Kugelmann Maschinenbau DUPLEX User manual

// OPERATING INSTRUCTIONS
DUPLEX | DUPLEX INOX
Mountable Spreader
Art.Nr. 10039518 19.10.2015 | Version 1.1 | DE, EN
Kugelmann Maschinenbau is a family-owned and family-operated enterprise located
in the Allgäu region of Southern Germany focusing on municipal tradition and
standing in its tradition. We are passionate about developing and constructing
reliable and forward-looking machinery – we love what we do.
www.kugelmann.com
[email protected]
+49 (0) 8860 | 9190-0
Kugelmann Maschinenbau e.K.
Gewerbepark 1-5
87675 Rettenbach a.A.
GERMANY

2
English

3
www.kugelmann.com
Important instructions
Chapter 01
Important instructions ...............................................................................................
.. 7
Intended use of spreader.................................................................................................................................. 8
Inappropriate use ............................................................................................................................................. 8
Warranty and liability ...............................................................................................................
......................... 9
EU-conformity declaration, mark of conformity, copyrights ..............................................................
.............. 1
Signs and symbols, general safety and accident prevention regulations and hazard warnings
..................... 11
Signs and symbols
.......
..............
...........................
................................................................................................ 11
Obligations of users ................................................ ...................................
........................................................... 12
The user has to observe the following
: .....................
....
...........................
............................................................. 12
C
hapter
02
Labelling and hazard warnings ...............................................................
...................15
Chapter 03
Technical data equipment..............................................................................
...........19
Producer ...................................................................................................................
...................................... 2
Working areas and possible use ...........................................................................................
......................... 2
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4
Machine data
................................
.
......
........
..............................................................
..................................... 2
Requirements to carrier vehicle ...............................................................................................................
....... 21
Standard version ............................................................................................................................................ 21
Spreading disc versions ................................................................................................................................. 21
Extra equipment, additonal features, options ................................................................................................. 22
Electrical spread pattern adjustment (ESB) ...................................................................................................................................................................... 22
Damp salt equipent .........................................................................................................................................................................
................................... 22
Assembly kit ...................................................................................................................................................................................................................... 22
Description, special properties ....................................................................................................................... 23
Chapter 04
Assembly disassembly of the spreader................................................................... 25
Assembly of the spreader .............................................................................................................................. 26
With tripod ......................................................................................................................................................................................................................... 26
With hangers ..................................................................................................................................................................................................................... 28
Disassembly of the spreader ......................................................................................................................... 29
Assembly ready for use.................................................................................................................................. 29
Roll-Fix ........................................................................................................................................................... 3
Set-down of a spreader using Roll-Fix .............................................................................................................................................................................. 32
Assembly with spider ..................................................................................................................................... 34
.
Assembly of the spreader with spider understructure ....................................................................................................................................................... 35
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Chapter 05
Spreader operation .....................................................................
.............................. 37
Control ........................................................................................................................................................... 38
Operation of spreader .................................................................................................................................... 4
Filling of spreader .............................................................................................................................................................................................................. 40
Start-up of spreader .......................................................................................................................................................................................................... 4
Setting of spreader ........................................................................................................................................................................................................... 43
Brine equipment ............................................................................................................................................. 46
Filling ................................................................................................................................................................................................................................ 46
Setting the brine nozzle...................................................................................................................................................................................................... 47
Non-return valve ................................................................................................................................................................................................................ 48
Large debris filter ............................................................................................................................................................................................................... 48
Emptying of brine tanks...................................................................................................................................................................................................... 49
Manual operation via flow divider block ......................................................................................................... 5
Emptying the spreading material chambers after work.................................................
.................................. 52
CHAPTER
Maintenance and care wear parts .................................................::...........
............. 53
Maintenance and care ..................................................................................................::............................... 54
Wear parts ................................................................................................::.................................................. 55
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Repair of paint
......................................
..
........
....................................................
.......................................
..... 56
Welding work at spreader............................................................................................................................... 56
Error diagnosis .............................................................................................................................................. 56
Maintenance plan for spreader ...................................................................................................................... 58
English

Chapter 0 7
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CHAPT R 01
Important Instructions
Subject to changes
English

8Important notices
Intended use of spreader
The speader must only be used as intended.
Grit, de
-
i ing salt and brine are spread with the spreading disk on
the road surfa e. For beyond this the produ er does not take over any warranty or liability.
To intended use also belongs observation of the operation and repair and maintenan e instru tions stipulated by
the produ er.
Operation of the equipemnt
its
care
,
repair and mainte
nance must only be dome by instructed
expert personnel.
Unauthorized changes of equipment preclude liabilty of the producer for resulting damages.
T
he relevant a ident prevention regulations are to be observed. This extends to the gener
ally re ognized safety
-
relevant, o upational medi al and road law requirements. The safety requirements are laid down in DIN EN 292-
1, DIN EN 292-2 and DIN EN 1553. In additon to the regulations being present the spe ifi safety regulations of
the ountry, in whi h the equipment is operated, have to be observed.
Inappropriate use
It is imparative that the permitted axle loads and also the permitted weights of the carrier vehicle are
observed. In case you transport equipment in attachments or the structure
it is imparative to ta e this into
consideration.
Subject
t
o
changes
English

Chapter 0 9
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Warranty and liability
The ompany
Kugelmann Mas hinenbau e.K., 87675 Rettenba h, g
uarantees that its
ma hines/equipment are
free of defe ts on erning materials and quality and ommits itself to repla e all parts without harge ex-works
whi h were pur hased from approved Kugelmann dealers and whi h are re ognized as faulty by the ompany
after an inspe tion.
The hereby expressly given guarantee is limited to the duration of 12 months beginning at the date of delivery to
the ustomer and pre ludes any further laims.
The produ ing ompany does not offer any guarantee on third party produ ts not produ ed by it.
It does, however,
assign its laims whi h it has against sub- ontra tors to the ustomer
. No warranty is given for used, se ond hand
pur hased and hanged or modified ma hines.
Claims have to be made immediately after the damage o urred, after thirty days at the latest and in writing. The
faulty parts have to be sent in.
Furthermore, the ompany Kugelmann is not liable for injury to persons or damage to equipment whi h is aused
by the following:
- operation of the mountable
spreader while safety installations are defe t or not installed appropriately
or non-fun tioning safety and prote tion installations.
- non-observan e of danger and warning noti es in the operating instru tions
- non-observan e of important noti es in the operating instru tions su h as start-up, operation and
maintenan e/ are of the spreader
- insuffi ient monitoring of ma hine parts whi h are subje t to wear
- inappropriately arried out repair work
- for e majeure or atastrophies
Subject to changes
English

10 Important notices
EU- onformity de laration, mark of onformity, opyrights
EU
-
onformity de laration
:
Hereby the ompany Firma Kugelmann e.K., Gewerbepark 1-3, D 87675 Rettenba h de lares, that the mounting
salt spreader Duplex, onforms to EU dire tives be ause of iits design and the way it is produ ed.
The EU-Dire tive
91/368/EEC
98/37/EC for ma hines
As well as the 93/68/EEC for marking were observed.
Also DIN EN 292-1
DIN EN 292-2
DIN EN 1553 are fulfilled.
All basi safety
and health requirements are fulfilled
with the equipment brought on the market.
Copy right of
this te hni al do umentation a
s well as all other opyrights and
property rights rest with ompany
Kugelmann e.K., 87675 Rettenba h.
For mistakes in the translation into other languages the ompay Kugelmann takes no responsibility. Claims an
only be made to the do umantation in the German language.
Josef Kugelmann
Subject to changes
English

Chapter 0 11
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Signs and symbols, general safety and accident prevention
regulations and hazard warnings
Besides the noti es in this operating manual observe all generally valid safety and a ident prevention
regulations!
The atta hed warning and noti e signs give important information for safe operation.Observing them serves your
safety!
Every person who operates or drives this vehi le ombination has to be familiar with the operation instru tion of
the arrying vehi le.
Explantion of symbols
Wor safety symbol:
Danger
!
Direct danger for life and health
!
WARNING
Warning notice! Possibly threatening danger for life and health!
Info
Important information for appropriate use of machine!
Tip
Suggestion for ma ing wor easier!
Subject t
o
changes
English

12 Important notices
Ob
ligations of operator
He has to ta e care that only instructed and trained personnel operate the spreader. The
responsibillity of the personnel is to be defined clearly concerning setting-up, operating, handling and
repair and maintenance of the equipment.
All persons confronted with
operating, repair and maintenance of the machine must have read and
understood the safety and warning notices
The operatiing instructions ha
ve to be ept at the place of wor at all times
,
in this case, e.g.
in the driver’s cab.
The operator has to o
bserve the following
:
He has to ta e care that the vehicle combination is in safe operating and roadworthy condition!
Wor which does not meet regualtions has to be refused.
Before driving the driver has to chec the fixation (tension belts, chains, bolts etc.) of the
spreading equipment.
Unauthorized persons have to
be
sent away from the vehicel/eq
ui
pment and its danger and
wor ing zone.
All safety and danger notices at the spreading vehicle have to be ept in legible condition.
Sub ect to changes
English

Chapter 0 13
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Most accidents can be avoided by observing some simple safety measures.
In case of danger for humans and equ
ipment
the equipment has to be closed
down immediately and the customer service be contacted.
SWITCH ENGINE OF AND REMOVE IGNITION KEY
!!!
No
wor while machine is running!
SWITCH ENGINE OFF AND REMOVE IGNITION KEY!!!
Never wor near engine in
loose clothes which can get entangled in running parts
!
Ma e
sure that when the machine is in operation all protections are installed!
After turning off of the equipment tools/machine parts may continue to run!
During wo
r at the equipment use a ladder
,
if available. If not, create slip
-
resistant climb
-
up.
The required protecti
ve equipment has to be supplied by the
owner and to be worn by
personnel!
When loading the spreading equipment the permissible loads of the carrying vehicle have to be
observed (axle weight, permitted total weight)! Especially with further additions and mountings it is
imparative that the permissible axle weights are not exceeded.
Adjust your driving to the operation at full load! This is especially true under slippery road
conditions and and downward slopes!
Subject to changes
English

14 Important notices
Important noticesImportant notices
Important notices
Be
BeBe
Be aware that the centre of gravity rises with full load although the construction is ept
low by design. There is, in general, an increased ris of tipping.
Safety rules for the handling of hydraulic conduits, couplings an
d parts.
Remember that high pressures are reated in hydrauli onduits. Squirting out oil an lead to injuries and fires.
Remove pressure in pressure lines before coupling on and off.
Damaged hydraulic hosepipes are to be replaced immediately.
In ge
neral. Hydraulic
hosepipes have to be exchanged after 6 years.
Only personnel with spec
ial nowledge and experiences are
allowed to wor at hydraulic
installations. Better go to a special wor shop immediately.
S
ubject to
changes
English

Chapter 02 15
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CHAPT R 02
Labelling and hazard warnings
Subject to changes
English

16 Labelling and hazard warnings
Warning sign
: „
Stay in danger zone prohibited
.
Before operating read
and observe the operating instructions!"
Warning sign
:
During all wor at the machine
shut down engine and remove ignition ey!"
Reflecting
warning mar ings on bac of spreader
Spreading equipment label
Duplex
Inox, stainless steel version VA
CE
–
sign on the basis of EU
-
conformity declaration
Subject to changes
English
WINTERSERVICE

Chapter 02 17
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Producing company Kugelmann
Danger noti e
.
I
f this hute is not in
operating position ontrol and hydrauli may
only be swit hed on for emptying pro edure.
Subject to changes
English

18 Labelling and warning noti es
Kugelmann
mountable
spreader wi
th labelling warning notices
,
working lights and all
-
round beacon.
Subject to changes
English

Chapter 03 19
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Chapter 03
Technical data, equipment
English

20 Technical data, equipment
Produ er
The ompany
Kugelmann Mas hinenbau e.K., Gewerbepark 1
-
3, D
-
87675 Rettenba h a.A.,
Tel. [phone], Fax. [phone], is the produ er of the mountable salt spreader
„Duplex".
Working areas and possible uses
The Kugelmann
-
mountable
spreader equip
ment an spread grit, de
-
i ing salt and brine solution in all variations
.
With the ontrol (MCSS 3/4and k-troni , respe tively) individual omponents as well as two or 3 omponents an
be spread in an extremely pre ise way.
Freely adjustable depending on the design of the spreading dis , the spread pattern an be varied from flush with
the kerbside to asymmetri al a ross the on oming lane. What always applies is, you mix your spreading material
in any ratio. The driving speed has to be adjusted to the spreading width and the spread quantity.
Ma hine data
The mountable
spread
er
equipment
„Duplex"
has a apa ity of 0.4 to 5
m³
for solid spre
a
ding material.
The
spreading equipment has 2 equally sized hambers. There is another option of dividing the spreading material
hambers into 1/3 to 2/3.
Another option is to supply the spreading equipment with brine equipment for spreading damp salt.
The volume of
the brine tanks is designed for FS30.
The hydrauli s of the arrying vehi le serves as drive as long as the apa ity of the pump is suffi ient. For this
pressureless return flow is required
In ase the hydrauli pump of the arrying vehi le does not have the required output the ompany Kugelmann
Mas hinenbau e.K. offers an additional p.t.o. hydrauli pump. As a further variant, mounting of a motor aggregate
is possible.
The spreader an be delivered in the version sheet steel / partly VA or ompletely VA (designation Inox). The
operation of the spreader is done through ontrols MCSS 3/4 and k-troni , respe tively.
English