COMAC CS500 User manual

PROFESSIONAL SWEEPING MACHINES
USE AND MAINTENANCE MANUAL
TRANSLATION OF THE ORIGINAL INSTRUCTIONS DOK. 10130339 - Ver. AA - 09-2023
The constructive elements and content of this manual, including the structure, text, diagrams, images and logo, are the exclusive property of COMAC S.P.A..
They are protected, both collectively and individually, by the current regulations regarding intellectual property (including copyright laws), and cannot be either wholly or partially copied or imitated. Any reproduction,
reprocessing, distribution or dissemination is strictly prohibited.

CONTENTS
CONTENTS.......................................................................................................................................................... 3
DEFINITION OF LEVELS OF WARNING............................................................................................................ 5
GENERAL SAFETY REGULATIONS.................................................................................................................. 5
GENERAL DESCRIPTION .................................................................................................................................. 5
SYMBOLS USED IN THE MANUAL ................................................................................................................... 6
TECHNICAL DESCRIPTION............................................................................................................................... 6
INTENDED USE.................................................................................................................................................. 7
SAFETY............................................................................................................................................................... 7
REGULATIONS................................................................................................................................................... 7
SERIAL NUMBER PLATE ................................................................................................................................... 8
MAIN MACHINE COMPONENTS........................................................................................................................ 9
STANDARD COMPONENTS .............................................................................................................................. 9
OPTIONAL COMPONENTS.............................................................................................................................. 11
TECHNICAL DATA ............................................................................................................................................ 12
SYMBOLS USED ON THE MACHINE .............................................................................................................. 13
LABELS USED ON THE MACHINE.................................................................................................................. 14
CONTROL STATION.......................................................................................................................................... 17
CONTROL PANEL............................................................................................................................................ 18
CONTROL DISPLAY ........................................................................................................................................ 18
PREPARING THE MACHINE ............................................................................................................................ 18
HANDLING THE PACKAGED MACHINE ......................................................................................................... 18
HOW TO UNPACK THE MACHINE .................................................................................................................. 19
SECURING THE MACHINE.............................................................................................................................. 20
HOW TO MOVE THE MACHINE................................................................................................................... 22
TYPE OF BATTERY TO BE USED ................................................................................................................... 22
BATTERY MAINTENANCE AND DISPOSAL.................................................................................................... 23
INSERTING THE BATTERY IN THE MACHINE ............................................................................................... 23
RECHARGING THE BATTERY......................................................................................................................... 23
WITHOUT BUILT-IN BATTERY CHARGER: .................................................................................................... 24
WITH BUILT-IN BATTERY CHARGER (OPTIONAL)....................................................................................... 25
MOUNTING AND ADJUSTING THE HANDLEBARS........................................................................................ 27
DISASSEMBLING THE CENTRAL BRUSH...................................................................................................... 27
ASSEMBLING THE CENTRAL BRUSH............................................................................................................ 28
DISASSEMBLING AND ASSEMBLING THE SIDE BRUSH ............................................................................. 29
WORK PREPARATION CHECKLIST................................................................................................................ 29
STARTING WORK ............................................................................................................................................. 30
SIDE BRUSH .................................................................................................................................................... 31
BATTERY CHARGE LEVEL INDICATOR ......................................................................................................... 32
HOUR METER .................................................................................................................................................. 32
THERMAL CIRCUIT BREAKER........................................................................................................................ 32
EMPTYING THE DEBRIS HOPPER................................................................................................................. 33
OPTIONAL FUNCTIONS ................................................................................................................................... 34
WORKING LED HEADLIGHTS......................................................................................................................... 34
AT THE END OF THE WORK............................................................................................................................ 34
MAINTENANCE PLAN ...................................................................................................................................... 35
ROUTINE MAINTENANCE................................................................................................................................ 38
CLEANING THE RUBBER BLADES OF THE CENTRAL BRUSH DUST GUARD........................................... 38
CLEANING THE CENTRAL BRUSH................................................................................................................ 39
CLEANING THE SIDE BRUSH......................................................................................................................... 39
CLEANING THE PANEL FILTER ...................................................................................................................... 40
CLEANING THE HEPA FILTER ........................................................................................................................ 40
CLEANING THE CARPET FLOOR FILTER...................................................................................................... 40
CLEANING THE DEBRIS HOPPER ................................................................................................................. 40
EXTRAORDINARY MAINTENANCE WORK .................................................................................................... 41
REPLACING THE CENTRAL BRUSH .............................................................................................................. 41
ADJUSTMENT INTERVENTIONS..................................................................................................................... 41
Page 3

ADJUSTING THE CENTRAL BRUSH............................................................................................................... 41
ADJUSTING THE SIDE BRUSH....................................................................................................................... 42
DISPOSAL ......................................................................................................................................................... 43
CHOOSING AND USING BRUSHES ................................................................................................................ 43
TROUBLESHOOTING....................................................................................................................................... 45
THE MACHINE DOES NOT START.................................................................................................................. 45
THE MACHINE DOES NOT VACUUM CORRECTLY....................................................................................... 46
THE MACHINE DOES NOT MOVE .................................................................................................................. 48
THE MACHINE DOES NOT SWEEP CORRECTLY ......................................................................................... 49
VERY LOW WORKING AUTONOMY................................................................................................................ 51
THE BATTERIES DO NOT WORK PROPERLY ............................................................................................... 52
THE BATTERY IS NOT FULLY CHARGED ...................................................................................................... 54
EC DECLARATION OF CONFORMITY ............................................................................................................ 56
UKCA DECLARATION OF CONFORMITY ....................................................................................................... 60
Page 4

GENERAL DESCRIPTION
The descriptions contained in this document are not binding. The company therefore reserves the right to make
any modications 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 modications. The images are shown
as reference only, and are not binding as to the actual design and/or equipment.
DEFINITION OF LEVELS OF WARNING
DANGER: indicates an imminent dangerous situation that, unless avoided,
will result in death or serious injuries.
WARNING: Indicates a potentially dangerous situation that, unless avoided,
could cause death of serious injury.
ATTENTION: Indicates a potentially dangerous situation that, unless
avoided, could cause slight or moderate injuries.
N.B.: instructs the reader to pay particular attention to the topic that follows.
GENERAL SAFETY REGULATIONS
Before using the machine, please read the following document
carefully and follow the instructions contained herein, along
with the instructions in the document supplied with the machine
itself, "GENERAL SAFETY REGULATIONS" (document number
10083659).
Page 5

SYMBOLS USED IN THE MANUAL
Open book symbol with an "i":
Indicates the need to consult the instruction manual.
Open book symbol:
Tells the operator to read the user manual before using the device.
Covered place symbol:
The operations preceded by this symbol must always be carried out in a dry, covered area.
Information symbol:
Indicates additional information for the operator, to improve the use of the device.
Warning symbol:
Carefully read the sections preceded by this symbol meticulously following the instructions indicated
for the safety of the operator and the device.
Danger symbol (moving carriages):
Indicates that the packed product should be handled with suitable carriages that conform to legal
requirements.
Symbol indicating the compulsory use of protective gloves:
Indicates that the operator should always wear protective gloves, to avoid the risk of serious injury to
his hands from sharp objects.
Recycling symbol:
Tells the operator to carry out the operations in compliance with environmental regulations in force in
the place where the appliance is being used.
Disposal symbol:
Carefully read the sections marked with this symbol for disposing of the appliance.
TECHNICAL DESCRIPTION
The CS500 is a walk-behind sweeping machine powered
by batteries with an output voltage of 12V. It is designed
to clean tiled, cement or tarred ooring, both indoors and
outdoors.
The CS500 must be used on dry surfaces, but can also
work on wet surfaces if necessary as long as the vacuum
is not activated.
This sweeping machine features a central brush for
collecting brushed-up material, a side brush for cleaning
along edges and in corners, a vacuum system with lter
to avoid raising dust, and a debris hopper that is moved
manually by the operator.
The machine must be used only for this purpose.
Page 6

INTENDED USE
This machine is designed and built to clean both indoor and outdoor ooring surfaces in tile, cement and asphalt.
They are intended exclusively for professional use by a qualied operator in industrial, commercial and public
contexts, in guaranteed safe conditions.
ATTENTION: the sweeping machine is not designed to clean carpet oors or rugs. It is not suitable for use in
closed places and should be used in open but covered areas (it must not be used in the rain or underneath
jets of water).
IT IS FORBIDDEN: to use the sweeping machine in places with an explosive atmosphere or to collect
hazardous dust or inammable liquids. In addition, it must not be used for transporting people or objects.
SAFETY
Operator cooperation is paramount for accident prevention. No accident prevention programme can be e󰀨ective
without the full cooperation of the person directly responsible for machine operation. The majority of occupational
accidents that happen either in the workplace or whilst moving are caused by failure to respect the most basic
safety rules. An attentive, careful operator is most e󰀨ective guarantee against accidents and is fundamental in
order to implement any prevention programme.
REGULATIONS
All references to forwards and backwards, front and rear, right and left indicated in this manual should be
understood as referring to the operator in a driving position with his/her hands on the handlebars wheel.
Page 7

SERIAL NUMBER PLATE
111
210
39
48
57 6
The serial number plate is located at the rear of the
bonnet, and indicates the general characteristics
thereof, specically the serial number of the machine.
The serial number is a very important piece of
information and should always be provided together
with any request for assistance or when purchasing
spare parts. The serial number plate contains the
following information:
1. The weight of the batteries that power the
machine (expressed in kg).
2. The IP protection rating of the machine.
3. The value in kg of the GVW (Gross vehicle
weight) - refer to “TECHNICAL DATA”.
4. The machine ID code.
5. The machine serial number.
6. The machine ID name.
7. The nominal power consumed by the machine
(expressed in W) - refer to “TECHNICAL DATA”.
8. The maximum gradient that the machine can
handle during work tasks (expressed as %) - refer to
“TECHNICAL DATA”
9. The year of machine manufacture.
10. The nominal voltage of the machine (expressed in
V) - refer to “TECHNICAL DATA” .
11. The commercial name of the machine, and the
manufacturer's address.
Fill in the following table at the time of delivery and/
or installation, so it can be used as a future reference
when necessary.
MACHINE ID NAME
SERIAL NUMBER
DATE OF DELIVERY AND/
OR INSTALLATION
Page 8

MAIN MACHINE COMPONENTS
STANDARD COMPONENTS
Page 9
1 Right side brush
2 Brush carter
3Front swivel wheel
6Bumper wheel
7 Frame
10 Bonnet
11 Rear debris hopper
8Central brush carter
9Central brush
12 Battery connector
13 Vacuum motor
14 Conveyor
3Control handle
4Instrument panel locking key
5Instrument panel
2
6
10
8
13
12
41
3
7
11
9
14
5
3

Page 10
18 Battery
19 Bonnet prop
20 Bonnet prop retainer bracket
15 Filter
16 Traction wheel
17 Rear hopper closing levers
21 Locking knob
22 Brush locking bracket
23 Brush pulley
24 Rear wheel pulley (BT version)
25 Timing belt
Drive pulley
Brush movement wheel
Drive movement wheel (BT version)
1916
22
1815
21
2017
23
25
25
26
25
24

OPTIONAL COMPONENTS
Page 11
4 Battery charger
5 Lithium batteries
1HEPA lter, padel court lter, football
pitch lter
2lter shaker
3Hopper with padel court net, hopper
with football pitch net
6LED headlights
52
41
3
6

TECHNICAL DATA
TECHNICAL DATA UM
[SI] CS500 B CS500 BT
Rated voltage
[IEC 60335-2-72; IEC 62885-9] V 12 12
Nominal input power
[IEC 60335-2-72; IEC 62885-9] KW 0.75 0.75
Working gradeability with GVW
[IEC 60335-2-72; IEC 62885-9] %2 2
Machine working weight (gross weight - GVW)
[IEC 60335-2-72; IEC 62885-9] kg 164 167
Weight during transport
[IEC 60335-2-72; IEC 62885-9] kg 112 115
Machine dimensions during working phase
(length; height width) mm
1265
900
660
1265
900
660
Operator station sound pressure level (LpA)
[IEC 60335-2-72; IEC 62885-9; ISO 11201] dB (A) 64 64
Sound power level (LwA)
[IEC 60335-2-72; IEC 62885-9; ISO 3744] dB (A) 80 80
Uncertainty KpAdB (A) ±1,5 ±1,5
Hand-arm vibrations
[IEC 60335-2-72; IEC 62885-9; ISO 5349-1] m/s22,15 2,15
Vibration measurement uncertainty ±4% ±4%
TECHNICAL DATA UM
[SI] CS500 B CS500 BT
Rated voltage
[IEC 60335-2-72; IEC 62885-9] V 12 12
Nominal input power
[IEC 60335-2-72; IEC 62885-9] KW 0.75 0.75
Working gradeability with GVW
[IEC 60335-2-72; IEC 62885-9] %2 2
Machine working weight (gross weight - GVW)
[IEC 60335-2-72; IEC 62885-9] lb 361,5 368,2
Weight during transport
[IEC 60335-2-72; IEC 62885-9] lb 247 253,5
Machine dimensions during working phase
(length; height width) in
49,8
35,5
26
49,8
35,5
26
Operator station sound pressure level (LpA)
[IEC 60335-2-72; IEC 62885-9; ISO 11201] dB (A) 64 64
Sound power level (LwA)
[IEC 60335-2-72; IEC 62885-9; ISO 3744] dB (A) 80 80
Uncertainty KpAdB (A) ±1,5 ±1,5
Hand-arm vibrations
[IEC 60335-2-72; IEC 62885-9; ISO 5349-1] m/s22,15 2,15
Vibration measurement uncertainty ±4% ±4%
N.B.: for all other technical data, contact the COMAC service centre of reference or the one closest to you,
or visit the website www.comac.it.
Page 12

SYMBOLS USED ON THE MACHINE
Page 13
Ignition symbol 0/I:
located on the top of the bonnet, to indicate the main key switch I/0
Rear hopper open/close symbol:
located on the back of the rear hopper, to indicate the debris hopper fastening knobs - refer to
"EMPTYING THE DEBRIS HOPPER"

LABELS USED ON THE MACHINE
Page 14
Label indicating that it is forbidden to vacuum hazardous elements: located on the debris
hopper, to indicate that it is strictly forbidden to vacuum incandescent particles or ammable and/or
explosive dust and/or liquids, and even to use the machine in their vicinity.
Label indicating that touching the brush when it is moving is forbidden: located at the top of
the side brush carter, to indicate that it is forbidden to bring your hands near the brush while it is
moving

Page 15
Battery box charging instructions label: informs the user about the procedures to be carried out
to recharge the battery box properly - refer to "RECHARGING THE BATTERY"
Label warning about battery emissions: located on the inside of the machine, to warn the user
that the cells may release highly ammable hydrogen gas during the recharging phase - refer to
"RECHARGING THE BATTERY".

Page 16
Instrument panel label with manual lter shaker: located on the back of the machine, to indicate
the instrument panel to the user
Instrument panel label with electric lter shaker: located on the back of the machine, to indicate
the instrument panel to the user (optional)

Page 17
CONTROL STATION
3
1
2
The machine has an easy and user-friendly control station,
comprised of mainly the following:
1. Control handle with height adjustment - refer to
"MOUNTING AND ADJUSTING THE HANDLEBARS"
2. traction control lever (for BT version) - refer to "STARTING
WORK"
3. Control panel - refer to "CONTROL PANEL"
4. ignition key
4
Label warning about the risk of crushed hands: located on the left side of the machine body (in
the area housing the vacuum head), to indicate the areas where there is a risk of getting your hands
crushed

CONTROL PANEL
The control panel is sub-divided as follows:
1. control display - refer to "CONTROL DISPLAY"
2. vacuum motor thermal circuit breaker switch - refer to "THERMAL CIRCUIT BREAKER"
3. manual lter shaker lever (not present with electric lter shaker kit) - refer to "STARTING WORK"
4. vacuum control lever - refer to "STARTING WORK"
5. side brush control lever - refer to "SIDE BRUSH"
13
CONTROL DISPLAY
4
3
2
1
The control display consists mainly of:
1. Graphic battery charge level symbol - refer to
“BATTERY CHARGE LEVEL INDICATOR”
2. Graphic battery charge level icon - refer to
“BATTERY CHARGE LEVEL INDICATOR”
3. Graphic hour meter icon - refer to "HOUR
METER"
4. Graphic hour meter symbol - refer to "HOUR
METER"
PREPARING THE MACHINE
HANDLING THE PACKAGED MACHINE
The overall dimensions of the entire package are:
DIMENSIONS [cm] [in] [kg] [lb]
Length 1430 56,3
Width 660 26
Height 1180 46,1
Weight 108 238
N.B.: it is recommended that all the packaging components be kept for any future machine transportation.
452
Page 18

HOW TO UNPACK THE MACHINE
The machine is shipped in specic packaging. To remove it, proceed as follows:
1. Place the lower part of the outer packaging in contact with the oor.
N.B.: use the pictograms printed on the box as a reference.
2. Remove the outer package.
WARNING: the machine is contained in specic packaging materials, whose elements (plastic bags, staples,
etc.) can pose potential hazards, and must not be left within reach of children, disabled persons, etc.
3. Remove any boxes containing brushes or optionals.
CAUTION: it is recommended to wear the appropriate PPE (Personal Protective Equipment), suitable for the
work to be carried out.
4. Place two descent ramps at the rear of the machine.
WARNING: the descent ramps are consigned in the machine packaging. If there are no ramps provided,
bear in mind the one used must have a suitable slope to avoid damaging the machine and a su󰀩cient
load-bearing capacity to ensure it does not break when the machine moves across it. To obtain the net
weight of the machine and the safety percentage value required of the ramp, contact your COMAC service centre
of reference or the one closest to you. Alternatively, you can send an email to [email protected], or visit the website
www.comac.it.
5. check the main switch is on “0". If it isn't, make a quarter turn anti-clockwise with the key (g.3)
12
6. lift the
bonnet and secure it with the relative side catch (see SECURING THE MACHINE)
7. turn the handlebars (g.1) and tighten the 2 side screws (on both sides) in their respective holes (g.2), using
the Allen wrench provided with the machine documentation
8. tighten the other 2 screws (already inserted) as well, to fully secure the handlebars to the frame
9.
ATTENTION: for safety, use a torque spanner to check the tightening torque for all 4 hex head screws is
between 20 Nm and 25 Nm.
10. close the bonnet by releasing the catch and rotating the bonnet to the working position
DANGER: move the packaged product with handling trolleys that comply with the load handling directives in
force in the country of use, and with the dimensions and mass of the packaged product.
Page 19

11. the machine is secured to the pallet with wedges that lock the wheels; remove these wedges
12. check the parking brake on the front swivel wheel is disengaged (g.2); if it isn't, release the lever on the wheel
(for BT version)
13. push the machine in reverse to lower it o󰀨 the pallet
14. keep the pallet for any future transportation needs
34
SECURING THE MACHINE
To ensure the tasks are carried out in the best safety conditions (machine safety position), proceed as follows:
CAUTION: it is recommended to wear the appropriate PPE (Personal Protective Equipment), suitable for the
work to be carried out.
1. apply the parking brake on the front swivel wheel (g.2), pressing the lever (for BT version)
12
2. check the debris hopper is empty, emptying it if necessary - refer to “EMPTYING THE DEBRIS HOPPER”
3. turn the main switch to "0" (g.1) by turning the key anti-clockwise, then remove the key to open the bonnet
ATTENTION: the bonnet only opens if the key is not inserted
Page 20