123.8
1 - XR11002VS
60.0
67.5
75.0
82.5
2 - XR11002VS
120.0
135.0
150.0
165.0
3 - XR11002VS
180.0
202.5
225.0
247.5
1 - XR11005VS
116.3
131.3
146.3
161.3
25 Gallons Treat 200 Ton
55 Gallons Treat 440 Ton
Treatable Tons Per Hour at 32 OZ per Ton. (1/4 gal per Ton)
Qty - Tip Size
15 PSI
20 PSI
25 PSI
30 PSI
1 - XR11001VS
15.0
16.9
18.8
20.6
2 - XR11001VS
30.0
33.8
37.5
41.3
3 - XR11001VS
45.0
50.6
56.3
61.9
1 - XR11002VS
30.0
33.8
37.5
41.3
2 - XR11002VS
60.0
67.5
75.0
82.5
3 - XR11002VS
90.0
101.3
112.5
123.8
1 - XR11005VS
58.1
65.6
73.1
80.6
25 Gallons Treat 100 Ton
55 Gallons Treat 220 Ton
Treatable Tons Per Hour at 64 OZ per Ton. (1/2 gal per Ton)
Qty - Tip Size
15 PSI
20 PSI
25 PSI
30 PSI
1 - XR11001VS
7.5
8.4
9.4
10.3
2 - XR11001VS
15.0
16.9
18.8
20.6
3 - XR11001VS
22.5
25.3
28.1
30.9
1 - XR11002VS
15.0
16.9
18.8
20.6
2 - XR11002VS
30.0
33.8
37.5
41.3
3 - XR11002VS
45.0
50.6
56.3
61.9
1 - XR11005VS
29.1
32.8
36.6
40.3
25 Gallons Treat 50 Ton
55 Gallons Treat 110 Ton

14
CALIBRATION REMINDERS
*Watch the pressure 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!!!
ROUTINE SERVICE AND MAINTENANCE
1. Clean the tip check and main strainer every 10 hours of operation or more frequently if
required.
2. Although the pump can run dry, extended operation of a dry pump will increase wear. Watch
the inoculant level in the tank.
3. Cover the electronic cab control box on open station tractors if left outside.
4. Clean tank cap breather every 20 hrs or more frequently if required.
WINTER STORAGE
1. Thoroughly flush the system with water.
2. Remove the filter bowl and run dry until the water has cleared out of the intake side.
3. Drain all lines on the outlet side.
4. Never use oils or alcohol based anti-freeze in the system.
For spring start-up, or anytime the pump is frozen, turn off the power immediately to avoid burning the
motor out.

15
TROUBLE SHOOTING
PROBLEM
POSSIBLE CAUSE
SOLUTION
Pump will not run.
1. Circuit breaker tripped
on electronic unit.
1. Check for short, low voltage, and
reset breaker.
2. Pump locked up.
2. Clean or rebuild pump if motor is
OK.
3. Damaged wire.
3. Repair damaged wire.
Pump runs but will not prime.
1. Air leak in intake.
1. Tighten fittings on intake side.
2. Clogged intake.
2. Clean.
3. Restricted outlet.
3. Check and clean tips.
4. Check valve on outlet
stuck closed.
4. Clean or repair check valve.
Pump does not develop enough
output.
1. Air leaks or clogs on inlet
side.
1. Tighten or clean filter bowl
assembly.
2. Electronic box out of
adjustment.
2. Refer to box adjustment page.
3. Pump worn or dirty.
3. Rebuild pump.
4. Low supply voltage.
(Pump requires 12v
minimum)
4. Check voltage at connection with
voltmeter.
5. Bad gauge.
5. Gauge should read less than 10
PSI when not in use. Also tips
should lose spray pattern below 10
PSI. Check accuracy.
6. Mixing valve open
6. Tighten down knob
Pump output varies.
1. Clogged or restricted inlet.
1. Clean
2. Worn pump parts.
2. Rebuild pump.

16
APPLI-PRO BASIC PARTS BREAKDOWN
12 Gallon Base Unit
Ref
Description
Part #
Quantity
1
Base
001-4707B
1
2
Tank Lid 6” with Breather
005-9022C
1
3
Tank 12 Gallon
005-9211
1
4
Tank Fitting ¾”
005-9100
2
5
Tank Breather
005-9022B3
1
6
Wire Harness
006-4575AS
1
4
1
3
5
2
6

17
APPLI-PRO BASIC PARTS BREAKDOWN
25 Gallon Base Unit
Ref
Description
Part #
Quantity
1
Base
001-4707B
1
2
Saddle Strap
001-4707A
2
3
Tank Strap 1 ½ x 34”
001-4402
2
4
Tank Lid 6” with Breather
005-9022C
1
5
Tank 23” x 25 Gallon
005-9022
1
6
Tank Fitting ¾”
005-9100
2
7
Tank Breather
005-9022B3
1
8
Wire Harness
006-4575AS
1
1
2
3
4
5
6
7
8

18
APPLI-PRO BASIC PARTS BREAKDOWN
55 Gallon Base Unit
Ref
Description
Part #
Quantity
1
Base
001-4707B
1
2
Saddle Strap
001-4707A
2
3
Tank Strap 1 ½ x 34”
001-4402
2
4
Tank Lid 6” with Breather
005-9022C
1
5
Tank 23” x 55 Gallon
005-9203
1
6
Tank Fitting ¾”
005-9100
2
7
Tank Breather
005-9022B3
1
8
Wire Harness
006-4575AS
1
1
2
3
4
5
6
7
8
8

19
APPLI-PRO BASIC PARTS BREAKDOWN
Control Box
Ref
Description
Part #
Quantity
1
Control Box complete
030-0457
1
2
Control Box knob
008-0923
2
3
U-Bracket
001-2012E
1
4
Pump lead
006-4583
1
5
Speed Control knob
006-2022A
1
6
Switch
006-2196
1
7
Crop Eye plug
006-7500Z
1
8
Speed Control (inside)
006-2022
1
9
Power Lead
006-4580C
1
NP
Suction Cup Mount
001-2012SCM
1
5
1
4
2
7
3
6
8
9

20
APPLI-PRO BASIC PARTS BREAKDOWN
Parts
Ref
Description
Part#
Qty
Ref
Description
Part#
Qty
1
Mixing Valve
002-4715
1
11
Hose Clamp- Mini
003-9002
7
2
FPT Tee -½
003-TT12
3
12
Rubber Hose- 3/8”
002-9003AS
30ft
3
Nipple -½
003-M1212
3
13
Nipple- ¾-½ reducing
003-M3412
1
4
Fitting
003-A1238
4
14
Drain Cap
003-DC12
1
5
Nipple- 3/8-1/2 reducing
003-M1238
1
15
Drain Cap Washer
003-DCW12
1
6
Reducing bushing-1/2-1/4
003-RB1214
1
16
Drain Apt.
003-DCA12
1
7
Pump
007-4120AS
1
17
Ball Valve- ½”
002-2212
1
8
Elbow- ¾ MPT x 3/8 HB
003-EL3438
1
18
Bowl Filter
002-4313
1
9
Fitting- 3/8 MPT x 3/8 HB
003-EL3838
1
19
Elbow- ¼ MPTx3/8 HB
003-EL1438
1
10
Gauge- 2 ¼”
002-2207P
1
NP
Gauge Holder
001-4717B
1
1
2
2
3
2
2
2
4
2
4
2
5
2
6
2
7
2
8
2
9
2
10
2
11
2
12
2
14
2
14
2
13
2
15
2
16
2
3
2
3
2
2
2
17
2
18
2
19