Kugelmann Maschinenbau DUPLEX Operating Instructions Manual Download Page 1

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OPERATING INSTRUCTIONS

DUPLEX

DUPLEX INOX

Mountable Spreader

Art.Nr.

100

39518

.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

Summary of Contents for DUPLEX

Page 1: ...ated 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 office kugelmann com 49 0 8860 9190 0 Kugelmann Maschinenbau e K Gewerbepark 1 5 87675 Rettenbach a A GERMANY ...

Page 2: ...2 English ...

Page 3: ...ity declaration mark of conformity copyrights 10 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 Chapter 02 Labelling and hazard warnings 15 Chapter 03 Technical data equipment 19 Producer 20 Working areas and possible use 20 English ...

Page 4: ...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 30 Set down of a spreader using Roll Fix 32 Assembly with spider 34 Assembly of the spreader with spider understructure 35 English ...

Page 5: ...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 50 Emptying the spreading material chambers after work 52 CHAPTER Maintenance and care wear parts 53 Maintenance and care 54 Wear parts 55 English ...

Page 6: ...6 Repair of paint 56 Welding work at spreader 56 Error diagnosis 56 Maintenance plan for spreader 58 English ...

Page 7: ...Chapter 01 7 www kugelmann com CHAPTER 01 Important Instructions Subject to changes English ...

Page 8: ...ude liabilty of the producer for resulting damages The relevant accident prevention regulations are to be observed This extends to the generally recognized safety relevant occupational medical 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 specific safety regulations of the country in whic...

Page 9: ...ractors to the customer No warranty is given for used second hand purchased and changed or modified machines Claims have to be made immediately after the damage occurred after thirty days at the latest and in writing The faulty parts have to be sent in Furthermore the company Kugelmann is not liable for injury to persons or damage to equipment which is caused by the following operation of the moun...

Page 10: ... 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 basic safety and health requirements are fulfilled with the equipment brought on the market Copy right of this technical documentation as well as all other copyrights and property rights rest with company Kugelmann e K 87675 Rettenbach For mistakes in the translation into other languages t...

Page 11: ...portant information for safe operation Observing them serves your safety Every person who operates or drives this vehicle combination has to be familiar with the operation instruction of the carrying vehicle Explantion of symbols Work safety symbol Danger Direct danger for life and health WARNING Warning notice Possibly threatening danger for life and health Info Important information for appropri...

Page 12: ...ing instructions have to be kept at the place of work at all times in this case e g in the driver s cab The operator has to observe the following He has to take care that the vehicle combination is in safe operating and roadworthy condition Work which does not meet regualtions has to be refused Before driving the driver has to check the fixation tension belts chains bolts etc of the spreading equi...

Page 13: ...ions are installed After turning off of the equipment tools machine parts may continue to run During work at the equipment use a ladder if available If not create slip resistant climb up The required protective 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 perm...

Page 14: ... couplings and parts Remember that high pressures are created in hydraulic conduits Squirting out oil can lead to injuries and fires Remove pressure in pressure lines before coupling on and off Damaged hydraulic hosepipes are to be replaced immediately In general Hydraulic hosepipes have to be exchanged after 6 years Only personnel with special knowledge and experiences are allowed to work at hydr...

Page 15: ...Chapter 02 15 www kugelmann com CHAPTER 02 Labelling and hazard warnings Subject to changes English ...

Page 16: ...e operating instructions Warning sign During all work at the machine shut down engine and remove ignition key Reflecting warning markings on back 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 ...

Page 17: ...er 02 17 www kugelmann com Producing company Kugelmann Danger notice If this chute is not in operating position control and hydraulic may only be switched on for emptying procedure Subject to changes English ...

Page 18: ...18Labelling and warning notices Kugelmann mountable spreader with labelling warning notices working lights and all round beacon Subject to changes English ...

Page 19: ...Chapter 03 19 www kugelmann com Chapter 03 Technical data equipment English ...

Page 20: ...he spread quantity Machine data The mountable spreader equipment Duplex has a capacity of 0 4 to 5 m for solid spreading material The spreading equipment has 2 equally sized chambers There is another option of dividing the spreading material chambers 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 des...

Page 21: ...n indefinite period An additional p t o hydraulic pump can be delivered optionally if the carrying vehicle does not reach the necessary conveyed volume If the carrying vehicle does not have a p t o shaft a driving unit independent of the carrying vehicle can be supplied through the company Kugelmann Standard version An all round beacon at the rear of the spreader a working light at the spreading d...

Page 22: ...ment is so optimally placed that the centre of gravity of the spreader is even lower Mountable kits Various mountings are possible mounting kits Mounting is on the platform whereby the spreader is fixed with lashing straps Weight can be saved through mounting with an intermediate frame spider Thereby the tip truck platform and fixing with lashing straps are not required The spider is held directly...

Page 23: ...ad pattern adjustment leave no wishes of the customer unfulfilled The version partly in VA or Duplex Inox entirely stainless steel both with high quality special coating guarantee a long life With the MCSS 3 4 or k tronic control respectively the control unit can be operated simply and precisely Both controls work road speed related in a closed loop system of all drives Short set up times low desi...

Page 24: ...a or characteristics can be seen spreading chamber width in cm spreader Duplex spreading chamber height in cm spreading container length in cm M stands for medium rear length outlet long medium or short version here steel Change code S 180 095 220 M L ST 01 English ...

Page 25: ...Chapter 04 25 www kugelmann com CHAPTER 04 Mounting dismounting of the spreader Subject to changes English ...

Page 26: ...lower the spreader together evenly until the load is staken up by the carrying vehicle Is the spreader loaded on the platform it must of course be positioned correctly The spreader is secured with lashing straps only at the 4 corners to avoid shifting For the first mounting the type of sercuring is determined by the producer und must be observed by all means If the mountable spreader has an interm...

Page 27: ...vehicle hydraulics is insufficient and no power take off shaft is available The motor is factory made and firmly attached to the mountable spreader The prescribed maintenance intervals are to be kept Control MCSS 3 4 The control unit MCSS 3 4 is connected with the spreader via 3 cables with plug connection Two cables including connectors are connected with the cables coming from the spreader Pay a...

Page 28: ...flection above the container The diagram at slip shows you the maximum load Make sure that the carrying capacity of the heavy duty lashes or chain hangers are sufficient Create safety reserves The point of gravity of the spreader is viewed in driving direction behind the middle of the hull In this position the spreader can be lifted in the horizontal Fixing on the loading platform with lashing str...

Page 29: ...carrying vehicle can move out carefully When dismantiling pay attention to the real weight of the spreader Remaining spreading material may increase the total wieght considerably The tripod or the hangers must be designed for these loads Build in sufficient safety reserves When dissembling with hangers pay attention to the point of gravity of the spreader to assure an even horizontal lift down Car...

Page 30: ...during mounting If the angle is too small the folding columns cannot be folded because the columns are still resting on the gorund or the lever for folding is too unfavourable There is the danger that the spreader is pushed backwards Drive slowly centred and straigt under the spreader until the laterally attached indicators fold in The back edge of the tip truck dumping body must not touch the fol...

Page 31: ... Lift both support arms up with a hooked up cable winch Secure the lifted supports with both positioning bolts Secure the positioning bolts with the respective splints To pull the positioning bolts lift the supports slightly with the cable winch The vehicle lighting must not be covered Tie down the spreader on the tip truck dumping body with the supplied lifting tackle Insert the hydraulic pipes I...

Page 32: ... all fixing elements between the spreader and the carrying vehicle Lower both supporting legs with a hooked up cable winch to the ground Secure each supporting leg with two bolts each Use the lowest possible pair of holes for the bolts On both sides use the pair of holes at the same height Secure the bolts with the supplied safety elements against sliding out Lift the tip truck dumping body slight...

Page 33: ...English Chapter 04 33 www kugelmann com Subject to changes ...

Page 34: ...ed or the intermediate platform frame or the spreader can be damaged Drive under the spreader such that the tilt trays of the spider are directly above the ball points of the intermediate frame of the platform The persopn who serves as guide must never be between the spreader and the carrying vehicle So that the hydraulic pipes and hoses are not torn off bind them upward bevore you drive under the...

Page 35: ...rves or on uneven ground the feet of the tripods can touch and be damaged Remove positioning bolts at the back tilt trays Remove screws at the front tilt trays Lift spreader via hand cranks of the lowering tripods evenly from the carrying vehicle Put back security elements positioning bolts screws and security nuts into the tilt trays for safe keeping Often the back ball points are higher than the...

Page 36: ...icle the base setting of the lowering tripods must not be changed Do not put bolts into neighbouring holes It would then be possible that the dipping height of the lowering tripods is insufficient to lift the tilt trays of the ball holders In this case reduce the load so that the carrying vehicle is pressed further up by the springs Subject to changes ...

Page 37: ...Chapter 05 37 www kugelmann com CHAPTER 05 Operating the spreader Subject to changes English ...

Page 38: ... on the all round beacon the lights as well as the spreader In selection mode you set the values for automatic and manual spreading and you get into the setting menu For details see the control operating manual Display Switch all round beacon Switch working lights Switch control on off Selection key Spreading pause Dial knob left spreading density left Dial knob centre spreading width Dial knob ri...

Page 39: ...all round beacon Pause Working lights Switch key Various levels Spreading material key On off Spreading density left Spreading width Spread pattern Spreading density right See manual control k tronic operating manual Subject to changes English ...

Page 40: ... permissible total weight Weigh the vehicle when fully loaded and with all attachments Determine the weight with lifted and lowered front device In case the spreader vehicle is overloaded you have to make a filling mark Since grit has a higher density than de icing salt weighing with the latter is sufficient The grid of the spreading container is not to be removed during operation condition Only w...

Page 41: ...E IGNITION KEY After shutting down the equipment tool part of machine can still run on The spreading disc unit can be changed from transport mode to working mode with a few moves Draw fixing bolt of the locking device lever on the left side turn by 90 degrees and snap into place Fold locking device lever upwards or to the front while holding on to the spreader unit Swing spreader unit downwards Dr...

Page 42: ...ce inside not visible here Upper opblong hole Locking bolt outside Locking lever with handle knob The spreading disc is set in horizontal position with two spindles by the factory Hand wheel for mechanical adjustment of spread pattern Hand wheel to secure setting Subject to changes English ...

Page 43: ...terial Is the height of the spreading disc is changed so is the spreading width and the spread pattern Bigger wheels of a higher platform for example can cause this Adjustment of spreaded quantity The spreading unit is folded up the sensor in the chute assures that the spreading disc is turned off Pay attention to the warning notice Do not grab into the metering screw there is danger of severe inj...

Page 44: ...draulic system at the vehicle if it does not have a hydraulicconveyor system which adjusts volume to performance Load Sensing Manual operation on keep key down on the left side pressed Press key on the right at the top Let both keys go again Press key on the top right again spreading mode Screw and spreader disc are turning Never work near machine wearing loose clothes which can get caught in runn...

Page 45: ...ith the mechanical spread pattern adjustment the spreading disc is moved forward and backward with a hand wheel The more spreading material is moved to the centre the more the spread pattern is moved to the left The electric spread pattern adjustment funcions via k tronic Turn k tronic on press dial knob in the middle and turn left or right The arrow on the display moves left or right accordingly ...

Page 46: ... FS30 If only sections of the road are spread with damp salt the brine tanks can only be filled partially In this case the limit switch can be attached at a lower postion at the tank The arrow at the hexagon must show upwards The upper borehole is to be closed with a sealing plug Close stop valve at filler tube Remove filling hose and screw the sealing cover on the filler tube Unplug the limit swi...

Page 47: ...king the setting Adjust whole disc protection unit Tighten screws again Brine sensor The sole sensor serves to control the flow of brine to the spreading disc When control is on the green operation control pilot lamp LED is on If there is sufficient brine for safe operation of the spreader the yellow LED is on too The signals of the brine sensor are evaluated by the control and in case of a fault ...

Page 48: ...y catches of of the chute must be put in If the connection hose between the brine pump and the non return valve empties itself it has to be checked whether perhaps salt crystals have formed in the valve Salt crystals at the valve can have a negative influence on the tightness of the non return valve To prevent crystals from forming the non return valve should be flushed during the summer break Lar...

Page 49: ...kugelmann com Emptying the brine tanks Emptying of the brine tanks can be done through the hydraulic system or the brin pump Another possibility to empty them is through the filling connection Subject to changes English ...

Page 50: ...urth hand wheel on the far left for the emergency operation of the brine pump Hand wheel left screw conveyor Reverse key for screw conveyors Hand wheel for spreading disc emergency operation Hand wheel brine pump Hand wheel for right screw conveyors To eliminate disturbances at the k tronic control proceed as follows Turn hydraulic supply on Turn k tronic control on Push screw conveyor reverse key...

Page 51: ...r the defective part immediately contact your dealer or an expert repair shop If there is danger for humans or equipment the equipment has to be stopped immediately and the customer service be contacted STOP MOTOR AND REMOVE IGNITION KEY The operator has to take care that the vehicle combination is found in an operating and roadworthy condition Works which do not conform to regulations has to be r...

Page 52: ...cle in a shelter protected from the weather and covered by a roof After work fold the spraying unit upward move the safety catches up until they snap into the upper elongated hole Remove possible deposits from the chute Secure the unit with the locking lever and the locating pins folded upwards With the control the spreading material chambers can now be emptied Chose an appropriate parking place o...

Page 53: ...Chapter 06 53 www kugelmann com Chapter 06 Maintenance and care wear parts Subject to changes English ...

Page 54: ...be kept clean It moves the spreading disc forewards and backwards and thus has to be cleaned regularly Spreader with drive via p t o hydraulic pump After each work assigment the p t o hydraulic pump has to be checked for secure position so that it cannot turn The oil level can be checked at the inspection glass on the side Fill gear oil SAE 80 or 90 about 0 5l up to inspection glass height Change ...

Page 55: ... upward the spreading disc rotation stops Replace defective sensors immediately Danger through rotating tools Park vehicle and remove ignition key Wear parts Wear parts are the spreading disc both srew conveyors the cabin and the sprockets the bearings of the spreading disc and the screw conveyors all light bulbs all oil and water filters all hydraulic hoses are to be replaced every six years all ...

Page 56: ...turbances at the processor and failure of the control have to be expected Error diagnosis If the fault Sensor disc error appears this can have several causes The spreading equipment does not receive any oil Hydraulic onnections are not properly connected The srew conveyors are blocked The sensor is defect a cable has been torn off Check sensor and sesor adjustment in the detail menu See descriptio...

Page 57: ...preading material if the inappropriate spreading material has been filled and it does not follow Remove cover of the screw conveyor attach protective grid immediately The causes are seldom mechanical The driving chains of the screw conveyors or the hydraulic drive motors may be defect Do not work while machine is running STOP MOTOR AND REMOVE IGNITION KEY Brine system does not function Check with ...

Page 58: ...ader unit X Brine equipment and X Oil levels at motor and hydraulics X Torque support at p t o hydraulic pump X Visual check hydraulic hoses X Chain tightening drive screw conveyors X 1st month X Bearingscrew conveyor greasing X Check all wear parts X Check brine unit for sealing X Check of whole mountable spreader by expert X Repair damage to varnish X Rinse brine pumps andand fill with Glysantin...

Page 59: ......

Page 60: ...enbach a A GERMANY 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 ...

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