Tuchel HKM Instruction Manual

OPERATING INSTRUCTION MANUAL
SPARE PARTS CATALOGUE
HKM SWEEPER
November 2007

Contents
1 General Information .....................................................3
1.1 Intended Purpose............................................................3
1.2 Data concerning the product ..........................................3
1.2.1 General................................................................3
1.2.2 Manufacturer's address ......................................3
1.2.3 Marking................................................................3
1.2.4 Information Required for Orders ........................3
1.3 Technical data.................................................................4
2. Safety..............................................................................5
2.1 Basic safety rules............................................................5
2.2 Marking conventions in the manual...............................5
2.3 Safety rules for the operator...........................................5
2.4 Personnel qualification and training...............................6
2.5 Safety rules for working on the sweeper.......................6
3. Operation ................................................................
.......
7
3.1 Assembly instructions. ................................
....................
7
3.2 Preparing the machine for the initial use
.......................
8
3.3 Notes on use ................................................................
...
9
Startinq the Motor
Turning the motor off
Drivinq the sweeper
Drivinq speed
Brush drive
Brush speed
Settinq brush height
Settinq brush angle
Extras
4. Maintenance ................................................................
10
4.1 General..........................................................................
10
4.2 Adjusting the drive belt tension ....................................
10
4.3 Troubleshooting ............................................................
10
Parts Catalogue...................................................................11
Diagram 001..........................................................................12
Diagram 002..........................................................................14
Diagram 003..........................................................................16
Diagram 004..........................................................................18
Accessories............................................................................20

2

3
General
1 General Information
1.1 Intended Purpose
The HKM sweepers were specially developed for sweeping and showclearance.
Any other application should be discussed with the manufacturer prior to that use. Any damage caused by
usage outside these areas are fully at the risk of the user. The content of this manual describes correct usage
and maintainance of the machine.
1.2 Data concerning the product
1.2.1 General
This manualis valid for all the HKM sweeper series.
1.2.2 Manufacturer's address
Tuchel Maschinebau GmbH
Holsterfeld 15
48499 Salzbergen
Telephone [phone]
Fax[phone]
E-Mail: [e-mail]
1.2.3 Marking
Marking is by means of the vehicle identification plate.
NOTE Write your sweeper’s data is here, so that youalways have the information to hand.
Model/Type
Serial No.
Year of
construction/Order No.
Max.oil pressure (bar)
Max.oil flow (L/min)
Gross weight (kg)
WARNING
The identification plate serves a legal function and as such must not be changed or defaced so
as to be unreadable.
NOTE Replace those that are damaged or missing.
1.2.4 Information Required for Inquiries and Orders
When ordering spare parts or requesting information about the sweeper, quote the model, serial number and
yearof manufacture of the machine.
WARNING The use of spare parts from other manufacturers is not permitted without the
express written
permission of Agriquip. The use of original spare parts protects the machine and ensures its safe
operation. The use of other than original parts or accessories renders the warranty null andvoid.
WARNING
Neither the manufacturer nor their agents are responsible for any consequences arising from the
use of non-original parts or unapproved attachments.

4
General
1.3 Technical data
NOTE forengine specifications refer to the motor instruction booklet (included)
Working width HKM 100 : 1000 mm HKM 120 : 1200 mm
Distance between wheels 560 mm
Height including engine 600 mm
Brush diameter 330 mm
Driving speed 2.5 – 4.5 kph
Weight 85 kg
Tyre pressures Main wheels: 1.5 bar (max 2.5 bar).
Support wheel: 1 - 2 bar (max 2 bar).
Engine
Use 91 Octane petrol Honda GCV 160 orHonda GXV 140 or Briggs & Stratton5HP I/C
Oil 10W 40
Vibration through hand and
arm on the handle bars. ahwd = 3.6 ms-2 (Honda)
ahwd = 3.5 ms-2 (B&S)
Maximum noise level LWAd = 94 dB(A)/1pW (Honda)
LWAd = 93 dB(A)/1pW (B&S)
Noise level at operator’s ear LpAd = 84 dB(A)/20 Pa (Honda)
LpAd = 84 dB(A)/20 Pa (B&S)
Optional extras Collector, Snow Plough

5
Safety
2. Safety
2.1 Basic safety rules
This handbook contains safety information concerning the operation and maintenance and SHOULD BE
READ PRIOR TO OPERATING OR MAINTAINING THE SWEEPER.
Failure to observe these safetyrules canendanger the operator and cause damage to the environment.
Failure to conformto these rules removes all possible claims for damage.
The following dangers should be especially considered:
Danger to people coming into the workingarea because it has not been properly securedor cordoned off.
Failure of important machine functions.
Failure to carry out correctmethods of service andinspection.
Endangering people mechanically and chemically.
Endangering the environment with petrol and oil leaks.
ATTENTION
In addition to the included operating instructions and safety rules and notices, the requirements
of the relevant DoL-OSH Guidelinesshould be observed.
ÿPlease also heed of the safety notices and precautions of the engine manufacturer.
2.2 Marking conventions in the manual
The safety notes contained in this manual, which endanger persons if neglected, are flagged with
the general safety symbol ÿ
Safety notes, whose neglect would cause dangers for the machine, have the word ATTENTION
inserted.
Notes are indicatedas follows: NOTE
At the machine these safety symbols must be taken notice of and must be kept in good readable condition.
2.3 Safety rules for the operator
Beforestarting the machine familiarise yourself with all the controls and their functions.
Only start the machine when safety devices and covers are in place (especially the drive belt cover).
When using the machine wear suitable clothing and strong shoes. Do not wear loose clothing ÿ
scarvesor dresses that could be caught up in the broom.
Secure the machine against runningaway or against the use of the machine by unauthorised third parties.
Check that there is enough petrol before starting. Do not fill the tank with petrol etc in anenclosed room or
while the machine is running or hot. Wipe any petrol spills from the machine before starting or wait until
they have evaporated.
Other than when filling the motor tankwith petrol the tankcap shouldalways be kept firmly closed. When
handling petrol, fires, welding, smoking, andother potential ignition sources are forbidden.
If the petrol tank or the tankcap are damaged they must be replaced immediately
Never start the motor inan enclosed room, there is a danger of carbon monoxide poisoning.
Always operate the sweeper at an appropriate speed for the location and conditions.
When working onslopes or steepareas please note there is a dangerof the machine tippingover or rolling
away fromthe operator. (Do not rely on the broom as a brake).
Keep hands andfeet clear of rotating parts.
Ensure the area is clear of people and animals before commencing sweeping.
Do not allowpeople andanimals into the area while operatingthe sweeper.
Do not carry passengers on the machine!
Beforecleaning, inspection, repair or maintenance work, ensure that all moving parts have come to a
complete standstill. Set the gas lever to STOP andremove the spark plug lead to prevent starting.
Never leave the machine unattended when the motor is running.
Let the motor cool before storing the machine away in an enclosedroom.

6
Safety
2.4 Personnel qualification and training
The sweeper may only be operated, maintained and repaired by competent persons, that have beenfully
informed about the associated dangers. The area of responsibility, the competence and the monitoring of the
personnel must be regulated by the operator. If the personnel do possess the necessary knowledge, then
they are to be supervised and given instruction. Further it is to be verified by the operator that the contents of
the manual are fully understood by all personnel.
Those repairs and adjustments not describedin this manual, may only be performed by authorised agents.
2.5 Safety rules for working on the sweeper
Before cleaning, inspection, repair or maintenance work, ensure that all moving parts have come to
a complete standstill. Set the gas lever to STOP andremove the spark plug lead to prevent starting.
Only the service, inspection and maintenance work described in this operating manual should be ÿ
carriedout by the owner. All other work should be performed by an authorised dealer.
Once the machine has been turned off a number of parts including the silencer remain hot foranextended
period.
If guards and covers have been removed(especially the belt cover) there is a danger of entrapment
trappingextremities with painfulor damagingresults. Replace all guards and covers before re-startingthe
machine.
The operating and maintenance instructions in the motor manufacturer’s handbook should be followed.
NOTE Signsattachedto the sweeper mustbe maintained in good readable condition.
Missing or damaged signs must be replaced.

7
Operation
3. Operation
1. Throttle and motor stop.
2. Operating lever for the sweeping brush
3. Operating lever for the forward drive
4. Speed selection lever
5. Height adjustment for handles
6. Motor
7. Brush angling lever
8. Drive belt cover
9. Height adjustment for the brush
10. Support wheel
11. Attachment for collector etc.
12. Sweeping brush
13. Swivel locking for brush
The HKM 100 and HKM 120 machines come in 2 cartons.
Carton 1 – Main part with the motor mounted
1 Sweeper power component
2 Wheels
1 Cover
1 Power transmission cover
1 Packet containing: instructions and spares list, engine instructions & small components
Carton 2 – Front part with the brush system
1 Sweeper front part including brush
1 Swivelling lever
1 Power transmission belt
1 Power transmission belt cover
1 packet containingassembly components
Afteropening the topof the carton slit two sides down to the bottom, the machine may then be rolled out.
3.1 Assemblyinstructions.
a)
Attach the handles to the machine body using the bolts and washers provided. The front and back plates
of the handle structure are bolted together with M8 nuts and bolts.
b)
Attach the driving wheels with the air valves facinginwards.They are pushed onto the axle and secured
with a split pin.
ÿBe careful not to get your fingers caught between the parts.
c) Mount the brush.
Remove the M12 nutfrom the brushcore.
Remove the washer and brush end plate.
Push the brush segment into position making sure it goes correctly onto the square core.
Push the brush drive component onto the core andfinally the second brush segment.
Re-attach the end plate washerand nut.
d) Attach the brush angling lever 7.
Slide brush angling lever through guides (as shown in diagram at top of page).
Attach to the brush cover using the circlip.

8
Operation
e) Attach the support wheel.
f) Attach brush heightadjustment handle (in the pack containing small parts).
Place a washer over the thread and screw the handle into the hole (M – as in diagram at top of
previous page) until the machine starts to lift.
Note: When the machine is complete the brush should be adjusted until it makes a light contact with
the ground. The
pressure should never press the brush more than 15mm into the ground.
When the right height is achieved the handle is secured with the lever.
g) Fit drive and sweeping modules together.
Referring to figure at right, bring both parts
together.
Push the shaft L through the connecting
piece C and the drive belt pulley
Secure by inserting the split pinF.
Check the diagram to make sure that the
position of C is correct (refer step h).
ÿBe careful not to get your fingers caught.
h) Attach the drive belts.
Ensure that the throttle is at the motorstop
positionand remove the spark plug lead.
Drawthe drive belt over the motor pulley.
This machine maybe operated at 2 different brush speeds.
This is achieved by selecting one or other of the belt pulleys
Upper drive belt pulley — Faster brush speed (e.g. for snow)
Lower drive belt pulley — Slower for general sweeping.
Ease the belt over the sweeping drive pulley. You may assist this to go over by pulling the starter
cordbut do not get your fingers inthe way.
Note: The belt must be in the guide way and lay correctly on the pulleys and on the inner side of the
tensioner. This is
important because it will ensure that the drive disengages properly (
ie. when the brush lever is released the brush
does not continue to rotate) – refer to D.3 if problems occur.
i) Attach the drive belt cover (The drive beltcover is in two parts so that the rear pulley may be covered
when the drive part of the machine is attached to other devices).
Bringthe rearpart into position and screwinto place
Screwthe front piece into place, laying correctly on the profile shape of the rear cover.
ÿThe operation of the machine without the drive belt coveris strictlyforbidden.
3.2 Preparing the machine for the initial use
Lift the leverof the brush swivellingarm and use it to move the brush to a normal position. Pull the support
wheel up, taking care that it doesnot catch inthe cable.
Turn the support wheel height adjustment until the wheel
comesinto contact with the ground. The washer should be
between the tube andthe base of the handle.
The next item to deal with is the swivelling arm. The arm is slid
through the eye and mountedon the swivelling point. When
tightening the swivelling point ensure that the plastic washer
can still be turned by hand. The ratchet positioning needs to be
fixed on with the M12 nut.
Nextremove the transportsupports from the ends of the brush.
ÿUse gloves when doing this to avoid injury from the brush
or the edges of the metal.
Tighten the nut on the brush rotational point carefully.
ÿPrepare the engine (read the engine handbook
). The engine is delivered without any oil(use 10 W 40).
All HKM engines use 91 octane lead free petrol.

9
Operation
3.3 Notes on use
Priorto starting the machine familiarise yourself with the controls. The machine hascontrols for brush and
machine driving speed. The brushand drive operation levers are dead man levers and will go to the off
positionif released.T he ergonomic design means that little pressure is required to keepthe machine running.
If the levers are releasedthe machine will stop.
Startinq the Motor
If the motor has a petrol tap turn this on.
Move the gas control to MAX which puts the engine in the choke position.
Using either the elector start or the pull start cordstart the motor.
Aftera fewsecondsyou can move the gas control lever back off of choke to the full speed position.
Turning the motor off
Move the gas control lever to the Stop position
If presentturn off the petrol cock.
ÿWarning after the motor is turned off the motor parts are still hot for quite some time.
Drivinq the sweeper
To startthe machine moving forward gripthe red lever on the left handle bar (as seenfromthe operator
position). You will need to hold the lever down, if you let go the machine will stop.
Drivinq speed (2.5 – 4.5 kph)
The sweeper has a speed control on the left handle bar(as seen by the operator).
Move the lever forward to increase speedand backwards to decrease speed. This can be done white the
machine is running.
Brush drive
The brush is started by pressing down the red lever on the right hand handle bar (as seen by the operator).
You will need to hold the lever down to keep the brush rotating. If you let go the brush will stop.
ÿ
When you start the brush rotating it will be in contact with the ground. If the nature of the ground is such
that the brush can not freely rotate, the brush rotation will move the sweeper forward. It is better to put
the machine in drive first and move forward at the desiredspeed then startthe brush.
Brush speed
Five brush speeds can be selected on this machine.While the brush is running you can operate the speed
control lever on the lower part of the left handle bar (as seenby the operator).
Move the lever first towards the machine centre and then upor down.
Settinq brush height ( brush pressure)
The brush should have a contact area with the ground as seen from the side of between 15 and 20 mm.
Loosen the contra nut and rotate the handle (9 – on figure on page 7) until the brush looks right on the
ground. Then re-tightenthe locking nut..
Settinq brush angle
If youare using the-collector the brush head should be keptstraight. Angle the brush to sweep off to one side.
Raise the lever (13 – on figure on page 7
), move brush around to desiredangle, then lower the lever to lock
it into the new position.
Extras
The mostimportant and useful extra is a collector.
To attachit simply lowerit onto the 2 pin holders on the brush head.
If the conditions are very dusty a water spray systemis ideal for keeping the dust down. This is simple to
attach and a worthwhile extra.
It is possible to attach a snowplough to the sweeper for dealing with larger quantities of snowthan the brush
will deal with. It should also be noted thatthe correct brush for snow is the 8 x 2 Polypropylene.
Snowchains are also available for the machine to improve the grip in snow.