Operation manual
MCP -T
Empas B.V.
Kruisboog 43
3905 TE Veenendaal
+31(0)318-525888
www.empas.nl
1
Index
EG declaration ......................................................................................................................................................................................................................................................... 3
The Empas MCP-T at a glance ................................................................................................................................................................................................................ 4
Introduction ............................................................................................................................................................................................................................................................... 4
Starting the hot water unit .......................................................................................................................................................................................................................... 4
Filling the fuel tank with diesel .......................................................................................................................................................................................................................... 4
Filling the water tank .................................................................................................................................................................................................................................................... 4
Switching the burner boilers on/off ............................................................................................................................................................................................................ 4
Switching the complete hot water unit on/off ............................................................................................................................................................................... 4
Adjusting and operating the flow tray .................................................................................................................................................................................................... 4
Adjusting the nozzles ................................................................................................................................................................................................................................................... 5
Reversing camera ........................................................................................................................................................................................................................................................... 5
Operating the hot water unit .................................................................................................................................................................................................................... 5
Switching the flow tubes in the flow tray on/off ........................................................................................................................................................................... 5
Switching the nozzles on/off ................................................................................................................................................................................................................................ 5
Switching the flow tubes and nozzles on/off .................................................................................................................................................................................... 5
Switching between the flow tray and the work lance ........................................................................................................................................................... 6
Operating the reel ........................................................................................................................................................................................................................................................... 6
Operating the work lance and work gun .............................................................................................................................................................................................. 6
Cleaning application work lance .................................................................................................................................................................................................................. 6
Switching the compressor on/off ................................................................................................................................................................................................................. 6
After use ...................................................................................................................................................................................................................................................................................... 6
Major safety data ................................................................................................................................................................................................................................................. 6
Use ..................................................................................................................................................................................................................................................................................................... 6
Protective clothing ......................................................................................................................................................................................................................................................... 6
Meaning of warning symbols ............................................................................................................................................................................................................................ 6
Major technical usage data ....................................................................................................................................................................................................................... 7
Safeguards in the unit ................................................................................................................................................................................................................................................. 7
Tractor ........................................................................................................................................................................................................................................................................................... 7
Temperature during use ........................................................................................................................................................................................................................................... 7
Resetting the unit .............................................................................................................................................................................................................................................................. 7
Information on usage .................................................................................................................................................................................................................................................. 7
Transportation ...................................................................................................................................................................................................................................................................... 7
Important maintenance data .................................................................................................................................................................................................................. 7
Check .............................................................................................................................................................................................................................................................................................. 7
Maintenance diagram MCP-T (diagram 1) ......................................................................................................................................................................................... 8
Clean the fine filter ....................................................................................................................................................................................................................................................... 10
Cleaning the flow tubes of the flow tray ............................................................................................................................................................................................. 10
Failures ........................................................................................................................................................................................................................................................................... 11
Possible pump failures and remedies ..................................................................................................................................................................................................... 11
Possible hot water unit failures and remedies .............................................................................................................................................................................. 11
Warranty ...................................................................................................................................................................................................................................................................... 12
Important ................................................................................................................................................................................................................................................................................. 12
Antiscalant dosage ........................................................................................................................................................................................................................................... 13
2
EC Declaration of conformity
(according to appendix II.1.A of the machine directive 2006/42/EC)
Empas B.V. Kruisboog 43, 3905 TE Veenendaal, The Netherlands
Declares that the machine with the following specifications:
Machine name
Type
Serial number
Constrution year
Complies with the provisions of the machine directive (2006/42/EC) and the extensions of it, the machine
directive (2009/127EC), related to environmental requirements.
And declares further that standards mentioned below have been applied.
EMC directive (2004/108/EG) (if applicable for this specific machine)
………………………………………………………………………………………………………………………………
Low voltage directive (2006/95/EG) (If applicable for this specific machine)
………………………………………………………………………………………………………………………………
And declares also that (components of) the harmonised standard mentioned below has been applied:
NEN-EN-ISO 12100:2010 ……………………………………………………………………………
And declares in addition that the national standards mentioned below have been applied.
NVVK Standard P 169 high pressure cleaning with fluid (only for P> 100 bar)
Standard Vewin worksheet 3.8 ……………………………………………………………………
Veenendaal, The Netherlands, date: 01-10-2017
Empas B.V., represented by:
H.G. Doornenbal, director
Signature:
3
The Empas MCP-T at a glance
components. While surface water is being taken in, the MCP
must be operational. You must close the flow tray via the
control box in the cabin (see ‘ switching the main switch for
the flow tray on/off ‘) and set the tool carrier to the parking
position.
Switching the burner boilers on/off
Open the rear valve of the hot water unit. At the top left you
will see the electric box. By means of switches 1 and 3 you
can switch both burner boilers on and off separately. These
switches may be on at all times. Boiler one will heat the water
to approx. 60 °C, boiler two will heat the water to 105 ºC.
Fig. 1
Temperature reading
display
1. Burner boiler on/off
2. Start/stop filling pump
3. Burner boiler on/off
Increase/decrease
water temperature
Reset of the
burner system
Fig. 2
Introduction
The hot water unit is only intended to control weed with
boiling water of approximately 102 ºC on (semi) hard
surfaces. Depending on the presence of the high pressure
cleaning option, the unit will be suitable for cleaning at high
pressure.
Starting the hot water unit
Filling the fuel tank with diesel
You will be able to fill the fuel tank with diesel by unscrewing
the tank cap and then start filling up. You will find the tank
opening at the side of the unit. Level reading in the machine
room at the rear of the hot water unit.
Filling the water tank
You can fill the water tank by means of the filling pump
(optional). Place the end of the hose with the coarse filter in
the water and switch on the filling pump by means of button
2 on the electric box in the machine room at the rear of the
hot water unit. If you do not have a filling pump, it will be
possible to fill the tank manually via the coupling at the
bottom left of the cabinet. If necessary, you will be able to
empty the water tank with the tap at the side of the tank.
IMPORTANT: Add MC210 antiscalant while filling the water tank.
You will find the tank at the rear of the unit (see fig. 2). This will
prevent problems as a result of scaling in pipes and
4
Fig. 3
Switching the complete hot water unit on/off
You can switch the complete unit on and off by turning the
PTO on or off. The PTO activates he oil flow and the electrical
drive. When there is no hydro set on the unit, follow the steps
in the tractor manual.
IMPORTANT: Check the outside for visible deviations each day
before starting the unit for the first time. Do note the fumes
produced by the unit. Contact a mechanic or your dealer if
the fumes remain visible.
Adjusting and operating the flow tray
Lowering and lifting the flow tray is done by means of the
joystick. Moving forwards and backwards is moving the tray
up and down, left and right are used for the tray's side shift.
By means of the top rod you will be able to adjust the
position of the flow tray. By turning left or right you will make
the top rod shorter or longer, as a result the front of the flow
tray will go up or down. When adjusting, the swivel casters on
the ground must be in the forward driving direction (fig. 4
and 5). The rubber flaps should not make contact with the
ground.
Operating the hot water unit
INSTRUCTION: When using the hot water unit, keep a close eye
on the surroundings, immediately stop the unit when people
or animals are at risk due to your activities.
Fig. 4
Switching the flow tubes in the flow tray on/off
You can switch the flow tray on and off by means of the
buttons on the control box in the cabin. The left flow tube in
the tray is switched off with selection switch 1, the central
flow tube (only in case of MCP-T-32) with selection switch 2,
and the right flow tube with selection switch 3.
NOTE: The driving speed used depends on the weed load, if
the weeds are plentiful and high, we recommend adjusting
the speed to 1.5 km per hour. If the weeds are low, you can
drive with 3 km per hour.
Switching the nozzles on/off
You can switch the nozzles on and off by means of the
control box in the cabin. Selection switch 4 is the left nozzle,
Selection switch 6 is the right nozzle.
Switching flow tubes and nozzles on/off
You can switch the flow tubes and nozzles on or off in one go
by means of switch 5. This is the main switch for the flow
tubes in the flow tray and the nozzles.
Fig. 5
IMPORTANT: If the swivel casters, while adjusting the flow tray,
are not in forward direction, this will ensure that the flow tray
is pressed down in contrary direction (low in forward
direction, down in reverse direction). This will lead to excess
wear of the rubber flaps and the flow tray.
Temperature gauge
1. Left flow tube in flow tray on/off
2. Central flow tube in flow tray on/off
3. Right flow tube in flow tray on/off
Adjusting the nozzles
Manual adjustment of the height, manual adjustment of the
angle. Adjust the nozzle to the lowest point of the weed.
4. Left nozzle on/off
5. Main switch flow tray and nozzles
6. Right nozzle on/off
Fig. 7
Fig. 6
IMPORTANT: Set the nozzles to the lowest point. For the best
result you will spray the weed as low as possible.
INSTRUCTION: Always wear protective gloves while adjusting
the nozzles. When working with hot water, the materials will
also become hot.
Reversing camera
The reversing camera is started at the same time as the
machine and is on continuously, so you can always see what
is happening behind you.
5
IMPORTANT: While working with the hot water unit, keep an
eye on the temperature gauge on the control box in the
cabin. If the temperature on the gauge does not get above
90 ºC, this could indicate a failure. Then check the
temperature indicated by the digital gauge on the electric
box at the rear of the unit. If the indicated temperature is too
low here as well, you must contact your dealer for service.
Switching between the flow tray and the work lance
In the unit you will find the three-way valve, it will allow you to
switch between flow tray and work lance. It is easiest to
reach the three-way valve via the hole in the side of the unit
that is also used for filling the fuel tank (you will see the
three-way valve if you look upwards into the hole).
INSTRUCTION: When working with the reel and work lance,
always wear protective clothing as described in the Major
safety data to prevent injuries through burns.
IMPORTANT: Take into account that local legislation can
prescribe a licence for operating a high pressure sprayer
with a high water temperature from 102 ° C.
Switching the compressor on/off
You can find the switch for switching the compressor on and
off next to the opening for filling the fuel tank with diesel. The
compressor is always on and should remain on at all times. It
is possible that it is switched off as a result of the
overpressure safeguard.
Fig. 8
Fig. 9
Operating the reel
In order to unwind the reel you must pull the hose. During
unwinding you will hear a rattle at each rotation. Allow the
hose to veer in the middle of the rattle, so that the blocking is
placed on it. For rewinding the hose you must first pull further
to release the blocking (rattle stops). Then calmly allow it to
veer until the hose has been rewound.
Operating the work lance and work gun
Squeeze the handle of the work gun to allow the water to flow
from the pouring head. After a few seconds the water will be
at the right temperature and you will be able to control weed.
Fig. 10
IMPORTANT: Spray the weed as low as possible near the
ground. In case of higher weeds, work from the bottom to the
top for the best result.
NOTE: After use, store the lance and switch the three-way
valve back to the flow tray
Cleaning application work lance
The pouring head can simply be screwed off the work lance.
Then you will screw the high pressure nozzle on the lance and
the lance will be ready for cleaning work.
Fig. 11
6
After use
Switch off the electric control after use. Leave the flow tubes
open and then wait approximately 30 seconds before you
switch off the PTO. These actions allow the machine to cool
down.
IMPORTANT: Not observing the above-mentioned actions will
result in overloading the material and a short life span of the
unit.
Major safety data
If you do not observe the safety instructions below, this may
lead to physical harm to you or bystanders, damage to the
hot water unit or other properties. Read all safety information
below, prior to using the hot water unit.
Use
Always handle the hot water unit with great care. The unit is
made from technical and electronic components and has a
steel or aluminium housing. The unit can be damaged if it is
penetrated, dented, or if it makes contact with other fluids
than water. If the unit is damaged and shows signs of leaks,
there is a risk of injury or environmental damage, and you
should not use the unit. When using the hot water unit,
observe the applicable laws and regulations.
NOTE: The hot water unit is only intended to control weed with
boiling water of approximately 102 ºC on (semi-) hard
surfaces. Depending on the presence of the high pressure
cleaning option, the unit will be suitable for cleaning at high
pressure.
Protective clothing
While working with the hot water unit, always wear the
required protective clothing. Important are: protective
gloves, work shoes or boots and protective trousers or
overall.
Meaning of warning symbols
Symbols have been attached to the unit to support major
safety measures, including warning and operating symbols.
These should be easy to see, never remove these symbols.
Prior to using the hot water unit, read the
manual and safety instructions
Wear protective shoes
Wear protective gloves
the cabin or the beacon switch (depends on your tool
carrier).
Information on usage
The MCP-T has an hour counter, you can read the hours via
the display in the electric box. The electric box is opened by
means of the key and the handle. Then you will press buttons
A and B (fig. 12). The tractor has its own hour counter, for this
you can consult the tractor’s manual.
Wear protective clothes
Warning: hazardous (hot) vapours
Warning: high pressure cleaning with hot water
Warning: hot surfaces due to cleaning or weed
control with boiling water
Major technical usage data
Safeguards in the unit
The burner boilers have been provided with a temperature
and pressure sensor. The boilers are switched off if the
temperature gets too high or if the pressure gets too high or
too low.
For additional safety, the circuit consists of a thermostatic
safeguard. This safeguard will block the supply to the boiler in
case of a temperature that is too high.
The flow safeguard ensures that the boilers are switched off
when there is no flow in the circuit.
NOTE: All safeguards run via the unit’s PLC placed in the
switch box.
Tractor
For the optimal and safe working of the hot water unit, the
tractor has a few requirements:
•
A minimum of 50 HP
•
The weight of the tractor must be more than 1700 kg
•
PTO
•
Frontlift
IMPORTANT: Due to working with boiling water and the
potential hazard of burns, the tool carrier must be provided
with beacons. When driving on public roads, it must be
switched on.
Temperature during use
The hot water unit was designed for use in an environment
between 0 and 40ºC. The unit's components can get
damaged if this temperature is lower or higher.
Resetting the unit
You can reset the burners by pressing the reset button on the
electric box (See fig. 3). You must do this when the reset
button flashes, in that case you will have a burner failure. For
resetting the electric circuit, you must use the tool switch in
7
Fig. 12
Transportation
When driving with the tractor equipped with the hot water
unit, you will participate in traffic. Observe the applicable
traffic regulations.
INSTRUCTION: While driving with a hot water unit filled with
water there is an extra weigh load on the tractor, take this
weight very seriously. The maximum speed in driving mode is
20 km/h.
Important maintenance data
Check
Regularly check the fluids and the condition of all
components, parts and pipes in order to use the hot water
unit without problems and safely. For the benefit of
maintenance, observe the diagram 1. For the maintenance
diagram for your tractor, consult the accompanying manual.
Maintenance diagram MCP-T (diagram 1)
Prior to maintenance or repairs, always switch off the unit,
burners and tractor.
Complete machine
8
Annually
X
Burner boilers
Hydraulic circuit,
Pipes couplings
1x300 hours
After 100
hours
Work
Weekly
Daily
Frequency of
Each time
water is
taken in
Components
Global visual inspection by operator
•
General impression
•
Sensitive leak positions
•
Filter for benefit of work pump / high pressure
pump
•
Filter between filling pump and tank
•
Spray gun
•
Taps
•
Damage to cabling
•
Fluids
X
X
X
X
X
Check/adjust/return to a good condition:
•
Fuel solenoid valve
•
Pressure of the fuel pump
•
Thermostat
•
Flue gas temperature
•
Measuring the water delivery rate without
tubing
•
Diesel feed pump with filter
•
Measure the CO2 emission
•
Water temperature yield front
•
Soot formation in the boilers
•
Scaling in boiler
•
Ignition electrodes
•
Transformers and cabling
•
Water tank contamination
•
Pressure switch
Clean
•
Diesel filter
•
Flow switch
Replace
•
Electrodes (if necessary)
•
Vaporizers
Weekly inspection: check for damages
After 1st 100 hours: replace oil
Every 300 hours, major inspection: check for damages
mounted couplings for tight and good assembly; if
damaged, replace the part concerned
Annually: replace all high pressure hoses
High pressure water
pump
X
Electric
components
Fine filter
Flow tray
Annually
1x300 hours
After 100
hours
Work
Weekly
Daily
Frequency of
Each time
water is
taken in
Components
X
After 1st 100 hours, replace oil
Check:
•
Leaks at sensitive points water/oil
•
Manometer
•
Valves
•
Prevalence pressure relief valve for maximum
pressure and leakage
•
Plungers
Replace:
•
Sleeves
•
Seals
•
Oil
•
Seals pressure regulator/unloader
•
Seal overpressure
X
Check/replace:
•
Dynamo, if present
•
V-belt
•
Connections wiring and plug components
•
General condition of electric box and
connections
•
Control box cabin
•
Thermostat cabin
X
Flush, clean, replace if damaged
Check:
•
•
•
•
•
Clean:
•
•
•
•
General inspection
IMPORTANT: Drain the water before storing the unit for a long
period, in this way you will prevent it from freezing. As an
alternative you can fill the circuit with anti-freeze.
9
X
Water/oil leakage
Taps
Hoses (watch out for possible damage)
Air pipes (watch out for possible damage)
Cabling (watch out for possible damage)
Hinging and sliding components (including
re-lubrication)
Swivel casters
Support rollers
Flow tubes and flow heads at and in the tray
General inspection and maintenance by specialised
maintenance company
Clean the fine filter
The fine filter must be flushed clean regularly. In case of dirty
water, it is recommended to flush more often. See chapter 1
for the location of the filter.
General method for cleaning filter:
1.
Turn yellow button a ¼ turn anti-clockwise
2. Remove yellow button
3. Loosen filter
4. Disassemble filter house
5. Flush out filter
6. Mount filter
7. Mount, tighten filter house
8. Place back yellow button
Fig. 13
Cleaning the flow tubes of the flow tray
If necessary, thoroughly clean the spray tubes (flush clean,
blow clean). The spray tubes will have tob e dissembled.
Loosen 4 bolts – per tube – (1 metre flow tray and 1.5 metre
front tray). Remove the 2 split pins (1.4 metre flow tray), the
split pins will then have to be replaced when the spray tubes
are mounted again.
Fig. 14 Bolts 1 metre flow tray
Fig. 15 Attach bolts 1.5 metre flow tray
Fig. 16 Attach split pins 1.4 metre flow tray
10
Failures
Below you will find failures related to the hot water unit and
failures that could be related to the pump. In the diagram
you will find the possible causes and remedies for the failure.
Do not hesitate to contact your dealer when you have
questions or if there are problems concerning a failure.
Possible pump failures and remedies
Failure
Insufficient pressure/no water
Cause
Remedy
Pump sucks in air
Check fluid in tank
Check supply hose and couplings
Pump insufficiently bled
Supply blocked
The valves are dirty or worn
Water in the oil
The sleeves or plungers are leaking
High air humidity
Worn plunger seal
Pump is leaking fluid
Pump is leaking oil
Pump is not running
Worn oil catcher
Worn plunger/seal
Worn O-rings of the plunger guide
Oil level too high
Worn oil catcher/carter
Hydraulic circuit not switched on
Hydro safeguard flow/pressure
Bleed
Check water filters
Check, clean or replace
Check, clean or replace
Check and double the oil replacement
frequency
Check and replace
Check and replace
Check and replace
Check and replace
Check and adjust
Check and replace
Check
Check adjustment
Possible hot water unit failures and remedies
Failure
Temperature water too low
Too little water
No water
No power
Cause
Remedy
Sprayer contaminated
Clean sprayers
Diesel depleted
Filter blocked
Nozzles intake point blocked
Too little supply of hydraulic oil by pump
on tool carrier
Possible that high pressure water pump is
defective
Dynamo of tool carrier is not working
Machine switched off
11
Fill
Clean
Clean nozzles
Check hydraulics tool carrier for delivery
capacity
Replace/revise pump
Check power delivery of complete tool carrier;
check fuse of dynamo; if necessary, replace
dynamo
Switch on machine (by means of tool or beacon
switch)
Warranty
In case of professional personal use, the warranty period will
be six months after the date of purchase. This warranty
applies if a failure occurs with the product within the
applicable warranty period, under normal working
conditions. A recognised Empas dealer will replace the part
concerned in accordance with the warranty conditions.
NOTE: Transportation costs for defective, repaired or new
parts, components or accessories are not compensated.
Important
The following cases do not fall under the warranty condition:
•
Any failure that is the result of neglecting the user
instructions, adjustments and maintenance as
described in this manual.
•
Damage resulting from accidents, incorrect use,
negligence, changes to the machine or the use of
other parts, components or accessories not
recommended by Empas.
•
Replacing the filters.
•
Wear of parts, such as: rubber flaps, (high pressure)
hose, pump parts (valves and sleeves).
•
Additional or consequential damage.
Your legal right are not affected by this warranty condition.
12
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