Professional Documents
Culture Documents
CS 140 DIESEL
ED. 02 - 2011 - EN
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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. The images are for reference purposes only, and are not binding in terms of design and supply. SYMBOLS USED IN THE MANUAL
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 3
GENERAL SAFETY REGULATIONS ..................................................................................................................................... INTRODUCTORY COMMENT ................................................................................................................................................ GENERAL WARNINGS ........................................................................................................................................................... PURPOSE OF THE MANUAL ................................................................................................................................................. DECLARATION OF CONFORMITY ........................................................................................................................................ SERIAL NUMBER AND PLATES OF THE MACHINE ............................................................................................................ SPARE PARTS AND MAINTENANCE ................................................................................................................................... MODIFICATIONS .................................................................................................................................................................... ON CONSIGNMENT OF THE MACHINE................................................................................................................................ TOOLS AND SYMBOLS USED ON THE MACHINE .............................................................................................................. ACCESSORIES/OPTIONALS ................................................................................................................................................ MACHINE DESCRIPTION ...................................................................................................................................................... TECHNICAL CHARACTERISTICS ......................................................................................................................................... WIRING DIAGRAM.................................................................................................................................................................. HYDRAULIC DIAGRAM .......................................................................................................................................................... USING THE MACHINE............................................................................................................................................................ BEFORE START-UP .............................................................................................................................................................. START-UP AND STOP OF THE DIESEL ENGINE................................................................................................................. START-UP AND STOP OF THE MACHINE ........................................................................................................................... SETTING THE MACHINE IN "TRANSFER" MODE ............................................................................................................... SETTING THE MACHINE IN WORKING MODE ................................................................................................................... SETTING THE MACHINE IN CENTRAL BRUSH CHANGE MODE ...................................................................................... EMPTYING THE DEBRIS HOPPER ...................................................................................................................................... USING THE WINDSHIELD WIPER/WASHER ....................................................................................................................... USING THE HEATING SYSTEM OF THE OPERATOR'S CAB ............................................................................................. USING OF THE AIR CONDITIONING SYSTEM OF THE OPERATOR'S CAB (Optional) ..................................................... OPERATION OF THE LIGHTING SYSTEM............................................................................................................................ ACTIVATION OF THE EMERGENCY LIGHTS ...................................................................................................................... ACTIVATION OF THE WORKING LIGHTS ........................................................................................................................... MANUAL LIFTING OF THE DEBRIS HOPPER ..................................................................................................................... MANUAL TIPPING OF THE OPERATOR'S CAB.................................................................................................................... USING THE REAR VACUUM HOSE (Optional)...................................................................................................................... USING THE HIGH PRESSURE LANCE (Optional)................................................................................................................. USING THE VIDEO CAMERA KIT (Optional) ......................................................................................................................... USING THE FILTER LIFTING CRANE (Optional)................................................................................................................... OPERATIONS TO PERFORM AFTER USING THE MACHINE ............................................................................................ EMPTYING THE DUST SUPPRESSION SYSTEM WATER TANKS .................................................................................... CLEANING THE DUST SUPPRESSION SYSTEM NOZZLES .............................................................................................. DUST SUPPRESSION SYSTEM WATER PUMP (Optional) ..................................................................................................
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Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 4
TOWING THE MACHINE ....................................................................................................................................................... TRANSPORT/HANDLING ...................................................................................................................................................... LONG MACHINE INACTIVITY ............................................................................................................................................... FIRST TIME USE .................................................................................................................................................................... MAINTENANCE OPERATIONS ON THE MACHINE ............................................................................................................ CLEANING THE DEBRIS HOPPER ....................................................................................................................................... CLEANING THE DEBRIS HOPPER FILTER ......................................................................................................................... CLEANING THE DEBRIS HOPPER FILTER WITH LIFTING CRANE (Optional) ................................................................... REPLACING THE DEBRIS HOPPER SEALS AND VACUUM DUCT ................................................................................... CONTROL AND ADJUSTMENT OF THE CENTRAL BRUSH ............................................................................................... CONTROL AND ADJUSTMENT OF THE SIDE BRUSHES .................................................................................................. CONTROL AND ADJUSTMENT OF THE THIRD BRUSH ..................................................................................................... REPLACING THE CENTRAL BRUSH..................................................................................................................................... REPLACING THE SIDE BRUSHES/THIRD BRUSH .............................................................................................................. REPLACING THE RUBBER FRONT, REAR AND SIDE FLAPS ........................................................................................... REPLACING THE HYDRAULIC OIL ...................................................................................................................................... REPLACING THE HYDRAULIC OIL FILTER .......................................................................................................................... CHECKING THE CLEANLINESS OF THE HYDRAULIC OIL RADIATOR FINS ................................................................... GREASING OF BEARINGS ................................................................................................................................................... CONTROLLING THE BATTERY FLUID LEVEL .................................................................................................................... CONTROLLING THE BRAKE FLUID LEVEL ......................................................................................................................... CONTROLLING THE PARKING BRAKE ............................................................................................................................... CONTROLLING THE REVERSE HORN ACTIVATION SENSOR ......................................................................................... REPLACING THE AIR FILTER OF THE OPERATOR'S CAB ................................................................................................ CONTROLLING THE TYRE PRESSURE .............................................................................................................................. CONTROLLING THE FOUR-WHEEL STEERING TOE-IN .................................................................................................... REPLACING THE WHEELS.................................................................................................................................................... CONTROLLING THE ELECTRICAL COMPONENTS ............................................................................................................ REPLACING THE FUSES ...................................................................................................................................................... CHOOSING AND USING THE BRUSHES ............................................................................................................................. MAINTENANCE OPERATIONS ON THE ENGINE ............................................................................................................... REPLACING THE ENGINE OIL ............................................................................................................................................. REPLACING THE ENGINE OIL FILTER ................................................................................................................................ CLEANING THE ENGINE AIR FILTER .................................................................................................................................. CHECKING THE CLEANLINESS OF THE DIESEL ENGINE RADIATOR FINS ................................................................... CHECKING THE ENGINE COOLANT LEVEL ....................................................................................................................... REPLACING THE DIESEL ENGINE FUEL FILTER ............................................................................................................... REPLACING THE DIESEL ENGINE FUEL PRE-FILTER ...................................................................................................... REPLACING THE DIESEL ENGINE ALTERNATOR BELT ................................................................................................... MAINTENANCE ......................................................................................................................................................................
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004 Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
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SCHEDULED MAINTENANCE DIAGRAM ............................................................................................................................. WINTER MAINTENANCE ....................................................................................................................................................... SAFETY FUNCTIONS ............................................................................................................................................................ TROUBLESHOOTING ............................................................................................................................................................ FAULTS AND SOLUTIONS .................................................................................................................................................... SCRAPPING ........................................................................................................................................................................... DECLARATION OF CONFORMITY........................................................................................................................................
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
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INTRODUCTORY COMMENT
Even the best machines will only work well if used correctly and kept in good working order. We therefore suggest you
read this instruction booklet carefully and read it again whenever difficulties arise while using the machine. If necessary, remember that our assistance service (organised in collaboration with Comac SpA dealers) is always at your service for advice or direct intervention.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
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GENERAL WARNINGS
DANGER This machine must only be used by properly trained and authorized personnel. Furthermore, the driver must be: adult holder of the necessary driver's license in a normal physical and mental condition not under the influence of substances, which can alter nerve reflexes (alcohol, psychoactive drugs, drugs, etc..). Before performing any maintenance or repair operations, remove the ignition key, engage the parking brake and, if necessary, disconnect the battery. When working near moving parts, remove all jewellery or materials that could become entangled. Do not work under the raised machine without adequate fixed safety props. Do not operate with this machine in environments where there are toxic, hazardous, flammable and/or explosive powders, liquids or vapours. Warning, the fuel is highly flammable. Do not smoke or carry naked flames in the fuel filling or storage areas. Perform refuelling outdoors or in a well ventilated locations with the combustion engine turned off. To allow the fuel to expand, do not fill the tank more than 4 cm from the neck of the filler pipe. After refuelling, make sure the fuel tank cap is securely closed. If fuel is spilled during refuelling, clean the affected area, and allowing fuel vapours to evaporate before starting the engine. Avoid fuel contact with the skin and do not inhale the vapours. Every time you work under open hoods/hatches, make sure that the hood/hatch can not shut accidentally. When access to the engine compartment for maintenance is necessary with the debris hopper raised, close the two safety valves near the lifting pistons. The fuel tank must be empty during transportation of the sweeping machine by truck/container. WARNING: The exhaust gases of diesel engines contains carbon monoxide, a poisonous, odourless and colourless gas. Avoid inhalation. Do not keep the engine running in enclosed spaces. If you need to keep the engine running in enclosed spaces, do so only if there is adequate ventilation and in the presence of a helper. Carbon monoxide (CO) can cause brain damage or death. The internal combustion engine of this machine emits carbon monoxide. Do not inhale the exhaust fumes. The silencer heats up when the diesel engine is running; Do not touch the silencer while it is hot to avoid burns or fire. Do not place any objects on the engine. Turn the diesel engine off before working on it. To prevent the accidental starting of the engine, disconnect the negative battery terminal. Do not crank the diesel engine with insufficient oil to avoid serious damage. Check the oil level with the engine off and the machine in a horizontal position. Never run the diesel engine without the air filter to avoid damage. The cooling system of the diesel engine is under pressure. Carry out checks with the engine off and only after it has cooled. Even with the engine cool, open the radiator cap with care. The hydraulic oil radiator is fitted with a fan; do not approach it if the engine is hot because the fan could start even when the machine is idle. The repair of the diesel engine must be performed by an Authorized Dealer. Use ORIGINAL spare parts only for the diesel engine. The use of non-original spare parts, can seriously damage the engine. See also the SAFETY REGULATIONS given in the manual of the diesel engine, to be considered an integral part of this Manual.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
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WARNING! The machine must be equipped with vehicle registration and license plate for use on public roads. Do not use the machine for purposes different from that of a sweeping machine, for which it was designed. When using this machine, ensure to safeguard the safety of people and property. - Do not use the machine as a means of transport. Do not leave the machine unattended without removing the ignition key and without having engaged the parking brake. Be very careful when lifting and emptying the debris hopper. Adapt the speed to the adhesion conditions of the road surface. Read all relevant instructions carefully before performing any maintenance/repairs operations.
Adequately protect body parts (eyes, hair, hands, etc..) when cleaning with compressed air or water guns. Avoid contact with battery acid, do not touch parts at high temperature. - Avoid using the brushes while the machine is standing still, so as not to cause damages on the floor.
In case of fire use a powder fire extinguisher and not water. Do not wash the machine with corrosive substances. Do not use the machine in particularly dusty environments. Do not tamper with the machine's protections under any circumstances, follow the instructions provided for routine maintenance. Do not remove or alter the labels affixed to the machine. If the machine does not work properly, check this is not caused by failure to carry out maintenance. Otherwise, request the intervention of authorized personnel or an Authorized service centre. If you need to replace any components, request the ORIGINAL spare parts from a COMAC SpA dealer and/or Authorised Retailer. For safety reasons as well as for smooth functioning, the routine maintenance indicated in the related chapter of this manual, should be performed by authorized personnel or an authorized Comac SpA service centre The machine must not be discarded at the end of its life cycle, due to the presence of harmful toxic materials (oil, batteries, plastics, etc..), subject to regulations providing for their disposal at special centres (see the chapter Scrapping).
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
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DECLARATION OF CONFORMITY
The declaration of the sweeping machine's compliance with the applicable provisions of the law, are indicated on page 44 of this manual .
MODIFICATIONS
Comac SpA aims to constantly improve its products and reserves the right to make changes and improvements when deemed necessary, without having to modify the machines previously sold. It is understood that any modification and/or addition of accessories must be explicitly approved and carried out by Comac SpA
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 10
Fuel level indicator Engine rev counter Water temperature indicator Hour counter
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
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Three level vacuum speed selector Three level machine ground height selector: 1. 2. Working position Transfer or working position in cases of voluminous material (leaves, boxes or bottles) 3. Central brush change position
Heating adjustment buttons (temperature and ventilation) Air conditioning on button (optional)
Diesel engine manual acceleration lever Cab ventilation/cab air recirculation vents
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
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Lights and horn Functions of the buttons near the steering wheel: lights off, with switch on symbol O position lights on with switch on the second notch dipped headlights on, with switch on the third notch - main beam on, with switch on the symbol and lever lifted main beam temporarily on, lifting the lever Right-turn indicator engaged, bringing the lever up left-turn indicator engaged, bringing the lever down
activation of the horn, pressing the button on the end of the lever
activation of the 2 flashing working lights activation of the windshield wiper activation of the windshield lever actuation of the 2 working lights to illuminate the right side (right side brush and third brush) and the left side of the machine (the left brush). All references: FORWARD BACKWARDS FRONT REAR RIGHT LEFT
indicated in this manual, refer to the position of the operator sitting at the driver's seat
ACCESSORIES / OPTIONALS
The machine can be equipped with the following accessories/optionals: left side brush third brush brushes with bristles harder or softer than the standard spraying system for third brush and side brush complete with 200 litre tank washing system with high pressure water lance air conditioning system for the cab rear vacuum system (hand operated waste collection pipe)
hydraulic crane for hopper filter lifting/replacement radio with CD player rear video camera kit debris hopper spare filter kit.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
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MACHINE DESCRIPTION
TECHNICAL CHARACTERISTICS
CLEANING TRACK Working width with central brush Cleaning width with 1 side disc brush Cleaning width with 2 side disc brushes Cleaning width with 2 side disc brushes + third disc brush Cylindrical central brush diameter Diameter of 2 side disc brushes and third brush DEBRIS HOPPER Debris hopper volume (total) Debris hopper volume (usable) with filter Maximum hopper lifting height VACUUM ACTION Air flow Filtering surface Vacuum motor rated power PERFORMANCE Maximum speed Working speed Max gradient when empty ENGINES (*) ENGINE Power supply Cylinders no. Displacement Motor power Engine rpm Diesel engine coolant Engine oil type Diesel engine oil pan capacity (maximum / minimum) (*) For other data/values of the diesel engine, refer to the related Manual. (**) See the coolant characteristics table below and the reference specifications table. (**) See the engine oil characteristics table below and the reference specifications table. AGIP ECO PERMANENT CHARACTERISTICS Boiling point Freezing point Colour Density at +20 C AGIP SIGMA TRUCK PLUS 15W-40 CHARACTERISTICS SAE GRADE Viscosity at +100 C Viscosity at +40 C Viscosity at -25 C Viscosity index Flash point O.C. Pour point Density at +15 C C C kg/l mm /s mm /s mm /s
2 2 2
mm mm mm mm mm mm
l l mm
m /h m
2
14.000 50 45
kW
km/h km/h %
40 15 20
cm
3
Perkins Diesel 4 4.400 100/75 2.200 Eco Permanent (**) Sigma Truck Plus 15W-40 (***) 7.0-7.5 kg
C C kg/l
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
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HYDRAULIC SYSTEM Drive system maximum pressure Maximum pressure of the vacuum fan system Maximum pressure of the services system Hydraulic system oil viscosity [with ambient temperature over +10 C (*) Hydraulic system oil type bar bar bar cSt AGIP 350 250 200 46 ARNICA S (ISO 46) (**)
Braking system oil type ATE Brake Fluid DOT 3 (***) (*) If the machine is used at temperatures below +10 C, the oil should be replaced with other equivalent oil having a viscosity of 32 cSt. For temperatures below 0 C, using oils with even lower viscosities. (**) See the hydraulic oil characteristics table below and the reference specifications table. (**) See the brake fluid characteristics table below and the reference specifications table.
AGIP ARNICA S (ISO 46) CHARACTERISTICS Viscosity at +40 C Flash point O.C. Pour point Density at +15 C ATE BRAKE FLUID DOT 3 CHARACTERISTICS Dry boiling point Colour CLIMATE CONTROL SYSTEM DATA (optional) Gas type Gas quantity REAR CAMERA DATA (optional) Brand Rear colour camera DIMENSIONS AND WEIGHTS Machine length Machine width Machine height when in operation Machine height in transfer Brush change machine height Machine weight in running order Maximum weight in running order GENERAL SPECIFICATIONS OF THE VEHICLE Turning circle Service brake Parking and emergency brake Rear wheel traction Front and rear wheels Tyre pressures Suspensions Machine height control Diesel tank capacity Water tank capacity (optional) Maximum noise level in the driving seat (Sound Pressure Level) (ISO/EN3744) at maximum rpm (Lpa) Guaranteed sound power level (2000/14/EC) at maximum speed (Lwa) Electrical system supply Starter battery
mm /s C C 3 kg/m
kg
mm mm mm mm mm kg kg
4.250 Hydraulic Mechanical Hydraulic 205/65 R17.5 6 bar 4 hydraulic and independent Electronic on all 4 wheels 105 200 77 109 12 12 160 Ah
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 15
WIRING DIAGRAM
Fuses
F4A F3A F2A F1A HYDRAULIC OIL RADIATOR FAN FILTER SHAKER ENGINES GLOWPLUGS GENERAL POWER SUPPLY 30A 40A 80A 120A
Fuses
F16 F15 F14 F13 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 INDICATORS STOP LIGHTS - LIGHT SWITCHES REVERSE BUZZER HORN CAB VENTILATION - AIR-CONDITIONER SUSPENSION SUPPLY SENSORS - MULTIFUNCTION INSTRUMENT - ALARM BUZZER RIGHT SIDE BRUSH ROTATION - LEFT SIDE BRUSH ROTATION DEBRIS HOPPER MOVEMENTS CENTRAL BRUSH UP/DOWN RIGHT SIDE BRUSH UP/DOWN LEFT SIDE BRUSH UP/DOWN LOADING SCREW CONVEYORS FORWARD PEDAL FUEL PUMP - PREHEATING UP/DOWN/IN/OUT THIRD BRUSH - VACUUM WIPER WASHER - RADIO - HEATED MIRRORS - FLASHING LIGHTS CIGARETTE LIGHTER - OPTIONAL RIGHT INDICATOR LIGHTS LEFT INDICATOR LIGHTS EMERGENCY ARROWS HIGH BEAM LIGHTS LOW BEAM LIGHTS WORKING HEADLIGHTS +30 INSTRUMENT PANEL RADIO MEMORY FAN, HEATER, AIR CONDITIONER - AIR CONDITIONER COMPRESSOR 10A 20A 15A 15A 15A 20A 15A 15A 20A 15A 10A 10A 25A 15A 7.5A 25A
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 16
HYDRAULIC DIAGRAM
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 17
WARNING
CAUTION While reading this manual, the operator must fully understand the meaning of the symbols depicted on the plates. Do not cover the plates for any reason and replace them immediately if they are damaged or unreadable. This machine has been designed as a high performance and load carrying capacity sweeping machine and, thanks to the 4-wheel steering, can operate in confined spaces. Therefore, it is characterized by a very small track and tight steering angles. These characteristics of the machine can, under certain conditions, determine instability during movement. This instability can be caused by the speed, sudden manoeuvres, operation in the presence of a steep slope, low tyre pressure, the weight of waste in the hopper, or the hopper lifted. For these reasons, the machine must be driven by a qualified operator, properly trained on the correct use of the machine and aware of potential risks.
BEFORE START-UP
1. Check the fuel level and the reserve light by turning the ignition key on the instrument panel one position clockwise and leave it in this position. If necessary, open the right side hatch, turning the key, unscrewed the cap of the tank, and refuel through the nozzle. CAUTION! To allow the fuel to expand, do not fill the tank more than 4 cm from the neck of the filler nozzle. 2. Check the water level of the diesel engine cooling system. 3. Check the fluid level of the brake system. 4. Check the level of the hydraulic oil. 5. Check the level of the engine oil. 6. Check the level of the windscreen washer liquid. 7. Check the engine air filter is not clogged. 8. Check the tyre pressures. 9. Check that the machine does not have hoods/hatches open and is in normal use conditions.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 18
6. Check that the brushes are lifted, otherwise check that the brush activation switch is off, to prevent any inconvenience caused by the immediate starting of the brushes when the engine is started. 7. Check that the machine is in neutral [drive pedal is not pressed]. 8. Insert the start-up key, turning it clockwise by one position and leave it in this position. At this point the following lights light on the panel: diesel engine glow plugs preheating indicator light battery charger indicator light diesel engine oil pressure indicator light hydraulic parking brake indicator light When the glow plug preheating light turns off, turn the ignition key fully clockwise, and release it when the diesel engine starts. CAUTION! Especially for colder climates, the preheating time must be respected to prevent excessive smoke. CAUTION! So as not to damage the starter motor when starting the diesel engine, do not turn the ignition key for too long (maximum 15 seconds). If the engine doesn't start, wait for one minute before trying to start the engine again. Before repeating the start-up, turn the key anticlockwise to its initial position. If after two attempts the diesel engine still does not start, do not insist, but request the intervention of the person in charge of the machine. 9. Check that with the engine running, all warning lights are off. 10. With the accelerator halfway, leave the engine to warm up for a few minutes, especially in conditions with low ambient temperature. 11. Move the accelerator lever of the engine until the rev. counter shows 2,000 rpm (the ideal movement and working speeds) Shut-down of the diesel engine 1. Move the accelerator lever of the engine to idle for a few minutes to stabilize the system. 2. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 19
4. Make sure the vacuum fan is turned off; the button must be disabled. 5. Make sure the central brush is raised; the button must be disabled. 6. Check that the side brushes are raised; the buttons must be disabled. 7. Lift the machine by placing the selector in a central position and the side brushes by pressing the button 8. Get out of the machine and hook up the chains of the two side brushes by pressing the red button. 9. Sit in the driver's seat and disengage the parking brake. 10. Move the accelerator lever gradually forward and adjust the engine speed on the display to 2,000 rpm. 11. Make sure the selector is set on transfer (machine in the intermediate position). 12. Start the transfer, manoeuvring the machine with the steering wheel and slowly pressing the right pedal for the forward movement or the left for reverse. The forward speed is adjustable from zero to the maximum value according to the pressure exerted on the pedal. WARNING! Remember that steering is in all four wheels. Use the mirrors to check the manoeuvring space in tight placers. WARNING! Remember to place the machine in transfer mode before tackling an obstacle (such as a sidewalk). Stop the machine in transfer mode 1. To stop the machine, release the forward/reverse pedal 2. To stop the machine quickly, press the service brake pedal as well. 3. Move the accelerator lever of the engine to idle for a few minutes to stabilize the system. 4. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 20
13. Start the sweeping operation, manoeuvring the machine with the steering wheel and slowly pressing the right pedal for the forward movement or the left for reverse. The forward speed is adjustable from zero to the maximum value according to the pressure exerted on the pedal. During work the machine collects both light material such as dust, paper, leaves, etc.. as well as heavy material such as stones, bottles, etc.. 14. Avoid staying with the machine in the same position for too long with the brushes rotating: Unwanted furrows could be made on the pavement. 15. In the event of very dusty areas, turn off the vacuum turbine and activate the filter shaker every 20-30 minutes by pressing the related button, after having turning off the vacuum action of the turbine. NOTE All brushes can be lowered and raised even when the machine is moving. The brushes only turn when lowered. CAUTION! If the ground is wet during operation, move the hopper filter exclusion lever to the by-pass position, in order to prevent the fabric filter to become wet, resulting in its blockage. CAUTION! If it is necessary to collect piles of wet leaves during operation, raise the machine in transfer mode and proceed slowly with a maximum vacuum action. Stop the machine in working mode 1. To stop the machine, release the pedal To stop the machine quickly, press the service brake pedal as well. 2. Engage the parking brake with the button. 3. Disengage the water pumps of the dust suppression system using the appropriate button. 4. Raise the third third brush by means of the joystick. 5. Raise the two side brushed by means of the related buttons. NOTE The third brush is equipped with a protection system against accidental impacts (pavements, walls, holes) that allows the automatic withdrawal of the brush. To put it back in place simply overcome the resistance of the safety spring and rotate the brush forward. 5. Raise the other two side brushes by means of the relative buttons. 6. Raise the central brush by means of the relative button. 7. Stop the vacuum fan by means of the relative button. 8. Move the accelerator lever of the engine to idle for a few minutes to stabilize the system. 9. Verify that the hopper is lowered and that the related indicator light is off. 10. Engage the parking brake with the lever. 11. Turn off the engine by turning the ignition key counter-clockwise until it stops, then remove it. 12. If open, close the taps of the dust suppression system positioned up
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 21
WARNING! Before emptying the debris hopper, ensure that there is nobody within the operating range of the machine. WARNING: with debris hopper up, move the machine very slowly. Maximum speed 5km/h. Avoid unloading with the machine on an incline or on soft ground. Do not activate the filter shaker when the hopper is raised.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 22
activation of the buzzer by pressing the button on the end of the lever
WARNING! For safety reasons, close BOTH locking taps before operating in the area of the raised hopper. This is necessary even if the hopper lifting cylinders are equipped with parachute valves, which prevent the unforeseen descent of the hopper in case of breakage/leak of a hydraulic pipe/fitting. Manual lowering of the debris hopper 1. Manually open the two debris hopper locking taps. 2 Move the slide switch in the lower position and activate the pump with the lever until the debris hopper is fully lowered. 3. Remove the lever from the pump and put it back into its original position. 4. Return the cursor of the pump to the centre. 5. Close the side door with the supplied key.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 23
WARNING! Do not operate the high pressure pump with the tanks empty or in reserve (the pump could be damaged if it runs dry). 1. Open the right door (front) with the key in order to withdraw the high-pressure water lance. 2. Take the lance and unwind its hose. 3. Turn the tap in the position that excludes the sprinklers for the brushes and diverts the flow to the lance 3. Start the diesel engine at low speeds, as indicated in the related paragraph. 5. Press the water spraying button to the brushes (the electric pump starts) 6. Take the engine to the desired speed. 7. Use the lance by pressing the lever on the gun.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 24
WARNING! Adequately protect body parts (eyes, hair, hands, etc..) when cleaning with with compressed air or water guns. WARNING! Do not leave the high-pressure pump running for a long time without using the lance. 8. After using the lance, perform steps 1 to 7 in reverse order.
WARNING: this operation must be performed by 2 people. 1. Engage the hydraulic parking brake. 2. Raise the crane's hydraulic piston located on the right side of the hopper, using the button on the yellow control panel and manually rotate it so that the hooks at the ends of the steel cables are aligned with the eyelets on the hopper roof. 4. Manually attach the filter cover to the cables of the winch, through the two lifting eyelets, after having disconnected the quick connectors and disconnected the electric cables of the two cameras and the two filter shakers (electrical connections with quick release connectors). 5. Lift the cover controlling the electric winch of the cables through the button on the yellow control panel. 6. Place the cover with the filter on two trestles (operation to be carried out by 2 people). 7. Unhook the hooks from the eyelets of the cover. 8. Manually rotate the crane until it is positioned in correspondence with the new debris hopper filter kit. 9. Hook the hooks to the eyelets of the cover. 10. Electrically lift the winch. 11. Manually rotate the crane until the filter kit is positioned in correspondence with hopper. 12. Lower the winch cable, pressing the button on the yellow control panel, until the filter kit is perfectly housed in the hopper. Pay special attention to the seal, replacing it immediately if it is damaged. 13. Manually rotate the crane and hydraulically lower the piston by pressing the button on the yellow control panel until it reached its housing. 14. Hook the quick couplings of the hopper to the cover of the filter. 15. Connect the cable of the filter shaker and rear camera. WARNING: these operations must be carried out using gloves to protect the hands from contact with dangerous elements. Wear protective goggles and a mask to protect from dust.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 25
CLEANING THE NOZZLES OF THE DUST SUPPRESSION SYSTEM ON THE SIDE BRUSHES (optional)
WARNING! Adequately protect the body parts (eyes, hair, hands, etc.) when cleaning with compressed air or water guns. Preliminary operations 1. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it. 2. Unscrew the ring nuts of the nozzles. 3. Clean any impurities from the nozzles and filters with a jet of compressed air. 4. Remove any deposits of limestone. If necessary, replace the metal filter and the nozzles. 5. Refit the filters and nozzles and secure them with the ring nuts.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 26
TRANSPORT/MOVEMENT
To transport/move the machine, use the hooks and procedures for anchoring indicated below. WARNING! The anchoring/lifting of the machine must be performed by qualified personnel. Available hooks The machine is equipped with the following hooks: No. 2 lifting hooks, for use with the empty debris container. No. 1 front towing/anchoring hook. No. 1 rear towing/anchoring hook. Anchoring For anchoring the machine in case of transport, the operations to be performed are as follows: Set the machine in transfer mode (see procedure in the specified paragraph). Apply the hydraulic parking brake. Remove the start-up key. Close all lids, bulkheads, etc. Anchor the machine with the front and rear tow hooks. Anchor the machine with appropriate bands respectively inserted above the rear axle support and on the front left and right platforms for access to the cab. Temporary lifting For the temporary lifting of the machine, the steps to perform are the following: 1. Set the machine in transfer mode (see procedure in the specified paragraph). 2. Verify that the debris container is empty. WARNING! If in an emergency it is necessary to lift the machine with the debris container not empty, operate with greater caution, as the weight of the debris results in an unbalance of the machine, and the hooks are also subjected to greater stress. 3. Engage the parking brake. 4. Remove the start-up key.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 27
5. Close all lids, bulkheads, etc. 6. Anchor the machine with suitable ropes to the two lifting hooks. 7. Carefully lift the machine, for the shortest possible time, with a suitable lifting system and in compliance with current safety regulations.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 28
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 29
2. Raise the crane's hydraulic piston located on the right side of the hopper, using the button on the yellow control panel and manually rotate it so that the hooks at the ends of the steel cables are aligned with the eyelets on the hopper roof. 4. Manually attach the filter cover to the wires of the electric winch, through the two lifting eyelets, after removing the quick hooks and after disconnecting the electric wires of the cameras and the two filter shakers (electrical connections with quick uncoupling connectors). 5. Lift the cover, controlling the electric winch lifting the metallic cable via the yellow button on the control panel. 6. Place the cover with the filter on two trestles (operation to be carried out by 2 people). 4. Attach the filter cover to the cables of the hydraulic winch through the two lifting eyelets, after removing the quick hooks. 5. Lift the cover, controlling the crane via the button located in the cab 6. Fully remove the filter (operation to be performed by 2 people). 7. Carefully clean the filter using a vacuum cleaner with filter suitable to the type of dust to remove 8. Reassemble everything in reverse order. Pay special attention to the seal, replacing it immediately if it is damaged.
WARNING: these operations must be carried out using gloves to protect the hands from contact with dangerous elements. Wear protective goggles and a mask to protect from dust.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 30
Adjusting the lateral position of the side brushes This adjustment is useful to optimise the lateral position of the brushes with respect to the central brush. To adjust, loosen/tighten the nuts by varying the lateral position of the brushes. The best adjustment is to position the arms in slight tension towards the outside. When the excessive consumption of brushes does not allow more adjustment, replace them as indicated in the specific paragraph.
Adjusting the forward inclination angle of the side brushes From both sides of the support arm of the brush loosen the two locknuts, then adjust the forward inclination angle. When the adjustment has been carried out, tighten the locknuts.
Adjusting the side inclination angle of the side brushes Within the support arm of the brush loosen the two horizontal locknuts, then adjust the side inclination angle. When the adjustment has been carried out, tighten the screws. The adjustment of the surface pressure of the moving brush is NOT required since it is already set at the factory; an automatic pressure regulating system enables the same brush pressure to be maintained on the ground in all work conditions. Using the selector switch on the control dashboard in the cab, you can adjust the height of the entire machine in three different positions.
Page 31
4. Stop and lift the third brush, then move the machine. 5. Engage the parking brake and turn off the engine by moving the start-up key to OFF and remove it . 6. Check that the mark left by the third brush is, in size and orientation, as shown below: - The brush must touch the floor at an arc of between "10 o'clock" and "2 o'clock". - The angle of forward inclination angle of the brush must be 10 degrees. 7. Proceed to adjust the brush, if it has a different mark, operate as shown below.
Adjusting the inclination angle of the third brush Act on the two self locking nuts at the two ends of the horizontal bar, considering that: by unscrewing the nut the brush lowers; by tightening the nut the brush is lifted.
Adjusting the side inclination angle of the third brush Loosen the locknuts, then adjust the side inclination angle. When the adjustment has been carried out, tighten the locknuts. When the excessive consumption of brush does not allow more adjustment, replace it as indicated in the specific paragraph. The adjustment of the surface pressure of the third brush is NOT required since it is already set at the factory; an automatic pressure regulating system enables the same brush pressure to be maintained on the ground in all work conditions. Using the selector switch on the control dashboard in the cab, you can adjust the height of the entire machine in three different positions.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 32
6. Replace the worn brush with a new one. 7. Screw the lower tightening screws. 8. Turn on the machine and place it in Transfer or Working position. WARNING: these operations must be carried out using gloves to protect the hands.
WARNING: protect yourself with DPI suitable for hydraulic oil WARNING: for all other maintenance operations, you are advised to contact our technical assistance centre (organised in collaboration with our dealers), as these interventions require specific technical skills and the use of the right equipment. WARNING! The oil and filters eliminated must be sent to separate waste collection in compliance with the environmental health regulations in force.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 33
3. Remove the filter under the cap, replace it and put it back in place. 4. Refill the plastic orange cap and close the side door of the machine. WARNING: dispose of the filters and used oil in the correct manner WARNING: protect yourself with DPI suitable for hydraulic oil WARNING: for all other maintenance operations, you are advised to contact our technical assistance centre (organised in collaboration with our dealers), as these interventions require specific technical skills and the use of the right equipment.
WARNING!
The oil and filters eliminated must be sent to separate waste collection in compliance with the environmental health regulations in force.
2 Greasing points on the arm of the front right brush. 2 Greasing points on the arm of the front left brush (optional).
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 34
2 Greasing points on the piston head joints of the front wheel suspensions. 2 Greasing points on the piston head joints of the rear wheel suspensions.
2 Greasing points on the head joints of the pistons lifting the debris collecting hopper.
2 Greasing points on the joints of the rear closing door of the debris collecting hopper. The average amount of grease to be injected should be: 4 to 5 pump strokes, if using a manual pump. 15 - 20 seconds of injection, if using an air pump.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 35
Page 36
WARNING! The lifting jack is not provided. Use a jack with adequate characteristics and with a minimum lifting capacity of 5,600 kg (12,345 lb). 4. Carefully, operate the jack or hydraulic jack and lift the wheel to be removed until lifting it slightly from the ground. 5. Unscrew the fixing nuts and remove the wheel. 6. Replace the wheel by performing steps 1 through 5 in reverse. Tightening torque of the wheel retainer nuts: 450 Nm (332 lbft). Removing/fitting a rear wheel 1. Remove the grey side protection, which hides the central brush, placed between the two wheels. 2. In the vicinity of the wheel to be removed, place the jack or hydraulic jack on the supports of the machine chassis as shown in the figure. 3. Before lifting the wheel with the jack or the hydraulic jack, slightly loosen the fixing nuts. WARNING! The lifting jack is not provided. Use a jack with adequate characteristics and with a minimum lifting capacity of 5,600 kg (12,345 lb). 4. Carefully, operate the jack or hydraulic jack and lift the wheel to be removed until lifting it slightly from the ground. 5. Unscrew the fixing nuts and remove the wheel. 6. Replace the wheel by performing steps 1 through 5 in reverse. Tightening torque of the wheel retainer nuts: 450 Nm (332 lbft).
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
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Page 37
The pink lever located near the manual accelerator serves to disable the movement of the brushes FUSE REPLACEMENT
The fuse box is located in the driver's cab, on the dashboard next to the driver and is protected by a black plastic cover. 1. Stop the machine on a flat surface and engage the parking brakes. 2. Turn the start-up key to the OFF position and remove it. 3. Remove the fuse box cover and replace the fuses in question among the following:
F16 F15 F14 F13 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 INDICATORS STOP LIGHTS - LIGHT SWITCHES REVERSE BUZZER HORN CAB VENTILATION - AIR-CONDITIONER SUSPENSION SUPPLY SENSORS - MULTIFUNCTION INSTRUMENT - ALARM BUZZER RIGHT SIDE BRUSH ROTATION - LEFT SIDE BRUSH ROTATION DEBRIS HOPPER MOVEMENTS CENTRAL BRUSH UP/DOWN RIGHT SIDE BRUSH UP/DOWN LEFT SIDE BRUSH UP/DOWN LOADING SCREW CONVEYORS FORWARD PEDAL FUEL PUMP - PREHEATING UP/DOWN/IN/OUT THIRD BRUSH - VACUUM WIPER WASHER - RADIO - HEATED MIRRORS - FLASHING LIGHTS CIGARETTE LIGHTER - OPTIONAL RIGHT INDICATOR LIGHTS LEFT INDICATOR LIGHTS EMERGENCY ARROWS HIGH BEAM LIGHTS LOW BEAM LIGHTS WORKING HEADLIGHTS +30 INSTRUMENT PANEL RADIO MEMORY FAN, HEATER, AIR CONDITIONER - AIR CONDITIONER COMPRESSOR 10A 20A 15A 15A 15A 20A 15A 15A 20A 15A 10A 10A 25A 15A 7.5A 25A
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 38
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 39
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 40
WARNING: dispose of the filters and used oil in the correct manner
WARNING: protect yourself with DPI suitable for hydraulic oil. WARNING: for all other maintenance operations, you are advised to contact our technical assistance centre (organised in collaboration with our dealers), as these interventions require specific technical skills and the use of the right equipment. WARNING! The oil and filters eliminated must be sent to separate waste collection in compliance with the environmental health regulations in force. CAUTION! When replacing the engine oil filter, is recommended to also replace the engine oil, following the instructions indicated in the specific paragraph.
Cyclone pre-filter cleaning 1. When you need to clean the cyclone pre-filter block, unscrew the fixing screw from the threaded insert and remove the cyclone block from its housing. 2. Clean the cyclone block with compressed air or water. 3. Refit the cyclone block. Filter cleaning/replacement 1. Remove the plastic cover and remove the filtering element. 2. Remove the secondary filtering element. 3. With a jet of compressed air [maximum 6 bar (87.0 psi)], carefully clean the filter elements blowing from the inside outwards (in the opposite direction to the vacuum air flow). 4. If necessary, replace the filtering elements, and dispose of them according to the environmental regulations in force. WARNING: these operations must be carried out using gloves to protect the hands. WARNING: do not touch the hot parts of the engine. WARNING: empty the debris hopper before any intervention. WARNING: as the debris hopper must be kept lifted for interventions, use the safety taps located below the hydraulic cylinders.
Page 41
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 42
MAINTENANCE
The service life of the machine and maximum operating safety is ensured by careful and regular maintenance.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 43
WINTER MAINTENANCE
In the winter, carefully follow the maintenance procedures listed below.
Procedure for storing the sweeping machines that operate at temperatures below 0 C (+32F)
1. Empty the nozzles and the water tank (optional). 2. Empty and clean/replace the water filter (optional). 3. Add antifreeze fluid to the water tank (check the quantity per litre). 4. Circulate the antifreeze fluid in the water system until it leaks from the nozzles of the brushes, operating the water pump (see the specific paragraphs). When the fluid starts to leak from the nozzles, stop the pump. 5. Start the diesel motor as indicated in the specific paragraph. 6. Circulate the antifreeze fluid in the high-pressure water system until it leaks from the nozzle by operating the pump with the lever that is located in the cab (see the specific paragraphs). When the fluid starts to leak from the nozzles, stop the pump. WARNING! Do not use the dust removal system when the ambient temperature is below 0 C (+32 F) as this may create sheets of ice on the road surface.
SAFETY FUNCTIONS
The following security functions are prepared on the machine.
Reverse signal
The machine is equipped with a sensor with the corresponding horn to indicate when the machine is in reverse.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 44
TROUBLESHOOTING
Below are listed the most common problems that may occur while using the machine, the probable causes that determine them and the likely solutions to be taken to eliminate them. WARNING! The implementation of the solution indicated must be carried out by qualified personnel, at all times complying with the instructions described in specific paragraphs of this manual, if present, or contact Comac SpA Service Centre, who are in possession of the Service Manual. For questions or information, contact the Comac SpA Service Centre. For troubleshooting of the following optional equipment, refer to the corresponding manuals: camera kit
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 45
FILTER SHAKER
Problem The filter shaker engine does not work Probable cause The filter shaker engine connector is not correctly connected Circuit protection fuse Solution Restore connections Restore the F3A fuse
VACUUM FAN
Problem The vacuum fan is noisy Probable cause The fan bearings are not lubricated The fan bearings are worn The hydraulic motor is damaged The dust filters are clogged The vacuum hose is clogged The seal between the vacuum inlet and the debris container is broken or not properly positioned The drive pump of the vacuum fan motor does not generate pressure The debris container is not fully resting on the frame in the lower position Position the machine on a flat surface and lower the debris container until the proximity microswitch touches the container The distributor is locked The motor is damaged The pump is damaged The diesel motor is not at rpm speed The vacuum fan does not turn The debris container is not fully resting on the frame in the lower position Position the machine on a flat surface and lower the debris container until the proximity microswitch touches the container Solution Lubricate Replace Repair Clean the filters Clean Replace/adjust the position
The vacuum fan turns, but does not draw in sufficient air
Adjust the pump pressure Fully lower the bucket, until the red warning light on the instrument panel turns off Check that the proximity microswitch is in its position and that the electrical cable is not interrupted Repair Replace Replace the pump Increase the motor speed up to a maximum Fully lower the bucket, until the red warning light on the instrument panel turns off Check that the proximity switch is in its position and that the electrical cable is not interrupted
DEBRIS CONTAINER
Problem The debris container does not go up/down and tilt/return horizontally Probable cause The distributor is locked The button is broken The fuse is blown The relay board is damaged The solenoid valves are burned out There is no voltage to the actuator Command button broken The actuator pistons are not adjusted Solution Repair Replace the button Replace the relay Replace Replace the solenoid valves Repair the electrical system Replace the button Adjust the actuator pistons
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 46
STEERING
Problem The machine does not have a proper rectilinear course The steering is hard Probable cause The convergence of the rear axle is incorrect The power steering is damaged The priority valve is damaged The hydraulic drive cylinder of the steering wheels is damaged Solution Adjust Replace Replace Replace
BRAKES
Problem Probable cause The brake oil is low The braking mass is worn or greasy Air present in the system The brake drum cylinder is damaged The brake oil pump is damaged The brake is not properly adjusted Solution Check the oil level of the brakes Replace Bleed the system Replace Check Adjust
STABILITY
Problem The machine in motion has little stability Probable cause The tyres are not inflated to the correct pressure Solution Check the pressure of the tyres
TRACTION POWER
Problem The machine has little traction power Probable cause The drive pedal is defective Power losses of the traction system pump occur The traction system engines are worn The traction system pump deactivation screw to facilitate the pulling movement of the machine is turned on Oil leaks in the hydraulic circuit The traction system pump is broken The traction system engines are broken Parking brakes engaged Parking brakes locked (no power to the solenoid valve) Solution Replace Check the oil pressure of the hydraulic system on the traction system pump Replace Deactivate Repair Replace the pump Replace Disengage the parking brake. Check the electrical system (solenoid valve)
The machine does not move with the drive pedal pressed down
DRIVE PEDALS
Problem The machine moves even with travel pedal idle (free) Probable cause The travel pedal is not properly adjusted Solution Adjust
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 47
DIESEL MOTOR
Problem The engine does not start Probable cause Disconnected battery Machine without fuel The fuse is blown For the diesel motor troubleshooting, refer to the corresponding Manual. Solution Connect the battery Refill it Replace the fuse
SCRAPPING
Proceed to the scrapping of the machine at an authorised wrecker. Before scrapping the machine, it is necessary to remove and separate the following materials and send them for separate waste collection in accordance with the environmental hygiene regulations in force: Brushes Engine oil Hydraulic system oil Hydraulic system oil filter Plastic parts - Electric and electronic parts* NOTE (*) In particular, contact Comac S.p.A. in the area in order to scrap the electric and electronic parts.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289
Page 48
EC DECLARATION OF CONFORMITY
The undersigned company: COMAC S.p.A. Via Maestri del Lavoro, 13 37059 Santa Maria di Zevio (VR) declares under its sole responsibility that the ROAD SWEEPING MACHINE mod. COMAC CSS 140 D, frame complies with the requirements of the following Directives: 98/37/EEC: Machinery Directive 2004/08/EC: Electromagnetic Compatibility Directive and subsequent modifications. 2000/14/EC: Directive by the European Parliament and Council date 8th May, 2000. Noise emission by machines and equipment for outdoor use. Falling within the power sweeper category (as defined in enclosure I no.46 of the Directive 2000/14/EC of the European Parliament and Council), it is subject to noise marking only. The conformity evaluation was carried out in accordance with enclosure III.B.46 of the said directive. Technical documents are kept at the Technical department Comac S.p.A., Via Maestri del Lavoro, No. 13 37059 Santa Maria di Zevio, Verona, Italy. The measured and guaranteed acoustic power level is 78 dB(A) It also complies with the following standards: EN 12100-1: Machine safety - Basic concepts, general principles for design - Part 1: Basic terminology and methodology EN 12100-2: Machine safety - Basic concepts, general principles for design - Part 2: Technical principles EN 55022: Devices for information technology Radio interference characteristics Limits and measurement methods. EN 61000-2-6: Electromagnetic compatibility (EMC) - Part 6-2: Generic standards Immunity for industrial environments. Santa Maria di Zevio, COMAC S.p.A. Legal representative Giancarlo Ruffo
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004
Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289