Maximize sprayer productivity with proper filter maintenance

They are usually inexpensive and not the first thing you think about when conducting routine maintenance on your Apache Sprayer. But, when you operate in dry, dusty conditions, filters are an especially important element to keeping your sprayer well-maintained. That’s particularly true considering the cost of the damage poorly maintained filters can cause down the road.

Today’s modern filters are light years ahead of those in the past. More advanced designs and materials make air filters more effective in trapping dust and dirt that would otherwise reach critical system components and inflict damage. But, because they’re so much more effective and working in much more efficient engines today, they require more attention during routine maintenance.”
Apache Sprayers Senior Application Specialist John Casebolt.

John Casebolt
Apache Sprayers Senior Application Specialist

“With modern engines, especially Tier 4, we’re actually doing more filtration than we used to. Filter systems are high-efficiency units, which means we’re going to clean the air better before it gets to the engine,” he said. “Those filters tend to become contaminated and plug more quickly, and people who have been running some of the older equipment with older engines and filtration systems aren’t accustomed to checking them as often as they should.”

Staying attentive to filters

Working in dry, dusty conditions can accelerate wear on filters simply by virtue of the volume of sediment they’re filtering, as well as the heat that typically accompanies that kind of intake. But, generally, there are other signs your filters are clogged or not performing optimally. Sometimes they’re the first thing to watch for in diagnosing filters that are nearing the end of their operational lives.

“All components are going to get dirtier working in hot, dusty conditions, and you need to clean out filters more frequently to prevent engine performance issues,” Casebolt said. “If it’s hot and your A/C system isn’t working, the air filter for your cab needs to be cleaned out more frequently, too. Keep your eye on these types of things when working with more dust.”

Cleaning filters

When cleaning air filters, it’s important to do so in a way that doesn’t alter or damage its structure or shape. It may be tempting to either knock dry sediments loose from the filter or use an air compressor that will get more of the loose material than cleaning by hand. These are likely overkill, though, and stand to potentially damage the filter worse than simply wiping the excess dust and sediment away gently by hand.

“If you try to clean it out with compressed air, it has to be done with low pressure and from the inside out so you don’t damage the fleece or paper in the filter,” Casebolt said. “Some people just grab an air hose at 100 or 120 PSI that you could blow something across the room with. I don’t think that’s wise because there can be more damage done to an air filter doing that than what they’ll gain. My recommendation is to clean it by hand and just get the loose stuff out of it.”

Tech tools help

The good news is that modern equipment, like an Apache Sprayer, typically has on-board diagnostics and warning systems that alert the operator when a filter’s performance is slowing down or being altered in a way that affects overall performance. But, don’t use those warning systems as the primary means of diagnosing filter issues.

“I’m not a fan of depending on those safeguards as a means of determining when I’m going to change my filter,” Casebolt said. “They’re there to warn us in those situations where it’s gotten a lot dustier than we realize, but by the time the warning goes off, I should have already checked my filter instead of running as long as I have with it in that condition.”

Casebolt recommends changing air filters at least once a year, or every 250 hours of operation, whichever comes first. For those who don’t operate that many hours in a season, it’s still important to change filters annually.

“Some will hit that 250-hour mark in a season, and some will hit 500 hours. For some operators, a filter will last an entire season, but for others, they’ll be changing it twice or three times a year,” he said. “If you run a filter too long, you are sacrificing engine performance, so you need to be proactive in changing them.”

Plan ahead

Though it’s not common among farmers today, keeping a basic supply of filters on hand is a good idea, Casebolt said. If you have a replacement already on hand for when a filter needs to be swapped out, you can minimize the time to do the job. During the off-season, that may not be that big of a deal. But, during spraying season when time is money, it can be huge.

“I’m in favor of operators planning ahead and not just buying what they need to service the machine right now, but getting what they will need for the next service. If they plan on putting 250 hours on a machine in a year, I would plan for that and have those filters on the shelf so I’m not spending precious time during the season waiting on filters to arrive or spending time trying to track them down,” Casebolt said. “Filters are consumables. It’s not like you are buying extra parts to sit on the shelf and maybe have to use. You are going to have to use them.”

Looking to purchase filters for your Apache Sprayer? Head to our parts store.

Regular testing prevents crop damage from worn sprayer tip nozzles

Tip nozzles are among the least expensive components of a modern sprayer, but underestimating their importance and being lax with maintenance can quickly get costly. That makes it critical to test them and ensure they’re functioning properly before beginning a busy spraying season.

Why nozzle testing matters

Why is testing tip nozzles so important? A clogged or damaged nozzle can alter spray patterns, and depending on the chemical you’re applying, can have major implications for your crop, both in growth and weed/pest control.

“Think about how many dollars per acre you are spending on chemical. With the price of chemicals, you want those nozzles to do their jobs. When they get worn, they lose their pattern and you start getting droplets in different places,” according to Apache Sprayers Service Technician and Application Parts Specialist Chris Weaver. “You run the risk of overapplication, spray drift and streaking in the field. The more worn your nozzles get, the worse it is going to be. If you’re spraying herbicide, weeds will be worse in those areas.”

Testing your tip nozzles begins by knowing your nozzle size, spray pattern and the volume for which they’re rated. Having a firm grasp on these variables will help determine exactly how they should be optimally performing based on the required 40-PSI pressure. That pressure information is critical to have on hand when manually testing tip nozzles, Weaver said.

Nozzle testing methods

Measuring the output of each tip for nozzle wear and tear is the basic testing procedure for justifying replacement, and there are both manual and automated (via rate controllers) ways to do so. If done manually, which typically gives the operator a better feel for the condition of his or her nozzles, Weaver recommends using a metering bucket, calibration jug or other container that can measure specific output levels for each nozzle. Once the system reaches 40 PSI, each tip should emit a specific amount of liquid. Weaver recommends testing each nozzle for either 30 seconds or one minute, though the longer you test, the more accurate your nozzles and spray pattern will be.

This is where nozzle size comes in; the size dictates the amount of output per tip, and if that output is greater than that specified amount, the nozzle is likely to be damaged or worn. That means it should be replaced soon to prevent inconsistent and potentially damaging applications.

“If you have an XR11002 spray nozzle, that’s a 0.2-gallon-per-minute nozzle rated at 40 PSI. You should get 0.2 gallons of spray per minute per nozzle. If you are at 40 PSI and you’re getting 0.25 gallons/minute, you have a worn nozzle,” Weaver said. “There are also tip calibrators that have flow meters built into them. You hold one under a nozzle and it will tell you your gallons per minute.”

When to test nozzles

Testing your sprayer’s tip nozzles is something that should be done at least once a year, starting when you perform pre-season maintenance on your machine. How often you need to actually replace your nozzles depends on use and nozzle type.

“If you use polymer nozzles, they’ll likely last around 15,000 acres before needing to be replaced, whereas stainless steel nozzles will last up to 25,000 acres,” Weaver said. “But, given the simplicity and brevity of the process, especially when performing regular preseason maintenance, thoroughly testing nozzles is the best way to find out their condition and replace them if necessary.”

“It’s something that’s so easy to do when you’re getting your sprayer ready for the season. You are already spending a good amount of time getting your sprayer ready in the spring,” Weaver said. “It literally takes one minute per nozzle or less to do it.”

To prevent further wear and tear on your nozzles, be sure to reference our Nozzle Maintenance 101 Guide.

Calibration keeps your ZF transmission shifting smoothly

When Apache Sprayers transitioned to the ZF transmissions for the 2011 sprayer model year, operators had access to a new way to boost fuel economy and performance in the field through features like a locking torque converter.

Like any drivetrain component, ZF transmissions require regular maintenance to perform optimally. Though it is fairly automated and offers a lot of safety features to simplify and streamline the process, it’s important to go through calibration at least once per season to ensure components are protected and the transmission is shifting smoothly, said Apache Sprayers Application Specialist Chris Smith. Many operators calibrate their ZF transmissions when performing routine service and fluid changes.

“The process keeps everything within the recommended specifications, because over time, things are going to start wearing out. It helps minimize typical wear and tear by reading and recalibrating new clutch pressures,” Smith said.

An automated process

When calibrating a ZF transmission in an Apache Sprayer, the machine’s on-board computer — tied to its transmission control unit (TCU) — essentially takes care of the process for you. After the operator runs the machine to get it to operating temperature — around 180 degrees Fahrenheit — the TCU runs a diagnostic check of all clutch pressures and provides performance feedback.

The process helps the operator stay on top of potential maintenance issues like replacing the system’s 15W40 oil as needed. In newer Apache Sprayer models, the TCU helps manage operations to optimize performance under different conditions.

“With our new 30-series machines, we’ve reprogrammed the TCU to where you can spray better in the 3rd- to 4th-gear range,” Smith said. “You can go into the TCU and change things like torque curves to accommodate the optimal speed and spraying speed and volume.”

Ultimately, ZF transmissions help operators not only stay on top of key maintenance schedules, but do so with the highest level of safety, given the number of safeguards the transmissions feature.

“You can’t do anything to tear it up, really,” Smith said. “There are so many safety features built in that, and with the ability to lock the torque converter, you can improve fuel efficiency and overall engine performance.”

Are you calibrating your ZF transmission as part of your annual maintenance schedule? See what else you should be doing on a yearly basis with our maintenance checklist. Start here.

Cabin filters do a lot more than keep you comfortable

Spraying agriculture chemicals can be a dirty and sometimes dangerous job. That makes it important to have an enclosed sprayer cab with a strong air filtration system, like today’s Apache Sprayers. Simply having a cabin filter system isn’t enough; it’s just as important to take the right steps to ensure it’s functioning properly, especially during the busiest time of year when farmers are spending a lot of hours in the cab.

A three-layer filter system
Apache Sprayers utilize a three-layer activated charcoal filter comprising a charcoal layer sandwiched between two paper layers with varying levels of filtration. The outer layer is pleated paper designed to catch the largest particles of dirt and dust from entering the middle layer comprising activated charcoal. The third inner-most layer is also paper, but is designed to catch finer particles that may have made it past the charcoal layer.

The lifespan of the filter layers

The cabin filter is designed to do more than just trap dust and dirt particles. The middle activated charcoal layer traps chemical fumes and odors that can sometimes be dangerous to the operator. Though the lifespan of the outer paper filter layers is typically based on the number of hours of operation, the charcoal filter’s efficacy over time is partially determined by the speed at which you operate your HVAC fan, according to Apache Sprayers Senior Application Specialist John Casebolt.

“Activated charcoal deteriorates more quickly with increased air volume,” he said. “If you’re running your fan on high speed all the time so you can feel the air in the cab, you’re pulling more air across the charcoal filter, so you will consume that more quickly.”

The reason for this deterioration is the charcoal’s contact with air in general. Activated charcoal’s long-term efficacy in preventing chemical fumes from entering the cab also depends on how the machine’s heating and air-conditioning system is used. If you crank up the A/C most of the time while you’re spraying, your charcoal filter’s lifespan will be adversely affected because of the increased airflow over the filter. Even when it’s not in operation, if the filter is installed and exposed to open air, it’s slowly losing long-term efficacy, Casebolt said. It’s an important factor to account for in how you store your filter during the off-season, just as much as accounting for how you operate during the season.

When to change your filter
Just as the machine’s A/C system can be the culprit of shorter cabin filter operating life, it can also be one of the first symptoms of a filter reaching the end of its life. When the filter stops working, it’s common for A/C systems to slow down or not function optimally.

When is the best time to change your cabin air filter? “If you start noticing chemical odors in the cab, then it’s time to take a look at that filter and see when it was changed last, because that activated charcoal begins to deactivate as soon as it’s exposed to air. It doesn’t deteriorate as much when it’s just sitting there versus when air is moving across it, but it does happen,” Casebolt said. If there aren’t noticeable performance issues, the cabin filter should be changed at least once a year, depending on overall use.

“Whether it’s more often than once a year depends on the hours on the machine and the conditions in which you’re running,” Casebolt added.

Storing and replacing the filters
Because activated charcoal starts deteriorating with any contact with the air, it’s also important to store filters in a way that minimizes that contact, thereby maximizing the functional life of filters containing the material, like Apache Sprayers cabin filters.

“When you buy filters, they come wrapped in plastic cellophane or something to prevent the air from getting to it even when it’s sitting on a shelf. It’s wrapped very well. I recommend putting a new filter on right before you start spraying. Get your sprayer ready during the off-season, but leave that charcoal filter wrapped up, set it on the seat and wait until right before you go to the field to put it in.”

Replacing cabin air filters is just one part of regular maintenance on an Apache Sprayer. Do you want more maintenance ideas? Start with our annual maintenance checklist.