Page 1: Service Manual
SW4000 2013-04 Form No. 1464811000 Service Manual Advance SW4000 Battery - 9084403010...
Page 2: Table Of Contents
Machine Nomenclature (know your machine) (SW4000 Battery) ....12 Control Panel (SW4000 Battery) ....... 15 Machine Nomenclature (know your machine) (SW4000 Petrol/LPG) .
Page 3 Relay/Electromagnetic Switch/Diodes ......64 Wiring Diagram (SW4000 Battery) ......65 Wiring Diagram (SW4000 Petrol/LPG) .
Page 4 an al Table of Contents Side Broom System ........187 Functional Description .
Page 5: General Information
SW4000 Battery) SW4000 Petrol) with a battery charged by a LPG gas engine (SW4000 LPG) 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.
Page 6: Conventions
an al ene al nfo at on Conventions ing. Service and Spare Parts 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.
Page 7: Safety
It indicates a remark related to important or useful functions. General Instructions Warning! Make sure to follow the safety precautions to avoid situations that may lead to serious injuries. (For SW4000 Battery/Petrol/LPG) – nect the battery connector). – This machine must be used by properly trained operators only.
Page 8 – – 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.
Page 9 (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 Warning! Make sure to follow the safety precautions to avoid situations that may lead to serious injuries, damages to materials or equipments.
Page 10 30° from its horizontal position to prevent the highly corrosive acid to remove the batteries. – the User Manual). (For SW4000 Petrol/LPG) – – the oil level with the engine off and the machine on a level surface.
Page 11: Machine Lifting
an al ene al nfo at on – Do not use the machine if the battery charger cable or plug is damaged. If the machine is not Service Center. – – Do not smoke while charging the batteries. Guide lines to bacteria control and other dangers coming from the presence of microbes in the Dust- Guard™...
Page 12: Machine Nomenclature (Know Your Machine) (Sw4000 Battery)
Machine Nomenclature (know your machine) (SW4000 Battery) Driver's seat with safety microswitch Flashing light Safety belts Battery compartment Can holder hood Seat position adjusting lever Hopper release and discharge lever Steering wheel Left...
Page 13 Machine Nomenclature (SW4000 Battery) (Continues) Serial number plate/technical data/conformity certification Electronic battery charger Hopper manual returning handle Drive pedal Rear hood with vacuum system Anchoring slots for transport (not for lifting) Dust filter...
Page 14 Machine Nomenclature (SW4000 Battery) (Continues) Hopper hydraulic lifting system control unit Drive system electronic board attery caps useholder bo (for E batteries only) acuum system ead batteries attery motor connector ( E ) or optional...
Page 15: Control Panel (Sw4000 Battery)
Control Panel (SW4000 Battery) acuum system Switch for Dust guard system warning light acuum system activation (upper part) warning light (green) ilter shaker activation (lower part) (green) ilter shaker switch Semi-discharged battery warning light (yellow)
Page 16: Machine Nomenclature (Know Your Machine) (Sw4000 Petrol/Lpg)
Machine Nomenclature (know your machine) (SW4000 Petrol/LPG) Driver s seat with safety microswitch lashing light Safety belts Engine compartment an holder hood Seat position ad usting lever Hopper release and discharge Steering wheel...
Page 17 Machine Nomenclature (SW4000 Petrol/LPG) (Continues) Serial number plate/technical data/ conformity certification iller plug Petrol) uel tank Petrol) Hopper manual returning handle Drive pedal Rear hood with vacuum system Anchoring slots for transport (not for lifting)
Page 18 Machine Nomenclature (SW4000 Petrol/LPG) (Continues) Hopper hydraulic lifting system control unit Drive system electronic board useholder bo Right side cover Dynamotor acuum system atteries motor connector Engine Electrical component pen hood safety rod...
Page 19: Control Panel (Sw4000 Petrol/Lpg)
Control Panel (SW4000 Petrol/LPG) Switch for acuum Dust guard acuum system activation (upper part) system warning ilter shaker activation (lower part) system warning light (green) ilter shaker/vacuum system switch light (green) Hopper lifting...
Page 20: Service And Diagnostic Equipment
an al ene al nfo at on Service and Diagnostic Equipment 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 P200091...
Page 21: Technical Data
Technical Data Model SW4000 B Hopper capacity Filter area 75 ft 4 μm Power Honda GX-200 2 US gal motor power 550 rpm motor power 110 rpm motor power Drive type gearmotor power...
Page 22 Technical Data (Continues) Model SW4000 B (**) 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...
Page 23 an al ene al nfo at on 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.
Page 24: Dimensions
an al ene al nfo at on Dimensions 1640 mm (64.6 in) 1065 mm (42 in) P200092...
Page 25: 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- Scheduled Maintenance Table (SW4000 Battery) Every Every Every Every Upon...
Page 26: Scheduled Maintenance Table (Sw4000 Petrol/Lpg)
Scheduled Maintenance Table (SW4000 Petrol/LPG) Every Every Every Every Upon Every delivery year (1) Daily or after using the machine. (2) Or before start-up. (3) Or more frequently if the machine is used on slopes.
Page 27: Chassis System
an al C ass s Chassis System Chassis (main parts) Front side supporting the steering assembly and side brooms. Center side supporting batteries/engine with dynamotor and main broom. Rear side supporting the hopper and rear wheels on hubs. supporting the hopper lifting linkages. P200093...
Page 28: Control System
an al Cont ol Control System Functional Description 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).
Page 29 an al Cont ol a. HOUR COUNTER b. BATTERY VOLTAGE DISPLAY 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.
Page 30 an al Cont ol d. BATTERY PROTECTION V>22.0 V>22.2 22.0>V>20.4 22.2>V>21.6 V>20.4 V>21.6 e. BATTERY TYPE DISPLAY (WET/GEL) Battery Type f. PROCEDURE FOR BATTERY SETTING (WET/GEL) you turn the key on and hold it for 5 sec. The 3 LEDs will then show again the current setting with the push-button (B) will change the current setting.
Page 31: Wiring Diagram (Sw4000 Battery)
Cont ol Wiring Diagram (SW4000 Battery) ( R M MA H E E ERM A VACUUM SYSTEM FILTER SHAKER HOPPER LOWERING HOPPER LIFTING RELAY (K1) RELAY (K2) RELAY (K3B) RELAY (K3A) D SP A SE ( HOPPER J1.1 - Electronic board power supply + TEMPERATURE J1.14 - Electronic board configurator return...
Page 32 Cont ol Wiring Diagram (SW4000 Battery) POSITIVE SIGNAL (FROM MACHINE ON K4 ) BATTERY NEGATIVE TERMINAL EMER E P SH- E E E R MA SE ( H (ES ) E (S MA H E RE A (...
Page 33: Wiring Diagram (Sw4000 Petrol/Lpg)
Cont ol Wiring Diagram (SW4000 Petrol/LPG) ( R M MA H E E ERM A D SP A E E SE ( HOPPER LOWERING HOPPER LIFTING FILTER SHAKER VACUUM SYSTEM RELAY (K3B) RELAY (K3A) RELAY (K2) RELAY (K1)
Page 34 Cont ol Wiring Diagram (SW4000 Petrol/LPG) ( R M MA H E E ERM A KEY CIRCUIT FUSE (F4) EMERGENCY PUSH BUTTON (SW ) R MA H (ES ) IGNITION KEY (SW1) ENGINE SPARK PLUG (SPK) FRAME (FR)
Page 35: Component Locations
an al Cont ol Component Locations Dashboard Dashboard electronic board (EB2) Ignition key (SW1) Dashboard electronic Dashboard board (EB2) Ignition key (SW1) P200096...
Page 36: Troubleshooting
Cont ol Troubleshooting Remedy For SW4000 Battery indication P200247...
Page 37: Dashboard Electronic Error Codes
an al Cont ol Dashboard Electronic Error Codes The drive system warning light (A) on the dashboard electronic board (EB2) shows the error codes of the drive P200097...
Page 38 an al Cont ol Connectors on the dashboard electronic board J1: MOLEX MINIFIT type, 18-ways vertical (A) P200221 Electronic V ref. <1A <1A K4.30 <1A <1A <1A <1A EB1.J2.10 <1A K1.85 K2.85 <1A K4.30/SW1 <1A K4.30 <1A Hopper lifting control K3A.85 <1A SW8.2...
Page 39 an al Cont ol 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 PIN J1.14 - NOT connected = Petrol/LPG version . Battery version (PIN - J1.14 at +24V) P200247b reset the status is the machine switching off by using the ignition key (SW1).
Page 40 an al Cont ol J1: MOLEX MINIFIT type, 18-ways vertical (A) (continues) Petrol/LPG version (PIN - J1.14 not connected) P200247a...
Page 41 an al Cont ol J2: MOLEX MINIFIT type, 4-ways vertical (B) P200098 Electronic V ref. <1A <1A SW3.1 <1A SW3.3 <1A...
Page 42: Removal And Installation
Disengage the four nuts (G) and remove the Open the battery/engine compartment hood. dashboard electronic board (F). Disconnect the battery connector (SW4000 Battery) - Disconnect the batteries (SW4000 Assembly Petrol/LPG). 10. Assemble the components in the reverse order of Remove the fastening screws (A) of the fairing (B) from the steering column.
Page 43: Dust Control System
an al st Cont ol Dust Control System Functional Description ated by the dust control system. feedbox into the hopper itself. The operation of the system depends on the activation of the main broom. 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- the machine moving signal received by the drive system electronic board(EB1) and by the lifted hopper sensor (S1).
Page 44: Component Locations
an al st Cont ol Component Locations Filter shaker/vacuum system switch (SW3) Vacuum system motor (M1) Vacuum system motor fuse (25 A - Battery) (30 A Gasket Petrol/LPG) (F1) Filter shaker motor (M2) Filter shaker motor fuse (25 A - Battery) (30 A Petrol/LPG) (F2) Filter shaker/vacuum...
Page 45: Maintenance And Adjustments
- Wear appropriate dust mask to avoid breathing in dust. 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). Disconnect the vacuum system motor connector (A).
Page 46 (K). must be replaced. disengaging it by the knobs (D) and then by the knobs (E). wards (arrow (I) upwards). (Only for SW4000 Battery and Petrol). Fasten shaker assembly (F). machine. Method “A” remove dust and dirt. Caution! Take care not to damage the the gasket.
Page 47: Troubleshooting
an al st Cont ol Troubleshooting Remedy Repair/replace damaged Replace Replace Repair/replace Replace Replace Repair/replace...
Page 48: Removal And Installation
Disassembly 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). Disconnect the vacuum system motor connector (A). Disengage the retainers (B) and remove the vacuum system hood (C).
Page 49 an al st Cont ol Filter Shaker Motor Disassembly/Assembly (Continues) disengaging it by the knobs (D) and then by the knobs (E). (I). Retrieve the washers (J). Assembly 10. Assemble the components in the reverse order of disassembly. P200106...
Page 50 an al st Cont ol Electric Vacuum Fan Motor Amperage Check Open the battery/engine compartment hood with the handle and fasten it with the support rod. Apply the amp clamps (A) on one cable (B) of the electric vacuum fan (C). Turn the ignition key to “I”.
Page 51 Disassembly 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). Disconnect the vacuum system motor connector (A). Disengage the retainers (B) and remove the vacuum system hood (C).
Page 52 an al st Cont ol Electric Fan Disassembly/Assembly (Continues) Unscrew the bulkhead cap (F). Remove the external screws (G) and remove the electric fan assembly (H) with its wiring harness (E). Unscrew the three nuts (J) and remove the screws (K). Remove the plate (L) and the electric fan (I).
Page 53 Cont ol SW4000 Battery 75 ft 75 ft 0.6 in H...
Page 54: Dust Guard System
an al Dust Guard System Functional Description 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- The system has a pump motor (M8) which is powered by the relay (K6) and protected by the fuse (F5).
Page 55: Component Locations
an al Component Locations Dust guard system switch (SW8) Water tank Spraying nozzle Dust guard system fuse (5 A) (F5) Water pump (M8) Dust guard system switch (SW8) Water tank Water pump (M8) Spraying nozzle Dust guard system fuse (5 A) (F5) P200111...
Page 56: Maintenance And Adjustments
an al Maintenance and Adjustments Dust guard System Water Filter Cleaning Turn the ignition key to “0” and engage the parking brake. Clean and install them on the holder (F). P200112...
Page 57 an al Nozzle and Filter Cleaning Turn the ignition key to “0” and engage the parking brake. P200113...
Page 58: Troubleshooting
an al Troubleshooting Clean/replace Clean/replace Repair/replace Clean/replace Replace Replace...
Page 59: Removal And Installation
Turn the ignition key to “0” and engage the parking brake. 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). Lift and disassemble the right side bulkhead.
Page 60 an al Dust guard System Water Pump Disassembly/Assembly (Continues) Disconnect the connector (F) of the water pump (D). water pump (D) from the holder. Assembly 10. Assemble the components in the reverse order of disassembly. P200115...
Page 61 SW4000 Battery...
Page 62: Electrical System
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 The drive system consists of a driving wheel (M0) driven by the drive system electronic board (EB1).
Page 63: Fuses
an al le t Fuses All the circuits are protected by non-resettable fuses. Type Nominal Nominal Size Size GENERAL GENERAL MAIN BROOM MAIN BROOM BATTERY/DYNAMOTOR RECHARGE RIGHT SIDE BROOM RIGHT SIDE BROOM LEFT SIDE BROOM LEFT SIDE BROOM VACUUM SYSTEM VACUUM SYSTEM FILTER SHAKER FILTER SHAKER...
Page 64: Relay/Electromagnetic Switch/Diodes
an al le t Relay/Electromagnetic Switch/Diodes Nominal Nominal Size Size VACUUM SYSTEM RELAY VACUUM SYSTEM RELAY FILTER SHAKER RELAY FILTER SHAKER RELAY 30/40A HOPPER LIFTING 30/40A HOPPER LIFTING RELAY 30/40A HOPPER LOWERING 30/40A HOPPER LOWERING RELAY 30/40A MACHINE ON RELAY 30/40A MACHINE ON RELAY 30/40A...
Page 65: Wiring Diagram (Sw4000 Battery)
Wiring Diagram (SW4000 Battery) WITHOUT ON BOARD BATTERY CHARGER SE ( SE ( EMER E P SH- MA H E RE A ( ER ( A ) HAR ER ( H) R - ( ( R M MA H E...
Page 66: Wiring Diagram (Sw4000 Petrol/Lpg)
Wiring Diagram (SW4000 Petrol/LPG) SE ( EMER E HAR E SE ( P SH- E S AR R MA H (ES ) E (S SPAR P (SP ) A ER RAME ( R) MA H E...
Page 67: Component Locations (Sw4000 Battery)
Component Locations (SW4000 Battery) Emergency push-button (SW0) Wiring harnesses Battery charger (CH) Electrical component box Flashing light (BE) Battery connector (C1) Batteries (BAT) Battery charger (CH) Emergency push-button (SW0) Flashing light (BE) Wiring harnesses Battery connector (C1)
Page 68: Component Locations (Sw4000 Petrol/Lpg)
Main fuse (150 A) (F0) Electrical component box Right side broom motor fuse (15 A) (FR1) Batteries (BAT) Left side broom motor fuse (15 A) (FR2) Dynamotor (M5) (SW4000 P/LPG) Battery charge fuse (80 A) (FC) Emergency push-button (SW0) Flashing light (BE) Dynamotor (M5)
Page 69 (3 A) (F3) Filter shaker motor Vacuum system fuse (25 A) (F2) motor fuse (25 A) (F1) SW4000 Petrol / LPG Hopper lifting fuse Dust guard system (30 A) (F6) fuse (5 A) (F5) Main fuse (key circuit)
Page 70: Maintenance And Adjustments
Battery charge status is shown by the 3 LEDs depending on the type of battery (WET or GEL/AGM) according GEL-AGM V>22.0 V>22.2 22.0>V>20.4 22.2>V>21.6 V>20.4 V>21.6 Battery Type Display (WET or GEL-AGM) (SW4000 Battery) Battery Type GEL-AGM On Board Battery Charger Setting (SW4000 Battery) EXTERNAL CHARGING CURVES DIP1 DIP2...
Page 71 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.
Page 72 Battery Removal/Installation and Battery Type Setting (WET or GEL/AGM) (SW4000 Battery) (Continues) Battery Setting (WET or GEL-AGM) 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 11.
Page 73 Battery Removal/Installation and Battery Type Setting (WET or GEL/AGM) (SW4000 Battery) (Continues) Battery Removal Engage the parking brake. Remove the ignition key. Open the battery compartment hood (A) with the handle (B) and fasten it with the support rod (C).
Page 74 Battery Voltage Check (SW4000 Petrol) Turn on the machine and engage the parking brake. Open the engine compartment hood with the handle and fasten it with the support rod. Check the voltage at the battery pins.
Page 75: Fuse Check/Replacement (Sw4000 Battery)
Fuse Check/Replacement (SW4000 Battery) Turn the ignition key to “0” and engage the parking brake. 15. Place the cover (I) and tighten screws. Open the battery/engine compartment hood with the handle and fasten it with the support rod.
Page 76 Fuse Check/Replacement (SW4000 Petrol/LPG) Turn the ignition key to “0” and engage the parking brake. Open the battery/engine compartment hood with Place the cover (I) and tighten screws. the handle and fasten it with the support rod.
Page 77: Troubleshooting
an al le t Troubleshooting Remedy Replace Repair Replace Repair Replace...
Page 78: Removal And Installation
Removal and Installation Battery Charger Disassembly/Assembly (SW4000 Battery) Disassembly Turn the ignition key to “0” and engage the parking brake. Open the battery compartment hood with the handle and fasten it with the support rod. Disconnect the battery connector.
Page 79 Dynamotor Carbon Brush Check/Replacement (SW4000 Petrol) Disassembly Turn the ignition key to “0” and engage the parking brake. Open the engine compartment hood with the handle and fasten it with the support rod. Disconnect the batteries.
Page 80 Dynamotor Carbon Brush Check/Replacement (SW4000 Petrol) (Continues) Remove the fastening screws (G) of the electrical connections of the four carbon brushes (H). springs (I). The contact surface is not integral The stroke is less than 0.12 in (3 mm)
Page 81 Dynamotor Disassembly/Assembly (SW4000 Petrol) Disassembly Remove the dynamotor carbon brushes (refer to the procedure “Dynamotor Carbon Brushes Check/ Replacement”). with the end of the shaft. Remove the two screws (C) with nuts (D) fastening the dynamotor (M) to the holder (E). Retrieve the washers.
Page 82 Dynamotor Disassembly/Assembly (SW4000 Petrol) (Continues) between dynamotor and the engine. Assembly P200126...
Page 83: General Wiring Diagram (Sw4000 Battery)
General Wiring Diagram (SW4000 Battery) ( R M MA H E E ERM A S DE R R MA RE A ( H (ES ) SE ( A) P200127A...
Page 84 General Wiring Diagram (SW4000 Battery) ( R M MA H E E ERM A H PPER EMPERA SE S R (S ) D SP A SE ( H PPER S DE R SE S R (S )
Page 85 General Wiring Diagram (SW4000 Battery) WITHOUT ON BOARD BATTERY CHARGER POSITIVE SIGNAL (FROM MACHINE ON K4 ) BATTERY NEGATIVE TERMINAL REVERSE GEAR BUZZER (BZ1) EMERGENCY KEY CIRCUIT LINE ELECTROMAGNETIC PUSH BUTTON (SW ) FUSE (F4) SWITCH (ES )
Page 86: General Wiring Diagram (Sw4000 Petrol - Lpg)
General Wiring Diagram (SW4000 Petrol - LPG) POSITIVE SIGNAL (FROM MACHINE ON K4 ) BATTERY NEGATIVE TERMINAL HAR E SE ( E S AR R MA H (ES ) S DE R RE A ( MAIN BROOM FUSE (FA)
Page 87 General Wiring Diagram (SW4000 Petrol - LPG) ( R M MA H E E ERM A H PPER EMPERA SE S R (S ) D SP A SE ( S DE R H PPER SE S R (S )
Page 88 General Wiring Diagram (SW4000 Petrol - LPG) ( R M MA H E E ERM A RE ERSE EAR ER ( SE ( EMER E P SH- D DE (D ) E E E R MA...
Page 89 SW4000 Battery SW4000 Battery SW4000 Battery 24V 30A >90% IP30 SW4000 Battery Dynamotor...
Page 90: Engine System - Petrol
an al n ne et ol Engine System - Petrol Functional Description The engine system generates electric current for all machine functions. rear side of the machine. The tank has a fuel level in- The assembly consists of an internal combustion en- The choke lever on the engine has been extended in main crankshaft.
Page 91: Component Locations
an al n ne et ol Component Locations Petrol engine Reserve sensor (S5) Filler neck Diode (S1) Fuel tank Oil Alert Sensor Fuel opening/closing valve Petrol engine Filler neck Reserve sensor (S5) Fuel tank Fuel opening/closing valve Oil Alert Sensor Diode (S1) P200129...
Page 92: Maintenance And Adjustments
an al n ne et ol Maintenance and Adjustments Engine RPM Check (B) which can be seen from the front outer side of the engine compartment. Alternatively use a rev counter (C) to be applied to the spark plug wire (D). P200130...
Page 93 an al n ne et ol Engine Air Filter Cleaning Check Caution! Running the engine without air that the gasket (H) is properly placed under the can cause a faster engine wearing. wing nut (C). Drive the machine on a level ground and engage 12.
Page 94 an al n ne et ol Engine Oil Level Check Caution! Running the engine with a low oil level can damage the engine itself. start-up. Drive the machine on a level ground and engage the parking brake. Turn the ignition key to “0”. Open the engine compartment hood with the handle and fasten it with the support rod.
Page 95 an al n ne et ol Engine Oil Change Caution! The discharged engine oil must be disposed of properly according to the Law in force. Drive the machine on a level ground and engage the parking brake. Turn the ignition key to “0”. Open the engine compartment hood with the handle and fasten it with the support rod.
Page 96 an al n ne et ol Engine Filter Trap Cleaning Handle the fuel outdoors only. Wipe immediately any fuel accidentally spilled out. Drive the machine on a level ground and engage the parking brake. Turn the ignition key to “0”. Open the engine compartment hood with the handle and fasten it with the support rod.
Page 97 an al n ne et ol Engine Spark Plug Check/Replacement Data chapter. tighten 1/8 - 1/4 turn once the spark plug is in place to press the washer. Warning! A wrong spark plug can damage the engine. Drive the machine on a level ground and engage the parking brake.
Page 98 an al n ne et ol Warning! If the engine was running, the silencer will be very hot. Let it cool down before operating on Drive the machine on a level ground and engage the parking brake. Turn the ignition key to “0”. Open the engine compartment hood with the handle and fasten it with the support rod.
Page 99: Troubleshooting
an al n ne et ol Troubleshooting Remedy level. Replace code. code.
Page 100: Removal And Installation
an al n ne et ol Removal and Installation Engine-Dynamotor Unit Disassembly/Assembly Disassembly Turn the ignition key to “0” and engage the parking brake. Open the engine compartment hood with the handle and fasten it with the support rod. Disconnect the batteries.
Page 101 an al n ne et ol Engine-Dynamotor Unit Disassembly/Assembly (Continues) Disconnect the wiring harnesses (F) of the dynamotor (G) from the electrical cable (H) and the batteries (I) (mark each position for proper reassembly). Disconnect the engine start electrical connector (J). 10.
Page 102 an al n ne et ol Engine Unit Disassembly/Assembly Disassembly Remove the engine-dynamotor unit (see the procedure in the previous paragraph). Remove the dynamotor unit (see the procedure in Electrical System paragraph). approx. Assembly Assemble the components in the reverse order of disassembly. P200139...
Page 103 an al n ne et ol Honda Model GX-200 Oil type SAE 5 W 30 - SYNTHETIC API SJ 12 in Forced air...
Page 104: Engine System - Lpg
an al n ne Engine System - LPG Functional Description The engine system generates electric current for all The IMPCO T60-A-NN-2 two-phase pressure reducer machine functions. The assembly consists of an internal combustion en- burettor. The LPG system is protected against any overpres- main crankshaft.
Page 105: Component Locations
an al n ne Component Locations LPG tank fastening band Hose LPG tank Pipe Safety valve LPG tank opening/closing valve Diode (D3) LPG tank LPG tank opening/ closing valve LPG tank Safety valve LPG tank fastening band Hose Pipe Diode (D3) P200141...
Page 106 an al n ne Component Locations (Continues) LPG wiring harness Hose Engine Hose Pressure valve (reserve) (S4) LPG pressure regulator LPG wiring harness Engine Solenoid valve Hose LPG pressure Pressure valve regulator (reserve) (S4) P200141-2...
Page 107: Maintenance And Adjustments
an al n ne Maintenance and Adjustments Engine RPM Check (B) which can be seen from the front outer side of the engine compartment. Alternatively use a rev counter (C) to be applied to the spark plug wire (D). P200130...
Page 108 an al n ne Engine Air Filter Cleaning Check Warning! Running the engine without air that the gasket (H) is properly placed under the can cause a faster engine wearing. wing nut (C). Drive the machine on a level ground and engage 12.
Page 109 an al n ne Engine Oil Level Check Caution! Running the engine with a low oil level can damage the engine itself. start-up. Drive the machine on a level ground and engage the parking brake. Turn the ignition key to “0”. Open the engine compartment hood with the handle and fasten it with the support rod.
Page 110 an al n ne Engine Oil Change Caution! The discharged engine oil has to be disposed of properly according to the Law in force. Drive the machine on a level ground and engage the parking brake. Turn the ignition key to “0”. Open the engine compartment hood with the handle and fasten it with the support rod.
Page 111 an al n ne Engine Spark Plug Check/Replacement 13. Perform steps 4 and 3 in the reverse order. Data chapter. Warning! A wrong spark plug can damage the engine. Drive the machine on a level ground and engage the parking brake. Turn the ignition key to “0”.
Page 112 an al n ne Warning! If the engine was running, the silencer will be very hot. Let it cool down before operating on Drive the machine on a level ground and engage the parking brake. Turn the ignition key to “0”. Open the engine compartment hood with the handle and fasten it with the support rod.
Page 113 an al n ne LPG System Leakage Check Warning! This procedure has to be performed by personnel systems, according to the law in force. Moreover, it is necessary to wear accident-prevention clothes, according to the law in force (heavy gloves, antistatic non-synthetic clothes, suitable to cover the whole body, antistatic and...
Page 114 an al n ne LPG System Leakage Check (Continues) the spry product. then tighten them again (see the procedure in “LPG System Hose Removal/Installation”). Perform again LPG System Leakage Check. P200214...
Page 115 an al n ne Solenoid Valve Filter Cleaning systems, according to the law in force. Moreover, it is necessary to wear accident-prevention clothes, according to the law in force (heavy gloves, antistatic non-synthetic clothes, suitable to cover the whole body, antistatic and antispark shoes, helmets with visor; etc.). Disassembly Empty the LPG system (see the procedure in LPG System Emptying).
Page 116 an al n ne Solenoid Valve Filter Cleaning (Continues) 10. Remove the fastening screws (G) of the pressure regulator assembly with valves (H). 11. Remove the pressure regulator assembly with valves (H). P200144...
Page 117 an al n ne Solenoid Valve Filter Cleaning (Continues) 14. Overturn the solenoid valve (N) and fasten its body on a vice (P) with soft jaws. P200229...
Page 118 an al n ne Solenoid Valve Filter Cleaning (Continues) Take care in order not to damage the remaining part of the solenoid valve; do not sink the coil in solvent or water. Assembly in Lbs). 20. Perform the LPG System Leakage Check (see the procedure in LPG System Leakage Check paragraph). P200230...
Page 119 an al n ne Adjustment systems, according to the law in force. Check the CO emissions. the machine is used. Adjustment Turn the ignition key to “0” and engage the parking brake. Open the engine compartment hood with the handle and fasten it with the support rod. Remove the sealant from the housing (A) of the LPG pressure regulator (B).
Page 120: Troubleshooting
an al n ne Troubleshooting Remedy level Replace Replace code. code.
Page 121: Removal And Installation
an al n ne Removal and Installation LPG System Emptying systems, according to the law in force. Moreover, it is necessary to wear accident- prevention clothes, according to the law in force (heavy gloves, antistatic non- synthetic clothes, suitable to cover the whole body, antistatic and antispark shoes, helmets with visor;...
Page 122 an al n ne LPG System Hose and Fitting Disassembly/Assembly systems, according to the law in force. Moreover, it is necessary to wear accident-prevention clothes, according to the law in force (heavy gloves, antistatic non-synthetic clothes, suitable to cover the whole body, antistatic and antispark shoes, helmets with visor;...
Page 123 an al n ne LPG System Hose and Fitting Disassembly/Assembly (Continues) again after having applied new sealant, as shown below. Assembly instructions on the package of the product. enters the system. P200147...
Page 124 an al n ne Pressure Regulator Removal/Installation systems, according to the law in force. Moreover, it is necessary to wear accident-prevention clothes, according to the law in force (heavy gloves, antistatic non-synthetic clothes, suitable to cover the whole body, antistatic and antispark shoes, helmets with visor; etc.). Disassembly Empty the LPG system (see the procedure in LPG System Emptying).
Page 125 an al n ne Pressure Regulator Removal/Installation (Continues) Disconnect the electrical connections (D) and (F). 10. Remove the fastening screws (G) of the pressure regulator assembly with valves (H). 11. Remove the pressure regulator assembly with valves (H). 15. Retrieve the pressure regulator (K). Assembly 16.
Page 126 an al n ne Pressure Valve Removal/Installation systems, according to the law in force. Moreover, it is necessary to wear accident-prevention clothes, according to the law in force (heavy gloves, antistatic non-synthetic clothes, suitable to cover the whole body, antistatic and antispark shoes, helmets with visor; etc.). Disassembly Empty the LPG system (see the procedure in “LPG System Emptying”).
Page 127 an al n ne Solenoid Valve Removal/Installation systems, according to the law in force. Moreover, it is necessary to wear accident-prevention clothes, according to the law in force (heavy gloves, antistatic non-synthetic clothes, suitable to cover the whole body, antistatic and antispark shoes, helmets with visor; etc.). Disassembly Empty the LPG system (see the procedure in “LPG System Emptying”).
Page 128 an al n ne Solenoid Valve Removal/Installation (Continues) Disconnect the electrical connections (D) and (F). 10. Remove the fastening screws (G) of the pressure regulator assembly with valves (H). 11. Remove the pressure regulator assembly with valves (H). 15. Retrieve the solenoid valve (J). Assembly 16.
Page 129 an al n ne Engine-Dynamotor Unit Disassembly/Assembly Disassembly Empty the LPG system (see the procedure in “LPG System Emptying”). Turn the ignition key to “0” and engage the parking brake. Open the engine compartment hood with the handle and fasten it with the support rod. Disconnect the batteries.
Page 130 an al n ne Engine-Dynamotor Unit Disassembly/Assembly (Continues) Disconnect the wiring harnesses (F) of the dynamotor (G) from the electrical cable (H) and the batteries (I) (mark each position for proper reassembly). Disconnect the engine start electrical connector (J). 10. Disconnect the engine ground (K). 11.
Page 131 an al n ne Engine Unit Disassembly/Assembly Disassembly Remove the engine-dynamotor unit (see the procedure in the previous paragraph). Remove the dynamotor unit (see the procedure in Electrical System paragraph). approx. Assembly Assemble the components in the reverse order of disassembly. P200139...
Page 132 an al n ne Honda Model GX-200 Oil type SAE 5 W 30 - SYNTHETIC API SJ 12 in Forced air...
Page 133: Hopper System
an al Hopper System Functional Description The hopper lifting system is operated by an hydraulic cylinder driven by an electric pump motor (M3) with integrated hydraulic unit. ing. The pump is protected by the fuse (F6). The relays are driven by the hopper movement enabling switch (SW4) and by the hopper lifting/lowering switch (SW5).
Page 134: Wiring Diagram
an al Wiring Diagram HOPPER HOPPER LIFTING DISPLAY ELECTRONIC LOWERING RELAY (K3A) BOARD FUSE (F3) RELAY (K3B) J1.1 - Electronic board power supply + HOPPER HOPPER PUMP LIFTING/LOWERING FUSE (F6) SWITCH (SW5) J2.4 - Control panel switch power supply (-) HOPPER PA E E E ARD (E...
Page 135: Hydraulic Diagram
an al Hydraulic diagram HYDRAULIC CILINDER VALVE LOCK DOWN HIGH PRESSURE PRESSURE RELIEF VALVE RELIEF VALVE HYDRAULIC POWER UNIT P200152...
Page 136: Component Locations
an al Component Locations Hopper lifting system warning light Closed hopper sensor (S1) Hopper movement enabling switch (SW4) Hopper linkages Hopper lifting/lowering switch (SW5) Hopper Hopper lifting system warning light Hopper movement enabling switch (SW4) Hopper lifting/lowering switch (SW5) Closed hopper sensor (S1) Hopper linkages...
Page 137 an al Component Locations (Continues) Check valve Hydraulic hoses Hydraulic cylinder Hydraulic control unit Hydraulic oil tank Hopper lifting fuse (25 A - Battery) (30 A Petrol/LPG) (F6) Hydraulic cylinder Hydraulic control unit Check valve Hydraulic oil tank Hydraulic hoses Hopper lifting fuse (25 A - Battery) (30 A Petrol/LPG) (F6)
Page 138: Maintenance And Adjustments
an al Maintenance and Adjustments Hydraulic System Oil Level Check Warning! Procedure to be performed with the hopper fully retracted. Turn the ignition key to “0” and engage the parking brake. Open the battery/engine compartment hood with the handle and fasten it with the support rod. disengage it from the fasteners.
Page 139: Troubleshooting
an al Troubleshooting Remedy...
Page 140: Removal And Installation
Turn the ignition key to “0” and engage the parking brake. 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). from its housing (A).
Page 141 an al Hopper Disassembly/Assembly Disassembly Empty the hopper. Engage the parking brake. Turn the ignition key to “0”. Turn the lever (E) to rest position. adjusted after the hopper reassembly. Remove the two screws (G) on both sides of the hopper (A) and retrieve the components (H). 10.
Page 142 an al Hopper Disassembly/Assembly (Continues) Assembly 11. Assemble the components in the reverse order of disassembly. 12. Check that the hopper operates properly and that it is properly aligned; if necessary align it as shown below. Alignment Adjustment below. engaging the notch (M) on the tooth (N) of the hopper housing (A). Perform steps 2 to 5.
Page 143 Hopper System Hopper and Lifting Arm Disassembly/Assembly Disassembly Empty the hopper and then close it. Engage the parking brake. Ensure that the hopper is closed. components (G). P200158...
Page 144 Hopper System Hopper and Lifting Arm Disassembly/Assembly (Continues) Remove the side screws (I) and remove the rotating pins (J). lifting it. Assembly Assemble the components in the reverse order of disassembly. P200159...
Page 145 Turn the ignition key to “0” and engage the parking brake. 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). Disconnect the vacuum system motor connector (B).
Page 146 Hopper System Hydraulic Control Unit Disassembly/Assembly (Continues) Disconnect the electrical connector (E) of the hydraulic unit (F). Remove the hollow screws (G) and disconnect the hydraulic hoses (H) from the hydraulic unit (F). Retrieve the gaskets (I). Warning! Hydraulic system oil is highly corrosive. Warning! The hydraulic system oil should be disposed of properly according to the Law in force.
Page 147 Hopper System Hydraulic Control Unit Disassembly/Assembly (Continues) 10. Remove the front screw (J) and the rear screw (K) fastening the hydraulic unit (F). 11. Remove the hydraulic control unit (F). Assembly P200161...
Page 148 Hopper System Hydraulic Hose Disassembly/Assembly Disassembly Ensure that the hopper is closed. Turn the ignition key to “0” and engage the parking brake. Open the battery/engine compartment hood with the handle and fasten it with the support rod. Remove the hollow screws (B) and disconnect the hydraulic hoses (C) from the hydraulic unit (D). Retrieve the gaskets (A).
Page 149 Hopper System Hydraulic Hose Disassembly/Assembly (Continues) Collect the hydraulic system oil in a proper container. Warning! Hydraulic system oil is highly corrosive. Warning! The hydraulic system oil should be disposed of properly according to the Law in force. Open the fastening clamps (F) and the hoses (C). Collect the hydraulic system oil in a proper container.
Page 150 Hopper System Hydraulic Cylinder Disassembly/Assembly Disassembly Warning! The hydraulic system oil should be disposed of properly according to the Law in force. Ensure that the hopper is closed. Turn the ignition key to “0” and engage the Remove the screw (D) and remove the lower pin parking brake.
Page 151 Hopper System SW4000 Battery Hopper capacity SW4000 Battery 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.
Page 152: Optional And Accessories
pt o essor es Optional and Accessories...
Page 153 pt o essor es...
Page 154: Steering System
Steer System Steering System Functional Description The steering wheel is fastened to the steering column and connected to a shaft with a cardan joint. gear is fastened to the driving wheel.
Page 155: Component Locations
Steer System Component Locations Steering wheel Steering shaft Steering column Steering assembly Cardan joint Steering chain Steering Steering column wheel Steering shaft Cardan joint Steering assembly Steering chain P200165...
Page 156: Removal And Installation
Steer System Removal and Installation Steering Wheel Disassembly/Assembly Disassembly Turn the ignition key to “0” and engage the parking brake. Disengage and remove the cover (A). Unscrew the nut (B) and remove the washer (C). lower edge (G) itself. Assembly Assemble the components in the reverse order of disassembly.
Page 157 Steer System Steering Chain Disassembly/Assembly Disassembly Turn the ignition key to “0” and engage the parking brake. Steer the front wheel until the junction link (A) of the steering chain (B) becomes visible. Disengage the link (A) and remove the chain (B). Retrieve the chain tensioner pulley (C).
Page 158 Steer System Steering Assembly Removal/Installation...
Page 159: Main Broom System
room System Main Broom System Functional Description a metal cable; the broom is kept pressed to the ground by two gas springs that ensure the contact with the ground at all times. The electric motor transmits the motion to the main broom by means of a drive belt connected to an hexagonal driver that supports the broom.
Page 160: Component Locations
room System Component Locations Main broom lifting/lowering lever Main broom motor fuse (50A) (FA) Main broom overload warning light Front skirt lifting pedal Main broom height adjusting knob Main broom Main broom lifting/lowering lever Main broom overload warning light Main broom height adjusting knob Main broom motor fuse (50A) (FA)
Page 161 room System Component Locations (Continues) Rear skirt Motor pulley Front skirt Right side skirt Left side skirt Broom pulley Lowered main broom enabling sensor (S2) Device to adjust the parallelism between the Driving belt Main broom motor (M4) Device to adjust the Lowered main broom parallelism between enabling sensor (S2)
Page 162: Maintenance And Adjustments
room System Maintenance and Adjustments Main Broom Height Check And Adjustment procedure is applicable to all types of brooms. bristle wear. Perform step 1 again to check that the main broom is at the correct distance from the ground. When the broom is too worn and can no broom and turn it on for a few seconds.
Page 163 room System Main Broom Height Check and Adjustment (Continues) Turn the fasteners and remove the left door. Loosen the locknuts (C). Lift the lever (E) to lower the left side of the broom; Lower the lever (E) to lift the left side of the broom. Perform step 1 again to check that the main broom is at the correct distance from the ground.
Page 164 room System Main Broom Disassembly/Assembly types of brooms. Warning! It is advisable to wear protective gloves when replacing the main broom because there can be sharp debris between the bristles. Disassembly Drive the machine on a level ground and engage the parking brake. Turn the ignition key to “0”...
Page 165 room System Main Broom Disassembly/Assembly (Continues) Assembly (J) of the machine chassis. 11. Turn the levers (B) to lock the latch (C) in its housing. 12. Screw down the knob (A). 13. Install the left door and secure it with the relevant fasteners. P200171...
Page 166: Skirt Height Check And Adjustment
room System Skirt Height Check and Adjustment Preliminary Operations affect the skirt height check. Drive the machine on a level ground that is suitable for checking the skirt height. Turn the ignition key to “0” and engage the parking brake. Side Skirt Check Remove the machine left and right doors by turning the relevant fasteners.
Page 167 room System Skirt Height Check and Adjustment (Continues) Front and Rear Skirt Check Remove the main broom. Check the front skirt (F) and rear skirts (G) and (H) for integrity. Replace the skirts when they have cuts (C) larger than 20 mm or cracks/tears (D) larger than 10 mm (see the procedure in “Skirt Disassembly/Assembly”).
Page 168: Troubleshooting
room System Troubleshooting Remedy Replace Replace clean properly Replace Replace...
Page 169: Removal And Installation
room System Removal and Installation Driving Belt Visual Inspection and Replacement Check Turn the ignition key to “0” and engage the parking brake. Remove the machine right door by turning the relevant fasteners. Replacement Remove the belt (A). Install the new belt (A). (D).
Page 170 room System Skirt Disassembly/Assembly Preliminary Operations affect the skirt height check. Drive the machine on a level ground that is suitable for checking the skirt height. Turn the ignition key to “0” and engage the parking brake. Side Skirt Removal and Installation Remove the machine left and right doors by turning the relevant fasteners.
Page 171 room System Skirt Disassembly/Assembly (Continues) Front Skirt Removal and Installation 10. Remove the main broom. 11. Remove the side brooms. skirt lifting tie rod form the bracket (G). 13. Remove the six nuts (H) then remove the strap (I) from the main broom compartment. 14.
Page 172 room System Skirt Disassembly/Assembly (Continues) Rear Skirt Removal and Installation 19. Remove the main broom. 20. Lift the hopper to the end-of-stroke. Warning! Place a safety rod under the lifted hopper. 23. Install the rear skirts (T) and (R) in the reverse order of disassembly. 24.
Page 173 room System Main Broom Motor Amperage Check Remove the main broom. Remove the right side broom. Place wedges (A) on the rear wheels of the machine. Apply amp clamps (C) on a cable (D) of the main broom motor (E). Turn the ignition key to “I”.
Page 174 room System Main Broom Motor Amperage Check (Continues) Check the relevant fuse (FA) for proper tightening. Check the motor carbon brushes (see the procedure in “Main Broom Motor Carbon Brush Check/Re- placement”). all its components. the procedure in the next paragraph). Reassembly Install the right side broom.
Page 175 room System Main Broom Motor Disassembly/Assembly Disassembly Remove the main broom driving belt (see the procedure in “Driving Belt Visual Inspection and Replacement”). Disconnect the connector (A) of the main broom motor (B). Loosen the screws (C). Remove the main broom motor (B). Assembly Assemble the components in the reverse order of disassembly.
Page 176 room System Main Broom Motor Carbon Brush Check/Replacement Disassembly Remove the main broom motor (see the procedure in the previous paragraph). Disengage the cam lever (E) and remove the protection band (D). Remove the fastening screws (F) of the electrical connections of the four carbon brushes (G). springs (H).
Page 177 room System Main Broom Motor Pulley Disassembly/Assembly Disassembly Remove the main broom motor belt (see the procedure in “Driving Belt Visual Inspection and Replacement”). Remove the pulley (C) and retrieve the spacer (D) and the key (E). Assembly Assemble the components in the reverse order of disassembly. P200178...
Page 178 room System Main Broom Drive Hub and Bearing Disassembly/Assembly BEARINGS Disassembly Remove the main broom. Lift the hopper to the end-of-stroke. Warning! Place a safety rod under the lifted hopper. Remove the main broom driving belt (see the procedure in “Driving Belt Visual Inspection and Replacement”).
Page 179 room System Main Broom Drive Hub and Bearing Disassembly/Assembly (Continues) DRIVE HUB Disassembly Remove the main broom. Lift the hopper to the end-of-stroke. Warning! Place a safety rod under the lifted hopper. Retrieve the washer (N). Remove the drive hub (M) and retrieve the keys (P). Assembly Assemble the components in the reverse order of disassembly.
Page 180 room System Main Broom Gas Spring Disassembly/Assembly Disassembly Place the machine on a hoisting system. Remove the main broom. Use the lever (B) to lower the main broom. main broom lifting control cable (E) from the pin. P200217...
Page 181 room System Main Broom Gas Spring Disassembly/Assembly (Continues) Insert and tighten the screw with a 8 mm nut (H) in the hole (I). direction shown by the arrow until the screw (K) is disengaged by its housing and moved to the position (L) (thus the gas spring (G) will be extended).
Page 182 room System Main Broom Lifting Cable Disassembly/Assembly Disassembly Remove the main broom. Remove the fastening screws (A) of the fairing (B) from the steering column. Slightly lift the steering column (B) by disengaging it from the lower fastener (C). Disconnect the dust guard system quick coupling (D). Remove the fairing (B).
Page 183 room System Main Broom Lifting Cable Disassembly/Assembly (Continues) 11. Unscrew the nut (I) and remove the pin (J). 12. Remove the screw (K). 13. Remove the locknut (L) and disconnect the tie rod (M) from the housing with cut (N). 14.
Page 184 room System Main Broom Lifting Cable Disassembly/Assembly (Continues) Assembly and Adjustment 21. Turn the handwheel (F) clockwise until the end of the stroke (the broom must be fully lifted). 22. Turn the main broom lifting/lowering lever to working position (lowered broom). 23.
Page 185 room System Lowered Main Broom Enabling Sensor Disassembly/Assembly and Adjust- ment Disassembly its housing. Retrieve the proximity sensor (B) with the electrical cable. Assembly and Adjustment fasteners. Turn the main broom lifting/lowering lever to lower the broom. P200183...
Page 186 System SW4000 Battery - 550 rpm...
Page 187: Side Broom System
S e room System Side Broom System Functional Description The broom is fastened to the reduction unit shaft with a safety pin. The side broom motors turn only when the main broom is activated. (right FR1) and (left FR2). The relay (K5) is activated directly by the sensor (S3) (side broom control lever position) only when the side broom is activated too.
Page 188: Component Locations
S e room System Component Locations Side broom lifting/lowering lever Broom height adjusting ring nuts Side broom motor (M6) (M7) Side broom Lowered right side broom enabling sensor (S3) Left side broom motor fuse (15 A) (FR1) Right side broom motor fuse (15 A) (FR2) Side broom lifting/lowering lever Lowered side broom...
Page 189: Maintenance And Adjustments
S e room System Maintenance and Adjustments Side Broom Height Check and Adjustment Turn the fasteners and remove the left or right door. procedure is applicable to all types of brooms. gear by loosening the ring nut (C) and by adjusting the adjuster (D) until the correct print (A) is achieved.
Page 190: Troubleshooting
S e room System Troubleshooting Remedy not clean properly Replace Remove and clean Replace.
Page 191: Removal And Installation
S e room System Removal and Installation Side Broom Disassembly/Assembly types of brooms. Warning! It is advisable to wear protective gloves when replacing the main broom because there can be sharp debris between the bristles. Disassembly Drive the machine on a level ground and engage the parking brake. Turn the ignition key to “0”.
Page 192: Side Broom Motor Amperage Check
S e room System Side Broom Motor Amperage Check Remove the side broom of the relevant motor. Place wedges (A) on the rear wheels of the machine. Apply amp clamps (C) on a cable (D) of the broom motor (E). Turn the ignition key to “I”.
Page 193 S e room System Side Broom Motor Amperage Check (Continues) Check the motor carbon brushes (see the procedure in “Side Broom Motor Carbon Brush Check/Re- placement”). all its components. the procedure in the relevant paragraph). Reassembly Install the side broom of the relevant motor. Remove the front hoisting system of the machine.
Page 194 S e room System Side Broom Motor Disassembly/Assembly Disassembly Remove the side broom of the motor to be detached. Lower the side broom with the lever. Disconnect the connector (A) of the broom motor (B). Remove the four screws with nut (C). Remove the broom motor (B).
Page 195 S e room System Side Broom Motor Carbon Brush Check/Replacement Disassembly Remove the side broom motor (see the procedure in the previous paragraph). motor body (for proper reassembly). Remove the screws (D). Carefully remove the cap (C) by disengaging the carbon brushes inside the motor armature. The contact surface is not integral The stroke is less than 0.12 in (3 mm) The spring is broken...
Page 196 S e room System Side Broom Lifting Cable Disassembly/Assembly Disassembly Remove the relevant side broom. to be removed. Unscrew the locknut (E) and remove the cable (C) from the cut (D). P200191...
Page 197 S e room System Side Broom Lifting Cable Disassembly/Assembly (Continues) the cable (C) to be removed. Unscrew the locknut (H) and remove the cable (C) from the cut (I). Retrieve the cable (C). Assembly keeping the adjusters (J) in an intermediate position. P200192...
Page 198 S e room System Lowered Right Side Broom Enabling Sensor Disassembly/Assembly and Adjustment Disassembly Remove the right side broom. (B) from its housing. Retrieve the enabling sensor (B) with the electrical cable. Assembly and Adjustment fasteners. Turn the side broom lifting/lowering lever to lower the brooms. 10.
Page 199 S e room System SW4000 Battery - 110 rpm...
Page 200: Wheel System, Non-Traction
ee System Wheel System, Non-Traction Functional Description The rear wheels turns freely without any drive or stop system. placed near the letter “S”; in case of polyurethane wheels the notch must be placed near the letter “P”. Component Locations Rear wheels Hexagon castle nut Rear wheels castle nut...
Page 201 System SW4000 Battery...
Page 202: Wheel System, Traction
ee System Wheel System, Traction Functional Description gear buzzer starts to sound until the forward gear is not restored. On the driving wheel there is a disc brake keyed to a reduction unit fast shaft. The brake pedal activates the disc brake piston with a sheathed cable. The parking brake lever mechanism is integrated in the brake pedal.
Page 203 ee System malfunction warning light (A) on the electronic board (EB2) will turn on. ignition switch (SW1). P200195 Wiring Diagram REVERSE GEAR LINE ELECTROMAGNETIC BUZZER (BZ1) SWITCH (ES ) MAIN FUSE (F ) DRIVER S SEAT SAFETY MICROSWITCH (SW ) J2.9 - Buzzer output J2.16 - Reverse gear warning light output LINE ELECTROMAGNETIC...
Page 204: Component Locations
ee System Component Locations Forward/reverse gear switch (SW2) Drive system malfunction warning light Service brake pedal Parking brake lever Drive pedal (R1) Drive system malfunction warning light Forward/reverse gear switch (SW2) Service brake pedal Drive pedal (R1) Parking brake lever Driver’s seat safety microswitch (SW7)
Page 205 ee System Component Locations (Continues) Driving wheel (M0) Disc brake Drive system electronic board (EB1) Main fuse (150 A) (F0) Driving wheel (M0) Disc brake Drive system electronic board (EB1) Main fuse (150 A) (F0) Reverse gear buzzer (BZ1) P200242...
Page 206: Troubleshooting
ee System Troubleshooting Remedy Replace Replace damaged Replace Replace Replace pedal. Center.
Page 207: Drive System Electronic Board Error Codes Table
ee System Drive System Electronic Board Error Codes Table No. of Not active error Potentiometer activated at integrity. Undervoltage Overvoltage Amperometric protection Not active EEPROM error P200195...
Page 208: Drive System Electronic Board Parameter Table
ee System Drive System Electronic Board Parameter Table the ITALSEA programmer (P/N 9097297000). RESET TO DEFAULT PARAMETERS ACCELERATION RAMP REVERSE DECELERATION RAMP NEUTRAL DECELERATION RAMP FORWARD MAXIMUM SPEED BACKWARD MAXIMUM SPEED MINIMUM SPEED Not active BATTERY VOLTAGE SPEED REFERENCE SINGLE ENDED Pedal type REFERENCE DEAD-BAND 0.00...
Page 209 ee System PIN 11-J1 HARDWARE N.C. SWITCH CONFIGURATION A1 ALARM ENABLING DISABLE A2 ALARM ENABLING DISABLE A3 ALARM ENABLING ENABLE A4 ALARM ENABLING ENABLE A12 ALARM ENABLING DISABLE...
Page 210 ee System Connectors on Drive System Electronic Board Power Connections - Battery Ref. V ref. 250A 250A BAT- 0 - 24V 250A 0 - 24V 250A...
Page 211 ee System J2: MOLEX MINIFIT type, 16-ways vertical Electronic V ref. <1A <1A <1A <1A J2.14 <1A <1A <1A <1A <1A <1A <1A <1A...
Page 212: Removal And Installation
ee System Removal and Installation Brake Caliper, Pad, Brake Disc Disassembly/Assembly Disassembly Turn the ignition key to “0”. Ensure that the machine cannot move by placing opposite wedges on the rear wheels. Unscrew nut and locknut (A) then remove the brake cable (B) from the brackets (C). Retrieve the spring (D).
Page 213 ee System Brake Caliper, Pad, Brake Disc Disassembly/Assembly (Continues) Disengage the retaining ring (O) and remove the spring (P). Retrieve the washer (R). Retrieve the inner pad (M). P200199...
Page 214 ee System Brake Caliper, Pad, Brake Disc Disassembly/Assembly (Continues) Assembly Adjust the position of the nuts (F) until the bracket (G) comes into contact with the brake disc (I) and tween the brake disc (I) and the pads (L) and (M). Also check the parallelism of the bracket (G) with Screw down and tighten the nuts (E).
Page 215 ee System Brake Cable Disassembly/Assembly Disassembly Turn the ignition key to “0”. Ensure that the machine cannot move by placing opposite wedges (A) on the rear wheels. Unscrew nut and locknut (B) then remove the brake cable (C) from the brackets (D). Remove the clip with the pin (F).
Page 216: Brake Cable Adjustment
ee System Brake Cable Disassembly/Assembly (Continues) Assembly Adjust the brake according to the following procedure. Brake Cable Adjustment Ensure that the machine cannot move by placing opposite wedges on the rear wheels. Loosen the locknut (A) and the nut (B). Turn the nut (B) until the distance between the braking masses (C) and the brake disc (D) is 0.5 mm (as Tighten the locknut (A) with the nut (B).
Page 217 ee System Driving Wheel Amperage Check Place wedges (A) on the rear wheels of the machine. Open the battery/engine compartment hood. Apply the amp clamp (C) on the electrical cable (D) of the drive system electronic board (E). Turn the ignition key to “I”. on the drive system at the maximum speed and check that the driving wheel amperage is within 4 and 6 A at 24 V.
Page 218 ee System Driving Wheel Amperage Check (Continues) from turning. Check the carbon brushes of the drive system motor (see the procedure in the relevant paragraph) driving wheel must be replaced (see the procedure in Driving Wheel and Steering Unit Disassembly/ Assembly paragraph).
Page 219 Disassembly Turn the ignition key to “0” and engage the parking brake. Open the battery/engine compartment hood. Disconnect the battery connector (SW4000 Battery) - Disconnect the batteries (SW4000 Petrol/LPG). Remove the cover (A) (bayonet joint). Remove the O-ring (B). Loosen the screws (C).
Page 220 ee System Drive System Motor Carbon Brush Check/Replacement (Continues) The contact surface is not integral The stroke is less than 0.47 in (12 mm) The spring is broken Loosen the two screws (E) Remove the lateral cover (F) Loosen the screws (G) Remove the carbon brushes with the spring (H) The contact surface is not integral The stroke is less than 0.47 in (12 mm)
Page 221 ee System Front Wheel Rubber Ring Disassembly/Assembly Disassembly Turn the ignition key to “0”. Ensure that the machine cannot move by placing opposite wedges (A) on the rear wheels. Unscrew nut and locknut (C) then remove the brake cable (D) from the brackets (E). Retrieve the spring (F).
Page 222 ee System Front Wheel Rubber Ring Disassembly/Assembly (Continues) Remove the screws (G) on the left side of the front wheel assembly. Remove the spacer (H). Remove the left bracket (I); if necessary use a puller (J). Unscrew the nuts (K) and remove the fastening screws (L) of the rubber ring (N). Retrieve the washers (M).
Page 223 Open the battery/engine compartment hood. Disconnect the battery connector (SW4000 Battery) - Disconnect the batteries (SW4000 Petrol/LPG). Remove the fastening screws (C) of the fairing (D) from the steering column. Slightly lift the steering column fairing (D) by disengaging it from the lower fastener (E).
Page 224 ee System Driving Wheel and Steering Unit Disassembly/Assembly (Continues) 10. Unscrew nut and locknut (G) then remove the brake cable (H) from the brackets (I). Retrieve the spring (J). 11. Remove the screws (L) and the cover (M). 12. Remove the nuts and disconnect the electrical connections (N) from the driving wheel. P200206...
Page 225 ee System Driving Wheel and Steering Unit Disassembly/Assembly (Continues) 14. At the base of the steering column (R) remove the screws (S) and remove the cover (T). 15. Remove the four fastening screws (U) of the driving wheel assembly (V). the hub (X) from the steering shaft;...
Page 226 ee System Front Driving Wheel Armature Disassembly/Assembly Disassembly Remove the driving wheel and steering assembly (see the procedure in the previous paragraph). Remove the spacer (B). Remove the left bracket (C); if necessary use a puller (D). for a proper reassembly (to avoid that the driving wheel turns in the wrong direction). P200208...
Page 227 ee System Front Driving Wheel Armature Disassembly/Assembly (Continues) Remove the fastening screws (H) of the carbon brush cap (J). Retrieve the washers (I). Remove the carbon brush cap assembly (J); take the greatest care in order not to remove/displace the stator from its position.
Page 228 ee System Front Driving Wheel Armature Disassembly/Assembly (Continues) Assembly Remove any dust or debris from the stator and removed components. Lubricate with grease the grommet lips (P) before reassembling the armature (N). Check that the bearings of the armature (N) are properly installed on the shaft. To ease the installation of the carbon brush cap assembly (J) unscrew the caps and temporarily re- move the carbon brushes (refer to the procedure “Drive System Motor Carbon Brush Check/Replace- ment”...
Page 229 ee System Accelerator Pedal Disassembly/Assembly Disassembly Loosen the screw (B) under the accelerator pedal (A). Remove the accelerator pedal (A) from the shaft (C). Remove the three fastening screws (D) of the accelerator pedal control (E). Disconnect the accelerator pedal control connector (F). Disengage the electrical cable (G) from the retaining clamps (H).
Page 230 Turn the ignition key to “0” and engage the parking brake. Open the battery/engine compartment hood. Disconnect the battery connector (SW4000 Battery) - Disconnect the batteries (SW4000 Petrol/LPG). disconnect the electrical connections of the drive system electronic board (B). Remove the four side socket head screws (C) fastening the drive system electronic board (B).
Page 231 Disassembly Turn the ignition key to “0” and engage the parking brake. Open the battery/engine compartment hood. Disconnect the battery connector (SW4000 Battery) - Disconnect the batteries (SW4000 Petrol/LPG). (B) from its housing and disconnect it. Close the hood (A).
Page 232 System SW4000 Battery - 315 rpm...

Nilfisk-Advance SW4000 Service Manual

Quick Links

Service Manual

Troubleshooting

Need help?

Questions and answers

Related Manuals for Nilfisk-Advance SW4000

Summary of Contents for Nilfisk-Advance SW4000

Table of Contents