Tuchel Simplex User manual

1.0 / 2008-05-19
Operating manual
Sweeper

Table of contents
2
Foreword............................................................................................................................ 5
1General information about this operating manual................................................... 6
A word about this operating manual...................................................................................................... 6
Declaration of conformity........................................................................................................................ 7
2Safety........................................................................................................................... 9
General safety information ..................................................................................................................... 9
Intended use............................................................................................................................................. 9
Safety instructions in the operating manual....................................................................................... 10
Safety stickers on the accessory equipment......................................................................................11
Safety regulations.................................................................................................................................. 12
Safety devices ........................................................................................................................................ 12
Clothing................................................................................................................................................... 12
Modifications to the accessory equipment......................................................................................... 13
Before leaving the host vehicle............................................................................................................ 13
Preventing injuries................................................................................................................................. 13
Operating the accessory equipment.................................................................................................... 13
Basic safety instructions when operating the articulated shaft drive.............................................. 14
Transporting........................................................................................................................................... 14
Safety measures during maintenance................................................................................................. 15
Before performing maintenance work................................................................................................. 15
During the maintenance........................................................................................................................ 15
3Technical data........................................................................................................... 16
Dimensions............................................................................................................................................. 16
Work values............................................................................................................................................ 17
Working hydraulics................................................................................................................................ 17
Attachment with mount......................................................................................................................... 17
Additional equipment (option).............................................................................................................. 17
4Description / overview.............................................................................................. 18
General view........................................................................................................................................... 19
Accessories (optional)........................................................................................................................... 20
Debris collector ........................................................................................................................................ 20
Side broom............................................................................................................................................... 20
Hydraulic lateral adjustment..................................................................................................................... 21
Splash guard............................................................................................................................................ 21
Type plate ............................................................................................................................................... 22
Identification marking locations........................................................................................................... 23
5Operation................................................................................................................... 24
Working with accessory equipment..................................................................................................... 24
Safety regulations when working with accessory equipment...................................................................24
Placing into operation ........................................................................................................................... 25
Checks before placing into operation....................................................................................................... 25
Installing the sweeper............................................................................................................................ 26

Table of contents
3
Initial installation........................................................................................................................................26
Mounting the A-frame ...............................................................................................................................27
Mounting the three-point linkage ..............................................................................................................29
Hitching the PTO shaft to the host vehicle ...............................................................................................31
Attaching accessories (optional)...............................................................................................................31
Operating the sweeper...........................................................................................................................32
Adjusting the parking jacks.......................................................................................................................32
Adjusting the sweeping profile..................................................................................................................33
Adjusting the revolution speed..................................................................................................................33
Simple sweeping mode.............................................................................................................................34
Containing the sweepings (optional).........................................................................................................35
Emptying the debris collector (optional) ...................................................................................................36
Swivelling the side broom to the operating/normal position (optional).....................................................37
Installing the sweeper ............................................................................................................................38
Preparing for disassembly........................................................................................................................38
Unlocking the A-frame ..............................................................................................................................40
Unlocking the three-point linkage .............................................................................................................40
Placing out of operation.........................................................................................................................41
Turning off of the accessory equipment safely.........................................................................................41
Storing the accessory equipment over longer periods of time .................................................................41
6Operation...................................................................................................................42
Adjusting the compensation system....................................................................................................42
Re-adjusting the sweeper ......................................................................................................................42
Adjusting the support wheels ...............................................................................................................43
Debris collector (optional) .....................................................................................................................44
Disassembling the debris collector...........................................................................................................44
Adjusting the debris collector....................................................................................................................45
Adjustment of the Vulkollan rubber wear tip (optional)......................................................................46
Side broom (option)................................................................................................................................47
Adjusting the circular brush ......................................................................................................................47
Setting the inclination and contact of the side broom...............................................................................47
Adjusting the revolution speed..................................................................................................................48
Splash guard...........................................................................................................................................49
Installing the splash guard........................................................................................................................49
Adjusting the clearance between splash guard and ground.....................................................................49
7Maintenance ..............................................................................................................50
Safety measures .....................................................................................................................................50
Safety-relevant parts ..............................................................................................................................50
Maintenance preparation .......................................................................................................................51
Lubricants and operating materials......................................................................................................52
Screw connections.................................................................................................................................52
Wearing parts/spare parts .....................................................................................................................53
Lubricating points...................................................................................................................................55
Replacing the sweeper cylinder............................................................................................................56
Re-tensioning the chain.........................................................................................................................59
Replacing the Vulkollan rubber wear tip (optional).............................................................................60

Table of contents
4
Replacing the splash guard (option).................................................................................................... 61
Changing the circular brush (option)................................................................................................... 61
Hydraulic circuit diagrams.................................................................................................................... 62
8Troubleshooting ....................................................................................................... 65
9Index.......................................................................................................................... 66

Foreword
5
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Foreword
Dear Customer,
The "Simplex" sweeper you have purchased has been
manufactured to the highest quality standards. In order to
eliminate any possibility of damage to persons or property, you
must read and observe the respective safety and warning
instructions in this manual and on the accessory equipment
before using or servicing the accessory equipment.
Before placing the accessory equipment into operation, all
machine operators must make themselves familiar with the
handling of the accessory equipment using this operating manual.
The safety regulations are to be strictly adhered to. Adherence to
the valid safety regulations for your country is also obligatory.
Table of contents
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General information about this operating manual
6
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1 General information about this
operating manual
A word about this operating manual
A professional operation and conscientious care and maintenance
of the device are necessary in order to maintain the safety and
utilisability of the accessory equipment. This operating manual will
help you to use the accessory equipment for its intended purpose
and to avoid damages to persons and property. The manual takes
the necessary legal conditions and guidelines into account and
contains important information.
The operating manual is part of the device and should be stored
so that it is readily available at any time. If the operating manual
becomes soiled or gets lost, a new replacement manual can be
requested from Tuchel Maschinenbau GmbH at any time. If the
device is sold, the operating manual must be transferred to the
new owner.
The owner of the device bears the responsibility for the following
points:
•Every operator must be at least the legal minimum age
and be physically as well as mentally fit to reliably fulfil the
tasks assigned to them.
•Every person who operates or services the accessory
equipment must have read and understood the operating
manual beforehand.
•The accessory equipment may only be used for its
intended purpose and in accordance with applicable
regulations.
•The accessory equipment may not be modified or altered.
The declaration of conformity of the Tuchel Maschinenbau GmbH
expires if the owner allows safety-relevant modifications to be
performed on the accessory equipment. The party performing the
modifications must issue a new declaration of conformity. If you
have questions concerning this, please contact Tuchel directly.
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General information about this operating manual
7
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Declaration of conformity
The "Simplex" sweeper satisfies the "essential health and safety
requirements" of the Machinery Directive 98/37/EC and is
authorised to carry the CE mark.
Furthermore, the harmonised European Standards DIN EN 292-
1/2, DIN EN 982, DIN EN 474-1/3/4, DIN EN 1553 and the
German Regulations for the prevention of industrial accidents
(UVV) were used for the development of the machine. These are
documented in the EC declaration of conformity.
The manufacturer's address is located on the back side of the
operating manual.
NOTE!
The declaration of conformity is depicted on the
following page.

General information about this operating manual
8
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Safety
9
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2 Safety
General safety information
Most accidents are caused by the disregard of the essential
safety regulations. In order to prevent accidents and thus
eliminate any possibility of damage to persons or property, you
must have read and understood the respective safety and
warning instructions in this manual and in the manual of the host
vehicle before performing any work.
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Intended use
The accessory equipment is designed to be used solely for the
purpose defined in chapter "Description / overview", Page 18 and
in conjunction with the approved components.
Any other use does not comply with the regulations/requirements
or intended use. The manufacturer cannot assume liability for any
damages resulting from an unintended use. The user/owner alone
bears the risk for this.
Follow the corresponding safety instructions and working steps
from this operating manual and the manual of the host vehicle.
These also pertain to the intended use.
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Safety
10
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Safety instructions in the operating manual
In the operating manual at hand, the following signal words and
signs are used to make the safety instructions recognisable as
such at a glance:
This is the hazard warning. It warns you about the risk
of injury.
•Compliance with all activities labelled with the
hazard warning in order to prevent injuries or fatal
injuries is mandatory.
DANGER! – Risk of fatal injuries
Identifies risks that can result in severe injuries to
health or lead to death if the respective danger warning
is not observed or is not observed sufficiently.
WARNING! – Bodily injuries
Identifies risks that can cause physical injury if the
respective warning is not observed or is neglected.
CAUTION! – Minor injuries
Identifies risks that can cause minor bodily injury.
This is the cautionary sign. It warns you about the risk
of property damage. It differs from the hazard warning
since it warns about property damage and not about
bodily injury.
•Compliance with instructions provided on
cautionary signage is mandatory. It is intended to
prevent property damage and damage caused to
the environment.
ATTENTION! – Property damage
Identifies solely the risk of potential property damage
and damage caused to the environment.
NOTE!
Identifies application tips and useful information.
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Safety
11
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Safety stickers on the accessory equipment
Information and symbols attached directly to the accessory
equipment such as safety stickers must be observed without fail.
Safety stickers must not be removed and must be kept legible.
The following information and symbols are attached to the
accessory equipment:
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Read and observe the operating manual and safety instructions
before placing into operation.
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Crush hazard! Do not reach inside danger zone. Keep hands
clear of moving parts.
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Risk of debris ejected from sweeper's rotating cylinder. . Stay
clear!
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Do not operate machine with guards open or removed. Crush
hazard! Keep hands clear of moving parts.
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Do not reach into rotating machine parts. Wait until the machine
parts have come to a standstill.
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Safety
12
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Stay clear of rotating/pivoting parts.
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Crush hazard! Keep feet clear. Stay out of hazard zone. Keep
back a sufficient distance.
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Safety regulations
You may only operate or perform maintenance work on the
accessory equipment if you have been trained accordingly and
are authorised to do so.
Observe all regulations, measures and safety instructions when
operating or performing maintenance work on the accessory
equipment.
When working in a team, hand signals that are intended to be
used during specific tasks must be discussed and agree upon. A
coordinating person must be designated before starting the work.
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Safety devices
Ensure that all guards and covers are properly attached to the
accessory equipment.
Make sure that damaged guards and covers are repaired.
Under no circumstances may any safety installations be removed
such as e.g. the protective grating.
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Clothing
You may not wear loose-fitting clothing, jewellery or wear your
hair open. These items could get caught in control elements or in
moving or rotating parts and cause severe injuries.
Change clothing that is soiled with highly inflammable substances
immediately.
Always wear the operationally required protective equipment e.g.
hearing protection, protective glasses, safety shoes, dust mask or
gloves when operating or performing maintenance work on the
machine.
Make sure that no unauthorised person(s) are remaining in the
hazard area.
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Safety
13
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Modifications to the accessory equipment
Tuchel Maschinenbau GmbH assumes no liability for
modifications that are made without the express permission of the
manufacturer.
Tuchel Maschinenbau GmbH assumes no responsibility for
injuries or damages caused by unapproved modifications.
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Before leaving the host vehicle
Lower the accessory equipment to the ground.
Secure the hydraulics system and place it into its neutral position.
Activate the holding brake of the host vehicle and turn off the
engine.
Remove the ignition key from the host vehicle and keep it in safe
custody.
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Preventing injuries
Stay clear of moving parts, e.g. do not reach between accessory
equipment and host vehicle. Always stay clear of hazardous
areas.
When activating the support system, some equipment may extend
beyond its untoleranced dimensions. This may lead to serious
injuries.
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Operating the accessory equipment
When driving
Drive particularly slowly when driving on uneven terrain and
ensure that the path of travel is free from obstacles.
When working
Ensure that no one stays near the accessory equipment or behind
the host vehicle.
Perform work in the direction that the wind is blowing as much as
possible to protect yourself from dust and limited visibility.
High visibility
When working in dark areas, provide additional lighting for the
working area.
Stop working when visibility is poor e.g. during fog, rain or snow
and wait until the visibility has improved enough to ensure that
work can continue safely.
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Safety
14
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Basic safety instructions when operating the
articulated shaft drive.
It is the owners responsibility to ensure that the user of the
machine is thoroughly familiar with the inherent hazards of the
articulated shaft and that he/she has adequate knowledge of the
operating instructions provided by the drive shaft manufacturer.
The machine shall only be operated with original drive shafts.
Their length, size, type of overload clutch, and free-wheel clutch
are indented specifically for this purpose. Any application other
than the intended use of the articulated shaft drive, overload and
free-wheel clutch is not permitted.
Prior to the machine's use, please ensure that all safety
equipment are properly installed onto the articulated shaft and the
host vehicle. Verify that the accessory equipment is fully
functional.
Only use OME parts to replace damaged components or retrofit
missing part according to instructions.
Before starting any daily work routine, verify that the articulate
shaft is mounted securely to the host vehicle and accessory
equipment.
Prior to entering the work area and before starting any
maintenance work.
Shut-off the motor, remove the key from the ignition and keep it in
a secure place.
For your own safety, never wear loose-fitting clothes, belts or any
other loose items. Risk of accidents!
Never exceed the extension length while moving or working on
the equipment. Regardless of the application, the profiled pipes
must overlap at least 1/3 of their length.
Use small but consistent angular movements. Shut down the
power take-off shaft if the articulation angle exceeds 35°.
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Transporting
Loading and transporting
Use the host vehicle to lift the accessory equipment onto the
loading area.
Place suitable cushioning material (rubber mats) underneath.
Follow the transporting instructions from the operating manual of
the host vehicle.
Position the accessory equipment correctly onto the transporting
vehicle and secure the accessory equipment onto the loading
space using belts.
In order to prevent the accessory equipment from slipping or
dropping off the vehicle, use proper safety precautions.
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Safety
15
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Safety measures during maintenance
Personnel
You may only perform service or repair work on the machine if
you are a qualified specialist or if you have been carefully
instructed about the work to be performed by a qualified
specialist.
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Before performing maintenance work
Read and observe the operating manual and, in particular, the
safety instructions when you perform maintenance work on the
accessory equipment.
If maintenance work is being performed on the accessory
equipment, the engine of the host vehicle may not be started and
operating elements may also not be activated without prior
consultation. This can lead to accidents with severe injuries.
Remove the key from the ignition and secure the host vehicle in
order to prevent unauthorised start-up.
Tools
Use appropriate tools only. The use of damaged, poor quality,
faulty or makeshift tools can lead to injuries.
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During the maintenance
Keeping the accessory equipment clean
Always keep the accessory equipment clean.
Do not clean the accessory equipment with a high pressure
cleaner.
Never use fuel to rinse off or clean parts.
High-pressure hoses
Do not kink the high-pressure hoses. Never hit against the high-
pressure hoses with hard objects. Do not use hydraulic lines or
hoses with cracks or kinks. They will burst under use.
Exposure to high pressure oil
Always remember that the hydraulic system is under high
pressure. To depressurise the hydraulic circuits, follow the
instructions in the separate operating manual of the host vehicle.
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Technical data
16
3 Technical data
Dimensions
000114
894 1145
S2S1
550
400
B A
* The centre of gravity changes depending on the sweeper's equipment and when the sweeper's debris
collector is full

Technical data
17
Work values
Type: Sweeper "Simplex" 120 135 150
Working width "A" [mm] 1200 1350 1500
Working width when tilted 20° [mm] 1130 1270 1410
Total width "B" [mm] 1360 1510 1660
Empty weight (basic machine) [kg] 90 95 100
Empty weight (incl. debris collector) [kg] 113 120 127
Debris collector (volume) [L] 70 80 90
Sweeper cylinder Ø [mm] 400
Sweeping power
at 6 km/h [m²/h] 7200 8100 9000
Centre of gravity spacings
A-frame, simple sweeping S1 [mm] 400
A-frame attachment,
incl. debris collector S2 [mm]
500
Attachment of three-point linkage, simple sweeping S1 [mm] 560
Attachment of three-point linkage,
incl. debris collector S2 [mm] 660
Working hydraulics
Type: Sweeper "Simplex" 120 135 150
Working
hydraulics Working pressure (max.) [bar] 140
required flow 20
Attachment with mount
Three-point linkage incl.
A-frame incl.
Hitching system for front mower (direct mount) excl.
Additional equipment (option)
Type: Sweeper "Simplex" 120 135 150
Side broom (circular brush Ø) [mm] 500
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Description / overview
18
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4 Description / overview
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The "Simplex" sweeper is an accessory device for the sweeping
and gathering dirt. This type of sweeper is only approved for front
installation.
The sweeper is suitable for the sweeping, collecting, and
removing dirt and sand from streets, walkways, and any paved
surfaces.
The three-point linkage or the A-frame are used to mount the
sweeper to any municipal tractor vehicle. When using a front
mower, the attachment system is used for the direct mounting.
An articulated shaft or the host vehicle's hydraulic system is used
to activate the sweeper.
A chain drive rotates the sweeper's cylinder. The rotational speed
of the sweeper's cylinder depends on the speed of the power
take-off shaft or the oil flow of the host vehicle.
The contact pressure of the sweeper cylinder onto the ground is
adjusted by raising or lowering the support wheels.
As a rule, the sweeper cylinder is equipped with a full bristol brush
made of 100% PPN. The sweeper cylinder has a diameter of 400
mm.
The machine frame of the sweeper is made of a robust and
torsion-free welded construction.
The sweeper "Simplex" can be equipped with the following
accessories:
•Splash guards for services during the winter time.
•Debris collector for gathering sweepings
•Hydraulic system for emptying the debris collector
•Side broom for sweeping close to corners
•Hydraulic lateral adjustment for simple sweeping applications
and adaptation to various work environments
•Hydraulic drive of the sweeper cylinder

Description / overview
19
General view
000126
1
2 3
1011121415 13
5
7
8
9
6
4
1 Side broom (circular brush)
2 Rotational speed adjustment of side broom
3 Emptying, using a pulley system
4 Level compensation system
5 Support beam
6 Mechanical lateral adjustment
7 Chain protection
8 Parking jacks
9 Debris collector
10 Vulkollan rubber wear tip
11 Sweeper cylinder
12 Type plate
13 Support wheels
14 Articulated shaft connection
15 A-frame

Description / overview
20
Accessories (optional)
Debris collector
000182
4
12
3
3
1 Debris collector
2 Broom strip
3 Set screws
4 Vulkollan rubber wear tip
000179
5
5 Hydraulic emptying (hydraulic cylinder)
Side broom
000127
1
2
3
5
4
6
7
8
9
1 Hydraulic connections
2 RPM adjustment (control valve)
3 Locking device for normal position
4 Inclination precision adjustment
5 Swivelling range setting
6 Pressure angle setting
7 Hydraulic motor
8 Bumper
9 Circular brush