COMAC SIMPLA 65BT Use and Maintenance Manual

Category
Scrubber
Type
Use and Maintenance Manual

This manual is also suitable for

ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 1 of 16
READ THE USE AND MAINTENANCE MANUAL
Electric System Testing
1. Disconnect the battery connector.
2. Check the functioning of the electric system switches,
motors, solenoid valve, contactors, power fuses and
thermal trip units.
3. Check the condition and tightening of all power cables:
contactors, fuses, motors, etc.
4. Check the functioning and condition of the potentiometer
and the base confirmation microswitches (water and brush
rotation) and working operation, and those for automatic
squeegee rise and descent (AUTOMATIC VERSION only).
5. Check the handlebars lever is centrally positioned and that
the threaded rod does not touch the measuring device
card located beneath the instrument panel (if it does touch,
adjust it within the plastic joints.
6. Check the condition and connections of the battery poles on
the battery connector.
7. Reconnect the battery connector.
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 2 of 16
8. Check the functioning of the chopper.
9. If necessary, calibrate the chopper card as
follows:
raise the machine (free traction wheels);
unscrew the rear instrument panel to access
the chopper;
set the continuous voltage measurement
tester with a full scale of 50V;
insert the test prods on the fastons marked
with M+ and M- on the chopper card;
switch on via the main key;
select the forward movement until activating
the movement microswitch (so you can hear
the click of the relays) slightly rotating the
potentiometer on the handlebars with respect
to zero;
in that moment, the voltage measured by the
test prod must be 3-5V. If necessary, adjust
the VMIN trimmer so the output voltage is at
the required value;
at this point, press the operation levers fully
down until you reach maximum speed. You
should see a value of 24V (battery
maximum); if this is not the case, adjust the
VMAX trimmer to obtain the required output
voltage;
acceleration adjustment: rotate the ACC
trimmer clockwise. This adjustment brings the
voltage to the maximum required value (24V)
in about 7-8 seconds;
check the reverse gear is functioning;
check the motor braking (releasing the
accelerator, the machine must stop within
about 1 metre)
Adjusting the battery charger
1. Check the set-up of the battery charger corresponds to the
type of battery actually installed on the machine.
2. To adjust the battery charger, proceed as follows:
use a screwdriver to remove the small plastic cap;
set the dip switches inside, on the basis of the table
below;
close the plastic cap
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 3 of 16
The dip switches are set as follows (DP1 and DP2 are the SW1
and DP3 and DP4 are SW2):
DP1 DP2 SET-UP
OFF OFF EXIDE SONNENSCHEIN gel
OFF ON General GEL or AGM batteries
ON OFF Wet-cell batteries
ON ON TROJAN gel
DP3:
ON for all the batteries (not used)
DP4:
OFF for all the batteries (not used)
Carefully read the battery charger operating manual
Battery charger alarm signals:
Flashing YELLOW LED:
WRONG BATTERY
BATTERY NOT CONNECTED
OUTPUT SHORT-CIRCUIT
Flashing RED LED:
SAFETY TIMER EXCEEDED
INTERNAL SHORT-CIRCUIT
Initial battery charger test:
GREEN LED with 2 flashes: battery charger with set-up for GEL or AGM batteries
RED LED with 2 flashes: battery charger with set-up for wet-cell batteries
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 4 of 16
Check the functioning of the “service menu”. Remember that to access it, you must keep the
button pressed while starting up the machine (when you turn the key).
Keeping the button pressed for
a few seconds will zero-set the
total hour-counter (only in the
first hour of operation).
Pressing the button
Keeping the button pressed
for a few seconds will zero-
set partial hour-counter 1.
Pressing the button
Pressing
the button
Keeping the button pressed for
a few seconds will zero-set
partial hour-counter 2.
Pressing the button
Keeping the button pressed for
a few seconds will change the
battery technology setting.
Keeping the button pressed
for a few seconds will give
you access to the “service”
sub-menu: every time the
button is subsequently
pressed, the setting will
Pressing the button
Pressing the button
Pressing the button
Keeping the button pressed for a
few seconds will zero-set the
number of loads.
Pressing the button
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 5 of 16
Water System Testing
1. Check the solution filter just underneath the tank cap is
clean and functioning.
2. Check the cleanliness and seal of the solution filter (in the
rear part of the machine, at frame level).
3. Completely fill the solution tank with water.
4. Check the seal of the tubes, the solenoid valve, and the
water tap adjustment.
5. Check the solution pours onto the floor in a continuous
manner when the tap is open.
Adjusting the brakes
1. Fix the brake cable to the frame, tightening the sheath
completely down on the support.
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 6 of 16
2. Adjust the pads on the wheels, so that when the pin is
inserted on the handbrake lever, the machine is blocked.
3. To adjust the pads, proceed as follows:
loosen the M8 locknut
Loosen or tighten the pad so that it is correctly adjusted
(make sure that with the machine working, batteries
installed, the pad does not touch the wheel).
tighten the M8 locknut
Suction Testing
1. Check the filter – float is clean and functioning.
2. Check the air seal of the cap on the recovery tank.
3. Check the connections and seal of the suction tubes and the
squeegee tube.
4. Check the seal of the squeegee nozzle.
5. Check the seal of the drainage tube and cap.
6. Adjusting the suction microswitch (MANUAL MACHINE
VERSION):
adjust the microswitch so that when the lever is turned, the
switch closes (thereby activating the suction), leaving a gap
of about 0.5mm between the roller and the main body
after adjusting, check the microswitch is functioning
correctly
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 7 of 16
7. Adjusting the suction microswitch (AUTOMATIC MACHINE
VERSION):
adjust the upper microswitch so that when the cam is
turned, the switch closes, leaving the squeegee 4-5cm
above the ground
adjust the lower microswitch so that when the cam is
turned, the switch closes with the squeegee on the ground
(thereby activating the suction)
after adjusting, check the microswitch is functioning
correctly
Adjusting the Washing Base (55BT and 65BT)
- MANUAL VERSION MACHINE -
1. With the pedal fixed in place, check the base confirmation
microswitch changes over and the roller remains about
0.5mm from the main body of the switch.
2. If necessary, adjust the microswitch as follows:
loosen the M3 locknut and the relative M3 screw;
move the microswitch in its slot;
fix the M3 locknut and relative M3 screw until the
microswitch is blocked, taking care not to over-tighten
(and therefore damage the device itself);
after adjusting, check the microswitch is functioning
correctly and, if necessary, repeat the calibration.
3. Carry out a functional test to check that, with the base
down, the brushes begin turning when the machine is set for
working operation.
4. Check the brushes can be easily disassembled and that there
is enough space for the fixing buttons to pass beneath the
brush-holder plates. If the brushes are not clean:
lift the base;
loosen the M6 locknut;
loosen the M6 screw until there is enough space to affix
and remove the brushes from the base;
at the same time, check the base does not interfere with
the solution tank.
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 8 of 16
- AUTOMATIC VERSION MACHINE -
5. Ensure that the base microswitch block the operation of
the brushes when the base is lifted a few centimetres from the
ground.
6. If necessary, adjust the blade of the microswitch.
7. Carry out a functional test to check that, with the base down,
the brushes begin turning when the machine is set for working
operation.
8. For the correct height of the base, check that the thread of the
stem protrudes about 5 mm. Ensure that the brushes can be
easily removed and that there is sufficient space for the
passage of the fastening buttons below the brush holder
plates. Otherwise act on the thread adjustment.
9. Check the adjustment of the base lowering limit switches
in order to give the correct pressure of the base to the ground.
Pay attention that in the event of excessive pressure, the
wheels may rise slightly.
10. Check that when lifting, the base does not touch the tank and
when lowering without brushes it does not touch the floor.
Otherwise, proceed as follows:
Using a small screwdriver as a lever, remove the plastic
cover of the microswitches inside the jack;
Loosen the screws holding the micro sliding them to
determine the correct position;
Tighten the screws;
Replace the plastic cover;
Perform a functional test.
11. Adjust the belt-stretcher spring to a length of 27mm under
compression.
12. Adjust the transversal inclination of the base:
position the machine on an even, flat floor
lower the base onto the floor with the brushes assembled
loosen the screw and M8 nut that fix the left lifting arm
to the base
rest the base on the floor so that the brushes touch the
floor simultaneously
tighten the M8 screw and the locknut
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 9 of 16
13. Check the M8 screw that fixes the arm to the third point
allows the longitudinal movement of the base, so this can
adjust itself to the specific floor.
14. If the base vibrates because of the brush or pad movement,
tighten the nut to further compress the spring and soften the
vibrations.
Adjusting the Washing Base (50BST)
1. Ensure that the brushes can be easily removed and that there
is sufficient space for their passage. If the brushes are not
clean:
lift the base;
loosen the M6 locknut;
loosen the M6 screw until there is enough space to affix
and remove the brushes from the base;
at the same time, check the base does not interfere with
the solution tank.
2. Adjust the transversal inclination of the base:
position the machine on an even, flat floor
lower the base onto the floor with the brushes assembled
loosen the screw and M8 nut that fix the left lifting arm
to the base
rest the base on the floor so that the brushes touch the
floor simultaneously
tighten the M8 screw and the locknut
3. Check the M8 screw that fixes the arm to the third point
allows the longitudinal movement of the base, so this can
adjust itself to the specific floor.
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 10 of 16
4. Adjust the pressure relief spring by tightening the M6 screw
on the tie rod until 5-6 mm of thread remain, so as to obtain
the correct pressure on the base.
5. Assemble the transmission coupling so that there are 2 mm.
between the two hubs and that the rubber toothed star
situated between the two works properly, no vibrations or
misalignments.
6. Tighten the dowels and related nuts.
7. Adjust the drive belt tension by means of the
M8 nut, so that the thread protrudes from the support by
approx. 28-29 mm.
Refer to the WASHING version for the adjust of the automatic version.
Adjusting the Washing Base (50 B-BT)
1. With the pedal fixed in place, check the base confirmation
microswitch changes over and the roller remains about
0.5mm from the main body of the switch.
2. If necessary, adjust the microswitch as follows:
loosen the M3 locknut and the relative M3 screw;
move the microswitch in its slot;
fix the M3 locknut and relative M3 screw until the
microswitch is blocked, taking care not to over-tighten
(and therefore damage the device itself);
after adjusting, check the microswitch is functioning
correctly and, if necessary, repeat the calibration.
3. Carry out a functional test to check that, with the base
down, the brushes begin turning when the machine is set for
working operation.
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 11 of 16
4. Ensure that the brush can be easily removed and that there
is sufficient space for its passage. If the brushes are not
clean:
lift the base;
loosen the M6 locknut;
loosen the M6 screw until there is enough space
to affix and remove the brush from the base;
At the same time, check the base does not interfere with
the solution tank.
5. Base horizontal tilt adjustment.
Position the machine on an even and level floor
Mount the brush and lower the base to the floor.
Loosen the nut on the left-hand lifting arm and allow the
base to adapt to the floor.
The slotted bracket of the base automatically positioned
correctly.
Tighten nut and bolt.
This operation ensures the correct alignment of the base to the
floor for uniform cleaning on the work-track.
Attention
: an incorrect angle will cause the machine to pull to
the right or to go into reverse.
6. Base vertical tilt adjustment:
Loosen the self-locking nut .
Adjust the base without the brush so that it touches at
the back first and that the front is 6-7 mm higher.
Tighten the self-locking nut.
Correct adjustment ensures the correct tilt of the brush on
the floor.
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 12 of 16
7. Traction adjustment: adjust the M8 screw so as to
distribute the weight of the motor to the rear of the base.
The adjustment of the screw effects the traction of the
machine.
Act on the screw shown in the figure:
Unscrew to increase the traction effect;
Screw to decrease the traction effect.
ATTENTION: increasing the traction of the machine diminishes
the width of the floor cleaned.
8. Check, and if necessary, adjust the tightening spring to a
compression length of 27 mm.
9. Check that the round headed screw of the brush
support touches the flat section of the brush on which it
lies. The play between the head and brush must be a
maximum of 1-2 mm with the brush hooked and lowered.
Refer to the WASHING version for the adjust of the automatic version.
27
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 13 of 16
Testing the Detergent Dosing System
1. Check the contacts and the detergent control card seat are
clean.
2. Check the set-up of the two jumpers (J4A and J4B) of the
detergent dosing card.
3. Check the two jumpers are positioned on the two contact
points so they are
both closed (as shown in the photos below).
4. Check the detergent tubes and the detergent canister tubes
are clean, in good condition, and functioning correctly.
5. Check the detergent dosing system bypass is functioning
correctly. The bypass system is activated by means of a tap
on the base.
6. Check the dosing system is activated when the tap lever is in
the position shown in the photo (up
).
7. Check no detergent solution ever emerges when the tap lever
is in the position shown in the photo (down
).
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 14 of 16
8. Check the solution emerges due to gravity only (i.e. the
dosing system is not activated) when the tap lever is in the
position shown in the photo (central
).
Check the functioning and connections of the water and detergent
pumps.
Check the solution tubes are clean and in good condition.
Adjusting the squeegee
1. Adjust the inclination of the rear rubber, with the suction
motor ON, so it is even.
2. Use the special handwheel to adjust the height of the
wheels, checking the rubber inclination is between 30° and
45° and is even across its entire length.
About 30° - 45°
Rear rubber
Front rubber
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 15 of 16
3. When the squeegee is up, check it does not interfere with the
base movement pedal. If it does, adjust the M6 nut in the
spring connected to the squeegee lifting cable. Proceed as
follows:
lift the squeegee and place a shim of about 40mm beneath
it
lower the squeegee command lever
check the threaded pin and the nut are visible
loosen or tighten the nut, depending on whether you want
to raise or lower the squeegee
with the squeegee up, check there is no interference
between the base movement pedal and the squeegee
support
4. Check the pressure of the squeegee on the floor. Check the
pressure created by the spring and actual weight of the
squeegee is sufficient to bend the squeegee rubbers and to
make the wheels rest evenly on the floor.
5. Check the level of pressure is not making steering difficult and
causing excessive wear on the squeegee wheels when
steering.
6. To adjust, proceed as follows:
lower the squeegee;
tighten the M8 locknut to increase the pressure, or
loosen it to reduce the pressure.
ADJUSTMENTS
AND
TESTING
SIMPLA 50B-BT
SIMPLA 55BT
SIMPLA 65BT
SIMPLA 50BST
Doc. 10021896
Issued 09/2010
Ver. AB
Page 16 of 16
Testing machine operation
Check the functioning of the switches and indicator lights.
Check the functioning of the speed regulator.
Check the functioning of the base.
Check the functioning of the brush motor.
Check the functioning of the solenoid valve.
Check the functioning of the suction motor.
Check the functioning of the dosing system (when present).
Check the functioning of the jacks that raise and lower the squeegees and base (when
present).
Check the functioning of the parking brake.
Check the condition of the batteries, clamps and cables.
Machine functional tests
Fill the tanks with water and check for any leaks.
Check the seal of the water system and check the water falls evenly onto the two brushes.
Adjust the inclination and wheels of the squeegee, carrying out a functional test.
Adjust the brush pressure and base inclination, carrying out a functional test.
Check the efficiency of the parking brake.
Check forward movement, backward movement, acceleration and braking.
Final Testing
Check all the functions: washing, drying, forward movement.
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COMAC SIMPLA 65BT Use and Maintenance Manual

Category
Scrubber
Type
Use and Maintenance Manual
This manual is also suitable for

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