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ULTRA100 BS ULTRA100 GS BI-FUEL

1. a G0 REPLAGING THE GYLINDRIGAL BRUSHES isaianinnianannnanaiah nAn AAA NAAN SAANANE ARANAN NA 51 OLREPLACING THE SIDE BRUSH A AE AN O a ate 52 62 AAAA AANRAAI AAAA 53 63 REPLAGING THE RUBBER iirinn ainina aaa aaa aa 54 64 REPLACING THE SIDE SPLASH GUARD RUBBER OF THE BRUSH HEAD 54 65 REPLACING THE SPLASH GUARD RUBBER OF THE SIDE 55 66 REPLACING THE LPG CYLINDER COMBUSTION ENGINE VERSION sssssssssssssssssssssusssusssusssssssusssssiussiusstussinuseiussiisstsussinussinastsnstsussnestsasstust 55 67 REPLACING THE STARTER BATTERY 68 WASHING THE DOSING SYSTEM VERSIONS WITH 05 57 TROUBLESHOOTING e aaar sien 59 69 THE MACHINE DOES NOTS TART 5 59 70 COMBUSTION ENGINE DOES NOT START ssssssssssssssssssssssssssssssussstussissssusstniss
2. 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 6 Remove the nuts 4 from the right hand carter 7 Remove the screw 5 from the right hand carter 8 Remove the nut 6 and washer from the rear brush tie rod 30 MACHINE PREPARATION 9 Remove the right hand carter 7 from the brush head unit and place it on the ground 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 Push the front brush into the tunnel until it couples with the drive hub on the opposite side of the tunnel WARNING Make sure the brushes are correctly connected 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 37 SIDE BRUSH ASSEMBLY To assemble the side brush proceed as follows 1 Check the side brush is in its standard resting position If this is not the case use the lever 1 on the instrument panel to move it to the left 2 Turn the main switch key anticlockwise to the 0 position 3 Engage the parking brake l
3. 0 ON I 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 machine Symbol denoting acoustic alarm Indicates the acoustic alarm button Symbol denoting forwards and backwards speed selector Used on the instrument panel to indicate the speed of the forwards or backwards movements of the machine Side brush movement symbol Used on the instrument panel to indicate the side brush lever Sideways movements of the lever correspond with sideways movements of the side brush Symbol denoting front rear lights Used on the instrument panel to indicate the lights control switch Symbol denoting ammetric check of the brush motor Used on the instrument panel for the red indicator light showing the brush motor is under pressure force SYMBOLS USED ON THE MACHINE Symbol denoting incorrect functioning Used on the instrument panel to indicate the red warning light showing incorrect machine functioning Symbo
4. Refit the cap of the detergent tank 8 Check there is clean water in the solution tank 9 Check the water tap 3 is fully turned on 10 Check that the by pass tap is in the dosing system position 11 Turn the water flow rate adjustment knob 4 to the maximum position 12 Turn the detergent percentage adjustment knob 5 to the maximum position 13 Insert the battery connector into the machine connector 14 Place the main switch in position ON I 15 Disengage the parking brake 16 Make sure that the work programme is set to Work position C 17 Press the accelerator pedal 6 gently to activate the brush head and the dosing system 18 Wait a few moments keeping the accelerator pedal gently depressed normally 20 to 40 seconds to allow engagement of the system 19 Proceed with the desired adjustment for normal cleaning 39 CHECKING THE COMBUSTION ENGINE WARNING Always check the motor before using it and read the relevant use and maintenance manual In this way you will avoid any accidents or damage to the motor 32 WORK 40 MACHINE PREPARATION If you have a battery version before starting to work you must 1 2 sure the recovery tank is empty otherwise empty it completely 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
5. 4 Check the parking brake is engaged If it is not engage it by means of the lever 4 Make sure the electrical system connector is disconnected from the battery connector 57 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 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 Turn the detergent percentage adjustment knob 4 to the maximum position 12 Insert the battery connector into the machine connector 13 Place the main switch in position ON I 14 Disengage the parking brake 15 Make sure that the work programme is set to Work position C 16 Press the accelerator pedal 5 gently to activate the brush head and the dosing system 17 Wait a few minutes keeping the dead man s levers pressed normally 2 to 4 minutes to allow the cleaning of the dosing system 18 Completely empty the solution tank and the detergent canister 19 Park the machine in a safe manner WARNING The machine will deliver solution during this operation 58 TROUBLESHOOTING 69 THE MACHINE DOES NOT START Check the batteries are charge
6. Washing position to lower the brush head 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 If it is not turn the key a quarter turn to the left 4 Check the parking brake is engaged If it is not engage it by means of the lever 1 48 WEEKLY MAINTENANCE 5 Turn the knobs 2 on the brush head unit to adjust the height of the side splash guards 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 To clean the basin proceed as follows 1 sure the brush head unit is in its working position if necessary turn the I DRIVE selector to the Washing position to lower the brush head 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 Make sure the main switch is in the 0 position If it is not turn the key a quarter turn to the le
7. 32 RECOVERY 33 ASSEMBLING THE SQUEEGEE 1 S4 ADJUSTING THE SQUEEGEE INCLINATION i Aea a aAA a ae 35 ADJUSTING THE SQUEEGEE HEIGHT RAN RAAN RAA 36 ASSEMBLING THE CYLINDRICAL BRUSHES 37 SIDE BRUSH 5 lt 38 DETERGENT PUMP PRIMING VERSIONS WITH 39 CHECKING aN NAANA NANNNA RRO TANANA 41 MOVEMENT OF THE SIDE BRUSH 42 OVERFLOW AT THE 5 savtvaeseseccdstaavtvsesenetccuanextenucas aaea eaa Aaaa raaa aa a Aeee aan aaaea ahaaa aaa aant 43 AT THE END OF WORK AAAA AA lt AAAA 40 AA CLEANING THE SUC TION AE A a A 40 5 40 46 CLEANING THE SOLUTION TANK FILTER a aan ARNAN NANNAN NRAN
8. Check the parking brake is released 4 Turn the key of the main switch a quarter of a turn clockwise to position 1 Immediately on the instrument panel the display will turn on indicating the charge level of the batteries With switch on three consecutive screens are displayed on the monitor The first screen shows on the top line what type of hour counter has been set in this case it is a total hour counter to display a different type for instance partial contact the qualified COMAC trained personnel The bottom line shows the service setting in this case there is no setting The second screen displays what battery technology has been set for machine operation in this case it is lead batteries to set another type of battery for instance gel contact the qualified COMAC trained personnel The third and last screen known as work displays the battery charge status and the total functioning time When the batteries supplied are fully charged the upper line contains 8 light indicators that represent a battery As the batteries gradually run down the indicators go out and with the batteries completely run down only the battery outline flashes The bottom line indicates the hours and minutes of functioning The flashing symbol indicates that the hour counter is counting the machine functioning time 33 WORK If you have a combustion engine version before
9. electrical devices and similar equipment Part 1 Emission Regulation for product family e EN 55014 2 Electromagnetic compatibility Regulations for household appliances electrical devices and similar equipment Part 2 Immunity Regulation for product family EN 62233 Household and similar electrical appliances Electromagnetic fields Methods for evaluation and measurement The person authorised to compile the technical file Giancarlo Ruffo Via Maestri del Lavoro 13 37059 Santa Maria di Zevio VR ITALY Santa Maria di Zevio VR 01 02 2012 COMAC S p A Legal representative f ffo COMAC spa Via Maestri del Lavoro 13 37059 Santa Maria di Zevio Verona ITALY Tel 39 045 8774222 Fax 39 045 8750303 E mail com comac it info comac it www comac it 64
10. sssssssssssssssssssssssssssssussstustssstesiustiusstsussinusssnustiusstsusssnussstssniusstsassssstoussinastannsnsasstes 21 18 INDICATOR FOR BATTERY CHARGE LEVEL AND HOUR METER BATTERY VERSION sssssssssssssssssssssssssssussssusssusssusstiussssusssnaststnsssinassannstausstust 19 FILLING THE FUEL TANK COMBUSTION ENGINE VERSION 20 CONNECTING THE LPG CYLINDER COMBUSTION ENGINE VERSION 21 HOUR METER VERSION WITH COMBUSTION ENGINE ssssssssssssssssssssssssssussssusssussossssssussitustsusstsusssnusestssssussssusstnuseitastiiassnsssusstausstoassonasesnstausstuat 22 TURNING LIGHTS ON OF F 23 SERVICE BRAKE PARKING BRAKE 24 WORKING FORWARD 25 MOVEMENT OF THE SIDE 26 INCREASING THE PRESSURE ON THE BRUSH HEAD 2T SOLUTION GAN cecal att ata each 28 FILLING THE DETERGENT SOLUTION TANK VERSION WITHOUT CDS 29 FILLING THE DETERGENT SOLUTION TANK VERSION WITH CDS 30 DETERGENT REGULATION VERSION WITHOUT CDS ssssssssssssssssssssussssussssssssssssusstusssiusssuseitastiusstsusstnasestastausstsussssasestassussttastsusstausstoassinasnsasstasst 31 DETERGENT REGULATION VERSION WITH CDS
11. 2 on the instrument panel will immediately illuminate the lights will remain on until you again operate the switch 23 SERVICE BRAKE PARKING BRAKE The machine has an electronic braking system To brake in normal conditions just remove your foot from the accelerator pedal If this service brake is working badly or if necessary activate the brake pedal 1 pushing it downwards If there is no oil in the braking system the red warning light 2 on the instrument panel will come on contact a technician to have the brake oil level checked 24 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 24 WORKING FORWARD SPEED 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 To set the machine in motion simply depress the accelerator pedal 2 the machine speed is controlled by varying the pressure on the pedal The machine has three pre set speed levels to select them simply operate the switch 3 on the instrument panel the forward speed during operation depends on the amount of dirt to be removed and the type of floor to be cleaned WARNING The reverse speed is lower than the forward speed to comply with current
12. Carefully clean the inside of the filter and the filter cartridge of 46 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 If it is not turn the key a quarter turn to the left 4 Check the parking brake is engaged If it is not engage it by means of the lever 1 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 WARNING These operations must be carried out using gloves to protect against contact with dangerous solutions 6 Remove the nuts 4 from the right hand carter 7 Remove the screw 5 from the right hand carter 8 Remove the nut 6 and washer from the rear brush tie rod 47 WEEKLY MAINTENANCE 9 Remove the right hand carter 7 from the brush head unit and place it on the ground 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 th
13. During the first metres check there is sufficient solution and that the squeegee dries perfectly The machine will now work normally until the detergent solution runs out the batteries run down for the battery version or the fuel runs out for the combustion engine version 35 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 WARNING The machine version with combustion engine is not fitted with an LPG fuel reserve warning light If the LPG runs out while you are working you can carry on with the aid of the gasoline fuel in the tank of the combustion engine To select the fuel type proceed as follows 1 Turn the main switch key 1 anticlockwise by a quarter of a turn to position 0 2 Turn the 2 way fuel selection switch 2 to GASOLINE 3 Turn the main switch key 1 clockwise by a quarter of a turn to position 1 Bring the motor ignition switch to the START position turning the key further to the right and keep it there until the motor starts up you can now release the key WARNING Only carry ou
14. Front cylindrical brush rotations rpm 960 960 Rear cylindrical brush rotations rpm 520 520 Cylindrical brush motor V W 36 2000 36 2000 Maximum pressure on the cylindrical brushes kg 55 55 Traction motor V W 36 2000 36 2000 Traction wheel diameter width mm 310 x 100 310 x 100 Maximum forward speed km h 8 8 Maximum gradient with full load 10 10 Vacuum motor No V W 2 36 670 2 36 670 Suction vacuum mbar 190 190 Rear elastic wheels diameter width 370 140 370 140 Solution tank 280 280 Recovery tank 285 285 Detergent tank CDS version only 15 Steering diameter mm 3420 3420 Machine length mm 2075 2075 Machine height mm 1569 1758 Machine width without squeegee mm 1192 1192 Battery compartment x L x h mm 880x600x450 Rated battery voltage 36 Battery weight max kg 510 Starter battery compartment w x L x h mm 229x132x165 Rated starter battery voltage V 12 Starter battery weight Max kg 6 LPG cylinder dimensions w x L x h mm 300x300x600 LPG cylinder weight tare LPG kg 23 Machine weight empty and without batteries kg 830 Machine weight empty and without LPG cylinder kg 933 Gross weight in running order machine batteries water operator kg 1200 Gross machine weight when ready for use machine gasoline LPG k 1330 cylinder water operator 9 Sound pressure level ISO 11201 dB A Hand vibration level ISO 5349 1 m s2 Body vibration level m s
15. Incorrect connection of the connector may cause machine malfunctions gt 7 Connect the rewired cable to the external battery charger 8 After the charging cycle is complete the battery connector 2 must be reconnected to the electrical system connector 1 WARNING Carefully read the use and maintenance instructions of the battery charger that is used for charging WARNING Keep the seat mounting plate raised for the whole duration of the battery recharging cycle to allow gas fumes to escape WARNING Danger of gas exhalation and leakage of corrosive liquids e gt A WARNING Danger of fire do not go near with free flames 18 INDICATOR FOR BATTERY CHARGE LEVEL AND HOUR METER BATTERY VERSION On the instrument panel of the machine there is a monitor 1 indicating amongst other things the battery charge status If the upper line contains 8 light indicators the battery charge level is 100 If the edges of the indicators are flashing this means the batteries are run down WARNING A few seconds after the last indicator on the monitor has flashed the brush motor will automatically switch off With the remaining charge it is possible to complete the drying process before recharging gt 19 FILLING THE FUEL TANK COMBUSTION ENGINE VERSION The machine is supplied without any fuel in the tank of the combustion engine To fill the tank proceed as follows 1 Engage the parking brake 1 2 Check the main machine sw
16. Safety Part 1 Generic standards e EN 60335 2 72 Household and similar electrical appliances Part 2 Generic standards for automatic machines for floor treatment for commercial and industrial use e EN 60335 2 29 Household and similar electrical appliances Part 2 Special standards for battery chargers e EN 12100 1 Machine safety Fundamental concepts fundamental principles of design Part 1 Basic terminology and methodology e EN 12100 2 Machine safety Fundamental concepts fundamental principles of design Part 2 Technical principles EN 61000 6 2 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments e EN 61000 6 3 Electromagnetic compatibility EMC Part 6 3 Generic standards Standard emission for residential commercial and light industrial environments e EN 61000 3 2 Electromagnetic compatibility EMC Part 3 2 Limits Limits for harmonic current emissions Equipment with input current lt 16 A phase e EN 61000 3 3 Electromagnetic compatibility EMC Part 3 3 Limits Restriction of voltage variations and flicker in low voltage power supply systems for devices with a rated current lt 16 A e EN 55014 1 Electromagnetic compatibility Regulations for household appliances electrical devices and similar equipment Part 1 Emission Regulation for product family e EN 55014 2 Electromagnetic compatibility Regulations for household appliances e
17. are positioned as shown in this Use and Maintenance Manual e remove the guards that can only be removed with the aid of tools except for maintenance work see the relevant paragraphs Do not wash the machine with direct water jets or with pressurised water nor with corrosive substances e prevent scaling in the solution tank filter do not fill the tank with detergent solution many hours before using the machine use acid or basic solutions that could damage the machine and or harm people e Have the machine checked by an authorised technical assistance centre every year e When disposing of consumable materials observe the laws and regulations in force e When your machine has reached the end of its long working life dispose of the materials it contains especially oils batteries and electronic components in an appropriate manner taking into account that the machine itself was constructed using 100 recyclable materials e batteries must be removed from the machine before its disposal The batteries must be disposed of in a safe manner fully observing the laws and regulations in force 13 1 MACHINE PREPARATION 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
18. e machine does not cause harmful vibrations Do not use the machine an explosive atmosphere Do not vacuum inflammable liquids Do not use the device to collect dangerous powders e Do not mix different types of detergent as this may produce harmful gases e The machine is not suitable for cleaning carpets e Do not place any liquid containers on the machine e Avoid working with the brushes when the machine is standing still so as not to damage the floor e Inthe event of a fire use a powder extinguisher Do not use water Do not knock against shelving or scaffolding where there is a danger of falling objects The operator must always be equipped with the appropriate safety devices gloves shoes helmet goggles etc e The machine is designed to carry out the washing and drying operations simultaneously Different operations should only be carried out in areas where the passage of unauthorised persons is prohibited Signal the presence of damp floors with suitable signs e f the machine does not work properly check this is not caused by failure to carry out routine maintenance Otherwise ask for intervention of the authorised technical assistance centre e If you need to replace any components request the ORIGINAL spare parts from an Authorised dealer and or Retailer e Restore all electrical connections after any maintenance interventions e Before using the machine check that all the hatches and covers
19. 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 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 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 2 Make sure the main switch is in the 0 position If it is not turn the key a quarter turn to the left 3 Check the parking brake is engaged If it is not engage it by means of the lever 1 4 Ensure the solution tank is empty otherwise empty it a Close the water tap 2 Disconnect the solution tank drain hose 3 located at the rear of the machine Unscrew the solution tank drain hose cap 8 Unscrew the solution tank filling plug 4 located behind the operator s seat 9 Rinse the inside of the tank with a jet of water 10 Refit all the parts WARNING These operations must be carried out using gloves to protect against contact with dangerous solutions 54 CLEANING THE DETERGENT TANK VERSIONS WITH CDS Proceed as follows for cleaning 1 Check the electric system connector is disconnected from the battery connector for battery versions or from the gene
20. it 2 Turn the main switch key anticlockwise to the 0 position 3 Engage the parking brake 4 Remove the filler cap 1 and check that the solution filter is fitted correctly 5 Fill it with clean water at a temperature not exceeding 50 C It is possible to fill the tank without having to constantly watch the water level using the optional rapid filling system 2 this system is fitted with a float to control overflow The water pipe previously modified is inserted into the quick release coupling remember to unscrew the cap 1 to allow proper air venting The solution tank has a maximum capacity of about 280 litres Add the liquid detergent to the tank in the concentration and manner indicated on the detergent manufacturer s label The formation of excess foam could damage the suction motors so only use the minimum amount of detergent needed WARNING Always use detergents suitable for scrubbing machines as indicated on their label Do not use acid or alkaline products or solvents without this indication In addition you are advised to always use low foam detergents Do not use pure acids or detergents with a stronger gradation than that indicated on the label supplied WARNING Protective gloves should always be worn when handling detergents or acid alkaline solutions to avoid serious injury to hands WARNING Always use low foam detergent To avoid the production of foam before starting to clean put a minimum quantity of anti
21. legal requirements HP gt OB Disposal symbol Carefully read the sections marked with this symbol for the disposal of the machine CONTENTS ON CONSIGNMENT OF THE a aara ranno eenaa aana aei aaa a aaa aaae aaaea aa aaa aa aade aa aaaea Va daora iaaa 5 SERIAL NUMBER PLATE wene ketenes eaa Sanaa a aaa wad aaae aa aaraa aaa a aa Aaea Ea NEENAKE aTa dab ANE aaa 5 INTRODUCTORY COMMENT saeara e era ae a txts aa aa araa a r aaraa rA Eea aea aa Aa AAA o ai aaraa a aaaea 5 INTENDED 6 2 5 COMBUSTION ENGINE TECHNICAL DATA HONDA IGX 440 22 042 44 1 1 5 2 2 2 2 anaie SYMBOLS USED ON THE MACHINE aar aE aaar T e E a aa aae a e aea aeaaea aa AE eaer aaae aaa alaran aa aaaea a envuecdecenststeutsesaceeesstesresveeadets GENERAL SAFETY REGULATIONS v i iiaiiiiina Tiiainen uii MACHINE 1 HANDLING TH
22. machine lights on off 3 Knob to control direction of machine movement forward reverse 14 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 7 Display service confirmation button 8 Battery level hour counter display 9 Working program adjustment switch I Drive device 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 10 Red warning light indicating that the motor brush head is working under pressure force 11 Red warning light indicating that there is a malfunction in the machine traction 12 Red warning light indicating low brake oil level down to reserve 13 Red warning light indicating that the parking brake is on 14 Red warning light indicating that the level of detergent solution version without CDS or the water level version with CDS is low down to reserve 15 Red warning light indicating that the level of dirty water in the recovery tank has reached a critical level for correct operation of the suction motors 15 MACHINE PREPARATION 16 Gr
23. of wear and tear of the brushes and if necessary replace them The brushes should be changed when the bristles are about 15mm long To replace them see REPLACING THE BRUSHES or DISASSEMBLING THE BRUSHES and ASSEMBLING THE BRUSHES Working with over worn brushes may cause damage to the floor 2 Use a different kind of brush to the one fitted as standard For cleaning floors where the dirt is particularly resistant we recommend the use of special brushes supplied upon request and according to needs see CHOOSING AND USING THE BRUSHES 74 EXCESSIVE FOAM PRODUCTION Verify that a low foam detergent has been used If necessary add a small quantity of anti foam liquid to the recovery tank Remember that when the floor is not very dirty more foam is generated In this case the detergent solution should be more diluted 75 THE SUCTION MOTOR DOES NOT FUNCTION 1 Check whether the recovery tank is full and if necessary empty it 2 Check the float switch on the suction cap is working well see also CLEANING THE RECOVERY TANK under DAILY MAINTENANCE 59 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 Check that the base is lowered during start up 2 The operator must be properly seated the driving position 3 Check no thermal protection device has intervened 4 Check the corr
24. the main switch to the 0 position by turning the key a quarter turn to the left 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 2 3 4 Check the parking brake is engaged If it is not engage it by means of the lever 1 54 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 Take the rubber 4 out and turn or replace it 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 65 REPLACING THE SPLASH GUARD RUBBER OF THE SIDE BRUSH If the splash guard rubber of the side brush is worn and does not dry well it is possible to change the drying edge twice To do this proceed as follows 1 Make sure the brush head unit is in its working position if necessary turn the I DRIVE selector to the Washing position to lower the brush head 2 Place the side brush in its Working position by means of the relevant lever on the instrument panel 3 Set the main switch to the 0 position by turning the key a quarter turn to the left 4 Check the electric system connector is disconnected from the battery connector for batte
25. there is a fault in the machine traction system Contact a specialised technician as soon as possible If the warning light 19 on the instrument panel comes on while you are working this means the brake oil level is low down to reserve Top up the level as soon as possible 41 MOVEMENT OF THE SIDE BRUSH This machine is able to increase the working width by exploiting the right hand side brush just move the lever 1 on the instrument panel to the right In this way the brush is lowered and begins working To bring the brush back to its safety standard position move the lever 1 to the left 42 OVERFLOW DEVICE The machine is equipped with an electromechanical device which indicates that the level reached in the recovery tank is dangerous for proper functioning of the suction motors when it is activated the suction motors are switched off and the green warning light on the button 1 goes out In this case raise the squeegee unit and take the machine to the area used for emptying the recovery tank Then empty the recovery tank using the special drain hose 37 AT THE END OF THE WORK 43 AT THE END OF WORK 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 10 11 12 machine versions with the
26. total weight of the machine with packaging is 1030kg Ultra100 GS sirueL without cylinder The dimensions of the packaging is as follows N gt 3 ULTRA100 A 1800 mm 1340 mm 2150 mm Remove the outer packaging The machine is fixed to the pallet with wedges which block the wheels Remove the wedges Use a chute to get the machine down from the pallet pushing it backwards Do not assemble the rear squeegee before unloading the machine and avoid violently jolting the brush base To assemble the squeegee read the ASSEMBLING THE SQUEEGEE paragraph Keep the pallet for any future transport needs WARNING If the product is delivered in cardboard containers handle the packed product with suitable lifting means that comply with the legal requirements AN WARNING During this operation check there are no people or objects near the machine HOW MOVE THE MACHINE Make sure the solution tank and the recovery tank are empty Make sure that the detergent can is empty CDS version Check that the brush head and squeegee are in the raised position Place it on a pallet using a chute Check that the key switch is in the 0 position and remove the key Engage the parking brake Secure the machine to the pallet using wooden wedges INSTRUMENT PANEL COMPONENTS The instrument panel components are identified as follows 1 Horn button 2 Toggle switch for turning the
27. 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 W TOL Label with instructions for the use of standard or concentrated detergents CDS system only Label with warnings on the type of detergent to use CDS system only 11 SYMBOLS USED ON THE MACHINE min 4 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 CHEMICAL 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 e Read the labels on the machine carefully Do not cover them for any reason and replace them immediately if they become damaged e The machine must be used exclusively by authorised and trained personnel e 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 e machine is not suitable for cleaning rough or uneven floors Do
28. 41 47 CLEANING THE DEBRIS HOPPER AND HOPPER SUCTION FILTER sssssssssssssssssssssssssusssssssussssusssnussosaussttassossniussinassenastiastoussnnassinastsnaasstinnsnaasstaat 41 48 DAILY MAINTENANCE COMBUSTION ENGINE ainaani aiana A aiani 42 49 0 a aan iA 43 AIR FILTER NANE AAN 43 WEEKLY MAINTENANCE CEEANING THE SUGTIONIHOSE 92 CLEANING THE RECOVERY TANK 53 CLEANING THE SOLUTION 54 CLEANING THE DETERGENT TANK VERSIONS WITH CDS 55 CLEANING THE SOLUTION TANK 56 CLEANING THE CYLINDRICAL BRUSHES ssssssssssssssssssussssusssussstussiussssusssssusstusstnassinastisstiusssnusesnastouastiussssmeausstsassinaseasssniassnnasstnastonastaansnnassenuastaas SA 55 atten AAN NAANA RAA AARNA NANANA NANANA NANA 58 ADJUSTING THE HEIGHT OF THE SIDE SPLASH GUARDB 59 CLEANING THE DETERGENT SOLUTION DISTRIBUTION EXTRAORDINARY MAINTENANCE
29. CDS system 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 Take the machine to the place provided for draining off the dirty water Turn the machine off by turning the key a quarter turn anticlockwise to the 0 position and remove it from the instrument panel Engage the parking brake Raise the seat mounting plate and disconnect the electric system connector from the battery connector for battery versions or from the generator connector for versions with a combustion engine WARNING Before carrying out any type of maintenance remove the keys from the panel and disconnect the battery connector for battery versions or from the generator connector for versions with a combustion engine Disconnect the recovery tank drainage tube 4 from its housing unscrew the drainage cap and empty the recovery tank Disconnect the solution tank drainage tube 5 from its housing unscrew the drainage cap and empty the solution tank Press the release lever 6 to allow rotation of the squeegee support Turn the squeegee unit clockwise Clean the squeegee unit and the rubbers thoroughly with a jet of water After cleaning the squeegee and rubbers replace the squeegee by turning it anticlockwise returning it to its original position making sure that the lever 6 is returned to its normal position WARNING This operation must be carried out by usi
30. E PACKAGED MACHINE 2 HOW TO MOVE THE S 4A STEERING COLUMN COMPONE NT Sa lcs ERO E E EA 5 FOOTBOARD 6 SEAT MOUNTING PLATE COMPONENTS 7 MACHINE S SIDE e MACHINE S REAR COMPONEN S a A AA S 5 2 AAAA ARRANA ANAAO 10 TYPE OF BATTERY TE TYPE OF STARTER BATTERY A ANRA ARNAN OANE ceases 12 BATTERY MAINTENANCE AND DISPO SAD E ANR N E 19 13 MAINTENANCE AND DISPOSAL OF THE COMBUSTION ENGINE 20 M MAINTENANCE AND DISPOSAL OF THE LPG 20 15 HANDLING AND INSERTING THE BATTERIES BATTERY VERSION sssssssssssssssssssssssssssussssusssussssstssussssssiusstsusssiassiustiusstiussinassenastesiimessesussnaasst 20 16 CONNECTING THE BATTERIES AND BATTERY CONNECTOR BATTERY VERSION sssssssssssssssssssssssssstusssussssussssussstusssusstausstsusessausssnusesnastaussnsasst 21 CONNECTING THE BATTERY CHARGER BATTERY VERSION
31. 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 ABRASIVE BRUSH The bristles of this type of brush are charged with highly aggressive abrasives It is used to clean very dirty floors To avoid floor damage work only with the pressure strictly necessary THICKNESS OF THE BRISTLES Thicker bristles are more rigid and are therefore used on smooth floors or floors with small joints On uneven floors or those with deep joints it is advisable to use softer bristles which can enter the gaps more easily Remember that when the bristles are worn and therefore too short they will become rigid and are no longer able to penetrate and clean deep down In this case like with over large bristles the brush tends to jump PAD HOLDER The pad holder is recommended for cleaning shiny surfaces There are two types of pad holder 1 _ the traditional pad holder is fitted with a series of anchor points that allow the abrasive floor pad to be held and dragged while working 2 CENTRE LOCK type pad holder not only has anchor points but also snap type central locking system in plastic that allows the abrasive floor pad to be perfectly centred and held without any risk of it becoming detached This type of holder is especially suitable for machines with several brushes where the centring of the
32. ONT SQUEEGEE RUBBER Suction will be poor and the machine will not dry perfectly if the front squeegee rubber is worn Proceed as follows to replace 1 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 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 Make sure the main switch is in the 0 position If it is not turn the key a quarter turn to the left 4 Check the parking brake is engaged If it is not engage it by means of the lever 1 5 Disconnect the squeegee by loosening the knobs 2 6 Loosen the rubber pressing blade securing screws 3 7 Remove the rubber pressing blade 4 then the rubber for replacement 8 To replace the rubber proceed in reverse order WARNING These operations must be carried out using gloves to protect against contact with dangerous solutions 53 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 sure the brush head unit is in its working position if neces
33. USE AND MAINTENANCE MANUAL ULTRA100 BS ULTRA100 GS BI FUEL ED 02 2012 EN ORIGINAL INSTRUCTIONS Doc 10033331 al Ver AA The descriptions contained 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 Open book symbol with an i Indicates the need to consult the instruction manual Open book symbol Used to tell the operator to read the manual before using the machine Warning symbol Carefully read the sections marked with this symbol and observe the indications for the safety of the operator and the machine Warning symbol Indicates danger of gas exhalation and leakage of corrosive liquids Warning symbol Indicates operator should take safety measures to avoid damage to limbs Warning symbol Indicates the danger of fire Do not go near with free flames Warning symbol Indicates that the packed product should be handled with suitable lifting means that comply with the
34. ace it proceed as follows 1 Check the side brush is in its idle position if necessary turn the I DRIVE selector to the Transfer position and push the relevant lever on the instrument panel 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 Make sure the main switch is in the 0 position If it is not turn the key a quarter turn to the left 4 Check the parking brake is engaged If it is not engage it by means of the lever 1 WARNING During this operation verify that there are no people or objects near the brush 52 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 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 62 REPLACING THE FR
35. al combustion engine with LPG Used on the front right hand panel to indicate the switch for selecting the type of fuel to be injected into the combustion engine carburettor 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 suction motor thermal circuit breakers Label indicating the position of the quick release coupling for filling the solution tank MAX 50 C ay Label indicating the maximum temperature of the water used to fill the solution tank Label indicating the position of the solution tank drain pipe 10 SYMBOLS USED ON THE MACHINE Label indicating the position of the recovery tank drain pipe X 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
36. aximum error of 5 compared with the nominal value selected WARNING The dosing system is suitable for frequent maintenance cleaning Acid or alkaline maintenance detergent tank be used with pH values between 4 and 10 and that do not contain oxidising agents chlorine or bromine formaldehyde mineral solvents The detergents used must be suitable for use with scrubbing machines Wash the circuit with water after use if the system is not used daily The system is can be excluded In case of sporadic use of detergents with pH between 1 3 or 11 14 use the scrubbing machine in the traditional way by adding the detergent in the clean water tank and excluding the dosing circuit WARNING Always use detergents suitable for scrubbing machines as indicated on their label Do not use acid or alkaline products or solvents without this indication In addition you are advised to always use low foam detergents Do not use pure acids or detergents with a stronger gradation than that indicated on the label supplied WARNING Protective gloves should always be worn before handling detergents or acidic or alkaline solutions to avoid serious injury to hands 30 DETERGENT REGULATION VERSION WITHOUT CDS Detergente standard Standard detergent Detergente concentrato 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 Driv
37. bustion engine 45 CLEANING THE SQUEEGEE Careful cleaning of the whole suction group ensures better drying and cleaning of the floor as well as greater duration of the suction motor Proceed as follows for cleaning 1 Check the electric system connector is disconnected from the battery connector for battery versions or from the generator connector for the combustion engine version Make sure the main switch is in the 0 position Ensure the parking brake is engaged Undo the mounting clamp and remove the suction hose from the squeegee sleeve Disconnect the squeegee by loosening the knobs 1 6 Clean the squeegee unit and the rubbers thoroughly with a jet of water verify that there are dirt residues in the vacuum chamber of the squeegee WARNING This operation must be carried out by using gloves in order to protect against contact with dangerous solutions If the front squeegee rubber is worn suction will be poor and the machine will not dry the floor properly in this case replace it see section REPLACEMENT OF FRONT SQUEEGEE RUBBER If the rear squeegee rubber is worn suction will be poor and the machine will not dry the floor properly in this case replace it see section REPLACEMENT OF REAR SQUEEGEE RUBBER 40 DAILY MAINTENANCE After cleaning replace the squeegee on its support 1 2 Insert the squeegee right hand pin 1 into the right hand slot of the sque
38. ch is in the 0 position If it is not turn the key a quarter turn to the left Check the parking brake is engaged If it is not engage it by means of the lever 1 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 6 Remove the nuts 4 from the right hand carter 7 Remove the screw 5 from the right hand carter 8 Remove the nut 6 and washer from the rear brush tie rod 51 EXTRAORDINARY MAINTENANCE 9 Remove the right hand carter 7 from the brush head unit and place it on the ground 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 Take the front 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 Make sure the brushes are correctly connected 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 61 REPLACING THE SIDE BRUSH If the side brush is worn it will no longer clean the floor efficiently To repl
39. d 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 Check the key switch is 7 Check there is fuel in the engine tank and that the LPG cylinder is full combustion engine version 70 THE COMBUSTION ENGINE DOES START WARNING If the combustion engine does not start up check the diagnostics in the motor use and maintenance manual the booklet supplied with the machine itself 71 INSUFFICIENT WATER ON THE BRUSHES 1 Check there is water in the solution tank 2 Check that the water detergent solution release adjustment lever 1 is open 3 Check that the water detergent selectors 2 3 are open for CDS versions only 4 Clean the solution filter located at the front of the machine 5 Make sure the detergent solution distribution tank on the brush head unit is not clogged 72 THE SQUEEGEE DOES NOT DRY PERFECTLY 1 Check the squeegee is clean 2 Check the squeegee settings see MACHINE PREPARATION 3 Clean the entire vacuum unit see WEEKLY MAINTENANCE 4 Replace the rubbers if worn 73 THE MACHINE DOES NOT CLEAN WELL 1 Check the state
40. dents or damage to the motor 42 DAILY MAINTENANCE 49 CHECKING THE MOTOR OIL LEVEL 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 Lift the handle 3 to access the motor compartment A A WARNING To correctly evaluate the oil level you must scrupulously follow the steps indicated in the user and maintenance manual of the engine itself WARNING If the oil level is below the upper limit notch on the dip stick top up with recommended oil as far as the upper limit notch To do this use the tube 4 Do not over fill WARNING Check the oil level when the motor is switched off and with the machine on an even surface WARNING Refer to the motor use and maintenance manual supplied with the machine to check the most suitable type of oil 50 CHECKING THE AIR FILTER A dirty air filter will limit the flow of air towards the carburettor thereby reducing engine performance so you are advised to check it at least once a day in the following way 1 Check the parking brake is engaged if it is not engage it by means o
41. drain pipe cap 2 at the rear of the machine is correctly closed 28 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 First insert the right hand pin of the squeegee 3 into the right hand slot of the squeegee support and screw the stud 4 on to the pin making sure they fit tightly into their seats on the squeegee support 5 6 Insert the left hand pin of the squeegee into the left hand slot of the squeegee support and screw the stud on to the pin making sure they fit tightly into their seats on the squeegee support 7 Insert the suction hose into the squeegee coupling and secure it with the clamp also verify correct insertion of the suction hoses from the brush head cover WARNING These operations must be carried out using protective gloves to avoid any possible contact with the edges or tips of metal objects 34 ADJUSTING THE SQUEEGEE INCLINATION During working operation the rear rubber is slightly tilted backwards by about 5mm in a u
42. e battery connector cable to the machine connector WARNING You are advised to have the electric connections made by a qualified COMAC trained technician WARNING You are advised to always wear protective gloves to avoid the risk of serious injury to your hands 17 CONNECTING THE BATTERY CHARGER BATTERY VERSION In order not to cause permanent damage to the batteries it is essential to avoid their complete discharge arrange the recharge within a few minutes of the switching on of the flashing discharged batteries signal WARNING Never leave the batteries completely discharged even if the machine is not being used Check the battery charger is suitable for the batteries installed in terms of both capacity and type To connect the battery charger you must Move the machine near to the battery charger Make sure that the key switch in the 0 position Engage the parking brake Grip the handle at the side of the seat to raise the seat mounting plate Disconnect the electrical system connector 1 from the battery connector 2 Connecting the battery charger cable connector gt 21 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
43. e device press the accelerator pedal to operate the brushes the machine starts to move and the detergent solution starts to come out In the first few metres check that the quantity of solution is sufficient to wet the floor but not so much that it goes beyond the splash guard The amount of detergent released can be adjusted by turning the lever 1 turn it clockwise to reduce the flow and anticlockwise to increase it If turned fully to the right the flow of detergent is stopped Bear in mind that the correct amount of solution is always depends on the nature of the floor the degree of dirt and the forward speed 27 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 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 The quantity of solution varies from a minimum of 55 litres hour to a maximum of 230 litres hour with 7 set measurement points The right solution flow should be proportional to the degree of dirt on the floor In addition remember that the time available for continuous working depends on the quanti
44. e of maintenance remove the keys from the panel and disconnect the battery connector for battery versions or from the generator connector for versions with a combustion engine WARNING This operation must be carried out using gloves to protect against contact with dangerous solutions 8 Disconnect the suction hose from the squeegee nozzle 4 9 Disconnect the suction hose from the holder 5 at the rear of the recovery tank 10 Clean the hose with a jet of fresh water entering from the end where it is inserted into the holder at the rear of the recovery tank 11 Refit all the parts 52 CLEANING THE RECOVERY TANK Proceed as follows for cleaning 1 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 2 Make sure the main switch is in the 0 position If it is not turn the key a quarter turn to the left 3 Check the parking brake is engaged is not engage it by means of the lever 1 4 Check the recovery tank is empty if necessary empty it 5 Check the recovery tank drainage tube 2 is firmly attached to the machine and that the cap is closed 6 Unscrew the recovery tank drain hose cap 3 at the rear of the machine 44 WEEKLY MAINTENANCE 7 Release the recovery tank stop hinges 4 located at the side of the tank 8 Rotate the recovery tank as
45. e tunnel and rest it on the ground Clean it with a jet of water 12 Refit all the parts 57 CLEANING THE SIDE BRUSH Proceed as follows for cleaning 1 Check the side brush is in its idle position if necessary turn the I DRIVE selector to the Transfer position and push the lever 1 on the instrument panel 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 If it is not turn the key a quarter turn to the left 4 Check the parking brake is engaged If it is not engage it by means of the lever 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 Clean it under a jet of running water 7 Refit all the parts WARNING You advised always wear protective gloves to avoid the risk of serious injury to your hands 58 ADJUSTING THE HEIGHT OF THE SIDE SPLASH GUARDS If the side splash guard rubbers in the brush head unit are not well adjusted they will not channel the solution to the middle of the squeegee To make the correct adjustment proceed as follows 1 Make sure the brush head unit is in its working position if necessary turn the I DRIVE selector to the
46. ect connection of the motor to the terminal under the footboards 77 ELECTRIC FUSES AND THERMAL CUT OUTS The machine is fitted with the following electrical protection systems Power fuses arranged in the electrical box to protect against short circuiting thermal circuit breakers arranged on the outside of the handlebars to protect the following motors 1 25A circuit breaker 1 for left hand side suction motor 2 25A circuit breaker 2 for right hand side suction motor 3 20A circuit breaker 3 for the side brush motor In the event of malfunctioning check a thermal cut out has not intervened If the motor overheats its thermal cut out intervenes to block the electricity supply Wait a few minutes until it has cooled down then press the specific circuit breaker button to reactivate the power supply and motor operation If the problem persists contact the technical assistance centre 78 THE AUTOMATIC WATER DETERGENT DOSING SYSTEM DOES NOT WORK The automatic water detergent dosing system has been designed with criteria of extreme sturdiness and reliability but there is a special by pass system that allows you to use the machine even if the system is out of use To by pass the automatic water detergent dosing system you must rotate the tap lever 1 on the rear centre of the base downwards in this way you can go on working even with the system out of use Remember however to put not only water in the solution tank but the right qua
47. ective MODEL LwA dB A LwA guaranteed dB A They also comply with the following standards e EN 60335 1 Household and similar electrical appliances Safety Part 1 Generic standards e EN 60335 2 72 Household and similar electrical appliances Part 2 Generic standards for automatic machines for floor treatment for commercial and industrial use e EN 60335 2 29 Household and similar electrical appliances Part 2 Special standards for battery chargers e EN 12100 1 Machine safety Fundamental concepts fundamental principles of design Part 1 Basic terminology and methodology e EN 12100 2 Machine safety Fundamental concepts fundamental principles of design Part 2 Technical principles EN 61000 6 2 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments e EN 61000 6 3 Electromagnetic compatibility EMC Part 6 3 Generic standards Standard emission for residential commercial and light industrial environments e EN 61000 3 2 Electromagnetic compatibility EMC Part 3 2 Limits Limits for harmonic current emissions Equipment with input current lt 16 A phase e EN 61000 3 3 Electromagnetic compatibility EMC Part 3 3 Limits Restriction of voltage variations and flicker in low voltage power supply systems for devices with a rated current lt 16 A e EN 55014 1 Electromagnetic compatibility Regulations for household appliances
48. een 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 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 Green warning light indicating that the squeegee unit has reached its operating position 22 Green warning light indicating that the left hand suction motor is in operation 23 Green warning light indicating that the right hand suction motor is in operation 4 STEERING COLUMN COMPONENTS The components of the steering column left side are as follows 24 Solution water control lever 25 Detergent adjustment knob CDS version 26 Water adjustment knob CDS version 27 Safety thermal circuit breakers on the suction motors and on the side brush motor 16 MACHINE PREPARATION The components of the steering column right side are as follows 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 31 Main key switch on versions with combust
49. egee support 2 secure it by means of the handwheel 3 Insert the squeegee left hand pin into the left hand slot of the squeegee support secure it by means of the handwheel Finally insert the squeegee hose in its sleeve and secure it using the clamp WARNING These operations must be carried out using gloves to protect against contact with dangerous solutions 46 CLEANING THE SOLUTION TANK FILTER Careful cleaning of the detergent water solution filter ensures a better working capacity Proceed as follows for cleaning 1 2 3 4 a Check the electric system connector is disconnected from the battery connector for battery versions or from the generator connector for the combustion engine version Ensure the main switch key is set to 0 Ensure the parking brake is engaged Open the filler cap 1 Disconnect the clean water drain hose 2 from its housing at the rear of the machine unscrew the cap and empty the tank Close the water tap 3 Unscrew the filter 4 at the front of the machine Remove the internal filter cartridge and rinse everything thoroughly with running water Reassemble all the elements WARNING Before carrying out any type of maintenance remove the keys from the panel and disconnect the battery connector for battery versions or from the generator connector for versions with a combustion engine WARNING These operations must be carried out using gloves to protect against con
50. f 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 Lift the handle 3 to access the motor compartment WARNING To correctly evaluate the degree of cleanliness of the air filter you must scrupulously follow the steps indicated in the user and maintenance manual of the engine itself 43 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 Both the base and the squeegee rise and after a few seconds the suction motor will turn off 4 Turn the key switch to the 0 position and remove the key from the instrument panel 5 Engage the parking brake by means of its lever 1 6 Disconnect the electric system connector from the battery connector for battery versions or from the generator connector for versions with a combustion engine 7 Release the clamp 2 and pull on the handle 3 to remove the debris hopper Place it on the ground WARNING Before carrying out any typ
51. foam liquid into the recovery tank Do not use pure acids 29 FILLING THE DETERGENT SOLUTION TANK VERSION WITH CDS Proceed as follows to fill the solution tank 1 Turn the main switch key anticlockwise to the 0 position 2 Engage the parking brake 3 Remove the filler cap 1 and check that the solution filter is fitted correctly 4 Fill it with clean water at a temperature not exceeding 50 C It is possible to fill the tank without having to constantly watch the water level using the optional rapid filling system 2 this system is fitted with a float to control overflow The water pipe previously modified is inserted into the quick release coupling remember to unscrew the cap 1 to allow proper air venting 26 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 To regulate the water detergent mixture carefully read the REGULATING THE DETERGENT WITH THE MACHINE PREPARATION CDS SYSTEM paragraph A WARNING The DS automatic dosing system is designed to work with any liquid detergent For this reason the percentage of detergent in the solution is subject to a m
52. ft 4 Check the parking brake is engaged If it is not engage it by means of the lever 1 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 WARNING These operations must be carried out using gloves to protect against contact with dangerous solutions 49 WEEKLY MAINTENANCE 6 Remove the screw 4 from the right hand carter 7 Remove the tube 5 connected to the distribution basin cover 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 Refit all the parts 50 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 2 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 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 Make sure the main swit
53. grinding wheels is difficult TABLE FOR CHOOSING THE BRUSHES 405618 PPL 1 Rear brush black 405619 NYLON 1 2 Rear brush black 405620 ABRASIVE 1 0 5 Rear brush 405621 UNIONMIX Rear brush 405622 ABRASIVE 1 5 Rear brush 5 405624 PPL 0 5 Front brush white 405625 NYLON 04 Front brush white 422189 PPL Side brush light blue 422971 PPL 0 6 340 Side brush white 422972 PPL Side brush black 422981 ABRASIVE Side brush 62 EC DECLARATION 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 e 2000 14 EC Directive by the European Parliament and Council date 8th May 2000 Noise emission by machines and equipment for outdoor use Falling into the category of road sweeper as defined in Annex 46 of Directive 2000 14 EC of the European Parliament and the Council is subject to noise marking only Conformity assessment was carried out as set out in Annex III B 46 of the said directive MODEL LwA dB A LwA guaranteed dB A They also comply with the following standards e EN 60335 1 Household and similar electrical appliances
54. health and safety standards 25 MOVEMENT OF THE SIDE BRUSH This machine is able to increase the working width by exploiting the right hand side brush just move the joystick 1 on the instrument panel to the right To move it back into its original place move the joystick 1 to the left 26 INCREASING THE PRESSURE ON THE BRUSH HEAD UNIT This machine can increase the pressure on the brushes via the joystick 1 located on the instrument panel it has three different settings Step01 the weight exerted on the floor is 10kg Step02 the weight exerted on the floor is 45kg Step03 the weight exerted on the floor is 55kg WARNING The pressure must be chosen according to the type of floor and the amount of dirt Increasing the pressure results in greater wear and tear on the brushes and higher power consumption for further information read CHOOSING AND USING THE BRUSHES 25 MACHINE PREPARATION 27 SOLUTION TANK 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 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
55. ing 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 suction motor is in operation Symbol denoting right hand suction motor Used on the instrument panel to indicate the green warning light showing that the left hand suction motor is in operation Symbol of main switch ON only on versions with internal combustion engine Used on the front right hand panel to indicate the green warning light showing that the main key switch is ON Symbol for the combustion engine rpm potentiometer only on versions with internal combustion engine Used on the front right hand panel to indicate the knob for commanding the potentiometer and hence for adjusting the combustion engine rotations 4 60 p o a Starter button symbol only on versions with internal combustion engine with LPG Used on the front right hand panel to indicate the button that injects LPG in the combustion engine carburettor 9 Symbol for the main switch or key switch only on versions with internal combustion engine Used on the instrument panel to indicate the key switch for machine operation on I or off O Symbol for the switch used to select the type of fuel only on versions with intern
56. ion engine 32 2 way switch for selecting the type of fuel to be injected into the combustion engine carburettor on versions with combustion engine 5 FOOTBOARD COMPONENTS The components at the front right of the footboard are identified as follows 33 accelerator pedal 34 Brake pedal 6 SEAT MOUNTING PLATE COMPONENTS The seat mounting plate components are identified as follows 35 Handle for raising seat plate 36 Parking brake lever 7 MACHINE S SIDE COMPONENTS The components on the right hand side of the machine are identified as follows 37 Detergent filler cap CDS version 38 Detergent level warning light CDS version 17 MACHINE PREPARATION The components on the front side of the machine are identified as follows 39 Step to assist getting on to machine The components on the rear side of the machine are identified as follows 40 Suction cover release hinge X 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 43 Recovery tank drain pipe 44 Solution tank drain pipe 45 Flashing warning light 46 Water detergent solution filler cap 47 Rapid refill kit optional 18 MACHINE PREPARATION 48 Rear lights 9 MACHINE S FRONT COMPONENTS The front components
57. itch 2 is in the 0 position If this is not the case turn the key by a quarter rotation to the right 22 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 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 WARNING Top up the fuel in a well ventilated area with the motor switched off Do not smoke or take any unprotected flames or sparks near the motor while it is being filled or in the area where the gasoline is stored WARNING During the filling operation be careful not to spill the fuel Spilt fuel or fuel vapours could ignite If any fuel is accidentally spilt remove it thoroughly before switching on the motor gt gt gt 20 CONNECTING THE LPG CYLINDER COMBUSTION ENGINE VERSION The machine is supplied without an LPG cylinder To connect the cylinder to the machine proceed as follows 1 Engage the parking brake 1 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 right 3 Pos
58. ition the 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 4 Fix the cylinder to its support by means of the straps 4 To do this hook the spring 5 to the screw 6 on the support WARNING Use only cylinders measuring 300 600 max 0 x height in millimetres and weighing no more than 23kg 23 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 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 The flashing symbol indicates that the hour counter is counting the machine functioning time WARNING If the border of the light indicators is flashing this means the combustion engine has not reached its standard work speed As soon as it does reach this speed the eight indicators will appear on the display 22 TURNING LIGHTS ON OFF The machine is equipped with two headlights and a rear spotlight to help the operator to work in low light To switch on the headlights simply turn the switch 1 located on the instrument panel to the I position and the green indicator light
59. king brake In addition do not park the machine in open places or on sloping floors WARNING For machine versions with a combustion engine powered with LPG when parking the machine remember to close the cylinder tap 1 39 DAILY MAINTENANCE PERFORM ALL MAINTENANCE OPERATIONS IN SEQUENCE 44 CLEANING THE SUCTION MOTOR FILTER 1 Check the electric system connector is disconnected from the battery connector for battery versions or from the generator connector for the combustion engine version Ensure that the main switch is in the 0 position Ensure the parking brake is engaged Check the recovery tank is empty if necessary empty it Release the recovery tank stop hinges 1 and rotate as far as possible Release the suction hood stop hinges 2 and rotate as far as possible Remove the suction filter protection 3 by rotating it clockwise Remove the suction filter 4 from its seat Use a jet of water to clean the walls and base of the filter gt 10 Perform steps 7 to 9 for the second filter of the second suction motor too 11 Refit all the parts WARNING These operations must be carried out using gloves to protect against contact with dangerous solutions WARNING Before carrying out any type of maintenance remove the keys from the panel and disconnect the battery connector for battery versions or from the generator connector for versions with a com
60. l 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 light showing a low level of water detergent solution in the solution tank Symbol denoting full recovery tank Used on the instrument panel to indicate the red warning light showing that the dirty water level has reached a critical level Symbol indicating main switch is on It is used on the instrument panel to indicate the green warning light showing that the main key switch is in operation Symbol indicating lights are on Used on the instrument panel to indicate the green warning light showing that the front lights are on Symbol denoting solenoid valve open Used on the instrument panel to indicate the green light showing operation of the solenoid valve Symbol indicating brush motor in operation Used on the instrument panel to indicate the green warning light showing the brush motor is in operation D 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 indicat
61. lectrical devices and similar equipment Part 2 Immunity Regulation for product family EN 62233 Household and similar electrical appliances Electromagnetic fields Methods for evaluation and measurement The person authorised to compile the technical file Giancarlo Ruffo Via Maestri del Lavoro 13 37059 Santa Maria di Zevio VR ITALY Santa Maria di Zevio VR 01 02 2012 COMAC S p A Legal representative f ffo COMAC spa Via Maestri del Lavoro 13 37059 Santa Maria di Zevio Verona ITALY Tel 39 045 8774222 Fax 39 045 8750303 E mail com comac it info comac it www comac it 63 EC DECLARATION 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 e 2000 14 EC Directive by the European Parliament and Council date 8th May 2000 Noise emission by machines and equipment for outdoor use Falling into the category of road sweeper as defined in Annex 46 of Directive 2000 14 EC of the European Parliament and the Council is subject to noise marking only Conformity assessment was carried out as set out in Annex III B 46 of the said dir
62. main machine switch is in the 0 position 3 Use a suitable tool to remove the right hand carter 1 by unscrewing the nuts 2 WARNING You are advised to use airtight batteries only to avoid the leakage of acids WARNING You are advised to always wear protective gloves to avoid the risk of serious injury to your hands 4 Disconnect the quick release coupling 3 located behind the side cover to prevent damage to the coupling itself CDS version 20 MACHINE PREPARATION 5 Remove the detergent tank 4 by unscrewing the nuts 5 Remove the battery compartment cover 6 by unscrewing the nuts 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 Place the batteries in the battery compartment with the and poles opposite each other N WARNING You are advised to only lift and move the batteries with lifting and transportation means suitable for the specific weight and size 16 CONNECTING THE BATTERIES AND BATTERY CONNECTOR BATTERY VERSION 1 Connect the batteries in series to the and poles using the supplied jumper cable 2 Connect the battery connector cable to the and poles in order to obtain a voltage of 36V at the connection terminals 3 Connect th
63. ng gloves in order to protect against contact with dangerous solutions 38 16 17 18 19 20 21 22 AT THE END OF THE WORK 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 WARNING This operation must be carried out using gloves to protect against contact with dangerous solutions Insert the debris hopper in the machine and lock it in place by means of the clamp 7 Raise the seat mounting plate and connect the electric system connector to the battery connector for battery versions or to the generator connector for versions with a combustion engine Sit on the driver s seat Insert the key in the main switch block and switch on the machine Disengage the parking brake Park the machine in a closed place in an area where it cannot cause damage to people or other property but also be protected from an accidental fall of objects Engage the parking brake Turn the ignition key a quarter turn anticlockwise position 0 and remove the key Raise the seat mounting plate and disconnect the electric system connector from the battery connector for battery versions or from the generator connector for versions with a combustion engine WARNING Do not leave the machine unattended without first removing the start up switch key and applying the par
64. niform way for its whole length If you need to increase the bend of the rubber in the central part you must tilt the squeegee unit To do this proceed as follows 1 Loosen the locknut 1 2 Turn the screw 2 anticlockwise to increase the bend of the rubber in the central part of the squeegee To increase the bend of the rubber at the sides of the squeegee turn the screw 2 clockwise 3 When fully adjusted fix the locknut 1 35 ADJUSTING THE SQUEEGEE HEIGHT The height of the squeegee must be adjusted on the basis of the state of wear and tear of the rubber To do this turn the knob 1 anticlockwise to raise the squeegee and clockwise to lower it Remarks the right and left wheels must be adjusted to the same level so the squeegee can work parallel to the floor WARNING These operations must be carried out using protective gloves to avoid any possible contact with the edges or tips of metal objects 36 ASSEMBLING THE CYLINDRICAL BRUSHES To assemble the cylindrical brushes of the brush head body proceed as follows 1 Lift the brush head unit by operating the joystick 1 the selected work programme must be 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 WARNING During this operation check there are no people or objects near the brush 29
65. not use the machine on slopes e power supply cable of the battery charger is damaged contact an Authorised service centre immediately e Inthe event of danger quickly intervene on the handle located the battery connector e For all maintenance interventions switch off the machine and disconnect the battery connector and or the power supply cable e Children must be supervised to ensure they do not play with the device e During the working of the machine pay attention to other people and especially to children e Only use the brushes supplied with the machine or those specified in the CHOOSING AND USING THE BRUSHES paragraph of the instruction manual The use of other brushes could compromise safety levels WARNING e The machine is not suitable for use by children and persons with reduced physical mental and sensory capabilities or people who lack experience and knowledge e The machine must not be used or stored outdoors in damp conditions or directly exposed to rain e The storage temperature must be between 25 C and 55 C do not store outdoors in damp conditions e Conditions of use room temperature between 0 C and 40 C with relative humidity between 30 95 e socket for the machine s power cable electric version or for the battery charger power cable battery version must be correctly earthed e Adapt the speed to the adhesion conditions e Do not use the machine as a means of transport
66. ntities of both water and detergent With the dosing system out of use the water flow is regulated via the tap on the steering column Contact a COMAC authorised dealer to have the system repaired 79 ALARMS The machine is fitted with a flashing warning light 1 for diagnosing faults in the traction motor control system Each sequence number of consecutive flashes indicates a particular type of fault When flashing begins with an accompanying operating fault you should contact the technical assistance centre specifying the number of flashes 60 DISPOSAL To dispose of the machine take it to a demolition centre or an authorised collection centre Before scrapping the machine it is necessary to remove and separate the following materials and send them to the appropriate collection centres in accordance with the environmental hygiene regulations currently in force brushes o filter e electric and electronic parts e batteries e plastic parts tanks and handlebars metal parts levers and frame In particular to scrap the electric and electronic parts contact your area distributor 61 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
67. ocated on the left side of the machine 4 Remove the key from the instrument panel WARNING During this operation verify that there are no people or objects near the brush 31 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 DETERGENT PUMP PRIMING VERSIONS WITH CDS Before starting work the detergent pump must be primed to do so proceed as follows 1 Check that the main switch is in the Off 0 position Check that the battery connector is disconnected from the machine connector Check the parking brake is correctly engaged Make sure the recovery tank is empty otherwise empty it completely Check that the quick release coupling 1 under the detergent tank is properly fitted oF WP 6 Unscrew the cap of the detergent canister 2 and fill it with the desired product WARNING Always use low foam detergent To avoid the production of foam before starting to clean put a minimum quantity of anti foam liquid into the recovery tank Do not use pure acids
68. of the machine are identified as follows 49 Headlights 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 the norms CEI EN 60254 1 2005 12 CEI 21 5 CEI EN 60254 2 2008 06 CEI 21 7 For a good operating performance we suggest the use of two 18V 480 Ah battery cases 11 TYPE OF STARTER BATTERY As a starter battery you are advised to use 12V 35 Ah C5 battery OTHER TYPES MUST NOT BE USED The battery must meet the requisites indicated in standards CEI EN 50342 CEI EN 60095 2 and CEI EN 60095 4 12 BATTERY MAINTENANCE AND DISPOSAL For maintenance and recharging comply with the instructions provided by the battery manufacturer Particular attention must be paid when choosing the battery charger if not supplied since there are different kinds according to the type and capacity of the battery When the battery reaches the end of its working life it must be disconnected by expert trained personnel then lifted using the grips and suitable lifting devices to remove it from the battery compartment DEAD BATTERIES ARE CLASSIFIED AS DANGEROUS WASTE AND MUST BE DELIVERED TO THE AUTHORISED BODIES FOR CORRECT DISPOSAL WARNING You are advised to always wear protective gloves to avoid the risk of serious injury
69. overed places The machine is not suitable for use in the rain or under water jets It is FORBIDDEN to use the machine in places with a potentially explosive atmosphere for picking up dangerous dusts or inflammable liquids In addition it is not suitable as a means of transport for people or objects COMBUSTION ENGINE TECHNICAL DATA HONDA iGX 440 UM Type of motor Single cylinder OHC gasoline engine with horizontal shaft Otto cycle 4 stroke forced air cooling Bore per stroke mm 88 x 72 1 Displacement cm 438 Compression ratio 8 1 1 Net power kW rpm 9 5 3600 Maximum torque Nm rpm _ 29 8 2500 Start up Self winding Electric Starter Choker Automatic Fuel cut off valve Automatic Tank capacity 5 9 Fuel consumption at rated power rpm 3 6 3600 Oil sump capacity 1 1 Dry weight kg 39 TECHNICAL DESCRIPTION UM ULTRA100 BS ULTRA100 GS sr rueL Working width without side brush mm 970 970 Working width with side brush mm 1080 1080 Squeegee width mm 1265 1265 Working capacity up to m h 8640 8640 No Side disc brush mm Hee Side disc brush rotations rpm 218 218 Side disc brush motor V W 36 650 36 650 Maximum pressure on the disc brush kg 27 5 27 5 Cylindrical brush front mm 150 150 Cylindrical brush rear mm 280 280
70. r to insert the seal that s supplied with the cylinder Fully open the cylinder tap 3 WARNING The seal between the tap 3 and the tube 4 must be changed every time the LPG cylinder is replaced WARNING The LPG cylinder must not be replaced near flames cinders or active electric devices WARNING Before replacing the LPG cylinder make sure the taps 3 of both the old cylinder and the new one are closed WARNING The cylinder and tube 4 must never be exposed to heat sources 67 REPLACING THE STARTER BATTERY The battery must be housed in the special compartment beneath the seat mounting plate It should be handled using lifting equipment that is suitable in terms of both weight and lifting method It must also meet the requisites of the following standards CEI EN 50342 CEI EN 60095 2 and CEI EN 60095 4 The dimensions of the battery compartment are 229 mm x 132 mm x H165mm mm If you need to replace the starter battery proceed as follows 1 2 3 Check the parking brake is engaged If it is not engage it by means of the lever 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 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 Make sure the main switch is in the 0 posi
71. rator connector for versions with a combustion engine Make sure the main switch is in the 0 position If it is not turn the key a quarter turn to the left Check the parking brake is engaged If it is not engage it by means of the lever 1 Make sure the detergent solution tank is empty otherwise empty it 45 WEEKLY MAINTENANCE 1 Remove the right hand carter 2 by unscrewing the nuts 3 2 Disconnect the quick release coupling 4 located behind the side cover to prevent damage to the coupling itself 3 Remove the detergent tank 5 by unscrewing the nuts 6 4 Unscrew the detergent filler cap 7 5 Rinse the inside of the tank with a jet of water 6 Refit all the parts WARNING These operations must be carried out using gloves to protect against contact with dangerous solutions A AG 55 CLEANING THE SOLUTION TANK FILTER Proceed as follows for cleaning 1 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 Make sure the main switch is in the 0 position If it is not turn the key a quarter turn to the left Check the parking brake is engaged If it is not engage it by means of the lever 1 Close the water tap 1 25 Unscrew the detergent solution filter 2 located at the front of the machine mw
72. ry versions or from the generator connector for versions with a combustion engine 5 Check the parking brake is engaged If it is not engage it by means of the lever 1 9 Use a suitable tool to remove the rubber pressing blade 2 loosening the screws 3 that fix it to the side brush head 10 Take the rubber 4 out and turn or replace it 11 To replace the rubber proceed in reverse order 66 REPLACING THE LPG CYLINDER COMBUSTION ENGINE VERSION To replace the LPG cylinder when it is empty proceed as follows 1 Engage the parking brake 1 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 right 3 Unscrew the tube 4 from the tap 3 remembering to remove the seal between the two elements 55 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 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 Fix the cylinder to its support by means of the straps 5 To do this hook the spring 6 to the screw 7 on the support WARNING Use only cylinders measuring 300x600 0 x height in millimetres and weighing no more than 10kg Tighten the tube 4 to the tap 3 Remembe
73. sary turn the I DRIVE selector to the Transfer position to raise both the brush head and the squeegee A DAN 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 Make sure the main switch is in the 0 position If it is not turn the key a quarter turn to the left Check the parking brake is engaged If it is not engage it by means of the lever 1 2 5 Disconnect the squeegee by loosening the knobs 2 Rotate the fixing plates 3 Remove the rubber pressing blade 4 and then the rubber to turn it over or replace it To replace the rubber proceed in reverse order Adjust the height of the squeegee depending on the rubber see ADJUSTING THE HEIGHT OF THE SQUEEGEE SUPPORT WARNING These operations must be carried out using gloves to protect against contact with dangerous solutions 64 REPLACING THE SIDE SPLASH GUARD RUBBER OF THE BRUSH HEAD If the splash guard side rubber in the brush head cover 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 operation can be carried out with the side splash guard support removed proceeding as follows 1 sure the brush head unit is in its working position if necessary turn the I DRIVE selector to the Washing position to lower the brush head Set
74. starting to work you must 1 2 3 4 10 11 Make sure the recovery tank is empty otherwise empty it completely 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 Check the main machine switch 4 is set to 0 Check the fuel selector 5 is on LPG Turn the motor rotation adjustment knob 6 anticlockwise as far as it will go Raise the seat mounting plate and connect the generator connector 1 to the electric system connector 2 Check the fuel level if it is low top up the tank as indicated in FILLING THE FUEL TANK Open the tap 7 on the LPG cylinder Bring the seat mounting plate back to its working position and sit on the seat Disengage the parking brake 3 Inject LPG into the system by repeatedly pressing the button 8 at least three times Turn the main switch key 4 clockwise by a quarter of a turn to position 1 Bring the motor ignition switch to the START position turning the key further to the right and keep it there until the motor starts up you can now release the key WARNING Do not use the starter for more than 5 seconds at a time If the motor does not start up release the key and wait for 10 seconds before making a new attempt The green indicator light 9 will immediately come on indicating that the main switch has been enabled WARNING No indicator light will be illuminated on the command panel on the in
75. strument panel until the combustion engine has reached its working speed Turn the motor rotation adjustment knob 5 clockwise as far as it will go When the combustion engine is at full speed the work screen of the control display will show the generator charge status and the total operating time When the machine generator is working correctly the upper line consists of 8 light indicators in the form of a battery The bottom line indicates the hours and minutes of functioning The flashing symbol indicates that the hour meter is counting the machine functioning time 34 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 2 Choose the forward operating speed by operating the knob 1 on the instrument panel This machine can operate at three different speeds via the knob 1 located on the instrument panel you have three different settings Step01 the maximum speed is 3 9 km h Step02 the maximum speed is 5 7 km h Step03 the maximum speed is 8 km h WARNING The reverse speed is lower than the forward speed to comply with current health and safety standards 3 Choose the direction of movement by opera
76. stusstousssnassenssnsusstsussinasestastsussnauessuensusssnasesnastauastoasstnaseonassaasnaanstast 59 JL INSUFFIGIENT WATER ON THE BRUSHES thovtadntacbastbsdeencoatatvcueseancui 59 72 THE SQUEEGEE DOESNOT DRY PERFECTLY sx 59 73 7 HE MAGHINE DOES NOT CLEANS WEEL TA EXCESSIVE FOAM 75 THE SUCTION MOTOR DOES NOT FUNCTION 76 THE BRUSH MOTOR DOES NOT WORK TIELEGTRIC FUSES AND THERMAL CUTOUTS wististsacsctscausteactenscscnatecstestsncactcencshstutacncatsateaiesnactbatacndasencusbinsncasascabetbmebboctishcantadncadanchadesuantithcbadishastiadn st 78 THE AUTOMATIC WATER DETERGENT DOSING SYSTEM DOES NOT 60 79 ALARMS DISPOSAL CHOOSING AND USING THE BRUSHEG cssssssesesececserssssrseseseeseressesseeeceecnesessersssseseseararsesessoeeeeeeasssseseeeeneneneaeasisorssesnsnenarartaes 62 DECLARATION 4 15 ces anaccedzebstnacaetecestseqodestaneactusiunadeeatenaveeds sbadeeeaetscneesedice 63 EC DECLARATION OF 9 taiate iedit 64 On consignment of the machine Serial number plate When the machine is delivered to
77. t this procedure with the machine switched off and when you are absolutely sure the LPG cylinder is completely empty to replace the cylinder refer to REPLACING THE LPG CYLINDER WARNING The machine version with combustion engine is not fitted with a gasoline fuel reserve warning light so keep an eye on the level of fuel in the combustion engine tank To fill the fuel tank refer to FILLING THE FUEL TANK When the level of solution for versions without CDS or water for versions with CDS is about to run out the red warning light 16 on the instrument panel will come on when the solution or water is completely used up take the machine to the place designated for emptying the recovery tank On completion of the emptying operation refill the solution tank 36 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 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 Check to see if the knob 8 to increase the pressure on the brushes has been operated and if so turn it anticlockwise as far as it will go If the warning light 18 on the instrument panel comes on while you are working this means
78. tact with dangerous solutions 47 CLEANING THE DEBRIS HOPPER AND HOPPER SUCTION FILTER The thorough cleaning of the debris hopper and its filter will ensure better work results Proceed as follows for cleaning 1 2 3 Make sure the recovery tank is empty otherwise empty it completely Check that the main switch of the machine is set to 0 Check the electric system connector is disconnected from the battery connector for battery versions or from the generator connector for the combustion engine version 41 DAILY MAINTENANCE 4 Check the parking brake is engaged If it is not engage it by means of the lever 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 6 Rinse the inside of the hopper with a jet of clean water 7 the suction filter 4 out of the debris hopper and clean it under a jet of running water 8 Reassemble the suction filter 4 in the debris hopper 9 Replace the debris hopper in the machine and lock it in place by means of the clamp 2 48 DAILY MAINTENANCE COMBUSTION ENGINE WARNING Perform the daily maintenance as explained in the user and maintenance manual of the engine itself In this way you will avoid any acci
79. 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 It is only by prompt action of this type that the missing material can be obtained and compensation for damage successfully claimed Introductory comment The ULTRA100s are floor scrubbing machines which by means of the mechanical action of the rotating brush and the chemical action of a water detergent solution can clean any type of flooring As they advance they also collect any removed dirt as well as the detergent solution not absorbed by the floor The machine must only be used for this purpose 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 customer assistance service organised in collaboration with our dealers is always available for advice or direct intervention Intended use The scrubbing machine is designed exclusively for the professional cleaning of surfaces and floors in industrial commercial and public environments The machine is only suitable for use in closed or at least c
80. ting the knob 2 on the instrument panel 4 Choose the pressure exerted on the brushes by operating the knob 3 on the instrument panel 5 If the machine does not have the CDS device move the tap lever 4 anticlockwise and adjust the amount of solution required 6 If the machine is equipped with the CDS dosing system the tap lever 10 must be turned fully anticlockwise allowing maximum flow of water This lever should not be used to make adjustments To ensure the correct dose on the brushes use only the knobs for adjusting the amount of water solution 5 and detergent 6 See paragraph DETERGENT ADJUSTMENT WITH CDS SYSTEM To avoid any tampering with the set regulation you can remove the two switches and cover the two holes with the plastic caps supplied with the machine 7 When you press the accelerator pedal 7 the machine starts moving the squeegee is automatically lowered the warning light 8 will come on automatically to indicate that the squeegee is moving and the suction motors will start operating At the same time the brush head is also automatically lowered and the warning light 9 indicating that the brush head motor is in operation will come on automatically This will happen only if the Drive selector is set to work program 8 As soon as the brush head is in the work position the solenoid valve will begin operating and the warning light 10 indicating that the valve is operating will automatically come on
81. tion If it is not turn the key a quarter turn to the left 56 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 10 Use suitable means to insert the new battery in the machine positioning it as shown in the figure 11 Use a suitable tool to connect the battery to the machine system WARNING The first cable to be disconnected is the pole followed by the pole 12 Fix the battery to its support with the aid of the clamp 3 68 WASHING THE DOSING SYSTEM VERSIONS WITH CDS The dosing system should be cleaned when the machine is not used for a long period more than 48 hours to do so proceed as follows 1 Make sure the squeegee unit is in its idle raised position if necessary turn the I DRIVE selector to the Transfer position to raise both the brush head and the squeegee 2 Make sure the electrical system connector 1 is disconnected from the battery connector 2 if necessary disconnect it 3 Make sure the main switch 3 is the 0 position If it is not turn the key a quarter turn to the left
82. to your hands WARNING You are advised to only lift and move the batteries with lifting and transportation means suitable for the specific weight and size 19 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 MAINTENANCE AND DISPOSAL OF THE LPG CYLINDER WARNING For the maintenance and disposal of the LPG cylinder observe the instructions given by the cylinder manufacturer for maintenance and current environmental hygiene norms for disposal 15 HANDLING AND INSERTING THE BATTERIES BATTERY VERSION The batteries must be housed in the special compartment beneath the seat mounting plate They should be handled using lifting equipment that is suitable in terms of both weight and method of lifting They must also satisfy the requirements of Standard CEI 21 5 The dimensions of the battery compartment are 879 mm x 599 mm x H450 mm WARNING For battery maintenance and daily recharging you must carefully follow the instructions provided by the manufacturer or retailer All installation and maintenance operations must be carried out by specialised personnel To insert batteries proceed as follows 1 Immobilise the machine with the parking brake 2 Make sure the
83. ty of water in the tank For example the work autonomy with a full tank about 280 litres and the selector 2 set at 55 is about 4 hours 2 Regulate the percentage of detergent in the solution by rotating the right hand knob 3 clockwise The lower value is equal to 0 5 for standard detergents or 0 1 for a concentrated detergent diluted as indicated on the label supplied with the machine while the higher value is equal to 3 5 or 0 7 with 7 set points Use high detergent percentages to remove very greasy dirt from the floor To avoid any tampering with the set regulation you can remove the two switches and cover the two holes with the plastic caps supplied with the machine WARNING Verify that the tap lever 1 is fully open the lever is located at the rear of the steering column ATTENTION before regulating the solution check there is detergent in the inner can and that the side water tap is turned on To resolve any malfunctioning of the CDS system contact the COMAC assistance centre WARNING If the CDS system fails to function or you want to work without this device turn the lever of the tap 4 on the front right hand side of the machine clockwise Also turn the knobs 2 and 3 anticlockwise to the OFF position 32 RECOVERY TANK Make sure the recovery tank is empty otherwise empty it completely Check the cap of the drainage tube 1 on the rear of the machine is correctly closed Check that the

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