Welcome to John Deere Sprayers Supplemental
Direct Injection Video Training Segment. In this training we will cover proper set-up
and calibration of the optional direct injection system available on a 4 series sprayer.
Before starting the set-up procedures of the direct injection system, you should complete
all other SprayStar system inputs before continuing. Reference the SprayStar section of the machine’s
operators manual for guidance. IMPORTANT NOTE: Always read and follow ALL
safety and use information available in the machine’s operators manual, chemical labels
and MSDS sheets pertaining to all chemicals. Read and follow all PPE recommendations within
these documents. All chemical residue must be disposed of according
to local, state and federal regulations. This video provides supplemental material
and does not replace the operators manual information and safety instructions outlined
within it. Let’s start by going through an example of
the direct injection pump set-up procedure. First, before beginning to apply any product,
verify that the direct injection system is capable of spraying at target application
rates and speeds. Verify the calculated volume per minute is
within operating tolerance of the injection pump installed on the machine.
See Verifying Flow Rate Limits calculation formula in the System Overview section of
the Direct Injection operators manual. In our example we will be applying a herbicide
to standing field corn. For perennial weed control, the recommended
rate is 22 oz./acre as found on the specimen label.
Our 4 series sprayer has a 120-foot boom and our target speed will be 15 mph.
Plugging those figures into the equation formula, we arrive at a volume of 80 oz./min.
This means our high volume pump can inject anywhere from 5 to 200 oz./min to do the job.
To set up the pump in the GreenStar display, go to the main menu button, then select the
pump to be used. Select the Information tab, and from the product
information screen, select the pump number to be set up from the drop down menu.
Next, select the Settings tab from the top of the page.
Select the pump size, in this case the high volume.
Then enter the meter calibration number that is found on the direct injection pump motor
label; in this case we see it is 110. In the next box check that the valve calibration
value is 123. The next box for valve calibration, 2, we
leave alone; it is used for advanced tuning by field support if needed.
Then enter the tank capacity of the system being used in the fourth box.
The next entry is injection line pressure calibration.
For this to be accurate, a zero pressure condition must exist.
To do this, set the recirculation-injection valve on the outlet of the injection pump
to the recirculation position. Also lift up the plunger on the pump calibrator.
This should achieve 0 pressure. Then enter “0” for the calibration in the
display. The last entry on this set-up page is to allow
you to set the desired chemical rate increase or decrease amount. You can change the target
rate with a button push on the main operating page while spraying in the Auto or Manual
mode. For example, we want a 2 oz./acre change to
be available, so enter 2.0 here. In this section we will set-up the Alarms
page. From the menu, select the pump being used,
and then the “tools” button on the direct injection main page.
Then select the Alarms set-up tab. There are 3 settings to enter here.
Select the low tank input box and enter the minimum tank volume of chemical that you want
to see when the alarm sounds. In this example we will enter 20 gallons.
Next, select the Off Rate input box and enter the percent of rate variance acceptable, allowing
the operator to adjust sensitivity of the injection system to rate error.
When the injection rate is above this limit, a rate error alarm will be displayed.
We will enter 20% for this example. The last box is the FER (Flow to Encoder Ratio)
Calibration input box where we adjust the sensitivity of the direct injection system
to flow errors. The range for the FER error calibration is
0 through 9. The default value for the Direct Injection
pump is 6. Increase the FER error calibration value to
set a tighter tolerance. Set the FER error calibration to zero to turn
off all flow monitor alarms for the injected chemical.
We will use the default value of 6 for this example.
That completes the alarm set-up. Before using the injection system, each injection
pump must be primed to ensure that chemical is present at the outlet of the pump.
When the pump is started, chemical flow and pressure builds immediately at the outlet
of the pump. Chemical is pulled from the tank into the
injection pump, and recirculated back to the tank.
The Pump will need to be primed when any of the following applies:
Switching chemicals Pump maintenance is performed
Chemical tank has run completely dry The suction line is blocked
Pump is rinsed Before use at beginning of season.
Let’s review the priming process. Start at the back of the machine. Check there
is enough chemical in the tanks, then verify the tank access valves on the bottom of the
tanks and the strainer flow valve are in the open position.
Set the pump supply valve to the open position. Set the recirculate-injection valve to the
recirculate position. Next, the calibration plunger needs to be
in the up position or problems with priming can occur.
Remove the calibration cover and raise the calibration plunger all the way up.
Now let’s move up into the cab and look at the GreenStar display settings.
Select the main menu, then the pump to be set up.
Select the drop down box below “pump mode” and choose “Cal/Prm” (Calibration/Prime),
then press the tool’s softkey, which brings up the direct injection main page.
Now, select the “ON” button in the top right corner of the page to enable the pump, then
select the “Start prime” button. Press the “OK” button on the valve position
warning. After pushing the OK button, priming will
commence and finish when a primed condition is detected by the pump.
At this time the display should show the words “Prime Complete, Check Cal”.
To finish, switch recirculate-inject valve at the pump to the inject position.
If a priming error occurs, see the Troubleshooting section of the operators manual for possible
solutions, or contact your local John Deere dealer.
Next let’s look at the Injection pump calibration process.
Before performing the calibration, each injection pump must be primed to ensure that chemical
is present at the outlet of the pump as we just demonstrated.
The Direct injection pump is calibrated to verify that each pump revolution delivers
the amount of chemical expected. Chemical is pulled from the tank into the
injection pump, and recirculated back to the tank during calibration.
To begin, verify tank valves and strainer valves are in the open position.
Set the recirculate/injection valve to the recirculate position.
Remove the calibration cover plunger and push the plunger down all the way, then replace
the cover. Now move up to the GreenStar display in the
cab and select the pump to be calibrated from the main menu.
Select the “tools softkey” from that page. On the pump diagnostics page, select the pump
enable button and then the start calibration button.
At this time the system will attempt to pump 1 fluid ounce of chemical.
When the screen message “calibration complete” appears, verify the result by going to the
calibration plunger you pushed down earlier and check if the top of the plunger aligns
within the “marked window” on the calibration cover.
If the plunger is within the marked lines you are good to go.
If the top of the plunger does not align within the marked window, then the Meter Calibration
value we entered during the pump set-up routine located on the Product Setup page may be adjusted
to refine the calibration of the chemical injection pump.
If the plunger handle aligns above the window, reduce the meter calibration value on product
setup page. If the handle aligns below the window, meter
calibration value should be increased. Meter Calibration values should be increased
or decreased by no more than 1% of the default value.
If Meter Calibration must be increased or decreased by more than 5% of default, perform
pump maintenance procedures found in the operators manual.
If the problem persists, see the Troubleshooting section of the operators manual for possible
solutions to the pump issues or contact your local John Deere dealer.
Let’s look at the Injection pump transducer calibration.
Remember we went through a procedure during injection pump set-up for this. This calibration
is for when you question the pressure reading and want to verify it further to be accurate.
Verify the machine ignition is turned “OFF”, then shut the pump chemical supply line valve
“OFF”. Next, loosen the pressure transducer located
at the pump. Allow product trapped in the pump to drain
from the transducer threads; have a catch pan and shop towels to capture the leakage.
When the product is drained, the transducer can be calibrated.
Next, go up in the cab, turn the ignition to “ON”, engine NOT RUNNING.
In the GreenStar display, select the injection pump you are working with from the main menu.
Select input box next to Pressure Calibration and enter a value of zero using the pop-up
keyboard. Go back to the pump and tighten the pressure
transducer. IMPORTANT NOTE: Agricultural chemicals are
present during this procedure. Read carefully the directions printed on the
chemical manufacturer’s labels before handling chemicals or you may be exposed to hazardous
materials which could poison and injure you. Wear protective clothing, eyewear, and gloves.
Do not drain solution onto the ground. Drain into a container.
Drain solution in an area where people, animals, vegetation, and water supply, etc., cannot
be contaminated. Lastly, let’s discuss the Auto system prime
procedure. Auto system priming is a sprayer feature that
allows the operator to fully charge the solution system and direct injection plumbing with
chemical or mixed solution so that the sprayer is ready to begin field spraying.
During this procedure the boom will spray solution.
IMPORTANT NOTE: Spray system can contain hazardous material which can cause serious injury or
death to you or others. Wear protective clothing, eyewear, and gloves.
Spray chemical solutions in an area where people, animals, vegetation and water supply,
etc., cannot be contaminated. To begin, unfold the booms and lower the center
frame. Verify that the direct injection pumps have
been primed. Select the Auto Prime softkey from the sprayer
menu “RUN” page. CAUTION: During the priming process, all spray
sections turn on and off automatically. Press the “Enter” button at the step 1 page
to proceed. On the next page enter a target spray speed.
In this example, we will enter 15 mph. Open the drop down menu for system prime volume
of solution tank carrier to run through for priming and choose “3” which is the default
that will work for all of our boom sizes. If you feel a different amount of flow is
needed to achieve priming, lower the volume used with a 1 or 2 and raise the volume amount
with a 4 or 5. Next, select the check box for each injection
pump to have its injection line primed out to the injection mixing module.
Then select the check box for each injection pump to have its output primed through the
entire boom. Press the enter button to proceed.
Now follow the screen instructions to turn the machine’s solution pump and mater spray
switch to “ON”. The injection line prime will run first.
The flow indicator will be a green check mark. If flow is greater than zero, the flow indicator
will be a red X if the flow rate is zero. The Boom Prime will run next.
Active or open spray sections are indicated with the standard blue indicator.
All sections will automatically turn on and off, starting with the center section, during
this procedure. The approximate prime time for the injection
line is 30-40 seconds and for the overall boom is 2 minutes.
An Auto System prime complete message will show on the display screen when the prime
is complete. We hope this short video was helpful.
Please use the feedback loop for additional comments and suggestions.
IMPORTANT NOTE: Always read and follow ALL safety and use information available in the
machine’s operators manual, chemical labels and MSDS sheets pertaining to all chemicals.
Always follow all local, state and federal regulations dealing with handling and disposal
of chemicals and chemical residue.