Flotation Overwintering
November 14, 2011 Unlike many self-propelled liquid sprayers, high-volume, high-capacity flotation application equipment never really enjoys much of an off season. This is particularly true for “floaters,” such as the TerraGator TG7300, TG8300 and TG9300 three-wheel self-propelled applicators and the TG8400 four-wheel applicator, because these machines often have multiple seasons that don’t leave much time for putting them away for any real length of time.
This is especially true when floaters like the TerraGator series can be outfitted for both liquid and dry applications. During the spring, the TerraGator is widely used for preplant applications of both liquid and dry fertilizer. In a few situations, such as in young wheat, or alfalfa and pastures, this floater is used for in-crop applications of fertilizer and crop protection products. In the fall following harvest, these same floaters are used to make postharvest applications of both dry and liquid crop inputs.
Depending on what area of the country a TerraGator is working, its spring season can run from 10 days to a month or more, then the machine will sit during the growing season. Post-harvest use also depends on geographic location and crop mix and can average one to three months in duration. In certain areas, that post-harvest season can run up to a month or less prior to the preplant season. Season lengths are different for different regions of the country, but in many situations, a TerraGator and other similar floaters don’t benefit from a lot of downtime.
The fact that floaters are often used so relentlessly makes it all the more important that these machines be maintained properly, especially during what little downtime they might have, in order to minimize and even prevent costly downtime during the application seasons.
Storage Opportunity
It is when floaters are put away between the two application seasons — even if just for a few weeks — that a really savvy operator will take the time to go over his machine with a fine-toothed comb, looking for existing and potential problem areas. Once problems or problems in the making are identified, the period between application seasons is the best possible time to make repairs, replace parts and take care of other tasks that will ensure the floater will be in top condition to roll again when the time comes.
Inversely, if you do not take care of repairs and proper maintenance during the downtime, you greatly increase the risk that small problems will become big problems, and you will be confronted with those big problems at the very time you can least afford to deal with them — during the beginning and height of the application period.
So the best possible time to take inventory of your machine’s condition and address any repairs or adjustments that might be needed is when you are retiring your floater for its brief rest. Equally important, this is also the best time to write down the problem areas so that you have a written record to refer to while working on the machine during its limited downtime. Failure to capture all potential problems can result in a host of production-related problems in the field, such as under- and over-applications, incorrect spray patterns, leaky seals or hoses and engine or transmission problems.
Making The Most Of Downtime
The following are some recommendations and guidelines for servicing and storing your self-propelled floater during its off season:
General Recommendations
• Clean the machine thoroughly to prevent rust from fertilizer and chemicals. There are many potential problems that cannot be detected if the floater is not thoroughly cleaned.
• Grease all service points after cleaning.
• Touch up any chips, scratches and rusted areas with protective paint. Put corrosion inhibitor on unpainted metal parts, such as hydraulic cylinders, rods, control linkages, etc.
• Inspect for cracks or stress fractures.
• Check all bolts and hardware for tightness.
• Service hydraulic oil leaks.
• Change hydraulic oil and filters.
• Lubricate bearings.
• Lubricate pivot points.
• Check all fluid levels.
• Align chain and sprocket.
• Inspect electrical connections.
• Check conveyor chain tension.
• Check for proper calibration by employing bag or pan testing.
• Replace engine oil and filter. Operate engine until it is warm to allow new oil to circulate.
• Replace engine air filter and cab air filter.
• Inspect and service the unit’s air-conditioning system as needed.
• Check and service axle breather.
• Drain, flush and fill the engine-cooling system. Consult your operator’s manual for recommendations on use of antifreeze and water mixtures.
• Change the pressure washer pump oil before storage if the unit is equipped with one.
• Add diesel fuel conditioner to the fuel tank that contains a biocide in order to inhibit fungal and bacterial growth and increase shelf life.
• Disengage the battery connections. Remove, clean, charge and put batteries in storage.
• Make sure all components and systems are in good shape and operating correctly.
• Check tires carefully for leaks and wear. Repair or replace tires as necessary.
Liquid Application Systems
• Flush the spray system with water.
• Clean the liquid system thoroughly.
• If below-freezing temperatures are anticipated, put an antifreeze and water solution in the main product tank and rinse tank. Follow manufacturer’s recommendations for proper antifreeze-water solutions.
• Before flushing with antifreeze and water, put plugs in all boom nozzle bodies except the outside nozzle bodies for each pipe of boom plumbing.
• Install a hose with a fitting in open-nozzle bodies and run the hose to a container for proper collection and reuse.
• Open and close the tank sump valve and reload valve several times before operating the liquid pump.
• Operate engine at idle speed. Make sure the tank valve is open, increase engine speed to 1,500 rpm, and engage liquid pump.
• Turn on controller. Increase or decrease the flow after you have engaged the liquid pump.
• Open sparger valve completely for several minutes to fully mix antifreeze.
• Open the by-pass valve to flush the by-pass line. Close by-pass valve.
• Open the clean water valve to draw antifreeze solution from the rinse tank and properly flush the clean water lines.
• Open tank rinse valve to flush the tank rinse line. Close the tank rinse valve.
• If equipped with the chemical eductor option, open chemical eductor valve to flush line going to the eductor. Operate each function of the eductor to properly flush all lines. Close eductor valve.
• Move boom spray controls on and off a number of times to flush pressure plumbing. Collect solution that comes out of end outlets on boom for use again. Move boom spray controls to off.
• Disengage the liquid pump. Open the reload valve and let the solution flow into a container until the tank is empty.
• Pivot down each end of the boom by hand to let the remaining liquid flow out.
• Leave all valves half open.
• Open hand rinse valve on safety water tank.
• Remove product line strainer.
• Remove boom strainers if installed.
• Disconnect all hose quick couplers to remove any remaining liquid.
• Remove plug from bottom of product pump.
• Remove drain plug from rinse tank.
• Remove plug from bottom of boom manifolds.
• Store loose parts (strainers, nozzles, plugs, etc.) in a labeled container.
• Open the drain valve on the bottom of the foam markers and let the liquid flow out.
Dry Box/Conveyor Systems – Air Max Precision
• Check tightness and condition of conveyor chain — do not over tighten. Adjust as needed.
• Check gate openings for product build up. Measure side to side through the chain.
• Check metering rods (dividers) into the distributor box.
• Do not drop funnel weldments to clean out excess material.
• Align funnel weldments.
• Manifold — look into tubes for buildup and obstructions.
• Check fan system for vacuum and fan wear.
• Check screens, V hoods, stair step and bin sensors.
• Grease conveyor bearings.
Air Spreader
• Adjust conveyor chain.
• Adjust gate pointer and gate opening.
• Measure both sides of gate opening through chain to floor.
• Check under doormat chain at rear of the box for build up.
• Check horizontal and vertical augers for build up and clean as needed.
• Check stator fan and boom shut offs.
• Inspect and service J-cups.
• Inspect and clean drop tubes.
• Check impellor in fans.
• Check and maintain hydraulic coolers.
Boom System
• Check boom fold, hinge and pivot pin. Grease boom.
• Check boom for proper adjustment. Check pivot support. Adjust Clevis on fold cylinder.
• For AirMax boom fold adjustment, there should be one finger width between the manifold and boom.
• AirMax boom struts should be ½- to 1-inch at cradle.
• Check boom tips.
• Carefully inspect nozzles for wear. Replace worn nozzles as needed.
• Inspect break-away latch.
Whether you are a professional applicator or grower, following these guidelines will ensure your floater is properly serviced and stored. Then, when the spring or fall application season rolls around again, you can focus on things like seasonal fluid changes, simple checks of light operation, tire inflation and controller calibration verifications. You’ll be up and running a lot faster with fewer delays and headaches if you have put your floater away in proper condition.
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