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6 - Maintenance

1. 11

Occasional Maintenance

The maintenance and replacement intervals for the following will depend very much on the conditions under
which the sprayer will be operated and are therefore impossible to specify.

The following items are subject to occasional maintenance and need to be check on a regular basis;

•

Tyre Changing

•

Pump Valves & Diaphragms replacement

•

Pressure Cone Check / Replacement

•

Flow Meter Inspection

•

Pressure Regulator checks

•

Section valve checks

•

Drain valve seal replacement

•

Drain valve cord replacement

•

Off Season storage

Tyre Changing

Should it be necessary to replace tyres, HARDI recommended to
leave this task to a specialist tyre fitting company and follow the
mentioned rules.

•

Never exceed the maximum mounting pressure molded on
the tyre!

•

After mounting tyres adjust inflation pressure to operation
pressure recommended by the tyre manufacturer.

•

Do not use tubes in tubeless tyres.

•

Refit wheel to trailer and torque wheel nuts to 330Nm (243
ft.lb) in the sequence shown below

Содержание Mercury Covamax series

Страница 1: ...MERCURY COVAMAX Operator Instruction Manual 67002404 100 HAU 08 2009 www hardi com au...

Страница 2: ...supply operational information and is to be read in conjunction with the Spray Technique book and any other manuals supplied with your sprayer Illustrations technical information and data in this boo...

Страница 3: ...Y DRIFT 1 MECHANICAL SAFETY 2 DISPOSAL OF CHEMICAL CONTAINERS 2 CHEMICAL SAFETY 3 Safety Equipment 3 Contaminated Clothing and Equipment 3 Australian Safety Standards 3 Chemical Information 3 SPRAYER...

Страница 4: ...in Product Pump 7 Manifold System 8 Filters 8 BoomZone Selection Valves 9 Operating Units 10 MC 2 Manual Operating Unit 10 CB 2 Electric Control Unit 10 EVC Operating Control Unit 11 HARDI CB 2 Switch...

Страница 5: ...ty 1 Transporting Mistblower 2 Truck transport 2 Connecting Mistblower to tractor 3 Adjusting drawbar length 3 Hitching Drawbar 4 Sprayer levelling with wide angle drawbar 5 Connecting Hydraulics 6 Br...

Страница 6: ...Unit Distribution Stack Outlet Spouts 5 Boom Operations 6 Lift 6 Individual Fold Manual Hydraulic Tilt 6 Electric over Hydraulic Tilt EOH 6 Filling of water 7 Filling the clean water tank 8 Cleaning 8...

Страница 7: ...3 O Ring and Filter lubrication 4 Gearbox lubrication 4 Pump Maintenance 4 Servicing 5 10 Hour Servicing 5 50 Hour Servicing 7 250 Hour Servicing 8 1000 Hour Servicing 9 Occasional Maintenance 10 Boo...

Страница 8: ...1 Sensors 4 Flow Sensor Inspection 4 Technical Specifications Section 8 Weights and Measures 1 Conversion factors Metric to Imperial units 2 Filter mesh specifications 2 Recommended Tyre Sizes Load R...

Страница 9: ...conditions 1 Risk Assessment Section 10 Entanglement 1 Cutting Stabbing Puncturing or Striking 1 Shearing 1 Crushing 2 Electrical 3 Explosion 3 Friction 3 Pressure 4 Slips Trips Falls 4 Ergonomics 5...

Страница 10: ...Table of Contents TOC 8...

Страница 11: ...1 Welcome 1 1 MERCURY COVAMAX Operator Instruction Manual 67002404 100 HAU 08 2009 HARDI Australia 534 538 Cross Keys Road Cavan South Australia 5094...

Страница 12: ...ections and warnings in this publication and all related material must be thoroughly read and understood before attempting to operate this equipment DANGER Failure to comply with the above may result...

Страница 13: ...result of spray drift Certain climatic conditions can increase the risk of spraydrift onto neighbouring crops Although calibration information is provided in the Mistblowing Techniques Manual it is v...

Страница 14: ...r local authorities before commencing operation WARNING When using an arc welder disconnect any power leads to the sprayer prior to welding and remove any flammable or explosive material from the area...

Страница 15: ...so be safely isolated and carefully washed and decontaminated Australian Safety Standards Protective clothing and equipment must conform to Australian Safety Standards and must always be used when han...

Страница 16: ...uct tank before leaving the field Do not attempt to drive this vehicle at high speeds with product in the tank Fill product tank once you have reached the area of operation WARNING Turn on the hazard...

Страница 17: ...rical components generate heat To avoid serious burns never touch internal components immediately after use DANGER Disassembly or attempted repairs if accomplished incorrectly can create electrical sh...

Страница 18: ...2 Safety 2 6...

Страница 19: ...boom design is a simple but sturdy construction utilising maintenance free no grease bushes for trouble free operation The boom is a perfect platform for supporting the COVAMAX air delivery system It...

Страница 20: ...Drawbar 4 Main Tank 5 Blower Fan 6 Tool Box Main Tank Lids 7 EC Control Valves 8 Tilt Cylinder If fitted 9 Upper Nozzle Spouts Outer Arm 10 Lower Nozzle Spouts Outer Arm 11 Fold Cylinder 12 Lift Cylin...

Страница 21: ...ocated at the rear of the machine Sprayer Details It is important to record details of your sprayer for future reference These details may help to identify your sprayer when requiring spare parts or r...

Страница 22: ...time also to fill out your warranty form and return it to HARDI Australia within fourteen days of delivery Road worthiness When driving on public roads and other areas where the highway code applies o...

Страница 23: ...ation and prevent chemical from becoming trapped in tight spots The main tank also features a fluid level indicator The Handwash tank has a nominal capacity of 15 litres and is situated at the front o...

Страница 24: ...the PTO make sure that the diameter and number of splines on the driveshaft is the same as that of the tractor s output shaft Make sure that the tractor s PTO output speed is matched to the speed of...

Страница 25: ...er min delivery rate Self priming Oil bath lubrication Cast alloy construction 363 Pump The Hardi 363 7 pump has a 6 splined 1 3 8 shaft for connection to the tractor PTO The normal operating revoluti...

Страница 26: ...pressure filters Suction Filter The suction filter captures impurities in the liquid system in order to protect the machines components It is located at the front of the sprayer in the lower left hand...

Страница 27: ...boom These filters are located directly in front of the fan and are connected immediately before the boomzone selection valves BoomZone Selection Valves Located immediately after the pressure filters...

Страница 28: ...pressure valve 1 and a pressure gauge 2 These are connected on to the end of the supply manifold and serve to regulate and read the system pressure With the use of two control handles connected to th...

Страница 29: ...the pressure Its constituent elements are Pressure Gauge Electro Valves for section control Electro Valve for pressure control Spray Box 2 pressure section ON OFF Pressure Equaliser Valves The power...

Страница 30: ...ontrols the system pressure allowing excess fluid to bypass back to the main tank Pressure Gauge The pressure gauge gives a visual indication of the system pressure and can easily be viewed from the t...

Страница 31: ...des user feedbackof spray applicationin addition to visual and audio alarms that notify the operator when conditions have changed HC 5500 Display Like the HC 2500 the HC 5500 display gives valuable fe...

Страница 32: ...nt and rear of the machine that is then divided and directed into the boom tubes by the distribution stack Warning Do not put hands or other objects near fan Fan operates at high speeds and can draw n...

Страница 33: ...CURY COVAMAX is a two speed gearbox This gearbox is mounted directly in front of the fan unit and controls fan speed between the PTO shaft and the blower by positioning the lever in one of three posit...

Страница 34: ...it from moving Carry out this operation with empty tanks Loosen the nuts and bolts on the axle housing Extend the half axle to the desired length without exceeding the maximum Tighten the nuts and bol...

Страница 35: ...r and life from the mistblower s wheels and to avoid punctures and unnecessary strain In areas of difficult access with many slopes or for working on tall crops always choose a wheel that guarantees s...

Страница 36: ...s time spent on trips for filling etc The suspension is ACTIVE when the machine is load free and it gets lower as the tank is filled When the tank of the mistblower reaches half full the suspension is...

Страница 37: ...hepowdermixing feature with thelidremovedaschemicalproductmay beforced from the basket and cause chemical contamination to surrounding areas or contact with operator Activate the powder mixer by turni...

Страница 38: ...itted to the MERCURY COVAMAX has numerous features that enable flexibility for operators when setting up and operating Some of the benefits are Lift Fold Tilt Breakaway Arms Adjustable nozzle position...

Страница 39: ...time Tilt The MERCURY COVAMAX has two options available for tilting of the boom Electric over Hydraulic EOH Manual Hydraulic Electric over Hydraulic EOH The electric tilt option allows independent til...

Страница 40: ...aroftheboomcentre allows the boom tubes to independently move out should the boom arm come in contact with an object Adjustable Nozzles Independent control The nozzle bodies fitted to the Covamax allo...

Страница 41: ...ur work area has lifting and safety equipment of a suitable load bearing capacity Always wear safety eye protection overalls safety boots and gloves where appropriate Keep animals and people away from...

Страница 42: ...k trailer make sure the trailer is of adequate size and properly placarded with safety signs should they be required Do not allow heavy objects to be loaded on top of the mistblower as this may cause...

Страница 43: ...sted The basic steps to follow are Support mistblower on jockey wheel Loosen bolts C where the drawbar passes through the chassis Remove nut bolt B Slide drawbar in or out of the frame to desired posi...

Страница 44: ...Wide Angle Drawbar connected to linkage arms Standard Drawbar The standard drawbar is hitched to the tractor and secured with a pivot pin Wide Angle Drawbar The wide angle drawbar is directly connecte...

Страница 45: ...ide angle drawbar By having the drawbar hitched to the tractors linkage arms it provides the ability to level the sprayer as shown below this will provide a better ride and more accurate readings when...

Страница 46: ...d to only four hoses two hoses control the boom lift function and two supply the EOH hydraulic manifold the EOH switchbox controls operate the independent boom fold and tilt operations through electro...

Страница 47: ...r s hydraulic braking system because they permit progressive braking before the wheels are blocked in the case of emergency Attention The tractor s proportional outlet should be adjusted to a maximum...

Страница 48: ...r Prevent protection guards from rotating by attaching the chains allowing sufficient slack for turns Make sure that protection guards around tractor P T O and implement shaft are intact Always STOP E...

Страница 49: ...rtened equally Use a saw and file the profiles afterwards to remove burrs Grease the profiles and assemble male and female parts again Fit the shaft to tractor P T O and sprayer pump shaft Fit the cha...

Страница 50: ...RY COVAMAX is working in the unfolded position a chain and brace is fitted to the wide angle drawbar to prevent the sprayer from tipping up when rearward weight conditions are present The brace is att...

Страница 51: ...yer for detailed information on connection and operation Electric over Hydraulic Tilt This optional extra allows the tilt and fold functions of the boom to be remotely controlled from the tractor cab...

Страница 52: ...h either the HC 2500 or the HC 5500 and allows for operator control of spray zone selection and remote pressure regulation HC2500 HC5500 Displays The HC 2500 and HC 5500 displays offer spray data to t...

Страница 53: ...been chosen retighten 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 with the adjustment it i...

Страница 54: ...andnozzleshroudsarefluidsupply lines and nozzle body assemblies Care should be taken not to damageanyoftheseitemswhenmakingadjustmentstotheboom tubes Nozzle Positioning The ball and socket joint desig...

Страница 55: ...n be considered in two parts Fluid Delivery Air Delivery Fluid Delivery Pump Operation Pump operation is controlled by the power take off connection at the tractor An input shaft on the pump transmits...

Страница 56: ...se the first section valve 1 by turning off at the switchbox When system pressure has stabilised adjust the first equalisation valve A until the original spraying pressure is restored then reopen the...

Страница 57: ...sure Filters Optional Operation of the suction filter is by turning the handle to point towards the desired fluid source Pressure filters are simple inline filters that do not require any opening or c...

Страница 58: ...are clashing Move the gearbox lever to the off neutral position and turn over the PTO when PTO has come to a stop attempt to engage gearbox again Blower Unit Distribution Stack Outlet Spouts The HF60...

Страница 59: ...ydraulic tilt is fitted then the fold function is made by connecting the four hydraulic fold hoses and four manual hydraulic tilt hoses to the double acting outlets on the tractor Fold and Tilt contro...

Страница 60: ...of the tank B at all times and only point it towards the inside If the hose were inside the tank and the pressure from the water supply point dropped the chemical products could be siphoned from the...

Страница 61: ...rea can be obtained from the Department of Primary Industries and the Environmental Protection Agency Cleaning Guidelines Read the whole chemical label Take note of any particular instructions regardi...

Страница 62: ...wder mixer lines Turn tap OFF after cycling for several minutes 6 Open the section control valves boom zone valves and outlet nozzle valves to allow clean water to spray through boom lines and nozzles...

Страница 63: ...tem surfaces are rendered neutral before spraying a new crop or changing chemicals Chemical labels contain important information regarding safety cleaning neutralising agents and decontamination proce...

Страница 64: ...Option 13 Distribution Valves EVC or CB 2 14 Pressure Filters 15 Boom Spray Zone Selector Valves 16 Left Boom Outer Nozzles 17 Left Boom Inner Nozzles 18 Right Boom Inner Nozzles 19 Right Boom Outer N...

Страница 65: ...Covamax Air Delivery System 1 Product Pump 2 Drive Shaft 3 Main Tank 4 Gearbox 5 Blower Fan 6 Distribution Stack 7 Left Boom Outer Nozzles 8 Left Boom Inner Nozzles 9 Right Boom Inner Nozzles 10 Righ...

Страница 66: ...en driven through the pump 8 and onto the manifolds as no taps are open the fluid will be bypassed to the main tank Agitation may be left on during this procedure External Fill Suction 1 Main Tank 5 A...

Страница 67: ...old When the agitation handle is opened the fluid flows through line 20 and is ejected through the agitators in the tank 5 Mercury Covamax Agitation 1 Main Tank 5 Agitators 6 Suction Filter 7 External...

Страница 68: ...lose tap when not in use DANGER Do not operate the powder mixing feature with the lid removed as chemical product may be forced from the basket and cause chemical contamination to surrounding areas or...

Страница 69: ...main tank via the bypass agitation line 21 Spray Distribution 1 Main Tank 5 Agitators 6 Suction Filter 8 Main Pump 9 Manual Pressure Relief 10 Manifold 11 Pressure Regulator 12 Flow Meter Option 13 D...

Страница 70: ...sure regulator 11 which allows electronic control of system pressure and a bypass agitation line 21 from the rear of the regulator which diverts excess fluid back to the main tank agitators Pressure R...

Страница 71: ...here appropriate Keep animals and people away from the service area at all times unless involved in the procedure Keep children away Position the sprayer on a suitable flat surface with enough room fo...

Страница 72: ...eral oil products for long periods Always follow the directions concerning recommended quantity If no recommended quantity is given feed the lubricator until new grease becomes visible Pictogram in lu...

Страница 73: ...10 working hours and the tubes and axles B every 20 hours Drawbar lubrication To avoid the wear and seizing up of the drawbar s rotating parts keep them greased at all times Both the ring drawbar and...

Страница 74: ...to maintain boom efficiency Fold Cylinder Pivots Tilt Cylinder Pivots Axle lubrication The hub is the part of the axle that must be greased Remove hub cap and grease the inside of the rotating head In...

Страница 75: ...on the fill point on top of the gearbox and extends to the boom centre frame where it has a capped fitting in an easily accessible area Pump Maintenance On HARDI363pumps grease thepump every50 working...

Страница 76: ...suction filter when servicing Extreme care should be taken to avoid contact or contamination from spray chemicals Please refer to chemical manufacturers safety advice when dealing with spray chemical...

Страница 77: ...boom may be equipped with optional In Line Filters when fitted should be serviced at 10 hourly intervals Unscrew the filter bowl to inspect and clean the filter When reassembling the O ring should be...

Страница 78: ...243 ft lb Tightening sequence See illustration and tighten in order of numbering Tyre Pressures 50 hour intervals Check the tyre pressures every 50 hours Only inflate to recommended pressure of tyre...

Страница 79: ...rvals WARNING If you do not feel totally confident changing wheel bearings contact your HARDI dealer s workshop Check for play in the wheel bearings Place stop wedges in front of and behind LH wheel a...

Страница 80: ...rythem Replace if worn or damaged Fill the hub and bearings with fresh grease Assemble the hub and bearings using a new sealing ring 7 Fit castle nut Rotate hub and tighten castle nut until a slight r...

Страница 81: ...Flow Meter Inspection Pressure Regulator checks Section valve checks Drain valve seal replacement Drain valve cord replacement Off Season storage Tyre Changing Should it be necessary to replace tyres...

Страница 82: ...3 Reinstall components and torque Valve Cover to 45 ft lb 60 Nm Diaphragms Remove the diaphragm bolt 4 Change the diaphragm 5 Reinstall components and torque Diaphragm Bolt to 45 ft lb 60 Nm Diaphragm...

Страница 83: ...litres per minute the valve cylinder C piston F and o ring D must be changed Remove the screws and lift the motor housing off the valve housing Undo the nut E and replace the valve cylinder C piston...

Страница 84: ...e cord is damaged or broken the cord can be replaced the following way Remove U Clip and remove Drain Valve Remove old cord and handle Attach new cord to handle Working from the top of the tank feed t...

Страница 85: ...e regardless of intervals stated When the sprayer is dry remove rust from possible scratches or damages in the paint and touch up the paint Remove the glycerine filled pressure gauges and store them f...

Страница 86: ...Lubricate boom grease nipples X X Lubricate boom pivots X X Retorque wheel nuts to 330Nm 243 ft lb X Lubricate wheel bearing caps X Lubricate product pump input shaft grease nipple HARDI 363 X Adjust...

Страница 87: ...17 Record maintenance activities on the following pages whenever it is performed This will help to record the servicing history of your trailer for future reference Maintenance Activity Record Date Se...

Страница 88: ...6 Maintenance 1 18 Maintenance Activity Record Date Service Performed...

Страница 89: ...ers are clean Check hoses for leaks and cracks paying particular attention to suction hoses Check gaskets and O ring seals are present and in good condition Check that the pressure gauge is in good wo...

Страница 90: ...tem Fault Possible cause Suggested action No spray from boom when turned on Air leak on suction line Check if suction filter O ring is sealing Check suction tube and fittings Check tightness of pump d...

Страница 91: ...eck tightness gaskets O rings of all fittings on suction side Excessive liquid agitation Reduce agitation Make sure that returns inside tank are present Use foam damping additive Liquid leaks from the...

Страница 92: ...7 Fault Finding 1 4...

Страница 93: ...3875Kg SIZE Overall Length 4 6m Max height during transport 3 8m Max height boom fully lifted 4 1m Max width Folded 2 6m Max width Unfolded 7 0m 3300L CONDITION MEASURE WEIGHT Weight on Drawbar Empty...

Страница 94: ...th Full Tank Load Per Tyre Max Speed Max Pressure PSI 2300 L 12 5 80 x 15 3 14 ply 3350Kg 1675Kg 30 Km h 33PSi 3300 L 12 5 80 x 15 3 14 ply 4195Kg 2097Kg 30 Km h 46 PSi 3800 L 400 60 x 15 5 14 ply 462...

Страница 95: ...8 Technical Specifications 8 3 50 mesh 0 30 mm BLUE 80 mesh 0 18 mm RED 100 mesh 0 15 mm YELLOW...

Страница 96: ...torque shown Threa d Size Nut Size across flats Torque Value Turns to Tighten After Finger Tightening In In Nm lb ft Flats Turns 3 8 1 2 8 6 2 1 3 7 16 9 16 12 9 2 1 3 1 2 5 8 16 12 2 1 3 9 16 11 16 2...

Страница 97: ...5 16 18 11 9 17 13 25 18 5 16 24 12 9 19 14 25 20 3 8 16 20 15 30 23 45 35 3 8 24 23 17 35 25 50 35 7 16 14 32 24 50 35 70 55 7 16 20 36 27 55 40 80 60 1 2 13 50 35 75 55 110 80 1 2 20 55 40 90 65 12...

Страница 98: ...posal of the sprayer When the equipment has completed its working life it must be thoroughly cleaned and de contaminated before disposal The tank hoses and synthetic fittings can be incinerated at an...

Страница 99: ...st and most innovative spray products to the Australian market In addition our spare parts and field support staff are working closely with our regional dealer network to provide you the best after sa...

Страница 100: ...8 Technical Specifications 8 8...

Страница 101: ...al or replacement of components The customer will be responsible for and bear the costs of Normal maintenance such as greasing maintenance of oil levels minor adjustments etc Decontamination and Trans...

Страница 102: ...ormed or warranty shall be void Parts requested must be returned prepaid within thirty 30 days for warranty settlement Warranty claims must be COMPLETELY filled out properly or will be returned DISCLA...

Страница 103: ...ate guards are in place and not allow anyone near the wheels underneath sprayerorinboomoperating zone when in motion C Plant parts of plant or work pieces disintegrating No D Work pieces being ejected...

Страница 104: ...ay gather speed during downhill turn manoeuvres so reduce speed accordingly Operator to make sure the sprayer is operated at a safe turning speed taking into consideration field conditions and terrain...

Страница 105: ...ections E Damaged electrical switches Yes Low voltage only Inspect and replace damaged leads switches or connections F Water near electrical equipment Yes operating near electrical equipment is danger...

Страница 106: ...ace will affect safety Use handrails provided Operator to perform risk assessment of task and conditions B Poor housekeeping e g spillage not cleared build up of waste Yes Operator to maintain a safe...

Страница 107: ...n climbing ladder with boom in transport position Operator should take care when using ladder RISK ITEM RISK ASSESSMENT CONTROL MEASURE A Can anyone be suffocated due to lack of oxygen or atmospheric...

Страница 108: ...sure suitability Check with chemical manufacturer before mixing chemicals D Dust No E Noise No F Vibration No G Radiation or Lasers No H Other factors not mentioned No RISK ITEM RISK ASSESSMENT CONTR...

Страница 109: ...uidelines and environmental protection authority requirements RISK ITEM RISK ASSESSMENT CONTROL MEASURE A Are there any abnormal situations misuse or fluctuations in operating conditions which you can...

Страница 110: ...ularly C What are the arrangements for access and egress to plant during operation for maintenance in an emergency Improper access and egress can create any of the above hazards Proper housekeeping an...

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