Workhorse ATV 25BL Parts list manual

ATV 25BL
PSE-PRECISION SPRAY EQUIPMENT®, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.green-leaf.us 800-654-9808
a division of Green Leaf, Inc ®
PRECISION SPRAY EQUIPMENT
PSE
®
®
Assembly / Operation Instructions / Parts
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®
®
— GENERAL INFORMATION — WARRANTY / PARTS / SERVICE
DELUXE ATV BOOMLESS SPRAYER
— ASSEMBLY
Tools required:
1 – 7/16” End Wrench
1 – 3/16” Allen Wrench
1 – Phillips Screwdriver
1 – Thread Sealant
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.
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 of your sprayer.
Part description and part numbers can be obtained from the illu-
strated 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.
Polyethylene Tank
12 Volt Diaphram Pump
4.0 G.P.M.
Lever Handgun
15 Ft. of 3/8” Hose (handgun)
Pressure Gauge
Adjustable Pressure range (0-45 PSI Max.)
2 Nozzle Boomless Tips
Quick Detach Spray Boom Feature

PSE-PRECISION SPRAY EQUIPMENT®, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.green-leaf.us 800-654-9808
a division of Green Leaf, Inc ®
PRECISION SPRAY EQUIPMENT
PSE
®
®
— SPEED CHART —
— CALIBRATION
— AFTER SPRAYING
— WINTER STORAGE
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 wand and
boom. Refill the tank about half full with plain water and
use a chemical neutralizer such as Nutra-Sol® or equiv-
alent 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.
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 main-
tenance will prolong the life of the sprayer.
— OPERATION
This sprayer is designed to be attached to an ATV rack or
other stable surface. The pumping system draws solution
from the tank, through the strainer and to the pump. The
pump forces the solution under pressure to the spray wand
and spray boom. 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 bypass valve
located on the top of the tank. Also, the spray nozzles can
independently be cycled on and off with the Y-valve
located on the top of the tank. See the illustration in this
manual for more details on using the bypass valve.
Regularly inspect the suction supply screen on the inside
of the tank. Flush with water to clear any accumulated debris.
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 man-
ufacturers instructions on disposal of all waste water from the
sprayer.
Chemical labels may show application rates in gallons per
acre. 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 chem-
ical label carefully. Determining the proper speed of the
tractor can be done by marking off 100, 200 and 300 feet.
The speed chart indicates the number of seconds it takes
to travel the distances.
Set the throttle and with a running start travel the distances.
Adjust the throttle until you travel the distances in the
number of seconds indicated by the speed chart. Once
you have reached the throttle setting needed, mark the
throttle location so you can stop and go again (returning to
the same speed). Add water and proper amount of chem-
ical to tank and drive to the starting place for spraying.
When you are ready to spray, turn the boom valve to the
“on” position. This will start solution spraying from the tips
once the pump is turned on. The pressure will decrease
slightly when the boom is spraying.
— BOOMLESS NOZZLE SPRAY INFORMATION
When boom spraying, the recommended boom nozzle
height is 24”- 48” above ground level. (Fig. 4)and the pump
pressure should be between 14psi and 18psi (See tip
chart at the bottom of this page). The manifold has
three (3) valves; 2 for left/right spray control on the boom
and the other agitates and adjusts pressure. The pressure
is adjusted while the sprayer is running. We recommend
testing/setting theboom pressure using water. Turn the
pump on and open the ¼ turn valve to the boom; then
adjust the ¼ turn valve on the bypass/agitation line by
opening and/or closing the valve to the desired pressure
(your gauge will indicate pressure). Once desired pressure
has been set, turn off the valve to the boom and leave
the bypass/agitation valve set. It is normal to see a raise
in pressure while the pump is returning to the tank which
also helps to agitate the tank contents. The pressure is
set for the boom; you will also be able to use the wand
while the boom is off without adjusting the setting. The
pump will run until you shut off the pump with the in-line
on/off switch.
SPEED IN MPH Time Required in Seconds to Travel a distance of:
(Miles Per Hour) 100 ft 200 ft 300 ft
1.0
2.0
3.0
4.0
5.0
6.0
7.0
68.0
34.0
23.0
17.0
14.0
11.0
9.7
136
68
45
34
27
23
19
205
102
68
51
41
34
29
1200PS
PSI
20
30
40
GPM
1.0
1.2
1.4
SPRAY
DISTANCE
14 ft.
14 ft.
14 ft.
35
42
49.5
18
21
25
12
14
16.5
9
10
12
7
8
10
6
7
8
5
6
7
1 2 3 4
SPEED (MPH)(1/4” MNPT)
5 6 7
GALLONS PER ACRE
Gallons per 1000 sq. ft = GPM x 136
MPH x Spray Width in Inches
Gallons per Acre = GPM x 5940
MPH x Spray Width in Inches
CONVERSION FORMULAS

PSE-PRECISION SPRAY EQUIPMENT®, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.green-leaf.us 800-654-9808
a division of Green Leaf, Inc ®
PRECISION SPRAY EQUIPMENT
PSE
®
®
Assembly Instructions
PARTS LIST
DESCRIPTIONPART NUMBERQTYITEM
25 Gallon Tank
60013211
Tank Lid60013312
Tank Lid Tether600134
1
3
ATV Boom Mount
6001893
4
ATV Helix Lever
60019035
5/16-18 x 3/4 FLT Head Screw
60018866
Drain Cap Assembly
60029817
Deluxe Spray Wand and 15ft Hose
60015618
Spray Wand Clip60015129
#10-24 x 3/8 Screw600152210
Lead Wire Assy. w/ Switch (96")
600153111
ATV Angle Bracket
600191112
Assembly Instructions
1.0--Install ATV Boom Mounts & ATV Helix Lever
on bottom of tank as illustrated using 5/16"
Flat Head Screws. Note the the orientation
of all parts as their orientation is essent ai l
for proper assembly.
1.1--Install Drain Cap Assembly
1.2--Slide ATV Angle Bracket into Center ATV
Boom Mount and Slide Rotate Lever to lock
into position.
1.3--Insert Lead Wire Assembly into plug at rear
of the pump.
1.4--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
23
11
1
7
66
4
66
4
5
4
66
9
10
8
12

PSE-PRECISION SPRAY EQUIPMENT®, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.green-leaf.us 800-654-9808
a division of Green Leaf, Inc ®
PRECISION SPRAY EQUIPMENT
PSE
®
®
Spray Assembly Instructions
PARTS LIST
DESCRIPTIONPART NUMBERQTYITEM
ATV Angle Bracket60019111
Boomless Manifold Assembly600283
1
2
Bonnet Cap60028223
1200 PSL Tip (Left)600248
14
1200 PSR Tip (Right)
60024915
5/16" x .875" Hex Bolt
60026946
5/16" Hex Nut60017247
Boomless Mounting Plate630023
1
8
Boomless Hose Assembly600252
1
9
Quick Clip600274
1
10
9
6
6
33
4
5
77
1
2
8
6
2.0--Install Boomless Mounting Brackets onto ATV Angle
Bracket using 5/16" x .875" bolts and 5/16" nuts.
2.1--Insert Quick Clip into the back of the Boomless Manifold
Assembly (The Quick Clip can only be installed before
mounting the Boomless Manifold to the Mounting Bracket)
2.2--Install Boomless Manifold Assemlby onto Boomless
Mounting Bracket using 5/16" x .875" bolts and 5/16"
Nuts.
2.3--Install Bonnet Caps onto both ends of the Boomless
Manifold Assembly.
2.4--Using a quaility thread tape install the Left Boomless
Tip onto the Left Bonnet Cap and the Right Boomless
Tip onto the Right Bonnet Cap. Making sure both are
oriented correctly to achieve the correct spray pattern.
DO NOT OVERTIGHTEN.
2.5--Install Boomless Hose Assembly to Boomless Manifold
and secure with Quick Clip. Then Install other end to
Pump Manifold.
2
10

PSE-PRECISION SPRAY EQUIPMENT®, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.green-leaf.us 800-654-9808
a division of Green Leaf, Inc ®
PRECISION SPRAY EQUIPMENT
PSE
®
®
Pump & Valve Illustration
Valve Operation
View looking down on the
top of the valve assembly
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.

PSE-PRECISION SPRAY EQUIPMENT®, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.green-leaf.us 800-654-9808
a division of Green Leaf, Inc ®
PRECISION SPRAY EQUIPMENT
PSE
®
®
PowerFLO™5900 Series
12 Volt DC Motor-Driven Diaphragm Pumps
Specifications —
Motor:
Type: 12 VDC, permanent magnet, totally enclosed, non-ventilated
Leads: 14 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 180°F (82°C) (see Heat Rise graph above right).
Pump:
Type: 5 chamber positive displacement diaphragm pump, self
priming, capable of being run dry, demand or bypass mode.
Certifications: NSF Standard 58
Liquid Temperature: 140°F (60°C) Max.
Priming Capabilities: 14 feet (4 m)
Max Pressure: 60 PSI
Inlet/Outlet Ports: 5900: Quick Attach
Materials of Construction:
Housing: Polypropylene Diaphragm: Santoprene
Valves: Viton Fasteners:
Stainless steel & Zinc plated
Weight: 6 lbs (2.7 kg)
Recommendations —
Electrical:
1. The 5900 series pumps are designed for intermittent duty.
Make sure that “OFF” periods are sufficient. Refer to Rapid
ON/OFF Operation. Consult the factory for particular data and
design criteria.
2. Be sure power supply used is adequate for the application.
3. Pump and motor specifictions are based on an alternator
charged battery (13.7 VDC)
4. Use sufficient battery supply power. Smaller ATV and lawn
tractor batteries may affect pump performance due to low
voltage and amp ratings.
* 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: 5900: 4.0 GPM
Operation Precautions —
1. The pump is equipped with a pressure sensing demand switch that controls the maximum operating pressure.
2. 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.
3. 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).
4. Do not pump gasoline or other flammable liquids. Pump head materials are designed for use with water only. Do not use with
petroleum products.
5. Do not assume fluid compatibility. If the fluid is improperly matched to the pumps’ elastomers, a leak may occur.
6. 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.

PSE-PRECISION SPRAY EQUIPMENT®, a divison of Green Leaf, Inc. 9490 N BALDWIN ST FONTANET, IN 47851 www.green-leaf.us 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 adust 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 2.0 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.
11/15