Kugelmann KS 1200 User manual

// ORIGINAL OPERATING INSTRUCTIONS
Art.Nr.: 10045132 09.07.2018 | Version 1.1 | EN
Kugelmann Maschinenbau e.K.
Gewerbepark 1-5
87675 Rettenbach a.A.
GERMANY
www.kugelmann.com
[email protected]om
+49 (0) 8860 | 9190-0
Kugelmann Maschinenbau is a family-run Allgäu business with its main emphasis and
tradition in municipal technology. With passion, we manufacture reliable and pioneering
machines - we love what we do.
ORIGINAL OPERATING INSTRUCTIONS
Sweeping suction combination type E800 / E1200
KS 1200 | KS 1600

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Copyrights and trademarks 27.06.2018 2/79
Copyrights and trademarks
© Kugelmann Maschinenbau e.K.
Gewerbepark 1-5
87675 Rettenbach a.A. (Germany)
Tel.: [phone] / 9190-0
Fax: [phone] / 9190-19
Mail: [e-mail]
Web: www.kugelmann.com
All company names and designations used in this manual may also be registered trademarks
of the respective manufacturing companies and shall not be used commercially or otherwise.
Errors and omissions excepted.
All rights reserved. No part of this manual shall be reproduced or copied in any form (printing,
photocopying, storing or distribution in electronic form) without prior written consent of
Kugelmann Maschinenbau e.K.
We are constantly developing our products to offer our customers maximum convenience.
Therefore, we ask for your understanding that the manual can deviate from the product in some
regards.

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2 Content
1 Title............................................................................................................. 1
2 Content........................................................................................................3
3 General information.....................................................................................6
3.1 Identification of the machine.......................................................................................................6
3.2 Service information......................................................................................................................7
3.3 EC Declaration of Conformity in terms of the EC Machinery Directive 2006/42/EC....................8
4 Operating instructions..................................................................................9
4.1 Target group...............................................................................................................................10
4.2 Use............................................................................................................................................. 10
4.3 Conventions used.......................................................................................................................11
4.4 Change history........................................................................................................................... 11
5 General description....................................................................................12
5.1 Components container unit....................................................................................................... 12
5.2 Components brush unit............................................................................................................. 15
5.3 Designated use...........................................................................................................................17
5.4 Obvious misuse..........................................................................................................................17
6 Safety instructions......................................................................................18
6.1 General safety instructions........................................................................................................ 18
6.2 Commissioning...........................................................................................................................19
6.3 Use............................................................................................................................................. 23
6.4 Maintenance..............................................................................................................................27
6.5 Designations.............................................................................................................................. 31

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7 Commissioning...........................................................................................34
7.1 Fitting.........................................................................................................................................34
7.2 Wiring diagram hydraulic system...............................................................................................37
7.3 Controller...................................................................................................................................39
7.4 Settings for commissioning........................................................................................................41
7.4.1 Setting of attachment frame............................................................................................41
7.4.2 Setting of sweeping area................................................................................................. 42
7.5 Deactivate pendulum compensation.........................................................................................44
7.6 Starting the sweeping suction combination.............................................................................. 45
7.7 Transport journey...................................................................................................................... 46
8 Operating instructions................................................................................47
8.1 Settings...................................................................................................................................... 47
8.1.1 Setting of brush arms...................................................................................................... 47
8.1.2 Setting of suction mouth................................................................................................. 48
8.2 Lifting......................................................................................................................................... 49
8.3 Empty container.........................................................................................................................50
8.4 Water supply..............................................................................................................................51
8.4.1 Recirculating water.......................................................................................................... 52
8.4.2 Fresh water...................................................................................................................... 53
8.5 Multifunction tool / cleaning lance............................................................................................54
9 Options...................................................................................................... 55
9.1 Leaf rake.....................................................................................................................................56
9.2 Manual suction.......................................................................................................................... 57
9.3 High-pressure cleaner................................................................................................................59
10 Maintenance............................................................................................ 62
10.1 Checklist for cleaning............................................................................................................... 63
10.2 Maintenance intervals............................................................................................................. 66
10.3 Wear parts............................................................................................................................... 68
10.4 Lubrication schedule................................................................................................................69
10.5 Safety....................................................................................................................................... 71
11 Transport..................................................................................................72
12 Storage.....................................................................................................73
13 Disconnecting the system.........................................................................74

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14 Technical Data.......................................................................................... 75
15 Tightening torques................................................................................... 77
Warranty...................................................................................................... 78

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3 General information
This chapter gives you information on the following:
•Chapter 3.1 "Identification of the machine", page 6
•Chapter 3.2 "Service information", page 7
•Chapter 3.3 "EC Declaration of Conformity in terms of the EC Machinery Directive
2006/42/EC", page 8
3.1 Identification of the machine
The type plate refers to device type, serial number, article number, year of
construction and manufacturer.
Type plate (Pos. 10) at rear part.

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Type plate (Pos. 20) at brush unit.
3.2 Service information
Customer service:
Tel.: [phone] / 9190-90
Fax: [phone] / 9190-49
E-Mail: [email protected]

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3.3 EC Declaration of Conformity
in terms of the EC Machinery Directive 2006/42/EC
We herewith declare that the machine designated below complies with the relevant
essential health and safety requirements of the respective EC Directives due to its
design and construction, and in the version supplied by us.
If the machine is modified without our consent, this declaration shall cease to apply.
Designation: Sweeping suction combination
Machine type: KS 1200 / KS 1600
Relevant EC machinery directives:
EN standards:
DIN EN 292-1/292-2/1553
EMC standards:
72/245/EEC
Rettenbach a.A., December 2016 Josef Kugelmann

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4 Operating instructions
This chapter gives you information on the following:
•Chapter 4.1 "Target group", page 10
•Chapter 4.2 "Use", page 10
•Chapter 4.3 "Conventions used", page 11
•Chapter 4.4 "Change history", page 11

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4.1 Target group
These operating instructions are intended for skilled persons who are responsible for
the following work at the sweeping suction combination:
•Commissioning
•Control system
•Operation
•Use
•Maintenance
At least once a year, all personnel must be trained in the operation of the sweeping
suction combination in accordance with the guidelines of the business liability
insurance. The use of the sweeping suction combination by untrained or unauthorized
persons is prohibited.
4.2 Use
These operating instructions contain all necessary data and information for a secure
control, operation and maintenance of the sweeping suction combination.
Make sure that all persons responsible for operation or maintenance of the sweeping
suction combination or persons working in the immediate environment of the
machine are familiar with the operating and maintenance instructions as well as the
safety information in this manual.
These operating instructions are part of the product and have to be kept in a safe
place. In case of resale or transfer of the machine to third parties, these operating
instructions have to be included.
All information, illustrations and technical data correspond to the technical state at
the time of printing. Subject to technical modifications.

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4.3 Conventions used
This manual uses the following typographic conventions:
Symbol Signal
word Meaning
Danger
Indicates an imminent dangerous situation, which - in case of
non-observance of the safety instructions - will entail death or
grievous bodily harm.
Warning
Indicates a possibly dangerous situation, which - in case of non-
observance of the safety instructions - may entail death or
grievous bodily harm.
Caution
Indicates a possibly dangerous situation, which - in case of non-
observance of the safety instructions - may result in minor
injuries or damage to property.
Notice Contains useful information with respect to proper handling of
the machine.
4.4 Change history
Date Version Modification
02.12.2016 1.1 First edition
30.03.2017 1.2 Constructive changes/enhancements
20.06.2017 1.3 Change of machine type, addition of options
27.06.2018 1.4 Constructive changes/enhancements

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5 General description
This chapter gives you information on the following:
•Chapter 5.1 "Components container unit", page 12
•Chapter 5.2 "Components brush unit", page 15
•Chapter 5.3 "Designated use", page 17
•Chapter 5.4 "Obvious misuse", page 17
5.1 Components container unit
Please see the following illustration for components of the container unit:
Pos. No. Component
10 Debris container
20 Container cover
30 Leaf rake to clean the intake grille (option) (see Chapter 9.1 "Leaf rake", page 56)
40 Lifting cylinder
50 Water distributor (see Chapter 8.4 "Water supply", page 51)
60 Fresh water tank
70 Base rails
80 Side cover
90 Tilting quick lock to remove the side cover (Pos. 80)

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Pos. No. Component
10 Side panel
20 Side cover
30 Lifting cylinder
40 Hose flange
50 Electrical water pump for the supply of the water jets at the brush units (see Chapter
8.4.2 "Fresh water", page 53)
60 Hose pump for recirculating water (see Chapter 8.4.1 "Recirculating water", page 52)
70 Power box
80 Tilting quick lock to remove the side cover (Pos. 20)
90 Base frame

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Pos. No. Component
10 Filter frame
20 Blower motor
30 Blower housing
40 Air exit
50 Center of rotation of container

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5.2 Components brush unit
Please see the following illustration for components of the brush unit:
Pos. No. Component
10 Brush 2L
20 Brush 2R
30 Brush 3 (option)
40 Suction mouth
50 Seating of lower link (three-point linkage)
60 Hand lever
70 Water jet with stopcock
80 Brush motor

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Pos. No. Component
10 Hydraulic block
20 Coarse dirt flap cylinder
30 Seating of upper link
40 Power box
50 Feeler wheel

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5.3 Designated use
With this sweeping and suction combination, only sweeping and suction of the
following debris is permitted:
•Grit
•Sand
•Dust
•Leaves
The manufacturer assumes no liability or responsibility for any use which goes beyond
these limits.
Use, maintenance and reconditioning of the sweeping suction combination may only
be carried out by trained and competent personnel.
To operate the equipment within the limits of its designated use, please note the
following:
•These operating instructions as well as all enclosed documentation.
•Road traffic regulations.
•The relevant accident prevention regulations.
•The generally recognized rules relating to technical safety requirements and
occupational health.
•The operating instructions of the carrier vehicle.
5.4 Obvious misuse
The sweeping suction combination may not be used to carry persons or goods.
The sweeping suction combination and its attached parts may not be used as climbing
aid.

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6 Safety instructions
This chapter gives you information on the following:
•Chapter 6.1 "General safety instructions", page 18
•Chapter 6.2 "Commissioning", page 19
•Chapter 6.3 "Use", page 23
•Chapter 6.4 "Maintenance", page 27
•Chapter 6.5 "Designations", page 31
6.1 General safety instructions
Warning
Use or maintenance of the sweeping suction combination by untrained persons.
Risk of serious injury.
•Make sure that all persons responsible for operation or maintenance of the
sweeping suction combination are trained in the operation of the same and are
familiar with the operating and maintenance instructions as well as the safety
information in this manual!
•Insist on compliance with the applicable safety regulations!
Warning
Loose-fitting garments.
Risk of serious injury.
•Always wear tight-fitting clothes during the operation of the sweeping suction
combination!

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Warning
Non-observance of guidelines.
Risk of serious injury or death.
•Please observe the regulations relating to accident prevention!
•Please observe the generally applicable safety regulations, industrial standards
and medical guidelines!
•Please observe the road transport guidelines!
•Please pay attention to the general advice in these operating instructions!
Caution
Accidental ignition of residual dirt.
Risk of injury or property damage.
•Please make sure that the sweeping suction combination is always kept in a clean
condition!
Caution
Modifications at the sweeping suction combination.
Impairment of functionality and danger of property damage.
•Do not make any changes at the sweeping suction combination!
6.2 Commissioning
Danger
Carrier vehicle rolls away when mounting the sweeping suction combination.
Risk of serious injury or death.
•Before mounting the sweeping suction combination onto the carrier vehicle, apply
the parking brake, stop the engine and remove the ignition key!
•Never stand between carrier vehicle and sweeping suction combination while the
sweeping suction combination is mounted!
•Apply all locking bolts and screws at the carrier vehicle and secure them!

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Danger
Lifting of vehicle.
Risk of serious injury or death.
•Switch off hydraulic system during transportation!
Warning
Lifting of vehicle.
Risk of injury, death or damage to property.
•Only single-acting operation of front hydraulic during sweeping and mowing!
Warning
Overload or possible tilting of the carrier vehicle.
Risk of injury, death or damage to property.
•Please observe axle load limits and admissible overall weight!
Warning
Mounting of sweeping suction combination at a malfunctioning carrier vehicle.
Risk of serious injury or death.
•Please make sure that the carrier vehicle is in a safe and proper condition!
•Please make sure that the carrier vehicle is equipped with an appropriate braking
system!
•Make sure that the carrier vehicle may transport the sweeping suction
combination!
•Before every journey, make sure that the sweeping suction combination is
securely attached to the carrier vehicle!
Warning
Loose screwed or bolted connections.
Risk of injury or property damage.
•After having mounted the sweeping suction combination, please make sure that
all screwed and bolted connections are always in place and secure!