ZATURN Instruction book Version 1.0 GB

Transcription

1 ZATURN Instruction book Version 1.0 GB We congratulate you for choosing a HARDI plant protection product. The reliability and efficiency of this product depend upon your care. The first step is to carefully read and pay attention to this instruction book. It contains essential information for the efficient use and long life of this quality product. As this instruction book covers all versions of the ZATURN with different capacities, different pump models and all operating units, please pay attention to the paragraphs dealing with precisely your model. This book is to be read in conjunction with the Mistblowing Technique book. Illustrations, technical information and data in this book are to the best of our belief correct at the time of printing. As it is HARDI INTERNATIONAL A/S policy permanently to improve our products, we reserve the right to make changes in design, features, accessories, specifications and maintenance instructions at any time and without notice. HARDI INTERNATIONAL A/S is without any obligation in relation to implements purchased before or after such changes. HARDI INTERNATIONAL A/S cannot undertake any responsibility for possible omissions or inaccuracies in this publication, although everything possible has been done to make it complete and correct. As this instruction book covers more models and features or equipment, which are available in certain countries only, please pay attention to paragraphs dealing with precisely your model. Published and printed by HARDI INTERNATIONAL A/S

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3 Table of contents 1 - EC Declaration Declaration of Conformity Safety notes Operator safety General info Description General information...1 General view...1 Use of the mistblower...2 Roadworthiness...2 Identification plate...3 Chassis...3 Tank...3 Liquid system...4 General information...4 HLC circuit...4 Diaphragm pump...4 Valves...4 Diagram - EVC Suction filter...6 Safety valve...6 Pressure manifold...6 Suction and pressure dampener...6 Agitator...6 Operating unit...7 MC/2 operating unit...7 EVC/2 operating unit...7 Filters...7 Powder mixer...7 Air kit...8 Technical information...8 AG750 air kit...8 AG820 air kit...8 Aif flow for the AG750 and AG820 air kits...9 Protection grid...9 Gearbox...10 Fan...10 Equipment...11 Ring drawbar...11 Fork drawbar...11 Turnable drawbar...11 Wedges...11 Light kit...12 TOC. 1

4 Table of contents 4 - Mistblower set up General info...1 Unloading the mistblower from the lorry...1 Before starting up for the first time...1 Counterweights...1 Mechanical connections...2 Adjusting the lenght of the connection shaft...2 Jack...2 Fork drawbar...2 Ring drawbar...2 Turnable drawbar...2 Attaching the transmission shaft...3 Electrical connections...4 General info...4 EVC/2 operating unit...4 Liquid system...5 Suction filter...5 Pressure damper...5 Diaphragm pump Operating Air kit...1 Safety note...1 Speed selector...1 Adjusting the fan...1 Liquid system...2 Filling water in the tank...2 Filling through tank lid...2 Filling the rinse tank...2 Rinse nozzle...2 Filling the clean water tank...3 Emptying valve...3 Adjusting the EVC/2 operating unit...4 Adjusting the BK/2 operating unit...5 MC/2 operating unit...5 Cleaning...6 General information...6 Cleaning and maintenance of filters...6 Cleaning the tank and liquid system...7 TOC. 2

5 Table of contents 6 - Maintenance Lubrication...1 Technical information...1 Recommended lubricants...1 Lubrication and grease of the mistblower...1 Transmission shaft...2 Diaphragm pump...2 Filters and fittings...2 Fork, ring and turnable drawbar...3 Changing the oil of the gearbox...3 Frequency of services and maintenance checks...4 Technical information...4 Every 10 hours of operation - Spraying circuit...4 Every 50 hours of operation - Transmission shaft, chassis, air pressure and diaphragm pump...4 Every 100 hours of operation - Drawbar...4 Every 250 hours of operation - Wheels, hoses and gearbox...4 Every 1000 hours of operation - Complete service...4 Occasional maintenance...5 Every 10 hours of operation - Suction filter...5 Every 10 hours of operation - Pressure filters...5 Every 10 hours of operation - Nozzles...5 Replacing the 321 valves and diaphragms...6 Cone check/renewal for EVC operating unit...6 Cone check/renewal for EVC distribution valve...6 Replacing the 363 valves and diaphragms...7 Adjusting the 3-way valve...7 Off-season storage program...8 Preparing the sprayer for use after storage...8 Shield renewal on transmission shaft...9 Replacement of transmission shaft cross journals Fault finding Operating problems...1 General information...1 Liquid system...2 Air kit...3 Electrical problems...4 Emergency operating - Liquid system Technical specifications Dimensions and weights...1 Dimensions...1 Weight when empty...1 Conversion factors, SI to Imperial units...1 Specifications...2 Pump model 363/ Pump model 321/ Filters and nozzles...2 Temperature and pressure ranges...2 Materials and recycling...3 Disposal of the mistblower...3 Control box connections for the EVC/2 operating unit...4 TOC. 3

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7 1 - CE Declaration Declaration of Conformity Manufacturer: Importer: ILEMO HARDI S.A.U. Polígono El Segre, Lleida SPAIN declare that the following product; A. was manufactured in conformity with the provisions in the COUNCIL DIRECTIVE of 22 June 1998 on mutual approximation of the laws of Member States on the safety of machines (98/37/EEC) with special reference to Annex 1 of the Directive on essential health and safety requirements in relation to the construction and manufacture of machines. B. was manufactured in conformity with the provisions in other relevant COUNCIL DIRECTIVES. C. was manufactured in conformity with the current standards implementing harmonised standards in accordance with Article 5 (2) and other relevant standards. Lleida, Josep Maria Godia Technical Manager ILEMO HARDI S.A.U. 1. 1

8 1 - CE Declaration 1. 2

9 2 - Safety notes Operator safety This symbol means DANGER. Be very alert as your safety is involved! This symbol means WARNING. Be alert as your safety can be involved! This symbol means ATTENTION. This guides to better, easier and more safe operation of your sprayer! General info Note the following recommended precautions and safe operating practices. Read and understand this instruction book before using the equipment. It is equally important that other operators of this equipment read and understand this book. Local law may demand that the operator is certified to use spray equipment. Adhere to the law. Wear protective clothing. Rinse and wash equipment after use and before servicing. Never service or repair the equipment while it is operating. Always replace all safety devices or shields immediately after servicing. Do not eat, drink or smoke while spraying or working with contaminated equipment. Wash and change clothes after spraying. Wash tools if they have become contaminated. In case of poisoning, immediately seek medical advice. Remember to identify chemicals used. Keep children away from the equipment. If any portion of this instruction book remains unclear after reading it, contact your HARDI dealer for further explanation before using the equipment. Be carefull not to hit people or surroundings when manoeuvring the mistblower, especially when reversing. Slow down when driving in uneven terrain as the machine might be in risk of turning over. 2.1

10 2 - Safety notes Pressure test with clean water prior to filling with chemicals. Disconnect electrical power before servicing and depressurize equipment after use and before servicing. Do not attempt to enter the tank. Do not go under any part of the mistblower unless it is secured to avoid. The boom is secure when placed in the transport brackets. If an arc welder is used on the equipment or anything connected to the equipment, disconnect power leads before welding. Remove all inflammable or explosive material from the area. Never dismount the hose if the machine is in operation. Disconnect the cleaner and the water supply before the high pressure hose is dismounted. The External Cleaning Device should not be used if important parts of the equipment have been damaged, including safety devices, high pressure hoses, etc. UNDER ANY CONCEPT 540 r.p.m should surpass on the PTO due to the serious danger of explosion of the air kit. Always stop PTO before turning when carry out very closed turns although it has a wide angle transmission fitted. If doesn't make in this way it, the low radius turnings with PTO rotating can end up provoking the breaking of the PTO or of the crankshaft of the pump and it produces big vibrations in the gearbox, being able to even end up originating the breaking of the fan or the whole air kit. No persons are allowed in the operations area of the sprayer. Do not exceed the max. recommended r.p.m. 2.2

11 3 - Description General information General view Main tank 2. Front and side level indicator 3. Operating unit 4. Suction filter 5. Pump 6. Rinse tank 7. Clean water tank 8. Lid of main tank 9. Step 10. Hitch 3.1

12 3 - Description General view Main fan support 12. Fan housing 13. Air guide and grid 14. Main hubcap 15. Bumper 16. Cap of oil gear box 17. Air outlet 18. Spray line 19. Lower deflector 20. Position for light kit Use of the mist blower The HARDI mist blower is designed for applying chemical products used for crop protection. This equipment may only be used for this purpose. Use of this equipment for other purposes is not allowed. If there is no special law in your region which obliges the user to have a permit, it is recommended you are well-prepared for protecting crops in a correct way and for handling chemical products safely so as to avoid unnecessary risks to people and the environment while spraying takes place. Roadworthiness When driving on public highways and other places where the highway code is applicable, or in places where there are special rules and regulations as to what signs and lights are to be used on equipment, please equip your machinery following those regulations. TAKE NOTE! 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 existing local legislation. Contact your local authorities to find out the current maximum speed limits. 3.2

13 3 - Description Identification plates MARCA The identification plate, which is on the front right-hand side of the machine and riveted onto the chassis, indicates the make, model, serial number and date of manufacture. ILEMO - HARDI SAU Pol. Ind. El Segre Parcela Apartado Lleida (SPAIN) Tel Telefax MODELO Nº SERIE MES AÑO Nº HOMOLOGACION The serial number is also to be found embossed on the chassis, on the front of the beam right next to the identification plate. Chassis The monoblock cold-pressed metal chassis is highly rigid and resistant to what is required of it during everyday use and under extreme conditions. It is made entirely by the most advanced laser cutting and automated soldering processes. To protect it from corrosion, apply one layer of a special paint with a polyurethane bi-component on top of a highly adherent, bullet-cleaned base. Tank The main tank made of impact-proof, UV-resistant and chemical resistant polyethylene, has a purposeful design with no sharp corners for easy cleaning. Nominal contents 1000, 1500 or 2000 l. A large, easy to read tank contents indicator is placed on the front - right side and another one is placed on the left side. First one is visible from the tractor cabin. The filling hole is placed so it can be accessed from the left side. This ensures an easy access for the filling of sprays, cleaning of the tank, etc. The mistblower is equipped with a clean water tank incrusted on the main tank. It s possible to have a rinse tank according to the equipment. 3.3

14 3 - Description Liquid system General information All the suction system functions are operated via a 3-way valve. The pressure valve is also to be found in the pressure circuit. The low pressure circuit is called HLC (Hardi Liquid Circuit). HLC circuit The low pressure circuit is called HLC (Hardi Liquid Circuit). It can only be combined with those models having a diaphragm pump. The pressure manifold is made of plastic and delivers the flow to three different places. The section on the HLC Pressure Manifold indicates what each of the valves on the manifold is used for. This manifold is fitted with a safety valve (see section on Safety Valve ). The maximum pressure levels for this type of circuit are those allowed for diaphragm pumps. Diaphragm pump Pumps with a diaphragm: Models 321/10 (max. 20 bar) ord 363/7 (max. 20 bar) They are low pressure and robustly built. Use only grease for lubrication. The 363 model is fitted with six diaphragms, the 1303 has 3 and the 321 two. This type of pump is self-priming and works without oil or water for as long as necessary. Valves The suction valve is to be found above the pump and allows you to select the tank from which the pump is to extract water from, namely the main tank for spraying or the rinse tank for internal cleaning of the liquid circuit. The tank is selected by turning the handle of the valve towards the desired function. TAKE NOTE! If one of the handles is too tight - or too loose (= liquid loss) - the valve needs to be serviced. For more information, see section on Maintenance. 3.4

15 3 - Description Diagram EVC Pump 2. Suction Filter 3. Pressure Manifold 4. Operating Unit 5. Main tank 6. Powder Mixer 7. Rinsing tank 8. Rinsing Nozzle 9. Agitator 10. Nozzles 11. Pressure Filters 12. Three-way valve 13. Safety valve 14. Fan 3.5

16 3 - Description Suction filter The suction filter is to be found underneath the three-way suction valve. Safety valve The pressure manifold is situated inside the HLC circuit. The maximum pressure allowed by this valve depends on the circuit. The maximum amounts are shown in the diagram. MAX. 20 bar HLC circuit Return to tank Pressure manifold It is made of plastic and is situated at the front of the machine next to the operating unit. From this manifold it is possible to activate the agitator and the shower for internal cleaning, if it is fitted with one.os. Suction and pressure dampener In the suction circuit of the 321 pump there is a dampener loaded with air. Its function is to cushion the blows the liquid circuit receives from the connecting rods when the pump is in use. The pressure circuit is fitted with a dampener that carries out the same function. Agitator At the front and on each side of the inside of the tank there are two trumpet-shaped agitators. These two agitators become activated by means of one of the valves inside the pressure manifold. On each side of the inside of the tank there is a nozzle (D), each being 3 mm in diameter. D 3.6

17 3 - Description Operating unit The mist blower can be equipped with various operating units: namely the models MC/2, SV/2, EVC/2 (low pressure). MC/2 Operating unit It is made up of two valves or taps which open and close the distribution sectors. The opening and closing is carried out from the tractor by means of two levers which are connected to the valves via two stiff cables. EVC/2 Operating unit An electric operating unit fitted with a control box for you to be able to operate all the spraying functions from the tractor. The advantage of this system is that there is no pressure hose near the user, thus avoiding the risk of contamination to him. This operating unit is fitted with pressure compensation valves. Filters The pressure filters are to be found on the bumper next to the air outlet nozzle. In the HLC circuit the filters are made of plastic and in the HPC circuit they are made of brass. All filters should be in perfect condition and be cleaned regularly. Make sure you correctly combine the filter with the mesh size. The mesh size should always be less than the average of the total flow from the nozzles. Powder mixer Its only function is to rinse the filter on the main tank s filling device when adding powdered products that do not dissolve properly and would otherwise form lumps on contact with the water in the tank. After using the powder mixer it must be disconnected, as it uses a large amount of available flow. 3.7

18 3 - Description Air kit Technical information The air kits fitted on the HARDI ZATURN mist blowers are the AG750 and the AG820, both having a polyethylene nozzle and a fan with blades made of a hardened synthetic material. Their aerodynamic shape offers a high quantity and perfect distribution of air, low noise levels and low power consumption when adjusted at standard levels. The fan clutch enables it to start up and stop smoothly. AG750 air kit The AG750 air kit is fitted with a grid with 6 air guides for the suction of air, which put it on course before it reaches the fan, thus decreasing the imbalance in the airflow. The fan is 750mm in diameter and is fitted with blades made of a hardened synthetic material. This means minimum power consumption due to the lightness of the materials used. AG820 air kit The AG820 air kit is fitted with a grid with 9 air guides for the suction of air, which put it on course before it reaches the fan, thus decreasing the imbalance in the airflow. The fan is 820mm in diameter and is fitted with blades made of a hardened synthetic material. This means minimum power consumption due to the lightness of the materials used. Between the suction nozzle and the cone in the air kit there is a channel which increases the speed of the air through the outlet and at the same time improves greatly the uniformity of the distribution of the outflow. UNDER NO CIRCUMSTANCES should the tractor P.T.O. exceed 540 r.p.m. as there is a grave risk the air kit may explode. KEEP AWAY from the air inlets and outlets while the fan is on. Some objects may be shot out of the air outlet or a piece of clothing could be sucked into the air inlet. The air kit is the most dangerous part of the machine. Do not try to change any of the parts without consulting your nearest dealer beforehand. Handling air kits in order to change their characteristics should be carried out by qualified people. 3.8

19 3 - Description Aif flow for the AG750 and AG820 air kits Air kit Speed Relation Inclination Power Flow AG750 1st speed º 4 kw m3/h 40º 6 kw m3/h 45º 10 kw m3/h 2nd speed º 6 kw m3/h 40º 10 kw m3/h 45º 18 kw m3/h Air kit Speed Relation Inclination Power Flow AG820 1st speed º 15 kw m3/h 40º 26 kw m3/h 45º 33 kw m3/h 2nd speed º 26 kw m3/h 40º 33 kw m3/h 45º 44 kw m3/h AG750 at 540 r.p.m. AG820 at 540 r.p.m. Cubic meters per hour º Standard 40º 45º Cubic meters per hour º Standard 40º 45º 1st speed 2nd speed 15 kw 26 kw 26 kw 33 kw 33 kw 44 kw Blade angle and power consumption 1st speed 2nd speed 15 kw 26 kw 26 kw 33 kw 33 kw 44 kw Blade angle and power consumption Protection grid The AG750 and AG820 air kits are fitted with protection grids. They are fundamental for avoiding accidents and for stopping foreign bodies from getting inside the air kit. Tractor drivers seat is the intended working place during operation. Air outlet Air inlet Never use the air kit without its protection grid. Do not go near the fan when it is on. Never put foreign bodies inside the fan via the grid, regardless of whether it is on or off. When working, protect your ears from the noise the fan makes by wearing EN 352-1:1992 homologated earmuffs. If you were to notice vibrations or bangs, switch off the fan immediately. 3.9

20 3 - Description Gearbox The AG750 air kit is fitted with a gear box which has two gears and neutral. The lower part of the gear box is attached to the chassis by four screws. The speed ratio is the following: 1st speed, low gear: nd speed, high gear: The AG820 is fitted with a gear box which has two gears and neutral. The front and lower area of the gear box are attached to the chassis. It is fitted with a speed selection system that stops it from coming out of gear whilst in use or going along a road. The speed ratio is the following: 1st speed, low gear: nd speed, high gear: Fan The axial fan has a sintetic type of wings very resistant to the impacts, high and low temperatures and chemical products. The fan on the AG750 air kit has mounted 6 wings and the AG820 air kit has mounted 8 wings. It s possible to change the position of the wings in 4 different angles. to improve the air flow. To change the angle see the section Adjusting the fan. (page 5.1). 3.10

21 3 - Description Equipment Ring drawbar Its hook-up point is near the tractor s framework. Before switching on the tractor PTO (Power take-off ), make sure the connecting shaft is firmly in place and the tractor s wheels do not touch the mist blower as they go round. There needs to be a CV joint on the side of the tractor. The length of the connecting shaft can be adjusted (see section Adjusting the length of the connecting shaft). Fork drawbar Its hook-up point is on the transversal boom with holes in it that is on the tractor s hydraulic arms. Before switching on the tractor PTO make sure the connecting shaft is firmly in place and the tractor s wheels do not touch the mist blower as they go round. There does not need to be a CV joint. The length of the connecting shaft can be adjusted (see section Adjusting the length of the connecting shaft). Turnable drawbar This hooks onto the tractor s hydraulic arms. Before switching the tractor PTO on, make sure the diameter of the shaft coincides with the diameter of the hole on the balls of the hydraulic arms. Also make sure to put the safety bolts on and check the tractor s wheels do not touch the mist blower as they go round. This type of coupling enables you to turn in a smaller space, but there needs to be a CV joint on the side of the mist blower. The length of the connecting shaft can be adjusted (see section Adjusting the length of the connecting shaft).. Always stop PTO before turning when carry out very closed turns although it has a wide angle transmission fitted. If doesn't make in this way it, the low radius turnings with PTO rotating can end up provoking the breaking of the PTO or of the crankshaft of the pump and it produces big vibrations in the gearbox, being able to even end up originating the breaking of the fan or the whole air kit. Wedges They are made of galvanised metal and are to be found on the lefthand side of the machine. They should always be carried in their support so as to be able to get at them quickly if parked on uneven ground. 3.11

22 3 - Description Light kit The set of lights can be fitted onto the robust bumper of the air kit. They are connected via a universal plug adaptable to any make and model of tractor. Lights must be used when going along the public highway, both within and outside urban areas. If any of the components should break, they should be replaced immediately. In order for the device to work, connect the plug to the base of the tractor adapted for this purpose. 3.12

23 4 - Mistblower set up General information Unloading the mist blower from the lorry When unloading the mist blower from a lorry by using a lever and pulley or a crane, use the suspension points shown on the diagram and make sure the straps used are strong enough. Nobody must stand below or in the immediate vicinity of the machine during loading or unloading. Before starting up for the first time Although the surface of the metallic parts of the mist blower have been treated with a strong, protective product, we recommend you apply to all the metallic parts a layer of anti-corrosion oil (e.g. CASTROL RUSTILLO or SHELL ENSIS FLUID) so as to avoid chemical products discolouring the enamel, as well as helping future cleaning. This treatment should be carried out whenever the protective layer wears off. Counterweights Check if it is necessary to place a counterweight on the front of the tractor to which the machine is to be attached, to avoid excessive rocking or an accident occurring. 4.1

24 4 - Mistblower set up Mechanical connections Adjusting the length of the connecting shaft 1. Put the jack in the position indicated in the photo. 2. Loosen the three screws A situated where the connecting shaft fits into the chassis. 3. Take out screw B. 4. Put the connecting shaft into the required position. 5. Put screw B back into place, making sure it passes through the holes in both the chassis and the shaft. 6. Tighten up screws A. Jack The jack enables the mist blower to be hooked up to and unhooked from the tractor. When the mist blower is hooked up to the tractor it will be in position 1. It should then be unhooked from the tractor and put into position 2. In both these positions, the jack is fixed to the chassis of the mist blower by way of two bolts. The height of the machine can be regulated by turning handle (C). C Fork drawbar The hitch point is located on the cross boom mounted on the tractor linkage. Before connecting the PTO make sure that the coupling is well attached and that the tractor s wheels do not touch the mistblower when turning. A transmission shaft with CV joint is not necessary. It is possible to adjust the lenght of the drawbar. Ring drawbar Its coupling point is close to the body of the tractor. Before connecting the PTO make sure that the coupling bar is well attached and that the tractor s wheels do not touch the mistblower when turning. A transmission shaft with CV joint is needed on the tractor s side. It s possible to adjust the length of the drawbar. Turnable drawbar It s coupled to the tractor s linkage. Before connecting the PTO make sure that the diameter of the axle is the same as that of the socket on the tractor s hydraulics, that the snap locks are in the place and check that the tractor s wheels do not touch the mistblower when turning. Of the three hitch types this is the one that permits the greatest turning angles, but a transmission shaft with CV joint s needed on the mistblower side. The length of the drawbar is adjustable. 4.2

25 4 - Mistblower set up Attaching the transmission shaft Putting the transmission shaft on for the first time may mean you will have to cut it to adapt it to the type of tractor it is going to be attached to. In order to carry this out follow the steps set out below. 1. Attach the mist blower to the tractor so that the tractor s PTO and the mist blower s pump are as near each other as possible. 2. Turn off the engine and take out the ignition key. 3. If the transmission shaft has to be cut, dismantle both parts of the shaft. Place one part of the shaft onto the tractor and the other onto the mist blower and measure the length that it has to be cut. Mark the protection grids. The shafts must always overlap at least 1/3 of their length. 4. Both parts must be cut to the same size. Use a saw and then file the pipes down afterwards. 5. Grease the pipes and join the male and female pipe ends once more. 6. Fit the tractor s shaft to the mist blower s pump. 7. Place the female pipe end towards the tractor. Put the chains on so that the protection grids do not turn with the shaft. In order to ensure that the transmission shaft will last for many years, avoid working at angles above 15º. 4.3

26 4 - Mistblower set up Electrical connections General info Power requirement is 12V DC. Note polarity! The wires must have a cross sectional area of at least 4.0 mm to ensure a sufficient power supply. For the operating unit the tractor circuit should have an 8 Amp fuse. The delivered power connector follows the standard of most newer tractors. If having a tractor with another power connector it is necessary to disassemble connector and fit it to the actual tractor connector. Red cable = 12V (+ positive) Black cable = (- negative) EVC/2 operating unit Find a place in the tractor s cab where it is possible to put a control box so that you can work it in as comfortable a way as possible. The most recommended place is to the right of the driver s seat. ON ON A B B C The control box should be firmly attached to avoid bangs or excessive vibration. HARDI 1 2 The type of connector is universal and you should be able to plug it into any tractor. As an emergency solution you can take out the connecting lead and connect the cables directly to the battery. Always remember: red cable (+), black cable (-). 4.4

27 4 - Mistblower set up Circuito de líquido Suction filter The size of the standard filter is 50 mesh. 80 and 100 mesh filter are available and it s posssible to substitute it opening the bottom cover of the filter. Check the O-ring before to re-assembly the cover and change it if necessary. To improve the airtightness between the cover and the O-ring, put grease on the area where the cover encase with the O-ring. Every little leakage or air suction will be retrieved. Pressure damper The air pressure damper (bomba 321) is adjusted from factory at 2 bar to help spraying pressures from 3 at 15 bar. When spraying at different pressures that the anteriors, you must change the pressure on the dumper. Follow the list to adjust it to the correct pressure. This table is also engraved on the dumper. Spraying pressure Air pressure Bar Bar Diaphragm pump Before starting to use the machine, make sure the diaphragm pump is perfectly greased; otherwise this could cause serious damage. These pumps are perfectly greased in the factory, but for safety reasons, we recommend you add as much grease as is needed by means of a hand pump until it comes out of the crankshaft gasket or the hole on the lower part of the casing. 4.5

28 4 - Mistblower set up 4.6

29 5 - Operation Air kit Safety note Fan mustn t be rotating during the road trip on public areas. Neither open the spraying nozzles on public areas. Any error could provokes damages to the people, animals or crops. In case you need to drive with the PTO engaged (agitation) during the trip on public roads, sure that speed selector is in neutral position. In the case of any vibration or high noise on the air kit, stop the PTO immediately and call your HARDI service to check the mistblower. Speed selector immediately It s possible to select the 1st or 2nd speed on the gearbox through the selector lever adapted for it. On the back left side of the mistblower between the main tank and the air kit there s a hole to access to the selector lever. To change the speed will be necessary to throw toward it was and later to move up or below as it is required. Fix the lever in the encase of the selector plate. Down: 1st speed Up: 2nd speed Central: Fan won t rotate. Adjusting the fan The angle of the fan blades can be adjusted to 4 positions. It is normally in position 3 to start off with (40º). Decreasing the angle of the blades (minimum angle, pos. 1 (30º)), lessens the airflow and decreases power consumption. Increasing the angle (maximum angle, pos. 4 (45º)), it is possible to increase the flow but also power consumption. In this way the mist blower can be adapted to the different spraying treatments needed as well as the power of the tractor. To change the position of the angle of the fan blades you should follow these steps:: 1. Loosen the Allen screws without taking them out completely. 2. Loosen the Allen screws whilst holding the nut at the back of the fan. 3. With both hands on opposite blades, turn them to the position wanted 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. Tighten all the screws

30 5 - Operation Liquid system Filling water in the tank 3/3 Tank should normally be filled 1/3 with water before adding chemicals. Always follow instructions given on the chemical container! 2/3 WARNING! If the sprayer is put aside with liquid in the main tank all MANIFOLD valves must be closed. 1/3 0 ZATURN HARDI Filling through tank lid Water is filled into the tank by removing the tank lid located at front of sprayer tank which is accessible from platform. It is recommended to use as clean water as possible for spraying purposes. Always fill water through the strainer basket to prevent foreign particles from entering the tank. An overhead tank can be used in order to obtain high filling capacity. ZATURN HARDI Do not put the water hose right into the tank. Keep it outside and simply aim inside. If the hose were to get inside the tank and the pressure from the water supply were to be reduced, the chemi- cal products could siphon from the tank to the water source and contaminate the water there.warning! Do not let the filling hose enter the tank. Keep it outside the tank, pointing towards the filling hole. If the hose is lead into the tank and the water pressure drops at the water supply plant, chemicals may be syphoned back and contaminate the water supply lines, plant and well. Filling the rinse tank The rinse tank is situated on the back of the machine and hidden beneath the main tank. Take off the lid of this tank and fill it with clean water. After that, replace the lid. Capacity: 130 litres in 2,000-litre tanks and 90 litres in 1,000- and 1,500- litre tanks. The diagram shows where the rinse tank is situated. Only fill it with clean water. To avoid the formation of algae, rinse the liquid circuit with clean water if the machine is not to be used for a long time. Rinse nozzle This is to be found inside the main tank. When the water flow arrives at the nozzle at pressure, it makes it turn at high speed and the clean water comes out at pressure in all directions. If the machine is fitted with a rinsing system, there is a rinse nozzle inside the 1,000-litre tanks, and inside the 1,500- and 2,000-litre tanks there are two. 5.2

31 5 - Operation Filling the clean water tank It is on the upper part on the main tank and it is incrusted on it. It is used to clean the hands, the gloves, the nozzles, etc. after to get in contact with the chemicals. WARNING! Althougth this is a clean water tank, this water is not capable to drink. Emptying valve The valve for safe emptying is to be found below the tank. To get to it crouch down to the left of the machine, just where the jack is attached to the chassis when the machine is hooked up to the tractor. To empty the tank, you should push the handle towards the valve. To fill the tank up again, pull the handle towards the front of the machine and it will close again. OPEN WARNING! Be careful when you open the valve that the liquid does not spill out over your hand or feet. CLOSE 5.3

32 5 - Operation Adjusting the EVC/2 operating unit Before spraying, the EVC operating unit is adjusted using clean water (without chemicals). Adjust the pressure: 1. Choose the correct nozzle turning the nozzle holder if the mistblower is equipped with the double jet nozzle holder. See the Mistblowing technique book. 2. Switch ON/OFF (A) has to be on the lower position. 3. Both section switches (B) have to be on the lower position.put the pressure to the minimum with the pressure switch (C). 5. Put the tractor in neutral and adjust the P.T.O. and thereby the number of revolutions of the pump corresponding to the intended travelling speed. 6. Pressure regulation switch is activated until the required pressure is shown on the pressure gauge. Adjustment of pressure equalization 1- Open the section valves throug the control box. 2- Put the pressure at 10 bar for example. 3- Close one of the section valves. 4- With it adjusting screw (D) adjust the pressure to 10 bar again. 5- OPen again the section valve and close the another one. 6- Test opening the sections individually to see that the operating unit has been adjusted correctly. D ON ON A B B C 1 2 HARDI ATTENTION! HEREAFTER ADJUSTMENT OF PRESSURE EQUALISATION WILL ONLY BE NEEDED WHEN: 1. YOU CHANGE TO NOZZLES WITH OTHER CAPACITIES 2. THE NOZZLE OUTPUT INCREASES AS THE NOZZLES WEAR 5.4

33 5 - Operation Adjusting the BK/2 Operating Unit A manual low-pressure operating unit that can be fitted together with the diaphragm pumps. By turning two lever taps, the right- and left-hand sectors of the spray line open and close. Using a mechanical remote ON/OFF control, the flow is let through to or shut off from the nozzles and consequently the return valve is opened or closed. To start operation, you must increase the pressure using the red handle in the centre of the operating unit next to the pressure gauge. Turn clockwise to increase pressure or anti-clockwise to decrease it. Check the pressure gauge to see when it is at the correct pressure level. It is of utmost importance for the operating unit to be well adjusted. For this reason, before using the equipment for the first time, it is necessary to adjust the section valves. During this procedure, the individual return capacity of each sector is regulated, so that it returns the same amount of liquid as is expelled through all its nozzles when open. This avoids variations in pressure when one or both sectors are shut off. The regulation procedure is the following: 1- Open both sectors via the electrical control box. 2- Put the pressure level at, for example, 3 bar. 3- Close one of the sectors. 4- With the section valve of the closed sector, adjust the pressure until the pressure gauge indicates 3 bar. 5- Open the sector again and repeat the operation with the other sector. 6- Carry out a test by opening both sectors at the same time or one by one. If the operating unit is perfectly adjusted the pressure always ought to be the same. It is recommendable to carry out this adjustment at as near a pressure as that at which the machine is going to operate. Carry out this adjustment every so often as somebody may accidentally change the position of the pressure equalisation valve MC/2 Operating Unit A manual high-pressure operating unit that can be fitted together with the piston pumas or diaphragm pumps. It is a pressure valve that is fitted with a pressure gauge. To Increase pressure you should turn the black handle clockwise or anti-clockwise to decrease it. By means of two levers, from the tractor it is possible to select the direction to send the flow in at pressure. Each lever opens one of the sectors. It is possible to operate with one sector open, both, or neither. 5.5

34 5 - Operation Cleaning General information In order to derive full benefit from the mistblower for many years the following service and maintenance program should be followed. ATTENTION! Always read the individual paragraphs. Read instructions for service/maintenance jobs carefully before starting on the job. If any portion remains unclear or requires facilities which are not available, then for safety reasons please leave the job to your HARDI dealer s workshop. ATTENTION! Clean mistblowers are safe mistblowers. Clean mistblowers are ready for action. Clean mistblowers cannot be damaged by pesticides and their solvents. Guidelines 1. Read the whole chemical label. Take note of any particular instructions regarding recommended protective clothing, deactivating agents, etc. Read the detergent and deactivating agent labels. If cleaning procedures are given, follow them closely. 2. Be familiar with local legislation regarding disposal of pesticides washings, mandatory decontamination methods, etc. Contact the appropriate department, e.g. Dept. of Agriculture. 3. Pesticide washings can usually be sprayed out on a soakaway. This is an area of ground that is not used for cropping. You must avoid seepage or runoff of residue into streams, water courses, ditches, wells, springs, etc. The washings from the cleaning area must not enter sewers. Drainage must lead to an approved soakaway. 4. Cleaning starts with the calibration, as a well calibrated mistblower will ensure the minimal amount of remaining spray liquid. 5. It is good practice to clean the mistblower immediately after use and thereby rendering the mistblower safe and ready for the next pesticide application. This also prolongs the life of the components. 6. It is sometimes necessary to leave spray liquid in the tank for short periods, e.g. overnight, or until the weather becomes suitable for spraying again. Unauthorised persons and animals must not have access to the sprayer under these circumstances. 7. If the product applied is corrosive, it is recommended to coat all metal parts of the mistblower before and after use with a suitable rust inhibitor. Cleaning and maintenance of filters Clean filters ensure: MIstblower components such as valves, diaphragms and operating unit are not hindered or damaged during operation. Nozzle blockages do not occur whilst spraying. Long life of the pump. A blocked suction filter will result in pump cavitation. The main filter protecting sprayer components is the suction filter. Check it regularly. 5.6

35 5 - Operation Cleaning the tank and liquid system The incorporated rinsing tank is used as follows. 1. Empty the mistblower until the tank has around 50 litres. Close the agitation valve (no agitation) and spray the liquid through the nozzles. 2. Turn the suction 3-way valve towards Rinsing tank and open the rinsing nozzle to rinse the tank. 3. Engage the PTO and put it at 300 r.p.m. 4. When 1/3 of content in rinsing tank are used, turn Suction SmartValve towards Main tank and operate all valves on the pressure side of the system in the following order, so all hoses and components are rinsed: powder mixer, agitation, etc. 5. Turn the suction valve towards Main tank and spray liquid through the nozzles. 6. When 1/3 of content in rinsing tank are used, close the valve for the rinsing nozzle. 7. Spray the liquid in the field. 8. Disengage pump again. ATTENTION! The rinsing nozzles cannot always guarantee a 100% cleaning of the tank. Always clean manually with a brush afterwards, especially if crops sensitive to the chemical just sprayed are going to be sprayed afterwards! ATTENTION! It is advisable to increase the forward speed (double if possible) and reduce the pressure to 1.5 bar (20 psi) when spraying diluted remaining liquid in the field just sprayed. ATTENTION! If a cleaning procedure is given on the chemical label, follow it closely. ATTENTION! If the sprayer is cleaned with a high pressure cleaner lubrication of the entire machine is recommended. 5.7

36 5 - Operation 5.8

37 6 - Maintenance Lubrication Technical information Always store lubricants clean, dry and cool - preferably at a constant temperature - to avoid contamination from dirt and condensed water. Keep oil filling jugs, hoppers and grease guns clean, and clean the lubricating points thoroughly before lubricating. Avoid skin contact with oil products for longer periods. Always follow the shown direction concerning recommended quantity. If no recommended quantity is given, feed lubricator till new grease becomes visible. Pictograms in lubrication & oiling plans tell the following: 1. Lubricant to be used (see Recommended lubricants ). 2. Operating hours before next lubrication. ATTENTION! If the sprayer is cleaned with a high pressure cleaner lubrication of the entire machine is recommended. Recommended lubricants BALL BEARINGS: Universal Lithium Grease, NLGI No. 2 SHELL RETINAX EP2 Grease CASTROL LMX LUBRICATION WITH OIL: SAE 30W SAE 20W/50 ROLL BEARINGS: Lithium Grease with Molybedenum disulphate or graphite lubricant SHELL RETINAX HDM2 CASTROL MOLYMAX LUBRICATION WITH OIL: TOTAL Transmission TM SAE 80W/90 Castrol EPX 80W/90 SHELL Spirax 80W/90 Mobil Mobilube 80W/90 Lubrication and grease of the mistblower A- 50 A- 50 C-250 B-100 B-50 A-10 B-100 B-250 B

38 6 - Maintenance Transmission shaft The universal joints and bearings should be lubricated with grease. At the points shown (A), you should do it after every 10 hours of operation and the tubes and axles (B) after every 50 hours. A A A A B A A B Diaphragm Pump Grease the pump after every 50 hours of operation or once a month via the grease gun found in the crankshaft. The grease goes along some internal channels in the crankshaft to the ball bearings, connecting rods, etc. On both the 321 and 363 pump models, greasing is done in the same way. A lack of grease in the pump could cause it to overheat and all its inner mobile parts could break. Filters and fittings Check the filters after every 50 hours of operation. As well as checking that they are clean, make sure the mesh is in perfect condition. If it is not, the filter will not be effective at all. Whenever you dismantle a filter or hose, be careful not to twist the sealings it is fitted with. When you put the fittings back in place, cover the sealing with oil or grease so that it fits easily into its slot. Not having filters in good condition leads to numerous unwanted stops during a working day and worktime is unnecessarity lengthened. Whenever you dismantle a fitting to check the condition of the sealing or for any other reason, remember to lubricate the sealing with oil or grease to avoid it from being twisted and breaking when putting the fitting back in place. A lack of grease in the pump could cause it to overheat and all its inner mobile parts could break. 6.2

39 6 - Maintenance Fork drawbar It is fitted with a grease gun in its upper area. To avoid wear and tear and stiffness of the giratory parts it is necessary to always keep them lubricated. Another of the parts that should be lubricated is the revolving part that holds the fork hitch in place. Ring drawbar It is fitted with a grease gun in its upper area. To avoid wear and tear and stiffness of the giratory parts it is necessary to always keep them lubricated. Another of the parts that should be lubricated is the revolving part that holds the ring hitch in place. Turnable drawbar It is fitted with a grease gun in its upper area. To avoid wear and tear and stiffness of the giratory parts it is necessary to always keep them lubricated. In the revolving axlet there is a second grease gun to enhance turning. Another of the parts that should be lubricated is the revolving part that holds the hitch arms in place. The stop welded onto the turnable drawbar stops it from turning when the machine risks being broken in some way or form. In any case, this stop does not guarantee that, if the user makes the machine turn sharply, thus forcing the safety stop, the machine will be completely safe from any breakage. Always switch off the tractor PTO when making sharp turns even though it has a CV transmission. The low radius turns with the PTO on can cause the crankshaft in the pump to break and it could create a lot of vibration in the gear box, which could even result in the fan or the air kit breaking. Changing the oil of the gear box The gear box situated in the air kit is one of the mechanical elements which works the most. During the spraying season, you should check from time to time the level of oil in the gear box and change it after the number of hours recommended (see Maintenance section). Replace the oil after the first 150 hours of operation. The following oil changes should be carried out after every 250 hours or once a year. Level indicator AG750-1,3 l. AG820-1,25 l. SAE

40 6 - Maintenance Frequency of services and maintenance checks Technical Information Maintaining and the frequency of replacing the elements mentioned below will depend greatly on the conditions in which the mist blower is used, and, as a result, these are impossible to assess. Every 10 hours of operation Spraying circuit Fill the tank with clean water, activate all its functions and check for leaks by setting it at a higher pressure than normal. Look at the coneof spray from the nozzles to detect any imperfections. Every 50 hours of operation - Transmission, chassis, air pressure and diaphragm pump Check the condition of the transmission. Replace any damaged parts, if there are any. Tighten the screws on the wheels and in the areas which work the hardest or receive the most torsion. Make sure the pressure in the wheels and the pressure dampener in the pump is at the correct level. Lubricate the diaphragm pump. Every 100 hours of operation - Drawbar Lubricate the mistblower s hitch or the turnable drawbar. Check the revolving axles are not blocked or have lost their shape. Every 250 hours of operation Wheels, hoses and gearbox Check and lubricate the axle casing and the braking system of the wheels. Take a look at all the hoses in the circuit. Change the oil in the gear box. Check the gear box support and tighten the screws that keep it in place. Every 1,000 hours of operation Complete service Carry out a complete service on all those elements described before. 6.4

41 6 - Maintenance Occasional manteinance Every 10 hours of operation Suction Filter In order to get the most out of your suction filter, do the following: 1. Undo the nut (A) and open up the filter. 2. Remove the filter (B) from its housing. 3. Replace the sealings (C) if necessary. To put it back together: 4.Grease the sealings. 5.Place the filter inside its housing. 6. Grease the sealingt inside the cover of the filter 7. Put the cover back on and screw it on tightly. Every 10 hours of operation Pressure filters To extract the pressure filter, unscrew the filter casing to have a look at it and clean the filter. When you put it back together, the sealing should be greased. There is a variety of mesh thicknesses. See section Technical Specifications Filters and Nozzles Every 10 hours of operation - Nozzles To clean or replace them, you should use a special key to help you undo the nut ( D ). Take off the nozzle and clean it with air, water or a toothbrush. Do not use a piece of wire or a needle as they are sure to damage the nozzle. If any of the nozzles leak when the sectors have been closed up, replace the anti-drip diaphragm (E). D E 6.5

42 6 - Maintenance Replacing the 321 valves and diaphragms Diaphragms Dismantle the crankcase (4). Now, the diaphragm (5) can be sustituted. Grease the pump if the liquid has penetrated inside it. Make sure that the draining hole is not obstructed. Reassemble the pump again. Torque settings for the 321 are: Cranckcase: 60 Nm / 44.4 lbft Crankshaft: 70 Nm / 51.8 lbft Diaphragm screws: 60 Nm / 44.4 lbft Before to assembly the covers, turn the shaft with the hand and make that the connecting rods are ascending and lowering alternatively. If not change the position of the connecting rods. The first connecting rod must be assemblied towards the right side. Cone check/renewal for EVC operating unit If it becomes difficult to build up sufficient pressure or if pressure fluctuations occur, it may be necessary to renew cone and cylinder. 1. Remove 4 x screws (A) and remove the housing. 2. Remove 4 x screws (B). 3. Replace cylinder (C) and O-ring (D). 4. Loosen the nut (E), remove and replace the cone (F). 5. Reassemble in reverse order. Cone check/renewal for EVC distribution valve The level indicator reading 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 found, pull out the plug (B), loosen screws (C), and adjust the length of the cord. 6.6

43 6 - Maintenance Replacing the 363 valves and diaphragms 363 Model The repair kit for the 363 diaphragm pump (valves, joints, diaphragms, etc.) can be acquired using the reference HARDI nº Valves Take off the cover of the casing (1) before replacing the valves (2). Remember which direction they were in so as to be able to put them back on correctly!. When you take off the cover of the casing, you will see that the 2 valves (2A) are somewhat different to the rest. So that they work properly, remember to put them back in the same position and place as they were in before. Diaphragms Take the cover off the diaphragm (4). The diaphragm (5) can then be replaced. If liquid has got inside thecasing, grease the pump thoroughly. Also make sure the drainage hole in the lower part of the casing is not blocked up. Put the pump completely back together The torque values for the 363 pump are the following: The cover of the casing: 90 Nm The diaphragm bolt: 90 Nm TAKE NOTE! Before tightening the 4 screws on the cover of the casing (B), the diaphragms should be put in a central position to ensure correct sealing between the casing and its cover. Turn the crankshaft if necessary. Adjusting the 3-way valve The 3-way valve can be adjusted if, when it is turned, it is very stiff or very loose (liquid loss). It is correctly adjusted when the valve handle can be turned using one hand only. To make it easier to turn the handle, keep clean the area where the ball (B) and the seat (A) of the valve rub together. Grease the valve every time you dismantle it to clean it. This will lengthen the time the ball and the seat last. A B 6.7

44 6 - Maintenance Off-season storage program When the spraying season is over, you should devote some extra time to the sprayer. If chemical residue is left over in the sprayer for longer periods, it can reduce the life of the individual components. To preserve the sprayer intact and to protect the components, carry out following off-season storage program. 1. Clean the sprayer completely - inside and outside - as described under Cleaning of the mistblower. Make sure that all valves, hoses and auxiliary equipment have been cleaned with detergent and flushed with clean water afterwards, so no chemical residue is left in the sprayer. 2. Renew possible damaged seals and repair possible leaks. 3. Empty the sprayer completely and let the pump work for a few minutes. Operate all valves and handles to drain as much water off the spraying circuit as possible. 4. Pour appr. 50 litre (11 Imp.gal) anti-freeze mixture consisting of 1/3 automotive anti-freeze and 2/3 water into the tank. 5. Engage the pump and operate all the functions of the 3-way valve, operating unit, chemical inductor etc. allowing the anti-freeze mixture to be distributed around the entire circuit. Open the operating unit main on/off valve and distribution valves so the anti-freeze is sprayed through the nozzles as well. The anti-freeze will also prevent O-rings, seals, diaphragms etc. from drying out. 6. Lubricate all lubricating points according to the lubricating scheme - regardless of intervals stated. 7. When the sprayer is dry, remove rust from possible scratches or damages in the paint and touch up the paint. 8. Remove the glycerine-filled pressure gauges and store them frost free in vertical position. 9. Apply a thin layer of anti-corrosion oil (e.g. SHELL ENSIS FLUID, CASTROL RUSTILLO or similar) on all metal parts. Avoid oil on rubber parts, hoses and tyres. 10. All electric plugs and sockets are to be stored in a dry plastic bag to protect them against damp, dirt and corrosion. 11. Remove the control boxes and computer display from the tractor, and store them dry and clean (in-house). 12. To protect against dust the sprayer can be covered by a tarpaulin. Ensure ventilation to prevent condensation. Preparing the sprayer for use after storage After a storage period the sprayer should be prepared for the next season the following way: 1. Remove the cover. 2. Remove the support from the wheel axle and adjust the tyre pressure. 3. Wipe off the grease from hydraulic ram piston rods. 4. Fit the pressure gauges again. Seal with Teflon tape. 5. Connect the sprayer to the tractor including hydraulics and electric s. 6. Check all hydraulic and electric functions. 7. Empty the tank for remaining anti-freeze. 8. Rinse the entire liquid circuit on the sprayer with clean water. 9. Fill with clean water and check all functions. 10. Check function of brakes. Please note that brake power will be reduced until the rust are worn off the drums. Always brake lightly until the drums are clean. 6.8

45 6 - Maintenance Shield renewal on transmission shaft 1. Remove bolt (A), lock (B) and grease nipple (C). Twist uni CV-joint cover 1/4 turn and pull it backwards. 2. Remove the synthetic bearings and protection tube. 2a. Remove inner bush from protection tube. 3. Assemble again in reverse order, using new parts where necessary. Remember to fit chains again. 4. Grease bearings. 5. Repeat procedure to the opposite part of the transmission shaft. ATTENTION! Only use genuine HARDI spare parts to service the transmission shaft. Replacement of transmission shaft cross journals 1. Remove protection guard as described previously. 2. Remove Seeger circlip rings. 3. Press the cross journal sidewards - use hammer and mandrel if necessary. 4. Remove needle bearing cups and cross journal can now be removed. 5. Carefully remove needle bearing cups from new cross journal and install it in reverse order. Before fitting the needle bearing cups again, check that needles is placed correctly. Avoid dust and dirt in the new bearings. 6. Repeat procedure to the opposite part of the transmission shaft. 6.9

46 6 - Maintenance 6.10

47 7 - Fault finding Operational problems General information In cases where breakdowns have occurred, the same factors always seem to come into play: 1. Minor leaks on the suction side of the pump will reduce the pump capacity or stop the suction completely. 2. A clogged suction filter will hinder or prevent suction so that the pump does not operate satisfactorily. 3. Clogged up pressure filters will result in increasing pressure at the pressure gauge but lower pressure at the nozzles. 4. Foreign bodies stuck in the pump valves with the result that these cannot close tightly against the valve seat. This reduces pump efficiency. 5. Poorly reassembled pumps, especially diaphragm covers, will allow the pump to suck air resulting in reduced or no capacity. 6. Hydraulic components that are contaminated with dirt result in rapid wear to the hydraulic system. Therefore ALWAYS check: 1. Suction, pressure and nozzle filters are clean. 2. Hoses for leaks and cracks, paying particular attention to suction hoses. 3. Gaskets and O-rings are present and in good condition. 4. Pressure gauge is in good working order. Correct dosage depends on it. 5. Operating unit functions properly. Use clean water to check. 6. Hydraulic components are maintained clean. 7.1

48 7 - Fault finding Liquid system FAULT CAUSE SOLUTION No spray Air inlet Check if suction filter O-ring is sealing. Check suction tube and fittings. Check tightness of pump diaphragm and valve covers. Air in system Suction and pressure filters obstructed Fill suction hose with water for initial prime. Clean the filters Lack of pressure. Incorrect assembly. Pump valves blocked or worn. Defect pressure gauge. Boost valve is open. Safety valve spring for Self-cleaning filter not tight. Too little distance between yellow suction pipe and tank bottom. Check for obstructions and wear. Check for dirt at inlet of gauge. Pressure dropping. Filters clogging. Clean all filters. Fill with cleaner water. If using powders, make sure agitation is on. Nozzles worn. Check flow rate and replace nozzles if it exceeds 10%. Pressure increasing. Tank is air tight. Sucking air towards end of tank load. Pressure filters beginning to clog. Check vent in tank lid is clear. Lower pump r.p.m. Clean all filters. Formation of foam. Air is being sucked into system. Excessive liquid agitation. Check tightness/gaskets/o-rings of all fittings on suction side. Reduce pump r.p.m. Check safety valve is tight. Ensure returns inside tank are present. Use foam damping additive. Liquid leaks from bottom of pump. Damaged diaphragm. Replace. See changing of valves and diaphragms. Operating unit not functioning. Blown fuse(s). Wrong polarity Valves not close correctly Check the microswitches. Put lubricating liquid if there s a false contact. Control box: Red - pos. (+). Black - neg. (-). Electrovalves: Brown - pos. (+). Blue - neg (-). Check valve seals for obstructions. Check microswitches. No power Wrong polarity. Brown pos. (+), Blue neg. (-). Check the printed circuit. Check if there s contact between the fuse and its holder. 7.2

49 7 - Fault finding Air kit FAULT CAUSE SOLUTION Vibrations or high noise from the air kit Fan is not well counterweighed Loose screws on the air kit Counterbalance the fan Re-tight the screws The clutch shoes are worn away Change the shoes and the springs on the clutch Vibrations or high noise from the gearbox The speed is not well engaged Wear away of the engagements Low level of oil Put the lever correctly Change the engagements Refill oil and check the gearbox internally 7.3

50 7 - Fault finding Electrical problemss Emergency operation - Liquid system In case of power failure it is possible to operate all functions of the operating unit manually. First disconnect the multi plug from the control box. Now manually turn the emergency control knobs. The problem may be due to a blown fuse. A fuse is placed inside the box. Fuse type: Thermo 7.4

51 8 - Technical specifications Dimensions and weights Dimensions Capacity Air kit Measurements (litres) (model) A x B x C x D (cm) 1000 AG x1535x1200x125 AG x1535x1200x AG x1590x1350x110 ó 175 AG x1590x1350x110 ó AG x1590x1500x25 ó 100 AG x1590x1500x25 ó 100 A B C D Weight when empty Capacity Air kit Weight (litres) (model) (kg) 1000 AG AG AG AG AG AG Conversion factors, SI to Imperial units All units used in this manual are SI units. In some occasions Imperial units are used. Use following factors to convert SI units to Imperial units: SI unit Imperial unit Factor Weight kg lb x Surface ha acres x Length cm in x m ft x m yd x km mile x Speed km/h mile/h x km/h m/s x Volume/Surface l/ha gal/acre x Volumen ml fl. oz x Torque l Imp. pt. x l gal x 0.22 Pressure bar lb./inv (p.s.i.) x Temperature C F ( C x 1.8) + 32 Power kw hp x Torque strength Nm lb.ft. x