Original Operating Manual

Transcription

1 matev GmbH Nuernberger Str Langenzenn T +49 (0) F +49 (0) info@matev.eu Original Operating Manual Sand and Salt Spreader SPR - IX 125 SPR - IX 250 SPR - IX 400 Version: Jan. 2012

2 n Contents Table of Contents 1 About this Operating Manual Safety Intended Use Qualification of personnel General Safety Information Special Safety Instructions Task and Application Delivery and Shipment Lifting the spreading machine from the pallet Transport over long distances Installation Installation in the rear three-point assembly unit of the tractor Adjusting the drive shaft Lighting Installing the hydraulic spreading quantity regulator Operation Filling the spreading machine Adjusting the spreading pattern Regulating the spreading quantity Spreading width Spreading density Calibration test Spreading table Lighting Covering the spreader container Boundary spreading equipment Maintenance Maintenance Repairs Disposal Warranty Technical Specifications and Accessories Technical Specifications Accessories Table of Figures EC - Declaration of Conformity Page 2

3 About this Operating Manual 1 About this Operating Manual Dear Customer, We thank you for purchasing the sand and salt spreading machine and the trust that you have reposed in us. Please read this Operating Manual completely and conscientiously before using the spreading machine for the first time. Keep this Operating Manual handy so that it is easily accessible. You can then refer to important information and handling instructions as and when required. Enumerations are marked with bullets as follows: Text Text Text... Handling instructions are given in the sequence in which you need to carry them out, marked as follows: 1. Text 2. Text 3. Text... The sand and salt spreading machine is subject to technical development. All information, figures and technical specifications conform to the latest version at the time of publication. The manufacturer reserves the right to make modifications at any time in the context of technical developments. Page 3

4 Safety 2 Safety Regulations and instructions that you need to observe and follow are summarised in this chapter. 2.1 Intended Use The spreader should be mounted only on tractors having adequate power and rear PTO (Power Take-Off) shaft. In the process, the speed of the PTO shaft must match the speed at the spreading machine (see the sticker on the spreader for this purpose). The ballast specified for the tractor and the maximum axle load must be complied with. All other applications are excluded. Threats in case of unintended use include: Risks to the health of the operator or third persons Damage to the tractor or other devices mounted on it Environmental damage 2.2 Qualification of personnel Only such persons who are qualified as given in the following should install, operate and maintain the spreading machine: They are at least 18 years of age. They have read and understood this Operating Manual. 2.3 General Safety Information General information on safety is explained in this chapter and this is used in the subsequent chapters. Follow these safety instructions in order to ensure safe operation of the spreading machine and to save working time and costs. Danger! The most severe injuries may occur to the operator or third persons. Follow the safety instructions. Attention! Minor injuries may occur to the operator or third persons. The tractor, the spreading machine or the environment may get damaged. Follow the information on safety. Note! Important and helpful tips or information for the operator. Please read this note. It simplifies your work. Page 4

5 Safety Attention! Injuries may occur. Wear protective clothing. 2.4 Special Safety Instructions Safety instructions are listed in the following and these are placed in the form of stickers on the devices mounted. Follow these safety instructions in order to ensure safe operation of the spreading machine and to save working time and costs. Attention! Risk of injury caused by moving parts. Pull out the ignition key before you perform any maintenance or servicing work on the equipment. Risk of injury caused by rotating parts. Switch the equipment off. Wait until all machine parts stop moving before you convert or maintain the equipment. Attention! Injuries may occur as a result of unintended operation. The equipment may get damaged. Read the Operating Manual completely. Follow the safety instructions. Attention! Risk of crushing by moving parts. Never reach into the area posing a risk of crushing as long as there are parts moving or could move there. Follow the instructions in the Operating Manual. Attention! There is an enhanced risk of accident posed by the rotating PTO shaft. Enter the working area of the PTO only when it is no longer rotating. Do not wear any loose clothing or cloth pieces that could get caught in the PTO shaft. Page 5

6 Task and Application 3 Task and Application The Matev centrifugal spreaders have been developed especially for winter services and are of top class in quality and design. The models of the SPR-IX family are centrifugal spreaders that have been developed especially for deployment in winter. They are excellently suited for spreading dry sand, salt and winter road sand. In order to ensure long service life and optimal deployment capability, special attention has been paid to all components with respect to the peculiarities and demands of winter services provided by municipal authorities. A solid and anti-twist stainless steel structure is used for the supporting frame with triangular mounting, and this ensures maximum protection against corrosion. The spreader containers are manufactured using 8 10 mm thick, shock-proof, flexible and corrosion-free special plastic. The container base with the dosing sliders, the spreader discs, the adjustable paddles, the adjusting mechanisms and the fastening elements are similarly designed and made entirely of stainless steel. The specially manufactured and robust special gear box with housing made of grey cast iron ensures operation that is vibration-free with low wear and tear and few faults. With the three container sizes we have been able to offer the matching spreading machine for all tractors deployed by various municipal authorities and thus ensure large effective radius of action and a high level of area coverage. The spreading widths of 1 to 8 metres can be adjusted with the help of the adjustable spreader width limit and the PTO shaft speed. The quantity spread can be controlled via the operating lever and an adjustable stop gives you the option of fixing the ideal setting. The adjustable paddles of the stainless steel spreading discs ensure clean and exact distribution of the road grit over the working area. Steep conical walls ensure smooth sliding of the road grit. 4 Delivery and Shipment The spreading machine is rigged to a pallet and delivered. Figure 1 Delivery of the spreading machine 4.1 Lifting the spreading machine from the pallet 4. Remove the protective packaging and the transport locks. 5. Lift the spreading machine using suitable means (crane or forklift) from the pallet and put it down. Page 6

7 Installation 4.2 Transport over long distances If you would like to transport the spreading machine over longer distances (e.g. dispatch by forwarding agency), you must rig the machine to a pallet as at the time of delivery. 5 Installation 5.1 Installation in the rear three-point assembly unit of the tractor Note! Spreading machines of the SPR-IX family are compact machines that can be installed on a number of tractors. For this purpose, please pay attention to the mounting recommendations, the current price list and the limitations or restrictions mentioned in this manual. Note! Enter the chassis number of the tractor in the 10 section of this Operating Manual. This spreading machine can be installed to any tractor having a suitable rear three-point hydraulic system, Cat 1, Cat 1-N, Cat 2 (with adapter) and to the John Deere Tractors of the X-series with the Matev basic mounting mechanism (with adapter). All mounting points must be secured with suitable locking pins. The installation manual for a rear three-point assembly unit, if required, is available in the documentation of your tractor or the rear three-point assembly unit. Before you put the spreading machine into operation the first time, you must carry out the following activities: Install the spreading machine in the rear three-point assembly unit of your tractor. While doing so, take care to select the coupling points properly depending on the rear threepoint assembly unit. Danger! If you do not follow the following instructions, the machine may fall down while mounting or dismounting it: Ensure that the spreading machine is located or placed on an even and solid surface. Page 7

8 Installation Cat. 1 Figure 2 Mounting points for Cat. 1 Cat. 2 Cat. 2 with adapter Figure 3 Mounting points for Cat. 2 Cat. 1-N Page 8

9 Installation Figure 4 Mounting points for Cat. 1-N Basic mounting mechanism Basic mounting mechanism with adapter Figure 5 Mounting points of the basic mounting mechanism on the John Deere X Check whether the drive shaft for use on your tractor has the proper length. If required, adjust the length of the drive shaft as described in the 5.2 section. Note! The spreading pattern depends on the PTO shaft speed of the tractor. Maintain the working speed specified by the tractor manufacturer, since it is only by doing so that the optimal speed is reached on the PTO shaft. 5.2 Adjusting the drive shaft Attention! The spreading machine or the tractor may get damaged. Use only the drive shaft supplied. Follow the Operating Manual on the drive shaft of the respective manufacturer. Note! Install the drive shaft as described in the original manual of the drive shaft manufacturer supplied. Note! Depending on the tractor type, the drive shaft supplied may be too long. In this case, it must be shortened in accordance with the following steps. Page 9

10 Installation 1. Separate the drive shaft halves from one another. 2. Install one end of the drive shaft on the tractor. 3. Install the other end of the drive shaft on the spreading machine. Figure 6: Adjusting the drive shaft 4. At the shortest working position mark the piece to be sawed off on one half of the drive shaft. 5. Cut off the drive shaft protective cover up to the marking. 6. Saw off the pipe section. 7. Repeat the instructions 4 to 6 on the second half of the drive shaft. 8. Deburr all edges that have been cut. Figure 7: Grease the pipe sections 9. Grease the pipe sections. 10. Push the section pipes together Installing the drive shaft 1. Press the locking pin at the external bracket and keep it pressed. 2. Push the external bracket on the stub section of the rear PTO shaft. 3. Release the locking pin. 4. Move the drive shaft somewhat to and fro until the locking pin latches audibly. 5. Repeat the instructions 1 to 4 for the other side of the drive shaft. Page 10

11 Installation Figure 8: Safety chain at the drive shaft 6. Mount the safety chains of the drive shaft to a fixed element on the tractor and on the material holding system. 7. The drive shaft is installed Dismounting the drive shaft 1. Loosen the safety chain on both sides. 2. Press the locking pin of the external bracket and keep it pressed. 3. Pull out the outer bracket from the stub section. 4. Release the locking pin. 5. Repeat the instructions 2 to 4 for the other side of the drive shaft. 6. The drive shaft is dismounted. 5.3 Lighting To operate the lighting system, the plug-in connector of the spreading machine must be inserted into the trailer socket of the tractor. The proper working of the lighting system must be checked and ensured every time before it is used. Page 11

12 Installation 5.4 Installing the hydraulic spreading quantity regulator If you would like to retrofit your spreading machine with a hydraulic spreading quantity regulator, install the individual components as illustrated in the following figure. Connection to the tractor's hydraulic system Figure 9 Connecting the hydraulic spreading quantity regulator Install the pressure limiting valve at the position on the spreading machine shown. Pressure limiting valve Hydraulic cylinder Figure 10 Hydraulic spreading quantity regulator Page 12

13 Operation 6 Operation Danger! The most severe injuries may occur to the operator or third persons. By installing the spreading machine, you are changing the load distribution on the tractor. This affects the steering and braking capacity and the tilting behaviour. Adopt counter measures provide adequate ballast on the front wheels! Danger! The most severe injuries may occur to the operator or third persons. Never reach in the area of the stirrer, the casting disc and the paddle while these are turning. Switch the tractor off and pull out the ignition key before you reach into the area of moving parts. During operation, keep the safety guard always in the protective position. Attention! There is an enhanced risk of accident posed by the rotating PTO shaft. Enter the working area of the PTO only when it is no longer rotating. Do not wear any loose clothing or cloth pieces that could get caught in the PTO shaft. 6.1 Filling the spreading machine Before filling the spreading machine, lower the rear hydraulic system of the tractor and place the spreading machine on the ground. Shut off the tractor engine and pull the hand brake. Every time that the spreading container is refilled, it must be checked for the presence of foreign bodies. Similarly, the proper working of the material pusher must also be checked. Note! Pay attention to the max. payload. The warranty becomes null and void if the payload is exceeded. Depending on the condition of the material to be spread, there are other specific weights applicable Spreading road grit or granulated fertiliser The standard agitator finger must be used to spread road grit or granulated fertiliser Note! The hook agitator should not be used for road grit or granulated fertiliser. Page 13

14 Operation Spreading sand and salt The hook agitator must be used to spread sand, salt or sand - salt mixtures. It is recommended to place the hook agitator in the vertical position when filling the material to be spread. 6.2 Adjusting the spreading pattern Adjusting a uniform spreading pattern Under normal circumstances, when you open both pushers equally wide and the paddle is in the centre position, you achieve a uniform spreading pattern. Depending on the type and degree of moisture of the material to be spread, it may become necessary to configure other settings, see and Spreading quantity regulation - Adjusting the pusher If you would like to spread only on one side, you can open the corresponding pusher and leave the other one closed. Unlock the connecting bolts, remove it from the lever 1 and lock it so that it remains only in the lever 2. Shift the desired lever. When you move lever 1 while lever 2 remains closed, you are spreading on the left side. If you wish to spread on the right side, you must open the lever 2 and keep lever 1 closed. The result depends on the material being spread and the moisture. Both levers may also be operated simultaneously, and to do this, insert and latch the arresting bolt in lever 1. Lever 2 Lever 1 Connecting bolts Figure 11 Spreading quantity regulator Adjusting the paddles In order to ensure uniform discharge of the material to be spread, you have the option to adjust the paddles depending on the property and weight of the material to be spread. Adjusting the paddles from the centre position to the right or the left increases the quantity being discharged in the corresponding direction. An adjustment against the direction of rotation of the casting disc causes the material being spread to be discharged Page 14

15 Operation earlier. As a result, the spreading density increases on the right side with the casting disc rotating clockwise. An adjustment against the direction of rotation of the casting disc causes the material being spread to be discharged later. As a result, the spreading density increases on the left side with the casting disc rotating clockwise. In order to adjust the paddle, pull it up to unlock it and turn it in the desired position. After the adjustment, satisfy yourself that the latching bolt is hooked in the desired position. You can hook the paddles in various positions. Figure 12 Casting disc and paddle 6.3 Regulating the spreading quantity In order to regulate the spreading quantity, the spreading machine has a mechanical spreading quantity adjustment mechanism via a hand lever with a scale, see Figure 11. Remote operation via the rear hydraulic system of the tractor is available as an optional accessory. The opening lever is used to regulate the spreading quantity. Lowering or raising the same leads to increased or reduced quantity of the material to be spread. Downward more, upward less. If you move the lever up to the stop, the spreading is interrupted. The opening limit can be set manually with the help of the thumbscrew. Adjustable stop Figure 13 Opening limiter Page 15

16 Operation 6.4 Spreading width You can achieve spreading widths of 1 m to about 8 mm, with the spreading basket at a height of about 50 cm above the ground, using the setting of the spreading width limiter. You can also vary the spreading width by using a higher or lower mounting height. Moreover, the spreading width is also dependent on the PTO shaft speed. Apart from the standard manual spreading width restriction, hydraulic and electric remote operation options are available as optional accessories. Figure 14 Spreading width restriction 6.5 Spreading density The spreading density, gm/m² depends on the following factors: Setting of the spreading quantity regulator Setting of the spreading width restriction Driving speed PTO shaft speed Spreading material (Density, grain size) Condition of the material being spread (dry, moist) Height of the casting disc above the ground The quantity of material / minute to be spread with known driving speed, spreading width and desired spreading density can be calculated as follows: Driving speed Spreading width Spreading density desired Material quantity spread / minute Calculation formula: v [] b [m] D [gm/m²] S [kg/min.] S = D*b*v/60 In order to achieve the desired target quantity (quantity of material spread / minute), it is absolutely necessary to carry out a calibration test. Page 16

17 Operation 6.6 Calibration test Danger! The most severe injuries may occur to the operator or third persons. Never reach in the area of the stirrer, the casting disc and the paddle while these are turning. Switch the tractor off and pull out the ignition key before you reach into the area of the paddles. Attention! Risk of crushing by moving parts. Never reach into the area posing a risk of crushing as long as there are parts moving or could move there. Attention! There is an enhanced risk of accident posed by the rotating PTO shaft. Enter the working area of the PTO only when it is no longer rotating. Do not wear any loose clothing or cloth pieces that could get caught in the PTO shaft. To conduct a calibration test, proceed as follows: 1. Close the pusher of the spreading quantity regulator 2. Fill the material to be spread in the container 3. Set the spreading width restriction to the lowest position 4. Adjust the quantity stop of the spreading width restriction according to the table or based on experience or empirical values 5. Pull a plastic sack from below on the spreader installed on the tractor in such a manner that it does not make any contact with the casting disc / paddle 6. Switch on the tractor and the PTO shaft to 540 rpm 7. Open the pusher or slider of the spreading quantity regulator up to the stop 8. Conduct the calibration test for exactly 60 sec. 9. Switch off the tractor and remove the ignition key 10. Collect the spread material and weigh it 11. If the quantity discharged does not match the target quantity obtained by calculation, choose another pusher (or slider) opening and repeat the calibration test. 6.7 Spreading table Note! The information in the following spreading tables are merely reference values. The actual values depend on a number of factors, see In order to obtain the exact spreading values, a calibration test must be conducted, see 6.6. Page 17

18 Operation Table 1 Spreading table for salt gm/m² Scale no. Spreading width 2 m 4 m 6 m Table 2 Spreading table for sand gm/m² Scale no. Spreading width 2 m 4 m 6 m Table 3 Spreading table for road grit gm/m² Scale no. Spreading width 2 m 4 m 6 m Page 18

19 Maintenance Lighting To operate the lighting system, the 7-pin plug-in connector of the spreading machine must be inserted into the trailer socket of the tractor. The proper working of the lighting system must be checked and ensured every time before it is used. 6.9 Covering the spreader container Covering the spreading machine protects the material to be spread from moisture. The cover and its fixing mechanism are designed for speeds of max. 30 If the spreading machine is operated or transported on vehicles that exceed this speed, the container cover must be secured separately or removed Boundary spreading equipment The boundary spreading equipment serves to spread the material to be spread accurately and conserves vehicles that are being parked, house walls and parks. Border sprinkling equipment folded down Figure 15 Boundary spreading equipment You can use the boundary spreading equipment on the left or right side as desired. You can fold the boundary spreading equipment upwards when you do not need it. 7 Maintenance Attention! Risk of injury caused by moving parts. Pull out the ignition key before you perform any maintenance or servicing work on the equipment. Page 19

20 Disposal 7.1 Maintenance After using the spreading machine or prior to longer time periods during which the equipment remains unused, the following steps must be taken: Clean the equipment well and remove salt and road grit completely. Check the equipment for damage and faults and replace any parts that are damaged. Tighten all screws. Lubricate the drive shaft with multi-purpose grease. Lubricate all bolted connections, the sliders and joints of the spreading quantity regulating mechanism and the stirrers with grease Check hose pipes and connecting cables for being intact and replace them, if necessary Check the rubber tyre treads of the hoe stirring machine and replace the tyres, if necessary. The container may grind through if the rubber tyre tread is worn out and the stainless steel ring comes into contact with the container Attend to damage caused by rust immediately and oil the equipment. The gearbox is filled with oil at the factory and is maintenance-free. 7.2 Repairs Attention! Risk of injury caused by moving parts. Pull out the ignition key before you perform any maintenance or servicing work on the equipment. In the event of faults, problems or other indications, please get in touch with your sales advisor or take up direct contact with: matev GmbH Nuernberger Str Langenzenn Tel.: +49 (0) Disposal The spreading machine must be disposed of in conformity with the applicable rules and regulations of the municipal corporation or at the national level. Depending on the material, please dispose of them by feeding it to the household waste, special waste or send it for recycling. Matev GmbH does not provide any arrangements for disposal. Page 20

21 Warranty 9 Warranty The general terms and conditions of matev GmbH are applicable. 10 Technical Specifications and Accessories Please enter the item number and chassis number. These are given on the nameplate of the sand and salt spreading machine. Item number: Chassis number: 10.1 Technical Specifications Table 4 Technical Specifications Units SPR-IX 125 SPR-IX 250 SPR-IX 400 Capacity L Dead weight of the standard kg design Height cm 90,1 108,6 126,6 Width cm 90, Depth cm 90, point (Delta) Cat. 1, Cat. 1 N, Cat. 2 with adapter, basic mounting connection mechanism with adapter Gearbox housing Cast iron PTO shaft speed rpm 540 Noise level db (A) 70 Page 21

22 Technical Specifications and Accessories 10.2 Accessories Table 5 Accessories Part number Accessories Boundary spreading machine, folding, with vehicle canvas Hydraulic spreading quantity control with diaphragm storage Hydraulic spreading width control Adaptation Cat Electrical spreading width control Adapter for mounting on the basic mounting mechanism John Deere X 740 / 748 X 495 / 595 X 415 / Covering canvas for SPR-IX Covering canvas for SPR-IX 250 and 400 Page 22

23 Table of Figures 11 Table of Figures Figure 1 Delivery of the spreading machine... 6 Figure 2 Mounting points for Cat Figure 3 Mounting points for Cat Figure 4 Mounting points for Cat. 1-N... 9 Figure 5 Mounting points of the basic mounting mechanism on the John Deere X Figure 6: Adjusting the drive shaft Figure 7: Grease the pipe sections Figure 8: Safety chain at the drive shaft Figure 9 Connecting the hydraulic spreading quantity regulator Figure 10 Hydraulic spreading quantity regulator Figure 11 Spreading quantity regulator Figure 12 Casting disc and paddle Figure 13 Opening limiter Figure 14 Spreading width restriction Figure 15 Boundary spreading equipment Page 23

24 EC - Declaration of Conformity 12 EC - Declaration of Conformity EC Declaration of Conformity for a machine to confirm compliance with the Machinery Directive 2006/42/EC and with the legal regulations enacted for their implementation. The manufacturer matev GmbH Nuernberger Str Langenzenn Declares herewith that the machines Sand and salt spreaders of type SPR-IX 125 / SPR-IX 250 / SPR-IX / / Comply with the provisions of the Machinery Directive 2006/42/EC and with the national legal regulations implementing the same. The signatory is authorised to compile the technical documentation. The signature is that of the manufacturer. Date / Signature December Name of the signatory Designation of the signatory Georg Hemmerlein Managing Director (CEO) Page 24