Hardi ATV sprayer 550 L service schedule

Sprayers · 2005 manual (67302803, Hardi Inc., North America)

Covers the Hardi ATV sprayer 550 L (150 US gal), diaphragm pump.

Every maker's service job for the Hardi ATV sprayer 550 L, counted in hours, with the oils, filters and parts each one needs. Add your implement to Farmyard Workshop and it works out what's due from your hours and dates, and keeps the service history.

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Service intervals

Job	When
Grease axle, boom and trapeze (every 8 hours)	every 8 hours
Grease the pump; oil the agitation control	every 40 hours
Torque the boom breakaway clutch (every 40 hours)	every 40 hours
Wheel nuts and wheel bearing play	every 50 hours
Repack axle bearings	every 1,000 hours or every year
Off-season storage and frost protection	every year
Sprayer test (NSTS)	every 3 years
Pump valves and diaphragms (1203 pump)	when needed

Service jobs and parts

Grease axle, boom and trapeze (every 8 hours)

Lubrication · every 8 hours

Hardi's lubrication table for this sprayer gives 8 hours for the axle, the MB boom and the 40 ft trapeze, and daily (8 hours) for the boom breakaway clutch.

Part	Qty	Notes	Part number
Grease	1	NLGI 2 lithium grease.. Aztec Oils match: VOLCATEC LITHIUM EP 2	check your handbook

Step-by-step

Park the quad and sprayer on level ground, stop the sprayer engine and the quad, and take both keys out. Chock the sprayer wheels.
Wear chemical-resistant gloves and wipe each nipple clean.
Grease the axle points, the boom pivots, the trapeze (40 ft boom) and the breakaway clutch.
Wipe off surplus. Wash gloves before taking them off and wash your hands.

Tools: Grease gun, Rags

Grease the pump; oil the agitation control

Pump · every 40 hours

Hardi's table gives 40 hours for the pump grease point and 50 hours for oiling the agitation control. Done together at 40 hours.

Part	Qty	Notes	Part number
Grease	1	NLGI 2 lithium grease.. Aztec Oils match: VOLCATEC LITHIUM EP 2	check your handbook
Light oil	1	For the agitation control; grade not given	check your handbook

Step-by-step

Stop the sprayer engine and take the key out. Wear chemical-resistant gloves.
Grease the pump crankshaft nipple.
Oil the agitation control valve.
Wash gloves before taking them off and wash your hands.

Tools: Grease gun, Oil can

Torque the boom breakaway clutch (every 40 hours)

Boom · every 40 hours

Hardi says the breakaway clutch cap screws must be torqued to 55 Nm (40 lb ft) every week (40 hours) to prevent boom damage, and the clutch lubricated daily.

Step-by-step

Stop the sprayer engine and the quad and take the keys out. Unfold the boom on level ground.
Never put your fingers into an open breakaway clutch: it can snap shut.
Grease the clutch, then torque the cap screws to 55 Nm (40 lb ft).
If the wing breaks away too easily, tighten nut C; if too stiff, loosen it. It is right when the wing returns into line by itself. Tighten the jam nut. Do not overtighten.

Tools: Torque wrench

Wheel nuts and wheel bearing play

Wheels · every 50 hours

Hardi: check wheel nuts after the first 8 hours and then every 50 hours (85 lb ft maximum). Check bearing play after 8 and 50 hours and then every 100 hours; done here at the 50-hour wheel check.

Part	Qty	Notes	Part number
Split pin (cotter pin)	2	New if the old one is damaged	check your handbook

Step-by-step

Drain the tank completely first. Park on level ground, stop the engines, take the keys out and chock the wheels.
Torque the wheel nuts to 85 lb ft (≈115 Nm) maximum.
To check the bearings, jack one side up and support it on a stand. Rock the wheel; there should be no slack.
To adjust: remove the hub cap and split pin, tighten the axle nut until the hub just drags, then back off to the first split pin hole. Fit a new split pin and the hub cap.
Check the tyres: 23 x 10.5-12 at no more than 20 psi (1.5 bar), and do not tow faster than 15 mph.

Tools: Torque wrench, Jack and axle stand, Wheel chocks, Pliers

Repack axle bearings

Wheels · every 1,000 hours or every year

Hardi says repack the axle bearings with new grease after 1,000 hours or once a year.

Part	Qty	Notes	Part number
Wheel bearing grease	1	NLGI 2 lithium grease.. Aztec Oils match: VOLCATEC LITHIUM EP 2	check your handbook
Hub seals	2	Check your handbook	check your handbook
Split pins	2		check your handbook

Step-by-step

Drain the tank. Park level, stop the engines, take the keys out, chock the wheels and support the axle on stands.
Remove the wheel, hub cap, split pin and nut, then the hub.
Clean out the old grease, check the bearings and races for pitting, and pack with new grease.
Refit, set the bearing play as in the wheel task, fit a new split pin and refit the wheel.

Tools: Jack and axle stands, Wheel brace, Bearing packer or gloves, Pliers

Off-season storage and frost protection

Storage · every year

Hardi's off-season programme for this sprayer: clean out all residues, drain, run anti-freeze through every line and nozzle, store the gauge frost-free, protect the electrics and take the weight off the tyres.

Part	Qty	Notes	Part number
Ethylene glycol anti-freeze	1	Mixed for the frost protection you need	check your handbook
Anti-corrosion oil	1	e.g. Shell Ensis Fluid or Castrol Rustillo	check your handbook

Step-by-step

Wear chemical-resistant gloves and eye protection. Clean the sprayer inside and out with detergent, then flush with clean water.
Replace damaged seals and fix leaks. Empty the sprayer and run the pump until air comes out of every nozzle.
Pour in anti-freeze mixture, run the pump and work every valve. Spray the spray gun into the tank and open the boom valves until anti-freeze comes out.
Touch up the paint, grease every point and oil bare metal (not rubber, hoses or tyres).
Remove the glycerine-filled gauge and store it frost-free and upright. Bag the plugs and sockets and store the control boxes dry.
Jack up the axle and put the wheels on wooden blocks. Cover with a ventilated tarpaulin.
In spring: drain the anti-freeze (dispose of it properly), rinse the whole circuit with clean water and test all functions.

Tools: Jack, Wooden blocks, Plastic bags, Tarpaulin

Sprayer test (NSTS)

Legal · every 3 years

Under UK law (SI 2012/1657 reg. 11) a professional boom sprayer with a boom over 3 m must be tested before it is 5 years old and then at least every 3 years. All the MB booms on this sprayer are over 3 m.

Step-by-step

Book a test at an NSTS test centre before the certificate runs out.
Wear chemical-resistant gloves and eye protection. Clean the sprayer inside and out.
Check hoses, pressure gauge, nozzles and the boom breakaway work properly.
Keep the certificate and diary the next date. Wash your hands afterwards.

Tools: Pressure washer, Nozzle brush, PPE as the last chemical label says

Pump valves and diaphragms (1203 pump)

Pump · when needed

No fixed interval. Hardi recommends that if one diaphragm or valve needs replacing, all are replaced, using the complete 1203 rebuild kit.

Part	Qty	Notes	Part number
Complete rebuild kit, 1203 diaphragm pump	1	Genuine Hardi	750696
Valve O-rings	1	Genuine Hardi; number per manual, quantity: check your pump	330072

Step-by-step

Clean and rinse the sprayer. Stop the engine and take the key out. Wear chemical-resistant gloves and eye protection.
Remove the valve covers; note which way each valve faces.
Remove the diaphragm covers and diaphragm bolts and change the diaphragms.
If liquid reached the crankcase, re-grease the pump and clear the drain hole underneath.
Refit: valve cover 60 Nm (45 lb ft), diaphragm bolt 60 Nm (45 lb ft), diaphragm cover 70 Nm (50 lb ft).
Test with clean water before using chemical.

Tools: Spanners and sockets, Torque wrench (to 70 Nm), Chemical-resistant gloves, Eye protection

Oils, fluids and capacities

System	Oil or spec	Capacity
Engine	Petrol engine with reduction gearbox, directly coupled to a Hardi 1203 diaphragm pump (engine make: check your handbook)
Engine oil	As the engine maker's manual says (Hardi refers you to it)
Grease points	Ball bearing grease (lithium grease No. 2)
Agitation control	Oil (grade not given)
Engine crankcase and reduction gearbox	Engine maker's handbook	Shipped dry: fill before first use
Frost protection	Ethylene glycol anti-freeze and water, at the strength for the frost expected	Enough to keep the tank sump full while pumping

Specifications


Tank	550 L (150 US gal) polyethylene, with optional 15 L clean water tank
Booms	MB, 20, 26, 33 or 40 ft (≈6–12 m), 20 in (50 cm) nozzle spacing
Pump	Hardi 1203 diaphragm pump, engine driven
Tyres	23 x 10.5-12, maximum 20 psi (1.5 bar)
Maximum speed	15 mph (24 km/h)
Wheel nut torque	85 lb ft (≈115 Nm) maximum
Pump cover torques	Valve cover 60 Nm (45 lb ft); diaphragm bolt 60 Nm (45 lb ft); diaphragm cover 70 Nm (50 lb ft)
Breakaway clutch cap screws	55 Nm (40 lb ft)
Sprayer test (NSTS)	All MB booms are over 3 m: every 3 years in the UK

Known problems

Engine shipped dry

Hardi ships the engine crankcase and reduction gearbox without oil. Check both before first start.

North American manual

This is Hardi Inc.'s North American manual; US gallons and US part numbers. Check parts with a UK Hardi dealer.

Mesh sizes

Hardi matches filter mesh to nozzle size: 50 mesh suction filter for 01–015 nozzles, 30 mesh standard for 04 and larger.

Repair guides

No spray, low or jumping pressure: suction air leaks and blocked filters (Easy, 30–60 minutes): Nothing comes out of the boom when it is switched on, pressure low or falling, gauge needle jumping, pump losing prime near the end of a tank, foam in the tank.
Liquid from the pump drain hole: diaphragm and valve replacement (Moderate, 2–3 hours): Spray liquid or milky grease dripping from the hole under the pump, pump output falling, pressure will not build, pump sucking air after a rebuild.
Worn or blocked nozzles and filters (uneven spray, streaks) (Easy, 1 hour): Striping in the crop, one nozzle spraying less or more than its neighbours, a nozzle dribbling, pressure creeping up as a tank empties, output above the chart.
Sprayer calibration (owner check with a jug and stopwatch) (Easy, 1 hour): Running out of spray before the field is done, or having liquid left over; new nozzles fitted; different forward speed or rate needed; start of the season.
ATV sprayer: pressure control, agitation and boom section faults (Easy, 30–90 minutes): Pressure won't rise or falls when spraying, a boom section won't switch on or off, control box dead, poor agitation, can't empty the tank.
Boom breakaway too stiff or too loose, boom out of line or yawing (NK, NV and ATV booms) (Moderate, 30 minutes (ATV) to 2 hours (NK/NV)): Boom swings forward and back when spraying, breakaway doesn't give when it hits something, wing folds back on small bumps or stays swung back, wing doesn't line up with the centre, hinge stiff to fold, HFM wing drooping.
Leaking hoses, nozzle bodies and boom fittings (Easy, 30–60 minutes): Drips from nozzle bodies or boom tube joints, wet patches along the boom, a hose weeping at a clip, spray delayed mid-job by a split hose.
Frost damage: split pump, valves or gauge, and frost-proofing (Moderate, 1–2 hours (plus parts)): After a frost: pump leaking from a cover, cracked valve housing or filter bowl, gauge needle stuck or glycerine leaking, no pressure on the first fill of spring.
Ordering pump kits and parts: identify your pump and manual first (Easy, 20 minutes): Diaphragm kit doesn't fit, parts numbers in the book don't match the dealer's, sprayer bought second-hand with no paperwork, North American manual with US part numbers.
ATV sprayer engine won't run or seizes: oil check before first start (Easy, 20 minutes): New or rebuilt ATV sprayer: engine noisy, seizes or the low-oil cut-out stops it; pump drive gearbox whining.

The full step-by-step guides are in Farmyard Workshop once you add your implement.

Sources

Open Farmyard Workshop