SW4000

Service Manual
Advance SW4000 Battery - 9084403010
Nilfisk SW4000 Battery - 9084400010
Nilfisk SW4000 Petrol - 9084401010
Nilfisk SW4000 LPG - 9084402010
Advance (SW4000 BR) - 9084407010 (LPG)

English

2013-04 Form No. 1464811000

Service Manual – SW4000 Table of Contents 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

Chassis System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chassis (main parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Dashboard Electronic Board Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 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
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Service Manual – SW4000 Table of Contents 3

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
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Service Manual – SW4000 Table of Contents 4

Side Broom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Service Manual – SW4000 General Information 5

General Information

Machine General Description

The SW4000 is a “ride-on” industrial machine designed to clean/sweep floors, in civil or industrial environ-
ments, 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 - Nilfisk 9084400010 1464809000 1464810000
SW4000 Petrol - Nilfisk 9084401010 1464815000 1464816000
SW4000 LPG - Nilfisk 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 SW4000 Battery Advance – SW4000 Battery/Petrol/LPG
PROTECTION ROOF KIT 1465246000 Nilfisk

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 Nilfisk-Advance Retailer
- Nilfisk-Advance website: www.nilfisk.com - www.advance-us.com
Service Manual – SW4000 General Information 6

Conventions
Forward, backward, front, rear, left or right are intended with reference to the operator’s position when driv-
ing.

Service and Spare Parts

Service and repairs must be performed only by authorised personnel or Nilfisk Service Centers. The authorised
personnel is trained directly at the manufacturer’s premises and has original spare parts and accessories.
Contact Nilfisk 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
identification data.

P200082

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

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

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

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

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

Service Manual – SW4000 General Information 7

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

WARNING! WARNING!
Carefully read all the instructions before Hot parts, danger of burns.
performing any operation on the machine.

DANGER! WARNING!
Internal combustion engine. Moving parts.
Do not inhale exhaust gas fumes.
Carbon monoxide (CO) can cause brain
damage or death.

WARNING! WARNING!
Do not wash the machine with direct or Moving parts. Danger of crushing.
pressurized water jets.

WARNING! WARNING!
X% Do not use the machine on slopes with a Parts under voltage. Presence of corrosive
gradient exceeding the specifications. fluids.

Symbols
Danger! It indicates a dangerous situation with risk of death for the operator.

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
Specific warnings and cautions to inform about potential damages to people and machine are shown below.

Warning! Make sure to follow the safety precautions to avoid situations that may lead to
serious injuries.

(For SW4000 Battery/Petrol/LPG)

–– Before performing any maintenance, repair, cleaning or replacement procedure remove the igni-
tion key, engage the parking brake and disconnect the battery (For SW4000 Petrol/LPG - Discon-
nect the battery connector).
–– This machine must be used by properly trained operators only.
Service Manual – SW4000 General Information 8

–– 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, flames 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, flammable 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, flames 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.

(For SW4000 Petrol/LPG)

–– Be careful: fuel is highly flammable.

–– Do not smoke or bring naked flames 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 filler to allow the fuel to expand.
–– After refuelling, check that the fuel tank cap is firmly 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 Nilfisk-
Advance Service Center.
Service Manual – SW4000 General Information 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
and away from naked flames.

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 muffler, 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 Nilfisk-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 specifications.
–– 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 specified 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 floor 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.
Service Manual – SW4000 General Information 10

–– The machine maximum capacity, operator’s weight not included, is 100 kg (the weight of waste).
–– In case of fire, use a powder fire extinguisher, not a water one.
–– Adjust the operation speed to suit the floor 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 flow.
–– (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 affixed 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).

(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 fires.
–– Running the engine with an insufficient 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 filter is not installed, because the engine could be damaged.
–– Technical service procedures on the engine must be performed by an authorised Dealer.
–– Only use original spare parts or parts of matching quality for the engine. Using spare parts of
lower quality can seriously damage the engine.
–– See also the SAFETY RULES in the Engine Manual, which is to be considered an integral part of
this Manual.

(For SW4000 Battery)

–– Before using the battery charger, ensure that frequency and voltage values, shown on the ma-
chine serial number plate, match the electrical mains voltage.
–– Do not pull or carry the machine by the battery charger cable and never use the battery charger
cable as a handle. Do not close a door on the battery charger cable, or pull the battery charger
cable around sharp edges or corners. Do not run the machine on the battery charger cable.
–– Keep the battery charger cable away from heated surfaces.
Service Manual – SW4000 General Information 11

–– 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 fire, 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 Dust-
Guard™ system.
To prevent the operators and other people from developing infections caused by microbes and Legionella that
may flourish in the dust guard system, take the following precautions:
–– If possible, fill the tank with cold water (< 20°C).
–– DO NOT use stagnant water to fill 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 floor only, from preventing possible inhaling.
–– Do not store the machine outdoors or near sources of heat.
–– Do not over-fill the tank. Fill the tank sufficiently 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.

Machine Lifting
Warning! Do not work under the lifted machine, if it is not securely fixed.

Machine Transportation
Warning! Before transporting the machine, make sure that:

All covers are closed.

The tanks are empty.

The battery connector is disconnected.

The machine is securely fastened to the means of transport.

Service Manual – SW4000 General Information 12

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
Steering wheel and discharge lever

Dust guard system Left

water filler neck plug side
cover

Front column / Dust guard

system water tank

Parking brake lever

Forward/reverse gear pedal

Rear
wheels
Front skirt
lifting pedal
Side broom guards
Left door
Service brake pedal
Right side broom
Left side broom
Working lights
Dust guard system nozzles
Front driving and steering wheel
P200083
Service Manual – SW4000 General Information 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
container

Right side cover

Panel filter with Right door

filter-shaker
Main broom
Hopper
Rear wheels

Anchoring slots for transport (not for lifting)

P200084
Service Manual – SW4000 General Information 14

Machine Nomenclature (SW4000 Battery) (Continues)

Hopper hydraulic
lifting system
control unit Drive system electronic board
Battery caps
(for WET batteries only) Fuseholder box
Vacuum system
Lead batteries Battery motor connector
(WET) or optional connector
gel batteries (GEL) Electrical
component
Open hood box
safety rod

Battery
compartment
hood opening
handle

Battery connection diagram

Left side broom motor
BATTERY circuit breaker
PLUG
Right side broom
motor circuit breaker
6V 6V

6V 6V

P200085
Service Manual – SW4000 General Information 15

Control Panel (SW4000 Battery)

Vacuum system Switch for:
warning light Dust guard system • Vacuum system activation (upper part)
(green) warning light • Filter shaker activation (lower part)
(green) Filter shaker switch

Semi-discharged battery
warning light (yellow)
Charged
battery warning Hopper lifting
light (green) system warning Side broom
Main broom
light (yellow) lifting/lowering lever
lifting/lowering lever

Discharged
battery warning
light (red)

Display

Button: Horn switch

• Working hours
• Battery voltage (V)
Hopper movement
enabling switch

Main broom overpressure

warning light (red)
Forward/reverse
Drive system malfunction
gear switch
warning light (red)

Dust guard Emergency Hopper Working light Main broom Ignition key
system switch push-button lifting/lowering switch height adjusting knob
switch
P200086
Service Manual – SW4000 General Information 16

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

Driver's seat with safety microswitch

Flashing light
Safety belts
Engine compartment
Can holder hood
Seat position adjusting lever Hopper release
and discharge
Steering wheel
lever
Dust guard system Left
water filler neck plug side
cover

Front column / Dust guard

system water tank

Parking brake lever

Drive pedal

Rear
wheels
Front skirt
lifting pedal
Side broom guards
Left door
Service brake pedal
Right side broom
Left side broom
Working lights
Dust guard system nozzles
Front driving and steering wheel
P200087
Service Manual – SW4000 General Information 17

Machine Nomenclature (SW4000 Petrol/LPG) (Continues)

Serial number plate/technical data/
conformity certification

Filler plug
(SW4000 Petrol) Fuel tank
(SW4000 Petrol)
Hopper manual
returning handle

Drive pedal
Rear hood with
vacuum system Anchoring slots
for transport
(not for lifting)
Dust filter
container

Right side cover

Panel filter Right door

with filter-shaker
Hopper Main broom

Rear wheels
Fuel opening/closing
valve (SW4000 Petrol)
Anchoring slots for transport
(not for lifting)
P200088
Service Manual – SW4000 General Information 18

Machine Nomenclature (SW4000 Petrol/LPG) (Continues)

Hopper hydraulic
lifting system control unit Drive system electronic board

Right side cover Fuseholder box

Dynamotor Vacuum system

Batteries motor connector

Engine Electrical
component
Open hood box
safety rod

Engine
compartment
hood lifting
handle

Choke lever
Engine serial number and model plate
Right side broom motor
circuit breaker
Left side broom motor
circuit breaker

Battery connection diagram

12V
LPG tank (SW4000 LPG) LPG adjuster solenoid valve (SW4000 LPG)
12V
LPG tank fastening band (SW4000 LPG)
P200089
Service Manual – SW4000 General Information 19

Control Panel (SW4000 Petrol/LPG)

Vacuum Switch for:
system warning Dust guard • Vacuum system activation (upper part)
light (green) system warning • Filter shaker activation (lower part)
light (green) Filter shaker/vacuum system switch

Hopper lifting
Main broom system warning Side broom
lifting/lowering light (yellow) lifting/lowering lever
lever

Fuel reserve
warning light (yellow)

Display

Button: Horn switch

• Working hours
• Battery voltage (V)
Hopper movement
enabling switch
Main broom overpressure
warning light (red)
Drive system
Forward/reverse
malfunction warning
gear switch
light (red)

Dust guard Emergency Hopper lifting/lowering Working light Main broom height Ignition
system switch push-button switch switch adjusting knob key
P200090
Service Manual – SW4000 General Information 20

Service and Diagnostic Equipment

Besides a complete set of standard meters, the following instruments are necessary to perform fast checks and
repairs on Nilfisk-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 Nilfisk-Advance websites).
The following equipment is also available at Nilfisk-Advance Centers:
• Italsea universal programmer, P/N 9097297000

P200091
Service Manual – SW4000 General Information 21

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 ft2/h (4,900 m2/h)
with two side brooms 73,463 ft2/h (6,825 m2/h)
with two side brooms 94,184 ft2/h (8,750 m2/h)
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 filter shaker
area 75 ft2 (7 m2)
filtering 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 -
(7,8 litres)
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 machine body 64.5 x 40.7 x 52.3 in (1,640 x 1,035 x 1,330 mm)
(length x width x height)
machine with side brooms 64.5 x 41.3 x 52.3 in (1,640 x 1,050 x 1,330 mm)
machine with flashing 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 14.2 x 15 x 8.7 in
in (370x812x390 (360 x 380 x 220 mm)
mm)
LPG tank maximum size (length x diameter) - - 28.3 x 11.8 in
(720 x 300 mm)
Service Manual – SW4000 General Information 22

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 1,708 lb (775 Kg) 1,770 lb (803 Kg)
Kg)
Wheel specific pressure on the floor (front - rear wheels, in running conditions) (**) 130 - 58 lbf/in2 116 - 29 lbf/in2
(0.9 - 0.4 N/mm2) (0.8 - 0.2 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/s2 (< 2.5 m/s2)
Vibration level at the operator’s body (ISO 2631-1) < 19.6 in/s2 < 35.4 in/s2
(< 0.5 m/s2) (< 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 floor checked on cement for each single wheel
Result expressed as maximum value for both front and rear wheels

Machine material composition and recyclability

Type SW4000 B SW4000 P SW4000 LP
Recyclable
weight weight weight
percentage
percentage percentage percentage
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 %
Service Manual – SW4000 General Information 23

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) in2/s (mm2/s) 0.07 (45) 0.05 (32)

Viscosity at 212 °F (100 °C) in2/s (mm2/s) 0.012 (7.97) 0.009 (6.40)

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)

Service Manual – SW4000 General Information 24

Dimensions

1330 mm (52.4 in)

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

P200092
Service Manual – SW4000 General Information 25

Maintenance
The lifespan of the machine and its maximum operating safety are ensured by correct and regular mainte-
nance.

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 defined by the person in charge of the maintenance.
For instructions on maintenance procedures, see the following paragraphs.

Scheduled Maintenance Table (SW4000 Battery)

Every Every Every Every
Upon Every
Procedure 10 50 100 200
delivery year
hours hours hours hours
Battery charging (1)
Battery (WET) fluid level check (2)
Side and main broom height check
Service brake cable adjustment (3)
Hopper dust filter check and cleaning (“A” method) (4)
Hopper hydraulic lifting system oil level check (2)
Skirt height and operation check
Dust guard system water filter check and cleaning
Hopper dust filter 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 filter 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)

(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 first 8 running-in hours.
(6) Change the hydraulic system oil for the first time after 500 hours, then every 2,000 hours or every year.
Service Manual – SW4000 General Information 26

Scheduled Maintenance Table (SW4000 Petrol/LPG)

Every Every Every Every
Upon Every
Procedure 10 50 100 200
delivery year
hours hours hours hours
Engine oil level check (1)
Battery fluid level check (2)
Side and main broom height check
Engine air filter check (1)
Service brake cable adjustment (3)
Hopper dust filter check and cleaning (“A” method) (4)
Hopper hydraulic lifting system oil level check (2)
Skirt height and operation check
Dust guard system water filter check and cleaning
Engine air filter cleaning (4) (4)
Hopper dust filter 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 filter trap cleaning
Engine baffle plate cleaning
Fuel filter cleaning (7)
Brake pad check/adjustment/replacement (3)
Hopper dust filter check and cleaning (“C” method) (4)
Main broom driving belt replacement
Hopper gasket integrity check
Lifted hopper sensor operation check/adjustment
Fuel valve filter cleaning (Petrol)
Engine paper air filter 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)

(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 first 20 running-in hours.
(7) Maintenance procedures to be performed by an authorised Honda dealer.
(8) Change the hydraulic system oil for the first time after 500 hours, then every 2,000 hours or every year.
Service Manual – SW4000 Chassis System 27

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.

1
P200093
Service Manual – SW4000 Control System 28

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.
Service Manual – SW4000 Control System 29

Dashboard Electronic Board Specifications

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 flashing. 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 flash). To reset,
turn the ignition key on and off (SW1).

P200219
Service Manual – SW4000 Control System 30

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 (fixed) V>22.0 V>22.2
2 Yellow LED on (fixed) 22.0>V>20.4 22.2>V>21.6
3 Red LED flashing V>20.4 V>21.6

When the red LED starts flashing, 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 flashes of the RED warning light
GEL 4 flashes 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 flashing 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).

E F

C
B
I
P200220
 Service Manual – SW4000 Control System 31

Wiring Diagram (SW4000 Battery)

POSITIVE SIGNAL
(FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

VACUUM SYSTEM FILTER SHAKER HOPPER LOWERING HOPPER LIFTING

RELAY (K1) RELAY (K2) RELAY (K3B) RELAY (K3A)

DISPLAY
ELECTRONIC
BOARD FUSE (F3)
HOPPER J1.1 - Electronic board power supply +
TEMPERATURE
SENSOR (S4) J1.14 - Electronic board configurator return
REVERSE GEAR J1.13 - Key return HOPPER ENABLING
BUZZER (BZ1) SWITCH (SW4)
J1.11 - Vacuum system relay power supply
HOPPER LIFTING/LOWERING
J1.12 - Filter-shaker relay power supply SWITCH (SW5)
DUSTGUARD™
SWITCH (SW8)
J2.4 - Control panel switch power supply (-)
J1.15 - Fire alarm signal
J2.2 - Vacuum system activation signal
CONTROL PANEL ELECTRONIC BOARD (EB2)

FILTER SHAKER/ J1.17 - Water pump activation signal DUSTGUARD™

VACUUM SYSTEM PUMP RELAY (K6)
J2.3 - Filter-shaker activation signal
SWITCH (SW3) MAIN BROOM
J2.1 - Control panel switch power supply (+) ELECTROMAGNETIC
J1.4 - Broom fuse voltage drop reading + SWITCH (ES1)

J1.5 - Broom fuse voltage drop reading -

J1.2 - Broom activation lever signal
HORN SWITCH (SW6)
J1.10 - Broom electromagnetic switch power supply
J1.8 - Lifted hopper signal B
HORN (HN) J1.7 - Drive system electronic board diagnostic signal C
J1.18 - Machine moving signal D
MAIN BROOM SIDE BROOM
J1.9 - Electronic board power supply - LEVER SENSOR (S3)
LEVER SENSOR (S2)
HOPPER LIFTING SIDE BROOM
SENSOR (S1) RELAY (K5)

E
P200094A
Service Manual – SW4000 Control System 32

Wiring Diagram (SW4000 Battery)

POSITIVE SIGNAL
(FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

EMERGENCY
PUSH-BUTTON (SW0)
LINE ELECTROMAGNETIC KEY CIRCUIT FUSE (F4)
SWITCH (ES0)

IGNITION KEY (SW1)

MACHINE ON
RELAY (K4)

DRIVE SYSTEM
ELECTRONIC BOARD (EB1)
WORKING
LIGHT SWITCH
(SW9)
J2.15 - Key input
WORKING
LIGHT (L1)
WORKING
B J2.11 - Lifted hopper input LIGHT (L2)
C J2.10 - Diagnostic warning light output MACHINE ON
RELAY (K4)
D J2.7 - Machine moving signal

E
P200094B
 Service Manual – SW4000 Control System 33

Wiring Diagram (SW4000 Petrol/LPG)

POSITIVE SIGNAL
(FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

A
DISPLAY ELECTRONIC
BOARD FUSE (F3) FILTER SHAKER HOPPER LOWERING HOPPER LIFTING
VACUUM SYSTEM
RELAY (K1) RELAY (K2) RELAY (K3B) RELAY (K3A)

FUEL RESERVE
SENSOR (S4) J1.1 - Electronic board power supply +
J1.14 - Electronic board configurator return
REVERSE GEAR HOPPER ENABLING
J1.13 - Key return
BUZZER (BZ1) SWITCH (SW4)
J1.6 - Fuel reserve signal HOPPER LIFTING/LOWERING
J1.11 - Vacuum system relay power supply SWITCH (SW5)

J1.12 - Filter-shaker relay power supply DUSTGUARD™

SWITCH (SW8)
J2.4 - Control panel switch power supply (-)
J1.15 - Fire alarm signal
J2.2 - Vacuum system activation signal
CONTROL PANEL ELECTRONIC BOARD (EB2)

FILTER SHAKER/ J1.17 - Water pump activation signal DUSTGUARD™

VACUUM SYSTEM PUMP RELAY (K6)
J2.3 - Filter-shaker activation signal
SWITCH (SW3) MAIN BROOM
J2.1 - Control panel switch power supply (+) ELECTROMAGNETIC
SWITCH (ES1)
J1.4 - Broom fuse voltage drop reading +
J1.5 - Broom fuse voltage drop reading -
J1.2 - Broom activation lever signal
HORN SWITCH (SW6)
J1.10 - Broom electromagnetic switch power supply
J1.8 - Lifted hopper signal B
HORN (HN) J1.7 - Drive system electronic board diagnostic signal C
J1.18 - Machine moving signal D
MAIN BROOM SIDE BROOM LEVER
J1.9 - Electronic board power supply - SENSOR (S3)
LEVER SENSOR (S2)
HOPPER LIFTING SIDE BROOM
SENSOR (S1) RELAY (K5)

E
P200095A
Service Manual – SW4000 Control System 34

Wiring Diagram (SW4000 Petrol/LPG)

POSITIVE SIGNAL
(FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

KEY CIRCUIT FUSE (F4)

LINE EMERGENCY PUSH-BUTTON (SW0)

ELECTROMAGNETIC
SWITCH (ES0) IGNITION
KEY (SW1)

ENGINE SPARK
PLUG (SPK)

FRAME (FR)

MACHINE ON
DRIVE SYSTEM ELECTRONIC RELAY (K4)
BOARD (EB1)
WORKING LIGHT
DIODE
SWITCH (SW9) (D3)
J2.15 - Key input
WORKING
LIGHT (L1)
WORKING
B J2.11 - Lifted hopper input LIGHT (L2)

C J2.10 - Diagnostic warning light output LPG SAFETY TIMER

RELAY (KT1)
D J2.7 - Machine moving signal

LPG SAFETY
SOLENOID VALVE (EV1)

Only for LPG version ENGINE START

ELECTROMAGNETIC
SWITCH (ES2)
P200095B
Service Manual – SW4000 Control System 35

Component Locations
• Dashboard
• Dashboard electronic board (EB2)
• Ignition key (SW1)

Dashboard
electronic Dashboard
board (EB2)

Ignition key
(SW1)

P200096
Service Manual – SW4000 Control System 36

Troubleshooting
Trouble Possible Cause Remedy
(For SW4000 Battery) The battery connector is disconnected. Connect the battery connector.
When turning the ignition key to “II”, the
The fuse (F3) and/or (F0) is open. Check/replace the fuses.
display does not turn on and the machine
does not operate. The emergency push-button has been Check and release the emergency push-
pressed. button.
(For SW4000 Petrol/LPG) Decrease the main broom pressure on the
“L O U” (A) (Low Voltage) display indication floor.
“L O U” (A) (Low Voltage) display indication
Battery voltage lower than 24.0 V.
If the problem persists, it may be necessary
to calibrate the engine rpm (see Petrol
Engine – LPG Engine chapter).
(For SW4000 Petrol/LPG) Turn off the engine each time the machine is
“H I U” (A) (High Voltage) flashing display stopped.
indication Battery voltage higher than 32.4V. If the problem persists, it may be necessary
to calibrate the engine rpm (see Petrol
Engine chapter).

P200247
Service Manual – SW4000 Control System 37

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
Service Manual – SW4000 Control System 38

Connectors on the dashboard electronic board

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

18 17 16 15 14 13 12 11 10
A
9 8 7 6 5 4 3 2 1

P200221

PIN Description Electronic V ref. I max. Connected to

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 configurator 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

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

Service Manual – SW4000 Control System 39

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
status (V, toll.±0,1)

WET GEL

1 LED (A) Green fixed <=> LED (B) Yellow fixed 22,0 22,2

2 LED (B) Yellow fixed <=> LED (C) Red flashing 1Hz 20,4 21,6

C B A

P200247b
The change status is filtered 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 fixed. The only way to
reset the status is the machine switching off by using the ignition key (SW1).
Service Manual – SW4000 Control System 40

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 fixed to 2.750 rpm ± 50 rpm

The fixed 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) flashed, if
are not matched for more than 5 consecutive minutes the following conditions:

Shown on display Battery conditions Solution Alternative actions in case the

solution does not solve the problem

LOU V < 24,0V (Low Voltage) Avoid using the machine for long Recharge the battery with a suitable
periods at maximum power or on charger and then adjust the engine RPM
slopes: leave the engine running with (increase the engine RPM till reach
all features turned off for at least ten again the recommended tension ranges).
minutes after each usage.

HIU V > 32,4V (High Turn the engine off when you are not Adjust the RPM engine (reduce the
Voltage) working: do not leave the machine engine RPM till reach again the
for long periods without using any recommended tension ranges).
functions.

A B A B
P200247a
Service Manual – SW4000 Control System 41

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

4 3
2 1

P200098

PIN Description Electronic V ref. I max. Connected to

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

Service Manual – SW4000 Control System 42

Removal and Installation

Dashboard Electronic Board Disassembly/Assembly

Disassembly 7. Retrieve the fairing (B).

1. Drive the machine on a level floor. 8. Under the left side of the control panel,
disconnect the connectors (E) of the dashboard
2. Turn the ignition key to “0” and engage the electronic board (F).
parking brake.
9. Disengage the four nuts (G) and remove the
3. 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
4. Remove the fastening screws (A) of the fairing
disassembly, and note the following:
(B) from the steering column.
• Set the type of batteries installed on the ma-
5. Slightly lift the steering column (B) by chine (see Electrical System chapter).
disengaging it from the lower fastener (C).

6. Disconnect the dust guard system quick coupling

(D).

A A
B
A

B
A D

G F G

P200101
Service Manual – SW4000 Dust Control System 43

Dust Control System

Functional Description
The dust raised in the compartment of the main broom, is collected in the rear cargo area by a flow of air gener-
ated by the dust control system.
The filter 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/filter 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 filter shaker.
There is an electric filter 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/filter 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 filter.
The vibrating motor shakes the filter allowing dirt trapped in the folds of the same to fall by gravity into the
hopper.
This reduces filter maintenance and helps to maintain proper airflow through the filter.

Wiring Diagram

DISPLAY ELECTRONIC VACUUM

SYSTEM RELAY (K1) FILTER SHAKER RELAY (K2)
BOARD FUSE (F3)
VACUUM
SYSTEM FUSE (F1)

J1.1 - Electronic board power supply +

FILTER SHAKER POSITIVE SIGNAL
FUSE (F2) (FROM MACHINE ON “K4”)
J1.11 - Vacuum system relay power supply
FILTER SHAKER/VACUUM
SYSTEM SWITCH (SW3) J1.12 - Filter-shaker relay power supply BATTERY NEGATIVE TERMINAL

J2.2 - Vacuum system activation signal

CONTROL PANEL ELECTRONIC DRIVE SYSTEM

BOARD (EB2) ELECTRONIC BOARD (EB1)

J2.3 - Filter-shaker activation signal

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

FILTER SHAKER RELAY (K2)

J1.2 - Broom activation lever signal
VACUUM SYSTEM RELAY (K1)
J1.8 - Lifted hopper signal J2.11 - Lifted hopper input
M1 M2 J1.18 - Machine moving signal J2.7 - Machine moving signal
J1.9 - Electronic board power supply -

FILTER SHAKER MOTOR MAIN BROOM

LEVER SENSOR (S2)
VACUUM SYSTEM MOTOR HOPPER LIFTING
SENSOR (S1)

P200102
Service Manual – SW4000 Dust Control System 44

Component Locations
• Filter shaker/vacuum system switch (SW3) • Panel filter
• 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
system switch (SW3)

Vacuum system
motor (M1)
Gasket

Panel filter

Filter shaker
motor (M2)

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

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

P200103
Service Manual – SW4000 Dust Control System 45

Maintenance and Adjustments

Panel Dust Filter Cleaning and Integrity Check

Caution! The dust filter must be regularly cleaned to maintain the efficiency of the vacuum
system. Follow the recommended filter service intervals for the longest filter life.

Warning! - Wear safety glasses when cleaning the filter.

- Do not puncture the filter.
- Clean the filter in a well-ventilated area.
- Wear appropriate dust mask to avoid breathing in dust.

1. Drive the machine on a level floor, 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).

B C B

B B
P200223
Service Manual – SW4000 Dust Control System 46

Panel Dust Filter Cleaning and Integrity Check (Continues)

6. (Only for LPG SW4000). Disconnect the filter 12. Assemble the dust filter in the reverse order of
shaker connector (K). disassembly and note the following:
• Clean the filter housing.
7. Loosen the knobs (D) and (E), then remove the • If the filter gasket is damaged or missing, it
filter shaker assembly (F), by sliding it forward, must be replaced.
disengaging it by the knobs (D) and then by the • Install the filter with the strainer facing up-
knobs (E). wards (arrow (I) upwards).
8. (Only for SW4000 Battery and Petrol). Fasten
the filter shaker assembly (F) to the holder (G). G

9. (Only for LPG SW4000). Remove the filter

shaker assembly (F).

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

11. Clean the dust filter using one of the methods

below: K E
E F
Method “A”
Vacuum loose dust from the filter. Gently tap the fil-
ter against a flat 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.

Method “B”
Vacuum loose dust from the filter. Blow compressed
air (maximum pressure 6 Bar) into the clean side of D H I D
the filter (in the opposite direction of the airflow). P200104

Method “C”
Vacuum loose dust from the filter. Then soak the filter
in warm water for 15 minutes, then rinse it under a
gentle stream of water (maximum pressure 2.5 Bar).
Let the filter dry completely before installing it back
into the machine.
For a better cleaning, it is allowed to wash the filter
with water and non-lathering detergents.
This provides better quality cleaning but reduces the
life of the filter, which will have to be replaced more
frequently. The use of inadequate detergents can
damage the filter.

Caution! For paper filter: Do not use

water or detergents to clean it,
otherwise it can be damaged.
Service Manual – SW4000 Dust Control System 47

Troubleshooting
Trouble Possible causes Remedy

Dust/debris vacuuming is insufficient The filter is clogged Clean the dust filter by using the filter shaker
or by disassembling it.

The vacuum system compartment gasket is Repair/replace

damaged

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

The switch (SW3) is not efficient Replace

The relay (K1) is not efficient Replace

The vacuum system is broken Repair/replace

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

The filter shaker is disconnected. Connect the filter shaker connector.

The switch (SW3) is not efficient Replace

The relay (K2) is not efficient Replace

The filter shaker is broken Repair/replace

Service Manual – SW4000 Dust Control System 48

Removal and Installation

Filter Shaker Motor Disassembly/Assembly

Disassembly

1. Drive the machine on a level floor, 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
Service Manual – SW4000 Dust Control System 49

Filter Shaker Motor Disassembly/Assembly (Continues)

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

7. Loosen the knobs (D) and (E), then remove the filter 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 filter shaker motor
(I). Retrieve the washers (J).

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

Assembly

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

B C B

K E
E F

B B
D D

I
H

G
P200106
Service Manual – SW4000 Dust Control System 50

Electric Vacuum Fan Motor Amperage Check

Warning! This procedure must be performed by qualified personnel only.

1. Clean the dust filter.

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.

C
B

P200107
Service Manual – SW4000 Dust Control System 51

Electric Fan Disassembly/Assembly

Disassembly

1. Drive the machine on a level floor, 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).

B C B

B B
P200108
Service Manual – SW4000 Dust Control System 52

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

E
F

G H

J
J

K
J
H

P200109
Service Manual – SW4000 Dust Control System 53

Specifications
Values
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 filter 75 ft2 (7 m2)

Paper dust filter 75 ft2 (7 m2)

Main broom compartment vacuum 0.6 in H2O (14 mm H2O)

Service Manual – SW4000 Dust Guard System 54

Dust Guard System

Functional Description
The dust guard system sprays a thin film 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.

P200224

Wiring Diagram

DISPLAY ELECTRONIC
BOARD FUSE (F3)

DUSTGUARD™ DUSTGUARD™
J1.1 - Electronic board power supply + SWITCH (SW8)
PUMP FUSE (F5)

J1.17 - Water pump activation signal

CONTROL PANEL ELECTRONIC BOARD (EB2)

DUSTGUARD™
DUSTGUARD™ J1.10 - Broom electromagnetic switch power supply PUMP RELAY (K6)
PUMP RELAY (K6)

M8 POSITIVE SIGNAL
J1.9 - Electronic board power supply - (FROM MACHINE ON “K4”)

DUSTGUARD™ BATTERY NEGATIVE TERMINAL

PUMP MOTOR

P200110
Service Manual – SW4000 Dust Guard System 55

Component Locations
• Dust guard system switch (SW8) • Water filter
• Water tank • Spraying nozzle
• Tank filler • Dust guard system fuse (5 A) (F5)
• Water pump (M8)

Tank filler

Dust guard
system switch
(SW8)
Water tank

Water pump (M8)

Spraying
nozzle

Water filter

Dust guard
system fuse
(5 A) (F5)

P200111
Service Manual – SW4000 Dust Guard System 56

Maintenance and Adjustments

Dust guard System Water Filter Cleaning

Note: To prevent water from flowing out when cleaning the filter, turn on the dust guard
system and empty the system tank.

1. Drive the machine on a level floor.

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

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

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

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

Note: Install the gasket (D) and the filter strainer (E) properly on the transparent cover (C)
and on the holder (F).

D A

B
C

P200112
Service Manual – SW4000 Dust Guard System 57

Nozzle and Filter Cleaning

1. Drive the machine on a level floor.

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 filters (C) with compressed air. Remove any
calcium deposit. If necessary, replace the filters (C).

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

C
D
B
A
P200113
Service Manual – SW4000 Dust Guard System 58

Troubleshooting
Electrical components Electrical components Values

Little water comes out from The filter and/or nozzle is clogged Clean/replace
the spray nozzles
The water filter is clogged Clean/replace

The pump is not working Repair/replace

No water to the nozzles The water filter is clogged Clean/replace

The fuse (F5) is open Replace

The relay (K6) is not efficient Replace

Service Manual – SW4000 Dust Guard System 59

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
Service Manual – SW4000 Dust Guard System 60

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 filter assembly input hose (E).

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

8. Remove the holder assembly with pump and filter (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.

I H
F

E G
D

P200115
Service Manual – SW4000 Dust Guard System 61

Specifications
Values
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)
Service Manual – SW4000 Electrical System 62

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 in-
side 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 dif-
ference 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 acces-
sories 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).
Service Manual – SW4000 Electrical System 63

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 Dash-
board Electronic Board Specifications chapter).
All the circuits are protected by non-resettable fuses.

Battery Versions Petrol and LPG Versions

Pos. Type Nominal Nominal
Protected Function Protected Function
Size Size

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

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

SW4000 BATTERY SW4000 PETROL / LPG

F8 F0 FA FC F0 FA
F8
F7 F7
FR1 FR1
F6 F6
F5 FR2 F5 FR2

F4 F4
F3 F3
F2 F2
F1 F1

P200116
Service Manual – SW4000 Electrical System 64

Relay/Electromagnetic Switch/Diodes
Battery Versions Petrol and LPG Versions
Pos. Nominal Nominal
Protected Function Protected Function
Size 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

SW4000 BATTERY SW4000 PETROL / LPG

ES1

ES2
ES1

K3B K3B

K3A K3A

ES0 K1 K2 K4 K5 K6 D1 ES0 KT1 K1 K2 K4 K5 K6

P200117
Service Manual – SW4000 Electrical System 65

Wiring Diagram (SW4000 Battery)

WITHOUT ON BOARD BATTERY CHARGER

KEY CIRCUIT
FUSE (F4)

IGNITION KEY MAIN FUSE (F0)

(SW1) EMERGENCY
PUSH-BUTTON (SW0)

CONNECTOR + (C1)

MACHINE ON
RELAY (K4) 24V BATTERY (BAT)

BATTERY CHARGER
(CH)

CONNECTOR - (C1)
POSITIVE SIGNAL
(FROM MACHINE ON “K4”) FLASHING
MACHINE ON LIGHT
RELAY (K4) (BE)
BATTERY NEGATIVE TERMINAL

P200118
Service Manual – SW4000 Electrical System 66

Wiring Diagram (SW4000 Petrol/LPG)

KEY CIRCUIT FUSE (F4)

EMERGENCY
CHARGE FUSE (FC) PUSH-BUTTON (SW0)
ENGINE START
ELECTROMAGNETIC
FUSE (F0)

SWITCH (ES2) IGNITION

ENGINE KEY (SW1)
MAIN

SPARK PLUG (SPK)

ENGINE

OIL
ALERT
DIODE (D1)

FRAME (FR)
24V BATTERY (BAT)

MACHINE ON
RELAY (K4)

POSITIVE SIGNAL
(FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

LPG SAFETY
TIMER RELAY (KT1) DIODE
(D3)
G
ENGINE ON RELAY (K4)
DYNAMOTOR (M5)

LPG SAFETY
SOLENOID VALVE (EV1)
FLASHING
LIGHT (BE)

Only for LPG version

ENGINE START
ELECTROMAGNETIC
SWITCH (ES2)
P200119
Service Manual – SW4000 Electrical System 67

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)

Electrical component
box
Batteries (BAT)

P200120
Service Manual – SW4000 Electrical System 68

Component Locations (SW4000 Petrol/LPG)

• Emergency push-button (SW0) • 8-way fuse holder
• Wiring harnesses • Main broom motor fuse (50 A) (FA)
• Flashing light (BE) • 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)
Wiring harnesses

Batteries (BAT) Electrical component

box

Right side broom

8-way fuse motor fuse (15 A)
holder (FR1)

(SW4000 P/LPG) Left side broom

Battery charge fuse motor fuse (15 A)
(80 A) (FC) (FR2)

Main broom
Main fuse
motor fuse (50 A)
(150 A) (F0)
(FA)

P200121
Service Manual – SW4000 Electrical System 69

Component Locations (Continues)

• Hopper lifting fuse (25 A - Battery) (30 A Petrol/ • Filter shaker motor fuse (25 A - Battery) (30 A
LPG) (F6) Petrol/LPG) (F2)
• Dust guard system fuse (5 A) (F5) • Vacuum system motor fuse (25 A - Battery) (30 A
• Main fuse (key circuit) (10 A) (F4) Petrol/LPG) (F1)
• Display electronic board fuse (3 A) (F3)

SW4000 Battery
Hopper lifting
fuse (25 A) (F6) Dust guard system
fuse (5 A) (F5)
Main fuse
(key circuit) Display electronic
(10 A) (F4) board fuse (3 A) (F3)
Filter shaker motor
fuse (25 A) (F2) Vacuum system
motor fuse
(25 A) (F1)

SW4000 Petrol / LPG

Hopper lifting fuse
(30 A) (F6) Dust guard system
fuse (5 A) (F5)
Main fuse
(key circuit)
Display electronic
(10 A) (F4)
board fuse (3 A) (F3)
Filter shaker
motor fuse Vacuum system
(30 A) (F2) motor fuse
(30 A) (F1)

P200096-2
Service Manual – SW4000 Electrical System 70

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 (fixed) V>22.0 V>22.2

2 Yellow LED on (fixed) 22.0>V>20.4 22.2>V>21.6

3 Red LED flashing V>20.4 V>21.6

(*) When the red LED starts flashing, 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 bat-
tery type as follows:
Battery Type Flashing pattern

WET 4 flashes of the RED warning light

GEL-AGM 4 flashes of the GREEN warning light

On Board Battery Charger Setting (SW4000 Battery)

EXTERNAL INTERNAL DIPSWITCHES (D) (*)
CHARGING CURVES
SWITCH (C) DIP1 DIP2 DIP3 DIP4 DIP5 DIP6 DIP7 DIP8
WET OFF ON/OFF ON/OFF ON/OFF OFF OFF OFF ON IUIa Pb-Acid Wet (SPE specifications)
GEL-AGM OFF ON ON ON OFF OFF OFF ON IUUa Gel-AGM generic (SPE specifications) (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

B
D

P200225
(*) Located under the label, in the dotted area
Service Manual – SW4000 Electrical System 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. This could cause dangerous short-
circuits.

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.

B C

E
BATTERY
PLUG

6V 6V F

6V 6V

A
P200226
Service Manual – SW4000 Electrical System 72

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 flashes:
• 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 flashing (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).

I
K

H L

P200124
Service Manual – SW4000 Electrical System 73

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).

D
J
B C

A
P200227
Service Manual – SW4000 Electrical System 74

Battery Voltage Check (SW4000 Petrol)

1. Drive the machine on a level floor.

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).
Service Manual – SW4000 Electrical System 75

Fuse Check/Replacement (SW4000 Battery)

7. Drive the machine on a level floor. 14. Check/replace the following fuses:
• (J): FA main broom motor fuse (50 A).
8. Turn the ignition key to “0” and engage the • (K): F0 main fuse (150 A).
parking brake.
15. Place the cover (I) and tighten screws.
9. Open the battery/engine compartment hood with
the handle and fasten it with the support rod.
Fuse Check
Disconnect the battery connector.
16. Check one of the following fuses for deactivation:
Lamellar Fuse Check/Replacement • (L): FR1 right side broom motor fuse (15 A)
• (M): FR2 left side broom motor fuse (15 A)
10. On the electrical component box, remove the
fuse box cover (A). Reset any deactivated fuse, when the component
that caused deactivation has fully cooled down.
11. Check/replace the relevant fuse among the
following:
Reassembly
• (B): F1 vacuum system motor fuse (25 A).
• (C): F2 filter shaker motor fuse (25 A). 17. Connect the batteries.
• (D): F3 display electronic board fuse (3 A).
• (E): F4 main fuse (key circuit) (10 A). 18. Remove the support rod and close the battery/
• (F): F5 dust guard system fuse (5 A). engine hood.
• (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).

A H K J I M L H

25A F
5A

10A E
3A

25A D
25A

B
P200222
Service Manual – SW4000 Electrical System 76

Fuse Check/Replacement (SW4000 Petrol/LPG)

1. Drive the machine on a level floor. 8. Check/replace the following fuses:
• (J): FA main broom motor fuse (50 A).
2. Turn the ignition key to “0” and engage the • (K): F0 main fuse (150 A).
parking brake. • (L): FC battery fuse (80 A)
3. Open the battery/engine compartment hood with 9. Place the cover (I) and tighten screws.
the handle and fasten it with the support rod.
Disconnect the batteries.
Fuse Check

Lamellar Fuse Check/Replacement 10. Check one of the following fuses for deactivation:
• (M): FR1 right side broom motor fuse (15 A)
4. On the electrical component box, remove the • (N): FR2 left side broom motor fuse (15 A)
fuse box cover (A).
Reset any deactivated fuse, when the component
5. Check/replace the relevant fuse among the that caused deactivation has fully cooled down.
following:
• (B): F1 vacuum system motor fuse (30 A).
Reassembly
• (C): F2 filter shaker motor fuse (30 A).
• (D): F3 display electronic board fuse (3 A). 11. Connect the batteries.
• (E): F4 main fuse (key circuit) (10 A).
• (F): F5 dust guard system fuse (5 A). 12. Remove the support rod and close the battery/
• (G): F6 hopper lifting fuse (30 A). engine hood.

6. Reinstall the fuse box cover (A).

7. Remove the screws (H), then remove the

electrical component box cover (I).

A H L K J I N M H

30A F
5A

10A E
3A

30A D
30A

P200100
Service Manual – SW4000 Electrical System 77

Troubleshooting
Trouble Possible causes Remedy

The machine is not working The batteries are discharged or its connections are not Charge the batteries or clean/repair the
efficient connections

The batteries are broken Check the battery no-load voltage

(SW4000 Battery) Replace

The battery charger is broken

(SW4000 Petrol/LPG) Repair

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

Service Manual – SW4000 Electrical System 78

Removal and Installation

Battery Charger Disassembly/Assembly (SW4000 Battery)

Disassembly

1. Drive the machine on a level floor.

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.

E E

D F

E
E
P200125
Service Manual – SW4000 Electrical System 79

Dynamotor Carbon Brush Check/Replacement (SW4000 Petrol)

Disassembly

1. Drive the machine on a level floor.

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).

P200122
Service Manual – SW4000 Electrical System 80

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 insufficient
• 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.

G
I

P200123
Service Manual – SW4000 Electrical System 81

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 flush
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 baffle plate (H).

N G

B
G
A D

C
P200228
Service Manual – SW4000 Electrical System 82

Dynamotor Disassembly/Assembly (SW4000 Petrol) (Continues)

7. Place a lever between the flange (I) of the dynamotor and the flange (J), then by means of the lever itself
push the dynamotor in the direction of the arrow (K); in this condition, give a firm 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.

A I J
K

P200126
 VACUUM SYSTEM
MOTOR

M1
VACUUM SYSTEM RELAY (K1)
VACUUM SYSTEM
Service Manual – SW4000

FILTER SHAKER
MOTOR FUSE (F1)

M2
FILTER SHAKER RELAY (K2)
FILTER SHAKER
POSITIVE SIGNAL

HOPPER LIFTING RELAY (K3A) HOPPER FUSE (F2)

PUMP FUSE (F6)
(FROM MACHINE ON “K4”)

HOPPER
BATTERY NEGATIVE TERMINAL

M3
PUMP MOTOR

RIGHT SIDE HOPPER LOWERING RIGHT SIDE BROOM

BROOM MOTOR RELAY (K3B) RESET FUSE (FR1)

M6
LEFT SIDE
BROOM MOTOR
RELAY (K5)
General Wiring Diagram (SW4000 Battery)

SIDE BROOM

M7
DUSTGUARD™ LEFT SIDE BROOM
PUMP MOTOR RESET FUSE (FR2)

M8
MAIN BROOM
MOTOR DUSTGUARD™ DUSTGUARD™
PUMP RELAY (K6) PUMP FUSE (F5)

FUSE (FA)
MAIN BROOM
M4
MAIN BROOM

SWITCH (ES1)

F
C
B
A
ELECTROMAGNETIC

P200127A
Electrical System
83
 F
C
B
A
Service Manual – SW4000

FILTER SHAKER/VACUUM
SYSTEM SWITCH (SW3)
HORN (HN)
DISPLAY

HORN SWITCH (SW6)

ELECTRONIC
POSITIVE SIGNAL

BOARD FUSE (F3)

(FROM MACHINE ON “K4”)

CONTROL PANEL ELECTRONIC BOARD (EB2)

BATTERY NEGATIVE TERMINAL

HOPPER VACUUM SYSTEM

ENABLING RELAY (K1)
SWITCH (SW4) FILTER SHAKER

SENSOR (S1)
RELAY (K2)

HOPPER LIFTING
General Wiring Diagram (SW4000 Battery)

SENSOR (S4)

SENSOR (S2)
HOPPER TEMPERATURE

HOPPER LOWERING
RELAY (K3B)

MAIN BROOM LEVER

HOPPER LIFTING

RELAY (K5)
SIDE BROOM
RELAY (K3A)
HOPPER
LIFTING/LOWERING
DUSTGUARD™ SWITCH (SW5)
PUMP RELAY (K6)
MAIN BROOM DUSTGUARD™
ELECTROMAGNETIC SWITCH (SW8)

SIDE BROOM
SWITCH (ES1)

LEVER SENSOR (S3)

F
E
D
C
B
A
Electrical System

P200127B
84
Service Manual – SW4000 Electrical System 85

General Wiring Diagram (SW4000 Battery)

WITHOUT ON BOARD BATTERY CHARGER

POSITIVE SIGNAL
(FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

REVERSE GEAR
BUZZER (BZ1)

KEY CIRCUIT EMERGENCY

LINE ELECTROMAGNETIC PUSH-BUTTON (SW0)
SWITCH (ES0) FUSE (F4)
IGNITION KEY

FUSE (F0)
(SW1)

MAIN
DRIVER’S SEAT

MICROSWITCH

LINE ELECTR.
SWITCH (ES0)
SAFETY

B
(SW7)

CONNECTOR + (C1)
FORWARD/REVERSE
GEAR SWITCH (SW2)

MACHINE ON
RELAY (K4)

24V BATTERY (BAT)

DRIVE SYSTEM ELECTRONIC BOARD (EB1)

WORKING LIGHT
SWITCH (SW9)

BATTERY CHARGER
ACCELERATOR

(CH)

CONNECTOR - (C1)
PEDAL (R1)

M0 MACHINE ON
RELAY (K4)
WORKING LIGHT (L1)

WORKING LIGHT (L2)

DRIVING
WHEEL
C
FLASHING
D LIGHT (BE)
E

P200127C
 MAIN
DYNAMOTOR (M5) 24V BATTERY (BAT) FUSE (F0)

G
DIODE (D1)
ENGINE ON RELAY (K4)
Service Manual – SW4000

VACUUM
SYSTEM MOTOR
POSITIVE SIGNAL

SWITCH (ES2)

M1
ENGINE START
VACUUM SYSTEM RELAY (K1)
FILTER SHAKER VACUUM SYSTEM
CHARGE FUSE (FC)

FUSE (F1) ELECTROMAGNETIC

(FROM MACHINE ON “K4”)

MOTOR
BATTERY NEGATIVE TERMINAL

M2
FILTER SHAKER RELAY (K2)
FILTER SHAKER
HOPPER LIFTING RELAY (K3A) HOPPER FUSE (F2)
PUMP FUSE (F6)

HOPPER

M3
PUMP MOTOR
HOPPER
LOWERING RIGHT SIDE BROOM
RIGHT SIDE
RELAY (K3B) RESET FUSE (FR1)
BROOM MOTOR

M6
General Wiring Diagram (SW4000 Petrol - LPG)

LEFT SIDE
BROOM MOTOR

M7
RELAY (K5)
SIDE BROOM

DUSTGUARD™ LEFT SIDE BROOM

PUMP MOTOR RESET FUSE (FR2)

M8
MAIN BROOM
MOTOR DUSTGUARD™ DUSTGUARD™
PUMP RELAY (K6) PUMP FUSE (F5)

M4
MAIN BROOM
ELECTROMAGNETIC

MAIN BROOM FUSE (FA)

SWITCH (ES1)

F
A

C
B

P2001272A
Electrical System
86
 F
A

C
B
Service Manual – SW4000

HORN (HN)
DISPLAY

FILTER SHAKER/VACUUM
HORN SWITCH (SW6) SYSTEM SWITCH (SW3)
POSITIVE SIGNAL

ELECTRONIC
BOARD FUSE (F3)
(FROM MACHINE ON “K4”)

CONTROL PANEL ELECTRONIC BOARD (EB2)

BATTERY NEGATIVE TERMINAL

HOPPER VACUUM SYSTEM

RELAY (K1)

SENSOR (S1)
ENABLING
SWITCH (SW4) FILTER SHAKER

HOPPER LIFTING
RELAY (K2)
SENSOR (S4)

SENSOR (S2)
General Wiring Diagram (SW4000 Petrol - LPG)

HOPPER LOWERING
HOPPER TEMPERATURE

RELAY (K3B)

MAIN BROOM LEVER

RELAY (K5)
HOPPER LIFTING

SIDE BROOM
RELAY (K3A)
HOPPER LIFTING/
LOWERING
DUSTGUARD™ SWITCH (SW5)
PUMP RELAY (K6)
DUSTGUARD™
MAIN BROOM SWITCH (SW8)
ELECTROMAGNETIC

SENSOR (S3)
SWITCH (ES1)

SIDE BROOM LEVER

F
E
D
C
B
A

P2001272B
Electrical System
87
 Service Manual – SW4000 Electrical System 88

General Wiring Diagram (SW4000 Petrol - LPG)

POSITIVE SIGNAL
(FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

REVERSE GEAR
BUZZER (BZ1) KEY CIRCUIT FUSE (F4)

A
EMERGENCY
DIODE (D2) PUSH-BUTTON (SW0)
LINE ELECTROMAGNETIC
SWITCH (ES0)
IGNITION
ENGINE KEY (SW1)
SPARK PLUG (SPK)
DRIVER'S SEAT

MICROSWITCH

LINE ELECTR.
SWITCH (ES0)
ENGINE
SAFETY

B OIL
(SW7)

FORWARD/REVERSE GEAR ALERT

FRAME (FR)
SWITCH (SW2)
DRIVE SYSTEM ELECTRONIC BOARD (EB1)

MACHINE ON
RELAY (K4)
WORKING LIGHT
SWITCH (SW9)
ACCELERATOR
PEDAL (R1)

DIODE
TIMER RELAY (KT1)

(D3)
LPG SAFETY

M0
SOLENOID VALVE (EV1)

DRIVING
WORKING LIGHT (L2)
WORKING LIGHT (L1)

WHEEL
C
D
LPG SAFETY

Only for LPG version ENGINE START

ELECTROMAGNETIC
SWITCH (ES2)
P2001272C
Service Manual – SW4000 Electrical System 89

Specifications
Values
Electrical components
SW4000 Battery SW4000 Petrol SW4000 LPG

Total absorbed power 2.7 hp (2.0 kW)

Values
Batteries
SW4000 Battery

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)

Values
Battery charger
SW4000 Battery

Input 230V ± 15% 50/60Hz (Imax:15A)

Output 24V 30A

Efficiency >90%

Min. Vbatt 2V

Casing protection IP30

Values
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)

Values
Electrical components
SW4000 Battery SW4000 Petrol SW4000 LPG

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

Service Manual – SW4000 Engine System - Petrol 90

Engine System - Petrol

Functional Description
The engine system generates electric current for all The fuel tank is fastened outside the engine, in the
machine functions. rear side of the machine. The tank has a fuel level in-
The assembly consists of an internal combustion en- dicator with float, and a valve with integrated filter.
gine and dynamotor, which are both connected to the The choke lever on the engine has been extended in
main crankshaft. order to be easily activated from the driver’s seat po-
The engine is a single-cylinder air-cooled petrol type. sition.
The engine start-up is made by the dynamotor to The fuel reserve warning light turns on when the fuel
which it is connected. in the tank is less than 2.2 liters.
The dynamotor acts as a starter, using the battery
only for the time necessary to start the engine. The engine is equipped with an oil level sensor (Oil
At a later stage, the running engine supplies the Alert), which purpose is to avoid damages caused by
power to the dynamotor to generate the current and an insufficient oil quantity in the oil pan. Before the
to power the electrical systems of the machine. The oil level goes below the safety limit, the system (Oil
surplus current is used to charge the batteries. Alert) automatically stops the engine shorting the
The engine speed is fixed, 2,750 rpm, to grant a con- spark plug to the chassis..
stant current to the electrical system. If the engine stops and do not restart, check the en-
gine oil level before doing any other troubleshooting
procedure.

Wiring Diagram
KEY CIRCUIT
FUSE (F4)

EMERGENCY
PUSH-BUTTON (SW0)

IGNITION
ENGINE KEY (SW1)
SPARK PLUG (SPK)

ENGINE

OIL
ALERT

FRAME (FR)

MACHINE ON
RELAY (K4)

ENGINE START
ELECTROMAGNETIC
SWITCH (ES2)

P200128
Service Manual – SW4000 Engine System - Petrol 91

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
Service Manual – SW4000 Engine System - Petrol 92

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 Specifications paragraph.

A A B

C D

P200130
Service Manual – SW4000 Engine System - Petrol 93

Engine Air Filter Cleaning Check

Caution! Running the engine without air 11. Assemble the foam filter (D) on the paper filter
filters, or with damaged filters, (E), then assemble the filter element. Ensure
can cause a faster engine that the gasket (H) is properly placed under the
wearing. filter element. Screw down the filter element
wing nut (C).
1. Drive the machine on a level ground and engage 12. Install the cover (B) and screw down the wing
the parking brake. nut (A).
2. Turn the ignition key to “0”. 13. Perform steps 4 and 3 in the reverse order.
3. Open the engine compartment hood with the
handle and fasten it with the support rod. A
4. Lift and disassemble the right side bulkhead.
B
5. Remove the wing nut (A) and remove the cover
(B).

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

filter element.

7. Separate the foam filter (D) from the paper filter

(E). C
8. Check both filters and replace them if necessary.
Replace the paper filter (D) when required (see
the scheduled maintenance table). E
9. To use again the filters, clean them as shown
below:
• Paper filter (E): Hit the filter several times
D
against a hard surface to remove the dust, or H
blow compressed air (no more than 207 kPa
(2.1 kgf/cm)) from inside the filter. Do not use
a brush, otherwise the fibre will be damaged. G
• Foam filter (D): Clean with warm water
and soap, rinse and let it dry completely, or
clean with a non-flammable solvent and let it
F
dry. Soak the filter 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 filter. Pay attention to avoid that
dirt enters the air duct (G) to the carburettor.

P200131
Service Manual – SW4000 Engine System - Petrol 94

Engine Oil Level Check

Caution! Running the engine with a

low oil level can damage the
engine itself.
A

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. B

1. Drive the machine on a level ground and engage

the parking brake.

2. Turn the ignition key to “0”. A

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

4. Lift and disassemble the right side bulkhead.

5. Remove the oil filler plug/dipstick (A) and clean

it.

6. Insert the oil filler plug/dipstick in the filler 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
specified oil up to the upper limit mark (D) C
(lower edge of the oil filling hose). Do not overfill.
P200132

8. Install the oil filler plug/dipstick (A).

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

Service Manual – SW4000 Engine System - Petrol 95

Engine Oil Change

Caution! The discharged engine oil

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

Note: It is advisable to change the oil A

when the engine is still hot, to
make the oil downflow easier.

1. Drive the machine on a level ground and engage

the parking brake.

2. Turn the ignition key to “0”.

B
3. Open the engine compartment hood with the
handle and fasten it with the support rod.
E
4. Lift and disassemble the right side bulkhead.

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

A
hose (E) in a position that eases the oil drain,
then remove the plug (F).
D

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 filler neck (B) up to the

upper limit mark (D) (lower edge of the oil filling
hose) on the dipstick.
P200133
Note: For the engine oil type and
quantity, see Specifications
paragraph.

9. Install the oil filler plug/dipstick (A) and tighten

it.

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

Service Manual – SW4000 Engine System - Petrol 96

Engine Filter Trap Cleaning

Warning! The petrol is highly flammable and explosive, it can burn or cause serious injuries.
Turn off the engine, and keep it far from sparks, flames 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 filter cup (B) and the O-ring (C).

6. Wash the fuel filter trap (B) and the O-ring (C) with a non-flammable solvent, then dry them accurately.

7. Place the O-ring (C) and assemble the filter 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.

ON

OFF

A
C

P200134
Service Manual – SW4000 Engine System - Petrol 97

Engine Spark Plug Check/Replacement

For the type of spark plug to be used, see Technical 12. When the original spark plug is reinstalled,
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 Note: A loose spark plug can overheat
damage the engine. and damage the engine. Do
not overtighten, otherwise the
threads in the cylinder head
can be damaged.
1. Drive the machine on a level ground and engage
the parking brake.
13. Perform steps 4 and 3 in the reverse order.
2. Turn the ignition key to “0”.

3. Open the engine compartment hood with the A

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). C
7. Check the spark plug. Replace it if it is
damaged, dirty, if the sealing washer (B) is 0.70 - 0.80mm
damaged or if the electrode is worn.

8. Measure the distance between the spark plug

electrodes with a feeler gauge. Correct the B
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. P200135

11. When a new spark plug is installed, tighten 1/2

turn once the spark plug is in place to press the
washer.
Service Manual – SW4000 Engine System - Petrol 98

Engine Baffle Plate Cleaning

Warning! If the engine was running, the

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

1. Drive the machine on a level ground and engage

the parking brake.

2. Turn the ignition key to “0”. B A

3. Open the engine compartment hood with the E
handle and fasten it with the support rod. F
E
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). D C
7. Remove the screws (E) and carefully remove
silencer guard (F).
A

8. Remove the screw (G) and remove the baffle

plate (H) from the silencer.
G
9. Use a brush to remove the carbon deposits from
the baffle plate shield (I). Take care not to cause
damage to the shield. Replace the baffle plate if H
it cracked or perforated.

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

11. Assemble the components in the reverse order of

disassembly.

I
P200136
Service Manual – SW4000 Engine System - Petrol 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.

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

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

The spark plug (SPK) is wetted with fuel Dry the spark plug and reinstall it. Start the
engine with the choke lever turned to MAX
position.

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 engine loses power or The filter element or elements are clogged Clean or replace the filter elements
stops during operation.
Low quality of the fuel Drain the tank and refuel with fresh petrol

The fuel filter is clogged, the carburettor is broken, the Replace or repair the faulty components as
start system is broken, the valves are locked, etc. necessary (take the engine to an authorized
Honda service centre)

The display shows the LOU The working conditions are disadvantageous for the Decrease the main broom pressure on the floor.
code. batteries.
Avoid driving uphill for long.

Turn off the working lights.

If the problem persist, maybe it is necessary to

calibrate the engine rpm.

The display shows the HIU The battery charge is excessive. Turn off the engine each time the machine is
code. stopped.

If the problem persist, maybe it is necessary to

calibrate the engine rpm.
Service Manual – SW4000 Engine System - Petrol 100

Removal and Installation

Engine-Dynamotor Unit Disassembly/Assembly

Disassembly

1. Drive the machine on a level floor.

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 fittings to prevent foreign materials from entering into the system.

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

P200137
Service Manual – SW4000 Engine System - Petrol 101

Engine-Dynamotor Unit Disassembly/Assembly (Continues)

8. Disconnect the wiring harnesses (F) of the dynamotor (G) from the electrical cable (H) and the batteries
(I) (mark each position for proper reassembly).

9. Disconnect the engine start electrical connector (J).

10. Disconnect the engine ground (K).

11. Remove the four fastening nuts (L) of the engine holder (M).

12. Remove the fastening screws and then remove the case (N).

13. Disengage the engine oil drain hose (P), from the fastening clamps (Q).

14. Place a proper and safe lifting belt (R) transversally on the flange (S), as shown in the figure (the belt (R)
have to slide smoothly along the dynamotor).

15. With a proper hoisting system, carefully lift the dynamotor assembly and let it swing slightly to avoid
the obstacles (Weight of the engine-dynamotor unit: 40 kg)

Assembly

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

H
N

F I
S

M
L

Q
J

K P
Q
P200138
Service Manual – SW4000 Engine System - Petrol 102

Engine Unit Disassembly/Assembly

Disassembly

1. Remove the engine-dynamotor unit (see the procedure in the previous paragraph).

2. Remove the dynamotor unit (see the procedure in Electrical System paragraph).

3. Remove the screws (A) and separate the engine assembly (B) from the holder (C). Engine weight: 24 kg
approx.

4. If necessary, unscrew the three screws (D) and remove the air deflector (E) from the engine.

Assembly

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

A
A
P200139
Service Manual – SW4000 Engine System - Petrol 103

Specifications
Values
Engine System - Petrol
SW4000 Petrol

Make Honda

Model GX-200

Regulated power (ISO 1585) 6.7 kW

Working speed 2,750 ± 50 rpm

Oil type SAE 5 W 30 - SYNTHETIC API SJ

Average consumption 0.45 gph US (1.7 liters/hour)

Fuel tank capacity 2.0 gal US (7.8 liters)

Reserve 0.6 gal US (2.2 liters)

Length Width Height (engine only) 12.3 x 14.8 x 13.2 in (313 x 376 x 335 mm)

Displacement (bore x stroke) 12 in3 [2.68 x 2.13 in] (196 cm3 [68 x 54 mm])

Maximum output 4.8 kW (6.5 PS) at 3,600 min (rpm)

Max torque 117 lbf•in - 2,500 rpm (min) (13.2 N•m (1.35 kgf•m) at 2,500 min (rpm))

Engine oil quantity 0.16 gal US (0.60 liters)

Cooling system Forced air

Starting system Transistor magnet

PTO shaft rotation Counter-clockwise

Distance between the spark plug electrodes 0.028 - 0.031 in (0.70 - 0.80 mm)

Idle speed 1,400 min (rpm)

INTAKE: 0.0059 ± 0.00079 in (0.15 ± 0.02 mm)

Valve clearance (cold)
EXHAUST: 0.0079 ± 0.00079 in (0.20 ± 0.02 mm)

Unleaded fuel

U.S.A.: Pump octane number not less than 86

Fuel
Except in the U.S.A.: Research octane number not less than 91

Except in the U.S.A.: Pump octane number not less than 86

BPR6ES (NGK)
Spark plug
W20EPR-U (DENSO)
Service Manual – SW4000 Engine System - LPG 104

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. lowers the gas pressure, which then reaches the car-
The assembly consists of an internal combustion en- burettor.
gine and dynamotor, which are both connected to the The LPG system is protected against any overpres-
main crankshaft. sure by a relief valve which activates at 27 atm (400
The engine is a single-cylinder air-cooled LPG type. PSI). The fuel reserve warning light turns on when
The engine start-up is made by the dynamotor to the sensor in the power supply system detects a pres-
which it is connected. sure lower than 1.1. bar.
The dynamotor acts as a starter, using the battery For safety reasons, if the engine is not started (igni-
only for the time necessary to start the engine. At a tion key to “II”) within 2/3 seconds after turning on
later stage, the running engine supplies the power to the control panel (ignition key to “I”), the safety sole-
the dynamotor to generate the current and to power noid valve automatically closes the gas power supply.
the electrical systems of the machine. The surplus The engine is equipped with an oil level sensor (Oil
current is used to charge the batteries. Alert), which purpose is to avoid damages caused by
The engine speed is fixed, 2,750 rpm, to grant a con- an insufficient oil quantity in the oil pan. Before the
stant current to the electrical system. oil level goes below the safety limit, the system (Oil
The LPG tank is fastened to the relevant holder in the Alert) automatically stops the engine. If the engine
rear side of the machine and connected to the power stops and do not restart, check the engine oil level
supply system with a hose and a double safety valve. before doing any other troubleshooting procedure.
When turning the ignition key, the safety solenoid
valve opens, the liquid gas passes through the filter
in the solenoid valve, thus reaching the pressure re-
ducer.

Wiring Diagram
KEY
CIRCUIT FUSE (F4)

EMERGENCY
PUSH-BUTTON (SW0)

IGNITION
ENGINE KEY (SW1)
SPARK PLUG (SPK)

ENGINE

OIL
ALERT

FRAME (FR)
MACHINE ON
RELAY (K4)

LPG SAFETY
TIMER RELAY (KT1)

DIODE
LPG SAFETY (D3)
SOLENOID VALVE (EV1)

ENGINE START
ELECTROMAGNETIC
SWITCH (ES2)

P200140
Service Manual – SW4000 Engine System - LPG 105

Component Locations
• LPG tank fastening band • Hose
• LPG tank • Pipe
• LPG tank fitting • Safety valve
• LPG tank opening/closing valve • Diode (D3)

LPG tank
fitting LPG tank opening/
closing valve

LPG tank
Safety valve

LPG tank
fastening band

Hose

Pipe

Diode (D3)

P200141
Service Manual – SW4000 Engine System - LPG 106

Component Locations (Continues)

• LPG wiring harness • Hose
• Engine • Solenoid valve with filter (EV1)
• Hose • Pressure valve (reserve) (S4)
• LPG pressure regulator

LPG wiring harness

Engine

Solenoid valve
with filter (EV1) Hose

Pressure valve LPG pressure

(reserve) (S4) regulator

P200141-2
Service Manual – SW4000 Engine System - LPG 107

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 Specifications paragraph.

A A B

C D

P200130
Service Manual – SW4000 Engine System - LPG 108

Engine Air Filter Cleaning Check

Warning! Running the engine without air 11. Assemble the foam filter (D) on the paper filter
filters, or with damaged filters, (E), then assemble the filter element. Ensure
can cause a faster engine that the gasket (H) is properly placed under the
wearing. filter element. Screw down the filter element
wing nut (C).
1. Drive the machine on a level ground and engage 12. Install the cover (B) and screw down the wing
the parking brake. nut (A).
2. Turn the ignition key to “0”. 13. Perform steps 4 and 3 in the reverse order.
3. Open the engine compartment hood with the
handle and fasten it with the support rod. A
4. Lift and disassemble the right side bulkhead.
B
5. Remove the wing nut (A) and remove the cover
(B).

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

filter element.

7. Separate the foam filter (D) from the paper filter

(E). C
8. Check both filters and replace them if necessary.
Replace the paper filter (D) when required (see
the scheduled maintenance table). E
9. To use again the filters, clean them as shown
below:
• Paper filter (E): Hit the filter several times
D
against a hard surface to remove the dust, or H
blow compressed air (no more than 207 kPa
(2.1 kgf/cm)) from inside the filter. Do not use
a brush, otherwise the fibre will be damaged. G
• Foam filter (D): Clean with warm water
and soap, rinse and let it dry completely, or
clean with a non-flammable solvent and let it
F
dry. Soak the filter 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 filter. Pay attention to avoid that
dirt enters the air duct (G) to the carburettor.

P200131
Service Manual – SW4000 Engine System - LPG 109

Engine Oil Level Check

Caution! Running the engine with a

low oil level can damage the
engine itself.
A

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 B
start-up.

1. Drive the machine on a level ground and engage

the parking brake.
A
2. Turn the ignition key to “0”.
D
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 filler plug/dipstick (A) and clean

it.

6. Insert the oil filler plug/dipstick in the filler 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 C
specified oil up to the upper limit mark (D) P200132
(lower edge of the oil filling hose). Do not overfill.

8. Install the oil filler plug/dipstick (A).

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

Service Manual – SW4000 Engine System - LPG 110

Engine Oil Change

Caution! The discharged engine oil has

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

Note: It is advisable to change the oil A

when the engine is still hot, to
make the oil downflow easier.

1. Drive the machine on a level ground and engage

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

3. Open the engine compartment hood with the

handle and fasten it with the support rod. E
4. Lift and disassemble the right side bulkhead. A
5. Remove the oil filler plug/dipstick (A). Place the
D
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 filler neck (B) up to the

upper limit mark (D) (lower edge of the oil filling
hose) on the dipstick. P200133

Note: For the engine oil type and

quantity, see Specifications
paragraph.

9. Install the oil filler plug/dipstick (A) and tighten

it.

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

Service Manual – SW4000 Engine System - LPG 111

Engine Spark Plug Check/Replacement

For the type of spark plug to be used, see Technical 13. Perform steps 4 and 3 in the reverse order.
Data chapter.
A
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 C

handle and fasten it with the support rod.
0.70 - 0.80mm
4. Lift and disassemble the right side bulkhead.

5. Disconnect the spark plug cap and remove dirt

around the spark plug. B
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.

8. Measure the distance between the spark plug

P200135
electrodes with a feeler gauge. Correct the
distance by bending carefully the side electrode
(C). The distance between the electrodes has to
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.

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.
Service Manual – SW4000 Engine System - LPG 112

Engine Baffle Plate Cleaning

Warning! If the engine was running, the

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

1. Drive the machine on a level ground and engage

the parking brake.

2. Turn the ignition key to “0”. B A

3. Open the engine compartment hood with the E
handle and fasten it with the support rod. F
E
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). D C
7. Remove the screws (E) and carefully remove
silencer guard (F).
A

8. Remove the screw (G) and remove the baffle

plate (H) from the silencer.
G
9. Use a brush to remove the carbon deposits from
the baffle plate shield (I). Take care not to cause
damage to the shield. Replace the baffle plate if H
it cracked or perforated.

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

11. Assemble the components in the reverse order of

disassembly.

I
P200136
Service Manual – SW4000 Engine System - LPG 113

LPG System Leakage Check

Warning! This procedure has to be

performed by personnel C
qualified to handle the LPG
systems, according to the law
in force.
Moreover, it is necessary to
wear accident-prevention
clothes, according to the
law in force (heavy gloves, E
antistatic non-synthetic
clothes, suitable to cover the D A
whole body, antistatic and
antispark shoes, helmets with
visor; etc.).
B
1. After any maintenance or replacement
procedure involving operations on the fittings or
movement of LPG system components, check for
any LPG gas leaks as shown below.

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.

4. Remove the machine right body side, by lifting it

to disengage it from the fasteners.

5. If the engine is hot, wait that it cools down.

P200142
6. By proceeding as shown in the User Manual,
check that the fitting (A) of the hose (B) is
properly connected to the fitting (C) of the LPG
tank (D). Check that the valve (E) of the LPG
tank (D) is closed.
Service Manual – SW4000 Engine System - LPG 114

LPG System Leakage Check (Continues)

7. Apply evenly the spry product that detects gas leaks “SUPER BALL, OFF. PROD. C.C.I.A.A. 186231
(VI)” (or equivalent) on all the fittings of the LPG system, starting from the LPG tank fitting (A) to the
fitting (F) between the hose and carburettor (G). Proceed according to the instructions on the package of
the spry product.

8. Open the LPG tank valve, then check for LPG gas leaks, shown by gas bubble development, on all LPG
system fittings, starting from LPG tank fitting (A) to the solenoid valve (H).

9. Turn the ignition key to the first position “I”, then check for LPG gas leaks, shown by gas bubble
development, on all LPG system fittings, starting from the solenoid valve (H) to the fitting (F).

10. In case LPG leaks are detected, it is necessary to open the relevant fittings, manage them as described,
then tighten them again (see the procedure in “LPG System Hose Removal/Installation”).
Perform again LPG System Leakage Check.

H
P200214
Service Manual – SW4000 Engine System - LPG 115

Solenoid Valve Filter Cleaning

Warning! This procedure has to be performed by personnel qualified to handle the LPG
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

1. Empty the LPG system (see the procedure in LPG System Emptying).

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.

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

5. Turn the fasteners and remove the machine right door.

6. If the engine is hot, wait that it cools down.

7. Unscrew the fitting (A).

Caution! For disassembly/assembly of the various hoses and fittings of the LPG system, refer
to the procedure in “LPG System Hose and Fitting Disassembly/Assembly”.

8. Loosen the retaining bands (B) and disconnect the hoses (C).

9. Disconnect the electrical connections (D) and (F).

F
D
B C

P200143
Service Manual – SW4000 Engine System - LPG 116

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).

12. At the workbench, remove the “T” fitting (I) from the fitting (L).

13. Remove the fitting (L) from the fitting (M) of the solenoid valve (N).

I L H

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Service Manual – SW4000 Engine System - LPG 117

Solenoid Valve Filter Cleaning (Continues)

14. Overturn the solenoid valve (N) and fasten its body on a vice (P) with soft jaws.

15. Unscrew the solenoid valve fitting (M).

16. Remove the filter holder (Q).

Inside the filter holder there is a cylinder with magnet (R) which will be cleaned and placed in the lower
side of the filter holder itself (as shown in the figure).

The filter holder gasket (S) has to be replaced with the corresponding spare part, before reassembly.

M M

N
P

Q Q

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Service Manual – SW4000 Engine System - LPG 118

Solenoid Valve Filter Cleaning (Continues)

17. Remove the filter (T).

The filter holder gasket (U) has to be replaced with the corresponding spare part, before reassembly.

18. Remove and discard the gaskets (U) and (S), then clean the filter (T), the flange (V) of the solenoid
valve body, the filter holder (Q) and the fitting (M) with compressed air (maximum pressure 6 Bar). If
necessary, replace the filter (T).

Take care in order not to damage the remaining part of the solenoid valve; do not sink the coil in solvent
or water.

Assembly

19. Assemble the components in the reverse order of disassembly, and note the following:
• On the solenoid valve, tighten the fitting (M) at the tightening torque of approximately 16.6 Nm (147
in Lbs).

20. Perform the LPG System Leakage Check (see the procedure in LPG System Leakage Check paragraph).

Q
M

U
T Q

U
S

V
P200230
Service Manual – SW4000 Engine System - LPG 119

CO2 Adjustment
Warning! This procedure has to be performed by personnel qualified to handle the LPG
systems, according to the law in force.

Check the CO2 emissions.

1. With the proper tool, check the engine CO2 emissions, according to the law in force in the country where
the machine is used.

2. If necessary, adjust the engine CO2 emission, according to the following procedure.

Adjustment

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

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

5. Remove the machine right body side, by lifting it to disengage it from the fasteners.

6. Remove the sealant from the housing (A) of the LPG pressure regulator (B).

7. Restart checking and adjusting the engine CO2 emissions, then adjust the emission value by turning the
screw (C) as necessary.

8. After adjusting, apply sealant to the housing (A).

Reassembly

9. Perform steps 4 and 5 in the reverse order.

A
C
B

P200145
Service Manual – SW4000 Engine System - LPG 120

Troubleshooting
Trouble Possible causes Remedy

The engine does not start The fuel does not reach the carburettor. Check that the tank valve is open (LPG)

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

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

The spark plug is damaged, dirty or the distance between Correct the distance between the electrodes and
the electrodes is wrong replace the spark plug

The spark plug is wetted with fuel Dry the spark plug and reinstall it. Start the
engine with the choke lever turned to MAX
position.

The spark plug 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 LPG safety relay (KT1) 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 engine loses power or The filter element or elements are clogged Clean or replace the filter elements
stops during operation.
Poor quality power supply Replace the tank.

The fuel filter is clogged, the carburettor is broken, the Replace or repair the faulty components as
start system is broken, the valves are locked, etc. necessary (take the engine to an authorized
Honda service centre)

The display shows the LOU The working conditions are disadvantageous for the Decrease the main broom pressure on the floor.
code. batteries.
Avoid driving uphill for long.

Turn off the working lights.

If the problem persist, maybe it is necessary to

calibrate the engine rpm.

The display shows the HIU The battery charge is excessive. Turn off the engine each time the machine is
code. stopped.

If the problem persist, maybe it is necessary to

calibrate the engine rpm.
Service Manual – SW4000 Engine System - LPG 121

Removal and Installation

LPG System Emptying

Warning! This procedure has to be performed by personnel qualified to handle the LPG
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.).

1. Before operating on the LPG system for maintenance/replacement of parts, bleed the LPG system, as
shown below.

2. Close the LPG tank valve.

3. Start the engine and let it run until it stops because it has run out of LPG.

Warning! This procedure has to be performed where there is a proper ventilation and under
the SAFETY conditions indicated in this Manual.

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

5. The LPG system is empty. In the next phases of LPG system part removal, consider that there may be
some minimum residual LPG gas leaks.

Warning! Avoid to come into direct contact with any residual LPG in the system.
Service Manual – SW4000 Engine System - LPG 122

LPG System Hose and Fitting Disassembly/Assembly

Warning! This procedure has to be performed by personnel qualified to handle the LPG
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.).

Warning! The hoses (A) and (B) has to be replaced periodically, according to the law in force.
The hose (B) has to be of a specific length, in order to comply with the safety
technical data; it must not be shortened for any reason.

Disassembly

1. Empty the LPG system (see the procedure in the previous paragraph).

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.

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

5. If the engine is hot, wait that it cools down.

6. Check that the LPG tank valve is closed.

7. Unscrew and remove the relevant hoses (A), (B) or (C) and/or the relevant fittings, and note the
following:

C
B

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Service Manual – SW4000 Engine System - LPG 123

LPG System Hose and Fitting Disassembly/Assembly (Continues)

• The fittings (D) are equipped with inner gaskets.
• The fittings (E) are provided with sealant.

Caution! If the fittings (E) are turned very slightly, their tightness can be compromised
(because the sealant “brakes”), thus those fittings has to be unscrewed and screwed
again after having applied new sealant, as shown below.

• The fittings (F) are equipped with fastening bands.

Assembly

8. Before tightening the fittings (D) clean them accurately and replace the inner gaskets.

9. Before screwing down the fittings (E) carefully remove any remaining of sealant, then apply the new
sealant; use PTFE by WURTH saBesto, P/N 0893 511 050 – S/I (or equivalent). Proceed according to the
instructions on the package of the product.

10. Before tightening the fittings (F) clean them accurately and replace the fastening bands.

11. After assembling the fittings (E) wait the time necessary for the sealant to harden, before the LPG gas
enters the system.

D
D
E D
A
D E

E
D
E
C

F
E E
B

E F
E
E
E
E E

E E
D
P200147
Service Manual – SW4000 Engine System - LPG 124

Pressure Regulator Removal/Installation

Warning! This procedure has to be performed by personnel qualified to handle the LPG
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

1. Empty the LPG system (see the procedure in LPG System Emptying).

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.

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

5. Turn the fasteners and remove the machine right door.

6. If the engine is hot, wait that it cools down.

7. Unscrew the fitting (A).

Caution! For disassembly/assembly of the various hoses and fittings of the LPG system, refer
to the procedure in “LPG System Hose and Fitting Disassembly/Assembly”.

8. Loosen the retaining bands (B) and disconnect the hoses (C).

B C

P200148
Service Manual – SW4000 Engine System - LPG 125

Pressure Regulator Removal/Installation (Continues)

9. 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).

12. At the workbench, remove the fitting (I) from the fitting (J).

13. Unscrew the fitting (J) from the pressure regulator (K).

14. If necessary, unscrew the fittings (L) and (M) from the pressure regulator (K).

15. Retrieve the pressure regulator (K).

Assembly

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

17. Perform the LPG System Leakage Check (see the procedure in LPG System Leakage Check paragraph).

18. If a new pressure regulator has been installed, adjust the CO2 (see the procedure in “CO2 Adjustment”).

F
D
I J

H
K

M
G

P200231
Service Manual – SW4000 Engine System - LPG 126

Pressure Valve Removal/Installation

Warning! This procedure has to be performed by personnel qualified to handle the LPG
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

1. Empty the LPG system (see the procedure in “LPG System Emptying”).

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.

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

5. Turn the fasteners and remove the machine right door.

6. If the engine is hot, wait that it cools down.

7. Disconnect the electrical connections (A).

8. Unscrew the pressure valve (B) while holding the fitting (C).

Caution! For disassembly/assembly of the various hoses and fittings of the LPG system, refer
to the procedure in “LPG System Hose and Fitting Disassembly/Assembly”.

Assembly

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

10. Perform the LPG System Leakage Check (see the procedure in LPG System Leakage Check paragraph).

P200149
Service Manual – SW4000 Engine System - LPG 127

Solenoid Valve Removal/Installation

Warning! This procedure has to be performed by personnel qualified to handle the LPG
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

1. Empty the LPG system (see the procedure in “LPG System Emptying”).

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.

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

5. Turn the fasteners and remove the machine right door.

6. If the engine is hot, wait that it cools down.

7. Unscrew the fitting (A).

Caution! For disassembly/assembly of the various hoses and fittings of the LPG system, refer
to the procedure in “LPG System Hose and Fitting Disassembly/Assembly”.

8. Loosen the retaining bands (B) and disconnect the hoses (C).

B C

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Service Manual – SW4000 Engine System - LPG 128

Solenoid Valve Removal/Installation (Continues)

9. 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).

12. At the workbench, remove the “T” fitting (I) from the fitting (L).

13. Remove the solenoid valve (J) from the fitting (K).

14. Unscrew the fitting (L) from the solenoid valve (J).

15. Retrieve the solenoid valve (J).

Assembly

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

17. Perform the LPG System Leakage Check (see the procedure in LPG System Leakage Check paragraph).

F
D
K

I L
H

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Service Manual – SW4000 Engine System - LPG 129

Engine-Dynamotor Unit Disassembly/Assembly

Disassembly

1. Empty the LPG system (see the procedure in “LPG System Emptying”).

2. Drive the machine on a level floor.

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

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

5. Disconnect the batteries.

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

7. Disconnect the LPG hose (B) from the carburettor (C), as shown in “LPG System Hose and Fitting
Disassembly/Assembly LPG”.

Close with sealing plugs the disconnected fittings to prevent foreign materials from entering into the
system.

P200215
Service Manual – SW4000 Engine System - LPG 130

Engine-Dynamotor Unit Disassembly/Assembly (Continues)

8. Disconnect the wiring harnesses (F) of the dynamotor (G) from the electrical cable (H) and the batteries
(I) (mark each position for proper reassembly).

9. Disconnect the engine start electrical connector (J).

10. Disconnect the engine ground (K).

11. Remove the four fastening nuts (L) of the engine holder (M).

12. Remove the fastening screws and then remove the case (N).

13. Disengage the engine oil drain hose (P), from the fastening clamps (Q).

14. Place a proper and safe lifting belt (R) transversally on the flange (S), as shown in the figure (the belt (R)
have to slide smoothly along the dynamotor).

15. With a proper hoisting system, carefully lift the dynamotor assembly and let it swing slightly to avoid
the obstacles (Weight of the engine-dynamotor unit: 40 kg)

Assembly

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

H
N

F I
S

M
L

Q
J

K P
Q
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Service Manual – SW4000 Engine System - LPG 131

Engine Unit Disassembly/Assembly

Disassembly

1. Remove the engine-dynamotor unit (see the procedure in the previous paragraph).

2. Remove the dynamotor unit (see the procedure in Electrical System paragraph).

3. Remove the screws (A) and separate the engine assembly (B) from the holder (C). Engine weight: 24 kg
approx.

4. If necessary, unscrew the three screws (D) and remove the air deflector (E) from the engine.

Assembly

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

A
A
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Service Manual – SW4000 Engine System - LPG 132

Specifications
Values
Engine System - LPG
SW4000 LPG

Make Honda

Model GX-200

Regulated power (ISO 1585) 6.7 kW

Working speed 2,750 ± 50 rpm

Oil type SAE 5 W 30 - SYNTHETIC API SJ

Reserve 17.4 psi (1.2 Bar)

Length Width Height (engine only) 12.3 x 14.8 x 13.2 in (313 x 376 x 335 mm)

Displacement (bore x stroke) 12 in3 [2.68 x 2.13 in] (196 cm3 [68 x 54 mm])

Maximum output 4.8 kW (6.5 PS) at 3,600 min (rpm)

Max torque 117 lbf in - 2,500 rpm (min) (13.2 N•m (1.35 kgf•m) at 2,500 min (rpm))

Engine oil quantity 0.16 gal US (0.60 liters)

Cooling system Forced air

Starting system Transistor magnet

PTO shaft rotation Counter-clockwise

Distance between the spark plug electrodes 0.028 - 0.031 in (0.70 - 0.80 mm)

Idle speed 1,400 min (rpm)

INTAKE: 0.15 ± 0.02 mm

Valve clearance (cold)
EXHAUST: 0.20/0.02 mm

Fuel LPG tank

BPR6ES (NGK)
Spark plug
W20EPR-U (DENSO)
Service Manual – SW4000 Hopper System 133

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.
The pump motor (M3) is powered by 2 relays (K3A) and (K3B), driven respectively for hopper lifting and lower-
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).
To lift or lower the hopper is essential to simultaneously operate both switches.
This may create a potential hazard to people who might be near the arm system and hopper while moving.
When the hopper comes out of its rest position, the position sensor (S1) provides its signal to the dashboard
electronic board (EB2) and to the drive system electronic board (EB1) in order to obtain the following automat-
ic functions: Reduction of machine maximum speed (by EB1 electronic board), activation of the buzzer (BZ1)
and hopper lifting warning light (A), switching off of the vacuum system motor (M1) and of the broom motors
(M4, M6, M7) (by EB2 electronic board).
At different heights of the lifting system, the release lever for hopper dumping can be activated.
The lever, by means of a metal cable, controls a rod which opens the locking system and releases the telescopic
arm thus allowing the hopper to rotate and dump.
Once the hopper is turned for dumping, it can be shaken or engaged back to its position by using the hopper
manual returning handle. If it is not manually engaged, it engages automatically when the hopper returns to
the rest position (closed).

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Service Manual – SW4000 Hopper System 134

Wiring Diagram
HOPPER HOPPER
DISPLAY ELECTRONIC LOWERING LIFTING
BOARD FUSE (F3) RELAY (K3B) RELAY (K3A)

J1.1 - Electronic board power supply +

HOPPER PUMP HOPPER

FUSE (F6) LIFTING/LOWERING
SWITCH (SW5)

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

HOPPER
LOWERING CONTROL PANEL ELECTRONIC BOARD (EB2)
RELAY (K3B) HOPPER ENABLING
SWITCH (SW4)
LINE
ELECTROMAGNETIC
HOPPER LIFTING
SWITCH (ES0)
RELAY (K3A)

M3
DRIVE SYSTEM
ELECTRONIC BOARD (EB1)
HOPPER LIFTING
SENSOR (S1)
HOPPER PUMP
MOTOR J1.8 - Lifted hopper signal J2.11 - Lifted hopper input

J1.9 - Electronic board power supply -

POSITIVE SIGNAL
(FROM MACHINE ON “K4”)

BATTERY NEGATIVE TERMINAL

P200151
Service Manual – SW4000 Hopper System 135

Hydraulic diagram
HYDRAULIC CILINDER

VALVE LOCK

UP DOWN

HIGH PRESSURE PRESSURE

RELIEF VALVE RELIEF VALVE

HYDRAULIC POWER UNIT

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Service Manual – SW4000 Hopper System 136

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

Hopper

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Service Manual – SW4000 Hopper System 137

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)

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Service Manual – SW4000 Hopper System 138

Maintenance and Adjustments

Hydraulic System Oil Level Check

Warning! Procedure to be performed with the hopper fully retracted.

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

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

3. (Only for SW4000 Battery, with battery box). Remove the machine right body side (A), by lifting it to
disengage it from the fasteners.

4. Check that the oil level in the hydraulic unit tank is between the minimum (MIN) (B) and maximum
(MAX) (C) marks shown.

5. If necessary, add oil through the plug (D); use the oil specified in Technical Data paragraph.

Warning! Hydraulic system oil is highly corrosive.

Warning! The hydraulic system oil should be disposed of properly according to the Law in
force.

6. (Only for SW4000 Battery, with battery box). Install the right body side (A) and engage it with the
fasteners.

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

B
P200155
Service Manual – SW4000 Hopper System 139

Troubleshooting
Trouble Possible causes Remedy

The hopper does not lift. The fuse (F6) is open. Replace the fuse.

The hopper does not dump. The hopper is too low. Lift the hopper at a minimum height of 350 mm.

The hopper does not give a The sensor (S1) is misadjusted or broken. Adjust/replace
signal of being closed.

The hopper does not lift. The hydraulic system oil level is incorrect. Check the hydraulic system oil level in the tank.

The hopper does not lower. In case of low temperatures, the hydraulic system oil is Wait a few moments to let the hydraulic system
slow in flowing through the safety valve. oil flow.
Service Manual – SW4000 Hopper System 140

Removal and Installation

Closed Hopper Sensor Disassembly/Assembly and Adjustment

Disassembly

1. Drive the machine on a level floor.

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. On the right rear upper side of the machine, remove the connector (B) of the closed hopper sensor (C)
from its housing (A).

5. Cut the fastening clamp (D) and disconnect the connector (B).

6. Remove the locknut (E) and remove the sensor (C) with the wiring harness.

Assembly

7. Assemble the components in the reverse order of disassembly, and note the following:
• Adjust the distance (F) between the sensor (C) and the bracket (G) at 4-5 mm, then tighten the lock-
nut (E).

C F
4-5mm

G
E

B
P200216
Service Manual – SW4000 Hopper System 141

Hopper Disassembly/Assembly
Disassembly

1. Empty the hopper.

2. Drive the machine on a level floor.

3. Engage the parking brake.

4. Operating on the machine controls, as shown in the User Manual, lift the hopper (A), then lower it by
laying it on a wide holder (B), as shown in the figure (to safely support it during the disassembly).

5. Turn the ignition key to “0”.

6. On the left side of the hopper (A), remove the screw (C) and retrieve the components (D).

7. Turn the lever (E) to rest position.

8. The side flange (F) for hopper adjustment must be left in its original position. If necessary, it will be
adjusted after the hopper reassembly.

9. Remove the two screws (G) on both sides of the hopper (A) and retrieve the components (H).

10. Remove the hopper (A) by disengaging the lifting arms (I) with the lever.

E
F

C
E C
D

A I

G
B

G H H H H G

P200156
Service Manual – SW4000 Hopper System 142

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
• To allow for a proper vacuuming capacity it is necessary that, when the hopper (A) is closed, all the pe-
rimeter of its gasket (J) is sticks to the chassis (K) of the machine. If this condition is not satisfied because
the hopper and machine chassis are misaligned, these must be aligned with the side flange (F), as shown
below.

13. The standard assembly of the flange (F) is performed by placing the “V” groove (L) at “6 o’clock”, thus
engaging the notch (M) on the tooth (N) of the hopper housing (A).

14. To adjust the hopper alignment:

• Perform steps 2 to 5.
• Remove the screw (C) and retrieve the components (D).
• Remove the screw (P) and remove the flange (F) from its housing, then insert it again after turning it
as necessary to restore the alignment (each notch corresponds in negative or positive to 0.5 degrees,
as shown on the flange itself).
• Tighten the screw (P).
• Assemble the components (D), on the flange (F) and tighten the screw (C).

15. Removing the main broom and checking that there is no light passing through the seal and the chassis.

16. Check that the hopper operates properly and that it is properly aligned; if necessary repeat the
alignment procedure.

N
F

C
D
C
A
J
P F

25 28
25.5 27.5

26 27
26.5
A

L M K
P200157
Service Manual – SW4000 Hopper System 143

Hopper and Lifting Arm Disassembly/Assembly

Disassembly

1. Empty the hopper and then close it.

2. Drive the machine on a level floor.

3. Engage the parking brake.

4. Ensure that the hopper is closed.

5. On the upper area of the right hopper arm (A), remove the cotter pin and the pin (B).

6. Move the hydraulic cylinder rod (C) forward until it is flushed with the machine chassis.

7. On the upper area of the left hopper arm (D), remove the nut (E) and the screw (F), then retrieve the
components (G).

A D

E
B

G E
C
F

P200158
Service Manual – SW4000 Hopper System 144

Hopper and Lifting Arm Disassembly/Assembly (Continues)

8. Apply a proper safety lifting rope (H) on the upper part of the hopper arms, as shown in the figure.
(Hopper weight with lifting arms: 16 kg)

9. Remove the side screws (I) and remove the rotating pins (J).

10. With a proper hoisting system (K), remove the hopper with lifting arms (L), by moving it backwards and
lifting it.

Assembly
Assemble the components in the reverse order of disassembly.

K H

I
J

P200159
Service Manual – SW4000 Hopper System 145

Hydraulic Control Unit Disassembly/Assembly

Disassembly

1. Drive the machine on a level floor.

2. Ensure that the hopper is closed.

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

4. 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).

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

6. Disconnect the vacuum system motor connector (B).

7. Disengage the retainers (C) and remove the vacuum system hood (D).

C D C
A

C C
P200233
Service Manual – SW4000 Hopper System 146

Hydraulic Control Unit Disassembly/Assembly (Continues)

8. Disconnect the electrical connector (E) of the hydraulic unit (F).

9. Remove the hollow screws (G) and disconnect the hydraulic hoses (H) from the hydraulic unit (F).
Retrieve the gaskets (I).

If necessary, collect the hydraulic system oil in a proper container.

Plug the disconnected fittings, to prevent debris from entering into the hydraulic system.

Warning! Hydraulic system oil is highly corrosive.

Warning! The hydraulic system oil should be disposed of properly according to the Law in
force.

F
G I G I
I

H
H
I H E

G
F

P200234
Service Manual – SW4000 Hopper System 147

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

12. Assemble the components in the reverse order of disassembly, and note the following:
• After the installation of the hydraulic unit (either the same unit or a new one), fill the tank with
hydraulic oil up to the Max level, then run some hopper handling (the hydraulic system is self-bleed-
ing); then, check the hydraulic system oil level.

F
J

F
P200161
Service Manual – SW4000 Hopper System 148

Hydraulic Hose Disassembly/Assembly

Disassembly

1. Drive the machine on a level floor.

2. Ensure that the hopper is closed.

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

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

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

6. Remove the hollow screws (B) and disconnect the hydraulic hoses (C) from the hydraulic unit (D).
Retrieve the gaskets (A).

B E B E
E

C A

C
C
E C

B
A
P200160
Service Manual – SW4000 Hopper System 149

Hydraulic Hose Disassembly/Assembly (Continues)

Collect the hydraulic system oil in a proper container.

Plug the disconnected fittings, to prevent debris from entering into the hydraulic system.

Warning! Hydraulic system oil is highly corrosive.

Warning! The hydraulic system oil should be disposed of properly according to the Law in
force.

7. Open the fastening clamps (F) and the hoses (C).

8. Unscrew the connecting fittings (G) of the hydraulic cylinder hoses (H).

Collect the hydraulic system oil in a proper container.

9. Retrieve the hydraulic hoses (C).

Assembly

10. Assemble the components in the reverse order of disassembly, and note the following:
• After the installation of the hoses (either the same hoses or new ones), fill the tank with hydraulic
oil up to the Max level, then run some hopper handling (the hydraulic system is self-bleeding); then,
check the hydraulic system oil level.

C
H

C
F
C
C

A
P200163
Service Manual – SW4000 Hopper System 150

Hydraulic Cylinder Disassembly/Assembly

Disassembly Warning! The hydraulic system oil

should be disposed of
1. Drive the machine on a level floor. properly according to the Law
in force.
2. Ensure that the hopper is closed.

3. Turn the ignition key to “0” and engage the 7. Remove the screw (D) and remove the lower pin
parking brake. (E) of the cylinder.
4. Open the battery/engine compartment hood with 8. Remove the cotter pin and the upper pin (F) of
the handle and fasten it with the support rod. the cylinder.
5. Remove the machine right side bulkhead, by 9. Remove the cylinder (C).
lifting it to disengage it from the fasteners.

6. Unscrew the connecting fittings (B) of the Assembly

hydraulic cylinder hoses (C).
10. Assemble the components in the reverse order of
Collect the hydraulic system oil in a proper disassembly, and note the following:
container. • After the installation of the cylinder (either
the same cylinder or a new one), fill the tank
Plug the disconnected fittings, to prevent debris with hydraulic oil up to the Max level, then
from entering into the hydraulic system. run some hopper handling (the hydraulic sys-
tem is self-bleeding); then, check the hydrau-
Warning! Hydraulic system oil is highly lic system oil level.
corrosive.

B D

E
P200164
Service Manual – SW4000 Hopper System 151

Specifications
Values
Hopper System
SW4000 Battery SW4000 Petrol SW4000 LPG

Hopper capacity 19.8 US gal (75 liters)

Maximum weight liftable by the hopper 220 lb (100 kg)

Hopper maximum lifting height 62.6 in (1,590 mm)

Values
Hopper hydraulic lifting system
SW4000 Battery SW4000 Petrol SW4000 LPG

Pump Parker 108 AE S32 - 24 V

Maximum pressure 1,595 psi (110 Bar)

Oil tank capacity 0.2 US gal (0.75 liters)

Hydraulic circuit total capacity 0.4 US gal (1.4 liters)

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 /s (mm²/s)

2
0.07 (45) 0.05 (32)

Viscosity at 212 °F (100°C) in2/s (mm²/s) 0.012 (7.97) 0.009 (6.40)

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 59°F (15°C) lb/gal (kg/l) 1.9 (0.87) 1.9 (0.865)

Service Manual – SW4000 Optional and Accessories 152

Optional and Accessories

Description Illustration
DUSTGUARD™ SYSTEM KIT
(See Dust Guard System chapter)

SAFETY BELT KIT

ROOF COVER KIT

Service Manual – SW4000 Optional and Accessories 153

Description Illustration
PROTECTION ROOF KIT

WORKING LIGHT KIT

The working light kit improves visibility in dark

environments.
The headlights are installed under the chassis,
in the front side of the sweeper.
The kit includes one switch (SW9) to turn
the lights on, one holder with two 24V 70W
headlights (L1, L2) and the wiring harness.

SIDE BROOM GUARD KIT

Service Manual – SW4000 Steering System 154

Steering System

Functional Description
The steering wheel is fastened to the steering column and connected to a shaft with a cardan joint.
The movement is transmitted with pinion and chain to the ring gear, which determines the steering. The ring
gear is fastened to the driving wheel.
Service Manual – SW4000 Steering System 155

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
Service Manual – SW4000 Steering System 156

Removal and Installation

Steering Wheel Disassembly/Assembly

Disassembly

1. Drive the machine on a level floor.

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

3. Disengage and remove the cover (A).

4. Unscrew the nut (B) and remove the washer (C).

5. With a suitable puller, remove the steering wheel (D) using the surface (E) of the steering shaft and the
threaded holes (F) of the steering wheel, or its lower edge (G); in case the lower edge (G) is used, insert
metal plates between the edge and the puller, in order to distribute the load and prevent damage to the
lower edge (G) itself.

Assembly

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

E
B BD
A

C
F

P200166
Service Manual – SW4000 Steering System 157

Steering Chain 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. Steer the front wheel until the junction link (A) of the steering chain (B) becomes visible.

4. Disengage the link (A) and remove the chain (B).

5. Retrieve the chain tensioner pulley (C). Check the operation of the chain tensioner pulley (C).

Assembly

6. Assemble the components in the reverse order of disassembly, and note the following:
• Do not lubricate the chain (B), otherwise dust and debris will stick to the lubricant.

B C
A

P200167
Service Manual – SW4000 Steering System 158

Steering Assembly Removal/Installation

1. Refer to the procedure: Driving Wheel and Steering Unit Disassembly/Assembly
Service Manual – SW4000 Main Broom System 159

Main Broom System

Functional Description
By using the left lever on the dashboard the main broom support system lowers, because it is released by
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.
The machine must be moving otherwise the main broom motor does not run.
The front skirt lifting pedal allows to collect medium size waste materials (cans, boxes, etc.). The front skirt
must be lifted only when necessary, because it affects the operation of the dust control system.
The main broom motor (M4) is supplied by the electromagnetic switch (ES1) and protected by the fuse (FA).
The electromagnetic switch (ES1) is activated by the dashboard electronic board (EB2) according to the infor-
mation received by: sensor (S2) (main broom control lever position), machine moving signal (information that
EB2 receives from EB1), lifted hopper signal, battery voltage (see Dashboard Electronic Board Specifications,
step d).
The fuse (FA) activates in case of short circuit or blocked rotor, but in case of overload, the dashboard elec-
tronic board (EB2) reads the voltage drop on the fuse, thus deactivating ES1 before the fuse can activate (see
Main Broom Motor Protection, in Dashboard Electronic Board Specifications). The activation of an electronic
protection is indicated by the main broom overload warning light (A).

P200235

Wiring Diagram
MAIN BROOM
ELECTROMAGNETIC DISPLAY ELECTRONIC
SWITCH (ES1) BOARD FUSE (F3)

J1.1 - Electronic board power supply + MAIN BROOM LEVER

SENSOR (S2)
MAIN BROOM
ELECTROMAGNETIC
MAIN BROOM SWITCH (ES1)
MOTOR
CONTROL PANEL ELECTRONIC BOARD (EB2)

M4 J1.2 - Broom activation lever signal

J1.10 - Broom electromagnetic switch power supply

J1.4 - Broom fuse voltage drop reading +

POSITIVE SIGNAL
MAIN BROOM
FUSE (FA) V (FROM MACHINE ON “K4”)

J1.5 - Broom fuse voltage drop reading - BATTERY NEGATIVE TERMINAL

J1.9 - Electronic board power supply -

P200168
Service Manual – SW4000 Main Broom System 160

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)

Main broom
Front skirt lifting pedal

P200236
Service Manual – SW4000 Main Broom System 161

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 and the floor.
• Main broom motor (M4)

Device to adjust the

Lowered main broom parallelism between
enabling sensor (S2) the main broom and
the floor

Rear skirt

Left side skirt

Front skirt

Driving belt Motor pulley

Broom pulley

Main broom motor

(M4)
Right side skirt

P200169
Service Manual – SW4000 Main Broom System 162

Maintenance and Adjustments

Main Broom Height Check And Adjustment

Note: Brooms with harder or softer Note: The knob can be used both to
bristles are available. This adjust the print and to adjust
procedure is applicable to all the broom according to the
types of brooms. bristle wear.

1. Check the main broom distance from the ground, 3. Perform step 1 again to check that the main
according to the following procedure: broom is at the correct distance from the ground.
• Drive the machine on a level floor.
• Keep the machine stationary, lower the main 4. When the broom is too worn and can no
broom and turn it on for a few seconds. longer be adjusted, replace it according to the
• Stop and lift the main broom, then move the procedure shown in the relevant paragraph.
machine and switch it off.
• Check that the main broom print (A), along Note: After the main broom height
its length, is 2 to 4 cm wide. has been adjusted, check that
the main broom overload
If the print (A) is not within specifications, warning light does not flash in
adjust the main broom height according to the the first minutes of operation.
following procedure. Otherwise the main broom
pressure on the ground must
2. Turn the knob (B) and consider that:
be reduced by means of the
• to increase the print length, turn the knob
relevant adjusting knob.
counter-clockwise
• to decrease the print length, lift the broom
with the lever and then turn the knob clock- 5. If the print (A) cannot be properly adjusted,
wise. because the broom pressure differs from one end
to another, proceed as follows.

A
0.8 - 1.6 in / 2 - 4 cm

A
0.8 - 1.6 in / 2 - 4 cm

P200237
Service Manual – SW4000 Main Broom System 163

Main Broom Height Check and Adjustment (Continues)

6. Turn the fasteners and remove the left door.

7. Loosen the locknuts (C).

8. Turn the screws (D) to adjust the height of the broom left side, and adjust it to the right side, as follows:
• Lift the lever (E) to lower the left side of the broom;
• Lower the lever (E) to lift the left side of the broom.

When the adjustment is completed, tighten the locknuts (C).

9. Perform step 1 again to check that the main broom is at the correct distance from the ground.

10. If necessary, adjust the transmission cable adjuster.

D
P200170
Service Manual – SW4000 Main Broom System 164

Main Broom Disassembly/Assembly

Note: Brooms with harder or softer bristles are available. This procedure is applicable to all
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

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

2. Turn the ignition key to “0” and remove it.

3. Turn the fasteners and remove the left door.

4. Unscrew and remove the knob (A).

5. Turn the levers (B) upwards.

6. Remove the broom compartment latch (C) by grabbing it from its fold (D).

7. Remove the main broom (E).

B
D
B

A
C
E
P200238
Service Manual – SW4000 Main Broom System 165

Main Broom Disassembly/Assembly (Continues)

Assembly

8. Check that the drive hub (F) is free from dirt or foreign materials (cords, rags, etc.) accidentally rolled
up.

9. The main broom (E) must be installed with the bristles rows (G) bent as shown in the figure.

During assembly, ensure that the broom hexagonal mesh (H) fits into the relevant drive hub (F).

10. Install the broom compartment latch(C). Ensure that its fasteners (I) are properly fitted in the housings
(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.

14. Check and, if necessary, adjust the main broom height.

G
B
F
B

A
C

J J I
I
C
E

P200171
Service Manual – SW4000 Main Broom System 166

Skirt Height Check and Adjustment

Preliminary Operations

1. Empty the hopper (as shown in the User Manual), because the weight of the waste inside the hopper can
affect the skirt height check.

2. Drive the machine on a level ground that is suitable for checking the skirt height.

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

Side Skirt Check

4. Remove the machine left and right doors by turning the relevant fasteners.

5. Check the side skirts (A) 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”).

6. Check that the distance from the ground (E) of the side skirts (A) is 0 - 3 mm. If necessary, loosen the
knobs (B) and adjust the skirt position. Then tighten the knobs (B).

> 10 mm > 20 mm
(> 0.4 in) (> 0.8 in)
D

B A B

0÷3 mm
(0÷0.12 in)

E
P200239
Service Manual – SW4000 Main Broom System 167

Skirt Height Check and Adjustment (Continues)

Front and Rear Skirt Check

7. Remove the main broom.

8. 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”).

9. Check that the front skirt (F) and rear skirt (H) slightly rub the floor without being detached from it (see
the diagram (I)).

Reassembly

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

> 10 mm > 20 mm
(> 0.4 in) (> 0.8 in)
D

F G H
P200172
Service Manual – SW4000 Main Broom System 168

Troubleshooting
Trouble Possible causes Remedy

The main broom does not The safety system has activated. Turn off the machine and then turn it on again.
work and the warning light Check the condition of the main broom (debris
(76) flashes. that slows down the broom or excessive
pressure on the ground).

The fuse (FA) is open. Wait for the main broom motor to cool down,
then replace the fuse.

The electromagnetic switch (ES1) is not efficient Replace

The driving belt is misadjusted/damaged/broken Tighten/replace

The motor (M4) is faulty Check the motor amperage/replace

The sensor is misadjusted or broken Adjust/replace

The main broom has not been properly adjusted in height/ Adjust
parallelism

The main broom does not The main broom is too worn out Replace
clean properly
The skirts are misadjusted or damaged Adjust/replace

The gas springs are damaged or without pressure Replace

The main broom jumps or The gas springs are damaged Replace
vibrates
Service Manual – SW4000 Main Broom System 169

Removal and Installation

Driving Belt Visual Inspection and Replacement

Check

1. Drive the machine on a level floor.

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

3. Remove the machine right door by turning the relevant fasteners.

4. Visually inspect the entire length of the belt (A) to make sure it is intact and shows no signs of cuts,
tears or cracks, if necessary replace it.

Replacement

5. Loosen the screws (C) and (D), then loosen the belt by turning the motor assembly (B).

6. Remove the belt (A).

7. Install the new belt (A).

8. Tighten the belt (A) as necessary by turning the motor assembly (B), then tighten the screws (C) and
(D).

Reassembly

9. Install the machine right door by turning the relevant fasteners.

D
A

P200173
Service Manual – SW4000 Main Broom System 170

Skirt Disassembly/Assembly
Preliminary Operations

1. Empty the hopper (as shown in the User Manual), because the weight of the waste inside the hopper can
affect the skirt height check.

2. Drive the machine on a level ground that is suitable for checking the skirt height.

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

Side Skirt Removal and Installation

4. Remove the machine left and right doors by turning the relevant fasteners.

5. Unscrew the knobs (A).

6. Remove the plate (B) and the right/left skirt (C).

7. Assemble the right/left skirt (C) and the plate (B).

8. Screw down the knobs (A), without tightening them.

9. Check the skirt height.

B A C A
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Service Manual – SW4000 Main Broom System 171

Skirt Disassembly/Assembly (Continues)

Front Skirt Removal and Installation

Note: It is advisable to place the machine on a hoisting system.

10. Remove the main broom.

11. Remove the side brooms.

12. On the left front side of the front skirt (D), disengage the clip (E) then disconnect the terminal (F) of the
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. Remove the front skirt assembly (J) from the front.

15. At the workbench, unscrew the six nuts (K) and remove the section bar (L) and the strap (M).

16. Retrieve the front skirt (N).

17. Install the front skirt (N) in the reverse order of disassembly.

18. Check the front skirt height.

H
N

L
D
G J
P200244
Service Manual – SW4000 Main Broom System 172

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.

21. In the hopper compartment, remove the nuts (P) and then remove the strap (Q) and the skirt (R).

22. In the main broom compartment, remove the strap (S) and remove the skirt (T).

23. Install the rear skirts (T) and (R) in the reverse order of disassembly.

24. Check the rear skirt height.

Reassembly

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

T
P
S R

P200174
Service Manual – SW4000 Main Broom System 173

Main Broom Motor Amperage Check

Warning! This procedure must be performed by qualified personnel only.

1. Remove the main broom.

2. Check that the main broom drive hub is free from dirt or foreign materials (ropes, rags, etc.) accidentally
rolled up, which can prevent it from rotating.

3. Remove the right side broom.

4. Place wedges (A) on the rear wheels of the machine.

5. With a proper hoisting system applied to the machine chassis, to the front wheel area (B), lift the
machine a few centimetres, in order to let the front wheel turn freely without touching the floor.

6. Apply amp clamps (C) on a cable (D) of the main broom motor (E).

7. Turn the ignition key to “I”.

8. Turn on the main broom and check that the amperage of the motor (E) is 5 - 7 A at 24 V.

Stop the main broom rotation.

Turn the ignition key to “0”.

Remove the amp clamps (C).

E D

A
B
C

P200175
Service Manual – SW4000 Main Broom System 174

Main Broom Motor Amperage Check (Continues)

If the amperage is higher, perform the following procedures to detect and correct it:
• Check the relevant fuse (FA) for proper tightening.
• Check if there is dust or dirt (cords, cables, etc.) on the broom drive hub.
• Check that the driving belt is efficient and properly tightened.
• Check the motor carbon brushes (see the procedure in “Main Broom Motor Carbon Brush Check/Re-
placement”).
• If necessary, disassemble the motor (see procedure in the next paragraph), and check the condition of
all its components.

If the above-mentioned procedures do not lead to a correct amperage, the motor must be replaced (see
the procedure in the next paragraph).

Reassembly

9. Install the right side broom.

10. Install the main broom.

11. Remove the front hoisting system of the machine.

12. Remove the wedges from the rear wheels.

Service Manual – SW4000 Main Broom System 175

Main Broom Motor Disassembly/Assembly

Disassembly

1. Remove the main broom driving belt (see the procedure in “Driving Belt Visual Inspection and
Replacement”).

2. Disconnect the connector (A) of the main broom motor (B).

3. Loosen the screws (C).

4. Remove the main broom motor (B).

Assembly

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

P200176
Service Manual – SW4000 Main Broom System 176

Main Broom Motor Carbon Brush Check/Replacement

Disassembly

1. Remove the main broom motor (see the procedure in the previous paragraph).

2. At the workbench, remove the nuts (A) and the guard (B) of the main broom motor (C).

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

4. Disengage the cam lever (E) and remove the protection band (D).

5. Remove the fastening screws (F) of the electrical connections of the four carbon brushes (G).

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

7. Check the carbon brushes (G) for wear. The carbon brushes are worn when:
• The contact with the motor armature is insufficient
• 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 motor carbon brushes.

Assembly

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

B
D E

C C

G
P200177
Service Manual – SW4000 Main Broom System 177

Main Broom Motor Pulley Disassembly/Assembly

Disassembly

1. Remove the main broom motor belt (see the procedure in “Driving Belt Visual Inspection and
Replacement”).

2. While keeping the pulley (C) locked, remove the screw (A) and retrieve the washer (B).

3. Remove the pulley (C) and retrieve the spacer (D) and the key (E).

Assembly

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

B A
C
D
E

P200178
Service Manual – SW4000 Main Broom System 178

Main Broom Drive Hub and Bearing Disassembly/Assembly

BEARINGS

Disassembly

1. Remove the main broom.

2. Lift the hopper to the end-of-stroke.

Warning! Place a safety rod under the lifted hopper.

3. Remove the main broom driving belt (see the procedure in “Driving Belt Visual Inspection and
Replacement”).

4. While keeping the pulley (A) locked, remove the screw (B) and retrieve the washers (C) and (D).

5. Remove the pulley (A) and retrieve the spacer (E) and the key (F).

6. Push the assembly (G) inside the machine, and then retrieve it.

7. In the hopper compartment, remove the snap ring (H).

8. On the machine outer side, with a proper pad and a mallet, push the bearings (I) outside their housings.

Assembly

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

C B
A D
E
H I
F
G

P200241
Service Manual – SW4000 Main Broom System 179

Main Broom Drive Hub and Bearing Disassembly/Assembly (Continues)

DRIVE HUB

Disassembly

1. Remove the main broom.

2. Lift the hopper to the end-of-stroke.

Warning! Place a safety rod under the lifted hopper.

3. In the hopper compartment, remove the nut (L) while keeping the drive hub locked (M).

4. Retrieve the washer (N).

5. Remove the drive hub (M) and retrieve the keys (P).

Assembly

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

P
M
N
L

P200179
Service Manual – SW4000 Main Broom System 180

Main Broom Gas Spring Disassembly/Assembly

Disassembly

1. Place the machine on a hoisting system.

2. Remove the main broom.

3. With the knob (A), lower the main broom until the end of stroke.

4. Use the lever (B) to lower the main broom.

5. In the left front lower side of the machine, unscrew the nut (C) and disconnect the grommet (D) of the
main broom lifting control cable (E) from the pin.

E
D E

C C

P200217
Service Manual – SW4000 Main Broom System 181

Main Broom Gas Spring Disassembly/Assembly (Continues)

6. In front of the main broom, loosen the nut (F) of the gas springs (G).

7. Insert and tighten the screw with a 8 mm nut (H) in the hole (I).

8. Insert a lever (J) between the screw (K) and the screw (H), as shown in the figure, then push it in the
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).

9. Unscrew the nut (M) and remove the screw (N).

Caution! Pay attention to the release of the gas springs (G) due to any residual tension.

10. Remove the gas springs (G).

Assembly

11. Assemble the components in the reverse order of disassembly, and note the following:
• To place the screws (L) back in the housing (O), the screw with nut (H) must be turned to position (P),
then place the lever (J) in the position (Q) and push it in the direction shown by the arrow, as shown
in the figure.

12. Adjust the main broom height.

H
I
K

F F
G
G

L P L
O

G
M
P200218
Service Manual – SW4000 Main Broom System 182

Main Broom Lifting Cable Disassembly/Assembly

Disassembly

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

2. Remove the main broom.

3. Remove the left side broom, if equipped.

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. Remove the fairing (B).

8. If necessary, drain the water from the tank in the steering column (B), through the filler neck.

9. On the rear side of the steering column, remove the screws (E).

10. Turn the knob (F) counter-clockwise until its screw (G) is removed from the arms (H).

A A
B
A

B
A D

E
H

G
F

P200180
Service Manual – SW4000 Main Broom System 183

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. Remove the pin (P).

15. In the left front lower side of the machine, unscrew the nut (Q) and disconnect the grommet (R) of the
cable (S) to be removed.

16. Unscrew the locknut (T) and remove the cable (S) from the cut (U).

17. Unscrew the nut (V) and remove the screw (W).

18. Remove the cable (S) by disengaging it from the pulleys (X) and from the fastener (Y).

U
R
J
M

Q T
I K S

P
N

S
S

X X W S
X
P200181
Service Manual – SW4000 Main Broom System 184

Main Broom Lifting Cable Disassembly/Assembly (Continues)

Assembly and Adjustment

19. Assemble the components in the reverse order of disassembly, and note the following:
• Adjust the cable (S) as shown below:

20. Place the locknut (T) near the relevant nut, without tightening it.

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. Remove the machine right door by turning the relevant fasteners.

24. Adjust the nut-locknut adjuster (T) to reach, on the machine right side, a distance (Z) of 165 mm from
the main broom shaft centre to the ground.

After adjusting, tighten the nut-locknut adjuster (T).

25. Adjust the same distance of 165 mm (AA) from the main broom shaft centre to the ground, also on the
machine left side; for the adjustment use the opposed adjusters with locknuts (AB).

After adjusting, tighten the locknuts (AB).

U
R F

Q T
S

AB

AB AA

165 mm

Z
AB

165 mm

AB

P200182
Service Manual – SW4000 Main Broom System 185

Lowered Main Broom Enabling Sensor Disassembly/Assembly and Adjust-

ment
Disassembly

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

2. Remove the left side broom, if equipped.

3. On the machine left lower front side, unscrew the locknut (A) and remove the enabling sensor (B) from
its housing.

4. Disengage the sensor electrical cable (C) from its fasteners, then disconnect the relevant connector.

5. Retrieve the proximity sensor (B) with the electrical cable.

Assembly and Adjustment

6. Place the enabling sensor (B) and connect its connector, then engage the wiring harness from its
fasteners.

7. Screw down the locknut (A), without tightening it.

8. Turn the main broom lifting/lowering lever to lower the broom.

9. Adjust the distance (D) between the sensor (B) and the pin (E) to 4±1 mm, then tighten the locknut (A).

10. Install the left side broom, if equipped.

A B C

D
4±1mm

A
E B
P200183
Service Manual – SW4000 Main Broom System 186

Specifications
Values
Main Broom System
SW4000 Battery SW4000 Petrol SW4000 LPG

Main broom size (length x diameter) 27.6 x 13.4 in (700 x 340 mm)

Main broom motor 0.8 hp (600 W) - 550 rpm

Gas spring pressure (Q.ty 2) 90 lb (400 N)

Service Manual – SW4000 Side Broom System 187

Side Broom System

Functional Description
By using the right lever on the dashboard the side brooms lower, because they are released by a metal cable.
In case of side impact, the system can return by means of a spring which absorbs the shock.
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.
The side broom motors (right M6, left M7) are powered by the relay (K5) and protected by the resettable fuses
(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.

Wiring Diagram

SIDE BROOM DISPLAY ELECTRONIC

RELAY (K5) BOARD FUSE (F3)

SIDE BROOM LEVER

SENSOR (S3)

LEFT SIDE BROOM

RESET FUSE (FR2)

J1.1 - Electronic board power supply +

RIGHT SIDE BROOM
RESET FUSE (FR1) CONTROL PANEL ELECTRONIC BOARD (EB2)

LEFT SIDE BROOM

MOTOR J1.10 - Broom electromagnetic switch power supply
SIDE BROOM
RELAY (K5)
M6 M7
POSITIVE SIGNAL
(FROM MACHINE ON “K4”)

J1.9 - Electronic board power supply -

RIGHT SIDE BROOM BATTERY NEGATIVE TERMINAL
MOTOR

P200184
Service Manual – SW4000 Side Broom System 188

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

enabling sensor (S3)

Side broom
motor (M6) (M7)

Broom height
adjusting ring nuts

Side broom

Left side broom motor

fuse (15 A) (FR1)

Right side broom

motor fuse (15 A) (FR2)

P200185
Service Manual – SW4000 Side Broom System 189

Maintenance and Adjustments

Side Broom Height Check and Adjustment

Note: Brooms with harder or softer 4. Turn the fasteners and remove the left or right
bristles are available. This door.
procedure is applicable to all
types of brooms. 5. For the right side broom, operate on the idle
gear by loosening the ring nut (C) and by
adjusting the adjuster (D) until the correct print
1. Check the side broom distance from the ground, (A) is achieved. Finally lock the adjuster (D) into
according to the following procedure: position with the ring nut (C).
• Drive the machine on a level floor.
• Keep the machine stationary, lower the side For the left side broom, operate on the idle gear
brooms and turn them on for a few seconds. by loosening the ring nut (E) and by adjusting
• Stop and lift the side brooms, then move the the adjuster (F) until the correct print (B) is
machine. achieved. Finally lock the adjuster (F) into
• Check that the side broom prints are as position with the ring nut (E).
shown in the figure (A and B).
6. Perform step 1 again to check the proper
If the print is not within specifications, adjust adjustment of the side broom height.
the side broom height according to the following
procedure. 7. When the broom is too worn and can no
longer be adjusted, replace it according to the
2. Engage the parking brake. procedure shown in the relevant paragraph.

3. Turn the ignition key to “0”.

B A

F D

E C

P200186
Service Manual – SW4000 Side Broom System 190

Troubleshooting
Trouble Possible causes Remedy

The right/left side broom does The broom has not been properly adjusted in height/ Adjust
not clean properly parallelism

The broom is excessively worn Replace

The side brooms do not work The sensor is misadjusted or broken Adjust/replace

The motor (M6) or (M7) is faulty Check the motor amperage/replace

There are ropes or debris restraining the broom rotation Remove and clean

The side broom fuse (FR1) or (FR2) is open. Wait for the side broom motor to cool down, then
reset the fuse by pressing the relevant push-
button.

The relay (K5) is not efficient Replace.

Service Manual – SW4000 Side Broom System 191

Removal and Installation

Side Broom Disassembly/Assembly

Note: Brooms with harder or softer bristles are available. This procedure is applicable to all
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

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

2. Turn the ignition key to “0”.

3. Lift the side broom with the lever.

4. Disengage the fastener and remove the pin (A).

5. Remove the side broom (B) form the hub (D) and retrieve the protection flange (C).

Assembly

6. Install the protection flange (C) on the hub (D) and the side broom (B).

7. Insert the pin (A) and engage its fastener.

8. Check the side broom height.

C A

P200187
Service Manual – SW4000 Side Broom System 192

Side Broom Motor Amperage Check

Warning! This procedure must be performed by qualified personnel only.

1. Remove the side broom of the relevant motor.

2. Place wedges (A) on the rear wheels of the machine.

3. With a proper hoisting system applied to the machine chassis, to the front wheel area (B), lift the
machine a few centimetres, in order to let the front wheel turn freely without touching the floor.

4. Apply amp clamps (C) on a cable (D) of the broom motor (E).

5. Turn the ignition key to “I”.

6. Turn on the side broom and check that the amperage of the motor (E) is 1.5 - 2 A at 24 V.

Stop the side broom rotation.

Turn the ignition key to “0”.

Remove the amp clamps (C).

E D

A
B
C

P200188
Service Manual – SW4000 Side Broom System 193

Side Broom Motor Amperage Check (Continues)

If the amperage is higher, perform the following procedures to detect and correct it:
• Check if there is dust or dirt (cords, cables, etc.) on the side broom hub.
• Check the motor carbon brushes (see the procedure in “Side Broom Motor Carbon Brush Check/Re-
placement”).
• If necessary, disassemble the motor (see procedure in the next paragraph), and check the condition of
all its components.

If the above-mentioned procedures do not lead to a correct amperage, the motor must be replaced (see
the procedure in the relevant paragraph).

Reassembly

7. Install the side broom of the relevant motor.

8. Remove the front hoisting system of the machine.

9. Remove the wedges from the rear wheels.

Service Manual – SW4000 Side Broom System 194

Side Broom Motor Disassembly/Assembly

Disassembly

1. Remove the side broom of the motor to be detached.

2. Lower the side broom with the lever.

3. Disconnect the connector (A) of the broom motor (B).

4. Remove the four screws with nut (C).

5. Remove the broom motor (B).

Assembly

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

7. Perform the side broom height check and adjustment.

A
B

P200189
Service Manual – SW4000 Side Broom System 195

Side Broom Motor Carbon Brush Check/Replacement

Disassembly

1. Remove the side broom motor (see the procedure in the previous paragraph).

2. Take the motor (A) to the workbench and, if necessary, mark the position (B) of the cap (C) as to the
motor body (for proper reassembly).

3. Remove the screws (D).

4. Carefully remove the cap (C) by disengaging the carbon brushes inside the motor armature.

5. Inside the cap, disconnect the connections (E) and remove the carbon brushes with wiring harness (F).

6. Check the carbon brushes (F) for wear. The carbon brushes are worn when:
• The contact with the motor armature is insufficient
• 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 motor carbon brushes.

Assembly

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

C D
E

F
E

P200190
Service Manual – SW4000 Side Broom System 196

Side Broom Lifting Cable Disassembly/Assembly

Disassembly

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

2. Remove the relevant side broom.

3. Above the side broom motor, remove the screw with nut (A) and release the grommet (B) of the cable (C)
to be removed.

4. Unscrew the locknut (E) and remove the cable (C) from the cut (D).

A B
P200191
Service Manual – SW4000 Side Broom System 197

Side Broom Lifting Cable Disassembly/Assembly (Continues)

5. On the other cable terminal (C), remove the screw with nut (G) and release the relevant grommet (F) of
the cable (C) to be removed.

6. Unscrew the locknut (H) and remove the cable (C) from the cut (I).

7. Retrieve the cable (C).

Assembly

8. Assemble the components in the reverse order of disassembly, and note the following:
• Adjust the position of nuts/locknuts (E) and (H) until the proper side broom height is reached, by
keeping the adjusters (J) in an intermediate position.

J
C

F
E

I H C C G
P200192
Service Manual – SW4000 Side Broom System 198

Lowered Right Side Broom Enabling Sensor Disassembly/Assembly and

Adjustment
Disassembly

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

2. Remove the right side broom.

3. On the right front lower side of the machine, unscrew the locknut (A) and remove the enabling sensor
(B) from its housing.

4. Disengage the sensor electrical cable (C) from its fasteners, then disconnect the relevant connector.

5. Retrieve the enabling sensor (B) with the electrical cable.

Assembly and Adjustment

6. Place the enabling sensor (B) and connect its connector, then engage the wiring harness from its
fasteners.

7. Screw down the locknut (A), without tightening it.

8. Turn the side broom lifting/lowering lever to lower the brooms.

9. Adjust the distance (D) between the sensor (B) and the pin (E) to 4±1 mm, then tighten the locknut (A).

10. Install the right side broom.

A
C

D m
4±1m

B
A

P200193
Service Manual – SW4000 Side Broom System 199

Specifications
Values
Side Broom System
SW4000 Battery SW4000 Petrol SW4000 LPG

Working width (with one side broom) 38.3 in (975 mm)

Working width (with two side brooms) 49.2 in (1,250 mm)

Side broom diameter 17.7 in (450 mm)

Side broom reduction unit 0.12 hp (90 W) - 110 rpm

Service Manual – SW4000 Wheel System, Non-Traction 200

Wheel System, Non-Traction

Functional Description
The rear wheels turns freely without any drive or stop system.
These are hold in place by means of a pin on eccentric flange, fastened to the chassis by means of screws.
On SW4000 Battery, only super elastic wheels are available.
On SW4000 Petrol/LPG, polyurethane wheels are standard and super elastic wheels are optional.
For both polyurethane and super elastic wheels, the non-marking version is available.
On the lower part of the chassis, near the flange, there are the letters “S” and “P” to be taken as a reference for
the positioning notch on the support flange of each wheel.
(Only for SW4000 Petrol/LPG). In case of super elastic wheels, the notch on the wheel support flange must be
placed near the letter “S”; in case of polyurethane wheels the notch must be placed near the letter “P”.

Component Locations
• Rear wheels
• Hub
• Hexagon castle nut

Rear wheels

Hub

Hexagon
castle nut

P200194
Service Manual – SW4000 Wheel System, Non-Traction 201

Specifications
Values
Wheel System, Non Traction
SW4000 Battery SW4000 Petrol SW4000 LPG

Rear axle kerb weight 860 lb (390 Kg) 672 lb (305 Kg) 670 lb (304 Kg)

Rear wheel specific pressure on the floor 102 psi (0.7 N/mm2) 73 psi (0.5 N/mm2)

Rear wheels (diameter x length) 12.2 x 3.8 in (310 x 96 mm)

Service Manual – SW4000 Wheel System, Traction 202

Wheel System, Traction

Functional Description
The main components for the drive system are: the driving wheel assembly with integrated disc brake, the
drive pedal, the electronic board, forward/reverse gear switch and the brake pedal with parking brake lever.
The direction of travel is defined by the switch on the dashboard. If the switch is set to reverse, the reverse
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.

The driving wheel (M0) is powered by the drive system control electronic board (EB1).
The driving wheel is electronically protected by the drive system control electronic board (EB1), which limits
the current supplied at the values set in the relevant parameters (see parameters 19, 20, 21 in Drive System
Electronic Board Parameter Table).
The electronic board power circuit (EB1) is powered through the safety electromagnetic switch (ES0).
The electromagnetic switch (ES0) is activated by the same electronic board (EB1), after the first check on the
conformity of the input conditions, when it receives the start-up signal by the ignition switch circuit (SW1)
through the relay (K4).
The main control inputs of the electronic board (EB1) are the hall-effect pedal (R1) and the forward/reverse
gear switch (SW2).
Other inputs of the electronic board (EB1) are: the driver’s seat microswitch (SW7) and the lifted hopper sen-
sor (S1) signal. The drive system is inhibited when the microswitch (SW7) does not detect the operator on
the driver’s seat, but when the sensor (S1) detects that the hopper is lifted, the maximum machine speed is
decreased to a safety value (see parameter 12, in Drive System Electronic Board Parameter Table).
Upon start-up (with the ignition switch SW1) or when the driver’s seat microswitch signal (SW7) is inter-
rupted and then restored, the system is always set to forward speed. Pressing the forward/reverse gear switch
(SW2) changes to reverse gear until the switch is pressed again. When the reverse gear is selected, the warn-
ing light on the switch (SW2) and the buzzer (BZ1) turn on.
The position of the drive pedal (R1) determines the machine speed. The safety condition for drive system ac-
tivation is that the drive pedal (R1) is totally released (machine stopped) when the system is turned on (with
the ignition switch SW1).
When the machine is stopped, the output signal for R1 is less than 1V.
When the machine reaches the maximum speed, the output signal for R1 is higher than 5V.
This calibration should be correct for 100% of pedals. Otherwise, if a different pedal calibration is necessary,
perform the following learning procedure for the electronic board:

1. Connect the programmer (9097297000) and enter the potentiometer calibration enabling page

2. Confirm by pressing the MODE key

3. Release the pedal and confirm by pressing the MODE key

4. Press the pedal until the end of stroke (max. speed) and confirm by pressing the MODE key
Service Manual – SW4000 Wheel System, Traction 203

If the electronic board detects a fault in the drive system, this will appear as a code on the display and the
malfunction warning light (A) on the electronic board (EB2) will turn on.
The error code is a number of flashes of the malfunction warning light (A), which is repeated until reset by
ignition switch (SW1).

P200195

Wiring Diagram
REVERSE GEAR
BUZZER (BZ1) LINE ELECTROMAGNETIC
SWITCH (ES0)

MAIN
FUSE (F0)
DRIVER'S SEAT SAFETY
J2.9 - Buzzer output MICROSWITCH (SW7)
J2.16 - Reverse gear warning light output
LINE ELECTROMAGNETIC
J2.8 - Main electromagnetic switch output SWITCH (ES0)

J2.12 - Driver's seat microswitch input

J2.5 - Not used
(must be shorted to +BAT)
J2.14 - Auxiliary power supply for switches FORWARD/REVERSE
GEAR SWITCH (SW2)
J1.7 - Drive system electronic 24V
board diagnostic signal
J2.10 - Diagnostic warning light output 24V BATTERY (BAT)
J1.18 - Machine moving signal J2.7 - Machine moving signal

J2.13 - Reverse gear button input

ACCELERATOR
PEDAL (R1)
J2.1 - Potentiometer positive power supply

J2.2 - Potentiometer input

J2.3 - Potentiometer negative power supply

5V
M0
DRIVING
WHEEL

CONTROL PANEL DRIVE SYSTEM

ELECTRONIC BOARD (EB2) ELECTRONIC BOARD (EB1)

P200196
Service Manual – SW4000 Wheel System, Traction 204

Component Locations
• Forward/reverse gear switch (SW2)
• Drive system malfunction warning light
• Driver’s seat safety microswitch (SW7)
• 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)

P200197
Service Manual – SW4000 Wheel System, Traction 205

Component Locations (Continues)

• Driving wheel (M0)
• Disc brake
• Drive system electronic board (EB1)
• Main fuse (150 A) (F0)
• Reverse gear buzzer (BZ1)

Driving
wheel (M0)

Disc brake

Drive system
electronic board (EB1)

Main fuse
(150 A) (F0)

Reverse gear
buzzer (BZ1)

P200242
Service Manual – SW4000 Wheel System, Traction 206

Troubleshooting
Trouble Possible causes Remedy

The machine does not move The batteries are discharged or its connections are not Charge the batteries or clean/repair the
efficient connections

The drive pedal control assembly (R1) is broken Replace

The drive system electronic board (EB1) is faulty Replace

The wiring harness is damaged Check the electrical connections/repair the

wiring harness

The carbon brushes of the driving wheel (M0) are worn/ Replace the carbon brushes/replace the driving
damaged wheel

The ignition key (SW1) is not working Replace

The driver’s seat safety microswitch (SW7) is broken Replace

The brake does not operate The braking masses are worn Replace

The brake cable is misadjusted Adjust it

The machine does not move The drive pedal has been pressed before or at machine Start up the machine without pressing the drive
when pressing the drive pedal start-up. pedal.
and the drive system warning
light (red) flashes. Drive system failure. Turn off the machine and then turn it on again.
If the trouble persists, contact the Service
Center.
Service Manual – SW4000 Wheel System, Traction 207

Drive System Electronic Board Error Codes Table

No. of MEANING FIRST PROCEDURE IF THE PROBLEM PERSISTS
flashes of
the warning
light (A)

2 Not active - -

3 Potentiometer wiring harness Check the pedal wiring harness R1 Repair the wiring harness or replace
error the pedal

4 Potentiometer activated at Check that the pedal is not pressed (the Replace the pedal or perform the
start-up potentiometer output must be <1V as to the calibration procedures described
battery negative terminal) above

5 Thermal protection Allow the electronic board to reduce the inner Check the amperage of the driving
temperature while leaving the machine stopped for wheel
a few minutes

6 Damaged power stage Replace the EB1 electronic board -

7 Overcurrent Check the amperage of the driving wheel -

8 Open external electromagnetic Check the ES0 electromagnetic switch operation Replace the EB1 electronic board
switch and the electronic board power wiring harness
integrity.

9 Undervoltage Check the battery voltage Replace the damaged batteries

10 Overvoltage Check the battery voltage and the power -

connection tightening

11 Amperometric protection Check the amperage of the driving wheel -

12 Not active - -

13 Switching off sequence detected Check the machine switch on control wiring Replace SW0, SW1, K4.
harness from SW0 to SW1 to K4

14 EEPROM error Switch on the machine again Replace the EB1 electronic board

P200195
Service Manual – SW4000 Wheel System, Traction 208

Drive System Electronic Board Parameter Table

The drive system electronic board software contains some parameters which can be modified by the user with
the ITALSEA programmer (P/N 9097297000).

PAR PARAMETER DEFAULT NOTE

1 RESET TO DEFAULT OFF Turn to ON to reset all default values

PARAMETERS

2 ACCELERATION RAMP 3.0 Time (Sec) to accelerate from 0 to the maximum speed. Decrease
to have a better response from the system, increase to have a less
aggressive behaviour

3 REVERSE DECELERATION 0.8 Time (Sec) to decelerate from the maximum speed to 0 in case of
RAMP reversing the gear.

4 NEUTRAL DECELERATION 0.8 Time (Sec) to decelerate from the maximum speed to 0 in case the pedal
RAMP is suddenly released.
WARNING! When this value is increased, the machine braking
distance is increased too, when the service brake is not applied.

5 FORWARD MAXIMUM SPEED 100 Maximum forward speed (%)

6 BACKWARD MAXIMUM 60 Maximum reverse speed (%)

SPEED

7 MINIMUM SPEED 0 Not active

8 BATTERY VOLTAGE 24 Battery rated voltage value

(DO NOT MODIFY!)

9 SPEED REFERENCE SINGLE ENDED Pedal type

(DO NOT MODIFY!)

10 REFERENCE DEAD-BAND 0.00 Not active

11 BRAKE DELAY 2.0 Delay (sec) at which the electronic board sends the “machine stopped”
signal to EB2 after the machine has been stopped. It is used by EB2 to
stop the components (brooms, vacuum system, dust guard system) when
the machine is stopped.

12 SPEED IN MULTIMODE 50 Maximum speed (%) when the hopper is lifted

13 CURRENT IN MULTIMODE 250 Maximum current (Amp) available (peak value) when the hopper is lifted

14 BACKWARD SAFETY TIME 0.0 Not active

15 BACKWARD SAFETY SPEED 0 Not active

16 LOW BATTERY LIMIT 17 Safety limit for discharged batteries (V). It inhibits the drive system when
the battery voltage drops below this threshold.

17 RXL FUNCTION 0 Not active

18 RUN-AWAY FUNCTION 0 Not active

19 CONTROLLER’S CURRENT 250 Maximum current (Amp) available (peak value) It can be reduced to
LIMIT prevent the machine from travelling on excessive slopes (rising)

20 MOTOR’S RATED CURRENT 50 Maximum current (Amp) available (continuous value)

WARNING! When increasing this value, the risk of driving wheel
overheating is increased too, in case of use on excessive slopes.

21 MOTOR’S OVERLOAD TIME 60 Maximum time (sec) during which the electronic board can supply a
current higher than the value of parameter 20.
WARNING! When increasing this value, the risk of driving wheel
overheating is increased too, in case of use on excessive slopes.

22 PIN 5-J1 HARDWARE N.C. SWITCH Parameter connected to the hardware configuration
CONFIGURATION (DO NOT MODIFY!)

23 PIN 6-J1 HARDWARE N.O. SWITCH Parameter connected to the hardware configuration
CONFIGURATION (DO NOT MODIFY!)
Service Manual – SW4000 Wheel System, Traction 209

PAR PARAMETER DEFAULT NOTE

24 PIN 11-J1 HARDWARE N.C. SWITCH Parameter connected to the hardware configuration
CONFIGURATION (DO NOT MODIFY!)

25 A1 ALARM ENABLING DISABLE Parameter connected to the hardware configuration

(DO NOT MODIFY!)

26 A2 ALARM ENABLING DISABLE Parameter connected to the hardware configuration

(DO NOT MODIFY!)

27 A3 ALARM ENABLING ENABLE Parameter connected to the hardware configuration

(DO NOT MODIFY!)

28 A4 ALARM ENABLING ENABLE Parameter connected to the hardware configuration

(DO NOT MODIFY!)

29 A12 ALARM ENABLING DISABLE Parameter connected to the hardware configuration

(DO NOT MODIFY!)
Service Manual – SW4000 Wheel System, Traction 210

Connectors on Drive System Electronic Board

Power Connections - Battery

B+ B-

M2

M1

Power Connections (male screw terminals M 6)

Ref. Description Electronic board V ref. I max. Connected to

in/out

B+ Electronic board power supply + in 24V 250A BAT+, ES0

B- Electronic board power supply - in 0V 250A BAT-

M1 Drive system motor + out 0 - 24V 250A M0+

M2 Drive system motor - out 0 - 24V 250A M0-

Service Manual – SW4000 Wheel System, Traction 211

J2: MOLEX MINIFIT type, 16-ways vertical

J2

PIN Description Electronic V ref. I max. Connected to

board in/out

1 Potentiometer positive power supply out 5V <1A R1

2 Potentiometer input in 0 - 5V (0V when the pedal is released <1A R1

5V when the pedal is pressed)

3 Potentiometer negative power supply in 0V <1A R1

4 Not used - - - -

5 Not used (must be shorted to +BAT) in 24V <1A J2.14

6 Not used - - - -

7 Machine moving signal out 24V (when the machine is moving) <1A EB2, J1.18

8 Main electromagnetic switch output out 0V (when the machine is ON) 1A ES0

9 Buzzer output out 24V (when the buzzer is active) 1A BZ1

10 Diagnostic warning light output out 24V (when the light is active) <1A EB2, J1.7

11 Lifted hopper input in 24V (when the hopper is lifted) <1A S1

12 Driver’s seat microswitch input in 24V (when the micro is pressed) <1A SW7

13 Reverse gear push-button input in 24V (when the button is pressed) <1A SW2

14 Auxiliary power supply for switches out 24V <1A ES0, SW2

15 Key input in 24V (when the key is position I) <1A K4

16 Reverse gear warning light output out 24V (when the reverse is active) <1A SW2
Service Manual – SW4000 Wheel System, Traction 212

Removal and Installation

Brake Caliper, Pad, Brake Disc Disassembly/Assembly

Disassembly

1. Drive the machine on a level floor.

2. Turn the ignition key to “0”. Ensure that the machine cannot move by placing opposite wedges on the
rear wheels.

3. Steer the front wheel to the right, about 90°.

4. Unscrew nut and locknut (A) then remove the brake cable (B) from the brackets (C). Retrieve the spring
(D).

5. Remove the nuts (E).

6. Unscrew the nuts (F) and then remove the bracket assembly with outer pad (G).

7. Remove the springs (H).

8. Remove the brake disc (I). If necessary, retrieve the relevant key.

9. Remove the inner pad (L).

H I
C H

F F
A

B
E
E D G

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Service Manual – SW4000 Wheel System, Traction 213

Brake Caliper, Pad, Brake Disc Disassembly/Assembly (Continues)

10. If necessary, separate the outer pad (M) from the bracket (N), as shown below:
• Disengage the retaining ring (O) and remove the spring (P).
• Remove the bracket (N) and the lever (Q).
• Retrieve the washer (R).
• Retrieve the inner pad (M).

M
R

Q N
P
O N

O P

P200199
Service Manual – SW4000 Wheel System, Traction 214

Brake Caliper, Pad, Brake Disc Disassembly/Assembly (Continues)

Assembly

11. Assemble the components in the reverse order of disassembly, and note the following:
• Adjust the position of the nuts (F) until the bracket (G) comes into contact with the brake disc (I) and
with the inner pad (L); then, unscrew the nuts (F) for 3/4 of a turn, thus giving a 1 mm clearance be-
tween the brake disc (I) and the pads (L) and (M). Also check the parallelism of the bracket (G) with
the fixed part, by equating the two portions (N).
• Screw down and tighten the nuts (E).

12. Adjust the brake according to the following procedure.

F
F

E
G E

M L I

N F N
F

E E
G
P200248
Service Manual – SW4000 Wheel System, Traction 215

Brake Cable Disassembly/Assembly

Disassembly

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

2. Turn the ignition key to “0”. Ensure that the machine cannot move by placing opposite wedges (A) on the
rear wheels.

3. Remove the left side broom, if equipped.

4. Steer the front wheel to the right, about 90°.

5. Unscrew nut and locknut (B) then remove the brake cable (C) from the brackets (D).

6. Under the brake pedal, loosen the nut-locknut (H) of the brake cable (C).

7. Remove the clip with the pin (F).

8. Disconnect from the brake pedal the terminal (G) of the cable (C) of the brake.

9. Remove the cable (C) through the slot (L).

C
E A
I

F C

P200200
Service Manual – SW4000 Wheel System, Traction 216

Brake Cable Disassembly/Assembly (Continues)

Assembly

10. Assemble the components in the reverse order of disassembly, and note the following:
• Adjust the brake according to the following procedure.

Brake Cable Adjustment

1. Ensure that the machine cannot move by placing opposite wedges on the rear wheels.

2. Steer the front wheel to the right, about 90°, so that the brake system becomes accessible.

3. Loosen the locknut (A) and the nut (B).

4. Turn the nut (B) until the distance between the braking masses (C) and the brake disc (D) is 0.5 mm (as
shown in the figure).

5. Tighten the locknut (A) with the nut (B).

6. Remove the wedges from the rear wheels.

7. Check the proper adjustment of the brake cable (E) by pushing the machine manually (do not apply the
brake).

8. Before starting to operate on the braking masses, check that the stroke of the brake pedal (F) is 1/3 or
less of the total stroke (G).

9. Perform brake tests and check the proper operation of the service and parking brake.

0,5 mm
0,02 in G

D
F
E C
B A

1/3

D
P200213
Service Manual – SW4000 Wheel System, Traction 217

Driving Wheel Amperage Check

Warning! This procedure must be performed by qualified personnel only.

1. Place wedges (A) on the rear wheels of the machine.

2. With a proper hoisting system applied to the machine chassis, to the front wheel area (B), lift the
machine a few centimetres, in order to let the front wheel turn freely without touching the floor.

3. Open the battery/engine compartment hood.

4. Apply the amp clamp (C) on the electrical cable (D) of the drive system electronic board (E).

5. Turn the ignition key to “I”.

6. With the help of an assistant, carefully press on the driver’s seat to activate the microswitch, then turn
on the drive system at the maximum speed and check that the driving wheel amperage is within 4 and 6
A at 24 V.

Stop the drive system.

Turn the ignition key to “0”.

Remove the amp clamps (C).

A D
B

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Service Manual – SW4000 Wheel System, Traction 218

Driving Wheel Amperage Check (Continues)

If the amperage is higher, perform the following procedures to detect and correct it:
• Check that there is no dust or debris (ropes, cables, etc.) on the driving wheel, that can prevent it
from turning.
• Check the carbon brushes of the drive system motor (see the procedure in the relevant paragraph)
• If necessary, disassemble the drive system motor (see the procedure in Driving Wheel and Steering
Unit Disassembly/Assembly paragraph), and check the condition of all its components.

If the above-mentioned procedures do not lead to correct readings for the driving wheel amperage, the
driving wheel must be replaced (see the procedure in Driving Wheel and Steering Unit Disassembly/
Assembly paragraph).

Reassembly

7. Close the battery/engine compartment hood.

8. Remove the front hoisting system of the machine.

9. Remove the wedges from the rear wheels.

Service Manual – SW4000 Wheel System, Traction 219

Drive System Motor Carbon Brush Check/Replacement

Disassembly

1. Drive the machine on a level floor.

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 in sequence each of the four carbon brushes of the drive system motor, as shown below:
• Remove the cover (A) (bayonet joint).
• Remove the O-ring (B).
• Loosen the screws (C).
• Remove the carbon brush with the spring (D).

A C
B

P200202
Service Manual – SW4000 Wheel System, Traction 220

Drive System Motor Carbon Brush Check/Replacement (Continues)

5. Check the four carbon brushes (D) for wear. The carbon brushes are worn when:
• The contact with the motor armature is insufficient
• The contact surface is not integral
• The stroke is less than 0.47 in (12 mm)
• The spring is broken

6. Remove the two lateral carbon brushes of the drive motor, as shown below:
• Loosen the two screws (E)
• Remove the lateral cover (F)
• Loosen the screws (G)
• Remove the carbon brushes with the spring (H)

7. Check the two carbon brushes (H) for wear. The carbon brushes are worn when:
• The contact with the motor armature is insufficient
• The contact surface is not integral
• The stroke is less than 0.47 in (12 mm)
• The spring is broken

In this cases, replace all the six motor carbon brushes.

Assembly

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

P200243

E F E G H G H

P200243A P200243B
Service Manual – SW4000 Wheel System, Traction 221

Front Wheel Rubber Ring Disassembly/Assembly

Disassembly

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

2. Turn the ignition key to “0”. Ensure that the machine cannot move by placing opposite wedges (A) on the
rear wheels.

3. With a proper hoisting system applied to the machine chassis, to the front wheel area (B), lift the
machine a few centimetres, in order to reach the rubber ring and remove it.

4. Steer the front wheel to the right, about 90°.

5. Unscrew nut and locknut (C) then remove the brake cable (D) from the brackets (E). Retrieve the spring
(F).

F
D
A
B
P200203
Service Manual – SW4000 Wheel System, Traction 222

Front Wheel Rubber Ring Disassembly/Assembly (Continues)

6. Remove the screws (G) on the left side of the front wheel assembly.

7. Remove the spacer (H).

8. Remove the left bracket (I); if necessary use a puller (J).

9. Unscrew the nuts (K) and remove the fastening screws (L) of the rubber ring (N). Retrieve the washers
(M).

10. Remove the rubber ring (N) from the reduction unit (P).

Assembly

11. Assemble the components in the reverse order of disassembly, and note the following:
• To ease the installation of the rubber ring (N) on the reduction unit (P), slightly hit the side edge of
the rubber ring with a plastic mallet in a criss-cross pattern.
• Tighten the rubber ring fastening nuts (K) at 16 Nm.
• Tighten the left bracket fastening screws (G) at 22 Nm.

12. Adjust the brake as described in the procedure for brake cable disassembly/assembly.

K J I
M H
N
M I
L

K
M P

M
L
P200204
Service Manual – SW4000 Wheel System, Traction 223

Driving Wheel and Steering Unit Disassembly/Assembly

Disassembly

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

2. Turn the ignition key to “0”. Ensure that the machine cannot move by placing opposite wedges (A) on the
rear wheels.

3. Open the battery/engine compartment hood.

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

4. With a proper hoisting system applied to the machine chassis, to the front wheel area (B), lift the
machine a few centimetres, in order to easily remove the driving wheel assembly.

5. Remove the fastening screws (C) of the fairing (D) from the steering column.

6. Slightly lift the steering column fairing (D) by disengaging it from the lower fastener (E).

7. Disconnect the dust guard system quick coupling (F).

8. Retrieve the fairing (D).

A
B

C C
D
C

D
C F

P200205
Service Manual – SW4000 Wheel System, Traction 224

Driving Wheel and Steering Unit Disassembly/Assembly (Continues)

9. Steer the front wheel to the right, about 90°.

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.

13. Disconnect the brake cable (P) from the clamps (Q).

J
H

L M Q
L

Q P N

P200206
Service Manual – SW4000 Wheel System, Traction 225

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).

16. Remove from the machine the driving wheel assembly (V) with the steering assembly (W), by removing
the hub (X) from the steering shaft; retrieve the key (Y).

17. If necessary, remove the screws (Z) and then separate the driving wheel assembly (V) from the steering
wheel assembly (W).

Assembly

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

19. Adjust the brake as described in the procedure for brake cable disassembly/assembly.

U
Y
X U S
W U
U

P200207
Service Manual – SW4000 Wheel System, Traction 226

Front Driving Wheel Armature Disassembly/Assembly

Disassembly

1. Remove the driving wheel and steering assembly (see the procedure in the previous paragraph).

2. Workbench, remove the screws (A) on the left side of the front wheel assembly.

3. Remove the spacer (B).

4. Remove the left bracket (C); if necessary use a puller (D).

5. With a marker, draw an alignment sign (E) between the rubber ring (F) and the carbon brush cap (G),
for a proper reassembly (to avoid that the driving wheel turns in the wrong direction).

A
D

F G
P200208
Service Manual – SW4000 Wheel System, Traction 227

Front Driving Wheel Armature Disassembly/Assembly (Continues)

6. Remove the fastening screws (H) of the carbon brush cap (J). Retrieve the washers (I).

7. Remove the carbon brush cap assembly (J); take the greatest care in order not to remove/displace the
stator from its position.

8. Remove the compensating ring (K).

9. Place the assembly (L) with the outer side (M) of the right bracket laying horizontally on the workbench,
in order to prevent the oil from spilling out when removing the armature (N).

10. Remove the armature (N) taking care not to damage the reduction unit oil grommet (P).

I
H K
J
J
L L

M
N

N P
P200209
Service Manual – SW4000 Wheel System, Traction 228

Front Driving Wheel Armature Disassembly/Assembly (Continues)

Assembly

11. Assemble the components in the reverse order of disassembly, and note the following:
• 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” in the relevant paragraph).
• Assemble the carbon brush cap assembly (J) with the reference mark (E) matching the position
marked during the removal procedure.
• Tighten the fastening screws (H) of the carbon brush cap (J) at 5.5 Nm.
• Tighten the fastening screws (A) of the left bracket (C) at 22 Nm.

12. Check the proper operation of the driving wheel.

13. Reassemble the driving wheel and steering assembly (see the procedure in the previous paragraph).

J H
E
P200265
Service Manual – SW4000 Wheel System, Traction 229

Accelerator Pedal Disassembly/Assembly

Disassembly

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

2. Loosen the screw (B) under the accelerator pedal (A).

3. Remove the accelerator pedal (A) from the shaft (C).

4. Remove the three fastening screws (D) of the accelerator pedal control (E).

5. Disconnect the accelerator pedal control connector (F).

6. Disengage the electrical cable (G) from the retaining clamps (H).

7. Retrieve the accelerator pedal control (E) with the wiring harness.

Assembly

8. Assemble the components in the reverse order of disassembly, and note the following:
• Fasten the accelerator pedal (A) on the shaft (C) with the screw (B) under the following condition:
• with the accelerator pedal at the front end of stroke, the surface (I) must be aligned with the surface
(J).

E G

H
C J E
I B
P200210
Service Manual – SW4000 Wheel System, Traction 230

Drive System Electronic Board Disassembly/Assembly

Disassembly

1. Drive the machine on a level floor.

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. On the left rear side of the battery/engine compartment, disengage the protection caps (A) and
disconnect the electrical connections of the drive system electronic board (B).

5. Remove the four side socket head screws (C) fastening the drive system electronic board (B).

6. Slightly lift the drive system electronic board (B) and disconnect its connector (D), then retrieve it.

Assembly

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

B
C

A D
P200211
Service Manual – SW4000 Wheel System, Traction 231

Driver’s Seat Microswitch Disassembly/Assembly

Disassembly

1. Drive the machine on a level floor.

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. On the lower side of the battery/engine compartment (A), remove the driver’s seat microswitch connector
(B) from its housing and disconnect it.

5. Close the hood (A).

6. Move the seat (C) forward and remove it from the rails (D).

7. Retrieve the seat (C) with the wiring harness (E).

8. If necessary, remove the screws (F) and remove the seat rails (D).

Assembly

9. Assemble the components in the reverse order of disassembly, and note the following:
• Before tightening the screws (F) check that the seat rails (D) are aligned.
• After the seat have been reinstalled, check that it slides properly on the rails, and also check that it
engages properly in each position.

A C

F
D F

F
B
F D
P200212
Service Manual – SW4000 Wheel System, Traction 232

Specifications
Values
Wheel System Traction
SW4000 Battery SW4000 Petrol SW4000 LPG

U-turn space (right - left) 75.6 - 74.4 in (1,920 - 1,890 mm)

Forward speed 4.3 mi/h (7 km/h)

Maximum reverse speed 2.8 mi/h (4.5 km/h)

Gradeability 20%

Front wheel specific pressure on the floor 131 psi (0.9 N/mm2)

Front driving and steering wheel (diameter x width) 9.8 x 3.5 in (250 x 90 mm)

Drive system motor 1.35 hp (1,000 W) - 315 rpm