Abbey Machinery Slurry Tanker, Maintenance, Operating Instructions And Spare Parts List

Page 1: ...Slurry Tanker ...

Page 2: ...bolt on hitch bolts where fitted optional Check all hose clips Check all safety guarding and devices are fitted and in good working order Check all lubrication points and grease sprung drawbar where fitted optional Check all lighting is working correctly Check and ensure the right PTO shaft is cut to the correct length Check the oil lubrication drop rate while running the pump and the pressure set...

Page 3: ... Pump Check gearbox oil level Function of hydraulic functions in sequence In Cab Electric Control Valves Check each hydraulic function is working correctly Check wiring and hose routing cannot be fouled Mount control box in cab and explain functions to the customer Air over Hydraulics Test brakes on air only Check that tractor is building up required pressure Auto Weight Transfer System Check func...

Page 4: ...tches 23 5 5 Auto Filler Unit 24 5 6 Steering Axle Tandem Tanks 29 6 0 Tanker Care and Maintenance 31 7 0 Vacuum Pump 7 1 Use 37 7 2 Maintenance 40 8 0 Replacement Parts 42 9 0 Trouble Shooting 68 10 0 Warranty EC Declaration of Conf 70 11 0 Terms and conditions 71 IMPORTANT NOTICE 1 Drawings in this manual are not to scale 2 While every care is taken to ensure that all information in this manual ...

Page 5: ...c tank uses a second pump whereby the liquid can be land spread via a raingun which is mounted on the side of the tank This raingun should be used in line with the regulations of the particular EC country in question The open top tank is a non pressurised tank which is filled through a hopper shaped opening in the top of the tank The Abbey topfill slurry pump can be used for this purpose The slurr...

Page 6: ...ter a tank then wear a safety harness with a lifeline held by two men 6 Airline breathing equipment should be worn where continuous adequate ventilation is not possible 7 Lift the minimum number of slats to permit access for the tanker pipe pump or mixer Where the slats have been lifted erect temporary barriers to stop anyone falling into the tank 8 Do not stand over openings when slurry is being ...

Page 7: ... Valve 2 Manometer Gauge 3 Front Ball Valve 4 Pressure Relief Valve 5 Pump Control Handle 6 Oil Drip Feed Adjustment 7 Sight Glass 8 Ram Spring Assembly 9 Inlet Valve 10 2 High Pressure Hose Attachment 11 6 Outlet ...

Page 8: ... with excessively worn hitch eye Replace it The hitch eye should be checked regularly particularly on tanks used for long periods during the season 12 Damaged or worn hydraulic hoses should be replaced 13 Both standard lifting points on the top of the barrel of the tank must be used if the tank is to be lifted off the ground Drawing A page 8 shows the positions of the lifting points 14 Never opera...

Page 9: ... spread Pump pressures tank Handle in neutral Free flow of air through pump Handle in Fill Pump creates a vacuum in tank 5 Max Tractor input PTO speed 6 Max Tanker speed 7 Lifting Point Jacking point Support Point On 2500R and 3000R Tankers on Back dome Tanker should not be filled above the level of this sight glass when going on the public road IMPORTANT READ INSTRUCTIONS CAREFULLY BEFORE OPERATI...

Page 10: ... near overhead power lines operated do not climb the ladder Tandem Tankers Bolts on bogie to be kept tight and checked at regular intervals PTO PTO Shaft Warning Pump Vacuum Pump Safety Warnings DO NOT CLIMB LADDER WHILE MACHINE IS WORKING DANGER NEVER USE RAINGUN NEAR OVER HEAD POWER LINES Bogie U bolts undercarriage nuts and wheel nuts to be kept tight ...

Page 11: ...amps can be tightened If this does not resolve the problem remove the door rubber seal and check that it is intact d Check that wheel nuts are tight and hubs are greased R Remould N New Check Tyre Pressures 16 5 x 22 5 R 43 P SJ 560 60 R 22 5 N 58 P S I 1300 x 530 533 N 51 P SJ 600 55 R26 5 N 36 P S I 400R 22 5 R 60 P S I 650 55 R26 5 N 58 P S I 15R x 22 5 R 60 P S I 710 50 R26 5 N 58 P S I 18 4 x...

Page 12: ...liquid is allowed to drip from the centrifugal pump shaft to lubricate the graphite cord packing This is not necessary when the pump is fitted with a mechanical seal Hydraulic Break Away Brake Before using the tanker fitted with the hydraulic break away system the following check should be used to ensure it operates correctly Also the complete brake system needs to be checked at regular intervals ...

Page 13: ...ain the pressure and now the station is ready for use When the arm lowers the tanker side valve will open automatically Carefully read and understand fully the Abbey instructions prior to operating this machine Principles of the Station Slowly forcing the self filler arm into the docking station hopper and pushing down will cause the double gate valves to open automatically and allow the tanker to...

Page 14: ...y to vent the pressure from the system To re set Connect a hose to the hopper and an available tractor open the hydraulic ball valve and slowly prime the system This will cause the docking station to raise and the 6 valves to open fully a good time to flush out the pipe work with water Now dump the system pressure which will allow the valves close and the hopper lower to a pre set height At this h...

Page 15: ...n Gate valves x2 hydraulic top fill Trailing shoe working and folding Inlet turbo pump or rota cut filters Self Filler units and tandem axle steering A feeder version is also available with other functions Hydraulic Valve Banks Typically the Electronic control is linked to a hydraulic valve bank via a junction box See over leaf All logic is controlled by this unit and fault finding is simplified w...

Page 16: ...ller Controls all hydraulic functions with application rate data being recorded and application rates controlled as the tanker is spreading Above are the electro hydraulic solenoids operated by the cab controller to work the hydraulic functions on the tanker The cab mounted electronic unit controls all the solenoids on an individual basis via the blue junction box on the right side of this photo M...

Page 17: ...prior to operating this machine Mounting the control rod position on the tractor for forced steering The hitch position for the control rod will need to be fitted beside the tractor hitch A horizontal dimension of 240mm from the hook centre to the mounting pin of the control rod should be maintained It is preferable to mount the control Rod position lower than the pickup hook for max clearance bet...

Page 18: ...vent it varying in length when the locking pin assembly is faced away from the chassis Once adjusted to suit a particular tractor no further adjustment of the control rod is required Use the locking pin in future to hitch the machine to the tractor Open the ball valves to prime the steering system Keep pressurising the system until the pressure clocks read 80 bar Close all taps and test the steeri...

Page 19: ...tone of the pump changes while it is working Immediately close the inlet valve the tank may be full 7 Remove the suction hose set up the spread plate and check all fill points are closed SPREADING 1 Move the handle on the pump to the central position for a few seconds until the vacuum is released Then set the pump handle into the spread position This operation could be made at the end of the filli...

Page 20: ... pressure valve 5 Engage PT O and commence spreading 6 The rain gun can then be rotated 360 to the required position 7 Empty the stone trap on the tank at regular intervals during the working day 8 When operating a Centivac tanker always engage the tractor P T O at low rev s when using the Vacuum Pump to fill or spread Revs can gradually be built up to the correct level after engaging the P T O 9 ...

Page 21: ...oses automatically Rearspread valve CLOSED on rain gun pipe Vacuum pump in FILL position Vacuum and Turbo Pumps on Connect Hose at left right front Fill as normal Trap system will cut when tanker full Please note For fuller loads 3 4 way thru filling switch pump vacuum pump to neutral and continue turbo pump filling Shut off PTO prior to slurry reaching tanker top Caution When filling the tank wit...

Page 22: ... Neutral position and Vacuum Pump off Turbo Pump on Application rate pre set set forward speed and spread load through shoe or plate To spread OPEN rear valve then PTO on To turn at headland PTO off then close rear valve turn valve open and PTO on When Tanker empty and no pressure on the cylinder empty the primary stone trap Hydraulic spread valve Application rate setting Rear spread valve Rain Gu...

Page 23: ...y because this will cause an excessive amount of slurry to be spread in one place 5 4 TOP FILL HATCHES 1 This hatch is used for both filling and can also be used as an inspection point note the tank must not be pressurised Read through the safety warning of this manual before using this hatch as an inspection point 2 Open the hatch make it secure and reverse or drive the tank under the filling pip...

Page 24: ...h load The Abbey auto filler is set up to lower the filling arm at a pre set speed and seat the coupling into the hopper with the minimum of hydraulic pressure Lowering the auto filling arm changes the vacuum pump to the fill position and opens the hydraulic gate valve for filling Lifting the arm closes the hydraulic gate valve and changes the pump to the spread position If at any stage the flow v...

Page 25: ...be filled as follows Connect the suction hose to the filling hopper and lower the opposite end of the hose into the storage tank Drive the tanker forward and while lowering the arm locate it in the filling hopper With the arm seated in the hopper Note Do not force maximum pressure down on the hopper with the ram engage the tractor P T O and ensure the pump has changed to the fill position and the ...

Page 26: ...to filler Unit from Left to Right fill position the following procedure most be followed Step 1 1 Raise Arm into Transport Position ensuring arm is locked in place for transport 2 Remove Lower Locking Pin Step 2 1 Slide Lower Ram Bracket fully across 2 Re fit Locking Pin Step 3 1 Lower Arm into Fill Position 2 Rotate Fill Arm End Elbow ...

Page 27: ...ate Valve 1 ART5F2 6 5 Double Flanged Adaptor 6 1 ABY352 6 Swivel Unit 6 1 ABYBP2001 G 7 Small Ram Mounting Plate 1 ABY355 8 Large Ram Mounting Plate 1 ABY353 9 Auto Filler Ram Mounting Bracket 1 ABY354 10 Auto filer Arm Ram 1 ABY4916 11 Auto Filler Arm 1 ABY358 12 Auto Filler Arm End 1 ABY356 13 Milkolar Jubilee Clip 1 CLP162 174 14 6 Auto Filler Rubber Coupling 1 ABYBP1101 G 15 6 Auto Filler Hop...

Page 28: ...ABY4946 4 Jubilee Clip 1 CLP201 213 19 Locking Roll Pin 1 PIN4946 5 8 Auto Filler Arm End 1 ABY 356 8 20 Locking Ram Return Spring 1 ABY97841001 6 8 Rubber Gasket 1 ABY 8309800 21 Locking Pin 1 ABY366 7 8 Bi Directional Auto Filler Arm 1 ABY360 22 Locking Ram 1 ABYTS 46 8 Lower Ram Br Locking Pin 1 ABY515 23 Return Spring Locator 2 ABY367 9 Lower Ram Br Flange 1 ABY361 10 Lower Ram Bracket Bushes ...

Page 29: ...ve the above braking efficiency and is now supplied on all Abbey machines It is essential the above coupling is used in conjunction with the upgraded brakes because braking is achieved gradually with the assistance of the tractor brake pedal It is important to note that it is not recommended to use a standard male hydraulic coupling in the place of the standard female brake coupling to achieve the...

Page 30: ... 36 12 4 5M 12 Note The cone must set up as shown to achieve the correct spread pattern Pushing the splash plate down so that the half moon shape band hits the rubber cone is not the prober set up Spreading width may vary depending on the density of the slurry Check for blockages form time to time X ...

Page 31: ...sk to the safety of the operator If there is any confusion when refitting parts contact your local dealer before completing operation 12 Caution Special care should be taken to replace damaged hydraulic fittings or hoses 13 Caution When vacuum pump doesn t work for a long period we suggest to operate as stated in the Washing Section 7 2 3 14 Caution Insufficient lubrication will cause damage to th...

Page 32: ...up by light sanding of the damaged area and then painting over the area 3 Regular washing is the most effective method of maintaining a machine s paint finish i e at the end of each day s work 4 Mechanical or acid damaged areas of the paint work should not be left for prolonged periods without repainting If left exposed the damaged area will rust and cause more extensive damage to the paint work G...

Page 33: ...fficient lift capacity Check the unladen weight of the machine off the CE stamp against the tonnage lift capacity of your equipment Place under the suggested jacking point See Figure 1 6 Place jack under jacking point axle on the side of the axle you wish to raise Please ensure that ground conditions are suitable to withstand the load of the machine 7 When raising the machine always use an axle st...

Page 34: ...event the lifting equipment slipping for any reason Position on the flat under the side support between the axle and transport hook only the side of the wheel change Position on the flat under the side support between the axle bolts and transport hook only the side of the wheel change Position on the flat under the side support between the axle bolts and transport hook only the side of the wheel c...

Page 35: ...YLS01 for lifting that will fit to all tankers produced after June of 2012 This tool slots up into the hole as shown below and prevents slippage between two metal surfaces Also this position is on the very end of each chassis rail keeping the operator out of the crush zone at all times when setting up Please revert to your local Abbey dealer for more details Machines build prior to this can order ...

Page 36: ...36 ...

Page 37: ...e For internal lubrication the min oil level is stated by the mark at the lower end of the level fig 1 which is on manifold and consequently the max level is at full reservoir MEC 6500 13500 MEC 6500 13500 Fig 1 Fig 2 The reservoir capacity is stated on the following table Model MEC 6500 MEC 8000 MEC 9000 MEC 1100 MEC 13500 Star 60 Star 72 Capacity L 3 1 3 8 2 2 5 3 3 7 3 7 ...

Page 38: ...Engler viscosity at 50 SAE low 2 30 3 30 Gearbox The recommended gear oil for all seasons is 80 W90 approximate quantity in Mec 8000 pump is 0 25 litres Mineral oil Engler viscosity at 50 SAE 60 w 20 26 or SAE 90 Don t use hydraulic oil or a cleansing for lubrication You can use Ecological oil but with the same specifications of the mineral oil suggested 7 1 3 OIL QUANTITY FOR LUBRICATION During w...

Page 39: ...ase the air capacity in excess of 0 5 BAR CAUTION This valve is factory set but should be checked at regular intervals to ensure the max pressure isn t exceeded See section 8 for setting Vacuum Too high a vacuum can cause ovalization and waving of the body or vane breakage For this reason we suggest the use of a vacuum control valve 7 1 6 RUNNING TIME The max running time we suggest is not over 6 ...

Page 40: ... as the rotor Model Blade Number Dimensions Mec 6500 7 370x46 5x6 3 Mec 8000 7 450x46 5x6 3 Mec 9000 5 300x60x6 5 Mec 1100 5 370x60x6 5 Mec 13500 5 460x60x6 5 Star 60 SE 10000 6 350x70x7 5 Star 72 SE 12000 6 400x70x7 5 7 23 WASHING Washing of the pump internal with diesel oil is recommended during the working day If slurry gets into the vacuum pump it is necessary to immediately wash the internal ...

Page 41: ...ing collar and check that the blow off pressure is correct PROCEDURE FOR THE SETTING OF THE DEPRESSION VALVE A Take off the cover 1 from the adjusting bell 2 by using the point of a screwdriver in the special incision B Loosen the stop set nut 3 by holding firm the adjusting bell 2 C Regulate the pressure on the spring by turning the adjusting bell 2 Turn in clockwise for increasing the pressure a...

Page 42: ...0 11 Rubber Washer ABY2140 L 2 Hose Clip 85mm 90mm CLP85 91 12 Top Trap Hosing 3 80mm Trap Hose HOS6031 80 13 60mm Manometer Gauge ABY2130 60 4 Main Trap 14 3 8 Dowdy Washer 4a 60mm Main Trap ABY9019 15 M12x160 Bolt Din 931 M12x160 4b 80mm Main Trap ABY9051 16 Rubber Ball ABY2135 100 4c 100mm Main Trap ABY9052 17 Main Trap Base Plate To be Created 5 1 1 2 Safety Valve ART13 1 1 2 19 Rubber O Ring ...

Page 43: ...cription Part Number 1 6 Heavy Duty Gate Valve ART5F2 51 6 2 O Ring ART6F 6 10 3 Rear Door Seal ABY2170 44X25MM 4 Door Closing Hook ABY2179 5 Ring Nut Ring Nut M20 6 M12x30 DIN 931 1 M12 x 30 7 M12 Lock Nut DIN985 M12 8 Pin For Back Door ABY9331 P 9 4mm R Clip CLP3553 ...

Page 44: ...te ABY4356200TP 1b Cross Plate ABY4356200BP 2 M16x40 DIN913 1 16x40 3 M16 Lock Nut DIN085 M16 4 Grease Nipple NIP1 8X180 5 Parabolic Spring ABY4356200 6 M20x120 DIN982 M20X120 12 9 7 M20 Lock Nut DIN085 M20 8 Pivot Pin ABY3523B 9 Grease Pipe ABY3528 10 Handbrake Lever ABY3618 11 Sprung Drawbar ...

Page 45: ... Description Part Number 1 3 Treaded Sleeve ABY2156 3 2 O Ring ABY2154 3 3 Glass Eye ABY2152 3 4 O Ring ART6F 6 10 5 6 Gate Valve ART7F2 6 6 Manual Handles ABY9135 8 Clevis ART5 6 9 9 Rubber Flange ABY2080 10 Blank Off Plate ABY2080 1 11 Flanged sleeve ABY2085 ...

Page 46: ...ate Valve ART3 4 5 100mm Female Plug ABY2554 100 19 M12x35 DIN 933 M12x35 6 Rubber O Ring ABY2620 100 20 Garda Pump GRDPUMP 8 M12x35 DIN 933 M12x35 21 M16x55 bolt DIN933 M16x55 9 M12x40 DIN933 M12x40 22 M16 Flat Washer DIN125A M16 10 Rain Gun ABYJET99H 23 M16 Lock Nut DIN985 M16 11 M12x35 DIN 933 M12x35 24 8 Rubber Coupling ABYBP1101 H 12 Rubber O Ring ABY2620 100 25 Clip 214 226mm CLP214 226 13 1...

Page 47: ...l MEC Pumps Sold in Kit form only Part No ABY9180 __________________________________________________________________________ Part No ABY9160 10 000 12 000 Part No ABY9140 MEC Pumps __________________________________________________________________________________________ Part No ABY9160 CL MEC Pumps ...

Page 48: ...48 8 0 Replacement Parts Con d 8 7 Vacuum Pumps ...

Page 49: ...49 8 0 Replacement Parts Con d ...

Page 50: ...50 8 0 Replacement Parts Con d ...

Page 51: ...51 8 0 Replacement Parts Con d ...

Page 52: ...52 8 0 Replacement Parts Con d ...

Page 53: ...53 8 0 Replacement Parts Con d ...

Page 54: ...54 8 0 Replacement Parts Con d 8 9 Garda Pump with Gland Seal ...

Page 55: ...55 8 0 Replacement Parts Con d ...

Page 56: ...luminium washer Ø 10x16 GRDG74 Scroll and impeller support forpreshaped ring GARDA 3500 GRDG60 WPT1000 Gearbox WPT STAR 1000 RPM GRDG80 Brass nut M 10 GRDG66 Central gear wheel with idle gear GRDG81 Stud bolt M 10x64 GRDG68 Bushing Ø 30x40x60 GRDG82 Scroll support gasket GRDG71 Scroll GARDA 3500 GRDG84 Connection flange GARDA 3500 GRDG72 Ring seal OR 4950 GRDG85 Centrifugal shaft for preshaped rin...

Page 57: ...lf locking nut M 30x2 GRDG39 Screw M 12x30 TE GRDG40 Smooth washer Ø 12 GRDG42 Seal ring Ø 298x3 53 GRDG49 Scroll GARDA 6500 GRDG49 140 Scroll GARDA 6500 Ø 140 GRDG52 Impeller GARDA 6500 GRDG88 Closing flange GRDG89 Blade GRDG90 Counter blade GRDG91 Blade holder flange GRDG92 Extension GRDG93 Spacer GRDG96 Screw M 10x30 TE 6 GRDG98 Centrifugal frontal mechanical seal ...

Page 58: ...58 8 0 Replacement Parts Con d ...

Page 59: ...59 8 0 Replacement Parts Con d ...

Page 60: ...60 8 0 Replacement Parts Con d 8 10 Traps ...

Page 61: ...es 350X60 Braked Axel Item No Description Part No 1a Brake Assembly ADR9RE0014 1b Camshaft ADR9RE0014 1c Retaining Ring ADR9RE0014 1d Washer ADR9RE0014 1e M24x1 5 ADR9RE0014 2 Spring ADR9RK0004 3 Lever ADR9RQ0001 4 Drum 8 Holes ADR66LNF0804 ...

Page 62: ... Axel Item No Description Part No 1a Brake Assembly ADR9RE0048 1b Adapter ADR9RE0048 1c Camshaft ADR9RE0048 1d Retaining Ring ADR9RE0048 1e Washer ADR9RE0048 1f M24x1 5 ADR9RE0048 2 Spring ADR9RK0005 3 Lever ADR9RQ0001 4 Drum 8 Holes ADR66LNF0801 ...

Page 63: ...63 8 0 Replacement Parts Con d ADR 1800x150 Axel420x180 Brake Shoe ...

Page 64: ...64 8 0 Replacement Parts Con d ADR 1800x150 Axel420x180 Brake Shoe ...

Page 65: ...65 8 0 Replacement Parts Con d ADR 1800x150 Axel420x180 Brake Shoe ...

Page 66: ...66 8 0 Replacement Parts Con d Tandem Bogie ...

Page 67: ...67 8 0 Replacement Parts Con d ...

Page 68: ...ve you used the correct oil Heavy oil will not travel through the system Check pipes connecting reservoir pump and that oilers are not blocked Clean out oiler Oil pump on back housing may be defected and needs to be replaced 3 Pumps veins sticking Revs too low increase to 540 RPM Run diesel through the pump to clean out Have you been using milking machine oil This swells the veins and causes veins...

Page 69: ... replaced 11 Brakes making noise or don t seem to be functioning Make sure both Cam levers are traveling the same distance Adjust so both levers are pulling even Check hydraulic brake line and fitting on tractor Brake pads need to be replaced Tank 12 Slurry not coming out or not coming out pressurized Rear gate valve not open fully or not open at all Obstruction in spread plate nozzle Tank not bui...

Page 70: ...Warranty claims will only be assessed when all alleged faulty parts have been returned to the manufacturer All parts dispatched to replace damaged parts under warranty consideration are chargeable pending decision on claim 7 For general warranty consideration please see terms and conditions of sale set out overleaf EC Declaration of Conformity for machinery according to Machinery Directive 2006 42...

Page 71: ...cts is intended to affect or prejudice nor will affect or prejudice the contractual rights enjoyed by the purchaser by virtue of the Sale of Goods Act 1893 and 1980 and in particular of sections 12 13 14 and 15 of the said Act of 1893 as amended or where goods are sold outside the jurisdiction of the Republic of Ireland the statutory rights of a Purchaser who is a Consumer as hereinafter defined C...

Page 72: ...uling on the date of dispatch This clause also applies to backorders All prices are exclusive of V A T and the same together with carriage when charged shall be borne by the Purchaser The Company must be paid in full without deduction in respect of alleged or counterclaims in accordance with the terms specified by the company from time to time and if no date for payment has been specified by the l...