Tuchel Kompakt HD 400 Series, Operating Manual

Page 1: ... Preface Operating Manual Sweeping Machine ...

Page 2: ...Preface ...

Page 3: ...miliarise with the use of the machine and its service and maintenance The manual also helps you to avoid dangers and damage We wish you optimum results with your Kompakt sweeping machine Tuchel Maschinenbau GmbH This operating manual is current as of February 2006 Our continuous efforts towards an improvement of the Kompakt sweeping machine may lead to changes in detail The introduction of improve...

Page 4: ...Preface ...

Page 5: ... the operating manual 15 2 2 Qualiication and training of personnel 15 2 3 Dangers in the case of nonobservance of the safety notices 16 2 4 Safety oriented work 16 2 5 Safety notes for the operator user 17 Attachment 17 Transport trips 18 Operation 18 Conversion 19 Detachment 19 For hydraulic components only 19 2 6 Basic safety instructions for drive shaft operation 20 2 7 Special safety notes fo...

Page 6: ...yard loader 30 4 5 Attachment to other carrier vehicles 30 Operation 5 1 Transport trips 31 5 2 Start up 32 Sweeping drums brush rings 32 Start up without collector vessel 32 Start up with collector vessel 32 Start up of side broom 32 5 3 Side broom adjustment 33 Adjust operating width A 33 Adjust side support point B for area of impact C 33 Adjust the inclination D for height of impact 33 5 4 RPM...

Page 7: ...e bearing side 46 Disassembly on the drive side chain case 46 7 9 Replacing sweeping drum for Kompakt ø 400 48 Disassembly on the bearing side 48 Disassembly on the drive side chain case 48 Beeline brush rings 49 Sunline brush rings 49 7 10 Replacing sweeping drum for Kompakt ø 520 50 Disassembly on the bearing side 50 Disassembly on the drive side chain case 50 7 11 Replacing sweeping drum for Ko...

Page 8: ...verzeichnis Appendix 7 Hydraulic circuit diagrams 57 Circuit diagram for additional control circuit 57 Circuit diagrams for power take off drive 58 Circuit diagrams for hydraulic operation 59 Index 61 Notes 64 ...

Page 9: ... Through hydraulic opening of the large volume dirt collection vessel the Kompakt sweeping machine may also be used as an open sweeping machine to sweep large sealed surfaces Various optional equipment allows for the Kompakt sweeping machine to be adapted to different working environments This optional equipment includes e g the water spraying device to bind dust a side broom to sweep close to edg...

Page 10: ...in Net weight kg The entire labelling type label safety label etc constitutes a certiicate and must not be altered or made illegible It must be replaced if it is damaged or missing Notes regarding the declaration of conformity The compliance of this attachable sweeper with the basic safety and health requirements of the machine directive 98 37 EWG entitles it to bear the CE label In the developmen...

Page 11: ...ereof 7 Connections Hydraulic connectors required in the following conigurations of the Kompakt sweeping machine hydraulic inclination one double acting control circuit for Type of drive power take off shaft hydraulic vessel emptying one double acting control circuit hydr vessel emptying and side broom one double acting control circuit for Hydraulic drive hydraulic drive one single acting control ...

Page 12: ... lever system The sweeping drum is adjusted via the raster levers The adjustments ensure a continuously good sweeping result The standard brush itted to the sweep drum is a honeycomb shaped brush made from 100 PP The brush is 520 mm in diameter The frame of the Kompakt sweeping machine is made of a robust and torsion free welded construction With the mechanical or hydraulic side adjustment the swe...

Page 13: ...ng pump reinforced durable castors in various designs Equipment for legal operation on public roads in the Federal Republic of Germany according to the StVZO consisting of contour illumination lamps 0 Intended usage You may attach and operate the Kompakt sweeping machine only if you have carefully read and understood the operating manual have the respective technical training are authorised by you...

Page 14: ...20 diameter of side broom mm 500 600 Hydraulic drive volume current required l min 20 25 Maximum operating pressure at continuous load bar 175 Use the weights to check compliance with the maximum allowed axle load of the carrier vehicle Weights are approximate values and vary depending on the machine coniguration receptacle is excluded We reserve the right to incorporate changes resulting from fur...

Page 15: ... is hazardous for the machine and its functions have the word attached Notices are labelled as follows Notes that are directly attached to the machine must deinitely be adhered to and must be kept in a fully legible state 2 2 Qualiication and training of personnel The Kompakt sweeping machine must only be used serviced and maintained by persons that are familiar with the machine and are informed a...

Page 16: ...emical inluences hazards to the environment due to leakage of hydraulic oil Safety oriented work The safety notices listed in this operating manual current national accident avoidance regulations as well as company internal regulations governing work operation and safety that apply must be followed The safety notices of the vehicle manufacturer must be followed Note the permitted axle loads The ac...

Page 17: ...sen German ministry for transport construction and housing Attachment Check attachment receptacle and its interlocking mechanism for damage prior to attachment Have all damage repaired immediately Before start up check the attachment receptacle of the sweeping machine and its interlocking mechanisms for irm seating During attachment put the supports into their respective position Attach the Kompak...

Page 18: ...cidental operation Your Kompakt sweeping machine changes the driving behaviour and inluences steering and braking Take this into account when transporting the machine Operation Start the Kompakt sweeping machine only if all safety equipment is attached and in protection position No person may be present in the area of operation Check the immediate area before starting to drive and before start up ...

Page 19: ...o a standstill For hydraulic components only Only connect the hydraulic hoses if the vehicle hydraulics are depressurized Wear protective gloves when deconnecting the hoses as the hydraulic connectors can become extremely hot and there is a risk of burns Before start up check the positioning of the hydraulic hoses as damages occur easily if hydraulic hoses get entangled or squashed Replace hydraul...

Page 20: ...tached properly at the drive shaft tractor and machine and whether they are functional Replace or properly retroit any damaged or missing parts with original parts before beginning drive shaft operation Before work check whether the drive shaft is already irmly connected to the tractor and the working machine For your safety you must not wear loose clothing straps or other loose items In case of t...

Page 21: ...ts of the carrier vehicle before attaching the sweeping machine During attachment or coupling special caution must be exercised Carry out maintenance and modiications on the Kompakt sweeping machine only if the power take off hydraulic drive is switched off Pull the ignition key and secure the carrier vehicle against unintended restart and movement During the attachment follow the operating manual...

Page 22: ...ing the sweeping drum and sweeping rail Lawfully dispose of oil and grease Directly after inishing work all safety and protection equipment must be reattached or made functional Before restarting the points listed in the sections on start up must be adhered to 9 Unauthorised conversion and spare parts manufacturing Conversion of or changes to the machine are only permitted after consultation with ...

Page 23: ...fore start up Only touch engine parts when they have come to a complete standstill drum shaft side broom Never reach into the squashing hazard area as long parts may move dirt collection vessel open close pendulum compensation at the carrier vehicle receptacle Never open or remove protective equipment while the motor is running Chain case at the side of the sweeping machine N O T E ...

Page 24: ...ficient distance Do not stand in the area of the lifted sweeping machine Do not stand in the rotation area of the sweeping machine during operation hydraulic tilting to place the Kompakt sweeping machine at an angle The notice signs attached to the machine must be kept in a clearly legible state Replace notice signs that are no longer legible When ordering new notice signs specify the article numb...

Page 25: ...umidity and leads to the formation of rust If necessary repair paint damage Lubricate the sweeping machine Chapter 7 12 Lubrication plan describes the lubricating points of the Kompakt sweeping machine Storage of brush rings Pull the hand grips 1 of the drum shaft adjustment s raster lever system backwards and let them engage in the top position 2 Danger of getting squashed The palm of the hand mu...

Page 26: ...e residual water remains in the hoses Storage with collector vessel Close the tap to the hydraulic cylinder of the collection vessel emptying mechanism See label on the machine roof Storage of the side broom Turn off close the adjustment wheel of the hydraulic valve for the side broom See label on the hydraulic valve Tilt the side broom 3 upwards and secure with it the spring plug 1 behind the sto...

Page 27: ...ft must be carried out according to the drive shaft manufacturer s speciications see operating manual of the drive shaft Slide the fork of the joint 3 onto the drive shaft 2 of the gear 5 and secure it with the locking screw 1 Sweeping machine with brush ø520 drive shaft with pull back cover 5 See the drive shaft manufacturer s operating manual Hook the chain 4 of the anti twist device into a suit...

Page 28: ...anufacturer Lift the sweeping machine and carry out a functionality check Lower the sweeping machine until the two or three castor wheels touch the ground The receptacle structure must be perpendicular to the ground Securing via plug bolt Pull out the spring plug 3 Slide the plug bolt 2 through the bolt bushings 1 and secure it by pushing the spring plug 3 through the respective hole part 1 and 2 ...

Page 29: ...category and attach and secure the upper hook and the upper hook bolt Adjust the upper hook so that the attachment receptacle is perpendicular to the ground see also the operating manual for the carrier vehicle Verify the correct seating of the attachment receptacle Mount the drive shaft on the tractor s side and hook the chain of the anti twist device into a suitable location If present connect t...

Page 30: ... the upper hook is shortened or lengthened Connect the hydraulic lines if present according to the instructions of the vehicle manufacturer Lift the sweeping machine and carry out a functionality check Lower the sweeping machine until the two or three castor wheels touch the ground The receptacle structure must be perpendicular to the ground Attachment to other carrier vehicles Before carrying out...

Page 31: ... Emptying dirt collection vessel Transport trips with side broom carry out the following tasks Turn off close the adjustment wheel of the hydraulic valve for the side broom See label on the hydraulic valve Tilt the side broom 3 upwards and secure with it the spring plug 1 behind the stopper 2 Lift out sweeping machine and secure the operating levers for the sweeping machine at the carrier vehicle ...

Page 32: ...m appears After storage shift brush down The adjustment of the sweeping proile is described in Chapter 5 8 Start up without collector vessel Shift the two supports 1 upwards and secure them Start up with collector vessel Open the tap of the hydraulic cylinder of the vessel emptying mechanism see label on the machine s cover Start up of side broom Pull out spring plug 2 and tilt the side broom down...

Page 33: ...side support point B for area of impact C When operating the sweeping machine the side broom should sweep the side margin between a 12 o clock and 3 o clock position see arc C Loosen screw connection 3 and turn the side broom until the optimum support point 12 3 o clock C is reached Firmly tighten the screw connection Adjust the inclination D for height of impact The stopper 1 meets the screw 2 if...

Page 34: ...ng tasks irst read the safety instructions in Chapter 2 Safety Also familiarise yourself with the task sequence described The adjustment is carried out on the adjustment screw 1 of the low control valve This diagram shows the functioning of the hydraulic valve Turning towards the rabbit increases the rpm and turning towards the turtle decreases the rpm If the adjustment wheel is closed completely ...

Page 35: ... the dumping area The high level illing lap permits the collector vessel to be illed to a higher level Lift the sweeping machine No person must be present below the machine during emptying Flip the respective control lever for the sweeping machine hydraulics in the carrier vehicle The direction of low changes and the collector vessel opens Close collector vessel by lipping back the previously ment...

Page 36: ...eeping machine until the two rear castor wheels touch the ground The receptacle must be positioned perpendicular to the ground and the sweeping machine roof must be parallel to the area to be cleaned Carry out maintenance and modiications on the Kompakt sweeping machine only if the hydraulic drive is switched off Pull the ignition key and secure the carrier vehicle against unintended restart and m...

Page 37: ...t close to the ground Remove spring plug and bolt 1 Tilt the sweeping machine into the desired direction material swept to the left or right Insert the bolt 1 into the pitch rod 2 and the respective hole 3 and secure using the spring plug Lower the sweeping machine Hydraulic swivelling The swivelling is carried out via a hydraulic cylinder 1 The second hydraulic circuit of the carrier vehicle is u...

Page 38: ... suficient or the pressure of the sweeping drum onto the ground is too low the suspension of the sweeping drum must be readjusted evenly on both sides 1 2 via the raster lever system 1 Take into account the sweeping drum s weight when adjusting the levers Danger of getting squashed The palm must always point towards the centre of the machine when operating the raster levers Pull the raster lever 1...

Page 39: ...clean place Lower the Kompakt sweeping machine until all castor wheels touch the ground Support wheels must point towards the attachment receptacle Carry out work on the Kompakt sweeping machine only the drive is switched off Pull the ignition key and secure the carrier vehicle against restart and movement Unmount the drive shaft on the tractor s side and detach the anti twist chain Protect drive ...

Page 40: ...ier vehicle at the 3 point linkage of the sweeping machine Drive carrier vehicle backwards Detachment yard loader Before carrying out the following tasks irst read the safety instructions in Chapter 2 Safety Also familiarise yourself with the task sequence described Unlock the receptacle as described in the carrier vehicle s operating manual Lower the receptacle of the carrier vehicle and drive ba...

Page 41: ...UES BY VARIOUS SCREW MANUFACTURERS WE DO NOT ACCEPT LIABILITY FOR THEIR APPLICATION Regularly check the hydraulic hoses Hydraulic hoses must be replaced no later than after 6 years of usage including storage time of at most 2 years Replace hydraulic hoses that are damaged or aged The replacement hoses must meet the technical requirements of the manufacturer A 0 9 9 ø MA Nm M 3 43 4 51 8 73 10 3 14...

Page 42: ...e safety instructions in Chapter 2 Safety Also familiarise yourself with the task sequence described Replace the Vulkollan rail only when the sweeping machine is attached to the carrier vehicle and lifted Do not move underneath the lifted machine Secure sweeping machine and carrier vehicle against unintended restart sagging and movement Pull the ignition key The dirt collection vessel must be empt...

Page 43: ...he side broom Take the plate broom s own weight into account Remove the old plate broom Drill a hole through the new plate broom to suit the lange 1 or 2 If the plate broom has a mixed coniguration an additional cover sheet is mounted between plate broom and lange hexagonal screws are used as spacers between broom and cover sheet Mount new plate broom using new self securing nuts Swing the side br...

Page 44: ...the ilter sieve 3 Clean the ilter sieve 3 with water Re insert sieve 3 into the casing 2 and screw on ilter lid 4 Screw water ilter 2 3 4 on intake hose of the water pump 1 below the water tank 7 Tightening the chain Before carrying out the following tasks irst read the safety instructions in Chapter 2 Safety Also familiarise yourself with the task sequence described Unscrew attachment screws 1 Re...

Page 45: ... 5 Remove chain from rear chain wheel Loosen headless screw 6 and remove chain wheel Remove screws 7 from the bearing shell Loosen headless screw 8 in the bearing insert Remove bearing insert and shell Secure gear against sagging Unscrew screws 11 at gear 12 and remove Take the side gear s own weight into account Detach gear 12 and coupling parts 13 14 15 Pull out drive shaft 17 Remove old spring ...

Page 46: ...nt screws 1 from the lange bearing 2 and remove together with the bearing shell 3 Unscrew threaded bolts 4 pull off bearing insert 5 with bearing shell 6 so that the brush shaft 21 is exposed Disassembly on the drive side chain case Unscrew attachment screws 7 at the chain case 8 and remove with the chain case Unscrew locking screw 9 of the chain tightener 10 Open chain 11 at the chain joint 12 an...

Page 47: ...the new sweeping drums 24 onto the brush shaft 21 Before assembly clean all parts and replace if necessary When ordering spare parts please specify the type label serial number and the year of construction of the machine For article numbers refer to the list of spare parts The assembly of the brush shaft is carried out in the opposite order to the disassembly The chain wheels must be mounted in su...

Page 48: ...threaded bolts 4 pull off bearing insert 5 with bearing shell 6 so that the drum shaft 7 is exposed Disassembly on the drive side chain case Unscrew attachment screws 8 at the chain case 9 and remove with the chain case Unscrew locking screw 10 of the chain tightener 11 Open chain 12 at the chain joint 13 and put it down Loosen threaded bolt 14 at the cog 15 and pull it off together with the cog T...

Page 49: ...y onto the brush shaft 7 corrugated wire 28 spacer 29 plastic 30 spacer 29 corrugated wire 28 The brush rings must be pushed onto the drum shaft 7 in such a way that the groove 31 sits on the driver 27 Before assembly clean all parts and replace if necessary When ordering spare parts please specify the type label serial number and the year of construction of the machine For article numbers refer t...

Page 50: ...ve protective cap 4 in the bearing shell 3 Unmount attachment screw 5 with U washers in the brush shaft 6 Unscrew threaded bolts 7 pull off bearing insert 8 with bearing shell 9 so that the brush shaft 6 is exposed Disassembly on the drive side chain case Unscrew attachment screws 10 at the chain case 11 and remove with the chain case Unscrew locking screw 12 of the chain tightener 13 Open chain 1...

Page 51: ...e new sweeping drums 27 onto the brush shaft 6 Before assembly clean all parts and replace if necessary When ordering spare parts please specify the type label serial number and the year of construction of the machine For article numbers refer to the list of spare parts The assembly of the brush shaft is carried out in the opposite order to the disassembly The chain wheels must be mounted in such ...

Page 52: ...earing 2 and remove together with the bearing shell 3 Remove protective cap 4 in the bearing shell 3 Unmount attachment screw 5 with U washers in the drum shaft 6 Unscrew threaded bolts 7 pull off bearing insert 8 with bearing shell 9 so that the brush shaft is exposed Disassembly on the drive side chain case Unscrew attachment screws 10 at the chain case 11 and remove with the chain case Unscrew ...

Page 53: ...Pull off worn out brush rings Beeline brush rings Slide the new brush rings 28 onto the drum shaft 6 such that a honeycomb like structure appears The brush rings must be pushed onto the drum shaft 6 in such a way that the groove 29 sits on the drivers 30 Sunline brush rings Push the new brush rings alternatingly onto the brush shaft 6 corrugated wire 31 spacer 32 plastic 33 spacer 32 corrugated wi...

Page 54: ...se yourself with the task sequence described Grease the bearings weekly Use grease according to DIN 51502 e g Gresalit 2 by Westfalen Grease weekly Lubricating points sweeping machine On the pendulum bolt receptacle left and right On the central swivel bolt on the side in the middle Machine frame at the holder for the drive shaft and on the opposite side Level compensation on the machine frame lef...

Page 55: ...hains lubricated once only Lubricating the drive shaft The lubricating points on the drive shaft are described in the drive shaft manufacturer s operating manual Observe the notes for winter operation Gearbox lubricant The lubricant SAE 90 EP must be replaced after approximately 50 operating hours or after the irst season The new gearbox lubricant must meet the performance class speciied above An ...

Page 56: ...ntake hose closed Check connections Ask a qualiied workshop Turn the 2 way tap 4 Water spraying device defective Water tank empty Fuse in the cabinet defective Water ilter clogged Nozzles clogged Top up water Replace fuse Clean water ilter Clean nozzles 5 Side broom does not move Intake hose closed Hydraulic connections not correct One way restrictor Hydraulic motor defective Open low control valv...

Page 57: ... 7 Appendix Appendix Hydraulic circuit diagrams Circuit diagram for additional control circuit Hydraulic side adjustment ...

Page 58: ...Appendix Circuit diagrams for power take off drive Hydraulic emptying Hydraulic emptying side broom ...

Page 59: ... 9 Appendix Circuit diagrams for hydraulic operation Hydraulic drive Hydraulic emptying Hydraulic drive ...

Page 60: ...Appendix 0 Hydraulic emptying side broom Hydraulic drive ...

Page 61: ...for power take off drive 58 Connections 11 Conversion 19 D Dangers in the case of nonobservance of the safety notices 16 Deinstallation in general 39 Description of the product and accessories 12 Detachment 39 Detachment 3 point linkage 40 Detachment coupling triangle 40 Detachment other carrier vehicles 40 Detachment yard loader 40 Detachment 19 Disassembly on the bearing side 46 Disassembly on t...

Page 62: ...Intended usage 13 L Labelling of warning signs in the operating manual 15 Labelling 10 Lubricating points sweeping machine 54 Lubricating the chain 55 Lubricating the drive shaft 55 Lubrication plan 54 M Malfunctions causes and rectification 56 Manufacturing Address 9 Modes of operation that are not permitted 22 N Notes regarding the declaration of conformity 10 Notes 64 O Open sweeping 36 Operati...

Page 63: ...nt 42 Side broom rpm adjustment 34 Special safety notes for attachment 21 Specifications for enquiries and orders 11 Start up 32 Start up of side broom 32 Start up with collector vessel 32 Start up without collector vessel 32 Storage 25 Storage of brush rings 25 Storage of the side broom 26 Storage of the water spraying device 26 Storage with collector vessel 26 Storage without collector vessel 25...

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