SW4000
Service Manual
Advance SW4000 Battery - 9084403010
Nilsk SW4000 Battery - 9084400010
Nilsk SW4000 Petrol - 9084401010
Nilsk SW4000 LPG - 9084402010
Advance (SW4000 BR) - 9084407010 (LPG)
English
2013-04 Form No. 1464811000
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Machine General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Service Manual Purpose and Field of Application . . . . . . . . . . . . . . . . . . . . . . 5
Other Reference Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Service and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Serial Number Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Visible Symbols On The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Machine Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Machine Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Machine Nomenclature (know your machine) (SW4000 Battery) . . . . . . . . . . . . . .12
Control Panel (SW4000 Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Machine Nomenclature (know your machine) (SW4000 Petrol/LPG) . . . . . . . . . . . .16
Control Panel (SW4000 Petrol/LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Service and Diagnostic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Scheduled Maintenance Table (SW4000 Battery) . . . . . . . . . . . . . . . . . . . . . .25
Scheduled Maintenance Table (SW4000 Petrol/LPG) . . . . . . . . . . . . . . . . . . . .26
Table of Contents 2Service Manual – SW4000
Chassis System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chassis (main parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Dashboard Electronic Board Specications . . . . . . . . . . . . . . . . . . . . . . . . . .29
Wiring Diagram (SW4000 Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Wiring Diagram (SW4000 Petrol/LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dashboard Electronic Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Dust Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Dust Guard System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Table of Contents 3Service Manual – SW4000
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Relay/Electromagnetic Switch/Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Wiring Diagram (SW4000 Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Wiring Diagram (SW4000 Petrol/LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Component Locations (SW4000 Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Component Locations (SW4000 Petrol/LPG) . . . . . . . . . . . . . . . . . . . . . . . . . 68
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fuse Check/Replacement (SW4000 Battery) . . . . . . . . . . . . . . . . . . . . . . . . .75
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
General Wiring Diagram (SW4000 Battery) . . . . . . . . . . . . . . . . . . . . . . . . .83
General Wiring Diagram (SW4000 Petrol - LPG). . . . . . . . . . . . . . . . . . . . . . .86
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Engine System - Petrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Engine System - LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Hopper System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Optional and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Main Broom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Table of Contents 4Service Manual – SW4000
Side Broom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Wheel System, Non-Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Wheel System, Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Drive System Electronic Board Error Codes Table . . . . . . . . . . . . . . . . . . . . .207
Drive System Electronic Board Parameter Table. . . . . . . . . . . . . . . . . . . . . . 208
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
Service Manual – SW4000
General Information
General Information
Machine General Description
The SW4000 is a “ride-on” industrial machine designed to clean/sweep oors, in civil or industrial environments, in one pass. The machine can be supplied in one of the following version:
• with a rechargeable battery, installed on the machine (SW4000 Battery)
• with a battery charged by a petrol engine, both installed on the machine (SW4000 Petrol)
• with a battery charged by a LPG gas engine (SW4000 LPG)
The machine is equipped with one main cylindrical broom, and one or two side disc brooms.
The rear hopper and a vacuum system allow for dust and dirt collection.
The hopper is equipped with a lifting system to discharge the collected debris.
Service Manual Purpose and Field of Application
The Service Manual is a technical resource intended to help service technicians when carrying out mainte-
nance and repairs on the SW4000, to guarantee the best cleaning performance and a long working life for the
machine.
Please read this manual carefully before performing any maintenance and repair procedure on the machine.
5
Other Reference Manuals
Model Product Code User Manual Spare Parts List
SW4000 Battery - Nilsk 9084400010 1464809000 1464810000
SW4000 Petrol - Nilsk 9084401010 1464815000 1464816000
SW4000 LPG - Nilsk 9084402010
SW4000 Battery - Advance 9084403010 1464818000 1464819000
Assembly Instructions Instruction Code Machines concerned
MTR/250 NON-MARKING MOTOR RING 1465241000
WORKING LIGHT KIT 1465245000
ROOF COVER KIT 1465247000
LEFT BROOM KIT 1465242000
PIVOTING LIGHT KIT 1465248000
NON-MARKING SKIRT KIT 1465241000
LEFT ARMREST KIT 1465249000
PROTECTION ROOF KIT 1465246000
24V DUST GUARD SYSTEM KIT 1465244000
SAFETY BELT KIT 1465248000
RIGHT SIDE BROOM SHIELD KIT 1465243000
LEFT SIDE BROOM SHIELD KIT 1465243000
MTR/250 NON-MARKING MOTOR RING 1465241000
WORKING LIGHT KIT 1465245000
These manuals are available at:
- Local Nilsk-Advance Retailer
- Nilsk-Advance website: www.nilsk.com - www.advance-us.com
SW4000 Battery Advance – SW4000 Battery/Petrol/LPG
Nilsk
Service Manual – SW4000
General Information
Conventions
Forward, backward, front, rear, left or right are intended with reference to the operator’s position when driving.
Service and Spare Parts
Service and repairs must be performed only by authorised personnel or Nilsk Service Centers. The authorised
personnel is trained directly at the manufacturer’s premises and has original spare parts and accessories.
Contact Nilsk Retailer indicated below for service or to order spare parts and accessories, specifying the ma-
chine model and serial number.
(Apply Retailer label here)
6
Serial Number Label
The machine model name and serial number are
marked on the plate (see the example to the side).
Product number and year of production are marked
on the same plate.
This information is useful when requiring machine
spare parts.
Use the following table to write down the machine
identication data.
MACHINE model .............................................................................................
PRODUCT code ..............................................................................................
P200082
MACHINE serial number .................................................................................
ENGINE model ................................................................................................
ENGINE serial number ....................................................................................
Service Manual – SW4000
General Information
Safety
The following symbols indicate potentially dangerous situations. Always read this information carefully and
take all necessary precautions to safeguard people and property.
Visible Symbols On The Machine
7
X %
Symbols
Danger! It indicates a dangerous situation with risk of death for the operator.
WARNING!
Carefully read all the instructions before
performing any operation on the machine.
DANGER!
Internal combustion engine.
Do not inhale exhaust gas fumes.
Carbon monoxide (CO) can cause brain
damage or death.
WARNING!
Do not wash the machine with direct or
pressurized water jets.
WARNING!
Do not use the machine on slopes with a
gradient exceeding the specications.
WARNING!
Hot parts, danger of burns.
WARNING!
Moving parts.
WARNING!
Moving parts. Danger of crushing.
WARNING!
Parts under voltage. Presence of corrosive
uids.
Warning! It indicates a potential risk of injury for people or damage to objects.
Caution! It indicates a caution related to important or useful functions.
Note: It indicates a remark related to important or useful functions.
General Instructions
Specic warnings and cautions to inform about potential damages to people and machine are shown below.
Warning! Make sure to follow the safety precautions to avoid situations that may lead to
serious injuries.
(For SW4000 Battery/Petrol/LPG)
– Before performing any maintenance, repair, cleaning or replacement procedure remove the igni-
tion key, engage the parking brake and disconnect the battery (For SW4000 Petrol/LPG - Discon-
nect the battery connector).
– This machine must be used by properly trained operators only.
Service Manual – SW4000
– Sharp turns must be made at slowest possible speed. Avoid: abrupt turns on incline, turns when
the hopper is lifted.
– Do not lift the hopper when the machine is on incline. The machine loses stability on incline or
when the hopper is full.
– Keep the batteries away from sparks, ames and incandescent material. During the normal op-
eration explosive gases are released.
– Do not wear jewels when working near electrical components.
– Do not work under the lifted machine without supporting it with safety stands.
– When working under the open hood, ensure that it cannot be closed by accident.
– Do not operate the machine near toxic, dangerous, ammable and/or explosive powders, liquids
or vapors: This machine is not suitable for collecting dangerous powders.
– (For WET batteries only). Keep the battery away from sparks, ames and incandescent material.
During the normal operation explosive gases are released.
(For SW4000 Petrol/LPG)
– Carbon monoxide (CO) can cause brain damage or death.
– The internal combustion engine of this machine can emit carbon monoxide.
– Do not inhale exhaust gas fumes.
– Only use indoors when adequate ventilation is provided, and with the help of an assistant.
General Information
8
(For SW4000 Petrol/LPG)
– Be careful: fuel is highly ammable.
– Do not smoke or bring naked ames in the area where the machine is refuelled or where the fuel
is stored.
– Refuel outdoors or in a well-ventilated area, with the engine off.
– Turn off the engine and let it cool down for a few minutes, then remove the fuel tank plug.
– Leave at least a space of 4 cm in the ller to allow the fuel to expand.
– After refuelling, check that the fuel tank cap is rmly closed.
– If any fuel is spilled while refuelling, clean the tank area and allow the vapors to evaporate be-
fore starting the engine.
– Do not let fuel come into contact with the skin; do not breathe fuel vapors. Keep out of reach of
children.
– Do not tilt the engine too much to avoid fuel spillage.
– When moving the machine, the fuel tank must not be full and the fuel valve must be closed.
– Do not lay any object on the engine.
– Stop the engine before performing any procedure on it. To avoid any incidental start, disconnect
the spark plug cap or disconnect the battery negative terminal.
– See also the SAFETY RULES in the Engine Manual, which is to be considered an integral part of
this Manual.
– (For LPG version). Do not use the machine in case of gas leaks. Disconnect the fuel hose and
replace the LPG tank. If the gas leak persists, disconnect the fuel hose and contact the Nilsk-
Advance Service Center.
Service Manual – SW4000
(For SW4000 Battery)
– (For WET batteries only). Battery charging produces highly explosive hydrogen gas. Keep the
battery cover open during battery charging and perform this procedure in well-ventilated areas
and away from naked ames.
Warning! Make sure to follow the safety precautions to avoid situations that may lead to
serious injuries, damages to materials or equipments.
(For SW4000 Battery/Petrol/LPG)
– Carefully read all the instructions before performing any maintenance/repair procedure.
– When working near the hydraulic system, always wear protective clothes and safety glasses.
– Pay attention to hot parts when working near the engine, the mufer, the manifold and the
cooler.
– This machine is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have been given
supervision or instruction concerning use of the machine by a person responsible for they safety.
Children should be supervised to ensure that they do not play with the machine.
– Close attention is necessary when used near children.
– Use only as shown in this Manual. Only Nilsk-Advance recommended accessories must be used.
– Check the machine carefully before each use, always check that all the components have been as-
sembled before use. If the machine is not perfectly assembled it can cause damages to people and
properties.
– Take all necessary precautions to prevent hair, jewels and loose clothes from being caught by the
machine moving parts.
– To avoid any unauthorized use of the machine, remove the ignition key.
– Do not leave the machine unattended without being sure that it cannot move independently.
– Do not use the machine on slopes with a gradient exceeding the specications.
– Do not tilt the machine more than the angle indicated on the machine itself, in order to prevent
instability.
– Use only brooms supplied with the machine or those specied in the User Manual. Using other
brooms could reduce safety.
– Before using the machine, close all doors and/or covers as shown in the User Manual.
– Do not wash the machine with direct or pressurised water jets, or with corrosive substances.
– Use the machine only where a proper lighting is provided.
– Working lights have to be used only to enhance visibility on the oor to be cleaned, but they do
not authorize anyone to use the sweeper in dark environments.
– If the machine is to be used where there are other people besides the operator, it is necessary to
install the pivoting light.
– While using this machine, take care not to cause damage to people or objects.
– Do not bump into shelves or scaffoldings, especially where there is a risk of falling objects.
– Do not lean liquid containers on the machine, use the relevant can holder.
– The storage temperature must be between 0°C and +40°C.
– The machine working temperature must be between 0°C and +40°C.
– The humidity must be between 30% and 95%.
– Always protect the machine against the sun, rain and bad weather, both under operation and
inactivity condition. Store the machine indoors, in a dry place. This machine must be used in dry
conditions, it must not be used or kept outdoors in wet conditions.
– Do not use the machine as a means of transport, or for pushing/towing.
General Information
9
Service Manual – SW4000
– The machine maximum capacity, operator’s weight not included, is 100 kg (the weight of waste).
– In case of re, use a powder re extinguisher, not a water one.
– Adjust the operation speed to suit the oor conditions.
– Avoid sudden stops when the machine is going downhill. Avoid sharp turns. Drive at slow speed
when going downhill.
– This machine cannot be used on roads or public streets.
– Do not tamper with the machine safety guards.
– Follow the routine maintenance procedures scrupulously.
– Do not allow any object to enter into the openings. Do not use the machine if the openings are
clogged. Always keep the openings free from dust, hairs and any other foreign material which
could reduce the air ow.
– (Only for versions equipped with DustGuard™ system). Pay attention during machine trans-
portation when temperature is below freezing point. The water in the tank or in the hoses could
freeze and seriously damage the machine.
– Do not remove or modify the plates afxed to the machine.
– When the machine is to be pushed for service reasons (lack of fuel, engine break-down, etc.), the
speed must not exceed 4 km/h.
– In case of machine malfunctions, ensure that these are not due to lack of maintenance. If neces-
sary, request assistance from the authorised personnel or from an authorised Service Center.
– If parts must be replaced, require ORIGINAL spare parts from an Authorised Dealer or Retailer.
– To ensure machine proper and safe operation, the scheduled maintenance shown in the relevant
chapter of this Manual, must be performed by the authorised personnel or by an authorised Ser-
vice Center.
– (For WET batteries only). When lead batteries (WET) are installed on this machine, do not tilt
the machine more than 30° from its horizontal position to prevent the highly corrosive acid to
leak out of the batteries. If the machine must be tilted to perform any maintenance procedure,
remove the batteries.
– The machine must be disposed of properly, because of the presence of toxic-harmful materials
(batteries, oils, etc.), which are subject to standards that require disposal in special centres (see
the User Manual).
General Information
10
(For SW4000 Petrol/LPG)
– While the engine is running, the silencer warms up; do not touch the silencer when it is hot to
avoid burns or res.
– Running the engine with an insufcient quantity of oil can seriously damage the engine. Check
the oil level with the engine off and the machine on a level surface.
– Never run the engine if the air lter is not installed, because the engine could be damaged.
– Technical service procedures on the engine must be performed by an authorised Dealer.
– Only use original spare parts or parts of matching quality for the engine. Using spare parts of
lower quality can seriously damage the engine.
– See also the SAFETY RULES in the Engine Manual, which is to be considered an integral part of
this Manual.
(For SW4000 Battery)
– Before using the battery charger, ensure that frequency and voltage values, shown on the ma-
chine serial number plate, match the electrical mains voltage.
– Do not pull or carry the machine by the battery charger cable and never use the battery charger
cable as a handle. Do not close a door on the battery charger cable, or pull the battery charger
cable around sharp edges or corners. Do not run the machine on the battery charger cable.
– Keep the battery charger cable away from heated surfaces.
Service Manual – SW4000
– Do not use the machine if the battery charger cable or plug is damaged. If the machine is not
working as it should, has been damaged, left outdoors or dropped into water, return it to the
Service Center.
– Before performing any maintenance procedure, disconnect the battery charger cable from the
electrical mains to avoid any risk of re, electric shock or injuries.
– Do not smoke while charging the batteries.
Guide lines to bacteria control and other dangers coming from the presence of microbes in the DustGuard™ system.
To prevent the operators and other people from developing infections caused by microbes and Legionella that
may ourish in the dust guard system, take the following precautions:
– If possible, ll the tank with cold water (< 20°C).
– DO NOT use stagnant water to ll the tank.
– DO NOT use recycled water, undrinkable water or water that has been in contact with the soil.
– Adjust and turn the nozzles towards the oor only, from preventing possible inhaling.
– Do not store the machine outdoors or near sources of heat.
– Do not over-ll the tank. Fill the tank sufciently so that it can be emptied by using the system.
– Empty the tank every 10 hours or once a week, according to the use.
– If the machine is not used for more than one week, empty the tank completely, and let it dry.
– If the tank cannot be cleaned regularly, consider using a biocide that can kill or exert a control-
ling effect on Legionella bacteria. Biocide must be chosen according to the local regulations and
must be used according to the relevant instructions and cautions, to avoid that the personnel
gets affected by dangerous chemical substances.
– If chemical products have to be used in the water tank, it is mandatory to apply the relevant
information and caution labels of the product.
General Information
11
Machine Lifting
Warning! Donotworkundertheliftedmachine,ifitisnotsecurelyxed.
Machine Transportation
Warning! Before transporting the machine, make sure that:
All covers are closed.
The tanks are empty.
The battery connector is disconnected.
The machine is securely fastened to the means of transport.
Service Manual – SW4000
Driver's seat with safety microswitch
Machine Nomenclature (know your machine) (SW4000 Battery)
General Information
12
Seat position adjusting lever
Dust guard system
water filler neck plug
Front column / Dust guard
system water tank
Parking brake lever
Forward/reverse gear pedal
Safety belts
Can holder
Steering wheel
Flashing light
Battery compartment
hood
Hopper release
and discharge lever
Left
side
cover
Side broom guards
Right side broom
Working lights
Front driving and steering wheel
Rear
wheels
Front skirt
lifting pedal
Left door
Service brake pedal
Left side broom
Dust guard system nozzles
P200083
Service Manual – SW4000
Serial number plate/technical
Machine Nomenclature (SW4000 Battery) (Continues)
data/conformity certification
Electronic
battery charger
Hopper manual
returning handle
Rear hood with
vacuum system
Dust filter
container
General Information
Drive pedal
Anchoring slots
for transport
(not for lifting)
13
Panel filter with
filter-shaker
Hopper
Anchoring slots for transport (not for lifting)
Right side cover
Right door
Main broom
Rear wheels
P200084
Service Manual – SW4000
Hopper hydraulic
Machine Nomenclature (SW4000 Battery) (Continues)
lifting system
Battery caps
(for WET batteries only)
Lead batteries
(WET) or optional
gel batteries (GEL)
Open hood
safety rod
Battery
compartment
hood opening
handle
control unit
Battery
connector
Drive system electronic board
Fuseholder box
General Information
Vacuum system
motor connector
Electrical
component
box
14
Battery connection diagram
BATTERY
PLUG
6V
6V
6V
6V
Left side broom motor
circuit breaker
Right side broom
motor circuit breaker
P200085
Service Manual – SW4000
Switch for:
Vacuum system
Control Panel (SW4000 Battery)
General Information
15
Semi-discharged battery
warning light (yellow)
Main broom
lifting/lowering lever
Discharged
battery warning
light (red)
Display
Button:
• Working hours
• Battery voltage (V)
warning light
(green)
Charged
battery warning
light (green)
Dust guard system
warning light
(green)
• Vacuum system activation (upper part)
• Filter shaker activation (lower part)
Filter shaker switch
Hopper lifting
system warning
light (yellow)
Side broom
lifting/lowering lever
Horn switch
Hopper movement
enabling switch
Main broom overpressure
warning light (red)
Drive system malfunction
warning light (red)
Dust guard
system switch
Emergency
push-button
Hopper
lifting/lowering
switch
Working light
switch
Forward/reverse
gear switch
Main broom
height adjusting knob
Ignition key
P200086
Service Manual – SW4000
Driver's seat with safety microswitch
General Information
Machine Nomenclature (know your machine) (SW4000 Petrol/LPG)
Flashing light
Safety belts
16
Seat position adjusting lever
Dust guard system
water filler neck plug
Front column / Dust guard
system water tank
Parking brake lever
Drive pedal
Can holder
Steering wheel
Engine compartment
hood
Hopper release
and discharge
lever
Left
side
cover
Side broom guards
Right side broom
Working lights
Front driving and steering wheel
Rear
wheels
Front skirt
lifting pedal
Left door
Service brake pedal
Left side broom
Dust guard system nozzles
P200087
Service Manual – SW4000
Serial number plate/technical data/
Machine Nomenclature (SW4000 Petrol/LPG) (Continues)
conformity certification
Filler plug
(SW4000 Petrol)
Hopper manual
returning handle
Rear hood with
vacuum system
Dust filter
container
Fuel tank
(SW4000 Petrol)
General Information
Drive pedal
Anchoring slots
for transport
(not for lifting)
17
Panel filter
with filter-shaker
Fuel opening/closing
valve (SW4000 Petrol)
Hopper
Right side cover
Right door
Main broom
Rear wheels
Anchoring slots for transport
(not for lifting)
P200088
Service Manual – SW4000
Machine Nomenclature (SW4000 Petrol/LPG) (Continues)
Hopper hydraulic
lifting system control unit
Drive system electronic board
General Information
18
Open hood
safety rod
Engine
compartment
hood lifting
handle
Right side cover
Dynamotor
Engine
Batteries
Fuseholder box
Vacuum system
motor connector
Electrical
component
box
Choke lever
Engine serial number and model plate
LPG tank (SW4000 LPG)
LPG adjuster solenoid valve (SW4000 LPG)
LPG tank fastening band (SW4000 LPG)
Right side broom motor
circuit breaker
Left side broom motor
circuit breaker
Battery connection diagram
12V
12V
P200089
Service Manual – SW4000
Switch for:
Vacuum
Control Panel (SW4000 Petrol/LPG)
General Information
19
Main broom
lifting/lowering
lever
Fuel reserve
warning light (yellow)
Display
Button:
• Working hours
• Battery voltage (V)
Main broom overpressure
warning light (red)
Drive system
malfunction warning
light (red)
system warning
light (green)
Dust guard
system warning
light (green)
Hopper lifting
system warning
light (yellow)
• Vacuum system activation (upper part)
• Filter shaker activation (lower part)
Filter shaker/vacuum system switch
Side broom
lifting/lowering lever
Horn switch
Hopper movement
enabling switch
Forward/reverse
gear switch
Dust guard
system switch
Emergency
push-button
Hopper lifting/lowering
switch
Working light
switch
Main broom height
adjusting knob
Ignition
key
P200090
Service Manual – SW4000
General Information
Service and Diagnostic Equipment
Besides a complete set of standard meters, the following instruments are necessary to perform fast checks and
repairs on Nilsk-Advance machines:
Laptop computer charged with the current version of EzParts, Adobe Reader and (if possible) Internet con-
nection
• Digital Volt Meter (DVM)
• Amp clamp with possibility of making DC measurements
• Hydrometer
• Battery charge tester to check 12V batteries
• Static control wrist strap
• Dynamometric wrench set
• A copy of the User Manual and Spare Parts List of the machine to be serviced (provided with the machine
or available at www.advance-us.com or other Nilsk-Advance websites).
The following equipment is also available at Nilsk-Advance Centers:
• Italsea universal programmer, P/N 9097297000
20
P200091
Service Manual – SW4000
General Information
Technical Data
Model SW4000 B SW4000 P SW4000 LP
Cleaning width with one side broom 38.3 in (975 mm)
with two side brooms 49.2 in (1,250 mm)
Main broom size (length x diameter) 27.6 x 13.4 in (700 x 340 mm)
Side broom diameter 17.7 in (450 mm)
Theoretical working capacity main broom 52,743 ft
with two side brooms 73,463 ft
with two side brooms 94,184 ft
Hopper capacity 19.8 US gal (75 liters)
maximum liftable weight 220 lb (100 kg)
maximum lifting height 62.6 in (1,590 mm)
Filter cleaning system Electrical lter shaker
area 75 ft
ltering capacity 4 µm
Power source 24 Volt batteries Power - 4,1 kW (5,5 CV) @ 3.600 giri/min
Engine model (*) - Honda GX-200
Tank capacity - 2 US gal
LPG Tank capacity - - 33 lb (15 Kg)
Main broom motor power 0.8 hp (600 W)
speed 550 rpm
Side broom motor power 0.12 hp (90 W)
speed 110 rpm
Vacuum motor power 0.35 hp (260 W)
Drive type Electric drive on front wheel
gearmotor power 1.35 hp (1,000 W)
forward speed 4.3 mi/h (7 km/h)
reverse speed 2.8 mi/h (4.5 km/h)
Maximum gradient when working 20 %
Hopper hydraulic control unit 0.33 hp (250 W)
Filter shaker motor 0.12 hp (90 W)
Total absorbed power 2.7 hp (2.0 kW)
Working autonomy 4,5 h 13 h 25 h
Dimensions
(length x width x height)
machine body 64.5 x 40.7 x 52.3 in (1,640 x 1,035 x 1,330 mm)
machine with side brooms 64.5 x 41.3 x 52.3 in (1,640 x 1,050 x 1,330 mm)
machine with ashing light 64.5 x 41.3 x 57.7 in (1,640 x 1,035 x 1,390 mm)
machine with FOPS protective roof (optional) 64.5 x 40.7 x 78.3 in (1,640 x 1,035 x 1,990 mm)
battery compartment 14.5 x 32 x 15.3
in (370x812x390
mm)
LPG tank maximum size (length x diameter) - - 28.3 x 11.8 in
2
/h (4,900 m2/h)
2
/h (6,825 m2/h)
2
/h (8,750 m2/h)
2
(7 m2)
(7,8 litres)
14.2 x 15 x 8.7 in
(360 x 380 x 220 mm)
-
(720 x 300 mm)
21
Service Manual – SW4000
General Information
Technical Data (Continues)
Model SW4000 B SW4000 P SW4000 LP
Weight kerb weight without batteries 954 lb (433 Kg) - -
kerb weight - 1,126 lb (511 Kg) 1,135 lb (515 Kg)
total kerb weight (*) 1,816 lb (824 Kg) 1,309 lb (594 Kg) 1,371 lb (622 Kg)
front axle kerb weight (*) 696 lb (316 Kg) 553 lb (251 Kg) 560 lb (254 Kg)
rear axle kerb weight (*) 1,120 lb (508 Kg) 756 lb (343 Kg) 811 lb (368 Kg)
gross vehicle weight (GVW) 2,215 lb (1,005
Kg)
Wheel specic pressure on the oor (front - rear wheels, in running conditions) (**) 130 - 58 lbf/in
(0.9 - 0.4 N/mm2)
Sound pressure level at workstation (ISO 11201, ISO 4871, EN 60335-2-72) (LpA) 65 ±3 dB(A) 75 ±3 dB(A)
Machine sound pressure level (ISO 3744, ISO 4871, EN 60335-2-72) (LwA) 86 dB(A) 94 dB(A)
IP protection class X3
Dust guard system water tank (optional) capacity 5.3 US gal (20 liters)
U-turn space (right - left) 75.6 - 74.4 in (1,920 - 1,890 mm)
Vibration level at the operator’s arms (ISO 5349-1) < 98 in/s
Vibration level at the operator’s body (ISO 2631-1) < 19.6 in/s
(< 0.5 m/s2)
1,708 lb (775 Kg) 1,770 lb (803 Kg)
2
2
116 - 29 lbf/in
(0.8 - 0.2 N/mm2)
2
(< 2.5 m/s2)
< 35.4 in/s
(< 0.9 m/s2)
2
2
22
(*) With operator on board, without batteries and with hopper empty.
(**) Machines have been tested under the following conditions:
• With operator on board (165.3 lb - 75 kg)
• Battery of maximum size
• Brooms of maximum size
• Full Tanks
• Optional components installed
• Weight on wheels checked
• Print on the oor checked on cement for each single wheel
Result expressed as maximum value for both front and rear wheels
Machine material composition and recyclability
Type
Aluminium 100 % 0.0 % 0,0 % 0,0 %
Electric motors - various 29 % 10.8 % 21,1 % 21,1 %
Ferrous materials 100 % 53.5 % 48,3 % 48,8 %
Wiring harnesses 80 % 1.2 % 0,8 % 0,8 %
Liquids 100 % 0.4 % 0,5 % 0,5 %
Plastic - non-recyclable material 0 % 1.0 % 0,9 % 0,8 %
Plastic - recyclable material 100 % 9.8 % 8,6 % 8,4 %
Polyethylene 92 % 7.0 % 6,0 % 5,9 %
Rubber 20 % 4.1 % 3,5 % 3,5 %
Cardboard - paper - wood 100 % 12.2 % 10,3 % 10,2 %
Recyclable
percentage
SW4000 B
weight
percentage
SW4000 P
weight
percentage
SW4000 LP
weight
percentage
Service Manual – SW4000
Technical Data (Continues)
Caution! If the machine is to be used at ambient temperatures below +10°C, the oil should be
changed with equivalent oil having a viscosity of 32 cSt. For temperatures below 0°C,
use an oil with lower viscosity.
Hydraulic oil technical data
AGIP ARNICA 46 32
Viscosity at 104 °F (40 °C) in
Viscosity at 212 °F (100 °C) in
Viscosity index / 150 157
Flash point COC °F (°C) 419 (215) 396 (202)
Pour point °F (°C) -32.8 (-36) -32.8 (-36)
Density at 15 °C (59 °F) lb/gal (kg/l) 1.9 (0.87) 1.9 (0.865)
2
/s (mm2/s) 0.07 (45) 0.05 (32)
2
/s (mm2/s) 0.012 (7.97) 0.009 (6.40)
General Information
23
Service Manual – SW4000
Dimensions
General Information
24
1330 mm (52.4 in)
1065 mm (42 in)1640 mm (64.6 in)
P200092
Service Manual – SW4000
General Information
Maintenance
The lifespan of the machine and its maximum operating safety are ensured by correct and regular maintenance.
Warning! Read carefully the instructions in the Safety chapter before performing any
maintenance procedure.
The following tables provides the scheduled maintenance. The intervals shown may vary according to particu-
lar working conditions, which are to be dened by the person in charge of the maintenance.
For instructions on maintenance procedures, see the following paragraphs.
Scheduled Maintenance Table (SW4000 Battery)
Procedure
Battery charging (1)
Battery (WET) uid level check (2)
Side and main broom height check
Service brake cable adjustment (3)
Hopper dust lter check and cleaning (“A” method) (4)
Hopper hydraulic lifting system oil level check (2)
Skirt height and operation check
Dust guard system water lter check and cleaning
Hopper dust lter check and cleaning (“B” method) (4)
Filter shaker operation check
Main broom driving belt check
Brake adjustment
Nut and screw tightening check (5)
Steering chain cleaning
Safety system operation check (2)
Brake pad check/adjustment/replacement (3)
Hopper dust lter check and cleaning (“C” method) (4)
Main broom driving belt replacement
Hopper gasket integrity check
Lifted hopper sensor operation check/adjustment
Motor carbon brush check and replacement
Hydraulic system oil change (6)
Upon
delivery
Every
10
hours
Every
50
hours
Every
100
hours
Every
200
hours
Every
year
25
(1) Daily or after using the machine.
(2) Or before start-up.
(3) Or more frequently if the machine is used on slopes.
(4) Or more often in dusty areas.
(5) And after the rst 8 running-in hours.
(6) Change the hydraulic system oil for the rst time after 500 hours, then every 2,000 hours or every year.
Service Manual – SW4000
General Information
Scheduled Maintenance Table (SW4000 Petrol/LPG)
Procedure
Engine oil level check (1)
Battery uid level check (2)
Side and main broom height check
Engine air lter check (1)
Service brake cable adjustment (3)
Hopper dust lter check and cleaning (“A” method) (4)
Hopper hydraulic lifting system oil level check (2)
Skirt height and operation check
Dust guard system water lter check and cleaning
Engine air lter cleaning (4) (4)
Hopper dust lter check and cleaning (“B” method) (4)
Filter shaker operation check
Main broom driving belt visual inspection
Brake replacement
Engine oil change (5) (6)
Spark plug check/cleaning
Nut and screw tightening check (6)
Steering chain cleaning (*)
Safety system operation check (2)
Engine lter trap cleaning
Engine bafe plate cleaning
Fuel lter cleaning (7)
Brake pad check/adjustment/replacement (3)
Hopper dust lter check and cleaning (“C” method) (4)
Main broom driving belt replacement
Hopper gasket integrity check
Lifted hopper sensor operation check/adjustment
Fuel valve lter cleaning (Petrol)
Engine paper air lter replacement
Spark plug replacement
Engine idle speed check/adjustment
Valve clearance check/adjustment (7)
Hydraulic system oil change (8)
Supply hose replacement (LPG)
Engine combustion chamber check Every 500 hours (7)
Fuel hose check/replacement (Petrol) Every 2 years (7)
Upon
delivery
Every
10
hours
Every
50
hours
Every
100
hours
Every
200
hours
26
Every
year
(1) Daily or after using the machine.
(2) Or before start-up.
(3) Or more frequently if the machine is used on slopes.
(4) Or more often in dusty areas.
(5) Or every 6 months.
(6) And after the rst 20 running-in hours.
(7) Maintenance procedures to be performed by an authorised Honda dealer.
(8) Change the hydraulic system oil for the rst time after 500 hours, then every 2,000 hours or every year.
Service Manual – SW4000
4
Chassis System
Chassis System
Chassis (main parts)
1. Front side supporting the steering assembly and side brooms.
2. Center side supporting batteries/engine with dynamotor and main broom.
3. Rear side supporting the hopper and rear wheels on hubs.
4. Central holder for separating wall between engine compartment/vacuum system compartment, and for
supporting the hopper lifting linkages.
27
3
2
1
P200093
Control System 28Service Manual – SW4000
Control System
Functional Description
The machine is started by the ignition key (SW1), located on the steering column.
The key starts the machine when turned to II, thus powering the relay (K4). The relay (K4) stays on even when
the key returns to I. All the accessories (except the buzzer) are on only when the relay (K4) is on too.
Ahead of the ignition key (SW1) there is the emergency push-button (SW0). The key circuit is protected by the
relevant fuse (F4).
The machine different functions are mainly controlled by the switches located on the main dashboard (on the
steering column) and on the secondary dashboard (beside the driver’s seat) and by the 2 broom levers.
For functions not requiring an electronic management, the switches operate directly or by means of relays,
on the relevant drives. For functions requiring timers or electronic controls, the commands generated when
operating the switches are read by the dashboard electronic board (EB2) which drives the outputs directly or
by means of external relays.
The electric drive system control is made by the forward/reverse gear switch (SW2) and the gear pedal (R1)
which provide signals to the drive system electronic board (EB1).
For all the details concerning the described functions, see the relevant chapters.
Control System 29Service Manual – SW4000
DashboardElectronicBoardSpecications
The dashboard electronic board performs the following:
a. HOUR COUNTER: By default, the 3-digit display (A) shows the number of hours stored in the hour
counter. The hour counter proceeds with counting, only when the main broom turns. When the hour
counter reaches 999, the next numbers are shown by the 3 more meaningful digits by adding a (low)
dot for separating thousands (i.e.: 1234 will be shown as 1.23).
b. BATTERY VOLTAGE DISPLAY: by pressing the push-button (B) (with the machine running)
the display will switch from the 3-digit hour counter (A) to the battery voltage. The display will
automatically return to the hour counter 5” after the last pressing of the push-button (B).
c. MAIN BROOM MOTOR PROTECTION: By reading the voltage drop on main broom fuse (FA), the
main broom motor amperage (M4) is monitored. If the voltage drop is higher than 40mV, the warning
light (C) starts ashing. If this condition persists, after a time inversely proportional to the value of
voltage drop detected, the broom motor is stopped (the warning light continues to ash). To reset,
turn the ignition key on and off (SW1).
A
B
C
P200219
Control System 30Service Manual – SW4000
EF
d. BATTERY PROTECTION: Battery charge status is shown by the 3 LEDs depending on the type of
battery (WET/GEL) according to the following diagram:
WET GEL
1 Green LED on (xed) V>22.0 V>22.2
2 Yellow LED on (xed) 22.0>V>20.4 22.2>V>21.6
3 Red LED ashing V>20.4 V>21.6
When the red LED starts ashing, broom function is automatically deactivated.
e. BATTERY TYPE DISPLAY (WET/GEL): Each time the machine is turned on with the ignition
key, the 3 battery charge LED indicators show the battery type as follows:
Battery Type Flashing pattern
WET 4 ashes of the RED warning light
GEL 4 ashes of the GREEN warning light
f. PROCEDURE FOR BATTERY SETTING (WET/GEL): Hold the push-button (B) down while
you turn the key on and hold it for 5 sec. The 3 LEDs will then show again the current setting with
the continuous ashing of the corresponding LED (see the previous step), while further pressing
the push-button (B) will change the current setting. The last setting will be stored when (B) is not
pressed for more than 5 sec.
g. TIMED FUNCTION ACTIVATION: BROOM, VACUUM and FILTER SHAKER are turned on and
off by pressing the relevant controls and according to the conditions of the relevant sensors as shown
in their respective chapters
OTHER INDICATIONS WITH DEDICATED WARNING LIGHTS: fuel reserve warning light
(D), vacuum system warning light (E), dust guard system warning light (F), hopper lifting warning
light (G), main broom overpressure warning light (C), drive system diagnostic warning light (I).
G
D
B
C
I
P200220
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