Nilfisk-Advance SW4000, 9084403010, 9084400010, 9084401010, 9084402010 Service Manual

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Page 1

SW4000

Service Manual

Advance SW4000 Battery - 9084403010

Nilsk SW4000 Battery - 9084400010

Nilsk SW4000 Petrol - 9084401010

Nilsk SW4000 LPG - 9084402010

Advance (SW4000 BR) - 9084407010 (LPG)

English

2013-04 Form No. 1464811000

Page 2

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 Specications . . . . . . . . . . . . . . . . . . . . . . . . . .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

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Dust Guard System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

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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

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Engine System - Petrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Engine System - LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

Page 4

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

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232

Page 5

Service Manual – SW4000

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.

Other Reference Manuals

Model Product Code User Manual Spare Parts List

SW4000 Battery - Nilsk 9084400010 1464809000 1464810000 SW4000 Petrol - Nilsk 9084401010 1464815000 1464816000 SW4000 LPG - Nilsk 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 Nilsk-Advance Retailer

- Nilsk-Advance website: www.nilsk.com - www.advance-us.com

SW4000 Battery Advance – SW4000 Battery/Petrol/LPG

Nilsk

Page 6

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 Nilsk Service Centers. The authorised personnel is trained directly at the manufacturer’s premises and has original spare parts and accessories. Contact Nilsk Retailer indicated below for service or to order spare parts and accessories, specifying the ma-

chine model and serial number.

(Apply Retailer label here)

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

identication data.

MACHINE model .............................................................................................

PRODUCT code ..............................................................................................

P200082

MACHINE serial number .................................................................................

ENGINE model ................................................................................................

ENGINE serial number ....................................................................................

Page 7

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

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 specications.

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

Specic 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.

Page 8

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

(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 Nilsk-

Advance Service Center.

Page 9

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 mufer, 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 Nilsk-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 specications. – 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 specied 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

Page 10

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 afxed 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

(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 insufcient 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.

Page 11

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 sufciently 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

Machine Lifting

Warning! Donotworkundertheliftedmachine,ifitisnotsecurelyxed.

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.

Page 12

Service Manual – SW4000

Driver's seat with safety microswitch

Machine Nomenclature (know your machine) (SW4000 Battery)

General Information

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

Page 13

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)

Panel filter with

filter-shaker

Hopper

Anchoring slots for transport (not for lifting)

Right side cover

Right door

Main broom

Rear wheels

P200084

Page 14

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

Battery connection diagram

BATTERY PLUG

Left side broom motor circuit breaker

Right side broom motor circuit breaker

P200085

Page 15

Service Manual – SW4000

Switch for:

Vacuum system

Control Panel (SW4000 Battery)

General Information

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

Page 16

Service Manual – SW4000

Driver's seat with safety microswitch

General Information

Machine Nomenclature (know your machine) (SW4000 Petrol/LPG)

Flashing light

Safety belts

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

Page 17

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)

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

Page 18

Service Manual – SW4000

Machine Nomenclature (SW4000 Petrol/LPG) (Continues)

Hopper hydraulic lifting system control unit

Drive system electronic board

General Information

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

Page 19

Service Manual – SW4000

Switch for:

Vacuum

Control Panel (SW4000 Petrol/LPG)

General Information

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

Page 20

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 Nilsk-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 Nilsk-Advance websites).

The following equipment is also available at Nilsk-Advance Centers:

• Italsea universal programmer, P/N 9097297000

P200091

Page 21

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

/h (4,900 m2/h)

/h (6,825 m2/h)

/h (8,750 m2/h)

(7 m2)

(7,8 litres)

14.2 x 15 x 8.7 in

(360 x 380 x 220 mm)

(720 x 300 mm)

Page 22

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 specic 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)

116 - 29 lbf/in

(0.8 - 0.2 N/mm2)

(< 2.5 m/s2)

< 35.4 in/s

(< 0.9 m/s2)

(*) 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

Page 23

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)

/s (mm2/s) 0.07 (45) 0.05 (32)

/s (mm2/s) 0.012 (7.97) 0.009 (6.40)

General Information

Page 24

Service Manual – SW4000

Dimensions

General Information

1330 mm (52.4 in)

1065 mm (42 in)1640 mm (64.6 in)

P200092

Page 25

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 dened 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

hours

Every

hours

Every

100

hours

Every

200

hours

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) 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.

Page 26

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 bafe 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

hours

Every

hours

Every

100

hours

Every

200

hours

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.

Page 27

Service Manual – SW4000

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.

P200093

Page 28

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.

Page 29

Control System 29Service Manual – SW4000

DashboardElectronicBoardSpecications

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).

P200219

Page 30

Control System 30Service Manual – SW4000

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).

P200220

Page 31

Wiring Diagram (SW4000 Battery)

Control System 31Service Manual – SW4000

HOPPER TEMPERATURE

REVERSE GEAR BUZZER (BZ1)

FILTER SHAKER/ VACUUM SYSTEM SWITCH (SW3)

HORN SWITCH (SW6)

SENSOR (S4)

HORN (HN)

VACUUM SYSTEM

FILTER SHAKER

RELAY (K1)

DISPLAY ELECTRONIC BOARD FUSE (F3)

J1.1 - Electronic board power supply +

J1.14 - Electronic board congurator return

J1.13 - Key return

J1.11 - Vacuum system relay power supply

J1.12 - Filter-shaker relay power supply

J2.4 - Control panel switch power supply (-)

J1.15 - Fire alarm signal

J2.2 - Vacuum system activation signal

CONTROL PANEL ELECTRONIC BOARD (EB2)

J1.17 - Water pump activation signal

J2.3 - Filter-shaker activation signal

J2.1 - Control panel switch power supply (+)

J1.4 - Broom fuse voltage drop reading +

J1.5 - Broom fuse voltage drop reading -

J1.2 - Broom activation lever signal

J1.10 - Broom electromagnetic switch power supply

J1.8 - Lifted hopper signal

J1.7 - Drive system electronic board diagnostic signal

J1.18 - Machine moving signal

J1.9 - Electronic board power supply -

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

RELAY (K2)

HOPPER LIFTING SENSOR (S1)

HOPPER LOWERING RELAY (K3B)

MAIN BROOM LEVER SENSOR (S2)

HOPPER LIFTING RELAY (K3A)

HOPPER ENABLING SWITCH (SW4)

HOPPER LIFTING/LOWERING SWITCH (SW5)

DUSTGUARD™ SWITCH (SW8)

DUSTGUARD™ PUMP RELAY (K6)

SIDE BROOM

LEVER SENSOR (S3) SIDE BROOM RELAY (K5)

MAIN BROOM ELECTROMAGNETIC SWITCH (ES1)

B C D

P200094A

Page 32

Wiring Diagram (SW4000 Battery)

Control System 32Service Manual – SW4000

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

LINE ELECTROMAGNETIC SWITCH (ES0)

KEY CIRCUIT FUSE (F4)

IGNITION KEY (SW1)

MACHINE ON RELAY (K4)

EMERGENCY PUSH-BUTTON (SW0)

B C D

DRIVE SYSTEM ELECTRONIC BOARD (EB1)

J2.15 - Key input

J2.11 - Lifted hopper input

J2.10 - Diagnostic warning light output

J2.7 - Machine moving signal

WORKING LIGHT SWITCH (SW9)

WORKING LIGHT (L1)

WORKING LIGHT (L2)

MACHINE ON RELAY (K4)

P200094B

Page 33

Wiring Diagram (SW4000 Petrol/LPG)

Control System 33Service Manual – SW4000

FUEL RESERVE SENSOR (S4)

REVERSE GEAR BUZZER (BZ1)

FILTER SHAKER/ VACUUM SYSTEM SWITCH (SW3)

HORN SWITCH (SW6)

HORN (HN)

DISPLAY ELECTRONIC BOARD FUSE (F3)

J1.14 - Electronic board congurator return

J1.13 - Key return

J1.6 - Fuel reserve signal

J1.15 - Fire alarm signal

J2.2 - Vacuum system activation signal

CONTROL PANEL ELECTRONIC BOARD (EB2)

J2.3 - Filter-shaker activation signal

J2.1 - Control panel switch power supply (+)

J1.4 - Broom fuse voltage drop reading +

J1.5 - Broom fuse voltage drop reading -

VACUUM SYSTEM RELAY (K1)

J1.1 - Electronic board power supply +

J1.11 - Vacuum system relay power supply

J1.12 - Filter-shaker relay power supply

J2.4 - Control panel switch power supply (-)

J1.17 - Water pump activation signal

J1.2 - Broom activation lever signal

J1.10 - Broom electromagnetic switch power supply

J1.8 - Lifted hopper signal

J1.7 - Drive system electronic board diagnostic signal

J1.18 - Machine moving signal

J1.9 - Electronic board power supply -

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

FILTER SHAKER RELAY (K2)

MAIN BROOM

LEVER SENSOR (S2) HOPPER LIFTING SENSOR (S1)

HOPPER LOWERING RELAY (K3B)

HOPPER LIFTING RELAY (K3A)

HOPPER ENABLING SWITCH (SW4)

HOPPER LIFTING/LOWERING SWITCH (SW5)

DUSTGUARD™ SWITCH (SW8)

DUSTGUARD™ PUMP RELAY (K6)

SIDE BROOM LEVER

SENSOR (S3) SIDE BROOM RELAY (K5)

MAIN BROOM ELECTROMAGNETIC SWITCH (ES1)

B C D

P200095A

Page 34

Wiring Diagram (SW4000 Petrol/LPG)

Control System 34Service Manual – SW4000

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

LINE ELECTROMAGNETIC SWITCH (ES0)

KEY CIRCUIT FUSE (F4)

EMERGENCY PUSH-BUTTON (SW0)

IGNITION KEY (SW1)

ENGINE SPARK PLUG (SPK)

FRAME (FR)

DRIVE SYSTEM ELECTRONIC BOARD (EB1)

WORKING LIGHT SWITCH (SW9)

J2.15 - Key input

WORKING LIGHT (L1)

WORKING

B C D

J2.11 - Lifted hopper input

J2.10 - Diagnostic warning light output

J2.7 - Machine moving signal

LIGHT (L2)

LPG SAFETY TIMER RELAY (KT1)

LPG SAFETY SOLENOID VALVE (EV1)

Only for LPG version

MACHINE ON RELAY (K4)

DIODE (D3)

ENGINE START ELECTROMAGNETIC SWITCH (ES2)

P200095B

Page 35

Component Locations

• Dashboard

• Dashboard electronic board (EB2)

• Ignition key (SW1)

Dashboard

electronic

board (EB2)

Control System 35Service Manual – SW4000

Dashboard

Ignition key (SW1)

P200096

Page 36

Troubleshooting

Trouble Possible Cause Remedy

(For SW4000 Battery) When turning the ignition key to “II”, the display does not turn on and the machine does not operate.

(For SW4000 Petrol/LPG) “L O U” (A) (Low Voltage) display indication

(For SW4000 Petrol/LPG) “H I U” (A) (High Voltage) ashing display

indication

Control System 36Service Manual – SW4000

The battery connector is disconnected. Connect the battery connector.

The fuse (F3) and/or (F0) is open. Check/replace the fuses.

The emergency push-button has been pressed.

Battery voltage lower than 24.0 V.

Battery voltage higher than 32.4V.

Check and release the emergency pushbutton.

Decrease the main broom pressure on the oor.

“L O U” (A) (Low Voltage) display indication

If the problem persists, it may be necessary to calibrate the engine rpm (see Petrol Engine – LPG Engine chapter).

Turn off the engine each time the machine is stopped.

If the problem persists, it may be necessary to calibrate the engine rpm (see Petrol Engine chapter).

P200247

Page 37

Control System 37Service Manual – SW4000

Dashboard Electronic Error Codes

The drive system warning light (A) on the dashboard electronic board (EB2) shows the error codes of the drive

system electronic board (EB1). For the details, see the Wheel System, Drive chapter.

P200097

Page 38

Connectors on the dashboard electronic board

J1: MOLEX MINIFIT type, 18-ways vertical (A)

101112131415161718

123456789

Control System 38Service Manual – SW4000

P200221

PIN Description Electronic

board in/out

1 Electronic board power supply + in 24V 3A F10 2 Broom activation lever signal in 24V (when the description is ON) <1A S2 3 Engine on signal in 24V (when the description is ON) <1A K4.30

4* Broom fuse voltage drop reading + in 0V (when the description is OFF) <1A FA + 5* Broom fuse voltage drop reading - in 0V (when the description is OFF) <1A FA-

6 Fuel reserve signal in 0V (when the description is OFF) <1A S5 7 Drive system electronic board diagnostic signal in (24V) <1A EB1.J2.10 8 Lifted hopper signal in 24V (when the description is ON) <1A S1

9 Electronic board power supply - in 0V (when the description is OFF) 3A -B 10 Broom electromagnetic switch power supply out 0V (when the description is OFF) 1A ES1, K5 11 Vacuum system relay power supply out 0V (when the description is OFF) 1A K1.85 12 Filter shaker relay power supply out 0V (when the description is OFF) 1A K2.85 13 Return from key in 24V (when the description is ON) <1A K4.30/SW1

14** Electronic board congurator return (Battery) in 24V (when the description is ON) <1A K4.30

15 Fire alarm signal in 0V (when the description is OFF) <1A S4 16 Hopper lifting control out 0V (when the description is OFF) 1A K3A.85

V ref. I max. Connected to

17 Water pump activation signal in 24V (when the description is ON) <1A SW8.2 18 Machine moving signal in 0V (when the description is OFF) <1A EB1.7

Page 39

Control System 39Service Manual – SW4000

CBA

J1: MOLEX MINIFIT type, 18-ways vertical (A) (continues)

Further notes about dashboard electronic board (PIN - J1.14)

The dashboard electronic board (EB2) recognises if it has been assembled on a Battery or Petrol/LPG machine

version depending on the PIN J1.14 status:

• PIN J1.14 - connected to +24V = Battery version,

• PIN J1.14 - NOT connected = Petrol/LPG version .

Battery version (PIN - J1.14 at +24V)

SAFETY BATTERY FUNCTION: The battery loading status is displayed by means of 3 LEDs (A) Green, (B) Yellow, (C) Red, up to the battery type installed (WET/GEL) as shown below:

Threshold values Threshold values of change

1 LED (A) Green xed <=> LED (B) Yellow xed 22,0 22,2 2 LED (B) Yellow xed <=> LED (C) Red ashing 1Hz 20,4 21,6

status (V, toll.±0,1) WET GEL

The change status is ltered with a 3 sec. delay as regards to the battery tension reading. When threshold value 2 is reached, the J1.10 output is automaticaly shutted off with 5 sec. delay. Without any regards to the battery tension reading value the change values status 2 is xed. The only way to

reset the status is the machine switching off by using the ignition key (SW1).

P200247b

Page 40

Control System 40Service Manual – SW4000

J1: MOLEX MINIFIT type, 18-ways vertical (A) (continues)

Petrol/LPG version (PIN - J1.14 not connected)

The RPM value of the Petrol/LPG engine is xed to 2.750 rpm ± 50 rpm

The xed RPM value of the Petrol/LPG engine should be in any case as follows

• with the loaded batteries, engine On, all functions Off => the battery tension is between 27,0V and 31,0V

• with the loaded batteries, engine On, all functions On => the battery tension is higher than 24,0V

The dashboard electronic board (EB2) displays 2 alarms, shown by the display (A) and the LED (B) ashed, if are not matched for more than 5 consecutive minutes the following conditions:

Shown on display Battery conditions Solution Alternative actions in case the

L O U V < 24,0V (Low Voltage) Avoid using the machine for long

H I U V > 32,4V (High

Voltage)

periods at maximum power or on slopes: leave the engine running with all features turned off for at least ten minutes after each usage.

Turn the engine off when you are not working: do not leave the machine for long periods without using any functions.

solution does not solve the problem

Recharge the battery with a suitable charger and then adjust the engine RPM (increase the engine RPM till reach again the recommended tension ranges).

Adjust the RPM engine (reduce the engine RPM till reach again the recommended tension ranges).

AB AB

P200247a

Page 41

J2: MOLEX MINIFIT type, 4-ways vertical (B)

Control System 41Service Manual – SW4000

P200098

PIN Description Electronic

board in/out

1 Dashboard switch power supply (+) out 24V <1A SW3, SW8 2 Vacuum system activation signal in 24V (when the description is ON) <1A SW3.1 3 Filter-shaker activation signal in 24V (when the description is ON) <1A SW3.3 4 Dashboard switch power supply (-) out 0V <1A SW4

V ref. I max. Connected to

Page 42

Removal and Installation Dashboard Electronic Board Disassembly/Assembly

Control System 42Service Manual – SW4000

Disassembly

1. Drive the machine on a level oor.

2. Turn the ignition key to “0” and engage the parking brake.

3. Open the battery/engine compartment hood. Disconnect the battery connector (SW4000 Battery) - Disconnect the batteries (SW4000 Petrol/LPG).

4. Remove the fastening screws (A) of the fairing (B) from the steering column.

5. Slightly lift the steering column (B) by disengaging it from the lower fastener (C).

6. Disconnect the dust guard system quick coupling (D).

7. Retrieve the fairing (B).

8. Under the left side of the control panel, disconnect the connectors (E) of the dashboard electronic board (F).

9. Disengage the four nuts (G) and remove the dashboard electronic board (F).

Assembly

10. Assemble the components in the reverse order of

disassembly, and note the following:

• Set the type of batteries installed on the ma-

chine (see Electrical System chapter).

P200101

Page 43

Dust Control System 43Service Manual – SW4000

Dust Control System

Functional Description

The dust raised in the compartment of the main broom, is collected in the rear cargo area by a ow of air generated by the dust control system.

The lter located between the vacuum system and the hopper, retains dirt which is then conveyed through a

feedbox into the hopper itself. The operation of the system depends on the activation of the main broom.

By deactivating the main broom, the dust control system turns off automatically.

There is a vacuum system motor (M1) which is powered by the relay (K1) and protected by the fuse (F1). The relay (K1) is directly controlled by the dashboard electronic board (EB2) according to the information re-

ceived by the vacuum system/lter shaker switch (SW3), by the sensor on the broom activation lever (S2), by

the machine moving signal received by the drive system electronic board(EB1) and by the lifted hopper sensor (S1).

Normally the vacuum function is turned on when the main broom is lowered with the lever; it can, however, be turned on or off independently with the push-button SW3, it turns off when the machine is stopped, when the hopper is lifted and during activation the electric lter shaker. There is an electric lter shaker motor (M2) which is powered by the relay (K2) and protected by the fuse (F2).

The relay (K2) is directly controlled by the dashboard electronic board (EB2) according to the information re-

ceived by the vacuum system/lter shaker switch (SW3): When the button is activated for a cycle of 20 seconds

during which it is driven 0.5 sec ON and 0.5 sec. OFF for continuously modulating the number of revolutions

and the resulting vibration frequencies of the lter. The vibrating motor shakes the lter allowing dirt trapped in the folds of the same to fall by gravity into the

hopper.

This reduces lter maintenance and helps to maintain proper airow through the lter.

Wiring Diagram

VACUUM SYSTEM FUSE (F1)

FILTER SHAKER FUSE (F2)

FILTER SHAKER/VACUUM SYSTEM SWITCH (SW3)

FILTER SHAKER RELAY (K2)

VACUUM SYSTEM RELAY (K1)

M2M1

FILTER SHAKER MOTOR

VACUUM SYSTEM MOTOR

DISPLAY ELECTRONIC BOARD FUSE (F3)

J2.2 - Vacuum system activation signal

CONTROL PANEL ELECTRONIC BOARD (EB2)

J2.3 - Filter-shaker activation signal

J2.1 - Control panel switch power supply (+)

VACUUM SYSTEM RELAY (K1)

J1.1 - Electronic board power supply +

J1.11 - Vacuum system relay power supply

J1.12 - Filter-shaker relay power supply

J1.2 - Broom activation lever signal

J1.8 - Lifted hopper signal

J1.9 - Electronic board power supply -

J1.18 - Machine moving signal

FILTER SHAKER RELAY (K2)

MAIN BROOM

LEVER SENSOR (S2) HOPPER LIFTING SENSOR (S1)

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

DRIVE SYSTEM ELECTRONIC BOARD (EB1)

J2.11 - Lifted hopper input

J2.7 - Machine moving signal

P200102

Page 44

Component Locations

• Filter shaker/vacuum system switch (SW3)

• Vacuum system motor (M1)

• Gasket

• Filter shaker motor (M2)

Dust Control System 44Service Manual – SW4000

• Panel lter

• Vacuum system motor fuse (25 A - Battery) (30 A

Petrol/LPG) (F1)

• Filter shaker motor fuse (25 A - Battery) (30 A Petrol/LPG) (F2)

Filter shaker/vacuum system switch (SW3)

Gasket

Filter shaker

motor (M2)

Filter shaker

motor fuse

(25 A - Battery)

(30 A Petrol/LPG) (F2)

Vacuum system motor (M1)

Panellter

Vacuum system

motor fuse

(25 A - Battery)

(30 A Petrol/LPG) (F1)

P200103

Page 45

Dust Control System 45Service Manual – SW4000

CBB

Maintenance and Adjustments Panel Dust Filter Cleaning and Integrity Check

Caution! Thedustltermustberegularlycleanedtomaintaintheefciencyofthevacuum

system.Followtherecommendedlterserviceintervalsforthelongestlterlife.

Warning! -Wearsafetyglasseswhencleaningthelter.

 -Donotpuncturethelter.  -Cleanthelterinawell-ventilatedarea.

- Wear appropriate dust mask to avoid breathing in dust.

1. Drive the machine on a level oor, engage the parking brake and turn the ignition key to “0”.

2. Open the battery/engine compartment hood with the handle and fasten it with the support rod.

3. Disconnect the battery connector (SW4000 Battery) - Disconnect the batteries (SW4000 Petrol/LPG).

4. Disconnect the vacuum system motor connector (A).

5. Disengage the retainers (B) and remove the vacuum system hood (C).

P200223

Page 46

Panel Dust Filter Cleaning and Integrity Check (Continues)

Dust Control System 46Service Manual – SW4000

6. (Only for LPG SW4000). Disconnect the lter shaker connector (K).

7. Loosen the knobs (D) and (E), then remove the

lter shaker assembly (F), by sliding it forward,

disengaging it by the knobs (D) and then by the knobs (E).

8. (Only for SW4000 Battery and Petrol). Fasten

the lter shaker assembly (F) to the holder (G).

9. (Only for LPG SW4000). Remove the lter shaker assembly (F).

10. Lift the dust lter (H) and remove it from the machine.

11. Clean the dust lter using one of the methods

below:

Method “A”

Vacuum loose dust from the lter. Gently tap the lter against a at surface (with the dirty side down) to

remove dust and dirt.

Caution! Take care not to damage the

metallipwhichextendspast

the gasket.

12. Assemble the dust lter in the reverse order of disassembly and note the following:

• Clean the lter housing.

• If the lter gasket is damaged or missing, it

must be replaced.

• Install the lter with the strainer facing up-

wards (arrow (I) upwards).

Method “B”

Vacuum loose dust from the lter. Blow compressed

air (maximum pressure 6 Bar) into the clean side of

the lter (in the opposite direction of the airow).

Method “C”

Vacuum loose dust from the lter. Then soak the lter in warm water for 15 minutes, then rinse it under a

gentle stream of water (maximum pressure 2.5 Bar).

Let the lter dry completely before installing it back

into the machine.

For a better cleaning, it is allowed to wash the lter

with water and non-lathering detergents. This provides better quality cleaning but reduces the

life of the lter, which will have to be replaced more

frequently. The use of inadequate detergents can

damage the lter.

Caution! Forpaperlter:Donotuse

water or detergents to clean it, otherwise it can be damaged.

DHID

P200104

Page 47

Troubleshooting

Trouble Possible causes Remedy

Dust Control System 47Service Manual – SW4000

Dust/debris vacuuming is insufcient The lter is clogged Clean the dust lter by using the lter shaker

The vacuum system compartment gasket is

damaged

No vacuuming The fuse (F1) is open. Replace the fuse.

The switch (SW3) is not efcient Replace The relay (K1) is not efcient Replace The vacuum system is broken Repair/replace

The lter shaker does not operate. The fuse (F2) is open. Replace the fuse.

The lter shaker is disconnected. Connect the lter shaker connector.

The switch (SW3) is not efcient Replace The relay (K2) is not efcient Replace The lter shaker is broken Repair/replace

or by disassembling it.

Repair/replace

Page 48

Dust Control System 48Service Manual – SW4000

Removal and Installation Filter Shaker Motor Disassembly/Assembly

Disassembly

1. Drive the machine on a level oor, engage the parking brake and turn the ignition key to “0”.

2. Open the battery/engine compartment hood with the handle and fasten it with the support rod.

3. Disconnect the battery connector (SW4000 Battery) - Disconnect the batteries (SW4000 Petrol/LPG).

4. Disconnect the vacuum system motor connector (A).

5. Disengage the retainers (B) and remove the vacuum system hood (C).

P200105

Page 49

Dust Control System 49Service Manual – SW4000

CBB

Filter Shaker Motor Disassembly/Assembly (Continues)

6. Release the fastening clamp and disconnect the lter shaker connector (K).

7. Loosen the knobs (D) and (E), then remove the lter shaker assembly (F), by sliding it forward, disengaging it by the knobs (D) and then by the knobs (E).

8. At the workbench, remove the nuts (G) and remove the fastening clamps (H) of the lter shaker motor (I). Retrieve the washers (J).

9. Remove the lter shaker motor (H), by disengaging the dowel (L) from its seat.

Assembly

10. Assemble the components in the reverse order of disassembly.

J G

P200106

Page 50

Dust Control System 50Service Manual – SW4000

Electric Vacuum Fan Motor Amperage Check

Warning! Thisproceduremustbeperformedbyqualiedpersonnelonly.

1. Clean the dust lter.

2. Open the battery/engine compartment hood with the handle and fasten it with the support rod.

3. Apply the amp clamps (A) on one cable (B) of the electric vacuum fan (C).

4. Turn the ignition key to “I”.

5. With the help of an assistant, carefully press on the driver’s seat to activate the microswitch, then turn on the vacuum system and check that the electric fan motor amperage is within 7 and 9 A at 24 V.

Stop the vacuum system.

Turn the ignition key to “0”.

Remove the amp clamps (A).

If the amperage is higher, perform the following procedures to detect and correct it:

• Check that the F1 fuse is properly tightened

• Remove the electric fan motor (see the procedure in the next paragraph), and check the condition of

all its components.

If the above-mentioned procedures do not produce the correct readings for the electric fan motor

amperage, the motor must be replaced (see the procedure in the relevant paragraph).

Reassembly

6. Close the battery/engine compartment hood.

P200107

Page 51

Dust Control System 51Service Manual – SW4000

CBB

Electric Fan Disassembly/Assembly

Disassembly

1. Drive the machine on a level oor, engage the parking brake and turn the ignition key to “0”.

2. Open the battery/engine compartment hood with the handle and fasten it with the support rod.

3. Disconnect the battery connector (SW4000 Battery) - Disconnect the batteries (SW4000 Petrol/LPG).

4. Disconnect the vacuum system motor connector (A).

5. Disengage the retainers (B) and remove the vacuum system hood (C).

P200108

Page 52

Dust Control System 52Service Manual – SW4000

Electric Fan Disassembly/Assembly (Continues)

6. At the workbench, disconnect the connector (D) from the electrical cable (E), by disengaging its pins.

7. Unscrew the bulkhead cap (F).

8. Remove the external screws (G) and remove the electric fan assembly (H) with its wiring harness (E).

9. If necessary, remove the electric vacuum fan (I) from the assembly (H) as shown below.

• Unscrew the three nuts (J) and remove the screws (K).

• Remove the plate (L) and the electric fan (I).

Assembly

10. Assemble the components in the reverse order of disassembly.

G D

P200109

Page 53

Specications

Dust Control System 53Service Manual – SW4000

Dust Control System

SW4000 Battery SW4000 Petrol SW4000 LPG

Vacuum system motor 0.35 hp (260 W) - 3,000 rpm

Filter shaker motor 0.12 hp (90 W) - 6,000 rpm

BIA C polyester dust lter 75 ft Paper dust lter 75 ft Main broom compartment vacuum 0.6 in H

Values

(7 m2)

O (14 mm H2O)

Page 54

Dust Guard System 54Service Manual – SW4000

Dust Guard System

Functional Description

The dust guard system sprays a thin lm of water in front of each side broom, thus minimizing the dust raised

by the broom itself. The water used by the dust guard system is in a tank to be found inside the front column. The water tank is connected to the machine hose system by means of a quick coupling equipped with an inte-

grated valve, which allows to disconnect the tank without causing any water leaks.

The system has a pump motor (M8) which is powered by the relay (K6) and protected by the fuse (F5). The relay (K6) is directly activated by the dust guard system switch (SW8) which powers also the warning light (A) which signals the function activation on the dashboard electronic board (EB2).

By turning on the switch in the panel besides the operator, the pump, which is under the machine bed, collects water from the tank inside the front column; through the hoses, the water reaches the nozzles which spray it

on the side brooms.

The relay (K6), and then the system, turns only when the main broom is turning. When the main broom is off, the water pump turns off automatically.

Wiring Diagram

DUSTGUARD™ PUMP FUSE (F5)

DISPLAY ELECTRONIC BOARD FUSE (F3)

J1.1 - Electronic board power supply +

J1.17 - Water pump activation signal

DUSTGUARD™ SWITCH (SW8)

P200224

DUSTGUARD™ PUMP RELAY (K6)

DUSTGUARD™ PUMP MOTOR

CONTROL PANEL ELECTRONIC BOARD (EB2)

J1.10 - Broom electromagnetic switch power supply

J1.9 - Electronic board power supply -

DUSTGUARD™ PUMP RELAY (K6)

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

P200110

Page 55

Component Locations

Dust Guard System 55Service Manual – SW4000

• Dust guard system switch (SW8)

• Water tank

• Tank ller

• Water pump (M8)

Tankller

Water tank

Water pump (M8)

• Water lter

• Spraying nozzle

• Dust guard system fuse (5 A) (F5)

Dust guard system switch (SW8)

Waterlter

Dust guard

system fuse

(5 A) (F5)

Spraying nozzle

P200111

Page 56

Dust Guard System 56Service Manual – SW4000

Maintenance and Adjustments Dust guard System Water Filter Cleaning

Note: Topreventwaterfromowingoutwhencleaningthelter,turnonthedustguard

systemandemptythesystemtank.

1. Drive the machine on a level oor.

2. Turn the ignition key to “0” and engage the parking brake.

3. Operating in the area (A) of the machine, reach the water lter assembly (B) of the dust guard system.

4. Unscrew and remove the transparent cover (C) with the gasket (D), then remove the lter strainer (E).

5. Clean and install them on the holder (F).

Note: Installthegasket(D)andthelterstrainer(E)properlyonthetransparentcover(C)

andontheholder(F).

P200112

Page 57

Dust Guard System 57Service Manual – SW4000

Nozzle and Filter Cleaning

1. Drive the machine on a level oor.

2. Turn the ignition key to “0” and engage the parking brake.

3. On the front side of the side brooms, remove the ring nuts (A) (bayonet joint).

4. Remove and clean the nozzles (B), the gaskets (D) and the lters (C) with compressed air. Remove any

calcium deposit. If necessary, replace the lters (C).

5. Reinstall the lters, gaskets and the nozzles, then fasten them with the ring nuts.

P200113

Page 58

Troubleshooting

Electrical components Electrical components Values

Dust Guard System 58Service Manual – SW4000

Little water comes out from the spray nozzles

No water to the nozzles

The lter and/or nozzle is clogged Clean/replace The water lter is clogged Clean/replace The pump is not working Repair/replace The water lter is clogged Clean/replace The fuse (F5) is open Replace The relay (K6) is not efcient Replace

Page 59

Dust Guard System 59Service Manual – SW4000

Removal and Installation Dust guard System Water Pump Disassembly/Assembly

Disassembly

1. If possible, place the machine on a hoisting system.

2. Turn the ignition key to “0” and engage the parking brake.

3. Open the battery/engine compartment hood with the handle and fasten it with the support rod. Disconnect the battery connector (SW4000 Battery) - Disconnect the batteries (SW4000 Petrol/LPG).

4. Lift and disassemble the right side bulkhead.

5. On the right front upper side of the machine bed, remove the fastening screws (A) and (B) of the dust guard system water pump support plate.

(For SW4000 Battery) If the screws (B) are hidden under the battery, the battery has to be removed (see the procedure in the Electrical System chapter).

P200114

Page 60

Dust Guard System 60Service Manual – SW4000

Dust guard System Water Pump Disassembly/Assembly (Continues)

6. On the right front upper side of the machine bed, disconnect the hose (C) of the water pump (D); disconnect the lter assembly input hose (E).

7. Disconnect the connector (F) of the water pump (D).

8. Remove the holder assembly with pump and lter (G).

9. If necessary, at the workbench, unscrew the four screws (H), disconnect the hose (I), then remove the water pump (D) from the holder.

Assembly

10. Assemble the components in the reverse order of disassembly.

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Page 61

Specications

Dust Guard System 61Service Manual – SW4000

Dust Guard System

SW4000 Battery SW4000 Petrol SW4000 LPG

Water tank capacity 5.3 US gal (20 liters)

Pump 3A - 24V - 1.5 gpm US - 49 psi (3A - 24V - 5.7 l/min - 3.4 bar)

Values

Page 62

Electrical System 62Service Manual – SW4000

Electrical System

Functional Description (SW4000 Battery)

The electrical system is basically an electromechanical system at 24Vdc rated voltage in which the main part of the accessories are powered by relays controlled by switches. The timing control of certain accessories and

battery charging, as well as the display of the warning lights, takes place by dashboard electronic board (EB2).

The drive system consists of a driving wheel (M0) driven by the drive system electronic board (EB1). The battery is connected to the system by means of the ANDERSON POWER connector (C1). Downstream of

the connector, there is a safety fuse (F0). The fuse is sized to activate only in case the power side of the wiring

harness becomes seriously damaged.

The on board battery charger (CH) is directly connected on the battery pins for the power side, to connector (C2) for the inhibition signal. When the battery charger is not connected to the electrical mains, the relay inside the battery charger closes the contact between the 2 wires connected to (C2), this contact opens when the battery charger is connected to the electrical mains. When the battery charger is not installed, the connector

(C2) is closed by a jump connection. The connector contacts (C2) are upstream of the ignition key (SW1) and cut off the power supply to all control section of the electrical system.

For further details, see the descriptions of individual sub-systems.

(SW4000 Petrol/LPG)

The electrical system of Petrol/LPG versions is substantially equal to that of the battery versions, the difference is that the 24V battery pack is replaced by one with lower capacity (2 12Vdc starter batteries) kept charged by a dynamo and a power diode. The system guarantees a correct charging and battery management on the condition that the rpm of the engine are as constant as possible and that the use of the machine is as

regular as possible, avoiding long stops (not more than 5 minutes) with the engine switched on and the accessories off, and long periods (not more than 10% utilization of the machine) with all accessories turned on to

their maximum load.

When the above conditions are not met, if the batteries are under abnormal voltages, a protection system

warns the operator by means of the dashboard electronic board display (EB2) (see Control System chapter).

The dynamotor (M5) also acts as an electric starter for the engine, when powered by the electromagnetic switch (ES2), which is activated when the ignition switch (SW1) is turned to position II (Ignition).

Page 63

Electrical System 63Service Manual – SW4000

GPL / LORTEP 0004WSYRETTAB 0004WS

Fuses

All circuits and components are protected by fuses, located inside or outside the electrical component box. To protect motors from overloads when using the machine, there are manually resettable fuses (side brooms) or fuses interlocked to electronic protection systems (main broom, see Main Broom Motor Protection in Dashboard Electronic Board Specications chapter).

All the circuits are protected by non-resettable fuses.

Battery Versions Petrol and LPG Versions

Pos. Type

F0 Not resettable 150 GENERAL 150 GENERAL FA Not resettable 50 MAIN BROOM 50 MAIN BROOM

FC Not resettable - - 80 BATTERY/DYNAMOTOR RECHARGE FR1 Resettable 15 RIGHT SIDE BROOM 15 RIGHT SIDE BROOM FR2 Resettable 15 LEFT SIDE BROOM 15 LEFT SIDE BROOM

F1 Not resettable 25 VACUUM SYSTEM 30 VACUUM SYSTEM

F2 Not resettable 25 FILTER SHAKER 30 FILTER SHAKER

F3 Not resettable 3 KEY CIRCUIT 3 KEY CIRCUIT - EV LPG

Nominal

Size

Protected Function

Nominal

Size

Protected Function

F4 Not resettable 10 HORN - PIVOTING LIGHT - HEADLIGHT 10 HORN - PIVOTING LIGHT - HEADLIGHT

F5 Not resettable 5 WATER PUMP 5 WATER PUMP

F6 Not resettable 25 HOPPER PUMP 30 HOPPER PUMP

F7 Not resettable 25 SPARE 30 SPARE

F8 Not resettable 10 SPARE 10 SPARE

F8 F7 F6 F5 F4 F3 F2 F1

F0 FA

FR1 FR2

F8 F7 F6 F5 F4 F3 F2 F1

F0 FAFC

FR1 FR2

P200116

Page 64

Electrical System 64Service Manual – SW4000

GPL / LORTEP 0004WSYRETTAB 0004WS

Relay/Electromagnetic Switch/Diodes

Battery Versions Petrol and LPG Versions

Pos.

Nominal

Size

K1 40A VACUUM SYSTEM RELAY 40A VACUUM SYSTEM RELAY

K2 40A FILTER SHAKER RELAY 40A FILTER SHAKER RELAY K3A 30/40A HOPPER LIFTING 30/40A HOPPER LIFTING RELAY K3B 30/40A HOPPER LOWERING 30/40A HOPPER LOWERING RELAY

K4 30/40A MACHINE ON RELAY 30/40A MACHINE ON RELAY

K5 30/40A SIDE BROOM RELAY 30/40A SIDE BROOM RELAY

K6 30/40A DUSTGUARD™ PUMP RELAY 30/40A DUSTGUARD™ PUMP RELAY KT1 - - 5A LPG SAFETY RELAY (only for LPG) ES0 120A LINE ELECTROMAGNETIC SWITCH 120A LINE ELECTROMAGNETIC SWITCH ES1 70A MAIN BROOM ELECTROMAGNETIC SWITCH 70A MAIN BROOM ELECTROMAGNETIC SWITCH ES2 - - 70A ENGINE START ELECTROMAGNETIC SWITCH

D1 - - - DIODE ELECTRONIC BOARD

Protected Function

Nominal

Size

Protected Function

K1ES0 K2 K4 K5 K6

ES1 K3B K3A

KT1

ES1

ES2

K3B K3A

K1ES0 K2 K4 K5 K6

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Page 65

Wiring Diagram (SW4000 Battery)

KEY CIRCUIT FUSE (F4)

Electrical System 65Service Manual – SW4000

WITHOUT ON BOARD BATTERY CHARGER

IGNITION KEY (SW1)

MACHINE ON RELAY (K4)

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

EMERGENCY PUSH-BUTTON (SW0)

MACHINE ON RELAY (K4)

MAIN FUSE (F0)

CONNECTOR + (C1)

24V BATTERY (BAT)

BATTERY CHARGER (CH)

CONNECTOR - (C1)

FLASHING LIGHT (BE)

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Page 66

Wiring Diagram (SW4000 Petrol/LPG)

Electrical System 66Service Manual – SW4000

KEY CIRCUIT FUSE (F4)

MAIN

FUSE (F0)

CHARGE FUSE (FC)

ENGINE START ELECTROMAGNETIC SWITCH (ES2)

DIODE (D1)

ENGINE SPARK PLUG (SPK)

ENGINE

OIL ALERT

FRAME (FR)

EMERGENCY PUSH-BUTTON (SW0)

IGNITION KEY (SW1)

MACHINE ON RELAY (K4)

24V BATTERY (BAT)

DYNAMOTOR (M5)

ENGINE ON RELAY (K4)

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

LPG SAFETY SOLENOID VALVE (EV1)

FLASHING LIGHT (BE)

Only for LPG version

LPG SAFETY TIMER RELAY (KT1)

DIODE (D3)

ENGINE START ELECTROMAGNETIC SWITCH (ES2)

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Page 67

Component Locations (SW4000 Battery)

Electrical System 67Service Manual – SW4000

• Emergency push-button (SW0)

• Battery charger (CH)

• Flashing light (BE)

• Batteries (BAT)

Battery charger (CH)

Flashing

light (BE)

• Wiring harnesses

• Electrical component box

• Battery connector (C1)

Emergency push-button (SW0)

Battery

connector (C1)

Batteries (BAT)

Wiring harnesses

Electrical component

box

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Page 68

Component Locations (SW4000 Petrol/LPG)

Electrical System 68Service Manual – SW4000

• Emergency push-button (SW0)

• Wiring harnesses

• Flashing light (BE)

• Electrical component box

• Batteries (BAT)

• Dynamotor (M5)

Flashing

light (BE)

• 8-way fuse holder

• Main broom motor fuse (50 A) (FA)

• Main fuse (150 A) (F0)

• Right side broom motor fuse (15 A) (FR1)

• Left side broom motor fuse (15 A) (FR2)

• (SW4000 P/LPG) Battery charge fuse (80 A) (FC)

Emergency push-button (SW0)

Dynamotor (M5)

Batteries (BAT)

8-way fuse

holder

(SW4000 P/LPG)

Battery charge fuse

(80 A) (FC)

Wiring harnesses

Electrical component

box

Right side broom motor fuse (15 A) (FR1)

Left side broom motor fuse (15 A) (FR2)

Main fuse

(150 A) (F0)

Main broom motor fuse (50 A) (FA)

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Page 69

Component Locations (Continues)

Electrical System 69Service Manual – SW4000

• Hopper lifting fuse (25 A - Battery) (30 A Petrol/ LPG) (F6)

• Dust guard system fuse (5 A) (F5)

• Main fuse (key circuit) (10 A) (F4)

• Display electronic board fuse (3 A) (F3)

SW4000 Battery

Hopper lifting

fuse (25 A) (F6)

Main fuse

(key circuit)

(10 A) (F4)

Filter shaker motor

fuse (25 A) (F2)

• Filter shaker motor fuse (25 A - Battery) (30 A Petrol/LPG) (F2)

• Vacuum system motor fuse (25 A - Battery) (30 A Petrol/LPG) (F1)

Dust guard system fuse (5 A) (F5)

Display electronic board fuse (3 A) (F3)

Vacuum system motor fuse (25 A) (F1)

Hopper lifting fuse

(30 A) (F6)

Main fuse

(key circuit)

(10 A) (F4)

Filter shaker

motor fuse

(30 A) (F2)

SW4000 Petrol / LPG

Dust guard system fuse (5 A) (F5)

Display electronic board fuse (3 A) (F3)

Vacuum system motor fuse (30 A) (F1)

P200096-2

Page 70

Electrical System 70Service Manual – SW4000

Maintenance and Adjustments Battery Voltage Display (SW4000 Battery)

By pressing the push-button (A) (with the machine running) the display will switch from the 3-digit hour counter (B) to the battery voltage. The display will automatically return to the hour counter 5” after the last pressing of the push-button (A).

Battery Charge Status Display (SW4000 Battery)

Battery charge status is shown by the 3 LEDs depending on the type of battery (WET or GEL/AGM) according

to the following diagram:

WET GEL-AGM

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.

Battery Type Display (WET or GEL-AGM) (SW4000 Battery)

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-AGM 4 ashes of the GREEN warning light

On Board Battery Charger Setting (SW4000 Battery)

EXTERNAL

SWITCH (C)

WET OFF ON/OFF ON/OFF ON/OFF OFF OFF OFF ON IUIa Pb-Acid Wet (SPE specications) GEL-AGM OFF ON ON ON OFF OFF OFF ON IUUa Gel-AGM generic (SPE specications) (DEFAULT) GEL-AGM OFF ON ON OFF OFF OFF OFF ON IUIa EXIDE approved GEL-AGM OFF OFF ON OFF OFF OFF OFF ON IUUo OPTIMA approved GEL-AGM OFF ON OFF OFF OFF OFF OFF ON IUIa AGM DISCOVER approved GEL-AGM OFF OFF OFF OFF OFF OFF OFF ON IUIa AGM FULLRIVER approved

DIP1 DIP2 DIP3 DIP4 DIP5 DIP6 DIP7 DIP8

INTERNAL DIPSWITCHES (D) (*)

CHARGING CURVES

(*) Located under the label, in the dotted area

P200225

Page 71

Electrical System 71Service Manual – SW4000

Battery Removal/Installation and Battery Type Setting (WET or GEL/AGM) (SW4000 Battery)

Warning! Do not tilt the lead batteries (WET) to prevent the highly corrosive acid from leaking

out of the batteries. Do not connect, not even accidentally, the battery positive and negative terminals by using tools, keys, etc. This could cause dangerous shortcircuits.

Battery Installation

For approved battery types, see the Technical Data paragraph.

The batteries must be installed as shown in the diagram (A).

According to the battery dimensions, check if it is possible to place them inside the relevant plastic container,

supplied with the machine.

If the batteries are larger than the container, use the square guides, supplied with the machine, to ensure the

stability inside the battery compartment.

Warning! Non-sealed WET batteries always need an appropriate container to prevent the acid

form leaking. Do not install the WET batteries without an appropriate container.

1. Engage the parking brake.

2. Check that the ignition key has been removed.

3. Open the battery compartment hood (A) with the handle (B) and fasten it with the support rod (C).

4. Disconnect the battery connector (D).

5. With the help of an assistant and an appropriate hoisting system, install the batteries (E) and connect them as shown in the diagram (F).

6. Connect the batteries according to the diagram (F).

7. Connect the battery connector (D).

8. Set the battery type (WET or GEL-AGM), according to the following procedure.

BATTERY PLUG

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Page 72

Electrical System 72Service Manual – SW4000

Battery Removal/Installation and Battery Type Setting (WET or GEL/AGM) (SW4000 Battery) (Continues)

Battery Setting (WET or GEL-AGM)

9. Remove the support rod and close the battery compartment hood with the handle.

10. Turn the ignition key to “I” by pressing the push-button (G) and by holding it (for about 5”) until the

warning light corresponding to the current setting ashes:

• Red warning light (H): WET batteries

• Green warning light (I): GEL-AGM batteries

11. Release and press again the push-button (G) within 5 seconds to change setting.

12. Wait until the warning light corresponding to the new setting stops ashing (5 seconds approx.).

13. The new setting is properly stored.

14. Set the type of batteries (WET or GEL-AGM) on the battery charger (K) (if equipped) too by activating the relevant selector (L).

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Page 73

Electrical System 73Service Manual – SW4000

Battery Removal/Installation and Battery Type Setting (WET or GEL/AGM) (SW4000 Battery) (Continues)

Battery Removal

1. Engage the parking brake.

2. Remove the ignition key.

3. Open the battery compartment hood (A) with the handle (B) and fasten it with the support rod (C).

4. Disconnect the battery connector (D).

5. Disconnect the battery wiring harnesses (E).

6. Remove any square guide or bracket fastening the batteries (E).

7. Check that WET battery caps (J) are closed, to prevent the highly corrosive acid from leaking out of the batteries.

8. With the help of an assistant and an appropriate hoisting system, remove the batteries (E).

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Page 74

Electrical System 74Service Manual – SW4000

Battery Voltage Check (SW4000 Petrol)

1. Drive the machine on a level oor.

2. Turn on the machine and engage the parking brake.

3. Open the engine compartment hood with the handle and fasten it with the support rod.

4. Check the voltage at the battery pins.

5. With the accessories turned off and the engine running, the voltage must be between 27 V and 31 V.

6. If the voltage is lower, check the diode electronic board (EBD) and battery operation. If necessary, charge the batteries with a battery charger suitable for cars (slow charging).

Page 75

Fuse Check/Replacement (SW4000 Battery)

Electrical System 75Service Manual – SW4000

7. Drive the machine on a level oor.

8. Turn the ignition key to “0” and engage the parking brake.

9. Open the battery/engine compartment hood with the handle and fasten it with the support rod. Disconnect the battery connector.

Lamellar Fuse Check/Replacement

10. On the electrical component box, remove the fuse box cover (A).

11. Check/replace the relevant fuse among the

following:

• (B): F1 vacuum system motor fuse (25 A).

• (C): F2 lter shaker motor fuse (25 A).

• (D): F3 display electronic board fuse (3 A).

• (E): F4 main fuse (key circuit) (10 A).

• (F): F5 dust guard system fuse (5 A).

• (G): F6 hopper lifting fuse (25 A).

12. Reinstall the fuse box cover (A).

13. Remove the screws (H), then remove the electrical component box cover (I).

14. Check/replace the following fuses:

• (J): FA main broom motor fuse (50 A).

• (K): F0 main fuse (150 A).

15. Place the cover (I) and tighten screws.

Fuse Check

16. Check one of the following fuses for deactivation:

• (L): FR1 right side broom motor fuse (15 A)

• (M): FR2 left side broom motor fuse (15 A)

Reset any deactivated fuse, when the component

that caused deactivation has fully cooled down.

Reassembly

17. Connect the batteries.

18. Remove the support rod and close the battery/ engine hood.

25A

10A

3A 25A 25A

A H K LMJ I H

E D

P200222

Page 76

Fuse Check/Replacement (SW4000 Petrol/LPG)

Electrical System 76Service Manual – SW4000

1. Drive the machine on a level oor.

2. Turn the ignition key to “0” and engage the parking brake.

3. Open the battery/engine compartment hood with the handle and fasten it with the support rod. Disconnect the batteries.

Lamellar Fuse Check/Replacement

4. On the electrical component box, remove the fuse box cover (A).

5. Check/replace the relevant fuse among the

following:

• (B): F1 vacuum system motor fuse (30 A).

• (C): F2 lter shaker motor fuse (30 A).

• (D): F3 display electronic board fuse (3 A).

• (E): F4 main fuse (key circuit) (10 A).

• (F): F5 dust guard system fuse (5 A).

• (G): F6 hopper lifting fuse (30 A).

6. Reinstall the fuse box cover (A).

7. Remove the screws (H), then remove the electrical component box cover (I).

8. Check/replace the following fuses:

• (J): FA main broom motor fuse (50 A).

• (K): F0 main fuse (150 A).

• (L): FC battery fuse (80 A)

9. Place the cover (I) and tighten screws.

Fuse Check

10. Check one of the following fuses for deactivation:

• (M): FR1 right side broom motor fuse (15 A)

• (N): FR2 left side broom motor fuse (15 A)

Reset any deactivated fuse, when the component

that caused deactivation has fully cooled down.

Reassembly

11. Connect the batteries.

12. Remove the support rod and close the battery/ engine hood.

30A

10A

3A 30A 30A

A H L K J I N M H

E D

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Page 77

Troubleshooting

Trouble Possible causes Remedy

Electrical System 77Service Manual – SW4000

The machine is not working The batteries are discharged or its connections are not

efcient

The batteries are broken Check the battery no-load voltage

(SW4000 Battery)

The battery charger is broken

(SW4000 Petrol/LPG)

The dynamotor is broken

The fuses are open Replace The wiring harness is cut or pressed or short circuited Repair The ignition key is not working Replace

Charge the batteries or clean/repair the connections

Replace

Repair

Page 78

Electrical System 78Service Manual – SW4000

Removal and Installation Battery Charger Disassembly/Assembly (SW4000 Battery)

Disassembly

1. Drive the machine on a level oor.

2. Turn the ignition key to “0” and engage the parking brake.

3. Open the battery compartment hood with the handle and fasten it with the support rod. Disconnect the battery connector.

4. Remove the screws (A) and the battery charger connector (B).

5. Remove the screws (C) on the rear side of the bulkhead, then remove the battery charger protection (D).

6. Remove the screws with the nut (E) and remove the battery charger (F) with the wiring harness (G).

Assembly

7. Assemble the components in the reverse order of disassembly, and note the following:

• The selector (H) must be turned to WET or GEL, according to the type of batteries (WET or GEL)

installed on the machine.

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Page 79

Electrical System 79Service Manual – SW4000

Dynamotor Carbon Brush Check/Replacement (SW4000 Petrol)

Disassembly

1. Drive the machine on a level oor.

2. Turn the ignition key to “0” and engage the parking brake.

3. Open the engine compartment hood with the handle and fasten it with the support rod. Disconnect the batteries.

4. Remove the machine right side bulkhead, by lifting it to disengage it from the fasteners.

5. Remove the two screws (A) and remove the case (B).

6. If necessary, clean the external side of the dynamotor (C) in the area of the protection band (D).

7. Disengage the cam lever (E) and remove the protection band (D) of the dynamotor (C).

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Page 80

Electrical System 80Service Manual – SW4000

Dynamotor Carbon Brush Check/Replacement (SW4000 Petrol) (Continues)

8. Remove the fastening screws (G) of the electrical connections of the four carbon brushes (H).

9. Remove the four carbon brushes (H) from their housings, by disengaging them from the retaining springs (I).

10. Check the four carbon brushes (H) for wear. The carbon brushes are worn when:

• The contact with the motor armature is insufcient

• The contact surface is not integral

• The stroke is less than 0.12 in (3 mm)

• The spring is broken

In this cases, replace all all dynamotor carbon brushes.

Assembly

11. Assemble the components in the reverse order of disassembly.

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Page 81

Electrical System 81Service Manual – SW4000

Dynamotor Disassembly/Assembly (SW4000 Petrol)

Disassembly

1. Remove the engine-dynamotor (see the procedure at the relevant paragraphs in Engine System, Petrol or Engine System, LPG).

2. Remove the dynamotor carbon brushes (refer to the procedure “Dynamotor Carbon Brushes Check/ Replacement”).

3. Hold the crankshaft by operating the outer pulley in the area (B), loosen the lock nut (A) until it is ush with the end of the shaft.

4. Remove the two screws (C) with nuts (D) fastening the dynamotor (M) to the holder (E). Retrieve the washers.

5. Remove the four screws (F) with nuts (G) fastening the dynamotor to the engine. Retrieve the washers.

6. Remove the screw in the area (N), then remove the bafe plate (H).

P200228

Page 82

Electrical System 82Service Manual – SW4000

Dynamotor Disassembly/Assembly (SW4000 Petrol) (Continues)

7. Place a lever between the ange (I) of the dynamotor and the ange (J), then by means of the lever itself push the dynamotor in the direction of the arrow (K); in this condition, give a rm blow on the nut (A) in the direction of the arrow (L) with a plastic mallet, thereby disengaging the conical connection of union

between dynamotor and the engine.

8. Loosen the nut (A) completely and remove the dynamotor (M) (Dynamotor weight: 17 kg approx).

Assembly

9. Assemble the components in the reverse order of disassembly, and note the following:

• The self-locking nut (A) must be fully screwed down, without tightening it.

P200126

Page 83

General Wiring Diagram (SW4000 Battery)

VACUUM SYSTEM

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

Electrical System 83Service Manual – SW4000

BATTERY NEGATIVE TERMINAL

VACUUM SYSTEM

FUSE (F1)

FILTER SHAKER

FUSE (F2)

HOPPER

PUMP FUSE (F6)

SIDE BROOM RELAY (K5)

RIGHT SIDE BROOM

RESET FUSE (FR1)

DUSTGUARD™

PUMP FUSE (F5)

LEFT SIDE BROOM

RESET FUSE (FR2)

MAIN BROOM ELECTROMAGNETIC SWITCH (ES1)

DUSTGUARD™

PUMP RELAY (K6)

VACUUM SYSTEM RELAY (K1)

FILTER SHAKER RELAY (K2)

HOPPER LOWERING

RELAY (K3B)

M1 M2 M3 M6 M7 M8 M4

HOPPER LIFTING RELAY (K3A)

FILTER SHAKER

MOTOR

RIGHT SIDE

BROOM MOTOR

HOPPER

PUMP MOTOR

LEFT SIDE

BROOM MOTOR

DUSTGUARD™

MAIN BROOM

MOTOR

PUMP MOTOR

MAIN BROOM FUSE (FA)

P200127A

Page 84

General Wiring Diagram (SW4000 Battery)

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

Electrical System 84Service Manual – SW4000

BATTERY NEGATIVE TERMINAL

DISPLAY ELECTRONIC BOARD FUSE (F3)

FILTER SHAKER/VACUUM

SYSTEM SWITCH (SW3)

HOPPER TEMPERATURE SENSOR (S4)

FILTER SHAKER

RELAY (K2)

VACUUM SYSTEM

RELAY (K1)

HOPPER LIFTING

HOPPER LOWERING

RELAY (K3B)

RELAY (K3A)

HOPPER

LIFTING/LOWERING

SWITCH (SW5)

DUSTGUARD™

SWITCH (SW8)

HOPPER

ENABLING

SWITCH (SW4)

CONTROL PANEL ELECTRONIC BOARD (EB2)

DUSTGUARD™

PUMP RELAY (K6)

MAIN BROOM

ELECTROMAGNETIC

SWITCH (ES1)

HORN SWITCH (SW6)

HORN (HN)

HOPPER LIFTING SENSOR (S1)

SIDE BROOM RELAY (K5)

MAIN BROOM LEVER SENSOR (S2)

C D

SIDE BROOM LEVER SENSOR (S3)

P200127B

Page 85

General Wiring Diagram (SW4000 Battery)

WITHOUT ON BOARD BATTERY CHARGER

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

Electrical System 85Service Manual – SW4000

REVERSE GEAR BUZZER (BZ1)

BATTERY NEGATIVE TERMINAL

LINE ELECTROMAGNETIC SWITCH (ES0)

DRIVER’S SEAT

SAFETY

MICROSWITCH

(SW7)

KEY CIRCUIT FUSE (F4)

IGNITION KEY (SW1)

LINE ELECTR.

SWITCH (ES0)

MACHINE ON RELAY (K4)

FORWARD/REVERSE

GEAR SWITCH (SW2)

EMERGENCY PUSH-BUTTON (SW0)

FUSE (F0)

MAIN

CONNECTOR + (C1)

24V BATTERY (BAT)

BATTERY CHARGER (CH)

WORKING LIGHT

SWITCH (SW9)

ACCELERATOR

PEDAL (R1)

DRIVE SYSTEM ELECTRONIC BOARD (EB1)

DRIVING

C D

WHEEL

WORKING LIGHT (L1)

WORKING LIGHT (L2)

MACHINE ON RELAY (K4)

FLASHING LIGHT (BE)

CONNECTOR - (C1)

P200127C

Page 86

General Wiring Diagram (SW4000 Petrol - LPG)

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

CHARGE FUSE (FC)

Electrical System 86Service Manual – SW4000

MAIN

FUSE (F0)

24V BATTERY (BAT)

ENGINE START ELECTROMAGNETIC SWITCH (ES2)

DIODE (D1)

VACUUM SYSTEM

FUSE (F1)

VACUUM SYSTEM RELAY (K1)

FILTER SHAKER

FUSE (F2)

HOPPER

PUMP FUSE (F6)

FILTER SHAKER RELAY (K2)

SIDE BROOM RELAY (K5)

RIGHT SIDE BROOM

RESET FUSE (FR1)

HOPPER

LOWERING

RELAY (K3B)

DUSTGUARD™

PUMP FUSE (F5)

LEFT SIDE BROOM

RESET FUSE (FR2)

DUSTGUARD™

PUMP RELAY (K6)

MAIN BROOM

ELECTROMAGNETIC

SWITCH (ES1)

M1GM2 M3 M6 M7 M8 M4

DYNAMOTOR (M5)

ENGINE ON RELAY (K4)

VACUUM

SYSTEM MOTOR

HOPPER LIFTING RELAY (K3A)

FILTER SHAKER

MOTOR

RIGHT SIDE

BROOM MOTOR

HOPPER

PUMP MOTOR

LEFT SIDE

BROOM MOTOR

DUSTGUARD™

MAIN BROOM

MOTOR

PUMP MOTOR

MAIN BROOM FUSE (FA)

P2001272A

Page 87

General Wiring Diagram (SW4000 Petrol - LPG)

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

Electrical System 87Service Manual – SW4000

BATTERY NEGATIVE TERMINAL

DISPLAY ELECTRONIC BOARD FUSE (F3)

FILTER SHAKER/VACUUM

SYSTEM SWITCH (SW3)

HOPPER TEMPERATURE SENSOR (S4)

FILTER SHAKER

RELAY (K2)

VACUUM SYSTEM

RELAY (K1)

HOPPER LOWERING

RELAY (K3B)

HOPPER LIFTING

RELAY (K3A)

HOPPER LIFTING/

LOWERING

SWITCH (SW5)

DUSTGUARD™

SWITCH (SW8)

HOPPER

ENABLING

SWITCH (SW4)

CONTROL PANEL ELECTRONIC BOARD (EB2)

DUSTGUARD™

PUMP RELAY (K6)

MAIN BROOM

ELECTROMAGNETIC

SWITCH (ES1)

HORN SWITCH (SW6)

HORN (HN)

HOPPER LIFTING SENSOR (S1)

SIDE BROOM RELAY (K5)

MAIN BROOM LEVER SENSOR (S2)

SIDE BROOM LEVER SENSOR (S3)

C D

P2001272B

Page 88

General Wiring Diagram (SW4000 Petrol - LPG)

POSITIVE SIGNAL (FROM MACHINE ON “K4”)

Electrical System 88Service Manual – SW4000

REVERSE GEAR BUZZER (BZ1)

DIODE (D2)

BATTERY NEGATIVE TERMINAL

LINE ELECTROMAGNETIC SWITCH (ES0)

DRIVER'S SEAT

SAFETY

MICROSWITCH

(SW7)

LINE ELECTR.

FORWARD/REVERSE GEAR

SWITCH (ES0)

SWITCH (SW2)

ENGINE SPARK PLUG (SPK)

ENGINE

OIL ALERT

FRAME (FR)

KEY CIRCUIT FUSE (F4)

EMERGENCY PUSH-BUTTON (SW0)

IGNITION KEY (SW1)

MACHINE ON RELAY (K4)

WORKING LIGHT

SWITCH (SW9)

DIODE

ACCELERATOR

PEDAL (R1)

DRIVE SYSTEM ELECTRONIC BOARD (EB1)

(D3)

LPG SAFETY

TIMER RELAY (KT1)

DRIVING

C D E

WHEEL

WORKING LIGHT (L1)

WORKING LIGHT (L2)

LPG SAFETY

SOLENOID VALVE (EV1)

Only for LPG version

ENGINE START ELECTROMAGNETIC SWITCH (ES2)

P2001272C

Page 89

Specications

Electrical System 89Service Manual – SW4000

Electrical components

SW4000 Battery SW4000 Petrol SW4000 LPG

Total absorbed power 2.7 hp (2.0 kW)

Batteries

Battery pack 1 12 x 2V x 360A 6 EPzS 360 (WET)

Battery pack 2 12 x 2V x 360A 6 EPzV 330 (GEL-AGM)

Size (length x width x height) 32.0 x 14.8 x 15.4 in (812 x 375 x 390 mm)

Battery pack 3 12 x 2V x 330A 12-55L-13 330 (WET)

Battery pack 4 4 x 6V x 255A FF 06 255 (WET)

Battery pack 5 4 x 6V x 180A (GEL-AGM) DF 06V 180A

Size (length x width x height) 16.6 x 24.8 x 5.9 in (420 x 630 x 150 mm)

Battery compartment maximum size (width x length x height) 32.0 x 14.8 x 14.6 in (812 x 375 x 370 mm)

Battery charger

Input 230V ± 15% 50/60Hz (Imax:15A)

Values

SW4000 Battery

Values

SW4000 Battery

Output 24V 30A Efciency >90% Min. Vbatt 2V Casing protection IP30

Batteries

SW4000 Petrol SW4000 LPG

Battery pack 2 x 12V 77Ah

Size (length x width x height) 15.0 x 14.2 x 8.9 in (380 x 360 x 225 mm)

Electrical components

SW4000 Battery SW4000 Petrol SW4000 LPG

Dynamotor - 1,400 W - 24V (70A - 1,600 rpm)

Values

Page 90

Engine System - Petrol

KEY CIRCUIT

Functional Description

The engine system generates electric current for all machine functions. The assembly consists of an internal combustion en-

gine and dynamotor, which are both connected to the

main crankshaft. The engine is a single-cylinder air-cooled petrol type. The engine start-up is made by the dynamotor to which it is connected.

The dynamotor acts as a starter, using the battery

only for the time necessary to start the engine.

At a later stage, the running engine supplies the

power to the dynamotor to generate the current and to power the electrical systems of the machine. The surplus current is used to charge the batteries. The engine speed is xed, 2,750 rpm, to grant a constant current to the electrical system.

Engine System - Petrol 90Service Manual – SW4000

The fuel tank is fastened outside the engine, in the

rear side of the machine. The tank has a fuel level in-

dicator with oat, and a valve with integrated lter.

The choke lever on the engine has been extended in order to be easily activated from the driver’s seat position. The fuel reserve warning light turns on when the fuel in the tank is less than 2.2 liters.

The engine is equipped with an oil level sensor (Oil

Alert), which purpose is to avoid damages caused by an insufcient oil quantity in the oil pan. Before the oil level goes below the safety limit, the system (Oil

Alert) automatically stops the engine shorting the spark plug to the chassis.. If the engine stops and do not restart, check the engine oil level before doing any other troubleshooting procedure.

Wiring Diagram

ENGINE SPARK PLUG (SPK)

ENGINE

OIL ALERT

FRAME (FR)

EMERGENCY PUSH-BUTTON (SW0)

IGNITION KEY (SW1)

FUSE (F4)

MACHINE ON RELAY (K4)

ENGINE START ELECTROMAGNETIC SWITCH (ES2)

P200128

Page 91

Component Locations

Engine System - Petrol 91Service Manual – SW4000

• Petrol engine

• Filler neck

• Fuel tank

• Fuel opening/closing valve

Petrol engine

Filler neck

• Reserve sensor (S5)

• Diode (S1)

• Oil Alert Sensor

Reserve sensor (S5)

Fuel tank

Diode (S1)

Fuel opening/closing valve

Oil Alert Sensor

P200129

Page 92

Engine System - Petrol 92Service Manual – SW4000

Maintenance and Adjustments Engine RPM Check

1. To check the engine speed, use the indicator (A) fastened to the engine pulley, with a rev counter light (B) which can be seen from the front outer side of the engine compartment.

2. Alternatively use a rev counter (C) to be applied to the spark plug wire (D).

For the engine rpm, see Specications paragraph.

P200130

Page 93

Engine Air Filter Cleaning Check

Engine System - Petrol 93Service Manual – SW4000

Caution! Running the engine without air

lters,orwithdamagedlters,

can cause a faster engine wearing.

1. Drive the machine on a level ground and engage the parking brake.

2. Turn the ignition key to “0”.

3. Open the engine compartment hood with the handle and fasten it with the support rod.

4. Lift and disassemble the right side bulkhead.

5. Remove the wing nut (A) and remove the cover (B).

6. Remove the wing nut (C) and disassemble the

lter element.

7. Separate the foam lter (D) from the paper lter (E).

8. Check both lters and replace them if necessary.

Replace the paper lter (D) when required (see

the scheduled maintenance table).

11. Assemble the foam lter (D) on the paper lter

(E), then assemble the lter element. Ensure

that the gasket (H) is properly placed under the

lter element. Screw down the lter element

wing nut (C).

12. Install the cover (B) and screw down the wing nut (A).

13. Perform steps 4 and 3 in the reverse order.

9. To use again the lters, clean them as shown below:

• Paper lter (E): Hit the lter several times

against a hard surface to remove the dust, or

blow compressed air (no more than 207 kPa

(2.1 kgf/cm)) from inside the lter. Do not use a brush, otherwise the bre will be damaged.

• Foam lter (D): Clean with warm water

and soap, rinse and let it dry completely, or clean with a non-ammable solvent and let it dry. Soak the lter in clean engine oil, then

squeeze it to remove the surplus oil.

10. Clean with a wet cloth the base (F) and the cover

(B) of the air lter. Pay attention to avoid that

dirt enters the air duct (G) to the carburettor.

P200131

Page 94

Engine Oil Level Check

Caution! Running the engine with a

low oil level can damage the engine itself.

Note: Theoilalertsystemwill

automaticallystoptheengine beforetheoillevelgoesdown underthesafetylimit.Toavoid asuddenenginestop,always checktheoillevelbeforeeach

start-up.

1. Drive the machine on a level ground and engage the parking brake.

Engine System - Petrol 94Service Manual – SW4000

2. Turn the ignition key to “0”.

3. Open the engine compartment hood with the handle and fasten it with the support rod.

4. Lift and disassemble the right side bulkhead.

5. Remove the oil ller plug/dipstick (A) and clean it.

6. Insert the oil ller plug/dipstick in the ller neck

(B), but do not tighten it, then remove it to check

the oil level.

7. If the oil level is near or under the lower limit

mark (C) on the dipstick, top up with the specied oil up to the upper limit mark (D) (lower edge of the oil lling hose). Do not overll.

8. Install the oil ller plug/dipstick (A).

9. Perform steps 4 and 3 in the reverse order.

P200132

Page 95

Engine Oil Change

Caution! The discharged engine oil

must be disposed of properly according to the Law in force.

Engine System - Petrol 95Service Manual – SW4000

Note: Itisadvisabletochangetheoil

whentheengineisstillhot,to maketheoildownoweasier.

1. Drive the machine on a level ground and engage the parking brake.

2. Turn the ignition key to “0”.

3. Open the engine compartment hood with the handle and fasten it with the support rod.

4. Lift and disassemble the right side bulkhead.

5. Remove the oil ller plug/dipstick (A). Place the

hose (E) in a position that eases the oil drain,

then remove the plug (F).

6. Drain all the engine oil through the hose (E) and collect it in a proper container.

7. Install the oil drain plug (F) and place the hose (E) back to the original position.

8. Pour new oil in the ller neck (B) up to the

upper limit mark (D) (lower edge of the oil lling

hose) on the dipstick.

Note: Fortheengineoiltypeand

quantity,seeSpecications paragraph.

9. Install the oil ller plug/dipstick (A) and tighten it.

10. Perform steps 4 and 3 in the reverse order.

P200133

Page 96

Engine System - Petrol 96Service Manual – SW4000

Engine Filter Trap Cleaning

Warning! Thepetrolishighlyammableandexplosive,itcanburnorcauseseriousinjuries.

 Turnofftheengine,andkeepitfarfromsparks,amesandothersourcesofheat.

Handle the fuel outdoors only. Wipe immediately any fuel accidentally spilled out.

1. Drive the machine on a level ground and engage the parking brake.

2. Turn the ignition key to “0”.

3. Open the engine compartment hood with the handle and fasten it with the support rod.

4. Lift and disassemble the right side bulkhead.

5. Move the fuel lever (A) to OFF, then remove the fuel lter cup (B) and the O-ring (C).

6. Wash the fuel lter trap (B) and the O-ring (C) with a non-ammable solvent, then dry them accurately.

7. Place the O-ring (C) and assemble the lter cup (B) by tightening it securely.

8. Move the fuel lever (A) to ON and check for leakages. If any leakage is found, replace the O-ring (C).

9. Perform steps 4 and 3 in the reverse order.

OFF

P200134

Page 97

Engine Spark Plug Check/Replacement

Engine System - Petrol 97Service Manual – SW4000

For the type of spark plug to be used, see Technical

Data chapter.

Warning! A wrong spark plug can

damage the engine.

1. Drive the machine on a level ground and engage the parking brake.

2. Turn the ignition key to “0”.

3. Open the engine compartment hood with the handle and fasten it with the support rod.

4. Lift and disassemble the right side bulkhead.

5. Disconnect the spark plug cap and remove dirt around the spark plug.

6. Remove the spark plug with a proper wrench (A).

7. Check the spark plug. Replace it if it is

damaged, dirty, if the sealing washer (B) is

damaged or if the electrode is worn.

12. When the original spark plug is reinstalled, tighten 1/8 - 1/4 turn once the spark plug is in place to press the washer.

Note: Aloosesparkplugcanoverheat

anddamagetheengine.Do notovertighten,otherwisethe threadsinthecylinderhead canbedamaged.

13. Perform steps 4 and 3 in the reverse order.

0.70 - 0.80mm

8. Measure the distance between the spark plug electrodes with a feeler gauge. Correct the distance by bending carefully the side electrode (C). The distance between the electrodes must be of 0.70 - 0.80 mm.

9. Install the spark plug manually with great care, to avoid tightening it improperly.

10. Once the spark plug is in place, tighten it with a proper wrench to press the sealing washer.

11. When a new spark plug is installed, tighten 1/2 turn once the spark plug is in place to press the washer.

P200135

Page 98

EngineBafePlateCleaning

Warning! If the engine was running, the

silencer will be very hot. Let it cool down before operating on

thebafeplate.

1. Drive the machine on a level ground and engage the parking brake.

2. Turn the ignition key to “0”.

3. Open the engine compartment hood with the handle and fasten it with the support rod.

4. Lift and disassemble the right side bulkhead.

5. Remove the screws (A) and carefully remove silencer guard (B).

6. Remove the screws (C) and remove the exhaust manifold (D).

7. Remove the screws (E) and carefully remove silencer guard (F).

Engine System - Petrol 98Service Manual – SW4000

8. Remove the screw (G) and remove the bafe plate (H) from the silencer.

9. Use a brush to remove the carbon deposits from

the bafe plate shield (I). Take care not to cause damage to the shield. Replace the bafe plate if

it cracked or perforated.

10. Install the bafe plate (H), the silencer guard (F) and the exhaust manifold (D).

11. Assemble the components in the reverse order of disassembly.

P200136

Page 99

Troubleshooting

Trouble Possible causes Remedy

The engine does not start The fuel valve lever is closed Open the fuel lever

The air control is in standard position. Turn the lever to cold start position.

Engine System - Petrol 99Service Manual – SW4000

The engine loses power or stops during operation.

The display shows the LOU

code.

The oil level is low. The Oil Alert sensor is activated. Top up with the recommended oil to the proper

The spark plug (SPK) is damaged, dirty or the distance between the electrodes is wrong

The spark plug (SPK) is wetted with fuel Dry the spark plug and reinstall it. Start the

The spark plug (SPK) does not produce a spark. Check or replace the spark plug.

The fuse (F3) and/or (F0) is open. Check/replace the fuses.

The electromagnetic switch (ES2) is faulty Replace

The batteries are discharged. Recharge with a proper battery charger.

The emergency push-button has been pressed. Check and release the emergency push-button.

The lter element or elements are clogged Clean or replace the lter elements

Low quality of the fuel Drain the tank and refuel with fresh petrol

The fuel lter is clogged, the carburettor is broken, the start system is broken, the valves are locked, etc.

The working conditions are disadvantageous for the batteries.

level.

Correct the distance between the electrodes and replace the spark plug

engine with the choke lever turned to MAX position.

Replace or repair the faulty components as necessary (take the engine to an authorized Honda service centre)

Decrease the main broom pressure on the oor.

Avoid driving uphill for long.

Turn off the working lights.

The display shows the HIU

code.

If the problem persist, maybe it is necessary to calibrate the engine rpm.

The battery charge is excessive. Turn off the engine each time the machine is

stopped.

If the problem persist, maybe it is necessary to calibrate the engine rpm.

Page 100

Engine System - Petrol 100Service Manual – SW4000

Removal and Installation Engine-Dynamotor Unit Disassembly/Assembly

Disassembly

1. Drive the machine on a level oor.

2. Turn the ignition key to “0” and engage the parking brake.

3. Open the engine compartment hood with the handle and fasten it with the support rod. Disconnect the batteries.

4. Remove the machine right side bulkhead (A), by lifting it to disengage it from the fasteners.

5. Close the fuel valve (B).

6. Open the clamp (C) and disconnect the fuel hose (D) from the valve. Close with sealing plugs the

disconnected ttings to prevent foreign materials from entering into the system.

7. Open the clamp (E) fastening the fuel hose (D).

P200137

Nilfisk-Advance SW4000, 9084403010, 9084400010, 9084401010, 9084402010 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual