SECTION B—Machine Assembly Instructions

Final Boom Assembly Instructions

Please use the following instructions to aid in the final assembly of your Weed Zapper boom.
NOTE: Please see our boom installation video on our website www.theweedzapper.com. To
navigate to the videos, hover mouse over “Support”, then click on “Instructional Videos” in drop
down menu, then “Installation Videos” and finally “Boom Assembly Procedures”. You may also
enter this link in your web browser- https://youtu.be/4lacFX3u_sU?si=Q6T2T23GWBYbV5lD

1. With the boom attached to the tractor, use hydraulics to slowly lower boom wings to the field
   (down) position.
2. Place “Insulator Arms” in front of the boom and remove banding that secures them together.
3. Make note of the colored zip-ties on both the “Insulator Arms” and the ends of the “Wing
   Transfer Wires” wrapped around the pockets on the boom.
4. We recommend laying the “Insulator Arms” with colored zip-ties in front of the pockets with
   matching colored zip-ties. This will ensure the arms are placed in the correct location as there
   are two different length arms (57” and 59”).
5. There will be two insulator arms on all booms (20′, 30’ and 40’) without colored zip-ties.
   These will have “DANGER – High Voltage” decals located on one side of them. Install the arm
   so this decal ALWAYS faces outwards or away from the center of the boom.
6. Remove 5/8” bolts from boom pockets while leaving the spacer plate in the pocket.
7. Insert “Insulator Arms” into the steel mounting pockets. Slide the arm beside the spacer plate
   while inserting it toward the back of the pocket until the bolt hole is aligned. Using a small
   Alignment punch may help with this process.
8. If you did not slide the “Insulator Arm” alongside the pocket spacer plate in the previous step,
   do so now and align with the hole in the arm and pocket. (This may be done while sliding arm
   into pocket.)
9. Install 5/8” bolts and tighten until threads are into locking portion of nut.
10. Locate two small pilot holes approximately 8” inward from font end of “Insulator Arm” (the
    end closest to the front copper HV electrode). Using the screws that were provided, install
    the “Small Black Angle Brackets” using these holes. The long side of the bracket, with the
    LARGE hole, should go towards the tractor or away from the crop.
11. Attach each end of flexible conduit to the “Small Black Angle Brackets”. Use the galvanized
    2-hole straps and screws that were provided to secure conduit to top of the insulator arms.
12. Upon customer request, aluminum wedges will be provided for additional leveling of the
    insulator arms. If they are ordered, install them between the bottom of the insulator arm and
    bottom of pocket to aid in leveling of arms. These are not necessary in order to use the
    machine but can be used in obtaining a perfectly uniform insulator arm height. If they are
    used, install a self-drilling screw through a hole in the aluminum wedge into the bottom of
    the insulator arm to hold wedges in place.
13. Install large insulators on the “Insulator Stems” located on the bottom of the “Insulator
    Arms”. Make sure the black shear rings located on the insulator clamp are facing the tractor
    away from the crop.
14. Open the insulator clamp about 2” by loosening the black nylon bolts and sliding the clamp open.
15. Starting with the center section of the boom, slide the longest copper electrode through the
    insulators and center it. Repeat the process on remaining sections and overlap them at
    hinge points approx. 2”.
16. Route “HV Transfer Cable” through the eyelet plate that’s welded to the boom and across
    the top of the center right insulator arm. It can be zip-tied to the right “Wing Transfer Cable”
    on the insulator arm top.
17. Adjust the “HV Wing Transfer Cable” position by sliding it through the conduit so that it
    equally reaches the front electrode on both ends. These will be connected later on during
    the start-up sequence.
18. Using one of the copper clamps that was provided, fasten the boom end of the “HV
    Transfer Cable” to the “Center Section Electrode”.

High Voltage Copper Discharge Electrode Installation Instructions
Please read following instructions to aid in the final assembly of your Weed Zapper boom.
The copper discharge electrodes are shipped with each unit uninstalled to prevent damage
during shipping. Once you have installed the Boom Insulator Arms (see previous page) you are
ready to install the high voltage discharge electrodes. Please read and follow the steps below.

1. Remove the tape holding the copper tubes together. There will be various lengths of
   pipe in the bundle that correspond with the width of each boom section. Lay the tubes
   under their corresponding section insulators.
2. Make sure the insulators are tightened on the threaded steel stems that are fastened to
   the insulator arms. Firmly hand tighten each insulator. It may be necessary to loosen the
   5/8″ nuts holding the steel stem to the arm so you can align the insulator in the proper
   position. The nylon thumb screws (hex head) used to tighten the insulator tubing clamps
   should be facing rearward in all applications. This helps to prevent weeds from snagging
   or accumulating on the insulators.
3. Once insulators are aligned and tightened, insert proper lengths of copper tubing into
   insulators of each section and firmly tighten the clamps with the nylon bolts. All models
   use 1 1/4″ diameter tubing for the main electrodes and the 6R and 12R30 models use
   extension electrodes that are 1 1/2″ diameter tubing that slip over the 1 1/4″ tubing. On
   all models, the 1 1/4″ tubes must overlap each other at the hinge points on the boom.
   The following list shows the lengths and location placement for each model.
4. After Initial Start-Up Procedure has been accomplished, fasten all high voltage cables to
   the appropriate points on the copper discharge electrodes using the copper clamps
   supplied in the kit (see instructions on previous page)

Final Cart Assembly Instructions

1. Place the cart on a hard surface (concrete) after unloading and before hooking it to the tractor.
2. Open both large side doors on the cart. Locate and remove the following items:
   a) Insulator kit (BOX on left side of cart)
   b) Spare parts kit (BOX on left side of cart)
   c) Spare belt (on top of the generator on left side of cart)
   d) HV Transfer cable (on left side of cart)
   e) Large PTO shaft with key taped to it (behind the LARGE pulley at the rear of cart)
   f) 2” x 10” hydraulic cylinder (behind the LARGE pulley at the rear of cart)
   g) Monitor Harness (front right side of cart) (Note: Large Round End goes into tractor cab)
   h) Boom Harness (front right side of cart). Must be routed under the cab and along the frame
   with along with the “HV Transfer Cable” and “Hydraulic Hoses” to the front boom. (attach the
   rectangular plug on the end of the cable to the boom plug).
3. Inside the monitor kit is a 12” long piece of EMERY cloth. Use it to remove any surface rust
   on the solid 2” keyed driveshaft. DO NOT drive the PTO shaft and this solid shaft together.
4. Couple the telescoping PTO shaft to the solid 2” keyed shaft that drives the large pulley.
   Using a hammer to do this is not recommended. Use emery cloth, a file, or a grinder to
   remove burs if needed.
5. There are two options to secure the telescoping shaft to the solid shaft:
   a) Use the hex wrench set screws with LOC-TITE and tighten as tight as you can.
   b) Use ½” diameter x 1.5” long bolts with LOC-TITE. Torque to approx. 65 foot lbs.
6. Next, CAREFULLY unroll the HV Transfer Cable. Notice that one end has a “Ring Terminal”
   on it and one does not. The end with the ring terminal will attach to the “Front Boom”. The
   other end, without the ring terminal, will be routed through the SMALL top hole that is located
   on the front of the cart. It is towards the cart top, slightly to the right and well above the cart
   top link mount. The gray conduit male adapter will attach to the cart using this hole and the
   “HV Transfer Cable” will get connected to the Left or Rear terminal post of the transformer.
   Do this by stripping off about 1” of insulation from the HV Transfer Cable and insert the bare
   cable into the transformer eye-bolt clamp terminal. If the cable is too long, the excess cable
   should be cut off prior to attaching this end to the transformer terminal post.
7. After the HV Transfer Cable is connected to the transformer, place it along with the front
   Boom Harness and the Monitor Harness safely to the side and attach the cart to the tractor.
8. After cart is attached to tractor, route the HV Transfer Cable below the tractor cab towards
   the Front Boom. Secure it very well with clamps or large zip-ties keeping it away from rear
   tires and PTO. MAKE SURE TO ROUTE IT IN A WAY THAT WILL ALLOW THE CART AND
   BOOM TO RAISE AND LOWER WITHOUT PINCHING OR STRETCHING THE CABLE!
9. Next, route the Boom Harness below the cab but preferably not below the tractor where the
   crop could rub against and damage it. Secure with zip-ties away from the tractor tires and
   PTO. There is a round hole about 3” in diameter just above the right, rear lower 3pt. arm.
   This is for the Boom Harness and Monitor Harness to exit the cart safely.
10. Next, route the Monitor Harness to inside of tractor cab. Make sure to correctly align the
    male 21-pin plug to the female 21-pin plug on the side of the Monitor. DO NOT FORCE IT!
11. Inside of the tractor cab, connect the 3’ long, 2-pin round power connector cord, that comes
    out of the monitor harness, to the tractor supplied 30-amp 3-pin 12V power source.
12. Finally, connect the Seat Sensor pad to the 6” long 2-pin female connector that comes from
    the Monitor harness inside of the tractor cab. Place the pad with the Black side against the
    tractor seat cushion and the colored side towards the operator.

High Voltage Transfer Cable Connection Information
The Weed Zapper is shipped with a high voltage cable housed in steel reinforced liquid tight
conduit. This must be connected to the transformer located in the cart. It is designed to be
routed from the high voltage discharge post to the front mounted boom (see Pages B-6 – B-10).
Please study the following photos and read the info posted on each one. This info, along with
the locations identified in the photos, are the proper points of connection for this transfer cable.

OSM offers two different Telescopic PTO shaft models; one made by Weasler and one by BARE-
Co. The shafts vary in length by 6 inches as seen in the photo. The Weasler shaft, shown with the
all-black shield, has a maximum extended length of 60″ from U-joints center-to-center. The
BARE-Co shaft, shown with the yellow shield collars, has a maximum extended length of 54″
from U-joints center-to-center. The PTO shaft is shipped unattached. Follow these
instructions to install/attach shaft.

1. All models are equipped with a 2″ diameter driveshaft. If the driveshaft is too long for
   your tractor, it may be cut to a shorter length using a portable bandsaw, reciprocating
   saw with metal cutting blade. or an angle grinder with metal cutting wheel. Also notice
   that there is a flat spot ground on the shaft to allow for the set screw to seat securely.
   This will need to be reground on the shaft after you cut off a portion. After cutting,
   chamfer the end with a file or grinder.
2. A piece of ½” square key stock is taped to the PTO shaft when shipped. Remove this
   key and place it in keyway on driveshaft.
3. Slide PTO yoke onto driveshaft until driveshaft end is flush with inside of U-joint yoke
   surface.
4. Remove set screws and place thread-locker on screws. Place back into threaded
   holes and tighten with appropriate size hex wrench.