USE AND MAINTENANCE MANUAL ULTRA100 BS ULTRA100 GS BI-FUEL ED. 02-2012 ORIGINAL INSTRUCTIONS Doc. 10033331 Ver.
The descriptions contained in this document are not binding. The company therefore reserves the right to make any modifications at any time to elements, details, or accessory supply, as considered necessary for reasons of improvement or manufacturing/commercial requirements. The reproduction, even partial, of the text and drawings contained in this document is prohibited by law. The company reserves the right to make any technical and/or supply modifications.
CONTENTS ON CONSIGNMENT OF THE MACHINE............................................................................................................................................. 5 SERIAL NUMBER PLATE ................................................................................................................................................................. 5 INTRODUCTORY COMMENT ............................................................................................................................
DAILY MAINTENANCE ................................................................................................................................................................... 40 44. CLEANING THE SUCTION MOTOR FILTER..................................................................................................................................................................................................... 40 45. CLEANING THE SQUEEGEE ...............................................................
On consignment of the machine Serial number plate When the machine is delivered to the customer, an immediate check must be performed to ensure all the material mentioned in the shipping documents has been received, and also to check the machine has not been damaged during transportation. If this is the case, the carrier must ascertain the extent of the damage at once, informing our customer service office.
TECHNICAL DESCRIPTION Working width (without side brush) Working width (with side brush) Squeegee width Working capacity, up to Side disc brush Side disc brush rotations Side disc brush motor Maximum pressure on the disc brush Cylindrical brush (front) Cylindrical brush (rear) Front cylindrical brush rotations Rear cylindrical brush rotations Cylindrical brush motor Maximum pressure on the cylindrical brushes Traction motor Traction wheel (diameter / width) Maximum forward speed Maximum gradient with full l
SYMBOLS USED ON THE MACHINE Symbol for the main switch or key switch (only on versions with a battery-operated motor) Used on the instrument panel, to indicate the key switch for machine operation on (ON-I) or off (OFF-0) Base/squeegee operating symbols Used to indicate the I-DRIVE programs selector Symbol denoting pressure applied to the brushes Used to indicate the knob for increasing the brush pressure Label showing the direction of movement - forward or reverse Used to indicate the direction of the
SYMBOLS USED ON THE MACHINE Symbol denoting incorrect functioning Used on the instrument panel to indicate the red warning light showing incorrect machine functioning Symbol denoting brake Used on the instrument panel to indicate the red warning light showing the absence of oil in the work braking system Symbol denoting brake Used on the instrument panel to indicate the red warning light showing parking brake on Symbol denoting solution tank empty Used on the instrument panel to indicate the red warning
SYMBOLS USED ON THE MACHINE Symbol for sideways movements of the side brush Used on the instrument panel to indicate the green warning light, showing that the side brush has returned to its normal position Symbol indicating movement of the squeegee unit Used on the instrument panel to indicate the green warning light showing the brush head has reached its operating position Symbol denoting left-hand suction motor Used on the instrument panel to indicate the green warning light showing that the left-hand
SYMBOLS USED ON THE MACHINE Label warning that squeegee should be cleaned every day Label warning that recovery tank and solution tank should be cleaned every day Symbol indicating the position for inserting the battery charger connector (only on battery versions) Symbol denoting tap regulation Used on the central panel of the steering cover, to indicate the tap lever to regulate the water Label warning operator to take safety measures to avoid damage to limbs Label indicating the position of the suct
SYMBOLS USED ON THE MACHINE Label indicating the position of the recovery tank drain pipe Indicates the maximum gradient Indicates the risk of burns due to the hot surface Indicates the display service screen confirmation button Indicator showing battery charge level on the upper line and hour meter on the lower line Indicator showing the type of hour meter (total) on the upper line and the type of service (none) on the lower line Indicator showing the type of technology of the batteries used (lead)
SYMBOLS USED ON THE MACHINE Label with Ph value of the detergent to use (CDS system only) Symbol indicating regulation of water and detergent quantity (CDS system only) Used on the left-hand panel, to indicate the knobs for adjusting the percentage level of detergent dissolved in the water, and the level of water distributed on the brushes Detergent symbol (CDS system only) Used on the detergent tank cap, to indicate the presence of chemical substances 12
GENERAL SAFETY REGULATIONS The regulations below must be carefully followed in order to avoid harm to the operator and damage to the machine. WARNING: Read the labels on the machine carefully. Do not cover them for any reason and replace them immediately if they become damaged. The machine must be used exclusively by authorised and trained personnel. The machine is designed for dry use only. Do not use the machine on surfaces with an inclination greater than the one shown on the plate.
MACHINE PREPARATION 1. HANDLING THE PACKAGED MACHINE The machine is contained in specific packaging with a pallet for the handling with fork trucks. The packages cannot be placed on top of each other. The total weight of the machine with packaging is 930kg (Ultra100 BS without batteries). The total weight of the machine with packaging is 1030kg (Ultra100 GS BIFUEL without cylinder). A The dimensions of the packaging is as follows: C B ULTRA100 A: 1800 mm B: 1340 mm C: 2150 mm 1. 2. 3. 4.
MACHINE PREPARATION 4. 3-way switch to set working speed 5. Main key switch (battery versions) 6. 3-way switch to set force applied to brushes during operation 4 7. Display service confirmation button 8. Battery level / hour-counter display 9. Working program adjustment switch, I-Drive device 5 6 7 8 Choose the desired operating program with the I-Drive device: A. Transfer: movement of the machine without working B. Drying: use the squeegee only C.
MACHINE PREPARATION 16. Green warning light indicating that the main switch of the machine is active 17. Green warning light indicating that the machine headlights are on 18. Green warning light indicating that the solenoid valve is in operation 16 17 18 19. Green warning light indicating that the brush head motor is in operation 20. Green warning light indicating that the side brush has returned to its normal position 21.
MACHINE PREPARATION The components of the steering column (right side) are as follows: 28 28. Green warning light indicating that the main switch of the machine is active (on versions with combustion engine) 29. Knob for adjusting the combustion engine rpm (on versions with combustion engine) 30. Button for injecting LPG into the combustion engine carburettor at switch-on (on versions with combustion engine) 29 30 31. Main key switch (on versions with combustion engine) 32.
MACHINE PREPARATION The components on the front/side of the machine are identified as follows: 39. Step to assist getting on to machine 39 The components on the rear/side of the machine are identified as follows: 40 41 40. Suction cover release hinge 41. Recovery tank release hinge 8. MACHINE'S REAR COMPONENTS The rear components of the machine are identified as follows: 42. Recovery tank discharge cap 42 43. Recovery tank drain pipe 44. Solution tank drain pipe 43 45. Flashing warning light 46.
MACHINE PREPARATION 48. Rear lights 48 9. MACHINE'S FRONT COMPONENTS The front components of the machine are identified as follows: 49. Headlights 49 10. TYPE OF BATTERY To power the machine it is necessary to use: liquidelectrolyte lead traction batteries; sealed traction batteries with gas recombination or gel technology. OTHER TYPES MUST NOT BE USED. The batteries must meet the requirements laid out in the norms: CEI EN 60254-1:2005-12 (CEI 21-5) + CEI EN 60254-2:2008-06 (CEI 21-7).
MACHINE PREPARATION 13. MAINTENANCE AND DISPOSAL OF THE COMBUSTION ENGINE WARNING: For the maintenance and disposal of the combustion engine, observe the instructions given by the engine manufacturer (for maintenance) and current environmental hygiene norms (for disposal). 14.
MACHINE PREPARATION 5. Remove the detergent tank (4) by unscrewing the nuts (5) 4 5 6. Remove the battery compartment cover (6) by unscrewing the nuts (7) 7. Grip the handle at the side of the seat to raise the seat mounting plate, move it to the end of travel stop 8. Place the batteries inside the battery compartment using transport and handling equipment suitable for the weight and size of the batteries 9.
MACHINE PREPARATION The coupling connector of the battery charger is supplied inside the bag containing this instruction booklet, and must be fitted to the battery charger cables as shown in the instructions. WARNING: This process must be carried out by qualified personnel. Incorrect connection of the connector may cause machine malfunctions. 7. Connect the rewired cable to the external battery charger 8.
MACHINE PREPARATION 3. Lift the handle (3) to access the motor compartment 4. Raise the seat mounting plate by turning it as far as it will go 5. With regard to the safe filling of the combustion engine fuel tank, you must scrupulously observe the indications given in the motor use and maintenance manual (supplied with the machine) 3 WARNING: The machine does not have a fuel level indicator, so you must always check the level before using it. WARNING: Gasoline is highly inflammable and may explode.
MACHINE PREPARATION 5. Tighten the tube (7) to the tap (3). Remember to insert the seal that's supplied with the cylinder 6. Fully open the cylinder tap (3) 3 7 21. HOUR METER (VERSION WITH COMBUSTION ENGINE) On the instrument panel of the machine there is a display (1) indicating the effective number of working hours. The display shows an upper line (consisting of 8 light indicators) and a lower line (indicating the hours and minutes of operation).
MACHINE PREPARATION To engage the parking brake pull the lever (4) located near the seat, the red warning light (3) on the instrument panel will come on. 4 24. WORKING FORWARD SPEED 1 This machine is equipped with electronic traction control. To move the machine, after turning the ignition key to "ON - I", you must select the direction of movement by operating the switch (1) located on the instrument panel.
MACHINE PREPARATION 27. SOLUTION TANK 1 Remove the filler plug (1) at the back of the seat and check that the solution filter is installed properly. Check that the drain pipe cap (2) located at the rear of the machine is properly closed. WARNING: The recovery tank must be completely empty each time the solution tank is filled. 2 28. FILLING THE DETERGENT/SOLUTION TANK (VERSION WITHOUT CDS) Proceed as follows to fill the solution tank: 1. Check that the recovery tank is empty, otherwise empty it 2.
MACHINE PREPARATION 5. Check that the quick coupling (4) under the detergent tank is properly inserted. 6. Unscrew the cap (3) of the tank on the right-hand side of the machine and fill with liquid detergent as indicated on the label supplied with the machine. Check the screw cap is well closed, to avoid any liquid leaking out while the machine is being used. 3 To regulate the water/detergent mixture, carefully read the “REGULATING THE DETERGENT WITH THE CDS SYSTEM” paragraph.
MACHINE PREPARATION 31. DETERGENT REGULATION (VERSION WITH CDS) First, fully open the tap in the rear part of the machine by turning the lever (1) anticlockwise. Choose the required work programme using the I-Drive device; press the accelerator pedal to operate the brushes, the machine starts to move and the detergent solution starts to come out. During the first few metres make the following adjustments: 1. Regulate the flow of detergent solution to the brushes by rotating the left-hand knob (2) clockwise.
MACHINE PREPARATION 33. ASSEMBLING THE SQUEEGEE The squeegee, that for reasons of packaging comes disassembled from the machine, must be assembled while assembling the machine. Proceed as follows for assembly: 1. Make sure the squeegee unit is raised, and that the selected work programme is "Transport" (position A) 2. Turn the main switch key anticlockwise to the "0" position 3. Engage the parking brake located on the left side of the machine 4. Remove the key from the instrument panel 5.
MACHINE PREPARATION 5. Use a suitable tool to remove the right-hand splash guard pre-assembly (2), loosening the screws (3) that fix it to the brush head 3 2 3 6. Remove the nuts (4) from the right-hand carter 4 4 4 7. Remove the screw (5) from the right-hand carter 5 8.
MACHINE PREPARATION 9. Remove the right-hand carter (7) from the brush head unit, and place it on the ground 7 10. Push the rear brush into the tunnel until it couples with the drive hub on the opposite side of the tunnel WARNING: Pay attention to the direction of the brush bristles during assembly, the point of the brush viewed from the above should be towards the front of the machine. 11.
MACHINE PREPARATION 5. With the brush head up, insert the brush in the brush-holder plate seat, and turn it clockwise until the three studs are inserted in the notches on the plate itself. Turn, so the stud is pushed towards the coupling spring and the plate is locked in place WARNING: Check the brush is correctly inserted. If they are not, the machine may not work properly. WARNING: You are advised to always wear protective gloves, to avoid the risk of serious injury to your hands. 38.
WORK 40. MACHINE PREPARATION If you have a battery version, before starting to work you must: 1. Make sure the recovery tank is empty, otherwise empty it completely 2. Check that the main switch (3) of the machine is set to "0" 3. Connect the battery connector (1) to the electric system connector (2) 4. Sit on the driver’s seat 3 5. Check the parking brake is released (4) 6. Turn the key of the main switch a quarter of a turn clockwise (to position 1).
WORK If you have a combustion engine version, before starting to work you must: 1. Make sure the recovery tank is empty, otherwise empty it completely 2. Check the parking brake is engaged; if it is not, engage it by means of the lever (3) near the left side of the seat 3. Check the main machine switch (4) is set to "0" 4. Check the fuel selector (5) is on LPG 4 3 5. Turn the motor rotation adjustment knob (6) anticlockwise, as far as it will go 6.
WORK After starting up the machine, proceed as follows: 1. Choose the desired operating program with the I-Drive device: A. Transfer: movement of the machine without working B. Drying: use the squeegee only C. Washing / Drying: use both the brushes and the squeegee D. Washing only: use brushes only B D A C 2.
WORK For the battery version, as the batteries run out, the battery charge indicators on the command display will go blank. When the batteries are fully discharged, the brush motor automatically switches off, so it is necessary to recharge them as soon as possible. A residual charge remains available to complete the drying process and to move the machine to the charging point; to do this, choose the "Transfer" programme.
WORK When the brush motor overload limit is exceeded, the red warning light (17) on the instrument panel begins to flash. After a few seconds the motor stops and the indicator light of the brush switch goes off. 17 To restart the motor, turn the main switch key off and on again. If the motor stops again, check the reason of the overload in order to prevent damage to the motor.
AT THE END OF THE WORK 43. AT THE END OF WORK 1 At the end of work, and before carrying out any type of maintenance, perform the following operations: 1. Close the tap (1) for machine versions without the CDS system or turn the knobs (2-3) to OFF for machine versions with the CDS system 2 2. Turn the I-DRIVE selector to the “Transfer” position. Both the base and the squeegee rise and after a few seconds the suction motor will turn off 3. 4.
AT THE END OF THE WORK 13. Release the clamp (7) and pull on the handle (8) to remove the debris hopper; place it on the ground, then take it to the appropriate disposal point and empty it 7 WARNING: This operation must be carried out using gloves to protect against contact with dangerous solutions. 14. Insert the debris hopper in the machine, and lock it in place by means of the clamp (7) 8 15.
DAILY MAINTENANCE PERFORM ALL MAINTENANCE OPERATIONS IN SEQUENCE 44. CLEANING THE SUCTION MOTOR FILTER 1. 2. 3. 4. 5. 6. 7. 8. 9.
DAILY MAINTENANCE After cleaning, replace the squeegee on its support: 3 1. Insert the squeegee right-hand pin (1) into the right-hand slot of the squeegee support (2), secure it by means of the handwheel (3) 2. Insert the squeegee left-hand pin into the left-hand slot of the squeegee support, secure it by means of the handwheel 3. Finally, insert the squeegee hose in its sleeve and secure it using the clamp.
DAILY MAINTENANCE 4. Check the parking brake is engaged. If it is not, engage it by means of the lever (1) 1 5. Release the clamp (2) and pull on the handle (3) to remove the debris hopper; place it on the ground, then take it to the appropriate emptying point WARNING: This operation must be carried out using gloves to protect against contact with dangerous solutions. 2 6. Rinse the inside of the hopper with a jet of clean water 3 7.
DAILY MAINTENANCE 49. CHECKING THE MOTOR OIL LEVEL 3 Using the combustion engine with insufficient oil may seriously damage it. You are therefore advised to check the level at least once a day, in the following way: 1. Check the parking brake is engaged; if it is not, engage it by means of the lever (1) near the left side of the seat 2. Check the main machine switch (2) is in the “0” position. If this is not the case, turn the key by a quarter rotation to the left. 3.
WEEKLY MAINTENANCE 51. CLEANING THE SUCTION HOSE Whenever suction seems to be unsatisfactory, check that the suction tube is not obstructed. If necessary clean with a jet of water as follows: 1. Connect the electric system connector to the battery connector (for battery versions) or to the generator connector (for versions with a combustion engine) 2. Turn the key switch to the “1” position 3. Turn the I-DRIVE selector to the “Transfer” position.
WEEKLY MAINTENANCE 7. Release the recovery tank stop hinges (4), located at the side of the tank 8. Rotate the recovery tank as far as it will go. Release the suction cover stop hinges (5) on the side of the cover 9. Rotate the suction cover as far as it will go 10. Clean and rinse the recovery tank 11. Refit all the parts 5 4 WARNING: These operations must be carried out using gloves to protect against contact with dangerous solutions. 53. CLEANING THE SOLUTION TANK Proceed as follows for cleaning: 1.
WEEKLY MAINTENANCE 1. Remove the right-hand carter (2) by unscrewing the nuts (3) 2 3 2. Disconnect the quick release coupling (4) located behind the side cover, to prevent damage to the coupling itself 4 3. 4. 5. 6. Remove the detergent tank (5) by unscrewing the nuts (6) Unscrew the detergent filler cap (7) Rinse the inside of the tank with a jet of water Refit all the parts 7 WARNING: These operations must be carried out using gloves to protect against contact with dangerous solutions. 5 6 55.
WEEKLY MAINTENANCE 56. CLEANING THE CYLINDRICAL BRUSHES Proceed as follows for cleaning: 1. Make sure the brush head unit is raised off the ground (if necessary, turn the I-DRIVE selector to the “Transfer” position to raise both the brush head and the squeegee) 2. Check the electric system connector is disconnected from the battery connector (for battery versions) or from the generator connector (for versions with a combustion engine) 3. Make sure the main switch is in the "0" position.
WEEKLY MAINTENANCE 9. Remove the right-hand carter (7) from the brush head unit, and place it on the ground 7 10. Take the rear brush out of the tunnel and rest it on the ground. Clean it with a jet of water 11. Take the front brush out of the tunnel and rest it on the ground. Clean it with a jet of water 12. Refit all the parts 57. CLEANING THE SIDE BRUSH 1 Proceed as follows for cleaning: 1.
WEEKLY MAINTENANCE 5. Turn the knobs (2) on the brush head unit, to adjust the height of the side splash guards 2 During working operation, the side rubber splash guard is slightly but evenly tilted outwards (by about 5mm) along its whole length. 59. CLEANING THE DETERGENT SOLUTION DISTRIBUTION BASIN If the detergent solution distribution basin in the brush head unit is clogged with dirt, it will not channel the detergent solution evenly onto the floor, and so the machine will not clean thoroughly.
WEEKLY MAINTENANCE 6. Remove the screw (4) from the right-hand carter 4 7. Remove the tube (5) connected to the distribution basin cover 5 8. Push the distribution basin towards the left side of the machine, then lift it and remove it from the brush head unit 9. Remove the cover (6) from the detergent solution distribution basin 10. Clean the basin with a jet of running water 11.
EXTRAORDINARY MAINTENANCE 60. REPLACING THE CYLINDRICAL BRUSHES If the cylindrical brushes in the brush head base are worn, they will no longer clean the floor efficiently. To replace them, proceed as follows: 1. Make sure the brush head unit is in its idle position (if necessary, turn the I-DRIVE selector to the “Transfer” position to raise both the brush head and the squeegee) 2.
EXTRAORDINARY MAINTENANCE 9. Remove the right-hand carter (7) from the brush head unit, and place it on the ground 7 10. Take the rear brush out of the tunnel and rest it on the ground. Push the new brush in, until it couples with the drive hub on the opposite side of the tunnel WARNING: Pay attention to the direction of the brush bristles during assembly, the point of the brush viewed from the above should be towards the front of the machine. 11.
EXTRAORDINARY MAINTENANCE 5. With the brush head up, release the brush from the brush-holder plate seat, and turn it anticlockwise until the three studs slip out of the notches on the plate itself. Turn, so the stud is pushed away from the coupling spring WARNING: You are advised to always wear protective gloves, to avoid the risk of serious injury to your hands. 6.
EXTRAORDINARY MAINTENANCE 63. REPLACING THE REAR SQUEEGEE RUBBER If the squeegee rear rubber is worn and does not dry well, it is possible to change the drying edge using one of the 4 edges of the rubber. This can be done with the squeegee removed, proceeding as follows: 1. Make sure the brush head unit is in its working position (if necessary, turn the I-DRIVE selector to the “Transfer” position to raise both the brush head and the squeegee) 2.
EXTRAORDINARY MAINTENANCE 5. Use a suitable tool to remove the rubber-pressing blade (2), loosening the screws (3) that fix it to the splash guard support. 6. Take the rubber (4) out, and turn or replace it 7. To replace the rubber, proceed in reverse order 8. Adjust the height of the splash guard rubber according to the rubber itself (refer to “ADJUSTING THE HEIGHT OF THE SIDE SPLASH GUARDS”) 4 3 2 65.
EXTRAORDINARY MAINTENANCE 4. Fully close the cylinder tap (3) 5. Remove the straps (5) by releasing the springs (6) from the screws (7) on the cylinder support, then take off the cylinder 7 3 5 6 6. Position the new cylinder as shown in the figure. If it is in the right place, the tap (3) will be on the left side of the machine 7. Fix the cylinder to its support by means of the straps (5).
EXTRAORDINARY MAINTENANCE 5. Lift the handle (2) to access the motor compartment 6. Turn the seat mounting plate as far as it will go 7. Use a suitable tool to disconnect the battery from the machine system + WARNING: The first cable to be disconnected is the “+” pole, followed by the “-“ pole. 8. Remove the battery clamp (3) 9. Use suitable means to lift the battery out of the machine 3 10. Use suitable means to insert the new battery in the machine, positioning it as shown in the figure 11.
EXTRAORDINARY MAINTENANCE 5. Unscrew the cap of the detergent canister (1) and fill it with clean water 6. Refit the cap of the detergent tank 7. Check there is clean water in the solution tank 2 1 8. Check that the tap lever is fully opened, the lever is positioned at the rear of the machine 9. Check that the by-pass tap is in the “dosing system” position 10. Turn the water flow rate adjustment knob (3) to the maximum position 11.
TROUBLESHOOTING 69. THE MACHINE DOES NOT START 1. 2. 3. 4. 5. Check the batteries are charged (battery version) Check the starter battery is charged (combustion engine version) Check the starter battery is connected to the machine system (combustion engine version) Check the electric system connector is connected to the battery connector (battery version) Check the electric system connector is connected to the generator connector (combustion engine version) 6. Check the key switch is ON/I 7.
TROUBLESHOOTING 76. THE BRUSH MOTOR DOES NOT WORK ATTENTION: To avoid damaging the floor, the motor only starts up when the machine is moved forwards 1. 2. 3. 4. Check that the base is lowered during start-up The operator must be properly seated in the driving position Check no thermal protection device has intervened Check the correct connection of the motor to the terminal under the footboards 77.
DISPOSAL To dispose of the machine, take it to a demolition centre or an authorised collection centre.
CHOOSING AND USING THE BRUSHES POLYPROPYLENE BRUSH (PPL) Used on all types of floors. Good resistance to wear and tear, and hot water (no greater than 60°C). The Polypropylene brush is non-hygroscopic and therefore retains its characteristics even when working in wet conditions. NYLON BRUSH Used on all types of floors. Excellent resistance to wear and tear, and hot water (even over 60°C). The nylon is hygroscopic and so tends to lose its characteristics over time when working in wet conditions.
EC DECLARATION OF CONFORMITY The undersigned manufacturer: COMAC S.p.A. Via Maestri del Lavoro, 13 37059 Santa Maria di Zevio (VR) declares under its sole responsibility that the product ULTRA100 BS FLOOR SCRUBBING MACHINES comply with the requirements of the following Directives: 2006/42/EC: Machinery Directive 2006/95/EC: Low Voltage Directive 2004/108/EC: Electromagnetic Compatibility Directive 2000/14/EC: Directive by the European Parliament and Council date 8th May, 2000.
EC DECLARATION OF CONFORMITY The undersigned manufacturer: COMAC S.p.A. Via Maestri del Lavoro, 13 37059 Santa Maria di Zevio (VR) declares under its sole responsibility that the product ULTRA100 GS FLOOR SCRUBBING MACHINES comply with the requirements of the following Directives: 2006/42/EC: Machinery Directive 2006/95/EC: Low Voltage Directive 2004/108/EC: Electromagnetic Compatibility Directive 2000/14/EC: Directive by the European Parliament and Council date 8th May, 2000.
