SECTION F—Adjustments, Maintenance and Troubleshooting Info
Speed/Motion Sensor Adjustment The following photos and information pertains to the coulter assemblies on your machine. Please note the info in the boxes on the photos as well as that which follows. (The 2021 models and newer will have additional shielding.)
Speed/Motion Sensor Adjustment NOTE: The purpose of the speed/motion sensor is to provide a safety measure by indicating forward motion. Speeds shown on monitor are approximate and may not match the tractor speedometer indication.
Lift applicator boom or boom wings off ground and place supports under them.
Stop tractor engine, set park brake, and remove key.
Loosen the jamb nuts that secure the speed sensor to the mounting bracket.
Adjust speed sensor distance in or out until amber lights on back of sensor turn on when coulter solid surface is aligned with the sensor and turn off when coulter hole is aligned with the sensor. Distance on all models should initially be set at 5/8″ measured through a coulter disc hole from the outside surface of disc face (surface furthest from the sensor) to speed sensor surface. Minor tweaking of this distance may be required to obtain optimum performance. View the instructional video at www.theweedzapper.com or enter the following address into your web browser: https://youtu.be/hVgxKHOsZ78?si=i32GadZhd9_uBarS
Inspect surface of sensor face to determine if there is damage or excessive wear. Operating in muddy or sandy soil conditions can accelerate the wearing process. Replacement is necessary when wear causes intermittent and unacceptable operation.
Retighten sensor jamb nuts once adjustment is complete
Utilizing Ground Radar to Detect Speed/Motion
NOTE: The purpose of the ground radar sensor is to provide a safety measure by indicating forward motion. Speeds shown on monitor are approximate and may not match the tractor speedometer reading. OSM began utilizing ground radar to detect motion and speed on the 2023 Annihilator series machines. The ground radar system consists of a ground radar module with mounting bracket, wiring harness and pertinent programming and software modifications for the onboard computer system. This change was implemented due to certain, harsh environmental conditions which rendered the previous motion and speed detection system intermittent in operation creating frustration for the machine operator. Shown in the images that follow are the position and mounting brackets for the 2023 and 2024 model machines. Notice on the image for the 2024 model that there are three mounting positions for the radar module: high, mid and low position. The module comes mounted in the mid position. This position should be used for most applications, however, if you are running in short crops and low weed height conditions, you may need to lower the module to the low position. Likewise, if you are running in tall crop conditions, you may need to raise the module to the high position. On the tall crop/weed conditions, it is required that you run the generator cart in a higher, raised position in order to not excessively bend the crop/weeds over while passing under the cart and then have them spring back up in a reverse motion to the forward traveling motion you are running in. This reverse motion will create false readings and intermittent malfunctioning of the ground radar and stop the machine operation
Radar Calibration Instructions:
Proper cart orientation is imperative to the calibration process. The cart REAR should be approximately 5” higher than the cart FRONT (See Fig. 1 above).
Move to an area of the field that has bare dirt or VERY short vegetation. Tall vegetation will move or sway in the wind and the radar will detect the movement. This will cause the radar system to have a much higher minimum speed.
Advance to the Radar calibration screen by first pressing the pink/purple right arrow at the bottom of the run screen (See Fig. 2 on next page). Then advance again from the Diagnostic screen by pressing the pink/purple right arrow at the bottom of the diagnostic screen (See Fig. 3 on next page). Next press and hold the button marked RADAR on the screen titled “More Diagnostic Options” (See Fig. 4 on next page).
You are now on the Radar Speed Sensor screen (See Fig. 5 on next page). There are 2 different calibrations available on this screen; one is for speed calibration and the other is for vibration calibration.
Press the Calibrate Radar button to access both options (See Fig. 5 on next page). Speed Calibration Instructions:
After following the instructions listed above, press and hold the Calibrate Radar button.
The Radar Calibration screen will appear (See Fig.6 on next page). Adjustments are made by pressing the + or the – buttons. Pressing the + button will cause the radar to read a faster speed and pressing the – button will read a slower speed. The system comes preset at 1.0 but can be changed by the operator as needed.
After the adjustments are made the new settings are automatically saved to the system. Press the Exit button to return to the RUN screen
Vibration Calibration Instructions: This procedure can be initiated by the operator, or it may be initiated by the computerized safety system. A calibration is required after every 40 hours of Zapping. This requirement is triggered at the next power cycle after 40 hours of operation. MAKE CERTAIN that the CART is located OVER an area with SHORT vegetation or BARE dirt.
For manual selection follow the steps listed in the Radar Calibration section above. The automatic trigger will direct the operator to the test once they go past the Weed Selection screen.
Turn on tractor PTO and increase tractor RPM to achieve 950 PTO rpm. Press the Start Calibration button. Once this portion is satisfied the screen will change automatically.
Follow instructions on the screen by increasing the PTO rpm to 1000. The screen will automatically change once this rpm is recognized.
Lastly, increase PTO RPM to 1050. The test will complete once this RPM is achieved. If the test fails it is likely due to one of the following reasons:
Wind causing moving plant material below the Radar. Move to an area with shorter plants.
Excessive vibration in the PTO driveline. Prior to calibration test, raise or lower the cart to reduce vibration. If this does not work to reduce vibration inspect the large PTO shaft making sure it is straight and not bent
NOTE: An informational and training video is available on our YouTube channel and can beaccessed through our website, theweedzapper.com. Additional information and step-by-stepinstructions are given in this video. To navigate to the video, hover mouse over “Support”, thenclick on “Instructional Videos” in drop down menu, then “System Diagnostic Videos” and finally“Radar Calibration Video”. You may also enter the following link in your web browser:https://youtu.be/0MH0oFfk-kw?si=PE2vEFmWmTjEYXdM
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Wing Position Sensor Adjustment
There is no adjustment needed or provided for on the wing position sensors. A green light illuminated on the sensor indicates power is present. An amber light illuminated on the sensor indicates a sensor signal is present (see page F-8)
Large Insulator Replacement
Loosen the plastic setscrews and remove the copper discharge electrode from the insulators.
Once the copper discharge electrode has been removed, unthread the insulator in a counter clockwise motion and remove it from the threaded stem bolt.
Replace with a new insulator in reverse motion.
Insert the copper discharge electrode and re-torque the set screws.
Recheck the set screw torque after 2 acres (.8 hectare) of use.
Drive Belt Replacement with Turnbuckle Tensioner (Do Not Overtighten)
Lower cart to Park Mode (See Page E-12).
Shut OFF tractor engine and remove key.
Open door on right side of cart and apply the door safety lock.
Loosen turnbuckle moving PTO pulley fully to left hand or driver’s side of machine.
Remove the two bolts that hold the rear pillow block bearing and loosen two bolts that hold the front pillow block bearing. Exercise caution concerning pinch hazard.
To remove old belt, slide it between the rear bearing and frame.
To install new belt, slide it between the rear bearing and frame.
Reverse steps 1-6 to complete belt replacement. Tighten belt slightly. Check pulley alignment with a straight edge before final tightening of pillow block bearings. After tightening bearing blocks, recheck pulley alignment.
Retighten belt tension to a point where 1/4 (.6 cm) of deflection can be obtained between pulleys (45-50 lbs. of pull on tensioner ratchet handle-(see Pages F-10 – F-13).
Remove the door safety lock and close the service door.
Recheck belt tension after 1 acre (.4 hectare) of use.
Checking and Adjusting Belt Tension with Turnbuckle Tensioner (Do Not Overtighten)
Lower cart to Park Mode (See Page E-12).
Shut OFF the tractor engine and remove key.
Open the service door and apply the door safety lock.
Check the belt for an ideal tension of approximately 1/4 to 1/2 inch (.6 to 1.2 cm) of deflection (45-50 lbs. of pull on belt tensioner ratchet handle-(see Pages F-10 – F-13).
If adjustment is required, do so as needed by rotating the ratcheting turnbuckle to obtain the proper tension for the belt.
Remove the door safety lock and close the service door.
2022 Models Drive Belt Replacement with Turnbuckle Tensioner
Lower cart to Park Mode (See Page E-12).
Shut OFF tractor engine and remove key.
Open door on right side of cart and apply the door safety lock.
Loosen turnbuckle moving PTO pulley fully to left hand or driver’s side of machine.
Remove the two bolts that hold the rear pillow block bearing and loosen two bolts that hold the front pillow block bearing. Exercise caution concerning pinch hazard.
To remove the old belt, slide it between the rear bearing and frame.
To install the new belt, slide it between the rear bearing and frame. (Continued on next page)
Reverse steps 1-6 to complete belt replacement. Tighten belt slightly. Check pulley alignment with a straight edge before final tightening of pillow block bearings. After tightening bearing blocks, recheck pulley alignment.
Retighten belt tension with turnbuckle so the multi-purpose tool fits snugly between the 2 washers on either side of tension springs (1 1/8” in length) (see photo below).
Remove the door safety lock and close the service door.
Recheck belt tension after 1 acre (.4 hectare) of use.
Checking and Adjusting Belt Tension with Turnbuckle (Do Not Overtighten)
Lower cart to Park Mode (See Page E-12).
Shut OFF tractor engine and remove key.
Open the service door and apply the door safety lock.
Check the belt for an ideal tension where the multi-purpose tool fits snugly between the 2 washers on either side of tension springs (1 1/8” in length) (see photo below).
If adjustment is required, do so as needed by rotating the turnbuckle to obtain the proper tension for the belt.
Remove the door safety lock and close the service door.
Drive Belt Replacement with Air Tensioner (Do Not Overtighten) Please visit our website www.theweedzapper.com and view the instructional video.
Lower cart to Park Mode (See Page E-12).
Shut OFF tractor engine and remove key.
Open both doors on sides of cart and apply the door safety locks.
Visually inspect the gap between the small Aluminum pulley and large Drive pulley (see Pages F-10 – F-13). It should be closer to the smaller Generator pulley than the larger PTO pulley (see step 13). If belt has stretched, aluminum pulley may be against large PTO pulley which will cause belt slippage due to the tensioner arm not able to move taking up the slack.
Release air pressure via the air Schrader valve.
Manually pull the tensioner arm that holds the small aluminum pulley all the way to the left.
Mark the bearing plate locations on the machine framing, then remove the two bolts that hold the rear flange bearing mount and loosen two bolts that hold the front flange bearing mount. Exercise caution concerning a potential pinch hazard.
Remove the belt from the pulleys.
Place floor jack under the center of the Large PTO pulley and raise it about 2″ or as needed.
To remove old belt, rotate rear bearing flange 180 degree. Then slide the belt between the bearing mount and framing.
To install new belt, slide it between the rear bearing mount and framing.
Reverse steps 1-6 to complete belt replacement. Check pulley alignment with a 48″ straight edge before final tightening of flange mounting bolts. After tightening bearing blocks, recheck pulley alignment.
Visually inspect gap between small aluminum pulley and both larger pulleys to make sure it is closer to the Generator pulley (see page 98). If it is not, adjust gap by loosening the 2 flange bearing bolts on front flange and 2 Flange bearing bolts on rear flange. Then slide Large PTO pulley to the passenger side. (Realignment with a straight edge will be required.)
Check the belt for an ideal tension of approximately 1/4 inch (.6 cm) of deflection. The Air Pressure Gauge should be set to 35 PSI. (DO NOT OVER INFLATE).
Remove the door safety locks and close the service doors.
Recheck belt tension after 1 acre (.4 hectare) of use
Checking and Adjusting Drive Belt Tension with Air Tensioner (Do Not Overtighten) Please visit our website www.theweedzapper.com and view the instructional video.
Lower cart to Park Mode (see Page E-12).
Shut OFF tractor engine and remove key.
Open the left service door and apply the door safety lock.
Visually inspect gap between small aluminum pulley and both large pulleys to make sure it is closer to the Generator pulley (see Page F-13). If not, adjust gapping by loosening the two flange bearing bolts on the front and rear mounting plates. Then slide large PTO pulley to the right side (away from generator). Align drive pulleys using a 48″ straight edge and tighten bearing plate bolts. Observe steps for Drive Belt Replacement on page F-9.
Check the belt for an ideal tension of approximately 1/4 (.6 cm) of deflection. The Air Pressure should be set to 35 PSI (DO NOT OVER INFLATE).
If adjustment is required, add air to the system via the Schrader valve beside Air Gauge.
Remove the door safety lock and close the left service door
Performing Regular Maintenance
Clean insulators and dry with a clean cotton rag.
Check high voltage wiring and conduit for damage. IMMEDIATE REPLACEMENT is required if any damage has occurred. DO NOT attempt to repair damaged HIGH VOLTAGE wire or conduit. Replacement with new HIGH VOLTAGE wire is required. Any damage left unattended can create an extremely dangerous and potentially lethal situation. Contact your nearest OSM dealer or OSM direct @ 660-851-8800 for replacement of HIGH VOLTAGE wiring and/or conduit.
Multi-Meter Basic Operation Instructions There may be times when the use of a multi-meter will be required in order to diagnose an electrical issue with the machine. The multi-meter needs to be a digital model with ohms, DC voltage and continuity measuring capabilities. The following pictures reflect several setting positions along with explanations of each setting
