03 - Repair and Overhaul Instructions En-F

MEYCO Spraymobile Potenza
Operating Instructions
Chapter 9 Overhaul
9 Overhaul
9.1 Introduction...................................................................................................................... 9-3

9.1.1 Qualification of personnel ................................................................................................ 9-3
9.1.2 Safety regulations............................................................................................................ 9-3
9.2 Removal and installation of expendable parts................................................................. 9-5
9.2.1 Wear plate and wear ring ................................................................................................ 9-5
9.2.2 S-tube .............................................................................................................................. 9-6
9.2.2.1 Removal .......................................................................................................................... 9-7
9.2.2.2 Installation ....................................................................................................................... 9-7
9.2.3 Conveyor piston collars ................................................................................................... 9-8
9.2.3.1 Removal .......................................................................................................................... 9-9
9.2.3.2 Installation ..................................................................................................................... 9-10
9.2.4 Robojet spray manipulator – replace the upper track roller........................................... 9-11
9.2.5 Robojet spray manipulator – replacing the lower track rollers....................................... 9-12
9.2.6 Replace the universal joint between support arm and mounting................................... 9-14
9.2.6.1 Removal of the universal joint ....................................................................................... 9-14
9.2.6.2 Replacing bearing bushes ............................................................................................. 9-16
9.2.6.3 Universal joint – installation ........................................................................................... 9-16
9.2.7 Replacing the guide rails on the extension boom.......................................................... 9-16
9.2.7.1 Removing the extension boom ...................................................................................... 9-17
9.2.7.2 Replacing the guide rails ............................................................................................... 9-19
9.2.7.3 Installing the extension boom ........................................................................................ 9-20
9.2.8 Replacing mounting - track rollers ................................................................................. 9-21
9.2.9 Replacing the chain, sprocket and deflection roller ....................................................... 9-22
9.2.10 Replace mounting – limit switch for the lance ............................................................... 9-24
9.2.11 Delivery unit of the dosing pump ................................................................................... 9-25
9.2.12 Cable reel ...................................................................................................................... 9-26
9.2.13 High-pressure cleaner ................................................................................................... 9-26
9.2.14 Water pump HP012E..................................................................................................... 9-26
9.2.15 Compressor (optional) ................................................................................................... 9-26
046-en-F 9-1
Chapter 9 Overhaul
9-2 046-en-F
Chapter 9 Overhaul
9.1 Introduction
9.1.1 Qualification of personnel
The machine may only be overhauled and qualified skilled personnel (e.g. mechanics,
electricians) who have completed instruction in overhauling authorised by the manufactu-
rer.
9.1.2 Safety regulations
R STOP – Beware of residual dangers:

First read Chapter 2 «Safety» and take note of all information on dangers
contained therein.
R STOP
The fire extinguisher mounted on the Spraymbile (option) may never be
removed from the vehicle except in case of fire fighting!
When the extinguisher is serviced, a spare device must be provided.
q WARNING
The vehicle should be secured against unwanted rolling before com-
mencing main-tenance work:
Switch off the engine, apply the handbrake securely and move the direc-
tion of travel lever to the neutral position.
q WARNING
The operator of the manual lever valves must ensure that nobody is in the
danger zone when lowering/extending the support feet.
Danger of crushing!
q WARNING
Work on electrical components should only be carried out by a qualified
electrician.
q WARNING
Ensure that the system is completely relieved of pressure before carrying
out main-tenance work on hydraulic components.
q WARNING
Ensure that pipes and connections under pressure are not leaking after
completion of maintenance work on hydraulic systems.
046-en-F 9-3
Chapter 9 Overhaul
q WARNING
Ensure that pipes are completely relieved of pressure when working on
the pneumatic system. Switch off the compressor!
q WARNING
Covers and protective elements should be refitted on completion of main-
tenance work.
q WARNING
Original MEYCO®spare parts should be used for maintenance work.
Meyco bears no responsibility if products from other manufacturers are
used.
q WARNING
Never reach into the area of the switch cylinder when the machine is swit-
ched on. This cylinder executes movements during automatic switching
which could cause serious hand or finger crushing. Switch off the
machine first with the main switch.
q WARNING
Never reach into the hopper when the machine is switched on. The S-tube
executes movements during automatic switching which could cause
serious hand or finger crushing. Switch off the machine first with the main
switch.
q WARNING
Never touch the outlet pipe connections and coupling when the machine
is switched on. These move to and fro during automatic switching and can
cause crushing of fingers. Switch off the machine first with the main
switch.
t CAUTION
Never reach into the (decoupled) conveying pipe exit opening when the
machine is switched on. Your hand or arm could be seized by the S-tube and be
injured. Switch off the machine first with the main switch.
t CAUTION
Removed parts must be completely replaced, or replaced by original spare
parts. Always use new parts for securing elements (stop nuts, split pins, detent
springs, etc.).
h NOTE
The powder – fire extinguisher (option) can be used for both fighting oil fires and
electric fires. It meets the Norms EN3/AB III E and EN 791/5.12.2.
The operator company has to make sure that further requirements (country-
specific or building site-specific) for extinguishers are observed and appropriate
arrangements made.
9-4 046-en-F
Chapter 9 Overhaul
9.2 Removal and installation of expendable parts
9.2.1 Wear plate and wear ring
q WARNING
Before working in the interior of the hopper, switch the machine off at the
main switch and disconnect the power supply. In addition, the pressure
accumulator should be checked for absence of pressure.
q WARNING
Bodily parts can be injured by being jammed between the screen and hop-
per edges when closing the heavy hopper screen of the spraymobile. Pay
attention to other persons who may be in the danger zone when closing.
• Switch off machine at main switch (position «0»). Fit the padlock.
• Check: Accumulator gauge pressure at 0 bar.
• Remove the bulkhead above hopper.
• Pull out the Harting plug at the hopper and release upper part of hopper (4 screws).
• Remove hopper upper part and place on clean surface, as the rubber seals will other-
wise become contaminated.
• Refer to Fig. 9-1: Release bearing plate (3), remove nuts (4), if possible not completely.
• Release the hydraulic fittings on both swivel cylinders so that oil flows out (place collec-
ting container below).
• Use a crowbar and press the S-tube into middle position.
• Position the crowbar between wear plate (14) and wear ring (6) and press the S-tube (1)
completely towards the outlet flange.
h NOTE
Ensure care that the splines on the plunger cylinders do not tilt.
• The wear ring (6) is now exposed and can be removed.

• Release the 6 bolts on the hopper side (17) and 1 bolt on the rear (18) and remove the
wear plate (14).
h NOTE
When fitting the gland and ring ensure that all surfaces have been cleaned and
greased. The seals must be properly inserted and should not be damaged when
fitting. Note:
x Ring: 1 O-Ring, 1 sealing washer siding
x Plate: 2 O-Rings
• Slowly and alternately tighten the nuts of the bearing plate until the wear ring (6) uni-
formly touches the wear plate.
• Fully assemble the hopper, attach the bulkhead and connect the Harting plug.
046-en-F 9-5
Chapter 9 Overhaul
• Close the hopper sieve.

• Adjust the sealing of the S-tube as described in Chapter 7.4.6.
18
17
Fig. 9-1 S-tube cmpl.
1. S-tube 10. Discharge outlet

2. Switch seal ring 11.
3. Base plate (front) 12. Flange for coupling connection
4. Nuts (4 x) 13. Half-rings
5. Splined shaft 14. Wear plate
6. Wear ring 15. Flange
7. Upper bolts of swivel cylinder 16. Flange screws
8. Rear bearing of S-tube 17. Hopper side
9. Ring 18. Rear side
9.2.2 S-tube
q WARNING
q WARNING
9-6 046-en-F
Chapter 9 Overhaul
9.2.2.1 Removal
• Switch off machine at main switch (position «0»). Fit the padlock.
• Mark position of the S-tube (1) for assembly later (refer to Fig. 9-2)
• Remove 8 screws (16).
• Install 1 screw (16) each in the threaded holes on the flange (15) and, thus, press out
the complete
• S-tube by approx. 5 cm.
• Remove the wear ring (6).
• Move the complete S-tube out of the hopper.
h NOTE
Ensure that the spline is free of dirt.
9.2.2.2 Installation
• Insert the S-tube into the hopper through the flange opening (refer to Fig. 9-2).
• Install the wear ring.
• Position the flange (15) in the hopper so that the gearing of the S-tube is in the correct
position. 9-2).
• Lightly install 8 screws (16) by a few threads.
• Release 4 nuts (4) by three to four turns.
• Fully tighten the 8 screws (16).
• Adjustment of the S-tube sealing (refer to Chapter 7.4.2).
h NOTE
Take care that all seals are properly inserted and are not damaged when fitting.
18
17
Fig. 9-2 S-tube cmpl.
046-en-F 9-7
Chapter 9 Overhaul
1. S-tube 10. Discharge outlet

2. Switch seal ring 11.
3. Base plate (front) 12. Flange for coupling connection
4. Nuts (4 x) 13. Half-rings
5. Splined shaft 14. Wear plate
6. Wear ring 15. Flange
7. Upper bolts of swivel cylinder 16. Flange screws
8. Rear bearing of S-tube 17. Hopper side
9. Ring 18. Rear side
9.2.3 Conveyor piston collars
q WARNING
q WARNING
• Switch off machine at main switch (position «0»).

• Remove hopper part (see Chapter 9.2.1).
• Bridge the hopper monitoring.
• Remove wear plate (see Chapter 9.2.1).
• Remove all electrical connectors on the accumulator charge block.
• Remove the connector at pressure switch B632. The pressure switch is located on the
flushing manifold, on the Suprema hydraulic pump.
• Disconnect the plug from the electrical limit switch («Proximitor») at the hydraulic cylin-
der, of which the allocated conveying cylinder is exposed, viewed from the hopper.
q WARNING
Remove any objects from the feed hopper and do not reach into the hop-
per thereaf-ter (danger of injury!) so that the machine can be switched on
briefly for the move-ment of the piston.
• Switch on machine at main switch (position «1»).

• Switch on the main pump and feed, so that the piston in the exposed cylinder can move
fully forward to the stop.
• Switch off main pump and feed.
9-8 046-en-F
Chapter 9 Overhaul
q WARNING
Ensure that following conditions are achieved: Main switch is at «OFF»
position. Pressure accumulator is relieved of all pressure. Non-
compliance with this regulation can lead to serious injuries.
9.2.3.1 Removal
Now the conveyor piston packing can be replaced as follows:
The piston is located at front

The machine is switched off
Accumulator pressure is «0»
Remove safety wire

Undo 3 M10 screws and remove the cover disc.
The M12 threaded hole is visible.
Screw an M12 screw into the centre and draw out the
piston with its help.
Fig. 9-3 Removal of piston
h NOTE
The exchange of the second piston packing takes place later. But first, the new
packing must be installed as described below.
046-en-F 9-9
Chapter 9 Overhaul
9.2.3.2 Installation
Check parts for wear and replace if necessary.
Clean remaining parts.
Screw in 3 threaded rods (M10x150) into the piston

mounting. Re-adjust piston with support and locating
ring and tighten evenly with 3 M10 nuts on the piston
mounting.
Screw home circular base if the piston is properly set,

using the 3 original M10 screws.
Insert new safety wire and twist.
Fig. 9-4 Fitting piston
Replace the removed connector on the electrical limit switch («Proximitor») and simultane-
ously remove the connector from the other cylinder. Reconnect all electrical connectors on
the accumulator charge block without confusing them.
q WARNING
Remove any objects from the feed hopper and do not reach into the hop-
per thereaf-ter (danger of injury!) so that the machine can be switched on
briefly for the move-ment of the piston.
• Switch on machine at main switch (position «1»).

• Switch on main drive and feed. Wait until the S-tube switches once and the piston in the
exposed cylinder has moved completely to the front.
• Switch off main pump and feed.
• Remove all electrical connectors from the accumulator charge block.
9-10 046-en-F
Chapter 9 Overhaul
q WARNING
Ensure that following conditions are achieved: Main switch is at «OFF»
position. Pressure accumulator is relieved of all pressure. Non-
compliance with this regulation can lead to serious injuries.
Removal and installation of the conveying piston is as described above.

• Connect the disconnected plug to the electric limit switch («Proximitor»).
• Correctly connect all electrical connectors on the accumulator charge manifold.
• Connector the plug to the pressure switch.
• Install the wear plate (see Chapter 9.2.1).
• Install the upper part of the hopper (see Chapter 9.2.1).
• Remove the hopper monitoring.
q WARNING
Ensure that the provisional wire jumper in the Harting connector has
really been removed. If not, the hopper screen protection switch remains
ineffective. This can lead to serious accidents under certain circum-
stances.
9.2.4 Robojet spray manipulator – replace the upper track roller

• Fully retract the extension boom (function «B» on).
• Switch off the system and make sure that all hydraulic pressure has dissipated
Fig. 9-5
046-en-F 9-11
Chapter 9 Overhaul
1. Attachment bolt for shaft 7. Roller bearing

2. Shaft for rocker suspension 8. Track roller
3. Bearing bush 9. Attachment bracket for the track rollers
4. Rocker for both rollers 10. Bolts for the attachment bracket
5. Inner ring 11. Spacer plate
6. Shaft seals
• Release the screwed fittings on both sides (Pos. 10). Fully remove the bolts on one side.
• Remove the attachment bolt (1) on the opposite side.
• The attachment bracket released, together with the rocker and all the track rollers, can
be extracted from the side.
Spare parts:
It is recommended to replace all wear parts. For this, the following is defined by MEYCO®
Equipment as a recommended spare part kit:
«Track rollers complete» Item No. 041 41 13
This kit contains:

• Track roller including roller bearing, shaft sealing rings and spacers
• Shafts for track rollers, incl. fittings
• Rockers
• Bearing bushes for suspension
Assembly:
• Insert the new rocker and track rollers.
• Lightly lubricate the shaft (2) grease and install it.
• Install the attachment bolts and washers and fully tighten the bolts.
• Adjust the play of the extension boom in the support boom in accordance with chapter
7.4.4.
9.2.5 Robojet spray manipulator – replacing the lower track rollers
q WARNING
The extension boom must be supported to relieve the pressure on the
roller to be inserted or removed and avoid injuries to fingers.
• Retract the extension boom so that only approx. 50 cm protrudes. (Function «B» on),
Fig. 9-6
• Support the mounting and extension boom, so that there is no pressure on the lower rol-
lers (Fig. 9-6)
9-12 046-en-F
Chapter 9 Overhaul
Fig. 9-6
Fig. 9-7
1. Attachment screw 5. Inner ring

2. Shaft for rocker suspension 6. Shaft seal
3. Bearing bush 7. Roller bearing
4. Rocker for both rollers 8. Track roller
• Remove bolt (Pos. 01) on one side

• Remove shaft (Pos. 02)
• Extend forwards the complete rocker and both track rollers
Spare parts:
It is recommended to replace all expandable parts. For this, the following is defined by
MEYCO® Equipment as a recommended spare part kit:
«Track roller complete» Item No. 041 41 13
046-en-F 9-13
Chapter 9 Overhaul
This set is assembled and contains:

• Track rollers, incl. roller bearing, shaft seals and spacers
• Shafts for track rollers, incl. fittings
• Rockers
• Bearing bushes for suspension
Assembly:
• Retract the new rocker and track rollers.
• Lightly lubricate the shaft (Pos. 02) and install
• Install the attachment bolts and washers and fully tighten the bolts.
• Dissipate the pressure in the extension boom so that it rests on the two rollers
9.2.6 Replace the universal joint between support arm and mounting
When is it necessary to replace the universal joint or bearings?

As the peripheral between support boom and mounting, the universal joint is subject to
very high loads. The bearing bushes and bolts wear in the course of time. In the extreme
case, the bores on the universal joint wear. This is primarily detected when the vehicle is
moving, the mounting «jumps» relative to the support boom due to excessive play in the
connection.
9.2.6.1 Removal of the universal joint
q WARNING
The entire mounting, lance holder assembly (Pos 02), with the lance (Pos
01) and the support (Pos 03) are disconnected from the extension boom
headstock when removing the joint-piece (Pos 04).
It is imperative to ensure that this part be securely supported.
Collapse or falling of the disconnected parts can lead to severe machine
damage and serious injury.
t CAUTION
Resting the disconnected components on cylinders, hoses, cables and edges
can lead to damage to the machine.
h NOTE
No hydraulic hoses or electrical cables need be disconnected when dismantling
the lance and mounting.
9-14 046-en-F
Chapter 9 Overhaul
Fig. 9-8
• Extend the extension boom (function «B» off).
• Position the mounting (Fig. 9-7-1, Pos. 01) as near to the horizontal as possible.
• Release the clamps and cable ties of the hydraulic hoses (Pos. 08) and remove the
hoses from the head piece of the extension boom
• Use a crane and secure the mounting.
• Remove the connection (8 bolts M16) between the mounting and support (Pos. 03) and
pivot the mounting away from the support.
• Safely place down the lance (Pos.1) and mounting (Pos. 02)
• Remove the bolts from the C-cylinder (Pos. 06) at the universal joint (Pos. 04) and care-
fully lower the cylinder
t CAUTION
Tie the loose cylinder securely to the support and be careful that the cylinder rod
of the C-cylinder is not damaged.
• Use a crane and secure the support (Pos. 03).

• Remove the connecting bolts from the universal joint (Pos. 04) and support (Pos. 03).
• Pivot the support away place down safely
• Remove the bolts from the EG-cylinder (Pos. 07) at the universal joint (Pos. 04) and
carefully lower the cylinder
t CAUTION
Be careful that the cylinder rod of the EG-cylinder is not damaged and that no
lateral pres-sure is applied to the cylinder rod.
• Release the nut of the support bolt between the universal joint (Pos. 04) and head piece
of the extension boom (Pos. 05)
• When the universal joint is secured against falling, remove the bolts and universal joint.
046-en-F 9-15
Chapter 9 Overhaul
9.2.6.2 Replacing bearing bushes
• When replacing the universal joint, it is recommended to replace all bearing bushes and
bolts:
2 pieces. Bearing bushes in universal joint Item 2 255 206
2 pieces. Thrust washer on universal joint Item 2 255 210
2 pieces. Bronze bushes in support Item 041 49 10
• In all cases, replace both grooved lock nuts M30x1.5 (Item 2 219 350)
• Worn support bolts must be replaced
• If the bolt holes are oval or damaged, replace the complete universal joint.
For the numbers of the spare parts for the universal joint, bolts etc., refer to the detailed
parts list in the manuals (refer to parts list 041 43 01).
9.2.6.3 Universal joint – installation
Installation of the universal joint is carried out in the reverse sequence of the removal
(Chapter 9.2.6.1).
q WARNING
The maximum allowed torque for the safety nut M30 x 1.5 of both connec-
tion bolts lance assembly/joint-piece and joint-piece /carrier boom is:
Mmax = 100 Nm
9.2.7 Replacing the guide rails on the extension boom
The extension boom guide rails are made of special high-strength steel. However, over
time, they show signs of wear.
It is then necessary to remove the old guide rails and weld on new ones.
When is it necessary to replace old guide rails?
New guide rails are 40 mm wide and 7 mm thick.
It is recommended to replace guide rails if they are worn

down to 4 mm, or indicate excessive ruts.
Fig. 9-9
9-16 046-en-F
Chapter 9 Overhaul
9.2.7.1 Removing the extension boom
q WARNING
The entire mounting, lance, the joint assembly and support are discon-
nected from the extension boom headstock when removing the extension
boom.
It is imperative to ensure that this part can be securely supported.
Collapse or falling of the disconnected parts can lead to severe machine
damage and serious injury.
t CAUTION
Resting the disconnected components on cylinders, hoses, cables and edges
can lead to damage to the machine.
(refer to Fig. 9-10, Pos. 02)
h NOTE
No hydraulic hoses or electrical cables need be disconnected when dismantling
the lance and mounting.
Fig. 9-10
• Fully extend the extension boom (function «B» off).
• Position the mounting as near to horizontal as possible
• Securely support the lance and mounting (refer to Fig. 9-10, Pos. 01)
• Release both hydraulic hoses (Fig. 9-10, Pos. 04) and remove the hoses from the head
piece of the extension boom
• Remove the bolts from the EG-cylinder (Fig. 9-10, Pos. 05) and carefully lower the cylin-
der
t CAUTION
Be careful that the cylinder rod of the EG-cylinder is not damaged and that no
lateral pres-sure is applied to the cylinder rod.
• Release the nut from the support bolt between the universal joint and head piece (Fig. 9-
10, Pos. 03)
046-en-F 9-17
Chapter 9 Overhaul
• When the mounting and lance are securely supported, remove the bolt.
The complete front part of the spray manipulators is now disconnected from the exten-
sion boom.
Fig. 9-11
q WARNING
Ensure that none of the mounting and lance functions are active when the
hydraulic system is under pressure
o accident risk
• Only if necessary, slightly retract the extension boom (function «B»).

• Position the carrier boom as near to horizontal as possible (function «F») and swivel
away to the side (function «D»).
• Suspend the extension boom on the crane and secure (Fig. 9-11)
• Mass of extension boom with head piece: approx. 240 kg.
• The centre of gravity of the extension boom with head piece is located approx. 1.14 met-
res behind the head piece.
Fig. 9-12
Disconnect the connection between the B-cylinder (in the extension boom) and the exten-
sion boom: Remove the split pin and bolt, carefully lower the piston rod
9-18 046-en-F
Chapter 9 Overhaul
q WARNING
o accident risk
• Fully retract the B-cylinder to protect the piston rod (function «B» on).
• Pull out the extension boom, suspended on the crane, from the support boom
• Place the extension boom on a stable surface
9.2.7.2 Replacing the guide rails
• Only replace guide rails in pairs

• Cut off the old guide rails
• Grind and clean the surface of the extension boom.
The new guide rails must rest absolutely flat on the extension boom.
h NOTE
The extension boom guides are made of special highly-resistant steel.
Extension boom guides Art.no. 041 49 41 (1 x)
h NOTE
Heat must be kept to a minimum when welding on the guides!
Guides can otherwise become soft.
Apply short welds on alternating sides for this purpose (see Fig. 9-12)
Weld on the new guide rails in accordance with Fig. 9-13 and Fig. 9-14
Caution during welding!

The heat input must be kept as low
as possible!
Otherwise the material becomes
weld alternately
Fig. 9-13
046-en-F 9-19
Chapter 9 Overhaul
Fig. 9-14
Check the overall height of 230 mm after welding on the guide rails. If the dimension
exceeds 230 mm, rework the surface!
9.2.7.3 Installing the extension boom
• Release the upper track roller on the carrier boom (in accordance with Chapter 7.4.4,
«Adjustment of play»).
• Retract the extension boom into the support boom. However, do not yet remove the
safety straps.
• Pressurise the hydraulic system.
• Extend the B-cylinder far enough to align the eye of the cylinder with the eye on the
extension boom.
• Connect the B-cylinder and extension boom with the bolt. Secure with split pins!
q WARNING
o accident risk
q WARNING
It is imperative that bolts are secured with split-pins!
Bolts can otherwise loosen during operation and the extension boom
could move of its own accord o accident risk
• Carefully fully retract the extension boom (function «B» on).
• Adjust the play of the extension boom in accordance with Chapter 7.4.4
• Connect the mounting to the extension boom
9-20 046-en-F
Chapter 9 Overhaul
q WARNING
The maximum allowed torque for the safety nut M30 x 1.5 of both connec-
tion bolts lance assembly/joint-piece and joint-piece /carrier boom is:
Mmax = 100 Nm
• Connect the EG-cylinder to the extension boom.

• Install the hydraulic fittings on the head piece
9.2.8 Replacing mounting - track rollers
Track rollers must be replaced when the guide rails indicate severe wear and rutting, or
the rollers are worn so that the play can no longer be taken up by adjusting the eccentric
shaft.
Spare parts:
MEYCO® Equipment recommends the following spare parts:
«Roller (complete)» Item No. 041 05 20

(consisting of the roller, roller bearing and distance bush)
«Eccentric shaft» Item No. 041 35 54
1. Track roller
2. Eccentric shaft
3. Hexagon-headed bolt
4. Roller bearing for roller
5. Spacer bush for track roller
6. Lance
7. Mounting
8. Track roller housing with
removable cover (integral part of
mounting)
Fig. 9-15
Removing and mounting the upper rollers:

• Move the lance to the central position (relative to the mounting) to prevent it tilting for-
wards or backwards when loosening the rollers.
• Remove the roller cover
046-en-F 9-21
Chapter 9 Overhaul
• Remove the hexagon-headed bolts (Pos. 03) of the lower rollers and rotate the eccentric
shafts (Pos. 02) so that the track rollers (Pos. 01) at at the lowest position (thus, there is
no pressure on the upper rollers)
• Remove the hexagon-headed bolts from the upper rollers and tap out the eccentric shaft
with a punch
• Replace the old rollers with new rollers
• Before installing the eccentric shaft, check the bearing surfaces. If necessary, replace
the eccentric shaft. Lightly lubricate the bearing surfaces with grease.
• Put the eccentric shaft in position and lightly install the hexagon-headed bolts
Removal and installation of the lower rollers:

• Support the lance at the front and rear, or slightly raise with a crane (Fig. 9-15)
• Make sure that there is no pressure on the lower track rollers, raise the lance
• Removal and installation of the lower track rollers is the same as the upper track rollers
• Remove the lance supports and disconnect from crane
Fig. 9-16
Adjusting the play:

Adjust the play of the lance relative to the mounting (in accordance with Chapter 7.4.5).
9.2.9 Replacing the chain, sprocket and deflection roller
Chain offset and high stresses result in wear of the sprocket and deflection roller. It is
recommended to periodically check these components and, if signs of excessive wear,
replace them.
Wear of components:
Replace the sprocket if the tooth flanks or peaks indicate
excessive wear (Pos. 02). As a check, compare with a new
sprocket (Pos. 01).
9-22 046-en-F
Chapter 9 Overhaul
The track rollers are replaced if signs of rolling tracks are

visible on the running surfaces (Pos. 04) or extreme depo-
sits have formed on the edges (Pos. 03). Or also if the roller
bearing is worn and the inner ring does not rotate correctly.
The chain must be replaced if the following is indicated: The

webs and rollers of the parts are worn (Pos. 05). Excessive
elongation of the chain. Elongation must not exceed 102%
of the original length (refer to Fig. 9-16).
Chain distortion:
The distance over 10
links on a new chain is
245 mm.
Stress causes the chain

to expand. The chain
must be replaced if the
distance formed by 10
links is greater than 259
mm.
Lmax. permitted = 102 % x Lnew
Spare parts:
«Sprocket (1"), 11 teeth" Item No. 041 38 48
«Tensioning wheel» (deflection roller with roller bearing) Item No. 041 35 89
«Chain (1"), L=4476 mm" (175 links) Item No. 041 35 48
Fig. 9-17
046-en-F 9-23
Chapter 9 Overhaul
1. Sprocket (1") 5. Spacer tube

2. Deflection pulley incl. roller bearing 6. Hex.-headed bolt as axis for deflection
pulley
3. Spacer 7. Gearbox with splined shaft
4. End plate
Removal and installation

• Position the mounting as near to horizontal as possible and secure the lance to prevent
it moving when the drive chain is released
q WARNING
The lance can move of its own accord in the mounting if it is not secured
when the drive is disconnected. This can lead to serious injuries (crus-
hing).
• Remove the cover plate from the sprocket (2 screws)
• Release the drive chain on the tensioner so that it can be lifted off the drive pinion
• Release both bolts (Pos. 06) of the deflection roller and remove the rollers
• Release the end plate (Pos. 04) and spacer (Pos. (03) from the gearbox shaft (one hex.-
headed bolt M6 and three countersunk screws)
• Pull the sprocket off the splined shaft
• If the chain must be replaced: Fully release the chain using the tensioner and remove
• Install in reverse sequence
h NOTE
Secure the three countersunk screws in the end disk against loosening after
assembly by striking them with a centre punch. Apply Loctite to the hexagonal
screw (M6)!
9.2.10 Replace mounting – limit switch for the lance
If damage occurs to one of the two limit switches for the function «Lance automatic», this
must be replaced.
Thereby, it is important to correctly position the new switch (height setting).
q WARNING
Only qualified and instructed electrical personnel should carry out work
on electrical wiring and components.
9-24 046-en-F
Chapter 9 Overhaul
• Move the lance to the limit stop position

so that the welded contact element on
the lance is above the switch
• Switch off system electrically (main
switch on the E-cabinet to «OFF»)
• Remove defective switch and disconnect
electrically (at the switch)
• Install new limit switch, however, do not
fully tighten the screws
• Push the switches upwards until the
electrical contact closes (electrician
should check the make contact)
• Observe instruction for Fig. 9-19. Fully
tighten screws
• Connect electrical power supply and
close housing
• Install cover
Fig. 9-18
Pos. 01:
Limit switch in non-contact position
Pos. 02:
The contact roller pushed in by at least 4 -
5 mm until a contact is established (electri-
cal make contact)
As soon as the contact is closed, push the
limit switch approx. another 2 mm upwards
and fully tighten the screws.
Fig. 9-19
9.2.11 Delivery unit of the dosing pump
Maintain and service the dosing pump in accordance with the manufacturer's instructions
given in the appendix «Commissioning and maintenance of MOINEAU PUMPS».
h NOTE
We recommend NEVER-SEEZ grease from Bostik for the universal joints.
046-en-F 9-25
Chapter 9 Overhaul
9.2.12 Cable reel
Maintenance tasks for the cable reel are described in the separate operating instructions
from manufacturer of the cable reel.
Spare parts drawings and lists are also contained in these operating instructions.
9.2.13 High-pressure cleaner
Maintenance tasks for the high-pressure cleaner are described in the separate operating
instructions provided by the manufacturer of the high-pressure cleaner.
9.2.14 Water pump HP012E
Maintenance tasks for the water pump are described in the separate operating instructions
provided by the manufacturer of the water pump.
9.2.15 Compressor (optional)
Maintenance tasks for the compressor are described in the separate operating instructions
provided by the manufacturer of the compressor.
9-26 046-en-F

03 - Repair and Overhaul Instructions En-F

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

03 - Repair and Overhaul Instructions En-F

Uploaded by

Copyright:

Available Formats

MEYCO Spraymobile Potenza

9.1 Introduction...................................................................................................................... 9-3

9.1.1 Qualification of personnel

9.1.2 Safety regulations

R STOP – Beware of residual dangers:

9.2 Removal and installation of expendable parts

9.2.1 Wear plate and wear ring

• The wear ring (6) is now exposed and can be removed.

• Close the hopper sieve.

1. S-tube 10. Discharge outlet

1. S-tube 10. Discharge outlet

9.2.3 Conveyor piston collars

• Switch off machine at main switch (position «0»).

• Switch on machine at main switch (position «1»).

Now the conveyor piston packing can be replaced as follows:

The piston is located at front

Remove safety wire

Fig. 9-3 Removal of piston

Check parts for wear and replace if necessary.

Clean remaining parts.

Screw in 3 threaded rods (M10x150) into the piston

Screw home circular base if the piston is properly set,

Fig. 9-4 Fitting piston

• Switch on machine at main switch (position «1»).

Removal and installation of the conveying piston is as described above.

9.2.4 Robojet spray manipulator – replace the upper track roller

1. Attachment bolt for shaft 7. Roller bearing

This kit contains:

9.2.5 Robojet spray manipulator – replacing the lower track rollers

1. Attachment screw 5. Inner ring

• Remove bolt (Pos. 01) on one side

This set is assembled and contains:

When is it necessary to replace the universal joint or bearings?

9.2.6.1 Removal of the universal joint

• Use a crane and secure the support (Pos. 03).

9.2.6.2 Replacing bearing bushes

9.2.6.3 Universal joint – installation

9.2.7 Replacing the guide rails on the extension boom

It is recommended to replace guide rails if they are worn

9.2.7.1 Removing the extension boom

• Only if necessary, slightly retract the extension boom (function «B»).

9.2.7.2 Replacing the guide rails

• Only replace guide rails in pairs

Caution during welding!

9.2.7.3 Installing the extension boom

• Connect the EG-cylinder to the extension boom.

9.2.8 Replacing mounting - track rollers

MEYCO® Equipment recommends the following spare parts:

«Roller (complete)» Item No. 041 05 20

«Eccentric shaft» Item No. 041 35 54

Removing and mounting the upper rollers:

Removal and installation of the lower rollers:

Adjusting the play:

9.2.9 Replacing the chain, sprocket and deflection roller

The track rollers are replaced if signs of rolling tracks are

The chain must be replaced if the following is indicated: The

Stress causes the chain

Lmax. permitted = 102 % x Lnew

1. Sprocket (1") 5. Spacer tube

Removal and installation

9.2.10 Replace mounting – limit switch for the lance

• Move the lance to the limit stop position

9.2.11 Delivery unit of the dosing pump