Hardi Mercury Series Instruction Book Download Page 18

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2 - General Safety Instructions

Residual Energy

Possible Dangers

Note that there may be residual energy from mechanical, hydraulic, pneumatic and electric / electronic parts on the sprayer.

Use appropriate measures to inform the operators.

Prevent any accidents from happening due to residual energy.

Below are some examples on where the sprayer’s residual energies may be present.

Mechanical Energy

•

springs under tension

•

weights exposed to gravity

Hydraulic Energy

•

trapped oil under pressure in cylinders, hoses and accumulators

•

heat from cylinders and oil tank.

Pneumatic Energy

•

air tank

•

air activated brake system

•

pressure dampers for fluid system

Electric Energy

•

energy stored in capacitors

•

tractor battery

Summary of Contents for Mercury Series

Page 1: ...Mercury Zaturn Instruction book 67029104 100 Version 1 00 GB 10 2016 www hardi com au...

Page 2: ...d data in this book are believed to be correct at the time of printing As it is the policy of HARDI AUSTRALIA to continuously improve our products we reserve the right to make changes in design featur...

Page 3: ...on 17 Protection Equipment 17 Residual Energy 18 Possible Dangers 18 Service and Maintenance Work 19 Statutory Inspection 19 Preventive Measures 19 Design Changes 20 Operator Limitations 20 Spare Part...

Page 4: ...rbines 45 Protective grid 45 Gearbox 46 HF 640D Turbines 46 Clutch All blower types 46 Equipment 47 Ring drawbar 47 Turnable drawbar 47 Wedges 47 Boom 48 Breakaway Arms 48 4 Sprayer setup Connecting t...

Page 5: ...82 Diaphragm pump 83 Ring drawbar 84 10 hours service In Line filter not PrimeFlow 86 Every 10 working hours Nozzles 86 Every 1000 working hours or annual whichever comes first Full service 87 Every...

Page 6: ...6...

Page 7: ...your national regulations regarding the content of the workplace assessment the frequency of repeating the workplace assessment Worker Operator Instructions Only let those people work with or on the s...

Page 8: ...count by the owner Obligationsof the Operator Before starting work the operator or anyone incharge of working with on the sprayer is obliged to comply with the basic workplace safety instructions and...

Page 9: ...following causes Improper use of the sprayer Improper installation commissioning operation and maintenance of the sprayer Operation of the sprayer with defective safety equipment or improperly attache...

Page 10: ...rovided by the manufacturer of the plant protection product to be used such as This Instruction Book must always be kept together with the sprayer must always be easily accessible for the operator Che...

Page 11: ...erious physical injury if the instruction is not followed This symbol means WARNING Be alert as your safety can be involved The WARNING symbol indicates a medium risk for immediate death or serious in...

Page 12: ...ations about chemical preparation before handling the machine Observe instructions and safety rules when operating Service Carefully read the Instruction Book before handling the machine Observe instr...

Page 13: ...isk of falling off Do not ride on platform or ladder Risk of sprayer tipping over Be aware when disconnecting the sprayer Grapping area Manual handling of the boom etc Not for drinking This water must...

Page 14: ...er is started up all the safety and protection equipment must be properly attached and fully functional Check all safety and protection equipment regularly Repair or replace the equipment as needed Fa...

Page 15: ...The applicable workplace safety Follow these regulations especially when driving on public roads and routes Comply with the appropriate statutory road traffic regulations These vary from country to c...

Page 16: ...al training shall be considered as a specialist Due to their specialist training and their knowledge of the appropriate regulations they can evaluate the work with which they have been appointed to an...

Page 17: ...in Normal Operation Protection Equipment Only operate the sprayer if all the safety and protection equipment is fully functional Check the sprayer at least once a day for visible damage and check the...

Page 18: ...nts from happening due to residual energy Below are some examples on where the sprayer s residual energies may be present Mechanical Energy springs under tension weights exposed to gravity Hydraulic E...

Page 19: ...position to relieve oil pressure turn off the tractor and remove the ignition key dismount the hydraulic hoses connected from the tractor to the sprayer Electric system turn off the tractor and remov...

Page 20: ...he state specified by the approval It is strictly forbidden to drill holes in the steel frame or in the running gear increasethe size of existing holes in the steel frameor inthe running gear weld sup...

Page 21: ...Instructions 21 Cleaning and Disposal Environmental Protection Carefully handle and dispose of any materials used in particular when carrying out work on oiled or lubricated sprayer parts when cleanin...

Page 22: ...r person disturbs or interferes with the operator or if the operator is trying to operate the sprayer from places other than the tractor s driver seat can result in risk of the operator loosing his ab...

Page 23: ...to people to the environment and to the sprayer danger to people through non secured working areas danger to people through mechanical and chemical influences failure of important sprayer functions fa...

Page 24: ...s forbidden to stay in the working area of the sprayer s drawbar on the sprayer s platform or behind the operating area the tractor unless the hydraulic pressure to the sprayer has been switched off O...

Page 25: ...led sprayers are stable Use of The Sprayer Before starting work ensure that you understand all the equipment and actuation elements of the sprayer and their function There is no time for this when the...

Page 26: ...be strained or caught in the tractors wheels when cornering 14 Crop residues and dirt are removed 15 All moveable or loose equipment are securely latched or stowed away in the designated compartments...

Page 27: ...or into the transport position turn off depressurize the hydraulic system turn off the tractor engine engage the parking brake remove the ignition key Havethe hydraulic hose lines checkedat leastonce...

Page 28: ...nto the sprayer during service work be aware of the low voltage danger from electric components Only use the prescribed fuses If the fuses used are too highly rated the electrical system will be destr...

Page 29: ...g a free flow of water from the mains water supply or from an external water tank Environmental Precautions It is essential to reduce the environmental impact of plant protection chemicals to a minimu...

Page 30: ...ayer to prevent unintentional movements of the sprayer switch off the PTO switch off the tractor and remove the ignition key to prevent unintentional starting activate the parking brake to prevent rol...

Page 31: ...l info View 1 Main tank 2 Level indicator optionally on top of the tank 3 Manifold valves 4 Suction filter 5 Pump 6 Rinsing tank 7 Clean water tank 8 Main lid and strainer 9 TurboFiller Not used 10 Dr...

Page 32: ...house 14 Grid and air guide 15 Centre cover 16 Bumper and light bar 17 Gear box filling point 18 Air outlet 19 Spray line 20 Adjustable bottom deflector 21 Operating unit and hydraulic valves 12 16 1...

Page 33: ...ipped to comply with these regulations ATTENTION For models not fitted with brakes the maximum speed is 25 km h and 40 km h for those with This could vary according to local legislation Contact your l...

Page 34: ...r 4000 l A large easy to read tank contents indicator is placed on the front right hand side and another one is placed on the left side First one is visible from the tractor cabin The filling hole is...

Page 35: ...Use only grease for lubrication This type of pump is self priming works without oil and can run dry as long as necessary Valves The suction valve is located above the pump and is used to select where...

Page 36: ...tation and for rinsing nozzle optional equipment Agitation Tank rinse valve Zaturn only The Agitation Tank rinse valve can be adjusted for desired agitation or tank rinse In vertically position the va...

Page 37: ...he main tank or from the fast filling device ATTENTION If any of the valve handles are too stiff or too loose loss of fluid the valve needs to be serviced For more information see the section on Maint...

Page 38: ...ler DB3610 1 2 3 4 Fluid section Odd on left Even on right 5 6 7 8 Hydraulic selectors 9 Menu Left 10 Up 11 Escape Right 12 Down 13 Enter Regulator 14 ON OFF sonars Screen views 15 ON OFF Pause 1 2 14...

Page 39: ...or 920mm of diameter and is fitted with blades made of a hardened synthetic material This reduces the power consumption to a minimum as a result of low material density There is a channel between the...

Page 40: ...less of whether the fan is in use or not DANGER During the working day protect your hearing from the noise produced with EN 352 1 1992 approved hearing protection or similar DANGER If you notice vibra...

Page 41: ...ovide direction of air and spray mist in direction to the target according to adjustment Gearbox The AG820 and AG920 are fitted with a 2 speed gear box with a neutral position The front and lower area...

Page 42: ...he fan page 5 1 Specific for SF fans After changing pitch the fan needs to be balanced Position P1 35 must coincide with C1 in other words the first groove on the fan blade with the first groove on th...

Page 43: ...ement is white and has a mesh size of 30 0 58 mm For more information on the mesh size see the section on Technical specifications Pressure filters The pressure filters are located in the bumper besid...

Page 44: ...lowing section gives more details about the different pneumatic air kits available The letters HF640D means High Flow and Double respectively They have a polyethylene casing and turbines of 640 mm dia...

Page 45: ...idden to use the blower unit without the protective grid DANGER Do not approach the fan when in use DANGER Do not introduce foreign bodies through the grid regardless of whether the turbine is in use...

Page 46: ...um of 540 r p m The clutch is at the centre of the turbines which ensures smooth startup and stops see section Clutch for further information Clutch All blower types The clutch is integrated at the ce...

Page 47: ...e tractor s wheels do not touch the mistblower when turning This type of coupling allows narrow turns if a CV joint is fitted at the mist blower s power intake The length of the drawbar can be adjuste...

Page 48: ...rear spar of the boom centre allows the boom tubes to independently move out should the boom arm come in contact with an object Hydropneumatic spray system The hydropneumatic system is medium high pr...

Page 49: ...r the first time Although the metal parts of the mistblower have received a strong protective surface treatment a film of anti corrosion oil e g CASTROL RUSTILLO or SHELL ENSIS FLUID should be applied...

Page 50: ...wbar This is attached to the standard clevis type coupler closeto the tractor body Before connecting the PTO make sure that the drawbar is correctly attached and secured and that the tractor wheels do...

Page 51: ...B again 5 Repeat this operation with the other axle DANGER Do not remove the axle from the housing more than that allowed The correct position for the axle is when the axle is properly fastened with t...

Page 52: ...he shaft one to the tractor and the other to the mistblower crankshaft and measure out the length that needs to be removed Mark the protection guards ATTENTION The shafts must always have a minimum ov...

Page 53: ...oil check the level of hydraulic oil in the tractor and refill if required DANGER Testing the hydraulic system should be done with care Air may have entered the system and cause sudden movements DANG...

Page 54: ...er s seat The control box must be properly attached to prevent it from being hit or from excessive vibrations The connector type is universal and it should be able to be connected to any tractor Do no...

Page 55: ...4 Sprayer setup 55 Rate controller Rate controller DB 3610 Display DB 3610 Fluid Box FB 3610 Hydraulic box HB 3610 Power BOX out put out put The Job boxes for input and out put signals...

Page 56: ...placing the lid and replace it if it is damaged ATTENTION For better sealing between the lid and the o ring coat the area between the joint and the lid with grease This will make the O rings seal and...

Page 57: ...rd between 2 tree rows adjusted it visuallyto point towards the tree top Tight up adjustment bolts test with clean water And verify target is well sprayed Top S or L S is for the short version L the s...

Page 58: ...rayer setup 58 Adjustable bottom deflector Allows directing the air upwards avoiding air turbulence on the ground and stems as often used in e g plum orchards Adjust it between rows test with clean wa...

Page 59: ...vide adjust ability in the top of the deflector to secure direction of air and spray mist towards the target Loose the hand wheel position the adjustable part in visual direction to the target tighten...

Page 60: ...e required position has been chosen re tighten clamps to prevent any movement of the bar Note Both the inner and outer boom sections may be repositioned to suit user requirements Crop Height Adjust As...

Page 61: ...d nozzle shrouds are fluid supply lines and nozzle body assemblies Care should be taken not to damage any of these items when making adjustments to the boom tubes Nozzle Positioning The balland socket...

Page 62: ...may be used They can be bent and shortened A spacer C is also supplied to allow further attachment possibilities Find the best solution for your tractor or vehicle Tube B plate is staggered so that if...

Page 63: ...with another power connector it is necessary to disassemble the connector and fit it to the actual tractor connector The number and the type of connectors may vary on the specific sprayer depending o...

Page 64: ...4 Sprayer setup 64...

Page 65: ...65 5 Operation General info Environmental info For environmental info please refer to the following parts in the Mistblowing Technique book Spray quality Fan speed Spraying speed...

Page 66: ...neutral position DANGER If any unusual noise or excessive vibration in the air kit is detected then stop the equipment immediately and have it serviced by an authorised HARDI technician Selecting the...

Page 67: ...oy structure due to movements caused from lack of firm position See maintenance and starting up Adjustment of hydraulic fold Secure folding cylinder is correctly adjusted and eventually the stop posit...

Page 68: ...fan 3 With both hands on opposite blades turn them to the desired position between 1 and 4 All the blades should turn at the same time 4 Finally check that all the blades are in the correct position 5...

Page 69: ...drinking purposes treatment sumps and cesspools of drainage systems and 3 50 metres from surface water watercourses lakes and coastal waters and from nature reserves B Alternatively the sprayer can b...

Page 70: ...ne should be provided with a check valve as additional safety precaution Follow local legislation in force at any time ATTENTION The water supply should be provided with a meter to avoid spillage by o...

Page 71: ...ly separate from the main tank and should only be filled with clean water this does not mean that the water is suitable for drinking Drain valve The valve for safe draining is located on the underneat...

Page 72: ...way valve supplied with the equipment by using a quick fitting To load turn the pump on at 540 r p m and turn the 3 way valve lever towards the position indicated in the illustration SV operating unit...

Page 73: ...ressure regulation no adjustment is needed This photo illustrates a 2 section operating unit CB2 CB operating unit with bypass valve The operating unit is used in case of low dose rates as it is often...

Page 74: ...610 optional F0 Main Switch valves section F1 F3 F2 F4 Fluid sections Odd on left Even on right S1 S2 S3 S4 Hydraulic selectors P P PRESSURE Regulation STB ON OFF F3 F1 S1 F0 F2 F4 STB P P S4 S2 S3 F3...

Page 75: ...ON decr cent e Decrease a value D e the cur alue al scr ey a the hydraulic ement Max hydraulic System pressure L ha in r L ha programmed e REG KE e REG K e BLA e t d e State of automa egulator KE e K...

Page 76: ...witch from one number to the next one press or To end press tosa ethenew alue Finally press toreturntothemainscreen Tostartthesprayjob pressthebutton Thestateoftheautoma r torREG will eto The pressure...

Page 77: ...5 Operation 77...

Page 78: ...a washing location See Filling washing location requirements This must be an area not used for crop growing You must avoid seepage or runoff of residue into watercourses wells springs pools etc The f...

Page 79: ...em immediately 10 Replace all the filters and nozzles and store the mistblower If from previous experiences it is noted that the solvents in the pesticide are particularly aggressive store the sprayer...

Page 80: ...ing agent 12 Clean the whole system again 13 To get the best cleaning effect the Self Cleaning Filter and the Suction Filter sieves should be washed with clean water 14 Rinse the sprayer with clean wa...

Page 81: ...see Recommended lubricants below 2 Recommended intervals Shown in hours or with a symbol for occasional maintenance 3 Amount to be used Only shown if an amount is specified ATTENTION If the sprayer h...

Page 82: ...t Loosen the two nuts on the PTO protection in ends pumps and gear box Twist and pull back the protection Grease the yoke Put back both protections and tighten the nuts Driveshaft The universal joints...

Page 83: ...an make sure that the mesh is in good condition Otherwise the effectness of the filter will be nil Whenever dismantling any filter or hose pipe take care not to pinch the o rings fitted to them When r...

Page 84: ...pins and lower link balls The turnable drawbars must be greased as per every 100 hours through indicated grease nipples ATTENTION The turn stop welded to the ball prevents the equipment from performi...

Page 85: ...r of anti corrosion oil as described in the table reed out Suitable Lubricants Before storing as well clean the liquid circuit and mix in anti freeze liquid or as minimum sun flower oil of equivalent...

Page 86: ...the nozzles leak on closing the spray zone the non drip diaphragm should be replaced E The nozzles should be replaced when their unit flow varies more than 10 If not the damaged nozzle could cause dam...

Page 87: ...the level hole B See section Recommended lubricants for oil specification Capacity Approximately 1 25 litres A For Oil filling B Oil Level indicator Every 1000 working hours Fan clutch inspection Ever...

Page 88: ...te the male and female part of the shaft 6 Clean the profile tubes inside and outside thoroughly with a degreasing fluid Alt petrol white spirit or similar and wipe them dry 7 Inspect the cardan joint...

Page 89: ...e the PTO shaft out Pull the PTO apart in male and female parts Clean it well Grease it Grease Gearbox PTO tap and pump PTO tap Put back in the PTO shaft and bolt on the gear box tap Put back the pump...

Page 90: ...small piston activated by the solenoid opens up a small hole hereinafter the liquid pressure opens op the larger diaphragm B in the valve and allows the liquid to flow to the nozzles The pilot line ca...

Page 91: ...Therefore the motor keep turning unlimited It will burn the fuse Pull out the clip as illustrated lift gently up the gear motor replace the micro switch as illustrated in the picture showing the gear...

Page 92: ...up to overlap the last notch on valve body Screw on and lock up to beat the nut holding the handle while tightening WARNING To operate the gear motor unit 1 install 1 25A fuse on12Vdc line The mark on...

Page 93: ...entation to build up If it built up and drop of in uneven locations it creates unbalance in the air kit and destroys drive line and the air kit itself Rinse the fan blade and inner fan house wall and...

Page 94: ...g should be checked regularly When the tank is empty the float should lie on the stop pin of the rod and the O ring on the indicator should be positioned at the top position line A If any deviation is...

Page 95: ...r 6 7 The diaphragm 7 may then be changed 8 Check that the drain hole 8 at the bottom of the pump is not blocked 9 Apply a small amount of pump grease on the underside of the diaphragms between diaphr...

Page 96: ...he valve must be closed and the lever loose 3 Remove the U clip A and pull the connection part B Now the whole valve can be removed 4 Check the condition and wear of the cord and the valve C replace t...

Page 97: ...l it back 2 Remove the synthetic bearings and the protection guard 3 Remove the inner bush from the protection guard 4 Re assemble in the reverse order using new parts if necessary Remember to assembl...

Page 98: ...ny possible scratches or marks in the paint and touch up the paintwork 8 Remove the pressure gauge and store it a vertical position in a frost free location 9 Apply a thin layer of anti corrosion oil...

Page 99: ...ed by the pump may prevent the valves from closing correctly thus reducing the pump flow 6 A poor reassembly of the pump elements especially the diaphragm covers causes air leaks and reduces the pump...

Page 100: ...oduct is being used check that agitation is on Worn nozzles Check that the air flow does not exceed 10 Tank suction clogged Check the suction tube Air suction Reduce revolutions in the PTO Increase in...

Page 101: ...that hold the air kit are loose Tighten the nuts The clutch pads are broken or worn Change the pads and the clutch springs or replace the clutch for a new one Vibrations or noises in the gearbox The g...

Page 102: ...7 Fault finding 102...

Page 103: ...ed with ring drawbar Tare weight Model Measurements AxBxC cm Zaturn 2000 DUO T AG820 4300x2500x1500 Zaturn Plus 3000 Mercury 2300 SF65 4600x1900x1650 Mercury 4000 SF85 4850x2050x1900 Model Weight kg Z...

Page 104: ...ons Measurement A for sprayer fitted with ring drawbar Tare weight Model Measurements A x B x C cm Zaturn 2000 plus Covamax Zaturn 3000 Covamax 4800x3800x2600 Mercury 4000 Covamax Model Weight kg Zatu...

Page 105: ...its SI unit Imperial unit Factor Weight kg lb x 2 205 Surface area ha acres x 2 471 Length cm in x 0 394 m ft x 3 281 m yd x 1 094 km mile x 0 621 Speed km h mile h x 0 621 km h m s x 0 277 Volume Sur...

Page 106: ...8 Technical specifications 106 Specifications Pump Model 464 10 0 4 40 2 2 2 20...

Page 107: ...8 mm 50 mesh 0 30 mm 80 mesh 0 18 mm 100 mesh 0 15 mm Temperature and pressure range Working temperature range 2 40 C 36 F 104 F Pressure that activates the safety valve 20 bar in HLC Maximum pressure...

Page 108: ...hed the end of its useful working life it must be thoroughly cleaned The tank hoses and synthetic fittings can be incinerated in an authorised disposal depot The metal parts can be scrapped Always com...

Page 109: ...Disposal 21 Disposal of the sprayer 108 Drain valve 71 Drain valve maintenance 96 drawbar length adjustment 50 E Electrical System 28 Environmental Precautions 29 Protection 21 Equipment Personal Prot...

Page 110: ...ng tank and nozzles 79 Road Transport 26 S Safety Accident Prevention 24 Informal Measures 15 Information is Ignored 23 Normal Operation 17 Symbols 11 Safety info 69 Service and Maintenance Work 19 Se...

Page 111: ...U Unloading from the truck 49 W Washing location requirements 69 Wheel base adjustment 51 WORKING LIGHT CONNECTOR 63...

Page 112: ......

Page 113: ...113 Spare parts To see updated spare part information the website www agroparts com can be visited Here all parts information can be accessed when free registration has been made...

Page 114: ...HARDI Australia P L 534 538 Cross Keys Rd Cavan SA 5094 AUSTRALIA...

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