USE AND MAINTENANCE MANUAL

CS 140 DIESEL

ED. 02 - 2011 - EN

Page 2

The descriptions contained in this document are not binding. The company therefore reserves the right to make any modifications at any time to elements, details, or accessory supply, as considered necessary for reasons of improvement or manufacturing/commercial requirements. The reproduction, even partial, of the text and drawings contained in this document is prohibited by law. The company reserves the right to make any technical and/or supply modifications. The images are for reference purposes only, and are not binding in terms of design and supply. SYMBOLS USED IN THE MANUAL

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 3

GENERAL SAFETY REGULATIONS ..................................................................................................................................... INTRODUCTORY COMMENT ................................................................................................................................................ GENERAL WARNINGS ........................................................................................................................................................... PURPOSE OF THE MANUAL ................................................................................................................................................. DECLARATION OF CONFORMITY ........................................................................................................................................ SERIAL NUMBER AND PLATES OF THE MACHINE ............................................................................................................ SPARE PARTS AND MAINTENANCE ................................................................................................................................... MODIFICATIONS .................................................................................................................................................................... ON CONSIGNMENT OF THE MACHINE................................................................................................................................ TOOLS AND SYMBOLS USED ON THE MACHINE .............................................................................................................. ACCESSORIES/OPTIONALS ................................................................................................................................................ MACHINE DESCRIPTION ...................................................................................................................................................... TECHNICAL CHARACTERISTICS ......................................................................................................................................... WIRING DIAGRAM.................................................................................................................................................................. HYDRAULIC DIAGRAM .......................................................................................................................................................... USING THE MACHINE............................................................................................................................................................ BEFORE START-UP .............................................................................................................................................................. START-UP AND STOP OF THE DIESEL ENGINE................................................................................................................. START-UP AND STOP OF THE MACHINE ........................................................................................................................... SETTING THE MACHINE IN "TRANSFER" MODE ............................................................................................................... SETTING THE MACHINE IN WORKING MODE ................................................................................................................... SETTING THE MACHINE IN CENTRAL BRUSH CHANGE MODE ...................................................................................... EMPTYING THE DEBRIS HOPPER ...................................................................................................................................... USING THE WINDSHIELD WIPER/WASHER ....................................................................................................................... USING THE HEATING SYSTEM OF THE OPERATOR'S CAB ............................................................................................. USING OF THE AIR CONDITIONING SYSTEM OF THE OPERATOR'S CAB (Optional) ..................................................... OPERATION OF THE LIGHTING SYSTEM............................................................................................................................ ACTIVATION OF THE EMERGENCY LIGHTS ...................................................................................................................... ACTIVATION OF THE WORKING LIGHTS ........................................................................................................................... MANUAL LIFTING OF THE DEBRIS HOPPER ..................................................................................................................... MANUAL TIPPING OF THE OPERATOR'S CAB.................................................................................................................... USING THE REAR VACUUM HOSE (Optional)...................................................................................................................... USING THE HIGH PRESSURE LANCE (Optional)................................................................................................................. USING THE VIDEO CAMERA KIT (Optional) ......................................................................................................................... USING THE FILTER LIFTING CRANE (Optional)................................................................................................................... OPERATIONS TO PERFORM AFTER USING THE MACHINE ............................................................................................ EMPTYING THE DUST SUPPRESSION SYSTEM WATER TANKS .................................................................................... CLEANING THE DUST SUPPRESSION SYSTEM NOZZLES .............................................................................................. DUST SUPPRESSION SYSTEM WATER PUMP (Optional) ..................................................................................................

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Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 4

TOWING THE MACHINE ....................................................................................................................................................... TRANSPORT/HANDLING ...................................................................................................................................................... LONG MACHINE INACTIVITY ............................................................................................................................................... FIRST TIME USE .................................................................................................................................................................... MAINTENANCE OPERATIONS ON THE MACHINE ............................................................................................................ CLEANING THE DEBRIS HOPPER ....................................................................................................................................... CLEANING THE DEBRIS HOPPER FILTER ......................................................................................................................... CLEANING THE DEBRIS HOPPER FILTER WITH LIFTING CRANE (Optional) ................................................................... REPLACING THE DEBRIS HOPPER SEALS AND VACUUM DUCT ................................................................................... CONTROL AND ADJUSTMENT OF THE CENTRAL BRUSH ............................................................................................... CONTROL AND ADJUSTMENT OF THE SIDE BRUSHES .................................................................................................. CONTROL AND ADJUSTMENT OF THE THIRD BRUSH ..................................................................................................... REPLACING THE CENTRAL BRUSH..................................................................................................................................... REPLACING THE SIDE BRUSHES/THIRD BRUSH .............................................................................................................. REPLACING THE RUBBER FRONT, REAR AND SIDE FLAPS ........................................................................................... REPLACING THE HYDRAULIC OIL ...................................................................................................................................... REPLACING THE HYDRAULIC OIL FILTER .......................................................................................................................... CHECKING THE CLEANLINESS OF THE HYDRAULIC OIL RADIATOR FINS ................................................................... GREASING OF BEARINGS ................................................................................................................................................... CONTROLLING THE BATTERY FLUID LEVEL .................................................................................................................... CONTROLLING THE BRAKE FLUID LEVEL ......................................................................................................................... CONTROLLING THE PARKING BRAKE ............................................................................................................................... CONTROLLING THE REVERSE HORN ACTIVATION SENSOR ......................................................................................... REPLACING THE AIR FILTER OF THE OPERATOR'S CAB ................................................................................................ CONTROLLING THE TYRE PRESSURE .............................................................................................................................. CONTROLLING THE FOUR-WHEEL STEERING TOE-IN .................................................................................................... REPLACING THE WHEELS.................................................................................................................................................... CONTROLLING THE ELECTRICAL COMPONENTS ............................................................................................................ REPLACING THE FUSES ...................................................................................................................................................... CHOOSING AND USING THE BRUSHES ............................................................................................................................. MAINTENANCE OPERATIONS ON THE ENGINE ............................................................................................................... REPLACING THE ENGINE OIL ............................................................................................................................................. REPLACING THE ENGINE OIL FILTER ................................................................................................................................ CLEANING THE ENGINE AIR FILTER .................................................................................................................................. CHECKING THE CLEANLINESS OF THE DIESEL ENGINE RADIATOR FINS ................................................................... CHECKING THE ENGINE COOLANT LEVEL ....................................................................................................................... REPLACING THE DIESEL ENGINE FUEL FILTER ............................................................................................................... REPLACING THE DIESEL ENGINE FUEL PRE-FILTER ...................................................................................................... REPLACING THE DIESEL ENGINE ALTERNATOR BELT ................................................................................................... MAINTENANCE ......................................................................................................................................................................
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004 Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

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SCHEDULED MAINTENANCE DIAGRAM ............................................................................................................................. WINTER MAINTENANCE ....................................................................................................................................................... SAFETY FUNCTIONS ............................................................................................................................................................ TROUBLESHOOTING ............................................................................................................................................................ FAULTS AND SOLUTIONS .................................................................................................................................................... SCRAPPING ........................................................................................................................................................................... DECLARATION OF CONFORMITY........................................................................................................................................

Page 42 Page 43 Page 43 Page 44 Page 44 Page 47 Page 48

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 6

GENERAL SAFETY REGULATIONS
The regulations below must be carefully followed in order to avoid harm to the operator and damage to the machine. - Read the labels on the machine carefully. Do not cover them for any reason and replace them immediately if they become damaged. - The machine must be used exclusively by authorised, trained personnel. - During the working of the machine, pay attention to other people and especially to passers-by and parked vehicles. – The machine works properly (*) within the following environmental parameters: • Temperature: from -10 °C to +40 °C • Humidity: from 30% to 95% (*) To use the machine at temperatures between -10° C and 0° C, the water of the dust suppression system and its water tank cannot be used, and the system itself should be emptied. - Do not use the machine as transport or pulling means. - Avoid using the brushes while the machine is standing still, so as not to cause damages on the floor. - Do not use the machine in flammable areas or with explosive atmosphere. - Do not use the machine to collect dangerous or toxic dust. - In case of fire, use a fire extinguisher (supplied with the machine). Do not use water. - Do not use the machine on surfaces with inclinations higher than the ones specified in the plate. - If the machine does not work properly, check this is not caused by failure to carry out routine maintenance. Otherwise, request the intervention of a Comac SpA authorised technical assistance centre. - If you need to replace any components, request the ORIGINAL spare parts from a Comac Spa dealer and/or Authorised Retailer. - Before carrying out any maintenance work, switch off the machine and engage the parking brake. - Do not remove any protection devices which require the use of tools in order to be removed and do not tamper with the protection devices - Do not wash the inside of the debris hopper with direct jets of water or water under pressure, or with corrosive substances, which could wet/damage the fabric filter. - Have the machine checked by an authorised technical assistance centre at the time intervals indicated in the maintenance schedule. - Before using the machine, check that all the hatches and covers are positioned as shown in this Use and Maintenance Manual. - Only use the brushes supplied with the machine, or those specified in this Manual. The use of other brushes could compromise safety levels - Do not lift the hopper when the machine is inclined. - If you must work on the machine with the hopper raised, close the anti-drop protection taps installed on the hydraulic system of the machine. - When working in ascent or descent inclinations, keep a straight trajectory - Consider the safety measures reported on the manual as regards endothermic engines . - Do not refill the fuel tanks completely, avoid leaks and close the plug correctly. If there are any leaks, dry and wait before starting up the engine. - Before every operation, check presence of possible liquid leaks - The machine is not suitable for use by children or people with reduced physical, mental and sensorial capacities, or people lacking experience and knowledge, unless supervised and instructed in the use of the machine by a person responsible for their safety. - For the transportation of the machine via truck, control that the debris hopper is empty and the fuel tank is not completely full. Carefully fasten the machine using the points provided on the machine and brake it with the parking brake. - Dispose of the consumption materials in compliance with the current standards. - The battery must be removed from the machine before its disposal and sent to an authorised company for its treatment. - When your machine has reached the end of its long working life, dispose of the materials it contains (especially oils and electronic components) in an appropriate manner, and bearing in mind that the machine itself was constructed using 100% recyclable materials

INTRODUCTORY COMMENT
Even the best machines will only work well if used correctly and kept in good working order. We therefore suggest you
read this instruction booklet carefully and read it again whenever difficulties arise while using the machine. If necessary, remember that our assistance service (organised in collaboration with Comac SpA dealers) is always at your service for advice or direct intervention.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 7

GENERAL WARNINGS
DANGER – This machine must only be used by properly trained and authorized personnel. – Furthermore, the driver must be: • adult • holder of the necessary driver's license • in a normal physical and mental condition • not under the influence of substances, which can alter nerve reflexes (alcohol, psychoactive drugs, drugs, etc..). – Before performing any maintenance or repair operations, remove the ignition key, engage the parking brake and, if necessary, disconnect the battery. – When working near moving parts, remove all jewellery or materials that could become entangled. – Do not work under the raised machine without adequate fixed safety props. – Do not operate with this machine in environments where there are toxic, hazardous, flammable and/or explosive powders, liquids or vapours. – Warning, the fuel is highly flammable. – Do not smoke or carry naked flames in the fuel filling or storage areas. – Perform refuelling outdoors or in a well ventilated locations with the combustion engine turned off. – To allow the fuel to expand, do not fill the tank more than 4 cm from the neck of the filler pipe. – After refuelling, make sure the fuel tank cap is securely closed. – If fuel is spilled during refuelling, clean the affected area, and allowing fuel vapours to evaporate before starting the engine. – Avoid fuel contact with the skin and do not inhale the vapours. – Every time you work under open hoods/hatches, make sure that the hood/hatch can not shut accidentally. – When access to the engine compartment for maintenance is necessary with the debris hopper raised, close the two safety valves near the lifting pistons. – The fuel tank must be empty during transportation of the sweeping machine by truck/container. WARNING: – The exhaust gases of diesel engines contains carbon monoxide, a poisonous, odourless and colourless gas. Avoid inhalation. Do not keep the engine running in enclosed spaces. If you need to keep the engine running in enclosed spaces, do so only if there is adequate ventilation and in the presence of a helper. • Carbon monoxide (CO) can cause brain damage or death. • The internal combustion engine of this machine emits carbon monoxide. • Do not inhale the exhaust fumes. – The silencer heats up when the diesel engine is running; Do not touch the silencer while it is hot to avoid burns or fire. – Do not place any objects on the engine. – Turn the diesel engine off before working on it. To prevent the accidental starting of the engine, disconnect the negative battery terminal. – Do not crank the diesel engine with insufficient oil to avoid serious damage. Check the oil level with the engine off and the machine in a horizontal position. – Never run the diesel engine without the air filter to avoid damage. – The cooling system of the diesel engine is under pressure. Carry out checks with the engine off and only after it has cooled. Even with the engine cool, open the radiator cap with care. – The hydraulic oil radiator is fitted with a fan; do not approach it if the engine is hot because the fan could start even when the machine is idle. – The repair of the diesel engine must be performed by an Authorized Dealer. – Use ORIGINAL spare parts only for the diesel engine. The use of non-original spare parts, can seriously damage the engine. – See also the SAFETY REGULATIONS given in the manual of the diesel engine, to be considered an integral part of this Manual.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 8

WARNING! – The machine must be equipped with vehicle registration and license plate for use on public roads. – Do not use the machine for purposes different from that of a sweeping machine, for which it was designed. – When using this machine, ensure to safeguard the safety of people and property. - Do not use the machine as a means of transport. – Do not leave the machine unattended without removing the ignition key and without having engaged the parking brake. – Be very careful when lifting and emptying the debris hopper. – Adapt the speed to the adhesion conditions of the road surface. – Read all relevant instructions carefully before performing any maintenance/repairs operations.

– Adequately protect body parts (eyes, hair, hands, etc..) when cleaning with compressed air or water guns. – Avoid contact with battery acid, do not touch parts at high temperature. - Avoid using the brushes while the machine is standing still, so as not to cause damages on the floor.

– In case of fire use a powder fire extinguisher and not water. – Do not wash the machine with corrosive substances. – Do not use the machine in particularly dusty environments. – Do not tamper with the machine's protections under any circumstances, follow the instructions provided for routine maintenance. – Do not remove or alter the labels affixed to the machine. – If the machine does not work properly, check this is not caused by failure to carry out maintenance. Otherwise, request the intervention of authorized personnel or an Authorized service centre. – If you need to replace any components, request the ORIGINAL spare parts from a COMAC SpA dealer and/or Authorised Retailer. – For safety reasons as well as for smooth functioning, the routine maintenance indicated in the related chapter of this manual, should be performed by authorized personnel or an authorized Comac SpA service centre – The machine must not be discarded at the end of its life cycle, due to the presence of harmful toxic materials (oil, batteries, plastics, etc..), subject to regulations providing for their disposal at special centres (see the chapter Scrapping).

PURPOSE OF THE MANUAL
This manual is an integral part of the machine; its purpose is to provide the operator with all the information necessary, in order to be able to use the machine in an appropriate and safe as possible manner. This includes information concerning technical aspects, safety, operational, downtime, maintenance, spare parts and scrapping. The operators and qualified technicians must read the instructions in this manual before carrying out any operation on the machine. If in doubt about the correct interpretation of instructions, consult Comac SpA to obtain the necessary clarification. The manual in question is aimed at the operator, as well as qualified technicians responsible for the maintenance of the machine. The operators must not perform the operations reserved for the qualified technicians. Comac SpA is not liable for damages resulting from failure to comply with this veto. The use and maintenance manual must be kept in the cab of the machine, away from liquids and anything else that may affect its legibility. The following documentation is also supplied with the sweeping machine in addition to the use and maintenance manual: – Combustion engine manual (paper) – Sweeping machine's spare parts catalogue (CD) – Sweeping machine's wiring diagram (CD and paper) – Sweeping machine's hydraulic diagram (CD and paper) – Video camera kit manual (optional)

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 9

DECLARATION OF CONFORMITY
The declaration of the sweeping machine's compliance with the applicable provisions of the law, are indicated on page 44 of this manual .

SERIAL NUMBER AND PLATES OF THE MACHINE
The serial number and model of the machine are shown on the label applied inside the cab. The serial number of the machine is also stamped on the frame of the machine. The serial number and model of the diesel engine are shown in the positions indicated by the manual. This information is required when ordering replacement parts for the machine and the diesel engine. Use the space below to note the identification data of the machine and the diesel engine, for future reference. MACHINE Model CS140 MACHINE serial number .................................................................. ENGINE model ................................................................................. ENGINE serial number ..................................................................... When asking for spare parts, always quote the product code (MAT. COD.) and serial number (No …) of the machine indicated on the serial number plate applied inside the cab. For the engine, refer to the plate applied on it by the manufacturer.

SPARE PARTS AND MAINTENANCE
For any problems concerning the use, maintenance and repair, contact qualified personnel or directly to a Comac SpA service centre.Always use original spare parts and accessories. Contact Comac SpA for assistance or to order spare parts and accessories, specifying the model and serial number.

MODIFICATIONS
Comac SpA aims to constantly improve its products and reserves the right to make changes and improvements when deemed necessary, without having to modify the machines previously sold. It is understood that any modification and/or addition of accessories must be explicitly approved and carried out by Comac SpA

ON CONSIGNMENT OF THE MACHINE
The machine is normally delivered fully assembled and perfectly functional, therefore unpacking/installation operations by the customer are not necessary. When the machine is delivered to the customer, an immediate check must be performed to ensure all the material mentioned in the shipping documents has been received, and also to check the machine has not been damaged during transportation. If this is the case, the carrier must ascertain the extent of the damage at once, informing Comac S.p.A. customer service office. It is only by prompt action of this type that the missing material can be obtained, and any compensation for damage successfully claimed. Check that the Service kit accompanies the machine. Composition of the Service Kit: • Use and maintenance manual of the sweeping machine • Diesel engine manual • CD with manuals • Wiring diagram • Hydraulic diagram • Bag with keys for disassembly and maintenance • Warranty booklet.
WARNING: The sweeping machines should only be operated by operators who have been adequately trained and authorized to work with the machine, after making sure that the machine is operating perfectly.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 10

TOOLS AND SYMBOLS USED ON THE MACHINE
INSTRUMENT PANEL INDICATORS

Fuel level indicator Engine rev counter Water temperature indicator Hour counter

INSTRUMENT PANEL WARNING LIGHT
Display functions: Display with panel on With the ignition key turned to the first position, all the warning lights on the display of the instrument panel light for a few seconds in order to control for any faulty lights.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 11

CONTROLS AND BUTTONS

Three level vacuum speed selector Three level machine ground height selector: 1. 2. Working position Transfer or working position in cases of voluminous material (leaves, boxes or bottles) 3. Central brush change position

Hydraulic parking brake button

Heating adjustment buttons (temperature and ventilation) Air conditioning on button (optional)

Diesel engine manual acceleration lever Cab ventilation/cab air recirculation vents

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 12

Lights and horn Functions of the buttons near the steering wheel: – lights off, with switch on symbol O – position lights on with switch on the second notch – dipped headlights on, with switch on the third notch - main beam on, with switch on the symbol and lever lifted – main beam temporarily on, lifting the lever – Right-turn indicator engaged, bringing the lever up – left-turn indicator engaged, bringing the lever down

– activation of the horn, pressing the button on the end of the lever

– activation of the 2 flashing working lights – activation of the windshield wiper – activation of the windshield lever – actuation of the 2 working lights to illuminate the right side (right side brush and third brush) and the left side of the machine (the left brush). All references: • • • • • • FORWARD BACKWARDS FRONT REAR RIGHT LEFT

indicated in this manual, refer to the position of the operator sitting at the driver's seat

ACCESSORIES / OPTIONALS
The machine can be equipped with the following accessories/optionals: – left side brush – third brush – brushes with bristles harder or softer than the standard – spraying system for third brush and side brush complete with 200 litre tank – washing system with high pressure water lance – air conditioning system for the cab – rear vacuum system (hand operated waste collection pipe)
– hydraulic crane for hopper filter lifting/replacement – radio with CD player – rear video camera kit – debris hopper spare filter kit.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 13

MACHINE DESCRIPTION
TECHNICAL CHARACTERISTICS
CLEANING TRACK Working width with central brush Cleaning width with 1 side disc brush Cleaning width with 2 side disc brushes Cleaning width with 2 side disc brushes + third disc brush Cylindrical central brush diameter Diameter of 2 side disc brushes and third brush DEBRIS HOPPER Debris hopper volume (total) Debris hopper volume (usable) with filter Maximum hopper lifting height VACUUM ACTION Air flow Filtering surface Vacuum motor rated power PERFORMANCE Maximum speed Working speed Max gradient when empty ENGINES (*) ENGINE Power supply Cylinders no. Displacement Motor power Engine rpm Diesel engine coolant Engine oil type Diesel engine oil pan capacity (maximum / minimum) (*) For other data/values of the diesel engine, refer to the related Manual. (**) See the coolant characteristics table below and the reference specifications table. (**) See the engine oil characteristics table below and the reference specifications table. AGIP ECO PERMANENT CHARACTERISTICS Boiling point Freezing point Colour Density at +20 °C AGIP SIGMA TRUCK PLUS 15W-40 CHARACTERISTICS SAE GRADE Viscosity at +100 °C Viscosity at +40 °C Viscosity at -25 °C Viscosity index Flash point O.C. Pour point Density at +15 °C °C °C kg/l mm /s mm /s mm /s
2 2 2

mm mm mm mm mm mm

1.400 1.810 2.220 2.620 600 700

l l mm

3.500 2.000 1.800

m /h m
2

3

14.000 50 45

kW

km/h km/h %

40 15 20

cm
3

Perkins Diesel 4 4.400 100/75 2.200 Eco Permanent (**) Sigma Truck Plus 15W-40 (***) 7.0-7.5 kg

HP/kW Rpm AGIP AGIP

°C °C kg/l

+108 -40 Turquoise 1,087

15W-40 13,7 100 6.700 138 +230 -27 0,885

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 14

HYDRAULIC SYSTEM Drive system maximum pressure Maximum pressure of the vacuum fan system Maximum pressure of the services system Hydraulic system oil viscosity [with ambient temperature over +10 °C (*) Hydraulic system oil type bar bar bar cSt AGIP 350 250 200 46 ARNICA S (ISO 46) (**)

Braking system oil type ATE Brake Fluid DOT 3 (***) (*) If the machine is used at temperatures below +10 °C, the oil should be replaced with other equivalent oil having a viscosity of 32 cSt. For temperatures below 0 °C, using oils with even lower viscosities. (**) See the hydraulic oil characteristics table below and the reference specifications table. (**) See the brake fluid characteristics table below and the reference specifications table.

AGIP ARNICA S (ISO 46) CHARACTERISTICS Viscosity at +40 °C Flash point O.C. Pour point Density at +15 °C ATE – BRAKE FLUID DOT 3 CHARACTERISTICS Dry boiling point Colour CLIMATE CONTROL SYSTEM DATA (optional) Gas type Gas quantity REAR CAMERA DATA (optional) Brand Rear colour camera DIMENSIONS AND WEIGHTS Machine length Machine width Machine height when in operation Machine height in transfer Brush change machine height Machine weight in running order Maximum weight in running order GENERAL SPECIFICATIONS OF THE VEHICLE Turning circle Service brake Parking and emergency brake Rear wheel traction Front and rear wheels Tyre pressures Suspensions Machine height control Diesel tank capacity Water tank capacity (optional) Maximum noise level in the driving seat (Sound Pressure Level) (ISO/EN3744) at maximum rpm (Lpa) Guaranteed sound power level (2000/14/EC) at maximum speed (Lwa) Electrical system supply Starter battery

mm /s °C °C 3 kg/m

2

46 +315 -30 920

°C

+245 Light yellow

kg

Reclin 134a 1.0

Brigant LCD 5” colour display

mm mm mm mm mm kg kg

4.480 1.755 2.500 2.540 2.585 4.500 5.800

mm litres litres dB (A) dB V V

4.250 Hydraulic Mechanical Hydraulic 205/65 R17.5 6 bar 4 hydraulic and independent Electronic on all 4 wheels 105 200 77 109 12 12 – 160 Ah

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 15

WIRING DIAGRAM

Fuses
F4A F3A F2A F1A HYDRAULIC OIL RADIATOR FAN FILTER SHAKER ENGINES GLOWPLUGS GENERAL POWER SUPPLY 30A 40A 80A 120A

Fuses
F16 F15 F14 F13 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 INDICATORS – STOP LIGHTS - LIGHT SWITCHES REVERSE BUZZER – HORN – CAB VENTILATION - AIR-CONDITIONER SUSPENSION SUPPLY SENSORS - MULTIFUNCTION INSTRUMENT - ALARM BUZZER RIGHT SIDE BRUSH ROTATION - LEFT SIDE BRUSH ROTATION DEBRIS HOPPER MOVEMENTS CENTRAL BRUSH UP/DOWN – RIGHT SIDE BRUSH UP/DOWN – LEFT SIDE BRUSH UP/DOWN – LOADING SCREW CONVEYORS FORWARD PEDAL – FUEL PUMP - PREHEATING UP/DOWN/IN/OUT THIRD BRUSH - VACUUM WIPER WASHER - RADIO - HEATED MIRRORS - FLASHING LIGHTS CIGARETTE LIGHTER - OPTIONAL RIGHT INDICATOR LIGHTS LEFT INDICATOR LIGHTS EMERGENCY ARROWS – HIGH BEAM LIGHTS – LOW BEAM LIGHTS WORKING HEADLIGHTS +30 INSTRUMENT PANEL – RADIO MEMORY FAN, HEATER, AIR CONDITIONER - AIR CONDITIONER COMPRESSOR 10A 20A 15A 15A 15A 20A 15A 15A 20A 15A 10A 10A 25A 15A 7.5A 25A

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 16

HYDRAULIC DIAGRAM

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 17

USING THE MACHINE
WARNING: Adhesive labels are applied on some points of the machine, indicating: – DANGER

– WARNING

– CAUTION While reading this manual, the operator must fully understand the meaning of the symbols depicted on the plates. Do not cover the plates for any reason and replace them immediately if they are damaged or unreadable. This machine has been designed as a high performance and load carrying capacity sweeping machine and, thanks to the 4-wheel steering, can operate in confined spaces. Therefore, it is characterized by a very small track and tight steering angles. These characteristics of the machine can, under certain conditions, determine instability during movement. This instability can be caused by the speed, sudden manoeuvres, operation in the presence of a steep slope, low tyre pressure, the weight of waste in the hopper, or the hopper lifted. For these reasons, the machine must be driven by a qualified operator, properly trained on the correct use of the machine and aware of potential risks.

BEFORE START-UP
1. Check the fuel level and the reserve light by turning the ignition key on the instrument panel one position clockwise and leave it in this position. If necessary, open the right side hatch, turning the key, unscrewed the cap of the tank, and refuel through the nozzle. CAUTION! To allow the fuel to expand, do not fill the tank more than 4 cm from the neck of the filler nozzle. 2. Check the water level of the diesel engine cooling system. 3. Check the fluid level of the brake system. 4. Check the level of the hydraulic oil. 5. Check the level of the engine oil. 6. Check the level of the windscreen washer liquid. 7. Check the engine air filter is not clogged. 8. Check the tyre pressures. 9. Check that the machine does not have hoods/hatches open and is in normal use conditions.

START-UP AND STOP OF THE DIESEL ENGINE
Start-up of the diesel engine 1. Insert the battery, by turning the key of the release device in a horizontal position. 2. Sit in the driver's seat and check that the parking brake is engaged. 3. Adjust the position of the seat as required with the lever 4. Fasten the seat belts. CAUTION! The seat belts should always be fastened to increased operator safety. 5. Move the engine accelerator lever to minimum.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 18

6. Check that the brushes are lifted, otherwise check that the brush activation switch is off, to prevent any inconvenience caused by the immediate starting of the brushes when the engine is started. 7. Check that the machine is in neutral [drive pedal is not pressed]. 8. Insert the start-up key, turning it clockwise by one position and leave it in this position. At this point the following lights light on the panel: • diesel engine glow plugs preheating indicator light • battery charger indicator light • diesel engine oil pressure indicator light • hydraulic parking brake indicator light When the glow plug preheating light turns off, turn the ignition key fully clockwise, and release it when the diesel engine starts. CAUTION! Especially for colder climates, the preheating time must be respected to prevent excessive smoke. CAUTION! So as not to damage the starter motor when starting the diesel engine, do not turn the ignition key for too long (maximum 15 seconds). If the engine doesn't start, wait for one minute before trying to start the engine again. Before repeating the start-up, turn the key anticlockwise to its initial position. If after two attempts the diesel engine still does not start, do not insist, but request the intervention of the person in charge of the machine. 9. Check that with the engine running, all warning lights are off. 10. With the accelerator halfway, leave the engine to warm up for a few minutes, especially in conditions with low ambient temperature. 11. Move the accelerator lever of the engine until the rev. counter shows 2,000 rpm (the ideal movement and working speeds) Shut-down of the diesel engine 1. Move the accelerator lever of the engine to idle for a few minutes to stabilize the system. 2. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it.

START-UP AND STOP OF THE MACHINE
The machine can be started in one of the two positions: – TRANSFER MODE – WORKING MODE Below are the relevant operations to be performed. WARNING! To avoid abrupt changes of direction during steering manoeuvres, always use extreme caution and drive at low speeds, especially when the debris hopper is full or the machine is on a slope. CAUTION! Before starting the transfer, check and, if necessary, adjust the tyre inflation pressure [6 Bar – 87 psi].

SETTING THE MACHINE IN TRANSFER MODE
The transfer mode must be set as follows during the transfer of the machine (without brushing): 1. Start the diesel engine as shown in the previous paragraph. 2. Make sure the hydraulic parking brake is engaged. 3. Verify that the hopper is lowered and that the related indicator light is off. CAUTION! Do not exceed 5 km/h with debris hopper raised, the body raised indicator signals the dangerousness of the manoeuvre.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 19

4. Make sure the vacuum fan is turned off; the button must be disabled. 5. Make sure the central brush is raised; the button must be disabled. 6. Check that the side brushes are raised; the buttons must be disabled. 7. Lift the machine by placing the selector in a central position and the side brushes by pressing the button 8. Get out of the machine and hook up the chains of the two side brushes by pressing the red button. 9. Sit in the driver's seat and disengage the parking brake. 10. Move the accelerator lever gradually forward and adjust the engine speed on the display to 2,000 rpm. 11. Make sure the selector is set on transfer (machine in the intermediate position). 12. Start the transfer, manoeuvring the machine with the steering wheel and slowly pressing the right pedal for the forward movement or the left for reverse. The forward speed is adjustable from zero to the maximum value according to the pressure exerted on the pedal. WARNING! Remember that steering is in all four wheels. Use the mirrors to check the manoeuvring space in tight placers. WARNING! Remember to place the machine in transfer mode before tackling an obstacle (such as a sidewalk). Stop the machine in transfer mode 1. To stop the machine, release the forward/reverse pedal 2. To stop the machine quickly, press the service brake pedal as well. 3. Move the accelerator lever of the engine to idle for a few minutes to stabilize the system. 4. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it.

SETTING THE MACHINE IN WORKING MODE
The machine must be set in the working mode to sweep and vacuum. 1. Check the position of the filter exclusion lever. If the surfaces to be cleaned are wet, exclude the filter. 2. Start the diesel engine as shown in the related paragraph and engage the parking brake via the appropriate button. 3. Verify that the hopper is lowered and that the related indicator light is off. 4. Move the accelerator lever gradually forward and adjust the engine speed on the display to 2,000 rpm. 5. Make sure the selector is set on work (machine in the low position). 6. Start the vacuum fan by turning the selector to the desired position. 7. Start the descent and rotation of the central brush, by means of the button. 8. If necessary, start the descent and rotation of the side brushes and the third brush by pressing the related buttons. 9. Check and, if necessary, refill the water tank of the dust suppression system, 10. If necessary, start the water spraying system of the side brushes and third brush dust suppression system by pressing the appropriate button. The spraying system may be required if the pavement is dry and very dusty. If spraying is not necessary for one or more brushes, act manually on the corresponding taps. CAUTION! Do not leave the sweeping machine at a standstill with the brushes rotating. 11. Translate and lower the arm of the third brush in the working position by means of the joystick. 12. Disengage the parking brake with the button.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 20

13. Start the sweeping operation, manoeuvring the machine with the steering wheel and slowly pressing the right pedal for the forward movement or the left for reverse. The forward speed is adjustable from zero to the maximum value according to the pressure exerted on the pedal. During work the machine collects both light material such as dust, paper, leaves, etc.. as well as heavy material such as stones, bottles, etc.. 14. Avoid staying with the machine in the same position for too long with the brushes rotating: Unwanted furrows could be made on the pavement. 15. In the event of very dusty areas, turn off the vacuum turbine and activate the filter shaker every 20-30 minutes by pressing the related button, after having turning off the vacuum action of the turbine. NOTE All brushes can be lowered and raised even when the machine is moving. The brushes only turn when lowered. CAUTION! If the ground is wet during operation, move the hopper filter exclusion lever to the by-pass position, in order to prevent the fabric filter to become wet, resulting in its blockage. CAUTION! If it is necessary to collect piles of wet leaves during operation, raise the machine in transfer mode and proceed slowly with a maximum vacuum action. Stop the machine in working mode 1. To stop the machine, release the pedal To stop the machine quickly, press the service brake pedal as well. 2. Engage the parking brake with the button. 3. Disengage the water pumps of the dust suppression system using the appropriate button. 4. Raise the third third brush by means of the joystick. 5. Raise the two side brushed by means of the related buttons. NOTE The third brush is equipped with a protection system against accidental impacts (pavements, walls, holes) that allows the automatic withdrawal of the brush. To put it back in place simply overcome the resistance of the safety spring and rotate the brush forward. 5. Raise the other two side brushes by means of the relative buttons. 6. Raise the central brush by means of the relative button. 7. Stop the vacuum fan by means of the relative button. 8. Move the accelerator lever of the engine to idle for a few minutes to stabilize the system. 9. Verify that the hopper is lowered and that the related indicator light is off. 10. Engage the parking brake with the lever. 11. Turn off the engine by turning the ignition key counter-clockwise until it stops, then remove it. 12. If open, close the taps of the dust suppression system positioned up

SETTING THE MACHINE IN CHANGE CENTRAL BRUSH MODE
To replace the central brush, the machine must be set in the change central brush mode. 1. Start the diesel engine as shown in the related paragraph and engage the parking brake via the appropriate button. 3. Verify that the hopper is lowered and that the related indicator light is off. 4. Move the accelerator lever gradually forward and adjust the engine speed on the display to 2,000 rpm. 5. Place the machine in the change central brush position (machine in the high position) acting on the appropriate selector. CAUTION! DO NOT travel with the machine in a high position (change brush) so as not to spoil the toe-in of the wheels. 6. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it. 7. To restore the machine in the working or transfer position carry out steps 6 to 1 in reverse.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 21

EMPTYING THE DEBRIS HOPPER
CAUTION! If the machine has problems to carry out collection, check the debris hopper filling state and, if necessary, empty it. Before unloading operations, it is advisable to clean the machine filter by means of the two electric filter shakers. Proceed as follows to activate the filter shakers: Pressing the filter shaker switch located on the instrument panel activates the motors of the two filter shakers releasing the dirt captured by the filter. WARNING! Always disable the vacuum turbine before turning on the electric filter shaker. CAUTION! In order to have an efficient vacuum action, operate the filter shaker every 20-30 minutes to clean the filter and always before emptying the debris hopper, after having previously turning off the vacuum action of the turbine. 1. Switch off the spraying system of the dust suppression (if turned on). 2. Disengage the two side brushes and the third brush. 3. Disengage the central brush and turn of the vacuum 4. Stand next to the debris hopper ready for unloading. 5. Engage the hydraulic parking brake. 6. Activate the debris hopper lifting button. 6. Once the hopper has reached its maximum height (1,800 mm), activate the debris hopper tilt button. 7. Once the hopper has reached its maximum tilt, activate the debris hopper opening button. If the hopper is filled with dry or compacted material and does not completely empty, push the hopper tilt button to shake the hopper and help the descent of the material. 8. After discharge, activate the hopper tilt button to restore it to the horizontal position. 9. Having reached the horizontal position, push the button to block the discharging bulkhead of the hopper. 10. with the discharging bulkhead blocked, press the button to lower the hopper until the red hopper raised warning light with triangle on the instrument panel turns off.

WARNING! Before emptying the debris hopper, ensure that there is nobody within the operating range of the machine. WARNING: with debris hopper up, move the machine very slowly. Maximum speed 5km/h. Avoid unloading with the machine on an incline or on soft ground. Do not activate the filter shaker when the hopper is raised.

USE OF THE WINDSHIELD WIPER/WASHER
1. Operate the switch to spray the cleaning solution on the windshield. 2. Operate the switch to start and stop the windshield wiper. Regularly check the fluid level in the tank by opening the front right side cover.

USE OF THE HEATING SYSTEM OF THE OPERATOR'S CAB
1. To turn on the heater in the cab, turn the knob clockwise as required. 2. Adjust the fan speed with the three-position switch. 3. To turn off the heating, turn the knob of the fan counter-clockwise until it stops.

USE OF THE AIR CONDITIONING SYSTEM OF THE OPERATOR'S CAB (Optional)
1. Activate the air conditioning button. 2. Turn the heating knob depending on the air conditioning requirement in the cab. 3. Adjust the fan speed with the three-position switch.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 22

OPERATION OF THE LIGHTING SYSTEM
– lights off, with switch on symbol O – position lights on with switch on the second notch – dipped headlights on, with switch on the third notch - main beam on, with switch on the symbol and lever lowered – main beam temporarily on, lifting the lever – Right-turn indicator engaged, bringing the lever up – left-turn indicator engaged, bringing the lever down

– activation of the buzzer by pressing the button on the end of the lever

ACTIVATION OF THE EMERGENCY LIGHTS
Activate emergency lights with the switch on the instrument panel.

ACTIVATION OF THE WORKING LIGHTS
Activate the right and left working lights (on the roof of the cab) with the switch on the instrument panel above the windshield.

MANUAL LIFTING OF THE DEBRIS HOPPER
To raise/lower the debris hopper manually (in the event the diesel engine fails), proceed as described below. MANUAL LIFTING OF THE DEBRIS HOPPER 1. Make sure that the machine is on firm and level ground, especially if the waste container is full. 2. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it. 3. Open the left rear door with the key provided. 4. Remove the pump's manual activation lever from its original location. 5. Position the lever on the manual activation pump. 6. Check that the debris hopper lifting/lowering sliding switch is in the lifting position and open the valve on the pipe. 7. Carefully activate the pump with the lever and completely lift the debris hopper. 8. Manually close the two debris hopper raised locking taps.

WARNING! For safety reasons, close BOTH locking taps before operating in the area of the raised hopper. This is necessary even if the hopper lifting cylinders are equipped with parachute valves, which prevent the unforeseen descent of the hopper in case of breakage/leak of a hydraulic pipe/fitting. Manual lowering of the debris hopper 1. Manually open the two debris hopper locking taps. 2 Move the slide switch in the lower position and activate the pump with the lever until the debris hopper is fully lowered. 3. Remove the lever from the pump and put it back into its original position. 4. Return the cursor of the pump to the centre. 5. Close the side door with the supplied key.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 23

MANUAL TIPPING OF THE CAB
1. Make sure that the machine is on firm and level ground. 2. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it. 3. Open the right front door with the provided key. 4. Remove the pump's manual activation lever from its original location. 5. Position the lever on the manual activation pump. 6. Check that the cab lifting/lowering slide switch is in the lifting position. 7. Carefully activate the pump with the lever and tilt the cab completely. The blocking hook of the cab has an electric switch, which signals on the instrument panel when the cab is fully hooked in the drive position.

USE OF THE REAR VACUUM HOSE (Optional)
To vacuum debris/dust with the rear vacuum hose (optional), proceed as follows. 1. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it. 2. Remove the vacuum hose from the guides of its rear support, and unwind it. 3. Remove the plug from the metal end of the hose. 4. Open the right side door (front) of the machine and operate the lever to exclude the lower vacuum, located under that of the filter by-pass. 5. Close the right side door of the machine. 5. Start the diesel engine as shown in the related paragraph. 6. Verify that the hopper is lowered and that the related indicator light on the instrument panel is off. 7. Move the accelerator lever gradually forward and adjust the engine speed on the display to: 2,000 rpm 8. Start the vacuum fan with the related button and move the vacuum speed selector to the third level (maximum). 9. Hold the hose firmly with both hands and vacuum the waste on the ground. 10. Disengage the parking brake with the button. 11. With the help of a second operator, begin the collection of the debris with the rear vacuum hose, holding it as shown in the figure. During work the machine collects both light material such as dust, paper, leaves, etc.. as well as heavy material such as stones, bottles, etc.. 12. To return the machine to the vacuum function with the vacuum nozzle, perform steps 2 to 10 in reverse.

USE OF THE HIGH PRESSURE LANCE (Optional)
The machine can be equipped with a low pressure water supply system (optional) to reduce particulate emissions and a high pressure lance system (optional) to be used for cleaning the machine, as well as other applications (cleaning between parked cars, poorly accessible places, etc ...). WARNING! Do not use the pressurized water lance for washing inside the hopper, as this may wet the filter located at the top of the hopper. The following describes the procedure used.

WARNING! Do not operate the high pressure pump with the tanks empty or in reserve (the pump could be damaged if it runs dry). 1. Open the right door (front) with the key in order to withdraw the high-pressure water lance. 2. Take the lance and unwind its hose. 3. Turn the tap in the position that excludes the sprinklers for the brushes and diverts the flow to the lance 3. Start the diesel engine at low speeds, as indicated in the related paragraph. 5. Press the water spraying button to the brushes (the electric pump starts) 6. Take the engine to the desired speed. 7. Use the lance by pressing the lever on the gun.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 24

WARNING! Adequately protect body parts (eyes, hair, hands, etc..) when cleaning with with compressed air or water guns. WARNING! Do not leave the high-pressure pump running for a long time without using the lance. 8. After using the lance, perform steps 1 to 7 in reverse order.

USE OF THE VIDEO CAMERA KIT (Optional)
Press the switch when the ignition key is inserted to turn on the camera and video equipment. The image transmitted from the rear camera is displayed on the monitor. For the use of the other switches on the right side of the monitor, refer to the manual of the video camera kit.

USE OF THE FILTER LIFTING CRANE (Optional)

WARNING: this operation must be performed by 2 people. 1. Engage the hydraulic parking brake. 2. Raise the crane's hydraulic piston located on the right side of the hopper, using the button on the yellow control panel and manually rotate it so that the hooks at the ends of the steel cables are aligned with the eyelets on the hopper roof. 4. Manually attach the filter cover to the cables of the winch, through the two lifting eyelets, after having disconnected the quick connectors and disconnected the electric cables of the two cameras and the two filter shakers (electrical connections with quick release connectors). 5. Lift the cover controlling the electric winch of the cables through the button on the yellow control panel. 6. Place the cover with the filter on two trestles (operation to be carried out by 2 people). 7. Unhook the hooks from the eyelets of the cover. 8. Manually rotate the crane until it is positioned in correspondence with the new debris hopper filter kit. 9. Hook the hooks to the eyelets of the cover. 10. Electrically lift the winch. 11. Manually rotate the crane until the filter kit is positioned in correspondence with hopper. 12. Lower the winch cable, pressing the button on the yellow control panel, until the filter kit is perfectly housed in the hopper. Pay special attention to the seal, replacing it immediately if it is damaged. 13. Manually rotate the crane and hydraulically lower the piston by pressing the button on the yellow control panel until it reached its housing. 14. Hook the quick couplings of the hopper to the cover of the filter. 15. Connect the cable of the filter shaker and rear camera. WARNING: these operations must be carried out using gloves to protect the hands from contact with dangerous elements. Wear protective goggles and a mask to protect from dust.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 25

OPERAZIONI DA OPERATIONS TO PERFORM AFTER USING THE MACHINE
At the end of the work day you must perform the following operations. 1. Turn off the water pump of the dust suppression system with the switch. 2. If open, close the water taps of the dust suppression system. 3. Lift the third brush, moving back the joystick, shortly afterwards the third brush stops the rotation 4. Lift the side brushes by pressing the respective buttons; the rotation of the brush stops simultaneously. 5. Stop the vacuum fan by pressing the respective button. 6. Lift the central brush by pressing the respective button; the rotation of the brush stops simultaneously. 7. Turn the engine accelerator level to idle and leave it in this condition for a few minutes to stabilise the system. 8. Check that the debris container is lowered and that its indicator light, located on the instrument panel, is turned off. 9. If they are on, turn off the lights and flashing lights. 10. Engage the parking brake and turn off the engine by moving the start-up key to OFF and remove it.

DRAINING THE WATER TANK OF THE DUST SUPPRESSION SYSTEM
When it is necessary to drain the water tank of the dust suppression system, proceed as follows. CAUTION! Two sensors are placed on the tank, the uppermost one warns that you have reached the reserve level and is connected to the warning light on the instrument panel. The sensor located below stops the water pump in order to avoid damaging it. 1. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it. 2. Open the right front lid, unscrew the plastic water loading cap and remove it. 3. Open the tap located at the base of the tank and drain all the water it contains. 4. Replace the metal cap and plastic cap.

CLEANING THE NOZZLES OF THE DUST SUPPRESSION SYSTEM ON THE SIDE BRUSHES (optional)
WARNING! Adequately protect the body parts (eyes, hair, hands, etc.) when cleaning with compressed air or water guns. Preliminary operations 1. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it. 2. Unscrew the ring nuts of the nozzles. 3. Clean any impurities from the nozzles and filters with a jet of compressed air. 4. Remove any deposits of limestone. If necessary, replace the metal filter and the nozzles. 5. Refit the filters and nozzles and secure them with the ring nuts.

WATER PUMP FOR DUST SUPPRESSION SYSTEM (optional)
The electric water pump is located behind the operator's cab in correspondence with the front right side door and requires no maintenance. It is however necessary to frequently clean the filter located near the pump to prevent impurities from damaging the water pump.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 26

TOWING THE MACHINE
WARNING! The machine can be towed for short distances and at low speeds. It cannot be towed at high speed for long distances. The machine is equipped with an emergency braking system, which intervenes if a hydraulic pipe of the braking circuit breaks or if an electrical fault occurs on the braking circuit. To move the machine by tow it is necessary to proceed as follows. 1. Place the machine in TRANSFER position, pressing the appropriate switch in the operator's cab. 2. Completely lift the debris hopper, open the two rear side lids and lock the two lifting pistons, closing the appropriate safety taps; if the engine or hydraulic system for lifting the hopper do not work, open the rear left side lid and operate the manual to lift the hopper. 3. DO NOT insert the parking brake and turn off the engine, moving the start-up key to position 1 and DO NOT remove it (this way the solenoid valves and the hydraulic parking brake button do not intervene and the parking brake accumulator enables 4-5 braking to be carried out; in any case, the service brake, even without the power brake, with engine off, allows you to stop the machine by acting on the pedal). 4. Loosen, with two turns, the screw of the traction system pump placed in the rear of the machine and connected to the engine (the lower one painted RED). 5. Open the two taps, lower the debris hopper and close the side lids. 6. Hook the machine to the front tow hitch and tow it. 7. At the end of the towing of the machine, tighten the RED screw.

TRANSPORT/MOVEMENT
To transport/move the machine, use the hooks and procedures for anchoring indicated below. WARNING! The anchoring/lifting of the machine must be performed by qualified personnel. Available hooks The machine is equipped with the following hooks: • No. 2 lifting hooks, for use with the empty debris container. • No. 1 front towing/anchoring hook. • No. 1 rear towing/anchoring hook. Anchoring For anchoring the machine in case of transport, the operations to be performed are as follows: • Set the machine in transfer mode (see procedure in the specified paragraph). • Apply the hydraulic parking brake. • Remove the start-up key. • Close all lids, bulkheads, etc. • Anchor the machine with the front and rear tow hooks. • Anchor the machine with appropriate bands respectively inserted above the rear axle support and on the front left and right platforms for access to the cab. Temporary lifting For the temporary lifting of the machine, the steps to perform are the following: 1. Set the machine in transfer mode (see procedure in the specified paragraph). 2. Verify that the debris container is empty. WARNING! If in an emergency it is necessary to lift the machine with the debris container not empty, operate with greater caution, as the weight of the debris results in an unbalance of the machine, and the hooks are also subjected to greater stress. 3. Engage the parking brake. 4. Remove the start-up key.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 27

5. Close all lids, bulkheads, etc. 6. Anchor the machine with suitable ropes to the two lifting hooks. 7. Carefully lift the machine, for the shortest possible time, with a suitable lifting system and in compliance with current safety regulations.

LONG INACTIVITY OF THE MACHINE
If not planning to use the machine for more than 30 days, you should: 1. Empty the water tank of the dust suppression system, operating as indicated in the specific paragraph. 2. Put the machine in idle mode operating as described in the section "Operations to be done after using the machine." 3. Store the machine in a closed, dry, clean environment, protected from weather and with the following ambient values: • Temperature: from +1 °C to +50 °C • Humidity: maximum 95% 4. Disconnect the negative battery connector. 5. Treat the diesel engine as indicated in its Manual.

FIRST PERIOD OF USE
1. After the first period of use (first 8 hours) it is necessary to check the tightness of the means of attachment and connection; check that the visible parts are intact and do not leak. 2. After the first 50 hours of work, carry out the controls and the replacements provided for in scheduled maintenance.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 28

MAINTENANCE OPERATIONS ON THE MACHINE
WARNING! The maintenance operations are to be carried out with the machine off (start-up key removed) and parking brake engaged (button). Also, read all instructions of the Safety chapter, before performing maintenance. All scheduled or extraordinary maintenance operations must be performed by qualified personnel or at an authorised Comac SpA service centre.

CLEANING THE DEBRIS HOPPER (after each use)
Adequately protect the body parts (eyes, hair, hands, etc.) when cleaning with compressed air or water guns. Preliminary operations 1. After emptying the debris container, take the machine to an area for cleaning/washing, then activate the hydraulic parking brakes. 2. Lift, tilt and open the lid of the debris container, operating as indicated in the specific paragraph. 3. In case you need to access the engine compartment, first close the 2 locking taps of the two hopper lifting pistons, operating as indicated in the specific paragraph. WARNING! DO NOT internally clean the debris container with a jet of pressurised water, as this jet may wet the cloth filter placed in the upper half of the debris hopper. 4. Remove the two locking pins, remove the horizontal grill positioned between the hopper and the filter area and clean it. 5. Replace the grill in place and lock it with the two locking pins. 6. Carefully check the integrity of the perimeter seal of the hopper lid and, if necessary, replace it.

CLEANING THE DEBRIS HOPPER FILTER
The pocket filter does not require maintenance at all, other than periodic use of the filter shaker. if a vacuum drop is detected, clean the filter carefully in the following way: 1. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it. 1. Engage the hydraulic parking brake. 2. Position the bridge crane or lifting crane until the hooks placed at the ends of the steel cables correspond with the lifting eyelets of the roof of the hopper. 4. Manually attach the filter cover to the wires, through the two lifting eyelets, after removing the quick hooks and after disconnecting the electric wires of the cameras and the two filter shakers (electrical connections with quick uncoupling connectors). 5. Lift the cover and place it on two stands (operation to be carried out by 2 people). 6. Carefully clean the filter using a vacuum cleaner with a filter suitable to the type of dust to remove 7. Reassemble everything in reverse order. Pay particular attention to the seal, if damaged replace it immediately. WARNING: these operations must be carried out using gloves to protect the hands from contact with dangerous elements. Wear protective goggles and a mask to protect from dust.

CLEANING THE DEBRIS HOPPER FILTER WITH LIFTING CRANE (optional)
WARNING: this operation must be carried out with 2 people. The pocket filter does not require maintenance at all, other than periodic use of the filter shaker. if a vacuum drop is detected, clean the filter carefully in the following way: 1. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it. 1. Engage the hydraulic parking brake.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 29

2. Raise the crane's hydraulic piston located on the right side of the hopper, using the button on the yellow control panel and manually rotate it so that the hooks at the ends of the steel cables are aligned with the eyelets on the hopper roof. 4. Manually attach the filter cover to the wires of the electric winch, through the two lifting eyelets, after removing the quick hooks and after disconnecting the electric wires of the cameras and the two filter shakers (electrical connections with quick uncoupling connectors). 5. Lift the cover, controlling the electric winch lifting the metallic cable via the yellow button on the control panel. 6. Place the cover with the filter on two trestles (operation to be carried out by 2 people). 4. Attach the filter cover to the cables of the hydraulic winch through the two lifting eyelets, after removing the quick hooks. 5. Lift the cover, controlling the crane via the button located in the cab 6. Fully remove the filter (operation to be performed by 2 people). 7. Carefully clean the filter using a vacuum cleaner with filter suitable to the type of dust to remove 8. Reassemble everything in reverse order. Pay special attention to the seal, replacing it immediately if it is damaged.
WARNING: these operations must be carried out using gloves to protect the hands from contact with dangerous elements. Wear protective goggles and a mask to protect from dust.

REPLACEMENT OF DEBRIS HOPPER AND VACUUM DUCT GASKETS
1. After emptying the debris container, take the machine to an area for cleaning/washing, then activate the hydraulic parking brakes. 2. Lift, tilt and open the lid of the debris container, operating as indicated in the specific paragraph. 3. Close the 2 locking taps of the two hopper lifting pistons, operating as indicated in the specific paragraph. 4. Remove the fixing screws and replace the two gaskets. 5. Retighten the screws, open the taps and lower the debris hopper.

CHECKING AND ADJUSTING THE CENTRAL BRUSH
NOTE Brushes of different hardness are provided. This procedure is applicable to all types of brushes. The adjustment of the surface pressure of the central brush is NOT required since it is already set at the factory; an automatic pressure regulating system enables the same brush pressure to be maintained on the ground in all work conditions. Using the selector switch on the control dashboard in the cab, you can adjust the height of the entire machine in three different positions.

CHECKING AND ADJUSTING THE SIDE BRUSHES
NOTE Brushes of different hardness are provided. This procedure is applicable to all types of brushes. Checking Check the correct height from the ground and inclination of the side brushes, operating as follows: 1. Take the machine to level ground. 2. With the machine stopped, completely lower the side brushes and run them for a few seconds. 3. Stop and lift the side brushes, then move the machine. 4. Engage the parking brake and turn off the engine by turning the ignition key to OFF and removing it. 5. Check that the marks left by the side brushes are, in size and orientation, as shown below: – the right hand side brush must touch the floor at an arc of between "11 o'clock" and "4 o'clock". – the left hand side brush must touch the floor at an arc of between "8 o'clock" and "1 o'clock". 5. Proceed to adjust of the brushes that have different fingerprints, operating as indicated below.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 30

Adjusting the height of the side brushes
From either side of the machine, turn the tensioning nut of the spring, considering that: • by unscrewing the nut the brush lowers; • by tightening the nut the brush is lifted.

Adjusting the lateral position of the side brushes This adjustment is useful to optimise the lateral position of the brushes with respect to the central brush. To adjust, loosen/tighten the nuts by varying the lateral position of the brushes. The best adjustment is to position the arms in slight tension towards the outside. When the excessive consumption of brushes does not allow more adjustment, replace them as indicated in the specific paragraph.

Adjusting the forward inclination angle of the side brushes From both sides of the support arm of the brush loosen the two locknuts, then adjust the forward inclination angle. When the adjustment has been carried out, tighten the locknuts.

Adjusting the side inclination angle of the side brushes Within the support arm of the brush loosen the two horizontal locknuts, then adjust the side inclination angle. When the adjustment has been carried out, tighten the screws. The adjustment of the surface pressure of the moving brush is NOT required since it is already set at the factory; an automatic pressure regulating system enables the same brush pressure to be maintained on the ground in all work conditions. Using the selector switch on the control dashboard in the cab, you can adjust the height of the entire machine in three different positions.

CHECKING AND ADJUSTING THE THIRD BRUSH (Optional)
NOTE Brushes of different hardness are provided. This procedure is applicable to all types of brushes. Checking the position of the third brush Check the correct height from the ground and inclination of the third brush, operating as follows: 1. Take the machine to level ground. 2. Start the machine and bring the arm of the third brush right in front of the driver's cab, operating as indicated in the specific paragraph. 3. With the machine stopped, completely lower the third brush and run it for a few seconds.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004 Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 31

4. Stop and lift the third brush, then move the machine. 5. Engage the parking brake and turn off the engine by moving the start-up key to OFF and remove it . 6. Check that the mark left by the third brush is, in size and orientation, as shown below: - The brush must touch the floor at an arc of between "10 o'clock" and "2 o'clock". - The angle of forward inclination angle of the brush must be 10 degrees. 7. Proceed to adjust the brush, if it has a different mark, operate as shown below.

Adjusting the inclination angle of the third brush Act on the two self locking nuts at the two ends of the horizontal bar, considering that: • by unscrewing the nut the brush lowers; • by tightening the nut the brush is lifted.

Adjusting the side inclination angle of the third brush Loosen the locknuts, then adjust the side inclination angle. When the adjustment has been carried out, tighten the locknuts. When the excessive consumption of brush does not allow more adjustment, replace it as indicated in the specific paragraph. The adjustment of the surface pressure of the third brush is NOT required since it is already set at the factory; an automatic pressure regulating system enables the same brush pressure to be maintained on the ground in all work conditions. Using the selector switch on the control dashboard in the cab, you can adjust the height of the entire machine in three different positions.

CENTRAL BRUSH REPLACEMENT
1. Turn off the brush motor, operating the lever for lifting the brush. 2. Acting on the selector switch place the machine in the highest position from the ground (Brush Change Position). 3. Engage the parking brake and turn off the engine by moving the start-up key to OFF and remove it . 4. Loosen the screws that hold the lower right grey bulkhead and remove it. 5. Loosen the screws that hold the right brush holder arm and remove it. 6 Remove the used brush and insert a new one paying attention to inserting it in the right place. 7. Refit the brush holder arm and the side bulkhead. 8. Turn on the machine and place it in Transfer or Working position. WARNING: these operations must be carried out using gloves to protect the hands.

REPLACEMENT OF SIDE BRUSHES / THIRD BRUSH
1. Turn off the brush motor, operating the lever for lifting the brush. 2. Acting on the selector switch place the machine in the highest position from the ground (Brush Change Position). 3. Engage the parking brake and turn off the engine by moving the start-up key to OFF and remove it . 4. Loosen the lower screws that support the brush, then remove it.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 32

6. Replace the worn brush with a new one. 7. Screw the lower tightening screws. 8. Turn on the machine and place it in Transfer or Working position. WARNING: these operations must be carried out using gloves to protect the hands.

REPLACING THE FRONT, REAR AND SIDE FLAP RUBBER
1. Engage the parking brake by acting on the appropriate button. 2. Acting on the selector switch place the machine in the highest position from the ground (Brush Change Position). 3. Turn off the engine by turning the start-up key to OFF position, and remove it. 4. Loosen the screws that hold the lower right grey bulkhead and remove it. 5. Loosen the screws that hold the right brush holder arm and remove it. 6. Remove the central brush. 7. Loosen the locking screws of the rubber flaps and replace the worn flaps. 8. Proceed in the opposite direction from point 7 to 3 and put the machine in transfer or working position. WARNING: these operations must be carried out using gloves to protect the hands.

HYDRAULIC OIL REPLACEMENT
WARNING: oil must be replaced every 1000 hours, regardless of its level, or every year. 1. Stop the machine, engage the parking brake and turn the key to position 0. 2. Open the left rear lid of the machine and unscrew the cap of the hydraulic oil tank. 3. Remove the mesh filter placed under the cap, clean it and put it back in place. 4. Unscrew the cap at the end of the rubber tube that comes out from the bottom of the hydraulic oil tank and drain the oil into a container placed under the machine. 5. Once all the hydraulic oil is drained, retighten the cap. 6. Fill the hydraulic oil tank until the upper indicator light appears full. 7. Retighten the fuel cap and close the side door of the machine. WARNING: dispose of the filters and used oil in the correct manner

WARNING: protect yourself with DPI suitable for hydraulic oil WARNING: for all other maintenance operations, you are advised to contact our technical assistance centre (organised in collaboration with our dealers), as these interventions require specific technical skills and the use of the right equipment. WARNING! The oil and filters eliminated must be sent to separate waste collection in compliance with the environmental health regulations in force.

HYDRAULIC OIL FILTER REPLACEMENT
NOTE: Operation to be performed when the engine oil has been removed. The check of the hydraulic oil level should be performed prior to each use the machine, checking that the upper level indicator light is full. Change the hydraulic oil filter every 500 hours or when the instrument panel warning light is on, proceed as follows: 1. Engage the parking brake and stop the engine, turning the key to position 0. 2. Open the left rear lid of the machine and unscrew, using a blade, the orange plastic cap of the hydraulic oil tank.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 33

3. Remove the filter under the cap, replace it and put it back in place. 4. Refill the plastic orange cap and close the side door of the machine. WARNING: dispose of the filters and used oil in the correct manner WARNING: protect yourself with DPI suitable for hydraulic oil WARNING: for all other maintenance operations, you are advised to contact our technical assistance centre (organised in collaboration with our dealers), as these interventions require specific technical skills and the use of the right equipment.
WARNING!

The oil and filters eliminated must be sent to separate waste collection in compliance with the environmental health regulations in force.

CLEANING CHECK OF HYDRAULIC OIL RADIATOR FINS
WARNING! Adequately protect the body parts (eyes, hair, hands, etc.) when cleaning using compressed air or water guns. 1. Unload the debris container 2. Put the machine on firm, level ground, then operate the parking brake. 3. Lift the debris container, operating as indicated in the specific paragraph. 4. Engage the parking brake and stop the engine, turning the key to position 0. 5. Prevent accidental lowering of the container by closing the two safety taps, operating as indicated in the specific paragraph. 6. Open the rear lid with the key supplied. 7. Clean the oil radiator fins of the hydraulic system with a jet of compressed air [up to 6 bar (87.0 psi)]. If necessary, direct the compressed air jet in the opposite direction to that of cooling air circulation. 8. Check that the relative fan rotates freely. 9. Follow steps 3 through 6 in reverse order.

GREASING THE BEARINGS
With the machine off, grease the following points: • 2 Greasing points on the transversal shaft for lifting the hopper, equipped with toothed wheels.

• 2 Greasing points on the arm of the front right brush. • 2 Greasing points on the arm of the front left brush (optional).

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 34

• 2 Greasing points on the arm of the third brush (optional).

• 2 Greasing points on the piston head joints of the front wheel suspensions. • 2 Greasing points on the piston head joints of the rear wheel suspensions.

• 2 Greasing points on the head joints of the pistons lifting the debris collecting hopper.

• 2 Greasing points on the joints of the rear closing door of the debris collecting hopper. The average amount of grease to be injected should be: • 4 to 5 pump strokes, if using a manual pump. • 15 - 20 seconds of injection, if using an air pump.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

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Page 35

CHECKING THE FLUID LEVEL OF THE BATTERY
WARNING! Adequately protect the body parts (eyes, hair, hands, etc.) when cleaning or cleaning operations. 1. Engage the hydraulic parking brake and stop the engine, turning the key to position 0. 2. Switch off the battery, turning the key of the release device. 3. Open the rear right side lid with the key supplied. 4. Check the fluid level of the battery from the outside (the plastic container is transparent). 5. If necessary top up with distilled water 6. If necessary, clean the battery from the outside of the container. 7. Check that the battery terminals are attached securely and are not oxidised.

CHECKING THE OIL LEVEL OF THE BRAKES
1. Engage the parking brake to stop the engine, turning the key to position 0. 2. Open the front right side lid with the appropriate wrench. 3. Check the brake fluid level in the tank. 4. Maintain the level at the MAX level. indicated on the clear plastic tank. 5. If necessary, top up with brake fluid of the same type present in the system (oil normally used: DOT3).

CHECKING THE PARKING BRAKE
1. Activate the hydraulic parking brake button and check its proper operation. Also check that the brake is acting equivalently on both rear wheels. 2. If necessary, adjust the parking brake, operating as follows: Holding the stem of the threaded screw still, inserting a screwdriver in its slot, unscrew (reduce the braking action) or screw (increase the braking action) the nut next to the brake piston. WARNING! DO NOT unscrew the threaded screw (only the nut), otherwise the brakes no longer act, detaching the piston with the Belleville springs.

CHECKING THE ACTIVATION SENSOR OF THE REVERSE HORN
Check that, when starting the machine in reverse, its horn is activated.

REPLACING THE AIR FILTER OF THE OPERATOR'S CAB
1. Engage the hydraulic parking brake and stop the engine, turning the key to position 0. 2. Tilt the driver's cab, as indicated by the corresponding paragraph. 3. Remove the air filter from under the cab by undoing the four screws with the black knob. 4. Install the new filter. 5. Return the cab to its original position

CHECKING TYRE PRESSURE
1. Engage the parking brake and stop the engine, turning the key to position 0. 2. The tyre pressure must be as follows: • front tyres: 6.0 Bar (87 psi) • rear tyres: 6.0 Bar (87 psi) WARNING! Observe the tire inflation pressure values indicated on the special stickers. Those indicated directly on the tyres refer to standardised load and speed conditions but not do not correspond to those of the machine.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004 Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 36

CHECKING CONVERGENCE OF THE FOUR-WHEEL STEERING
If the four-wheel steering is not aligned, proceed as follows: 1. Place the machine in "Transfer" position 2. Operate the hydraulic parking brake and do not stop the engine. 3. The two taps of the front and rear wheels must be closed. 4. Activating the steering and using an axle or a bracket, align the two front wheels, without worrying about of the two rear ones. 5. Once aligned, open the front tap. 6. Operating the steering and aligning the two rear wheels in the same way, while the two front wheels do not move. 7. Once the two rear wheels are also aligned, close the front tap.

REPLACING THE WHEELS
Preliminary operations 1. Place the machine in "Transfer" position 2. Operate the hydraulic parking brake and stop the engine by turning the key to position 0. 3. Check that the debris hopper is empty. 4.Check that the machine can not move independently, also with one raised wheel (the hydraulic braking system acts only on the rear wheels). If necessary, hold the machine still, applying wooden wedges to those wheels, which remain resting on the ground. 5. Remove the wheel in question by working as follows. Removing/fitting a front wheel 1. Remove the grey side protection, which hides the central brush, placed between the two wheels. 2. In the vicinity of the wheel to be removed, place the jack or hydraulic jack on the supports of the machine chassis as shown in the figure. 3. Before lifting the wheel with the jack or the hydraulic jack, slightly loosen the fixing nuts.

WARNING! The lifting jack is not provided. Use a jack with adequate characteristics and with a minimum lifting capacity of 5,600 kg (12,345 lb). 4. Carefully, operate the jack or hydraulic jack and lift the wheel to be removed until lifting it slightly from the ground. 5. Unscrew the fixing nuts and remove the wheel. 6. Replace the wheel by performing steps 1 through 5 in reverse. Tightening torque of the wheel retainer nuts: 450 N·m (332 lb·ft). Removing/fitting a rear wheel 1. Remove the grey side protection, which hides the central brush, placed between the two wheels. 2. In the vicinity of the wheel to be removed, place the jack or hydraulic jack on the supports of the machine chassis as shown in the figure. 3. Before lifting the wheel with the jack or the hydraulic jack, slightly loosen the fixing nuts. WARNING! The lifting jack is not provided. Use a jack with adequate characteristics and with a minimum lifting capacity of 5,600 kg (12,345 lb). 4. Carefully, operate the jack or hydraulic jack and lift the wheel to be removed until lifting it slightly from the ground. 5. Unscrew the fixing nuts and remove the wheel. 6. Replace the wheel by performing steps 1 through 5 in reverse. Tightening torque of the wheel retainer nuts: 450 N·m (332 lb·ft).

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 37

ELECTRONIC COMPONENTS CHECK
The box with the electronic boards and relays is located under the rubber floor protection of the driver's cab, passenger side. The following fuses are located on the relay board:
F4A F3A F2A F1A HYDRAULIC OIL RADIATOR FAN FILTER SHAKER ENGINES GLOWPLUGS GENERAL POWER SUPPLY 30A 40A 80A 120A

The pink lever located near the manual accelerator serves to disable the movement of the brushes FUSE REPLACEMENT
The fuse box is located in the driver's cab, on the dashboard next to the driver and is protected by a black plastic cover. 1. Stop the machine on a flat surface and engage the parking brakes. 2. Turn the start-up key to the OFF position and remove it. 3. Remove the fuse box cover and replace the fuses in question among the following:
F16 F15 F14 F13 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 INDICATORS – STOP LIGHTS - LIGHT SWITCHES REVERSE BUZZER – HORN – CAB VENTILATION - AIR-CONDITIONER SUSPENSION SUPPLY SENSORS - MULTIFUNCTION INSTRUMENT - ALARM BUZZER RIGHT SIDE BRUSH ROTATION - LEFT SIDE BRUSH ROTATION DEBRIS HOPPER MOVEMENTS CENTRAL BRUSH UP/DOWN – RIGHT SIDE BRUSH UP/DOWN – LEFT SIDE BRUSH UP/DOWN – LOADING SCREW CONVEYORS FORWARD PEDAL – FUEL PUMP - PREHEATING UP/DOWN/IN/OUT THIRD BRUSH - VACUUM WIPER WASHER - RADIO - HEATED MIRRORS - FLASHING LIGHTS CIGARETTE LIGHTER - OPTIONAL RIGHT INDICATOR LIGHTS LEFT INDICATOR LIGHTS EMERGENCY ARROWS – HIGH BEAM LIGHTS – LOW BEAM LIGHTS WORKING HEADLIGHTS +30 INSTRUMENT PANEL – RADIO MEMORY FAN, HEATER, AIR CONDITIONER - AIR CONDITIONER COMPRESSOR 10A 20A 15A 15A 15A 20A 15A 15A 20A 15A 10A 10A 25A 15A 7.5A 25A

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 38

CHOOSING AND USING THE BRUSHES
1. POLYPROPYLENE BRUSH (PPL) It is used on every type of ground and has good resistance to wear. The Polypropylene brush is non-hygroscopic and therefore retains its characteristics even when working in wet conditions. Replace the central brush when the bristle height is of 15-20 mm. 2. BRISTLE THICKNESS The thicker bristles are more rigid and should therefore be used on surfaces with solid or heavy dirt (e.g. gravel, drinks cans, etc.). Softer bristles are recommended for surfaces with light dirt or dust. Keep in mind that when the brush bristles are worn out and too short, they become stiff and can no longer properly collect dirt.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 39

MAINTENANCE OPERATIONS ON THE ENGINE
ENGINE OIL REPLACEMENT
WARNING: engine oil must be replaced every 300 hours, regardless of its level, or every year. 1. Engage the parking brake. 2. Lift the debris hopper of the machine. 3. Stop the engine by turning the key to position 0. 4. Close the two the safety manual taps of the lifting pistons. 5. Unscrew the cap of the engine oil loading filler. 6. Unscrew the two caps placed in the lower part of the engine oil pan and drain the oil into a container placed under the car. 7. Once all the engine oil is drained, retighten the two caps. 8. Pour the new engine oil from the loading filler until the dipstick with the yellow knob does not indicate the Max value. 9. Retighten the tank cap. WARNING: dispose of the filters and used oil in the correct manner WARNING: protect yourself with DPI suitable for hydraulic oil WARNING: for all other maintenance operations, you are advised to contact our technical assistance centre (organised in collaboration with our dealers), as these interventions require specific technical skills and the use of the right equipment. WARNING! The oil and filters eliminated must be sent to separate waste collection in compliance with the environmental health regulations in force. The engine oil level check should be performed prior to each use of the machine in the following manner: 1. Stop the machine on a flat surface and engage the parking brakes. 2. Lift the debris hopper of the machine. 3. Stop the engine by turning the key to position 0. 4. Close the two the safety manual taps of the lifting pistons. 4. Check oil level with the yellow rod and restore the level. 5. If below the MIN level, refer to the engine manual and then add engine oil until the Max level is restored. WARNING: these operations must be carried out using gloves to protect the hands. WARNING: do not touch the hot parts of the engine.

ENGINE OIL FILTER REPLACEMENT
NOTE Operation to be performed ONLY when the engine oil has been removed. CAUTION! When replacing the engine oil filter, is recommended to also replace the engine oil, following the instructions indicated in the specific paragraph. 1. Engage the parking brake. 2. Lift the debris hopper of the machine. 3. Stop the engine by turning the key to position 0. 4. Close the two the safety manual taps of the lifting pistons. 5. Unscrew the used engine oil filter. 6. Replace the used filter and tighten the new filter.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 40

WARNING: dispose of the filters and used oil in the correct manner
WARNING: protect yourself with DPI suitable for hydraulic oil. WARNING: for all other maintenance operations, you are advised to contact our technical assistance centre (organised in collaboration with our dealers), as these interventions require specific technical skills and the use of the right equipment. WARNING! The oil and filters eliminated must be sent to separate waste collection in compliance with the environmental health regulations in force. CAUTION! When replacing the engine oil filter, is recommended to also replace the engine oil, following the instructions indicated in the specific paragraph.

ENGINE AIR FILTER CLEANING
The engine is protected by a three-stage filter, which provides and purifies the vacuum air : - Cyclone pre-filter to separate the heavier parts - Primary cartridge for general dust - Safety cartridge for subtle particles Daily check the pre-filter, remove dirt and debris, if necessary. Primary cartridge can be cleaned, if necessary, four or six times before replacing it, replace it at least once a year. Safety cartridge does not have to be cleaned, but should be replaced every two or three cleanings of the primary filter. For further information, refer to the manual supplied with the engine.

Cyclone pre-filter cleaning 1. When you need to clean the cyclone pre-filter block, unscrew the fixing screw from the threaded insert and remove the cyclone block from its housing. 2. Clean the cyclone block with compressed air or water. 3. Refit the cyclone block. Filter cleaning/replacement 1. Remove the plastic cover and remove the filtering element. 2. Remove the secondary filtering element. 3. With a jet of compressed air [maximum 6 bar (87.0 psi)], carefully clean the filter elements blowing from the inside outwards (in the opposite direction to the vacuum air flow). 4. If necessary, replace the filtering elements, and dispose of them according to the environmental regulations in force. WARNING: these operations must be carried out using gloves to protect the hands. WARNING: do not touch the hot parts of the engine. WARNING: empty the debris hopper before any intervention. WARNING: as the debris hopper must be kept lifted for interventions, use the safety taps located below the hydraulic cylinders.

CLEANING CHECK OF DIESEL OIL RADIATOR FINS
1. Stop the machine on a flat surface and engage the parking brakes. 2. Turn the start-up key to the OFF position and remove it. 3. Tilt the driver's cab by operating the hand pump and operating as indicated in the specific paragraph. 4. Check the cleaning of the diesel motor radiator fins as indicated in the corresponding manual.
Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004 Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it
Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 41

CHECKING THE COOLANT LEVEL OF THE DIESEL MOTOR
1. Stop the machine on a flat surface and engage the parking brakes. 2. Turn the start-up key to the OFF position and remove it. 3. Open the front right side lid with the appropriate key. WARNING! The cooling circuit is under pressure, do not perform any checks until the engine has cooled down, and even then open the tank cap carefully. 4. Operating as indicated in the diesel motor manual, check that the coolant level in the tank is between the minimum and maximum level marks. If necessary, unscrew the plastic tank cap and top up. 5. After topping up, tighten the cap and close the side lid.

DIESEL MOTOR FUEL FILTER REPLACEMENT
1. Stop the machine on a flat surface and engage the parking brakes. 2. Turn the start-up key to the OFF position and remove it. 3. Open the rear left side lid with the key supplied. 4. Replace the fuel filter of the diesel motor as indicated in its manual. 5. Follow steps 1 through 3 in reverse order.

DIESEL MOTOR FUEL PRE-FILTER REPLACEMENT
1. Park the machine on a flat surface and engage the parking brakes. 2. Lift the debris hopper. 3. Turn the start-up key to the OFF position and remove it. 4. Open the left rear side lid to close the two safety taps on the lifting pistons. 5. Empty the fuel pre-filter by unscrewing the transparent lower part, paying attention to the fuel, which will leak during this operation. 6. Follow steps 4 through 1 in reverse order.

DIESEL MOTOR ALTERNATOR BELT REPLACEMENT
1. Park the machine on a flat surface and engage the parking brakes. 2. Lift the debris hopper. 3. Turn the start-up key to the OFF position and remove it. 4. Open the left rear side lid to close the two safety taps on the lifting pistons. 5. Unscrew the screw and nut that holds the alternator belt in traction. 6. Replace the belt and retighten the screw putting tension on the belt.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 42

MAINTENANCE
The service life of the machine and maximum operating safety is ensured by careful and regular maintenance.

SCHEDULED MAINTENANCE PLAN
The following is a summary diagram of scheduled maintenance. The frequency shown is subject to change depending on the particular working conditions, to be defined by the person responsible for maintenance.
INTEVENTI DI MANUTENZIONE PERIODICA CONSIGLIATA CS140
Procedura
Controllo livello olio motore diesel Controllo perdite nel circuito di raffreddamento Controllo livello liquido raffreddamento Controllo livello olio impianto idraulico Controllo livello liquido impianto frenante Controllo acustico clacson e avvisatore retromarcia Controllo tensione cinghia alternatore Controllo tensione cinghia compressore aria cond. Controllo freno stazionamento idraulico Pulizia spazzole Controllo funzionalità scuotifiltri Controllo pressione pneumatici Controllo livello liquido batteria Pulizia esterna radiatore motore e radiatore olio Controllo integrità flap Controllo usura guarnizione tra cassone e tubo aspir. Pulizia ugelli spruzzaggio Pulizia filtro aria motore diesel Sostituzione olio motore diesel Sostituzione filtro olio motore diesel Sostituzione filtro aria motore diesel Sostituzione liquido impianto di raffreddamento Sostituzione spazzola centrale Sostituzione spazzola laterale/traslante Sostituzione flap in gomma Pulizia filtro serbatoio acqua Verifica registrazione spazzole Controllo integrità guarnizioni (perdite olio) Ingrassaggio cuscinetti Controllo convergenza ruote Serraggio viti e raccordi carburante Controllo impianto frenante Sostituzione olio impianto idraulico Sostituzione filtro olio impianto idraulico Sostituzione cartuccia filtro carburante Sostituzione cinghia alternatore Sostituzione cinghia compressore aria condiz. Sostituzione filtro impianto aria condiz. Sostituzione sfiato motore diesel Sostituzione pinze freni anteriori Sostituzione ganasce freni posteriori Sostituzione pneumatici Controllo candelette motore diesel Serraggio testata motore diesel Controllo carboncini del motorino d'avviamento Controllo gioco valvole del motore diesel Controllo iniettori motore Diesel Controllo turbocompressore motore diesel Revisione motore diesel (1) la prima volta dopo 500 ore e dopo ogni 1.000 ore (2) in condizioni di lavoro gravoso ogni 150 ore (3) se terreno liscio ogni 250 ore, se ruvido ogni 150 ore (4) se terreno liscio ogni 150 ore, se ruvido ogni 100 ore (5) se terreno liscio ogni 500 ore, se ruvido ogni 300 ore (6) oppure ogni anno (7) oppure ogni due anni (8) operazioni da effettuarsi a cura del Centro Assistenza del produttore del motore (9) revisione parziale dopo 4.000 ore; revisione totale dopo 8.000 ore (operazioni da effettuarsi a cura del Centro Assistenza del produttore del motore) Operazioni da effettuarsi a cura dell'Utilizzatore (C) o del Servizio Assistenza Tecnica (S) alla dopo le prime giornaliera ogni 10 ore ogni 50 ore ogni 150 ore ogni 300 ore ogni 500 ore ogni 1.000 ore ogni 2.000 ore ogni 5.000 ore consegna 100 ore C C C C C C C C C C C C C C C C C C C S C C C C C C C C S C S C C C S S (2) (6) S S (6) S (8) S (7) S (2) S (3) S (5) S S S S S S S (7) S (1) S (6) S S (6) S (7) S S S (7) S S S S S S S (8) (8) (8) (8) S (8) S (8) S (8) (9)

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 43

WINTER MAINTENANCE
In the winter, carefully follow the maintenance procedures listed below.

Procedure for storing the sweeping machines that operate at temperatures below 0 °C (+32°F)
1. Empty the nozzles and the water tank (optional). 2. Empty and clean/replace the water filter (optional). 3. Add antifreeze fluid to the water tank (check the quantity per litre). 4. Circulate the antifreeze fluid in the water system until it leaks from the nozzles of the brushes, operating the water pump (see the specific paragraphs). When the fluid starts to leak from the nozzles, stop the pump. 5. Start the diesel motor as indicated in the specific paragraph. 6. Circulate the antifreeze fluid in the high-pressure water system until it leaks from the nozzle by operating the pump with the lever that is located in the cab (see the specific paragraphs). When the fluid starts to leak from the nozzles, stop the pump. WARNING! Do not use the dust removal system when the ambient temperature is below 0 °C (+32 ° F) as this may create sheets of ice on the road surface.

Procedures to be followed in the second month of storage
1. Replace engine oil and the corresponding filter (see the specific paragraphs). 2. Refill the fuel tank (see the specific paragraphs). 3. Lubricate the machine. 4. Charge the battery. 5. Check the pressure of the tyres (see the specific paragraphs).

Procedures to be followed in the third month of storage
1. Repeat the same procedures as the second month. 2. Every month connect a battery charger and keep the battery charging for 12/24 hours.

SAFETY FUNCTIONS
The following security functions are prepared on the machine.

Reverse signal
The machine is equipped with a sensor with the corresponding horn to indicate when the machine is in reverse.

Manual battery detachment
The machine is equipped with a battery manual detachment device for safety during storage for long periods or during unattended stops.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 44

TROUBLESHOOTING
Below are listed the most common problems that may occur while using the machine, the probable causes that determine them and the likely solutions to be taken to eliminate them. WARNING! The implementation of the solution indicated must be carried out by qualified personnel, at all times complying with the instructions described in specific paragraphs of this manual, if present, or contact Comac SpA Service Centre, who are in possession of the Service Manual. For questions or information, contact the Comac SpA Service Centre. For troubleshooting of the following optional equipment, refer to the corresponding manuals: – camera kit

PROBLEMS AND SOLUTIONS
CENTRAL BRUSH
Problem The brush does not clean properly The brush does not turn/can not be lowered Excessive or altered noise of the central brush Probable cause The brush is not properly adjusted Worn central brush No power to the solenoid valve Dirt around the brush Solution Adjust the brush Replace the brush Check the electrical system (F11 fuse) Remove the dirt

LEFT AND RIGHT FRONT BRUSH (optional)
Problem The brushes do no clean properly Probable cause The brushes are not properly adjusted No power to the solenoid valve Oil leaks of the hydraulic system from the fittings/pipes The hydraulic motors are damaged The hydraulic pump does not send the oil in the circuit under pressure The brushes start-up switch is turned off The fuse is blown The solenoid valve is burned out Solution Adjust the brushes Check the electrical system (F11 fuse) Repair/Replace Replace the hydraulic motors Check the oil pressure of the hydraulic system Turn the switch on Replace the fuse Replace the solenoid valve

The brushes do not turn

THIRD BRUSH ARM (optional)
Problem Probable cause The limit switch sensor is not properly adjusted No power to the solenoid valve The distributor is locked The cylinder seals are worn The switch is turned off The fuse is blown the left/right transfer joystick does not work The relay is blown The solenoid valves are burned out The distributor is locked The cylinder seals are worn The fuse is blown The descent joystick does not work The relay is blown The solenoid valve is burned out Solution Adjust the limit switch sensor Check the electrical system Repair Check the cylinder Turn the switch on Replace the F9 fuse Replace Replace the relay Replace Repair Check the cylinder Replace Replace Replace the relay Replace the solenoid valve

The third brush arm does not move sideways

The third brush arm does not go up/down

THE MACHINE RAISES DUST WHILE CLEANING
Problem Probable cause Intake system off Clogged dust filter Full debris container Vacuum pipe clogged The side brushes scrape the ground on their entire circumference Solution Turn on the intake system with the switch Clean the dust filter Empty the debris container Lift the hopper and remove the debris Adjust the inclination of the side brushes

The machine raises dust

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 45

FILTER SHAKER
Problem The filter shaker engine does not work Probable cause The filter shaker engine connector is not correctly connected Circuit protection fuse Solution Restore connections Restore the F3A fuse

VACUUM FAN
Problem The vacuum fan is noisy Probable cause The fan bearings are not lubricated The fan bearings are worn The hydraulic motor is damaged The dust filters are clogged The vacuum hose is clogged The seal between the vacuum inlet and the debris container is broken or not properly positioned The drive pump of the vacuum fan motor does not generate pressure The debris container is not fully resting on the frame in the lower position Position the machine on a flat surface and lower the debris container until the proximity microswitch touches the container The distributor is locked The motor is damaged The pump is damaged The diesel motor is not at rpm speed The vacuum fan does not turn The debris container is not fully resting on the frame in the lower position Position the machine on a flat surface and lower the debris container until the proximity microswitch touches the container Solution Lubricate Replace Repair Clean the filters Clean Replace/adjust the position

The vacuum fan turns, but does not draw in sufficient air

Adjust the pump pressure Fully lower the bucket, until the red warning light on the instrument panel turns off Check that the proximity microswitch is in its position and that the electrical cable is not interrupted Repair Replace Replace the pump Increase the motor speed up to a maximum Fully lower the bucket, until the red warning light on the instrument panel turns off Check that the proximity switch is in its position and that the electrical cable is not interrupted

DEBRIS CONTAINER
Problem The debris container does not go up/down and tilt/return horizontally Probable cause The distributor is locked The button is broken The fuse is blown The relay board is damaged The solenoid valves are burned out There is no voltage to the actuator Command button broken The actuator pistons are not adjusted Solution Repair Replace the button Replace the relay Replace Replace the solenoid valves Repair the electrical system Replace the button Adjust the actuator pistons

The rear lid of the debris container does not open/close

DUST REMOVAL SYSTEM (optional)
Problem No water comes out from the nozzles Probable cause The caps located near the nozzles are closed The water filter is clogged The nozzles are clogged The water electrical pump relay is blown The pump does not work The water pump switch is turned off The fuse is blown The water tank is empty The float is locked The float is fitted the wrong way Solution Open the caps Clean/replace Disassemble them and clean them Replace the relay Repair/Replace Turn the switch on Replace the fuse Refill the tank Repair the float Fit correctly

No water reaches the nozzles

The water pump does not stop

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 46

STEERING
Problem The machine does not have a proper rectilinear course The steering is hard Probable cause The convergence of the rear axle is incorrect The power steering is damaged The priority valve is damaged The hydraulic drive cylinder of the steering wheels is damaged Solution Adjust Replace Replace Replace

BRAKES
Problem Probable cause The brake oil is low The braking mass is worn or greasy Air present in the system The brake drum cylinder is damaged The brake oil pump is damaged The brake is not properly adjusted Solution Check the oil level of the brakes Replace Bleed the system Replace Check Adjust

The machine does not brake sufficiently

The hydraulic brake parking does not brake sufficiently

STABILITY
Problem The machine in motion has little stability Probable cause The tyres are not inflated to the correct pressure Solution Check the pressure of the tyres

TRACTION POWER
Problem The machine has little traction power Probable cause The drive pedal is defective Power losses of the traction system pump occur The traction system engines are worn The traction system pump deactivation screw to facilitate the pulling movement of the machine is turned on Oil leaks in the hydraulic circuit The traction system pump is broken The traction system engines are broken Parking brakes engaged Parking brakes locked (no power to the solenoid valve) Solution Replace Check the oil pressure of the hydraulic system on the traction system pump Replace Deactivate Repair Replace the pump Replace Disengage the parking brake. Check the electrical system (solenoid valve)

The machine has no traction power

The machine does not move with the drive pedal pressed down

DRIVE PEDALS
Problem The machine moves even with travel pedal idle (free) Probable cause The travel pedal is not properly adjusted Solution Adjust

DRIVER'S CAB HEATING
Problem Probable cause The hot water supply tap is closed The hot water supply pipe or tap is broken The heater leaks water The switch is turned off The fuse is blown Solution turn on the tap Replace Replace Turn the switch on Replace the fuse

No hot air reaches it

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 47

OPERATOR'S CAB AIR CONDITIONING
Problem Probable cause The compressor does not turn due to the slow/broken transmission belt The power button air conditioning is turned off Presence of gas leaking from the system The expansion valve is damaged The fuse is blown The gas pressure switch is broken The relay is blown Solution Properly tension/replace belt Turn the button on Repair the cause of leak and replenish the gas Replace the expansion valve Replace the F1 fuse Replace the pressure switch Replace relay

No cooled air reaches it

DIESEL MOTOR
Problem The engine does not start Probable cause Disconnected battery Machine without fuel The fuse is blown For the diesel motor troubleshooting, refer to the corresponding Manual. Solution Connect the battery Refill it Replace the fuse

SCRAPPING
Proceed to the scrapping of the machine at an authorised wrecker. Before scrapping the machine, it is necessary to remove and separate the following materials and send them for separate waste collection in accordance with the environmental hygiene regulations in force: – Brushes – Engine oil – Hydraulic system oil – Hydraulic system oil filter – Plastic parts - Electric and electronic parts* NOTE (*) In particular, contact Comac S.p.A. in the area in order to scrap the electric and electronic parts.

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289

Page 48

EC DECLARATION OF CONFORMITY
The undersigned company: COMAC S.p.A. Via Maestri del Lavoro, 13 37059 Santa Maria di Zevio (VR) declares under its sole responsibility that the ROAD SWEEPING MACHINE mod. COMAC CSS 140 D, frame …………………… complies with the requirements of the following Directives: • 98/37/EEC: Machinery Directive • 2004/08/EC: Electromagnetic Compatibility Directive and subsequent modifications. • 2000/14/EC: Directive by the European Parliament and Council date 8th May, 2000. Noise emission by machines and equipment for outdoor use. Falling within the power sweeper category (as defined in enclosure I no.46 of the Directive 2000/14/EC of the European Parliament and Council), it is subject to noise marking only. The conformity evaluation was carried out in accordance with enclosure III.B.46 of the said directive. Technical documents are kept at the Technical department Comac S.p.A., Via Maestri del Lavoro, No. 13 – 37059 Santa Maria di Zevio, Verona, Italy. The measured and guaranteed acoustic power level is 78 dB(A) It also complies with the following standards: • EN 12100-1: Machine safety - Basic concepts, general principles for design - Part 1: Basic terminology and methodology • EN 12100-2: Machine safety - Basic concepts, general principles for design - Part 2: Technical principles • EN 55022: Devices for information technology – Radio interference characteristics – Limits and measurement methods. • EN 61000-2-6: Electromagnetic compatibility (EMC) - Part 6-2: Generic standards – Immunity for industrial environments. Santa Maria di Zevio, ………………………… COMAC S.p.A. Legal representative Giancarlo Ruffo

Comac spa Share capital (fully paid-up) Euro 17.020.000,00 Tax code 03322910237 - VAT Registration no. 03322910237 Verona Register of Companies 03322910237 R.E.A. No. 327004

Via Maestri del Lavoro, 13 37050 S. Maria di Zevio (Verona) Italy Telephone: +39 045 8774222 http://www.comac.it e-mail: comac@comac.it info@comac.it

Sales Office Telefax + 39 045 8750303 Technical Services Fax + 39 045 8266468 Purchasing Department Fax + 39 045 8751125 Administration + 39 045 8751289